Sew Eurodrive SPIROPLAN Operating Instructions
Drive Technology \ Drive Automation \ System Integration \ Services
Assembly and Operating Instructions
Gear Units
R..7, F..7, K..7, K..9, S..7, SPIROPLAN
®
W
Edition 10/2013 20200544 / EN
SEW-EURODRIVE—Driving the world
Contents
Contents
1 General Information............................................................................................ 5
1.1 How to use this documentation................................................................... 5
1.2 Structure of the safety notes......................................... ... ........................... 5
1.3 Rights to claim under warranty ................................................................... 6
1.4 Content of the documentation..................................................................... 6
1.5 Exclusion of liability..................................................................................... 6
1.6 Product names and trademarks.................................................................. 6
1.7 Copyright..................................................................................................... 6
2 Safety Notes ........................................................................................................ 7
2.1 Preliminary information ............................................................................... 7
2.2 General information ................................................................ ... ... .............. 7
2.3 Target group ............................................................................................... 8
2.4 Designated use............................................. ... ... .... ... ... ... .... ....................... 8
2.5 Other applicable documentation................................................................. 8
2.6 Transport/storage........................................................................................ 9
2.7 Setup........................................................................................................... 9
2.8 Startup/operation ........................................................................................ 9
2.9 Inspection/maintenance.............................................................................. 9
3 Gear Unit Structure........................................................................................... 10
3.1 Basic structure of helical gear units .......................................................... 10
3.2 Basic structure of parallel-shaft helical gear units..................................... 11
3.3 Basic structure of helical-bevel gear units K..9......................................... 12
3.4 Basic structure of helical-bevel gear units K..37 – K..187........................ 13
3.5 Basic structure of helical-worm gear units ................................................ 14
3.6 Basic structure of SPIROPLAN
3.7 Basic structure of SPIROPLAN
3.8 Nameplate/type designation ............................ ... .... ... ... ... .... ... ... ... ... .... ... .. 17
4 Mechanical Installation..................................................................................... 18
4.1 Required tools/resources.......................................................................... 18
4.2 Installation requirements........................................................................... 19
4.3 Installing the gear unit............................................................................... 20
4.4 Gear units with solid shaft......................................................................... 27
4.5 Torque arms for shaft-mounted gear units................................................ 29
4.6 Shaft-mounted gear units with keyway or splined hollow shaft................. 32
4.7 Shaft-mounted gear units with shrink disk ................................................ 39
4.8 Shaft-mounted gear units with TorqLOC
4.9 Installing the protective cover ................................................................... 55
4.10 Coupling of AM adapters ................................. ... .... ... ... ... .... ... ... ... ... .... ... .. 57
4.11 AQ. adapter coupling ................................................................................ 61
4.12 EWH adapters............... ...... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ...... ... ... .... ... .. 64
4.13 AD input shaft assembly ........................................................................... 66
4.14 Accessory equipment................................................................................ 71
®
gear units W..10 – W..30...................... 15
®
gear units W..37 – W..47...................... 16
®
................................................ 43
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
3
Contents
5 Startup................................................................................................................ 80
5.1 Checking the oil level................................................................................ 81
5.2 Pseudo-leakage at shaft seals.................................................................. 81
5.3 Helical-worm and SPIROPLAN
5.4 Helical/parallel-shaft helical/helical-bevel gear units................................. 83
5.5 Gear units with backstop........................................................................... 83
5.6 Components made of elastomers with fluorocarbon rubber ..................... 84
6 Inspection/Maintenance ................................................................................... 85
6.1 Preliminary work regarding gear unit inspection/maintenance ................. 85
6.2 Inspection/maintenance intervals.............................................................. 86
6.3 Lubricant change intervals........................................................................ 87
6.4 Inspection/maintenance for the AL / AM / AQ. / EWH adapter ................. 88
6.5 Inspection/maintenance for the AD input shaft assembly......................... 88
6.6 Inspection/maintenance for the gear unit.................................................. 89
7 Mounting Positions......................................................................................... 104
7.1 Designation of the mounting positions................................................. ... 104
7.2 Churning losses ...................................................................................... 105
7.3 Mounting position MX ............................................................................. 105
7.4 Universal mounting position M0.............................................................. 105
7.5 Mounting positions of SPIROPLAN
7.6 Key.......................................................................................................... 106
7.7 Helical gearmotors R ................................................................. ............. 107
7.8 Helical gearmotors RX........................................ .... ... ............................. 110
7.9 Parallel-shaft helical gearmotors F ......................................................... 112
7.10 Helical-bevel gearmotors K..................................................................... 115
7.11 Helical-worm gearmotors S..................................................................... 123
7.12 SPIROPLAN
®
W gearmotors. .... ... ... ... .... ... ... .......................................... 129
8 Technical Data................................................................................................. 135
8.1 Extended storage ................................................................................... 135
8.2 Lubricants ............................................................................................... 136
9 Malfunctions.................................................................................................... 145
9.1 Gear units ............................................................................................... 145
9.2 Adapters AM / AQ. / AL / EWH ............................................................... 146
9.3 AD input shaft assembly ......................................................................... 147
9.4 Customer service ................................................................................... 147
9.5 Disposal .................................................................................................. 147
®
W gear units .......... ... ... .... ... ... ... ... .... ... .. 82
®
gear units...................................... 106
10 Address list...................................................................................................... 148
Index................................................................................................................. 160
4
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
General Information
How to use this documentation
1
1 General Information
Gear Units R..7, F..7, K..7, K ..9, S..7, SPIROPLAN® W
1.1 How to use this documentation
The documentation is an integral part of the product and contains impo rtant information
on operation and service. The documentation is written for all employees wh o assemble,
install, start up, and service this product.
The documentation must be accessible and legi ble. Make sure that persons responsible
for the system and its operation, as well as persons wh o work independently on the unit,
have read through the documentation carefully and understood it. If you are unclear
about any of the information in this documentation, or if you require further information,
contact SEW-EURODRIVE.
1.2 Structure of the safety notes
1.2.1 Meaning of signal words
The following table shows the graduation and meaning of the signal words for safety
notes, warnings regarding potential risks of damage to property, and other notes.
Signal word Meaning Consequences if disregarded
DANGER! Imminent hazard Severe or fatal injuries
WARNING! Possible dangerous situation Severe or fatal injuries
CAUTION! Possible dangerous situation Minor injuries
NOTICE Possible damage to property Damage to the drive system or its envi-
NOTE Useful information or tip: Simpli-
fies handling of the drive system.
ronment
1.2.2 Design of the section-related safety notes
Section-related safety notes do not apply to a specific action, but to se veral actions per taining to one subject. The symbols used either indicate a general hazard or a specific
hazard.
This is the formal structure of a safety note for a specific section:
SIGNAL WORD!
Type and source of danger.
Possible consequence(s) if disregarded.
• Measure(s) to prevent the danger.
1.2.3 Design of the embedded safety notes
Embedded safety notes are directly integrated into the instructions just before the description of the dangerous action.
This is the formal structure of an embedded safety note:
• SIGNAL WORD! Type and source of hazard.
Possible consequence(s) if disregarded.
– Measure(s) to prevent the hazard.
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
5
1
General Information
Rights to claim under warranty
1.3 Rights to claim under warranty
A requirement of fault-free operation and fulfillment of any rights to claim under limited
warranty is that you adhere to the information in the documentation. Therefore read the
documentation before you start working with the unit.
1.4 Content of the documentation
This document contains additional safety-related information and conditions for operation in safety-related applications.
1.5 Exclusion of liability
You must comply with the information contained in this documentation to ensure safe
operation and to achieve the specified product characteristics and performance features. SEW-EURODRIVE assumes no liability for injury to persons or damage to equipment or property resulting from non-observance of the se operating instructions. In such
cases, any liability for defects is excluded.
1.6 Product names and trademarks
All product names in this documentation are trademarks or registered trademarks of
their respective titleholders.
1.7 Copyright
© 2013 – SEW-EURODRIVE. All rights reserved.
Unauthorized reproduction, modification, distribution or any other use of the whole or
any part of this documentation is strictly prohibited.
6
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
2 Safety Notes
The following basic safety notes must be read carefully to prevent injury to persons a nd
damage to property. The operator must ensure that the basic safety notes a re read and
adhered to. Make sure that persons responsible for the system and its operation, as
well as persons who work independently on the unit, have read through the operating
instructions carefully and understood them. If you are unclear about any of the inform ation in this documentation or if you require further information, please contact SEWEURODRIVE.
2.1 Preliminary information
Safety Notes
Preliminary information
2
The following safety notes are primarily concerned with the use of th e followin g components: Gear unit series R..7, F..7, K..7, K..9, S..7, SPIRO PLAN
gearmotors, you must also observe the safety notes for motors in the correspondin g operating instructions.
Also observe the supplementary safety notes in the individual sections of this documentation.
2.2 General information
WARNING
Danger of fatal injury or risk of injury during the operation of motors or gearmotors
caused by live, bare (in the event of open connectors/terminal boxes) and movable or
rotating parts.
Risk of burns caused by hot surfaces
Severe or fatal injuries
• All work related to transport, storage, installation, assembly, connection, startup,
maintenance and repair may only be carried out by qualified personnel.
• For transport, storage, installation, assembly, connection, startup, maintenance
and repair it is important that you adhere to the information in the following documents:
– Warning and safety signs on the motor/gearmotor
– All the project planning documents, startup instructions and wiring diagrams re-
lated to the drive
– System-specific regulations and requirements
– National/regional regulations governing the safety and prevention of accidents
• Never install damaged products.
• Never operate or energize the unit without the necessary protection covers or
housing.
• Use the unit only for its intended purpose.
• Make sure the unit is installed and operated properly.
®
W. If you are using
INFORMATION
In the event of damage caused by transport, submit a complaint to the shipping company immediately.
This documentation provides additional information.
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
7
2
2.3 Target group
Safety Notes
Target group
Any mechanical work may only be performed by adequately qualified person nel. Qualified personnel in the context of this documentation are persons familiar with the design,
mechanical installation, troubleshooting and servicing of the product who possess the
following qualifications:
• Training in mechanical engineering, e.g. as a mechanic or mechatronics technician
(final examinations must have been passed).
• They are familiar with these operating instructions.
Any electronic work may only be per form ed by adequately qualified electricians. Qualified electricians in the context of this documentation are persons familiar with electrical
installation, startup, troubleshooting and servicing of the product who possess the
following qualifications:
• Training in electrical engineering, e.g. as an electrician, electronics or mechatronics
technician (final examinations must have been passed).
• They are familiar with these operating instructions.
All work in further areas of transportation, stor age, operation and was te disposal must
only be carried out by persons who are trained appropriately.
All qualified personnel must wear appropriate protective clothing.
2.4 Designated use
The gear unit series R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W is intended for use in
industrial systems.
The gear units may only be used according to the specifications in the technical documentation from SEW-EURODRIVE as well as the specifications on the nameplate. They
fulfill the applicable standards and regulations.
When installed in machines, startup (i.e. start of designated operation) is prohibited until
it is determined that the machine complies with the local laws and directives. In the individual area of application, you must especially observe the Machinery Directive
2006/42/EC as well as the EMC Directive 2004/108/EC. The EMC test specifications
EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-6 and EN 61000-6-2 form
the basis for this.
Use in potentially explosive atmospheres is prohibited unless specifically designated
otherwise.
2.5 Other applicable documentation
The following publications and documents have to be observed as well:
• "DR.71 – 225, 315 AC Motors" operating instructions for gearmotor s
• Operating instructions of any attached options
• "Gear Units" catalog or
• "Gearmotors" catalog
8
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
2.6 Transport/storage
Inspect the shipment for any damage that may have occurred in transit as soon as you
receive the delivery. Inform the shipping com pany immediately in the event of damage.
It may be necessary to preclude startup.
Tighten the eyebolts securely. They are designed to carry only the weight of the
motor/gearmotor; do not attach any additional loads.
The built-in lifting eyebolts comply with DIN 580. Always observe the loads and regulations listed in this standard. If the gearmotor is equipped with two eyebolts, then both
should be used for transportation. In this case, the tension force vector of the slings must
not exceed a 45° angle according to DIN 580.
Use suitable, sufficiently rated handling equipment if required. Reattach these in the
case of further transportation.
Store the motor/gearmotor in a dry, dust-free environment if it is not to be installed
straight away. You must not store the motor/gearmotor outdoors or on the fan guard.
The motor/gearmotor can be stored for up to 9 months without requiring any special
measures before startup.
Safety Notes
Transport/storage
2
2.7 Setup
NOTICE
Danger due to static overdetermination if gear units with foot (e.g. KA19/29B,
KA127/157B or FA127/157B) are mounted both via the torque arm and via the foot
plate.
Risk of injuries and damage to property.
• Especially with the KA.9B/T variant, it is not permitted to use the foot plates and the
torque arm at the same time.
• The KA.9B/T variant may only be mounted via torque arms.
• K.9 or KA.9B variants may only be mounted via the foot plate.
• If you want to use foot plates and torque arms for mounting, consult with SEW- EURODRIVE.
Observe the notes in the "Mechanical Installation" section.
2.8 Startup/operation
Check the oil level before startup as described in chapter Inspection/Maintenance
(page 85).
Check that the direction of rotation is correct in decoupled status. Listen out for unusual
grinding noises as the shaft rotates.
Secure keys for test mode without output elements. Do not deactivate monitoring and
protection equipment even in test mode.
Switch off the gearmotor if in doubt whenever changes occur in rela tion to normal o peration (e.g. increased temperature, noise, vibration). Determine the cause and contact
SEW-EURODRIVE, if required.
2.9 Inspection/maintenance
Observe the notes in chapter "Inspection/Maintenance".
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
9
3
Gear Unit Structure
Basic structure of helical gear units
3 Gear Unit Structure
INFORMATION
The following figures are block diagrams. Their purpose is only to make it easier to assign components to the spare parts lists. Discrepancies may occur depending on the
gear unit size and version.
3.1 Basic structure of helical gear units
[8]
Pinion
[1]
Gear
[2]
Pinion shaft
[3]
Gear
[4]
Pinion shaft
[5]
Gear
[6]
Output shaft
[7]
Key
[8]
Oil seal
[9]
Rolling bearing bearing
[11]
Retaining ring
[12]
Spacer tube
[17]
[181]
[41]
[7]
[131]
[42]
[19]
[39]
[2]
[43]
[3]
[9]
[37]
[506]
[507]
[508]
Key
[19]
Breather valve
[20]
Gear unit housing
[22]
Eyebolt
[24]
Rolling bearing
[25]
Rolling bearing
[30]
Key
[31]
Spacer tube
[32]
Rolling bearing
[34]
Rolling bearing
[37]
Retaining ring
[39]
Retaining ring
[41]
[12]
[31]
[45]
[11]
[5]
[515]
[516]
[517]
[47]
[17]
[6]
[34]
[25]
[88]
[42]
[43]
[45]
[47]
[59]
[88]
[100]
[101]
[102]
[131]
[181]
[506]
[101]
[100]
[102]
[59]
[521]
[522]
[523]
[30]
[32]
[4]
Rolling bearing
Key
Rolling bearing
Retaining ring
Screw plug
Retaining ring
Inspection cover
Hex head screw
Gasket
Closing cap
Closing cap
Shim
[59]
[20]
[507]
[508]
[515]
[516]
[517]
[521]
[522]
[523]
[24]
[1]
[22]
[59]
19194251
Shim
Shim
Shim
Shim
Shim
Shim
Shim
Shim
10
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
Gear Unit Structure
[181]
[41]
[517]
[508]
[516]
[507]
[515]
[506]
[42]
[3]
[43]
[2]
[45]
[30]
[59]
[101]
[100]
[102]
[160]
[165]
[161]
[59]
[59]
[20]
[22]
[1]
[521]
[522]
[523]
[25]
[88]
[183]
[32]
[4]
[31]
[5]
[37]
[39]
[131]
[14]
[16]
[81]
[9]
[11]
[17]
[6]
[7]
[91]
[92]
[93]
[94]
[19]
Basic structure of parallel-shaft helical gear units
3.2 Basic structure of parallel-shaft helical gear units
3
Pinion
[1]
Gear
[2]
Pinion shaft
[3]
Gear
[4]
Pinion shaft
[5]
Gear
[6]
[7]
[9]
[11]
[14]
[16]
[17]
[19]
[20]
Hollow shaft
Oil seal
Rolling bearing bearing
Hex head screw
Output flange
Spacer tube
Key
Breather valve
Gear unit housing
[22]
Rolling bearing
[25]
Rolling bearing
[30]
Key
[31]
Spacer tube
[32]
Rolling bearing
[37]
Retaining ring
[39]
Retaining ring
[41]
Rolling bearing
[42]
Key
[43]
Rolling bearing
[45]
Screw plug
[59]
Shield ring
[81]
Retaining ring
[88]
Retaining ring
[91]
Washer
[92]
Lock washer
[93]
Hex head screw
[94]
Inspection cover
[100]
Hex head screw
[101]
Gasket
[102]
Closing cap
[131]
Closing plug
[160]
Closing cap
[161]
Closing plug
[165]
Closing cap
[181]
Oil seal
[183]
[506]
[507]
[508]
[515]
[516]
[517]
[521]
[522]
[523]
19298059
Shim
Shim
Shim
Shim
Shim
Shim
Shim
Shim
Shim
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
11
3
[9]
[12]
[518]
[519]
[520]
[11]
[17]
[36]
[24]
[1]
[29]
[26]
[44]
[115]
[163]
[530]
[531]
[532]
[2]
[45]
[141]
[42]
[536]
[537]
[538]
[43]
[5]
[150]
[7]
[80]
[183]
[48]
[8]
[7]
[19]
[59]
[159]
[88]
[521]
[522]
[523]
[25]
[6]
[167]
[59]
[22]
[106]
[20]
[89]
Gear Unit Structure
Basic structure of helical-bevel gear units K..9
3.3 Basic structure of helical-bevel gear units K..9
Pinion
[1]
Gear
[2]
Pinion shaft
[5]
Gear
[6]
Output shaft
[7]
Key
[8]
Oil seal
[9]
Deep groove ball bearing
[11]
Retaining ring
[12]
Spacer tube
[17]
Key
[19]
Breather valve
[20]
Gear unit housing
[22]
Eyebolt
[24]
Deep groove ball bearing
[25]
[26]
[29]
[36]
[42]
[43]
[44]
[45]
[48]
[59]
[62]
[63]
Housing stage 1
Gasket
Stud
Tapered roller bearing
Key
Gasket
Tapered roller bearing
Supporting ring (only K..29)
Screw plug
Screw plug
Thread reduction
Key
[80]
Retaining ring
[88]
Closing cap
[89]
Stud
[106]
Retaining ring
[115]
Bushing
[141]
Hex nut
[150]
Closing plug
[159]
Supporting ring
[163]
Closing plug
[167]
Oil seal
[183]
Shim
[518]
Shim
[519]
[520]
[521]
[522]
[523]
[530]
[531]
[532]
[536]
[537]
[538]
7421610507
Shim
Shim
Shim
Shim
Shim
Shim
Shim
Shim
Shim
Shim
12
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
Gear Unit Structure
[100]
[102]
[3]
[101]
[43]
[538]
[535]
[537]
[534]
[536]
[533]
[42]
[119]
[45]
[2]
[20]
[22]
[59]
[59]
[59]
[59]
[1]
[114]
[113]
[116]
[89]
[59]
[88]
[521]
[522]
[523]
[25]
[84]
[19]
[8]
[7]
[6]
[17]
[83]
[11]
[12]
[9]
[37]
[5]
[4]
[30]
[135]
[542]
[543]
[544]
[133]
[132]
[161]
[31]
[506]
[507]
[508]
[137]
[39]
[131]
Basic structure of helical-bevel gear units K..37 – K..187
3.4 Basic structure of helical-bevel gear units K..37 – K..187
3
[25]
[30]
[31]
[37]
[39]
[42]
[43]
[45]
[59]
[83]
[84]
[88]
[89]
[100]
[101]
Pinion
[1]
Gear
[2]
Pinion shaft
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[11]
[12]
[17]
[19]
[20]
[22]
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
Gear
Pinion shaft
Gear
Output shaft
Key
Oil seal
Rolling bearing bearing
Retaining ring
Spacer tube
Key
Breather valve
Gear unit housing
Rolling bearing
Rolling bearing
Key
Rolling bearing
Retaining ring
Rolling bearing
Key
Rolling bearing
Screw plug
Shield ring
Shield ring
Retaining ring
Closing cap
Inspection cover
Hex head screw
Gasket
[102]
Slotted nut
[113]
Lock washer
[114]
Threadlocker
[116]
Spacer tube
[119]
Closing cap
[131]
Retaining ring
[132]
Supporting ring
[133]
Shield ring
[135]
Closing cap
[161]
Shim
[506]
Shim
[507]
Shim
[508]
Shim
[521]
Shim
[521]
[522]
[523]
[533]
[534]
[535]
[536]
[537]
[538]
[542]
[543]
[544]
19301131
Shim
Shim
Shim
Shim
Shim
Shim
Shim
Shim
Shim
Shim
Shim
13
3
[131]
[39]
[137]
[507]
[506]
[37]
[5]
[43]
[30]
[9]
[12]
[520]
[519]
[518]
[11]
[6]
[7]
[25]
[88]
[89]
[59]
[523]
[522]
[521]
[19]
[2]
[59]
[102]
[101]
[59]
[20]
[22]
[1]
[100]
[61]
Gear Unit Structure
Basic structure of helical-worm gear units
3.5 Basic structure of helical-worm gear units
Pinion
[1]
Gear
[2]
Worm gear
[5]
Worm gear
[6]
Output shaft
[7]
Oil seal
[9]
Rolling bearing bearing
[11]
Retaining ring
[12]
Key
[19]
Breather valve
[20]
Gear unit housing
[22]
Rolling bearing
[25]
Rolling bearing
[30]
Rolling bearing
[37]
Retaining ring
[39]
Key
[43]
Screw plug
[59]
Retaining ring
[61]
Retaining ring
[88]
Closing cap
[89]
Inspection cover
[100]
Hex head screw
[101]
Gasket
[102]
Closing cap
[131]
Supporting ring
[137]
Shim
[506]
Shim
[507]
[518]
[519]
[520]
[521]
[522]
[523]
19304203
Shim
Shim
Shim
Shim
Shim
Shim
14
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
Gear Unit Structure
[1]
[68]
[72]
[143]
[66]
[71]
[65]
[100]
[102]
[22]
[89]
[521]
[522]
[523]
[88]
[25]
[6]
[250]
[251]
[17]
[7]
[11]
[8]
[19]
[518]
[519]
[520]
[12]
[9]
[101]
Basic structure of SPIROPLAN® gear units W..10 – W..30
3.6 Basic structure of SPIROPLAN® gear units W..10 – W..30
3
Pinion
[1]
Gear
[6]
Output shaft
[7]
Key
[8]
Oil seal
[9]
Rolling bearing bearing
[11]
[12]
[17]
Retaining ring
Spacer tube
Key
[19]
[22]
[25]
[65]
[66]
[68]
[71]
[72]
Gear unit housing
Rolling bearing
Oil seal
Rolling bearing bearing
Retaining ring
Supporting ring
Retaining ring
[88]
[89]
[100]
[101]
[102]
[143]
[250]
[251]
Retaining ring
Closing cap
Inspection cover
Hex head screw
Gasket
Supporting ring
Retaining ring
Retaining ring
[518]
[519]
[520]
[521]
[522]
[523]
19307275
Shim
Shim
Shim
Shim
Shim
Shim
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
15
3
Gear Unit Structure
Basic structure of SPIROPLAN® gear units W..37 – W..47
3.7 Basic structure of SPIROPLAN® gear units W..37 – W..47
[518]
[519]
[520]
[12]
[9]
Pinion
[1]
Gear
[2]
Pinion shaft
[5]
Gear
[6]
Output shaft
[7]
Key
[8]
Oil seal
[9]
Deep groove ball bearing
[11]
Retaining ring
[12]
Key
[19]
[11]
[8]
[19]
[7]
[59]
Gear unit housing
[22]
Deep groove ball bearing
[25]
Housing stage 1
[26]
Deep groove ball bearing
[30]
Key
[31]
Spacer tube
[32]
Retaining ring
[33]
Hex head screw
[36]
Deep groove ball bearing
[37]
O-ring
[44]
[22]
[44]
[133]
[506]
[6]
[37]
[59]
[61]
[88]
[89]
[133]
[137]
[506]
[518]
[519]
[520]
[521]
[522]
[523]
[25]
[59]
[5]
[31]
[30]
Screw plug
Retaining ring
Retaining ring
Closing cap
Shim
Shim
Shim
Shim
Shim
Shim
[88]
[137]
[2]
[89]
[61]
[26]
[5]
[1]
[521]
[522]
[523]
[33]
[32]
[36]
9007199860613387
Shim
Shim
Shim
16
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
3.8 Nameplate/type designation
76646 Bruchsal
na
Mamax
Nm
Memax
Nm
IM
i
kg
M1A
70,46
105
2700
r/min
1400/20
K87 AD4
Made in Germany
06415911
CLP HC 220 Synth. Öl / 3,71l
41
3.8.1 Nameplate
The following figure shows an example of a nameplate for a helical-bevel gear unit with
input cover:
Gear Unit Structure
Nameplate/type designation
4472018699
3
n
a
M
amax
M
emax
i Gear unit ratio
IM Mounting position
3.8.2 Type designation
Helical-bevel gear
units
A helical-bevel gear unit with AQ adapter has, for example, the following type designation:
[r/min] Maximum permitted output speed
[Nm] Maximum permitted output torque
[Nm] Maximum permitted input torque
K37/RAQA80/1
Variants
Flange classification
Adapter designation: e.g. for servomotors
- AQA: Adapter with keyway
- AQH: Adapter with clamping ring hub
Option: e.g. for servo gear units .../ R:
Reduced circumferential backlash
Gear unit size: e.g. B. 37
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
Gear unit type: e.g. K
17
4
Mechanical Installation
Required tools/resources
4 Mechanical Installation
4.1 Required tools/resources
• Set of wrenches
• If necessary, torque wrench for:
– Shrink disks
– Motor adapter AQH Or EWH
– Input shaft assembly with centering shoulder
• Mounting device
• Compensation elements (shims, spacing rings)
• Fasteners for input and output elements
• Lubricant (e.g. NOCO
®
Fluid)
• Bolt locking compound (for input shaft assembly with centering shoulder), e.g.
Loctite
Standard parts are not included in the delivery
4.1.1 Installation tolerances
Shaft end Flanges
Diameter tolerance in accordance with DIN 748
• ISO k6 for solid shafts with Ø ≤ 50 mm
• ISO m6 for solid shafts with Ø > 50 mm
• ISO H7 for hollow shafts
• Center bore in accordance with DIN 332, shape
DR
®
243
Centering shoulder tolerance to DIN 42948
• ISO j6 for b1 ≤ 230 mm
• ISO h6 with b1 > 230 mm
18
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
4.2 Installation requirements
CAUTION
Risk of injury due to protruding gear unit parts.
Minor injuries.
• Keep a sufficient safety distance to the gear unit/gearmotor.
NOTICE
Damage to the gear unit/gearmotor due to improper installation.
Possible damage to property
• Strictly adhere to the notes in this chapter.
Make sure that the following requirements are met before you start installing the unit:
• The drive has not been damaged during transportation or storage.
Mechanical Installation
Installation requirements
4
• The entries on the nameplate of the gearmotor match the voltage supply system.
• When the unit is installed in abrasive ambient conditions, protect the output end oil
seals against wear.
• The output shafts and flange surfaces must be completely free from anti-corrosion
agents, contamination or similar. Use a commercially available solvent for cleaning.
Do not expose the sealing lips of the oil se als to the solvent – damage to the material.
• For standard drives:
– Ambient temperature according to the technical documentation, nameplate and
lubricant table in section "Lubricants".
– No harmful oils, acids, gases, vapors, radiation etc. in the vicinity
• For special designs:
– The drive is designed in accordance with the ambien t conditions. Observe the in-
formation on the nameplate.
®
• For helical-worm/SPIROPLAN
– No large external mass moments of inertia which could ex ert a retrodriving load
on the gear unit.
– Self-locking with η’ (retrodriving) < 0.5;
Calculation : η’ = 2 – 1/η
• For servomotor mounting:
– Do not assemble the drive without having ensured that there will be sufficient ven-
tilation after installation to prevent heat build-up.
W gear units:
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
19
4
Mechanical Installation
Installing the gear unit
4.3 Installing the gear unit
NOTICE
Danger due to static overdetermination if gear units with foot (e.g. KA19/29B,
KA127/157B or FA127/157B) are mounted both via the torque arm and via the foot
plate.
Risk of injuries and damage to property.
• Especially with the KA.9B/T variant, it is not permitted to use the foot plates and the
torque arm at the same time.
• The KA.9B/T variant may only be mounted via torque arms.
• K.9 or KA.9B variants may only be mounted via the foot plate.
• If you want to use foot plates and torque arms for mounting, consult with SEWEURODRIVE.
CAUTION
Improper installation may result in damage to the gear unit or gearmotor.
Possible damage to property.
• Protect the gear unit from direct cold air currents. Condensation may cause water
to accumulate in the oil.
• It is important that you observe the notes in this chapter.
CAUTION
Risk of trapping and crushing due to improper disassembly of heavy components.
Risk of injury.
• Remove the shrink disk properly.
• Work on the gear unit only when the machine is at a standstill. Secure the drive unit
against unintentional power-up.
The gear unit or gearmotor is only allowed to be installed in the specified mounting
position. Observe the information on the nameplate. SPIROPLAN
W10 – W30 are mounting position-independent.
The support structure must have the followin g fe at ur es :
• Level
• Vibration damping
• Torsionally rigid
The following table shows the ma ximally permit ted flatne ss defect for foot- an d flange-
mounting (guide values based on DIN ISO 1101) :
• Gear unit size ≤ 67: Max. 0.4 mm
• Gear unit size 77 – 107: Max. 0.5 mm
• Gear unit size 137 – 147: Max. 0.7 mm
• Gear unit size 157 – 187: Max. 0.8 mm
®
gear units of size
20
Do not tighten the housing legs and mounting flanges against one another and ensure
that you comply with the permitted overhung and axial loads. Observe chapter "Project
Planning" in the Gear unit/gearmotor catalog for calculating the permitted over hung and
axial loads.
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
Mechanical Installation
Installing the gear unit
Secure gearmotors using quality 8.8 screws.
Secure the following gearmotors using quality 10.9 screws:
• RF37, R37F with flange Ø = 120 mm
• RF37, RF47, R47F with flange Ø = 140 mm
• RF57, R57F with flange Ø = 160 mm
• FF, FAF, KF, KAF with flange Ø 250 mm
• and RZ37, RZ47, RZ57, RZ67, RZ77, RZ87
INFORMATION
When installing the gear unit, make sure that the oil level and drain plugs as well as
the breather plugs are easily accessible!
At the same time, also check that the oil fill corresponds to the specifications for the intended mounting position (see chapter "Lubricant fill quantities (page 139)" or refer to
the information on the nameplate). The gear units a re fi lled with the requ ired oil vol ume
at the factory. There may be slight deviations at the oil level plug as a result of the mounting position, which are permitted within the manufacturing tolerances.
Adjust the lubricant fill volumes and the positio n of the breather valve accordingly
in the event of a change of mounting position. Observe chapter "Lubricant fill quan-
tities" and chapter "Mounting Positions".
Consult the SEW customer service if you intend to change the mounting position of K
gear to M5 or M6 or between M5 and M6.
Please contact our SEW customer service if you want to change the mounting position
of size S47 – S97 helical-worm gear units to mounting position M2 or M3.
Use plastic inserts (2 – 3 mm thick) if there is a risk of electrochemical corrosion between
the gear unit and the driven machine. The material used must have an electrical leakage
resistance < 10
ample, cast iron and high-grade steel. Also fit the bolts with plastic wash ers. Ground the
housing additionally – use the grounding bolts on the motor.
9
Ω. Electrochemical corrosion can occur between various metals, for ex-
4
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
21
4
Mechanical Installation
Installing the gear unit
4.3.1 Tightening torques for retaining screws
Mount the gearmotors with the following tightening torques:
Bolt/nut
M6 11
M8 25
M10 48
M12 86
M16 210
M20 410
M24 710
M30 1450
M36 2500
M42 4600
M48 6950
M56 11100
Tightening torque screw / nut
Strength class 8.8
[Nm]
Mount the specified gearmotors in flange-mounted design with the following increased
tightening torques:
Flange Gear unit
120 RF37 M6 14
140 RF37, RF47 M8 35
160 RF57 M8 35
60ZR RZ37 M8 35
70ZR RZ47 M8 35
80ZR RZ57 M10 69
95ZR RZ67 M10 69
110ZR RZ77 M12 120
130ZR RZ87 M12 120
250
FF77, KF77,
FAF77, KAF77
Bolt/nut
M12 120
Tightening torque screw / nut
Strength class 10.9
[Nm]
22
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
4.3.2 Gear unit mounting
INFORMATION
For gear units in foot/flange-mounted design in connection with VARIBLOC® variablespeed gear units, use quality 10.9 bolts and suitable washers for connecting the customer flange.
To improve the friction contact between flange and mounting surface, SEWEURODRIVE recommends anaerobic gaskets or an anaerobic glue.
Mechanical Installation
Installing the gear unit
4
Foot-mounted gear
units
Gear units with
B14 flange design
and/or hollow shaft
The following table shows the thread sizes of the foot-mounted g ear units depending on
the gear unit type and size:
Gear unit type
Screw
M6 07 19 10/20
M8 17/27/37 27/37 29 37 30/37/47
M10 57 47 37/47 47/57
M12 47/57/67 67 57/67 57/67 67
M16 77/87 77/87 77/87 77 77
M20 97 97/107 97 87 87
M24 107 107 97 97
M30 137 127 107/167
M36 147/167 157 127/157/187
R / R..F RX F /
FH..B / FA..B
K / KH..B /
KV..B / KA..B
S W
The following table shows the thread sizes of the ge ar units with B1 4 flan ge a nd/o r hollow shaft depending on the gear unit type and size:
Gear unit type
Screw RZ FAZ / FHZ KAZ /
KHZ / KVZ
M6 07/17/27 37 10/20/30
M8 37/47 27/37/47 37/47 47/57 37
M10 57/67 47
M12 77/87 57/67/77 57/67/77 67/77
M16 87/97 87/97 87/97
M20 107/127 107/127
M24 157 157
1) For W30 gear units mounted directly to a CMP motor or mounted via an EWH.. adapter, the thread size
is M8.
SA /
SAZ / SHZ
WA
1)
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
23
4
Mechanical Installation
Installing the gear unit
Gear units with B5
flange
The following table shows the thread s izes of the gear units with B5 flange dependin g
on the gear unit type, size and flange diameter:
Gear unit type
Flange Ø
[mm]
80 M6 10
110 M8 20
120 M6 07/17/27 19 37 10/20/30/37
140 M8 07/17/27/37/47
160 M8 07/17/27/37/47 27/37 19/29/37 37/47 30/37/47
200 M10 37/47/57/67 47 29/47 57/67
250 M12 57/67/77/87 57/67 57/67 77
300 M12 67/77/87 77 77
350 M16 77/87/97/107 87 87 87
450 M16 97/107/137/147 97/107 97/107 97
550 M16 107/13 7/147/167 127 127
660 M20 147/167 157 157
Screw RF /
R..F / RM
FF /
FAF / FHF
KF / KAF /
KHF / KVF
SF /
SAF /SHF
WF / WAF
24
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
4.3.3 Installation in damp locations or outdoors
Drives are supplied in corrosion-resistant versions with a surface protection coating for
use in damp areas or outdoors. Repair any damage to the paint work (e.g. on the
breather valve or the eyebolts).
Mechanical Installation
Installing the gear unit
4
When mounting the motors onto AM, AQ adapters and to AR, AT start-up and friction
couplings, seal the flange areas with a suitable sealing compound, e.g. Loctite
Units installed outdoors must be protected from the sun. Suitable protective devices a re
required, such as covers or roofs. Avoid any heat accumulation. The operator must ensure that foreign objects do not impair the function of the gear unit (e.g. falling objects
or coverings).
4.3.4 Gear unit venting
The following gear units do not require venting:
• R..07 in mounting positions M1, M2, M3, M5 and M6
• R..17, R..27 and F..27 in mounting positions M1, M3, M5 and M6
• SPIROPLAN
• SPIROPLAN
• K..19, K..29 gear units in mounting positions M1, M2, M3, M5 and M6
SEW-EURODRIVE supplies all other gear units with the breath er valve installed and ac-
tivated according to the particular mounting position.
Exceptions:
1. SEW su pplies the following gear units with a screw plug on the vent hole provided:
M6
®
574.
®
W..10, W..20, W..30 gear units
®
W..37, W..47 gear units in mounting positions M1, M2, M3, M5 and
– Gear units with pivoted mounting positions, if possible
– Gear units for inclined mounting
The breather valve is located in the motor terminal box. Before startup, replace the
highest screw plug with the breather valve provided.
2. SEW supplies a breather valve in a plastic bag for mount-on gear units requiring
venting on the input side.
3. Enclosed gear units are supplied without a breather valve.
4. In some countries, the breather valve is installed, but not activated due to possible
pressure fluctuations during transport. In these cases, the breather valve must be activated by removing the transport protection as described in chapter "Activating the
breather valve".
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
25
4
Mechanical Installation
Installing the gear unit
Activating the
breather valve
Check whether the breather valve is activate d. If the breather valv e has not been activated, you must remove the transportation protection device from the breather valve before starting up the gear unit.
1. Breather valve with transportation protection device
211319051
2. Remove transport fixture
211316875
3. Activated breather valve
211314699
26
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
4.3.5 Painting the gear unit
NOTICE
Breather valves and oil seals may be damaged during painting or re-painting.
Possible damage to property.
• Thoroughly cover the breather valves and the sealing lip of the oil seals with strips
prior to painting.
• Remove the strips after painting .
4.4 Gear units with solid shaft
4.4.1 Notes on installation
INFORMATION
Mounting is easier if you first apply lubricant to the output element or heat it up briefly
(to 80 - 100 °C).
Mechanical Installation
Gear units with solid shaft
4
4.4.2 Assembling input an d ou t pu t ele m en t s
NOTICE
Bearing, hosing or shaft may be damaged due to improper assembly.
Possible damage to property
• Assemble the input and output components only using a mounting device. Use the
center bore and the thread on the shaft end for positioning.
• Never force belt pulleys, couplings, pinions, etc. onto the shaft end by hitting them
with a hammer.
• In the case of belt pulleys, make sure the belt is tensioned correctly in accordance
with the manufacturer's instructions.
• Power transmission elements should be balanced after fitting and must not give
rise to any impermissible radial or axial forces (see the "Gearmotors" or "ExplosionProof Drives" catalog for permitted values).
Using a mounting
device
The following figure shows a mounting device for installing couplings or hubs on gear
unit or motor shaft ends. Should you be able to tighten the screw without any problems,
you may not need the thrust bearing on the mounting device.
[1]
[2]
[3]
211368587
[1] Gear unit shaft end
[2] Thrust bearing
[3] Coupling hub
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
27
4
[A] [B]
[1]
[1]
a)
b) c)
Mechanical Installation
Gear units with solid shaft
Avoiding excessive
overhung loads
Avoid high overhung loads by installing the gear or chain sprocket according to figure B
if possible.
211364235
[1] Hub
[A] Unfavorable
[B] Correct
INFORMATION
Mounting is easier if you first apply lubricant to the output element or heat it up briefly
(to 80 - 100 °C).
4.4.3 Mounting of couplings
CAUTION
Risk of injury due to moving drive elements, such as belt pulleys or couplings, during
operation.
Risk of jamming and crushing.
• Cover input and output components with a touch guard.
Adjust the following misalignments according to the coupling manufacturer's specifications when mounting couplings:
a) Maximum and minimum clearance
b) Axial offset
c) Angular offset
211395595
28
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
Torque arms for shaft-mounted gear units
c
a
øb
+0.5
ød
[1]
[2]
[3]
4.5 Torque arms for shaft-mounted gear units
NOTICE
Improper mounting may result in damage to the gear unit.
Possible damage to property.
• Do not place torque arms under strain when mounting.
• Use screws of quality 8.8 to fasten torque arms.
4.5.1 Parallel-shaf t he li ca l ge ar units
The following figure shows the torque arm for parallel-shaft helical gear units.
Mechanical Installation
4
9007199466107403
[1] Screw
[2] Washer
[3] Nut
Proceed as follows to mount the rubber buffers:
1. Use screws [1] and washers according to the following table.
2. Use two nuts to secure the screw connection [3].
3. Tighten the screw until the initial stress "∆ L" of the buffers is reached according to
the table.
Rubber buffer
Gear unit
F..27 /G 40 12.5 20 5 1
F..37 /G 40 12.5 20 5 1
F..47 /G 40 12.5 20 5 1.5
F..57 /G 40 12.5 20 5 1.5
F..67 /G 40 12.5 20 5 1.5
F..77 /G 60 21.0 30 10 1.5
F..87 /G 60 21.0 30 10 1.5
F..97 /G 80 25.0 40 12 2
F..107 /G 80 25.0 40 12 2
F..127 /G 100 32.0 60 15 3
F..157 /G 120 32.0 60 15 3
Diameter Inner
diameter
d [mm] b [mm] c [mm] a [mm] [mm]
Length
(loose)
Washer width ∆ L (taut)
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
29
4
45°
[1]
Mechanical Installation
Torque arms for shaft-mounted gear units
4.5.2 Helical-bevel gear units K..19 – 29
The following figure shows the torque arm for helical-bevel gear units KA19 – 29.
• Apply bearings to both sides of the bushing [1].
• Mount connection side B so that it mirrors A.
Gear unit Screws Tightening torque
K..19 /T 4 x M8 × 22 – 8.8 25 Nm
K..29 /T 4 x M8 × 22 – 8.8 25 Nm
7717631499
4.5.3 Helical-bevel gear units K..37 – 157
The following figure shows the toque arm for helical-bevel gear units.
• Apply bearings to both sides of the bushing [1].
• Mount connection side B so that it mirrors A.
Gear unit Screws Tightening torque
K..37 /T 4 × M10 × 25 – 8.8 48 Nm
K..47 /T 4 × M10 × 30 – 8.8 48 Nm
K..67 /T 4 × M12 × 35 – 8.8 86 Nm
K..77 /T 4 × M16 × 40 – 8.8 210 Nm
K..87 /T 4 × M16 × 45 – 8.8 210 Nm
K..97 /T 4 × M20 × 50 – 8.8 410 Nm
K..107 /T 4 × M24 × 60 – 8.8 710 Nm
K..127 /T 4 × M36 × 130 – 8.8 2.500 Nm
K..157 /T 4 × M36 × 130 – 8.8 2.500 Nm
[1]
211362059
30
Assembly and Operating Instructions – Gear Units R..7, F..7, K..7, K..9, S..7, SPIROPLAN® W
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