Assembly Instructions for Cone Drive Double Enveloping Worm Gearing

Single Reduction Speed Reducers, Sizes 15 - 80

1

Siz es 15 - 80
Sizes
Single Reduction Speed Reducer
Assemb
Assemblly Instructions

Cone Drive Double En

Double veloping Worm Gear Units
Enveloping

Power Transmission
2 Assembly Instructions for Cone Drive Double Enveloping Worm Gearing
Single Reduction Speed Reducers, Sizes 15 - 80

Table of Contents

Introduction 2

General Information 3

Bearing Settings 4

Preparation for Rebuild 5

Disassembly Instructions 6

Assembly Instructions 6

Contact Patterns 7

Trouble Shooting 11

Introduction
This specification covers the assembly and servicing transmission equipment. Always use
disassembly of Cone Drive standard worm gear lifting equipment with heavy lifting capability.
speed reducers and gearsets. It applies to single Standard tools used for the assembly and disas-
reduction reducers and standard or low backlash sembly of reducers may be used to perform the
gearsets. instructions in this manual. A bearing press will
This manual assumes the person performing the also be necessary to install bearings and gears.
assembly and disassembly has experience with

CALL CONE DRIVE TOLL FREE:

Sales Phone: 888-99-4 Cone
Sales Fax: 888-907-Cone
Parts & Service: 888-726-Cone
Parts Fax: 888-916-Cone
Cone Drive
Assembly Instructions for Cone Drive Double Enveloping Worm Gearing
Single Reduction Speed Reducers, Sizes 15 - 80
3

Cone Drive Parts & Service Options

Field Service Remanufacturing Center
Experienced Cone Drive personnel are avail- Cone Drive's Remanufacturing Center at our
able to make sure that your Cone Drive reducer Traverse City manufacturing facility is capable
is ready to give you the reliable duty for which it of any level of rebuild. For information, please
was designed. call us toll free at 888-726-Cone, or ask for the
To arrange for service, please call us toll free at rebuild service extension.
888-726-Cone, or ask for the field service Technical Information
extension. Assembly drawings of your reducer or technical
assistance is available from Cone Drive.

Maintenance Workshops Cone Drive Training Center and Dynamometer

Test Facility. We can provide intensive training
Cone Drive's workshops are the most compre- and individual attention is provided by Cone
hensive technical educational program in the Drive engineers, technicians, and field service
worm gear industry. We offer a variety of personnel.
hands-on experience with double-enveloping Our programs focus on assembly, repair and
worm gear speed reducers and gearsets, and installation, lubrication, reducer selection and
teach valuable assembly, repair, and installation rating, bearing setting, trouble shooting, and
techniques. failure analysis.
At an advanced level, field simulation is bal-
anced with classroom instruction at the

The Controlling Dimensions Tolerances

The controlling dimensions for the proper assem- The recommended tolerance limits for the con-
bly of Cone Drive gearsets are: worm end trolling dimensions, (worm end position, gear
position, gear side position and center distance. side position, and center distance) are shown.
Since these dimensions are held during the
manufacture of gearsets, these same dimen-
center distance tolerances (+/-)
sions should be maintained within the specified
limits to properly locate the worm and gear in the up to 6" .001
housing at assembly.
Variations in housing flange face dimensions 6" to 8" .002
affect the end position of the worm and side BECKHA
BECKHA
position of the gear. We compensate for these
variations by inserting shims between the bear-
ing cap or carrier flange face and the housing
bore face. The shims are adjusted to centralize
Errors In Angularity
the worm and gear in the housing. Errors in angularity between the worm and
gearshaft, beyond permissible limits, cannot be
corrected by altering any of the locating dimen-
sions. Care should be taken that the housing
bores for the worm shaft and gear shaft are
machined square with each other within .004"
per linear foot.
4 Assembly Instructions for Cone Drive Double Enveloping Worm Gearing
Single Reduction Speed Reducers, Sizes 15 - 80

Shims and Shim Sets Each shim set includes an assortment of shims
which are color coded according to thickness as
Shims are used in Cone Drive gear units both to
shown in figure 2.
properly position the worm and gear within the
gear housing (see "Assembly Instructions"), and
to set the desired bearing end-play or pre-load color thickness color thickness
(see Recommended Tapered Roller Bearing
Settings).
Yellow .020" Blue .005"
The shims also serve as gaskets for the bearing
caps and carriers. As spare or replacement Brown .010" Green .003"
parts, the shims are packaged as "shim sets". BECKHA
BECKHA

Grease Packed Bearings Adjustment of Bearing

Bearings that are at least partially submerged in
oil or oiled by internal oil scoops do not require
Settings
special maintenance. However, bearings that Opposed mounted single row tapered roller
are not lubricated as above require grease bearings require adjustment for end play. Select
lubrication. Grease fittings and internal retainers proper worm bearing setting according to RPM
are furnished when required, see figure 6. They from figure 3.
should be greased with a high quality lithium
base NLGI #2 or NLGI #3 bearing grease at
normal maintenance intervals depending on the
duty cycle of the reducer.

Recommended Tapered Roller Bearing Settings

Single Reduction Reducer Worm Bearing Settings
Reducer Size Worm Speed Worm Speed
(center distance) (1,000 - 2,000 RPM) (2,001 - 3,600 RPM)

15 to 35 (1.500" to 3.500") .003 +/- .001 .005 +/- .001

40 to 60 (4.000" to 6.000") .004 +/- .001 .006 +/- .001

70 to 80 (7.000" to 8.000") .006 +/- .001 .007 +/- .001

BECKHA!
Notes: BECKHA!

a. Settings shown in figure 3 are axial loose- d. These bearing settings are for standard and
ness. special reducers unless otherwise specified on
b. All gear bearings up to and including 8.000" the assembly drawing.
C.D. are set to a pre-load of e. If low backlash is critical, some applications
(-).001+/-.001 for output speeds of 350 RPM or may require reduced settings. Contact Cone
less. Contact Application Engineering for gear Drive Application Engineering for review.
bearing settings for speeds in excess of 350
RPM.
c. 7.000" and 8.000" C.D. prior to 1980 have
preset worm bearings. Cone Drive
Assembly Instructions for Cone Drive Double Enveloping Worm Gearing
Single Reduction Speed Reducers, Sizes 15 - 80
5

"O" Markings "O markings will appear on all multiple threaded

worm gearsets that have been lapped and all
multiple threaded worm gearsets with low back-
lash. When "O" markings are present, care

20-200-10
should be taken during assembly to ensure that
worm the "O" marks are properly aligned. As indicated
normal input end
in figure 4, when properly aligned, the "O"
20-300-10 stamped worm thread will pass through the "O"
gear stamped space between two gear teeth.
BECKHA"
BECKHA"

Cone Drive Reducer Nameplate

Preparation for Rebuild Line #1 -Reducer Model Number
Applies to 1.5" through 8.0" Center Distance example: MSH040-2.
Single Reduction Speed Reducers. Line #2 -Serial Number
When calling for parts, please reference reducer example: 99174461-100-1.
model number and serial number. year manufactured (99)
To properly identify a Cone Drive speed reducer Cone Drive order number (174461)
we must have the reducer model number and order item number (100)
serial number. item sequence number (1)
Line #3 -Customer Part Number when required.
Line #4 -Ratio and Input Speed
Line #5 -Reducer Rating and Service Factor
Cone Drive 888-99-4-Cone Line #6 -Assembled Backlash and Lubricant No.
Model MSHO40-2
Drawings and Parts Lists
Serial 99174461-100-1
Cust. Pt. No. Assembly drawings, detail drawings, and parts
Ratio 10-1 Input RPM 2000 lists for all units are available from Cone Drive.
Rating 10.50 HP S.F. 1 An assembly drawing is required to rebuild the
Assembled Backlash
reducer. Note positions of input and output
in Arc Minutes Lube No. AGMA 8
Caution: shafts, breather and oil level plug. A photograph
Before operation Traverse City MI USA of the reducer before disassembly will be help-
read all instructions. 231-946-8410
ful.

Lubrication Oil Level

Contact Cone Drive for lubrication list. Cone Drive reducers are furnished with a bronze
colored hex head pipe plug to indicate oil level.
An oil level tag is affixed to the unit near the oil
level indicator. Oil level should always be
checked with the unit stopped. Cone Drive
CALL CONE DRIVE TOLL FREE:
reducers are all shipped without oil . However,
Sales Phone: 888-99-4 Cone
Sales Fax: 888-907-Cone
WhisperDrive units and Model RG units are
Parts & Service: 888-726-Cone shipped with oil .
Parts Fax: 888-916-Cone
6 Assembly Instructions for Cone Drive Double Enveloping Worm Gearing
Single Reduction Speed Reducers, Sizes 15 - 80

Disassembly Instructions HV-7A HU-1 SHO-1

1. Remove reducer from machine.

Caution: follow machine manufacturer's recom-
mendations, making sure to remove all load from
the reducer before removing reducer from ma-
chine.
2. Drain oil
3. Clean outside of housing This bearing will have a grease retainer
4. Position reducer on bench with gearshaft up. BECKHA#
BECKHA#
5. Remove one (1) gear carrier making sure the
shim packs stay with the carrier for determining 10. Lift worm out of housing.
the amount of new shims to use as a starting 11. Remove remaining worm and gear carriers
point when reassembling reducer. from housing making sure shims stay with carri-
6. Lift gearshaft assembly out of housing. ers.
7. Wipe off excess oil. 12. Remove bearing cups from all carriers.
8. Reposition housing so worm is pointing up. 13. Remove oil seals from open caps and
9. Remove one (1) worm bearing carrier making carriers.
sure shim pack stays with the carrier for deter- 14. Clean inside of housing and carriers.
mining the amount of new shims to use as a 15. Discard old parts, i.e. bearings, seals, and
starting point when reassembling the reducer. gearset.

Assembly Instructions There will be .024" more shims here

Worm
because of the grease retainer on this side.
Applies to 1.5" through 8.0" Center Distance carrier
Single Reduction Speed Reducers.
1. Refer to prints and parts lists for parts break- Gear carrier
down.
2. Check gearset for matched set numbers. The
worm and gear must have the same set number.
3. Determine the hand of assembly of the speed
reducer which is the relationship between the Grease Shims Shims
retainer
input and output shaft. This can be found on the
name tag as part of the model number (see
figure 5), the assembly drawing or from the
reducer to be rebuilt. Gear Grease
4. All speed reducers 3" C.D. and larger with a spacers retainer
vertical worm or gearshaft will have a grease
retainer under the upper bearing cone on the BECKHA$
BECKHA$
shaft. The grease retainer must be installed with
the rim toward the bearing cone, as shown in retainer (if required) and bearing cones onto the
figure 6. When a grease retainer is used under worm. Press the gear, gear spacers (if re-
a bearing, you must add .024" shims to the quired), grease retainer (if required), and bear-
carrier on that bearing. ing cones onto the gearshaft.
5. A 10 ton press will be required for installing
the bearings and gear for reducers as large as
3.5" C.D. and a 50 ton press for reducers as
large as 8.0" C.D. Press the bearing cups into
the worm and gear carriers. Press the grease Cone Drive
Assembly Instructions for Cone Drive Double Enveloping Worm Gearing
Single Reduction Speed Reducers, Sizes 15 - 80
7

Bearing Settings
1. The first step for checking bearing settings is to
assemble one (1) gear carrier starting with the
same number of shims as with old reducer or the Gearshaft Dial
Indicator
nomimal shim thickness caled for on the assem-
bly drawing. Install the gearshaft assembly and
bolt the remaining gear carrier and shims into the
housing. Rotate the shaft while tapping on the
end to seat the bearing rollers. Check the gear
bearing setting with an indicator as shown in
figure 7. With the dial indicator set at zero, pull
up on the shaft while watching the dial indicator.
Add or subtract shims as necessary to achieve Worm shaft
the proper bearing setting shown in figure 3. The Dial
shims should be equal under both carriers so that Indicator
the worm and gear are centered in the housing,
unless there is a grease retainer being used.

2. Remove one (1) gear carrier and the gear

shaft assembly from the housing. Note: Keep BECKHA%
track of the amount of shims needed under the
carrier.

3. The next step is to install the worm assembly

into the housing and check the bearing settings in
the same manner as the gear assembly. The
recommended bearing settings can be found in
figure 3, paying attention to reducer size and
worm speed. When finished with the bearing
settings the worm should be left in the speed
reducer.

Contact Pattern
1. Coat gear teeth and worm threads with a 4. The gearset must be positioned properly at
nondrying contact paste. Caution: On some assembly to obtain the desired contact between
multiple threaded worms, a zero marking will be the worm threads and gear teeth. If the gearset
on the worm and gear. These must be matched is properly aligned, contact will be approximately
during the assembly of the gear and the worm. as shown by the shaded portions in figures 9 or
(refer to "O" marking in figure 4). 13, depending on ratio. The correct pattern is
symmetrical with respect to the centerline of the
2. Install gearshaft assembly into the housing. worm and the gear but will vary with ratio. The
Replace gear carrier and shims. correct pattern for ratios 5:1 to 25:1 are shown in
figures 9 and 10, and for ratios 30:1 to 70:1 see
3. Rotate the worm shaft by hand until the gear figures 13 and 14.
has made one or more revolutions in each direc-
tion. Remove gear shaft assembly from the (discussion continues on page 10)
housing to observe the pattern on both the worm
and gear.
8 Assembly Instructions for Cone Drive Double Enveloping Worm Gearing
Single Reduction Speed Reducers, Sizes 15 - 80

Sample Contact Patterns for 5:1 - 25:1 Ratios

Correct contact pattern for 5:1 - 25:1 ratio Correct contact for 5:1 - 25:1 ratio
before running-in. pattern after running-in.

BECKHA'
BECKHA'
BECKHA
BECKHA

How to correct 5:1 - 25:1 ratio How to correct 5:1 - 25:1 ratio
for worm off end position. for gear off side position.

⇐
⇑

BECKHA
BECKHA BECKHA
BECKHA

Cone Drive
Assembly Instructions for Cone Drive Double Enveloping Worm Gearing
Single Reduction Speed Reducers, Sizes 15 - 80
9

Sample Contact Patterns for 30:1 - 70:1 Ratios

Correct contact pattern for 30:1 - 70:1 ratio Correct contact for 30:1 - 70:1 ratio
before running-in. pattern after running-in.

BECKHA!
BECKHA!
BECKHA"
BECKHA"

How to correct 30:1 - 70:1 ratio How to correct 30:1 - 70:1 ratio
for worm off end position. for gear off side position.

⇐
⇑

BECKHA#
BECKHA# BECKHA$
BECKHA$

CALL US TOLL FREE:

Sales Phone: 888-99-4 Cone
Sales Fax: 888-907-Cone
Parts & Service: 888-726-Cone
Parts Fax: 888-916-Cone
10 Assembly Instructions for Cone Drive Double Enveloping Worm Gearing
Single Reduction Speed Reducers, Sizes 15 - 80

Contact Pattern (continued)

shaft. Tap the oil seal into the cap or carrier and
thus onto the wear ring using a liberal amount of
5. All of the illustrations, figures 11, 12, 15, grease on the lip of the seal and the wear ring.
and 16, show a misalignment of the gear set.
Note: Be sure the outer lip of the seal is com-
6. Correct any misalignment by removing shims pletely onto the sealing surface of the wear ring.
from one bearing cap or carrier and adding an See drawing, figure 8, for position of wear ring.
equal amount to the opposite cap or carrier. See The dimension for positioning the wear ring is
figure 6. indicated on the reducer assembly drawing.

7. If contact is similar to figures 11 or 15, the 11. Fill the speed reducer to the proper oil level
worm is out of position. Move the worm in the with a recommended lubricant from the Cone
direction indicated by the arrow. If the contact Drive Approved List of Lubricants.
pattern is opposite to that shown move the worm
in the opposite direction. 12. Special applications and older style speed
reducers may use different assembly techniques.
8. If contact is similar to figures 12 or 16, the gear
is off side position. Move the gear in the direction
indicated by the arrow. If the contact pattern is
This area should
opposite to that shown, move the gear in the carrier
be 1/12" to 1/8"
opposite direction. from shoulder on
shaft.

9. Install pipe plugs, oil level indicator, all bolts,

and grease fittings if applicable. Bolt, torque
settings can be found on the print or contact
Cone Drive.

10. Install wear ring type oil seals. The wear ring
should be assembled onto the shaft by tapping
wear sleeve
against the flange. A piece of round tubing works
well as an assembly tool. Note: Tubing must
clear the sealing surface of the wear ring which
will expand up to .007" when pressed onto the BECKHA&
BECKHA&

CALL US TOLL FREE:

Sales Phone: 888-99-4 Cone
Sales Fax: 888-907-Cone
Parts & Service: 888-726-Cone
Parts Fax: 888-916-Cone
Cone Drive
Assembly Instructions for Cone Drive Double Enveloping Worm Gearing
Single Reduction Speed Reducers, Sizes 15 - 80
11

Trouble Shooting Guide

PROBLEM EFFECT CAUSE SOLUTION

Decrease Wear & scoring of Improper Replace gearset, bearings

in efficiency worm threads and lubricant and oil seals.
gear teeth Select correct lubricant from
approved lube list.
Decrease Wear & scoring of External Eliminate overload, replace
in efficiency worm threads and torque gearset, bearings and oil
gear teeth overload seals or select larger reducer.
Reducer Wear & scoring of Improper or Replace gearset, bearings
runs hot worm threads and insufficient and oil seals. Select correct
gear teeth lubricant lubricant from approved
lube list.
Reducer Wear & scoring of Input power Replace gearset, bearings
runs hot worm threads and exceeds and oil seals. Add Auxillary
gear teeth thermal rating cooling or select larger
reducer.
Reducer Gearset and/or Oil seal leaks Check condition of gearset
seizes up bearings and bearings, replace if
running hot necessary. Replace oil seals.
Reducer Bearings run hot Tight bearings Check condition of bearings,
seizes up replace if needed. Shim
bearings per bearing setting
instructions.
Reducer Bent worm External Eliminate overload, replace
seizes up or swedged torque gearset, bearings and oil
gear teeth overload seals or select larger reducer.
Loss of Broken worm External Eliminate overload, replace
ratio threads or torque gearset, bearings and oil
gear teeth overload seals or select larger reducer.
Reducer Broken reducer External Eliminate overload and
comes loose feet or foot bolts overload replace reducer, if necessary,
from mounting with same size or larger
reducer.
Knocking Bent gear tooth External Eliminate overload, replace
noise from torque gearset, bearings and oil
reducer overload seals or select larger reducer.
Squealing Damaged bearing Improper Replace bearings and oil
noise from installation or seals.
reducer inadequate lube
12 Assembly Instructions for Cone Drive Double Enveloping Worm Gearing
Single Reduction Speed Reducers, Sizes 15 - 80
''

Cone Drive WhisperDrive Series M Series G

Double Enveloping Servo Precision In Line Helical Helical parallel shaft
design in single, Gearhead in three Geared Motors and and Bevel Helical right
double, and triple precision levels. Reducers. angle drive gear units.
reduction types.

Series K
Model RG AccuDrive Series C Right angle Helical
Right Angle Zero Backlash Right angle drive Bevel Helical
Gearhead in two Gearing for positive Helical Worm Geared Geared Motors
precision levels. rotational positioning. Motors and Reducers. and Reducers.

Series Q DuoDrive Series F Series A

In Line Planetary Dual Gears on Parallel Helical shaft Worm Gear units
Geared Motors and parallel output mounted geared and geared motors
Reducers. shafts. motors and reducers. in single and double
reduction types.

Remanufacturing Series X
Center Nylicon and Cone Gear Institute
Extruder Drive Fast turnarounds on Ring Type flexible Gearing's most
Rugged duty rebuilds or preventative coupling, Gear Type comprehensive
reducer takes high maintenance, rigid and flexible technical educational
screw pressure. warranteed service. couplings. programs.

Power Transmission
240 E. 12th Street, P.O. Box 272, Traverse City MI 49685-0272 USA, 231-946-8410 -Phone, 231-933-8600 -Fax
888-99-4 Cone -Toll Free Sales, 888-726-Cone -Parts & Service
975 Dillingham Road, Pickering ON L1W 3B2 Canada, 905-420-4141 -Phone, 905-420-9513 -Fax
888-Radicon -Toll Free Sales, 800-295-37
800-295-3749 -Parts & Service Cone Drive