Siemens MOTOX BA 2010 Page 69 Operating Instructions Manual Download | Manualshive

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Service and maintenance

8.2 Checking and changing lubricants

BA 2010
Operating Instructions, 02/2018, A5E38093846A/RS-AC

67

8.2.6.3

Flushing the gearbox when changing between incompatible oils

WARNING

Impermissible mixing of oils results in damage
Residual quantities of original oil can impair the specific properties of the new oil.
A flushing process is required with biodegradable and physiologically safe oils.
The residual corrosion protection oil must amount to no more than 1% of the operating oil

volume.

Note
Polyglycol oil has a higher density than mineral oil. Therefore, polyglycol oil 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.

Note
We recommend that, after the second flush, the quality of the rinse is checked by an expert

analyzer.

Observe the symbols in the diagrams of the mounting positions (Page 87).

Ventilation

Oil filling

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 venting screw.

3.

Fill the gearbox with a detergent oil, using a filter (filter mesh max. 25

μm). For the

detergent oil, use either the new oil or one that is compatible with the new oil.

4.

Allow the gearbox to run 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. Drain all the oil into the receptacle.

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Summary of Contents for MOTOX BA 2010

Page 1: ......

Page 2: ......

Page 3: ...______________ MOTOX Gearbox BA 2010 Operating Instructions Translation of the original instructions 02 2018 A5E38093846A RS AC General information and safety notes 1 Technical description 2 Incoming goods transport and storage 3 Installation 4 Commissioning 5 Operation 6 Faults causes and remedies 7 Service and maintenance 8 Disposal 9 Technical data 10 Spare parts 11 Explanations 12 ...

Page 4: ...ed 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...

Page 5: ...3 Primed version 20 3 Incoming goods transport and storage 21 3 1 Incoming goods 21 3 2 Transport 22 3 2 1 General information on transport 22 3 2 2 Fastening for suspended transport 23 3 3 Storage 25 3 3 1 General information for storage 25 3 3 2 Storage up to 36 months with long term preservation optional 25 3 3 2 1 General notes for storage up to 36 months 25 3 3 2 2 Gearbox filled with operati...

Page 6: ...el helical gearboxes and helical worm gearboxes 48 5 Commissioning 49 5 1 General information for commissioning 49 5 2 Checking the oil level prior to commissioning 49 5 3 Vent filter 50 5 4 Gearbox with backstop optional 50 6 Operation 51 7 Faults causes and remedies 53 8 Service and maintenance 57 8 1 General notes about maintenance work 57 8 2 Checking and changing lubricants 59 8 2 1 General s...

Page 7: ...boxes Intermediate helical gearboxes 96 10 6 Oil quantities 96 10 6 1 Helical gearboxes 97 10 6 2 Parallel shaft gearboxes 98 10 6 3 Bevel helical gearboxes 99 10 6 4 Helical worm gearboxes 100 10 6 5 Tandem gearboxes Intermediate helical gearboxes 101 10 6 5 1 Two and three stage helical gearboxes 101 10 6 5 2 Parallel shaft gearboxes 103 10 6 5 3 Bevel helical gearboxes 104 10 6 5 4 Helical worm...

Page 8: ...Table of contents BA 2010 6 Operating Instructions 02 2018 A5E38093846A RS AC ...

Page 9: ...the standard version of the MOTOX gearboxes E Z and D helical gearboxes sizes 18 to 188 EK cooling tower version helical gearboxes sizes 88 to 148 and ZK sizes 68 to 188 FZ and FD parallel shaft gearboxes sizes 28 38B to 188B 208 B K bevel helical gearboxes sizes 28 to 188 C helical worm gearboxes sizes 28 to 88 The precise type designation is described in Section Type designation Page 81 Table 1 ...

Page 10: ...ons are updated regularly with new contents The latest versions of the operating instructions the declaration of incorporation and the declarations of conformity are available in electronic form in the Industry Online Support https support industry siemens com cs ww de ps 13424 man You can find technical configuration data spare parts lists and certificates of compliance on the Intranet at Once De...

Page 11: ...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 agreement of Siemens AG 1 3 Intended use ATEX version gearboxes The ATEX gearbox satisfies the requirements of the Explosion Protection Directive 2014 34 EU...

Page 12: ...order to Eliminate the risk to life and limb of users and other persons Ensure the operational safety of the geared motor Avoid disruptions and environmental damage through incorrect use 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 oper...

Page 13: ... edged tools to clean the geared motor Observe the permissible tightening torque of the fastening bolts Replace damaged bolts with new bolts of the same type and strength class Siemens AG accepts the warranty only for original spare parts The manufacturer who installs the geared motors in a plant must include the regulations contained in the operating instructions in its own operating instructions...

Page 14: ... Hot escaping oil Before starting any work wait until the oil has cooled down to below 30 C WARNING Poisonous vapors when working with solvents 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 s...

Page 15: ... 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 2 2 Shaft seals The radial shaft sealing ring combination shaft sealing ring labyrinth seal ...

Page 16: ...revent heat radiation and cause a high housing temperature 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 2 4 Backstop ATEX version gearboxes The dri...

Page 17: ...he gearbox is running in the specified direction the inner ring and the cage with the sprags also rotate while the outer ring remains stationary Where the backstop is used in the coupling lantern lifting of the sprags is ensured when the drive speed is above the speed listed in the table The backstop is wear free It does not require maintenance Table 2 1 Drive speed when using backstops Motor size...

Page 18: ...inishes are sprayed on ATEX version gearboxes The gearbox is delivered complete with primer and paint finish If the gearbox is delivered with primer only or unpainted a paint finish must be applied which meets the applicable guidelines for the specific application The primer does not provide adequate corrosion protection ATEX version gearboxes When applying conductive paint the operator must ensur...

Page 19: ...rnal protection If the paint finish is damaged the geared motor may corrode Do not damage the paint finish Note Information about the ability to be repainted does not guarantee the quality of the paint product supplied by your supplier Only the paint manufacturer is liable for the quality and compatibility 2 6 2 Painted version The corrosion protection system is classified according to the corrosi...

Page 20: ...ings 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 Corrosiveness category C3 for medium environmental stress 2 component epoxy zinc phosphate base coat 2 component polyurethane top coat...

Page 21: ...ronmental stress 2 component epoxy zinc phosphate base coat 2 component polyurethane 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 ...

Page 22: ...arts untreated Synthetic paint synthetic resin paint oil paint 2 component polyurethane paint 2 component epoxy paint Primed according to corrosiveness category C2 G 2 component epoxy zinc phosphate desired coat thickness 60 μm 2 component polyurethane paint 2 component epoxy paint 2 component acrylic paint Acid hardening paint Primed according to corrosiveness category C4 G 2 component epoxy zinc...

Page 23: ...ce 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...

Page 24: ... 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 Unless contractually agreed otherwise the seaworthy packaging complies with HPE Packaging Guidelines Bundesverband Holzpackmittel Paletten Exportverpackungen e V the German Federal Association for w...

Page 25: ...n the motor to transport the motor prior to mounting or following removal 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 NOTICE Do not rig eyebolts to the front threads at the shaft ends for transportat...

Page 26: ... kg mm K 38 200 22 K 128 800 40 K 48 250 22 K 148 1 300 44 K 68 350 26 K 168 1 800 55 K 88 600 30 K 188 2 300 55 K 108 750 35 Table 3 2 Maximum load of the eyebolt on the gearbox Thread size m d3 Thread size m d3 kg mm kg mm M8 140 36 M20 1 200 72 M10 230 45 M24 1 800 90 M12 340 54 M30 3 600 108 M16 700 63 Procedure 1 Mount the geared motor on the transport device by the heaviest permissible weigh...

Page 27: ...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 36 months with long term preservation optional 3 3 2 1 General notes for stor...

Page 28: ...essure breather valve with transport fixture For storage up to 36 months a VCI anti corrosion agent Volatile Corrosion Inhibitor is added 3 3 2 3 Gearbox completely filled with oil NOTICE Damage to the gearbox caused by incorrect oil quantities Prior to commissioning remove excessive oil until it has the correct oil level Observe the information and procedures for Correcting the oil level Page 59 ...

Page 29: ... gearboxes Effect on bearings of stray electric currents from electrical equipment When mounting the gearbox on or connecting it to the machine take care to ensure potential equalization The information on grounding and equipotential bonding provided by the motor supplier must be observed WARNING Operating under load Under load the system can start or reverse in an uncontrolled fashion The entire ...

Page 30: ...permissible oil sump temperature is reached The geared motor must be switched off when the maximum permissible temperature is exceeded If the geared motor is shut down then this can cause the machine to come to a stop 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 suff...

Page 31: ...neral tolerance for the tightening torque is 10 The tightening torque is based on a friction coefficient of μ 0 14 Table 4 1 Tightening torques for fastening bolts Thread size Tightening torque for 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 2...

Page 32: ...ollowing values For gearboxes up to size 88 0 1 mm For gearboxes as of size 108 0 2 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 accou...

Page 33: ...transmission Refer to Gearbox with foot mounting Page 30 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 Gearbox with C type housing flange In the case of sizes 108 to 188 the customer s interface can be pinned on the C type housing flange The output flange has been designed to...

Page 34: ...93846A RS AC NOTICE Observe the maximum drilling depth A A Spring pin heavy duty design to DIN 1481 Use pin holes provided in the housing flange Cylindrical grooved pin with chamfer to DIN EN 28740 ISO 8740 Drill connecting component together with housing Figure 4 1 C type case flange helical gearbox ...

Page 35: ...E Observe the maximum drilling depth A A Spring pin heavy duty design to DIN 1481 Use pin holes provided in the housing flange Cylindrical grooved pin with chamfer to DIN EN 28740 ISO 8740 Drill connecting component together with housing Figure 4 2 C type housing flange parallel shaft gearbox and bevel helical gearbox ...

Page 36: ...Premature wear or material damage due to misalignment Misalignment caused by excessive angular or axis displacement to the connecting shaft ends Ensure precise alignment of the individual components NOTICE Damage caused by improper handling Bearings housing shaft and locking rings are damaged due to improper handling Do not use impacts or knocks to force the input and output elements to be mounted...

Page 37: ...angement to minimize stress on shafts and bearings due to lateral forces Correct Incorrect a Hub F Force Figure 4 4 Mounting arrangement for low stress on shafts and bearings Procedure 1 Use either benzine or solvent to remove the anti corrosion protection from the shaft ends and flanges or remove the applied protective skin 2 Fit the drive input and output elements to the shafts Fasten the elemen...

Page 38: ...ers immediately The protection cover is delivered ready fitted to the gearbox flange The protection cover must be removed in order to fit the output shaft Protection cover for hollow shaft Protection cover for hollow shaft with shrink disk Screw Protection cover Gearbox housing Intermediate ring O ring Figure 4 5 Protection covers The O ring is only present with the ATEX version The intermediate r...

Page 39: ...stalled the protection cover for operation 4 10 Removing and installing the shaft mounted gearbox 4 10 1 General information on installing the shaft mounted gearbox NOTICE Damage to shaft sealing rings caused by solvent Avoid any contact of solvent or benzine with the shaft sealing rings NOTICE Subjecting stress to the hollow shaft causes bearing failure Skewing or stressing the hollow shaft incre...

Page 40: ...duct 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 4 10 2 Removing and installing the hollow shaft 4 10 2 1 Mounting the hollow shaft Figure 4 6 Installing the hollow shaft with parallel key Figure 4 7 Installing the hollow shaft with s...

Page 41: ...lvent 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 a disk threaded spindle and nut The counterforce is provided by the hollow shaft 4 For hollow shaft with parallel key and hollow shaft with splines Replace the nut and thre...

Page 42: ...released NOTICE Subjecting stress to the hollow shaft causes bearing failure It is essential to prevent misalignment when removing the unit NOTICE Excessive forces during removal Excessive forces can occur during removal of the hollow shaft via the housing Stresses in the hollow shaft can lead to bearing failure and damage to the gearbox housing Note If frictional corrosion has occurred on the sea...

Page 43: ...ft with parallel key Design suggestion for threaded block and disk Size b10 b11 b12 d10 d11 s11 tmax u mm mm mm mm mm mm mm 28 3 15 10 19 9 10 M6 22 5 6 24 9 14 M8 28 8 38 15 10 14 M8 28 8 6 29 9 18 M10 33 38 10 48 6 15 5 34 9 24 M12 43 10 39 9 28 12 68 7 20 7 39 9 28 M16 48 5 12 44 9 33 14 88 7 20 10 49 9 36 M16 64 14 59 9 45 18 108 10 24 10 59 9 45 M20 74 5 18 69 9 54 20 128 10 24 5 69 9 54 M20 ...

Page 44: ...f the hollow shaft caused by tightening the tightening bolts 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 Size 28 Tighten tightening bolts Sizes 38 208 What is of prim...

Page 45: ... machine shaft because it would reduce the transferred torque Note The shrink fitted disc connection fastens the hollow shaft axially on the machine shaft 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 Size 28 208 rein...

Page 46: ...g bolts by a turn each time not crosswise 3 Attach the rubber cover or protection cover included in the scope of delivery see Removing and installing the protection cover Page 36 You have now installed the shrink disk Table 4 3 Tightening torque for tightening bolt Gearbox size Thread size Strength class Tightening torque Nm 28 M5 8 8 5 38 48 68 88 M8 12 9 35 108 128 M10 12 9 70 148 M12 12 9 121 1...

Page 47: ... 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 ...

Page 48: ...damaged rubber elements will not function properly Impacts can cause sparks Damaged rubber elements must be replaced immediately NOTICE Dangerous transient torques due to excess backlash Take care to prevent the torque arm causing excessive constraining forces e g due to the driven shaft running out of true NOTICE Impermissible gearbox loading caused by incorrect mounting Do not tension torque arm...

Page 49: ...in the scope of delivery Figure 4 11 Mounting suggestion for torque arm on F 28 38B 188B Size 28 38B 48B 68B 88B 108B 128B 148B 168B 188B x mm 14 13 1 18 2 17 27 2 26 35 8 34 8 46 2 45 1 Size 208 Note The torque arm bush must be supported by bearings on both sides Figure 4 12 Mounting suggestion for torque arms on F 208 Procedure 1 Clean the contact surfaces between the housing and the torque arm ...

Page 50: ...uggestion for torque arm on foot Figure 4 14 Mounting suggestion for torque arm on flange 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 bolts with the specified torque You have now mounted the torque arm Table 4 5 Tightening torque for bolt of strength class 8 8 if to...

Page 51: ...um radial force can damage the bearings On cylindrical roller bearings in the input unit undershooting the minimum radial force can damage the bearings Prolonged test runs when off load must be kept to a minimum 5 2 Checking the oil level prior to commissioning Check the oil level before commissioning Correct the oil quantity when required Note Checking and changing lubricants Page 59 Siemens AG r...

Page 52: ...sure breather valve without securing clip You have now replaced the vent filter or pressure breather valve with the vent plug without the securing clip Pressure breather valve with securing clip The pressure breather valve with securing clip is fitted to gearboxes which require housing ventilation Figure 5 1 Pressure breather valve with securing clip Remove the transport fixture by pulling the sec...

Page 53: ...p or at the mounting surface in the case of output units Changes are an indication of possible incipient damage CAUTION Malfunctions can cause personal injuries or gearbox damage 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 Page 53 Remedy faults or have faults remedied Check the gear unit during oper...

Page 54: ...Operation BA 2010 52 Operating Instructions 02 2018 A5E38093846A RS AC ...

Page 55: ...use Table 7 1 Faults causes and remedies Faults Causes Remedy Unusual noise on the gearbox Oil level too low Check the oil level Page 59 Foreign objects in the oil irregular noise Checking the oil quality Page 64 Cleaning the gearbox Page 76 Change the oil Page 59 Excessive bearing play and or bearing defective Check the bearing and replace if necessary Defective gearing Check the gearing and repl...

Page 56: ...ir gap and adjust if necessary Converter parameterization Correct the parameterization Oil escapes Incorrect oil level for the mounting position being used Check the mounting position Page 87 and the oil level Page 59 Gearbox leaks Checking the gearbox for leaks Page 74 Overpressure due to lack of venting Mount the venting as appropriate for the mounting position Page 87 Overpressure due to soiled...

Page 57: ...earbox very dirty Clean the fan cover and surface of the geared motor Page 76 Incorrect oil level for the mounting position being used Check the mounting position Page 87 and the oil level Page 59 Incorrect oil being used e g incorrect viscosity Checking the oil quality Page 64 Oil is too old Check the date of last oil change If required change the oil Page 59 Excessive bearing play and or bearing...

Page 58: ...the drive input and output Check the load against rated data 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 the direction of motor or backstop rotation Excessive play at drive input and output Flexible elements worn e g on couplings Replace ...

Page 59: ...nly authorized qualified personnel may perform the maintenance and servicing Only original parts supplied by Siemens AG may be installed Only qualified personnel may perform the inspection maintenance and servicing work Note the General information and safety instructions Page 7 Table 8 1 Maintenance measures Measure Interval Description of work Monitor and check the gearbox for unusual noise vibr...

Page 60: ...earbox Cleaning the gearbox Page 76 Check the friction clutch and adjust if necessary After 500 hours thereafter once a year and after every blockage Maintenance of the friction clutch Page 77 Check the coupling For the first time after 3 months Please refer to the separate operating instructions Complete inspection of the geared motor Every 12 months Inspecting the gearbox Page 77 Check that fast...

Page 61: ...the position of the sealing elements are determined by the mounting position After removing the oil level screw up to and including gearbox size 128 the oil level may not be more than 3 mm and from gearbox size 148 not more than 5 mm below the recommended filling level NOTICE Damage to the gearbox due to open oil holes Dirt and damaging atmosphere can penetrate through open oil holes Close the gea...

Page 62: ...l changes with temperature If the temperature rises the volume increases Where temperature differences and filling quantities are significant the volume difference 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 Specified oil level Maximum oil level Minimum oil level Figure 8 1 Oil level in t...

Page 63: ...he sealing ring on the sealing element If the sealing ring is damaged replace the sealing element with a new one 6 After checking seal the gearbox immediately using the sealing element You have now checked the oil level in the gearbox housing Checking the oil level on size 38 gearbox housings with no screw plug for checking the oil level Size 38 gearboxes have no screw for checking the oil level I...

Page 64: ...vel with the surface of the gearbox 6 Pull the dipstick out vertically 7 Measure the distance x on the dipstick 8 Compare the value x with the value for distance x 9 Rectify the oil level if necessary and check it again 10 Check the condition of the sealing ring on the screw plug and replace the sealing ring if necessary 11 Seal the gearbox using the screw plug 12 Mount the geared motor You have n...

Page 65: ...il sight glass optional If there is an oil sight glass to check the oil level 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 is above the center of the sight glass The oil level of cold oil is below the center of the sight glass Figure 8 4 Oil level in the oil sight glass Top up the oil level if necessary and check it again 8 2 4 Che...

Page 66: ...87 Ventilation Oil filling 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 Remove 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 cond...

Page 67: ...t manufacturers must not be mixed Have the manufacturer confirm that the new oil is compatible with the remaining volume of used oil If very different types of oil or oils with very different additives are changed 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 compl...

Page 68: ...he sealing ring if necessary 7 Seal the gearbox using the sealing elements You have now drained the oil from the gearbox Draining oil for B38 with no additional screw plug type V5 00 V1 00 H 05 and V6 00 V3 00 H 06 Procedure 1 Switch off the power supply to the drive unit 2 Place a suitable and sufficiently large receptacle underneath the gearbox 3 Unscrew the oil filler screw 4 Using a length of ...

Page 69: ...al oil floats on top This makes the required complete draining of mineral oil from the gearbox extremely difficult Note We recommend that after the second flush the quality of the rinse is checked by an expert analyzer Observe the symbols in the diagrams of the mounting positions Page 87 Ventilation Oil filling Oil drain Procedure 1 After the oil has been drained wipe the gearbox clean of any rema...

Page 70: ...ity When changing mutually incompatible oils see Flushing the gearbox Page 67 Observe the symbols in the diagrams of the mounting positions Page 87 Ventilation Oil filling Procedure 1 Remove the vent plug or oil filler screw 2 Fill the gearbox with fresh oil Use a filler filter with mesh of max 25 μm 3 Check the oil level 4 Rectify the oil level if necessary and check it again 5 Check the state of...

Page 71: ...nt the gearbox is filled at the factory with special lubricant for the special applications referred to above the lubricant must be shown on the rating plate 8 2 8 Change the roller bearing grease The roller bearings are lubricated in the factory with the greases listed in the table Renew the grease quantify for grease lubricated bearings with each oil change Clean the bearing before filling it wi...

Page 72: ...lüber Summit HYSYN FG68 In the case of ambient temperatures of less than 20 C and greater than 60 C please contact Technical Support The backstop can also be filled with the oil used in the gearbox 8 2 10 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 betw...

Page 73: ...Physiologically safe oil according to USDA H1 H2 Synthetic oil 20 000 operating hours or 4 years Mineral oil Synthetic oil T Oil bath long term temperature C I Oil change interval in operating hours h Figure 8 6 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 co...

Page 74: ...missible temperature for Mineral oil 90 C for brief periods 100 C Polyglycols and polyalphaolefins 100 C for brief periods 110 C Synthetic esters 90 C The minimum permissible temperature for initial filling corresponds to the lowest ambient temperature specified on the rating plate The oil used must be approved for use in the ambient temperature range given on the rating plate When changing the oi...

Page 75: ...late The oil quality must meet the gearbox lubricant requirements specified in the NT 7300 table The Siemens warranty is otherwise null and void We recommend the use of one of these gearbox lubricants These gearbox oils are subject to constant testing and meet the specified requirements It is possible that the recommended oils are removed or replaced by oils that have been further developed at a l...

Page 76: ...ificant or leaking continues after the running in phase the shaft sealing ring must be replaced to prevent consequential damage Table 8 7 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 ...

Page 77: ...u have now cleaned the vent filter 8 6 Replacing the vent valve To ensure correct functioning renew the breather valve yearly When replacing prevent dirt and damaging atmospheres from entering the gearbox If too much oil is contained in the gearbox oil will escape from the breather valve Correct the oil quantity and replace the breather valve 8 7 Checking the oil level sensor optional The oil leve...

Page 78: ...he geared motor Seals can become damaged Do not use a high pressure cleaning appliance to clean the geared motor Do not use tools with sharp edges Switch off the power supply to the drive unit before cleaning it 8 9 Checking tightness of fastening bolts ATEX version gearboxes Loose parts can cause sparks through impact Entry of foreign bodies can cause sparks Note Replace damaged headless bolts wi...

Page 79: ...arry out a scheduled inspection of the gearbox once a year in accordance with the possible criteria listed in General notes about maintenance work Page 57 Check the gearbox in accordance with the criteria set out in General information and safety notes Page 7 Touch up damaged paintwork carefully 8 11 Maintenance of the friction clutch Note Check the condition of the friction clutch initially after...

Page 80: ...Service and maintenance 8 11 Maintenance of the friction clutch BA 2010 78 Operating Instructions 02 2018 A5E38093846A RS AC ...

Page 81: ...w optimal treatment of the oil 4 VI Used Oil oils with different disposal codes must not be mixed with one another 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 motor parts gear wheels shafts and roller bearings of the geared motor as scrap metal Th...

Page 82: ...Disposal BA 2010 80 Operating Instructions 02 2018 A5E38093846A RS AC ...

Page 83: ...Input unit F D F 108 B Z 38 K4 100 Gearbox type F Transmission stage D Type F Size 108 Revision marks B Transmission stage Z Size 38 Input unit K4 for motor size 100 Table 10 2 Type designation code Gearbox type Helical gearbox B Bevel helical gearbox two stage K Bevel helical gearbox three stage F Parallel shaft gearbox C Helical worm gearbox Transmission stage E Single stage Z Two stage D Three ...

Page 84: ...ckstop in intermediate stage Intermediate helical gearbox Transmission stage Z Two stage D Three stage Input unit A A5 Input unit with free input shaft K2 Coupling lantern with coupling for connecting an IEC motor K2TC Coupling lantern with coupling for connecting a NEMA motor K4 Short lantern with clamp connection for connecting an IEC motor K5TC Short coupling with clamp connection for connectin...

Page 85: ...tes the data for the entire drive In certain cases separate rating plates are mounted on the gearbox and the motor Figure 10 1 Rating plate example 1 Data matrix code 2 Applicable standard 3 Factory serial number FDU Siemens AG Bahnhofstr 40 72072 Tübingen Germany 4 CE marking or other marking if required 5 Article number 6 Type designation 7 Mounting position 8 Degree of protection acc to IEC 600...

Page 86: ...mbols IEC 60617 2 brake 28 Rated braking torque TBr Nm 29 Brake supply voltage U V Frequency 1 30 Rated frequency f Hz 31 Rated voltage range U V 32 Circuit graphical symbols as per DIN EN 60617 Part 6 IEC 60617 6 33 Rated current IN A 34 Power factor cos φ 35 Rated output PN kW 36 Duty type 37 Efficiency class marking according to IEC 60034 30 38 Rated speed nN rpm Frequency 2 39 Rated frequency ...

Page 87: ...tion 9 Weight m kg 10 Ambient temperature 11 1 Type of protection gas 11 2 Type of protection dust 12 Customer ID 13 Oil quantity l main gearbox intermediate gearbox extruder flange 14 Oil type 15 Oil viscosity ISO VG class according to DIN 51519 ISO 3448 16 Total transmission ratio i Frequency 1 17 Rated frequency f Hz 18 Gearbox output speed n2 rpm 19 Geared motor output torque T2 Nm 20 Service ...

Page 88: ... EN ISO 1680 with meters to DIN IEC 60651 The noise depends mainly on speed output and transmission ratio Figure 10 3 Sound energy level MOTOX geared motors The sound pressure levels of MOTOX geared motors fall mainly in the dark colored part of the range Gearboxes with very small transmission ratios high output and high input speed may fall into the cross hatched part If repeat measurements on si...

Page 89: ...at the correct quantity of lubricant is provided Note Gearbox sizes 18 and 28 are lubricated for life Screw plugs are not provided Explanation of symbols in type of construction diagrams Ventilation Oil filling Oil level Oil dipstick Oil drain A B Position of insert shaft solid shaft V Gearboxes of size 38 are fitted as standard with a screw plug at point V ventilation is not required On opposite ...

Page 90: ... positions BA 2010 88 Operating Instructions 02 2018 A5E38093846A RS AC 10 5 1 Single stage helical gearboxes Figure 10 4 Type of construction options for E sizes 38 148 Figure 10 5 Type of construction options for E sizes 38 148 ...

Page 91: ...tions BA 2010 Operating Instructions 02 2018 A5E38093846A RS AC 89 10 5 2 Two and three stage helical gearboxes Figure 10 6 Type of construction options for D Z sizes 18 88 Figure 10 7 Type of construction options for D Z sizes 108 168 ...

Page 92: ...5 Mounting positions BA 2010 90 Operating Instructions 02 2018 A5E38093846A RS AC Figure 10 8 Type of construction options for D Z188 Figure 10 9 Type of construction options for DF ZF DZ ZZ sizes 18 88 DR ZR sizes 68 88 ...

Page 93: ...l data 10 5 Mounting positions BA 2010 Operating Instructions 02 2018 A5E38093846A RS AC 91 Figure 10 10 Type of construction options for D Z sizes 108 168 Figure 10 11 Type of construction options for D Z 188 ...

Page 94: ...ons 02 2018 A5E38093846A RS AC 10 5 3 Parallel shaft gearboxes Note On types of construction V3 00 H 06 use the opening marked F to check the oil level Figure 10 12 Type of construction options for F 28 F sizes 38B 188B Figure 10 13 Type of construction options for F 208 ...

Page 95: ...perating Instructions 02 2018 A5E38093846A RS AC 93 10 5 4 Bevel helical gearboxes Figure 10 14 Type of construction options for B sizes 28 38 without additional screw plug Figure 10 15 Type of construction options for B 38 with additional screw plug ...

Page 96: ...ge mounted housing in size 188 Figure 10 16 Image of foot flange mounted housing K 188 Note On types of construction B3 00 H 01 use the opening marked K to check the oil level Figure 10 17 Type of construction options for K KA KAS KAT sizes 38 188 Figure 10 18 Type of construction options for KZ KF KM KAD KAZ KAF KAM KADS KAZS KAFS KADT KAZT KAFT sizes 38 188 ...

Page 97: ...ting Instructions 02 2018 A5E38093846A RS AC 95 10 5 5 Helical worm gearboxes Figure 10 19 Type of construction options for C CA CAS CAT sizes 28 88 Figure 10 20 Type of construction options for CZ CF CAD CAF CAZ CADS CAFS CAZS CADT CAFT CAZT sizes 28 88 ...

Page 98: ...rbox are lubricated for life Screw plugs are not provided Horizontal operating position Vertical operating position a Main gearbox b 2nd gearbox intermediate helical gearbox On opposite side 2 stage gearbox 3 stage gearbox Figure 10 21 Operating position for tandem gearbox 10 6 Oil quantities NOTICE Incorrect oil quantities damage the gearbox The oil quantities listed in the tables are guide value...

Page 99: ... 6 0 6 0 8 1 2 0 7 1 1 Z 48 1 1 1 0 1 4 1 7 1 5 1 6 1 3 1 5 1 8 2 4 1 9 2 4 Z 68 1 8 1 7 2 4 2 8 2 5 2 7 2 3 2 5 3 0 4 1 3 2 4 1 Z 88 4 1 3 7 5 5 6 3 5 7 6 1 5 3 5 7 6 8 8 3 7 5 8 8 Z 108 7 3 6 0 10 0 11 2 8 6 10 5 9 3 8 6 13 8 14 0 13 2 13 6 Z 128 9 5 7 0 15 4 17 3 13 2 16 0 14 1 13 2 18 5 20 7 19 9 20 9 Z 148 13 0 9 9 19 9 22 4 26 9 20 8 18 3 26 9 23 9 27 7 25 7 27 4 Z 168 21 0 15 3 33 0 37 7 32...

Page 100: ...8 4 6 7 0 6 6 FZ 108B 7 4 9 2 8 4 8 1 11 1 13 1 FZ 128B 13 8 13 7 15 5 14 8 22 1 22 7 FZ 148B 19 5 20 8 22 7 22 3 34 5 33 5 FZ 168B 32 8 30 0 37 0 35 8 53 8 53 0 FZ 188B 41 4 40 7 44 2 46 5 68 0 66 4 FZ 208 77 0 64 5 73 8 66 3 108 7 112 2 FD 28 0 6 0 45 0 5 0 5 0 65 0 75 FD 38B 0 9 0 6 0 7 0 7 0 9 1 1 FD 48B 2 0 0 9 1 3 1 3 1 8 2 0 FD 68B 3 3 2 3 2 4 2 3 3 2 3 8 FD 88B 6 3 5 0 4 7 4 7 6 8 6 7 FD 1...

Page 101: ...7 15 8 16 9 16 1 K 148 14 8 30 2 40 1 22 0 25 8 27 0 K 168 21 6 45 6 62 0 34 2 40 2 38 5 K 188 33 8 82 5 105 0 63 4 70 7 69 4 Table 10 7 Oil quantities l for BZ BF BAD BAF BAZ BADS BAFS BAZS BADT BAFT BAZT sizes 28 38 KZ KF KM KAD KAZ KAF KAM KADS KAZS KAFS KADT KAZT KAFT sizes 38 188 Type Type of construction B5 01 H 01 B5 03 H 02 B5 02 H 03 B5 00 H 04 V1 00 H 05 V3 00 H 06 B 28 0 25 0 6 0 9 0 55...

Page 102: ... C 28 0 2 0 4 0 6 0 2 0 6 0 35 C 38 0 5 1 2 1 3 1 2 1 2 1 2 C 48 0 7 1 6 1 7 1 6 1 3 1 3 C 68 1 5 3 3 4 1 3 3 2 8 2 9 C 88 1 7 6 1 6 5 5 1 4 5 4 5 Table 10 9 Oil quantities l for CZ CF CAD CAF CAZ CADS CAFS CAZS CADT CAFT CAZT sizes 28 88 Type Type of construction B5 01 H 01 B5 03 H 02 B5 02 H 03 B5 00 H 04 V1 00 H 05 V3 00 H 06 C 28 0 2 0 4 0 6 0 2 0 6 0 35 C 38 0 4 1 2 1 3 1 1 1 0 1 0 C 48 0 5 1...

Page 103: ... 8 0 5 15 3 14 1 0 5 14 6 D 128 Z48 9 4 1 0 10 4 6 8 1 0 7 8 16 1 1 0 17 1 17 1 1 0 18 1 14 1 1 0 15 1 15 8 1 0 16 8 14 8 1 0 15 8 14 1 1 0 15 1 D 128 D38 9 4 0 5 9 9 6 8 0 5 7 3 16 1 0 5 16 6 17 1 0 5 17 6 14 1 0 5 14 6 15 8 0 5 16 3 14 8 0 5 15 3 14 1 0 5 14 6 D 148 Z38 12 5 0 5 13 0 9 4 0 5 9 9 20 7 0 5 21 2 22 0 0 5 22 5 23 4 0 5 23 9 20 4 0 5 20 9 19 1 0 5 19 6 23 4 0 5 23 9 D 148 Z48 12 5 1 ...

Page 104: ...6 0 8 25 4 21 8 1 2 23 0 24 4 0 8 25 2 21 5 1 2 22 7 D 128 Z48 24 6 1 8 26 4 21 8 2 4 24 2 24 4 1 8 26 2 21 5 2 4 23 9 D 128 D38 24 6 0 9 25 5 21 8 1 1 22 9 24 4 0 9 25 3 21 5 1 1 22 6 D 148 Z38 30 6 0 8 31 4 28 2 1 2 29 4 32 2 0 8 33 0 27 9 1 2 29 1 D 148 Z48 30 6 1 8 32 4 28 2 2 4 30 6 32 2 1 8 34 0 27 9 2 4 30 3 D 148 D38 30 6 0 9 31 5 28 2 1 1 29 3 32 2 0 9 33 1 27 9 1 1 29 0 D 168 Z48 53 0 1 ...

Page 105: ... 0 5 17 3 13 5 0 5 14 0 15 2 0 5 15 7 14 8 0 5 15 3 21 6 0 9 22 5 22 5 1 1 23 6 FD 148B Z38 24 7 0 5 25 2 20 3 0 5 20 8 21 8 0 5 22 3 22 3 0 5 22 8 33 6 0 8 34 4 32 6 1 2 33 8 FD 148B Z48 24 7 1 0 25 7 20 3 1 0 21 3 21 8 1 0 22 8 22 3 1 0 23 3 33 6 1 8 35 4 32 6 2 4 35 0 FD 148B D38 24 7 0 5 25 2 20 3 0 5 20 8 21 8 0 5 22 3 22 3 0 5 22 8 33 6 0 9 34 5 32 6 1 1 33 7 FD 168B Z48 44 0 1 0 45 0 28 8 1...

Page 106: ...3 0 5 8 8 19 6 0 5 20 1 24 7 0 8 25 5 15 8 1 2 17 0 16 9 0 5 17 4 16 1 0 5 16 6 K 128 Z48 8 3 1 0 9 3 19 6 1 0 20 6 24 7 1 8 26 5 15 8 2 4 18 2 16 9 1 0 17 9 16 1 1 0 17 1 K 128 D38 8 3 0 5 8 8 19 6 0 5 20 1 24 7 0 9 25 6 15 8 1 1 16 9 16 9 0 5 17 4 16 1 0 5 16 6 K 148 Z38 14 8 0 5 15 3 30 2 0 5 30 7 40 1 0 8 40 9 22 0 1 2 23 2 25 8 0 5 26 3 27 0 0 5 27 5 K 148 Z68 14 8 1 7 16 5 30 2 1 7 31 9 40 1...

Page 107: ...38 8 7 0 5 9 2 19 6 0 5 20 1 25 4 0 8 26 2 14 8 1 2 16 0 17 5 0 5 18 0 16 6 0 5 17 1 K 128 Z48 8 7 1 0 9 7 19 6 1 0 20 6 25 4 1 8 27 2 14 8 2 4 17 2 17 5 1 0 18 5 16 6 1 0 17 6 K 128 D38 8 7 0 5 9 2 19 6 0 5 20 1 25 4 0 9 26 3 14 8 1 1 15 9 17 5 0 5 18 0 16 6 0 5 17 1 K 148 Z38 14 8 0 5 15 3 30 1 0 5 30 6 42 0 0 8 42 8 25 0 1 2 26 2 26 0 0 5 26 5 28 1 0 5 28 6 K 148 Z68 14 8 1 7 16 5 30 1 1 7 31 8...

Page 108: ...3 55 4 1 0 6 4 7 3 3 0 7 4 0 2 8 0 25 3 05 2 9 0 25 3 15 C 88 D Z28 1 7 0 25 0 95 6 1 0 25 6 35 6 5 0 6 7 1 5 1 0 7 5 8 4 5 0 25 4 75 4 5 0 25 4 75 Table 10 16 Oil quantities l for CZ CF CAD CAF CAZ CADS CAFS CAZS CADT CAFT CAZT sizes 38 88 Type Type of construction B5 01 H 01 B5 03 H 02 B5 02 H 03 B5 00 H 04 V1 00 H 05 V3 00 H 06 C 38 D Z28 0 4 0 25 0 65 1 2 0 25 1 45 1 3 0 6 1 9 1 1 0 7 1 8 1 0 ...

Page 109: ... by Siemens AG If you do not use original spare parts and original accessories Siemens AG excludes every liability and warranty Siemens AG accepts the warranty only for original spare parts Note that special manufacturing and delivery specifications often apply to individual components All spare parts offered by Siemens AG are state of the art and conform to the latest legal regulations Please sup...

Page 110: ...housing 225 Seal 101 Output shaft 301 Plug in pinion 103 Spacer bush 305 Helical gear wheel 105 Parallel key 335 Parallel key 130 Bearing 401 Screw plug 135 Locking ring 420 Vent filter 136 Locking ring 430 Eyebolt 140 Bearing 145 Locking ring 160 Shaft sealing ring 201 Adapter plate 205 Screw 210 Screw 211 Screw lock 220 Seal Figure 11 2 Single stage helical gearbox sizes 38 148 ...

Page 111: ...ing ring 220 Seal 030 Bearing 225 Seal 050 Housing cover 301 Plug in pinion 051 Screw 305 Helical gear wheel 055 Seal 306 Parallel key 101 Output shaft 315 Bearing 103 Spacer bush 320 Bearing 105 Parallel key 325 Pinion shaft 130 Bearing 330 Helical gear wheel 135 Locking ring 331 Parallel key 140 Bearing 335 Locking ring 141 Supporting disk shim 340 Pinion shaft 144 Supporting disk shim 345 Helic...

Page 112: ...018 A5E38093846A RS AC 160 Shaft sealing ring 401 Screw plug 201 Adapter plate 420 Vent filter 205 Screw 430 Eyebolt Figure 11 3 Two and three stage helical gearbox sizes 38 188 11 2 3 Parallel shaft gearbox sizes 38B 188B 208 Figure 11 4 Parallel shaft gearbox sizes 38B 188B ...

Page 113: ...Spare parts 11 2 Spare parts lists BA 2010 Operating Instructions 02 2018 A5E38093846A RS AC 111 Figure 11 5 Parallel shaft gearbox size 208 ...

Page 114: ...cer bush 078 O ring 310 Locking ring 090 Torque arm 311 Supporting disk shim 091 Rubber bush 315 Bearing 095 Screw 320 Bearing 096 Locking ring 321 Locking ring 097 Nut 322 Supporting disk shim 101 Drive shaft 325 Pinion shaft 109 Locking ring 330 Helical gear wheel 110 Locking ring 331 Parallel key 114 Protection cover optional 340 Pinion shaft 120 Shrink disk 345 Helical gear wheel 128 Supportin...

Page 115: ...Spare parts 11 2 Spare parts lists BA 2010 Operating Instructions 02 2018 A5E38093846A RS AC 113 11 2 4 Bevel helical gearbox sizes B38 38 188 ...

Page 116: ...g sealing cap 055 Seal 420 Vent filter 060 Bearing 061 Supporting disk shim 063 NILOS ring 065 Locking ring 070 Sealing cap 090 Torque arm 091 Rubber bush 095 Screw 096 Screw lock 101 Output shaft 130 Bearing 131 Supporting disk shim 133 NILOS ring 135 Locking ring 140 Bearing 143 NILOS ring 144 Supporting disk shim 146 Locking ring 160 Shaft sealing ring 201 Adapter plate 205 Screw 210 Screw 211 ...

Page 117: ...30 Bearing 210 Screw 032 Supporting disk shim 211 Screw lock 035 Locking ring 220 Seal 037 Locking ring 225 Seal 040 Output flange 301 Plug in pinion 045 Screw 305 Helical gear wheel 070 Sealing cap 331 Parallel key 090 Torque arm 335 Locking ring 091 Rubber bush 340 Worm shaft 095 Screw 345 Worm wheel 101 Output shaft 346 Parallel key 130 Bearing 401 Screw plug 131 Supporting disk shim 411 Screw ...

Page 118: ... A5E38093846A RS AC 133 NILOS ring 412 Screw lock 135 Locking ring 413 Disk 140 Bearing 415 Locking ring 143 NILOS ring 418 Plug sealing cap 144 Supporting disk shim 420 Vent filter 146 Locking ring 430 Eyebolt 160 Shaft sealing ring Figure 11 7 Helical worm gearbox sizes 38 88 ...

Page 119: ...the incomplete machine specified above and are complied with The risks not relevant for the product are not listed 1 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 designa...

Page 120: ...sive atmospheres Conformance with the regulations laid down in these Directives is proven by fully complying with the following standards DIN EN 1127 1 2011 DIN EN 80079 36 2016 DIN EN 80079 37 2016 DIN EN 80079 34 2012 DIN EN 60079 0 2014 DIN EN 15198 2007 Type of explosion protection for equipment group II of categories 2 and 3 II 2G Ex h IIB T4 Gb II 2G Ex h IIC T4 Gb II 2D Ex h IIIB T120 C Db ...

Page 121: ...ndards EN 60034 1 2010 EN 60034 all other relevant sections in the latest version in each case EN 60664 1 2007 EN 60204 1 2006 A1 2009 AC 2010 EC EU Declarations of Conformity and or manufacturer s declarations for all subassemblies integrated and add on units are available Specifically these are Electromagnetic brakes L ZL P FDX FDW KFB with connected accessories such as rectifiers and switching ...

Page 122: ...s been established that the end product conforms with Directive 2006 42 EC First time that the CE marking was applied 2016 Tübingen July 1 2017 Georg Böing Head of Research Development Florian Hanisch Vice President Lead Factory Simogear This declaration certifies compliance with the Directives named above but does not guarantee any specific properties or durability in the sense of 443 BGB Section...

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