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B 1050 – en

Industrial gear units

Operating and Assembly Instructions

Summary of Contents for B 1050

Page 1: ...B 1050 en Industrial gear units Operating and Assembly Instructions...

Page 2: ...Industrial gear units Operating and Assembly Instructions 2 B 1050 en 4419...

Page 3: ...ructions in this operating and assembly manual Keep this operating and installation manual in the vicinity of the gear unit so that it is available if required Please also note the following documents...

Page 4: ...corrections B 1050 April 2015 6052902 1915 General corrections B 1050 March 2016 6052902 0916 General corrections B 1050 May 2017 6052902 1817 Revised B 1050 May 2019 6052902 1819 Extension of the MA...

Page 5: ...t must be provided to all users in a suitable form Any editing or amendment or other utilisation of the document is prohibited Publisher Getriebebau NORD GmbH Co KG Getriebebau Nord Stra e 1 22941 Bar...

Page 6: ...Industrial gear units Operating and Assembly Instructions 6 B 1050 en 4419...

Page 7: ...3 1 5 on motor swing base or base frame 25 3 2 Storage 26 3 3 Long term storage 26 3 4 Preparing for installation 27 3 5 Installing the gear unit 27 3 6 Fitting hubs on the gear shafts 29 3 7 Gear un...

Page 8: ...it cooling with fan Option FAN 68 5 2 2 Heat exchanger option CS2 68 5 2 3 Oil level 69 5 2 3 1 Oil level screw 70 5 2 3 2 Oil inspection glass oil level glass Option OSG Oil level indicator Option OS...

Page 9: ...Types of lubricant oil 101 7 3 3 Lubricant quantities 103 7 3 3 1 Helical gear units 103 7 3 3 2 Helical bevel gear units 104 7 3 3 3 MAXXDRIVE XT industrial helical bevel gear unit 104 7 4 Screw tig...

Page 10: ...the coupling to the motor shaft 44 Figure 18 Fusible plug with separate mechanical switch 46 Figure 19 Cooling cover with cooling coil fitted schematic diagram 48 Figure 20 Industrial gear unit with C...

Page 11: ...11 17 63 Table 11 Obligatory checklist for commissioning 64 Table 12 Optional checklist for commissioning 65 Table 13 Service and Maintenance Intervals 67 Table 14 Disposal of materials 80 Table 15 Po...

Page 12: ...KG Damage to the gear unit may result if the gear unit is not used as intended and according to the information in the operating and assembly manual This may also result in personal injury The base or...

Page 13: ...n off a wide area around the hazard area Take care that there is adequate space to avoid swinging loads Never stand under suspended loads Use adequately dimensioned means of transport which are suitab...

Page 14: ...s and adhesives may cause skin irritation Oil mist may escape when vent screws are opened Due to lubricants and conservation materials gear units may be slippery and slip out of the hands There is a s...

Page 15: ...rous situation which may result in death or very serious injury if it is not avoided CAUTION Indicates a dangerous situation which may result in minor injuries if it is not avoided NOTICE Indicates a...

Page 16: ...10217 SK 10407 SK 10507 SK 11207 SK 11307 SK 11217 SK 11407 SK 11507 SK 12207 SK 12307 SK 12407 SK 12507 SK 13207 SK 13307 SK 13407 SK 13507 SK 14207 SK 14307 SK 14407 SK 14507 SK 15207 SK 15307 SK 15...

Page 17: ...X X FK Collar flange X S Shrink disc X X F1 Drive flange X V Solid output shaft X H H66 Covering cap as contact guard X X VL Reinforced bearings X IEC Standard IEC motor mounting X VL2 Agitator versio...

Page 18: ...gear units Operating and Assembly Instructions 18 B 1050 en 4419 Certain versions options can only be used for particular gear unit sizes or configurations Figure 1 MAXXDRIVE XT 2 stage helical bevel...

Page 19: ...types 3 Operating mode 4 Year of manufacture 5 No Serial number 6 M2 Nm Rated torque of gear unit output shaft 7 P1 kW Drive power 8 kg Weight according to ordered version 9 i Overall gear unit ratio...

Page 20: ...g information in the relevant sections 3 1 Transporting the gear unit WARNING Hazard due to falling loads Do not use the eye bolts on a mounted motor to lift the unit Note the centre of gravity of the...

Page 21: ...en 4419 21 3 1 1 Standard gear units Gear units may only be transported with lifting ropes and chains or lifting straps at an angle of 90 to 70 to the horizontal Legend 1 Lifting strap 2 Shackle Not p...

Page 22: ...with motor adapters may only be transported with lifting ropes and chains or lifting straps at an angle of 90 to 70 to the horizontal The ring bolts on the motor must not be used for transportation L...

Page 23: ...lt drives may only be transported with lifting ropes and chains or lifting straps at an angle of 90 to 70 to the horizontal The ring bolts on the motor and the motor bracket must not be used for trans...

Page 24: ...version gear units may only be transported with lifting ropes and chains or lifting straps at an angle of 90 to 70 to the horizontal The ring bolts on the motor must not be used for transportation Le...

Page 25: ...swing base or base frame may only be transported with lifting ropes and chains or lifting straps at an angle of 90 to 70 to the horizontal Only use the attachment points on the motor swing base or bas...

Page 26: ...apply a suitable rust inhibitor to the surfaces Gear units with the long term storage option are completely filled with lubricant or have VCI corrosion protection agent mixed with the gear oil see adh...

Page 27: ...ebebau NORD and take the recommended action Oil level tanks Option OT are fitted as standard prior to delivery of the gear unit If this is not the case the intended position can be obtained from the o...

Page 28: ...eight and torque taking into account the forces acting on the gear unit Bases which are insufficiently rigid may lead to radial and axial displacement during operation which is not measurable when the...

Page 29: ...ial forces to the gear unit In particular do not hit the hubs with a hammer Information Use the end thread of the shafts for pulling Fitting can be facilitated by coating the hub with lubricant or hea...

Page 30: ...R1 applies for the application of the radial force to the centre of the free shaft journal For output shafts the application of the radial force FR2 must not exceed the dimension xR2 If the radial for...

Page 31: ...Part No 089 00099 Excess grease or anti corrosion agent may escape after assembly and may drip off Clean these points on the driven shaft after a running in time of approx 24 hours This escape of grea...

Page 32: ...ing the fastening element The screw of the fastening element must be tightened with the appropriate torque please see chapter 7 4 Screw tightening torques Assembly Legend 1 Fastening element 2 Circlip...

Page 33: ...tighten the bolts if the solid shaft is not inserted When re assembling the shrink disc the thread and head surfaces of the tensioning bolts must be treated with grease which does not contain Molycot...

Page 34: ...ing the solid shaft of the machine must be greased in the area which will later come into contact with the bushing in the hollow shaft of the gear unit Figure 12 It is essential that the tensioning se...

Page 35: ...e the tensioning bolts from their thread 2 If the external ring does not detach from the inner ring after approx one turn of all screws the external ring can be released with the aid of the push off t...

Page 36: ...ion and torsionally rigid The bolting surfaces of both flanges must be clean The diameter of the hole circle and the size of the threaded holes on the flange of the gear unit must be obtained from the...

Page 37: ...ately Do not exceed the maximum permissible distortion of 0 1 mm at a distance of 1 m Check and correct the alignment of mounted components Pay attention to the manufacturers documentation Ensure a no...

Page 38: ...during installation work Pay attention to the additional information contained in the operating and assembly instructions for third party components Pay attention to the job specific information on br...

Page 39: ...element option S NORD recommends a g6 fit for the bolt supporting the elastic element To facilitate installation and to protect against corrosion a suitable lubricant may be applied to the inner diame...

Page 40: ...bushing of the pulley 3 Insert the tapered bushing in the hub and bring all connecting holes into alignment Half threaded holes must be opposite half smooth holes 4 Lightly oil studs or cylindrical sc...

Page 41: ...Tapered bushing 3 V belt pulley Figure 14 V belt pulley disassembled assembled Legend 1 Axle shaft 2 Belt 3 Belt pulley I Aligned pulleys on axially parallel shafts II Axial displacement of the pulle...

Page 42: ...severe injuries from rapidly rotating parts Secure the drive against accidental start up The maximum permitted motor weights and the dimension X max stated in the table below must not be exceeded whe...

Page 43: ...weights Transnorm 315 355 Centre of gravity X max1 mm 615 615 Weight kg 1500 1500 1 see Figure 16 for maximum permitted X dimension Table 6 Transnorm motor weights NORD must be consulted if the value...

Page 44: ...nto the motor shaft according to the instructions of the motor manufacturer The shaft end of the motor must be adjusted so that it is flush with the face of the coupling Figure 17 Fitting the coupling...

Page 45: ...upling WARNING Risk of oil being expelled in case of an overload The oil being expelled from the coupling is hot Danger of burns The coupling must be encased as a protection against oil being expelled...

Page 46: ...the fusible plug is reached The alignment of the mechanical switch must be checked with the aid of the manufacturer s documentation prior to commissioning The switch must be connected to the evaluati...

Page 47: ...coil The cooling coil must not be subjected to external forces Do not twist the connections after assembly Prevent vibrations from reaching the cooling coil during operation Information Using two coo...

Page 48: ...on sheet for the order Do not modify any of the pre assembled hoses without having consulted NORD beforehand The permissible maximum ambient temperature for operating the cooling systems is 40 C A tes...

Page 49: ...is driven via the gear unit drive shaft The motor pump has a separate drive Lubricant circulation systems are normally equipped with pressure switches The connection and evaluation of these sensors m...

Page 50: ...ssible For helical gear units with motor adapters the torque support is located opposite to the motor adapter Legend 1 Fork head with bolt 2 Threaded bolt 3 Maintenance free joint head 4 Fork plate wi...

Page 51: ...e operating instructions before commissioning WARNING Risk of brake malfunction from excessive wear Faulty or incorrectly adjusted brake linings can lead to a reduction in braking torque and braking e...

Page 52: ...ile being operated the brake lining of a mechanical brake is subject to wear The option SLW indicates when the wear limit is reached and the brake lining must be replaced 3 23 3 NC NO contacts option...

Page 53: ...tate of the manual release and can be accordingly evaluated by a higher level control unit Information You must check and if necessary correct the function of the limit switch after the brake linings...

Page 54: ...ard positions of the oil drain vent and oil level For more detailed information about the vent option used e g FV EF DB refer to section 5 2 10 Venting The sealing plug which is used for transport mus...

Page 55: ...ed with grease Re greasing is carried out via the conical grease nipple Legend 1 Bearing cover 1 2 Grease filled gap 3 Conical grease nipple 4 Bearing cover 2 Figure 24 Checking a Taconite seal As sta...

Page 56: ...re monitor can only be evaluated after the pump has been put into operation as a pressure must first be built up During commissioning a lower pressure is permissible for a short period The pressure mo...

Page 57: ...the pH value must be between pH 7 4 and pH 9 5 No aggressive liquids may be added to the coolant The coolant pressure must not exceed 8 bar The required coolant flow rate is 10 l min The maximum perm...

Page 58: ...defined during the planning phase and can be found in the order data If there is a danger of frost the operator should add a suitable anti freeze solution to the cooling water For oil water coolers op...

Page 59: ...used it is recommended that the gear unit is also equipped with a PT 100 to monitor the oil temperature 4 8 Temperature monitoring Option PT100 NOTICE Gear unit damage through overheating The customer...

Page 60: ...r maintenance work The back stop or freewheeling coupling is lubricated with the gear oil The back stops or the freewheeling coupling lift off due to centrifugal force above a certain lift off speed n...

Page 61: ...4 125 445 2740 SK 7207 2 7 1 25 400 SK 7307 2 28 315 430 15 25 624 SK 7407 3 28 50 1012 56 100 1636 SK 7507 4 112 400 1759 SK 8207 2 8 28 400 SK 8307 3 32 5 355 430 20 28 624 SK 8407 3 31 5 56 1012 6...

Page 62: ...2 5 6 20 250 SK 12307 3 22 4 112 320 12 5 28 352 SK 12407 3 31 5 45 544 50 71 888 SK 12507 4 80 400 1136 SK 13207 2 5 6 20 250 SK 13307 2 22 4 112 320 12 5 28 352 SK 13407 3 31 5 45 544 50 71 886 SK...

Page 63: ...oscillations or other movements Production of steam or smoke After the test run the gear unit should be checked for Leaks Slippage of the shrink disks To do this remove the cover and check whether the...

Page 64: ...n comply with the actual installation position 7 2 Has the correct oil level for the version been checked 5 2 3 Has the vent been fitted and activated 4 1 Has the gear unit been earthed 3 5 Has the ge...

Page 65: ...tion CS1 CC Is the cooling water connected to the cooling unit or the cooling coil and open 3 17 3 18 Option CS1 CS2 Is the cooling unit connected to the gear unit 3 18 Option LC LCX Is the pressure m...

Page 66: ...ces Check the condition of the oil Check the seals 3 3 Daily Visual inspection of the contamination indicator 5 2 6 Check oil temperature 4 8 Check oil pressure 4 3 Check if the operating noise has ch...

Page 67: ...the lining wear correction 3 23 Check the coupling Check the wear of dog couplings 3 15 3 16 For operating temperatures up to 80 C Every 10000 operating hours but at least every 2 years Higher tempera...

Page 68: ...of an elastomer material and are lubricated with a special grease at the factory This reduces the wear due to their function and ensures a long service life An oil film in the region of the rubbing se...

Page 69: ...nt of the oil An oil level below the Min marking is impermissible and may indicate a leak An impermissible oil level may damage the gear unit Find and correct the reason for the incorrect oil level If...

Page 70: ...ead cleaned and coated with securing adhesive e g Loctite 242 Loxeal 54 03 prior to insertion 4 Fit the oil level screw together with the sealing ring and tighten to the correct torque please see chap...

Page 71: ...below the minimum level lower edge of the inspection window the oil level must be corrected by topping up with lubricant a Oil level tank and dipstick standard configuration characteristic cylindrica...

Page 72: ...ecked with a dipstick The 3D oil inspection glass in the gear unit housing is used to check the oil level and must always be completely filled with oil The oil inspection glass in the SAFOMI IEC adapt...

Page 73: ...lines Hose lines are subjected to a natural ageing process due to external influences e g UV radiation to a greater extent than pipes When checking hose lines look out for leaks cuts cracks porous are...

Page 74: ...screwing in again In both cases tighten the screws with the correct torque please see chapter 7 4 Screw tightening torques 7 Fill the gear unit with the specified quantity of fresh oil according to t...

Page 75: ...replaced 1 Unscrew the old ventilation filter 2 Screw in the new ventilation filter with a new sealing ring please see chapter 7 4 Screw tightening torques Figure 28 Vent filter option FV 5 2 10 2 Cel...

Page 76: ...ft sealing ring Replace the shaft sealing ring Once the shaft sealing ring has reached the end of its service life the oil film in the region of the sealing lip increases and a measurable leakage with...

Page 77: ...nt for replacement of the grease in the roller bearings Recommended grease Petamo GHY 133N Kl ber Lubrication please see chapter 7 3 1 Roller bearing greases 5 2 13 Bearings is the output flange Optio...

Page 78: ...ap 3 Conical grease nipple 4 Bearing cover 2 Figure 31 Re greasing Taconite seals The precise position of the grease nipples can be obtained from the specific dimension sheet for the order The seal mu...

Page 79: ...belts it is essential to check the condition of the V belt pulleys After a running time of approx 4 5 hours with the drive under full load the tension of the V belts must be checked with a frequency...

Page 80: ...loy gear unit housing light alloy gear unit housing components Aluminium Worm gears bushes Bronze Shaft sealing rings sealing caps rubber components Elastomers with steel Coupling components Plastic a...

Page 81: ...13 7 13 7 13 7 13 M3 5 D 16 5 6 D 16 6 D 16 G M4 4 12 4 12 4 12 M5 M6 Oil gauge M1 OT OT OT OT OT OT OT M2 OT OT OT OT OT OT M3 OT OT OT OT OT OT M4 OT OT OT OT OT OT OT M5 OT OT OT OT OT OT OT M6 OT...

Page 82: ...16 OT 16 17 OT 16 17 OT M3 9 10 OT 9 10 OT 9 10 OT 9 10 OT 9 10 OT 9 10 OT M4 5 6 OT 5 6 OT 5 6 OT OT M5 13 14 OT 13 14 OT OT M6 7 8 OT 7 8 OT OT Key Housing Standard position in housing Lid Standard...

Page 83: ...7 Appendix B 1050 en 4419 83 Gear units SK 5207 SK 10507 M1 oil screw holes...

Page 84: ...Industrial gear units Operating and Assembly Instructions 84 B 1050 en 4419 Gear units SK 5207 SK 10507 M2 oil screw holes...

Page 85: ...7 Appendix B 1050 en 4419 85 Gear units SK 5207 SK 10507 M3 oil screw holes...

Page 86: ...Industrial gear units Operating and Assembly Instructions 86 B 1050 en 4419 Gear units SK 5207 SK 10507 M4 oil screw holes...

Page 87: ...7 Appendix B 1050 en 4419 87 Gear units SK 5207 SK 10507 M5 oil screw holes...

Page 88: ...Industrial gear units Operating and Assembly Instructions 88 B 1050 en 4419 Gear units SK 5207 SK 10507 M6 oil screw holes Figure 32 Numbering of oil screw holes on SK 5207 SK 10507...

Page 89: ...7 Appendix B 1050 en 4419 89 Gear units SK 11207 SK 15507 M1 oil screw holes...

Page 90: ...Industrial gear units Operating and Assembly Instructions 90 B 1050 en 4419 Gear units SK 11207 SK 15507 M2 oil screw holes...

Page 91: ...7 Appendix B 1050 en 4419 91 Gear units SK 11207 SK 15507 M3 oil screw holes...

Page 92: ...Industrial gear units Operating and Assembly Instructions 92 B 1050 en 4419 Gear units SK 11207 SK 15507 M4 oil screw holes...

Page 93: ...7 Appendix B 1050 en 4419 93 Gear units SK 11207 SK 15507 M5 oil screw holes...

Page 94: ...Industrial gear units Operating and Assembly Instructions 94 B 1050 en 4419 Gear units SK 11207 SK 15507 M6 oil screw holes Figure 33 Numbering of oil screw holes on SK 11207 SK 15507...

Page 95: ...7 Appendix B 1050 en 4419 95 Gear units SK 5217 SK 11217 M1 oil screw holes...

Page 96: ...Industrial gear units Operating and Assembly Instructions 96 B 1050 en 4419 Gear units SK 5217 SK 11217 M4 oil screw holes...

Page 97: ...7 Appendix B 1050 en 4419 97 Gear units SK 5217 SK 11217 M5 oil screw holes...

Page 98: ...Industrial gear units Operating and Assembly Instructions 98 B 1050 en 4419 Gear units SK 5217 SK 11217 M6 oil screw holes Figure 34 Numbering of oil screw holes on SK 5217 SK 11217...

Page 99: ...allation orientation 7 2 1 Helical gear unit Figure 35 Helical gear unit installation positions with standard mounting surface 7 2 2 Bevel helical gear unit Figure 36 Bevel gear unit installation posi...

Page 100: ...Synthetic 25 80 Energrease SY 2202 Tribol 4747 RENOLIT HLT 2 PETAMO GHY 133 N Mobiltemp SHC 32 Cassida EPS2 RENOLIT LST 2 Kl berplex BEM 41 132 Bio degradable 25 40 Biogrease EP 2 PLANTOGEL 2 S Kl be...

Page 101: ...facturer If different oil types are mixed damage to the gear unit is possible due to inadequate lubrication through oil incompatibility Fill the gear unit with the previously used oil type Mixing of o...

Page 102: ...Enersyn SG XP Tribol 1300 Renolin PG Gearmaster PGP Kl bersynth GH 6 Shell Omala S4 WE 320 680 20 40 CLP HC Synthetic hydrocarbon 220 40 40 Enersyn EP XF Optigear Synth X Tribol 1710 Renolin Unisyn CL...

Page 103: ...l gradually during operation Check and if necessary correct the oil level after 2 hours of operation 7 3 3 1 Helical gear units 1 Lubricant circulation Option LC 2 Lubricant circulation Option LCX 3 F...

Page 104: ...78 80 1413 SK 10407 10507 88 103 77 1014 97 101 1613 SK 11407 11507 117 137 572 102 1474 402 1421 452 1471 452 1973 SK 12407 12507 159 195 932 149 2134 652 2091 692 2091 692 2903 SK 13407 13507 159 27...

Page 105: ...3 78 91 48 11 17 27 M12 92 135 155 83 27 40 53 M16 230 335 390 207 35 92 M20 460 660 770 414 230 M24 790 1150 1300 711 80 460 M30 1600 2250 2650 1400 170 M36 2780 3910 4710 2500 1600 M42 4470 6290 754...

Page 106: ...eck operating values of the system Oil leaks from the gear unit Defective seal Consult NORD Service Oil escaping from pressure vent Oil level too high Correct oil level Unfavourable operating conditio...

Page 107: ...Replace rubber element Output shaft does not rotate although motor is running Motor coupling defective Replace coupling Shrink disc slip Check shrink disc Breakage in gear unit Consult NORD Service Co...

Page 108: ...Sealed No moisture apparent No reason for complaint No reason for complaint No reason for complaint No reason for complaint Damp Moisture film locally restricted not an area No reason for complaint No...

Page 109: ...our Internet site www nord com 7 10 Warranty NORD GmbH Co KG accepts no liability for damage to persons materials or assets as a result of failure to observe this operating manual operating errors or...

Page 110: ...m 48 58 F Fan 56 68 Fastening element 32 Fault 106 Flange mounted version Flange 36 G Gear unit types 16 General overhaul 79 H Heat exchanger 68 Hollow shaft 31 Hose lines 73 I Intended use 12 Interna...

Page 111: ...Radial shaft seal 76 Repairs 109 Roller bearing greases 100 Running noises 68 S Safety information 12 20 27 SAFOMI 72 Sensors 49 Service 109 Service intervals 66 Shrink disc 33 Sound emission 108 Sou...

Page 112: ...6052902 4419...

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