SIMOGEAR gearbox
BA 2030
Operating Instructions · 06/2012
SIMOGEAR
Answers for industry.
ꢀBA 2030ꢀ
SIMOGEAR
Gearbox
BA 2030
Operation
Operating Instructions
Faults, causes and remedies
Service and maintenance
Disposal
Technical data
Spare parts
Declaration of Incorporation
Original Operating Instructions
06/12
70000004040207
Legal information
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
70000004040207
Ⓟ 07/2012 Technical data subject to change
Copyright © Siemens AG 2012.
All rights reserved
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Table of contents
1
General information and safety notes ........................................................................................................ 7
1.1
1.2
1.3
1.4
1.5
General information .......................................................................................................................7
Copyright........................................................................................................................................8
Intended use ..................................................................................................................................9
Obligations of the user...................................................................................................................9
Particular types of hazards ..........................................................................................................11
2
Technical description............................................................................................................................... 13
2.1
2.2
2.3
2.4
General technical description.......................................................................................................13
Shaft seals ...................................................................................................................................14
Cooling.........................................................................................................................................14
Rating plate..................................................................................................................................15
2.5
Surface treatment ........................................................................................................................15
General information on surface treatment ...................................................................................15
Painted version ............................................................................................................................16
Primed version.............................................................................................................................18
2.5.1
2.5.2
2.5.3
3
Incoming goods, transport, and storage................................................................................................... 19
3.1
Incoming goods............................................................................................................................19
3.2
3.2.1
3.2.2
Transport......................................................................................................................................20
General information on transport.................................................................................................20
Fastening for suspended transport..............................................................................................21
3.3
Storage.........................................................................................................................................22
General information for storage...................................................................................................22
Storage up to 6 months................................................................................................................22
Storage up to 36 months with long-term preservation (optional).................................................23
3.3.1
3.3.2
3.3.3
3.3.3.1 Notes for storage up to 36 months ..............................................................................................23
3.3.3.2 Gearbox filled with operating oil and anti-corrosive agent...........................................................23
3.3.3.3 Gearbox completely filled with oil.................................................................................................23
4
Installation ............................................................................................................................................... 25
4.1
4.2
4.3
4.4
4.5
4.6
4.7
Unpacking ....................................................................................................................................25
General information on installation ..............................................................................................25
Thread sizes and tightening torques for fastening bolts..............................................................27
Fastening in the case of high shock loads...................................................................................28
Gearbox with foot mounting.........................................................................................................28
Gearboxes in foot or flange version.............................................................................................29
Mounting an input or output element on the gearbox shaft .........................................................29
BA 2030
Operating Instructions, 06/12, 70000004040207
3
Table of contents
4.8
Removing and installing the protection cover............................................................................. 32
4.9
Installing and removing the shaft-mounted gearbox................................................................... 33
General information on installing the shaft-mounted gearbox .................................................... 33
Mounting and removing the hollow shaft with feather key.......................................................... 34
4.9.1
4.9.2
4.9.2.1 Mounting the hollow shaft with parallel key................................................................................. 34
4.9.2.2 Removing the hollow shaft with parallel key ............................................................................... 35
4.9.3
Mounting the hollow shaft with shrink disk.................................................................................. 37
4.9.3.1 Mounting the hollow shaft with shrink disk.................................................................................. 37
4.9.3.2 Mounting the shrink disk ............................................................................................................. 38
4.9.3.3 Pulling off the shrink disk ............................................................................................................ 41
4.9.3.4 Cleaning and lubricating shrink disks.......................................................................................... 41
4.9.4
4.9.5
Mounting the hollow shaft with splines........................................................................................ 42
Torque arms with shaft-mounted gearboxes .............................................................................. 43
4.9.5.1 General information regarding torque arms................................................................................ 43
4.9.5.2 Mounting torque arms on parallel shaft gearboxes..................................................................... 44
4.9.5.3 Mounting torque arms on bevel gearboxes................................................................................. 45
5
Commissioning ........................................................................................................................................ 47
5.1
5.2
5.3
General information for commissioning ...................................................................................... 47
Checking the oil level prior to commissioning............................................................................. 47
Mounting the oil expansion unit .................................................................................................. 48
6
7
8
Operation................................................................................................................................................. 49
Faults, causes and remedies................................................................................................................... 51
Service and maintenance ........................................................................................................................ 55
8.1
General notes about maintenance work ..................................................................................... 55
8.2
Checking and changing lubricants.............................................................................................. 57
General safety notes for checking and changing lubricants ....................................................... 57
Checking the oil level .................................................................................................................. 58
Checking the oil level using the oil sight glass (optional)............................................................ 59
Checking the oil quality ............................................................................................................... 59
Changing the oil .......................................................................................................................... 60
8.2.1
8.2.2
8.2.3
8.2.4
8.2.5
8.2.5.1 General safety notes for changing the oil ................................................................................... 60
8.2.5.2 Draining the oil ............................................................................................................................ 61
8.2.5.3 Flushing the gearbox when changing between incompatible oils............................................... 62
8.2.5.4 Filling in oil................................................................................................................................... 63
8.2.6
8.2.7
8.2.8
8.2.9
Topping up with oil ...................................................................................................................... 64
Changing the roller bearing grease............................................................................................. 64
Service life of the lubricants ........................................................................................................ 65
Recommended lubricants ........................................................................................................... 67
8.3
8.4
8.5
8.6
8.7
8.8
Checking the gearbox for leaks .................................................................................................. 69
Replacing the vent valve............................................................................................................. 69
Checking the oil level sensor (optional) ...................................................................................... 70
Cleaning the gearbox.................................................................................................................. 70
Checking tightness of fastening bolts ......................................................................................... 71
Inspecting the gearbox or geared motor..................................................................................... 71
BA 2030
4
Operating Instructions, 06/12, 70000004040207
Table of contents
9
Disposal................................................................................................................................................... 73
Technical data ......................................................................................................................................... 75
10
10.1
10.2
10.3
10.4
10.5
Type designation..........................................................................................................................75
General technical data.................................................................................................................76
Weight..........................................................................................................................................78
Sound energy level ......................................................................................................................78
Mounting positions.......................................................................................................................79
10.5.1 General notes on mounting positions ..........................................................................................79
10.5.2 Two- and three-stage helical gearboxes......................................................................................80
10.5.3 Parallel shaft gearbox ..................................................................................................................87
10.5.4 Bevel gearboxes ..........................................................................................................................93
10.6
Oil quantities ..............................................................................................................................102
10.6.1 Helical gearbox ..........................................................................................................................102
10.6.2 Parallel shaft gearbox ................................................................................................................104
10.6.3 Bevel gearboxes ........................................................................................................................105
11
12
Spare parts............................................................................................................................................ 107
11.1
11.2
11.3
11.4
11.5
Stocking of spare parts ..............................................................................................................107
Helical gearboxes D / Z, sizes 19 - 89.......................................................................................108
Parallel shaft gearboxes F sizes 29 - 89....................................................................................110
Bevel gearbox B sizes 29 - 49 ...................................................................................................113
Bevel gearbox K sizes 39 - 89 ...................................................................................................116
Declaration of Incorporation................................................................................................................... 119
BA 2030
Operating Instructions, 06/12, 70000004040207
5
Table of contents
BA 2030
6
Operating Instructions, 06/12, 70000004040207
General information and safety notes
1
1.1
General information
NOTICE
Siemens does not accept liability for any damage or outages resulting from non-compliance
with these operating instructions.
These operating instructions are an integral part of the gearbox supplied and must be kept in
its vicinity for reference at all times.
These operating instructions apply to the standard version of SIMOGEAR gearboxes:
● Helical gearboxes Z and D, sizes 19 to 89
● Parallel shaft gearboxes FZ and FD, sizes 29 to 89
● Bevel gearboxes B, K, sizes 29 to 89
Table 1- 1
Order number code
SIMOGEAR gearbox
Structure of the order number - Position
1
2
2
2
2
2
2
3
J
J
J
J
J
4
3
3
3
3
3
5
1
2
3
4
5
Helical gearbox Z
K
K
K
K
K
Helical gearbox D
Parallel shaft gearbox FZ
Parallel shaft gearbox FD
Bevel gearbox B, K
Note
In addition to these operating instructions, special contractual agreements and technical
documentation apply to special gearbox designs and the associated supplementary
equipment.
Please refer to the other operating instructions supplied with the product.
BA 2030
Operating Instructions, 06/12, 70000004040207
7
General information and safety notes
1.2 Copyright
The gearboxes described here correspond to the state of the art at the time these operating
instructions were printed.
In the interest of technical progress we reserve the right to make changes to the individual
assemblies and accessories which we regard as necessary to preserve their essential
characteristics and improve their efficiency and safety.
If you have any technical questions, please contact Technical Support.
Europe - Germany
Phone: +49 (0) 911 895 7222
Fax: +49 (0) 911 895 7223
America - USA
Phone: +1 42 32 62 25 22
Asia - China
Phone: +86 10 64 75 75 75
Email: [email protected]
Internet German: http://www.siemens.de/automation/support-request
Internet English: http://www.siemens.com/automation/support-request
Applicable operating instructions
BA 2030 operating instructions for SIMOGEAR gearboxes.
BA 2330 operating instructions for LA / LE motors for mounting on SIMOGEAR gearboxes.
1.2
Copyright
The copyright to these operating instructions is held by Siemens AG.
These operating instructions must not be wholly or partly reproduced for competitive
purposes, used in any unauthorized way or made available to third parties without our
agreement.
BA 2030
Operating Instructions, 06/12, 70000004040207
8
General information and safety notes
1.3 Intended use
1.3
Intended use
The SIMOGEAR gearboxes described in these operating instructions have been designed
for stationary use in general engineering applications.
Unless otherwise agreed, the gearboxes have been designed for use in plants and
equipment in industrial environments.
The gearboxes have been built using state-of-the-art technology and are shipped in an
operationally reliable condition. Changes made by users could affect this operational
reliability and are forbidden.
Note
The performance data assumes an ambient temperature of -20 °C to +40 °C and an
installation altitude of up to 2 000 m above sea level.
In the case of other ambient temperatures and installation altitudes, please contact Technical
Support.
The gearboxes have been designed solely for the application described in Technical data
conditions must be contractually agreed.
Do not stand or walk on the gearbox or place objects on the gearbox.
1.4
Obligations of the user
The operator must ensure that all persons assigned to work on the gearbox have read and
understood these operating instructions and that they follow them in all points in order to:
● Eliminate the risk to life and limb of users and others
● Ensure the safety and reliability of the gearbox
● Avoid disruptions and environmental damage through incorrect use.
BA 2030
Operating Instructions, 06/12, 70000004040207
9
General information and safety notes
1.4 Obligations of the user
Note the following safety information:
Shut down the geared motors and disconnect the power before you carry out any work on
them.
Make sure that the drive unit cannot be turned on accidentally, e.g. lock the key-operated
switch. Place a warning notice at the drive connection point which clearly indicates that work
is in progress on the geared motor.
Carry out all work with great care and with due regard to safety.
Ensure compliance with the relevant safety and environmental regulations during transport,
mounting and dismantling, operation, and care and maintenance of the unit.
Read the instructions on the rating plates attached to the geared motor. The rating plates
must be kept free from paint and dirt at all times. Replace any missing rating plates.
In the event of changes during operation, immediately switch off the drive unit.
Take appropriate protective measures to prevent accidental contact with rotating drive parts,
such as couplings, gear wheels or belt drives.
Take appropriate measures to prevent accidental contact with parts and equipment that heat
up to over +70 °C during operation.
When removing protective equipment, keep fasteners in a safe place. Re-attach removed
protective equipment before commissioning.
Collect and dispose of used oil in accordance with regulations. Remove oil spillages
immediately with an oil-binding agent in compliance with environmental requirements.
Do not carry out any welding work on the gearbox. Do not use the gearbox as a grounding
point for welding operations.
Carry out equipotential bonding in accordance with applicable regulations and directives.
Such work must be carried out by qualified electrical personnel only.
Do not use high-pressure cleaning equipment or sharp-edged tools to clean the gearbox.
Observe the permissible tightening torque of the fastening bolts.
Replace damaged bolts with new bolts of the same type and strength class.
We will only accept liability for original spare parts supplied by Siemens AG.
If the geared motor is being installed in a plant or equipment, the manufacturers of such
plant or equipment must ensure that the contents of these operating instructions are
incorporated into their own instructions, information, and descriptions.
BA 2030
10
Operating Instructions, 06/12, 70000004040207
General information and safety notes
1.5 Particular types of hazards
1.5
Particular types of hazards
WARNING
Depending on operating conditions, the gearbox may exhibit extreme surface
temperatures.
Hot surfaces over +55 °C pose a burn risk.
Cold surfaces below 0 °C pose a risk of damage due to freezing.
Do not touch the gearbox without protection.
WARNING
Danger of scalding caused by hot oil emerging from the unit.
Before starting any work wait until the oil has cooled down to below +30 °C.
WARNING
Avoid breathing in vapors when working with solvents.
Ensure adequate ventilation.
WARNING
Risk of explosion when working with solvents.
Ensure adequate ventilation. Do not smoke!
WARNING
Risk of eye injury.
Rotating parts can throw off small foreign particles such as sand or dust. Wear protective
eyewear!
In addition to the required personal protective equipment, wear suitable protective gloves
and eyewear when working with the gearbox or the geared motor.
BA 2030
Operating Instructions, 06/12, 70000004040207
11
General information and safety notes
1.5 Particular types of hazards
BA 2030
12
Operating Instructions, 06/12, 70000004040207
Technical description
2
2.1
General technical description
The gearbox is supplied with two or three transmission stages.
The gearbox is suitable for various mounting positions. Observe the correct oil level.
Housing
The housings for sizes 19 and 29 are made of die-cast aluminum.
Depending on the gearbox type, the housings of sizes 39 and 49 are made of die-cast
aluminum or cast iron.
Table 2- 1
Housing material
Gearbox type
Size
39
49
Helical gearbox
Aluminum
Cast iron
Aluminum
Cast iron
Cast iron
Cast iron
Aluminum
Cast iron
Parallel shaft gearbox
Bevel gearbox B
Bevel gearbox K
From size 59, the gearbox housings are made of cast iron.
Geared components
The geared components are hardened and ground.
The bevel gear stage is lapped in pairs.
Lubrication
The geared components are supplied with adequate lubricant by means of dip lubrication.
Shaft bearings
All shafts are mounted in roller bearings. The roller bearings are lubricated by means of dip
lubrication or oil spray lubrication. Bearings that are not supplied with lubricant are closed
and grease-lubricated.
BA 2030
Operating Instructions, 06/12, 70000004040207
13
Technical description
2.2 Shaft seals
2.2
Shaft seals
The shaft seals on the output side prevent lubricant from escaping from the housing at the
shaft outlet and prevent pollution from entering the housing.
The optimum use of the seals depends on the ambient conditions and the lubricant being
used.
Radial shaft sealing ring
A high-quality radial shaft sealing ring is used as standard seal. It is provided with an
additional dust lip to protect against contaminants from outside.
Seal for a longer service life (optional)
The radial shaft sealing ring with dust lip has an additional buffer axial seal towards the
inside of the gearbox. This has a sinusoidally shaped sealing lip to protect against the
ingress of pollution in the oil in the sealing ring.
Seal to handle increased environmental stress (optional)
This seal is equipped with an additional fiber washer. In addition to a longer service life, it
also provides higher protection against increased environmental stress as a result of
humidity and dust.
2.3
Cooling
NOTICE
Dust deposits prevent heat radiation and cause high housing temperatures.
Keep the gearbox free from dirt, dust, etc.
The gearbox does not normally require additional cooling. The generously dimensioned
housing surface is sufficient for dissipating heat losses where there is free convection. If the
housing temperature exceeds a value of +80 °C, please contact Technical Support.
BA 2030
14
Operating Instructions, 06/12, 70000004040207
Technical description
2.4 Rating plate
2.4
Rating plate
The rating plate on the gearbox or geared motor is of coated aluminum foil. It is covered with
a special masking film which ensures permanent resistance to UV radiation and media of all
kinds, such as oils, greases, salt water and cleaning agents.
The adhesive and the material ensure firm adhesion and long-term legibility within the
operating temperature range from -40 °C to +155 °C.
The edges of the rating plate are paint-finished to match the color of the gearbox or motor to
which it is affixed.
2.5
Surface treatment
2.5.1
General information on surface treatment
All paint finishes are sprayed on.
NOTICE
Any damage to the paint finish will destroy the exterior protection and cause corrosion.
Do not damage the paint finish.
Note
Information about repaintability is not a guarantee of the quality of the paint product
purchased from your supplier.
Only the paint manufacturer is liable for the quality and compatibility.
BA 2030
Operating Instructions, 06/12, 70000004040207
15
Technical description
2.5 Surface treatment
2.5.2
Painted version
The corrosion protection system is classified according to the corrosiveness categories in
DIN EN ISO 12944-2.
Table 2- 2
Paint according to corrosiveness categories
Description
Paint system
Corrosiveness category C1, unpainted for gearbox housings made of aluminum
Indoor installation
Heated buildings with neutral atmospheres
Resistance to greases and some resistance
to mineral oils, aliphatic solvents
Standard
Corrosiveness category C1 for normal environmental stress
1-component hydro paint, top coat
Indoor installation
Heated buildings with neutral atmospheres
Resistance to greases and some resistance
to mineral oils, aliphatic solvents
Standard paint for gearbox casings made of
cast iron
Corrosiveness category C2 for low environmental stress
2-component polyurethane base coat
2-component, polyurethane top coat
Indoor and outdoor installation
Unheated buildings with condensation,
production areas with low humidity,
e.g. warehouses and sports facilities
Atmospheres with little contamination, mostly
rural areas
Resistance to greases, mineral oils and
sulfuric acid (10 %), caustic soda (10 %) and
some resistance to aliphatic solvents
BA 2030
Operating Instructions, 06/12, 70000004040207
16
Technical description
2.5 Surface treatment
Paint system
Description
Corrosiveness category C3 for medium environmental stress
2-component polyurethane base coat
2-component, polyurethane top coat
Indoor and outdoor installation
Production areas with high humidity and some
air contamination, e.g. food production areas,
dairies, breweries and laundries
Urban and industrial atmospheres, moderate
contamination from sulfur dioxide, coastal
areas with low salt levels
Resistance to greases, mineral oils, aliphatic
solvents, sulfuric acid (10 %), caustic
soda (10 %)
Corrosiveness category C4 for high environmental stress
2-component epoxy
zinc phosphate base coat
2-component polyurethane top coat
Indoor and outdoor installation
Chemical plants, swimming pools, wastewater
treatment plants, electroplating shops, and
boathouses above seawater
Industrial areas and coastal areas with
moderate salt levels
Resistance to greases, mineral oils, aliphatic
solvents, sulfuric acid (10 %), caustic
soda (10 %)
Corrosiveness category C5 for very high environmental stress
2-component epoxy
Indoor and outdoor installation
zinc phosphate base coat
Buildings and areas with almost constant
condensation and high contamination,
e.g. malt factories and aseptic areas
2-component epoxy iron mica intermediate coat
2-component polyurethane top coat
Industrial areas with high humidity and
aggressive atmosphere, coastal areas and
offshore environments with high salt levels
Resistance to greases, mineral oils, aliphatic
solvents, sulfuric acid (10 %), caustic
soda (20 %)
In case of corrosiveness category C1, can be overpainted with 1-component hydrosystem
after prior rubbing down.
In case of corrosiveness categories C2 to C5, can be overpainted with 2-component
polyurethane paint, 2-component epoxide paint and 2-component acrylic paint after prior
rubbing down.
BA 2030
Operating Instructions, 06/12, 70000004040207
17
Technical description
2.5 Surface treatment
2.5.3
Primed version
Table 2- 3
Primer according to corrosiveness category
Paint system
Can be overpainted with
Unpainted corrosiveness category C1
Cast iron parts immersion primed, steel parts
Plastic paint, synthetic resin paint, oil paint,
primed or zinc-plated, aluminum and plastic parts 2-component polyurethane paint,
untreated
2-component epoxide paint
Primed according to corrosiveness category C2 G
2-component metal primer, desired coat
thickness 60 μm
2-component polyurethane paint,
2-component epoxide paint and
acid-hardening paint, 2-component acrylic paint
Primed according to corrosiveness category C4 G
2-component epoxy zinc phosphate, desired coat 2-component polyurethane paint,
thickness 120 μm
2-component epoxide paint and
acid-hardening paint, 2-component acrylic paint
On gearbox or geared motor versions which are primed or unpainted the rating plate and the
masking film are covered with a paint-protective film. These facilitate repainting without
further preparation, e.g., masking with adhesive tape.
Peeling off the paint-protective film
The paint coat must have fully hardened before the paint-protective film is peeled off (be at
least "touch-proof").
ꢀꢁ
ꢂꢁ
ꢅꢁ
ꢃꢁ
ꢄꢁ
①
②
③
④
⑤
Company logo
Masking film
Rating plate
Paint-protective film
Peeling tab
Figure 2-1
Rating plate with paint-protective film
Procedure
1. Pull the peeling tab ⑤ up.
2. Carefully peel the paint-protective film ④ off diagonally from one corner (not parallel to
the plate).
3. Blow any paint fragments away or wipe them off with a clean cloth.
You have now removed the paint-protective film.
BA 2030
Operating Instructions, 06/12, 70000004040207
18
Incoming goods, transport, and storage
3
3.1
Incoming goods
NOTICE
Make sure that damaged gearboxes or geared motors are not put into operation.
Note
Do not open or damage parts of the packaging that preserve the product.
Note
Check that the technical specifications are in accordance with the purchase order.
Inspect the delivery immediately on arrival for completeness and any transport damage.
Notify the freight company of any damage caused during transport immediately (this is the
only way to have damage rectified free of charge). Siemens AG will not accept any claims
relating to items missing from the delivery and which are submitted at a later date.
The gearbox or geared motor is delivered in a fully assembled condition. Additional items
may be delivered packaged separately.
The products supplied are listed in the dispatch papers.
BA 2030
Operating Instructions, 06/12, 70000004040207
19
Incoming goods, transport, and storage
3.2 Transport
3.2
Transport
3.2.1
General information on transport
NOTICE
The use of force will damage the gearbox or geared motor.
Transport the gearbox or geared motor carefully. Avoid knocks.
Before putting the drive into operation, remove any transport fixtures and keep them safe or
render them ineffective. You can then use them again for transporting further items or you
can apply them again.
Different forms of packaging may be used, depending on the size of the gearbox or geared
motor and the method of transport. Notwithstanding contractual agreements to the contrary,
the seaworthy packaging complies with HPE Packaging Guidelines (Bundesverband
Holzpackmittel Paletten Exportverpackungen e.V., the German Federal Association for
wooden packaging, pallets, and export packaging).
Note the symbols which appear on the packaging. These have the following meanings:
This way up
Center of gravity
Fragile
Do not use hand hook
Attach here
Keep dry
Keep cool
BA 2030
Operating Instructions, 06/12, 70000004040207
20
Incoming goods, transport, and storage
3.2 Transport
3.2.2
Fastening for suspended transport
WARNING
Gearboxes or geared motors may come loose and fall down during transport if not secured
sufficiently.
Use only the transport eye or eyebolt of the gearbox to transport the gearbox or geared
motor. This is only designed for the weight of the gearbox or geared motor, and it is not
permissible to add additional loads.
Do not use the integrally cast lifting eyes on the motor for transport because of the risk of
breaking.
If necessary, use additional, suitable lifting accessories for transport or during installation.
When attaching by a number of chains and ropes just two strands must be sufficient to bear
the entire load. Secure lifting accessories against slipping.
CAUTION
Do not rig eyebolts to the front threads at the shaft ends for transportation purposes.
Table 3- 1
Maximum load of the eyebolt on the gearbox
Thread size
m
d3
Thread size
m
d3
[kg]
140
230
340
700
[mm]
36
[kg]
[mm]
72
M8
M20
M24
M30
1 200
1 800
3 200
M10
M12
M16
45
90
54
108
63
The eyebolt corresponds to DIN 580.
BA 2030
Operating Instructions, 06/12, 70000004040207
21
Incoming goods, transport, and storage
3.3 Storage
3.3
Storage
3.3.1
General information for storage
WARNING
Do not stack gearboxes or geared motors one on top of another.
NOTICE
Mechanical damage (scratches), chemical damage (acids, alkalis) and thermal damage
(sparks, welding beads, heat) cause corrosion which may render the external protective
coating ineffective.
Do not damage the paint finish.
Note
Notwithstanding contractual agreements to the contrary, the guarantee period for the
standard preservative lasts 6 months from the date of delivery.
In the case of storage in transit over 6 months, special arrangements must be made for
preservation. Please contact Technical Support.
Store the gearbox or geared motor in dry, dust-free rooms that are maintained at a constant
temperature.
The storage location must be vibration- and shock-free.
The free shaft ends, sealing elements and flange surfaces must have a protective coating.
3.3.2
Storage up to 6 months
The gearbox or geared motor must be covered and stored in its position of use on a
horizontal wooden support in a dry place not subject to significant temperature fluctuations.
BA 2030
22
Operating Instructions, 06/12, 70000004040207
Incoming goods, transport, and storage
3.3 Storage
3.3.3
Storage up to 36 months with long-term preservation (optional)
3.3.3.1
Notes for storage up to 36 months
Store the gearbox or geared motor in dry, dust-free rooms that are maintained at a constant
temperature. Special packing is then not necessary.
Otherwise, the gearbox or geared motor must be packed in plastic film or packed in airtight
sealed film and water absorbing agents. Cover them to provide protection against heat,
direct sunlight and rain.
The permissible ambient temperature range is -25 °C to +50 °C.
The life of the corrosion protection is 36 months from delivery.
3.3.3.2
Gearbox filled with operating oil and anti-corrosive agent
NOTICE
Check the oil level before commissioning.
The gearbox is filled with oil corresponding to the mounting position so that it is ready for
operation, and is sealed airtight using a screw plug or with a pressure breather valve with
transport fixture.
For storage up to 36 months, a VCI anti-corrosion agent (Volatile Corrosion Inhibitor) is
added.
3.3.3.3
Gearbox completely filled with oil
NOTICE
The gearbox is completely filled with operating oil.
Check the oil level before commissioning.
When using biologically degradable oils or oils for the foodstuff area, the gearboxes are
completely filled with operating oil and sealed airtight using a screw plug or with a pressure
breather valve with transport fixture.
Do not lower the oil level during short-time commissioning for 10 minutes in no-load
operation.
BA 2030
Operating Instructions, 06/12, 70000004040207
23
Incoming goods, transport, and storage
3.3 Storage
BA 2030
24
Operating Instructions, 06/12, 70000004040207
Installation
4
4.1
Unpacking
NOTICE
Make sure that damaged gearboxes or geared motors are not put into operation.
Check the gearbox or geared motor for completeness and for damage. Report any missing
parts or damage immediately.
Remove packaging and transport fixtures and dispose of them properly.
4.2
General information on installation
WARNING
The entire system must be load-free so that there is no danger during this work.
NOTICE
Irreparable damage to toothed components and bearings due to welding.
Do not carry out any welding work on the gearbox. The gearbox must not be used as a
grounding point for welding operations.
NOTICE
Overheating of the gearbox due to exposure to direct sunlight.
Provide suitable protective equipment such as covers or roofs. Prevent heat accumulation.
BA 2030
Operating Instructions, 06/12, 70000004040207
25
Installation
4.2 General information on installation
NOTICE
Malfunction resulting from foreign objects.
The operator must ensure that no foreign objects impair the function of the gearbox.
NOTICE
Exceeding the permissible oil sump temperature due to incorrect settings of temperature
monitoring equipment.
A warning must be given when the maximum permissible oil sump temperature is reached.
The geared motor must be switched off when the maximum permissible oil sump
temperature is exceeded. This switching off can cause plant shutdown.
Note
Use headless screws of strength class 8.8 or higher to fasten the gearbox.
Exercise particular care during mounting and installation. The manufacturer cannot be held
liable for damage caused by incorrect mounting and installation.
Make sure that there is sufficient space around the gearbox or geared motor for mounting,
maintenance and repair.
On geared motors with a fan, leave sufficient free space for the entry of air. Observe the
installation conditions for the geared motor.
Provide sufficient lifting gear at the start of mounting and fitting work.
Observe the mounting position specified on the rating plate. This ensures that the correct
quantity of lubricant is provided.
Use all the fastening means that have been assigned to the particular mounting position and
mounting type.
Cap screws cannot be used in some cases due to a lack of space. In such cases, please
contact Technical Support quoting the type of gearbox.
BA 2030
26
Operating Instructions, 06/12, 70000004040207
Installation
4.3 Thread sizes and tightening torques for fastening bolts
4.3
Thread sizes and tightening torques for fastening bolts
The general tolerance for the tightening torque in Nm is 10 %. The friction coefficient is
0.14 μ.
Table 4- 1
Tightening torques for fastening bolts
Tightening torque at strength class
Thread size
8.8
10.9
12.9
[Nm]
3
[Nm]
4
[Nm]
5
M4
M5
6
9
10
M6
10
15
18
M8
25
35
41
M10
M12
M16
M20
M24
M30
M36
50
70
85
90
120
295
580
1 000
2 000
3 600
145
355
690
1 200
2 400
4 200
210
450
750
1 500
2 500
Table 4- 2
Thread size of fastening bolts for gearboxes in a foot-mounted design
Thread size
Helical gearbox
Parallel shaft gearbox
Bevel gearbox
Size
Size
29, 39
49
Size
M8
29, 39
B29, B39
B49, K39, K49
K69, K79
K89
M10
M12
M16
49, 59, 69
79, 89
69, 79
89
Table 4- 3
Thread size of fastening bolts for gearboxes in a flange-mounted design
Thread
size
Flange
Helical gearbox
Parallel shaft gearbox Bevel gearbox
Size
Size
Size
M6
A120
19, 29, 39
19, 29, 39, 49, 59
39, 49, 59, 69
59, 69, 79, 89
89
29
B29
M8
A140, A160
A200
29, 39
49
B29, B39, K39
B39, B49, K49
K69, K79, K89
M10
M12
M16
A250, A300
A350
69, 79, 89
BA 2030
Operating Instructions, 06/12, 70000004040207
27
Installation
4.4 Fastening in the case of high shock loads
4.4
Fastening in the case of high shock loads
In the case of high shock loads provide additional suitable positive fastenings such as
cylindrical taper pins or spring pins.
NOTICE
Do not use spring washers, serrated lock washers, spring or toothed lock washers, cup
washers or conical spring washers as a substitute for the above positive fastenings.
Do not subject the housing to excessive stress when tightening the fastening bolts.
4.5
Gearbox with foot mounting
NOTICE
Do not subject the gearbox to excessive stress when tightening the fastening bolts.
The foundation must be level and free from dirt.
The levelness deviation of the gearbox support must not exceed the following values:
For gearboxes up to size 89: 0.1 mm
The foundation should be designed in such a way that no resonance vibrations are created
and no vibrations are transmitted from adjacent foundations.
The foundation structure on which the gearbox is to be mounted must be torsionally rigid. It
must be dimensioned according to the weight and torque, taking into account the forces
acting on the gearbox. If the substructure is too weak, it will cause radial or axial
displacement, which cannot be measured at a standstill.
When using foundation blocks to fasten the gearbox to a concrete foundation, suitable
recesses should be made in the foundation.
Align and grout the slide rails into the foundation.
Align the gearbox carefully with the units on the input and output side. Take into account the
elastic deformation due to operating forces.
Prevent displacement from external forces due to lateral impacts.
Use stud bolts or headless screws of strength class 8.8 or higher for the mounting foot.
Observe the tightening torque.
BA 2030
28
Operating Instructions, 06/12, 70000004040207
Installation
4.6 Gearboxes in foot or flange version
4.6
Gearboxes in foot or flange version
NOTICE
Do not subject the gearbox housing to excessive stress by adding add-on elements to the
foot or flange.
Add-on elements must not transmit forces, torques, and vibrations to the gearbox.
The gearbox must only be mounted at either the flange or the foot to transmit force and
torque in order to prevent excessive stress to the gearbox housing, see Gearbox with foot
The second mounting option (foot or flange) is intended for add-on elements, e.g. protection
covers with an intrinsic weight of up to max. 30 % of the weight of the gearbox.
4.7
Mounting an input or output element on the gearbox shaft
WARNING
Risk of burns due to hot parts.
Do not touch the gearbox without protection.
NOTICE
Damage to shaft sealing rings caused by solvent or benzine.
Avoid contact at all times.
NOTICE
Damage to shaft sealing rings caused by heating over 100 °C.
Protect shaft sealing rings from heating up due to radiant heat using thermal shields.
BA 2030
Operating Instructions, 06/12, 70000004040207
29
Installation
4.7 Mounting an input or output element on the gearbox shaft
NOTICE
Alignment errors caused by excessive angle or axial displacement of the shaft ends to be
joined lead to premature wear or material damage.
Ensure precise alignment of the individual components.
NOTICE
Damage to bearings, housing, shaft, and locking rings due to improper handling.
Do not use impacts or knocks to force the input and output elements to be mounted onto
the shaft.
Note
Deburr the parts of elements to be fitted in the area of the hole or keyways.
Recommendation: 0.2 x 45°
Where couplings are to be fitted in a heated condition, observe the specific operating
instructions for the coupling. Unless otherwise specified, the heat can be applied inductively,
using a torch or in a furnace.
Use the center holes in the shaft end faces.
Use a fitting device to fit the input or output elements.
Figure 4-1
Example of a fitting device
BA 2030
30
Operating Instructions, 06/12, 70000004040207
Installation
4.7 Mounting an input or output element on the gearbox shaft
Observe the correct mounting arrangement to minimize stress on shafts and bearings due to
lateral forces.
Correct
Incorrect
)
)
D
D
a
F
Hub
Force
Figure 4-2
Mounting arrangement for the lowest possible stress on shafts and bearings
Procedure
1. Using either benzine or solvent, remove the anti-corrosion protection from the shaft ends
and flanges and remove the protective skin provided.
2. Fit the input and output elements onto the shafts and secure them if necessary.
You have now fitted the input or output element.
BA 2030
Operating Instructions, 06/12, 70000004040207
31
Installation
4.8 Removing and installing the protection cover
4.8
Removing and installing the protection cover
The protection cover is delivered ready-fitted to the gearbox flange. The protection cover
must be removed in order to fit the output shaft.
ꢅ
ꢂ
ꢀ
ꢃ
①
②
③
④
Bolt
Protection cover
Gearbox housing
Flat seal
Figure 4-3
Protection cover for hollow shaft and hollow shaft with shrink disk
Procedure
1. Release the screws ① and remove the protection cover ② and the flat seal ④.
2. Fit the output shaft.
3. Using a suitable cleaning agent, clean the contact surface of the protection cover ② on
the gearbox.
4. Ensure that the flat seal ④ is correctly seated.
5. Screw on the protection cover ②.
6. Protect all remaining bare areas with a suitable permanent anti-corrosive agent.
You have now installed the protection cover for operation.
BA 2030
Operating Instructions, 06/12, 70000004040207
32
Installation
4.9 Installing and removing the shaft-mounted gearbox
4.9
Installing and removing the shaft-mounted gearbox
4.9.1
General information on installing the shaft-mounted gearbox
NOTICE
Damage to shaft sealing rings caused by solvent or benzine.
Avoid contact at all times.
NOTICE
Misalignment of and stress on the hollow shaft can lead to excessive load and cause the
bearings to fail.
The hollow shaft must be flush with the machine shaft to avoid misalignment.
Do not subject the hollow shaft to axial and radial stress.
NOTICE
For shrink disks:
Lubricants in the area between the hollow shaft and machine shaft impair torque
transmission.
Keep the bore in the hollow shaft and the machine shaft completely grease-free.
Do not use impure solvents and soiled cleaning cloths.
Note
Coat the contact surfaces with the mounting paste supplied with the product or any suitable
lubricant to prevent frictional corrosion.
Note
Observe the permissible concentricity tolerance of the cylindrical shaft extension of the
machine shaft to the housing axle according to DIN 42955.
BA 2030
Operating Instructions, 06/12, 70000004040207
33
Installation
4.9 Installing and removing the shaft-mounted gearbox
4.9.2
Mounting and removing the hollow shaft with feather key
4.9.2.1
Mounting the hollow shaft with parallel key
ꢆ
ꢆ
ꢇ
ꢉ
ꢀ
ꢈ
ꢄ
ꢂ
ꢃ
ꢅ
*
Not included in scope of supply
Machine shaft
Hollow shaft
Hexagon nut
Threaded spindle
Disk
Locking ring
Parallel key
Mounting paste
①
②
③
④
⑤
⑥
⑦
⑧
Figure 4-4
Mounting the hollow shaft with parallel key
Instead of the nut and threaded spindle shown in the diagram, other types of equipment such
as hydraulic lifting equipment may be used.
Procedure
1. Using benzine or a solvent, remove the anti-corrosion protection from the shaft ends and
flanges.
2. Check the seats or edges of the hollow and machine shafts for damage. Please contact
Technical Support if you notice any damage.
3. Evenly apply the mounting paste ⑧ to the machine shaft ①.
4. Fit the gearbox using the disk ⑤, threaded spindle ④ and nut ③. Support is provided by
the hollow shaft ②.
5. Replace the nut ③ and threaded spindle ④ with a setscrew and tighten them to the
specified torque.
You have now mounted the hollow shaft.
Table 4- 4
Tightening torque for setscrews
Thread size
M5
5
M6
8
M8
8
M10
14
M12
24
M16
60
M20
120
M24
200
M30
400
Tightening torque [Nm]
BA 2030
34
Operating Instructions, 06/12, 70000004040207
Installation
4.9 Installing and removing the shaft-mounted gearbox
4.9.2.2
Removing the hollow shaft with parallel key
NOTICE
Before driving out the machine shaft, fasten a suitably dimensioned means of absorbing the
load at the gearbox.
Slightly pretension the pulling equipment so that the gearbox does not drop onto it when the
insert shaft is released.
NOTICE
It is essential to prevent misalignment when removing the unit.
Note
If frictional corrosion has occurred on the seat surfaces, use rust solvent to facilitate the
removal of the gearbox. Allow an adequately long time for the rust solvent to take effect.
ꢅ
ꢀ
ꢂ
ꢃ
ꢄ
①
②
③
④
⑤
Disk
Threaded block
Parallel key
Hexagon nut
Threaded spindle
Figure 4-5
Removing the hollow shaft with parallel key
Items ① to ⑤ are not included in the scope of delivery.
1. Remove the axial locking element from the hollow shaft.
Procedure
2. Drive out the machine shaft using the disk ①, threaded block ②, parallel key ③,
threaded spindle ⑤, and hexagon nuts ④.
You have now removed the hollow shaft with parallel key.
BA 2030
Operating Instructions, 06/12, 70000004040207
35
Installation
4.9 Installing and removing the shaft-mounted gearbox
Design suggestion for threaded block and disk
X
Eꢅꢀ
Eꢅꢊ
šGꢅꢊꢋꢊꢌꢄ
Eꢅꢅ
Size
b10
b11
b12
d10
d11
s11
tmax
u
[mm]
3
[mm]
15
[mm]
10
[mm]
19.9
24.9
-
[mm]
10
[mm]
22.5
28
[mm]
29
39
M6
M8
6
8
8
14
-
15
10
14
M8
M10
28
6
29.9
18
33
38
10
10
12
12
14
12
14
18
49
69
6
6
15
20
5
9
34.9
39.9
39.9
44.9
39.9
49.9
59.9
24
28
28
33
28
36
45
M12
M16
43
48.5
79
89
6
7
20
20
9
M16
M16
48.5
64
10
BA 2030
Operating Instructions, 06/12, 70000004040207
36
Installation
4.9 Installing and removing the shaft-mounted gearbox
4.9.3
Mounting the hollow shaft with shrink disk
4.9.3.1
Mounting the hollow shaft with shrink disk
ꢆ
ꢆ
ꢆ
ꢅ
ꢉ
ꢀ
ꢄ
ꢂ
ꢃ
D
E
E
a
b
Greased
Absolutely grease-free
*
Not included in scope of supply
Machine shaft
Hollow shaft
Hexagon nut
Threaded spindle
Disk
①
②
③
④
⑤
⑧
Bronze bushing
Figure 4-6
Mounting the hollow shaft with shrink disk
Instead of the nut and threaded spindle shown in the diagram, other types of equipment such
as hydraulic lifting equipment may be used.
Procedure
1. Using benzine or a solvent, remove the anti-corrosion protection from the shaft ends and
flanges.
2. Check the seats or edges of the hollow and machine shafts for damage. Please contact
Technical Support if you notice any damage.
3. Fit the gearbox using the disk ⑤, threaded spindle ④ and nut ③. Support is provided by
the hollow shaft ②.
4. Remove the disk ⑤, threaded spindle ④ and nut ③.
You have now mounted the hollow shaft.
BA 2030
Operating Instructions, 06/12, 70000004040207
37
Installation
4.9 Installing and removing the shaft-mounted gearbox
4.9.3.2
Mounting the shrink disk
WARNING
Risk of injury due to freely rotating parts.
Fit a cover cap or protection cover.
NOTICE
The shrink disk is delivered ready for installation.
Do not dismantle it before the initial fitting.
NOTICE
Lubricants in the area of the shrink disk seat impair torque transmission.
Keep the bore in the hollow shaft and the machine shaft completely grease-free.
Do not use impure solvents and soiled cleaning cloths.
NOTICE
Plastic deformation of the hollow shaft when tightening the tightening bolts before fitting the
machine shaft.
First fit machine shaft. Then tighten the tightening bolts.
NOTICE
Avoid overloading the individual bolts.
Do not exceed the maximum tightening torque for tightening bolt.
Sizes 29 - 69:
Tighten the tightening bolts ③.
Sizes 79 - 89:
What is of prime importance is that the end faces of the outer ring ① and inner ring ② are
flush with one another. If they are not flush with one another when tensioning, the tolerance
of the insert shaft must be checked.
BA 2030
38
Operating Instructions, 06/12, 70000004040207
Installation
4.9 Installing and removing the shaft-mounted gearbox
Note
The machine shaft material must comply with the following criteria in order to safely and
reliably transfer the forces and torques.
Yield point, Re >= 360 Nm / mm2
Modulus of elasticity: approx. 206 kN / mm-2
Note
The hollow shaft is axially secured on the machine shaft by means of a shrink disk
connection.
Note
Apply a thin layer of grease to the shrink disk seat on the hollow shaft.
Note
Coat with a suitable lubricant to prevent frictional corrosion of the contact surface on the
customer's machine shaft in the vicinity of the bush.
Sizes 29 - 69
Sizes 79 - 89
D
D
D
D
D
E
E
ꢄ
ꢃ
ꢄ
ꢃ
ꢅ
ꢀ
ꢂ
ꢅ
ꢀ
ꢂ
a
b
Greased
Absolutely grease-free
BA 2030
Operating Instructions, 06/12, 70000004040207
39
Installation
4.9 Installing and removing the shaft-mounted gearbox
①
②
③
④
⑤
Outer ring
Inner ring
Tightening bolt
Hollow shaft
Machine shaft
Figure 4-7
Mounting the shrink disk
Procedure
1. Locate the shrink disk on the hollow shaft:
3-section (sizes 29-69) up to the endstop.
2-section (sizes 79-89) flush with the shaft end.
2. To start, tighten the tightening bolts ③ by hand, and then align the shrink disk so that the
clamping flanges are coplanar with one another.
3. To do this, turn each of the tightening bolts ③ equally by 1/6 revolution (not diagonally
opposite) using a torque wrench, repeating this procedure several times, until the screw
tightening torque is reached.
4. Attach the rubber cover or protection cover included in the scope of delivery,
You have now installed the shrink disk.
Table 4- 5
Tightening torque for tightening bolt
Gearbox size
Thread size
Strength class
Tightening torque
[Nm]
5
29
M5
8.8
39 - 69
79 - 89
M6
8.8
12
M10
12.9
35
BA 2030
Operating Instructions, 06/12, 70000004040207
40
Installation
4.9 Installing and removing the shaft-mounted gearbox
4.9.3.3
Pulling off the shrink disk
Procedure
1. Going around several times, release the tightening bolts ③ one after the other by a
¼ turn each time using a wrench. Do not completely remove the screws.
2. Pull the shrink disk off the hollow shaft.
Sizes 79 - 89:
If the outer ring does not come away from the inner ring, remove some of the tightening bolts
and insert them into neighboring forcing threads.
You will then be able to release the rings without difficulty.
4.9.3.4
Cleaning and lubricating shrink disks
Soiled shrink disks must be cleaned and regreased prior to fitting.
Shrink disks that have been released need not be disassembled and regreased before being
retensioned.
Procedure
1. Only grease the inner friction surfaces of the shrink disks. To do this, use a solid lubricant
with a friction coefficient of μ = 0.04.
2. Use a paste containing MoS2 to grease the bolts, applying the paste to the thread and
underneath the head.
The shrink disk is now ready for fitting.
Table 4- 6
Lubricant
Lubricants for shrink disks
Sold as
Spray
Manufacturer
DOW Corning
Molykote 321 R (lubricant paint)
Molykote spray (powder spray)
Molykote G Rapid
Spray or paste
Spray
Molykombin UMFT 1
Unimily P5
Klüber Lubrication
A. C. Matthes
Powder
Aemasol MO 19 P
Spray or paste
BA 2030
Operating Instructions, 06/12, 70000004040207
41
Installation
4.9 Installing and removing the shaft-mounted gearbox
4.9.4
Mounting the hollow shaft with splines
ꢆ
ꢆ
ꢅꢁ
ꢀꢁ
ꢈꢁ
ꢄꢁ
ꢂꢁ ꢃꢁ
ꢇꢁ
*
Not included in scope of supply
Machine shaft
Hollow shaft
Hexagon nut
Threaded spindle
Disk
①
②
③
④
⑤
⑥
⑦
Locking ring
Mounting paste
Figure 4-8
Mounting the hollow shaft with splines
Instead of the nut and threaded spindle shown in the diagram, other types of equipment such
as hydraulic lifting equipment may be used.
Procedure
1. Using benzine or a solvent, remove the anti-corrosion protection from the shaft ends and
flanges.
2. Check the seats or edges of the hollow and machine shafts for damage. Please contact
Technical Support if you notice any damage.
3. Evenly apply the assembly paste ⑦ to the machine shaft ①.
4. Fit the gearbox using the disk ⑤, threaded spindle ④ and nut ③. Support is provided by
the hollow shaft ②.
5. Replace the nut ③ and threaded spindle ④ with a setscrew and tighten them to the
specified torque.
You have now mounted the hollow shaft.
Table 4- 7
Tightening torque for setscrews
Thread size
M5
5
M6
8
M8
8
M10
14
M12
24
M16
60
M20
120
M24
200
M30
400
Tightening torque [Nm]
BA 2030
42
Operating Instructions, 06/12, 70000004040207
Installation
4.9 Installing and removing the shaft-mounted gearbox
4.9.5
Torque arms with shaft-mounted gearboxes
4.9.5.1
General information regarding torque arms
Torque arms can absorb the reaction torque and the weight force of the gearbox.
NOTICE
Dangerously high transient torques due to excess backlash.
Ensure that the torque arm does not result in excessive constraining forces (e.g. due to the
driven shaft running out-of-true).
NOTICE
Do not tension torque arms when mounting.
NOTICE
Worn or irreparably damaged rubber elements will not function properly.
Solvents, oils, greases, and fuels damage rubber elements. Keep them away from the
rubber elements.
BA 2030
Operating Instructions, 06/12, 70000004040207
43
Installation
4.9 Installing and removing the shaft-mounted gearbox
4.9.5.2
Mounting torque arms on parallel shaft gearboxes
We recommend using pretensioned, damping rubber elements.
Fixing accessories such as brackets, bolts, nuts, etc., are not included in the scope of
delivery.
Oꢅ[
FꢈꢁPLQꢍ
Oꢅ
5=ꢁꢃꢊ
\
5=ꢁꢀꢄ
Figure 4-9
Size
Mounting suggestion for torque arms on F.29 - F.89
Rubber buffer
Washer
d5
untensioned tensioned
l1
l1x
d6
d1
c6min
[mm]
15
[mm]
14.0
13.5
18.5
18.5
17.5
28
[mm]
30
[mm]
10.5
10.5
12.5
12.5
12.5
21
[mm]
40
[mm]
29
39
49
69
79
89
4
4
6
6
6
8
15
30
40
20
40
50
20
40
50
20
40
50
30
60
75
Procedure
1. Use the washers according to the table above.
2. Use 2 nuts to secure the screw connection (lock nuts).
3. Tighten the screws until the rubber buffers are pretensioned to the dimension l1x.
You have now mounted the torque arm.
BA 2030
Operating Instructions, 06/12, 70000004040207
44
Installation
4.9 Installing and removing the shaft-mounted gearbox
4.9.5.3
Mounting torque arms on bevel gearboxes
NOTICE
The torque arm bush must be supported by bearings on both sides.
Figure 4-10 Mounting suggestion for torque arms on bevel gearbox K
Figure 4-11 Mounting suggestion for torque arms on bevel gearbox B
The torque arm can be mounted in various positions, depending on the hole circle pitch.
Procedure
1. Clean the contact surfaces between the housing and the torque arm.
2. Tighten the screws to the specified torque.
You have now mounted the torque arm.
Table 4- 8
Tightening torque for screws of strength class 8.8 when mounting the torque arm
Thread size
M8
25
M10
50
M12
90
M16
210
M20
450
M24
750
M30
Tightening torque [Nm]
1 500
BA 2030
Operating Instructions, 06/12, 70000004040207
45
Installation
4.9 Installing and removing the shaft-mounted gearbox
BA 2030
46
Operating Instructions, 06/12, 70000004040207
Commissioning
5
5.1
General information for commissioning
WARNING
Secure the drive unit to prevent it from being started up unintentionally.
Attach a warning notice to the start switch.
WARNING
Remove any oil spillage immediately with an oil-binding agent in compliance with
environmental requirements.
Checking the pressure breather valve
Check that the pressure breather valve is activated.
If the pressure breather valve has a transport fixture, then this must be removed before
commissioning.
ꢅꢁ
Figure 5-1
Pressure breather valve with securing clip
Remove the transport fixture by pulling the securing clip ① in the direction of the arrow.
5.2
Checking the oil level prior to commissioning
Check the oil level before commissioning and top up if necessary, see Checking and
For gearboxes with long-term preservation that are shipped completely filled with oil, we
recommend that for storage times exceeding 24 months, the oil is completely
BA 2030
Operating Instructions, 06/12, 70000004040207
47
Commissioning
5.3 Mounting the oil expansion unit
5.3
Mounting the oil expansion unit
An oil expansion unit can be used depending on the power, drive speed, type of construction
and transmission ratio. This is used to equalize changes in the oil volume caused by
temperature fluctuations in operation.
The oil expansion unit is supplied as mounting set, and can either be mounted vertically on
the geared motor or at an angle.
The oil expansion unit for sizes 39 to 89 is mounted using a screw connection at the highest
hole on the gearbox housing or motor bearing shield.
Before commissioning the gearbox, replace the pressure breather valve that is already
installed by the oil expansion unit provided.
Figure 5-2
Example of an oil expansion unit
Procedure:
1. Completely unscrew the pressure breather valve with transport fixture.
2. Screw in the completely preassembled oil equalization unit.
3. Align the oil equalization unit so that it is in a vertical position.
The vent valve must be replaced every year to ensure perfect functioning. When replacing,
prevent dirt and damaging atmospheres from entering the gearbox.
BA 2030
Operating Instructions, 06/12, 70000004040207
48
Operation
6
CAUTION
In the event of changes during operation, the drive unit must be switched off immediately.
Determine the cause of the fault using the fault table in Section Faults, causes and
Remedy faults or have faults remedied.
Check the gearbox during operation for:
● Excessive operating temperature
● Changes in gear noise
● Possible oil leakage at the housing and shaft seals.
BA 2030
Operating Instructions, 06/12, 70000004040207
49
Operation
BA 2030
50
Operating Instructions, 06/12, 70000004040207
Faults, causes and remedies
7
Note
Faults and malfunctions occurring during the warranty period and requiring repair work on
the gearbox must be remedied only by Technical Support. In the case of faults and
malfunctions occurring after the warranty period, the cause of which cannot be precisely
identified, we advise our customers to contact our Technical Support.
If you need the help of Technical Support, please provide the following information:
Data on the rating plate
Nature and extent of the fault
Suspected cause.
Table 7- 1
Faults
Faults, causes and remedies
Causes
Remedy
Unusual noises on the gearbox Oil level too low
Check the oil level, see
Foreign bodies in oil (irregular
noise)
Check the oil quality, see
Change the oil, see Checking
Excessive bearing play and / or Check bearing and replace
bearing defective
if necessary
Defective gearing
Check the gearing and replace
if necessary
Fastening bolts loose
Tighten bolts / nuts; see
Excessive external load on drive Check load against rated data
input and output
(you might need to correct the
belt tension, for example)
Damage in transit
Check the gearbox for damage
in transit
Damage due to blockage during Call Technical Support
commissioning
BA 2030
Operating Instructions, 06/12, 70000004040207
51
Faults, causes and remedies
Faults
Causes
Remedy
Unusual motor noises
Excessive bearing play and / or Check bearing and replace
bearing defective
if necessary
Motor brake rubbing
Check air gap and adjust
if necessary
Inverter parameterization
Correct parameterization
Oil leak
Incorrect oil level for the
mounting position being used
Check the mounting position,
Overpressure due to lack of
venting
Mount the venting as
appropriate for the mounting
position, see Mounting positions
Overpressure due to soiled
venting
Clean the venting, see
(Page 69).
Shaft sealing rings defective
Cover / flange bolts loose
Replace the shaft sealing rings
Tighten bolts / nuts, see
bolts (Page 71). Continue to
monitor the gearbox
Surface sealing defective
(e.g. on cover, flange)
Reseal
Damage in transit (e.g. hairline
cracks)
Check the gearbox for damage
in transit
Oil leak at the gearbox vent
Incorrect oil level for the
Check the venting and mounting
incorrect venting position
Frequent cold starts, during
which the oil foams up
Call Technical Support
BA 2030
Operating Instructions, 06/12, 70000004040207
52
Faults, causes and remedies
Remedy
Faults
Causes
Gearbox overheating
Motor fan cover and / or
gearbox very dirty
Clean the fan cover and surface
of the geared motor, see
Incorrect oil level for the
mounting position being used
Check the mounting position,
Incorrect oil being used
(e.g. incorrect viscosity)
Check the oil in the gearbox,
Oil is out of date
Check date of last oil change
and change oil if necessary, see
Excessive bearing play and / or Check bearing and replace
bearing defective
if necessary
Output shaft does not turn when Force flow interrupted by
Call Technical Support
motor is running
breakage in gearbox
Geared motor only starts with
difficulty or not at all
Incorrect oil level for the
mounting position being used
Check the mounting position,
Incorrect oil being used
(e.g. incorrect viscosity)
Check the oil in the gearbox,
Excessive external load on drive Check load against rated data
input and output
(you might need to correct the
belt tension, for example)
Motor brake is not released
Check circuit / connection of
brake. Check brake for wear
and readjust if necessary
Geared motor runs against
backstop
Change direction of motor or
backstop rotation
BA 2030
Operating Instructions, 06/12, 70000004040207
53
Faults, causes and remedies
Faults
Causes
Remedy
Excessive play at drive input
and output
Flexible elements worn (e.g. on Replace flexible elements.
couplings)
Positive connection disrupted by Call Technical Support
overload
Drop in speed / torque
Belt tension too low (in case of
belt drive)
Check belt tension and replace
belt if necessary
BA 2030
Operating Instructions, 06/12, 70000004040207
54
Service and maintenance
8
8.1
General notes about maintenance work
WARNING
Secure the drive unit to prevent it from being started up unintentionally.
Attach a warning notice to the start switch.
NOTICE
Service and maintenance must only be carried out by properly trained and authorized
personnel. Only original parts supplied by Siemens AG can be used for servicing and
maintenance.
All inspection, maintenance, and repair work must be carried out with care by trained
personnel only. Observe the information in Section General information and safety notes
(Page 7).
Table 8- 1
Measure
Maintenance measures
Time interval
Description of work
Monitor and check the geared
motor for unusual noises,
vibrations, and changes
Daily; if possible, more
frequently during operation
Check housing temperature
After 3 hours, on the first day,
thereafter monthly
Check the oil level
After the first day, and then
at the latest after 6 months
Check the oil level sensor
Check the oil quality
Every 6 months
BA 2030
Operating Instructions, 06/12, 70000004040207
55
Service and maintenance
8.1 General notes about maintenance work
Measure
Time interval
Description of work
First oil change after
commissioning
After approximately
10 000 operating hours or at the
latest after 2 years
Subsequent oil changes
Check gearbox for leaks
Every 2 years or
10 000 operating hours 1)
After the first day, thereafter
monthly
When required, replace the
gearbox breather valve
Once a year
Clean the gearbox
at least every 6 months
Carry out a complete inspection Every 12 months
of the geared motor
Check that fastening bolts on
gearboxes and built-on
accessories are securely
tightened. Check that covers
and plugs are securely
fastened.
After 3 h, and then every 2
years
Change the roller bearing
grease
When the oil is changed
Check rubber buffers on torque Every 6 months
arms
1) When using synthetic oils, the intervals can be doubled. The data specified is valid for an oil
temperature of +80 °C. See the figure titled "Guide values for oil change intervals" for oil change
intervals for other temperatures.
BA 2030
Operating Instructions, 06/12, 70000004040207
56
Service and maintenance
8.2 Checking and changing lubricants
8.2
Checking and changing lubricants
8.2.1
General safety notes for checking and changing lubricants
WARNING
Danger of scalding from the hot oil emerging from the unit.
Before starting any work wait until the oil has cooled down to below +30 °C.
WARNING
Remove any oil spillage immediately with an oil-binding agent in compliance with
environmental requirements.
NOTICE
Incorrect oil quantities can damage the gearbox.
The oil quantity and the position of the sealing elements are determined by the mounting
position.
After removing the oil level screw, up to and including gearbox size 89, the oil level may not
be more than 3 mm below the recommended filling level.
NOTICE
Dirt and damaging atmospheres can penetrate into the gearbox through open holes used to
check or drain the oil.
Immediately close the gearbox after checking the oil level or changing the oil.
Note
For data such as type of oil, oil viscosity, and oil quantity required, refer to the rating plate.
Note
Gearbox sizes 19 and 29 are lubricated for life:
No oil changes are required.
BA 2030
Operating Instructions, 06/12, 70000004040207
57
Service and maintenance
8.2 Checking and changing lubricants
8.2.2
Checking the oil level
NOTICE
The volume of gearbox oils changes with temperature.
If the temperature rises, the volume increases. Where temperature differences and filling
quantities are significant, the increase can amount to several liters.
The oil level must therefore be checked while still slightly warm, approximately 30 minutes
after switching off the drive unit.
ꢅꢁ
Figure 8-1
Oil level in the gearbox housing
Procedure
1. Switch off the power supply to the drive unit.
3. Check the oil level ①.
4. Top up the oil level ① if necessary, and check it again.
5. Check the condition of the sealing ring on the sealing element and if the sealing ring is
damaged, replace the sealing element with a new one.
6. After checking the oil level, immediately seal the gearbox using the sealing element.
You have now checked the oil level in the gearbox housing.
BA 2030
Operating Instructions, 06/12, 70000004040207
58
Service and maintenance
8.2 Checking and changing lubricants
8.2.3
Checking the oil level using the oil sight glass (optional)
If there is an oil sight glass to check the oil level ①, the oil must be visible in the center of
the sight glass when the oil is cool. When the oil is hot, the oil level ① is above the center of
the sight glass. The oil level ① of cold oil is below the center of the sight glass.
ꢅꢁ
Figure 8-2
Oil level in the oil sight glass
Top up the oil level ① if necessary, and check it again.
8.2.4
Checking the oil quality
Signs of changes in the oil can be seen with the naked eye. Fresh oil is clear to the eye, and
has a typical smell and a specific product color. Clouding or a flocculent appearance
indicates water and / or contamination. A dark or black color indicates residue, serious
thermal decomposition or contamination.
Observe the symbols in the diagrams of the mounting positions, see Mounting positions
(Page 79):
Venting
Oil level
Procedure
1. Allow the geared motor to run for a short time. Wear and contaminant particles are visible
in the oil shortly after shutting down.
2. Switch off the power supply to the drive unit.
3. Unscrew the sealing element at one of the points marked with the symbols listed above.
4. Remove some oil, using a suction pump and a flexible hose, for example.
5. Check the condition of the sealing ring on the sealing element and replace the sealing
ring if necessary.
6. Seal the gearbox with the sealing element.
7. Check the oil for abnormalities. If you detect any abnormalities, change the oil
immediately.
You have now checked the oil quality.
BA 2030
Operating Instructions, 06/12, 70000004040207
59
Service and maintenance
8.2 Checking and changing lubricants
8.2.5
Changing the oil
8.2.5.1
General safety notes for changing the oil
NOTICE
An impermissible mixture of oils will lead to clouding, depositing, foam formation, changes
to the viscosity or reduced protection against corrosion and wear.
When changing oil of the same type, the residual volume of oil in the gearbox should be
kept as low as possible. Generally speaking, a small residual volume will cause no
particular problems.
Gear oils of different types and by different manufacturers must not be mixed. Have the
manufacturer confirm that the new oil is compatible with the remaining volume of used oil.
If changing very different types of oil or oils with very different additives, always flush out
the gearbox with the new oil. When changing from mineral oil to polyglycol oil (PG) or vice
versa, it is vital to flush the gearbox twice. All traces of old oil must be completely removed
from the gearbox.
NOTICE
Gearbox oils must never be mixed with other substances. Do not flush with paraffin or other
solvents, as traces of these substances will always be left behind inside the gearbox.
Note
The oil must be warm. If it is too cold, it will flow too sluggishly to drain properly. If necessary,
run the gearbox for 15 to 30 minutes to warm it up.
BA 2030
60
Operating Instructions, 06/12, 70000004040207
Service and maintenance
8.2 Checking and changing lubricants
8.2.5.2
Draining the oil
Observe the symbols in the diagrams of the mounting positions, see Mounting positions
(Page 79):
Venting
Oil level
Oil drain
Procedure
1. Switch off the power supply to the drive unit.
2. Unscrew the vent plug.
3. Unscrew the oil level screw.
4. Place a suitable and sufficiently large receptacle underneath the oil drain plug.
5. Unscrew the oil drain plug and drain all the oil into the receptacle.
6. Check the condition of the sealing ring on the sealing element and if the sealing ring is
damaged, replace the sealing element with a new one.
7. After draining the oil, immediately seal the gearbox using the sealing element.
You have now drained the oil from the gearbox.
BA 2030
Operating Instructions, 06/12, 70000004040207
61
Service and maintenance
8.2 Checking and changing lubricants
8.2.5.3
Flushing the gearbox when changing between incompatible oils
NOTICE
Polyglycol oil has a higher density than mineral oil. Therefore, it sinks down towards the oil
drain and the mineral oil floats on top.
This makes the required complete draining of mineral oil from the gearbox extremely
difficult.
NOTICE
A flushing process is required with biodegradable and physiologically safe oils.
Note
After the second flush, we recommend that an an appropriate analysis institute checks the
quality of the flushed fluid.
Observe the symbols in the diagrams of the mounting positions, see Mounting positions
(Page 79):
Venting
Oil drain
Procedure
1. After the oil has been drained, wipe the gearbox clean of any remaining mineral oil using
a cloth.
2. Unscrew the vent plug.
3. Fill the gearbox with a flushing oil, using a filter (filter mesh max. 25 μm). For the flushing
oil, use either the new oil or one that is compatible with the new oil and is less expensive.
4. Operate the gearbox for 15 to 30 minutes under a low load.
5. Place a suitable and sufficiently large receptacle underneath the oil drain plug.
6. Unscrew the oil drain plug and drain all the oil into the receptacle.
7. After flushing, immediately seal the gearbox using the sealing element.
8. Repeat this step for the second flushing.
You have now flushed the gearbox twice and can pour in the new oil.
BA 2030
62
Operating Instructions, 06/12, 70000004040207
Service and maintenance
8.2 Checking and changing lubricants
8.2.5.4
Filling in oil
NOTICE
When adding oil, use the same oil type and viscosity. If changing mutually incompatible
oils, flushing cycles are required, see Flushing the gearbox when changing between
Observe the symbols in the type of construction diagrams, see Mounting positions
(Page 79):
Venting
Procedure
1. Unscrew the vent plug.
2. Fill the gearbox with fresh oil, using a filter (filter mesh, max. 25 μm).
3. Check the oil level.
4. Top up the oil level if necessary and check it again.
5. Check the condition of the sealing ring on the sealing element and if the sealing ring is
damaged, replace the sealing element with a new one.
6. After filling the oil, immediately seal the gearbox using the sealing element.
You have now filled up the gearbox with oil.
BA 2030
Operating Instructions, 06/12, 70000004040207
63
Service and maintenance
8.2 Checking and changing lubricants
8.2.6
Topping up with oil
You may need to top the gearbox up with oil if the gearbox mounting position changes or if
oil is lost due to a leak. If you notice oil escaping, locate the leak and seal the affected area.
Top up and check the oil level.
At the time of going to print, the following types of oil are being used when the gearbox is
filled for the first time:
CLP ISO VG220: ARAL Degol BG 220
CLP ISO PG VG220: Castrol Tribol 1300 / 220
CLP ISO PG VG460: Castrol Tribol 1300 / 460
CLP ISO PAO VG68: Addinol Eco Gear 68S-T
CLP ISO PAO VG220: Addinol Eco Gear 220S
CLP ISO E VG220: Fuchs Plantogear Bio 220S
CLP ISO H1 VG460: Klüber Klüberoil 4 UH1 460 N
If, following agreement, gearboxes are filled at the factory with special lubricants for the
special applications referred to above, this is shown on the rating plate.
8.2.7
Changing the roller bearing grease
The roller bearings are lubricated in the factory with the greases listed in the table.
When changing the oil, the specified grease quantity of grease-lubricated bearings should
also be replaced.
Clean the bearing before filling it with fresh lubricant.
In the case of bearings on the output shaft or intermediate shafts, the grease quantity must
fill 2/3, and in the case of bearings on the input side, 1/3 of the space between the rolling
elements.
Table 8- 2
Roller bearing and shaft sealing ring grease
Fields of application
Standard
Ambient temperature
-40 °C to +80 °C
-30 °C to +40 °C
Manufacturer
Klüber
Type
Petamo GHY 133 N
Obeen UF F2 NSF H1
Foodstuff-compatible
for the food industry
Castrol
Biologically degradable, -35 °C to +40 °C
for agriculture, forestry
and water industries
BP
Biogrease EP 2
BA 2030
Operating Instructions, 06/12, 70000004040207
64
Service and maintenance
8.2 Checking and changing lubricants
8.2.8
Service life of the lubricants
Note
In case of ambient conditions deviating from normal conditions, e.g. high ambient
temperatures, high relative humidity, aggressive ambient media, the intervals between
changes should be shorter. In such cases please contact Technical Support for assistance in
determining the individual lubricant change intervals.
Note
Oil sump temperatures above +80 °C can reduce service life. In this context, the rule is that
increasing the temperature by 10 K will approximately halve the service life, as illustrated in
the figure titled "Guide values for oil change intervals".
For a +80 °C oil sump temperature, the following service life can be expected when
observing the properties specified by Siemens AG:
Table 8- 3
Service life of the oils
Type of oil
Mineral oil
Service life
10 000 operating hours or 2 years
Biodegradable oil
Physiologically safe oil according to USDA-H1/-H2
Synthetic oil
20 000 operating hours or 4 years
BA 2030
Operating Instructions, 06/12, 70000004040207
65
Service and maintenance
8.2 Checking and changing lubricants
ꢅꢈꢊ
ꢅꢄꢊ
ꢅꢃꢊ
ꢅꢂꢊ
ꢅꢀꢊ
ꢅꢅꢊ
ꢅꢊꢊ
ꢎꢊ
ꢀꢁ
ꢅꢁ
ꢉꢊ
ꢇꢊ
ꢀꢄꢊ ꢄꢊꢊ ꢅꢊꢊꢊ
ꢀꢄꢊꢊ ꢄꢊꢊꢊ ꢅꢊꢊꢊꢊ ꢀꢄꢊꢊꢊ ꢄꢊꢊꢊꢊ
,ꢁ>K@
①
②
T
Mineral oil
Synthetic oil
Oil-bath steady-state temperature [°C]
Oil change interval in operating hours [h]
I
Figure 8-3
Guide values for oil change intervals
Grease service life of roller bearing greases
Roller bearings and the clearance in front are filled with sufficient grease.
Under approved operating conditions and ambient temperatures, no regreasing is required.
We recommend that the grease in the bearings is also renewed when the oil or shaft sealing
rings are replaced.
BA 2030
66
Operating Instructions, 06/12, 70000004040207
Service and maintenance
8.2 Checking and changing lubricants
8.2.9
Recommended lubricants
DANGER
The lubricants used have not been approved to USDA -H1/-H2 (United States Department
of Agriculture). They are not or only conditionally approved for use in the foodstuff or
pharmaceutical industry.
For applications in the food or pharmaceutical industry, only use the lubricants with USDA -
H1/-H2 approval listed in the released and recommended gearbox lubricants T 7300.
NOTICE
For applications outside the temperature range specified in the BA 7300 Operating
Instructions, please contact Technical Support for advice on which oil to use.
If the housing temperature exceeds a value of +80 °C, please contact Technical Support.
NOTICE
As standard, the lubricants and shaft seals are harmonized and coordinated with one
another corresponding to the prevailing operating conditions. When the operating
conditions change, the oil type changes or new shaft seals are inserted, please contact
Technical Support.
Note
The lubricants used are not at all or only conditionally biodegradable. If biologically
degradable lubricants are required, then only use the lubricants with the appropriate
classifications, listed in the released and recommended gearbox lubricants T 7300.
Note
These recommendations are not a guarantee of the quality of the lubricant provided by your
supplier. All lubricant manufacturers are responsible for the quality of their own products.
BA 2030
Operating Instructions, 06/12, 70000004040207
67
Service and maintenance
8.2 Checking and changing lubricants
The oil selected for use in the gearbox must be of the viscosity stated on the rating plate
(ISO VG class). The viscosity class indicated applies for the contractually agreed operating
conditions.
In the case of different operating conditions, please contact Technical Support.
If, following agreement, gearboxes are filled at the factory with special lubricants for the
special applications referred to above, this is shown on the rating plate.
The quality of the oil used must comply with the requirements laid down in the BA 7300
Operating Instructions; otherwise, the Siemens warranty is null and void. We urgently
recommend using one of the oils listed in the released and recommended lubricants T 7300
tested and comply with the requirements.
The oils listed there are subject to continuous testing. Under certain circumstances, it is
therefore possible that the oils recommended there are at a later point in time removed or
replaced by oils that have been further developed.
We recommend that you regularly check as to whether the selected lubricating oil is still
recommended by Siemens. Otherwise, a different oil type should be selected.
BA 2030
68
Operating Instructions, 06/12, 70000004040207
Service and maintenance
8.3 Checking the gearbox for leaks
8.3
Checking the gearbox for leaks
Note
From the inherent principle of operation, oil mist can escape from the vent valve or a
labyrinth seal.
Oil or grease escaping in small quantities from the shaft sealing ring should be regarded as
normal during the running-in phase of 24 hours operating time.
If the quantities escaping are significant or leaking continues after the running-in phase, the
shaft sealing ring must be replaced to prevent consequential damage.
Shaft sealing rings are subject to natural wear. The service life depends on the operating
conditions. We recommend that shaft sealing rings are included in periodic maintenance and
servicing work on the system.
Leakage / tightness
Table 8- 4
Status
Description and measures
Description
Measures
Notes
Film of moisture on the Film of moisture as a
Remove using a clean
cloth and continue to
observe.
This does not represent
a fault; frequently, in
the course of operation,
the sealing ring dries
off.
shaft sealing ring
result of the inherent
principle of operation
(apparent leakage)
Leakage at the shaft
sealing ring
Identifiable small trickle, Replace the sealing
formation of drops, also ring, determine the
During the run-in
period, the shaft sealing
ring beds into the shaft.
after the running-in
phase
possible cause of the
sealing ring failure and A visible track can be
rectify.
seen on the shaft.
Optimum preconditions
for a perfect seal are
obtained after the run-in
period.
8.4
Replacing the vent valve
The vent valve must be replaced every year to ensure perfect functioning.
When replacing, prevent dirt and damaging atmospheres from entering the gearbox.
BA 2030
Operating Instructions, 06/12, 70000004040207
69
Service and maintenance
8.5 Checking the oil level sensor (optional)
8.5
Checking the oil level sensor (optional)
The oil level sensor indicates the oil level only when the gearbox is shut down.
Lower the oil level and fill it up again until the oil level sensor gives a switching signal.
Please refer to the separate operating instructions for the oil level sensor.
8.6
Cleaning the gearbox
NOTICE
Dust deposits prevent heat radiation and cause high housing temperatures.
Keep the gearbox free from dirt and dust.
NOTICE
Do not use a high-pressure cleaning appliance to clean the gearbox.
Do not use tools with sharp edges.
Switch off the power supply to the drive unit before cleaning it.
BA 2030
Operating Instructions, 06/12, 70000004040207
70
Service and maintenance
8.7 Checking tightness of fastening bolts
8.7
Checking tightness of fastening bolts
Note
Replace damaged headless screws with new screws of the same type and strength class.
Switch off the power to the drive unit and use a torque wrench to check the seating of all
fastening bolts.
The general tolerance for the tightening torque in Nm is 10 %. The friction coefficient is
0.14 μ.
Table 8- 5
Tightening torques for fastening bolts
Tightening torque for strength class
Thread size
8.8
10.9
12.9
[Nm]
3
[Nm]
4
[Nm]
5
M4
M5
6
9
10
M6
10
15
18
M8
25
35
41
M10
M12
M16
M20
M24
M30
M36
50
70
85
90
120
295
580
1 000
2 000
3 600
145
355
690
1 200
2 400
4 200
210
450
750
1 500
2 500
8.8
Inspecting the gearbox or geared motor
Carry out a scheduled inspection of the geared motor once a year in accordance with the
Check the geared motor in accordance with the criteria set out in Section General
Touch up damaged paintwork carefully.
BA 2030
Operating Instructions, 06/12, 70000004040207
71
Service and maintenance
8.8 Inspecting the gearbox or geared motor
BA 2030
72
Operating Instructions, 06/12, 70000004040207
Disposal
9
WARNING
Incorrect disposal of used oil is a threat to the environment and health.
After use, oil must be taken to a used oil collection point. The addition of foreign substances
such as solvents and brake and cooling fluid is prohibited.
Avoid prolonged contact with the skin.
Empty the used oil from the gearbox. The used oil must be collected, stored, transported and
disposed of in accordance with regulations. Do not mix polyglycols with mineral oil.
Polyglycols must be disposed of separately.
Please observe country-specific laws. Under German law, oils with different disposal codes
may not be mixed with one another to allow optimal treatment of the oil (§4 VI Used Oil).
Collect and dispose of used oil in accordance with regulations.
Remove oil spillages immediately with an oil-binding agent in compliance with environmental
requirements.
Dispose of the housing parts, gears, shafts, and roller bearings of the geared motor as steel
scrap. The same applies to cast iron parts, if not separately collected.
Dispose of the packing material according to regulations or recycle it.
Table 9- 1
Disposal codes for gear oils
Designation
Type of oil
Mineral oil
Polyglycols
Disposal code
13 02 05
CLP ISO VG220
CLP ISO PG VG220
CLP ISO PG VG460
CLP ISO PAO VG68
CLP ISO PAO VG220
CLP ISO H1 VG460
CLP ISO E VG220
13 02 08
Poly-Alpha-Olefines
13 02 06
13 02 07
Biologically degradable oils
BA 2030
Operating Instructions, 06/12, 70000004040207
73
Disposal
BA 2030
74
Operating Instructions, 06/12, 70000004040207
Technical data
10
10.1
Type designation
Table 10- 1 Example of the type designation structure
Example
F
F
D
D
F
F
89
89
Gearbox type
Transmission stage
Type
Size
Table 10- 2 Type designation code
Gearbox type
(-)
B
Helical gearbox
Bevel gearbox, two-stage
Bevel gearbox, three-stage
Parallel shaft gearbox
K
F
Transmission stage
(-)
Z
Two-stage
D
Three-stage
Type
Shaft
(-) Solid shaft
Hollow shaft
A
Mounting
(-) Foot-mounted design
B
F
Foot / flange-mounted design
Flange-mounted design (A type)
Housing flange (C type)
Z
D
G
Torque arm
Flange (A type) opposite output shaft
Connection
(-) Parallel key
S
T
Shrink disk
Hollow shaft with splines
BA 2030
Operating Instructions, 06/12, 70000004040207
75
Technical data
10.2 General technical data
10.2
General technical data
The most important technical data appears on the rating plate of the gearboxes and geared
motors.
This data, together with the contractual agreements for the geared motors, determines the
limits of intended use.
In the case of geared motors, a rating plate attached to the motor usually indicates the data
for the entire drive.
In certain cases separate rating plates are mounted on the gearbox and the motor.
1
IEC60034
M1
2
4
7
SIEMENS
FDU0412/8999999 nnn
2KJ3105-1EM22-2AV1-Z
ZF59-LE90SG4E-L32/14N
IP55
SIEMENS
3
5
6
30kg
8
9
K-Id: 1234567890
10
1.5L OIL CLP PG VG220 i=28
11
15
17
12
13
14
50Hz
n2:49.3/min 60Hz
fB:2.1 T2: 1203Nm
n2: 59.7/min
fB:2.2
16 19
18 21
20
22
T2: 1213Nm
3~Mot.ThCl.155(F)
14 Nm 205-240V AC
23
28
31
24
34
25
42
26
37
27
38
40
43
50Hz
230/400V +/-10% D/Y 60Hz
cosPhi 0.78 2.2 A
460V
Y
29
30 36
32 39
35 41
4.33/2.5A
cosPhi 0.78
1725/min
1.1kW IE2-81.4%
1425/min 1.27kW IE2-84%
33
44
Mot. 1LE1001-0EB0
Figure 10-1 Rating plate example for Simogear
1
2
3
Matrix code
Applied standard
Serial No.
FDU = Siemens AG, Bahnhofstr. 40, 72072 Tübingen, Germany
CE marking or other marking, if required
Order No.
4
5
6
Model - Type - Size
7
Mounting position
8
9
Degree of protection to IEC 60034-5 or IEC 60529
Weight m [kg]
10
11
12
13
14
Customer ID
Oil quantity [l] main gearbox / intermediate gearbox
Type of oil
Oil viscosity ISO VG class to DIN 51519 / ISO 3448
Total transmission ratio i
Frequency 1
15
16
17
18
Rated frequency f [Hz]
Gearbox output speed n2 [rpm]
Geared motor output torque T2 [Nm]
Service factor fB
BA 2030
76
Operating Instructions, 06/12, 70000004040207
Technical data
10.2 General technical data
Frequency 2
19
20
21
22
Rated frequency f [Hz]
Gearbox output speed n2 [rpm]
Geared motor output torque T2 [Nm]
Service factor fB
Motor data
23
24
25
26
27
Phase number and type of current for the motor
Temperature class Th.Cl.
Symbols (IEC 60617-2):
= brake
Rated braking torque TBr [Nm]
Brake supply voltage U [V]
Frequency 1
28
29
30
31
32
33
34
35
Rated frequency f [Hz]
Rated voltage / range U [V]
Circuit, graphical symbols as per DIN EN 60617 Part 6 / IEC 60617-6
Rated current I N [A]
Power factor cos φ
Rated power P N [kW], duty type (if ≠ S1)
Efficiency class marking acc. to IEC 60034-30
Rated speed n N [rpm]
Frequency 2
36
37
38
39
40
41
42
43
44
Rated frequency f [Hz]
Rated voltage / range U [V]
Rated current I N [A]
Power factor cos φ
Circuit, graphical symbols as per DIN EN 60617 Part 6 / IEC 60617-6
Rated power P N [kW], duty type (if ≠ S1)
Efficiency class marking
Rated speed n N [rpm]
Motor designation, active part
BA 2030
Operating Instructions, 06/12, 70000004040207
77
Technical data
10.3 Weight
10.3
Weight
The weight of the entire geared motor is given in the shipping papers.
If the weight exceeds 30 kg, the weight of the entire geared motor is indicated on the rating
plate of the gearbox or geared motor.
Where there are several rating plates on one geared motor, the specification on the main
gearbox is decisive.
The weight specification refers only to the product in the delivery state.
10.4
Sound energy level
SIMOGEAR geared motors have noise levels below the permissible noise levels defined for
gearboxes in VDI guideline 2159 and for motors in IEC 60034-9. In conjunction with
gearboxes, the motor noise values LpfA or LWA increase on average by 3 dB (A).
The circumferential velocity of the motor pinion has a significant influence on the additional
gearbox noise. As a consequence, higher speeds or lower ratios result in higher noise.
External noise
Noises not generated by the gearbox but emitted from it are not taken into consideration
here.
Similarly, noises emitted from the input and output machines and from the foundation are not
taken into consideration here, even if transmitted to these by the gearbox.
BA 2030
78
Operating Instructions, 06/12, 70000004040207
Technical data
10.5 Mounting positions
10.5
Mounting positions
10.5.1
General notes on mounting positions
The gearbox must be operated only in the mounting position specified on the rating plate.
This ensures that the correct quantity of lubricant is provided.
Note
Gearbox sizes 19 and 29 are lubricated for life.
There are no openings to check the oil level. Mounting positions M2 and M4 are equipped
with a vent valve.
Description of the symbols:
Venting
Oil level
Oil drain
A, B
*
Position of insert shaft / solid shaft
On opposite side
Two-stage gearbox
②
③
④
Three-stage gearbox
Tandem gearbox
Optional oil hole facing output side
Alternatively
⑤
- - -
BA 2030
Operating Instructions, 06/12, 70000004040207
79
Technical data
10.5 Mounting positions
10.5.2
Two- and three-stage helical gearboxes
M1
M2
2
1
4
A
D/Z19
*
D/Z29
D/Z19
4
1
2
A
M3
M4
A
4
1
2
A
4
2
1
D/Z29
D/Z19
*
D/Z19
M5
M6
A
1
3
3
1
4
2
2
4
A
Mounting position for helical gearboxes D / Z in a foot-mounted design, sizes 19 - 29
BA 2030
Operating Instructions, 06/12, 70000004040207
80
Technical data
10.5 Mounting positions
M1
M2
2
1
4
A
4
1
2
A
M3
M4
A
4
2
1
A
4
1
2
M5
M6
1
3
A
3
1
3
2
2
4
4
2
A
Mounting position for helical gearboxes D / Z in a foot-mounted design, sizes 39 - 89
BA 2030
Operating Instructions, 06/12, 70000004040207
81
Technical data
10.5 Mounting positions
M1
M2
2
1
4
A
4
1
2
A
M3
M4
A
4
1
2
A
4
2
1
M5
M6
3
1
1
3
A
4
2
2
4
A
Mounting position for helical gearboxes DB / ZB in a foot / flange-mounted design, size 29
BA 2030
Operating Instructions, 06/12, 70000004040207
82
Technical data
10.5 Mounting positions
M1
M2
2
1
4
A
4
1
2
A
M3
M4
A
4
2
1
A
4
1
2
M5
M6
1
3
A
3
1
3
2
2
4
4
2
A
Mounting position for helical gearboxes DB / ZB in a foot / flange-mounted design, sizes 39 -
89
BA 2030
Operating Instructions, 06/12, 70000004040207
83
Technical data
10.5 Mounting positions
M1
M2
2
1
4
D./Z.19
*
A
D./Z.29
4
A
1
2
D./Z.19
M3
M4
A
4
1
2
2
1
4
A
D./Z.29
D./Z.19
*
D./Z.19
29
M5
M6
1
3
A
3
4
2
2
4
1
A
Mounting position for helical gearboxes DF / ZF in a flange-mounted design and DZ / ZZ in a
housing flange-mounted design, sizes 19 - 29
BA 2030
84
Operating Instructions, 06/12, 70000004040207
Technical data
10.5 Mounting positions
M1
M3
M5
M2
M4
M6
2
1
4
A
4
A
1
2
2
1
4
A
A
4
1
2
3
2
Mounting position for helical gearboxes DF / ZF in a flange design and DZ / ZZ in a housing
flange design, size 39
BA 2030
Operating Instructions, 06/12, 70000004040207
85
Technical data
10.5 Mounting positions
M1
M2
2
1
4
A
4
1
2
A
*
M3
M4
*
2
1
4
A
A
4
1
2
M5
M6
*
1
A
*
3
3
2
4
2
4
2
3
*
*
A
1
Mounting position for helical gearboxes DF / ZF in a flange-mounted design and DZ / ZZ in a
housing flange-mounted design, sizes 49 - 89
BA 2030
86
Operating Instructions, 06/12, 70000004040207
Technical data
10.5 Mounting positions
M1
M2
2
1
4
3
A
2
4
1
2
A
M3
M4
A
4
2
1
A
4
1
2
M5
M6
*
3
1
1
A
2
2
A
3
*
Mounting position for parallel shaft gearboxes F.AD in a shaft-mounted design, sizes 39 - 89
BA 2030
88
Operating Instructions, 06/12, 70000004040207
Technical data
10.5 Mounting positions
M1
M3
M5
M2
2
1
4
A
4
A
1
2
M4
A
4
2
1
A
4
1
2
M6
3
1
1
3
A
2
2
A
*
Mounting position for parallel shaft gearbox F.F in a flange-mounted design and F.Z in a
housing flange-mounted design, size 29
BA 2030
Operating Instructions, 06/12, 70000004040207
89
Technical data
10.5 Mounting positions
M1
M2
3
2
1
4
A
4
A
1
2
2
M3
M4
A
4
2
1
A
4
1
2
M5
M6
*
1
3
A
3
1
2
2
A
*
Mounting position for parallel shaft gearbox F.F in a flange-mounted design and F.Z in a
housing flange-mounted design, sizes 39 - 89
BA 2030
Operating Instructions, 06/12, 70000004040207
90
Technical data
10.5 Mounting positions
M1
M3
M5
M2
2
1
4
A
4
A
1
2
M4
A
4
2
1
A
4
1
2
M6
3
1
1
A
2
2
*
A
3
Mounting position for parallel shaft gearbox F in a foot-mounted design, size 29
BA 2030
Operating Instructions, 06/12, 70000004040207
91
Technical data
10.5 Mounting positions
M1
M2
2
1
4
3
A
2
4
1
2
A
M3
M4
A
4
2
1
A
4
1
2
M5
M6
*
3
1
1
3
A
2
2
A
*
Mounting position for parallel shaft gearbox F in a foot-mounted design, sizes 39 - 89
BA 2030
Operating Instructions, 06/12, 70000004040207
92
Technical data
10.5 Mounting positions
0ꢅ
0ꢀ
$
%
%
$
$
$
%
%
%
$
0ꢂ
0ꢃ
%
%
$
%
$
$
%
$
%
$
0ꢄ
0ꢈ
$
%
%
$
Figure 10-3 Mounting position for bevel gearbox B foot-mounted design, sizes 39 - 49
BA 2030
Operating Instructions, 06/12, 70000004040207
94
Technical data
10.5 Mounting positions
0ꢅ
0ꢀ
B
A
A
B
A
B
0ꢂ
0ꢃ
B
A
B
A
0ꢄ
0ꢈ
B
A
A
B
Figure 10-4 Mounting position for bevel gearbox B.Z housing flange design and B.F flange design,
size 29
BA 2030
Operating Instructions, 06/12, 70000004040207
95
Technical data
10.5 Mounting positions
0ꢅ
0ꢀ
A
B
A
B
B
A
B
A
A
B
0ꢂ
0ꢃ
B
A
B
A
A
B
A
B
B
A
0ꢄ
0ꢈ
A
B
B
A
Figure 10-5 Mounting position for bevel gearbox B.Z housing flange design and B.F flange design,
sizes 39 and 49
BA 2030
96
Operating Instructions, 06/12, 70000004040207
Technical data
10.5 Mounting positions
0ꢅ
0ꢀ
$
%
%
$
%
$
0ꢂ
0ꢃ
$
%
%
$
0ꢄ
0ꢈ
%
$
$
%
Figure 10-6 Mounting position for bevel gearbox BAD shaft-mounted design, size 29
BA 2030
Operating Instructions, 06/12, 70000004040207
97
Technical data
10.5 Mounting positions
0ꢅ
0ꢀ
$
%
$
%
%
$
$
%
$
%
0ꢂ
%
0ꢃ
$
%
$
$
%
$
%
%
$
0ꢄ
0ꢈ
$
%
$
%
Figure 10-7 Mounting position for bevel gearbox BAD shaft-mounted design, sizes 39 - 49
BA 2030
Operating Instructions, 06/12, 70000004040207
98
Technical data
10.5 Mounting positions
M1
M2
B
A
A
B
2
1
4
A
B
B
A
B
A
B
A
A
1
A
2
3
4
A
1
2
*
M3
M4
*
A
4
A
1
2
1
3
2
A
4
1
2
A
B
A
B
B
A
B
A
A
B
M5
M6
*
A
1
B
A
A
3
2
2
3
*
B
1
A
Mounting position for bevel gearbox K in a foot-mounted design, sizes 39 - 89
BA 2030
Operating Instructions, 06/12, 70000004040207
99
Technical data
10.5 Mounting positions
M1
M2
B
A
2
1
4
A
B
B
A
A
B
A
A
B
1
A
2
3
4
1
2
*
M3
M4
*
A
4
A
1
2
1
3
2
A
4
B
A
1
2
A
B
B
A
B
A
M5
M6
A
*
A
1
B
A
3
2
2
3
B
*
1
A
Mounting position for bevel gearbox KAZ in a housing flange-mounted design and K.F in a
flange-mounted design, sizes 39 - 89
BA 2030
Operating Instructions, 06/12, 70000004040207
100
Technical data
10.5 Mounting positions
M1
M2
B
A
2
1
4
B
A
A
B
B
A
B
A
A
1
A
2
3
4
A
1
2
*
M3
M4
*
A
4
A
1
2
1
3
2
A
A
4
1
2
B
B
A
B
A
M5
M6
*
A
1
B
A
A
B
3
2
1
2
3
*
A
Mounting position for bevel gearboxes KAD in a shaft-mounted design, sizes 39 - 89
BA 2030
Operating Instructions, 06/12, 70000004040207
101
Technical data
10.6 Oil quantities
10.6
Oil quantities
NOTICE
Incorrect oil quantities damage the gearbox.
The oil quantities listed in the tables are guide values for changing the oil.
They are used, for example, for lubricant storage and procurement. The precise values
depend on the number of stages and transmission ratio of the gearbox.
The oil level must be checked before commissioning.
10.6.1
Helical gearbox
Table 10- 3 Oil quantities [l] for D / Z and DB / ZB. Sizes 19 - 89
Type
Mounting position
M1
M2
0.5
0.7
0.95
1.9
2
M3
0.4
0.45
0.85
1.9
1.9
2.6
4
M4
0.5
0.6
0.95
1.9
1.9
2.6
4
M5
0.35
0.55
0.9
1.8
1.9
2.3
3.8
6.6
0.35
0.55
0.8
1.7
1.8
2.2
3.5
6
M6
0.3
0.3
0.25
0.65
0.6
0.85
1.4
2.4
0.3
0.4
0.7
1.2
1.2
1.5
2.4
4.2
Z.19
Z.29
Z.39
Z.49
Z.59
Z.69
Z.79
Z.89
D.19
D.29
D.39
D.49
D.59
D.69
D.79
D.89
0.2
0.2
0.3
0.55
0.65
0.65
1.1
2.1
3.7
6.9
0.5
0.65
0.9
1.8
1.9
2
2.2
6.7
0.4
0.45
0.8
1.8
1.9
2.4
3.9
6.2
6.7
0.5
0.5
0.85
1.7
1.8
2.3
3.7
6
0.2
0.15
0.25
0.55
0.45
0.6
0.9
3.5
6.5
2
BA 2030
Operating Instructions, 06/12, 70000004040207
102
Technical data
10.6 Oil quantities
Table 10- 4 Oil quantities [l] for DF / ZF and DZ / ZZ sizes 19 - 89
Type
Mounting position
M1
0.2
0.2
0.3
0.55
0.65
0.65
1
M2
0.5
0.7
0.95
1.9
2
M3
0.4
0.45
0.85
19,
1.9
2.6
3.8
6.7
0.4
0.45
0.8
1.8
1.9
2.4
3.9
6.2
M4
0.5
0.6
0.95
19,
1.9
2.6
3.8
6.7
0.5
0.5
0.85
1.7
1.8
2.3
3.7
6
M5
0.35
0.55
0.9
1.8
1.9
2.3
3.6
6.6
0.35
0.55
0.8
1.7
1.8
2.2
3.5
6
M6
0.3
0.3
0.25
0.65
0.6
0.85
1.3
2.4
0.3
0.4
0.7
1.2
1.2
1.5
2.4
4.2
Z.19
Z.29
Z.39
Z.49
Z.59
Z.69
Z.79
Z.89
D.19
D.29
D.39
D.49
D.59
D.69
D.79
D.89
2.1
3.6
6.9
0.5
0.65
0.9
1.8
1.9
2
2.2
0.2
0.15
0.25
0.55
0.45
0.6
0.9
2
3.5
6.5
BA 2030
Operating Instructions, 06/12, 70000004040207
103
Technical data
10.6 Oil quantities
10.6.2
Parallel shaft gearbox
Table 10- 5 Oil quantities [l] for F., F.Z and F.D sizes 29 - 89
Type
Mounting position
M1
0.6
0.95
1.6
2.2
2.8
4.9
0.6
0.95
2.1
2.2
3
M2
0.9
1.3
2.5
2.8
4.1
7.7
0.8
1.1
2.3
2.7
3.8
7.6
M3
0.4
0.8
1.6
1.6
2.9
5.9
0.35
0.7
1.5
1.6
2.7
5.9
M4
0.7
1.4
2.5
2.9
4.2
8.4
0.6
1.2
2.3
2.7
3.9
7.8
M5
0.5
0.9
1.6
1.9
2.7
5.2
0.45
0.8
1.5
1.8
2.6
5.1
M6
0.45
0.85
1.6
1.9
2.9
5.5
0.45
0.8
1.5
1.8
2.7
5.2
FZ.29
FZ.39
FZ.49
FZ.69
FZ.79
FZ.89
FD.29
FD.39
FD.49
FD.69
FD.79
FD.89
5.6
Table 10- 6 Oil quantities [l] for F.F sizes 29 - 89
Type
Mounting position
M1
0.6
1
M2
0.9
1.4
2.4
2.8
4.2
7.8
0.8
1.2
2.3
2.7
3.9
7.7
M3
0.4
0.85
1.5
1.6
2.9
5.9
0.35
0.75
1.5
1.6
2.7
5.9
M4
0.7
1.6
2.6
3
M5
0.5
0.95
1.6
2
M6
0.45
0.9
1.6
1.9
2.8
5.5
0.45
0.85
1.5
1.8
2.6
5.2
FZ.29
FZ.39
FZ.49
FZ.69
FZ.79
FZ.89
FD.29
FD.39
FD.49
FD.69
FD.79
FD.89
1.8
2.3
2.9
5.1
0.6
1
4.3
8.6
0.6
1.3
2.4
2.8
4
2.9
5.4
0.45
0.8
1.6
1.9
2.7
5.3
2.2
2.3
3.1
5.7
7.9
BA 2030
Operating Instructions, 06/12, 70000004040207
104
Technical data
10.6 Oil quantities
10.6.3
Bevel gearboxes
Table 10- 7 Oil quantities [l] for B sizes 29 - 49
Type
Mounting position
M1
0.3
0.5
1.1
M2
0.6
1
M3
0.75
1.3
M4
0.9
1.7
3.2
M5
0.55
1
M6
0.5
B.29
B.39
B.49
0.85
1.6
1.8
2.5
1.9
Table 10- 8 Oil quantities [l] for K. and KA sizes 39 - 89
Type
Mounting position
M1
0.35
0.55
0.75
1
M2
0.85
1.4
2
M3
1.1
1.8
2.5
2.9
5.5
M4
1.2
1.9
2.7
3.4
6.3
M5
0.85
1.5
2.2
2.5
4.6
M6
0.9
1.6
2.2
2.6
4.8
K.39
K.49
K.69
K.79
K.89
2.2
4.3
1.8
Table 10- 9 Oil quantities [l] for KAF, KAZ and KAD sizes 39 - 89
Type
Mounting position
M1
M2
0.9
1.5
2.1
2.5
4.7
M3
1.2
1.9
2.8
3.4
6.2
M4
1.3
2.2
3.2
4.1
7.3
M5
0.95
1.6
2.4
2.9
5.3
M6
0.95
1.6
2.5
3.2
5.6
KA.39
KA.49
KA.69
KA.79
KA.89
0.4
0.65
0.85
1.2
2.2
Table 10- 10 Oil quantities [l] for KF sizes 39 - 89
Type
Mounting position
M1
M2
0.9
1.4
2
M3
1.2
2
M4
1.3
2.2
3.1
4.1
7.3
M5
0.95
1.6
2.4
2.9
5.3
M6
1
KF39
KF49
KF69
KF79
KF89
0.35
0.6
1.7
2.4
3.2
5.6
0.85
1.2
2.8
3.4
6.2
2.5
4.7
2.2
BA 2030
Operating Instructions, 06/12, 70000004040207
105
Technical data
10.6 Oil quantities
BA 2030
106
Operating Instructions, 06/12, 70000004040207
Spare parts
11
11.1
Stocking of spare parts
By stocking the most important spare and wearing parts on site, you can ensure that the
gearbox or geared motor is ready for use at any time.
NOTICE
Please note that spare parts and accessories not supplied by us have not been tested or
approved by us.
The installation and / or use of such products can therefore have a negative impact on the
design characteristics of the geared motor and might consequently impair the active
and / or passive safety features of the machine.
Siemens AG will accept no liability or warranty whatsoever for damage occurring as a result
of the use of non-original spare parts or accessories.
We can only accept liability for original spare parts supplied by us.
Please note that single components often have special production and supply specifications.
We always supply spare parts which meet state-of-the-art technical standards and comply
with the latest legal requirements.
Please state the following data when ordering spare parts:
● Serial no., see rating plate ③
● Type designation, see rating plate ⑥
● Part no. (4-digit item no. from spare parts list, 6-digit code no., 7-digit article no. or 14-
digit material no.)
● Quantity
1
9
IEC60034
M1
2
4
7
SIEMENS
FDU0412/8999999 nnn
2KJ3105-1EM22-2AV1-Z
ZF59-LE90SG4E-L32/14N
IP55
SIEMENS
3
5
6
30kg
8
K-Id: 1234567890
10
1.5L OIL CLP PG VG220 i=28
11
15
17
12
13
14
50Hz
n2:49.3/min 60Hz
fB:2.1 T2: 1203Nm
n2: 59.7/min
fB:2.2
16 19
18 21
20
22
T2: 1213Nm
3~Mot.ThCl.155(F)
14 Nm 205-240V AC
23
28
31
24
34
25
42
26
37
27
38
40
43
50Hz
230/400V +/-10% D/Y 60Hz
cosPhi 0.78 2.2 A
460V
Y
29
30 36
32 39
35 41
4.33/2.5A
cosPhi 0.78
1725/min
1.1kW IE2-81.4%
1425/min 1.27kW IE2-84%
33
44
Mot. 1LE1001-0EB0
Figure 11-1 Rating plate example
BA 2030
Operating Instructions, 06/12, 70000004040207
107
Spare parts
11.2 Helical gearboxes D / Z, sizes 19 - 89
11.2
Helical gearboxes D / Z, sizes 19 - 89
Note
For gearbox, sizes 19 and 29, we recommended that the gearbox is replaced if service is
required.
Parts subject to wear are available on request.
1001 Gearbox housing
1020 Bearing
1025 Locking ring
1028 Bearing
1030 Bearing
1031 Supporting disk
1032 Shim
1034 NILOS ring
BA 2030
Operating Instructions, 06/12, 70000004040207
108
Spare parts
11.2 Helical gearboxes D / Z, sizes 19 - 89
1035 Locking ring
1037 Locking ring
1038 Locking ring
1040 Output flange
1045 Bolt
1050 Housing cover
1051 Bolt
1055 Seal
1065 Sealing cap
1070 Sealing cap
1101 Output shaft
1105 Parallel key
1130 Bearing
1133 NILOS ring
1135 Locking ring
1140 Bearing
1141 Supporting disk / shim
1144 Supporting disk / shim
1145 Locking ring
1160 Shaft sealing ring
1210 Bolt
1212 Nut
1225 Seal
1301 Plug-in pinion
1305 Helical
1306 Parallel key
1315 Bearing
1316 Locking ring
1320 Bearing
1321 Locking ring
1325 Pinion shaft
1330 Helical
1331 Parallel key
1332 Bush / locking ring
1340 Pinion shaft
1344 Spacer / bush
1345 Helical
1346 Parallel key
1401 Screw plug
1420 Vent filter
1430 Eyebolt
Figure 11-2 Helical gearboxes D. / Z., sizes 19 - 89
BA 2030
Operating Instructions, 06/12, 70000004040207
109
Spare parts
11.3 Parallel shaft gearboxes F sizes 29 - 89
11.3
Parallel shaft gearboxes F sizes 29 - 89
Note
For gearbox, size 29, we recommended that the gearbox is replaced if service is required.
Parts subject to wear are available on request.
ꢐ
ꢐ
V
H
JHV
D
ꢐ
V
DJ
W
H
VW
V
ꢋ
ꢀ
ꢋ
DJ
ꢂ
W
ꢏ
ꢏ
ꢁ
ꢁ
V
ꢋ
ꢂ
)=
)'
ꢏ
ꢁ
)'
1001 Gearbox housing
1020 Bearing
1030 Bearing
1031 Supporting disk
1032 Shim
1034 NILOS ring
BA 2030
110
Operating Instructions, 06/12, 70000004040207
Spare parts
11.3 Parallel shaft gearboxes F sizes 29 - 89
1035 Locking ring
1040 Output flange
1043 Plug
1044 Plug
1045 Bolt
1050 Housing cover
1051 Bolt
1055 Seal
1065 Sealing cap
1070 Sealing cap
1091 Rubber bush
1093 Plug
1101 Output shaft
1102 Bronze bushing
1104 Seal
1105 Parallel key
1114 Cover NDE
1115 Seal
1116 Bolt
1117 Screw lock
1118 Plug / sealing cap
1120 Shrink disk
1121 Shrink disk
1129 Supporting disk
1130 Bearing
1131 Shim
1132 Supporting disk / shim
1133 NILOS ring
1135 Locking ring
1138 Locking ring
1139 Supporting disk
1140 Bearing
1141 Supporting disk / shim
1143 NILOS ring
1144 Supporting disk / shim
1146 Locking ring
1160 Shaft sealing ring
1162 O ring
1210 Bolt
1211 Screw lock
1212 Nut
1225 Seal
1301 Plug-in pinion
1305 Helical
1306 Parallel key
BA 2030
Operating Instructions, 06/12, 70000004040207
111
Spare parts
11.3 Parallel shaft gearboxes F sizes 29 - 89
1307 Spacer / bush
1315 Bearing
1320 Bearing
1321 Locking ring
1325 Pinion shaft
1330 Helical
1331 Parallel key
1340 Pinion shaft
1345 Helical
1346 Parallel key
1401 Screw plug
1410 Mounting accessories
1411 Bolt
1412 Locking ring
1413 Disk
1415 Locking ring
1418 Sealing cap
1420 Vent filter
1430 Eyebolt
Figure 11-3 Parallel shaft gearboxes F sizes 29 - 89
BA 2030
112
Operating Instructions, 06/12, 70000004040207
Spare parts
11.4 Bevel gearbox B sizes 29 - 49
1001 Gearbox housing
1020 Bearing
1027 Locking ring
1030 Bearing
1031 Supporting disk
1032 Shim
1035 Locking ring
1037 Locking ring
1040 Output flange
1045 Bolt
1050 Housing cover
1051 Bolt
1055 Seal
1070 Sealing cap
1090 Torque arm
1091 Rubber bush
1095 Bolt
1096 Screw lock
1101 Output shaft
1102 Bronze bushing
1104 Seal
1105 Parallel key
1114 Cover NDE
1115 Seal
1116 Bolt
1118 Plug / sealing cap
1120 Shrink disk
1129 Supporting disk
1130 Bearing
1131 Shim
1135 Locking ring
1139 Supporting disk
1140 Bearing
1144 Supporting disk / shim
1146 Locking ring
1160 Shaft sealing ring
1210 Bolt
1212 Nut
1214 Plug
1225 Seal
1301 Plug-in pinion
1305 Helical
1306 Parallel key
1313 Bolt
1314 Screw lock
BA 2030
114
Operating Instructions, 06/12, 70000004040207
Spare parts
11.4 Bevel gearbox B sizes 29 - 49
1320 Bearing
1351 Parallel key
1401 Screw plug
1410 Mounting accessories
1411 Bolt
1412 Locking ring
1413 Disk
1415 Locking ring
1418 Sealing cap
1420 Vent filter
1430 Eyebolt
Figure 11-4 Bevel gearbox B sizes 29 - 49
BA 2030
Operating Instructions, 06/12, 70000004040207
115
Spare parts
11.5 Bevel gearbox K sizes 39 - 89
1030 Bearing
1031 Supporting disk
1032 Shim
1040 Output flange
1043 Plug
1045 Bolt
1050 Housing cover
1051 Bolt
1055 Seal
1057 Bolt
1058 Supporting disk
1060 Tapered roller bearing
1061 Supporting disk
1062 Shim
1063 NILOS ring
1065 Sealing cap
1066 Locking ring
1067 Locking ring
1068 Tapered roller bearing
1070 Sealing cap
1090 Torque arm
1091 Rubber bush
1093 Plug
1095 Bolt
1096 Screw lock
1101 Output shaft
1102 Bronze bushing
1104 Seal
1105 Parallel key
1114 Cover NDE
1115 Seal
1116 Bolt
1118 Plug / sealing cap
1120 Shrink disk
1121 Shrink disk
1129 Supporting disk
1130 Bearing
1131 Shim
1132 Supporting disk / shim
1133 NILOS ring
1135 Locking ring
1138 Locking ring
1139 Supporting disk
1140 Bearing
1141 Supporting disk / shim
BA 2030
Operating Instructions, 06/12, 70000004040207
117
Spare parts
11.5 Bevel gearbox K sizes 39 - 89
1143 NILOS ring
1144 Supporting disk / shim
1146 Locking ring
1160 Shaft sealing ring
1162 O ring
1165 Seal
1210 Bolt
1212 Nut
1225 Seal
1301 Plug-in pinion
1305 Helical
1306 Parallel key
1312 Disk
1313 Bolt
1314 Screw lock
1320 Bearing
1325 Pinion shaft
1327 Parallel key
1328 Locking ring
1331 Parallel key
1340 Pinion shaft
1345 Helical
1346 Parallel key
1401 Screw plug
1410 Mounting accessories
1411 Bolt
1412 Locking ring
1413 Disk
1415 Locking ring
1418 Sealing cap
1420 Vent filter
1430 Eyebolt
Figure 11-5 Bevel gearbox K sizes 39 - 89
BA 2030
118
Operating Instructions, 06/12, 70000004040207
Declaration of Incorporation
12
Declaration of Incorporation according to Directive 2006/42/EC Annex II 1 B.
Manufacturer:
Address:
Siemens AG
Bahnhofstraße, 72072 Tübingen, Germany
Product designation:
SIMOGEAR
Types:
Two- and three-stage helical gearboxes, types
D. / Z.19, D. / Z.29, D. / Z.39, D. / Z.49, D. / Z.59,
D. / Z.69, D. / Z.79, D. / Z.89
Parallel shaft gearboxes, types
F.29, F.39, F.49, F.69, F.79, F.89
Bevel gearboxes, types
B.29, B.39, B.49, K.39, K.49, K.69, K.79, K.89
The designated product is an incomplete machine in the sense of Article 2 g of the directive
2006/42/EC. It is exclusively designed for incorporation into another machine or for assembly
with one or several machines.
The following essential safety and health requirements of directive 2006/42/EC, Annex I are
relevant for the incomplete machine specified above and are applied. The risks not relevant
for the product are not listed.
● 1.1, 1.1.2, 1.1.3, 1.1.5
● 1.2.4.4, 1.2.6
● 1.3.1, 1.3.2, 1.3.3, 1.3.4, 1.3.6, 1.3.8.1
● 1.4.1, 1.4.2, 1.4.2.1
● 1.5.1, 1.5.2, 1.5.4, 1.5.5, 1.5.6, 1.5.8, 1.5.9, 1.5.10, 1.5.11, 1.5.13, 1.5.15
● 1.6.1, 1.6.2
● 1.7.1, 1.7.1.1, 1.7.2, 1.7.3, 1.7.4, 1.7.4.1, 1.7.4.2, 1.7.4.3
When developing and manufacturing the above designated products, the following standards
and specifications were applied: EN ISO 12100-1:2011
The special technical documents according to Annex VII, B of the directive 2006/42/EC were
generated and will be provided to the appropriate authorities when justifiably requested in an
electronic form.
BA 2030
Operating Instructions, 06/12, 70000004040207
119
Declaration of Incorporation
Nominated person for compiling the technical documentation:
Georg Böing, Head of Research and Development Gears.
Before the final product is commissioned, in which the incomplete machine described here
should be incorporated, then it must be ensured that this is in conformance with directive
2006/42/EC.
Tübingen, May 1, 2012
Georg Böing
Head of Research & Development Gears
Lothar Hirschberger
Head of Quality Management
BA 2030
Operating Instructions, 06/12, 70000004040207
120
Futher information
SIMOGEAR on the Internet
www.siemens.com/simogear
Siemens AG
Subject to change
Industry Sector
Mechanical Drives
Postfach 1709
72007 Tübingen
GERMANY
© Siemens AG 2012
www.siemens.com/drivetechnology
|