No discussion of troubleshooting kilns, dryers, and other rotary equipment would be

complete without the inclusion of the special problems of gears, pinions, and drive trains.
Understanding the mechanical function of these parts and the differences in their design
will help to focus on areas that may cause problems in the future, or may already be
causing problems.

The alignment and mesh of the gear and pinion, the lubrication that is used, and the other
components involved in the drive train, are all areas that should be carefully inspected on
a regular schedule.

Covered in this section are the two most common types of gear mounting arrangements,
their pros and cons, and a recommended inspection program. Characteristics, advantages
and disadvantages of different types of lubrication are discussed as well.

Gears Page 1
Most flange-mounted gears are found on kilns or on equipment such as dryers and coolers
that operate in a lower temperature range. If the temperature of the shell is below 200°F
[100°C] then a flange mounted design is a good choice.They are generally constructed in 2
to 6 sections, and the mounting flange is typically welded directly to the shell.

If gear run-out becomes excessive the mounting flange must be cut loose and remounted or
more likely a new flange must be installed. If the run-out is a result of heat damage to the
shell then careful consideration should be given to using a spring mounted arrangement
instead.

Page 2 Gears
Anatomy of a Flange Mounted Gear
It is a simple arrangement whereby the shell flange, somewhat larger than the shell, is
mounted to run true radially by using shims. Then once axial alignment is also set
correctly within tolerance, the flange and shims are welded to the shell. The application
of weld must be done carefully and correctly such that alignment is preserved.
After many years of service the time may present itself when the tooth profile is worn
and reversing the gear to take advantage of the new surface still existing on the non-
loaded side, may be a good option. Then if both sides of the gear flange were originally
machined, which is usually the case, and the flange still runs true, reversing the gear
may be relatively easy to do. Relative to having to reset or replace the shell flange as
well.

Gears Page 3
 Spring-mounted gears are the predominant type of girth gear arrangement for kilns.
There are two basic variations, the most common, the tangential spring, and the
horizontal spring bar or spring-chair. The positive aspect of these designs is that they
allow the kiln shell to expand without restriction, unlike the flange-mounted gear.

When installing a new gear or reversing an existing gear, it is always advisable to replace
the spring plates and the pins. The plates are subjected to thousands of cycles over the
years and as such there is always concern for fatigue failure. Also, since the springs are
welded to the shell, they are usually compromised to some degree during the removal
process. Trying to reuse the spring plates can greatly inhibit the ability to achieve
. acceptable gear run-outs.
The cost of field repairs to the removed plates can easily exceed the cost of new shop
manufactured plates.

Page 4 Gears
Typical spring-chair designs consist of a set of chairs that are welded to the shell and a
corresponding stack of spring plates that are bolted between the chairs and the gear
flange. On installation radial and axial adjustments are easier since the gear is largely
self supporting without the use of temporary alignment and adjustment chairs.
The design may also be such that subsequent re-alignment may be possible without
having to reposition the chairs.
Serious hot spots and the associated shell distortion would still however pull the gear out
of alignment requiring a shell change.

Gears Page 5
The most important things to check around the gear and pinion are, the tightness
of gear joints and splice bolts, the welds holding the spring plates to the shell, the
integrity of the gear flange, the tightness of the spring pins, the solidity of the drive
base and of course the gear and pinion mesh and their lubrication.
To do this, visual access is essential. A guard like the one illustrated was
designed with this in mind. Fully enclosed guards need observation ports in the
appropriate areas. If you don’t have them, add them to your to-do-list for the next
shut down.
The best place to make these kinds of observations is directly above the
engagement point of the gear and pinion. Rotation is always (except with dual
pinion drives) such that the pinion pulls at the bottom of the gear and pushes it up.
This means the gear is in tension at the bottom coming into the pinion and then
loads in compression as the pinion pushes it up. Any looseness will be seen as
this happens especially if some lubricant is present, which will “breath” in and out.

Page 6 Gears
Add life to your gears through regular inspection. Establish a check list for systematic
inspections daily, monthly and annually. The following areas are critical elements of good
gear maintenance

Mesh - Proper backlash and root clearance are critical to smooth gear operation. Too
much or too little clearance can cause problems that contribute to accelerated wear and
loss of tooth profile. Also important is the longitudinal relationship of the gear relative to the
pinion.

Contact - The contact pattern across the tooth face is a telltale sign of gear alignment. If
an axial run out condition exists, the contact pattern will vary with the rotation of the kiln.
Angular misalignment between the gear and pinion results in partial tooth contact,
concentrated loads and premature gear wear or failure.

Reducer condition - Inspect for vibration and elevated temperatures of the reducer.
These are usually signs of worn bearings or gears, or a lubricant problem.

Gears Page 7
Inspection ports - It is important to have observation ports in the gear enclosure to allow
for adequate inspection of the gear teeth. There should be ports on both sides of the
enclosure to allow inspection of the depth of the mesh on both sides of the gear, and a port
in the area above the pinion to allow inspection of the contact pattern across the teeth, just
after the gear teeth are released from the pinion.

Drive base condition - The base should be anchored firmly to prevent vibration and
movement of the drive components.

Page 8 Gears
Totally enclosed?
With a totally enclosed guard as shown, the critical areas where observations need to be
made are often inaccessible due to lack of adequate inspection ports. Be sure to add
these in your next shut down.

Condition of the surrounding area - Housekeeping can be a major factor in maintenance

and upkeep. If there is product buildup and lubricant leaking or spilled around the drive
pier, safety can become a “big” issue for the technicians who are trying to inspect and
maintain the equipment. With today’s tight environmental restrictions, spilled lubricant can
also become an environmental problem.

Gears Page 9
On a spring-mounted gear, the hole where the spring plate attaches to the gear is
called the “boss hole”. Inspect the boss holes and the pivot pins for any sign of
wear or excessive movement.
Most girth gears are a two-piece segmented style. This means that the splice bolts
will also need to be checked to make sure they remain tight.
Both areas, boss pins and splice joints should be observed as they pass across the
pinion. In this area the gear is in tension before it comes into pinion mesh and in
compression after the mesh. This change of load from tension to compression will
be visible if there is any looseness of fit in the pins or bolts in the splices. Lubricant
should be present in both areas and movement can be detected as the lubricant is
squeezed or sucked into/out of the joint.
Page 13

Page 10 Gears
Noises - Listen for any unusual noises and try to find the source. A common problem that
can cause a squealing or thumping noise is the gear rubbing against the side of the
enclosure. When the kiln shifts longitudinally and there is excessive clearance between the
side face of the thrust tire and its retaining blocks or between the thrust tire and the thrust
rollers, the kiln can move too far longitudinally allowing the gear to interfere with the
enclosure. As part of your inspection always make a note of the position of the kiln with
respect to the thrust rollers, the location of the thrust tire between its retaining blocks and
the axial position of the gear with respect to the pinion.
Condition of the Drive System- Monitor the condition of the gear reducer and the pinion
support bearings. Elevated temperature or a high frequency vibration or chatter is an
indication of a bearing problem. This could be either the pinion support bearings or one of
the bearings in the gear reducer. Analyzing the vibration frequency by using vibration
analysis equipment can help pinpoint the source.
Mounting and Splices - Visually inspect for loose or missing mounting bolts on a flange-
mounted gear. On a spring-mounted gear, the hole where the spring plate attaches to the
gear is called the “boss hole”. Inspect the boss holes and the pivot pins for any sign of
wear or excessive movement. Most girth gears are a two-piece segmented style. This
means that the splice bolts will also need to be checked to make sure they remain tight.

Gears Page 11
Welds - On spring-mounted gears, check the welds attaching the spring plates to the
shell. On flange-mounted gears inspect the welds between the shell and flange. These
are both highly stressed areas subjected to cyclical loading and therefore susceptible to
fatigue cracking. Keep welds 1” (25mm) back of the tangent point.

Page 12 Gears
A simple variation on the flange mounting arrangement is a lug mount. This is perhaps
the most economical choice although it clearly has serious limitations to power
transmission capabilities. Lug mounting is for light weight, light duty equipment only.

Also shown is am example of a simple gear adjustment “chair” used to obtain both radial
an axial alignment.

These types of chairs can be used for spring mounts as well.

Gears Page 13
Weld repair in the critical areas must be done carefully. If cracks appear in these areas
the tendency is to extend the weld. This initiates even earlier failure. Grind/gouge out
the cracks, repair the shell and keep the new weld well back of the tangent point. The
tangent point is often difficult to see. In such cases make sure the weld does not pass
beyond where the spring plate is in full contact with the shell.

Page 14 Gears
Add life to your gears through regular inspection. Establish a check list for systematic inspections daily,
monthly and annually. The following areas are critical elements of good gear maintenance
Mesh - Proper backlash and root clearance are critical to smooth gear operation. Too much or too little
clearance can cause problems that contribute to accelerated wear and loss of tooth profile. Also important is the
longitudinal relationship of the gear relative to the pinion.
Contact - The contact pattern across the tooth face is a tell-tale sign of gear alignment. If an axial run-out
condition exists, the contact pattern will vary with the rotation of the kiln. Angular misalignment between the gear
and pinion results in partial tooth contact, concentrated loads and premature gear wear or failure.
Reducer condition - Inspect for vibration and elevated temperatures of the reducer. These are usually signs of
worn bearings or gears, or a lubricant problem.
Drive base condition - The base should be anchored firmly to prevent vibration and movement of the drive
components.
Condition of the surrounding area - Housekeeping can be a major factor in maintenance and upkeep. If there
is product buildup and lubricant leaking or spilled around the drive pier, safety can become a “big” issue for the
technicians who are trying to inspect and maintain the equipment. With today’s tight environmental restrictions,
spilled lubricant can also become an environmental problem.
Inspection ports - It is important to have observation ports in the gear enclosure to allow for adequate
inspection of the gear teeth. There should be ports on both sides of the enclosure to allow inspection of the depth
of the mesh on both sides of the gear, and a port in the area above the pinion to allow inspection of the contact
pattern across the teeth, just after the gear teeth are released from the pinion.

Gears Page 15
“False bottoming” occurs when the wear on the tooth flank results in a “ridge” across
part or all of the width of the gear. The tip of the mating gear tooth can be interfering
with this “ridge” and appear to have inadequate root clearance. This condition will
cause the same vibration problem as if the teeth were pounding against the bottom
land of the gears.

Page 16 Gears
This a n extreme example of a heavily worn tooth profile showing massive loss of tooth
thickness and the creation of a heavy “false bottom”. With this much loss of tooth
thickness it becomes questionable if gear reversal would be worthwhile. It would have
been a more obvious choice before wear progressed to this degree.

Gears Page 17
Puzzle:

1. Is this kiln turning left to right or right to left?

2. Is the far end the feed end or the discharge end?

Write your reasoning here:

Page 18 Gears
TOOTH PROFILE WEAR

If a kiln runs in one position as illustrated for a long period of time, the gear teeth will
develop a step based on this position. If and when the kiln shifts back to its normal axial
position, the gear also changes its position relative to the pinion and the teeth may run up
on the step. This means the teeth are running on a greatly reduced contact area resulting
in extremely high pressures. In many cases this extreme pressure will be high enough to
cause the lubrication to squeeze out and become ineffective. This leads to high sliding
friction and aggressive wear of the tooth profile if not outright tooth breakage.

The operator may see a high surge in the drive motor amps for the period of time it takes
to wear so the load is again spread across the entire width. During this process, the
portion of the tooth experiencing the high stresses may also experience spalling and,
cracking. As a result of this aggressive wear the lubricant will be contaminated with metal
fragments and shavings, creating a high potential for increases in wear on other areas of
the teeth.

Gears Page 19
CONTACT PATTERNS DUE TO ASSEMBLY FAULTS OR OPERATIONAL
CONDITIONS.

a. Pinion is running out (wobbling). Check fixation of pinion/shaft.

b. Ring gear is wobbling. Assembling and adjustment of ring gear must be
checked.
c. Edge pressure. Pinion must be realigned axially or slope corrected.
d. Pressure spot on total circumference ring gear. Manufacturing fault or new
pinion wearing into existing wear pattern of ring gear.
e. Pinion diameter enlarged on both sides due to wrong assembling or ring
clamping devices.
f. Ring gear joints and fixation of both ring gear sections must be checked.
g. Radial run-out of ring gear. The picture of contact is stronger over one half
of the circumference. Radial readjustment is necessary
h. The ring gear has opened on both sides due to thermal expansion.
i. Ideal pattern.

Page 20 Gears
The contact pattern that you should see is long - full-length of the gear tooth - and
evenly distributed over the working depth.

Gears Page 21
VIBRATION

Check to see that the gears are running with proper root clearance or backlash. Too little clearance will cause
gear teeth to “jam” together as they mesh causing a vibration problem as the top land of the tooth “pounds” into
the bottom land. If you observe a vibration that is intermittent, check first for interference on either end of the
kiln end of the gear enclosure. If there are no signs of any rubbing, it is most likely that the shell has a bend that
is causing the gear to run out. If this is the case, the vibration will be in a direct relationship with the shell warp.
As the bent area of the shell passes across the pinion, the vibration can be felt as the gear teeth “’bottom out”.
If the vibration is constant throughout the entire rotation, the kiln is acceptably straight but the contact surfaces
of the riding rings, support rollers or filler bars have worn enough to lower the kiln to a point of interference of
the gear mesh.

Too much clearance creates excessive backlash, which under certain conditions also causes a vibration
problem. If there is a severe bend in the shell, even though it is not an area that causes gear run out, or
perhaps a large uneven buildup of product coating, an unbalanced load is created in the kiln. As the heavy side
of the kiln passes over the top center and proceeds on the downward side of rotation, the gear will try to
“overrun” the pinion. If excessive backlash exists, intermittent vibration will appear at a frequency equal to gear
tooth engagement frequency.
Careful visual inspection of the gear for these conditions can help determine the cause and then a solution to
vibration problems. Usually a stroboscope must be used for the inspection, and you will need to pay close
attention to the occurrence and duration of the vibration with respect to the gear mesh. A temporary clamp on
current probe can also be used on the drive motor to evaluate an intermittent vibration problem. Typically if the
motor current reads high during the vibration phase, the unit is straining to lift the heavy zone of the kiln which
is causing gear run out and a resultant “bottoming” condition. Conversely, if the motor current is low during the
vibration phase, the motor is “loafing” as the bend in the shell advances to the down-turning side and backlash
allows the gear to “over run” the pinion.

Page 22 Gears
ANNUALLY
During the annual inspection, since the kiln will be shut down, more thorough inspections should
Gears Page 17
be made of the gear wear patterns. Remove a portion of the gear enclosure and with solvents,
clean a 1-2 foot long area of the gear teeth. Measure the tooth thickness on both the uphill and
downhill edge and make note of the type of wear pattern. Rotate the kiln and repeat this process
in 4-6 other areas. Look for ridges” or “steps” in the tooth profile. In some cases, if they are not
too severe, these areas can be ground down with a small hand grinder. This inspection should
give you a good indication of how the pinion has been meshing with the gear and if there is
excessive run out.
Gear lubrication should be changed out taking extra care to remove all spent lubrication in the
bottom of the enclosure. This is the area where most of the contamination will settle.
Inspect the labyrinth seal of the enclosure for signs of wear. Fix the seal and any holes in the
enclosure as necessary. Keeping the enclosure in good condition will help minimize dust and
other contaminants from getting into the lubricant. Lubrication contamination is one of the major
causes of wear.
If the inspection of wear patterns indicates a run out problem, check both the axial and radial run
out. These measurements can only be taken while the kiln is shut down. Also, if warranted, check
the slope of the pinion. If any adjustments or shimming of the pinion bearings are required,
realign the balance of the drive components and couplings .

Gears Page 23
AXIAL Run out
Axial run out occurs when a gear “wobbles” from side to side as it rotates. Some side-to-side
movement is inherent in the design of rotary equipment, however, the tolerances are small.
Excessive axial run out will wear gear teeth unevenly, cause uneven pressure on the pinion,
and will magnify other problems that the unit may have.
When correcting gear run-outs, the axial run out is generally corrected first. It should always
be measured using two dial indicators 180° apart, usually at the horizontal center line of the
gear. The stands used for the dial indicators must be rigid so as not to “sway” and give false
readings.
The gear should be divided into 12 equally spaced segments and the side rim of the gear
should be cleaned in these areas. As the kiln is slowly rotated, readings are taken on both
indicators. The readings directly opposite each other are then mathematically averaged to
find the amount of “wobble” in the gear.
The reason for using two indicators is to negate any axial float of the kiln and any “wobble” of
the thrust rollers.

Page 24 Gears
Illustrated on the chart above are typical curves for the amount of acceptable axial run out
of girth gears for kilns and similar roller-supported machines.

The allowable axial run out is a function of the gear diameter. For the most part, gear
manufacturers and OEMs of rotary equipment recommend 0.001” of axial run out per foot of
pitch diameter. This rule applies to new installations, and to gears running at 5 rpm and
over.

Another level of tolerances is shown for new installations with gears running at less than 5
rpm. This is generally a 25% additional run out allowance.

The “acceptable tolerances” should be applied to installations where the unit has been
heated and expansion has taken place, or wear is present. In this case, it is unlikely that
original tolerances can be attained.

This is just a guide. Values specific for any particular gear should be obtained from
the gear manufacturer.

Gears Page 25
Page 26 Gears
Gear run out measurements are used to set the gear originally and can be used anytime
thereafter to check alignment.
Radial run out occurs when the axis of rotation of the gear changes as the kiln rotates.
Some slight change can be expected, but if measurements are taken and show a large
variance, corrective action should be initiated. If the gear is accessible through the
inspection port, a dial indicator should be place on a 2” x 2” angle-iron tripod at the
appropriate position. If this is not possible, part of the enclosure will need to be removed to
provide access.
Measurement of radial run out is done by dial indicator. Twelve teeth, equally spaced and
numbered around the circumference, that is every 30°, should have their top faces cleaned.
The gear is slowly rotated. While the gear is moving the indicator stem is held back. The
gear is stopped at each of the twelve teeth and an indicator reading is recorded.

A rigid setup is required for the dial indicator and extreme caution should be taken so as not
to disturb the indicator placement during the procedure.

Take the maximum reading and subtract the minimum reading. This is the radial run out.
Compare this to the acceptable value for your gear. Values exceeding the acceptable
values will reduce the service life of the gear set.

Gears Page 27
Illustrated in the chart above are typical curves for the allowable radial run-out of girth
illustrated on the chart above are typical curves for the amount of acceptable axial run-out
of girth gears for kilns and similar roller-supported machines.

The allowable axial run-out is a function of the gear diameter. For the most part, gear
manufacturers and OEMs of rotary equipment recommend 0.001” of axial run-out per foot
of pitch diameter. This rule applies to new installations, and to gears running at 5 rpm
and over.

Another level of tolerances is shown for new installations with gears running at less than 5
rpm. This is generally a 25% additional run-out allowance.

The “acceptable tolerances” should be applied to installations where the unit has been
heated and expansion has taken place, or wear is present. In this case, it is unlikely that
original tolerances can be attained.

Values specific for any particular gear should be obtained from the gear manufacturer.

Page 28 Gears
 Preparation and Protecting the Equipment
• Measure the position of the tire as it relates to the transition.
• Check the gear and pinion axial alignment.
• Review inspection reports and discuss with the customer if the tire has full
contact with the carrying rollers during operation. Review all inspection data for
positions and conditions of all relevant tire(s) with relationship to carrying rollers,
thrust rollers, stops, etc.
• Does the above information require the tire to be repositioned?
• Cover the carrying rollers. (Nothing works better than a sheet of ½” plywood.)
Blow out the contact area of the rollers and tire with high-pressure air before
each kiln turn.
• Protect areas below the pier. (Make it a regular event to barricade ribbon off the
area below for personnel people protection.)
• Grounding – always ground directly to the kiln shell when welding on the shell or
filler bars. Do not ground through carrying roller frames or bearings.

Gears Page 29
 Preparation and Protecting the Equipment
• Measure the position of the tire as it relates to the transition.
• Check the gear and pinion axial alignment.
• Review inspection reports and discuss with the customer if the tire has full
contact with the carrying rollers during operation. Review all inspection data for
positions and conditions of all relevant tire(s) with relationship to carrying rollers,
thrust rollers, stops, etc.
• Does the above information require the tire to be repositioned?
• Cover the carrying rollers. (Nothing works better than a sheet of ½” plywood.)
Blow out the contact area of the rollers and tire with high-pressure air before
each kiln turn.
• Protect areas below the pier. (Make it a regular event to barricade ribbon off the
area below for personnel people protection.)
• Grounding – always ground directly to the kiln shell when welding on the shell or
filler bars. Do not ground through carrying roller frames or bearings.

Page 30 Gears