Related Manuals for Siemens FLENDER PLANUREX 2 PBUC Series
Summary of Contents for Siemens FLENDER PLANUREX 2 PBUC Series
- Page 1 Planetary Gear Unit Type PLANUREX 2 PBUC Sizes 21 to 42 for bucket wheel drives Assembly and operating instructions BA 9213 en 03/2012 FLENDER gear units...
- Page 2 12 1 Technical data Planetary Gear Unit Type 12 2 General notes PLANUREX 2 12 3 Safety instructions PBUC Transport and 12 4 storage Sizes 21 to 42 for bucket wheel drives Technical 12 5 description Assembly and operating instructions 12 6 Fitting Translation of the original assembly and operating instructions...
- Page 3 Notes and symbols in these assembly and operating instructions Note: The term "Assembly and operating instructions" will in the following also be shortened to "instructions" or "manual". 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 or an "Ex"...
- Page 4 Intended use of Siemens products Observe also the following: 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.
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Page 5: Table Of Contents
Contents Technical data ........... . . General technical data . - Page 6 Fitting ............. General information on fitting .
- Page 7 Maintenance and repair ..........10.1 General notes on maintenance .
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Page 8: Technical Data
Technical data General 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. ① ②... -
Page 9: Measuringsurface Soundpressure Level
P stated 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 measuringsurface soundpressure level includes addon lubrication units, if applicable. With outgoing and incoming pipes, the interfaces are the flanges. -
Page 10: List Of Equipment
BA HEL.PAT.000 EN Threaded connection / Mounting length Surface load max. 0.8 W/cm Type of protection Ventilation filter MANN B 5123 EN to Siemens standard W 5123 Siemens Resistance thermometer Siemens to Siemens standard F 61003 B 6100 EN Installation length EL 100 mm Resistance thermometer 2x Pt100 DIN IEC Cl. - Page 11 Quan num Operating Specification Technical data tity instructions Pressure monitor Siemens to Siemens standard W 5925 B 5925 EN Threaded connection G 1/4 A Setting range 0.3 to 1.5 bar Number of switching contacts Contact rating Type of protection set to <...
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Page 12: General Notes
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 disruption caused by disregard of these instructions. The "FLENDER planetary gear unit" described in these instructions has been developed for use in bucket wheel excavators. -
Page 13: Safety Instructions
Safety instructions Entry to the gear unit and its add-on components is not permitted! Caution! Risk of falling! Any changes on the part of the user are not permitted. This applies equally to safety features designed to prevent accidental contact. Obligations of the user •... -
Page 14: Environmental Protection
Screws which have been damaged during assembly or disassembly work must be replaced with new ones of the same strength class and type. • Spare parts should always be obtained from Siemens (see also section 11). Environmental protection • Dispose of any packing material in accordance with regulations or separate it for recycling. -
Page 15: Transport And Storage
If the unit is fitted with a shrink disk, this will be shipped as a loose component. Transport When transporting Siemens products, use only lifting and handling equipment of sufficient loadbearing capacity! Observe the notes regarding load distribution on the packing. -
Page 16: Storing The Gear Unit
Fig. 3: Attachment points For a detailed illustration of the gear unit and the position of the attachment points, please refer to the drawings of the orderspecific gearunit documentation. Storing the gear unit The gear unit must be stored in the position of use in a sheltered place; it must be placed on a vibrationfree, dry wooden base and covered over. -
Page 17: Interior Preservation With Preservative Agent
For storage periods longer than 24 months, renew the preservative agent. For storage periods longer than 36 months, Siemens should be consulted before. Table 4: Durability period and measures for interior preservation when using PGbased synthetic oil... -
Page 18: Exterior Preservation
4.4.2 Exterior preservation Table 5: Durability period for exterior preservation of shaft ends and other bright machined surfaces Duration Preservative Layer Remarks of protection agent thickness in case Longterm waxbased preservative of indoor storage agent: up to 36 months Tectyl 846 K19 approx. -
Page 19: Technical Description
Technical description Observe the instructions in section 3, "Safety instructions"! General description The gear unit described is a planetary gear unit developed for use in bucketwheel excavators. The bucketwheel drive is delivered as a complete drive unit assembled from various components. Fig. -
Page 20: Construction And Method Of Operation
Construction and method of operation Standard mounting position in operation: Longitudinal angle (low or high position) to ± 15°, constant transverse angle 10°. To ensure adequate lubrication here, a motor pump is normally required. For the current fitting position and maximum inclined positions, see the dimensioned drawing. 5.2.1 Bevelhelical planetary gear unit The bevelhelical planetary gear unit essentially comprises a planet stage, two helical gear stages, a bevel... -
Page 21: Cooling
5.2.1.6 Cooling The gear unit is cooled by heat radiation from the housing. The surface of the housing, which is enlarged by numerous ribs, is especially designed to radiate heat in this way. 5.2.2 Brake For operation, the specific operating instructions must be observed. 5.2.3 Shrink disk For the planetary gear unit a shrink disk should be used as a frictional clamping connection between the... -
Page 22: Starting When The Bucket Wheel Is At A Standstill
5.2.7.2 Starting when the bucket wheel is at a standstill The bucket wheel must have reached equilibrium. • Release brake. • Start pump. • After 10 minutes start main motor and/or auxiliary motor. 5.2.7.3 Changeover from main to auxiliary drive •... -
Page 23: Clutch
5.2.9 Clutch With this drive combination with integrated auxiliary drive the systemspecific requirements set out in section 3, “Safety Notes”, must be observed in all cases! Changeover must be carried out only when the main and auxiliary gear units are at a standstill. -
Page 24: Fitting
Fitting Observe the instructions in section 3, "Safety instructions"! General information on fitting When transporting the gear unit observe the notes in section 4. 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. -
Page 25: Unpacking
The products supplied are listed in the despatch 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. The packaging must not be opened or damaged, when this is part of the preservation method! •... -
Page 26: Shrink Disk, Mechanical Version
Shrink disk, mechanical version 6.5.1 Fitting the shrink disk • Before beginning installation, the hollow shaft and the stub shaft must be carefully cleaned. Observe manufacturer’s instructions for handling lubricants and solvents. Do not allow cleansing agent or solvent to affect surfaces with paint coating. The bore of the hollow shaft and the stub shaft must be absolutely clean, free of grease and oil in the area of the shrink disk seat. - Page 27 M 16 M 33 2650 The shrink disk has been identitymarked on the outer ring (4). In case of contacting Siemens this identification must be referred to. For safety reasons, a protective cover should be mounted to prevent contact! This cover must be applied after completion of all works on the shrink disk.
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Page 28: Demounting The Shrink Disk
6.5.2 Demounting the shrink disk • Remove the protective cover. • Remove any rust deposits from the shaft and the hollow shaft. Under no circumstances must the tensioning bolts be unscrewed one after the other. • Undo all 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. -
Page 29: Refitting The Shrink Disk
Table 7: Recommended lubricants for shrink disks after their cleaning Lubricant Form Manufacturer Molykote G Rapid Spray or paste DOW Corning Aemasol MO 19 P Spray or paste A. C. Matthes Unimoly P 5 Powder Klüber Lubrication gleitmo 100 Spray or paste Fuchs Lubritec Other lubricants may be used if they have the same characteristics. - Page 30 The maximum permissible clamping pressure is 450 bar! This allows the clamping condition to be checked visually. If alignment cannot be achieved by clamping, consult Siemens. • Turn lock nut fingertight against the outer ring. •...
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Page 31: Demounting The Type Hyd Shrink Disk
6.6.2 Demounting the type HYD shrink disk • Remove the protective cover. • Remove screw plugs from the "Clamp" and "Release" connections. Collect any hydraulic fluid that may run out! • Connect the oil pressure pump to the connection marked "Clamp". •... -
Page 32: Fitting Of The Brake And The Couplings
Fitting of the brake and the couplings 6.9.1 Fitting the brake When fitting the brake, the specific operating instructions for the brake must be observed. 6.9.2 Fitting the couplings When installing the couplings, the specific operating instructions for the couplings must be observed. -
Page 33: Final Work
6.11 Final 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 refitted. ─... -
Page 34: Tightening Torques And Initial-Tensioning Forces
6.12.2 Tightening torques and initial-tensioning forces The tightening torques apply to friction coefficients of μ = 0.14. The friction total coefficient μ = 0.14 applies here to lightly oiled steel bolts, blackannealed or phospatised 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. - Page 35 Nominal Strength Initial-tensioning force Tightening torque thread class of the for screwconnection classes for screwconnection classes diameter screw from table 9 from table 9 M min 1510000 968000 605000 30600 26300 23500 M90x6 10.9 2150000 1380000 860000 43500 37500 33400 12.9 2520000 1600000...
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Page 36: Startup
Startup Observe the instructions in section 3, "Safety instructions"! Procedure before startup 7.1.1 Removal of preservative agent • Unscrew and open oil drain plug and drain remaining preservative agent or runningin oil from the housing into a suitable container and dispose of in accordance with regulations. Any residualoil drain plugs should also be opened. -
Page 37: Filling With Lubricant
The quality of the oil used must meet the requirements of the separately enclosed BA 7300 operating instructions, otherwise the guarantee given by Siemens will lapse. We urgently recommend using one of the oils listed in BA 7300, because they have been tested and meet the requirements. -
Page 38: Removal From Service
Removal from service • Switch off drive unit. Secure the drive unit to prevent it from being started up unintentionally. Attach a warning notice to the start switch. • With gear units fitted with water oilcoolers, close the stop valves on the water in and outflow pipes. To prevent freezing, drain the water from the cooling coil or the water oilcooler. -
Page 39: Exterior Preservation
7.4.2 Exterior preservation 7.4.2.1 Exteriorpreservation procedure • Clean the surfaces. For separation between the sealing lip of the shaftsealing ring and the preservative agent, the shaft should be brushed with grease in way of the sealing lip. • Apply preservative agent. For preservative agent see table 5 in item 4.4.2! Operation Observe the instructions in section 3, "Safety instructions", in section 9, "Faults, causes and remedy", and... -
Page 40: Check
Check • During operation the gear unit must be monitored for: ─ Oil temperature (The gear unit is designed for a temperature of 90 °C with mineral oil in continuous operation. For higher temperatures, synthetic oils must be used. Shortterm operating temperature of up to 100 °C is permitted; see also section 10.) ─... -
Page 41: Starting With Auxiliary Drive
8.4.2 Starting with auxiliary drive I. 1. Main motor OFF. Secure motor against accidental starting up. I. 2. Blocking brake ON. I. 3. Release locking plate. I. 4. Move shift lever into "ON" position. If the lever cannot be moved into the correct position, proceed as described in section II .1. -
Page 42: Faults, Causes And Remedy
Siemens will not be bound by the terms of the guarantee or otherwise be responsible in cases of improper use of the gear unit, modifications carried out without the agreement of Siemens or use of spare parts not supplied by Siemens. - Page 43 Faults Causes Remedy The oil foams. Water in oil. Test the oil, change oil if necessary. Oil too old. Test the oil, change oil if necessary. (defoaming agent used up) Unsuitable oils mixed up. Test the oil, change oil if necessary. Water in oil.
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Page 44: Maintenance And Repair
Maintenance and repair Observe the instructions in section 3, "Safety instructions", and in section 9, "Faults, causes and remedy"! For information on maintenance of a hydraulic motor, refer to the operating instructions for the hydraulic motor. 10.1 General notes on maintenance All maintenance and repair work must be done with care and by duly trained and qualified personnel only. -
Page 45: General Oil Service Lives
Measures Periods Remarks Cleaning the gear unit Depending on requirements, see item 10.2.5 at least every 2 years Checking condition Depending on requirements, see item 10.2.7 of water oilcooler at least once a year Checking hose lines Yearly see item 10.2.9 Change the hose lines 6 years from the manufacturing see item 10.2.9... -
Page 46: Changing Oil
If there is a change to another oil grade or make, Siemens recommends flushing out the gear unit with the new grade of service oil. When changing the oil, the housing and the oilsupply system, if available, must be flushed with oil to remove sludge, metal particles and oil residue. -
Page 47: Cleaning The Air Filter
10.2.3 Cleaning the air filter If a layer of dust has built up, the air filter must be cleaned, whether or not the minimum period of 3 months has expired. • Unscrew the air filter including the reducing screw. • Clean the air filter using benzine or a similar cleanser. -
Page 48: Topping Up Oil
Damaged bolts must be replaced with new bolts of the same type and strength class. 10.3.1 General 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. -
Page 49: Lubricants
When ordering spare parts, always state the following: Order number, item Type, size Part number Quantity 11.2 Spare parts and customerservice addresses When ordering spare parts or requesting a service specialist, please contact Siemens first (see section 2). BA 9213 en 03/2012 49 / 55... -
Page 50: Spareparts Drawing
11.3 Spareparts drawing 11.3.1 PBUC, type A 150 151 550 451 208 206 241 221 Fig. 10: Spare parts drawing type PBUC, type A BA 9213 en 03/2012 50 / 55... -
Page 51: Pbuc, Type B
11.3.2 PBUC, type B 109 611 450 400 551 500 509 523 528 102 724 723 Fig. 11: Spare parts drawing type PBUC, type B BA 9213 en 03/2012 51 / 55... -
Page 52: Spareparts List, Main Gear Unit
11.4 Spareparts list, Main gear unit Table 13: Spareparts list, Main gear unit Part Part Quantity Designation Quantity Designation number number Heating element Hollow shaft Sealing ring Helical gear Bevelgear shaft Rolling bearing Bevel gear Rolling bearing Slotted nut Helicalgear shaft Adjusting ring Rolling bearing Shaftsealing ring... -
Page 53: Spareparts Drawing, Auxiliary Gear Unit
11.5 Spareparts drawing, Auxiliary gear unit 611 610 Fig. 12: Spareparts drawing, Auxiliary gear unit 11.5.1 Spareparts list, Auxiliary gear unit Table 14: Spareparts list, Auxiliary gear unit Part Part Quantity Designation Quantity Designation number number Helicalgear shaft Rolling bearing Helicalgear shaft Rolling bearing Rolling bearing... -
Page 54: Declarations
Declarations 12.1 Declaration of incorporation Declaration of incorporation in accordance with Directive 2006/42/EC, Annex II 1 B The manufacturer, Siemens AG, 46395 Bocholt, Germany, declares with regard to the partly completed machinery, Planetary Gear Unit Type PLANUREX 2 PBUC Sizes 21 to 42 for bucket wheel drives for use in bucketwheel excavators:...