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1. DRIVESYSTEMS 1 Importance of the operating instructions These operating instructions are intended to provide general information and safety guidelines It is the responsibility of the buyer machine builder installer and user of the NORD product to make sure that all the proper safetynotes and op erating instructions have been reviewed and understood If the contents of this instruction or any applicable operating instructions are not understood please consult NORD AK WARNING AN Electric motors gearmotors electrical brakes variable frequency drives and gear reducers contain potentially dangerous high voltage rotating components and surfaces that may become hot during operation All work involved in the transport connection commissioning and maintenance of any NORD product must be carried out by qualified and responsible technicians 2 Inspect incoming freight Before accepting shipment from the freight company thoroughly inspect the NORD equipment for any shipping and handling damage If any goods called for in the bill of lading or express receipt are damaged or if the quantity is short do not accept until the freight express agent makes an appropriate notation on your freight bill or express receipt If any concealed loss or damage is discovered later notify your freight carrier or express agent at once and request a formal review of your claim Claims for loss or damage in shipment must not be
2. RETAIN FOR FUTURE USE U10750 2 of 2 9 Drain and fill level plugs All reducer drain plugs are metric socket head cap screws For easier identification it is NORD s standard practice to provide a hex head screw for the fill level plug For ease of draining the used oil from the gear reducer use the socket head screw located at the lowest part of the gearbox e z Drain Plug Fill Level Plug 10 Vent plug locations Reducer venting allows for air pressure differences that occur during operation between the inner space of the reducer and the atmosphere while ensuring leak free operation The AUTOVENT is standard for all vented gear units unless oth erwise noted AUTOVENT The AUTOVENT helps prevent bearing and gear damage by behaving like a check valve to block the entry of foreign material water dust corrosives etc The breather opens at approximately 2 3 psi during operation and closes tightly as the gearbox cools This option is perfect for humid conditions and wash down environments help ing to maintain proper oil cleanliness and reducing foaming and oxidation NORD may choose to offer one of two style options as shown in Figure 1 The Type 2 AUTOVENT comes closed upon delivery with a transportation sealing plug see Warning Figure 1 AUTOVENT Types Type 1 Type 2 with trans
3. 3 Observe published performance range amp nameplate data HARMFUL SITUATION Observe the data on all reducer nameplates and verify published ratings for the NORD item s in question Do not operate any NORD equipment outside the published performance range Failure to comply may result in damage to the drive unit driven machine or the environment 2 Safety warnings AN AN All work involved in the transport connection commissioning and maintenance of any NORD product must be carried out by qualified and respon sible technicians All applicable national regional and local work regulations and safety requirements must also be complied with NORD assumes no liability for personal injury accidental death or equipment damage and malfunctions resulting from failure to comply with installation or operating instructions safety notes or any work regulations and laws GENERAL WARNINGS e Gear unit installation and maintenance work may only be performed when no power is available to the prime mover or motor Electric motors electrical brakes and variable frequency drives contain potentially dangerous high voltage Prior to installation or maintenance shut down the power at the circuit breaker or power switch While working on the drive make sure the power from the prime mover is isolated or secured on lock out to prevent accidental start up and to safeguard against injury e Surfaces of mot
4. of the assembly Always use sufficiently rated handling equipment and ensure that adequate safety measures are taken to protect personnel from injury during trans portation Once the NORD assembly is properly installed remove the transportation fixtures NORD Gear Corporation Toll Free in the United States 888 314 6673 06 09 09 www nord com docs SAFETY NOTES ee DRIVESYSTEMS RETAIN FOR FUTURE USE U10020 2 of 2 7 DISPOSAL ay ay Components Material ae MATERIAL DISPOSAL ae p p Gear wheels shafts rolling bearings Steel Properly dispose of all used gear units and internal parts parallel keys snap rings spacers in accordance with all local regulations In particular shims etc all lubricants must be properly collected and disposed Gear housing and housing Cast iron or Aluminum components depending on type and size For confirmation of specific materials used in a specific Worm gears Bronze alloy reducer or gearmotor assembly please consult NORD with Radial seals sealing caps and rubber Elastomers with some steel the appropriate unit identification or serial number components Coupling components Plastic or Elastomer with Steel Housing gaskets and flat oil seals Asbestos free sealing or gasket material various types used Gear Oil Mineral SHC Synthetic or PG Synthetic can vary NORD Gear Limited NORD Gear Corporation Toll Free in Canada 800 668 4378 Toll F
5. 0 39 0 002 in 0 39 1 18 0 004 in 1 18 3 9 0 008 in 3 9 11 8 0 016 in 11 8 39 0 024 in 39 118 0 031 in Above To amp General Tolerance on Including Straigtness amp Flatness mm mm ISO 2768 2 Tolerance Class K 0 10 0 05 mm 10 30 0 1 mm 30 100 0 2 mm 100 300 0 4 mm 300 1000 0 6 mm 1000 3000 0 8 mm Straightness Based upon the length of the corresponding line Flatness Based upon the longer lateral surface or the diameter of the circular surface The responsibility for the design and construction of the support foundation is with the user The foundation must be adequate to withstand normal operating loads and possible overloads while maintaining alignment to attached system components under such loads Motors and drive components mounted on prefabricated base plates can become misaligned during shipment Always check alignment after installation HARMFUL SITUATION 4 Steel foundation An engineered structural steel foundation should be designed to provide adequate rigidity and prevent loads from distorting the housing or causing misalignment of inter nal gears and shafts When foot mounting the gear reducer a base plate or sole plate with suitable thickness generally equal or greater than the thickness of the drive feet should be securely bolted to steel supports and extend under the entire gear drive assembly When flange mounting the gear unit the bulk
6. Element Kit US English 157 KB BIM1090 Motor Brakes US English 960 KB ps Kubler Encoder Wiring US English 200 KB ps All Documents for 820932346200 US English 2667 KB All Documents for 820932346200 US English 2454 KB 4 Intended use NORD is a supplier of electric motors gearmotors reduc ers electromechanical brakes mechanical variators and electrical variable frequency drives that are intended for commercial installations on larger systems and machines A N WARNING AN NORD does not accept any liability for damage or injury caused by e nappropriate use operation or adaptation of the drive system e Unauthorized removal of housing covers safety and inspection covers guarding etc e Unauthorized modifications to the drive system e Improper servicing or repair work on the drive system e Damage caused during shipment or transportation e Disregard of the important Safety Notes or Operating Instructions NORD Gear Limited NORD Gear Corporation Toll Free in Canada 800 668 4378 Toll Free in the United States 888 314 6673 06 09 09 www nord com docs DRIVESYSTEMS 5 Notes concerning warranty and liability All units are supplied according to the terms described in our standard Conditions of Sale The unit limited war ranty is also defined in our Conditions of Sale and is located in the back of our product catalogs as well as the back of your order invo
7. Units are shipped with a predetermined oil fill quantity based on mounting position NORD Gear Limited NORD Gear Corporation Toll Free in Canada 800 668 4378 Toll Free in the United States 888 314 6673 06 01 11 www nord com docs
8. belt or chain tension frequently over the first 24 to 48 hours of operation When using external chain or belt drives make sure the reducer is sized so that the shaft and bearings have adequate capacity To avoid unnecessary bearing loads and additional shaft deflection mount all power take off devices sprockets pulleys etc so that the applied load center is as close the gear housing as possible and check component alignment and tension of any belts or chains per the manufacturer s recommendation Do not over tension the belts or chains HARMFUL SITUATION 6 Outboard pinion gear alignment Align outboard pinion gears and adjust the gear tooth clear ance according to the manufacturer s recommendations checking for acceptable outboard pinion tooth contact The foundation bolts may have to be loosened and the gear unit moved slightly to obtain proper gear tooth contact After the unit is moved to correct tooth contact the prime mover may need to be realigned NORD Gear Corporation Toll Free in the United States 888 314 6673 www nord com docs REDUCER MOUNTING i5 FOOTED amp FLANGE MOUNT GEAR UNITS co DRIVESYSTEMS 1 Foot mounted reducers When installing the foot mounted gear unit observe the flatness specifications and bolt tightening torque guidelines provided in U10060 and make sure the mating mounting surface and reducer feet are clean and free of debris Use of shims under the feet of the gear uni
9. head plate must be engineered to minimize buckling distortions and support the cantilevered weight of the gear unit or gear motor Do not weld on the gear unit or use the gear unit as an earth or ground connection for any welding procedure as this may cause permanent damage to the bearings and gears HARMFUL SITUATION NORD Gear Limited NORD Gear Corporation Toll Free in Canada 800 668 4378 Toll Free in the United States 888 314 6673 06 09 09 www nord com docs DRIVESYSTEMS 5 Concrete foundation If a concrete foundation is used allow the concrete to set firmly before bolting down the gear drive Grout structural steel mounting pads and bolts of sufficient size into the concrete to adequately distribute the load stress onto the concrete foundation Figure 1 Concrete Foundation Q Grouted Structural Steel Mounting Pads Mounting Bolts Concrete Foundation 6 Bolt connections for footed amp flange mounted units NORD footed reducers and flange mount reducers with B5 flange have clearance designed into the mounting holes to allow for some minor adjustments in alignment Bolt size strength and quantity should be verified to insure proper torque reaction capacity whatever the mounting arrange ment Tightening torque for gear reducer mounting bolts and recommended fastener grades are provided in Table 2 Table 2A Tightening Torque for Inch Reducer Mounting Bolts UNIT IN
10. in the United States 888 314 6673 www nord com docs NORDBLOC 1 FOOT MOUNTED OILFILL QUANTITIES AO RETAIN FOR FUTURE USE U12900 1 of 1 DRIVESYSTEMS NORDBLOC 1 foot mounted lubrication The following NORD Gear reducers are shipped from the factory with a pre determined oil fill level in accordance to the specified reducer size and mounting position For additional information please refer to the Oil Plug amp Vent Locations documentation for your gear unit HARMFUL SITUATION Actual oil volume can vary slightly depending upon the gear case size mounting and ratio Prior to commission ing the reducer check the oil fill level using the reducer s oil level plug and drain or add addition oil as needed The minimum acceptable oil level is 0 15 in 4mm below the oil level hole For mounting orientations other than shown please consult NORD Gear Reducer modifications may be required Type M1 M2 M3 M4 M5 M6 Quarts Liters Quarts Liters Quarts Liters Quarts Liters Quarts Liters Quarts Liters SK 072 1 0 169 0 160 0 338 0 320 0 222 0 210 0 243 0 230 0 190 0 180 0 210 0 200 SK 172 1 0 285 0 270 0 624 0 590 0 444 0 420 0 529 0 450 0 338 0 320 0 412 0 390 SK 372 1 0 480 0 450 1 11 1 05 0 790 0 750 1 06 1 000 0 630 0 600 0 690 0 650 SK 373 1 0 480 0 450 1 11 1 05 0 791 0 750 1 06 1 000 0 630 0 600 0 690 0 650 SK 572 1 0 790 0 750 2 01 1 90 1 59 1
11. shaped shims at least 2 times the width of the bolt Avoid over shimming a very irregular surface as this will make it very difficult to achieve proper alignment For heavy shock applications it is advisable to field in stall dowel pins through the mounting flange connec tion in addition to the mounting bolts This will help control flange movement or flange rotation and relieve the mounting bolts from this additional stress IMPORTANT NOTE NORD Gear Limited NORD Gear Corporation Toll Free in Canada 800 668 4378 Toll Free in the United States 888 314 6673 06 09 09 www nord com docs REDUCER MOUNTING i5 FOOTED amp FLANGE MOUNT GEAR UNITS co DRIVESYSTEMS RETAIN FOR FUTURE USE 3 Flange mounted reducers with B14 flange When using the B14 flange to mount the gear unit the bulk head plate must be engineered to minimize buckling distor tions and support the cantilevered weight of the gear reducer or gearmotor When properly installed the output flange of the reducer housing is designed to enable the permissible torques and radial forces to be reliably transmitted by the bolt connections IMPORTANT NOTE When using the B14 flange face for mounting if dowel pin holes are provided in addition to the threaded holes then it is advisable to also use the proper dowel pins to help control flange movement or flange rotation and relieve the mounting bolts from this additi
12. 50 2 11 2 00 1 16 1 10 1 22 1 15 SK 573 1 0 790 0 750 2 00 1 90 1 59 1 50 2 11 2 00 1 16 1 10 1 22 1515 SK 672 1 1 16 1 10 245 2 60 2 27 2 15 2 85 2 70 1 64 1 55 1 74 1 65 SK 673 1 1 16 1 10 2 75 2 60 2 27 2 15 2 85 2 70 1 64 1255 1 74 1 65 SK 772 1 1 22 1 15 3 86 3 65 2 38 2 25 3 33 3 15 1 43 1 35 2 27 2 15 SK 773 1 2 06 1 95 3 70 3 50 3 38 3 20 3 06 2 90 2 38 2 25 3 12 2 95 SK 872 1 2 75 2 60 8 45 8 00 5 60 5 30 7 40 7 00 2 96 2 80 4 86 4 60 SK 873 1 4 28 4 05 8 03 7 60 7 24 6 85 6 92 6 55 5 28 5 00 6 92 6 55 SK 972 1 4 76 4 50 13 63 12 90 8 56 8 10 13 42 12 70 4 86 4 60 8 24 7 80 SK 973 1 7 82 7 40 12 89 12 20 1173 11 10 12 26 11 60 8 45 8 00 11 52 10 90 NORD Gear Limited NORD Gear Corporation Toll Free in Canada 800 668 4378 Toll Free in the United States 888 314 6673 06 01 11 www nord com docs NORDBLOC 1 OIL PLUG amp VENT LOCATIONS Se DRIVESYSTEMS RETAIN FOR FUTURE USE U14700 1 of 1 Oil plug connections Prior to commissioning the reducer check the oil fill level using the reducer s oil level plug and drain or add additional oil as needed The minimum acceptable oil level is 0 15 in Amm below the oil level hole For mounting orientations other than shown please consult NORD Gear New plug locations may be required SK 072 1 SK 072 1F SK 172 1 SK 172 1F V Vent WY Oil Level ll Oil Plug SK 372 1 SK 572 1 SK 672 1 SK 373 1 SK 573 1 SK 673 1 M3 H2 B5III
13. 93 1 170 98 132 5 8 11 1 660 138 188 2 340 195 264 3 4 10 2 960 247 334 4 180 348 472 7 8 9 4 750 396 537 6 700 558 757 1 8 7 100 592 802 10 000 833 1 130 1 1 8 7 14 800 1 233 1 672 1 1 4 7 20 600 1 717 2 327 1 3 8 6 27 200 2 267 3 073 1 1 2 6 35 800 2 983 4 045 1 3 4 5 53 500 4 458 6 045 align the gear drive with respect to the driven machine before attempting to align the prime mover or motor A After the main gear drive is properly aligned and bolted in place align the prime mover with respect to the reducer input shaft B Use shims under the feet of the prime mover as needed and secure in place with the proper mounting bolts Dowel pins may be field installed to help prevent misalignment and ensure proper realignment if removed for service When using a high speed coupling connection between the prime mover and the reducer check alignment per the coupling manufacturers recommendations If the coupling is misaligned the reducer alignment or shimming is incorrect Re align the gear reducer and IMPORTANT NOTE re check the high speed coupling alignment before re aligning the motor e Calculated tightening torques are based a conventional 60 clean and dry un lubricated thread with thread friction and head friction equal to 0 15 e When using inch fasteners NORD recommends a minimum Grade SAE 5 ASTM A 449 for sizes up to 1 8 UNC and Grade SAE 8 for all la
14. DO NOT DRIVE or HAMMER the coupling hub pulley sprocket or gear into place An endwise blow to the reducer shaft can generate damaging axial forces and cause damage to the reducer housing bearings or internal components AN WARNING A To avoid serious injury the user must provide suitable safety guards for all rotating shafts and shaft compo nents such as couplings chain drives belt drives etc All guarding must adhere to local regulations and safety standards 3 Installing interference fit hubs to the reducer shaft Prior to installing any interference fit hubs to the reducer shaft consult with the manufacturer to determine proper assembly and fit Interference fits usually require heating the coupling sprocket or gear hub per the manufacturer s rec ommendations Coupling hub installation typically follows ANSI AGMA 9002 A86 Always make sure the reducer shaft seals are protected from the heat source Apply uniform heat to the drive element hub to prevent distortion NORD does not recommend heating the drive element hub beyond 212 F to 275 F 100 C to 135 C J WARNING AN When using heat to mount a drive element hub do not use open flame in a combustible atmosphere or near flammable materials Use suitable protection to avoid burns or serious injury When using external chain or belt drives make sure the reducer is sized so that the shaft and bearings have adequate capacity To avoid unnecessary beari
15. LID SHAFT CONNECTIONS RETAIN FOR FUTURE USE e U10250 2 of 2 5 Installing sheaves pulleys sprockets and gears To avoid unnecessary bearing loads and additional shaft de flection mount all power take off devices sprockets pulleys gears etc so that the applied load center is as close to the gear housing as possible as shown in Figure 2 Figure 2 Sprocket or Gear Mounting pH N N 1 1 Sprocket A 1 L H Sprocket LS If t Preferred Mounting of Sprocket or Gear Align the driver sheave or sprocket with the driven sheave or sprocket by placing a straight edge length wise across the face of the sheaves or sprockets Alignment of bushed sheaves and sprockets should be checked only after bushings have been tightened Check horizontal shaft alignment by placing one leg of a square or a level vertically against the face of the sheave or sprocket Always check component alignment and tension any belts or chains per the manufacturer s recommendation The ideal belt or chain tension allows proper wrap of the driver and driven wheels while maintaining the lowest possible tension of the belts or chain so that no slipping occurs under load conditions Check
16. N220 NA EG 4 220 PAO 30to 60 C Mobil Omala Alphasyn Geralyn Kl bersynth 22 to 140 F SHC630 RL220 T220 SF220 GEM 4 220N VG220 PG 25 to 60 C Mobil Tivela Alphasyn Renolin Kl bersynth 13 to 140 F Glygoyle 220 S220 PG220 PG220 GH 6 220 0 to 40 C Mobil Fuchs is 32 to 104 F DTE FM 220 V dk FM220 ig 25 to 60 C Mobil Cibus Cassida Kl beroil pen 13 to 140 F SHC220 wa me GL220 4 UH 1 220N 25to 60 C Mobil Cassida Kl bersynth BR 13 to 140 F Glygoyle 220 MA WG220 UH1 6 220 MIN EP 0 to 25 C Spartan Omala Alpha Renolin Kl beroil 32 to 77 F EP150 150 SP150 EP150 GEM 1 150N PAO EP 30 to 25 C Mobilgear Omala Alphasyn Gearmaster Kl bersynth 22 to 77 F SHC150 HD150 EP150 SYN150 NA EG 4 150 PAO 30 to 25 C Mobil Omala Alphasyn Geralyn Kl bersynth 22 to 77 F SHC629 RL150 T150 SF150 GEM 4 150N VG150 PG 25 to 25 C Mobil Tivela Alphasyn Renolin Kl bersynth 13 to 77 F Glygoyle 150 S150 PG150 PG150 GH 6 150 0 to 25 C Mobil is 32to 77 F DTE FM 150 un ide PIS NS 25 to 25 C Cassida Kl beroil ams 13 to 77 F ee jus Ade GL150 4 UH 1 150N 25 to 25 C Mobil Kl bersynth Ai 13 to 77 F Glygoyle 150 e we UH1 6 150 Low end service temperature limit may vary for a specific lubricant Please also see the important notes on Page 1 NORD Gear Limited Toll Free in Canada 800 668 4378 06 01 11 NORD Gear Corporation Toll Free
17. STALLATION RETAIN FOR FUTURE USE e U10060 2 of 2 Table 2B Tightening Torque for Metric Reducer Mounting Bolts Above Tightening Torque ISO Grade 8 8 ISO Grade 10 9 mm Ib in lb ft Nm Ib in lb ft Nm M4 28 2 4 3 2 42 3 5 4 7 M5 57 4 7 6 4 82 6 9 9 3 M6 97 8 11 142 12 16 M8 239 20 27 345 29 39 M10 469 39 53 690 58 78 M12 814 68 92 1 195 100 135 M14 1 283 107 145 1 903 159 215 M16 2 036 170 230 2 965 247 335 M18 2 036 170 230 2 965 247 335 M20 4 071 339 460 5 841 487 660 M22 5 576 465 630 7 966 664 900 M24 6 992 583 790 10 178 848 1 150 M27 10 178 848 1 150 14 604 1 217 1 650 M30 14 161 1 180 1 600 19 914 1 660 2 250 M36 24 605 2 050 2 780 34 606 2 884 3 910 M42 39 563 3 297 4 470 55 671 4 639 6 290 e Calculated tightening torques are based on a conventional 60 clean and dry un lubricated thread with thread friction and head friction equal to 0 15 e When using metric fasteners minimum ISO Grade 8 8 bolt 7 Mounting the prime mover When the motor is not flange mounted or integrally mounted to the gearbox it is important to properly secure and NORD recommends Thread Tightening Torque Size PEA Grade SAE 8 in Ib in lb ft Nm Ib in lb ft Nm 1 4 20 85 7 1 9 6 120 10 0 13 6 5 16 18 190 16 21 267 22 30 3 8 16 330 28 37 470 39 53 1 2 13 825 69
18. a protective fluid boundary between mating parts and preventing direct metal to metal contact Lubricants also help prevent corrosion and oxidation mini mize foam improve heat transfer optimize reducer efficiency absorb shock loads and reduce noise Most NORD reducers are shipped from the factory with a pre determined oil fill level in accordance to the specified reducer size and mounting position 2 Standard oil type The following tables indicate the standard oil fill type used Please see user manual U11000 for more specific information and for optional helical and bevel gear lubricants RETAIN FOR FUTURE USE Serviceable Gear Units Helical In line Clincher Parallel Shaft Right Angle Bevel NORDBLOC Series In line NORDBLOC 1 Series In line Standard Series In line Standard Oil Fill ISO VG 220 Mineral Oil IMPORTANT NOTE For shipping purposes the following large Clincher gear units are supplied without oil e Clincher Sizes SK11282 SK11382 and SK12382 Maintenance free Lubricated For Life Gear Units Clincher sizes SK0182NB SK0282NB amp SK1382NB Standard Oil Fill NORDBLOC Sizes SK172 ISO VG220 SHC PAO SK272 SK371F SK372 SK373 Synthetic Oil SK320 IMPORTANT NOTE Maintenance free units are supplied as sealed units with no vent plug Consult NORD prior to ordering if interested in ordering any of the above sizes as serv
19. ake sure items are properly received M Make sure that you have all of the required Operating Instructions for your NORD electric motor gearmotor reducer electromechanical brake mechanical variable speed drives or electrical variable frequency drives Vv Consult NORD if you feel you are missing any documentation or if you have questions NORD Gear Corporation Toll Free in the United States 888 314 6673 www nord com docs DRIVESYSTEMS 1 Safety amp information symbols All work including transportation storage installation elec trical connection commissioning servicing maintenance and repair must be performed only by qualified specialists or personnel It is recommended that repairs to NORD Products are carried out by the NORD Service Department Instructions related to operational safety will be emphasized as shown Symbol Meaning General Warning or Hazard Severe risk or danger of personal injury or death by working around dan gerously high electrical voltage or moving machinery Proper safety precautions must be taken Possible Harmful Situation Care must be taken to avoid the possibility of damaging the drive unit driven machine or the environment Important Note Useful note or tip to help assure trouble free operation Material Disposal Note Important note concerning suggested material disposal fs gt SAFETY NOTES RETAIN FOR FUTURE USE e U10020 1 of 2
20. and should never be mixed with mineral oil or polyalphaolefin PAO synthetic oil NORD Gear Limited NORD Gear Corporation Toll Free in Canada 800 668 4378 Toll Free in the United States 888 314 6673 06 01 11 www nord com docs HELICAL amp BEVEL REDUCER LUBRICATION TYPES eo DRIVESYSTEMS RETAIN FOR FUTURE USE U11000 2 of 2 Oil Cross reference Chart ISO Oil Ambient LA Viscosity Type Temperature Mobil w G 7 Range Shell Castrol AKCUBEI MIN EP 0 to 40 C Spartan Omala Alpha Renolin Kl beroil 32 to 104 F EP460 460 SP460 EP460 GEM 1 460N PAO EP 20 to 80 C Mobilgear Omala Alphasyn Gearmaster Kl bersynth 4 to 176 F SHC460 HD460 EP460 SYN460 NA EG 4 460 PAO 20 to 80 C Mobil Omala Alphasyn Geralyn Kl bersynth 4 to 176 F SHC634 RL460 T460 SF460 GEM 4 460N VGA60 PG 20 to 80 C Mobil Tivela Alphasyn Renolin Kl bersynth 15 to 176 F Glygoyle 460 S460 PG460 PG460 GH 6 460 0 to 40 C Mobil DTE Fuchs ds 32 to 104 F FM460 a d FM460 D 20 to 80 C Mobil Cibus Cassida Kl beroil bun 4 to 176 F SHC460 i i GLA60 4 UH 1 460N 20 to 80 C Mobil Cassida Kl bersynth inus 4 to 176 F Glygoyle 460 N A nid WG460 UH1 6 460 MIN EP 0 to 40 C Spartan Omala Alpha Renolin Kl beroil 32 to 104 F EP220 220 SP220 EP220 GEM 1 220N PAO EP 30 to 60 C Mobilgear Omala Alphasyn Gearmaster Kl bersynth 22 to 140 F SHC220 HD220 EP220 SY
21. cation Tables Helical and Bevel Gear Units Standard Oil Lubricants ISO Viscosity Manufacturer Brand Type Mobil Spartan EP220 VG220 35 to 60 C 31 to 140 F Mobil SHC630 amp 6 Fuchs FM220 Optional Oil Lubricants ISO Viscosity Manufacturer Brand Type CAEU 35 to 80 C 31 to 176 F Mobil SHC634 35 to 80 C 31 to 176 F Mobil Cibus SHC460 VG220 34 to 60 C 29 to 140 F Mobil Cibus SHC220 VG150 Mobil SHC629 Grease Options applied to greased bearings and seal cavities NLGI Grade Manufacturer Brand Type 30 to 60 C 22 to 140 F Mobil Grease XHP222 6 NLGI 2 25 to 80 C 13 to 176 F Mobil Polyrex EP 2 amp 6 25 to 40 C 13 to 104 F Mobil Grease FM222 Stocked Lubricants Standard product on serviceable gear units Standard product on maintenance free gear units IMPORTANT NOTES e The Ambient Temperature is intended to be an operation guideline based upon the typical properties of all the lubricant The viscosity and other properties of the lubricant change based upon load speed ambient conditions and reducer operating temperatures The user should consult with their lubrication supplier amp NORD gear before considering changes in oil type or viscosity e To prevent reducer overheating observe the maximum operating oil temperature limits Mineral Oil 80 85 C 176 180 F Synthetic Oil 105 C 225 F e
22. cer and it helps locate the center of the reducer output shaft RETAIN FOR FUTURE USE U10500 1 of 2 Table Flange Pilot Tolerance Above To amp Tolerance ISO 286 2 Including in in in Fit Class 1 969 3 150 0 0005 0 0003 j6 3 150 4 724 0 0005 0 0004 j6 4 724 7 087 0 0006 0 0004 j6 7 087 9 055 0 0000 0 0005 h6 9 055 9 843 0 0000 0 0011 h6 9 843 12 402 0 0000 0 0013 h6 12 402 15 748 0 0000 0 0014 h6 15 748 19 685 0 0000 0 0016 h6 Above To amp Tolerance ISO 286 2 Including mm o9 mm mm Fit Class 50 80 30 012 0 007 je 80 120 0 013 0 009 je 120 180 0 014 0 011 je 180 230 0 000 0 013 h6 230 250 0 000 0 029 h6 250 315 0 000 0 032 h6 315 400 0 000 0 036 h6 400 500 0 000 0 040 h6 When installing the flange mounted gear unit observe the flatness specifications and bolt tightening torque guidelines provided in U10060 Make sure the mating mounting surface and reducer flange are clean and free of debris Use a straight edge or parallel bar to check for high spots on the mating mounting surface and remove any raised material around the mounting holes Set the gear unit into place and tighten the bolts until they are snug Before final bolt tightening check for any mate rial gaps between the mating surfaces and if shimming is re quired use U
23. deducted from the NORD invoice nor should payment of the NORD invoice be withheld awaiting adjustment of such claims as the carrier guarantees safe delivery NORD will try to assist in collecting claims for loss or damage during shipment how ever this willingness on our part does not remove the trans portation company s responsibility in reimbursing you for col lection of claims or replacement of material GENERAL INSTRUCTIONS RETAIN FOR FUTURE USE e U10000 1 of 2 3 Obtaining detailed operating instructions One can receive the detailed installation and maintenance instructions by entering a serial number or NORD order number at the appropriate location on the NORD web site i Record the serial number from your gearmotor gear reducer or motor nameplate or record the serial number found on your order confirmation ii Go to www nord com docs to download the appropriate operating instructions EXAMPLE www nord com docs Unit Documentation You can recieve your unit s installation and maintenance instructions by entering a serial number or order number The order number serial number can be found on your order confirmation or on the unit s nameplate 820932346200 Search g Information Serial number 8209323462 00 Model type 9032 1AX 132 M 4 CUS BRE100 HL F IG22 VZ Mounting position M4 Documents ps BIM1040 90 1 amp 92 Helical Bevel US English 1350 KB ps BIM1002 Hollow Keyed Shaft amp Fixing
24. ecom mends a condition based lubrication maintenance program One may take exceptions to this general recommendation on sealed for life or maintenance free gear units or smaller and less costly gear units In these instances the replacement cost of the gear unit is often small compared to the costs associated with this type of oil analysis program HARMFUL SITUATION NORD suggests replacing the gear oil if oil analysis indicates any of the following e Viscosity has changed by approximately 10 or more e Debris particles silicon dust dirt or sand exceed 25 ppm e ron content exceeds 150 200 ppm e Water content is greater than 0 05 500 ppm The total acid number TAN tests indicate a significant level of oxidative break down of the oil and a critical reduction in performance If the TAN number measured changes by more than 596 over the new oil then an oil change would be recommended 7 Mounting position and oil fill quantity All NORD Gear reducers are shipped from the factory with a pre determined oil fill level in accordance to the specified reducer size and mounting position For additional information please see the seperate mounting position diagrams and the corresponding oil fill quantity tables for the specified gear unit The gearbox nametag will indicate the mounting position that was provided For mounting orientations other than shown in the mounting position charts please consult NORD Gear
25. ice All NORD Safety Notes and all related NORD Operating instructions shall be considered up to date at the time in which they were compiled by the buyer machine builder installer or user NORD reserves the right to incorporate technical modifications and information updates to any safety operating instructions that are within the scope of providing additional knowledge or clarification com municating design changes or product enhancements Information updates may include any NORD product or subsequent products purchased and supplied by NORD No specific claims can be derived from the information or illustrations and descriptions contained in the safety notes or related operating instructions AN WARNING AN NORD assumes no liability for personal injury equipment damage or malfunctions resulting from failure to comply with any installation safety notes The appli cable national regional and local work regulations and safety requirements must also be complied with Failure to comply with any safety notes or regulations may result in serious injury damage to property or even death NORD Gear Limited Toll Free in Canada 800 668 4378 06 09 09 GENERAL INSTRUCTIONS RETAIN FOR FUTURE USE e U10000 2 of 2 6 Checklist for installation and operation V Verify that the purchased NORD product has been supplied with the expected accessories amp options Check the received goods and packing slip to m
26. iceable gear units Consult the sticker adjacent to the fill plug to determine the type of lubricant installed at the factory Some units have special lubricants designed to operate in certain environments or intended to extend the service life or service temperature range of the lubricant If in doubt about which lubricant is needed for a certain applica tion please contact NORD Gear IMPORTANT NOTE NORD Gear Limited Toll Free in Canada 800 668 4378 06 01 11 U10750 1 of 2 3 Lubrication replacement If the gear unit is filled with mineral oil the lubricant should be replaced at least after every 10 000 operating hours or after every two years If the gear unit is filled with synthetic oil the lubricant should be replaced at least after every 20 000 operating hours or after every four years Often gear reducers are exposed to extreme ambient conditions hostile environments wet conditions or dirty and dusty operating areas Especially in these situations it is important to estab lish a condition based oil service interval 4 Oil viscosity Viscosity or the oil s resistance to shear under load is often considered the single most important property of any gear oil e Often one will consider making a viscosity correction to the oil to improve the performance when operating the gear unit at low temperature or high temperature e n cases of extreme load conditions gear pairs and antifric t
27. ion bearings may be more susceptible to sliding or scuffing wear In these operating conditions it may also be ben eficial to consider an increased lubrication viscosity and or a lubrication with improved antiwear additive packages IMPORTANT NOTE The user should consult with their primary lubrication supplier before considering changes in oil type or viscosity 5 Maximum oil sump temperature limit To prevent reducer overheating the reducer s maximum oil sump temperature limit must not be exceeded for prolonged periods of operation up to 3 hours continuous operation depending upon reducer size Oil Type Maximum Oil Temperature Limit NORD AGMA 9005 D94 Mineral 80 85 C 176 185 F 95 C 203 F Synthetic 105 C 220 F 107 C 225 F IMPORTANT NOTE Use caution when specifying gear reducers for high tem perature service f there is concern about exceeding the allowable safe operating temperatures please consult NORD to discuss alternatives NORD Gear Corporation Toll Free in the United States 888 314 6673 www nord com docs 355 HELICAL amp BEVELREDUCER LUBRICATION amp c DRIVESYSTEMS 6 The importance of routine oil analysis Routine oil analysis sound lubrication practices and good tracking of oil performance trends will help establish prop er lubrication maintenance and change out intervals To maximize equipment reliability NORD Gear generally r
28. me smaller gear units are supplied as maintenance free lubricated for life gear units Oil level may not be checked on some of these units IMPORTANT NOTE e Check the condition of all shaft seals and all assembled flange gasket areas lf any change is detected in the shape color hardness or permeability or if any leaks are detected the corresponding shaft seals and or gaskets must be replaced e Remove all anti corrosive metal protectant from otherwise bare metal surfaces Follow product manufac turers directions and warnings during surface protection removal e Check the resistance of all motor and brake windings to verify the integrity of the winding insulation and inspect all terminal box openings and wire connection areas to verify that all components are dry and free of corrosion NORD Gear Limited Toll Free in Canada 800 668 4378 STORAGE amp COMMISSIONING RETAIN FOR FUTURE USE e Co U10040 1 of 1 3 Long Term Storage By taking special precautions problems such as seal leakage and reducer failure due to the lack of lubrication improper lubrication quantity or contamination can be avoided The following precautions will protect gear reducers during peri ods of extended storage e Store the gear unit in its actual mounting position in accordance with the specified oil fill level in a clean and dry temperature controlled area Avoid temperature fluctuations within the range of 0 C a
29. n the following instances please consult NORD for specific recommendations V Gear units will operate in high ambient temperature conditions exceeding 40 C 104 F V Gear units will operate in cold ambient temperature conditions approaching 0 C 32 F or lower V Lower than an ISO VG100 viscosity oil is being considered for a cold temperature service y Fluid grease is required for lubricating the gear unit e Observe the general lubrication guidelines outlined in user manual U10750 Oil Formulation Codes Lubrication Notes MIN EP Mineral Oil with EP Additive e Avoid using EP gear oils in worm gears that contain PAO EP Synthetic Polyalphaolefin Oil with EP Additive sulfur phosphorous chemistries as these additives can PAO Synthetic Polyalphaolefin Oil react adversely with bronze worm gears and accelerate PG Synthetic Polyglycol Oil wear FG Food Grade Oil e Food grade lubricants must be in compliance with FDA 212 dci E here ahs Pieds e oil CFR 178 3570 and qualify as a NSF H1 lubricant Please FG PG Food Grace synthetic Polyglycol Ol consult with lubrication manufacturer for more information e When making a lubrication change check with the lubrication supplier to assure compatibility and to obtain recommended cleaning or flushing procedures e Do not to mix different oils with different additive pack ages or different base oil formulation types Polyglycol PG oils are not miscible with other oil types
30. nd 40 C 32 F to 104 F and avoid relative humidity conditions in excess of 60 e Fill the reducer full with oil that is compatible with the product normally used or recommended during service e Apply grease to all unpainted or unprotected shafts bores keyways flange surfaces tapped holes and to the exterior of all oil seals e Store in a location free from shock and vibration to avoid false brinelling of bearing elements and raceways e Once every few months rotate the input shaft approximately 10 20 revolutions to redistribute the weight of gears and shafts and to prevent brinnelling of the bearings and drying of the seal track e Avoid direct exposure to the sun or UV light and aggressive or corrosive materials in the environment ozone gases solvents acids caustic solutions salts radioactivity etc 4 Commissioning After Long Term Storage e Remove all anti corrosive metal protectant from otherwise bare metal surfaces Follow product manufac turers directions and warnings during surface protection removal e Drain the reducer and refill it with the proper type and amount of lubricant e Observe start up and initial operation to make sure there are no seal or gasket leaks or unusual sounds vibration or heat rise during operation e Check the resistance of all motor and brake windings to verify the integrity of the winding insulation and inspect all terminal box openings and wire connection areas to verif
31. ng loads and additional shaft deflection mount all power take off devices sprockets pulleys etc so that the applied load center is as close to the gear housing as possible and check component alignment and tension of any belts or chains per the manufacturer s recommendation Do not over HARMFUL SITUATION tighten the belts or chains NORD Gear Corporation Toll Free in the United States 888 314 6673 Above To amp Tap size amp Depth Including in in in 0 375 0 500 10 24 x 0 43 in 0 500 0 875 1 4 20 x 0 59 in 0 875 0 938 5 16 18 x 0 71 in 0 938 1 100 3 8 16 x 0 87 in 1 100 1 300 1 2 13 x 1 10 in 1 300 1 875 5 8 11 x 1 42 in 1 875 3 500 3 4 10 x 1 73 in 3 500 7 500 1 8 x 2 20 in Above To amp Tap Size amp Depth Including o mm o mm mm 10 13 M4 x 10 mm 13 16 M5 x 12 5 mm 16 21 M6 x 16 mm 21 24 M8 x 19 mm 24 30 M10 x 22 mm 30 38 M12 x 28 mm 38 50 M16 x 36 mm 50 85 M20 x 42 mm 85 130 M24 x 50 mm 130 190 M30 x 60 mm NORD Gear Limited Toll Free in Canada 800 668 4378 06 09 09 www nord com docs DRIVESYSTEMS 4 Coupling installation The performance and life of any coupling depends upon how well it is installed Coupling hubs are typically mounted flush with the shaft ends unless specifically ordered for overhung mounting Shaft couplings should be installed according to the coupling manufacturer s recommendations for gap an gular and parallel alignment To help ob
32. not mounted in the position for which it is designed Observe the mounting position designated on the reducer nameplate or specified in the order acknowledgement Consult NORD prior to changing mounting position in the field While it is often possible to simply relocate the oil fill level and vent locations and adjust the oil fill amount in some cases different mounting positions may lend themselves to different internal construction features HARMFUL SITUATION 3 Reducer mounting e The support foundation must be straight level and flat Whether the gear unit is foot mounted or flange mounted NORD recommends that the straightness and flatness of the customer supplied support foundation follow Table 1 e The gear unit must be properly aligned with the driven shaft of the machine in order to prevent additional stress or load forces from being imposed upon the gear unit e To facilitate oil drainage it may be desirable to elevate the gear box foundation above the surrounding support structure e All bolting surfaces must be clean and free from contamination and corrosion UNIT INSTALLATION RETAIN FOR FUTURE USE e U10060 1 of 2 Table 1 Recommended Straightness and Flatness of Customer Supplied Support Foundation Above To amp General Tolerance on Including Straigtness amp Flatness in in ISO 2768 2 Tolerance Class K 0 00
33. onal stress This is especially important for heavy shock applications NORD Gear Limited Toll Free in Canada 800 668 4378 06 09 09 U10500 2 of 2 4 Foot amp flange reducer housings Some gear reducer housings are available with a foot and an output flange Units with a foot and a B5 Flange are desig nated with the suffix XF after the primary model number and units with a B14 face flange are designated with the suffix XZ after the primary model number When a gear unit is provided with both a foot and a flange the foot is consider the primary mounting surface The flange is generally consid ered to be the secondary mounting option and it is intended that this surface be used for auxiliary add on elements that place minimal load stress on the reducer housing To prevent overstress on the main gear unit housing never tighten the reducer mounting feet and the mounting flange against one another Auxiliary add on elements that are mounted to the reducer flange must not transmit excessive force torque or vibration to the main gear housing HARMFUL SITUATION NORD Gear Corporation Toll Free in the United States 888 314 6673 www nord com docs 355 HELICAL amp BEVELREDUCER LUBRICATION amp c DRIVESYSTEMS 1 Importance of proper lubrication Proper gearbox lubrication is essential in order to reduce friction heat and component wear Lubricants reduce heat and wear by inserting
34. ors and gear units may become hot during operation or shortly after start up In some instances additional protection against accidental contact may be necessary Use caution to avoid burns or serious injury NORD Gear Limited Toll Free in Canada 800 668 4378 U S Nameplate NORD GEAR CORPORATION USA WWW NORD COM Model Type Serial Number Gear Ratio TORQUE SPEED Q Service Factor Torque Rating Output Speed RPM Mounting Position LUBRICATION SEE MANUAL UNI DRIVESYSTEMS Getriebebau NORD GrbH amp Co KG DRIVESYSTEMS D 22934 Bargteheide Q Model Type O Serial Number Siehe Wartungsanleitung See maintenance instructions e Gear Ratio Voir instructions d entretien O S d pee 4 Transportation and handling Make sure that all eyebolts and lifting lugs are tight and lift only at designed points Protect the mounting surface from possible damage during transportation AN WARNING A N Do not attach other machinery or loads to the NORD assembly since the supplied lifting bolts are not designed for this purpose If the gearmotor or assembly is equipped with two sus pension eye bolts then both locations should be used for transportation and placement of the unit in this case the tension force of the slings must not exceed a 45 angle In some instances it may be appropriate to use additional lifting straps or slings in order to assure safe transportation
35. portation plug HARMFUL SITUATION Actual oil volume can vary slightly depending upon the gear case size mounting and ratio Prior to commissioning the reducer check the oil fill level using the reducer s oil level plug and drain or add additional oil as needed The minimum acceptable oil level is 0 15 in 4mm below the oil level hole 8 Oil plug locations All gear units are assembled with the oil fill level oil drain and vent plugs installed in their proper locations according to the specified mounting position All standard plugs are metric and utilize sealing gaskets between the head of the plug and the reducer housing NORD Gear Limited Toll Free in Canada 800 668 4378 06 01 11 Open Vent An optional open vent can be supplied by NORD The open vent comes closed upon delivery with a transporta tion sealing plug see Warning N WARNING A To prevent build up of excessive pressure sealed vents must be activated as shown prior to gear unit start up Au r wu en Mr a gt b Activated vent Sealed ven Filtered Vent NORD may offer an optional filtered vent which allows gases to permeate but does not allow dust and debris to pass through the vent NORD Gear Corporation Toll Free in the United States 888 314 6673 www nord com docs HELICAL amp BEVEL REDUCER LUBRICATION TYPES eo DRIVESYSTEMS RETAIN FOR FUTURE USE U11000 1 of 2 Lubri
36. ree in the United States 888 314 6673 06 09 09 www nord com docs DRIVESYSTEMS 1 Storage For storage periods longer than 9 months or for storage in less than desirable conditions please consult NORD for recommendations IMPORTANT NOTE Storage for up to 9 months is possible so long as the follow ing conditions are observed e Store the gear unit in its actual mounting position in accordance with the specified oil fill level in a clean and dry temperature controlled area Avoid temperature fluctuations within the range of 0 C and 40 C 32 F to 104 F and avoid relative humidity conditions in excess of 60 e Protect all exposed or unpainted shaft and flange surfaces with an anti corrosion agent or grease e Store in a location free from shock and vibration to avoid false brinelling of bearing elements and raceways e Whenever possible rotate the shafts periodically by hand if necessary to help prevent brinelling bearing damage and to help keep the shaft seals pliable e Avoid direct exposure to the sun or UV light and aggressive or corrosive materials in the environment ozone gases solvents acids caustic solutions salts radioactivity etc 2 Commissioning Prior to gear unit start up complete the following e Check the lubricant and be sure the gear unit is filled with the proper oil type to the proper level as determined by the mounting position Q9 Q9 1 1 So
37. rger sizes NORD Gear Limited Toll Free in Canada 800 668 4378 06 09 09 NORD Gear Corporation Toll Free in the United States 888 314 6673 www nord com docs DRIVESYSTEMS 1 Solid shaft diameter tolerance Reducer input and output shaft extensions have a diameter tolerance as specified in Table 1 Table 1 Solid Shaft Diameter Tolerance SOLID SHAFT CONNECTIONS RETAIN FOR FUTURE USE Above To amp Tolerance Including in in in 0 375 1 750 0 0000 0 0005 1 750 7 500 0 0000 0 0010 Above To amp Tolerance ISO 286 2 Including mm mm mm Fit Class 10 18 0 012 0 001 k6 18 30 0 015 0 002 k6 30 50 0 018 0 002 k6 50 80 0 030 0 011 m6 80 120 0 035 0 013 m6 120 180 0 040 0 015 m6 180 190 0 046 0 017 m6 2 Fitting drive elements onto the reducer solid shaft Solid input and output shaft extensions are provided with a drill and tap feature as indicated in Table 2 When installing drive elements such as coupling hubs pulleys sprockets or gears NORD recommends using the threaded hole in the end of the shaft along with a suitable assembly device fitted into the threaded hole Typical Assembly d Device Table 2 Solid Shaft End Threaded Holes e Go U10250 1 of 2 HARMFUL SITUATION
38. t may be required in order to align the output shaft to the driven equipment Make sure that all feet are supported so that the housing will not distort when it is bolted down Improper shimming will cause mis alignment and may reduce the life of the gear unit or cause component failure Dowel pins may be field installed to help prevent misalignment and ensure proper realignment if removed for service IMPORTANT NOTE Gear units may be subjected to radial loads or side pull caused by external chain drives or belt drives In these instances it is recommended that the mounting base be designed with a slide plate adjustment to accommodate extra slack in the chain or the belt after the feet are loosened When using an external chain or belt drive make sure the reducer is sized so that the shaft and bearings have adequate capacity 2 Flange mounted reducers with B5 flange When using the B5 flange to mount the gear unit the bulk head plate must be engineered to minimize buckling distor tions and support the cantilevered weight of the gear reduc er or gearmotor On the B5 mounting flange NORD provides a pilot register or and the flange pilot tolerance as listed per Table 1 When the mating hole is designed with the proper fit the flange pilot tenon provides a means of accurately po sitioning the reducer while the hold down bolts are properly secured once the reducer is secured the tenon helps prevent movement of the redu
39. tain critical shaft alignment coupling hubs may be installed to the machine shafts prior to final shimming or tightening of the founda tion bolts Proper coupling alignment allows for thermal and mechanical shaft movement during operation and ensures that only torque no radial load is transmitted between the mating shafts Coupling gap and angular alignment The shaft gap must be sufficient to accommodate any antici pated thermal or mechanical axial movement When setting the coupling gap insert a spacer or shim stock equal to the required spacing or gap between the coupling hub faces Measure the clearance using feeler gauges at 90 degree in tervals to verify the angular alignment Parallel or offset alignment Mount a dial indicator to one coupling hub and rotate this hub sweeping the outside diameter of the other hub The parallel or offset misalignment is equal to one half of the total indicator reading Another method is to rest a straight edge squarely on the outside diameter of the hubs at 90 intervals and measure any gaps with feeler gauges The maxi mum gap measurement is the parallel or offset misalignment Check alignment After both angular and parallel alignments are within speci fied limits tighten all foundation bolts securely and re check critical alignment If any of the specified limits for alignment are exceeded realign the coupling NORD Gear Limited Toll Free in Canada 800 668 4378 06 09 09 SO
40. y that all components are dry and free of corrosion NORD Gear Corporation Toll Free in the United States 888 314 6673 03 02 2011 www nord com docs DRIVESYSTEMS 1 Installation site Drives must be properly installed if they are to produce the rated torque Improper installation may lead to oil leaks re duced life or even catastrophic failure NORD gear drives and motors are intended to be installed at a suitable mount ing site under the following conditions e Unimpeded airflow to and around the units e Accessibility to oil drain level and breather plugs e On brakemotors allow adequate space for removing the fan guard and replacing and adjusting the brake e Mounting surfaces must be flat torsionally rigid and dampened against vibration e Unless special measures are taken the immediate vicinity around the gear drive or motor should not be exposed to any aggressive or corrosive substances contaminated air ozone gases solvents acids alkalis salts radioactivity etc 2 Mounting position Reducer mounting position charts illustrate the standard mounting positions for horizontal and vertical mounting All gear units are assembled with the oil fill level oil drain and vent plugs installed in their proper locations according to the customer specified mounting position For mounting orientations other than shown consult NORD Gear The gear reducer may not receive proper lubrication if the unit is

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