Assembly and operating instructions
BA 5080 en 06/2014
FLENDER gear units
Page 2
T
echnical data
T
T
1
Gear unit
General notes
H3LV
Sizes 6 to 18
Assembly and operating instructions
Translation of the original assembly and operating instructions
Safety instructions
ransport and
storage
echnical
description
Fitting
Startîup
Operation
2
3
4
5
6
7
8
Faults, causes
and remedy
Maintenance
and repair
Spare parts,
customer service
Declarations
9
10
11
12
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Page 3
Legal notes
Warning note concept
This manual comprises notes which must be observed for your personal safety and for preventing material
damage. Notes for your personal safety are marked with a warning triangle, those only for preventing
material damage appear without a warning triangle. Depending on the level of hazard, the warning notes
are shown in reverse order of seriousness, as follows.
DANGER
means, that death or serious injury will result, if the appropriate preventive action is not taken.
WARNING
means that death or serious injury may result, if the appropriate preventive action is not taken.
CAUTION
means that a slight injury may result, if the appropriate preventive action is not taken.
NOTICE
means that material damage may result, if the appropriate preventive action is not taken.
Where there is more than one hazard level, the warning note for whichever hazard is the most serious is
always used. If in a warning note a warning triangle is used to warn of possible personal injury, a warning
of material damage may be added to the same warning note.
Qualified personnel
The product or system to which this documentation relates may be handled only by persons qualified for
the work concerned and in accordance with the documentation relating to the work concerned, particularly
the safety and warning notes contained in those documents.
Qualified personnel must be specially trained and have the experience necessary to recognise risks
associated with these products and to avoid possible hazards.
Proper use of Siemens products
Observe also the following:
WARNING
Siemens products must be used only for the applications provided for in the catalogue and the relevant
technical documentation. If products and components of other makes are used, they must be
recommended or approved by Siemens. The faultfree, safe operation of the products calls for proper
transport, proper storage, erection, assembly, installation, startîup, operation and maintenance. The
permissible ambient conditions must be adhered to. Notes in the relevant documentations must be
observed.
Trademarks
All designations to which the registered industrial property mark ÂŽ is appended are registered trademarks
of Siemens AG. Other designations used in this document may be trademarks the use of which by third
parties for their own purposes may infringe holdersâ rights.
Exclusion of liability
We have checked the content of the document for compliance with the hardî and software described.
Nevertheless, variances may occur, and so we can offer no warranty for complete agreement. The
information given in this document is regularly checked, and any necessary corrections are included in
subsequent editions.
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Page 4
Foreword
The term "Assembly and operating instructions" will in the following also be shortened to "instructions"
or "manual".
Symbols in these assembly and operating instructions
This symbol additionally indicates an imminent risk of explosion in the meaning of Directive 94/9/EC.
This symbol additionally indicates an imminent risk of burns due to hot surfaces in the meaning of
standard "DIN EN ISO 13732î1".
This symbol warns against risks from lifted and/or suspended loads.
12.1Declaration of incorporation71..........................................................
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Page 8
1.Technical data
1.1General technical data
The most important technical data are shown on the rating plate. These data and the contractual
agreements between Siemens and the customer for the gear unit determine the limits of its correct use.
â
âĄ
â˘
â¤
âŚ
âŁ
âĽ
â§
â¨
âŠ
âŞ
âŤ
âŹ
Fig. 1:Rating plate on gear unit
â Company logo
âĄManufacturing number
â˘Total weight in kg
âŁSpecial information
â¤Type, size *)
âĽPower rating P
in kW or torque T2 in Nm
2
#)
âŚSpeed n
â§Speed n
â¨Oil data (oil type, oil viscosity, oil quantity)
âŠInstructions number(s)
âŞSpecial information
âŤManufacturer and place of manufacture
âŹCountry of origin
#)
Code production plant / order number, item, sequence number / year built
)
*
Example
1
2
H3 LV 6
Size6 ... 18......................
Mounting positionV = Vertical..........
Type of output shaftL = Lauter tun.........
Vertically adjustable output shaft
Number of stages3..........
Gear-unit typeH = Helical-gear unit.............
Data on weights and measuringîsurface soundîpressure levels of the various gearîunit types are given in
items 1.2 and 1.3.
For further technical data, refer to the drawings in the gearîunit documentation and the orderîspecific data
sheet.
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Page 9
1.1.1Ambient temperature
Note
Unless otherwise agreed by contract, the gear unit must not be exposed to harmful environmental factors
such as chemically aggressive products. By adopting various suitable measures the gear unit may be
used at ambient temperatures of between î 40 °C and + 60 °C. However, Siemens must always have
approved and confirmed this in the order specification.
1.2Measuringîsurface soundîpressure level
The measuringîsurface soundîpressure level for the gear unit at a distance of 1 m can be found in table 1.
The measurement is carried out to standard "DIN EN ISO 9614" Part 2, using the soundîintensity method.
The workplace of the operating personnel is defined as the area on the measuring surface at a distance
of 1 metre in the vicinity of which persons may be present.
The soundîpressure level applies to the warmedîup gear unit at input speed n
on the rating plate, as measurement obtained on the Siemens test bench. If several figures are given, the
highest speed and power values apply.
The measuringîsurface soundîpressure level includes addîon lubrication units, if applicable. With
outgoing and incoming pipes, the flanges are the interfaces.
The soundîpressure levels stated in the table were obtained by statistical evaluation by our Quality Control
Dept. The gear unit can be statistically expected to comply with these noise levels.
Measuring-surface sound-pressure level LpA in dB(A)
Gear-unit size
681012131415161718
79818283828381798283
Approximate weight (kg)
Gear-unit size
681012131415161718
760119017202770352042005150620066007200
Note
All weights are indicated for units without oil filling and without addîon parts. For the exact weights, refer
to the drawings in the gearîunit documentation.
1.4List of equipment
Note
All important accessory components are listed in the orderîspecific list of equipment as well as the
related technical data.
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Page 10
2.General notes
2.1Introduction
These instructions are an integral part of the gear unit supplied and must be kept in its vicinity for reference
at all times.
NOTICE
Material damage
Risk of damage to the gear unit or disruptions to operation.
All persons carrying out work on the gear unit must have read and understood these instructions and
must adhere to them.
Siemens accepts no responsibility for damage or disruptions to operation caused by disregard of these
instructions.
The "FLENDER gear unit" described in these Instructions has been designed for driving lauterîtun
spentîgrain cutting machines.
The gear unit is designed only for the application specified in section 1, "Technical data". Other operating
conditions must be agreed by contract.
The gear unit has been manufactured in accordance with the state of the art and is delivered in a condition
for safe and reliable use.
The gear unit must be used and operated strictly in accordance with the conditions laid down in the contract
governing performance and supply agreed by Siemens and the customer.
The gear unit described in these instructions reflects the state of technical development at the time these
instructions went to print.
In the interest of technical progress we reserve the right to make changes to the individual assemblies and
accessories which we regard as necessary to preserve their essential characteristics and improve their
efficiency and safety.
2.2Copyright
The copyright to these instructions is held by Siemens AG.
These instructions must not be wholly or partly reproduced for competitive purposes, used in any
unauthorised way or made available to third parties without our agreement.
Technical enquiries should be addressed to the following factory or to one of our customer services:
Risk of serious injury through falling.
The gear unit and its addîon parts must not be entered.
WARNING
Risk of injury through unauthorised modifications
Any changes on the part of the user are not permitted.
This applies equally to safety features designed to prevent accidental contact.
3.1Obligations of the user
â˘The operator must ensure that everyone carrying out work on the gear unit has read and understood
these instructions and is adhering to them in every point in order to:
â avoid injury or damage,
â ensure the safety and reliability of the gear unit,
â avoid disruptions to operation and environmental damage through incorrect use.
â˘During transport, assembly, fitting, demounting, operation and maintenance of the unit, the relevant
safety and environmental regulations must be complied with.
â˘The gear unit may only be operated, maintained and/or repaired by persons qualified for the work
concerned (see "Qualified personnel" on page 3 of this manual).
â˘The outside of the gear unit must not be cleaned with highîpressure cleaning equipment.
â˘All work must be carried out with great care and with due regard to safety.
DANGER
Danger to life through switchedîon installation
To carry out work on the gear unit, the gear unit must always be stopped.
The drive unit must be secured against being switched on accidentally (e.g. by locking the key switch
or removing the fuses from the power supply).
A notice should be attached to the ON switch stating clearly that work is in progress on the gear unit.
At the same time the complete installation must be without load, so that no danger occurs during
demounting operations.
â˘No welding work must be done at all on the drive system.
The drive systems must not be used as an earthing point for electricîwelding operations. Toothed parts
and bearings may be irreparably damaged by welding.
â˘A potential equalisation in accordance with the applying regulations and directives must be carried out!
If no threaded holes for earth connection are available on the gear unit, other appropriate measures
must be taken. This work must always be done by specialist electricians.
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Page 12
NOTICE
Material damage
Risk of damage to the gear unit.
If any inexplicable changes are noticed during operation of the gear unit, such as an important increase
in temperature or unusual noises, the drive unit must be stopped immediately.
DANGER
Danger to life through rotating and/or movable parts
Risk of being caught or drawn in by rotating and/or movable parts.
Rotating and/or movable parts must be fitted with suitable safeguards to prevent contact.
Note
When the gear unit is incorporated in plant or machinery, the manufacturer of such plant or machinery
must ensure that the prescriptions, notes and descriptions contained in these instructions are
incorporated in his own instructions.
â˘Removed safety equipment must be reîfitted prior to starting up.
â˘Notices attached to the gear unit, such as rating plate and direction arrow, must always be observed.
They must be kept free from dirt and paint at all times. Missing plates must be replaced.
â˘Screws which have been damaged during assembly or disassembly work must be replaced with new
ones of the same strength class and type.
â˘Spare parts must be obtained from Siemens (see section 11, "Spare parts, customer service").
3.2Special dangers and personal protective equipment
Depending on operating conditions, the surface of the gear unit may heat up or cool down to extreme
temperatures.
WARNING
Risk of burns
Risk of serious injury through burns on hot surfaces (> 55 °C).
Wear suitable protective gloves and protective clothing.
WARNING
Danger through low temperatures
Risk of serious injury through frost (pain, numbness, frostbite) on cold surfaces (< 0 °C).
Wear suitable protective gloves and protective clothing.
WARNING
Risk of scalding
Risk of serious injury through escaping hot operating media, when they are being changed.
Wear suitable protective gloves, protective glasses and protective clothing.
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WARNING
Risk of eye injury
Small foreign matter such as sand or dust can get into the cover plates of the rotating parts and be thrown
back by these.
Wear suitable protective glasses.
Note
In addition to any generally prescribed personal safety equipment (such as safety shoes, safety clothing,
helmet) handling the gear unit requires wearing suitable safety gloves and suitable safety glasses.
DANGER
Risk of explosion
Danger to life through ignition of any explosible atmosphere resulting from of the gear unit.
The gear unit does not comply with the requirements in Directive 94/9/EC and must therefore, in the
area of applicability of this directive, not be used in potentially explosive areas.
Should the gear unit be used outside the area of applicability of Directive 94/9/EC within potentially
explosive areas, the nationally applying protective prescriptions with regard to explosion protection must
always be observed.
3.3The five safety rules
For your personal safety and to avoid material damage, comply always with the safetyîrelevant instructions
and the safety rules to standard EN 50110î1 "Working in tensionîfree status" indicated below, when
working on electrical components of the plant. Apply the five safety rules in the indicated order, before
starting work on the machine.
3.3.1Five safety rules
1) Disconnect completely
Disconnect the auxiliary circuits, e.g. standîby heating
2) Secure against reîconnection
3) Verify that the installation is voltageîfree ("dead")
4) Carry out earth and shortîcircuiting
5) Provide protection against adjacent live parts
After completion of the work the taken measures should be undone in the reverse order.
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Page 14
3.4Environmental protection
â˘Dispose of any packaging material in accordance with regulations or separate it for recycling.
â˘When changing oil, the used oil must be collected in suitable containers. Any pools of oil which may
have collected should be removed at once with an oilîbinding agent.
â˘Preservative agents should be stored separately from used oil.
â˘Used oil, preservative agents, oilîbinding agents and oilîsoaked cloths must be disposed of in
accordance with environmental legislation.
â˘Disposal of the gear unit after its useful life:
â All the operating oil, preservative agent and/or cooling agent must be drained from the gear unit and
disposed of in accordance with regulations.
â Gearîunit components and/or addîon parts may have to be disposed of or separated for recycling
in accordance with national regulations.
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4.Transport and storage
Observe the instructions in section 3, "Safety instructions"!
4.1Scope of supply
The products supplied are listed in the dispatch papers. Check on receipt to ensure that all the products
listed have actually been delivered. Parts damaged and/or missing parts must be reported to Siemens in
writing immediately.
WARNING
Serious injury through defective product
If there is any visible damage, the gear unit must not be put into operation.
4.2Transport
Note
The weight of the product is specified on the rating plate.
DANGER
Danger of life
Danger to life from loads falling through incorrect slinging
Do not stay under suspended loads.
When attaching, lifting, lowering and shifting loads, observe the following:
â Note the load limits.
â Correct fastening of the slinging equipment.
â Any centre of gravity which is off the load centre.
â Even load distribution when using loadîcarrying means with several load hooks.
â Low displacement speed.
â The load must not be swung and/or attached to objects or building parts.
â Lifting hooks must not be loaded by the tip.
â Always place the items on an even, slipfree and stable surface.
WARNING
Danger of squeezing
Risk of being squeezed by a transported component, when the used lifting gear and loadîcarrying means
are not suitable and the component gets loose.
The unit may be attached only at the marked slinging points. Use only lifting and loadîcarrying equipment
of sufficient loadîbearing capacity.
When lifting items, observe the notes regarding load distribution on the packing.
The product must be handled slowly and carefully, when lifted, to avoid personal injury and damage to
the gear unit.
If, for example, the free shaft ends are knocked, this may cause damage in the gear unit.
The gear unit is delivered in the fully assembled condition. Additional items may be delivered separately
packaged, if applicable.
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Page 16
Different forms of packaging may be used, depending on the size of the unit and method of transport.
Unless agreed otherwise, the packaging complies with the HPE Packaging Guidelines.
The symbols marked on the packing must be observed at all times. They have the following meanings:
TopFragileKeep dryKeep coolCentre of
gravity
Use no hand
hook
Attach
here
Fig. 2:Transport symbols
Note
The gear unit must be transported only with appropriate transport equipment.
During transport the gear unit (main gear unit) should be left without oil filling and on the transport
packing.
The bevelîgear units are delivered ex works with oil filling.
In case of addîon bevelîgear motors the instructions applying must be observed.
NOTICE
Material damage
Risk of damage to the gear unit when using incorrect attachment points. Use only the eyes provided to
attach lifting equipment to the unit.
Transport of the unit by attaching it to the pipework is not permitted.
The pipework must not be damaged.
Do not use the front threads at the shaft ends to attach slinging and lifting gear for transport.
Slinging and lifting gear must be adequate for the weight of the gear unit.
1)
2)
Fig. 3:Attachment points
1)Lauter tun with hoist gear unit2)Lauter tun with lifting cylinder
For a detailed illustration of the gear unit and the position of the attachment points, refer to the drawings
in the orderîspecific gearîunit documentation.
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4.3Storing the gear unit
The gear unit must be stored in a sheltered place in the position of the original packaging or in the position
of use, placed on a vibrationîfree, dry base, and covered over.
NOTICE
Material damage
Any damage to the coating may cause failure of the exterior protective coating and thus corrosion.
When temporarily storing the gear unit and any single components supplied with it, the preservative
agent should be left on them.
Ensure that the coat is not damaged.
DANGER
Danger to life through tilting or falling gear unit
Risk of being squeezed or killed by a tipping or falling gear unit.
Do not stack gear units on top of one another
NOTICE
Material damage
Risk of damage to the gear unit through build up of a layer of foreign bodies or moisture. If the gear unit
is being stored out of doors, it must be particularly carefully covered, and care must be taken that neither
moisture nor foreign material can collect on the unit.
Waterlogging must be avoided.
NOTICE
Material damage
Risk of damage to the gear unit through external sources.
Unless otherwise agreed by contract, the gear unit must not be exposed to harmful environmental factors
such as chemically aggressive products.
Provision for special environmental conditions during transport (e.g. transport by ship) and storage
(climate, termites, etc.) must be agreed by contract.
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4.4Standard coating and preservation
The gear unit is provided with an interior preservative agent; the free shaft ends are painted for protection.
The characteristics of the exterior coat depend on the ambient conditions stipulated in the order relating
to method of transport and area of application.
NOTICE
Material damage
Risk of damage to the gear unit through corrosion.
The gear unit is normally delivered completely ready, with a priming and a finish coat.
Where gear units are delivered with a priming coat only, it is necessary to apply a finish coat in
accordance with directives applying to the specific application.
The priming coat alone is not suitable to provide a sufficient longîterm corrosion protection.
NOTICE
Material damage
Any damage to the coating may cause failure of the exterior protective coating and thus corrosion.
Ensure that the coat is not damaged.
Note
Unless otherwise contractually agreed, the durability periods of the interior gear unit preservation
specified in table 3 will apply, provided the related measures are adhered to. The durability period for the
exterior preservation and the related requirements can be found in table 4.
The guarantee period starts on the date of delivery or that of the notice that the item is ready for shipment.
In case of a storage period other than the durability periods indicated in tables 3 and in table 4, the interior
and the exterior preservation must be checked and, as necessary, be renewed (see items 7.6.1 and 7.6.2).
4.4.1Interior preservation with preservative agent
Table 3:Durability period and measures for interior preservation when using mineral oil
For storage periods longer than 24 months, renew the preservative agent (see item 4.4.1.1).
Note
The procedure for interiorîpreservation treatment is described in section 7 (see item 7.6.1).
None
â Close all holes on the gear unit.
â Replace the air filter or wet-air filter with
the screw plug. (Replace the screw plug
with the air filter or wet-air filter before
start-up.)
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4.4.1.1 Reîpreserving the interior of the gear unit (main gear unit) in case of longer periods of storage
CAUTION
Risk of injury
Risk of injury to eyes or hands through chemically aggressive operating media.
Wear suitable protective glasses and protective gloves.
Remove any oil spillage immediately with a binding agent.
For storage periods longer than 24 months (see table 3), renew the preservation in the interior of the gear
unit. The following procedure is recommended:
â˘Unscrew the air filter or wetîair filter (1) on the oilîequalising tank (see fig. 4 or fig. 5).
â˘Place a suitable container under the oilîdrain points (4 and 5) of the gearîunit housing.
â˘Open the oilîdrain cock (4) and unscrew the residualîoil drain plug (5) and drain the used preservative
oil into a suitable container.
â˘Dispose of the residue of the preservative oil in accordance with regulations.
â˘Shut the oilîdrain cock (4) and screw in the residualîoil drain plug (5).
â˘Fill the gear unit with "Castrol Alpha SP 220 S".
Determine the filling quantity according to the gearîunit dimensions: length x width x height x 0.05.
NOTICE
Material damage
Corrosion possible through use of an unsuitable preservative agent.
Use special oil "Castrol Alpha SP 220 S" with additional antiîcorrosive agent (additive "S").
â˘Screw in the air filter or wetîair filter (1).
â˘Replace the air filter or wetîair filter (1) with the screw plug.
NOTICE
Material damage
Corrosion possible through leaving the gear unit open too long.
Close the gear unit airtightly at the latest one hour after opening.
Before reîstarting the gear unit take the following measure:
â Replace the screw plug with the air filter or wetîair filter.
The gear unit has thus been preserved for another period of 24 months.
NOTICE
Material damage
Risk of damage to the gear unit through inadequate lubrication through preservative agent and operating
oil being mixed up.
The use of synthetic oil is not permissible.
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8
16
(II)
(III)
9
(II)
7
(II)
6
(Ia)
(Ib)
(III)
(III)
(I)
(I)
13
12
4
5
14
10
11
15
1
2,3
Fig. 4:Oil inlet and oil drain â gear unit with hoist gear unit
1Air filter or wet-ait filter
Ventilation (I) main gear unit
2Oil filling (I) main gear unit
3Dipstick; oil filling (I) main gear unit
4Oil-drain cock (Ia); oil drain main gear unit
5Oil-drain plug; residual oil (Ib) main gear unit
6Ventilation; oil filling (II) primary gear unit
7Oil level (II) primary gear unit
8Oil-drain plug (II) primary gear unit
9Ventilation / oil filling (III) hoist
gear unit
10Oil level (III) hoist gear unit
11Oil-drain plug (III) hoist gear unit
12Bellows
13Vent hole
14Leak hole
15Leak hole
16Inspection and/or assembly cover
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16
(II)
8
(Ia)
(Ib)
13
12
4
5
14
(II)
7
(II)
6
(I)
(I)
1
2,3
Fig. 5:Oil inlet and oil drain â gear unit with lifting cylinder
1Inspection and/or assembly cover
Ventilation (I) main gear unit
2Oil filling (I) main gear unit
3Dipstick (I); oil filling (I) main gear unit
4Oil-drain cock (Ia); oil drain main gear unit
5Oil-drain plug; residual oil (Ib) main gear unit
7Oil level (II) primary gear unit
8Oil-drain plug (II) primary gear unit
12Bellows
13Vent hole
14Leak hole
16Inspection and/or assembly cover
6Ventilation; oil filling (II) primary gear unit
For a detailed illustration of the gear unit and the position of the addîon parts, refer to the drawings in the
gearîunit documentation.
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4.4.2Exterior preservation
Table 4:Durability period for exterior preservation of shaft ends and other bright machined surfaces
Durability periodPreservative agent
In case of indoor storage up
to 36 months
In case of outdoor storage
up to 12 months
1)
The gear unit must be stored in the position of use in a sheltered place; it must be placed on
1)
Tectyl 846 K19Approx. 50 Îźm
2)
Layer thicknessRemarks
a vibrationîfree, dry base, and covered over.
2)
If the gear unit is being stored out of doors, it must be particularly carefully covered, and care must be
taken that neither moisture nor foreign material can collect on the unit. Waterlogging must be avoided.
Note
The procedure for exteriorîpreservation treatment is described in section 7 (see item 7.6.2).
4.4.2.1 Reîpreservation of the metallic bright exterior surfaces of the gear unit
In case of storage periods exceeding the periods specified in table 4 the exterior of the gear unit must be
reîpreserved using the preservative agent specified in table 4.
Long-term wax-based
preservative agent:
â resistant to seawater
â resistant to tropical
conditions
â soluble with
CH compounds
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5.Technical description
Observe the instructions in section 3, "Safety instructions"!
5.1General description
The gear unit described is a "FLENDER gear unit" designed for driving lauterîtun spentîgrain cutting
machines.
The gear unit can be operated in both directions of rotation.
The gear unit is characterised by a low noise level, which is achieved by helical gears with a high contact
ratio and a soundîdamping housing.
The good temperature characteristics of the gear unit are achieved by its high degree of efficiency, large
housing surface and performanceîrelated cooling system.
The lauter tun drive is delivered as a complete drive unit assembled from various components.
The drive is designed for vertical mounting and must be operated only with the vertically adjustable shaft
pointing upwards.
8
9
10
1
2
Fig. 6:Gearîunit configuration with hoist gear unit
1Bevel-gear motor (electric motor I)
2Helical-gear unit
3Bevel-gear motor (electric motor II)
4Stroke-mounting flange
5Gear-unit cam operated switch
7
6
4
3
5
6Oil-equalising tank
7Bellows
8Limit switch
9Shaft coupling
10Limit-switch plate
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6
5
1
4
2
3
7
Fig. 7:Gearîunit configuration with lifting cylinder
1Bevel-gear motor (electric motor I)
2Helical-gear unit
3Stroke-mounting flange
4Oil-equalising tank
5Bellows
6Shaft coupling
7Lifting cylinder
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5.2Construction and method of operation
The combination drive performs 3 functions:
ISpentîgrain removal (high speed)
Clockwise rotation (looking at the end of the drive shaft)
IISpentîgrain cutting (low speed)
Clockwise rotation (looking at the end of the drive shaft)
IIIVertical adjustment of the output shaft
while stationary, without load or during operation (under load)
5.2.1Spentîgrain removal and spentîgrain cutting
During cutting and removal of the spent grain the bevelîgear motor (electric motor I) drives the spentîgrain
cutting machine via a multiîstage helicalîgear unit. The required speed is set via a frequency inverter.
5.2.2Vertical adjustment of the spentîgrain cutting machine
The spentîgrain cutting machine can be displaced a previously specified lifting distance vertically by
means of a bevelîgear motor (electric motor II) or a hydraulic cylinder. Displacement can be carried out
at any time under load, without load or while stationary.
5.2.3Bevelîgear motor (electric motor I)
The electric motor complies with the relevant standards and regulations as well as any additional
agreements. The connecting dimensions deviate from any standard. The motor shaft and the connecting
flange are adapted to the bevelîgear unit. The motor is of a type designed for operation with a frequency
inverter, which can be additionally fitted with an incremental transmitter, PTCîthermistor sensors and
a separate fan.
Note
Be sure to observe the operating instructions for the bevelîgear motor for operation and maintenance.
For technical data, refer to the data sheet and/or the list of equipment.
The detailed view (position of terminal box and arrangement) is shown on the dimensioned drawing.
5.2.4Height adjustment
5.2.4.1 Bevelîgear motor (electric motor II)
The electric motor complies with the relevant standards and regulations as well as any additional
agreements. The connecting dimensions deviate from any standard. The motor shaft and the connecting
flange are adapted to the bevelîgear unit.
The rolling bearings of the motors are lubricated with grease.
The bevelîgear unit is supplied with oil by splash lubrication.
Note
Be sure to observe the operating instructions for the bevelîgear motor for operation and maintenance.
For technical data, refer to the data sheet and/or the list of equipment.
The detailed view (position of terminal box and arrangement) is shown on the dimensioned drawing.
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5.2.4.2 Hydraulic cylinder (optional)
The hydraulic cylinder is connected to the strokeîmounting flange and the adapter sleeve located inside
it. In this way the insert shaft of the helicalîgear unit can be vertically adjusted. When mounting, the
mounting dimensions specified on the dimensioned drawing must be observed.
Note
Be sure to observe the operating instructions for the hydraulic cylinder for operation and maintenance.
For technical data, refer to the data sheet and/or the list of equipment.
5.2.5Helicalîgear unit
The torque is transmitted to the vertically adjustable, upwardly protruding insert shaft via a multiîstage
vertical helicalîgear unit with shafts fitted on rolling bearings and a hollow output shaft provided with
splines.
The oil is fed to the toothed parts, the rolling bearings and the splines on the hollow shaft and the insert shaft
by splash lubrication. The gear unit thus requires very little maintenance.
5.2.6Strokeîmounting flange
5.2.6.1 Strokeîmounting flange with bevelîgear motor
The insert shaft is heightîadjusted on the drive via the spindle drive inside the strokeîmounting flange. It is
fitted on below the helicalîgear unit in the area of the output shaft. The spindle is guided in the
strokeîmounting flange by means of rolling bearing. This rolling bearing is adequately dimensioned to
enable it to absorb the axial forces exerted.
The drive journal of the spindle projects downwards from the strokeîmounting flange. Two shaftîsealing
rings at the shaft outlet prevent oil from escaping.
The rolling bearing and the spindle drive are also lubricated by splash lubrication. The stroke-mounting
flange together with the helicalîgear unit form a common oil chamber.
5.2.6.2 Strokeîmounting flange with lifting cylinder
The strokeîmounting flange is attached below the helicalîgear unit in the area of the output shaft (insert
shaft). Using an attached hydraulic cylinder, the insert shaft can be vertically adjusted via an adapter
sleeve with internal rolling bearing.
This rolling bearing is adequately dimensioned to enable it to absorb the axial forces exerted.
The rolling bearing is lubricated by splash lubrication. The stroke-mounting flange together with the
helicalîgear unit form a common oil chamber.
The junction of the strokeîmounting flange and the hydraulic cylinder is sealed with gaskets. If gaskets
made from PTFE are used, they should be preheated to 60 to 80 °C in an oil or water bath before fitting.
When the gasket has been placed in the groove on the intermediate cover, the piston rod of the hydraulic
cylinder must be inserted (for calibration).
5.2.7Gearîunit cam-operated switch (optional)
The gearîunit cam-operated switch is fitted with four freely adjustable cam operated switches for
positioning the spentîgrain cutting machine and a rotaryîangle transducer to indicate the lifting distance.
The gearîunit cam operated switch must be adjusted by the system constructor before startîup.
Note
Be sure to observe the operating instructions for the gearîunit cam operated switch for operation and
maintenance.
For technical data, refer to the data sheet and/or the list of equipment.
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5.2.8Oilîequalising tank
The oilîequalising tank ensures the appropriate volumetric compensation, when the volume of oil
increases with temperature.
5.2.9Bellows
The bellows protects the teeth of the insert shaft and thus the interior of the helicalîgear unit against
contamination. The air outlet is through a bore in the face collar of the shaft coupling.
5.2.10 Limit switch (optional)
Above the helicalîgear unit are two limit switches for switching the bevelîgear motor (electric motor II) OFF
in an EMERGENCY.
The unit is delivered loose and must be fitted by the system constructor before startîup. It must be precisely
positioned by the system constructor before startîup and regularly inspected.
Note
Be sure to observe the operating instructions for the limit switch for operation and maintenance.
For technical data, refer to the data sheet and/or the list of equipment.
5.2.11 Shaft coupling and limitîswitch plate (optional)
The shaft coupling connects the output shaft of the lauterîtun drive to the shaft of the spentîgrain cutting
machine by a friction fit. The limitîswitch plate actuates the EMERGENCYîOFF limit switch. The
limitîswitch plate is placed between the contact faces of the shaft and the shaft coupling.
The shaft coupling and the limitîswitch plate are delivered loose and must be fitted by the system
constructor before startîup.
5.2.12 Frequency inverter (optional)
The bevelîgear motors can be set by means of frequency inverters. This enables the rotation speed of the
drive shaft to be adjusted to requirement during cutting and removal of the spent grain.
Note
Be sure to observe the operating instructions for the frequency inverter for operation and maintenance.
For technical data, refer to the data sheet and/or the list of equipment.
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5.3Housing
The housing is designed as a multiîpiece. It is of torsionally rigid design and due to its shape imparts very
favourable noise and temperature characteristics.
The gearîunit housing comes with the following equipment:
â Lifting eyes (adequately dimensioned for transport)
â Dipstick with MIN and MAX marks (for checking the oil level)
â Oilîdrain plug and/or oilîdrain cock (to drain the oil)
â Air filter or wetîair filter (for aeration and ventilation)
Colour codes for bleeding, oil inlet, oil level and oil drainage:
Air-relief point
yellowOil-drain pointwhite
Oil-filling pointyellowLubricating pointred
Oil level:
Dipstick
red
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14
7
(I)
2,3
6
9
10
15
11
16
13
(Ia)
4
(Ib)
5
8
12
Fig. 8:Gearîunit features on gear units with hoist gear unit
1Air filter or wet-ait filter;
Ventilation (I) main gear unit
2Oil filling (I) main gear unit
3Dipstick (I); oil filling (I) main gear unit
4Oil-drain cock (Ia); oil drain main gear unit
5Oil-drain plug; residual oil (Ib) main gear unit
6Housing
7Shaft seal
Fig. 9:Gearîunit features on gear units with lifting cylinder
1Air filter or wet-ait filter;
Ventilation (I) main gear unit
2Oil filling (I) main gear unit
3Dipstick (I); oil filling (I) main gear unit
4Oil-drain cock (Ia); oil drain main gear unit
5Oil-drain plug; residual oil (Ib) main gear unit
6Housing
7Shaft seal
For a detailed illustration of the gear unit and the position of the addîon parts, refer to the drawings in the
gearîunit documentation.
5.4Toothed components
The externally toothed components of the gear unit are caseîhardened. The helicalîgear teeth are ground.
The high quality of the teeth leads to a significant noise reduction of the gear unit and ensures safe and
reliable running.
The gears are connected with the shafts by interference fits and parallel keys or by shrink fits. These types
of joints transmit the torques generated with adequate reliability.
Unless otherwise agreed in the order, the teeth and bearings are adequately splashîlubricated with oil. The
gear unit thus requires very little maintenance.
5.6Shaft bearings
All shafts are fitted in rolling bearings.
5.7Shaft seal
Radial shaftîsealing rings, labyrinth seals, Taconite seals or special seals at the shaft outlets prevent oil
from escaping from, or dirt from entering into the gear unit.
5.7.1Radial shaftîsealing rings
Radial shaftîsealing rings are the standard type of seal. Radial shaftîsealing rings seal with contact and
are fitted with an additional dust lip to protect the actual sealing lip from exterior contamination.
NOTICE
Material damage
Destruction of the radial shaftîsealing ring possible through high dust concentration.
Do not use radial shaftîsealing ring in an environment with high dust concentration.
Fig. 10: Radial shaftîsealing ring
5.8Oilîlevel monitoring (optional)
The gear unit can be fitted with an oilîlevel monitor by means of a fillingîlevel limit switch. The oilîlevel
monitoring device has been designed for checking the oil level when the gear unit is at a standstill, prior
to operating start.
If an oilîlevel monitoring device is in use, it is very important that the unit is in the horizontal position.
For a detailed illustration of the gear unit and the position of the addîon parts, refer to the drawings in the
gearîunit documentation.
Note
For the operation and maintenance the operating manuals specified in the orderîspecific annex must be
observed.
For technical data and control information, refer to the orderîspecific list of equipment.
5.9Indication of oil level
The gear unit is fitted with an oilîlevel indication (dipstick with MIN and MAX marks) for visual oilîlevel
checking at standstill. Checking of the oil level can be carried out by the dipstick when the oil has cooled
down.
For a detailed illustration of the gear unit and the position of the addîon parts, refer to the drawings in the
gearîunit documentation.
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6.Fitting
Observe the instructions in section 3, "Safety instructions"!
6.1General information on fitting
When transporting the gear unit, observe the notes in section 4, "Transport and storage".
Fitting work must be done with great care by authorised, trained and qualified personnel. The manufacturer
cannot be held liable for damage caused by incorrect assembly and installation.
As early as during the planning phase sufficient free space must be allowed around the gear unit for later
care and maintenance work.
Note
Free convection through the surface of the housing must be ensured by suitable measures.
Adequate lifting equipment must be available before beginning the fitting work.
NOTICE
Material damage
During operation the unit must not be allowed to heat up through exposure to heat from external sources
such as sunlight, and suitable measures must be taken to prevent this.
Heat concentration must be avoided.
This can be done as follows:
â fitting an additional cooling unit
NOTICE
Material damage
Risk of damage to the gear unit caused by falling objects, heaping over, welding work or insufficient
fastening.
The operator must ensure the following:
â The gear unit must be secured against falling objects and heaping over.
â No welding work must be done at all on the drive system.
â The gear unit must not be used as an earthing point for electricîwelding operations.
â All the fastening points provided by the design of the unit must be used.
â Screws which have been damaged during assembly or disassembly work must be replaced with new
screws of the same strength class and type.
Note
To ensure proper lubrication during operation, the mounting position specified on the drawings must
always be observed.
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6.2Unpacking
NOTICE
Material damage
Risk of damage to the gear unit through corrosion.
The packaging must not be opened or damaged beforehand, if this is part of the preservation method.
The products supplied are listed in the dispatch papers. Check immediately on receipt to ensure that all
the products listed have actually been delivered. Parts damaged and/or missing parts must be reported
to Siemens in writing immediately.
â˘Remove packaging material and transporting equipment and dispose of in accordance with
regulations.
â˘Perform a visual check for any damage and contamination.
WARNING
Serious injury through defective product
If there is any visible damage, the gear unit must not be put into operation.
The instructions in section 4, "Transport and storage", must be observed.
6.3Fitting the gear unit
6.3.1Fitting the gearîunit on a housing base
6.3.1.1 Foundation
NOTICE
Material damage
Risk of damage through insufficiently safe positioning of the gear unit.
The foundation must be horizontal and level. The gear unit must not be excessively stressed when
tensioning the fastening bolts.
The foundation should be designed in such a way that no resonance vibrations are created and that no
vibrations are transmitted from adjacent foundations. The structure on which the unit is to be fitted must
be rigid. It must be designed according to the weight and torque, taking into account the forces acting on
the gear unit.
Careful alignment with the units on the inî and output sides must be ensured. Any elastic deformation
through operating forces must be taken into consideration.
NOTICE
Material damage
Risk of damage through insufficiently safe positioning of the gear unit.
Fastening bolts and nuts must be tightened to the prescribed tightening torque.
For the correct tightening torque, refer to item 6.10. Bolts of at least strength class 8.8 must be used.
If external forces are acting upon the gear unit, it is advisable to prevent the unit from displacement by
means of lateral stops.
Note
For dimensions, space requirement and arrangement of supply connections, refer to the drawings in the
gearîunit documentation.
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6.3.1.2 Fitting the hydraulic cylinder
If the hydraulic cylinder is not part of the delivery by Siemens, the cylinder must be fitted in mounting
position prior to setting upright and prior to fitting the drive unit. To do so the transport lock must be
removed.
WARNING
Serious injury
Risk of injury through slippage of the insert shaft.
The insert shaft is no longer secured and may slip away if incorrectly stored.
â˘Remove hexagon nut (1) from the threaded rod (2).
8
5
3
2
1
Fig. 11: Fitting the hydraulic cylinder
9
11
5
12
4
7
10
3
6
1Hexagon nut
2Threaded rod
3Bolt
4Sealing plate
5Intermediate cover
6Sealing ring
â˘Undo the bolts (3) and demount the locking plate (4). The bolts are used again for fastening the
hydraulic cylinder.
â˘Demount the
â˘Place sealing ring (6) into the groove of the
â˘Place the
specified torque.
â˘Unscrew the threaded rod (2) from the centering of the insert shaft (8).
â˘Vent the hydraulic cylinder (7) and screw in the end of the piston rod, with the piston run out, into the
threaded flange (9).
Note
The fitting dimension is specified on the dimensioned drawing in the gearîunit documentation.
â˘Screw in and secure the set screw (10).
â˘Place the
strokeîmounting flange (11). Tighten the bolts (12) to the specified torque.
6.3.2Description of fitting work
Intermediate cover (5).
Intermediate cover (5) on the flange of the hydraulic cylinder (7). Tighten the bolts (3) to the
intermediate cover (5) and hydraulic cylinder (7) with slight rotary motions on the
WARNING
Serious injury
Risk of injury through ignition of solventîagent vapours during cleaning work.
Observe the following:
â Ensure adequate ventilation.
â Do not smoke.
Intermediate cover (5).
â˘Remove the antiîcorrosive agent from the shafts using a suitable cleaning agent.
CAUTION
Risk of injury through chemical substances
Observe manufacturerâs instructions for handling lubricants and solvents.
Wear suitable protective clothing.
NOTICE
Material damage
Risk of damage to the shaftîsealing rings through chemically aggressive cleaning agents.
The cleaning agent must in no way be allowed to come into contact with the shaftîsealing rings.
â˘Fit and secure drive elements (e.g. coupling parts) on shafts.
If these are to be fitted in heated condition, refer to the dimensioned drawings in the coupling
documentation for the correct joining temperatures.
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Unless specified otherwise, the components may be heated inductively, with a burner, or in a furnace.
WARNING
Risk of burns
Risk of serious injury through burns on hot surfaces (> 55 °C).
Wear suitable protective gloves and protective clothing.
NOTICE
Material damage
Risk of damage to the shaftîsealing rings through heating to over 100 °C.
Use heat shields to protect against radiant heat.
The elements must be pulled smartly onto the shaft as far as stated on the dimensioned drawing prepared
in accordance with the order.
NOTICE
Material damage
Damage to the gear unit possible through knocking or impacts.
Fit the coupling using suitable fitting equipment.
The shaftîsealing rings and running surfaces of the shaft must not be damaged when pulling on the
coupling parts.
NOTICE
Material damage
Risk of damage to the gear unit or single components through incorrect alignment.
When fitting the drives, make absolutely certain that the individual components are accurately aligned
in relation to each other. Inadmissibly large errors in the alignment of the shaft ends to be connected
through angular and/or axial misalignments result in premature wear and material damage.
Insufficiently rigid base frames or subîstructures can also during operation cause a radial and/or axial
misalignment, which cannot be measured when the unit is at a standstill.
Note
Gear units with a weight that requires the use of lifting gear must be attached at the points shown in
section 4, "Transport and storage". If the gear unit is to be transported with addîon parts, additional
attachment points may be required. The position of these attachment points is shown on the
orderîspecific dimensioned drawing.
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6.3.2.1 Alignment
Orderîspecific machined surfaces (alignment surfaces) are provided on the gearîunit top side for
preliminary alignment in horizontal direction.
Alignment surface:
For the exact position of the alignment surfaces, refer to the drawings in the gearîunit documentation.
These alignment surfaces are for aligning the gear unit horizontally, in order to ensure correct running of
the gear unit.
Note
The values punched into the alignment surfaces must be observed.
2
1
1
Fig. 12: Alignment surfaces on gear units type H3LV
2
1
1
The final fine alignment with the units on the inî and output side must be carried out accurately by the shaft
axes, using:
1Alignment surfaces2Alignment thread
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The final fine alignment with the units on the inî and output side must be carried out accurately by the shaft
axes, using:
â Rulers
â Spirit level
â Clock gauge
â Feeler gauge, etc.
Only then should the gear unit be fastened, and then the alignment should be checked once again.
â˘Record alignment dimensions.
Note
The record must be kept with these instructions.
DANGER
Danger to life through flying fragments
Nonîobservance of the alignment accuracy can cause shaft rupture, resulting in serious injury and
danger to life.
Align the gear unit precisely (adhere to the specified values).
Risk of damage to the gear unit or its components or addîon parts.
The accuracy of shaftîaxis alignment is an important factor in determining the life span of shafts, bearings
and couplings. If possible, the deviation should be zero (exception: ZAPEX couplings). For the special
requirements for the couplings, refer to the pertinent operating instructions as well.
6.3.2.2 Fitting on a foundation frame
â˘Clean the undersurface of the gearîunit bases.
â˘Using suitable lifting gear, place the gear unit on the foundation frame.
â˘Tighten the foundation bolts to the specified torque (see item 6.10); if necessary, use stops to prevent
displacement.
NOTICE
Material damage
Damage to the gear unit possible through uneven tightening of the fastening bolts.
Tighten the fastening bolts evenly; the gear unit must not be excessively stressed when tensioning the
fastening bolts.
â˘Align the gear unit exactly with the input and output units (see item 6.3.2.1).
â˘Record alignment dimensions.
Note
The record must be kept with these instructions.
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6.4Shrink disk
The shrink disk makes a pressîfit connection between a hollow shaft and a stub or drivenîmachine shaft,
in the following also called "stub shaft". The interference fit can transfer torques, bending moments and
forces. The joining pressure between the hollow and stub shafts generated by the shrink disk is essential
for the torque and/or force transmission.
The shrink disk is delivered ready for fitting.
WARNING
Serious injury
Risk of injury through flying fragments of the shrink disk.
The shrink disk must not be disassembled before fitting for the first time.
Fitting and startîup must be carried out by properly trained specialist personnel.
Prior to startîup these instructions must be read, understood and adhered to. Siemens accept no liability
for personal injury or damage due to nonîobservance of the instruction manual.
6.4.1Fitting the shrink disk
â˘Before beginning fitting work, the hollow shaft and the stub shaft must be carefully cleaned.
CAUTION
Risk of injury through chemical substances
Observe manufacturerâs instructions for handling lubricants and solvents.
Wear suitable protective clothing.
Note
Do not allow cleaning agent or solvent to affect surfaces with paint coating.
Note
The bore of the hollow shaft and the machine shaft must be absolutely free of grease in the area of the
shrinkîdisk seat.
This is essential for safe and reliable torque transmission.
Contaminated solvents and dirty cloths as well as cleaning agents containing oil (such as paraffin or
turpentine) are not suitable for removing grease.
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W
A
4
5
3
1
B
2
Fig. 13: Fitting the shrink disk
AGreasedBAbsolutely grease-
WInstallation height
and oil-free
1Stub shaft
2Hollow shaft
4Outer ring
5Tensioning bolt
3Inner ring
Note
The outer surface of the hollow shaft must be lightly greased in the area of the shrinkîdisk seat.
For a detailed view, refer to the dimensioned drawing in the gearîunit documentation.
â˘Place the shrink disk on the hollow shaft and fasten, if required. For the exact installation height "W" of
the shrink disk, refer to the dimensioned drawing.
WARNING
Serious injury
Risk of injury through falling shrink disk or single parts thereof.
Make absolutely sure that the shrink disk cannot slip off the hollow shaft.
For transporting and lifting the shrink disk it may be required to use a suitable lifting device.
NOTICE
Material damage
Risk of damage to the hollow shaft.
Do not tighten the tensioning bolts (5) until the stub shaft has been installed too.
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â˘Tighten the tensioning bolts (5) gradually one after the other, working round several times by quarter
turns.
â˘Tighten all the tensioning bolts (5) until the end faces of the inner ring (3) and outer ring (4) are flush and
the maximum tightening torque of the tensioning bolts has been achieved. The correct flush situation
is to be checked using a ruler. The maximum tolerance is Âą 0.2 mm.
Note
The correct clamping condition can thus be checked visually.
NOTICE
Material damage
Risk of damage to or destruction of the tensioning bolts through incorrect tightening or through
combination of components that do not match.
To avoid overloading the individual bolts, the maximum tightening torque (see table 5) must not be
exceeded.
Tightening the tensioning bolts using an impact screwdriver is not permitted.
If, when tightening the clamping bolts to maximum tightening torque, the inner and outer ring are not
flush, Siemens must be consulted.
Table 5:Maximum tightening torques for tensioning bolts
Maximum tightening
Tensioning-bolt
thread
torque per bolt
Strength class 12.9
Tensioning-bolt
thread
Nm
M 835M 20570
M 1070M 24900
M 12120M 271310
M 14193M 301800
M 16295M 332400
Maximum tightening
torque per bolt
Strength class 12.9
Nm
Note
The shrink disk has been identityîmarked on the outer ring (4). In case of contacting Siemens this
identification must be referred to.
DANGER
Danger to life through rotating and/or movable parts
Risk of being caught or drawn in by rotating and/or movable parts.
Rotating and/or movable parts must be fitted with suitable safeguards to prevent contact.
NOTICE
Material damage
Risk of damage to the shrink disk through the combination of components that do not match.
Only the complete shrink disks supplied by the manufacturer may be used.
Combining components from different shrink disks is not permitted.
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6.4.2Demounting the shrink disk
â˘Remove the protective cover.
â˘Remove any rust deposits from the shaft and the interior of the hollow shaft.
WARNING
Serious injury
Risk of injury through flying fragments of the tensioning bolts.
Do not unscrew the tensioning bolts one after the other, in order to avoid them to break off due to overload
or due to uncontrolled loosening of the shrink disk.
â˘Undo all the tensioning bolts one after the other by approx. 1/4 turn.
The stored energy of the outer ring is slowly loosened during disassembly via the bolts to be loosened. For
this to be carried out correctly, the procedure described here must be carefully adhered to.
â˘All the tensioning bolts should now be further undone by loosening one after the other by approx. 1 turn.
The outer ring should now release of its own accord from the inner ring. If this is not the case, the outer ring
can be detensioned with the forcing threads.
To this purpose screw some of the adjacent fastening bolts into the forcing threads. The now releasing
outer ring is braced against the remaining bolts. This operation must be carried out until the outer ring
completely releases of its own accord.
â˘The shrink disk is to be secured against axial shifting.
â˘Draw the stub shaft out of the hollow shaft.
â˘Pull the shrink disk off the hollow shaft.
WARNING
Serious injury
Risk of injury through falling shrink disk or single parts thereof.
Make absolutely sure that the shrink disk cannot slip off the hollow shaft.
For transporting and lifting the shrink disk it may be required to use a suitable lifting device.
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6.4.3Cleaning and greasing the shrink disk
Note
Only dirty shrink disks must be disassembled and cleaned.
â˘Check all parts for any damage.
WARNING
Serious injury
Risk of injury through single parts being slung out (e.g. tensioning bolts).
Damaged parts must be replaced with new ones.
The use of damaged parts is not permitted.
Only the complete shrink disks supplied by the manufacturer may be used.
Combining components from different shrink disks is not permitted.
â˘Thoroughly clean all parts.
CAUTION
Risk of injury through chemical substances
Observe manufacturerâs instructions for handling lubricants and solvents.
Wear suitable protective clothing.
Note
The conical surfaces of the inner and outer rings (positions 3 and 4, see figure 13) must be free of grease
and oil.
Contaminated solvents and dirty cloths as well as cleaning agents containing oil (such as paraffin or
turpentine) are not suitable for removing grease.
â˘A thin layer of lubricant must be applied evenly to the conical surfaces of the inner and outer rings
(positions 3 and 4, see figure 13).
â˘Provide the tensioning bolts (position 5, see figure 13) on the contact surface and on the thread with
lubricant.
Use a solid lubricant paste with a high MoS
slide during fitting work and which shows the following characteristics:
îbased molybdenum disulphide content which will not
2
â Friction coefficient "Îź" = 0.04
â Resistant to pressure up to a maximum pressure of 300 N/mm
2
â Ageingîresistant
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Table 6:Recommended lubricants for shrink disks after their cleaning
LubricantFormManufacturer
Molykote G RapidSpray or pasteDOW Corning
Aemasol MO 19 PSpray or pasteA. C. Matthes
Unimoly P 5PowderKlĂźber Lubrication
gleitmo 100Spray or pasteFuchs Lubritec
1)
Other lubricants may be used; however they must have the same characteristics.
â˘Join the inner ring (3) and the outer ring (4).
â˘Place the tensioning bolts and screw in some threads by your fingers.
6.4.4Reîfitting the shrink disk
Note
For reîmounting the shrink disk the procedure described in item 6.4.1 must be adhered to.
6.4.5Inspection of the shrink disk
Note
In all cases the examination of the shrink disk should be carried out simultaneously with the examination
of the gear unit, however at least every 12 months.
1)
Inspection of the shrink disk is limited to a visual assessment of its condition. The following must be
observed when carrying out this work:
â Loose bolts
â Damage caused by force
â Flush position of the inner ring (3) in relation to the outer ring (4)
6.5Oilîlevel monitoring (optional)
â˘Wire the oilîlevel limit switch electrically.
Note
Be sure to observe the corresponding operating instructions for operation and maintenance.
For technical data, refer to the data sheet and/or the list of equipment.
6.6General notes on addîon components
Note
For operating and servicing the components described in section 6, the corresponding operating
instructions and the specifications in section 5 must be observed.
For technical data, refer to the data sheet and/or the list of equipment.
6.7Fitting the limit switch (optional)
â˘Remove the protective plugs.
â˘Screw limit switches into the bores provided.
Note
For the position of the devices, refer to the dimensioned drawing.
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6.7.1Tangential alignment of the limit switch relative to the switch plate (optional)
â˘Screw the EMERGENCYîOFF limitîswitch unit delivered loose by Siemens oilî and splashwaterîtight
into the gearîunit housing over the tube.
â˘Align the rail with the limit switches at a tangent to the switch plate via the tube clips so that the
rollerîpressure pin of the limit switch can turn in the direction of run and not be subjected to additional
transverse forces from contact with the switch plate.
6.7.2Axial positioning of the limit switch relative to the switch plate (optional)
The EMERGENCYîOFF switch points for the height adjustment can be found on the dimensioned
drawing. The forcibly breaking safety switch with rollerîpressure pins used in this design has a switching
movement of 2 mm. The switching movement must be taken into account when positioning the switch.
6.8Fitting the frequency inverter (optional)
Note
Observe separate operating instructions.
6.9Final work
⥠After installation of the gear unit check all screw connections for tight fit.
⥠Check the alignment after tightening the fastening elements. The alignment must not have been
changed.
⥠Check that all the devices which have been demounted for transport reasons have been reîfitted.
For this refer to the details on the data sheet, in the list of equipment and on the associated drawings.
⥠Any oilîdrain cocks must be secured against accidental opening.
⥠The gear unit must be protected against falling objects.
⥠Protective devices for rotating parts must be checked for correct seating. Contact with rotating parts
is not permitted.
⥠A potential equalisation in accordance with the applying regulations and directives must be carried out!
If no threaded holes for earth connection are available on the gear unit, other appropriate measures
must be taken. This work must always be done by specialist electricians.
⥠Cable entries must be protected against moisture.
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Page 46
6.10Screwîconnection classes, tightening torques and initialîtensioning forces
6.10.1 Screwîconnection classes
The specified screw connections are to be fastened applying the tightening torques specified observing
the table below.
NOTICE
Material damage
Risk of damage to the bolts and/or mating threads through incorrect tightening.
Foundation bolts, hub bolts and bearingîcover bolts must always be tightened in accordance with
screwîconnection class "C".
Table 7:Screwîconnection classes
Fastening of
Gear unit
Motor*
Protective hoodE
Screw-connection
class
C
D
â Hydraulic tightening with mechanical screwdriver
â Hydraulic tightening with mechanical screwdriver
â Tightening with precision mechanical screwdriver
â Torque-controlled tightening with mechanical screwdriver
â Tightening with pulse screwdriver or impact wrench
â Tightening by hand, using a spanner without torque
*)The tightening torques applying to these addîon parts can be found in the instructions supplied by the
manufacturers of the parts.
6.10.2 Tightening torques and initialîtensioning forces
The tightening torques apply to friction coefficients of Îź
The friction coefficient Îź
= 0.14 applies here to lightly oiled steel bolts, blackîannealed or phosphatised
total
and dry, cut mating threads in steel or cast iron. Lubricants which alter the friction coefficient must not be
used and may overload the screw connection.
Tightening procedure
with dynamic torque measuring
without adjustment checking device
measuring device
= 0.14.
total
Table 8:Initialîtensioning forces and tightening torques for screw connections of strength classes
= 0.14
total
Tightening torque
for screw-connection classes
from table 7
M
A
Nm
Nominal
thread
diameter
d
mm
M10
M12
8.8; 10.9; 12.9 with a common friction coefficient of Îź
Strength
class
of the bolt
8.81800011500720044.638.434.3
10.926400169001060065.456.450.4
12.930900198001240076.566.058.9
8.826300168001050076.766.159.0
10.938600247001540011397.186.6
12.9451002890018100132114101
Initial-tensioning force
for screw-connection classes
from table 7
CDECDE
F
M min.
N
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Nominal
thread
diameter
d
mm
M16
M20
M24
M30
M36
M42
M48
M56
M64
M72x6
M80x6
M90x6
M100x6
Strength
class
of the bolt
8.8493003160019800186160143
10.9725004640029000273235210
12.9850005440034000320276246
8.8770004920030800364313280
10.91100007040044000520450400
12.91290008240051500609525468
8.81090006960043500614530470
10.91550009920062000875755675
12.9181000116000725001020880790
8.81700001090006800012101040930
10.924300015500097000172014801330
12.9284000182000114000201017401550
8.824600015700098300208017901600
10.9350000224000140000296025502280
12.9409000262000164000346029802670
8.8331000212000132000326028102510
10.9471000301000188000464040003750
12.9551000352000220000543046804180
8.8421000269000168000475040903650
10.9599000383000240000676058205200
12.9700000448000280000790068106080
8.8568000363000227000743064005710
10.98060005160003230001050090908120
12.994400060400037800012300106009500
8.87440004760002980001100094808460
10.91060000676000423000156001350012000
12.91240000792000495000183001580014100
8.8944000604000378000155001340011900
10.91340000856000535000220001890016900
12.915700001000000628000258002220019800
8.81190000760000475000215001850016500
10.916900001100000675000305002640023400
12.919800001360000790000357003140027400
8.81510000968000605000306002630023500
10.921500001380000860000435003750033400
12.9252000016000001010000510004380039200
8.818800001200000750000421003620032300
10.9267000017100001070000600005160046100
12.9313000020000001250000700006040053900
Initial-tensioning force
for screw-connection classes
from table 7
F
M min.
N
Tightening torque
for screw-connection classes
from table 7
M
A
Nm
EDCEDC
Note
Damaged bolts must be replaced with new bolts of the same type and strength class.
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7.Startîup
Observe the instructions in section 3, "Safety instructions"!
7.1Procedure before startîup
7.1.1Removal of preservative agent from exterior
â˘The preserved shaft ends in the area of the couplings to be fitted must be depreserved, using suitable
agents (special solvent etc.).
The depreservation also applies to bright surfaces of the gear unit, onto which components are to be
fitted.
CAUTION
Risk of injury through chemical substances
The solvent must not come into contact with the skin (e.g. the operatorâs hands).
The safety notes on the data sheets for the solvent used must be observed.
Remove any solvent spillage immediately with a binding agent.
Observe manufacturerâs instructions for handling lubricants and solvents.
Wear suitable protective clothing.
7.1.2Removal of preservative agent from interior
NOTICE
Material damage
Risk of damage to the gear unit through missing or insufficient ventilation.
Replace the screw plug with the air filter or wetîair filter before startîup.
The position of the oilîdrain points is marked by a symbol on the dimensioned drawing in the gearîunit
documentation.
Oilîdrain point:
â˘Place suitable containers under the oilîdrain points (4 and 5).
â˘Open the oilîdrain cock (4) and unscrew the residualîoil drain plug (5).
â˘Remove remaining preservative agent and/or runningîin oil from the housing using a suitable container;
to do so, unscrew all existing residualîoil drain plugs.
â˘Dispose of remaining preservative agent and/or runningîin oil in accordance with regulations.
CAUTION
Risk of injury through chemical substances
The oil must not come into contact with the skin (e.g. the operatorâs hands).
The safety notes on the data sheets for the oil used must be observed.
Remove any oil spillage immediately with a binding agent.
Observe manufacturerâs instructions for handling lubricants and binding agents.
Wear suitable protective clothing.
â˘Shut the oilîdrain cock (4) and screw in the residualîoil drain plug (5) again.
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8
16
(II)
(III)
9
(II)
7
(II)
6
(Ia)
(Ib)
(III)
(III)
(I)
(I)
13
12
4
5
14
10
11
15
1
2,3
Fig. 14: Oil inlet and oil drain â gear unit with hoist gear unit
1Ventilation (I) main gear unit
2Oil filling (I) main gear unit
3Dipstick; oil filling (I) main gear unit
4Oil-drain cock (Ia); oil drain main gear unit
5Oil-drain plug; residual oil (Ib) main gear unit
6Ventilation; oil filling (II) primary gear unit
7Oil level (II) primary gear unit
8Oil-drain plug (II) primary gear unit
9Ventilation / oil filling (III) hoist
gear unit
10Oil level (III) hoist gear unit
11Oil-drain plug (III) hoist gear unit
12Bellows
13Vent hole
14Leak hole
15Leak hole
16Inspection and/or assembly cover
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16
(II)
8
(Ia)
(Ib)
13
12
4
5
14
(II)
7
(II)
6
(I)
(I)
1
2,3
Fig. 15: Oil inlet and oil drain â gear unit with lifting cylinder
1Ventilation (I)
2Oil filling (I) main gear unit
3Dipstick (I); oil filling (I) main gear unit
4Oil-drain cock (Ia); oil drain main gear unit
5Oil-drain plug; residual oil (Ib) main gear unit
6Ventilation; oil filling (II) primary gear unit
7Oil level (II) primary gear unit
8Oil-drain plug (II) primary gear unit
For a detailed illustration of the gear unit and the position of the addîon parts, refer to the drawings in the
gearîunit documentation.
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7.1.3Filling with lubricant
7.1.3.1 Helicalîgear unit (main gear unit)
The gaps between the shaftîsealing rings, if fitted, have already been filled with grease.
â˘Unscrew the dipstick (2) on the oilîequalising tank.
Note
For data such as oil type, oil viscosity and oil quantity required, refer to section 1, "Technical data").
â˘Top up the gear unit with fresh oil, using a filter (mesh approx. 10 Îźm), to begin with with 60 to 70 % of
the oil quantity indicated on the rating plate.
Note
The quality of the oil used must meet the requirements of the separately supplied BA 7300 operating
instructions, otherwise the guarantee given by Siemens will lapse. We urgently recommend using one
of the oils listed in table "T 7300" (for a link to the Internet, see the back cover), as they have been tested
and meet the requirements.
Information on the type, quantity and viscosity of the oil is given on the rating plate on the gear unit.
The oil quantity shown on the rating plate is to be understood as an approximate quantity. The actual oil
quantity to be put in is the MAX mark on the dipstick, when the insert shaft has been run out.
CAUTION
Risk of injury through chemical substances
The oil must not come into contact with the skin (e.g. the operatorâs hands).
The safety notes on the data sheets for the oil used must be observed.
Remove any oil spillage immediately with a binding agent.
Observe the manufacturerâs instructions for handling lubricants.
Wear suitable protective clothing.
â˘Screw in the dipstick (2) again.
NOTICE
Material damage
Risk of damage to the wetîair filter.
Prior to using the wetîair filter, 2 of the 8 sealed bores at the underside of the wetîair filter must be opened.
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â˘Move the spentîgrain cutting machine to the upper position by means of the bevelîgear motor (electric
motor II) or the lifting cylinder.
NOTICE
Material damage
Risk of damage to the gear unit through incorrect direction of rotation.
Check the direction of rotation of the electric motor II before switching on.
Start the motor briefly. If the direction of rotation is incorrect, switch off immediately and interchanged the
connections.
Note
Vertical adjustment must be done only when the helicalîgear unit is filled with 60 to 70 % of the oil
indicated on the rating plate. Startup via the electric motor I is not yet permitted. Since there is no
adjustment of the limit switches the spindle drive must not be run out beyond the upper mark on the
mechanical height indicator. Adjust any residual height necessary manually via the fan wheel of the
electric motor II or via the lifting cylinder.
â˘Unscrew the dipstick (3) on the oilîequalising tank.
â˘Fill in a further approx. 30 to 40 % of the oil quantity specified on the rating plate, using a filter (mesh
approx. 10 Îźm) via the oilîfilling hole, until the oil comes up to the lower mark on the dipstick. Do not put
in any further oil. The viscosity of the oil in cold condition will cause the oil level to continue rising slowly.
If necessary, put in further oil up to the MAX mark on the dipstick, only after the oil level has steadied.
â˘Check the oil level using the dipstick (3).
Note
The oil must come up to the MAX mark on the dipstick, when the insert shaft has been run out.
CAUTION
Risk of injury through chemical substances
The oil must not come into contact with the skin (e.g. the operatorâs hands).
The safety notes on the data sheets for the oil used must be observed.
Remove any oil spillage immediately with a binding agent.
Wear suitable protective clothing.
â˘Screw in the dipstick (3) again.
7.1.3.2 Bevel-gear unit
â˘The bevelîgear units have already been filled with oil as indicated in section 1, "Technical data".
Note
Observe separate operating instructions.
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7.2Setting of the cam-operated switches (in the gearîunit cam operated switch)
â˘Move the spentîgrain cutting machine to the middle position by means of bevelîgear motor (electric
motor II).
â˘Determine the afterîrun in both directions (afterîrun is the number of revolutions between switching off
and motor standstill)
â˘Run the machine onto the switching points of the cam-operated switches.
â˘Turn the drive back by the amount of afterîrun determined.
NOTICE
Material damage
Risk of damage to the gear unit or lauter tun through setting of incorrect switch points.
Check the setting of the switch points
The switch points must be run onto from the same direction to set them, just as they will be in electrical
operation afterwards.
â˘Set the switching cams to the individual switch points until a ratcheting noise can be clearly heard.
Note
Observe separate operating instructions.
7.3Setting the rotary angle transducer (in the gearîunit cam operated switch)
â˘Move the spentîgrain cutting machine to the lower position by means of bevelîgear motor (electric
motor II).
â˘Using a screwdriver, set the 4 mA signal on the rear shaft bush of the rotary angle transducer.
â˘100 % adjustment is not required. The transmitters are set for the respective drive angle to ⤠20 mA at
the factory in accordance with order specifications.
Note
Observe separate operating instructions.
7.4Setting of the EMERGENCYîOFF limit switches
â˘Set the EMERGENCYîOFF limit switches so that the electric motor II or the lifting cylinder is switched
off immediately when the upper and lower switch contacts of the gearîunit cam operated switch are run
over.
NOTICE
Material damage
Risk of damage to the gear unit or lauter tun through incorrect setting.
Check the setting of the switch points
Adjustment must be done with the greatest care to avoid damaging the lauter tun or the gear unit.
Note
Observe separate operating instructions.
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7.5Startîup
NOTICE
Material damage
Risk of damage to the gear unit through missing or insufficient ventilation.
Replace the screw plug with the air filter or wetîair filter before startîup.
NOTICE
Material damage
Risk of damage to the wetîair filter.
Prior to using the wetîair filter, 2 of the 8 sealed bores at the underside of the wetîair filter must be opened.
â˘Check the oil level of the gear unit (see item 7.5.1).
7.5.1Oil level
The following oil level is correct:
â MAX mark on the dipstick with the insert shaft run out.
Note
When cooled down the oil must come up as far as between the MAX mark on the dipstick.
Hot oil may slightly exceed the MAX mark on the dipstick.
NOTICE
Material damage
Insufficient lubrication possible through too low oil level.
Check the oil level.
Under no circumstances must it fall below the MIN mark on the dipstick. If necessary, top up oil to the
correct level.
7.5.2Temperature measurement
During the first startîup and after maintenance work, the oilîsump temperature must be measured during
proper use (maximum drivenîmachine performance) after warming up.
NOTICE
Material damage
Risk of damage to the gear unit through insufficient lubrication resulting from too high oil temperature.
The maximum permissible oilîsump temperature is 90 °C.
At higher temperatures the gear unit must be shut down immediately and Siemens customer service
consulted.
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7.5.3Oilîlevel monitoring (optional)
The gear unit can be fitted with an oilîlevel monitor by means of a fillingîlevel limit switch. The oilîlevel
monitoring device has been designed for checking the oil level when the gear unit is at a standstill, prior
to operating start.
Note
Wiring should be in such a way that, when the signal "Oil level too low" is given, the drive motor cannot
start and that a warning signal is emitted. During operation, any signal should be bridged.
7.5.4Checking procedure
The following visual checks must be conducted and recorded when starting up:
âĄ
⥠Oil level
⥠Leaktightness of the oilîcooling or oilîsupply lines
⥠Opening condition of the shutîoff valves
⥠Effectiveness of the shaft seals
⥠Freedom of the rotating parts from contact
The tension pressures or pretensioning forces shown in item 6.3.2.2 must also be recorded in this
document.
Note
The record must be kept with these instructions.
7.6Shutting down
â˘Switch off the drive unit.
DANGER
Danger to life through switchedîon installation
To carry out work on the gear unit, the gear unit must always be stopped.
The drive unit must be secured against being switched on accidentally (e.g. by locking the key switch
or removing the fuses from the power supply).
A notice should be attached to the ON switch stating clearly that work is in progress on the gear unit.
â˘Start the gear unit and allow it to run briefly (5 to 10 minutes) approx. every 3 weeks (during a shutîdown
period no longer than 6 months).
â˘Treat the gear unit with preservative, see items 7.6.1 and 7.6.2 (before a removal from service for
a period exceeding 6 months).
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7.6.1Interior preservation for longer disuse
Depending on the type of lubrication and/or shaft sealing, the following types of interior preservation can
be applied.
7.6.1.1 Interior preservation with gearîunit oil
Gear units with splashîlubrication systems and contacting shaft seals can be topped up with the type of
oil already filled in to a level just below the air filter or wetîair filter.
The durability period of this type of preservation depends on the age of the shaftîsealing rings and the oil.
Note
After a preservation period exceeding 36 months the radial shaftîsealing rings must be replaced before
startîup.
NOTICE
Material damage
Risk of damage through insufficient lubrication through undetected leakage.
The leaktightness of the gear unit must be checked regularly every 4 weeks.
â˘Unscrew the air filter with reducing screw or the wetîair filter (1) (see fig. 14 or fig. 15 in item 7.1.2).
â˘Top up gearîunit oil through the hole up to just beneath the air filter or wetîair filter.
Note
For gearîunit oils refer to table "T 7300" (for a link to the Internet, see the back cover).
CAUTION
Risk of injury through chemical substances
The oil must not come into contact with the skin (e.g. the operatorâs hands).
The safety notes on the data sheets for the oil used must be observed.
Remove any oil spillage immediately with a binding agent.
Wear suitable protective clothing.
â˘Replace the air filter with reducing screw or the wetîair filter (1) with the screw plug.
â˘Place a suitable container under the oilîdrain point of the gearîunit housing.
â˘Open the oilîdrain cock (4). For this, refer to fig. 14 or fig. 15 in item 7.1.2.
â˘Drain the oil into a suitable container (see section 10, "Maintenance and Repair").
WARNING
Risk of scalding
Serious injury through escaping operating media possible whilst they are replaced.
Wear suitable protective gloves, protective glasses and protective clothing.
CAUTION
Risk of injury through chemical substances
The oil must not come into contact with the skin (e.g. the operatorâs hands).
The safety notes on the data sheets for the oil used must be observed.
Remove any oil spillage immediately with a binding agent.
Wear suitable protective clothing.
Note
Check the condition of the sealing ring; the sealing ring is vulcanised onto the oilîdrain plug. If necessary,
use a new oilîdrain plug.
â˘Shut the oilîdrain cock (4) again.
â˘Unscrew the air filter or wetîair filter (1) on the oilîequalising tank.
â˘Replace the air filter or wetîair filter (1) with the screw plug.
Note
Carefully clean the air filter (see item 10.2.4) and keep it on a safe place (it will be required again when
starting up again) or use a new wetîair filter at startîup.
â˘Unscrew the dipstick (3) on the oilîequalising tank.
â˘Fill the gear unit with "Castrol Alpha SP 220 S".
Determine the filling quantity according to the gearîunit dimensions: length x width x height x 0.1.
NOTICE
Material damage
Corrosion possible through use of an unsuitable preservative agent.
Use special oil "Castrol Alpha SP 220 S" with additional antiîcorrosive agent (additive "S").
â˘Screw in the dipstick (3) again.
NOTICE
Material damage
Corrosion possible through leaving the gear unit open too long.
Close the gear unit airtightly at the latest one hour after opening.
Before reîstarting the gear unit take the following measure:
â Replace the screw plug with the air filter or wetîair filter.
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7.6.2Exterior preservation
7.6.2.1 Exteriorîpreservation procedure
â˘Clean the surfaces.
NOTICE
Material damage
Risk of damage to the shaftîsealing ring through contact with chemically aggressive preservative agent.
For separation between the sealing lip of the radial shaftîsealing ring and the preservative agent, the
shaft should be brushed with grease in the area around the sealing lip.
â˘Apply preservative agent.
Note
For preservative agent, see table 4 in item 4.4.2.
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8.Operation
Observe the instructions in section 3, "Safety instructions", in section 9, "Faults, causes and remedy", and
in section 10, "Maintenance and repair"!
8.1General
To achieve a satisfying and troubleîfree operation of the equipment, be certain to observe the working
values specified in section 1, "Technical data".
During operation the gear unit must be monitored for the following:
⥠Operating temperatureThe gear unit is designed for an operating temperature
⥠Changes in gear noise
⥠Oil leakage at the housing and
shaft seals
8.2Oil level
in continuous operation of:
90 °C (applies to mineral oil)
The maximum permitted temperature is:
100 °C (applies to mineral oil)
Note
For checking the oil level, the gear unit must be stopped.
Depending on the type of the gearîunit housing the following oil levels are correct when the oil has cooled
down:
â MAX mark on the dipstick with the insert shaft run out
When cooled down the oil must come up as far as between the MAX mark on the dipstick. Hot oil may
slightly exceed the MAX mark on the dipstick.
NOTICE
Material damage
Insufficient lubrication possible through too low oil level.
Check the oil level.
Under no circumstances must it fall below the visible MIN mark on the dipstick. If necessary, top up oil
to the correct level.
8.3Irregularities
NOTICE
Material damage
Risk of damage to the gear unit through fault conditions.
Switch off the drive unit immediately on occurrence of the following situations.
⥠If irregularities are found during operation.
Note
Determine the cause of the fault, using table 9, "Faults, causes and remedy" (see item 9.2).
Table 9, "Faults, causes and remedy", contains a list of possible faults, their causes and suggested
remedies.
If the cause cannot be found, a specialist from one of the Siemens customerîservice centres should be
called in (see section 2, "General notes").
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9.Faults, causes and remedy
Observe the instructions in section 3, "Safety instructions", and in section 10, "Maintenance and repair"!
9.1General information on faults and malfunctions
Faults and malfunctions occurring during the guarantee period and requiring repair work on the gear unit
must be carried out only by Siemens customer service.
In case of faults and malfunctions occurring after the guarantee period and whose cause cannot be
precisely identified, we advise our customers to contact our customer service.
NOTICE
Material damage
Risk of damage to the gear unit through improper use.
Siemens will not be bound by the terms of the guarantee or otherwise be responsible for further operation
in cases of improper use of the gear unit, modifications carried out without the approval by Siemens or
use of spare parts not originally supplied by Siemens.
DANGER
Danger to life through switchedîon installation
To carry out maintenance and/or repair work, the gear unit must always be stopped.
Secure the drive unit to prevent unintentional switchîon. A notice should be attached to the ON switch
stating clearly that work is in progress on the gear unit.
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9.2Possible faults
Table 9:Faults, causes and remedy
Faults
Changes in gearîunit noise.Damage to gear teeth.
Excessive bearing play.
Bearing is defective.
Loud noises in the area of the
gearîunit fastening.
Increased temperature at the
bearing points.
Exterior of gear unit is oiled up.Inadequate sealing of housing
Gearîunit fastening has worked
loose.
Oil level in gearîunit housing too
low or too high.
Tighten bolts and nuts to the
specified tightening torque.
Replace damaged bolts and nuts.
Check oil level at room temperature.
Top up oil, if necessary.
Check date of last oil change.
Change oil, if necessary.
See section 10.
Contact Customer Service.
Check and, if necessary,
replace bearings.
Seal housing covers and/or joints.
Oil leakage from the gear unit.Inadequate sealing of housing
covers and/or joints.
Radial shaftîsealing rings defective.
Oil foaming in the gear unit.Preservative agent not completely
drained.
Gear unit too cold in operation.
Water in oil.
Oil too old
(defoaming agent used up).
Unsuitable oils are mixed up.
Check and, if necessary,
replace seals. Seal housing covers
and/or joints.
Check and, if necessary,
replace radial shaftîsealing rings.
Change oil.
Shut down gear unit and have oil
degassed. Restart without cooling
water.
Check state of oil by the testîtube
method for water contamination.
Have oil analysed by a chemical
laboratory.
Change oil, if necessary.
Examine the oil; change the oil,
if necessary.
Examine the oil; change the oil,
if necessary.
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Page 62
FaultsRemedyCauses
Water in oil.Gear unit exposed to cold air from
Increased operating
temperature.
Temperature too high at the
bearing points of the
helicalîgear unit with
strokeîmounting flange
Bevelîgear motors
(Electric motors I and II)
Gearîunit cam operated switch
EMERGENCYîOFF limit switchObserve separate operating
Frequency inverter (optional)Observe separate operating
machineîroom fan: Water
condensing.
Climatic conditions.
Oil level in housing too high.
Oil too old.
Oil badly contaminated.
Oil level in housing too low.
Oil too old.
Bearing defective.
Protect gear unit with suitable heat
insulation. Close air outlet or alter its
direction by structural measures.
Contact Customer Service.
If necessary, use wetîair filter.
Check the oil level. Adjust oil level,
if necessary.
Check date of last oil change.
If necessary, change the oil;
see section 10.
Change the oil; see section 10.
Check the oil level.
Top up oil, if necessary.
Check date of last oil change.
If necessary, change the oil;
see section 10.
Contact Customer Service. Check
and, if necessary, replace bearings.
Observe separate operating
instructions.
Observe separate operating
instructions.
instructions.
instructions.
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Page 63
9.2.1Leakage and leaktightness
In standard "DIN 3761" information is given on the subject of leakage on gear units. Based on this and
building on the extensive experience gained at Siemens
*)
and other FVA 1) member companies, brief
descriptions, required measures and notes on this subject are included in the following overview.
2)
Table 10: Notes on the leaktightness of radial shaftîsealing rings (RWDR
)
ConditionDescriptionMeasuresNotes
Leaktight, dryNo moisture to be seen on
radial shaft-sealing ring.
Leaktight, dampFilm of moisture formed
functionally in the area of
the sealing edge but not
extending beyond the
bottom side of the radial
shaft-sealing ring.
Leaktight, wetMoisture film extending
beyond the bottom side of
the radial shaft-sealing
ring but not dripping.
Measurable leakSmall trickle to be seen on
the bottom side of the
radial shaft-sealing ring,
dripping.
None
Only when contaminated,
wipe with clean cloth
underneath sealing lip.
The sealing lip must not
be contaminated.
Observe.
Wipe with clean cloth
underneath sealing lip.
The sealing lip must not
be contaminated.
Observe.
Change radial
shaft-sealing ring,
if necessary;
identify possible cause
of radial shaft-sealing ring
failure and rectify.
The radial shaft-sealing
ring often dries by itself in
further operation.
No reason for complaint.
The radial shaft-sealing
ring often dries by itself in
further operation.
No reason for complaint.
May be a reason for
complaint; one drop of oil
a day is acceptable.
Short-term leakShort-term failure of the
sealing system.
Apparent leakTemporary leak.Wipe with clean cloth
Wipe with clean cloth
underneath sealing lip.
The sealing lip must not
be contaminated.
Observe.
underneath sealing lip.
The sealing lip must not
be contaminated.
E.g. through small particles
on the seal edge, which
are removed again in
further operation.
No reason for complaint.
Due mostly to excessive
grease filling between seal
and dust lip or oil
secretions from the grease
filling of labyrinth seals.
No reason for complaint.
*)Siemens AG, Mechanical Drives "MD" Business Unit
1)
FVA = Forschungsvereinigung Antriebstechnik e. V.
2)
RWDR = radial shaftîsealing ring
Note
Oil mist escaping from a airîrelief valve or a labyrinth seal is functional and therefore
not a reason for complaint.
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10.Maintenance and repair
Observe the instructions in section 3, "Safety instructions", and in section 9, "Faults, causes and remedy"!
10.1General notes on maintenance
All maintenance and repair work must be carried out carefully and by qualified personnel only (see section
"Qualified Personnel" on page 3 of this manual).
The following applies to all work in item 10.2:
DANGER
Danger to life through switchedîon installation
To carry out maintenance and/or repair work, the gear unit must always be stopped.
Secure the drive unit to prevent unintentional switchîon. A notice should be attached to the ON switch
stating clearly that work is in progress on the gear unit.
The periods indicated in table 11 largely depend on the conditions under which the gear unit is operated.
Only average periods can therefore be stated here. These refer to the following values:
daily operating time of24 h
duty factor "ED" of100 %
input-drive speed of1500 1/min
operating temperature of90 °C(applies to mineral oil)
NOTICE
Material damage
Risk of damage to the gear unit through nonîobservance of the periods specified for maintenance and
repair work.
The operator must ensure that the intervals stated in table 11 are adhered to. This also applies if the
maintenance work is included in the operatorâs internal maintenance schedules.
Table 11: Maintenance and repair work
MeasuresPeriodsRemarks
Check the oil temperatureDaily
Check for unusual gear-unit noiseDaily
Check the oil levelMonthlyâ Upper mark on the dipstick
with the insert shaft run out
Check the gear unit for leaksMonthly
Examine the water content of the oilAfter approx. 400 operating hours,
at least once a year
Perform the first oil changeApprox. 400 operating hours
after start-up
See item 10.2.1.
See item 10.2.2.
Perform subsequent oil changesEvery 24 months
or 10 000 operating hours
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See item 10.2.2.
Page 65
MeasuresRemarksPeriods
Replace the wet-air filterAs requiredSee item 10.2.3.
Clean the air filterEvery 3 monthsSee item 10.2.4.
Clean the gear unitDepending on requirements,
at least every 2 years
Check tightness of fastening boltsAfter the first oil change,
then every 2 years
Check shrink disk.Every 12 monthsSee item 6.4.5.
Inspection of the gear unitEvery 2 yearsSee item 10.4.
Check electric motor I,
electric motor II, bevel-gear unit
and lifting cylinder
See separate instruction manualSee separate instruction
10.1.1 General service lives of oils
According to the oil manufacturers, the following are the expected periods during which the oils can be
used without undergoing any significant change in quality. They are calculated on the basis of an average
oil temperature of 80 °C:
â mineral oils, bioîdegradable oils and physiologically safe oils: 2 years or 10 000 operating hours.
Does not apply to natural esters such as rape seed oils.
Note
The actual service lives may differ. The general rule is that an increase in temperature of 10 K will halve
the service life and a temperature decrease of 10 K will approximately double the service life.
10.2Description of maintenance and repair works
See item 10.2.5.
See item 6.10.
manual
10.2.1 Examine water content of oil, conduct oil analyses
Detailed information about examining the oil for water content or conducting oil analyses is obtainable from
your lubricant manufacturer or the Siemens customer service.
â For reference purposes, a sample of the fresh operating lubricating oil in use must be sent with the
usedîoil sample to the analysing institute for analysis.
â A special sample container should be filled with the specified quantity of oil.
If there is no such sample container available, at least one litre of oil must be put in a clean,
transportworthy, sealable vessel.
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10.2.2 Changing the oil (main gear unit)
As an alternative to the oilîchange intervals specified in table 11 (see item 10.1), it is possible to have an
oil sample tested at regular intervals, every 4 weeks, by the technical service of the relevant oil company
and to have it cleared for further use.
If further usability has been confirmed, no oil change will be necessary.
Note
Please observe the separately annexed operating instructions BA 7300 and the notes in item 7.1.
â˘Drain the oil while the gear unit is still warm, i.e. immediately after stopping the machinery.
NOTICE
Material damage
Risk of damage to the gear unit through incorrect lubrication resulting from mixed oils.
When changing the oil, always reîfill the gear unit with the same type of oil.
Never mix different types of oil and/or oils made by different manufacturers.
The use of synthetic oil is not permissible.
â˘Place a suitable container under the oilîdrain points of the gearîunit housing.
â˘Open the oilîdrain cock (4) and drain off the oil into the container. See also fig. 14 or fig. 15 in item 7.1.2.
CAUTION
Risk of scalding
Risk of injury through escaping hot oil.
Wear suitable protective gloves, protective glasses and protective clothing.
Remove any oil spillage immediately with an oilîbinding agent.
Note
Check the condition of the sealing ring; the sealing ring is vulcanised onto the oilîdrain plug. If necessary,
use a new oilîdrain plug.
â˘Shut the oilîdrain cock (4).
â˘Unscrew the dipstick (3) on the oilîequalising tank.
â˘Fill fresh oil into the gear unit (see item 7.1.3).
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To top up oil:
â˘Unscrew the dipstick (3) on the oilîequalising tank.
â˘Top up the gear unit with fresh oil using a filling filter (mesh approx. 10 Îźm), until the oil reaches the lower
mark on the dipstick. Do not put in any further oil. The viscosity of the oil in cold condition will cause the
oil level to continue rising slowly. If necessary, put in further oil up to the MAX mark on the dipstick, with
the insert shaft run out, only after the oil level has steadied.
Note
Always top up with the same type of oil as already used in the unit (see also item 10.2.2).
For data such as oil type, oil viscosity and oil quantity required, refer to section 1 "Technical data").
â˘Check the oil level using the dipstick (3).
Note
The oil must come up to the MAX mark on the dipstick, when the insert shaft has been run out.
CAUTION
Risk of scalding
Risk of injury through escaping hot oil.
Wear suitable protective gloves, protective glasses and protective clothing.
Remove any oil spillage immediately with an oilîbinding agent.
10.2.3 Replace the wetîair filter
The wetîair filter has a container filled with "silica gel". The air humidity absorbed by the "silica gel" changes
the colour of the gel from "blue" to "pink" (visible through the transparent container). Replacement of the
complete wetîair filter is only necessary when the "silica gel" has gone completely pink.
â˘Unscrew the wetîair filter and replace it with a new one.
NOTICE
Material damage
Risk of damage to the wetîair filter.
Prior to using the wetîair filter, 2 of the 8 sealed bores at the underside of the wetîair filter must be opened.
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10.2.4 Clean the air filter
Note
A period of 3 months has been specified for cleaning the air filter.
If a layer of dust has built up, the air filter must already be cleaned, whether or not the period of 3 months
has expired.
Note
If the air filter is protected with a filter cap, the filter cap must be removed for cleaning the air filter. After
the air filter has been cleaned, the filter cap must be fitted again.
â˘Unscrew the air filter including the reducing screw.
â˘Clean the air filter using a suitable cleaning agent.
â˘Dry the air filter and/or blow out with compressed air.
WARNING
Risk of eye injury through compressed air
Remains of water and/or dirt particles may be harmful to the eyes.
Wear suitable protective glasses.
NOTICE
Material damage
Risk of damage to the gear unit through entry of foreign bodies.
Foreign bodies must be prevented from entering the gear unit.
10.2.5 Clean the gear unit
NOTICE
Material damage
Risk of damage to the gear unit through overheating.
Layers of dust may affect the withdrawal of heat by way of the housing surface and cause overheating.
To prevent the buildîup of dust on the gear unit, cleaning must be done in accordance with the local
operating conditions.
â˘Remove any dirt adhering to the gear unit, using a hard brush.
â˘Remove any corrosion.
NOTICE
Material damage
Risk of damage to the gear unit through entry of moisture.
The gear unit must not be cleaned with highîpressure cleaning equipment.
10.2.6 Top up oil
â˘The instructions in item 7.1 must be observed!
â˘Always top up with the same type of oil as already used (see also item 10.2.2).
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10.2.7 Check tightness of fastening bolts
â˘The instructions in item 10.1 must be observed!
â˘Check tightness of all the fastening bolts.
Note
Damaged bolts must be replaced with new bolts of the same type and strength class.
10.3Final work
Note
For operating and servicing all components, the pertinent operating instructions and the specifications
relating to the components in sections 5, "Technical description", and 7, "Startîup", must be observed.
For technical data, refer to the data sheet and/or the list of equipment.
The instructions in item 6.9 must be observed.
Damaged bolts must be replaced with new bolts of the same type and strength class.
10.4General inspection of the gear unit
The general inspection of the gear unit should be carried out by the Siemens Customer Service, as our
engineers have the experience and training necessary to identify any components requiring replacement.
10.5Lubricants
Note
The use of synthetic oil is not permissible.
The quality of the oil used must meet the requirements of the separately supplied BA 7300 operating
instructions, otherwise the guarantee given by Siemens will lapse. We urgently recommend using one of
the oils listed in table "T 7300" (for a link to the Internet, see the back cover), as they have been tested and
meet the requirements.
Note
To avoid misunderstandings, we should like to point out that this recommendation is in no way intended
as a guarantee of the quality of the lubricant supplied. Each lubricant manufacturer is responsible for the
quality of his own product.
Information on the type, viscosity and required quantity of the oil is given on the rating plate on the gear unit
and/or in the supplied documentation.
The oil quantity shown on the rating plate is to be understood as an approximate quantity. The actual oil
quantity to be put in is the MAX mark on the dipstick, when the insert shaft has been run out.
The BA 7300 manual relating to the gearîunit lubrication and table "T 7300" containing the current lubricant
recommendations of Siemens can also be consulted on the internet (see back cover).
The oils listed there are subjected to continuous tests. Under certain circumstances the oils recommended
there may therefore later be removed from the range or replaced with further developed oils.
We recommend checking before any oil change whether the chosen lubricant is still approved by Siemens.
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11.Spare parts, customer service
11.1Stocking spare parts
By stocking the most important spare and wearing parts on site you can ensure that the gear unit is ready
for use at any time.
To order spare parts, refer to the spareîparts list.
For further information refer to the spareîparts drawing stated in the spareîparts list.
NOTICE
Material damage
Risk of damage to the gear unit through improper use.
Siemens guarantees only the genuine spare parts supplied by Siemens.
Nonîgenuine spare parts have not been tested nor approved by Siemens. Nonîgenuine spare parts may
alter technical characteristics of the gear unit, thereby posing an active or passive risk to safety.
Siemens will assume no liability or guarantee for damage caused by spare parts not supplied by
Siemens. The same applies to any accessories not supplied by Siemens.
Please note that certain components often have special production and supply specifications and that
Siemens supplies you with spare parts which comply fully with the current state of technical development
as well as current legislation.
When ordering spare parts, always state the following:
Order number, positionType, sizePart numberQuantity
11.2Addresses for ordering spare parts and customer service
When ordering spare parts or requesting a service specialist, please contact Siemens first.
â The partly completed machinery must not be put into service until it has been established that the
machinery into which the partly completed machinery is to be incorporated has been declared
to be in conformity with the provisions of Directive 2006/42/EC, as appropriate.
â The manufacturer undertakes, in response to a reasoned request by the national authorities,
to transmit in electronic form relevant information about the partly completed machinery.
â The person authorised to compile the relevant technical documentation is: