Philadelphia Gear IOM Manual

High Speed Gear Drive
Installation, Operating, and

Maintenance Instructions
HSM-2014
September 2014

Philadelphia Gear/Timken Gears and Services
TABLE OF CONTENTS 6.1 Preliminary Checks 15

6.2 Start-Up Procedure 15
1. GENERAL NOTES 3 7. PREVENTIVE MAINTENANCE 18
1.1 General Description of Machinery 3 7.1 Keep Lubrication System Clean 18

1.2 General Design Features 4 7.2 Maintain Records 19
1.2.1 Housing 4 7.3 Scheduled Maintenance 19
1.2.2 Double Helical Gearing Arrangement 4 7.3.1 Daily 20
1.2.3 Oil Seals 4 7.3.2 Weekly 20
1.2.4 Special Seals 4 7.3.3 Monthly 20
1.2.5 Gearing 4 7.3.4 Two Month Intervals 20
1.2.6 Lubrication System 4 7.3.5 Six Month or 2500 Hour Intervals 20
1.3 Measuring Surface Sound Pressure Levels 5 7.3.6 One Year or 5000 Hour Intervals 21
1.4 Warranty 5 7.3.7 Extended Shutdown Periods 21
1.5 Upon Delivery 5 7.4 Troubleshooting 21
7.5 Heat Exchangers 21
7.5 Troubleshooting 21
2. SAFETY 6
2.1 Document Safety Symbols 6 8. DISASSEMBLY PROCEDURES 31

2.2 General Safety Notes/Foreseeable Misuse 6
8.1 Tips for Disassembly 31
3. INTRODUCTION 7
9. ASSEMBLY PROCEDURES 31
3.1 Installation Service 7
3.2 Handling 7 9.1 Tips for Assembly 32
3.3 Prolonged Storage 8
10. RENEWAL PARTS 33
4. INSTALLATION INSTRUCTIONS 10
Generic High Speed Gear Drive Layout & Parts List 33
4.1 Foundation 10 10.1 Note on Renewal Parts 33
4.2 Leveling 10
4.3 Alignment 11 11. PG LOCATIONS 35
4.4 Bolting Error! Bookmark not defined.
4.5 Coupling Installation and Unit Alignment 11 Corporate Office and Technical Center 35
Houston High Speed OEM Manufacturing Facility 35
5. LUBRICATION INSTRUCTIONS 12 Northeast Service Center 35
Southeast Service Center 35
5.1 Recommended Lubricant 12 Midwest Service Center 35
5.2 Low Temperature Operation 13 Gulf Coast Service Center 35
5.3 Synthetic Lubricants 13 Western Service Center 35
5.4 Oil Changes for Units Using Straight Mineral Oil 13 Standard Machine/Timken Gears and Services
5.5 Oil Changes for Units Using Synthetic Turbine Oil Canada 35
14
5.6 Service Life Guideline Checks for Lubricants 14
6. OPERATING INSTRUCTIONS 15
HSM-2014 September 2014

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1. General Notes
These instructions are the original instructions and have not been translated and will be translated into
languages of the final installation as required.
1.1 General Description of Machinery

Your Philadelphia High Speed Gear Unit is a high quality, rugged machine designed in accordance with
Standards of the American Gear Manufacturers Association to have a life of trouble free service. However,
certain precautions and procedures must be observed in handling, installing and servicing the unit in order to
obtain optimum performance. High-speed gear drives are less forgiving to errors in their use or maintenance.
Because of the rotational speeds, problems that may develop can progress more rapidly, with a higher wear
rate as compared to lower speed equipment. Consequently, more diligent care is recommended for your high-
speed gear unit. This manual contains general installation, operating, maintenance and trouble-shooting
instructions for your equipment. Should questions arise that are not addressed in this guide, additional infor-
mation may be obtained by contacting Philadelphia Gear at one of the locations given below.
Main Office & Technical Center

901 East 8th Avenue, Suite 100
King of Prussia, Pennsylvania 19406
Phone (toll free): 800-766-5120 Call for 24/7 technical support & emergencies
Phone (local): 610-265-3000
If dialing from outside the U.S. +1 610-265-3000
Fax: 610-337-5637
Email: info@philagear.com
Houston High Speed OEM Manufacturing Facility

5610 Brystone Drive
Houston, TX 77041
Phone (local): 713-340-5600
Email: high-speedplant@philagear.com
All inquiries must be accompanied by the following information which can be obtained from the gear drive
nameplate:
Gear Drive Size and Type

Philadelphia Gear Order Number
Philadelphia Gear Unit Serial Number
All orders for renewal or replacement parts must include the description and part number shown on the
typical or specific parts list supplied with this service manual. Contact Philadelphia Gear at the above phone
numbers if the parts list is missing.
Much of the information contained in this service manual is proprietary to Philadelphia Gear and has not
been disclosed to the general public. Reproduction of any or all parts of this manual without the express
written permission and consent of Philadelphia Gear is prohibited.
The gear drive is only intended to be operated according to the data plate operating conditions and only in the
direction of rotation specified on the outline dimension drawing or the rotation tag.

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1.2 General Design Features
1.2.1 Housing
The rotating parts of a Philadelphia High Speed Gear Unit are contained in an oil tight case or fabricated
housing which is split horizontally at the shaft centerlines. The surface of the housing split is machined to a
high finish and coated with a fluid sealing compound. The housing is fastened at the split by bolts secured
with Loctite. In some cases, studs are used with hex nuts and also held with Loctite (anaerobic liquid
adhesive).
1.2.2 Double Helical Gearing Arrangement

In Philadelphia High Speed Gear Drives using double helical gearing, the design arrangement results in only
radial loads on each shaft; however, lateral thrust loads can be applied to these shafts as a result of coupling
torque lock-up or limited float coupling designs from the driving and/or driven equipment. In general, these
units use sleeve-type radial bearings throughout with those on the low speed shaft having thrust shoulders to
center the gear set and take the lateral thrust in either direction from the driving and driven equipment. The
high speed pinion shaft sleeve bearings do not use the thrust shoulders and the shaft does not require
adjustment for end play since the double helical gearing centers the pinion shaft and any lateral thrust applied
is transmitted to the thrust shoulders of the low speed shaft bearings.
1.2.3 Oil Seals

Shaft extensions of high-speed gear units use thru-caps having an internal labyrinth-type construction. These
caps may be designed for possible use with an "air purge" system (supplied by others) having a pressure not
less than 10 PSI.
1.2.4 Special Seals

High speed gear units operated in dusty or corrosive atmospheres may be equipped with special seals and
breathers designed for these conditions. Similarly, units subjected to moisture and vapor-laden atmospheres,
or hose-down, may be furnished with special seals designed for these conditions. Typically, slingers are used
on thru shafts of units operating in a dusty atmosphere. Unusual environmental conditions should be detailed
to the manufacturer at the time the gear drive is ordered.
1.2.5 Gearing
Pinions are usually integral with their shafts. Gears and separate pinions are mounted on shafts with a
shrink fit. Some units, depending on design considerations, may have the gear cut integral with its
shaft.
1.2.6 Lubrication System

Lubrication of Philadelphia High Speed Gear Drives is accomplished by a pressure fed lubrication system
from an oil pump. The system may be wholly or in part supplied by Philadelphia Gear or may be completely
supplied by others. This system lubricates the gear mesh through spray nozzles, and pressure lubricates the
bearings. External lubrication piping is hose, threaded pipe and/or welded steel construction with flange type
fittings. All bearings have oil drain backs to the unit sump. Radial bearing drain backs are internal.
The gear unit housing may be designed to be used as a sump. The level of oil maintained in unit is normally
below the gear diameter so that the gear does not churn sump oil (proper level shown on certified dimension
drawing).

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It is recommended that gear drives have a dual lubrication system, a shaft driven pump and filter and a
separate turbine or motor driven standby or auxiliary pump which can be used to automatically supply
pressurized oil to gear mesh and bearings before start-up and during shutdown. The auxiliary pump may be
arranged to take over automatically should the main lubrication pump fail during operation.
Protective devices are incorporated into the lubrication system of some units to guard equipment against
low oil supply, low oil pressure and high temperature. The devices, in addition to performing these
automatic functions, can be wired to appropriate alarms or can shutdown the unit if any of these conditions
exist. Rapid wear of the gear teeth can occur if insufficient oil is supplied to the gears due to low supply
pressures, malfunctions, or fouling of lubrication piping.
Also, some units have dual filters or other components. Valves may divert the oil flow through one filter
while the other filter is being cleaned during normal operation of the gear drive, thereby avoiding a
shutdown. Units with single filters must be shut down for cleaning when necessary.
1.3 Measuring Surface Sound Pressure Levels

Sound pressure levels established at Philadelphia Gear test facilities will apply. Maximum noise level when
unit is properly assembled, properly aligned, properly installed, and operated within operating conditions is
specified on the API data sheet.
Sound pressure level measurement is to be performed in accordance with AGMA 625 or other specified
standards.
1.4 Warranty
The seller's warranty applies only when unit is installed and maintained in accordance with instructions
provided in this manual and operated within the rating and service conditions for which it was specifically
sold.
The purchaser must prevent exposure to any destructive external conditions which might typically include:
vibratory loads due to critical speeds; severe shock loading; mechanical or thermal overloads; and/or other
conditions which may adversely affect the operation.
In the event of malfunction within the warranty period, Philadelphia Gear must be notified promptly, or in
any event, within thirty (30) days of such alleged malfunction if it is intended that the warranty is to cover
the incident.
Unauthorized work performed on any Philadelphia Gear equipment during the warranty period (repairs,
modifications, etc.) done without the approval of Philadelphia Gear and/or without a Philadelphia Gear
representative present may void the warranty.
1.5 Upon Delivery

All equipment furnished must be carefully inventoried against shipping papers to determine whether any
shortages exist in delivered material. Any such shortages must be reported immediately to both Philadelphia
Gear and the carrier if a timely claim is to be made.
Any apparent or suspected damage sustained by equipment manufactured or furnished by Philadelphia Gear
and occurring during transport from the factory to the user should be reported immediately to both
Philadelphia Gear and the carrier.
Inspect the gear drive and any other equipment furnished by Philadelphia Gear for corrosion. If corrosion is
present, notify the service department at Philadelphia Gear immediately. To determine if a gear drive is

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protected for short term or limited term storage, check the internal rust protection warning tag attached to the
gear drive.
2. Safety
2.1 Document Safety Symbols
The following symbols will appear in these instructions whenever safety needs to be emphasized:
This symbol will be used whenever there is a personal safety issue.
This symbol will be used whenever there is a safety issue which could cause damage to the
gear box.
Note: This symbol will be used whenever there is a general note, which needs to be emphazized.
2.2 General Safety Notes/Foreseeable Misuse

In the installation, operation and maintenance of this equipment, SAFETY comes first. The
gear unit should NEVER be operated outside of the paramaters specified on the nameplate and
rotation arrow attached to the unit. All equipment should be installed, operated, adjusted, and
serviced by qualified personnel familiar with the construction and operation of this equipment
type. Also, they should be familiar with any potential hazards and the appropriate installation,
operating and maintenance instructions. Personal injury or equipment damage may result if
this warning is not observed. This manual lists a number of safety precautions. Follow them
and insist that those working for you do the same. Accidents are usually caused by neglect,
oversight, or unqualified personnel.
The user is responsible for furnishing and installing any guards or other safety equipment, including
utilization of proper PPE (personal protection equipment) needed to protect operating personnel as required
by Occupational Safety and Health Administration standards (OSHA in the United States) or other
applicable safety regulations promulgated for the jurisdiction in which the unit is located. Normally, this
equipment is not furnished by Philadelphia Gear except when specified as part of the order. In all cases,
however, the user has the responsibility of complying with all local safety regulations when installing the
equipment. This is including, but not limited to, shaft guarding on all rotating components to preclude
personal injury
All unauthorized personnel must be required to remain at least 1 meter from spinning shafts,
couplings, clutches, and any other rotating or moving components.
Refer to applicable national and local safety codes for proper procedures to shield rotating
elements and any other necessary safety requirements.
Only authorized and properly trained personnel who have read and understand the Installation,
Operation, and Maintenance Instructions are permitted to operate and/or service Philadelphia
Gear drives
All work performed on gear drives must be performed while the unit is stationary and secured
to prevent accidental startup (by locking a key switch, removing fuses in power supply, etc).

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The temperature of the gear drive in operation becomes hot enough to cause burns on
unprotected skin, and remains high for an extended period of time after operation has been
terminated. Use protective equipment to avoid direct contact with skin.
Oil change hazards may include burn, inhalation of vapors, and slip from any leaked or spilled
oil. Oil and oil vapors may escape the gear drive. Special vent and drain connections are
provided.
Rotating shaft extensions and couplings must have proper guarding installed prior to gear
drive operation.
3. Introduction
3.1 Installation Service
The installation of most power transmission equipment normally does not require the services of a factory
engineer. These services are not included in the selling price of the equipment unless specifically agreed
upon in writing between the seller and the purchaser. In applications requiring a more complex arrangement
of components, consideration should be given to the use of a factory engineer for assistance and check-out of
the installation. These services are available from Philadelphia Gear by arrangement with the company's
service department. See section 11 for contact information.
Note: If this unit is not to be placed into service immediately, read and follow the section
"Prolonged Storage" in section 3.3. Removal of all protective shipping covers and
preservative coatings should not be accomplished until the equipment is ready for installation.
3.2 Handling
The packing of the gear unit will differ depending on method of shipment and size. Refer to PG SHIP-05 for
shipping requirements. See unit data sheet for weight of assembled unit and lifting points.
The gear unit will be shipped assembled.
When handling the gear drive, care must be taken to avoid supporting or lifting in a manner that would place
excessive stress on parts that are not designed to support the unit's weight. When the gear drive is resting on
the floor, it must be in a normal, upright position with the weight resting on the mounting surface.
Never drag the gear drive. This will damage the machined mounting surfaces and may
overstress the housing.
The gear drive must be lifted only with the designated lifting holes provided for this purpose.
Slings, cables, or chains should be adjusted to distribute the load evenly. Never attempt to lift
the entire gear by light eyebolts fixed into covers or thinner- walled housing sections.

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Figure 3.2.1
Only lift gear box by the holes shown in the figure above or those shown on the unit data
sheet.
Only use lifting equipment that is adequately maintained and that possesses sufficient load
carrying capacity for the particular application. Secure and balance the load properly to
prevent shifting during suspension.
When attaching slings to the gear drive, attention must be given to the behavior of the sling
under load. Do not attach a sling in a manner which will cause it to crush or rip loose exterior
piping or gauges when it is placed under load.
3.3 Prolonged Storage

If installation of a gear drive and operation is to be delayed more than one month after shipment, special rust
preventative precautions must be taken. (These precautions may have been taken by the factory if complete
information concerning storage conditions was provided at the time of ordering.) To determine if a gear
drive is protected for short term or limited term storage, check the internal rust protection warning tag
attached to the gear drive. If necessary, long term preservation may be accomplished in the field by the user.
Note: The manufacturer's warranty on gear drives held in prolonged storage must be supplemented
by a special agreement reflecting the storage condition.

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When prolonged storage is necessary it should be indoors and preferably in a dry, vibration free area having
a relatively constant temperature. When outdoor storage is unavoidable, gear drives should be raised off the
ground on skids and covered by a tarpaulin or equivalent covering.
The following are three suggested methods of field preservation:
Field preservation can be accomplished by coating the interior with a heavy rust preventative such as
ESGARD PL-2 preservative or equivalent (such as Shell Ensis Fluid SDC). This is applied either by filling
the unit completely, rotating the shafts and draining, or by spraying. Special care must be taken to reach all
internal areas when applying preservation by spraying. External machined surfaces should be protected by
applying a protective coating of Daubert Nox- Rust 1101 or equivalent (such as Tectyl 846 K19).
Units that have been factory preserved or field preserved using the ESGARD PL-2 preservative do not
require flushing before use. Any other type of preservative may require flushing with a solvent prior to
filling the unit with the recommended operating lubricant if hardening as a result of solvent evaporation
has occurred.
As an alternative, some units can be field prepared by filling the gear drives to the top with the same oil used
during normal operation, using a stand pipe if necessary, to assure that oil reaches the uppermost parts of the
gear drive. The shafts should be rotated at least twice in order to assure proper coverage. All openings should
be sealed with plugs, vapor inhibitor paper, or caps. Labyrinth caps can be sealed with RTV around the shaft
clearance.
Note: When RTV is used to seal labyrinth caps, rotation of shafts is not recommended.
If the unit has been filled to the top with oil for long term storage, a periodic inspection should include a
visual check of oil level. Oil lost through leakage should be replaced immediately to prevent any possibility
of atmospheric vapor condensation within the unit. Units prepared for prolonged storage by filling com-
pletely with oil should be drained of the preservative oil and the recommended lubricant added to the proper
oil level before the unit is placed into operation.
Another alternative for long term storage preservation, normally utilized when the gear drive is installed in
position to await startup at a later date, is the use of vapor space-inhibited oil or the recommended lubricant
containing a mixture of a vapor space-inhibited oil concentrate. When using this type of protection, the lubri-
cant vendor's instructions should be followed. Normally these instructions require that a percentage of the oil
volume be drained at approximately three (3) month intervals and a new charge of vapor inhibitor installed.
It is extremely important when this procedure is used, that all openings be sealed to limit dissipation of the
rust preventative vapors to atmosphere. Any gear drive and associated equipment placed in storage must be
inspected periodically to ensure that there still is an effective coating of rust preventative on the internal
parts, external machined surfaces, and shafts. The coating should be replaced as required. Deterioration of oil
seals during prolonged storage must also be considered.
All protective shipping covers must be removed from the gear drive prior to operation. The shaft extensions
and outside machined surfaces are protected during shipment by an anti-rust compound, Daubert Nox Rust
1101 or equivalent (such as Tectyl 846 K19). This compound can be removed by using a solvent. Removal
of this compound and all protective shipping covers should not be accomplished until equipment is ready for
installation.
Follow all manufacturer s safety requirements when using preservatives, as they may require
proper ventillation of area
Note: See P-875 for detailed information regarding GearLogic long term preservation. Contact
Philadelphia Gear for a copy if GearLogic is provided.

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4. Installation Instructions
Note: The basic gear drive is shipped from the factory completely assembled. Gears and pinions
are carefully positioned at the factory to provide proper tooth contact with respect to each
other. Also, lateral clearances of bearings have been factory adjusted. Nothing should be done
to disturb these settings.
4.1 Foundation
The foundation must be solid and rigid enough to maintain the unit in correct alignment with connected
machinery. The foundation should have a flat mounting surface in order to ensure uniform support for the
gear. If the unit is to be mounted on a surface other than horizontal, consult Philadelphia Gear to ascertain
whether or not the design provides for proper tooth contact and adequate lubrication in such a situation.
Design of fabricated pedestals or base plates must be carefully analyzed to determine that they are
sufficiently rigid to withstand operating vibrations. Vibration dampening materials may be installed under
the base plate to minimize the effect of vibrations but must be sufficiently rigid to prevent distortion and
gear drive movement under load.
When installing the gear drive on structural steel, the use of a rigid base plate is strongly recommended. Bolt
gear drive and base plate securely to steel supports with proper shimming between gear unit and base plate,
and between base plate and supporting structure to ensure a level surface. When the gear drive is installed on
a concrete foundation, allow the concrete to set before bolting down the gear drive. Shimming is required in
this case to ensure a level surface.
For best installation, grout structural steel mounting pads into the concrete base, rather than grouting the gear
drive directly into the concrete.
4.2 Leveling
When shims are used to level or align the gear drive, they must be distributed properly around the base under
all mounting pads to equalize the support load and to avoid distortion of the housing which can produce
highly localized stresses and gear element misalignment.
Figure 4.2.1

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Check for a soft foot by using feeler gauges, laser equipment, or other similar methods. All pads must be
squarely supported to prevent distortion of the housing when the gear drive is bolted down.
Note: The maximum vertical deviation on the mounting surface before shimming must not exceed
0.0005 inches per foot of the horizontal width of the gearbox housing foot (0.00004 mm per
mm of horizontal housing width).
4.3 Alignment
If equipment is received mounted on a bedplate, it has been aligned at the factory. However, it may have
become misaligned in transit. During field mounting of the complete assembly, it is always necessary to
check alignment by breaking the coupling connection and shimming the bedplate under the mounting pads
until the equipment is properly aligned. (See section 4.6 for coupling alignment info). All bolting to the
bedplate and foundation must be torqued to proper levels and the alignment re-checked. If the alignment
changes during torquing, improper shimming has occurred and must be corrected. The gear unit, together
with the prime mover and the driven machine must be correctly aligned. After precise alignment, each
member must be securely bolted and doweled in place. It is essential
that a gear unit be securely bolted down to its foundation, utilizing bolts of the proper diameter to suit
mounting holes.
After start-up, the unit should be run until operating temperatures stabilize and the alignment checked again.
Any necessary corrections should be made at this time.
Note: It is good practice to check the alignment once more after operating under load for two
or three weeks. Provisions must be made for hot alignment check before startup.
4.4 Coupling Installation and Unit Alignment

Flexible couplings are not intended to correct shaft misalignment; however, they can compensate for small
amounts of shaft misalignment normally present due to temperature fluctuation and operating loads. In high-
speed applications, this misalignment must be kept to a minimum. Excessive misalignment may cause
vibration, noise, and may reduce gear and bearing life or cause other problems. Flexible couplings, when
properly aligned, will permit some temporary changes (misalignment) on shaft positions during start-up or
during some unusual momentary load conditions. Two rotating shafts connected by a flexible coupling are
considered to be in correct alignment when the relative position of the two shafts is such that during normal
operation no flexing occurs at the coupling.
Since coupling alignment is performed with shafts at rest and with equipment in a "cold" position,
compensation must be made for changes that occur in the equipment between start-up and when it reaches
normal operating condition. The factors to be considered include machine dimensional changes resulting
from thermal growth, radial bearing clearances and shaft loading, type of coupling, and rotational speed. The
compensation for the effect of these factors is made by specifying an "offset" when the machines are cold
during alignment. Thus, when the machines are started and reach normal operating temperature the shafts
may achieve near perfect alignment.
Where an offset "cold" alignment is performed, it is some-times easier to align the couplings to a perfect cold
alignment. Then, after alignment is complete, change shims to the exact amount required to achieve proper
final alignment under operating conditions. "Reverse indicator" methods of alignment with dial indicators is
recommended.
Once the procedure for alignment is understood, it can be readily applied to establish the proper final "cold"
alignment positions of the shafts. Information concerning the offset required to compensate for thermal
growth and radial bearing clearances of Philadelphia Gear High Speed Units can be obtained from the
factory.

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Note:
can be found on the unit data sheet.
5. Lubrication Instructions
5.1 Recommended Lubricant

The recommended lubricant for use in Philadelphia High Speed Gear Drives is a straight mineral oil
(turbine oil) having a viscosity in accordance with the table below unless otherwise specified on the
certified drawings. Most high speed gear drives are manufactured for use with an established central
100° F, 32 cSt @ 40° C). However, if unit was not originally designed for this oil, consult factory before
using a different viscosity oil.
ISO/AGMA OIL VISCOSITY CHART

FOR PHILADELPHIA HIGH SPEED GEAR DRIVES
CONTACT YOUR SUPPLIER FOR TRADE NAME OF LUBRICANT MEETING THESE SPECIFICATIONS
SEE DATA SHEET FOR REQUIRED LUBRICANT
STRAIGHT MINERAL STRAIGHT STRAIGHT

TYPE OF OIL
OIL MINERAL OIL MINERAL OIL
ISO VISCOSITY GRADE 32 46 68

AGMA VISCOSITY GRADE 0 1 2
VISCOSITY SSU @ 100°F 136-165 193-235 284-347
VISCOSITY cSt @ 40°C 28.8-35.2 41.4-50.6 61.2-74.8
Table 5.1.1
*The lubricant selected for this operating range must have a pour point below the lowest expected ambient
temperature.
In general, the straight mineral oil should be a high grade, well-refined petroleum oil within the
recommended viscosity range. It must be neutral in reaction and must not be corrosive to gear or bearing
materials. It should have good defoaming properties with resistance to oxidation for high operating
temperatures. Some High Speed Drives have been factory designed or approved for use with a Type II
synthetic turbine oil. Where permitted the use of synthetic turbine oil may necessitate different "oil
change" intervals than those required of straight mineral oil - refer to section 5.6
The synthetic turbine oils are not an alternate for standard drives in which straight mineral
oil is recommended and must not be used unless approved by Philadelphia Gear
Corporation.
Exercise care in handling some synthetic lubricants. Many of the chemical bases and other
organic additives are readily absorbed by the skin and are highly toxic.

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5.2 Low Temperature Operation

Philadelphia Gear must be fully advised of low temperature service conditions at the time that an enclosed
gear drive is purchased, in order that special design considerations can be incorporated. Oil temperatures
increase during operation; therefore, the oil used MUST have the required viscosity at normal operating
temperatures. Minimum viscosity at operating temperatures of the supply oil should range from
approximately 55 to 90 SSU (75-18.5 cSt).
Straight mineral oils, and some synthetic oils, are not normally satisfactory for cold- temperature starting.
When ambient starting and operating temperatures range below the minimum specified in the following
paragraphs for low temperature environments, sump heaters or special oil must be used. Contact the
factory for recommendations.
The straight mineral oil recommended for use in the lubrication system of a gear unit is normally
satisfactory for starting and operating above approximately 50° F (10° C). When ambient temperatures fall
below 50° F (10° C), either heaters or a different lubricant must be used to ensure adequate flow on start-
up.
In units designed or approved for use with synthetic turbine oil, the oil is satisfactory for starting above
25° F (-4° C). When ambient temperature falls below 25° F (-4° C), heaters must be used.
5.3 Synthetic Lubricants

Synthetic lubricants can be advantageous over refined petroleum oils in that they generally are more
stable, have a longer life, and operate over a wider temperature range. However, each type has different
characteristics and many synthetic lubricants have distinct disadvantages. In particular, compatibility with
gear assemblies and lube system components, behavior in the presence of moisture, lubrication qualities,
and overall economics should be analyzed carefully before using a synthetic lubricant.
Any synthetic lubricant selected should be a high grade lubricant specially formulated for industrial gear
use. It should be a non-reactive, oxidation resistant formulation that is non-corrosive to gears and
bearings. It should have good de-foaming properties. Viscosity must equal that of recommended
petroleum oils. Synthesized hydrocarbon lubricants are normally compatible with components designed
for use with petroleum oil. Consult the Philadelphia Gear Service Department before using other synthetic
lubricants to avoid possible compatibility problems. In the absence of previous field experience, the
selection and use of a synthetic lubricant should be carefully coordinated and monitored by the user with
the lubricant supplier and the Philadelphia Gear Service Department.
5.4 Oil Changes for Units Using Straight Mineral Oil

After the initial two weeks of operation of a Philadelphia High Speed Gear Drive, the first oil should be
changed. If desired, this oil may be filtered centrifuged and re-used. If a filter finer than 25 microns is
used, check with the supplier for the possibility of filtering out the additives, which gives the oil proper
lubricating characteristics. Sometimes, due to the wearing in process, small metal particles will show up in
the oil; this is not abnormal. It is recommended that the gear case and sump be thoroughly flushed-out
after the original oil has been drained. Fill the case to the indicated level with SAE 10 straight mineral
flushing oil that should not contain additives. The unit should be started, brought up to operating speed
(preferably without load) and immediately shutdown. Drain off flushing oil, clean filters, and refill with
recommended operating lubricant to proper level. After the break-in procedure outlined above, it is
recommended that a sample of the original oil removed from lubrication system be chemically analyzed.
If it is not satisfactory, refill the unit with new lubricant. Follow the lubricant suppliers recommendations
for repeated checks of the lubricant. The properties of the lubricant must be maintained to insure the life of
the gears and bearings. If there is any question, drain and refill with a new lubricant after every 2500 hours
of operation or every 6 months, whichever occurs first.

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5.5 Oil Changes for Units Using Synthetic Turbine Oil

Oil changes are recommended whenever a sample exhibits characteristics which indicates that continued
use may result in problems. The sample should be approximately 1 quart (1 liter) and taken from sump
after equipment has been stopped. Avoid taking samples from dead- ended areas.
During initial start-up, it is recommended that an oil sample be taken after each of the first three
successive 100-hour periods of operation. The samples should be analyzed to verify that satisfactory oil
conditions exist. If not, it should be changed. (If changed, repeat the sampling procedure every 100 hours
during first 300 hours of operation with the new fill). If oil is then satisfactory and exhibits no
characteristics detrimental to equipment, change the oil as specified in "normal operation" in next
paragraph.
After a satisfactory oil condition has been established at the end of a 300 hour operating period, oil
samples should be taken and analyzed at intervals not to exceed one calendar year or 5000 hours of
operation whichever comes first. After the first 5000 hours or one-year sampling (whichever comes first)
and the oil is satisfactory, subsequent samples should be taken and an analysis made every 6 months or
2500 hours (whichever comes first) thereafter.
When an oil change is indicated, follow this procedure:
1. Drain all oil from equipment (including sump and filter).

2. Clean or replace filtering elements and associated containers.
3. Fill with required amount of specified lubricant. Flushing of system is not required prior to
debris should be removed from bottom of unit and sump during each oil drain.
4. During start-up with a new oil supply, an oil sample should be taken and analyzed the same as
the original oil recommendations.
5.6 Service Life Guideline Checks for Lubricants

Service life of a lubricant is adversely affected by high bulk temperatures, water and/or emulsions, solid
contaminates, operating in an area with air-borne acid or alkalis, and the addition of lubricants other than
the type in the unit (see recommended lubricant).
1. Inspect gear case for deposits of sludge, etc.

2. Visually check for water or emulsions.
3. Perform a viscosity check - an increase or decrease in viscosity (+20% to -15% change) may be
an indication of limited life expectancy.
4. Perform a contaminate check - determine percentage of contaminates, type and determine source.
A 0.2 percent insoluble content may warrant a change unless improved by filtering.
5. Perform a demulsability check - a demulsability test such as ASTM D-27 11 will give an
indication of oil deterioration. A maximum of 38 milliliters of water separation out of 45
milliliters of added water is considered excellent.
6. An infrared or metals scan versus new oil will determine if any drastic change is occurring.
7. Depletion of additives is very seldom a problem but should be considered when the system has a
25-micron or finer filter.

Page 14/35
6. Operating Instructions
6.1 Preliminary Checks
Note: If the unit has been in storage, it is recommended that the drive be thoroughly cleaned and
flushed before initial oil fill unless preservative used was ESGARD PL-2.
When starting up any new equipment, it is wise to proceed cautiously. Even though the best installation
practices are followed, the possibility of errors or omissions always exists. Therefore, before initial start-
up, perform the following preliminary checks.
1. Have all pressure gauges, control devices, switches, electric circuits, etc., been properly and
securely mounted? Often it is necessary to box these items separately to prevent damage or loss
in shipment.
2. Are mounting bolts tight? Check all external bolts screws, accessories, etc., to make sure they
have not loosened in shipping or handling.
3. Has the proper rotation of the driver and the driven equipment been checked before coupling
together?
4. Are all couplings mounted on shaft extensions correctly with keys and fasteners in place?
5. Are couplings properly lubricated, if required?
6. Have coupling connections been made and tightened properly?
7. Check for proper installation of coupling guards and other safety devices at any hazardous
location, even though these items may not have been furnished with the unit.
8. Fill unit or sump (whichever is applicable) with proper oil to indicated level. Gear units are
emptied of all oil prior to shipment. All Philadelphia High Speed Gear Units and/or the
lubrication systems must be filled with the type and grade of lubricant specified. After initial
filling, the lube system should be run to fill all components and piping and then allowed to settle
and refill to proper level.
9. Have all inspection covers been closed and properly fastened?
10. Have all required piping connections been made? Tighten all pipe connections to make sure they
have not loosened during shipment or handling.
11. Where a separate lubrication sump is used, check the sump completely for leaks and check
cleanliness and tightness of all piping and fittings between sump and gear unit.
12. Have all the required electrical connections been made?
13. Have all control and indicating devices on the unit or supplied with the unit been mounted and
connected? Have such devices been set to recommended values? (These values vary among units
- contact factory for specific values applicable to your unit.) Where applicable, are these devices
wired to appropriate alarms?
14. On units having liquid cooled heat exchangers have all heat exchangers been connected to an
appropriate coolant supply? If water is used it should be clean and should not exceed 80° F
(27°C) on entry into cooler. (Some units may have a cooler selected by the manufacturer or
chosen in accordance with purchase specifications to allow for higher operating temperatures).
6.2 Start-Up Procedure

Do not proceed with initial start-up unless all preliminary checks listed above have been
completed.
Philadelphia High Speed Gear Drives are test run at the factory; however, during initial start-up, perform
the following recommended procedures. Remember, the nature of high-speed equipment dictates diligent
care to maintain the long life that has been designed into the gear units.
1. If the gear unit or lubrication sump is equipped with heaters for cold temperature operation, turn
on heaters and allow oil temperature to rise to at least 60°F (15.5°C) before starting the
lubrication system. The oil should be circulated with the motor driven/auxiliary oil pump until

Page 15/35
the skin temperature of the gearbox reaches the same temperature before starting up the machine.
In cases where the equipment has been s
may be necessary to utilize additional external heating to achieve desired temperatures. Some
applications may require higher temperatures before startup. Consult the factory if there are any
questions.
2. If the unit is equipped with a water-cooled heat exchanger, make sure that clean cooling water is
flowing to the exchanger. Cooling water should not exceed 80° F (27°C) on entry into cooler
unless otherwise specified.
3. If the unit has a self-contained lube system and is equipped with a separate motor driven oil
pump, start pump motor after oil has reached temperatures specified in step 1 and check visually
through inspection covers that the lubricant is flowing to gears and bearings. Also, observe that
the proper pressure (as specified on data sheet) is indicated on pressure gauges. Allow the oil to
circulate for 10 to 15 minutes to lubricate the gear unit prior to starting the drive system.
4. If unit is equipped with a dual lubrication system (both pumps being separately motor driven),
also check operation of the auxiliary system (oil pressure may be slightly lower).
5. Similarly, if unit is equipped only with a lubrication pump driven by rotation of main gear train,
the unit should be checked immediately on start-up through the full range of operating speeds to
determine that the lubricant is flowing properly to gears and bearings. Observe that the proper
pressure is also indicated on pressure gauges after unit reaches normal operating temperature.
(Normal operating temperature is approximately 150° to 160° F (66° to 71°C) at the lube oil
drain or unit sump. However, some units are designed for higher operating temperatures - see
certified data sheet or consult factory.
6. Start unit slowly under as light a load as possible. If rotation of the unit is limited to one direction
only the tag on the bearing block indicates direction of rotation. Make certain that direction of
shaft rotation is as shown on tag. DO NOT RUN IN THE WRONG DIRECTION.
7. If the pressure gauges indicate pressures less than specified, a precautionary visual inspection
should be made to ensure an adequate flow of oil to gears and bearings. Whenever oil pressures
register below 10 PSI (0.7 bar), shut down and determine from the factory if this condition
provides satisfactory lubrication.
8. Prime motor starting equipment should be arranged to start the unit slowly to avoid severe impact
loads. Across the line starting of motors should be avoided if possible, to prevent instantaneous
gear loads that may be in excess of rating.
9. As the unit is brought up to normal operating speed, it should be checked constantly for unusual
sounds, excessive vibration (see vibration plots below), excessive heat or oil leakage. If any of
these develop, the unit should be shut down immediately and the cause determined and corrected.
The external operating temperature of a standard High Speed Drive at the hottest point normally
should not exceed 180° F (82°C). (Special designs may operate at higher temperatures, consult
factory.)

Page 16/35
Figure 6.2.1 Displacement Limits
Figure 6.2.2 Velocity Limits

Page 17/35
Figure 6.2.3 Acceleration Limits
Note: Vibration plots are taken from AGMA 6000-B96
7. Preventive Maintenance
7.1 Keep Lubrication System Clean
The preventive maintenance instructions are presented as scheduled procedures and provide the
information necessary for prolonging the life of the gear unit and for the prevention and detection of gear
train failures before actual failure takes place. The majority of gear train failures can be attributed to
improper lubrication, misapplication and misalignment.
Improper lubrication is a prime cause of gear failures. Too frequently, unit operation is initiated without a
lubricant present. Conversely, the unit can be overfilled with a larger volume of oil than is specified in the
mistaken belief that better lubrication is obtained. A higher volume of oil usually results in more of the
input power going into churning of the oil, creating excessive temperatures with detrimental results to
gearing and bearings. Insufficient lubrication oil flow also creates excessive operating temperatures,
insufficient lubrication and cooling and premature damage to gearing and bearings.
Gear failure due to overload is a broad and varied area of misapplication of the gear train. The nature of
the load (input torque, output torque, duration of operating cycle, shocks, speed, acceleration, braking,
frequent starts and stops, etc.) determines the gear unit size and other design criteria. If there is any
question that the actual service conditions may be more severe than originally anticipated, consult
Philadelphia Gear before start-up. Often there are remedies that can be suggested before the gear train is
damaged by overload, but none are effective after severe damage is incurred.

Page 18/35
The prime mover should be analyzed while driving the gear train under fully loaded conditions to
determine that the prime mover is not overloaded and thus putting out more than rated torque. If it is
determined that overload does exist, the unit should be stopped and steps taken to either remove the
overload or contact the Philadelphia Gear to determine suitability of the gear train under observed
conditions. Lubrication systems are subject to contamination from several sources, and deposits may
accumulate even though the circulating oil is clean. The systems should, therefore, be inspected regularly
and cleaned when necessary. The frequency of such inspections depends on type of operation (whether
continuous for long periods or intermittent for short periods), frequency of starts, and whether the
lubricant used in gear unit is from a central source which is supplying the same lubricant to other
equipment (such as a turbine compressor).
Oil samples should be taken as previously discussed. Sample of deposits also should be examined. By this
means, the onset of deterioration, contamination and other troubles can be detected and corrective action
taken. Among the laboratory tests of greatest significance are those for viscosity, neutralization number,
and insolubles.
Unusual environmental or load conditions sometimes necessitate changing more frequently than specified
under "Oil Changes" - as determined by field inspection and analysis of the oil. Special attention must be
given to the inspection and analyses of lubricants when the following conditions exist.
1. High operating temperatures resulting from heavy intermittent loads, causing the temperature of
the gear case to rise rapidly and then cool.
2. Ambient temperature conditions which might tend to cause sweating on the inside walls of the
unit, thus contaminating oil and forming sludge.
3. Operating sump oil temperatures that remain constantly above 160° F (71°C).
4. When the unit is exposed to unusually moist atmosphere or corrosive vapors. Precautions should
be taken to prevent any foreign matter from entering the gear case.
Dust, dirt, moisture and chemical fumes form sludge, which is the biggest enemy of proper and adequate
lubrication. The Philadelphia Gear Corporation should be advised before manufacture of gear unit when
unusual environmental conditions are anticipated.
7.2 Maintain Records

Where protective instrumentation such as: temperature and/or vibration indicating devices are used in the
field records should be maintained. Records should include temperatures of oil to and from the oil cooler,
bearings and housing temperatures and supply pressure. If vibrations are recorded, speed, load and
temperature at the same time must be kept. Any sudden changes should be investigated immediately. In
connection with coolers, gradual changes may indicate the formation of deposits on the cooling surfaces.
If vibration detection devices are used, it is recommended that an accurate record be kept as a possible
guide to required maintenance. If available use analyzer to determine the predominant frequencies of
vibration. Records should be kept of gear unit operating hours; oil condition and service life; frequency
and amount of oil make-up, and whether new or strained oil was used. Records of filter changes, repairs
and replacements also should be kept.
7.3 Scheduled Maintenance

During initial start-up, clean oil filter daily or as often as required during the first week of operation (every
few hours may be necessary during the first day of operation).
Note: After the first 50 hours of operation, all external housing and hold-down bolts should be
torqued to make certain they have not loosened. Check all piping connections and tighten if
necessary.

Page 19/35
It is a good practice to re-check the alignment, as discussed, of all connected machinery after initially
operating for two to three weeks under load.
7.3.1 Daily
The gear drive must be routinely inspected for unusual sounds or visible oil leaks. If either occurs, the
gear drive must be stopped immediately, and the cause determined and corrected. If the gear drive is
equipped with force feed lubrication, the oil pressure must be checked. If any change from previous
reading is noted, the cause must be immediately determined and rectified.
Note: After the first 50 hours of operation, all external housing and hold-down bolts should be
torqued to make certain they have not loosened. Check all piping connections and tighten if
necessary.
7.3.2 Weekly
Check oil level. Add oil if necessary. Record data from the indicating devices. Inspect the filter(s) for
contamination and possible flow obstruction.
7.3.3 Monthly
After the initial break-in period, clean filter elements on a monthly basis. Review the recorded data for
trends that may indicate wear. Check foundation bolts for tightness.
7.3.4 Two Month Intervals

Visually check oil for contamination and clean out oil filter. Check operation of all gauges, alarm system
controls, etc. Also, it is recommended that in those systems using an auxiliary oil pump, the operation of
the auxiliary pump should be checked for proper cut-in, operation and pressure.
7.3.5 Six Month or 2500 Hour Intervals

1. For units using straight mineral oil, chemically analyze oil to determine usefulness. If oil is
satisfactory, it is recommended that the oil be drained from system, centrifuged and re-used.
Before replacing oil, the system should be thoroughly flushed. If oil is not satisfactory, drain oil
from system, flush system thoroughly and refill with new lubricant.
2. For units using synthetic turbine oil, a chemical analysis of the oil should be made at six month
or 2500 hour intervals (whichever comes first) only after the lubricant has successfully passed the
first one year or 5000 hour test and has been used continuously. If oil is satisfactory, continue its
use for another six months or 2500 hours. If oil is not satisfactory, drain and refill as specified
under "Oil Changes for Unit Using Synthetic Turbine Oil".
3. Check condition of cooler tubes for build-up of sediment and other deposits from cooling water.
Clean these members if necessary. Check for erosion of the tubes.
4. If chemical analysis is not performed as noted in 1 and 2 above, the lubricant must be changed in
5. Check coupling alignment and wear.

6. Check condition of the gear tooth contact and bearings.
Always refill gear drive with the same type of oil that was in it. Mixing different oils is not
permissible.
If any oil leaks out, clean immediatley with an oil binding agent

Page 20/35
7.3.6 One Year or 5000 Hour Intervals

Only in units using synthetic turbine oil, a chemical analysis of the oil should be made after the first year
or 5000 hours of operation (whichever occurs first) with a new fill of lubricant. If the oil is satisfactory
after this first year or 5000 hours and is retained in the system subsequent checks should be made at six-
month or 2500 hour intervals. If oil is unsatisfactory drain and refill as outlined in "Oil Changes for Units
Using Synthetic Turbine Oil".
7.3.7 Extended Shutdown Periods

If it becomes necessary to shutdown equipment for a period longer than one week, the gear unit should be
run for at least ten minutes during each week that it is idle. Precautions must be taken to prevent rusting
due to condensation and to prevent moisture from entering the gear unit.
7.4 Troubleshooting
See section on Lubrication Instructions for requirements.
7.5 Heat Exchangers

Gear drives supplied with water cooled heat exchangers should be piped to the cooling water lines where
the correct flow of can be monitored. Control devices should be wired and checked for correct operation.
Inspect the pipes periodically for sediment build-up and clean if necessary. Under extreme ambient
temperature conditions and/or in order to conserve water, the use of a water control valve should be
considered
7.5 Troubleshooting
Your Philadelphia Gear drive will perform satisfactorily if the suggestions described in this booklet are
carefully followed. It is estimated that approximately 98 percent of gear reduction failures can be
attributed to improper lubrication, misapplication, and misalignment.
Improper lubrication causes a high percentage of gear reduction unit failures. Too frequently speed
reducers are started up without any lubricant at all. Conversely, units are sometimes filled to a higher oil
level than specified in the mistaken belief that better lubrication is obtained. This higher oil level usually
results in more of the input power going into churning of the oil, creating excessive temperatures with
detrimental results to the bearings and gearing. Insufficient lubrication causes the same results.
Gear failure due to overload is a broad and varied area of misapplication. The nature of load (input torque,
output torque, duration of operating cycle, shocks, speed, acceleration, etc.) determines the gear unit
sizing and other design criteria. Frequently, a gear drive must be larger than the torque output capability of
the prime mover would indicate. An AGMA service factor compensates for varying severity of application
conditions by providing a higher nominal horsepower that in effect increases the size of the gear unit. If
originally anticipated it is recommended that this information be communicated to the gear manufacturer
before start-up. Often there are remedies that can be suggested before a gear unit is damaged by over-load,
but none are effective after severe damage.
Motors and other prime movers should be analyzed while driving the gear unit under fully loaded
conditions to determine that the prime mover is not overloaded and thus putting out more than rated
torque. If it is determined that overload does exist, the unit should be stopped and steps taken to either
remove the overload or contact the Philadelphia Gear to determine suitability of the gear drive under
observed conditions.

Page 21/35
Troubleshooting Chart
The troubleshooting chart lists possible problems, probable causes and corrective actions for the gear drive.
OVERHEATING
WHAT TO INSPECT ACTION
1. Unit overloaded 1. Reduce the loading or replace with drive of sufficient
capacity.
2. Oil cooler operation 2. Check coolant and oil flow. Vent system of air. Oil
temperatures into unit should be approximately 120 F.
Check cooler internally for build up of deposits from
coolant water.
3. Has recommended oil level been 3. Check oil level indicator to see that housing is accurately
exceeded, or is level too low? filled with lubricant to the specified level, and there is proper
drainage away from gears. Check for polish marks on babbitt.
4. Are bearings properly assembled? 4. Bearings must not be pinched. Bearings must be set at proper
bearing clearance. All shafts should spin freely when
disconnected from load.
5. Oil seals 5. Check for oil seal labyrinth rubbing, realign cap.
6. Breather 6. Breather should be open and clean. Clean breather
regularly in a solvent.
7. Grade of oil 7. Oil must be of grade specified in lubricant instructions.
If it is not, clean unit and refill with correct grade.
8. Condition of oil 8. Check to see if oil is oxidized, dirty, or of high sludge
content, change oil and clean filter.
9. Force feed lubrication system 9. Make sure oil pump is functioning. Check that oil
passages are clear and permit free flow of lubricant.
Inspect oil line pressure regulators, nozzles, orifices
and filters to be sure they are free of obstructions. Make sure
pump suction is not sucking air.
10. Coupling alignment 10. Disconnect couplings and check alignment. Realign as
required.
11. Coupling lateral float or torque 11. Adjust spacing between connected equipment, etc., to
lockup eliminate end pressure on shafts. Replace coupling with type
allowing sufficient lateral float.
12. Speed of unit excessive? 12. Reduce speed to design levels or replace with drive
suitable for speed.
SHAFT FAILURE
1. Type of coupling used 1. Does the coupling provide required flexibility, lateral
float, etc. (consult factory).
2. Coupling alignment 2. Realign equipment as required.
3. Is unbalance excessive? 3. Reduce coupling unbalance, Note: changing couplings in the
field requires rebalancing the rotor.
4. Is unit overloaded? 4. Reduce the loading or replace with drive of sufficient
capacity.
5. Is unit subjected to high-energy loads or 5. Apply couplings capable of absorbing shocks and if
extreme repetitive shocks? necessary, replace with drive of sufficient capacity to
withstand shock loads.

Page 22/35
6. Torsional or lateral critical speeds 6. The resulting vibrational stresses occur at particular speeds.
Reduce or increase operating speed away from critical speeds.
If necessary, adjust coupling weight and stiffness or change
system to relocate criticals.
BEARING FAILURE
capacity. Abnormal loading results in flaking, cracks,
fractures and wiping.
3. Speed of bearing excessive? 3. Reduce speed to design levels or replace with drive
suitable for speed.
4. Coupling alignment 4. Disconnect couplings and check alignment. Realign as
required.
5. Coupling lateral float or torque 5. Adjust spacing between connected equipment, etc., to
lockup. eliminate end pressure on shafts. Replace coupling with type
6. Are bearings properly adjusted? 6. Bearings must not be pinched. Bearings must be set at proper
disconnected from load. If bearing has excess clearance or
not square with axis - erratic wear or failure will result.
7. Are bearings properly lubricated? 7a. Check coolant and oil flow. Vent system of air. Oil
temperatures into unit should be approximately 120°F.
Check cooler internally for build up of deposits from
coolant water.
b. Check oil level indicator to see that housing is accurately
filled with lubricant to the specified level, and there is proper
c. Oil must be of grade specified in lubricant instructions. If it is
not, clean unit and refill with correct grade.
d. Check to see if oil is oxidized, dirty, or of high sludge
e. Make sure oil pump is functioning. Check that oil passages are
clear and permit free flow of lubricant. Inspect oil line
pressure regulators, nozzles, orifices and filters to be sure they
are free of obstructions. Make
sure pump suction is not sucking air.
Improper lubrication causes excessive wear and

discoloration of bearing.
8. Is bearing exposed to abrasive 8. Abrasive substance will cause excessive wear, evidenced
substance? by scratching of babbitt. Make necessary provision to
prevent entrance of abrasive substance. Clean and flush
drive thoroughly and add new oil.

Page 23/35
OIL LEAKAGE
1. Has recommended oil level been 1. Check through level indicator that oil level is accurately at
exceeded? level indicated on housing.
2. Is breather open? 2. Breather should be open and clean.
3. Are all oil drains open? 3. Check that all oil drain locations are clean and permit free
flow. Drains are normally drilled in the housing between
bearings and bearing cap where shafts extend through caps.
4. Oil seals 4. Check oil seal grooves, clean and/or rework if worn.
Check condition of shaft under seal and polish if
necessary. Slight leakage may require an air purge.
5. Force feed lubrication to bearing 5. Check flow of lubricant to bearing orifices. Refer to
excessive? factory for recommended actions.
6. Plugs at drains, levels, etc., and 6. Apply Loctite pipe joint sealant or equal, and tighten
standard pipe fittings. fittings.
7. Compressive type pipe fittings 7. Tighten fitting or disassemble and check that collar is
properly gripping tube.
8. Housing and caps 8. Tighten cap screws or bolts. If not entirely effective, remove
housing cover and caps. Clean mating surfaces and apply new
sealing compound. Reassemble. Check compressive joints by
tightening fasteners firmly.
GEAR WEAR
1. Gear tooth wear and failure 1. Contact PGC Service Department
2. Backlash 2. Contact PGC Service Department
3. Misalignment of gears 3. Check contact pattern to be over approximately 75% of face,
preferably in center area. Check condition of bearings.
4. Housing twisted or distorted? 4. Check shimming or stiffness of foundation.

capacity.
maintained? filled with lubricant to the specified level, and there is proper
7. Are bearings properly seated? 7. Bearings must not be pinched. Bearings must be set at proper
8. Grade of oil 8. Oil must be of grade specified in lubricant instructions. If it is
not, clean unit and refill with correct grade.
10. Force feed lubrication 10. Make sure oil pump is functioning. Check that oil passages are
clear and permit free flow of lubricant. Inspect oil line
are free of obstructions. Make
sure pump suction is not sucking air.

Page 24/35
GEAR WEAR
11. Coupling alignment. 11. Disconnect couplings and check alignment. Realign as
required.
12. Coupling lateral float. 12. Adjust spacing between connected equipment, etc., to
eliminate end pressure on shafts. Replace coupling with type
13. Excessive speeds. 13. Reduce speed to design levels or replace with drive
suitable for speed.
14. Torsional or lateral vibration 14. The resulting vibrational stresses occur at particular speeds.
condition. Reduce or increase operating speed away from critical speeds.
If necessary, adjust coupling weight and stiffness or change
system to relocate criticals.
15. Rust formation due to entrance of 15. Prevent moisture inside unit. Use lubricant with good rust
water or humidity inhibiting properties. Turn over gears frequently during
storage. Prolonged storage in moist, changing ambient
temperatures will cause destructive rusting of gears. When
rust is found, the unit must be disassembled, inspected and
damaged parts either thoroughly cleaned or replaced.
16. Gears exposed to an abrasive 16. Abrasive substance will cause excessive wear. Make
substance necessary provision to prevent entrance of abrasive
substance. Clean and flush drive thoroughly and add new
oil.
VIBRATION
Problem 1. High Speed Drive has increasing levels of vibration
1-1. Type of coupling used 1-1. Does the coupling provide required flexibility, lateral
1-2. Coupling alignment 1-2. Realign equipment as required.
1-3. Is unbalance excessive? 1-3. Reduce coupling unbalance, Note: changing couplings in
the field requires rebalancing the rotor.
1-4. Is unit overloaded? 1-4. Reduce the loading or replace with drive of sufficient
capacity.
1-5. Is unit subjected to high energy 1-5. Apply couplings capable of absorbing shocks and if
loads or extreme repetitive necessary, replace with drive of sufficient capacity to
shocks? withstand shock loads.
1-6. Torsional or lateral critical 1-6. The resulting vibrational stresses occur at particular
speeds speeds. Reduce or increase operating speed away from
critical speeds. If necessary, adjust coupling weight and
stiffness or change system to relocate criticals.
1-7. Gear tooth wear and failure 1-7. Contact PGC Service Department
1-8. Backlash 1-8. Contact PGC Service Department
1-9. Misalignment of gears 1-9. Check contact pattern to be over approximately 75% of
face, preferably in center area. Check condition of
bearings.
1-10. Housing twisted or distorted? 1-10. Check shimming or stiffness of foundation.
capacity.

Page 25/35
VIBRATION
1-12. Has recommended oil level been 1-12. Check oil level indicator to see that housing is accurately
maintained? filled with lubricant to the specified level, and there is proper
1-13. Are bearings properly oriented? 1-13. Check if bearing dams are oriented correctly for
direction of rotation.
1-14. Grade of oil 1-14. Oil must be of grade specified in lubricant
instructions. If it is not, clean unit and refill with correct grade.
1-15. Coupling lateral float. 1-15. Adjust spacing between connected equipment, etc., to
1-16. Excessive speeds. 1-16. Reduce speed to design levels or replace with drive
suitable for speed.
1-17. Torsional or lateral vibration condition. 1-17. The resulting vibrational stresses occur at particular
speeds. Reduce or increase operating speed away from critical
speeds. If necessary, adjust coupling weight and stiffness or
change system to relocate criticals.
1-18. Gears exposed to an abrasive substance 1-18. Abrasive substance will cause excessive wear. Make
necessary provision to prevent entrance of abrasive substance.
Clean and flush drive thoroughly and add new oil.
1-19. Are bearings properly lubricated? 1-19a. Check coolant and oil flow. Vent system of air. Oil
temperatures into unit should be approximately
120°F. Check cooler internally for build up of deposits from

coolant water.
b. Check oil level indicator to see that housing is accurately
c. Oil must be of grade specified in lubricant

Page 26/35
d. Check to see if oil is oxidized, dirty, or of high sludge

e. Make sure oil pump is functioning. Check that oil passages

are clear and permit free flow of lubricant. Inspect oil line
are free of obstructions. Make sure pump suction is not
sucking air.
f. Improper lubrication causes excessive wear and

discoloration of bearing.
1-20. Is bearing exposed to abrasive substance? 1-20. Abrasive substance will cause excessive wear, evidenced
by scratching of babbitt. Make necessary provision to prevent
entrance of abrasive substance. Clean and flush drive
thoroughly and add new oil.
1-21. Distortion of structural supports and 1-21. Recheck mounting and installation. Contact PGC Service
foundation. Department
Problem 2. Vibration frequency at 0.42 to 0.48 shaft speed.
2-1. Vibration frequency at 0.42 to .48 shaft speed 2-1. At light load, cause may be bearing wear, increase load
and/or lower oil temperature. Check if bearings are in
backwards.
Problem 3. Frequency at shaft rotation speed(s).

3-1. Frequency at shaft rotation speed(s). 3-1. Check dynamic balance of coupling.

3-3. Is unbalance excessive? 3-3. Reduce coupling unbalance, Note: changing couplings in
the field requires rebalancing the rotor.
3-4. Torsional or lateral critical speeds 3-4. The resulting vibrational stresses occur at particular
3-5. Check for case and foundation distortions. 3-5. Contact Philadelphia Gear Service Department
3-6. Check auxiliary equipment, piping and 3-6. Repair or replace as necessary.
supports.
Problem 4. Frequency at twice (2X) shaft rotational speed

Page 27/35

4-3. Check coupling wear. 4-3. Replace couplings

4-4. Check for piping and structural support 4-4. Contact PGC Service Department
Problem 5. Frequencies at higher multiples of shaft speed(s).

5-1. Check bearing condition. 5-1. Readjust or replace bearings
Problem 6. Mesh frequency (shaft speed times number of teeth) and multiples.
6-1. Gear tooth wear and failure 6-1. Contact PGC Service Department
6-2. Backlash 6-2. Contact PGC Service Department
6-3. Misalignment of gears 6-3. Check contact pattern to be over approximately 75% of
face, preferably in center area. Check condition of bearings.
6-4. Housing twisted or distorted? 6-4. Check shimming or stiffness of foundation.

capacity.
6-6. Has recommended oil level been maintained? 6-6. Check oil level indicator to see that housing is accurately
6-7. Are bearings properly seated? 6-7. Bearings must not be pinched. Bearings must be set at
proper bearing clearance. All shafts should spin freely when
6-8. Grade of oil 6-8. Oil must be of grade specified in lubricant
6-9. Condition of oil 6-9. Check to see if oil is oxidized, dirty, or of high sludge
6-10. Force feed lubrication 6-10. Make sure oil pump is functioning. Check that oil
passages are clear and permit free flow of lubricant. Inspect oil
line pressure regulators, nozzles, orifices and filters to be sure
they are free of obstructions. Make sure pump suction is not
sucking air.
6-11. Coupling alignment. 6-11. Disconnect couplings and check alignment. Realign as
required.

Page 28/35
6-12. Coupling lateral float. 6-12. Adjust spacing between connected equipment, etc., to
6-13. Excessive speeds. 6-13. Reduce speed to design levels or replace with drive
suitable for speed.
6-14. Torsional or lateral vibration condition. 6-14. The resulting vibrational stresses occur at particular
6-15. Rust formation due to entrance of water or 6-15. Prevent moisture inside unit. Use lubricant with good
humidity rust inhibiting properties. Turn over gears frequently during
temperatures will cause destructive rusting of gears. When rust
is found, the unit must be disassembled, inspected and
6-16. Gears exposed to an abrasive substance 6-16. Abrasive substance will cause excessive wear. Make
necessary provision to prevent entrance of abrasive substance.
Clean and flush drive thoroughly and add new oil.
Problem 7. Odd frequencies not related to rotational speeds.

7-1. Check condition of accessories and auxiliary 7-1. Contact PGC Service Department
equipment
NOISE
1. Gear tooth wear and failure 1. Contact PGC Service Department
2. Backlash 2. Contact PGC Service Department
3. Misalignment of gears 3. Check contact pattern to be over approximately 75% of face,
preferably in center area. Check condition of bearings.
4. Housing twisted or distorted? 4. Check shimming or stiffness of foundation.

capacity.
maintained? filled with lubricant to the specified level, and there is
proper drainage away from gears. Check for polish marks
on babbitt.
7. Are bearings properly seated? 7. Bearings must not be pinched. Bearings must be set at proper
8. Grade of oil 8. Oil must be of grade specified in lubricant instructions.
If it is not, clean unit and refill with correct grade.

Page 29/35
10. Force feed lubrication 10. Make sure oil pump is functioning. Check that oil passages
are clear and permit free flow of lubricant. Inspect oil line
pressure regulators, nozzles, orifices and filters to be
sure they are free of obstructions. Make sure pump suction is
not sucking air.
11. Coupling alignment. 11. Disconnect couplings and check alignment. Realign as
required.
12. Coupling lateral float. 12. Adjust spacing between connected equipment, etc., to
13. Excessive speeds. 13. Reduce speed to design levels or replace with drive
suitable for speed.
NOISE
14. Torsional or lateral vibration 14. The resulting vibrational stresses occur at particular
condition. speeds. Reduce or increase operating speed away from
15. Rust formation due to entrance of 15. Prevent moisture inside unit. Use lubricant with good rust
water or humidity inhibiting properties. Turn over gears frequently during
temperatures will cause destructive rusting of gears. When
rust is found, the unit must be disassembled, inspected and
16. Gears exposed to an abrasive 16. Abrasive substance will cause excessive wear. Make
substance necessary provision to prevent entrance of abrasive
substance. Clean and flush drive thoroughly and add new
oil.
17. Type of coupling used 17. Does the coupling provide required flexibility, lateral
18. Coupling alignment 18. Realign equipment as required.
capacity.
21. Is unit subjected to high energy loads or 21. Apply couplings capable of absorbing shocks and if
extreme repetitive shocks? necessary, replace with drive of sufficient capacity to
withstand shock loads.
22. Torsional or lateral critical speeds 22. The resulting vibrational stresses occur at particular
speeds. Reduce or increase operating speed away from
23. Perform Troubleshooting for

Vibration

Page 30/35
8. Disassembly Procedures
Do not work on this gear drive or couplings until absolutely certain that the prime mover
cannot be remotely or automatically started.
8.1 Tips for Disassembly
Make sure to wear protective gloves when removing drain pipe plug. Oil may be hot.
Note: After oil is drained from unit be sure to dispose of used oil in accordance with federal, state
and local regulations as they apply.
The unit should not be disassembled during the warranty period, unless the factory is consulted. Never
perform any work on the gear unit or couplings until absolutely certain that the prime mover cannot be
remotely or automatically started. Clean up area around unit before disassembly to keep parts clean and to
keep them in proper order for reassembly. Keep in mind that parts usually go back together in reverse
order of disassembly, and also note any match marks which might similarly affect reassembly. Provide
wooden blocks or skids for storing machined parts in order to prevent damage
to machined surfaces.
Before starting disassembly, carefully review typical parts list or assembly drawing of unit.
Disconnect unit completely from driving and driven machinery to avoid any possibility of accidental
rotation.
Drain oil from housing (if housing is used as the sump) by removing pipe lug at main drain.
Disconnect any lubrication piping that crosses housing split. When removing caps and thrust bearing
cartridges, be careful to avoid damaging O-rings, shims, and instrumentation wires.
To disassemble Philadelphia High Speed Gear Drives, proceed as follows:
1. Unbolt thru caps and either completely remove or slide caps back at least ½ inch away from
housing.
2. Unbolt and remove blind caps. If unit has a shaft driven pump, unbolt and remove pump cap-
pump will come away with cap.
Note: If an embedded temperature device was supplied care must be taken not to damage wires
during disassembly)
3. Unbolt and remove all capscrews holding upper housing to lower housing. Lift upper housing
straight up and off. Exercise care in removing, since top half of some radial bearings may come
away with upper housing, fall and be damaged. Remove these top halves before extensive
movement of upper housing.
4. Shaft assemblies are now exposed and can be lifted out of housing, if necessary. (Do not remove
shrink-fit low speed gear from low speed shaft).
5. If required slide sleeve bearings off shaft(s).
9. Assembly Procedures
Assembly should only be done by qualified personnel experienced with this type of
machinery. Before starting work they should review the service manual and familiarize
themselves with the assembly, parts list, and dimension drawings. All safety precautions
must be observed. Personal injury or equipment damage could result if these precautions
are not observed.

Page 31/35
9.1 Tips for Assembly

Assembly of the gear unit is accomplished by essentially reversing the order of disassembly beginning
with the last disassembly step performed. During assembly, the following recommendations and
instructions should be adhered to:
1. Clean all parts thoroughly before assembly. Examine all parts carefully for defects or signs of
wear and replace if necessary. Observe any match marks on gear teeth bearings or other parts.
2. Make sure all bearings are properly oriented and replaced in original positions.
3. Replace all damaged hardware. Any screws or
other securing methods, must be replaced in the same manner.
4. Any reassembly of the gear unit requires a check of the lateral endplay of the shafts. See
layout/parts list for lateral clearance.
5. It is recommended that new O-rings be installed as required during reassembly.
6. Clean housing split surfaces and cartridges split surfaces thoroughly and coat with liquid sealing
compound (Permatex No. 2 non-hardening type or an equivalent is recommended). Before
installing and fastening upper housing to lower housing, all connecting oil passages must be
correctly lined-up, as well as all dowel pin holes or bearing pin holes. After lowering upper
housing in place, seat all dowel pins before tightening bolt. When installing caps, be certain that
any oil passages are correctly lined-up with passage in housing.
7. On internally adjusted units, recheck the endplay.
8. Make all necessary lubrication piping connections.
9. Perform Initial Start-Up Procedure.
9.2 Bolting
For all gear box hardware (housing studs, housing split line bolts, caps, etc), use the torque values specified
in the table below. All values are for
Fastener Size ft*lbs N*m

1/2-13 57 77
5/8-11 110 149
3/4-10 200 271
7/8-9 320 434
1-8 480 651
1-1/4-7 840 1139
1-1/2-6 1500 2034
1-3/4-5 1700 2305
2-4.5 2600 3525
2-1/4-4.5 3800 5152
2-1/2-4 5200 7050
2-3/4-4 7000 9491
3-4 9200 12473
Table 9.2.1

Page 32/35
10. Renewal Parts

The parts lists and assembly drawings shown are representative of the majority of Philadelphia High
Speed Gear Drives. However, there are instances when operating conditions or design considerations
may require an alternate configuration for certain assemblies. if your unit differs in construction
from that shown, contact the factory for additional information. When ordering spare parts for a
unit, BE SURE TO SPECIFY THE ITEM NUMBER SHOWN ON APPLICABLE ASSEMBLY
DRAWING, IN ADDITION TO UNIT SERIAL NUMBER. UNIT SIZE AND TYPE, AND ORDER
NUMBER.
Generic High Speed Gear Drive Layout & Parts List
10.1 Note on Renewal Parts

Replacement parts from different manufacturers can differ on many levels - from the material used, to the
surface finish, to a part's heat treat process employed. Production costs can be minimized on any of these
operations leading to an inferior product that may be more trouble than it was worth to install. Only by
using Philadelphia Gear replacement parts can you guarantee that your new parts will provide the same
quality afforded by the originals. Please note that Philadelphia Gear is the exclusive provider of Delaval,
Western Gear and WesTech and certain General Electric renewal parts.
Purchasing Philadelphia Gear renewal parts for your Philadelphia Gear equipment ensures that all parts
are built to correct specifications, including any improvements that may have been incorporated into the
drive design. Plus, should you need to use Philadelphia Gear replacement parts, all existing guarantees and
warrantees on the original equipment are applicable, along with technical support (if needed) from our
world-class engineering and field service staff.
Philadelphia Gear offers a number of programs to meet your replacement parts needs. Such programs are
generally organized into the following categories:
Commissioning Spares: Oil filter elements

Operational Spares: Set of bearings with instrumentation (if supplied), labby caps, adjusting shims, and
gasket set
Capital Spares: Set of rotating elements

Page 33/35
The best way to determine your replacement parts needs is by talking to a Philadelphia Gear
representative. That can be accomplished by calling the regional service center in your area or by calling
our corporate headquarters with the contact information given in section 11. You can also submit a parts
quote request online at http://www.philagear.com/.
Spare parts not supplied by Philadelphia Gear are not tested or approved by Philadelphia
Gear. Philadelphia Gear will not be responsible for any damage caused to, or by the gear
drive if the unit is fitted with parts not approved by or manufactured by Philadelphia Gear.

Page 34/35
Philadelphia Gear Part # 35000-0656
SS Breather Caps
Vortox Air Technology, Inc. Breather Caps are
designed to be used in both negative and
positive pressure atmospheres. In a negative
pressure, the initial media filters out
contamination in the air stream that could
harm internal components. When used in a
positive pressure application, oil and dirt are
captured in the filter media contained within
the internal reservoir. As air flow stops, the oil
will flow back to its source from the reservoir.
The outer media serves as a secondary filter
prior to the air re-entering the atmosphere oil
free.
Filter Media
Standard Filter Media is a stainless steel wire
mesh. T316L stainless steel wire mesh can
also be provided upon request. Alternate
media of a non-toxic, washable cellular foam
is also available.
Service Instructions
Periodically inspect for accumulation of dirt.
Remove Breather Cap, wash in common
detergent and rinse. Allow media to dry, then
reinstall Breather Cap.
Breather Cap - SS Series: Stainless Steel

A B C D Net Wt.
Model No. Media
(In.) NPTM (In.) (In.) (In.) LBS
SS-DB75 ¾ 2.25 1.75 0.75 0.41 3
SS-DB75A* ¾ 2.25 1.75 0.75 0.60 4
SS-DB100 1 3.25 2.38 1.00 0.80 3
Type DB ** SS-DB150B 1½ 3.25 2.38 1.00 0.90 3
External Pipe Thread SS-DB200 2 5.06 3.06 1.00 2.00 3
SS-DB200A* 2 5.06 3.06 1.00 2.50 4
SS-DB300* 3 7.01 6.56 1.75 5.00 4
SS-DC125 1¼ 3.25 2.38 1.12 1.00 3
* Made of T316 S/S
MEDIA
1. Foam
2. Woven Steel Wire
3. T304 Stainless Steel Wire
Type DC 4. T316L Stainless Steel Wire
Internal Pipe Thread
www.vortox.com F-3008B
11-27-17
121 S. Indian Hill Boulevard, Claremont, CA 91711 • PH: (909)621-3843 • FX: (909)624-7212 • E-mail: vortox@vortox.com
11. PG Locations
Corporate Office and Technical Center
901 East 8th Avenue
King of Prussia, PA 19406
Houston High Speed OEM Manufacturing Facility
5610 Brystone Drive
Houston, TX 77041
Northeast Service Center
100 Anchor Mill Road
New Castle, DE 19720
Southeast Service Center
1242 24th Avenue
Hueytown, AL 35023
Midwest Service Center
8529 West 192nd Street
Mokena, IL 60448
Gulf Coast Service Center
10830 Train Court
Houston, TX 77041
Western Service Center
12935 Imperial Highway
Santa Fe Springs, CA 90670
Standard Machine/Timken Gears and Services Canada
868 60th St E.
Saskatoon, SK, Canada

Page 35/35

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What are the main components of a high speed gear unit?

What are the main components of a high speed gear unit?

What are the recommended procedures for installing a high speed gear unit?

What are the recommended procedures for installing a high speed gear unit?

High Speed Gear Drive

Installation, Operating, and

TABLE OF CONTENTS 6.1 Preliminary Checks 15

1. GENERAL NOTES 3 7. PREVENTIVE MAINTENANCE 18

1.1 General Description of Machinery 3 7.1 Keep Lubrication System Clean 18

2.1 Document Safety Symbols 6 8. DISASSEMBLY PROCEDURES 31

HSM-2014 September 2014

1.1 General Description of Machinery

Main Office & Technical Center

Houston High Speed OEM Manufacturing Facility

Gear Drive Size and Type

HSM-2014 September 2014

1.2 General Design Features

1.2.2 Double Helical Gearing Arrangement

1.2.3 Oil Seals

1.2.4 Special Seals

1.2.6 Lubrication System

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1.3 Measuring Surface Sound Pressure Levels

1.5 Upon Delivery

HSM-2014 September 2014

This symbol will be used whenever there is a personal safety issue.

2.2 General Safety Notes/Foreseeable Misuse

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The gear unit will be shipped assembled.

HSM-2014 September 2014

3.3 Prolonged Storage

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HSM-2014 September 2014

HSM-2014 September 2014

4.4 Coupling Installation and Unit Alignment

HSM-2014 September 2014

5.1 Recommended Lubricant

ISO/AGMA OIL VISCOSITY CHART

STRAIGHT MINERAL STRAIGHT STRAIGHT

ISO VISCOSITY GRADE 32 46 68

HSM-2014 September 2014

5.2 Low Temperature Operation

5.3 Synthetic Lubricants

5.4 Oil Changes for Units Using Straight Mineral Oil

HSM-2014 September 2014

5.5 Oil Changes for Units Using Synthetic Turbine Oil

When an oil change is indicated, follow this procedure:

1. Drain all oil from equipment (including sump and filter).

5.6 Service Life Guideline Checks for Lubricants

1. Inspect gear case for deposits of sludge, etc.

HSM-2014 September 2014

6.2 Start-Up Procedure

HSM-2014 September 2014

HSM-2014 September 2014

Figure 6.2.1 Displacement Limits

Figure 6.2.2 Velocity Limits

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Figure 6.2.3 Acceleration Limits

Note: Vibration plots are taken from AGMA 6000-B96

Fastener Size ftlbs Nm