Benzlers C Series Installation & Maintenance Download Page 17

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Appendix 2A

Page 15 Issue 2

Series C, K & F Standard Bore Assembly.

UNIT

Bore

22.000/

21.946

28.000/

27.948

0.6

0.4R

0.6

0.4R

1.2R

0.8R

71.0
70.8
90.0
89.8

M20 x 2.5

42 deep

M24 x 3.0

50 deep

225.5
225.0
238.5
238.0

120

150

79.6

99.6

260

327

C10

Reduced

Std

79.990/

79.971

99.988/

99.966

20.000/

19.948

25.000/

24.948

0.6

0.4R

0.6

0.4R

1.2R

62.5
62.3
81.0
80.8

M20 x 2.5

42 deep

M24 x 3.0

50 deep

177.5
177.0
221.5
221.0

105

135

69.6

76.6

227

C09

Reduced

Std

69.990/

69.971

89.988/

89.966

18.000/

17.957

20.000/

19.948

0.4

0.25R

0.6

0.4R

1.2R

53.0
52.8
62.5
62.3

M20 x 2.5

42 deep

M20 x 2.5

42 deep

148.5
148.0
177.5
177.0

105

59.6

183

69.990/

69.971

69.6

183

C08

Reduced

Std

59.990/

59.971

44.5
44.3

14.000/

13.957

0.4

0.25R

M20 x 2.5

42 deep

1.2R

53.0
52.8

18.000/

17.957

0.4

0.25R

M16 x 2
38 deep

1.2R

130.5
130.0
148.5
148.0

49.6

59.6

153

C07

Reduced

Std

49.991/

49.975

59.990/

59.971

0.8R

39.5
39.3

14.000/

13.957

0.4

0.25R

101.5
101.0

M16 x 2
36 deep

44.6

125

0.8R

35.0
34.8

12.000/

11.957

0.4

0.25R

100.5
100.0

M16 x 2
36 deep

39.6

125

C06

Reduced

Std

39.991/

39.975

44.991/

44.975

0.8R

30.0
29.8

10.000/

9.964

0.16

0.25R

77.3
77.0

M12 x 1.75

28 deep

34.6

104

0.8R

26.0
25.8

8.000/

7.964

0.16

0.25R

79.3
79.0

M10 x 1.5

22 deep

29.6

104

C05

Reduced

Std

29.993/

29.980

34.991/

34.975

0.8R

26.0
25.8

8.000/

7.964

0.16

0.25R

0.16

0.25R

29.993/

29.980

29.6

79.3
79.0

M10 x 1.5

22 deep

M10 x 1.5

22 deep

0.8R

21.0
20.8

8.000/

7.964

Std

C04

24.993/

24.980

24.6

16.5
16.4

6.000/

5.970

0.16

0.25R

Reduced

79.3
79.0

M6 x 1.0 16

deep

0.8R

61.3
61.0

C03

Std

19.993/

19.980

19.6

F03 & K03

29.993/

29.980

29.6

70.3
70.0

26.0
25.8

8.000/

7.964

0.16

0.25R

M10 x 1.5

22 deep

0.8R

F04 & K04

34.991/

34.975

34.6

109

90.5
90.0

M12 x 1.75

28 deep

0.8R

30.0
29.8

10.000/

9.964

0.16

0.25R

F05 & K05

39.991/

39.975

39.6

112

35.0
34.8

12.000/

11.957

0.4

0.25R

92.5
92.0

M16 x 2
36 deep

126

0.8R

F06 & K06

39.991/

39.975

39.6

100.5
100.0

M16 x 2
36 deep

0.8R

35.0
34.8

12.000/

11.957

0.4

0.25R

F07 & K07

44.991/

44.975

49.6

153

101.5
101.0

44.5
44.3

14.000/

13.957

0.4

0.25R

M16 x 2
36 deep

0.8R

F08 & K08

59.990/

59.971

59.6

173

148.5
148.0

M20 x 2.5

42 deep

0.8R

53.0
52.8

18.000/

17.957

0.4

0.25R

F09 & K09

69.990/

69.971

69.6

232

105

161.5
161.0

M20 x 2.5

42 deep

0.8R

62.5
62.3

20.000/

19.948

0.6

0.4R

F10 &K10

79.990/

79.971

79.6

275

120

188.5
188.0

M20 x 2.5

42 deep

0.8R

71.0
70.8

22.000/

21.946

0.6

0.4R

K12

99.988/

99.966

99.6

327

150

238.5
238.0

M24 x 3.0

50 deep

0.8R

90.0
89.8

28.000/

27.948

0.6

0.4R

F02

24.9931/

24.980

24.6

70.3
70.0

21.0
20.8

8.000 /

7.964

0.16

0.25R

M10 x 1.5

22 deep

0.8R

See next page for shaft assembly instructions

Summary of Contents for C Series

Page 1: ...INSTALLATION MAINTENANCE Series M C F K IGM1 00GBA0707 Series MCFK Cover English Cover Series F 06 07 17 7 07 16 54 Page 2 ...

Page 2: ...HQW LQ RUGHU WR SUHYHQW WKH PDFKLQHU EHLQJ VWDUWHG QVWDOODWLRQ 0DLQWHQDQFH DQG 6WRUDJH D Q WKH HYHQW WKDW HTXLSPHQW LV WR EH KHOG LQ VWRUDJH IRU D SHULRG H FHHGLQJ PRQWKV SULRU WR LQVWDOODWLRQ RU FRPPLVVLRQLQJ ORFDO DSSOLFDWLRQ HQJLQHHULQJ VWDII PXVW EH FRQVXOWHG UHJDUGLQJ VSHFLDO SUHVHUYDWLRQ UHTXLUHPHQWV 8QOHVV RWKHUZLVH DJUHHG HTXLSPHQW PXVW EH VWRUHG LQ D EXLOGLQJ SURWHFWHG IURP H WUHPHV RI WH...

Page 3: ... Maintenance 10 1 Prior to any Maintenance Operations 10 10 2 Oil Plugs Ventilator 10 10 3 Lubrication 11 10 4 Bearings 11 10 5 Grease Lubrication 11 10 6 Cleaning 11 11 Fault Diagnosis 12 Appendix 1 Shaft Alignment 13 14 2A Series C F K Hollow Output Bore Details 15 18 2B Series F Kibo Bush Details 19 20 2C Series K Shrink Disc Details 21 22 2D Series C F K Torque Arm Details 23 25 3 Three Phase ...

Page 4: ...n of Unit All Series M C F K units are provided with protection against normal weather conditions Where units are to operate in extreme conditions or where they are to stand for long periods without running eg during plant construction consult our application engineers so that arrangements for adequate protection can be made 3 Reading the Nameplate Unit Identification When requesting further infor...

Page 5: ... fitted corresponds with the classification of the potentially explosive atmosphere in which the unit is to be installed Understanding EU Directive 94 9 EC ATEX 100a Markings II 2 G EEx c k T4 Temp class Temp class Ex Atmosphere Category Group T3 Max surface temperature 200 C T4 Max surface temperature 135 C T5 Max surface temperature 100 C Protection type of gear unit G Gas D Dust Examples II 2 G...

Page 6: ...to be used of anti corrosion agents using a commercially available solvent Ensure solvent does not make contact with the oil seals 5 3 Fitting of components to either the unit input or output shaft The input or output shaft extension diameter tolerance is to ISO tolerance k6 for shaft diameter 50mm and m6 for shaft diameter 50mm and the fitted components should be to ISO tolerance M7 for bore diam...

Page 7: ... C units are supplied with a lifting eye Series F K units have a lifting hole in the gear housing as shown Lifting Hole Series K Lifting Hole Series F On units supplied with a lifting eye on the motor both the lifting point on the gear unit and motor should be used Use both lifting points ...

Page 8: ...ted and adjust if necessary by using steel packings Torque tighten bolts to torque specified in table 2 below 5 5 4 Secure unit or baseplate if fitted to a rigid foundation using heavy duty bolts to ISO grade 8 8 minimum M30 M36 1220 Nm 2150 Nm 350 Nm 610 Nm 10 Nm 18 Nm 37 Nm 64 Nm 150 Nm 260 Nm 25 Nm 50 Nm 85 Nm 200 Nm Tightening Torque Holding Down Bolts Output Flange Bolts Motors to Gearhead 10...

Page 9: ...ith no external heat input cooling air temperature should not exceed 40 C 5 7 6 Ensure mounting position corresponds to that marked on the nameplate Note ATEX approval is only valid for mounting position specified on the nameplate 5 7 7 Check motors couplings or any other equipment fitted to the gear unit has ATEX approval Check information listed on nameplates correspond to the environmental cond...

Page 10: ... Polyglycol based Synthetic type G Polyalphaolefin based Synthetic with EP additive type H CLP PG 5G VG 220 Ambient Temperature Range Lubricant ISO EP Mineral Oil type E CLP CC 5E VG 220 6E VG 320 7E VG 460 5 C to 20 C type E 30 C to 20 C type G H 0 C to 35 C 20 C to 50 C CLP HC 5H VG 220 5H VG 220 6H VG 320 Table L1 Note CLP CC CLP HC are the recommended lubricants for Series F K M 6 2 Ventilator...

Page 11: ...of dust deposits cannot form when the unit is used in Zone 21 Zone 22 classification areas 8 1 4 Remove any safety devices fitted to prevent machine rotation 8 1 5 Starting up should only be performed or supervised by suitably qualified personnel Caution Any deviation from normal operating conditions increased temperature noise vibrations power consumption etc suggest a malfunction inform maintena...

Page 12: ...el and or drain plug Warning do not stand over ventilator plug whilst removing as pressure build up behind valved ventilator may cause it to eject when removed 10 2 3 Place a container under the oil drain plug to be removed Note it is recommended that the oil should be slightly warm 40 50 C when drained Cooler oil will be more difficult to drain correctly 10 2 4 Top ups or refills should be done t...

Page 13: ...OR 18 MONTHS Oil Change Period Series C MINERAL OIL SYNTHETIC OIL 65 OR LESS 17000 HOURS OR 3 YEARS 26000 HOURS OR 3 YEARS 70 12000 HOURS OR 3 YEARS 26000 HOURS OR 3 YEARS 75 8500 HOURS OR 3 YEARS 22000 HOURS OR 3 YEARS 80 6000 HOURS OR 2 YEARS 15000 HOURS OR 3 YEARS 85 4200 HOURS OR 17 MONTHS 10500 HOURS OR 3 YEARS 90 3000 HOURS OR 12 MONTHS 7500 HOURS OR 2 1 2 YEARS 95 2100 HOURS OR 8 MONTHS 600...

Page 14: ...from the motor flange c Gear unit not ventilated b Contact our Application Engineers from the gear unit flange c Vent the gear unit see Appendix 4 Mounting positions from the output end oilseal Oil leaking a Gear unit over filled with oil a Correct the oil level see lubrication section from the ventilator b Gear unit installed in an incorrect mounting positon b Fit the ventilator in the correct po...

Page 15: ...Appendix 1 Page 13 Issue 2 ...

Page 16: ...pling type fitted Type of Coupling Unit Size Allowable Eccentricity mm SIZE 08 UNDER 0 025 SIZE 09 OVER 0 035 SPECIAL NOTE CONCERNING RIGID COUPLINGS In lining up elements involving rigid couplings it is important that no attempt is made to correct errors of alignment or eccentricity greater than those above by tightening of the coupling bolts This applies when the system is cold or at operating t...

Page 17: ... 3 79 0 3 23 M10 x 1 5 22 deep 29 6 104 45 15 C05 Reduced Std 29 993 29 980 34 991 34 975 0 8R 26 0 25 8 8 000 7 964 0 16 0 25R 0 16 0 25R 29 993 29 980 29 6 99 45 15 79 3 79 0 3 26 M10 x 1 5 22 deep M10 x 1 5 22 deep 0 8R 21 0 20 8 8 000 7 964 Std C04 24 993 24 980 24 6 16 5 16 4 6 000 5 970 0 16 0 25R Reduced 99 38 13 79 3 79 0 3 23 3 22 M6 x 1 0 16 deep 0 8R 82 30 10 61 3 61 0 C03 Std 19 993 19...

Page 18: ...ion in the output shaft 3 Fit the circlip into the output sleeve 4 Fit the output shaft into the output sleeve Remember to fit the spacer tube if the output shaft has no shoulder 5 Secure in place with the washer and bolt tighten to the values stated in the table below 6 Fit the protective cover over the open end of the output sleeve M10 15 M12 20 M16 45 M20 85 M24 200 Bolt Size Tightening Torques...

Page 19: ...18 Std 8 24 27 70 26 69 9 58 4 310 5 M30 x 3 5 74 5 20 Reduced 8 24 27 70 26 69 9 58 4 310 5 M30 x 3 5 74 5 20 Std 8 24 27 90 26 89 9 75 3 360 5 M30 x 3 5 95 25 Reduced 8 24 27 80 26 79 9 65 5 360 5 M30 x 3 5 85 22 Std 8 30 34 100 32 99 9 84 1 420 5 M36 x 4 106 28 F02 5 15 17 25 10 24 9 16 120 3 M12 x 17 5 28 8 F03 K03 5 15 17 30 13 29 9 20 8 130 3 M16 x 2 33 8 F04 K04 5 15 17 35 13 34 9 25 2 160 ...

Page 20: ...Appendix 2A Page 18 Issue 2 Series C K F Shaft Mount Units Alternative Shaft Fixing Methods ...

Page 21: ... is not squeezed but the nut is in contact with the shaft sleeve 5 Mount the end plate with its fixing bolt Tighten the bolt with correct torque The inner bushing is now locked 6 Loosen the bolt so the outer bushing is loose Turn the nut on the bushing in it s outer position 7 Tighten the bolt once again with correct torque The outer bushing is now locked The thicker end plate may be changed to th...

Page 22: ...0 163 104 1 6 M e k1 35 C38214 S1 1 M12 22 8 56 30 C38214 S3 2 25 C38214 S4 3 40 C38364 S2 1 M16 28 10 124 35 C38364 S3 2 M12 22 8 70 30 C38364 S4 3 M10 20 7 40 40 C38364 S2 1 M16 28 10 124 35 C38364 S3 2 M12 22 8 70 30 C38364 S4 3 M10 20 7 40 50 C38464 S9 1 45 C38464 S10 2 40 C38464 S11 3 60 C38614 S1 1 55 C38614 S2 2 50 C38614 S3 3 M16 28 10 169 70 C38648 S1 1 65 C38648 S2 2 60 C38648 S3 3 80 B9...

Page 23: ...7 32 20 37 25 75 102 112 29 K05 40 40 60 3 107 36 20 41 25 83 112 118 29 K06 40 40 70 3 5 132 38 20 43 25 90 118 130 29 K07 50 50 80 6 132 36 30 41 35 105 136 152 35 K08 65 65 90 5 160 41 40 46 45 120 161 175 58 K09 75 75 100 5 175 55 40 60 55 150 195 210 58 K10 95 95 120 5 200 65 60 70 65 175 230 245 100 K12 105 105 140 5 240 85 60 90 75 205 280 295 160 m6 m7 o o1 Locking Screws Torque Ta Nm SIZE...

Page 24: ...Appendix 2C Page 22 Issue 2 Shrink Disc Installation Maintenance ...

Page 25: ...Appendix 2D Page 23 Issue 2 Series C Torque Bracket Dimensions ...

Page 26: ...F10 82 12 38 485 44 5 26 F11 82 12 38 485 44 6 26 F12 102 12 48 550 54 6 33 Dim L mm F02 52 F03 52 F04 52 F05 52 F06 52 F07 80 F08 84 F09 110 F10 112 F11 116 F12 146 Unit Size L WASHER WASHER SERIES F TORQUE LUG LOCK NU T RUBBER BUFFER ANCHOR PLATE BOLT SIZ E M12 F02 F06 M20 F07 F08 M24 F09 F11 M30 F12 A E G F a9 C B Notes 1 Tighten bolt to give Dim A this will pre compress the rubber buffers 2 To...

Page 27: ...Appendix 2D Page 25 Issue 2 Series K Torque Bracket Dimensions ...

Page 28: ...are checked against the motor nameplate data and that they are connected as indicated on the nameplate The correct sizing of the cables to electrical regulations is essential To change the direction of rotation of the electric motor one of the three main line terminals should be changed with the other Connect the earth conductors to the marked earth terminals Note This instruction only applies to ...

Page 29: ... 320 13 460 10 Lubrication Engineers Inc Almasol Vari Purpose Gear 607 18 605 13 608 10 Mobil gear 600 series 630 13 632 13 634 1 Mobil gear XMP 220 19 320 13 460 7 Omega Manufacturing Division Omega 690 85w 140 15 Optigear BM 220 11 320 10 460 7 Optigear 220 18 320 9 460 7 Pertamina Indonesia Masri 220 4 320 4 460 7 Petro Canada Ultima EP 220 22 320 16 460 10 Rocol Sapphire Hi Torque 220 13 320 1...

Page 30: ...320 25 460 23 680 20 1000 28 Berox SL Range 220 40 320 37 460 23 Mobil Oil Company Limited Glygoyle 30 22 HE320 37 HE460 35 Optimal Ölwerke GmbH Optiflex A 220 28 320 28 460 28 680 28 1000 25 Tivela SB 25 SC 25 SD 23 Tivela S 220 34 320 34 460 34 Texaco Limited Synlube CLP 220 34 320 31 460 10 680 31 Total Carter SY 220 25 320 28 460 22 Tribol GmbH Tribol 800 220 27 320 25 460 25 680 25 1000 23 GR...

Page 31: ...lin Unisyn CLP 220 37 320 34 Klüber Lubrication Klübersynth GEM4 220 30 320 25 Kuwait Petroleum International Q8 El Greco 220 22 320 19 Lubrication Engineers Inc Synolec Gear Lubricant 9920 40 Mobilgear SHC 220 40 320 37 Mobil gear XMP 220 40 320 33 Optimal Ölwerke GmbH Optigear Synthetic A 220 31 320 31 Petro Canada Super Gear Fluid 220 43 320 37 Shell Oils Omala HD 220 43 320 40 Pinnacle EP 220 ...

Page 32: ...e above Double Reduction table for lubricant See above Double Reduction table for lubricant MOUNTING POSITION 1 4 6 DOUBLE REDUCTION FINAL STAGE QUADRUPLEREDUCTION Unit Size TRIPLEREDUCTION 6 MOUNTING POSITION C0741 QUADRUPLE REDUCTION Unit Size MOUNTING POSITION C0341 Unit Size C0441 C0541 C0641 See above Double Reduction table for lubricant C1041 See above Double Reduction table for lubricant Se...

Page 33: ...Appendix 4 Page 31 Issue 2 ...

Page 34: ...1 8 0 6 1 0 2 0 1 0 2 0 1 4 3 2 1 4 5 2 1 4 9 0 Primary Secondary Primary Secondary Primary Secondary M0522 F0822 M0522 F0921 M0722 F1021 1 1 5 11 1 5 19 2 6 34 2 1 5 7 1 5 13 2 6 22 3 1 5 9 1 5 17 2 6 28 4 1 5 5 1 5 15 2 6 27 5 2 0 10 2 0 24 3 2 43 6 2 6 17 2 6 25 4 7 43 SERIES F LUBRICATION Lubricant Quantities Litres F02 F03 F04 F05 F06 F08 Units Primary Units used for Quintuple Reduction are s...

Page 35: ...Appendix 4 Page 33 Issue 2 ...

Page 36: ... 1 5 9 3 2 6 15 2 6 23 2 1 5 3 7 1 5 8 3 2 6 15 2 6 27 3 1 5 7 6 1 5 18 2 6 28 2 6 33 4 1 5 7 5 1 5 17 2 6 30 2 6 39 5 2 0 9 6 2 0 21 3 2 34 3 2 50 6 2 6 7 6 2 6 16 4 7 25 4 7 35 SERIES K LUBRICATION MOUNTING POSITION K0352 Unit Size K03 K04 K05 K06 K07 Units Primary Units used for Quintuple Reduction are supplied factory filled w ith EPmineral oil Grade 6E appropriate to the intended mounting pos...

Page 37: ...Appendix 4 Page 35 Issue 2 ...

Page 38: ...M0622 M0722 M0822 M0921 M1021 M1321 M1421 M0352 M0452 M0552 M0652 M0752 M0852 M0951 M1051 M1351 M1451 M0132 M0332 M0332 M0332 M0332 M0532 M0532 M0732 M0732 M0732 M0322 M0422 M0522 M0622 M0722 M0822 M0921 M1021 M1321 M1421 SERIES M LUBRICATION SECONDARY UNIT PRIMARY STAGEQUADRUPLE REDUCTION Quantities obtained from above double and triple sizes indicated PRIMARY STAGE QUINTUPLEREDUCTION Quantities ...

Page 39: ...Appendix 4 Page 37 Issue 2 ...

Page 40: ...uropean Service Centre HQ Benzlers Netherlands Postbox 3303 NL 5902 Venlo RH Netherlands Tel 31 773 245 900 Fax 31 773 245 901 NORWAY David Brown Hydraulics Norway A S PO Box 73 Leirdal Stromsveien 372 NO 1008 Oslo Norway Tel 47 22 90 94 30 Fax 47 22 90 94 11 SOUTH AFRICA David Brown Gear Industries Ltd PO Box 540 Benoni 1500 South Africa Tel 27 11 748 0000 Fax 27 11 421 2963 SWEDEN AB Benzlers La...

Page 41: ...A Textron Company A Textron Company Series MCFK Cover English Cover Series F 06 07 17 7 07 17 02 Page 1 ...

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