Operating Instructions - SEVA
Contents
1.2. IN li So w lello f Oil Quantities It Symbols M Drain plug V Oil Filling and Vent plug W Oil level ANTRIEBSTECHNIK i ii S E VAJ 55 Bm A ENERGIEANLAGEN Operating Instructions K Series Lubrication 9 3 3 Four Stage K Series Oil Level Plugs
3. M5 A B M6 A B K 275 276 1 3 0 4 2 0 0 6 2 0 0 5 2100 153 905 1 3 0 4 KR375 376 2 10 0 65 3 3 0 9 3 2 0 7 3 7 0 9 2 410 7 2 8 0 7 K 475 476 50 12 69 20 6 0 2 0 10 20 4 8 1 4 5 5 1 4 K 575 576 6 5 1 9 995 59 9 5 3 0 10 0 3 3 1 3126 8 0 2 6 K 675 676 150720 190733 1600 351 20 5 3 4 18 0 2 8 Moe 246 K 775 776 21 0 2 0 31 0 3 4 29 0 3 1 34 0 3 4 25 0 2 8 21 0 2 6 ENERG K 875 876 IEANLAGEN 32 0120 M Drain plug 90 0 3 4 50 031 60 0 3 4 V Oil Filling and Vent plug 45 0 2 8 v 3320726 Oil level 57 Operating Instructions K Series Lubrication 9 4 Mounting Positions Figured
4. For K002 and K003 this plug doesn t exist Please refer to oil quantities Oil Quantities It Symbols M Drain plug V Oil Filling and Vent plug WV Oil level 54 JURE ENERGIEANLAGEN Operating Instructions K Series Lubrication 9 3 2 Three Stage K Series Oil Level Plugs
5. 9 3 4 Five Six Stage K Series Oil Level Plugs Oil Quantities liter Type M1 A B M2 A B M3 A B M4 A B
6. Oil Quantities It ferre pal eem O Lolo fo f O M1 A B M2 A B See M3 M4 A B A B
7. T ZE T1 9 E b e I U OA T Type KR273 10 KR373 10 KR473 10 KR573 10 KR673 10 KR773 10 KR873 10 ANTRIEBSTECHNIK SE V Aj 47 ENERGIEANLAGEN Operating Instructions K Series Mounting 7 11 K 00 K 20 TORGUE ARM ASSEMBLY DETAILS ANTRIEBSTECHNIK so SALI ENERGIEANLAGEN Operating Instructions K Series Mounting 7 12 Fitting output shaft elements Use the following illustration to assemble output shaft units 1 Gear shaft end 2 Thrust bearing 3 Coupling hub 7 13 Correct position of output shaft elements Output Shaft unit transmission elements must placed as close as possible to the gear unit so that the radial load is as closest as possible to the gear unit 1 Hub ANTRIEBSTECHNIK S E VAJ 49 ENERGIEANLAGEN Operating Instructions K Series Mounting 7 14 Fitting Couplings 7 14 1 By fitting couplings be sure that there is some clearance between the two ele ments 7 14 2 By fitting couplings be sure that there is no eccentricity between the two shafts se 7 14 3 By fitting couplings be sure that the two s
8. M5 A B M6 A B 21 025 331 025 3 2 0 25 3 110 25 2 41 0 25 2610125 9 0 0 4 6 5 0 4 6 0 0 4 010 4 4 8 0 4 5 5 0 4 639 05 93 09 937 05 10 0 0 5 Go s 8 0705 15 0 1 0 9 19 0 0 9 19 07 0 9 20 51 0 9 18 0 0 9 17 07 0 9 21 0 1 0 29 0 1 0 Zo OF 10 34 0 1 0 250 10 2100 Symbols 37 0 2 15 M Drain plug 50 0 2 15 50 0 2 15 60 0 2 15 V Oil Filling and Vent plug 45 0 2 15 39 0 2 15 Oil level STECHNIK 96 ANTRIEB ENERGIEA NLAGEN Operating Instructions K Series Lubrication
9. 92 ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions K Series Lubrication 9 Lubrication 9 1 Oil Types VENE Temperature VENE Lubricant Uli 51517 3 Dip Forced Lubrication Lubrication ISO VG 68 Beyond Castrol Kl ber Petroleum Lubrication bp OQ ha o LIBER 0 Energol Kl beroil Mobilgear 600 GR XP 680 GEM 1 680 N XP 680 Energol Kl beroil Mobilgear 600 GR XP 460 GEM 1 460 N XP 460 Energol Kl beroil Mobilgear 600 CLP GR XP 320 GEM 1 320 N XP 320 Energol Kl beroil Mobilgear 600 GR XP 220 GEM 1 220 N XP 220 Energol Kl beroil Mobilgear 600 GR XP 150 GEM1 150 N XP 150 Energol Kl beroil Mobilgear 600 GR XP 100 GEM 1 100 N XP 100 Energsyn _ Kl bersynth Mobil SG XP 680 GH 6 680 Glygoyle 680 Energsyn Aphasyn Kl bersynth Mobil SG XP460 PG460 GH 6 460 Glygoyle 460 Energsyn Aphasyn Klubersynth Mobil SG XP320 PG320 GH 6 320 Glygoyle 320 Energsyn Aphasyn Kl bersynth Mobil Glygoyle CLP SG XP 220 PG 220 GH 6 220 30 PG Energsyn Aphasyn Kl bersynth Mobil Glygoyle SG XP 150 PG 150 GH 6 150 22 _ B Kl bersynth Mobil Glygoyle GH 6 100 100 _ _ Kl bersynth Mobil SHC Gear GEM4 680 N 680 Enersyn Alphasyn Kl bersynth Mobil SHC Gear Synthetic EP XF 460 T 460 GEM4 460 N 460 Oil Enersyn Alphasyn Kl bersynth Mobil SHC Gear EP XF 320 T 320 GEM4 320 N 320 Enersyn Alphasy
10. Standard types basic part diagram Parts may differ for special applications Standard Part List 9 Bearing 17 Shim Ring 25 Bolt 33 Circlip 10 Shim Ring 18 Bearing 26 Closing Cap 34 Shim Ring 3 Housing 11 Key 19 Gear 2 Circlip 4 Circlip 12 Pinion Shaft 20 Output Shaft 28 Shim Ring 5 Shim Ring 13 Cover Plate 21 Key 29 Bearing 6 Gear 14 Bolt 22 Key 30 Pinion Shaft Bearing 15 Oil Seal 23 Shim Ring 31 Key 16 Circlip 24 Flange 32 Gear 19 Operating Instructions K Series Part Designations 3 14 Size K27 K87 Type 03 lications Standard types basic part diagram Parts may differ for special a Standard Part List 9 Bearing 17 Shim Ring 25 Closing Cap 10 Shim Ring 18 Bearing 26 Circlip 3 Housing 11 Key 19 Gear 2 Shim Ring 4 Circlip 12 Pinion Shaft 20 Shim Ring 28 Bearing 5 Shim Ring 13 Cover Plate 21 Key 29 Pinion Shaft 6 Gear 14 Bolt 22 Output Shaft 30 Key Bearing 15 Oil Seal 23 Flange 31 Gear 8 Spacer 20 16 Circlip 24 Bolt 32 Shim Ring ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions K Series Part Designations 3 15 Size K27 K87 Type 04
11. 8 Spacer Ring 11 Bolt 3 Bolt 6 Nut 46 9 Nut ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions K Series Mounting 7 10 For the fixing bold position refer to the following dimensions Ti Ko
12. ILU CAUCA a LES lt A 2 NL ENERGIEANLAGEN K Series Gear Units Edition OIKCE 0203 1014 Operating Instructions Operating Instructions K Series Contents CORIERIS i EIU KEIN NIME 02 1 How To Use This Manual iii 04 2 Unit DESIGNATO Maizieres Rainer ie ee i oa 05 2 1 Detained Unit AS SIMIAN aaa 05 2 2 Nameplate unit 988 II QONN siata on sa ono een 06 3 Standard type Gearbox Part LISt on nn nn 07 a teole UOZ PD OD c 07 32 926 DO 20 TYPE DIL een ee 08 IZ TRO RZ FD DIR ee ee E 09 3 4 9126 ROO KO Type DZ cm 10 3 9 9128 100 20 70 0074 ee E E 11 30 9126 SUR 20 TYPE oS ME 12 IZ RK OZ T DR ee ee ea 13 oos IZ Os ROO K20 TYPE Osoite E io idro 14 o ROZEK RO TT O E 15 3 410 91Z8 RUD N20 TYPE 0G sare E E EEES 16 SRE CU aaor IVDE Ole ee ee ea 17 0 12 170 K aS VDE lai aan 18 SMS 51201827 07 DPE E ee een 19 S PASA K2 Ker Type Q9 T era 20 319 928 Vm oras T ee ee 21 oi 8 SZ OE oro Osor oi re 22 ST SIZE K2 NO TPS tra an nt 23 10 120 K2 AKS NPE 0 ho lea 24 ho a bo eam 7420 SE o EC Peel E 25 SALOU DRE EA A E 26 EAE eee USB E EE AE ALE EEN IEEE o ET 26 A OPE RSO ee aaa 26 2 3 S alel VASU LIEH ONG ne R 27 4 3 1 General Safety Instructions nn ee m 27 4 3 1 1 Working on the gear FOOUCEN zes 27 4 3 1 25 PE 27 dA e la aleje Mo O 20 dos ase U a 1 zos no rar ia 20 5 Things to Check Before
13. Standard types basic part diagram Parts may differ for special a lications Standard Part List 9 Spacer 17 Shim Ring 25 Circlip 10 Bearing 18 Bearing 26 Shim Ring 3 Housing 11 Shim Ring 19 Gear 2 Bearing 4 Circlip 12 Pinion Shaft 20 Output Shaft 28 Pinion Shaft o Shim Ring 13 Cover Plate 21 Key 29 Key 6 Gear 14 Bolt 22 Key 30 Gear 1 Key 15 Oil Seal 23 Shim Ring 8 Bearing ENERGIEANLAGEN 16 Circlip 24 Closing Cap 21 Operating Instructions K Series Part Designations 3 16 Size K27 K87 Type 05 Standard types basic part diagram Parts may differ for special applications Standard Part List 9 Bearing 17 Shim Ring 25 Bolt 33 Circlip 10 Shim Ring 18 Bearing 26 Closing Cap 34 Shim Ring 3 Housing 11 Key 19 Gear 2 Circlip 4 Circlip 12 Pinion Shaft 20 Output Shaft 28 Shim Ring 5 Shim Ring 13 Cover Plate 21 Key 29 Bearing 6 Gear 14 Bolt 22 Key 30 Pinion Shaft Bearing 15 Oil Seal 23 Shim Ring 31 Key 8 Spacer 16 Circlip 24 Flange 32 Gear 22 Operating Instructions K Series Part Designations 3 17 Size K27 K87 Type 08 Standard types basic part diagram Parts may differ for special a lications Standard Part List 9 Be
14. The solvent must be re moved from the surfaces as well ANTRIEBSTECHNIK 42 S E V Aj ENERGIEANLAGEN Operating Instructions K Series Mounting 7 7 3 Insert the shaft and tighten the bolts as shown Be sure that there is a clearance between the shrink disk shoulder and the hollow shaft shoulder of the gearbox 1 Welle von Kunde 2 Ringaus bronze x ohlwelle 4 Schrumpscheibe Tightening Torque Nm 12 30 30 43 ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions K Series Mounting 7 8 Disassembling customer shaft with shrink disk 7 8 1 Loosen the bolts of the shrink disk and take out the shaft ANTRIEBSTECHNIK 44 JIZ ENERGIEANLAGEN u E O O 5 alan U o C D Sea O O V U lt c 5 c 2 O 7 9 Assembling Gear Unit with Torque Arm 7 9 1 The following connecting possibilities are available Use one position which is the most suitable 45 Operating Instructions K Series Mounting 7 9 2 Assemble the parts as shown bellow 1 Gear Unit 4 Spacer Ring Torque Arm 10 Rubber Buffer 2 Assembled Shaft 5 Machine Extension
15. To Use This Manual Take attention to the following safety and warning signs for proper understanding and quick reference H D gt 04 Electric Hazard Can cause severe or fatal injuries Mechanical Hazard Can cause severe or fatal injuries Likely to be Hazardous Can cause minor or fatal injuries Damage Risk Can damage the drive or environment Important Information EC Machinery Directive Within terms of the EC machinery directive 2006 42 EC the gear reducer is not consid ered an autonomous machine but as a component to install in machines Operation is prohibited within the area of validity of the 2006 42 EC directive until it has been determined that the machine in which this product is installed corresponds to the regulations within this directive The operating instructions contain important information to ensure Trouble free operation Fulfilment of any rights to claim under guarantee The operating instruction must be kept close to the gearbox and must be available in case it is needed This operating instruction is written for K Series gear units and is applicable only for K Series If any different type of gearbox is used please ask SEVA for the operating instruc tions of that type This instruction can be used only for standard type geared units of SEVA For special application and modified gear units ask SEVA for validity This manual does not cover 94 9 EC compatible gearboxes For 94 9 EC
16. and using ATEX conforming gear box immediately stop the system and contact SEVA If not ATEX gearbox the gearbox is designed to work under max 80 Celsius If higher than 80 Celsius check the oil type and oil quantitiy level according your mounting posi tion and check the nameplate mounting position If nameplate mounting posi tion does not fit the actual position go to ID 100 Standard Gearboxes are designed to work under 40 Celsius ambient tem perature If ambient temp is higher than 40 Celsius special solutions gear boxes are required Please contact SEVA Check Your moving parts for noise Disassemble the gearbox and run without load If you still hear the noise motor bearings or gearbox bearings are defect Change bearings Go to ID 100 Check Your moving parts for noise Disassemble the gearbox and run without load If you hear still the noise the oil may has some particles inside Change the oil and look for small particles If metal particles are found the gearbox may have some damage Go to ID 100 ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions K Series Troubleshooting Guide o foom foan C HN 013 Gearbox is Regular nocking Check Your moving parts for noise Disassemble the gearbox and run without noisy noise load If you still hear the noise one of the gears inside is defect Go to ID 100 Gearboxis Reiro and doan Check the output shaft connection elements for run out Take out the output 014 l 9
17. contact SEVA ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions K Series Unit Designation K 2 Unit Designation 2 1 Detailed unit designation R 3 7 3 02 R M2 T1 905 4 L05 L 220V With Fan P 24V With Fan S 220 V Without Fan Z 24 V Without Fan Motor Size For KV types 90 S 4 Pole Number Frame Lenght Motor size Torque Arm Position Mounting Position Output Shaft Flange Position Output Specification 00 Hollow output shaft 01 Solid output shaft 02 Solid output shaft and with Flange 03 Flanged and hollow output shaft 04 With double output shaft 05 Double flanged and double output shaft 08 Double flanged and hollow output shaft 0S Shrink disk output OE Extruder output Stage 2 Stages 3 Stages 4 Stages 5 Stages 6 Stages Revision Number 0 7 Housing Size 0 8 Input Type R With Motor N EC B5 B14 Flanged without Motor V IEC B5 B14 Flanged with Motor T Without Motor Gearbox Type K Serie ANTRIEBSTECHNIK SEVA ENERGIEANLAGEN Detailed K Series gear units designation for orderin This Designation is different from the short nameplate designation Brake 00 5 Nm 01 10 Nm 02 25 Nm 04 40 Nm 05 50 Nm For KN Types 63 B5 63 B14 A07 A08 B08 A09 B09 A06 B06 71 B5 80 B5 80 B14 90 B5 90 B14 10 100 Nm 20 200 Nm 30 300 Nm 40 400 Nm 50 500 Nm A10 B10 A11 A13 B13 A16 A18 100 B5 A20
18. p shaft element and run without load If you still hear the noise one of the gears noisy noise has run out problem Go to ID 100 Gearbox is with Basar braked motor and Low randomly clicking noise may come from the brake disk which is normal 015 WE noise is coming from If noise level is disturbing the brake may be defect or brake clearance is not y the brake side ran adjusted Go to ID 100 domly You are using fre asto guency inverter and The freguency inverter parameters are not optimised for the freguency range 016 NOI the noise level is or motor you are using Observe the frequency inverters manual If still same y changing according problem change the ratio of gearbox Go to ID 100 your speed Ai Leskage mom If ambient Temp is over 40 Celsius or none stop work over 16 hours please 017 Oil is Leaking S al 9 change the top plug with a breather plug Observe this manual for using breath er plug If this is not your case the seal could be damaged Go to ID 100 If you are using breather plug be sure it is in the correct place This is the most 018 Oil is Leakin Oil Leakage from top plug position according your mounting position The plug may be not tight 9 Plug enough There are some particles under the plug rubber surface Clean and tighten the plug If still same problem go to ID 100 Observe exactly where the oil is coming out It could be seal or plug point 019 Breker Oil Leakage from where it comes out and leaks over the housing If this is yo
19. the Gear Unit or Geared Motor is Installed 29 o HOD SOTO rali 29 E 160 gt eddie pP NE ee MEAM M MEUM LEES 30 6 Installing The Gear UNIL iii 30 sm fag Belo VOUS Hill 30 6 2 Check the shaft dimensions to fit ero si 6 3 Check the ambient temperature nnne 31 ANTRIEBSTECHNIK 02 SALI ENERGIEANLAGEN Operating Instructions K Series Contents 6 4 Check the voltage S DNY RTT EET 31 6 5 Check the mounting POSTO obostvons sat oreo ute enr top ii a ono 34 60 6 Useof Dreather PIUS NI RE M 34 MO edquu iel I Me 34 6 8 Check shaft ends and mounting faces ii 34 6 9 Cover abrasive Te T M 34 6 10 Check accessibility to filling breather and drain pIUGs esses 35 7 Mechanical Installation zau enie raj so ba i i iii 39 T T Iristalliig custoimer shaft with shoulder nu een 36 7 2 Installing customer shaft without shoulder anne nnne nn 37 7 3 Disassembling customer shaft with shoulder anne nnneneneenenen 38 7 4 Disassembling customer shaft without shoulder 0220 nnneneneenenen 39 Ps Shat NOE TOFQUES NETTE TT UTE 40 7 6 Recommended shaft dimensions for KT 00 tyPe S cccceecceeceseeeceeeceeeeeeeeeeeeeeeeaeens 41 7 7 Assembling customer shaft with shrink diSk nenn nnnnennnennne
20. 200 B5 100 B14 A22 225 B5 112 B5 A25 250B5 132 B5 A31 315 B5 132 B14 160 B5 180 B5 05 Operating Instructions K Series Type Designation 2 2 Nameplate unit designation Nameplate unit designation is a short abbreviation from the detailed designation A sample name plate for K Series e ANTHIEBSTECHNIK VA www seva tec de el gt iu Type KR373 00R Speed 20 rpm Ratio 12 33 Serial No 11 027165 Oil Qty 2 9 It C OIL FILLED MINERAL OIL VG320 Abreviations Serial N Serial Number M Pos Mounting Position Type Designation KR3 3 00 R Type Shaft Arrangement Viewed from input side L Right Input Left Output R Left Input Right Output USM ANTRIEBSTECHNIK 06 gt E ENERGIEANLAGEN Operating Instructions K Series Part Designations 3 Standard Type Gearbox Parts Lists 3 1 Size K00 K20 Type 00 Standard types basic part diagram Parts may differ for special a Standard Part List 9 Bolt lications 17 Gear 25 Output Shaft 10 Cover Plate 18 Spacer 26 Gear 3 Housing 11 Key 19 Spacer 2 Spacer 4 Circlip 12 Pinion Shaft 20 Circlip 9 Bearing 13 Shim Ring 21 Oil Seal 6 Gear 14 Circlip 22 Circlip 7 Pinion Shaft 15 Shim Ring 23 Bearing 8 Key ANTRIEBSTECHNIK ENERGIEANLAGEN 16 Bearing 24 Key 07 Operating Instructio
21. Pinion Shaft 20 Circlip 28 Spacer 5 Bearing 13 Shim Ring 21 Oil Seal 6 Gear 14 Circlip 22 Circlip 7 Pinion Shaft 15 Shim Ring 23 Bearing 8 Key 14 16 Bearing 24 Key ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions K Series Part Designations 3 9 Size K00 K20 Type 05 Standard types basic part diagram Parts may differ for special applications Standard Part List 9 Bolt 17 Gear 25 Output Shaft 10 Cover Plate 18 Spacer 26 Key 3 Housing 11 Key 19 Spacer 2 Gear 4 Circlip 12 Pinion Shaft 20 Circlip 28 Spacer 5 Bearing 13 Shim Ring 21 Oil Seal 29 Flange 6 Gear 14 Circlip 22 Circlip 30 Bolt 7 Pinion Shaft 15 Shim Ring 23 Bearing 8 Key 16 Bearing 24 Key ANTRIEBSTECHNIK S E V Aj 15 ENERGIEANLAGEN Operating Instructions K Series Part Designations 3 10 Size K00 K20 Type 08 Standard types basic part diagram Parts may differ for special a lications Standard Part List 1 Pinion 9 Bolt 17 Gear 25 Output Shaft 2 Plug 10 Cover Plate 18 Spacer 26 Gear 3 Housing 11 Key 19 Spacer 2 Spacer 4 Circlip 12 Pinion Shaft 20 Circlip 28 Flange 13 Shim Ring 21 Oil Seal 29 Bolt 14 Circlip 22 Circlip 7 Pinion Shaft 15 Shim Ring 23 B
22. Ring 25 Flange 33 Closing Cap 10 Shim Ring 18 Bearing 26 Bolt 34 Circlip 3 Housing 11 Key 19 Gear 2 Ekstruder Housing 35 Shim Ring 4 Circlip 12 Pinion Shaft 20 Shim Ring 28 Bolt 36 Bearing 5 Shim Ring 13 Cover Plate 21 Key 29 Bearing 3 Pinion Shaft 6 Gear 14 Bolt 22 Hollow shaft 30 Key 38 Key T Bearing 15 Oil Seal 23 Circlip 31 Shaft 39 Gear 16 Circlip 24 Shim Ring 32 Oil Seal Operating Instructions K Series Safety 4 Safety 4 1 Intended Use The gear reducer is designed for use in industrial machines Please refer to our catalogue or our web page for the maximum permitted torques and speeds The most important maximum permitted values are indicated on the nameplate of the product But the all data can be found on our product catalogues Using the product out of the product catalogue nameplate s permitted ranges will cancel the warranty manufacturer declaration and SEVA will not take any responsibility The gear units are intended for industrial machines and may only be used in accordance with the information provided in this manual the product catalogue and the nameplate of the gearbox They comply with the applicable standards and regulations and meet the requirements of the directive 2006 42 EC The gearbox must be started up maintained and operated according this manual The gearbox most be incorporated with 2006 42 EC confirming parts machines A motor conne
23. aked motor Please Check the voltage supply and frequency of your electric con nection They must be in accordance with the nameplate of the motor Observe motor manufacturers start up manual Still does not work go to ID 100 Please observe the frequency inverter driver manual Check the motor by supplying direct voltage to see if the problem is on your driver fre guency inverter Still does not work go to ID 001 Please Check the voltage supply and frequency of your electric con nection They must be in accordance with the nameplate of the motor Observe motor manufacturers start up manual Still same problem the load may be too high for the chosen motor Loosen the gearbox from the load torque If it works than the starting torque is insufficient and higher motor power is needed For monophaze motors check the starting up condansator and running condansator as well If nothing helps go to ID 100 Please observe the frequency inverters or drivers manual To see if the problem is on your driver or frequency inverter take out the driver fre guency inverter and make direct voltage supply to the motor according the motors nameplate Still does not work go to ID 100 Please Check the voltage supply and frequency of your electric con nection They must be in accordance with the nameplate of the motor Observe motor manufacturers start up manual Be sure that the brake is working Observe the brake manufacturers Manuel If brake is supplied fr
24. aring 17 Shim Ring 25 Closing Cap 10 Shim Ring 18 Bearing 26 Circlip 3 Housing 11 Key 19 Gear 2 Shim Ring 4 Circlip 12 Pinion Shaft 20 Shim Ring 28 Bearing 5 Shim Ring 13 Cover Plate 21 Key 29 Pinion Shaft 6 Gear 14 Bolt 22 Output Shaft 30 Key Bearing 15 Oil Seal 23 Flange 31 Gear 8 Spacer ANTRIEBSTECHNIK ENERGIEANLAGEN 16 Circlip 24 Bolt 29 Operating Instructions K Series Part Designations 3 18 Size K27 K87 Type 0S Standard types basic part diagram Parts may differ for special a Standard Part List 9 Bearing lications 17 Shim Ring 25 Bolt 10 Shim Ring 18 Bearing 26 Closing Cap 3 Housing 11 Key 19 Gear 2 Circlip 4 Circlip 12 Pinion Shaft 20 Key 28 Shim Ring 5 Shim Ring 13 Cover Plate 21 Output Shaft 29 Bearing 6 Gear 14 Bolt 22 Shim Ring 30 Pinion Shaft Bearing 15 Oil Seal 23 Shrink Disk 31 Key 8 Spacer 24 16 Circlip 24 Cap 32 Gear ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions K Series Part Designations 3 19 Size K27 K87 Type OE Standard types basic part diagram Parts may differ for special applications Standard Part List 9 Bearing 17 Shim
25. ation When the goods arrive first check for any damage If some damage observed imme diately contact the transport company and inform about the damage Contact SEVA for the damage and do not start to install the unit until it is agreed that the damage has no affect of operation Use the upper foot connection holes for lifting up the gear unit by using eyebolts The eyebolts should be capable to carry the weight of gearboxes Do not hang additional loads on the gear box by lifting Use suitable hoisting equipment which is capable to hold the gear units weight Refer to the catalogue for various types weights If the gearbox is delivered with steel carrying construction use the construction holes for lifting the gear unit See drawing bellow for hoisting point Do not stay beneath under the lifting hoisting equipment which may cause serious iniuries by falling down objects accidental movements unexpected accidents Falling or hard placement can damage the gear unit Only use hoisting and securing equipment which is permitted for the size weight of our gear unit Ensure that the load is slowly and carefully handled and placed 29 Operating Instructions K Series Checking 5 2 Storage If the geared unit or geared motor will be stored up to 3 years refer to the following instructions With Packing Use corrosion protection oil for the output shaft and connection surfaces like flange surface or foot assembling sur
26. cted to the gear unit is only allowed to be operated in the frequency entries so that the data provided on nameplate catalogue of the gear unit is not exceeded and is accordance with the nameplate catalogue The speed range will be provided on the name plate if SEVA is informed that the gear unit will be used with frequency inverter If not informed the nameplate will have a single fixed speed and only this speed is allowed The electric motor and frequency inverter must be in accordance with 2006 42 EC zi If the gear units input is used with variable speed gear unit this must be informed to SEVA before ordering and on the nameplate the allowed maximum and minimum speeds speed range will be provided If not mentioned by ordering the gear units speed will be a fixed single input speed and only this speed is allowed If the gear unit will be driven by belt coupling chain drive etc the gear unit is only allowed to be used according the nameplate catalogue entries Different speed higher motor power higher radial axial loads etc than nameplate catalogue is not allowed The ambient temperature must be between 5 40 celsius and no abrasive media must attack the paint and seals If different working conditions this must be informed to SEVA before ordering The gearbox maintenance oil change check must be done according this manual SEE E 4 2 Improper Use Every usage which exceeds the limits stated above the nameplate and catalo
27. e op timise Also for low speeds the efficiency of the gearbox may vary too much Specially for worm gearboxes The recommended frequency range is 20 70 Hz for worm gearboxes and 10 70 Hz for Helical Gear Boxes Use Higher mo tor power and Frequency inverter or change ratio of gearbox to work inside the recommended range The oil is not in accordance with your working conditions Change to lower viscosity oils Observe this Manuel for using the correct oil Working in higher ambient temperatures is an other solution if possible If still same problem you need higher motor power Measure the surface temp using a temperature measuring device under full load If the temp is under 80 Celsius this will make no harm to the gearbox and is normal All ATEX conforming gearboxes and standard worm gearboxes are designed to work under max 120 Celsius If higher than 120 Celsius and using ATEX conforming gear box immediately stop the system and contact SEVA Go to ID 100 If not ATEX confirming check the oil type and oil quantity level according your mounting position and check the nameplate mounting position If nameplate mounting position does not fit the actual position go to ID 100 Measure the surface temp using a temperature measuring device under full load If the temp is under 80 Celsius this will make no harm to the gearbox and is normal All ATEX conforming gearboxes are designed to work under max 120 Celsius If higher than 120 Celsius
28. e placed on a abrasive ambient be sure that the output seals are covered so that no abrasive material chemicals or water touches the seals Any pressure coming from outside over the seals can cause that the out staying substances to enter the gearbox and cause serious damage to the gear unit If pressure or abrasive material can not be prevented from coming over the sealing contact SEVA for solutions Abrasive material chemicals water positive or negative pressure exceeding 0 2 bar can af fect or damage the sealing lip or output shaft Inside entering substances from the seals can cause serious damage to the gear unit ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions K Series Checking gt e b s ANTRIEBSTECHNIK ENERGIEANLAGEN N 6 10 Check accessibility to filling breather and drain plugs The filling breather and drain plugs must be freely accessible for further checking and service 7 Mechanical Installation The gear unit can only be installed using the supplied connection points like foot and flange assembling points To install the gear unit without the supplied connection points can cause serious injuries by loosening or braking the gear unit Even the gear unit is installed totally correctly according this manual be sure that no one will be harmed by accidentally brake downs or loosening The mounting plate must be rigid enough not allowing torsions flat enough to prevent strains by t
29. earing 16 8 Key 16 Bearing 24 Key ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions K Series Part Designations 3 11 Size K27 K87 Type 00 lil Standard types basic part diagram Parts may differ for special a lications Standard Part List 9 Bearing 17 Shim Ring 25 Shim Ring 10 Shim Ring 18 Bearing 26 Bearing 3 Housing 11 Key 19 Gear 2 Pinion Shaft 4 Circlip 12 Pinion Shaft 20 Shim Ring 28 Key 5 Shim Ring 13 Cover Plate 21 Key 29 Gear 6 Gear 14 Bolt 22 Output Shaft 30 Shim Ring Bearing 15 Oil Seal 23 Closing Cap 8 Spacer ENERGIEANLAGEN 16 Circlip 24 Circlip 17 Operating Instructions K Series Part Designations 3 12 Size K27 K87 Type 01 Standard types basic part diagram Parts may differ for special applications Standard Part List 9 Spacer 17 Shim Ring 25 Circlip 10 Bearing 18 Bearing 26 Shim Ring 11 Shim Ring 19 Gear 2 Bearing 12 Pinion Shaft 20 Output Shaft 28 Pinion Shaft 13 Cover Plate 21 Key 29 Key 14 Bolt 22 Key 30 Gear 15 Oil Seal 23 Shim Ring 16 Circlip 24 Closing Cap ANTRIEBSTECHNIK 18 SAIS ENERGIEANLAGEN Operating Instructions K Series Part Designations 3 13 Size K27 K87 Type 02
30. f earth and gearbox motor Delayed Running Brake 220V L1 L2 L3 N 4 Sudden Brake 220 V L1 L2 L3 N S M Delayed Running Brake 24 V Brake Coil L1 L2 L3 N Brake Coil LE ANTRIEBSTECHNIK ENERGIEANLAGEN 3 Brake Coil In a Sudden Brake 24 V 11213 N Brake Coil ode In A SS 33 Operating Instructions B Series Checking A o 34 6 5 Check the mounting position The mounting position must be in accordance with the mounting position mentioned on the name plate If different please contact SEVA for possibilities of using in a different mounting position Refer to the mounting positions and oil quantities on this manual and adjust the oil level accordingly with the recommended oil types given on this manual Do not mix synthetic oils with mineral oils which can cause serious damage on the gear unit 6 6 Use of breather plug Breather plugs are not needed for K Series under normal ambient and working c
31. face Seal the unit in a plastic wrap and pack it in container A moisture indicator should be placed around the container to observe the moisture Relative atmospheric humidity should not exceed 5096 The container should be kept under roof which protects from snow and rain Under this condition the gear unit can be stored up to 3 year with regular check The ambient temperature should be between 5 to 60 Celsius degrees Without Packing Use protection oil for the output shaft and connection surfaces like flange surface or foot assembling surface If no packing is used and the gearbox is stored without packing the ambient temperature should be between 5 to 60 Celsius degrees The gearbox must be kept under enclosed roof with constant temperature and constant humidity not exceeding 509 The storage should be free of dust and dirt and ventilated with filter If the gearbox is stored without packing it is recommended not to store more than 2 years and regular check during this time is recommended If stored in open protect against insect damage 6 Installing The Gear Unit 6 1 Before you start Observe the gear unit for damages of storage or transportation If any damage please contact SEVA Be sure that you have all the equipment necessary for installing like Spanners torque wrench shims and distance rings fixing devices for input and output elements lubricant bolt adhesive etc This manual is not for 94 9 EC ATEX conforming
32. gear units For 94 9 EC conforming gear units refer to the ATEX range manual ATEX conforming gear units have name plates indicating the zone and the temperature class and are different from standard type geared units Therefore Standard units can not be installed on Potentially explosive atmospheres ANTRIEBSTECHNIK 30 S E VAF ENERGIEANLAGEN Operating Instructions K Series Checking ANTRIEBSTECHNIK ENERGIEANLAGEN 6 2 Check the shaft dimensions to fit Output Shaft l Hollow Hollow Output Tolerance Flange Centering Shaft Shaft Shaft DIN748 Centering Shoulder Diameter Tolerance Diameter UP to 50mm k6 Shoulder Tolerance Over 50mm m6 H7 Diameter 96 0 02 0 01 0 095 0 03 0 02 0 01 0 a 0 03 0 03 0 01 0 9130 0 04 0 03 0 01 0 en 0 04 0 03 0 01 0 zn 0 04 0 03 0 02 0 en 0 05 0 03 0 02 0 eot 0 05 0 03 0 02 0 en 0 05 0 04 0 02 0 2000 0 05 0 04 0 02 0 ot 0 06 6 3 Check the ambient temperature The ambient temperature must be between 5 celsius to 40 celsius for standart type gear units If different contact SEVA for special solutions 6 4 Check the voltage supply The standard geared motors are supplied with 230 400 V 50 60Hz up to 3kW includ ing 3kW and 400 690 V 50 60 Hz over 3kW and is indicated on the motors name plate unless it is differently ordered In case of only gear unit is suppl
33. gue of the product especially highest torques and speeds is not compliant with the regulations and thus prohibited The operation of the gear reducer is prohibited if It was not mounted installed according to regulations and this manual The gear reducer is very soiled It is operated without lubricant It is operated out of the permitted values provided on catalogues and or nameplate ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions K Series Safety 4 3 Safety Instructions 4 3 1 General Safety Instructions 4 3 1 1 Working on the gear reducer Inappropriately executed work can lead to injury or damage Make sure that the gear reducer is only installed maintained and dismantled by trained technicians Foreign bodies spinning through the air can cause grave injury Before putting the gear reducer into operation check that there are no foreign bodies or tools near the gear reducer 4 3 1 2 Operation Touching hot surfaces can lead to burns Do not touch the gear reducer if their operation temperatures are too high or use suit able safety equipment like gloves Rotating machinery can lead to injuries There is danger of being trapped or pulled in Keep a sufficient distance and make safeguarding to rotating machinery See relevant norms EN349 A 1 EN13857 4 3 1 3 Maintenance An unintentional start of the machine during maintenance work can lead to serious ac cidents Make sure no one can
34. haft elivery 7 4 2 Use the disassembly set from SEVA and fasten the bold as shown bellow to take out the output shaft For disassembly sets look the following pages 1 Retaining bolt 2 Circlip Fixed nut 4 Forcing Washer 5 Hollow Shaft 6 Customer Shaft ANTRIEBSTECHNIK JUR 39 ENERGIEANLAGEN Operating Instructions K Series Mounting 7 5 Shaft Tightening Torque values are as shown Tightening Torques Nm 8 20 20 20 40 40 80 80 ANTRIEBSTECHNIK 40 S E V Aj ENERGIEANLAGEN Operating Instructions K Series Mounting 7 6 Recommended shaft dimensions for KT 00 types e1 die b max bi b2 b3 ANTRIEBSTECHNIK SEVA ENERGIEANLAGEN 41 Operating Instructions K Series Mounting 7 7 Assembling customer shaft with shrink disk 7 7 1 Loosen the bolts of the shrink disk 7 7 2 Use a solvent available in your market to clean all the dirt an oil from the shaft and shrink disk hollow The surfaces must be free from oil or any dirt
35. hafts are not angular miss aligned ANTRIEBSTECHNIK 50 S E V Aj ENERGIEANLAGEN Operating Instructions K Series Lubrication 8 Maintenance and Inspections Under normal ambient and working conditions the gear unit should be checked according the following intervals For definition of normal working conditions refer to the product cata logue Selecting Gearbox section Every 3 000 work Item to check replace ing hours or every 6 i X Every 4 000 work Every 10 000 working Every 25 000 working ing hours hours or every 3 years hours x Change if neces Check Rubber buffer Check Bearings Noise Change Mineral Oil ter deo 45000 40000 35000 30000 25000 20000 15000 10000 5000 Mineral Synthetic PAO Synthetic PG Oil change interval Hours 70 80 90 100 110 120 130 140 150 160 Oil bath temperature Celcius reference For K series Mineral oil is used unless it is differently ordered For oil type and quantities refer to the following tables lil For normal ambient conditions 70 degrees Celsius oil bath temp should be taken as ANTRIEBSTECHNIK S E VAJ 51 ENERGIEANLAGEN Operating Instructions K Series Lubrication Notes
36. ications Standard Part List 9 Bolt 17 Gear 25 Output Shaft 10 Cover Plate 18 Spacer 26 Key 3 Housing 11 Key 19 Spacer 2 Gear 4 Circlip 12 Pinion Shaft 20 Circlip 28 Spacer 5 Bearing 13 Shim Ring 21 Oil Seal 29 Flange 6 Gear 14 Circlip 22 Circlip 30 Bolt 7 Pinion Shaft 15 Shim Ring 23 Bearing 8 Key 10 16 Bearing 24 Key ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions K Series Part Designations 3 5 Size K00 K20 Type 02R Standard types basic part diagram Parts may differ for special a lications Standard Part List 9 Bolt 17 Gear 25 Key 10 Cover Plate 18 Spacer 26 Key 3 Housing 11 Key 19 Spacer 2 Gear 4 Circlip 12 Pinion Shaft 20 Circlip 28 Flange 5 Bearing 13 Shim Ring 21 Oil Seal 29 Bolt 6 Gear 14 Circlip 22 Circlip 7 Pinion Shaft 15 Shim Ring 23 Bearing 8 Key ANTRIEBSTECHNIK ENERGIEANLAGEN 16 Bearing 24 Output Shaft 11 Operating Instructions K Series Part Designations 3 6 Size K00 K20 Type 03L Standard types basic part diagram Parts may differ for special a lications Standard Part List 9 Bolt 17 Gear 25 Output Shaft 10 Cover Plate 18 S
37. ied from SEVA please observe the name plate of the electric motor and the instructions of the supplier Check the basic electric connection diagrams below Use experienced electric technician Using wrong connection or voltage can damage the electric motor or environment 31 Operating Instructions K Series Checking The following wiring diagram is for standard 230 400 V 50Hz AC electric motors For different voltages please contact SEVA For gear units supplied without motor refer to the motor manufacturers user manuel A ences of earth and gearbox motor Nominal Powers at 400V 50Hz 230V A 400 V Y 400V A Leo oem I gt 4 The electric connection must be done by experienced electric technician The gearbox the motor and the brake must be grounded to prevent potential differ KW z 3kW m Basic motor connection wiring diagram Paz Principle m L1 LO L3 230V 230V U 230V 117 121 I3 Y 32 L1 L2 L3 400V 400V U m 400V 117 121 I3 Y V1 _U 48 V2 NW2 A 10 gt Ut WI Ul S Li 12 L3 Y ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions K Series Checking A Standard type brakes basic wiring diagram The electric connection must be done by experienced electric technician The gearbox and the motor must be grounded to prevent potential differences o
38. ightening the bolts and stable enough not allowing vibrations By using chain drives this becomes much more important because of the polygon effect on chain drives According to your connection elements the maximal permitted radial and axial load of the gear unit must be in accordance with your application Check the product catalogue for permitted radial loads and calculation If the output or input shaft is overloaded by radial or axial loads it can cause serious damage to the gear unit Secure the gear unit using 8 8 or higher quality bolts Cover all the turning parts from human entering or touching Turn ing parts can cause severe or fatal injuries For different kind of basic installations refer to the following illustrations 35 Operating Instructions K Series Mounting 7 1 Installing customer shaft with shoulder 7 1 1 Use anti seize assembling paste available in your market Use a brush to apply the paste 7 1 2 Fasten the bold as shown below ED 1 Short retaining bolt Standart scope of delivery Lock washer 5 Washer Circlip 5 ollow Shaft 6 Customer Shaft ANTRIEBSTECHNIK 36 S E V AJ ENERGIEANLAGEN Operating Instructions K Series Mounting 7 2 Installing customer shaft without shoulder 7 2 1 Use anti seize assembling pas
39. mounting positions of M1 to M6 are determined as reference of directional position of the gearbox Mounting surfaces are not binding ANTRIEBSTECHNIK 58 S E V Aj ENERGIEANLAGEN Operating Instructions K Series Troubleshooting Guide 10 Troubleshooting Guide All the operations bellow must be done by authorized and skilled mechanician electrician Inform SEVA before making any change to the gearbox Only oil change is allowed to change without information Do not make anything if you are not sure what you are doing and contact SEVA Any change or operation done without the information of SEVA is in your own risk and responsibility and SEVA does not take any responsibility e rem mmm Rm ooo Gearbox Does Not Start Up Gearbox Does Not Start Up Gearbox Does Not Start Up Gearbox Does Not Start Up Gearbox Does Not Start Up ANTRIEBSTECHNIK ENERGIEANLAGEN You hear no noise and shaft is not turning You are not using any driver or frequency inverter You hear no noise and shaft is not turning You are using frequency inverter or driver You hear some noise but both motor shaft and gearbox shaft is not turn ing You are not using any driver frequency inverter or braked motor You hear some noise but both motor shaft and gearbox shaft is not turn ing You are using driver or frequency inverter You hear some noise but both motor shaft and gearbox shaft is not turning You are using br
40. n Klubersynth Mobil SHC Gear EP XF 220 T 220 GEM4 220 N 220 pied Enersyn Alphasyn Kl bersynth Mobil SHC Gear EP XF 150 T 150 GEM4 150 N 150 Klubersynth GEM4 100 N Mobil SHC 627 Food CLP 45 5 495 320 _ Optileb Kl beroil 4 Mobil SHC Cassida Flu Grade Oil NSF H1 u GT 320 UH1 320 N Cibus 320 id GL 320 Biodegrad CLP Tribol BioTop Kl bersynth able Oil i Sepe MU ae 1418 320 GEM 2 320 Mineral Grease 20 120 Working Temperature C Synthetic Grease 100 Working Temperature C 30 ANTRIEBSTECHNIK ENERGIEANLAGEN Energrease LS 3 Energrease oY 2202 Spheerol Centoplex Alvania AP3 2 EP Mobilux EP 3 RL3 Petamo GHY 133 N Mobiltemp SHC100 Cassida RLS 2 53 Operating Instructions K Series 3 Lubrication 9 2 Changing the oil Refer to the nameplate to find out the correct oil filled inside the gearbox N Do not mix synthetic oils with mineral oils which will cause serious damage to the gear unit The oil change must be done by using the filling draining and level plugs according the mounting position illustrated in section 9 4 O Extended intensive contact with oils can lead to skin irritations s Avoid extended contact with oil and clean oil off skin thoroughly Hot oil can cause scalding When changing oil protect yourself against contacting hot oil 9 3 1 K 00 K 20 Two Three Stage Helical Bevel Geared Gearboxes Oil Level Plugs
41. nenenenn 42 7 8 Disassembling customer shaft with shrink diSK cece eeseeesaeeeeeeeaeeees 44 7 9 Assembling gear unit with torque arm iii 45 FIERE FING DOIA POSHO RR uu 47 7 11 K 00 K 20 Torgue arm assembly detallS ii 48 1 12 Fitting output shaft CIC SINS s so4stsitosoosv torte be ous av lav ee obria pi 49 7 12 Correct position of output shaft eleMEnts nov nn nn nn nen 49 ZR ES EN FINNO COMPAS RTT TA 50 8 Maintenance and Inspections uiucuzuzase ana Eu CENE REEF aan RARE PIER E EE SEE 51 Oa LAID FIC AU ON e 53 SSRSIUEDU YV 53 o RPA S NANIING WINS OM NN TT 54 9 3 Oil Quantities sE igekogolllo 54 studie MOUNU ado io di rs E o T 58 10 Troubleshooting E CIS o c 59 Ti LUSPOSA e 62 112 l DIEBO53 OL Ole E 62 TT 2 Disposal DIS eli S nes ee ee eier 62 11 3 Eae NITET EU ooo i eee v tady 62 Piso 63 YVALL any Ero pello n aree EO E 64 Warranty DeelarelloliSr oso ou ato to Ao een on on ts r nr 65 SENICE Comlacih IS en T 66 ANTRIEBSTECHNIK S E V Aj 03 ENERGIEANLAGEN Operating Instructions K Series General Informations 1 How
42. ng too late You are using braked motor For fast opening of big brakes over 100 Nm you may need Gearbox is starting too late You are using braked motor Shock transformators which is supplied by SEVA Go to ID 100 Please contact SEVA Service point See on the back side of this manual Changing mechanical parts of gearbox can only be Service Required No self solution found done by SEVA or with information of SEVA Any change without informing SEVA will cancel the warranty manufacturer declara tions and SEVA will take no responsibility 11 Disposal If your product is no longer of use and you wish to dispose of it refer to the instructions here If you have any questions regarding ecological disposal methods please consult our service points given on the backside of this Manuel 11 1 Disposal of Oil Lubricants oil and greases are hazardous substances which can contaminate soil and water Collect drained lubricant into suitable receptacles and dispose of it according to the valid national guidelines 11 2 Disposal of Sealings Remove the sealing rings from the gear reducer and clean them of oil and grease residues Dispose of the sealings as composite material metal plastic 11 3 Disposal of Metal Divide up the remainder of the gear reducer into iron aluminium non ferrous heavy metal if possible Dispose of it according to the valid national guidelines ANTRIEBSTECHNIK 62 S E VAJ ENERGIEANLAGEN
43. ns K Series Part Designations 3 2 Size K00 K20 Type 01L Standard types basic part diagram Parts may differ for special a lications Standard Part List 9 Bolt 17 Gear 25 Output Shaft 10 Cover Plate 18 Spacer 26 Key 3 Housing 11 Key 19 Spacer 2 Gear 4 Circlip 12 Pinion Shaft 20 Circlip 28 Spacer 5 Bearing 13 Shim Ring 21 Oil Seal 6 Gear 14 Circlip 22 Circlip 7 Pinion Shaft 15 Shim Ring 23 Bearing 8 Key 08 16 Bearing 24 Key ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions K Series Part Designations 3 3 Size K00 K20 Type 01R Standard types basic part diagram Parts may differ for special a lications Standard Part List 9 Bolt 17 Gear 25 Key 10 Cover Plate 18 Spacer 26 Key 3 Housing 11 Key 19 Spacer 2 Gear 4 Circlip 12 Pinion Shaft 20 Circlip 9 Bearing 13 Shim Ring 21 Oil Seal 6 Gear 14 Circlip 22 Circlip 7 Pinion Shaft 15 Shim Ring 23 Bearing 8 Key ANTRIEBSTECHNIK ENERGIEANLAGEN 16 Bearing 24 Output Shaft 09 Operating Instructions K Series Part Designations 3 4 Size K00 K20 Type 02L Standard types basic part diagram Parts may differ for special a l
44. nstructions K Series Troubleshooting Guide fo mme Tom Rm III Motor is running but Gear Scratching noise comes Some part key gear may be defect inside gearbox Go to ID box shaft does not turn out 10 The radial load or polygon effect of the chain may have caused the damage Check also if the assembly bolts are loosened or the plate you assemble the gearbox is rigid enough Check if you are using the correct diameter of chain drive and you are not exceeding max Allowed radial load Check the position of your output element and re calculate your radial load and check if this fit to the maximum allowed radial load Go to ID 100 You are using chain drive Gearbox Housing is Defect M or pinion gear The radial load or polygon effect of the chain may have caused the damage Check also if the assembly bolts are loosened or the plate you assemble the gearbox is rigid enough Check if you are using the correct diameter of chain drive and you are not exceeding max allowed radial load Check the position of your output element and re calculate your radial load and check if this fit to the maximum allowed radial load Go to ID 100 You are using chain drive Output Shaft is Defect Me or pinion gear Please check the wiring diagram of the brake There are two different kind of brake wiring diagram The standard gearbox delivered from our factory is set to delayed braking For sudden braking check the wiring diagram Gearbox is stoppi
45. om SEVA observe this Manuel for correct brake wiring diagram If still not work supply the brake with voltage according its nameplate directly For example 198V DC You will hear a clicking noise explaining that the brake is opening If you hear no noise the brake or rectifier is defect If you hear the clicking noise the brake is working You should this clicking noise by your normal electric connection as well By supplying direct sup ply to the brake you hear the clicking noise and at same time you supply the motor with direct voltage according to its name plate and still same problem the load may be too high for the chosen motor Go to ID 003 59 Operating Instructions K Series Troubleshooting Guide Gearbox Does Not Work in Low Speeds frequencies Gearbox Does Not Start Mornings or After Long Time Stop Gearbox is s Heating Up too Much Gearbox is Heating Up too Much Gearbox is Heating Up too Much Gearbox is noisy Gearbox is noisy 60 You are using fre quency inverter Ambient Temperature is below 5 Celsius You are using Worm Gear Box and ambi ent tenp is lower than 40 Celsius You are using Helical Gear Box Ambient temp is lower than 40 Celsius Ambient Temp is over 40 Celsius Nois is regular con tinious Nois is random For very low speeds the frequency inverters frequency is lowering down For very low frequencies the inverter parameter and motor parameter must b
46. onditions Up to 30 degree Celsius ambient temperature and up to 8 hours per day If heavy ambient conditions and long time working hours then breather plug are recommended by SEVA and delivered with the gearbox together Replace the breather plug with the most top plug accord ing to your mounting position Some plug positions are not machined according mounting position If no mounting position is mentioned by ordering the standard M1 position plugs are machined 6 7 Check the oil level On the mounting position tables the oil level plug is shown Please refer to those tables and be sure that the oil level is correct according the mounting position by screwing half way out the level plug and see if oil comes out from that plug If oil comes out tighten the plug again If no oil comes out take out the filling plug and add oil until oil comes out from the level plug and tighten both plugs after finish Be sure you are using the correct oil mentioned on the oil tables on this manual Do not mix synthetic oils with mineral which can cause serious damage on the gear unit 6 8 Check shaft ends and mounting faces Before you start to installing be sure that all the connection elements are free of oil and dust The output shaft may be protected by anti corrosion oil Please remove this using available solvents on your market By using this do not touch sealing lips or painting of the housing 6 9 Cover abrasive ambient If the gear unit will b
47. pacer 26 Gear 3 Housing 11 Key 19 Spacer 2 Spacer 4 Circlip 12 Pinion Shaft 20 Circlip 28 Flange 9 Bearing 13 Shim Ring 21 Oil Seal 29 Bolt 6 Gear 14 Circlip 22 Circlip 7 Pinion Shaft 15 Shim Ring 23 Bearing 8 Key 12 16 Bearing 24 Key ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions K Series Part Designations 3 7 Size K00 K20 Type 03R Standard types basic part diagram Parts may differ for special a lications Standard Part List 9 Bolt 17 Gear 25 Output Shaft 10 Cover Plate 18 Spacer 26 Gear 3 Housing 11 Key 19 Spacer 2 Spacer 4 Circlip 12 Pinion Shaft 20 Circlip 28 Flange 5 Bearing 13 Shim Ring 21 Oil Seal 29 Bolt 6 Gear 14 Circlip 22 Circlip 7 Pinion Shaft 15 Shim Ring 23 Bearing 8 Key ANTRIEBSTECHNIK ENERGIEANLAGEN 16 Bearing 24 Key 13 Operating Instructions K Series Part Designations 3 8 Size K00 K20 Type 04 Standard types basic part diagram Parts may differ for special a lications Standard Part List 1 Pinion 9 Bolt 17 Gear 25 Output Shaft 2 Plug 10 Cover Plate 18 Spacer 26 Key 3 Housing 11 Key 19 Spacer 2 Gear 4 Circlip 12
48. s over the gear unit housing For con necting elements refer to the mechanical installation part Bolt 4 5 Case of Fire The gear reducer itself is not combustible However it usually contains a synthetic or mineral gear oil Please observe the following if the gear reducer is situated in a burning environment 4 5 1 Suitable extinguishing agents Protective equipment Always keep suitable extinguishing protective equipment like carbon dioxide powder foam fog easily accessible around the gear unit High temperature produce irritating steam Use a protective breathing apparatus 4 5 2 Unsuitable extinguishing agents N Do not spray with water ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions K Series Safety ANTRIEBSTECHNIK ENERGIEANLAGEN 5 Things to Check Before the Gear Unit or Geared Motor is Installed If gear motors are used please also refer to the manual of the motor manufacturer Before you install the gearbox you have to be sure that the gearbox is arrived with the all necessary equipment and without damage Thinks to take into consideration before you start to install the unit You have received the correct operation manual of the your product The gearbox and all its parts are transported without damage The gearbox is stored correctly according the instructions in this manual You have the latest product catalogue or you have access to our web page 5 1 Transport
49. start the machine while you are working on it Even a brief running of the machine during maintenance work can lead to accidents if the safety devices are not operating Make sure that all safety devices are mounted and active 4 3 1 4 Lubricant Extended intensive contact with oils can lead to skin irritations Avoid extended contact with oil and clean oil off skin thoroughly Hot oil can cause scalding When changing oil protect yourself against contacting hot oil 4 3 1 5 Ambient Conditions Standard gearboxes are allowed to work in ambient temperatures between 5 to 40 celsius unless differently specified on the nameplate Using the gear unit out of this range can cause damage to the gear unit or environment Over 40 celsius ambient conditions the gear unit surface temp could be so high causing burns when touched gt PP Bb BB BP ANTRIEBSTECHNIK S E V Aj 2 ENERGIEANLAGEN Operating Instructions K Series Safety 28 A f the gear unit will be used in outdoor applications the gear unit must be prevented from rain snow and dust Entering substances inside the gear unit from seals can damage the gear unit Observe the safety instructions for outdoor use EN12100 2010 4 4 Tightening Torques All screwed connections for which a tightening torque is specified must on principle be tightened with a calibrated torque wrench and checked Use the following torques for the threaded bore
50. te available on your market Use a brush to ap ply the paste 7 2 2 Fasten the bold as shown indicated 1 Short retaining bolt Standart scope of delivery 2 Lock washer 3 Washer Circlip Customer Shaft ANTRIEBSTECHNIK ENERGIEANLAGEN 37 Operating Instructions K Series Mounting 7 3 Disassembling customer shaft with shoulder 7 3 1 Disassemble the bolt and take out the parts as shown 1 Shori Retaining Bolt 2 Lock Washer 3 Washer 4 Circlip 5 Hollow Shaft 6 Customer Shaft 7 3 2 Use the disassemble set from SEVA and fasten the bold as shown bellow to take out the output shaft For disassemble sets look the following pages 1 Retaining Bolt 2 Circlip 3 Fixed Nut 4 Forcing Washer 5 Delik Mil 6 Customer Shaft EIE na aaa ns a nn TS JB a Jana Ja FF FF ww aa wa az ZZ Js zz MN nn mr ANTRIEBSTECHNIK ENERGIEANLAGEN Operating Instructions K Series Mounting 7 4 Disassembling customer shaft without shoulder 7 4 1 Disassembly the bolt and take out the parts as shown 1 Short retaining bolt Standart scope of d 2 Lock washer 5 Washer 4 Circlip 9 Spacer 6 Hollow Shaft 7 Customer S
51. ur case go to ID 9 Housing 018 019 If you are sure oil comes out from housing than housing has some micro split crack Go to ID 100 Oi festaG nor The sealing liguid under cover is spli defect Disassemble the cover and put 020 Oil is Leaking Cover g new sealing liquid Assemble the cover and tighten the bolts If still same prob lem go to ID 100 Gearbox 021 o a You are using Torque The movement of gear box is because of the run out of the shaft which you on Arm assemble the gearbox This has no bad affect or harm to the gearbox and is g normal unless you are using torque arm point Gearbox is moving ran Vail Sree na Torde The movement of gear box is because of the run out and clearance of the shaft 022 domly on its ATA RS which you assemble the gearbox Check the clearance of the assembling shaft mounting and the clearances on your machine This has no bad affect or harm to the point gearbox unless you are using torque arm 023 iind irs x non er The motor power is not enough or some overload to the motor is possible The g up motor may be defect Go to ID 100 Horis HEAL Check the motor Fan Hub and rips They must be free of dust If you are using 023 Ambient is dusty forced external fan check if it is working If you are using frequency inverter ing up in low speeds and you do not have forced external fan you may need forced external fan Go to ID 100 ANTRIEBSTECHNIK m SEVA 61 Ex LA ENERGIEANLAGEN Operating I
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