Bevel Gearboxes - Operating Instructions
Contents
1. Ee 9 Tm ee 10 4 1 Type 10 4 2 Labelling on the gearbo8 nein ee anne nr ee 10 5 Receiving er een 11 5 1 REG EV artes cites 11 5 2 a 11 5 3 Shipping GE AL BONES NEN 11 Os E SUREE 12 6 1 Slorage UP 0 31 0 DE EET 12 6 2 Long term storage up to max 3 8 5 12 6 2 1 ie g o 12 6 2 2 Storage SPA eS a ee ee Ea ee eee eee es 12 6 2 3 Are E E 12 6 2 4 Temperature ade RE T 19 6 2 5 8 7490 ee ee 19 6 2 6 SITUE TM E en 19 cee anes LE 19 c DIC ATO Ms ER 19 9 VIA 19 10 Temperature temperature mea2. eeeeisssssssssssseseeeeseene nennen nennen nennen nnn nennen nnns nnn nnne nnns 31 19 2 Opening and assembling a gearbox sessista aE nnn 92 19 3 Maintaining ee 92 19 4 Replace NGS RR 33 19 5 Replace the radial shaft Seal fingen ee eae De teen cR Cea nni 34 196 re 34 20 a EE E E E E Se E E A T 34 Version 03 2013 www ageda gmbh com 3 ageda GETRIEBETECHNIK 1 Details 1 1 General These operating instructions along with applicable regulations form the basis for the proper handling of gearboxes and geared motors from ageda GmbH These instructions must be observed to exclude hazards for people and property damage to maintain guaranteed characteristics and guarantee possible warranty claims The manual is a part of the product and must be kept accessible in its immediate vicinity 1 2 Applicable area These instructions apply to bevel gearboxes whose start code first three letters contain a K 1 3 Safety and information signs
3. www ageda gmbh com S1 lt 10 angular minutes S2 6 angular minutes Motorflansch Motor flange Drehezahl Low speed mit NSF H1 Zulassung with NSF H1 certification g ISO VG 460 h ISO VG 220 i ISO VG 150 ISO VG 68 k Einspritzschmierung spray lubrication FlieBfett NLGI KI 00 grease lubrication 00 s special lubrication ageda GETRIEBETECHNIK 3 2 Optional equipment Area Abbreviation Side Description Toothing low backlash version 10 measured at the slowest shaft Toothing mE low backlash version 6 measured at the slowest shaft Applicaion 1 dutycycle lt xx Application HT high temperature version Application TT low temperature version Lcd EEE nu e gearbox Assembly BB x jfastenngboreonlyonside Installation BL x attachment strip fastening strip on side Shaft VA J x stailesssteelshaftonside Shaft si solid shaft on side smooth without groove for parallel key Shaft KW x solid shaft with splined hub profileonside Shaft PW x solid shaft with polygonal profile on side Shaft hollow shaft with shrunk on disc on side A Standard B Standard O a EI B Standard Bearing vv reinforced output shaftbearingonside lal rica Seal UW 38m WS under water seal m WS Seal 05br X over pressure vacuum seal on side
4. Lamm RN benennen sides or on side Seal shaft seal rings made of Vitom FKM on all sides or on side Seda PTFE X shaft seal ring made of PTFE on all sides or on side Coupling clamping hub without groove motor shaft without parallel key NENNEN Coupling KNN Coupling SN withtension ring hub motor shaft without parallel key Couping Ku X overload coupling fluid coupling on side Motor ZF coupling flange atthe motor flange Motor I EC with IEC motor size 1 1 1 1 Motor SGM with spur geared motor o 1 Motor _ with planetary geared motor 1 Motor mE PTC thermistor temperature sensor PTC resistor DIN 44 082 Motor TF temperature sensor contact as a bimetal switch Brake Br disc brake motor brake xx Nm o Brake a exterior standard parts made of stainless steel Surface CZ chemically nickel plated housing parts subsequently tinned shaft and exterior standard parts made of Stainless steel Surface RAL Custom colour RAL xxxx Version 03 2013 www ageda gmbh com 9 4 1 agedaka GETRIEBETECHNIK Area Abbreviation Side Description Documentation 5 x type plate information plate on side _ Documentation Dok documentation SOND 4 custom version Lubricaion OA oil expansion tank Lubri
5. To avoid overloading the supply voltage the switchover from the star to the delta connection should occur only in the proximity of the nominal motor speed Electronic smooth starters effect a jolt free motor start up even with simultaneously reduced starting current For using frequency converters and for protecting against overload short circuits or single phase operation the motor is to be provided with a protective switch PTC sensors thermistors inserted in the motor winding are to be connected to a suitable tripping unit Thermostats are pre wired self switching Version 03 2013 www ageda gmbh com 30 gt gt 5 gt e 19 19 1 agedaka GETRIEBETECHNIK Commissioning Gearboxes can become extremely hot due to the high power throughput There is a danger of burns For pressure compensation gearboxes with an operating temperature of gt 50 C 122 F or in the case of extreme temperature fluctuations are to be provided with ventilation This can be provided optionally on the side by means of pipe elbows screwed into the gearbox For this purpose a screw plug above the oil level as far from the gears as possible is to be unscrewed and replaced by the specially supplied ventilation filter Use caution to not permit any objects to fall into the gearbox and do not allow any oil to leak For further transport of the gearbox a sealed screw cap should be used In the case of any unusual running
6. gt Vi 7 A ei 9 i i 3 J i i 7 E e i E x a ib T in lt cH a E 9 iz ba Ir o u Br k h B in E i _ t ageda GETRIEBETECHNIK agedaka GETRIEBETECHNIK Content EP o cr 4 1 1 E e EE EEE EEEE 4 1 2 TET 4 1 3 Safety and information SIGNS ccccccccsssseeecceeecceeeseeeceeeeeeeeeeeeceeeeeeaaeeeeeceeeeeesaeseueeeeeseseeeseeceeeessseaaseeeeeeesssaaaeeeeeeees 4 1 4 VSO a ee 5 1 5 Handling instructions for packaging ccccccssecccceeececseeeeeceeeeeeseueeecaeeeeeseeeessaueeesaeeeeseeeeesaeeeessaueeesseeeesseeeessaeeeeas 5 1 6 Bite TNNT D m 6 1 7 uj m 6 EE E NEE SIEGER 6 2 1 Sale MU IG ANS Elis CREER 6 2 2 INES NN REN E tmm 7 2 9 Supplemental doGuie WallOlis cciueces eiut e eee nuteiRt eri roni aud onini alui Erkennen ee 7 C ide m 8 3 1 aec NEE HRLENER 8 3 2 SC Io
7. Definition Consequences of disregard environmental pollution fire hazard Table 1 Safety and information signs Version 03 2013 www ageda gmbh com 4 1 4 1 5 ageda GETRIEBETECHNIK Disposal For disposal observe local guidelines and ordinances This applies to oil grease and components coated with them Component Matea Standard housing Grey cast iron Lightweight construction gearbox housing Cover neck from size K120 Cover neck K065 K090 Motor flange adapter sleeve Shafts gears parallel keys screws bearings St discs Shaft ring seals screw caps rubber elements Spacer discs Couplings Coupling stars O ring seals Gear oil CLP PG Gear oil PAO Gear grease Series Man Ventilation filter Plastic steel Oil sight glass Scewcms see Cooling coil Colour Table 2 Gearbox materials used Handling instructions for packaging Please observe the following symbols during packing and unpacking kon Definition Do not use hand hooks Keep dry Center of gravity Permissible stacking load Table 3 Handling instructions for packaging Version 03 2013 www ageda gmbh com gt 1 6 1 7 agedaka GETRIEBETECHNIK Disclaimer ageda GmbH assumes no liability for any personal or property damage that arises from failure to follow the operating instructions Liability for defects is similarly excluded in the case of failing to follow the operating i
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9. gearbox can have substantially higher temperatures Exposed parallel keys must be removed before start up or must be secured against unintentional loosening Drive elements mounted on the shafts must be secured in their bearing against loosening Ensure that no loose extraneous parts come into contact with rotating components during operation Seals must be handled with extreme caution Oil leaks can lead to the failure of the gearbox and depending on the application can possibly represent a high safety risk Attached motors in the case of insufficient protection can have freely accessible moving parts or live parts Inputs with a unit weight gt 15 kg must be moved using suitable load carrying equipment No additional loads are to be attached to the gearbox during transport Transport means and lifting devices must have sufficient load bearing capacity Do not support gearboxes at the yellow shaft protecting sleeves Version 03 2013 www ageda gmbh com 6 BP N OM agedaka GETRIEBETECHNIK Damaged products must not be installed or must be taken out of service Upon accepting delivery if there is any damage due to transport immediately inform ageda GmbH and make a claim with the transport company All rotating parts must as a rule be covered so that no personal or property damage can occur at any time This also includes freely accessible shafts shrunk on discs polygon shafts spline shafts or op
10. 15 ageda GETRIEBETECHNIK o This should facilitate the disassembly of larger shafts and can also be to secure bearings of components e Hollow shafts for shrunk on discs o Under the shrunk on discs Fit ISO H6 countershaft ISO j6 o Under the guide bushings Fit ISO H7 countershaft ISO h6 e Centerings o Exterior centerings Fit ISO f7 o Internal motor centering Fit ISO H7 Determining the installation position lower side e The lower gearbox side is specified on the type plate as an installation position e Installation positions labelled with G have seals on all sides and can be mounted in any installation position e Installation positions labelled with W are for changing installation positions or positions inclined at a predetermined angle e Specific gearboxes are provided with additional adhesive decals for the positional orientation See Figure 6 Figure 5 Installation positions oben It Drive and direction of rotation il The drive of the gearboxes is possible from every drive shaft in both directions of rotation For pinion shafts with Figure 6 Position Orientation K series type F VH S pinion shaft at side C turning clockwise K series type R pinion shaft at side A turning clockwise K series type R pinion shaft at side A turning counterclockwise all axial forces are to be directed outwards and as result the sound level is reduced by up to 2 dB A The direction of rota
11. GS O ShA Gs 95 98 Sh A Gs green Gr 7 38 Table 16 Shore hardness of the spiders Version 03 2013 www ageda gmbh com 28 ageda GETRIEBETECHNIK 16 11 1 Assembly of couplings to clamping hub on the motor shaft KN clamping hub KNC clamping hub compact Carefully degrease the coupling bore hole and the motor shaft Slightly loosen clamping screw see Figure 14 Slide the hub onto the shaft Measure dimension A on the gearbox Figure 17 Adjust distance dimension B from Table 17 Tighten the clamping screws to the torque specified in Table 17 T A E e A Figure 17 Assembly of a servo motor Figure 18 Clamping hub 16 11 2 Assembly of jaw type couplings to tension ring hubs on the motor shaft Carefully degrease the coupling bore hole and the motor shaft Slightly loosen tension screws and slightly remove the tension ring from hub Slide the hub onto the motor shaft Measure dimension A on the gearbox Figure 17 Adjust distance dimension B from Table 17 Tighten the tension screws using a cross wise sequence to the tightening torque listed in Table 17 T until the tightening torque is attained at all screws 1 formula conven e an an an ROTEX GS Diameter Clamping screw DIN 912 Tightening torque Clearance Clearance ROTEX GS Compact Diameter Clamping screw DIN 912 Tightening torque Clearance Clearance ROTEX GS Spannring Diameter Du Ta Clampi
12. cccccseeeeeceeeeeeeeeeeceeeeeeceeeeeesaeeeeeaeeeesaeeeeens 27 16 9 Gearbox mounting 27 16 10 HIN 27 16 11 Motor attachment using jaw type 5 28 16 11 1 Assembly of couplings to clamping hub on the motor 8 29 16 11 2 Assembly of jaw type couplings to tension ring hubs on the motor 5 8 29 16 12 Installation of geared 5 annis nna n rris s naar nnns 30 16 13 ife dii TI UE 30 17 COMMISSIONING RNC een een enter nennen nee een nnd nern Ener 31 18 Te SP 40 c c HEP 31 19 MAINE AN Cc Q 31 19 1 General maintenance instructions
13. noises loss of lubricant vibrations or housing temperatures gt 95 C 203 F take the drive out of operation and consult with the factory e During commissioning the temperature of the gearbox should correspond to the room temperature e Fora gearbox with ventilation filter valve this should be screwed in before commissioning e Before commissioning check for the correct installation position and direction of rotation so there is no resulting damage to the working machine Before attaching the coupling please check that the drive shaft can rotate uniformly in both directions and without any hard points Listen for any unusual noises In the case of unusual noises vibrations or temperatures above 90 C stop the drive and immediately inform ageda GmbH Test run The test run should take place under unfavourable conditions max load and speed Upon reaching the maximum gearbox temperature note the following points Noises grinding knocking grating e Vibrations e Odor steam or smoke Oil leaking at the shaft seals the housing joints the ventilation filter valve if required During the test run ensure that there is sufficient protection from rotating small parts e g parallel keys or that theses are specially secured After completing the test run with the cooled gearbox check the following e Seals traces of oil fixed seating of all components clamped connections such as couplings shrunk on dis
14. position E Alternative Position alternative position Figure 4 Alternate positions of the ventilation Position of the ventilation Table 9 Dimensions of the ventilation Version 03 2013 www ageda gmbh com 16 gt PF 11 12 13 agedaka GETRIEBETECHNIK Temperature temperature measurement The gearboxes were designed for ambient temperatures of 10 to 30 C 14 to 86 F Large fluctuations or exceeding the limit temperature of 90 C 194 F must be discussed with ageda GmbH Before performing any work the drive must be cooled at least to a temperature of 30 C 86 F If the exterior has cooled the lubricant in the interior of the gearbox can have substantially higher temperatures Danger of burns The measurement device used for checking the gearbox temperature must be capable of measuring over the expected measurement range of at least 10 C to 130 C 4K and capable of measuring the temperatures of the housing oil and air Temperature measurement procedure 1 Place the gearbox into operation follow the instructions 2 Depending on the speed switch off the drive after approximately 20 to 90 minutes and secure against unintended starting 3 Determine the point with the highest temperature shafts in the area of the seal bearing points in the neck or covers or at the locations thermally loaded from outside 4 Record the measured values and locations 5 Measure the gearbo
15. reliability we recommend performing the first oil change after 500 hours of operation and then after 15 000 hours Avoid mixing types of oil Ventilation Gearboxes can become extremely hot due to the high power throughput and small convection surfaces Danger of burns For pressure compensation gearboxes with an operating temperature of gt 50 C or in the case of extreme temperature fluctuations are to be provided with ventilation aeration This can be provided optionally on the side by means of pipe elbows screwed into the gearbox For this purpose a screw plug above the oil level as far away from the gears as possible is to be unscrewed and replaced by the specially supplied ventilation filter Under unfavourable operating conditions installation position speed gearbox temperature oil oil foam can leak out of the ventilation filter If this occurs the drive is to be taken out of operation high losses of oil are to be replenished and back up storage containers are to be installed in front of the filter To ensure that a sufficient air exchange Is possible the operator must protect the ventilation from excessive contamination and impermissible deposits If no ventilation aeration is used or possible despite high operating temperatures the shaft seals can wear out prematurely The resulting loss of oil can lead to personal or property damage ageda GmbH assumes no liability in this case During assembly work do not permit a
16. 022 9d ufseudiv u sjeu3 dg d3 38 06aq a SECOS euosneuju S 097 V 097 097 9 097494 09 AXIS 097 097 S9 oqu 9 uAseud xeiido 64 9 4 yjuAsseqniy YALSVINYVSD u sieU3d8g d3HINASRN38 81 ond 09 dX OHS NOSI F N39 09 NAS OSL x oneuu s jeeDndO 0G Jx d3 u sieu3 051 eje 9 1 uju sieqnpyi YALSVWYVAD Og da U seudv OSL XLH UASIeUZ dO 38 a my OH d19 0cc V 9neuu s 027 dWX DHS NOZc v N39 06 NAS 06 x 9neuu g jeeDndO ozz Jx d3 UASJeU 077 027 SWd Ova oqu BJEWO 9 qufsieqny w3ISVWuV3O Ozzd3u seudv dOHINASRMOS 106ed ely Gee 101886 x OZE v oneuu s OZE dWX OHS NOC N39 OZE NAS OZE x oneuju s jeeDndo 068 3 3 u sieu3 0 OZE Svd oneuiuAS Oeste E 1eobyiqoy qu sieqni u3IsviHV3O OZE d3 u seudly dO HINASmu38 69 61 et pee OS aweqoneo G 09 v 9neuju S 09 dWX OHS NO9v W39 097 NAS 097 X oneuju g 666 40 097 1 43 uAs eug 09b i euosneuu s ee ee seab wiswiwio oeragufssudy UG do uidi Se NOLUV2IHIgI7 I I OF eq oo COW 2 38 7277 N V 10 WISCIE S zWww uoneuDiseq jueouqn 1 A ASOISIA BHunuysiezuuey gojsjenmuuos v dq ENSOXSIA E e 2 A o c 2 Qo pos D gt e agedale Empfohlene Position recommended
17. 03 2013 www ageda gmbh com 11 o o 6 2 6 2 1 6 2 2 6 2 3 agedaka GETRIEBETECHNIK in the paragraph above e Inspect the gearbox s shaft seal rings sealing caps and oil screw plugs for tightness e Wrap the gearbox in film to protect the packaging from sweat oil e Provide shafts and function surfaces that are not protected against corrosion excluding aluminum flanges with sufficient corrosion protection and put on shaft protection sleeves Ensure a stable and generous outer packaging and padding Storing Storage up to 3 months Improper storage can lead to personal or property damage The following must be observed during temporary storage of the gearbox e Dry dust free vibration free and reasonably ventilated storage room Protected from the elements environmental temperature of 5 C 41 F lt T lt 60 C 140 F lt 50 relative humidity Storage away from solvents and solvent vapours Do not wrap gearbox in film containing plasticizers Avoid short term and large temperature fluctuations Placement correctly fitted to shape and installation position Retain the operating instructions with the gearbox Screw in the ventilation filter if required only immediately before placing gearbox into operation as long as the storage temperature of 50 C 122 F is not exceeded e Protect against gnawing rodents and in the tropics protect against insect infestation In an ideal storage room the storage can be exte
18. Involute spiders made of plastic bored without bores e Motor side coupling Clamping hub in model 2 0 type KN standard or clamping hub with parallel key model 2 5 type KNN or tension ring hub model 6 0 type SN The torques that can be transmitted depend on the model of the motor shaft and its dimensions The couplings cannot transmit the entire gearbox torque in every case however they exceed the torques of the IEC standard motors and standard servo motors Factors to be considered for the operating temperature for the torsional rigidity and for the operating ratio can be found in the KTR catalogue at www ktr com If you have any questions please consult with ageda GmbH e Tolerance surfaces Rz s 16 um e Tolerances On the gearbox side the hollow shafts are acepted with tolerances according to the manufacturer Clamping hub with without groove Tension ring hub model 2 0 2 5 model 6 0 0 Shaft diameter dw lt 55 255 lt 55 255 mm H7 k6 H7 m6 H7 k6 G7 m6 Table 15 Tolerances with clamping ring and tension ring hub The jaw type couplings used can be delivered with spiders of different shore hardness The hardness of the elastomer star determines the extent of the maximum shaft misalignments and of the backlash The specified misalignment values are maximum values and must not occur simultaneously Resources for checking gauge straight edge feeler gauge Standard spider hardness Shore Marking colour BEN NNI ShA
19. ame running tracks Refinishing of the shaft fittings is to be performed on site by the customer only with appropriate specialised technical knowledge Checking the couplings The elastomer star of a jaw type coupling ROTEX is subjected to wear in the case of extreme shaft displacements or torque loading If the star width falls below the tolerance listed in the following table or has other damage or discolouration the star is to be replaced by a new star of the same quality Type 14 19 24 24 28 28 38 38 45 42 55 mm 0 07 00 00 O bmin 75 52 65 82 96 12 Table 18 Wear limits of the elastomer stars of jaw type couplings u SS a ae m e Sa m The elastomer star should be checked either after 1 000 hours of Figure 26 Gear coupling operation or after three months at the latest Malfunctions Inthe case of malfunction please have the following information on hand e Serial number and gearbox type e Type of malfunction e Application area of the gearbox e Temporal progression of the malfunction In case of emergency please contact ageda GmbH at our 24 hour hotline 49 0 4103 90 006 12 bearing must be replaced Conspicuous defective bearing should be replaced by the noises manufacturer bearing must be replaced ox defective bearing should be replaced by the y manufacturer Conspicuous steady running noises depending on the defective gear se
20. an run into cavities between the motor and the gearbox lantern A minimal oil loss can occur via the ventilation filter at the first time the gearbox reaches a maximum temperature Check the oil level after any loss of oil 19 3 1 Dismounting of the neck T SN p Mark the neck before dismounting A aa 7 E p e Turn shafts until the keys are facing each other Skia LA Remove carefully the slices between the i n Figure 23 neck markering housing and the neck O oil drip oft o the housing 1 e Check the oil level inside the housing a NN e Return the slices carefully FEAN e Mounting oft he neck check the neck dq urn markering M Vota e Fix the neck by the screws Check the 4 AN To torque amp s Figure 24 key placement Figure 25 plug puller 19 4 Replace bearings In the case of bearing damage temperature too high noise backlash etc it is necessary to replace the bearings The service life of the bearings corresponds to the relevant guidelines for industrial gearboxes Version 03 2013 www ageda gmbh com 33 19 5 19 6 20 ageda GETRIEBETECHNIK Replace the radial shaft seal rings Radial shaft seals are to be replaced according to the type of loading due environmental influences and the temperature highly speed dependent only by skilled personnel or the manufacturer Do not put new shaft seal rings on damaged shaft fittings or the s
21. ant Position of shafts on sides 2000 Low speed nz min D E F S1 Flank clearance Quantity of lubricant S1 lt 10 S2 6 L1110 Motor flange No 1110 Figure 2 Type plate description Labelling on the gearbox Warning signs with yellow backgrounds must not be removed All other information signs should only be removed if they impact the assembly or function If it is necessary to remove an information sign please inform us for consideration with subsequent orders Version 03 2013 www ageda gmbh com 10 5 2 9 3 agedaka GETRIEBETECHNIK Definition leon Definition Caution Hot surface Oil dipstick Before starting work cool to approx 30 C Caution Injury due to rotating parts Stop the drive before starting work Mounting orientation a filter Observe to avoid personal or property damage screw Preferred direction of rotation Relubrication poit O SEE Oil filling plug Oil cooler return flow Temperature NEN Oil level control Explosion proof equipment Table 5 Labelling on the gearbox Receiving and storage Receiving After receiving the delivery e Inspect the packaging for possible damage e Immediately inform ageda GmbH and the transport company in the case of damaged packaging or goods e The operational capability and assessment of the damage must be made by a qualified professional If necessary consult wi
22. ase tapered surfaces and contact surfaces of the screw heads e g Castrol 4 in 1 or Kl ber Quitsch Ex e Check shaft seat for the tolerance according to Table 12 e Contact surfaces between the hollow shaft interior and inserted shaft must be free of grease in the clamping region e Slightly loosen the tensioning screws do not remove them and slightly tighten them by hand until there is no play between the outer ring and inner ring e Never tighten the tensioning screws without the inserted solid shaft e Slide the clamping set onto the hollow shaft Version 03 2013 www ageda gmbh com 26 agedaka GETRIEBETECHNIK AN e Install the shaft so that the clamping region beneath the shrunk on disc is completely utilised and supports the bronze bushing in the complete length it must be easy to insert the shaft e Uniformly tighten the tensioning screws increasing the tightening torque in a step wise manner e The tightening torque found in Table 13 should be present for all screws WE C M torque mm 12 50 490 Nm Table 14 Tightening torques for the screw sizes e Check for uniform distribution of the clearance between the outer ring of the shrunk on disc e Mark the position of solid shaft and hollow shaft to each other using a felt tip pen scriber so S that slippage under load during test runs can be detected STOP e Freely accessible clamping sets are to be protected from access or parts falling in N Figure 15 Shru
23. cation OLlC x oil sight glass oil level control on side Ventilation EF ventilation filter Ventilation R ventilation filter with pipe bend Ventilation M metal ventilation filter Ventilation ventilation valve Ventilation EB aeration deaeration valve ee XX e B XXonsdeB XX AB XXonside AB XX XX onside CO XX XX on additionalneckonsideD o al gearbox versions Labelling Type plate For identification a 0 8 mm thick foil plate is applied to side E and is legible from side D If a neck is located on this side of the gearbox the type plate is applied to a different side or to the motor flange The type plate lists basic gearbox information It is manufactured according to the order and is binding for the individual application The applied bar code contains the serial number and the article number Do not remove the type plate loss of guarantee soe ee Lan a du tie Lie ie zr Gearbox model Mounting orientation Tel 49 4103 900 06 0 agedakKa Fox 249 4103 900 26 GETRIEBETECHNIK www ageda gmbh de 090 Gearbox size Typ K090 VL AB 1 A 2 b 2000 110 Grooved ball bearing 1 0 Transmission ratio i Tapered roller bearing 123456 V ni na Tapered roller bearing in neck AB Gearbox type F V H S R Tapered roller bearing in output p BoD a 0 Position output side Lubrication Lubric
24. cs etc for slippage In the case of unusual running noises loss of lubricant vibrations or housing temperatures gt 95 C the drive is to be taken out of operation and consultation with the factory is required e Check the shaft seat to the prescribed tolerance see Table 12 Maintenance General maintenance instructions All ageda GmbH drives are low maintenance The scope of maintenance is limited to a regular check of the seals running noises operating temperatures and the free inlet of the ventilation filter if this is necessary In addition the following is to be observed Version 03 2013 www ageda gmbh com 31 19 2 19 3 agedaka GETRIEBETECHNIK e Only lubricants of the same specification are to be used for supplementing or replacing lubricant e Do not use any solvents or solvent containing substances or other aggressive substances for cleaning the gearbox at the shaft seals e Depending on the environmental influences the corrosion protection is to be renewed or the paint is to be repaired e Depending on the degree of dust deposits the ventilation filter valves are to be replaced by authorised personnel only e The shaft seals must be inspected regularly e Inthe case of excessive shaft loading the radial or axial backlash must be checked at the shaft ends Opening and assembling a gearbox Opening the gearbox During opening of the gearbox ensure that e no particles of dirt or components fa
25. d hubs at the motor and gearbox e Observe the information from point 16 6 Flange connection e Refinish any damage such as compressions on the motor shaft the flanges the parallel key or their groove edges Version 03 2013 www ageda gmbh com 2 i 16 11 ageda GETRIEBETECHNIK e Adjust the length width and height of the parallel key to the dimensions of the hub e Parallel key connections must be able to be joined without resistance e Observe the instructions to avoid frictional corrosion e f placing outdoors seal the flange against the penetration of humidity water using a surface sealant e g Loctite 574 or Loxeal 58 14 e Place the motor or gearbox vertically using a hoist e Avoid canting and hammer blows e For large drives loosen the motor brake e Align the position of the parallel key parallel key groove and the flange holes to each other and lower motor gearbox e Before making the threaded connection check the flange connection using a sensor feeler to determine if both flange surfaces are in contact over the entire circumference e Tighten fastenings screws in a cross wise sequence Motor attachment using jaw type couplings In the ideal case motors are connected using axial insertable shaft couplings In this way the start up jolt is reduced in dynamic applications while still permitting a low backlash motor connection Coupling assembly ROTEX GS e The gearbox side coupling is pre assembled e
26. e axial play of the bearing and the force of gravity see Figure 12 Image 2 3 e For measuring the axial runout let the gauge run on a radius of one quarter of the sum of the flange outer diameter the hole circle diameter and the screw bore hole To exclude an axial shift of the shaft the stand for the gauge is moved for a second measurement by 180 onto the opposite side of the shaft and the measurement is repeated An average value is formed from the two measurements We recommend adhering to the reduced values Version 03 2013 www ageda gmbh com 25 agedaka GETRIEBETECHNIK 16 7 Assembly of slip on gear mechanisms e Slip on gear mechanisms are gears that for instance are placed on the pivot of a doubly mounted cylinder To avoid warping or statically over determined supports the torque is absorbed by a torque support To avoid additional forces the torque support is to be installed on the machine side e Forreducing start up jolts and for compensating for manufacturing tolerances we recommend installing a rubber buffer in the fastening point at the machine frame e The support point of a torque support must be sufficiently rigid and the threaded connection that is used is to be secured against loosening even with observing the tightening torque e g Loxeal 54 03 Loctite 242 e Ensure good coaxial alignment f the gearbox is used 85 a second support point of a machine part ensure a sufficient load capacity of t
27. e threaded bores and MB Nm avoid warping Keep contact surfaces and M6 105Nm screws free of grease The tightening torques depend on the respective screw MB 255Nm application If no tightening torque is MIO SON specified use the tightening torques in Mfg s85Nm MON 0 M Table 10 Tightening torques for the fastening screws Shafts loads imbalances Radial and axial shaft loads must lie below the catalog specifications In the case of assembling belt drives and chain drives their preload must be checked To keep the bearing loads as low as possible belts chains and toothed gears must be installed as close to the housing as possible Imbalances due to accessories are not permissible Assembly of accessories e For avoiding bearing damage accessories such as couplings sprocket wheels etc are not to be attached to the shaft by striking with a hammer or other impermissibly high axial forces bearing damage e Accessories should be wound onto the shaft according to the drawing e n addition accessories can be heated briefly to a max of 100 C An external heating of gt 90 C of the gearbox seals and of the oil is not permissible 1 shaft end 2 axial bearing unfavourable assembly correct assembly 3 coupling hub 4 hub Figure 11 Assembly of components Version 03 2013 www ageda gmbh com 24 ageda GETRIEBETECHNIK 16 6 Assembly of flange connection
28. en hollow shafts During and after assembly and disassembly customer machines components with or without gearboxes must be secured in their position against slipping or tipping b Before any work check whether during assembly disassembly of the gearbox locks or brakes have loosened or weights have shifted that could cause unintended subsequent movements Opening the gearbox subsequent mechanical processing galvanic chemical or thermal treatment e g welding without the consent of ageda GmbH leads to loss of warranty Any manipulation of the gearbox and its accessories by the customer is impermissible Gearboxes must not be used as a grounding point for welding work The connection of different metals e g stainless steel and cast iron without a plastic intermediate layer can lead to voltage potentials and with it to electrochemical corrosion Always ground these gearboxes Gearboxes must not be opened during operation or operated while open Tighten fastening screws to the recommended torque see also Point 16 3 3 Fastening screws In the case of any questions or contradictory statements with respect to other customer country specific instructions contact the manufacturer Intended use The gearboxes and geared motors are designed for commercial use and without Ex labelling must not be used in potentially explosive environments The technical data on the type plate the product related documents catalog drawi
29. eneeesseeeesseeeeeseeeesaeeeessaeeeeess 24 16 3 3 24 16 4 Shafts loads imbalances 24 165 EelE ee dc een eee 24 16 6 Assembly of flange connections 25 16 6 1 Smooth rotation of Lana ste ka ai a ee 25 16 6 2 Coaxial alignment of the flange centering sseseseissssssssssssseseeeeennn nennen nnne nennen nnn 25 16 6 3 Axial runout between motor shaft and flange centering coaxial 25 16 7 Assembly of slip on gear mechanisms ccccccccseecccceeeeeceeeeeeceeeeeeseeeeeseueeeseuueeeseaeeeeseeeeeesaeeeeseueeeesaneeeesneeesaees 26 16 8 Shaft hub connections with shrunk on CISCS cccccccecceeeeeeeeeeeeeeeeesceeeeeeeeeaaeseeeeeeeeseaeaaeeeeeeeeesaeaeeeeeseeeseaaaeees 26 16 8 1 Assembly shaft hub connections with shrunk on discs cccceeeeceseeeeeceeeeeeceeeeeeeeeeeeseeeeeseeeeesseeeenaeeenens 26 16 8 2 Disassembly shaft hub connections with shrunk on CISCS
30. ge of ultraviolet light e ultraviolet fluorescent light sources e mercury lamps Temperature humidity ideal storage temperature 15 C to 25 C Limits 5 C to 30 C keep temperature as constant as possible avoid short term fluctuations keep at least one meter from heat radiators no drafts humidity lt 50 Ozone gases Over the long term avoid the following in the direct vicinity e ozone and exhaust gases e solvent fumes petrol chemicals acids disinfectants rubber solvents e strong electrical discharges formation of sparks electrical motors Shaft seals e grease shaft seals with suitable grease e avoid damage to the seal lips and the shaft seat e before start up check all seals for dryness and cracks exchange if necessary Painting With subsequent painting cover the shaft seals type plate and ventilation filter to protect them from solvent containing substances and paint Lubrication All standard gearboxes have an immersion lubrication and are filled corresponding to our lubrication table see table 8 The basic data of the lubricant and the quantity of the lubricant are located on the type plate If the gearbox was ordered without lubricant it must be filled before storing or start up with the prescribed quality and quantity of lubricant corresponding to the intended installation position and speed In the standard case the gearboxes are maintenance free In the case of high demands on the service life or
31. he gearbox bearing along with the coaxial alignment Do not impinge hollow shafts and assemble as shown in figure 13 Disassemble hollow shafts using extracting tool or for hollow shaft bore holes 32 mm according to the figure 14 2 77722225 77 oll a oa Figure 13 Assembly of a slip on gear mechanism Figure 14 Disassembly of a slip on gear mechanism LLL A 16 8 Shaft hub connections with shrunk on discs Information for the layout of the clamping sets can be found at www kir com The clamping set used at the factory can transfer the maximum torque listed in the catalog in the case of proper design of the customer shaft In the case of additional axial forces please consult with us because these forces must be calculated separately In the case of clamping sets from another manufacturer please contact us e Tolerance surfaces Rz s 16 um e Tolerances The hollow shafts on the gearbox side are accepted with tolerances according to the manufacturer Shaft diameter dw Tolerance H6 j6 H6 h6 H6 g6 H7 g6 Table 13 seat tolerance test 16 8 1 Assembly shaft hub connections with shrunk on discs The customer side machine shaft should be sufficiently dimensioned and have a minimum yield A strength of 2 320 N mm e Clean contaminated or used clamping sets e The shrunk on discs sets should not be disassembled if possible e Disassemble only if absolutely necessary lightly gre
32. il level should be half the height of the housing Figure 21 Screw plug e Checking the oil level using an elbow pipe and dip stick on top Carefully unscrew the dipstick wipe it clean using lint free cloth screw the dipstick in and then unscrew it and read the level Version 03 2013 www ageda gmbh com 32 ageda GFTRIFRFTFCHNIK e Checking the oil level using an oil sight glass The oil level should at the center of the sight glass A Avoid mixing oil with different specifications The oil can be filled using the filler plug the bore hole of the ventilation filter the oil control bore hole the neck of the gearbox or side B Open bore holes must be securely closed If the thread Figure 22 elbow pipe or the seal of the screw is damaged exchange them Change the oil e Place a catch basin underneath the outlet plug and carefully unscrew the outlet plug Put the gearbox down in such a way that the oil can drain out completely e Check the screw and the seal If there is any damage exchange them e Fill in the quantity of oil specified in the information from ageda GmbH and after 15 minutes check the oil level at the check opening e Close the check opening Oil losses indicate a defect in the sealing system This is not always visible externally because the oil e Unfix the screws of the neck LAN e Use the plug puller to lift the neck Do NOT liftthe Oo EINZELHEIT A neck by using a screwdriver wa a c
33. indo HINASNUaE S 19 89 9A OSI LH vasn e 09 19 061 WA 9d d10 081 9 IHN uu sieqnpy LH OSL jero1dde 4SN Oo episse end get Ton Hate en 31a IIqoW OH d 19 N OSL FHN 7 lloJsan y ova ozz 19 gIndo HLNASNY38 De UJI JO 1999 022 19 0cc WA 9d d19 022 9 LHN uu sieqnpy LH 066 15 Oo oqu episse 9 end Ozz 0VgV lOqUL 077 19 epissed us gendo 31a IQON OH 41 N OZZ LHN v lloreqnbi Ovd 066 19 qeindo HINASNUaE 86 022 9 OSI yw d 097 19 097 WA 9d d10 097 9 IHN uu sieqnpy LH 097 9 O 0 episse 9 and 09 0181 OGL O9p TO PISSED IBUS ydo SIGIGOW OH dT N O8F LHN Y lorjeqn Ovd 097 19 qe ndo HINASNUag 909 71 097 ON OSI apely poo D dH ze S 5 1 I eus ala dH uelueg Ze 49 0 opA ds ONEIDA ZEIMVEPE ODL o shy jus ze op H Ilo YVHONYT 018 NIIONSY ZE SMY uldsAH ze jofieug ZE AN weyn piy GE 6Z ZE 9 OSI 110 oynespAH ejoxineapAH ya p G 9 89 9A OSI 001 V LL 64 9 001 9 H9 001 9dd 00 dx 9S 001 Od d 19 DS Xeyndo IIGOW yjuAsieqniy YILSVNYV39 u seug dg d3 38 Lab 4 09 V cc 9 061 9 H9 09 d9d 051 09 S9 no1eob DE Iqon qu sieqniy u3isvwuvgo 094 Od d3HINASmH38 06eq ely ae verona ozz V ozz 9 4 04 9 022 9 H9 027 d9d 0cc dX 9S 0cc ozz S9 09 BR RR xeyndo yjuAsieqny 931 9 349
34. installation space Version 03 2013 The installation space should allow sufficient air cooling with at least 10K below the maximally permissible ambient temperature Cooling using extremely cold air can lead to the formation of condensation and water accumulation in the oil and must be avoided In the case of a high degree of contamination use shaft seals with bar lip www ageda gmbh com 23 16 3 2 16 3 3 A agedaka GETRIEBETECHNIK e For coating or covering of the gearbox consult with ageda GmbH e Keep the environment free of high energy radiation e Protect from solar radiation e Gearboxes are to be fastened only in the ordered installation position on a suitable foundation that is free of warping and stress e Apply suitable corrosion protection measures for installations in moist spaces or outdoors Facilitating assembly frictional corrosion If the machine parts are to be greased do not use any Molykote oil or grease containing molybdenum disulfide MoS2 or other high pressure additives Light machine oil is a better choice e g Castrol 4 in 1 or Kl ber Quitsch Ex For facilitating assembly and for avoiding frictional corrosion a suitable separating agent is to be used at all shaft hub connections e g PTEF Teflon spray by OPN Chemie Company 57290 Neukirchen Germany Do not use beneath a shrunk on disc seat Fastening screws Check all fastening screws for sufficient screw in depth of th
35. ll into the gearbox e the position of all components particularly the shafts is marked and e the shims and adjustment discs are not interchanged with each other Opening the gearbox independently voids the warranty and guarantee Assembling the gearbox During assembly of the gearbox ensure that e O ring surface seals are replaced with the same quality dimension seals and lubricated before the assembly e new screws with the same strength class are used and are tightened to the appropriate torque The screws are assembled without grease Maintaining the oil levels By default bevel gearboxes are filled half full with oil For the specification of the type of oil used in your gearbox check the type plate The gearbox must be cooled before checking the oil level and the drive and output must be decoupled Position the gearbox in the ul installation position for the purpose of this test A Check oil level There are different variants to the oil level test For gearboxes from size K090 the following variant applies Figure 20 Screw plug on the side e Check the oil level using the screw plug on the side pom Carefully unscrew the screw plug and measure the oil level using N yg Nw a test wire e Check the oil level using the screw plug on top Carefully unscrew the screw plug Measure the oil level using a clean test stick wire and then hold the measuring stick wire at 1 the outer housing The o
36. nded up to 6 months Long term storage up to max 3 years Along with the measures named above the shaft seals necessitate special storage requirements In the case of storage of more than one year the service life of the shaft seal rings is reduced for grease lubricated bearings gearboxes for installation positions A B D or G Corrosion protection Outside e Provide shafts and functional surfaces that are not protected against corrosion excluding aluminum flanges with sufficient corrosion protection and renew if necessary e Paint the housing as far as possible a base coat is not sufficient e Refinish joints before storing Inside e Fill gearboxes with the VCI additive e g Anticorit VCI UNI IP 40 Fuchs Lubritec Company www fuchs lubritech com and replace already mounted ventilation filter valves with screw plugs Follow the instructions from the VCI manufacturer alternatively e Fill gearbox up to the edge with oil avoid mixing types of oil e urn the gearbox regularly approx every 3 month and turn the shafts several times Storage space The storage space should be vibration free closed cool dry sufficiently ventilated no drafts e protected from insect infestation and gnawing rodents Lighting The following must be avoided e direct exposure to sunlight Version 03 2013 www ageda gmbh com 12 6 2 4 6 2 5 6 2 6 A 2 agedaka GETRIEBETECHNIK e artificial light with a high percenta
37. ng screw DIN 912 Tightening torque Clearance Clearance ROTEX GS Spannringnabe light Diameter Clamping screw DIN 912 Tightening torque Clearance Clearance ROTEX GS miniature couplings Table 17 ROTEX coupling sizes Version 03 2013 www ageda gmbh com 29 16 12 agedaka GETRIEBETECHNIK Installation of geared motors Along with the instructions for assembling the gearbox and country specific regulations the following additional points are to be observed during the assembly of geared motors e Compare the type plate data to the order and the installation conditions labelling installation position electrical connection data power speed type of protection and heat class e 50 Hz motors can be connected to 60 Hz network thereby changing the voltage torque and speed e Electrical connections must be made only by specialised personnel and must correspond to the applicable safety regulations e Before commissioning check the isolation resistance of the motor windings at 25 C 77 F greater than 5MQ e Voltage and frequency fluctuations according to DIN EN 60034 1 e f no motor heating block is used use stationary heating in the case of temperatures lt 10 C 14 F in the case of large temperature fluctuations or high air humidity e n the case of air cooling check for sufficient fresh air draft free cooling fins inlet and outlet openings of the fans e A minimum space of at least one half of the mo
38. ngs data sheets and the product catalog must be observed Take note of any deviating performance data lubricant information or other technical information in the order documentation and consider the respective application case Supplemental documentation If a product is intended for use in a potentially explosive environment and labelled accordingly the operating instructions for the Ex environment must also be observed In the case that a customer has requested delivery of ageda gearboxes combined with third party products the documentation of these products especially the operating instructions must also be observed Version 03 2013 www ageda gmbh com 7 3 Gearbox labelling 3 1 Order key Ubersetzung Transmission ratio Getriebetyp Gearbox type Laterne Bell housing Getriebegr e Gearbox size Getriebeart Gearbox model Wellenanordnung Abtriebsseite Shaft position output side Einbaulage unten liegende Seite Mounting orientation downwand facing side Figure 1 Order key Version 03 2013 ageda GETRIEBETECHNIK Anordnung von Wellen an den Seiten D E F Position of shafts on sides D E F Spielarme Ausf hrung Low backlash version 81 10 Winkelminuten S2 lt 6 Winkelminuten Schmierung Lubrication ISO VG 460 ISO VG 220 ISO VG 150 ISO VG 68 Einspritzschmierung spray lubrication FlieBfett NLGI KI 00 grease lubrication KL 00 Sonderschmierung
39. nk on disc 16 8 2 Disassembly shaft hub connections with shrunk on discs e First loosen all tensioning screws by 1 4 screw rotation proceeding ina circular manner CR e Then further unscrew the tensioning screws but not completely e Screw the screws into the pressure test threading up to the stop A e Tighten all forcing screws uniformly until the clamping set loosens e Remove the shaft from the hollow shaft and if required use a release tool 2 NEVER STRIKE Olt 16 9 Gearbox mounting arrangement Figure 15 The gearbox must be installed according to the prescribed installation position A Shrunk on disc A change of the installation position is only permissible with the consent of ageda GmbH and with completed modification of the lubricant quantity and ventilation position e Attachment surface to which the gearbox is fastened must be kept clean resistant to warping and with low vibrations A For the smoothness of the attachment flange see DIN ISO 2768 2 Class K e Align the shaft axes and shaft heights to avoid bearing damage and shaft breakage use shims for adjusting e Observe the limit values for coupling distances radial and angular offset for the couplings used m Maximum and minimum offset Axial offset Angular offset Figure 16 Assembly tolerances 16 10 Motor attachment e Ensure that drive train and motor are load free and without current during the assembly e Clean and grease flanges shafts an
40. nstructions Repairs For safety reasons we recommend that ageda GmbH performs all repairs Safety Safety fundamentals Mechanical work must be performed only by authorised and specialised personnel who have completed mechanical or mechatronic training and have read and understood these operating instructions e System commissioning start up Installation of customer provided safety devices Storing Assembly of the gearbox Assembly of motors couplings or other drive elements Transport Servicing and maintenance Electrical work on current carrying machine parts or devices must be performed only by authorised and specialised personnel who are electricians or have completed mechatronic training and have read and understood these operating instructions Work such as transport storage painting operating and disposal must be performed only by authorised and specialised personnel who have completed appropriate training and have read and understood these operating instructions Protective clothing must be worn during all work Before performing any work on drive units ensure that the drive train is stopped and that the drive train motor is secured against unintentional switching on Remove safeguarding and attach warning signs Gearboxes can become extremely hot during operation and must be cooled to a temperature of at least 30 C 86 F before starting any work If the exterior has cooled the lubricant in the interior of the
41. ny objects to fall into the gearbox and do not allow any oil to leak The reference values for the use of ventilation for an ambient temperature of 20 C 68 F are listed in the following table labelled with E Version 03 2013 www ageda gmbh com 13 ageda GETRIEBETECHNIK Duty cycle 100 h Rotational speed Installation size K065 K090 K120 K140 K160 K200 K260 Table 6 Ventilation with a duty cycle 100 h Duty cycle 50 h Installation size K065 K090 K120 K140 K160 K200 K260 460 460 460 460 220 220 220 1600 460 220 220 3150 150 150 68 1700 220 220 220 150 150 150 68 L isoo 220 220 150 150 150 68 68 1900 0 220 150 150 150 150 68 E68 200 220 150 150 150 190 68 2200 220 150 150 150 6 amp 8 E68 ce E68 2700 220 150 150 68 E68 68 E 68 68 E 68 Table 7 Ventilation with a duty cycle 50 h Version 03 2013 www ageda gmbh com 14 15 100 WA 0091 7 LHN 02 90049 x 003019930 gegangen Qju sJeqniy 00 NATV439 Gall eel w SUR sje4 9994 4 29 79 LHN Zd NATVH39 apeid poo Z Z STH 560 915 c jn 19930 eseoiBIIqoyy uu sieqnys 7 NIS Zan a 063 Z IHM 00 Gd 00 3 089 11 39 00 I1 00 Qd eunfuo 00 911 euinfuo XniiqoyN xeidieqniy YALSYWYV39 955910 S10 0 3 5192091013 co waHoag N POSS a le d3
42. s e Carefully align shaft and flange connections A e Try to attain the reduced tolerance range from Table 10 excerpt from DIN 42955 and not to exceed the standard tolerance range additional details can be found in DIN 42955 e Use elastic couplings to equalize manufacturing assembly inaccuracies and compensate their adjustment possibilities with the actual displacements e Statically over determined supports are to be avoided or adjusted very accurately e Avoid overloading all screw connections also between housings covers necks and lanterns 16 6 1 Smooth rotation of the shaft end To avoid bearing coupling damage before assembling check the motor shaft for smooth rotation see Figure 12 Image 1 and the motor flange for coaxial alignment and axial runout 16 6 2 Coaxial alignment of the flange centering Diameter of the shaft end d Balanced rotation tolerance at the center of the shaft rma R reduced 05 OM Table 11 Balanced rotation tolerance at the center of the shaft r 1 4 F D s Figure 12 Avoidance of coupling damage 16 6 3 Axial runout between motor shaft and flange centering coaxial form Mounting flange 1 i Centering diameter b1 Coaxial alignment and axial runout tolerance Nr R reduced 40 to 100 over 100 to 230 over 230 to 450 Table 12 Coaxial alignment and axial runout tolerance e Position the motor shaft pointing vertically upwards in order to exclude an error from th
43. surement eene nnne nene n nnns eren nnns nne nnn nene nnn nnne 17 11 SIIE le 1119 Pete eee ene ne ee ne ett ee ens Pn ee ee nano 17 Version 03 2013 www ageda gmbh com 2 agedaka GETRIEBETECHNIK 12 ES Le ING SIC ee 17 13 Implementation of shafts and centering cccccccssseecccceeecceccaeeeceecceaeceesseaueceesseeueeeeesaaaeceeessaaeeeessaaeeeessaageeesssaaass 17 14 Determining the installation position lower side cccseeeecceeeeeeceeeeeeeeeeeecaueeeeseeeeeaeueeesseeeeeseueeessaeeeeseaseessaeeessaees 18 15 Drive and direction of rotation en a ee ei 18 16 hice qm ae 23 16 1 PASS SIMO TOOS ee 23 162 MAMI TO IS SMO ETE 23 16 2 1 Sues ce E ee A E A ee ee eee eee eee ee TEN 23 16 2 2 Ace ce T T Tnm 23 16 3 Generally applicable assembly instructions 23 16 3 1 Requirements on the installation space ccccccseeeeeceeeeeeceeeeeeeeeeeecaeeeeeseeeeeseueeeseaeeeesaeeeeesaneeesaeeeeeseneeeeas 23 16 3 2 Facilitating assembly frictional COFrOSION cccccesceeceeeeeeceeeeeceeeeeecaaeeeeseaeeess
44. t repair with new warranty engagement position of the teeth Gearbox noise with vibrations defective coupling exchange the coupling bearing must be replaced Gearbox noise with vibrations defective bearing should be replaced by the manufacturer Irregular running noises foreign body in the oil contact the manufacturer Smells like plastic defective coupling Replacing the coupling star Version 03 2013 www ageda gmbh com 34 ageda GETRIEBETECHNIK Smells like plastic defective shaft seal ring exchange the seal Oil leak at seal ring defective shaft seal exchange the seal Oil leak at the housing defective housing seal exchange housing seal unfavourable combination of Oil leak at the ventilation filter speed direction of rotation valve temperature oil level installation position contact the manufacturer multiple causes contact the manufacturer Blocked gearbox defective gear set or bearing exchange the defective parts Shafts do not rotate or do not Shaft hub connection is broken ES EN rotate uniformly at or in the gearbox No torque transfer contact the manufacturer oose gear Table 19 Malfunctions causes and corrections of operating malfunctions ageda GmbH Feldstra e 170 22880 Wedel Germany E Mail info ageda qmbh de Homepage www ageda gmbh de Phone 49 0 4103 90 006 0 Fax 49 0 4103 90 006 26 24h Hotline 49 0 4103 90 006 12 Version 03 2013 www ageda gmbh com 35
45. talled Remove shaft protective caps or carefully peel shaft protective paint manually Do not treat the seals with paint trichloroethylene carbon tetrachloride radioactive materials hydrocarbons solvents radioactive substances or other aggressive chemicals Seal lips on the shaft seals must not be damaged Seals with cuts cracks wear hardening softening tackiness discolouration loose positioning or porous locations must be exchanged In this case please consult with us Damage to the shafts in the area of the seal lips in form of scratches contamination or rust deposits is not permissible Check the free accessibility of the fastening bores and remove dirt or residue form subsequent painting if necessary Gearboxes arrive filled with oil ready for operation Compensate for lost oil After long storage times of more than two years drain the oil specification of the oil manufacturer and refill with the type and quantity of oil corresponding to the type plate If the oil is filled into the gearbox up to the brim reduce it to the prescribed quantity If you are changing the type of oil possibly flush with solvent free media lower viscosity oil 9 I e 16 2 2 Lubrication 9 ES petroleum Oil levels that are too high increase the gearbox temperature and thus reduce the service life of the seals Dispose of used oil properly 16 3 Generally applicable assembly instructions 16 3 1 Requirements on the
46. th ageda GmbH In plant transport e General instructions must be observed during in plant transfers and damage to the gearbox must be avoided e Gearboxes must not be carried at the yellow shaft protective sleeves because these sleeves can easily slip off from the lubricated shafts e Drives with a unit weight gt 15 kg must be moved using appropriate load carrying equipment No additional loads are to be attached to the gearbox during transport e Only sufficiently sized transport and lifting means that have been tested for safety are to be used as intended Avoid pulling at an angle In the case of transport using a pallet secure against slippage The weight of the gearboxes is listed in the transport documentation Observe the center of gravity e Standing under swaying loads is dangerous Secure hazardous zones e n the case of transport already installed ventilation filters ventilation valves are to be exchanged for a screw plug DIN 906 conical with PTFE sealing tape or screw plug DIN 908 with O ring seal n the case of leaking oil spread suitable absorbent material and secure area against entry Depending on the quantity of oil do not operate the gearbox e A fall from a great height can lead to damage in or at the gearbox and lead to potential danger e Damaged gearboxes must not be used Shipping gearboxes e Ventilation filters valves are to be removed when the gearbox is cool and sealed as described Version
47. tion of the individual shafts can be checked by manually rotating the drive shaft Version 03 2013 www ageda gmbh com 18 ageda GETRIEBETECHNIK Figure 7 Direction of rotation type F solid shaft with single bearings Version 03 2013 www ageda gmbh com 19 agedaka GETRIEBETECHNIK mv di Figure 8 Direction of rotation type V solid shaft Version 03 2013 www ageda gmbh com 20 ageda GETRIEBETECHNIK Figure 9 Direction of rotation type S hollow shaft with shrunk on disc type H hollow shaft Version 03 2013 www ageda gmbh com 21 22 ageda GETRIEBETECHNIK www ageda gmbh com Figure 10 Direction of rotation type R pinion shaft Version 03 2013 agedaka GETRIEBETECHNIK 16 Assembly Follow safety instructions listed under point 2 16 1 Assembly tool set Spanner corresponding to the selected fastening screws Torque spanner Extractor retractor Shims spacers PTFE paste or spray Measurement gauge with stand scale 0 01 mm depending on model size Machine spirit level and try square depending on installation case Heating ovens heating plates device for induction heating Equipment is a component of the scope of delivery 16 2 Preparing for assembly 16 2 1 Checking Compare the type of gearbox serial number article description Check the gearbox for transport storage damage particularly for leaks damaged drives must not be ins
48. tor diameter should be present between the fan grating and the next wall e n the case of vertically upright motors with fans on top a protective roof for the fan or other covering must be installed e he cross sectional area of the connection cables must be sufficiently dimensioned and correspond to DIN VDE 0298 country specific regulations Establish and check the earthing connection near or directly on the terminal box Cable entry points must be provided with screw connections according to DIN 46320 T 1 Before connection to other machine parts check the direction of rotation in the installed position Clockwise rotation of the machine Connect phase sequence L1 L2 L3 to terminals u1 v1 and w1 as shown For a reversed rotation exchange any two phase connection lines Anschlu Stern Stemschaltung Dreieckschaltung Draieckschalter W2 U2 V2 an vi LI Lz L3 1 12 1 Figure 19 Motor terminal strip Motor safeguards If the required starting torque of the working machine is less than the nominal torque of the geared motor the drive can be started using a direct start if the connected mains and the connection cables permit an increased starting current For increasing the service life of the drive in the case of frequent start procedures a star delta connection should be used With the use of a delta connection the starting current and the starting torque amount to approx 1 3 of the values without such a connection
49. x temperatures under maximum production conditions load speed temperature every 10 minutes according to the same procedure until the gearbox temperature increases less than 2 K h final heating 6 Record and save the temperature values and associated points mark if necessary 7 Measure the ambient temperature under operating conditions For long term tests the gearbox can be provided with a temperature measuring adhesive strip The determined temperature values can be used with consideration of the ambient temperature for assessing the operating state of the gearbox Side labelling The gearbox sides are labelled with the letters A to F Definition A Drive crown wheel low speed high torque C Drive bevel pinion high speed low torque for i gt 1 1 Fastening sides It is possible to fasten standard gearboxes on any side The preferred fastening sides are the corner bores present in the square shape because these permit direct connection to the base housing except for K065 side B In addition the attachment above the type plate that is more than 0 08 mm thick is also possible Implementation of shafts and centering e Solid shafts o FitISO j6 o Parallel key according to DIN 6885 1 Form A o Centering D according to DIN 332 e Hollow shafts Fit ISO H7 o Parallel key groove DIN 6885 1 o From bore diameters of 32 mm additional locking ring insert Version 03 2013 www ageda gmbh com 17 14
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