Rexnord Planetgear 7000 Owner'S Manual Download

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Owners Manual • Rexnord

Planetgear

™

7000 Speed Reducers

(Page 1 of 33)

Size Mercury/Mars

158-110

10/21 (Supersedes 01/15)

rexnord.com

rexnord.com/contact

TABLE OF CONTENTS

SECTION I — INTRODUCTION

Introduction .........................................................................2

Basic Operation and Design ...............................................2

Sectional View and Component Identification .....................2

Nameplate Information ........................................................2

SECTION II — INSTALLATION

Handling of Reducer ...........................................................3

Reducer Mounting ...............................................................3

Mounting of Transmission Accessories ...............................4

Motors (Standard Units) ......................................................4

Motors C-Face & IEC Motor Flange Units ...........................5

Couplings ............................................................................5

Sprockets or Sheaves ..........................................................5

SECTION III — LUBRICATION

Lubricant Selection Process ................................................6

Lubricant Changes & Analysis ............................................7

Stored & Inactive Gear Drives .............................................7

Food Grade Lubricants .....................................................10

Food Grade Lubrication Selection Process .......................10

Food Grade Lubricant Changes & Analysis ......................10

Stored and Inactive Gear Drives .......................................12

SECTION IV — START-UP

Pre Start-Up Checklist .......................................................13

Initial Start-Up....................................................................13

Prime Mover .......................................................................13

Reducer Rotation ...............................................................13

Start-Up .............................................................................13

Post Start-Up Checklist .....................................................13

SECTION V — MAINTENANCE

Filling Oil ............................................................................14

Draining Oil ........................................................................14

Adding Grease to Reducer Seals .....................................14

Replacing Seals in Service ...............................................14

SECTION VI — DISASSEMBLY AND ASSEMBLY

INSTRUCTIONS

Required Equipment .........................................................15

Taking Reducer of of Service ...........................................15

Replacing Seals ................................................................15

Removing Seals .................................................................15

Installing New Seals (Output Assembly) ..................... 16-17

Installing New Seals (Input Assembly) ........................ 17-18

Replacing Bearings — Input/Output Shaft Assemblies ....18

Removing Input or Output Shaft Assemblies to

Replace Bearings ....................................18

Disassembling Input Shaft Assembly to

Replace Bearings .............................. 18-19

Disassembling Output Shaft Assembly to

Replace Bearings ....................................19

Installing Bearing Cups into Input or

Output Housings ............................... 19-20

Assembling Input Shaft Assemblies ............................ 20-21

Assembling Output Shaft Assembly ............................ 21-22

Setting Proper Axial Bearing Clearances on

input Shaft Assemblies ............................22

Measuring Axial Clearance on Input Assembly .......... 22-23

Adjusting for too Much Axial Bearing Clearance ..............23

Adjusting for too Little Axial Bearing Clearance ................23

Gear Train Disassembly .............................................. 23-24

Gear Train Assembly .........................................................24

Fan and Shroud Installation ...............................................24

Shroud Clip Installation .....................................................24

Fan Installation ..................................................................24

Fan Shroud Installation ......................................................24

SECTION VII — VERTICAL SERVICE

Filling Oil ............................................................................25

Draining Oil ........................................................................26

SECTION VIII — STORAGE PROCEDURES

Spare Parts Storage ..........................................................27

Stored and Inactive Reducers ...........................................27

Long Term Storage ............................................................27

SECTION IX — TROUBLESHOOTING

Troubleshooting .................................................................28

SECTION X — TABLES

Average Weights ...............................................................29

Torque Requirements ........................................................29

Maximum Allowable Tilts for Standard Reducers .............29

SECTION XI — TABLES: REPLACEMENT SEALS AND

BEARINGS

Bearings for Standard Speed Reducers ...........................30

Seals for Standard Speed Reducers .................................30

SECTION XII — MAINTENANCE LOG

Maintenance Log ...............................................................31

Notes .................................................................................32

SECTION XIII — ACCESSORIES

Accessories .......................................................................33

Summary of Contents for Planetgear 7000

Page 1: ...emoving Seals 15 Installing New Seals Output Assembly 16 17 Installing New Seals Input Assembly 17 18 Replacing Bearings Input Output Shaft Assemblies 18 Removing Input or Output Shaft Assemblies to Replace Bearings 18 Disassembling Input Shaft Assembly to Replace Bearings 18 19 Disassembling Output Shaft Assembly to Replace Bearings 19 Installing Bearing Cups into Input or Output Housings 19 20 A...

Page 2: ...tained input and output shaft assemblies use a double row of tapered roller bearings mounted to a steel alloy shaft to provide high overhung and thrust load capacity This feature also keeps all external shaft forces isolated from the gearing Included in both shaft assemblies are two seals with a grease purgeable cavity between them This design prevents contamination from entering the gear reducer ...

Page 3: ...ndation If the reducer mounting surface is not horizontal refer to Table 19 Page 29 for Maximum Allowable Tilts for Standard Reducers NOTE If the reducer is tilted the oil requirements may change Bolts should be of the correct size to fit mounting holes They should be SAE Grade 5 or equivalent Grade 8 8 or better for metric applications Fasteners shall be torqued according to Table 18 Page 29 The ...

Page 4: ...facture specifications to determine required alignment accuracy Note Steps 1 to 4 may have to be repeated several times to achieve manufacturers required accuracies PROBLEM MOTOR REAR FEET LOW PROBLEM MOTOR FRONT FEET LOW SOLUTION SHIM REAR FEET UP SOLUTION SHIM FRONT FEET UP SOLUTION RAISE MOTOR UP PROBLEM ENTIRE MOTOR LOW PROBLEM ENTIRE MOTOR HIGH SOLUTION LOWER MOTOR DOWN PROBLEM MOTOR ANGLED L...

Page 5: ...result in oil leakage during operation 5 Align the mounting holes of the motor with the mounting holes of the reducer and fasten reference Table 18 Page 29 for recommended bolt torques SETSCREWS C FACE COUPLING REDUCER INPUT GEAR DOUBLE LIPPED SEAL 0 688 0 750 HOLD DIMENSION WHEN MOUNTING INPUT COUPLING TO MOTOR SHAFT Figure 2 3 1b C Face Cross Section 13mm 14mm HOLD DIMENSION WHEN MOUNTING COUPLI...

Page 6: ...emperature range all season operation and or extended lubricant change intervals The proper viscosity grade of lubricants is given in Table 5 Usable temperature ranges can sometimes be widened if specific application conditions are known WARNING Polyalkylene glycol PAG based synthetic lubricants cannot be used in Planetgear units EXTREME PRESSURE EP LUBRICANTS TABLES 6B 7B For highly loaded drives...

Page 7: ...onths or 1 500 to 2 000 hours If the drive is operated in an area where temperatures vary with the seasons change the oil viscosity grade to suit the temperature refer to Table 4 Lubricant suppliers can test oil from the drive periodically and recommend economical change schedules SYNTHETIC LUBRICANTS In the absence of oil analysis synthetic lube change intervals can be extended to 8 000 hours dep...

Page 8: ...632 Manufacturer Lubricant Name Lubricant Name Lubricant Name Kluber Lubrication Kluberoil GEM 1 N 220 Kluberoil GEM 1 N 320 V Minimum viscosity index of 90 Kinematic viscosity in units of mm2 s is equivalent to cSt centistokes TABLE 6A Petroleum Based R O Rust Oxidation Inhibited Lubricants Maximum Operating Temperature of Lubricants 200 F 93 C ISO Viscosity Grade 100 150 AGMA Viscosity Grade 3 4...

Page 9: ...nt Name Lubricant Name Lubricant Name Lubricant Name Lubricant Name Castrol Industrial Lubricants Alphasyn EP 150 Alphasyn EP 220 Alphasyn EP 320 Castrol Isolube EP 68 Castrol Isolube EP 150 Castrol Isolube EP 220 Castrol Isolube EP 320 Chevron Texaco Caltex Tegra Synthetic Gear Lubricant 150 Tegra Synthetic Gear Lubricant 220 Tegra Synthetic Gear Lubricant 320 Citgo Petroleum Corp CITGEAR Synthet...

Page 10: ...hould be changed every 3 to 4 months or 1 500 to 2 000 hours If the drive is operated in an area where temperatures vary with the seasons change the oil viscosity grade to suit the temperature refer to Table 10 Lubricant suppliers can test oil from the drive periodically and recommend economical change schedules SYNTHETIC LUBRICANTS FOOD GRADE In the absence of oil analysis synthetic lube change i...

Page 11: ...Oxidation Inhibited Lubricants NSF National Sanitation Foundation H1 Registered Maximum Operating Temperature of Lubricants 200 F 93 C ISO Viscosity Grade 32 68 150 220 320 AGMA Viscosity Grade 0 2 4 5 6 Viscosity cSt 40 C 28 8 35 2 61 2 74 8 135 165 198 242 288 352 Viscosity SSU 100 F 134 164 284 347 626 765 918 1122 1335 1632 Manufacturer Lubricant Name Lubricant Name Lubricant Name Lubricant Na...

Page 12: ...ing grease with grease gun will not remove all grease and cross contamination will likely occur Grease registered as H1 by NSF National Sanitation Foundation is suitable for food processing applications STORED AND INACTIVE GEAR DRIVES See Storage Procedures Section VIII Prior to shipment from the factory all Rexnord enclosed drives are protected internally against corrosion with rust preventative ...

Page 13: ...oil level and oil drain been inserted and properly tightened Have all electrical connections been made Does the motor shaft rotate in the proper direction Are all guards in place and properly secured 4 2 INITIAL START UP It is recommended that all Planetgear 7000 speed reducers be run in for a period of time before introduction to full service This will allow the gearing to mate properly prior to ...

Page 14: ... fill plug sealing it in the process using thread sealant BOTTOM VIEW OF REDUCER OIL DRAIN PORT SIDE VIEW OF REDUCER OUTPUT SIDE GREASE INSERT OIL LEVEL PORT OIL FILL PORT INPUT SIDE GREASE INSERT Figure 5 1 Reducer Oil Ports and Grease Insert Locations 8 Start up reducer under a no load condition Run reducer for a few minutes 9 Stop reducer and recheck oil at the oil level port If necessary add o...

Page 15: ...ipment 2 Remove all reducer mounting bolts 3 Lift reducer using the double rope sling method explained in Section 2 1 4 Drain oil from reducer reference Section 5 2 for procedure NOTE Care should be taken to protect the shafts from damage Damaged shaft may cause problems when reinstalling couplings sprockets or sheaves 6 2 REPLACING SEALS 6 2 1 REMOVING SEALS Input Output Sub Assembly NOTE If unit...

Page 16: ...NBOARD SEAL GARTER SPRING Figure 6 2 2 1 Orientation of Inboard Seal for Installation 4 Place the tube on the ring Reference Figure 6 2 2 2 5 Place the plate on the tube Reference Figure 6 2 2 2 6 With an arbor press push the seal into the hub Stop RING INBOARD SEAL TUBE PLATE Figure 6 2 2 2 Placement of Tooling for Installation of Inboard Seal pressing when the ring seats on the hub 7 Remove the ...

Page 17: ...ducer mounted vertically carefully place the inboard seal over the shaft garter spring side down Reference Figure 6 2 3 1 CAUTION Extreme care must be taken to not roll the lip of the seal or cut the seal on the keyway INBOARD SEAL DOUBLE LIPPED INBOARD SEAL GARTER SPRING Figure 6 2 3 1 Orientation of Inboard Seal for Installation 3 Place the ring on the seal Reference Figure 6 2 3 2 4 Place the t...

Page 18: ...incase to allow for removal of the assembly NOTE It is recommended that the input assembly be removed first then the gear train and finally the output assembly reference Section 6 5 for additional information 6 Remove assembly by lifting it straight up away from the maincase CAUTION If removing assembly by hand care should be taken when gripping the keyway of the shaft The keyway is very sharp and...

Page 19: ... of the shaft through the inboard bearing cone 6 At this time the shaft will be free from the housing and can be separated from the housing The inboard bearing cone will be free to remove and discard 7 To remove the outboard bearing from the shaft two procedures can be used 1 Support the shaft by the bearing cone with the inboard end of the shaft facing up With an arbor press or hydraulic press pr...

Page 20: ...misalignment and ultimately result in premature bearing damage 6 3 5 ASSEMBLING INPUT SHAFT ASSEMBLIES 1 Clean bearing surface on shaft With a thread chase 18 threads per inch chase thread where set screw was located 2 Make sure bearing cups are clean and installed properly in housing Reference Section 6 3 4 3 Set shaft on end with the spline end of the shaft facing up CAUTION Pilot assembly so th...

Page 21: ...te 14 Mark the location of the locknut 15 Loosen locknut approximately 5 16 8 mm from original mark 16 Tighten set screw on locknut 17 Hold housing on its side and with a blunt instrument rap on the inboard side of shaft Reference Figure 6 3 5 5 BEARING SPACER LOCKNUT Figure 6 3 5 5 Final Assembly of Input Shaft Housing NOTE Shaft should be able to rotate freely at this time Replace seals after be...

Page 22: ...NOTE An indication when the inboard bearing is fully seated is when the hub will not rotate on the shaft freely 12 Clean and place the bearing spacer onto the shaft 13 Clean and attach external retaining ring on output shaft If retaining ring was destroyed after disassembly replace with an Eaton 1065 R retaining ring external 14 Hold housing on its side and with a blunt instrument rap on the inboa...

Page 23: ... 5 Follow procedures in Section 6 4 1 to determine new axial bearing clearance 6 Repeat first 5 steps if axial bearing clearance is found to be still too much 6 4 3 ADJUSTING FOR TOO LITTLE AXIAL BEARING CLEARANCE 1 Loosen set screw on locknut 2 Mark the position of the locknut 3 Rotate locknut 1 16 to 1 8 1 5 to 3 0 mm in the counter clockwise direction from mark to loosen locknut NOTE The measur...

Page 24: ...MERCURY MARS INPUT SUB ASSEMBLY Figure 6 7 1a Location of Shroud Clips z Align shroud clip with center of reducer reference Figure 6 7 1 b and tighten bolts to torque requirements of Table 18 Page 29 CENTER OR REDUCER BOLT CLIP Figure 6 7 1B Location of Shroud Clips 6 7 2 FAN INSTALLATION z From Figure 6 7 2 determine the distance from the end of the input shaft to the front edge of the fan NA FAN...

Page 25: ...te both right hand or left hand oil reservoir mounting Apply pipe sealant to all threaded connections during assembly PRIMARY OIL FILL MAIN OIL DRAIN FINAL OIL DRAIN LOW SPEED SHAFT UP ORIENTATION HIGH SPEED SHAFT UP ORIENTATION MAIN OIL DRAIN PRIMARY OIL FILL SECONDARY OIL FILL DOUBLE MAINCASE STANDARD MAINCASE QUAD MAINCASE 13 12 11 12 13 11 Figure 7 1a Vertical Service Shaft Orientations Standa...

Page 26: ...Begin by draining oil from main oil drain in maincase Reference Figure 7 1a 2 Plug main oil drain and begin draining oil from final oil drain if orientation is high speed shaft up TABLE 16 Vertical Service Standard Reducers Mercury Mars Quantity Quantity Item Description 1 1 12 1 4 O D PLASTIC TUBE x 24 LG 600 mm 1 1 11 1 8 NPT x 1 4 O D TUBE 90 BRASS FITTING 1 1 10 1 8 NPT x 1 4 O D TUBE STRAIGHT...

Page 27: ...three months rotate the input shaft such that the output shaft rotates a full 360 This will insure that all internal parts will remain coated and will also keep the bearings from becoming lacquered Noncompliance with this procedure may cause bearing damage during start up C Every six months inspect the stored or inactive reducer and add Nox Rust VCI 10 if necessary Dry indoor storage is recommende...

Page 28: ...erature due to increase in internal windage RESTRICTED VENT PLUG Remove and clean vent plug Replace vent plug BEARING DAMAGE IMPROPER ADJUSTMENT Adjust bearing to proper axial bearing clearance as instructed in Section 6 0 LACK OF LUBRICATION IMPROPER LUBRICATION OLD OR CONTAMINATED OIL Replace damaged bearings as instructed in Section 6 0 Note Check hub and shaft for potential damage or heat dist...

Page 29: ... M22 M24 M27 M30 8 8 Torque Nm 6 15 10 5 17 5 26 51 89 141 215 295 420 570 725 1070 1450 10 9 Torque Nm 8 65 15 25 36 72 125 198 305 420 590 800 1020 1510 2050 12 9 Torque Nm 10 4 18 29 43 87 150 240 365 500 710 960 1250 1810 2450 The torques shown produce a clamp load of 80 of proof load They assume clean dry threads with a torque coefficient of 1 2 and a coefficient of friction of 0 14 Plated th...

Page 30: ...Inboard Cup Cone Outboard Cup Cone Inboard Cup Cone Outboard Cup Cone Mercury LM 501310 LM501349 LM 501310 LM501349 JM205110 JM205149 JM205110 JM205149 Mars LM 501310 LM501349 LM 501310 LM501349 JM205110 JM205149 JM205110 JM205149 TABLE 21 Seals for Standard Speed Reducers All Seals are Chicago Rawhide Unless Noted Otherwise REDUCER Input Seals Output Seals Nitrile Viton Nitrile Viton Inboard Outb...

Page 31: ...ucers Page 31 of 33 Size Mercury Mars 158 110 10 21 Supersedes 01 15 rexnord com Rexnord Corporation All Rights Reserved Contact us visit rexnord com contact Section XII Maintenance Log REDUCER SERIAL NUMBER DATE INSTALLED DATE MAINTENANCE PERFORMED ...

Page 32: ...rs Manual Rexnord Planetgear 7000 Speed Reducers Page 32 of 33 Size Mercury Mars 158 110 10 21 Supersedes 01 15 rexnord com Rexnord Corporation All Rights Reserved Contact us visit rexnord com contact NOTES ...

Page 33: ...sedes 01 15 rexnord com Rexnord Corporation All Rights Reserved Contact us visit rexnord com contact NOTES Section XIII Accessories Contact a Rexnord Account Executive or refer to Planetgear Reducer with Top Motor Mount Reducer with Scoop Motor Mount Reducer with Slidebase Reducer with Scoop and Slidebase ...

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