SIMOGEAR gearbox BA 2030 Operating Instructions · 06/2012 SIMOGEAR Answers for industry. BA 2030 General information and 1 ___________________ safety notes 2 ___________________ Technical description SIMOGEAR Gearbox BA 2030 Incoming goods, transport, 3 ___________________ and storage 4 ___________________ Installation ___________________ 5 Commissioning ___________________ 6 Operation Operating Instructions ___________________ 7 Faults, causes and remedies ___________________ 8 Service and maintenance ___________________ 9 Disposal ___________________ 10 Technical data ___________________ 11 Spare parts ___________________ 12 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 Industry Sector Postfach 48 48 90026 NÜRNBERG GERMANY 70000004040207 Ⓟ 07/2012 Technical data subject to change Copyright © Siemens AG 2012. All rights reserved Table of contents 1 2 3 4 General information and safety notes ........................................................................................................ 7 1.1 General information .......................................................................................................................7 1.2 Copyright........................................................................................................................................8 1.3 Intended use ..................................................................................................................................9 1.4 Obligations of the user ...................................................................................................................9 1.5 Particular types of hazards ..........................................................................................................11 Technical description ............................................................................................................................... 13 2.1 General technical description.......................................................................................................13 2.2 Shaft seals ...................................................................................................................................14 2.3 Cooling .........................................................................................................................................14 2.4 Rating plate ..................................................................................................................................15 2.5 2.5.1 2.5.2 2.5.3 Surface treatment ........................................................................................................................15 General information on surface treatment ...................................................................................15 Painted version ............................................................................................................................16 Primed version .............................................................................................................................18 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 3.3.1 3.3.2 3.3.3 3.3.3.1 3.3.3.2 3.3.3.3 Storage.........................................................................................................................................22 General information for storage ...................................................................................................22 Storage up to 6 months................................................................................................................22 Storage up to 36 months with long-term preservation (optional).................................................23 Notes for storage up to 36 months ..............................................................................................23 Gearbox filled with operating oil and anti-corrosive agent...........................................................23 Gearbox completely filled with oil.................................................................................................23 Installation ............................................................................................................................................... 25 4.1 Unpacking ....................................................................................................................................25 4.2 General information on installation ..............................................................................................25 4.3 Thread sizes and tightening torques for fastening bolts ..............................................................27 4.4 Fastening in the case of high shock loads...................................................................................28 4.5 Gearbox with foot mounting .........................................................................................................28 4.6 Gearboxes in foot or flange version.............................................................................................29 4.7 Mounting an input or output element on the gearbox shaft .........................................................29 BA 2030 Operating Instructions, 06/12, 70000004040207 3 Table of contents 5 4.8 Removing and installing the protection cover ............................................................................. 32 4.9 4.9.1 4.9.2 4.9.2.1 4.9.2.2 4.9.3 4.9.3.1 4.9.3.2 4.9.3.3 4.9.3.4 4.9.4 4.9.5 4.9.5.1 4.9.5.2 4.9.5.3 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 Mounting the hollow shaft with parallel key................................................................................. 34 Removing the hollow shaft with parallel key ............................................................................... 35 Mounting the hollow shaft with shrink disk.................................................................................. 37 Mounting the hollow shaft with shrink disk.................................................................................. 37 Mounting the shrink disk ............................................................................................................. 38 Pulling off the shrink disk ............................................................................................................ 41 Cleaning and lubricating shrink disks.......................................................................................... 41 Mounting the hollow shaft with splines........................................................................................ 42 Torque arms with shaft-mounted gearboxes .............................................................................. 43 General information regarding torque arms ................................................................................ 43 Mounting torque arms on parallel shaft gearboxes..................................................................... 44 Mounting torque arms on bevel gearboxes................................................................................. 45 Commissioning ........................................................................................................................................ 47 5.1 General information for commissioning ...................................................................................... 47 5.2 Checking the oil level prior to commissioning ............................................................................. 47 5.3 Mounting the oil expansion unit .................................................................................................. 48 6 Operation................................................................................................................................................. 49 7 Faults, causes and remedies ................................................................................................................... 51 8 Service and maintenance ........................................................................................................................ 55 8.1 General notes about maintenance work ..................................................................................... 55 8.2 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.5.1 8.2.5.2 8.2.5.3 8.2.5.4 8.2.6 8.2.7 8.2.8 8.2.9 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 General safety notes for changing the oil ................................................................................... 60 Draining the oil ............................................................................................................................ 61 Flushing the gearbox when changing between incompatible oils............................................... 62 Filling in oil................................................................................................................................... 63 Topping up with oil ...................................................................................................................... 64 Changing the roller bearing grease............................................................................................. 64 Service life of the lubricants ........................................................................................................ 65 Recommended lubricants ........................................................................................................... 67 8.3 Checking the gearbox for leaks .................................................................................................. 69 8.4 Replacing the vent valve ............................................................................................................. 69 8.5 Checking the oil level sensor (optional) ...................................................................................... 70 8.6 Cleaning the gearbox .................................................................................................................. 70 8.7 Checking tightness of fastening bolts ......................................................................................... 71 8.8 Inspecting the gearbox or geared motor ..................................................................................... 71 BA 2030 4 Operating Instructions, 06/12, 70000004040207 Table of contents 9 Disposal................................................................................................................................................... 73 10 Technical data ......................................................................................................................................... 75 11 12 10.1 Type designation..........................................................................................................................75 10.2 General technical data .................................................................................................................76 10.3 Weight ..........................................................................................................................................78 10.4 Sound energy level ......................................................................................................................78 10.5 10.5.1 10.5.2 10.5.3 10.5.4 Mounting positions .......................................................................................................................79 General notes on mounting positions ..........................................................................................79 Two- and three-stage helical gearboxes......................................................................................80 Parallel shaft gearbox ..................................................................................................................87 Bevel gearboxes ..........................................................................................................................93 10.6 10.6.1 10.6.2 10.6.3 Oil quantities ..............................................................................................................................102 Helical gearbox ..........................................................................................................................102 Parallel shaft gearbox ................................................................................................................104 Bevel gearboxes ........................................................................................................................105 Spare parts ............................................................................................................................................ 107 11.1 Stocking of spare parts ..............................................................................................................107 11.2 Helical gearboxes D / Z, sizes 19 - 89 .......................................................................................108 11.3 Parallel shaft gearboxes F sizes 29 - 89....................................................................................110 11.4 Bevel gearbox B sizes 29 - 49 ...................................................................................................113 11.5 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 1 General information and safety notes 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 The precise type designation is described in Section Type designation (Page 75). Table 1- 1 Order number code SIMOGEAR gearbox Helical gearbox Z Structure of the order number - Position 1 2 3 4 5 2 K J 3 1 Helical gearbox D 2 K J 3 2 Parallel shaft gearbox FZ 2 K J 3 3 Parallel shaft gearbox FD 2 K J 3 4 Bevel gearbox B, K 2 K J 3 5 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 8 Operating Instructions, 06/12, 70000004040207 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 (Page 75). Do not operate the gearboxes outside the specified power limits. Other operating 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 2 Technical description 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 Parallel shaft gearbox Cast iron Cast iron Bevel gearbox B Aluminum Aluminum Bevel gearbox K Cast iron Cast iron 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 Paint system Description 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 16 Operating Instructions, 06/12, 70000004040207 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 zinc phosphate base coat 2-component epoxy iron mica intermediate coat 2-component polyurethane top coat Indoor and outdoor installation Buildings and areas with almost constant condensation and high contamination, e.g. malt factories and aseptic areas 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 primed or zinc-plated, aluminum and plastic parts untreated Plastic paint, synthetic resin paint, oil paint, 2-component polyurethane paint, 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 thickness 120 μm 2-component polyurethane paint, 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"). 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 18 Operating Instructions, 06/12, 70000004040207 Incoming goods, transport, and storage 3.1 3 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 Keep dry Attach here Keep cool BA 2030 20 Operating Instructions, 06/12, 70000004040207 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 Thread size M8 Maximum load of the eyebolt on the gearbox m d3 [kg] [mm] 140 36 Thread size M20 m d3 [kg] [mm] 1 200 72 M10 230 45 M24 1 800 90 M12 340 54 M30 3 200 108 M16 700 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. Observe the information and procedures in Section Checking the oil level (Page 58). 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. Observe the information and procedures in Section Checking the oil level (Page 58). 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 4 Installation 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 Thread size Tightening torque at strength class 8.8 10.9 12.9 [Nm] [Nm] [Nm] M4 3 4 5 M5 6 9 10 M6 10 15 18 M8 25 35 41 M10 50 70 85 M12 90 120 145 M16 210 295 355 M20 450 580 690 M24 750 1 000 1 200 M30 1 500 2 000 2 400 M36 2 500 3 600 4 200 Table 4- 2 Thread size of fastening bolts for gearboxes in a foot-mounted design Thread size M8 Helical gearbox Parallel shaft gearbox Bevel gearbox Size Size Size 29, 39 29, 39 B29, B39 49 B49, K39, K49 M10 M12 49, 59, 69 69, 79 K69, K79 M16 79, 89 89 K89 Table 4- 3 Thread size of fastening bolts for gearboxes in a flange-mounted design Thread size Flange M6 M8 M10 M12 M16 Helical gearbox Parallel shaft gearbox Bevel gearbox Size Size Size A120 19, 29, 39 29 B29 A140, A160 19, 29, 39, 49, 59 29, 39 B29, B39, K39 A200 39, 49, 59, 69 49 B39, B49, K49 A250, A300 59, 69, 79, 89 69, 79, 89 K69, K79, K89 A350 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 mounting (Page 28). 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 a Hub F Force Figure 4-2 D 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. 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 32 Operating Instructions, 06/12, 70000004040207 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 * ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ Not included in scope of supply Machine shaft Hollow shaft Hexagon nut Threaded spindle Disk Locking ring Parallel key Mounting paste 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 M6 M8 M10 M12 M16 M20 M24 M30 Tightening torque [Nm] 5 8 8 14 24 60 120 200 400 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. 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. Procedure 1. Remove the axial locking element from the hollow shaft. 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 29 39 b10 b11 b12 d10 [mm] [mm] [mm] [mm] [mm] 3 15 10 19.9 - 15 10 6 49 69 G G V W E G Size E E 6 6 15 20 5 9 79 6 20 9 89 7 20 10 d11 s11 tmax [mm] [mm] 10 M6 22.5 6 24.9 14 M8 28 8 - 14 M8 28 8 29.9 18 M10 33 34.9 24 39.9 28 M12 u 38 10 43 10 12 39.9 28 44.9 33 M16 48.5 12 39.9 28 M16 48.5 12 49.9 36 M16 64 14 59.9 45 14 18 BA 2030 36 Operating Instructions, 06/12, 70000004040207 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 a D E E Greased b Absolutely grease-free * Not included in scope of supply ① ② ③ ④ ⑤ ⑧ Machine shaft Hollow shaft Hexagon nut Threaded spindle Disk 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 E E a Greased b Absolutely grease-free D 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, see Removing and installing the protection cover (Page 32). You have now installed the shrink disk. Table 4- 5 Gearbox size Tightening torque for tightening bolt Thread size Strength class Tightening torque [Nm] 29 M5 8.8 5 39 - 69 M6 8.8 12 79 - 89 M10 12.9 35 BA 2030 40 Operating Instructions, 06/12, 70000004040207 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 Lubricants for shrink disks Lubricant Sold as Manufacturer Molykote 321 R (lubricant paint) Spray DOW Corning Molykote spray (powder spray) Molykote G Rapid Spray or paste Molykombin UMFT 1 Spray Unimily P5 Powder Aemasol MO 19 P Spray or paste Klüber Lubrication A. C. Matthes 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 * ① ② ③ ④ ⑤ ⑥ ⑦ Not included in scope of supply Machine shaft Hollow shaft Hexagon nut Threaded spindle Disk 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 M6 M8 M10 M12 M16 M20 M24 M30 Tightening torque [Nm] 5 8 8 14 24 60 120 200 400 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. O[ FPLQ G G G G \ \ O \ Figure 4-9 Size 5= 5= Mounting suggestion for torque arms on F.29 - F.89 Rubber buffer Washer untensioned tensioned l1 l1x d6 d1 d5 c6min [mm] [mm] [mm] [mm] [mm] [mm] 29 15 14.0 30 10.5 40 4 39 15 13.5 30 10.5 40 4 49 20 18.5 40 12.5 50 6 69 20 18.5 40 12.5 50 6 79 20 17.5 40 12.5 50 6 89 30 28 60 21 75 8 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 44 Operating Instructions, 06/12, 70000004040207 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 M10 M12 M16 M20 M24 M30 Tightening torque [Nm] 25 50 90 210 450 750 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 5 Commissioning 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. 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 changing lubricants (Page 57). 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 replaced Checking and changing lubricants (Page 57). 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 48 Operating Instructions, 06/12, 70000004040207 6 Operation 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 remedies (Page 51). 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 7 Faults, causes and remedies 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, causes and remedies Faults Causes Remedy Unusual noises on the gearbox Oil level too low Check the oil level, see Checking and changing lubricants (Page 57) Foreign bodies in oil (irregular noise) Check the oil quality, see Checking the oil quality (Page 59). Clean the gearbox. Change the oil, see Checking and changing lubricants (Page 57) Excessive bearing play and / or bearing defective Check bearing and replace if necessary Defective gearing Check the gearing and replace if necessary Fastening bolts loose Tighten bolts / nuts; see Checking tightness of fastening bolts (Page 71) 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 commissioning Call Technical Support BA 2030 Operating Instructions, 06/12, 70000004040207 51 Faults, causes and remedies Faults Causes Remedy Unusual motor noises Excessive bearing play and / or bearing defective Check bearing and replace if necessary Motor brake rubbing Check air gap and adjust if necessary Inverter parameterization Correct parameterization Incorrect oil level for the mounting position being used Check the mounting position, see Mounting positions (Page 79). Check the oil level, see Checking and changing lubricants (Page 57) Overpressure due to lack of venting Mount the venting as appropriate for the mounting position, see Mounting positions (Page 79). Overpressure due to soiled venting Clean the venting, see Replacing the vent valve (Page 69). Shaft sealing rings defective Replace the shaft sealing rings Cover / flange bolts loose Tighten bolts / nuts, see Checking tightness of fastening 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 Incorrect oil level for the mounting position used and / or incorrect venting position Check the venting and mounting position, see Mounting positions (Page 79). Check the oil level, see Checking and changing lubricants (Page 57) Frequent cold starts, during which the oil foams up Call Technical Support Oil leak Oil leak at the gearbox vent BA 2030 52 Operating Instructions, 06/12, 70000004040207 Faults, causes and remedies Faults Causes Remedy Gearbox overheating Motor fan cover and / or gearbox very dirty Clean the fan cover and surface of the geared motor, see Cleaning the gearbox (Page 70) Incorrect oil level for the mounting position being used Check the mounting position, see Mounting positions (Page 79). Check the oil level, see Checking and changing lubricants (Page 57) Incorrect oil being used (e.g. incorrect viscosity) Check the oil in the gearbox, see Checking the oil quality (Page 59). Oil is out of date Check date of last oil change and change oil if necessary, see Checking and changing lubricants (Page 57) Excessive bearing play and / or bearing defective Check bearing and replace if necessary Output shaft does not turn when motor is running Force flow interrupted by breakage in gearbox Call Technical Support Geared motor only starts with difficulty or not at all Incorrect oil level for the mounting position being used Check the mounting position, see Mounting positions (Page 79). Check the oil level, see Checking and changing lubricants (Page 57) Incorrect oil being used (e.g. incorrect viscosity) Check the oil in the gearbox, see Checking the oil quality (Page 59). 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 couplings) Replace flexible elements. 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 54 Operating Instructions, 06/12, 70000004040207 8 Service and maintenance 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 Maintenance measures Measure Time interval Description of work Monitor and check the geared motor for unusual noises, vibrations, and changes Daily; if possible, more frequently during operation See Operation (Page 49) Check housing temperature After 3 hours, on the first day, thereafter monthly Check the oil level After the first day, and then every 3 000 operating hours, or at the latest after 6 months See Checking and changing lubricants (Page 57) Check the oil level sensor Regularly and after oil changes See Checking the oil level sensor (optional) (Page 70) Check the oil quality Every 6 months See Checking the oil quality (Page 59) 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 See Checking and changing lubricants (Page 57) Subsequent oil changes Every 2 years or 10 000 operating hours 1) Check gearbox for leaks After the first day, thereafter monthly See Checking the gearbox for leaks (Page 69) When required, replace the gearbox breather valve Once a year See Replacing the vent valve (Page 69) Clean the gearbox Depending on degree of soiling, at least every 6 months See Cleaning the gearbox (Page 70) Carry out a complete inspection of the geared motor Every 12 months See Inspecting the gearbox or geared motor (Page 71) 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 See Checking tightness of fastening bolts (Page 71) Change the roller bearing grease When the oil is changed See Changing the roller bearing grease (Page 64) Check rubber buffers on torque arms Every 6 months See Torque arms with shaftmounted gearboxes (Page 43) 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 56 Operating Instructions, 06/12, 70000004040207 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. For oil compatibility see Recommended lubricants (Page 67). 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. Figure 8-1 Oil level in the gearbox housing Procedure 1. Switch off the power supply to the drive unit. 2. Unscrew the oil level screw, see Mounting positions (Page 79). 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 58 Operating Instructions, 06/12, 70000004040207 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. 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 incompatible oils (Page 62). 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 Ambient temperature Manufacturer Type Standard -40 °C to +80 °C Klüber Petamo GHY 133 N Foodstuff-compatible for the food industry -30 °C to +40 °C Castrol Obeen UF F2 NSF H1 BP Biogrease EP 2 Biologically degradable, -35 °C to +40 °C for agriculture, forestry and water industries BA 2030 64 Operating Instructions, 06/12, 70000004040207 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 Service life Mineral oil 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 7>r&@ Service and maintenance 8.2 Checking and changing lubricants ,>K@ ① ② Synthetic oil T Oil-bath steady-state temperature [°C] I Oil change interval in operating hours [h] Mineral oil 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 (http://support.automation.siemens.com/WW/view/en/44231658), which were appropriately 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 8.4 Description and measures Status Description Measures Notes Film of moisture on the shaft sealing ring Film of moisture as a result of the inherent principle of operation (apparent leakage) 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. Leakage at the shaft sealing ring Identifiable small trickle, formation of drops, also after the running-in phase Replace the sealing ring, determine the possible cause of the sealing ring failure and rectify. During the run-in period, the shaft sealing ring beds into the shaft. A visible track can be seen on the shaft. Optimum preconditions for a perfect seal are obtained after the run-in period. 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 70 Operating Instructions, 06/12, 70000004040207 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 Thread size Tightening torque for strength class 8.8 8.8 10.9 12.9 [Nm] [Nm] [Nm] M4 3 4 5 M5 6 9 10 M6 10 15 18 M8 25 35 41 M10 50 70 85 M12 90 120 145 M16 210 295 355 M20 450 580 690 M24 750 1 000 1 200 M30 1 500 2 000 2 400 M36 2 500 3 600 4 200 Inspecting the gearbox or geared motor Carry out a scheduled inspection of the geared motor once a year in accordance with the possible criteria listed in Section Faults, causes and remedies (Page 51). Check the geared motor in accordance with the criteria set out in Section General information and safety notes (Page 7). 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 9 Disposal 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 Type of oil Designation Disposal code Mineral oil CLP ISO VG220 13 02 05 CLP ISO PG VG220 13 02 08 Polyglycols CLP ISO PG VG460 Poly-Alpha-Olefines CLP ISO PAO VG68 13 02 06 CLP ISO PAO VG220 CLP ISO H1 VG460 Biologically degradable oils CLP ISO E VG220 13 02 07 BA 2030 Operating Instructions, 06/12, 70000004040207 73 Disposal BA 2030 74 Operating Instructions, 06/12, 70000004040207 10 Technical data 10.1 Type designation Table 10- 1 Example of the type designation structure Example F Gearbox type F Transmission stage Type D F 89 D F Size 89 Table 10- 2 Type designation code Gearbox type (-) Helical gearbox B Bevel gearbox, two-stage K Bevel gearbox, three-stage F Parallel shaft gearbox Transmission stage (-) Z Two-stage D Three-stage Type Shaft (-) Solid shaft A Hollow shaft Mounting (-) Foot-mounted design B Foot / flange-mounted design F Flange-mounted design (A type) Z Housing flange (C type) D Torque arm G Flange (A type) opposite output shaft Connection (-) Parallel key S Shrink disk T 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. SIEMENS FDU0412/8999999 nnn 2KJ3105-1EM22-2AV1-Z ZF59-LE90SG4E-L32/14N IP55 30kg K-Id: 1234567890 1.5L OIL CLP PG VG220 i=28 50Hz n2:49.3/min T2: 1213Nm fB:2.1 3~Mot. ThCl.155(F) 230/400V +/-10% D/Y 50Hz 4.33/2.5A cosPhi 0.78 1425/min 1.1kW IE2-81.4% Mot. 1LE1001-0EB0 Figure 10-1 1 IEC60034 M1 60Hz T2: 1203Nm n2: 59.7/min fB:2.2 14 Nm 205-240V AC 460V Y 60Hz cosPhi 0.78 2.2 A 1.27kW IE2-84% 1725/min SIEMENS 3 5 6 8 10 11 15 17 23 28 31 33 44 1 2 4 7 9 12 13 14 16 19 18 21 24 25 29 34 30 36 32 39 35 41 42 26 37 20 22 27 38 40 43 Rating plate example for Simogear Matrix code 2 Applied standard 3 Serial No. FDU = Siemens AG, Bahnhofstr. 40, 72072 Tübingen, Germany 4 CE marking or other marking, if required 5 Order No. 6 Model - Type - Size 7 Mounting position 8 Degree of protection to IEC 60034-5 or IEC 60529 9 Weight m [kg] 10 Customer ID 11 Oil quantity [l] main gearbox / intermediate gearbox 12 Type of oil 13 Oil viscosity ISO VG class to DIN 51519 / ISO 3448 14 Total transmission ratio i Frequency 1 15 Rated frequency f [Hz] 16 Gearbox output speed n2 [rpm] 17 Geared motor output torque T2 [Nm] 18 Service factor fB BA 2030 76 Operating Instructions, 06/12, 70000004040207 Technical data 10.2 General technical data Frequency 2 19 Rated frequency f [Hz] 20 Gearbox output speed n2 [rpm] 21 Geared motor output torque T2 [Nm] 22 Service factor fB Motor data 23 Phase number and type of current for the motor 24 Temperature class Th.Cl. 25 Symbols (IEC 60617-2): = brake 26 Rated braking torque TBr [Nm] 27 Brake supply voltage U [V] Frequency 1 28 Rated frequency f [Hz] 29 Rated voltage / range U [V] 30 Circuit, graphical symbols as per DIN EN 60617 Part 6 / IEC 60617-6 31 Rated current I N [A] 32 Power factor cos φ 33 Rated power P N [kW], duty type (if ≠ S1) 34 Efficiency class marking acc. to IEC 60034-30 35 Rated speed n N [rpm] Frequency 2 36 Rated frequency f [Hz] 37 Rated voltage / range U [V] 38 Rated current I N [A] 39 Power factor cos φ 40 Circuit, graphical symbols as per DIN EN 60617 Part 6 / IEC 60617-6 41 Rated power P N [kW], duty type (if ≠ S1) 42 Efficiency class marking 43 Rated speed n N [rpm] 44 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 A, B Position of insert shaft / solid shaft * On opposite side ② ③ ④ ⑤ Two-stage gearbox --- Alternatively Oil drain Three-stage gearbox Tandem gearbox Optional oil hole facing output side 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 1 4 2 A M3 M4 A 4 A 1 1 2 D/Z29 2 4 * D/Z19 D/Z19 M5 M6 1 3 4 2 A 1 2 A 4 3 Mounting position for helical gearboxes D / Z in a foot-mounted design, sizes 19 - 29 BA 2030 80 Operating Instructions, 06/12, 70000004040207 Technical data 10.5 Mounting positions M1 M2 2 1 4 A 4 1 2 A M3 M4 A A 2 4 1 4 1 2 M5 M6 1 3 4 A 3 2 2 4 2 3 A 1 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 A M3 1 2 M4 A 4 A 1 2 1 4 2 M5 M6 3 4 1 2 A 1 2 A 4 3 Mounting position for helical gearboxes DB / ZB in a foot / flange-mounted design, size 29 BA 2030 82 Operating Instructions, 06/12, 70000004040207 Technical data 10.5 Mounting positions M1 M2 2 1 4 A 4 1 2 A M3 M4 A 2 A 4 1 4 1 2 M5 M6 1 3 3 2 4 A 2 4 2 3 A 1 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 A D./Z.19 * D./Z.29 4 D./Z.19 1 2 A M3 M4 A 4 1 2 1 D./Z.29 2 4 A * D./Z.19 D./Z.19 29 M5 M6 1 3 4 2 A 1 2 A 4 3 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 M2 2 1 4 A 4 1 2 A M3 M4 A 2 4 1 4 A 1 2 M5 M6 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 * M3 1 2 A M4 * A 2 4 4 1 A 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 10.5.3 Parallel shaft gearbox M1 M2 2 1 4 A 4 2 1 A M3 M4 A A 4 2 1 4 1 2 M5 M6 3 1 2 A 1 A 2 3 * Mounting position for parallel shaft gearboxes F.AD in a shaft-mounted design, size 29 BA 2030 Operating Instructions, 06/12, 70000004040207 87 Technical data 10.5 Mounting positions M1 M2 2 1 3 4 A 2 M3 4 A 1 2 M4 A 2 A 1 4 4 1 2 M5 M6 * 3 1 2 A 1 A 2 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 M2 2 1 4 A 1 4 A M3 2 M4 2 1 A 4 A 4 1 2 M5 M6 3 1 2 A 1 A 2 3 * 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 2 M3 1 2 M4 A 2 1 4 1 A A 4 1 2 M5 M6 * 3 2 A 1 2 3 * 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 90 Operating Instructions, 06/12, 70000004040207 Technical data 10.5 Mounting positions M1 M2 2 1 4 A 4 1 2 1 A 4 A M3 M4 2 A 4 1 2 M5 M6 3 1 2 A 2 * A 1 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 3 1 4 A 2 M3 4 A 1 2 M4 A 2 A 1 4 4 1 2 M5 M6 * 3 1 2 A 1 A 2 3 * Mounting position for parallel shaft gearbox F in a foot-mounted design, sizes 39 - 89 BA 2030 92 Operating Instructions, 06/12, 70000004040207 Technical data 10.5 Mounting positions 10.5.4 Bevel gearboxes 0 0 % $ 0 $ $ % % 0 $ % % 0 $ 0 % $ $ % Figure 10-2 Mounting position for bevel gearbox B foot-mounted design, size 29 BA 2030 Operating Instructions, 06/12, 70000004040207 93 Technical data 10.5 Mounting positions 0 0 $ % $ $ % $ 0 % $ % % 0 % $ $ % $ $ % % % 0 Figure 10-3 $ 0 % $ $ % Mounting position for bevel gearbox B foot-mounted design, sizes 39 - 49 BA 2030 94 Operating Instructions, 06/12, 70000004040207 Technical data 10.5 Mounting positions 0 0 B B A 0 A A B 0 B A B 0 A 0 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 0 0 A B B A B A B A A 0 B 0 B A A B A A B B B 0 0 B A Figure 10-5 A A B 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 0 0 % $ 0 $ $ $ % % 0 % % 0 $ 0 % $ $ % 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 0 0 $ % $ % $ $ % $ 0 % % 0 % $ % $ $ $ % % % 0 $ 0 $ % % $ Figure 10-7 Mounting position for bevel gearbox BAD shaft-mounted design, sizes 39 - 49 BA 2030 98 Operating Instructions, 06/12, 70000004040207 Technical data 10.5 Mounting positions M1 M2 B A 2 B A A A B B 1 4 A B A B A 1 * A M3 3 2 4 A 1 2 M4 2 A 4 A B B 1 A 4 3 2 B B A M5 A* 1 A 1 A 2 A B M6 B * A 1 3 2 A 1 A* A 2 3 B 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 B A A B 1 A B 4 A A B 2 1 * A M3 3 1 4 2 M4 A 2 4 1 A 4 3 B A * 1 B A 1 A 2 2 A B B M5 A M6 B * A 1 3 2 A A 1 A* 2 3 B 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 100 Operating Instructions, 06/12, 70000004040207 Technical data 10.5 Mounting positions M1 M2 B A 2 B A A 1 4 A B A A 1 * A M3 B B 2 3 1 A 4 4 A 2 1 M4 2 A A 4 3 A * 1 2 B 1 B 2 B A A M5 M6 B * A 1 3 2 A 1 A* A 2 3 B 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 Type Oil quantities [l] for D / Z and DB / ZB. Sizes 19 - 89 Mounting position M1 M2 M3 M4 M5 M6 Z.19 0.2 0.5 0.4 0.5 0.35 0.3 Z.29 0.2 0.7 0.45 0.6 0.55 0.3 Z.39 0.3 0.95 0.85 0.95 0.9 0.25 Z.49 0.55 1.9 1.9 1.9 1.8 0.65 Z.59 0.65 2 1.9 1.9 1.9 0.6 Z.69 0.65 2.1 2.6 2.6 2.3 0.85 Z.79 1.1 3.7 4 4 3.8 1.4 Z.89 2.2 6.9 6.7 6.7 6.6 2.4 D.19 0.2 0.5 0.4 0.5 0.35 0.3 D.29 0.15 0.65 0.45 0.5 0.55 0.4 D.39 0.25 0.9 0.8 0.85 0.8 0.7 D.49 0.55 1.8 1.8 1.7 1.7 1.2 D.59 0.45 1.9 1.9 1.8 1.8 1.2 D.69 0.6 2 2.4 2.3 2.2 1.5 D.79 0.9 3.5 3.9 3.7 3.5 2.4 D.89 2 6.5 6.2 6 6 4.2 BA 2030 102 Operating Instructions, 06/12, 70000004040207 Technical data 10.6 Oil quantities Table 10- 4 Type Oil quantities [l] for DF / ZF and DZ / ZZ sizes 19 - 89 Mounting position M1 M2 M3 M4 M5 M6 Z.19 0.2 0.5 0.4 0.5 0.35 0.3 Z.29 0.2 0.7 0.45 0.6 0.55 0.3 Z.39 0.3 0.95 0.85 0.95 0.9 0.25 Z.49 0.55 1.9 19, 19, 1.8 0.65 Z.59 0.65 2 1.9 1.9 1.9 0.6 Z.69 0.65 2.1 2.6 2.6 2.3 0.85 Z.79 1 3.6 3.8 3.8 3.6 1.3 Z.89 2.2 6.9 6.7 6.7 6.6 2.4 D.19 0.2 0.5 0.4 0.5 0.35 0.3 D.29 0.15 0.65 0.45 0.5 0.55 0.4 D.39 0.25 0.9 0.8 0.85 0.8 0.7 D.49 0.55 1.8 1.8 1.7 1.7 1.2 D.59 0.45 1.9 1.9 1.8 1.8 1.2 D.69 0.6 2 2.4 2.3 2.2 1.5 D.79 0.9 3.5 3.9 3.7 3.5 2.4 D.89 2 6.5 6.2 6 6 4.2 BA 2030 Operating Instructions, 06/12, 70000004040207 103 Technical data 10.6 Oil quantities 10.6.2 Parallel shaft gearbox Table 10- 5 Type FZ.29 Oil quantities [l] for F., F.Z and F.D sizes 29 - 89 Mounting position M1 M2 M3 M4 M5 M6 0.6 0.9 0.4 0.7 0.5 0.45 FZ.39 0.95 1.3 0.8 1.4 0.9 0.85 FZ.49 1.6 2.5 1.6 2.5 1.6 1.6 FZ.69 2.2 2.8 1.6 2.9 1.9 1.9 FZ.79 2.8 4.1 2.9 4.2 2.7 2.9 FZ.89 4.9 7.7 5.9 8.4 5.2 5.5 FD.29 0.6 0.8 0.35 0.6 0.45 0.45 FD.39 0.95 1.1 0.7 1.2 0.8 0.8 FD.49 2.1 2.3 1.5 2.3 1.5 1.5 FD.69 2.2 2.7 1.6 2.7 1.8 1.8 FD.79 3 3.8 2.7 3.9 2.6 2.7 FD.89 5.6 7.6 5.9 7.8 5.1 5.2 Table 10- 6 Type Oil quantities [l] for F.F sizes 29 - 89 Mounting position M1 M2 M3 M4 M5 M6 FZ.29 0.6 0.9 0.4 0.7 0.5 0.45 FZ.39 1 1.4 0.85 1.6 0.95 0.9 FZ.49 1.8 2.4 1.5 2.6 1.6 1.6 FZ.69 2.3 2.8 1.6 3 2 1.9 FZ.79 2.9 4.2 2.9 4.3 2.9 2.8 FZ.89 5.1 7.8 5.9 8.6 5.4 5.5 FD.29 0.6 0.8 0.35 0.6 0.45 0.45 FD.39 1 1.2 0.75 1.3 0.8 0.85 FD.49 2.2 2.3 1.5 2.4 1.6 1.5 FD.69 2.3 2.7 1.6 2.8 1.9 1.8 FD.79 3.1 3.9 2.7 4 2.7 2.6 FD.89 5.7 7.7 5.9 7.9 5.3 5.2 BA 2030 104 Operating Instructions, 06/12, 70000004040207 Technical data 10.6 Oil quantities 10.6.3 Bevel gearboxes Table 10- 7 Type Oil quantities [l] for B sizes 29 - 49 Mounting position M1 M2 M3 M4 M5 M6 B.29 0.3 0.6 0.75 0.9 0.55 0.5 B.39 0.5 1 1.3 1.7 1 0.85 B.49 1.1 1.8 2.5 3.2 1.9 1.6 Table 10- 8 Type Oil quantities [l] for K. and KA sizes 39 - 89 Mounting position M1 M2 M3 M4 M5 M6 K.39 0.35 0.85 1.1 1.2 0.85 0.9 K.49 0.55 1.4 1.8 1.9 1.5 1.6 K.69 0.75 2 2.5 2.7 2.2 2.2 K.79 1 2.2 2.9 3.4 2.5 2.6 K.89 1.8 4.3 5.5 6.3 4.6 4.8 Table 10- 9 Type Oil quantities [l] for KAF, KAZ and KAD sizes 39 - 89 Mounting position M1 M2 M3 M4 M5 M6 KA.39 0.4 0.9 1.2 1.3 0.95 0.95 KA.49 0.65 1.5 1.9 2.2 1.6 1.6 KA.69 0.85 2.1 2.8 3.2 2.4 2.5 KA.79 1.2 2.5 3.4 4.1 2.9 3.2 KA.89 2.2 4.7 6.2 7.3 5.3 5.6 M3 M4 M5 M6 Table 10- 10 Oil quantities [l] for KF sizes 39 - 89 Type Mounting position M1 M2 KF39 0.35 0.9 1.2 1.3 0.95 1 KF49 0.6 1.4 2 2.2 1.6 1.7 KF69 0.85 2 2.8 3.1 2.4 2.4 KF79 1.2 2.5 3.4 4.1 2.9 3.2 KF89 2.2 4.7 6.2 7.3 5.3 5.6 BA 2030 Operating Instructions, 06/12, 70000004040207 105 Technical data 10.6 Oil quantities BA 2030 106 Operating Instructions, 06/12, 70000004040207 11 Spare parts 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 14digit material no.) ● Quantity SIEMENS FDU0412/8999999 nnn 2KJ3105-1EM22-2AV1-Z ZF59-LE90SG4E-L32/14N IP55 30kg K-Id: 1234567890 1.5L OIL CLP PG VG220 i=28 50Hz n2:49.3/min T2: 1213Nm fB:2.1 3~Mot. ThCl.155(F) 230/400V +/-10% D/Y 50Hz 4.33/2.5A cosPhi 0.78 1425/min 1.1kW IE2-81.4% Mot. 1LE1001-0EB0 Figure 11-1 IEC60034 M1 60Hz T2: 1203Nm n2: 59.7/min fB:2.2 14 Nm 205-240V AC 460V Y 60Hz cosPhi 0.78 2.2 A 1.27kW IE2-84% 1725/min SIEMENS 3 5 6 8 10 11 15 17 23 28 31 33 44 1 2 4 7 9 12 13 14 16 19 18 21 24 25 29 34 30 36 32 39 35 41 42 26 37 20 22 27 38 40 43 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 108 Operating Instructions, 06/12, 70000004040207 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 109 110 JHV ))$)$) )$6 )')= ))) )= VWDJ HV )' VWD )' VWD JHV 11.3 Spare parts 11.3 Parallel shaft gearboxes F sizes 29 - 89 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. 1001 Gearbox housing 1020 Bearing 1030 Bearing 1031 Supporting disk 1032 Shim 1034 NILOS ring BA 2030 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 Operating Instructions, 06/12, 70000004040207 %% %% %$6 %$%$=%$' %) 11.4 Spare parts 11.4 Bevel gearbox B sizes 29 - 49 Bevel gearbox B sizes 29 - 49 Note For gearbox, size 29, we recommended that the gearbox is replaced if service is required. Parts subject to wear are available on request. BA 2030 113 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 115 116 .$6. .$. .). 11.5 Spare parts 11.5 Bevel gearbox K sizes 39 - 89 Bevel gearbox K sizes 39 - 89 1001 Gearbox housing 1020 Bearing 1021 Supporting disk / shim 1022 Supporting disk / shim BA 2030 Operating Instructions, 06/12, 70000004040207 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 12 Declaration of Incorporation Declaration of Incorporation according to Directive 2006/42/EC Annex II 1 B. Manufacturer: Siemens AG Address: 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 120 Operating Instructions, 06/12, 70000004040207 Futher information SIMOGEAR on the Internet www.siemens.com/simogear Siemens AG Industry Sector Mechanical Drives Postfach 1709 72007 Tübingen GERMANY Subject to change © Siemens AG 2012 www.siemens.com/drivetechnology