@ vutcan, 10. Maintenance & Repair INOUSTRAL 10.1 General Information on Maintenance Note!! Properly trained personnel should carry out maintenance with care & strictly observe ‘Safety’ notes given in section 2. Caution!! Periods listed under section 10.2 are largely dependent on the conditions of use. It is thus only feasible to state average periods which relate to: © Daily operating time of 24 hours. ‘© Duty factor - operating cycle of 100% © Input speed of 1500 rpm © Max oll temperature of 90° C for Mineral oils. Note!! With different operating conditions, the period should be adjusted accordingly. 10.2 Preventive Maintenance Guide Measures Periods Remarks [Check oil temperature Daily |Check gear unit noise for Daily |changes. |Check cil level. Monthly |Check gear unit for leakage. Weekly |Check oil tor water content. [After approximately 400 hrs, at least |See 10.3.1 lonce a quarter. Initial oll change after start up |Atter approximately 400 operating [See 7.4.1 las. |Subsequent oil changes. IEvery 18 months or 5000 operating |See 7.4.2 lhrs. Better quality mineral or synthetic, lls, lite can be doubled or tripled. |Clean oil fier. lEvery 3 months or at the same time See 8.5.1 las oil change. With synthetic oils, the times can be tripled [clean air fiter (breather) lEvery 3 months or at the same time las oll change. [Clean fan, fan cow! & housing. [After every oil change. ISee 10.3.2 |Check all fixing screws for _|At same time as oil change. tightness. |Check oil-water cooler lApproximately every year or during oil lcondition. Ichange. [carry out complete inspection Once every 6 months for main drives lof gear unit |& 1 year for other drives. Page 20,10.3 10.3.1 10.3.2 @ vutcan, Description of Maintenance & Repairs INOUSTR AL Examining oil for water content — detailed information on examining oil for water is available from the lubricant manufacturer. For a rough check light oll & observe it it splatters. Splattering indicates presence of moisture. Cleaning fan & gear unit: ‘+ Shut down gear unit by shutting off the drive unit ‘© Secure against accidental start-up & affix notice at switch-on point. + Remove fan cowl ‘+ Remove ditt from fan impeller, cow! & mesh guard with a stiff brush * Clean off any corrosion. ‘© Screw the mesh guard onto the fan cowl with fixing screws. Caution!! Cleaning gear unit with high-pressure cleaning devise is not permissible. 10.3.3 10.3.4 Checking all fixing screws for tightness: + Shut down gear unit by shutting off the drive unit * Secure against accidental start-up & affix notice at switch-on point. ‘* Close stop valves in the coolant inlet & outlet lines (in case of units with oil cooling system). © Check all fixing screws for tightness with a torque wrench. Unless otherwise specified, torque to be set is given in table below. Thread size Property class Tightening torque Mio 88 60. Nm Miz 88 405 Nm Mi6 88 255 Nm M20 88 500 Nm M24 88 870 Nm M30 88 1750 Nm M36 88 3050 Nm Maz 88 4950 Nm Mag 88 7400 Nm M56 88 41700 Nm We strongly recommend inspection of gear units should be entrusted to our Service Department, as by virtue of their experience, they can most reliably assess whether & which parts must be replaced. Page 21@ vutcan, 11. Lubricants INDUSTRIAL 11.1. Nameplate affixed to the gearbox specifies cil viscosity (VG class) to be used. The viscosity class is valid for the operating conditions in the contract. 11.2 If operating parameters are altered from those specified during ordering, it is essential to contact us or it will absolve us from any guarantee/warranty 11.3 Only CLP — quality oils containing active agents to DIN 51 517-3 (draft January 2002) for increasing corrosion protection & resistance to ageing & for reducing wear in mixed-friction areas are approved. Scuffing resistance in the FZG test to DIN 51354-2 must comply with stage 12 or higher under A/8,3/90 test conditions. In the FE-8 rolling bearing test to DIN 51 819-3 rolling element & cage wear must be under 30 & 100 mg respectively under test conditions D-7, 5/80-80. 11.4 Oils selected should meet following quality requirements demanded by us: ‘+ High wear protection. + Neutral towards micro pitting ‘+ High corrosion protection. + High fiterabilty at presence of water. ‘+ Excellent oxidation stability. + Excellent deposit control + Good anti foaming properties. 11.5. Considering above, we recommend selecting a lubricant trom the table given in ‘Appendix VI, taking account of the viscosity class given on the nameplate. The listing is only a guide for reference. 11.6 We are acquainted with their composition & in accordance with our present knowledge can confirm possessing values in respect of laudabilty. Manufacturers information for oils listed confirms being manufactured & supplied worldwide as per above mentioned quality stipulations. 11.7 As a precaution against misunderstanding, the recommendation does not imply release in the sense of warranty for the quality of lubricant procured. Each manufacturer must be requested to warrant the quality of his product. 11,8 Generally supplies from India only require use of MINERAL based oils with EP additive, 11.9. ISO-VG viscosity grades normally recommended are 320 or 460 depending on application as per DIN 51519 at 40° C. 11.10. If recommendation is not followed, you will assume full responsibility for the technical suitability of the lubricant. 11.11. To minimise risk, we recommend insisting on following pre-requisites. © Oil must fulil requirements imposed of CLP oil in accordance DIN 51517. Page 22@ yuucany + Failload stage 12+ must be reached in the FZG scuffing test, pout In the micro pitting test as per FVA project 54, the oil must reach Fail Stage 10+ & must possess GFT class HIGH ‘+ Incase of synthetic oils, the corrosiveness of it to our internal coating should also be checked. 11.12. Foaming leads to break of oll film hence metal-to-metal contact thus failures. We recommend a foam test, which major producers is aware & can undertake it to contirm compliance. Criterion for assessment i ‘© Up-to 5% is good anti foaming behaviour. © Up-to 10% is satisfactory. ‘© Up-to 15% is acceptable with reservation. © Over 15% is unacceptable. + We do not recommend oils over 15 % volume increase as it has a negative influence on the load carrying capacity of the gear teeth. 11.13. Other suitable grades may also exist but their details are not available with us. A few of these formulations meet requirements of products delivered in Europe. Test results forwarded by Indian Oil appear to comply with requirements though not tested byus. 11.14 We do not guarantee suitability of any given lubricant. 11.15 Do not interchange & mix oils of various grades/manutacturers. Under no circumstances Mineral oils should be mixed with Synthetic (Polyglycols) or vice versa. 11.16 Lubrication selection 11.16.1 Synthetic lubricants (polyglycols - PG as per DIN 51502) distinguished by their high ageing resistance & favourable efficiency of the gearbox. Suitable for operating temperatures between —20° to +100°C — briefly up-to + 110°C. 11.162 Mineral oils designated CLP as per DIN 51502, comply with the minimum requirements as specified in DIN 51517, part 3. They are suitable for operating temperatures from -10° to +90" C —briefly up-to + 100° C. Notel! if the operating temperature exceeds or undershoots the limiting values given under 11.15.1 & 2, the oil selected should be checked for suitability. Page 2322 2.24 2.22 2.23 2.24 2.3 23.4 APPENDIX — Operating Instructions Hollow shaft gear units Installation & Dismantling General Information These instructions refer to hollow shafts with keys as drive connection. Hollow shafts with other types of drive connection; follow instructions as issued by us. Installation Preparation Use suitable solvent to remove rust inhibitor from the hollow shaft Check hollow & machine shaft for any damage to seat & shoulders. If required, rework with a suitable tool & clean again. Protection of fitting surfaces by application of suitable lubricant, which prevents fretting corrosion, is a must, e.g. use Molycote grease. Mounting Using mounting devices as shown in figure 1 or 2 gear units can be mounted supported via the hollow shaft. Ensure that the hollow shaft is properly aligned with the machine shaft in order to prevent any canting or twisting. For blind hollow shafts (figure 2), a mounting device according to figure 1 cannot be used & suitable locations for accepting the mounting forces must be found on the gear unit (liting lugs, lifting pins, hubs, flanges or similar). A temporary wooden ot steel bridge construction could provide such points. Extra care for mounting is necessary; do not use a hammer, because the mounting forces are transmitted through the bearings of the hollow shaft to other gear parts & bearings. ‘Axial safeguards Depending on design, the hollow shaft must be axially secured on the machine shaft (e.g. citclips, end plate, set screws etc.) Disassembly Preparation Remove axial safeguard In case of fretting/corrosion of the seating surfaces, penetrating oil should be introduced into the recessed bore with the help of a pump through holes in the machine shaft - see figure 3. In case these holes are not provided after unsuccessfully trying to pull the unit off, proceed according to 3.2. Page 24 @ wacan ee@ vutcan, 3.2 Dismantling INOUSTRAL 3.2.1 After lapse of sufficient time for the penetrating oil to react, remove the gear unit extraction devices according to figure 3 or 4, Care should be taken to prevent canting the unit during pulling off 3.2.2 In case the gear unit cannot be removed as described under 3.2.1, depending on its assembly & design, the upper part or the complete housing has to be disassembled, The extraction device is then applied directly to the wheel hub of the gear or with screws to any tapped holes present — see figure 4 3.2.3 Where the gear wheel on disassembly is not pulled against a shaft collar or other fixing attachments on the hollow shatt, it can possibly be removed from the hollow shaft including the beating positioned on the front end, after pressing out gear & repressing the other bearing. The extraction can then be applied to the shaft shoulder. 3.2.4 In case the gear housing has been disassembled & in the absence of a centre bore in the machine shaft, the hollow shaft can be provided with a suitable hole to facilitate penetrating oil injection into the recessed part of the bore — see 3.1.2. If the hollow shaft has to be reused, this hole must be closed oil ight afterwards. 3.2.5 Units without a through hollow shaft, jacking devices are applied at suitable points (hubs, flanges etc.) between gear unit & driven machine, in order to press the gear Unit off the machine shaft. Great care must be taken during pressing out as the forces are transmitted via the hollow shaft to the bearings & other gearing parts. Do not apply impact blow.1.0 ww 12 13 14 18 16 2.0 24 2.2 23 APPENDIX - Il Fitting & Removal of Shrink Disc Connection Fitting Shrink discs are supplied ready for fiting & well greased on the inside surfaces. For transportation reasons, distance pieces have been placed between the outer ring of the shrink disc, They must be removed before tightening the clamping screws. Shrink disc which have been taken a part should be re-greased on assembly, i.e. the conical ting surfaces & the inside threads. For the purpose use grease containing molybdenum disulphide, e.g. “Molycote” grease. Make sure that all screw shafts are within the sealing ring, Damage sealing ring must be replaced. When mounting the shrink disc on the wheel hub extension to be clamped, grease the seat of the disc & on the hub as well. The relatively high surface pressure in the clamping zone will prevent any fretting corrosion. The hub bore in the clamping area as well as the shaft must be absolutely free from oll or grease. The safe transmission of torque will depend on it Never tighten the screws of un-mounted shrink disc to prevent deformation of the inner ring. The wheel hub extension will be permanently deformed if the screws of the shrink disc are tightened without the application shatt in its position in the wheel hub bore. Prior to fitting the shrink disc on the wheel hub extension, draw the two outer disc lose together with the help of a spanner & a sensitive touch so that the ring can just be turned. Check the gap between the discs around the circumference to ensure the concentricity with each other. Then push the shrink disc assembly on to the hub extension. Tighten all screw carefully & equally unti the shrink disc assembly cannot bbe turned on the hub by hand. With a suitable long handle spanner tighten the screw further one after the other up to an angle of 30° approximately each time making sure the disc stays parallel to each other. Finally check the screw with a torque spanner set to the desired value. Removing the shrink disc Release the screws equally one by one in several stages so as to avoid tilting the disc. The taper angle of the disc has been made so acute that the shrink disc set will open up with certainty. The shaft hub will widen again while the shrink disc remain in position, Notel! Do not remove screws completely before the outer rings have left their taper seat. First remove any rust, which may have found on the shaft adjacent to the hub. Before using the shrink disc again dismantled if possible & apply new grease at the appropriate places. Check the sealing ring, it may require replacement, the screws must be able to run well & easy into their corresponding taped hole. Page 26 @ wacan eeww 12 13 24 22 23 24 34 32 3.3 44 42 APPENDIX iit Backstop Mounting & Operating Instruction General informat Backstops permit only one direction of rotation. They may be mounted either in a horizontal or vertical position. Backstops of types RS/BI & FXM incorporate locking members, who are lifted by centrifugal force; inner race 2 with cage 3 rotates whilst outer ring 1 remains stationary. As a rule gear units are furnished with backstops fitted, If supplied separately to be build on by the user, attention should be paid to permissible eccentricity & angular deviations. Mounting Clean shaft end & centring location on housing or intermediate flange. Check direction of rotation conforms to the desired rotation, The backstop is mounted in the assembled condition, The outer ring of type FXM has a chamfer on both ends, whereas only one chamfer is there on the outer ring of type RS/BI. This chamfer must be positioned such that it is not pointing towards the centring spigot. If it is the case, dismount outer race & refit, turned through 180°, Inner race is mounted on the shaft, by a parallel key to DIN 6885/1: an end plate or Circip prevents axial movement, Careful & uniform application of heat to the inner race will facilitate mounting. ‘The outer ring 1 is either screwed directly onto the housing or an oil tight connection to it is effected via an adaptor flange. Sealing compound must be used carefully to prevent it coming into contact with the locking elements & thus impairing its correct function Operation Bofore starting, check the backstop can be rotated easily by hand in the direction of rotation required To avoid damage, do not run the motor prior to ensuring desired direction of rotation which may be safe guarded by: ‘+ Removal of the cage. + Dismantling of the coupling between the motor & gear unit * Prior to wiring the motor to the mains, check the rotating field with a phase sequence indicator. Fill required oil quantity prior to intial use &/or long storage, via the oil fiter opening provided, Oil filed should be exactly same as that in the gearbox. Maintenance Backstops with idling speeds above lift off speeds are not subject to wear & do not require lubrication. Some form of corrosion protection will suffice. For corrosion protection, oil the components before assembly, using acid free age resisting thin oil. Page 27 @ wacan ee64 62 63 7A a1 82 83 a4 85 86 @ yutcan Avoid over filing as this may impair movement of the locking members. AoUSTRAL Normally the backstop is mounted on a gear unit & is lubricated through the gearbox oil Oil Change & Cleanin The oil should be changed along with that of the gearbox without fail. Dismantling To dismantle, unscrew outer ring 1 which has withdrawal threads of same size as the screw threads. ‘After removing the retaining ring 4 the cage 3 can be withdrawn by using the tapped holes for that screws. Do not insert these screws further than the thickness of the cage side plates. The cage can be removed by hand, by slowly turning it in the idling direction — no special tools are required. Remove inner race by means of an extractor after that axial safeguards have been removed. Unlocking The unit is unlocked by withdrawal of cage 3. Reversi f rotation of, ct jon To reverse the direction of rotation, the cage 3 is to be turned by 180°. First remove circlip 4, withdraw cage, turn & refit it into the locking gap, Remounting will be easier if locking members are tied down against the spring force, When the locking members are correctly centred between inner race & outer ring, remove the tie & push the cage home completely. While inserting the cage of type RS/BI the screw or dog should be positioned between the circlip ends 4. Apply axial pressure lightly — turn cage in the idling direction until screw head snaps , into position. — Fit the second circlip 4 for type RSIBI: it also requires its ends positioned on either side of the —e screw. Design with, ShaftStep Check locking direction, close cover, using sealant, tighten screws with appropriate torque. Unlock or reversal of direction is not possible under load. Page 28APPENDIX VI Lubricating Oils & Preservatives, OD wacan He Code | Viscosity Oils fer Helical Bevel Helical & Planetary Gear Unite Lubricant Iso-ve DN s15t9.a40" | arat Bechem | OKs Castrol Emme) Degsl BG 480+ | Geo Gear |Mo.-Actve | Apha SP 460 [ Tribal Opigear ars | VS460 [Deporswe460"| 460m | 460 [AlpnaManaeo | 11000460 | BM 460 5 Dogo! 86.920 | Eco Gear |MoActve| AphasP 220 | trbat | opuigear Mineratoite| A | S320 | seam 320 ‘100320 | at 320 Degol BMBS20 ‘Alpha Maceo DegolBG 220+ | Eco Gear |Mo,-Rctve| Alpha SP 220 | trbot | onigear ais | va220 ‘ Sopa BT] 2M | 22 ba apesaan | 1190220 | aM 200 Berusynth Tibor [Opin A ara] vosso | depoics aso | Berusyn anita, [Pri Borusyath Tibot —[Opitiex A Potystyeots| Az24 | vasz0 | Degaiasaz0 | Perusynt anita, [Pies : Berusyath Tibol [Optiox A 26] ver20 | Degas 220 | Berusyn anita, [Pato aa egal Eco Gear ‘Aphasyn EP | Tibot ~JOptgear Aas | vese0 | Degol Pas 460 | “teas 460 | r7i0ie0 | A460. Poly-or- oa Eco Gear ‘iphasyn EP | Tibol | Optigear storm | 424 | _VE320 | Degot Pas 320 | “Gps 320 [710920 | A320 a ga Eco Gear ‘phasynEP | Tubal [Optgear ag | vG220 | Degat Pas 220 | To20'§ 220 | r7i0z20 | A220 Page 29