Siemens FLENDER PLANUREX 2 PBUC Series Assembly And Operating Instructions Manual Download Page 1

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FLENDER gear units

Planetary Gear Unit Type

PLANUREX 2

PBUC
Sizes 21 to 42
for bucket wheel drives

Assembly and operating instructions
BA 9213 en 03/2012

Summary of Contents for FLENDER PLANUREX 2 PBUC Series

Page 1: ...FLENDER gear units Planetary Gear Unit Type PLANUREX 2 PBUC Sizes 21 to 42 for bucket wheel drives Assembly and operating instructions BA 9213 en 03 2012 ...

Page 2: ...ice addresses 12 12 12 12 12 12 12 12 12 12 10 Maintenance and repair 12 12 12 12 12 12 12 12 12 12 9 Faults causes and remedy 12 12 12 12 12 12 12 12 12 12 8 Operation 12 12 12 12 12 12 12 12 12 12 7 Start up 12 12 12 12 12 12 12 12 12 12 6 Fitting 12 12 12 12 12 12 12 12 12 12 5 Technical description 12 12 12 12 12 12 12 12 12 12 4 Transport and storage 12 12 12 12 12 12 12 12 12 12 3 Safety ins...

Page 3: ...ge to the product Disregarding these notes may result in material damage NOTE The notes indicated by this symbol must be treated as general operating information Disregarding these notes may result in undesirable results or conditions WARNING Hot surfaces The notes indicated by this symbol are made to prevent risk of burns due to hot surfaces and must always be observed Disregarding these notes ma...

Page 4: ...nstructions may be trademarks the use of which by third parties for their own purposes may infringe holders rights Exclusion of liability We have checked the content of the instructions for compliance with the hard and software described Nevertheless variances may occur and so we can offer no warranty for complete agreement The information given in these instructions is regularly checked and any n...

Page 5: ...17 4 4 2 Exterior preservation 18 5 Technical description 19 5 1 General description 19 5 2 Construction and method of operation 20 5 2 1 Bevel helical planetary gear unit 20 5 2 1 1 Housing 20 5 2 1 2 Toothed components 20 5 2 1 3 Lubrication 20 5 2 1 4 Shaft bearings 20 5 2 1 5 Shaft seals 20 5 2 1 6 Cooling 21 5 2 2 Brake 21 5 2 3 Shrink disk 21 5 2 4 Coupling 21 5 2 5 Heating 21 5 2 6 Attachme...

Page 6: ...32 6 11 Final work 33 6 12 Screw connection classes tightening torques and initial tensioning forces 33 6 12 1 Screw connection classes 33 6 12 2 Tightening torques and initial tensioning forces 34 7 Start up 36 7 1 Procedure before start up 36 7 1 1 Removal of preservative agent 36 7 2 Filling with lubricant 37 7 3 Start up 37 7 4 Removal from service 38 7 4 1 Interior preservation during longer ...

Page 7: ...47 10 2 7 Checking oil cooling system 47 10 2 8 Topping up oil 48 10 2 9 Checking hose lines 48 10 2 10 Checking tightness of fastening bolts 48 10 3 Final work 48 10 3 1 General inspection of the gear unit 48 10 4 Lubricants 49 11 Spare parts customer service addresses 49 11 1 Stocking spare parts 49 11 2 Spare parts and customer service addresses 49 11 3 Spare parts drawing 50 11 3 1 PBUC type A...

Page 8: ...data Year built oil type oil viscosity oil quantity Total weight in kg Instructions number s Special information Special information Type size Manufacturer and place of manufacture Power rating P2 in kW or torque T2 in Nm Country of origin Speed n1 Example P B U C 36 Size 21 42 Configuration Bucket wheel Gear unit type P Planetary gear unit For specifications for the measuring surface sound pressu...

Page 9: ...ply The measuring surface sound pressure level includes add on lubrication units if applicable With outgoing and incoming pipes the interfaces are the flanges The sound pressure levels stated in the table were obtained by statistical calculation by our Quality Control Dept The gear unit can be statistically expected to comply with these sound pressure levels Table 1 Measuring surface sound pressur...

Page 10: ...gth Resistance thermometer 2x Pt100 DIN IEC Cl B Two wire circuit Immersion tube length Connection immersion tube Type of protection EL 100 mm 100 mm G 1 2 IP 65 Siemens B 6100 EN 700 1 Gear pump Type Delivery Three phase motor Type of protection Insulation material class F STEIMEL BA STE PUM 000 EN 712 1 Double change over filter to Siemens standard W 5921 Type Nominal width Rated pressure Flow r...

Page 11: ...er of switching contacts Contact rating Type of protection set to G 1 4 A 0 3 to 1 5 bar 1 0 8 bar Siemens B 5925 EN 749 1 Non return valve optional RHDI set to G approx 1 5 bar ERMETO BA ERM RSV 000 EN 775 1 Volumetric flow meter optional to Siemens standard W 5927 with visual indication Oil flow quantity equivalent to scale reading Number of switching contacts Contact rating Type of protection V...

Page 12: ...e use The gear unit must be used and operated strictly in accordance with the conditions laid down in the contract governing performance and supply agreed by Siemens and the customer The gear unit described in these operating instructions reflects the state of technical development at the time these instructions went to print In the interest of technical progress we reserve the right to make chang...

Page 13: ... switched on accidentally e g by locking the key switch or removing the fuses from the power supply A notice should be attached to the start switch stating clearly that work is in progress No electrical welding work must be done at all on the drive The drives must not be used as an earthing point for welding operations Toothed parts and bearings may be irreparably damaged by welding A potential eq...

Page 14: ...vironmental legislation Disposal of the gear unit after its useful life Drain all the operating oil preservative agent and or cooling agent from the gear unit and dispose of in accordance with regulations Depending on national regulations gear unit components and or add on parts may have to be disposed of or sent for recycling separately 3 3 Special dangers and personal protective equipment Depend...

Page 15: ...ging may be used depending on the size of the unit and method of transport Unless otherwise agreed the packaging complies with the HPE Packaging Guidelines The symbols marked on the packaging must be observed at all times These have the following meanings Top Fragile Keep dry Keep cool Centre of gravity Use no hand hook Attach here Fig 2 Transport symbols Transport of the gear unit must be carried...

Page 16: ...such as chemically aggressive products Provision for special environmental conditions during transport e g transport by ship and storage climate termites etc must be contractually agreed 4 4 Standard coating and preservation The gear unit is provided with an interior preservative agent the free shaft ends are painted for protection The characteristics of the external coat depend on the ambient con...

Page 17: ...r preservation when using mineral oil or PAO based synthetic oil Duration of protection Preservative agent Special measures up to 6 months Castrol Alpha SP 220 S none up to 24 months Close all holes in the gear unit Replace air filter or breather screw with screw plug replace plug screw with air filter or breather screw before start up For storage periods longer than 24 months renew the preservati...

Page 18: ... to tropical conditions soluble with CH compounds in case of outdoor storage up to 12 months 2 1 The gear unit must be stored in the position of use in a sheltered place it must be placed on a vibration free dry base and covered over 2 If the gear unit is being stored out of doors it must be particularly carefully covered and care must be taken that neither moisture nor foreign material can collec...

Page 19: ...xcavators The bucket wheel drive is delivered as a complete drive unit assembled from various components 2 7 3 4 6 5 1 8 Fig 4 Gear unit components 1 Bevel helical planetary gear unit 5 Protective cover 2 Torque arm 6 Coupling 3 Ball and socket joint optional 7 Brake 4 Setting screws for electrical motor 8 Shrink disk A detailed view of the gear unit can be obtained from the drawings in the gear u...

Page 20: ...d inspection and assembly covers It is also fitted with an oil dipstick for checking the oil level two drain plugs and a breather screw for venting the housing Colour codes for ventilating oil inlet oil level and oil drainage Ventilation yellow Oil drain white Oil inlet yellow Lubrication red Oil level red 5 2 1 2 Toothed components The externally toothed components of the gear unit are case harde...

Page 21: ...on the specific operating instructions must be observed When installing the drives the individual components must be very precisely aligned with one another in order to minimise restoring forces caused by angle and shaft offset and avoid premature wear to flexible coupling components 5 2 5 Heating The drive may be fitted with heating elements for heating For the exact position and quantity of the ...

Page 22: ...Close brake 5 2 8 Auxiliary drive optional The bucket wheel drive may optionally be provided with an auxiliary drive This auxiliary drive enables the gear unit to be operated at a lower output speed in the same direction of rotation The auxiliary drive is connected with the gear unit by a clutch Main and auxiliary motors must not be started together The auxiliary drive should be protected against ...

Page 23: ...leeve is shifted axially This is conditional upon at least one gear unit shaft being freely rotatable when changing over If however the teeth come together in such a way that shifting is no longer possible the motor of the auxiliary gear unit should be briefly run inching operation with the control lever in position OFF and the locking plate engaged and the shifting operation repeated or the clutc...

Page 24: ...l cooling unit or fitting the oil sump with a temperature monitoring device with a cut out function If a sunshade roof is fitted heat must be prevented from building up If a temperature monitoring device is fitted a warning signal must be emitted when the maximum permitted oil sump temperature is reached If the maximum permitted oil sump temperature is exceeded the drive must be shut off Such shut...

Page 25: ...rve current regulations The cleaner must not be allowed to come into contact with the shaft sealing rings Mount and secure input and output drive elements e g coupling components on the shafts If these are to be heated before mounting refer to the dimensioned drawings in the coupling documentation for the correct joining temperatures Unless otherwise specified the components may be heated inductiv...

Page 26: ... b A B B B 4 5 2 1 3 A Greased B Absolutely grease free Fig 6 Fitting the shrink disk 1 Stub shaft 3 Inner ring 5 Tensioning bolt 2 Hollow shaft 4 Outer ring The outer surface of the hollow shaft must be lightly greased in the area of the shrink disk seat For a detailed view refer to the dimensioned drawing in the gear unit documentation Place the shrink disk on the hollow shaft and fasten if requ...

Page 27: ... 6 Maximum torques for tensioning bolts Tensioning bolt thread max tightening torque per bolt Tensioning bolt thread max tightening torque per bolt Strength class 12 9 Nm Strength class 12 9 Nm M 8 35 M 20 570 M 10 70 M 24 980 M 12 120 M 27 1450 M 14 193 M 30 1970 M 16 295 M 33 2650 The shrink disk has been identity marked on the outer ring 4 In case of contacting Siemens this identification must ...

Page 28: ...llow shaft Pull the shrink disk off the hollow shaft For transporting and lifting the shrink disk it may be required to use a suitable lifting device 6 5 3 Cleaning and greasing the shrink disk Only dirty shrink disks must be disassembled and cleaned Inspection of all parts for any damage Damaged parts must be replaced with new ones The use of damaged parts is not permissible Only the complete shr...

Page 29: ...nk disk should be carried out simultaneously with the examination of the gear unit however at least every 12 months Inspection of the shrink disk is limited to a visual assessment of its condition The following must be observed when carring out this work loose screws damage caused by force flush position of the inner ring 3 in relation to outer ring 4 6 6 Shrink disk type HYD HYD hydraulic 6 6 1 F...

Page 30: ...se connections Collect any hydraulic fluid that may run out Connect the pressure line to the connection marked Clamp Clamping of the shrink disk The correct clamping condition has been reached as soon as the faces of the outer and inner rings are flush The maximum permissible clamping pressure is 450 bar This allows the clamping condition to be checked visually If alignment cannot be achieved by c...

Page 31: ...ing re clamped The shrink disk should only be disassembled and cleaned if it is dirty Following cleaning only the inner sliding surfaces of the shrink disk should be re greased Use a solid lubricant with a high MoS2 based molybdenum disulphide content and with a coefficient of friction of μ 0 04 according to the following table Table 8 Lubricants for shrink disk after cleaning Lubricant Form Manuf...

Page 32: ...s for the couplings 6 10 One sided torque arm In the case of a one sided torque arm a ball and socket joint see figure 8 or a flexible bush should be provided The screw on surface of the torque arm on the gear unit housing must be degreased and smeared with Loctite 640 This increases the reliability of the torque transmission and protects against corrosion 2 1 3 4 5 6 Fig 8 One sided torque arm 1 ...

Page 33: ...echnical specialists Cable entries should be protected against moisture Check that protective measures have been taken 6 12 Screw connection classes tightening torques and initial tensioning forces 6 12 1 Screw connection classes The specified screw connections are to be fastened applying the tightening torques specified in the table below Table 9 Screw connection classes Screw connection class Di...

Page 34: ...000 54400 34000 320 276 246 M20 8 8 77000 49200 30800 364 313 280 10 9 110000 70400 44000 520 450 400 12 9 129000 82400 51500 609 525 468 M24 8 8 109000 69600 43500 614 530 470 10 9 155000 99200 62000 875 755 675 12 9 181000 116000 72500 1020 880 790 M30 8 8 170000 109000 68000 1210 1040 930 10 9 243000 155000 97000 1720 1480 1330 12 9 284000 182000 114000 2010 1740 1550 M36 8 8 246000 157000 9830...

Page 35: ...w E D C E D C d mm MA Nm FM min N M90x6 8 8 1510000 968000 605000 30600 26300 23500 10 9 2150000 1380000 860000 43500 37500 33400 12 9 2520000 1600000 1010000 51000 43800 39200 M100x6 8 8 1880000 1200000 750000 42100 36200 32300 10 9 2670000 1710000 1070000 60000 51600 46100 12 9 3130000 2000000 1250000 70000 60400 53900 Damaged bolts must be replaced with new bolts of the same type and strength c...

Page 36: ...an appropriate symbol in the dimensioned drawing in the gear unit documentation Remove any oil spillage immediately with an oil binding agent Screw the oil drain plug in 1 2 3 4 Fig 9 Oil inlet oil drain gear unit 1 Inspection cover oil inlet 3 Air filter 2 Oil dipstick 4 Oil drain plug A detailed view of the gear unit can be obtained from the drawings in the gear unit documentation Before start u...

Page 37: ...motor driven oil pump must be observed The oil level at the oil dipstick marking must be checked with the input and output shafts in a horizontal position The oil level must be up to the upper mark on the oil dipstick Remove any oil spillage immediately with an oil binding agent The oil must not come into contact with the skin e g the operator s hands The safety notes on the data sheets for the oi...

Page 38: ...1 2 Interior preservation with preservative agent Before longer shut down periods gear units with pressure lubrication systems oil circulation cooling and or non contacting shaft seals should be filled with preservative agent and run without load 7 4 1 3 Interior preservation procedure Stop the gear unit Drain oil into a suitable container see section 10 Maintenance and Repair Unscrew the air filt...

Page 39: ...and the position of the add on parts please refer to the drawings of the gear unit documentation Never switch the heating element on unless complete immersion of the rod heater in the oil bath is ensured Fire hazard The max heating output of 0 8 W cm2 on the outer surface of the heating element must not be exceeded Operation and maintenance must be in accordance with the operating instructions spe...

Page 40: ...slightly exceeded It must in no case be allowed to fall below the mark If necessary top up to the correct level If any irregularities are noticed during operation or if the pressure monitor in the oil cooling system if installed triggers the alarm switch the drive unit off at once Determine the cause of the fault using the table in section 9 The trouble shooting table contains a list of possible f...

Page 41: ... Auxiliary drive ready for operation II 1 Move shift lever back to position OFF II 2 Engage and secure locking plate II 3 Briefly operate inching button of auxiliary drive II 4 Release locking plate and move shift lever into position ON Points II 1 to II 4 must be repeated until the shift lever can be moved to lever position ON II 5 Engage and secure locking plate II 6 Release blocking brake II 7 ...

Page 42: ...causes and remedies Faults Causes Remedy Changes in gear unit noise Damage to gear teeth Excessive bearing play Bearing defective Labyrinth rings dragging Contact Customer Service Check all toothed components and replace any damaged parts Contact Customer Service Adjust bearing backlash Contact Customer Service Replace defective bearings Readjust labyrinth rings Loud noises in the area of the gear...

Page 43: ...ks Protect gear unit with suitable heat insulation Close air outlet or alter its direction by structural measures Increased operating temperature Oil level in housing too high Oil too old Oil badly contaminated On gear units with oil cooling system Coolant flow too low Coolant temperature too high Oil flow through water oil cooler too low due to Badly clogged oil filter Check oil level and if nece...

Page 44: ... 90 C applies to mineral oil 100 C applies to synthetic oil The operator must ensure that the intervals stated in table 12 are adhered to This also applies if the maintenance work is included in the operator s internal maintenance schedules Table 12 Maintenance and repair work Measures Periods Remarks Checking oil temperature Daily Checking for unusual gear unit noise Daily Checking oil level Mont...

Page 45: ...ynthetic esters oils 2 years or 10 000 operating hours does not apply to natural esters rape seed oils etc for poly α olefins and polyglycols 4 years or 20 000 operating hours The actual service lives may differ The general rule is that an increase in temperature of 10 K will halve the service life and a temperature decrease of 10 K will approximately double the service life 10 2 Description of ma...

Page 46: ...pects Compatibility must be confirmed by the oil supplier If there is a change to another oil grade or make Siemens recommends flushing out the gear unit with the new grade of service oil When changing the oil the housing and the oil supply system if available must be flushed with oil to remove sludge metal particles and oil residue Use the same type of oil as is used for normal operation High vis...

Page 47: ... glasses Foreign bodies must be prevented from entering the gear unit 10 2 5 Cleaning the gear unit To prevent the build up of dust on the gear unit cleaning must be done in accordance with operating conditions Remove any dirt adhering to the housing with a hard brush Remove any corrosion The outside of the gear unit must not be cleaned with high pressure cleaning equipment 10 2 6 Refilling Taconi...

Page 48: ...rking condition by an expert before the plant is first put into operation and thereafter at least once a year If during inspections faults are found these must be rectified immediately or suitable countermeasures taken 10 2 10 Checking tightness of fastening bolts The instructions in item 10 1 must be observed Checking tightness of all fastening bolts Damaged bolts must be replaced with new bolts ...

Page 49: ...mmend regularly checking whether the selected lubricating oil is still recommended by Siemens If it is not the brand of oil should be changed 11 Spare parts customer service addresses 11 1 Stocking spare parts By stocking the most important spare and wearing parts on site you can ensure that the gear unit is ready for use at any time To order spare parts refer to the spare parts list For further i...

Page 50: ...rts drawing 11 3 1 PBUC type A 248 451 208 206 241 221 719 61 724 723 150 151 550 109 611 50 89 700 712 132 135 100 128 450 400 551 500 509 523 528 102 213 220 256 209 227 255 351 300 502 402 350 Fig 10 Spare parts drawing type PBUC type A ...

Page 51: ...11 3 2 PBUC type B 248 451 208 206 241 221 719 61 724 723 150 151 550 109 611 50 89 700 712 132 135 100 128 450 400 551 500 509 523 528 102 213 220 256 209 227 255 351 300 502 402 350 Fig 11 Spare parts drawing type PBUC type B ...

Page 52: ...ring 135 3 AS ring 500 1 Helical gear shaft 150 1 Rolling bearing 502 1 Helical gear 151 1 Rolling bearing 509 1 Slotted nut 206 1 Helical gear internal teeth 523 1 Sealing ring 208 1 Sealing cord 528 1 Adjusting ring 209 1 Sealing cord 550 1 Rolling bearing 213 b 3 AS ring 551 1 Rolling bearing 220 1 Shaft sealing ring 611 2 Ball and socket joint 221 b 1 V ring 700 1 Gear pump 227 1 Helical gear ...

Page 53: ...gnation Part number Quantity Designation 600 1 Helical gear shaft 624 1 Rolling bearing 602 1 Helical gear shaft 631 1 Rolling bearing 604 1 Rolling bearing 634 1 Rolling bearing 605 1 Rolling bearing 641 1 Rolling bearing 610 1 Helical gear shaft 642 1 Shift gear 611 1 Helical gear shaft 644 1 Rolling bearing 612 1 Helical gear 653 1 Control sleeve 614 1 Rolling bearing 665 3 AS ring 620 1 Helica...

Page 54: ...1 1 3 4 1 3 6 1 3 8 1 1 4 1 1 4 2 1 1 5 1 1 5 11 1 5 13 1 5 15 1 5 16 1 6 1 1 6 3 1 7 1 1 7 1 1 1 7 2 1 7 3 1 7 4 3 The partly completed machinery must not be put into service until it has been established that the machinery into which the partly completed machinery is to be incorporated has been declared in conformity with the provisions of Directive 2006 42 EC as appropriate The manufacturer und...

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