Contents Contents General Information .................... 5 How to use the operating instructions ............5 Structure of the safety notes ............... 5 Rights to claim under limited warranty ............6 Exclusion of liability..................6 Safety Notes ......................7 Preface......................7 General information ..................7 Target group ....................
Page 4
Contents Startup........................ 70 Checking the oil level ................70 Measuring surface and oil temperature ............ 70 ® Helical-worm and SPIROPLAN W gear units ......... 72 Helical/parallel shaft helical/helical-bevel gear units ......... 73 Gear units with backstop................74 Speed monitoring..................75 Installation and adjustment of the WEX speed monitor ......
General Information How to use the operating instructions General Information How to use the operating instructions The operating instructions are an integral part of the product and contain important in- formation on operation and service. The operating instructions are written for all employ- ees who assemble, install, startup, and service this product.
General Information Rights to claim under limited warranty Rights to claim under limited warranty Adhering to the operating instructions is a prerequisite for fault-free operation and the fulfillment of any right to claim under warranty. Read the operating instructions before you start working with the unit.
Safety Notes Preface Safety Notes The following basic safety notes are intended to prevent injury to persons and damage to property. The operator must ensure that the basic safety notes are read and ob- served. Make sure that persons responsible for the system and its operation, as well as persons who work independently on the unit, have read through the operating instruc- tions carefully and understood them.
Safety Notes Target group Target group Any mechanical work may only be performed by adequately qualified personnel. Quali- fied personnel in this context are persons who are familiar with the setup, mechanical installation, trouble shooting and maintenance for this product. Further, they are quali- fied as follows: •...
Safety Notes Other applicable documentation Other applicable documentation The following publications and documents have to be observed as well: • Operating Instructions "Explosion-Proof AC Motors, Asynchronous Servomotors" for gearmotors and asynchronous servo gearmotors • Operating Instructions "Explosion-Proof Synchronous Servomotors" for synchronous CFM and CMP servo gearmotors •...
Safety Notes Extended storage Extended storage Observe the notes in section "Extended storage" (see page 133). Installation/assembly Observe the notes in section "Mechanical Installation" (see page 21)! Startup/operation Check the oil level before startup as described in chapter Inspection/Maintenance (see page 81).
Checklists Before startup Checklists Before startup This checklist includes all activities that will have to be executed prior to startup of a gear unit according to Directive 94/9/EC for operation in potentially explosive atmo- spheres. Checked Information Check prior to startup in potentially explosive atmospheres in section ...
Checklists During startup During startup This checklist includes all activities that will have to be executed during startup of a gear unit according to Directive 94/9/EC for operation in potentially explosive atmo- spheres. Checked Information Check during startup in potentially explosive atmospheres in section ...
Gear Unit Design Basic design of helical gear units Gear Unit Design NOTE The following figures are block diagrams. Their purpose is only to make it easier to as- sign components to the spare parts lists. Discrepancies may occur depending on the gear unit size and version! Basic design of helical gear units [59]...
Gear Unit Design Nameplate/unit designation Nameplate/unit designation 4.7.1 Nameplate 210927627 = Service factor = Maximum overhung load on the output side Ra max = Maximum overhung load on the input side (with input shaft assembly AD) Re max = Gear unit reduction ratio = Mounting position IP..
Page 20
Gear Unit Design Nameplate/unit designation 4.7.2 Unit designation NOTE For a detailed overview of unit designations and additional information, refer to the fol- lowing publications: • "Gear Units" catalog • "Gearmotors" catalog • "Explosion-proof drives" catalog Example: Helical gear unit, category II2GD RF 47 / A / II2GD...
Mechanical Installation Prerequisites for assembly Prerequisites for assembly CAUTION! Improper assembly may result in damages to the gear unit/gearmotor. Potential damage to property! • Do closely observe the notes in this chapter. Ensure that the following conditions have been met: •...
Mechanical Installation Installing the gear unit Installing the gear unit The gear unit or gearmotor is only allowed to be installed in the specified mounting po- ® sition. Refer to the information on the nameplate. The SPIROPLAN gearmotors are not dependent on the mounting position, except for W37 in M4 mounting position.
Page 24
Mechanical Installation Installing the gear unit Check that the oil level is as specified for the mounting position. see section "Lubricants" (see page 134), or data on nameplate. The gear units are filled with the required oil vol- ume at the factory. There may be slight deviations at the oil level plug as a result of the mounting position, which are permitted within the manufacturing tolerances.
Page 25
Mechanical Installation Installing the gear unit 5.3.1 Tightening torques for retaining screws Mount the gearmotors with the following tightening torques: Tightening torque screw/nut Strength class 8.8 Screw/nut [Nm] 1450 2500 4600 6950 11100 Mount the helical gearmotors in flange-mounted design with the following increased tightening torques: Tightening torque screw/nut Screw/nut...
Page 26
Mechanical Installation Installing the gear unit 5.3.2 Mounting the gear units Foot-mounted gear The following table shows the thread sizes of the gear units in foot-mounted design de- unit pending on the gear unit type and size: Gear unit type Screw R / R..F K / KH..B /...
Page 27
Mechanical Installation Installing the gear unit 5.3.3 Installation in damp locations or in the open Drives are supplied in corrosion-resistant versions with an according surface protection coating for use in damp areas or outdoors. Repair any damage to the paint work (e.g. on the breather valve or the eyebolts).
Page 28
Mechanical Installation Installing the gear unit Activating the Check whether the breather valve is activated. If the breather valve has not been acti- breather valve vated, you must remove the transport fixture from the breather valve before starting up the gear unit! 1.
Mechanical Installation Gear units with solid shaft 5.3.5 Painting the gear unit CAUTION! Breather valves and oil seals may be damaged during the painting or re-painting pro- cess. Potential damage to property. • Thoroughly cover the breather valves and the sealing lip of the oil seals with strips prior to the painting process.
Page 30
Mechanical Installation Gear units with solid shaft 5.4.2 Assembling the input and output components CAUTION! Bearing, hosing or shaft may be damaged due to improper assembly. Potential damage to property! • Only assemble the input and output components with a mounting device. Use the center bore and the thread on the shaft end for positioning.
Page 31
Mechanical Installation Gear units with solid shaft Avoid excessive Avoid high overhung loads by: Installing the gear or chain sprocket according to figure overhung loads B if possible. 211364235 [1] Hub [A] unfavorable [B] correct NOTE Mounting is easier if you first apply lubricant to the output element or heat it up briefly (to 80 ...
Mechanical Installation Gear units and gearmotors in category II2GD Gear units and gearmotors in category II2GD NOTES ON EXPLOSION PROTECTION • Explosion-proof gear units and gearmotors in R, F, K, W and S series comply with the design requirements for unit group II, categories 2G (potentially explosive gas atmosphere) and 2D (potentially explosive dust atmosphere).
Page 33
Mechanical Installation Gear units and gearmotors in category II2GD 5.5.4 Degree of protection The degree of protection for all gear unit versions is IP65 according to EN 60529. 5.5.5 Ambient conditions Provide sufficient ventilation for the gear units and prevent external heat generation (e.g. via couplings).
Mechanical Installation Torque arms for shaft-mounted gear units Torque arms for shaft-mounted gear units CAUTION! Improper assembling may result in damages to the gear unit. Potential damage to property! • Do not place torque arms under strain during installation. • Use bolts of quality 8.8 to fasten torque arms.
Page 35
Mechanical Installation Torque arms for shaft-mounted gear units 5.6.2 Helical-bevel gear units The following figure shows the toque arm for helical-bevel gear units. • Bushing [1] with bearings on both ends. • Install connection end B as a mirror image of A. 211362059 Gear unit Screws...
Page 36
Mechanical Installation Torque arms for shaft-mounted gear units ® 5.6.4 SPIROPLAN W gear units ® The following figure shows the toque arm for SPIROPLAN W gear units. • Bushing [1] with bearings on both ends. 211489547 Gear unit Screws Tightening torque WA10 4 x M6 ×...
Mechanical Installation Shaft-mounted gear unit with keyway or splined hollow shaft Shaft-mounted gear unit with keyway or splined hollow shaft NOTE Concerning the configuration of the customer shaft, please also refer to the design notes in the Gearmotors catalog! 5.7.1 Installation notes ®...
Page 38
Mechanical Installation Shaft-mounted gear unit with keyway or splined hollow shaft 2B: Installation with SEW-EURODRIVE installation and removal kit (see page 42) – customer shaft with contact shoulder 211520523 [1] Retaining screw [2] Lock washer [3] Washer [4] Circlip [5] Customer shaft with contact shoulder 2C: Installation with SEW-EURODRIVE installation and removal kit (see page 42) –...
Page 39
Mechanical Installation Shaft-mounted gear unit with keyway or splined hollow shaft 3. Tighten the retaining screw to the appropriate torque (see table). 211524875 Screw Tightening torque [Nm] M10/12 NOTE In addition, to avoid contact corrosion, we recommend that you recess the customer shaft between the two contact surfaces! Operating Instructions –...
Page 40
Mechanical Installation Shaft-mounted gear unit with keyway or splined hollow shaft 5.7.2 Removal notes This description is only applicable when the gear unit was assembled using the installa- tion and removal kit (see page 42) from SEW-EURODRIVE. Observe section "Installa- tion notes"...
Page 41
Mechanical Installation Shaft-mounted gear unit with keyway or splined hollow shaft 5. Screw the retaining screw [1] back in. Now you can force the gear unit off the shaft by tightening the bolt. 211529227 [1] Retaining screw [4] Circlip [6] Customer shaft [7] Fixed nut [8] Forcing disk Operating Instructions –...
Page 42
Mechanical Installation Shaft-mounted gear unit with keyway or splined hollow shaft 5.7.3 SEW installation and removal kit The SEW-EURODRIVE assembly/disassembly kit can be ordered by quoting the spec- ified part number. 211531403 [1] Retaining screw [7] Fixed nut for disassembly [8] Forcing disk -0.5 -0.5...
Page 43
Mechanical Installation Shaft-mounted gear unit with keyway or splined hollow shaft NOTE The SEW installation kit for attaching the customer shaft is a recommendation by SEW-EURODRIVE. You must always check whether this design can compensate the axial loads. In particular applications (e.g. mounting mixer shafts), a different design may have to be used to secure the shaft axially.
Mechanical Installation Shaft-mounted gear units with shrink disk Shaft-mounted gear units with shrink disk 5.8.1 Installation notes CAUTION! Tightening the screws without installed shaft may result in the hollow shaft being de- formed. Potential damage to property! • Only tighten the locking screws with the shaft installed. 1.
Page 45
Mechanical Installation Shaft-mounted gear units with shrink disk 3. Hollow shaft/input shaft after degreasing. 211537931 ® 4. Apply NOCO Fluid to the input shaft in the area of the bushing. It is essential to make sure that the clamping area of the shrink disk is free from ®...
Page 46
Mechanical Installation Shaft-mounted gear units with shrink disk 5. Install the input shaft. – Make sure that the locking collars of the shrink disk are installed in parallel to each other. – For gear unit housings with shaft shoulder: Mount the shrink disk onto the stop on the shaft shoulder. –...
Page 47
Mechanical Installation Shaft-mounted gear units with shrink disk 5.8.2 Removal notes CAUTION! Risk of jamming and crushing due to improper removal of heavy components. Risk of injury. • Observe the following removal notes. • Removing the shrink disk properly. 1. Loosen the locking screws one after the other by a quarter rotation to avoid tilting the outer rings.
Mechanical Installation Shaft-mounted gear unit with TorqLOC® ® Shaft-mounted gear unit with TorqLOC 1. Clean the customer shaft and the inside of the hollow shaft. Ensure that all traces of grease or oil are removed. 2. Install the stop ring and the bushing on the customer shaft. 211941003 ®...
Page 49
Mechanical Installation Shaft-mounted gear unit with TorqLOC® 5. Preassemble the torque arm (do not tighten the screws). K... F... S... 211943179 6. Push the busing onto the gear unit up to the stop. 211945355 7. Tighten all the retaining screws of the torque arm. 211947531 Operating Instructions –...
Page 50
Mechanical Installation Shaft-mounted gear unit with TorqLOC® 8. Secure the bushing with the split ring. Tighten the split ring on the bushing using the appropriate torque as specified in the following table: 212000907 Type nickel-plated Stainless steel [Standard] KT/FT Torque [Nm] 57, 67 –...
Page 51
Mechanical Installation Shaft-mounted gear unit with TorqLOC® 10.Slide the counter bushing onto the customer shaft and into the hollow shaft 212005259 11.until the shrink disk is properly seated. 12.Tap lightly on the flange of the counter bushing to ensure that the socket is fitted se- curely in the hollow shaft.
Page 52
Mechanical Installation Shaft-mounted gear unit with TorqLOC® 14.Manually tighten the bolts of the shrink disk and ensure that the end rings of the shrink disk are parallel. 212011787 15.Tighten the locking screws with a torque wrench by working round several times from one bolt to the next (not in diametrically opposite sequence) according to the follow- ing table: >...
Page 53
Mechanical Installation Shaft-mounted gear unit with TorqLOC® 16.After the installation, make sure the remaining gap between the outer rings is > 0 mm. 17.The remaining gap between counter bushing and hollow shaft end as well as stop ring bushing and split ring must be > 0 mm. >...
Mechanical Installation Installing the protective cover 5.10 Installing the protective cover NOTE ON EXPLOSION PROTECTION Prior to installation, make sure that • there is a flawless glued connection between sealing and cover • the bores of the seal and the cover correspond CAUTION! During operation, output components are in fast motion.
Page 55
Mechanical Installation Installing the protective cover 5.10.2 Installation without cover In certain individual cases (e.g. through-shaft), you cannot install the cover. In such cases, the cover is not necessary if the system or unit manufacturer provides corre- sponding components to guarantee for the compliance with the required degree of pro- tection to EN DIN 13463-1.
Mechanical Installation Coupling of AM adapter 5.11 Coupling of AM adapter NOTE ON EXPLOSION PROTECTION You must not use distance bushings as an assembly tool! 5.11.1 IEC adapter AM63 - 280 / NEMA adapter AM56 - 365 212099979 Motor shaft [479] Coupling half [481] Setscrew [484] Key...
Page 57
Mechanical Installation Coupling of AM adapter 5. Check the dimension A. 6. Seal the contact surfaces between the adapter and motor using a suitable sealing compound. 7. Mount the motor on the adapter. Ensure that the coupling claw of the adapter shaft is engaged in the plastic cam ring.
Page 58
Mechanical Installation Coupling of AM adapter Permitted loads CAUTION! Impermissibly high loads may occur when mounting a motor. Potential damage to property! • The load data specified in the following table are not to be exceeded. 18513419 Adapter type NEMA [mm] IEC adapter NEMA adapter...
Page 59
Mechanical Installation Coupling of AM adapter AM adapter with Check the direction of rotation of the drive prior to assembly or startup. Please inform AM../RS backstop the SEW-EURODRIVE service in the case of incorrect direction of rotation. The backstop is maintenance-free in operation, and does not require any further main- tenance work.
Mechanical Installation Coupling of AQ adapter 5.12 Coupling of AQ adapter NOTE ON EXPLOSION PROTECTION You must not use distance bushings as an assembly tool! 5.12.1 AQA80 - 190 adapter / AQH80 - 190 adapter 212114955 1 Motor shaft 2 Grub screw 3 screws AQA = With keyway AQH = Without keyway...
Page 61
Mechanical Installation Coupling of AQ adapter 4. Type AQH: Tighten the screws evenly in diametrically opposite sequence, working round several times. Make sure that all the screws are tightened with the tightening torque T according to the following table. Type AQA: Secure the coupling halves using the setscrew (see table). 5.
Mechanical Installation Adapter with a torque limiting coupling AR 5.13 Adapter with a torque limiting coupling AR [1] Trigger cams [4] Friction lining [7] Friction hub [2] Encoder [5] Cup spring [8] Speed monitor [3] Driving disk [6] Slotted nut Drives with a torque limiting coupling consist of a standard gear unit and motor/variable speed geared motor with an adapter installed between them.
Page 63
Mechanical Installation Adapter with a torque limiting coupling AR 5.13.2 Assembly Mounting the 1. Remove the fan guard from the driving motor encoder 2. Slowly turn the motor or adapter shaft extension until a trip cam (= head of the cheese head screw) becomes visible in the threaded hole 3.
Mechanical Installation AD input shaft assembly Connecting moni- toring devices NOTE ON EXPLOSION PROTECTION Do not route the supply cables in multicore cables to avoid interference from parasitic voltages. Maximum line lengths 500 m with core cross section 1.5 mm .
Page 65
Mechanical Installation AD input shaft assembly 5.14.1 AD../P – cover with motor mounting platform Mounting the motor and adjusting the motor mounting platform. 212119307 [1] Motor mounting platform [2] Stud bolt (only AD6/P / AD7/P) [3] Support (only AD6/P / AD7/P) [4] Nut [5] Threaded column 1.
Page 66
Mechanical Installation AD input shaft assembly 5.14.2 Only AD6/P and AD7/P Unscrew the nuts on the stud bolts before adjustment to allow the stud bolts to move axially in the support without restriction. Do not tighten the nuts until the final adjustment position has been reached.
Page 67
Mechanical Installation AD input shaft assembly ® 4. Clean the threads of the new bolts and apply a bolt locking compound (e.g. Loctite 243) to the first few threads. 5. Attach the application to the centering shoulder and tighten the retaining screws with the specified tightening torque T (see table).
Page 68
Mechanical Installation AD input shaft assembly Permitted loads CAUTION! Impermissibly high loads may occur when mounting a motor. Potential damage to property! • The load data specified in the following table are not to be exceeded. 212123659 Type [mm] AD2/ZR AD3/ZR 1400 AD4/ZR...
Page 69
Mechanical Installation AD input shaft assembly 5.14.4 AD../RS – cover with backstop Check the direction of rotation of the drive prior to assembly or startup. Please inform the SEW-EURODRIVE service in the case of incorrect direction of rotation. The backstop is maintenance-free in operation, and does not require any further main- tenance work.
Startup Checking the oil level Startup NOTE ON EXPLOSION PROTECTION Prior to startup check that the oil level is as specified for the mounting position. The oil checking and drain screws and the breather valves must be freely accessible. Checking the oil level Before startup, make sure that the oil level corresponds to the mounting position.
Page 71
Startup Measuring surface and oil temperature °C 18669579 6.2.2 Measuring the oil temperature It is necessary to measure the oil temperature to determine the lubricant change inter- vals set forth in the section Inspection and Maintenance. (see page 81) To do so, mea- sure the temperature at the bottom of the gear unit.
Startup Helical-worm and SPIROPLAN® W gear units ® Helical-worm and SPIROPLAN W gear units NOTES Note: The direction of rotation of the output shaft in series S..7 helical-worm gear units has been changed from CW to CCW; this is different from the S..2 series. Change in direction of rotation: Swap two motor feeder cables.
Startup Helical/parallel shaft helical/helical-bevel gear units Helical/parallel shaft helical/helical-bevel gear units 6.4.1 Stand-alone gear units For gear units with an adapter, or input shaft assembly, you must ensure that the data specified on the nameplate are not exceeded. It is essential that the gear unit is not over- loaded.
Startup Gear units with backstop Gear units with backstop The purpose of a backstop is to prevent undesirable reverse rotation. During operation, the backstop permits rotation in only one specified direction of rotation. CAUTION! Operating the motor in the direction that is blocked could destroy the backstop. Potential damage to property! •...
Startup Speed monitoring Speed monitoring 6.6.1 WEX option standard design The standard version of the explosion-proof AR adapter features an M12x1 thread for mounting a voltage encoder in the motor flange of the adapter. Speed monitor and volt- age encoder are included in the scope of delivery. 6.6.2 Manufacturer's data Speed monitor in WEX design:...
Page 76
Startup Installation and adjustment of the WEX speed monitor 6.7.1 Installation and adjustment of the WEXA/WEX speed monitor Relay 2 can be used for creating a warning signal or for machine control (terminal as- signment 16-18). The wiring diagram below shows possible wiring of the speed monitor. +24V Arret DC 20-90V...
Page 77
Startup Installation and adjustment of the WEX speed monitor 18702219 Front side of the speed monitor: LED in CHK 1 (yellow/red) For indicating input pulses (flashes yellow), input interference (blinks red), and unit malfunction (continuously red) LED PWR (green) for indicating the supply voltage LED OUT 1 (yellow) For indicating that relay 1 is active LED OUT 2 (yellow)
Page 78
Startup Installation and adjustment of the WEX speed monitor 6.7.2 Installation and adjustment of other speed monitors If other speed monitors are used, they must feature an intrinsically safe sensor input (identification color: blue) for evaluation of sensors according to DIN 19234 (NAMUR) and be approved for use of this sensor in potentially explosive atmospheres.
Startup Installation of the voltage encoder Installation of the voltage encoder The following figure illustrates the installation of the voltage encoder and the setting of the switching interval x. 18712331 [1] Adapter flange bearing cover [3] Lock nut [2] Screw head [5] Voltage encoder 1.
Page 80
Startup Installation of the voltage encoder 6.8.1 Changing switching interval x If no circuit state change occurs at the voltage encoder (LED display) with rotating shaft of the adapter shaft operating with switching interval x = 1 mm, the switching interval can be changed as follows: 1.
Inspection/Maintenance Preliminary work regarding gear unit inspection/maintenance Inspection/Maintenance The following gear units are lubricated for life and are thus maintenance-free: • Helical gear units R07, R17, R27 • F27 Parallel Shaft Helical Gear Units ® • SPIROPLAN gear units Depending on external factors, the surface/corrosion protection might have to be re- paired or renewed.
Inspection/Maintenance Inspection/maintenance intervals 7.1.1 Cleaning the gear unit NOTE ON EXPLOSION PROTECTION Do not use materials or procedures (e.g. compressed air) that cause processes caus- ing electrical charge on the coating. Inspection/maintenance intervals Time interval What do I do? • Every 3000 operating hours, at least every 6 •...
Inspection/Maintenance Lubricant change intervals Lubricant change intervals The following figure shows the change intervals for standard gear units under normal environmental conditions. Change the oil more frequently when using special versions subject to more severe/aggressive environmental conditions! 30000 25000 20000 15000 10000 5000...
Inspection/Maintenance Inspection/maintenance for the AL/AM/AQ adapter Inspection/maintenance for the AL/AM/AQ adapter Time interval What do I do? • Every 3000 operating hours, at least every 6 months • Check running noise for possible bearing damage • Visually check the adapter for leakage •...
Page 85
Inspection/Maintenance Adapter AR 7.5.1 Required tools/resources • Standard tools • Hook spanner • Hydraulic press • Puller/extractor (threaded spindle with diameter like gear unit input shaft) • Torque wrench 7.5.2 Inspecting/changing the friction lining, adjusting the slip torque It is only possible to check and adjust the slip torque accurately by using a torque wrench with an appropriate connection piece.
Page 86
Inspection/Maintenance Adapter AR HAZARD! Risk of crushing if the drive starts up unintentionally. Severe or fatal injuries. • Disconnect the gearmotor from the power supply before starting work and protect it against unintentional re-start. 1. Disconnect the motor/variable speed geared motor from the adapter 2.
Page 87
Inspection/Maintenance Adapter AR Slip torques AR Cup springs No. of cams or slots "Z" Adapter Setting Num- Thick type range 15 16 17 18 19 20 21 ness mm Fig. Slip torque M in Nm 1.0-2.0 AR71 2.1-4.0 4.1-6.0 4.1 5.0 5.8 6.0 1.0-2.0 2.1-4.0 3.8 4.0...
Inspection/Maintenance Inspection/maintenance for the AD input cover 7.5.3 Replacing the encoder of the adapter HAZARD! Risk of crushing if the drive starts up unintentionally. Severe or fatal injuries. • Disconnect the gearmotor from the power supply before starting work and protect it against unintentional re-start.
Inspection/Maintenance Inspection/maintenance for the gear unit Inspection/maintenance for the gear unit 7.7.1 Checking the oil level and changing the oil The procedure when checking the oil level and changing the oil depends on the following factors: • Gear unit type •...
Page 90
Inspection/Maintenance Inspection/maintenance for the gear unit 7.7.2 Helical, parallel shaft helical, helical-bevel and helical-worm gear units with oil level plug Checking the oil level via the oil level plug CAUTION! The multi-stage gear units series: • R../R.. in mounting positions M1 and M2 •...
Page 91
Inspection/Maintenance Inspection/maintenance for the gear unit ∅ Oil level bore Minimum fill level = x [mm] = Check mark on oil dipstick M10 x 1 M12 x 1.5 M22 x 1.5 M33 x 2 M42 x 2 The correct minimum fill level according to the table (value "x") corresponds to the check marks on the oil dipstick (see following figure).
Page 92
Inspection/Maintenance Inspection/maintenance for the gear unit Checking the oil Proceed as follows to check the oil of the gear unit: via the oil drain 1. Observe the notes in section "Preliminary work regarding gear unit inspection/main- plug tenance" (see page 81). 2.
Page 93
Inspection/Maintenance Inspection/maintenance for the gear unit ® 7.7.3 Helical, parallel shaft helical, SPIROPLAN gear units without oil level plug with cover plate Checking the oil For gear units without oil level bore, the oil level is checked via the cover plate opening. level via the cover Proceed as follows: plate...
Page 94
Inspection/Maintenance Inspection/maintenance for the gear unit 4. Determine the vertical distance "x" between oil level and sealing surface of the gear unit housing (see following figure). 90° 18646283 5. Compare the determined value "x" to the max. distance between oil level and sealing surface of the gear unit housing specified in the following table.
Page 95
Inspection/Maintenance Inspection/maintenance for the gear unit 6. Close the gear unit after the oil level check: • Re-attach the seal of the cover plate. Make sure that the sealing surfaces are clean and dry. • Screw on the cover plate. Tighten the cover screws with the rated tightening torque according to the following table from the inside to the outside in the order illustrated in the figure.
Page 96
Inspection/Maintenance Inspection/maintenance for the gear unit Checking the oil Proceed as follows to check the oil of the gear unit: via the cover plate 1. Observe the notes in section "Preliminary work regarding gear unit inspection/main- tenance" (see page 81). 2.
Page 97
Inspection/Maintenance Inspection/maintenance for the gear unit 7.7.4 S37 helical-worm gear units without oil level plug and cover plate Checking the oil The S37 gear unit is not equipped with an oil level plug or a cover plate. This is why the level via the screw oil level is checked via the control bore.
Page 98
Inspection/Maintenance Inspection/maintenance for the gear unit 5. Determine the size of the section "x" of the dipstick covered with lubricant using a cal- iper (see following figure). 18661771 6. Compare the determined value "x" to the min. value depending on the mounting po- sition specified in the following table.
Page 99
Inspection/Maintenance Inspection/maintenance for the gear unit Checking the oil 1. Observe the notes in section "Preliminary work regarding gear unit inspection/main- via the screw plug tenance" (see page 81). 2. Open the cover plate of the gear unit according to section "Checking the oil via the screw plug"...
Page 100
Inspection/Maintenance Inspection/maintenance for the gear unit ® 7.7.5 SPIROPLAN W37 in mounting positions: M1, M2, M3, M5, M6 with oil level plug Checking the oil Proceed as follows to check the oil level of the gear unit: levelvia the oil 1.
Page 101
Inspection/Maintenance Inspection/maintenance for the gear unit Minimum fill level (min.): Maximum fill level (max.) less the value "x" depending on diameter (∅) of oil-level bore 3 (see following table). ∅ Oil level bore Minimum fill level = x [mm] = Check mark on oil dipstick M10 x 1 The correct minimum fill level according to the table (value "x") corresponds to the check marks on the oil dipstick (see following figure).
Page 102
Inspection/Maintenance Inspection/maintenance for the gear unit Checking the oil Proceed as follows to check the oil of the gear unit: via the oil level 1. Observe the notes in section "Preliminary work regarding gear unit inspection/main- plug tenance" (see page 81). 2.
Page 103
Inspection/Maintenance Inspection/maintenance for the gear unit ® 7.7.6 SPIROPLAN W37 in M4 mounting position without oil level plug and cover plate Checking the oil The W37 gear unit is not equipped with an oil level plug or a cover plate. This is why the level via the screw oil level is checked via the control bore.
Page 104
Inspection/Maintenance Inspection/maintenance for the gear unit 6. Compare the determined value "x" to the min. value depending on the mounting po- sition specified in the following table. Correct the fill level if required. Oil level = wetted section x [mm] of the dipstick Mounting position during the check Gear unit type Lying on the A side...
Page 105
Inspection/Maintenance Inspection/maintenance for the gear unit 6. Re-insert the lower screw plug. 7. Fill in new oil of the same type via the upper screw plug bore (otherwise consult the customer service). You must not mix different synthetic lubricants. – Fill the oil according to the quantity specified on the nameplate. –...
Mounting Positions Designation of the mounting positions Mounting Positions Designation of the mounting positions SEW differentiates between the six mounting positions M1 ... M6. The following illustra- tion shows the position of the gear unit in mounting positions M1 ... M6. Operating Instructions –...
Mounting Positions NOTE ® The SPIROPLAN gearmotors are not dependent on the mounting position, except for W37 in M4 mounting position. However, mounting positions M1 to M6 are also shown ® for SPIROPLAN gearmotors to assist you in working with this documentation. ®...
Technical Data Extended storage Technical Data Extended storage NOTE For storage periods longer than 9 months, SEW-EURODRIVE recommends the "Ex- tended storage" design. Gear units in this design are designated with a corresponding label. In this case, a VCI corrosion inhibitor (volatile corrosion inhibitor) is added to the lubri- cant in these gear units.
Technical Data Lubricants Lubricants Unless a special arrangement is made, SEW-EURODRIVE supplies the drives with a lubricant fill adapted for the specific gear unit and mounting position. You have to specify the mounting position (M1...M6, see section. "Mounting Positions") when you order the drive.
Page 135
Technical Data Lubricants Anti-friction bear- The anti-friction bearings in gear units and motors are given a factory-fill with the ing greases greases listed below. SEW-EURODRIVE recommends regreasing anti-friction bearings with a grease fill at the same time as changing the oil. Ambient temperature Manufacturer Type...
Page 137
Technical Data Lubricants 9.2.2 Lubricant fill quantities Refer to the gear unit nameplate for prescribed lubricant fill quantities in explosion-proof gear units. Check the oil level after the filling process. See section "Inspection/mainte- nance for the gear unit" (see page 89). Operating Instructions –...
Malfunctions/Service Gear unit Malfunctions/Service CAUTION! Improper handling of the gear unit and the motor may lead to damages. Potential damage to property! • Any repair work on SEW drives may be performed by qualified personnel only. • Only qualified personnel is permitted to separate drive and motor. •...
Malfunctions/Service AM / AQ / AL adapter 10.2 AM / AQ / AL adapter Malfunction Possible cause Remedy Unusual, regular running Meshing/grinding noise: Bearing damage. Contact SEW-EURODRIVE customer service noise Oil leaking Seal defective Contact SEW-EURODRIVE customer service Output shaft does not turn Connection between shaft and hub in gear Send the gear unit to SEW-EURODRIVE for repair.
Malfunctions/Service Adapter with a torque limiting coupling AR 10.4 Adapter with a torque limiting coupling AR Malfunction Possible causes Solution Unusual, regular running Meshing/grinding noise: Bearing damage. Contact SEW-EURODRIVE customer service noise Oil leaking Seal defective Contact SEW-EURODRIVE customer service •...
Malfunctions/Service Customer service 10.5 Customer service Please have the following information available if you require customer service assis- tance: • Nameplate data (complete) • Type and extent of the problem • Time the problem occurred and any accompanying circumstances • Assumed cause 10.6 Disposal Dispose gear units in accordance with the regulations in force regarding respective ma-...
130.04 according to EC Directive 94/9/EC, Appendix VIII au sens de la directive CE 94/9/CE, Annexe VIII SEW EURODRIVE GmbH & Co KG Ernst-Blickle-Straße 42, D-76646 Bruchsal erklärt in alleiniger Verantwortung die Konformität der folgenden Produkte: declares under sole responsibility conformity of the following products déclare, sous sa seule responsabilité, que les produits :...
111.05 according to EC Directive 94/9/EC, Appendix VIII au sens de la directive CE 94/9/CE, Annexe VIII SEW EURODRIVE GmbH & Co KG Ernst-Blickle-Straße 42, D-76646 Bruchsal erklärt in alleiniger Verantwortung die Konformität der folgenden Produkte: declares under sole responsibility conformity of the following products déclare, sous sa seule responsabilité, que les produits :...
106.05 according to EC Directive 94/9/EC, Appendix VIII au sens de la directive CE 94/9/CE, Annexe VIII SEW EURODRIVE GmbH & Co KG Ernst-Blickle-Straße 42, D-76646 Bruchsal erklärt in alleiniger Verantwortung die Konformität der folgenden Produkte: declares under sole responsibility conformity of the following products déclare, sous sa seule responsabilité, que les produits :...
Address List Gear units in category II3G and II3D with AR adapter Address List Germany Headquarters Bruchsal SEW-EURODRIVE GmbH & Co KG Tel. +49 7251 75-0 Production Ernst-Blickle-Straße 42 Fax +49 7251 75-1970 Sales D-76646 Bruchsal http://www.sew-eurodrive.de P.O. Box sew@sew-eurodrive.de Postfach 3023 •...
Page 146
16, rue des Frères Zaghnoun Fax +213 21 8222-84 Bellevue El-Harrach reducom_sew@yahoo.fr 16200 Alger Argentina Assembly Buenos Aires SEW EURODRIVE ARGENTINA S.A. Tel. +54 3327 4572-84 Sales Centro Industrial Garin, Lote 35 Fax +54 3327 4572-21 Service Ruta Panamericana Km 37,5 sewar@sew-eurodrive.com.ar 1619 Garin http://www.sew-eurodrive.com.ar...
Page 147
Address List Gear units in category II3G and II3D with AR adapter Canada Assembly Toronto SEW-EURODRIVE CO. OF CANADA LTD. Tel. +1 905 791-1553 Sales 210 Walker Drive Fax +1 905 791-2999 Service Bramalea, Ontario L6T3W1 http://www.sew-eurodrive.ca marketing@sew-eurodrive.ca Vancouver SEW-EURODRIVE CO. OF CANADA LTD. Tel.
Page 148
Address List Gear units in category II3G and II3D with AR adapter Czech Republic Sales Praha SEW-EURODRIVE CZ S.R.O. Tel. +420 255 709 601 Business Centrum Praha Fax +420 220 121 237 Lužná 591 http://www.sew-eurodrive.cz CZ-16000 Praha 6 - Vokovice sew@sew-eurodrive.cz Denmark Assembly...
Page 149
Address List Gear units in category II3G and II3D with AR adapter Hungary Sales Budapest SEW-EURODRIVE Kft. Tel. +36 1 437 06-58 Service H-1037 Budapest Fax +36 1 437 06-50 Kunigunda u. 18 office@sew-eurodrive.hu India Assembly Vadodara SEW-EURODRIVE India Private Limited Tel.
Page 150
Address List Gear units in category II3G and II3D with AR adapter Lebanon Sales Beirut Gabriel Acar & Fils sarl Tel. +961 1 4947-86 B. P. 80484 +961 1 4982-72 Bourj Hammoud, Beirut +961 3 2745-39 Fax +961 1 4949-71 gacar@beirut.com Lithuania Sales...
Page 151
Address List Gear units in category II3G and II3D with AR adapter Peru Assembly Lima SEW DEL PERU MOTORES REDUCTORES Tel. +51 1 3495280 S.A.C. Sales Fax +51 1 3493002 Los Calderos, 120-124 Service http://www.sew-eurodrive.com.pe Urbanizacion Industrial Vulcano, ATE, Lima sewperu@sew-eurodrive.com.pe Poland Assembly...
Page 152
Address List Gear units in category II3G and II3D with AR adapter Slovakia Banská SEW-Eurodrive SK s.r.o. Tel. +421 48 414 6564 Bystrica Rudlovská cesta 85 Fax +421 48 414 6566 SK-974 11 Banská Bystrica sew@sew-eurodrive.sk Košice SEW-Eurodrive SK s.r.o. Tel.
Page 153
Address List Gear units in category II3G and II3D with AR adapter Tunisia Sales Tunis T. M.S. Technic Marketing Service Tel. +216 71 4340-64 + 71 4320-29 5, Rue El Houdaibiah Fax +216 71 4329-76 1000 Tunis tms@tms.com.tn Turkey Assembly Istanbul SEW-EURODRIVE Tel.
Index Index Helical-worm gear units .........16 AD input shaft assembly ........64 Anti-friction bearing greases ........135 Inspection ..............81 AD input cover ...........88 AL/AM/AQ adapter..........84 Changing the mounting position ......24 Changing the Oil ..........89 Changing the oil .............89 Checking the oil ..........89 Checking the oil .............89 Checking the oil level.........89 Checking the oil level ..........89...
Page 155
Index Other applicable documentation ......9 Painting the gear unit ..........29 Parallel shaft helical gear units ......14 Repair ..............141 Rights to claim under limited warranty .....6 Run-in period ............72 Service ..............141 Shaft-mounted gear unit TorqLOC®............48 Shaft-mounted gear units Keyway ..............37 Shrink disk ............44 splined hollow shaft..........37 SPIROPLAN®...
Page 160
Drive Technology \ Drive Automation \ System Integration \ Services How we’re driving the world With people who With comprehensive With uncompromising think fast and With a worldwide With drives and controls knowledge in virtually quality that reduces the develop the service network that is that automatically every branch of...
Need help?
Do you have a question about the R 7 Series and is the answer not in the manual?
Questions and answers
COMO BAIXAR DESENHO AUTO CAD DO MOTOREDUTOR