DIN EN ISO 9001:2000 HELICAL BEVEL GEAR UNITS EXPLOSION-PROTECTED HELICAL BEVEL GEAR UNITS

Transcription

1 P DIN EN ISO 9001:2000 HELICAL BEVEL GEAR UNITS EXPLOSION-PROTECTED HELICAL BEVEL GEAR UNITS

2 Important notes Intended use Gear units/geared motors are designed for the purpose of converting rotary speed and torque. They are intended for use in industrial systems and may only be used as recommended in the Premium Stephan technical documentation and in accordance with the specifications on the type identification plate. Note Drives These operating instructions involve the storage, installation, operation, lubrication and maintenance of Premium Stephan CK4 helical geared motors and helical gear units. that are suitable for use in explosion-prone areas comply with guideline 94/9 / EC (ATEX). Only drives that have the symbol on the side on the name plate may be used in explosion-prone areas. Notes in these operating instructions that must be observed are also marked with the explosion symbol. Operation Warranty The observation of these operating instructions is essential to ensure trouble-free operation and in order for any warranty entitlements to be honoured. Therefore, first carefully read through the operating instructions before working with the drive unit! Start-up Maintenance Installation The personnel entrusted with the handling, storage, installation, start-up, inspection and maintenance of the drive unit must be qualified for industrial, mechanical and electrical equipment. The drive unit must be disposed of in compliance with currently applicable regulations. Disposal Housing parts, gearwheels, shafts, covers and flanges of the gear units are to be disposed of as steel scrap. Used oil is to be disposed of in accordance with applicable environmental protection regulations. Premium Stephan Hameln Branch of Premium Stephan B.V. Ohsener Str D Hameln info@premium-stephan.de Tel: Fax: Weekend freecall P0144-EN / / 2.0 Page 1

3 Table of Contents 1. ABOUT THIS DOCUMENTATION INTRODUCTION INTENDED USE QUALIFIED PERSONNEL LIABILITY DISCLAIMER PRODUCT NAME AND TRADEMARK DISPOSAL SYMBOL LEGEND OPERATING INFORMATION SAFETY INFORMATION INITIAL COMMENTS GENERAL SAFETY AND USAGE INFORMATION CONDITIONS OF USE DELIVERY CONTENTS TRANSPORT GENERAL GEAR UNIT ON THE MOTOR SHIFTING ARM OR BASE FRAME STANDARD CONSERVATION STORAGE DESIGN OF THE DRIVE SIDE CONSTRUCTION OF BASIC GEAR UNIT MODEL NAME NAME PLATE ATEX name plate POSITIONING MOUNTING SURFACE SHAFT POSITION STANDARD POSITIONING, MOUNTING SURFACE AND SHAFT POSITION ROTATION DIRECTION DEPENDENCIES POSITIONING OF ROTATION LOCK HOUSING GEARING DRIVE AND OUTPUT SHAFTS HIGH-SPEED SHAFT (HSS)T OUTPUT SHAFT (LSS) AS SOLID SHAFT WITH FEATHER KEY OUTPUT SHAFT AS A HOLLOW SHAFT WITH KEYWAY OUTPUT SHAFT AS A HOLLOW SHAFT WITH SHRINK-FIT RING SEALING SYSTEMS "ADVANCED PROTECTIVE SEALING" LUBRICANT TYPES LUBRICATING THE SHAFT SEALS ACCESSORIES FOR OIL CONTROL P0144-EN / / 2.0 Page 2

4 CONTROL OF OIL LEVEL BLEEDING OIL DRAINAGE OIL LEVEL CONTROL ELEMENTS LUBRICANT SYMBOLS ASSEMBLY POSITIONS SAFETY INFORMATION FOR USE IN HAZARDOUS LOCATIONS CHECK LISTS PRIOR TO START-UP DURING START-UP DURING OPERATION ATEX SYMBOL INSTALLATION GENERAL CONDITIONS INSTALLATION OF TRANSFER ELEMENTS MOUNTING COUPLING ON OUTPUT SHAFT MOUNTING COUPLING ON OUTPUT SHAFT MOUNTING IEC D FLANGE MOTOR ON GEAR UNIT WITH COUPLING LANTERN (U-LANTERN) START-UP CONTROLS MOTOR ELECTRICAL CONNECTION CABLE FITTING MEASURING SURFACE TEMPERATURES OIL LEVEL AND LEAK TIGHTNESS CONNECTING THE EARTHING WIRE ATEX INSPECTION AND MAINTENANCE PLAN ASSEMBLY OPTIONS AND ADDITIONAL DESIGNS TORQUE ARM ROTATION LOCK FAN WATER COOLING OIL-WATER COOLER WITH PUMP HEATING WATER HEATING ELECTRONIC HEATING MOTOR MOUNTING INSTALLATION / ASSEMBLY REQUIRED TOOLS AND ACCESSORIES STARTING TORQUE OF THE MOUNTING SCREWS PREPARATION FOOT MOUNTING MOUNTING SCREWS FOR FOOT MOUNTING: LOW SPEED SHAFT (LSS) DIMENSIONS HOLLOW SHAFT WITH FEATHER KEY CONNECTION P0144-EN / / 2.0 Page 3

5 6.6.1 DIMENSIONS ASSEMBLY FOR GEAR UNITS WITH HOLLOW SHAFTS HOLLOW SHAFT WITH SHRINK-FIT RING DIMENSIONS ASSEMBLY OF MACHINE SHAFT TORQUE ARM MOTOR LANTERN FOR D-FLANGE IN ACCORDANCE WITH IEC (B5) PERMISSIBLE MOTOR WEIGHTS INSTALLATION OF THE MOTOR COOLING / HEATING FAN WATER COOLING Mechanical connection Electrical Connection Cooling water HEATING ELECTRONIC HEATING START-UP GENERAL INFORMATION WARM-UP TIME ROTATION LOCK START UP IN EXTREMELY LOW AMBIENT TEMPERATURES INFORMATION ABOUT OPERATION WITH ELECTRONIC HEATING TAKING OUT OF OPERATION INSPECTION AND MAINTENANCE NOTE: MAINTENANCE INTERVALS LUBRICANT CHANGE INTERVALS CONTROL AND MONITORING OF OIL CONDITION CHECK OIL LEVEL OIL CHANGE PROCEDURE CLEAN BLEEDING SCREW CHECK AND LUBRICATE SEALS GREASE BEARINGS FAN WATER COOLING OIL-WATER COOLER WITH PUMP HEATING EXPLODED VIEWS CK THREE-STAGE CK FOUR-STAGE CK FIVE-STAGE CK INPUT SHAFT CK INTERMEDIATE SHAFT THREE-STAGE CK INTERMEDIATE SHAFT FOUR- AND FIVE-STAGE P0144-EN / / 2.0 Page 4

6 9.7 INTERMEDIATE SHAFT IMS CK INPUT SHAFT CK OIL PUMP LANTERN CK PRO COOL PARTS LIST ITEM NUMBERS MALFUNCTIONS INFORMATION REGARDING MALFUNCTION POSSIBLE MALFUNCTIONS AND CAUSES LUBRICANT TYPE AND QUANTITY INFORMATION ABOUT LUBRICANT TYPES BRANCH OFFICES AND DISTRIBUTION PARTNERS P0144-EN / / 2.0 Page 5

7 1. About this documentation 1.1 Introduction Compliance with these operating instructions is essential to ensure trouble-free operation and in order for any warranty entitlements to be honoured. For this reason, please read these operating instructions before you start working with the device! Make sure that the personnel responsible for the systems and operation, as well as persons who work on the device under their own responsibility, have access to the operating instructions. In addition, further technical documentation, delivery contracts or other agreements must be observed! 1.2 Intended use The intended use of this appliance assumes compliance with these operating instructions and in some cases, additional instructions Premium Stephan gear units and drives are for use in industrial systems and machines. They are only to be used under the conditions agreed-upon and/or indicated on the name plate. Other use, or altered surrounding conditions are considered improper and written permission from Premium Stephan is required. In accordance with the EC guidelines 78/37/EC, the gear unit components are for integration into machines and systems. Within the jurisdiction of the EC, the start of operation is not permitted until it has been determined that the conformity of final product is in accordance with the EC Machinery Directive 78/37/EC. EX INFORMATION Drives that are suitable for use in explosion-prone areas comply with guideline 94/9 / EC (ATEX). Only drives that have the symbol on the side on the name plate may be used in explosion-prone areas. The corresponding information in these operating instructions that must be observed is also marked with the explosion symbol. 1.3 Qualified personnel These gear units present a residual risk to persons and objects. Therefore, all assembly, installation, start of operation, and maintenance procedures may only be performed by trained personnel who are aware of possible risks. The personnel must be have the necessary qualifications for the corresponding procedure, and be familiar with the Assembly Installation Start-Up Operation of the product. For this purpose, the operating instructions, and especially the safety information must be carefully read, understood and followed. 1.4 Liability disclaimer Compliance with these operating instructions is a basic requirement for safe operation of the gear units and geared motors, for achieving the stipulated product features and performance characteristics. Premium Stephan assumes no liability for injury caused to persons or damage to property or financial losses caused by not observing the operating instructions. Warranty for defects is excluded in such cases. 1.5 Product name and trademark The brand names and product names mentioned in these operating instructions are trademarks or registered trademarks of the respective title holder. 1.6 Disposal Housing parts, gearwheels, shafts, covers and flanges of the gear units are to be disposed of as steel scrap. Used oil is to be disposed of in accordance with environmental protection regulations. 3P0144-EN / / 2.0 Page 6

8 1.7 Symbol legend NOTE STOP ADDITIONAL DOCUMENTS! POTENTIAL DANGER DUE TO ELECTRICAL CURRENT RISK OF BURNING PAGE INSPECTION AND MAINTENANCE DISPOSAL EX NOTIFICATION ERDUNGSSCHRAUBE NICHT HINEINFASSEN 1.8 Operating information The gear unit is delivered without oil filling. The name plate of the gear unit contains the most important technical information! The gear unit may only be used and operated under the conditions specified in the Service and Delivery Contract. Modifications to mounting may only be made after consulting with Premium Stephan. Without prior consultation, the warranty is void. 3P0144-EN / / 2.0 Page 7

9 2. Safety information 2.1 Initial comments These operating instructions are intended for Premium Stephan gear units with the model number EP... Should electro-motors or other electronic devices be in use for operation of the gear unit, the corresponding operating instructions must also be observed. Alterations to the gear unit which affect operational safety are not permitted. This applies in particular to coverings designed for contact protection. Please also read the safety information in the individual sections. 2.2 General safety and usage information Electrical connection! The electrical connection must be done by a professional electrician. General and local regulations are to be observed, particularly in regard to protective measures. Connection according to the enclosed wiring plan and/or circuit diagram in terminal boxes. Risk of burning! You can burn yourself if the gear unit has not cooled down. Under no circumstances should you touch the gear unit during operation or its cool-down phase after switching off. STOP Never install damaged products or put them into operation! Please submit damage claims to the transport company immediately. Industrial gear units, cascade gear units and motors have the following attributes during and after operation: Live components Moving parts Hot surfaces Only qualified professionals may perform the following procedures: Installation / Assembly Connection Start-Up Maintenance Upkeep Please observe the following information and documents: Respective operating instructions and circuit diagrams Premium Stephan order information documents The system-specific regulations and requirements The national/regional regulations for safety and accident prevention. Severe damage to persons and objects can occur by: Improper use Faulty installation or operation Impermissible removal of necessary protective coverings 3P0144-EN / / 2.0 Page 8

10 2.3 Conditions of use Please observe the information in the order-specific documents concerning surrounding temperature and surrounding conditions If the usage conditions change from the original planning, Premium Stephan must be consulted. EX INFORMATION Drives that are suitable for use in explosion-prone areas comply with guideline 94/9 / EC (ATEX). Only drives that have the symbol on the side on the name plate may be used in explosion-prone areas. The corresponding information in these operating instructions that must be observed is also marked with the explosion symbol. 2.4 Delivery contents The gear unit is delivered fully-assembled. If applicable, auxiliary units (such as oil coolers, pipe lines and fixtures) will be packaged separately. Upon receipt of the order, check immediately that the delivery content corresponds to the details in the shipping documents. The exact delivery content is described in the shipping documents. Premium Stephan does not offer warranty for claims regarding missing parts submitted at a later date. Report any visible transport damage to the supplier immediately. Report any obvious missing parts / deficiencies to your representative immediately. STOP If damage has occurred, the gear unit may not be put into operation! 3P0144-EN / / 2.0 Page 9

11 2.5 Transport General Use lifting devices and transport equipment with adequate load capacity! Observe the information included in the packaging. The gear unit must be transported without oil, and should remain in the transport packaging until arrival at the site of installation. Personal injury or damage to the gear unit must be avoided during transport. Ensure that no one is standing under a suspended load. The gear unit may only be attached to designated transport grommets. Hoisting cables or chains may not be attached to the shaft extensions. Sling gear must have adequate safety for the weight of the gear unit. If applicable, remove transport locks before putting into operation. Hoisting cables or chains and belts may only run vertically or at an angle of up to 70 from horizontal. Ring grommets on the motor may not be used for transport. The exact positioning of the tie-off point for transport can be found in the information documents and the diagrams Fixing points 1 Fixing points Threaded bore holes in the housing Fixing points V1 to V6 O1 to O6 U1 to U6 R1 to R6 M1 to M4 S1 to S4 3P0144-EN / / 2.0 Page 10

12 2.5.3 Gear unit on the motor shifting arm or base frame Hoisting cable or chains must be vertically tightened for transport. The exact positioning of the tie-off point for transport can be found in the information documents and the diagrams. Fig Schematic diagram 1 Fixing points 2 Hoisting cable 2.6 Standard conservation The gear units are delivered with an inner conservation and with a protective conservation of the exposed shaft extensions. The standard paint coating is resistant to light environmental stress in unheated rooms, in which condensation may accumulate. If no special agreement exists, the gear units may be stored for up to 6 months. In the case of longer storage periods, or different environmental storage conditions, please ask Premium Stephan for further information. 2.7 Storage The gear units are to be stored in a vibration-free, dry location in their operating position. Please ensure that the corrosion protection on the surfaces of the gear units and the auxiliary components is not damaged. Any damage which is occurs to be professionally rectified. The gear units should not be stacked on top of each other. Special conditions for storage and transport, such as storage in the open or sea transport, are to be arranged separately. 3P0144-EN / / 2.0 Page 11

13 2.8 Design of the drive side High speed shaft Normally the gear units are fitted with a solid shaft on the drive side, with a feather key to hold the coupling or pulley Motor lantern with coupling For assembly of flange motors, the gear units can be fitted with a lantern on the drive side. Motor type and belt drive Operated by foot motor with v-belt drive Base frame and motor shifting arm Ready-to-install drive units are combined according to customer requirements Fig. 2.8 concerns schematic diagrams 3P0144-EN / / 2.0 Page 12

14 3. Construction of basic gear unit 3.1 Model name Gear unit series E Environmental application C Conveyor application 2 Gear unit design P Parallel shaft gear units K Pin-spur gear units 3 Mounting Z Foot mounting F Flange mounting D Torque arm 4 Shaft design N Solid shaft H Hollow shaft with feather key S Hollow shaft with shrink-fit ring 5 Gear unit size J 25 knm K 31.5 knm L 40 knm M 50 knm 6 Construction type 1 7 Number of stages C Three-stage D Four-stage E Five-stage 8 Rated gear ratio 9 Input shaft I High speed shaft U Motor lantern for installation in IEC motors 10 type of cooling ) k K No additional cooling system L Fan on a fast rotating shaft (HSS) F Motor fan W Cooling coil for water cooling O Oil-water cooler 11 Additional information /M1/F2/W04 M1 - M6 Mounting position F1-F6 Mounting surfaces Wxx - Wxx Shaft arrangement ) k information for combined cooling: L/W/ fan on a HSS and integrated cooling coil for water cooling Example: C K Z N M 1 C 22,4 I - /L/W - /M1/F2/W03 1 C Premium Stephan C4 conveyor series 2 K Pin-spur gear units 3 Z Foot mounting 4 N Solid shaft 5 M Gear unit size M 50 knm 6 1 Construction type 7 C 3-stage gear unit 8 22,4 Rated gear ratio 9 I High speed shaft 10 /L Fan on a fast rotating shaft (HSS) /W Cooling coil for water cooling 11 /M1 Mounting positions M1 /F2 Mounting surface F2 /W03 Shaft arrangement 3P0144-EN / / 2.0 Page 13

15 3.2 Name plate Symbol Unit Description Model - Gear unit model as per type code No. - Serial number with information on year of manufacture IM - Information on shaft arrangement and positioning n 2 rpm Operation rpm (LSS) n 1 rpm Drive rpm (HSS) SF - Operating factor M1 Nm Gear unit output torque P1 KW Operating capacity of the high speed shaft (HSS) I - Gear ratio Fr1 N Actual shear force at the high speed shaft Fr2 N Actual shear force at the output shaft Fa1 N Actual axial force at the high speed shaft Fa2 N Actual axial force at the output shaft No. of greasing points - Number of greasing points Lubricant - Oil type and viscosity Litres - Oil quantity ( reference value) Fans - Number of fans installed Mass KG Weight of gear unit (delivery condition) Year - Year of construction 3P0144-EN / / 2.0 Page 14

16 3.2.1 ATEX name plate Symbol Unit Description Type - Gearbox type according to type code Ser. No. - Serial number with information on year of manufacture n a min -1 low speed shaft n e min -1 input speed IP - protection class Ma max Nm Maximum permissible low speed torque Me Nm input torque i ex - Exact ratio fb - Application factor M bmax Nm Maximum permissible bending moment at output Oil Descr. / Liter Information about oil type, viscosity and quantity - ATEX label Cert. No. Document filing number Determining the application factor: Application factor M fb M e a max I ex The output torque M bman and M amax may not be exceeded. In the case of non-observance, the ATEX approval is invalid. 3P0144-EN / / 2.0 Page 15

17 3.3 Positioning NOTE Standard positioning in room for C4 gear units is M1. Other mounting positions are possible. Specific indications must also be observed. There are some limitations regarding the conditions of use or designs 3.4 Mounting surface The surfaces F1 to F6 are defined for mounting. 3.5 Shaft position The shaft position is marked with 0, 3 and 4. There may be limitations in some options (reverse rotation lock, integrated pump). 3P0144-EN / / 2.0 Page 16

18 3.6 Standard positioning, mounting surface and shaft position Positioning: M1 Mounting surface F1 Shaft position W03 Ordering information: /M1/F1/W Rotation direction dependencies The gear units are suitable for both rotation directions The rotation direction of the output shaft is dependent of the number of gear speeds and the arrangement of the gear wheels within the gear unit. An installed rotation lock can prevent one rotation direction from operating. Rotation direction from the gear unit perspective: CW: right (clockwise) CCW: left (counter-clockwise) 3 and 5 speed 4 speed 3P0144-EN / / 2.0 Page 17

19 3.7.1 Positioning of rotation lock The rotation direction is defined from the perspective of the output shaft (LSS). The permissible rotation direction is marked on the casing. For full-length output shafts or double-sided solid shafts (W034), the rotation direction is defined for shaft position 3. Shaft arrangement W03 Shaft arrangement W04 C4 gear unit with hollow shaft C4 gear unit with solid shaft 10 Drive shaft (HSS) position "0" 20 output shaft (LSS) 30 shaft covering or shrink-fit ring CW rotation direction "right" (Clock-Wise) 40 rotation lock 50 View looking toward the gear unit 60 Customer shaft CCW rotation direction "left" (Counter-Clock-Wise) When using a rotation lock, a start-up in the locked direction must be excluded. 3P0144-EN / / 2.0 Page 18

20 3.8 Housing NOTE The sturdy single-piece block housings are manufactured in grey cast iron. The housings are optionally available in spheroidal cast iron. 3.9 Gearing The optimised gearing and shaft dimensions compensate for flexing under load. Carburised and annealed gears made of highquality case-hardened steels meet the highest quality requirements Drive and output shafts The shafts are made of tempered steels. The high-speed shaft (HSS) is normally the drive shaft. The low speed shaft (LSS) is normally the output shaft. If reversing the load flow, it is necessary to consult with Premium Stephan High-speed shaft (HSS)t NOTE The drive shafts are engineered with closed feather keys in accordance with DIN 6885/T1 and central bore holes in accordance with DIN 332. A feather key in accordance with DIN 6885/T1 Form A is enclosed. No blows to the shaft should occur when tightening drive elements such as couplings. Please use the appropriate equipment or the central bore hole. The dimension diagrams and information documents for your product apply output shaft (LSS) as solid shaft with feather key. NOTE The output shafts are engineered with closed feather keys in accordance with DIN 6885/T1 and central bore holes in accordance with DIN 332. A feather key in accordance with DIN 6885/T1 Form B is enclosed. No blows to the shaft should occur when tightening drive elements such as couplings. Please use the appropriate equipment or the central bore hole. The dimension diagrams and information documents for your product apply. 3P0144-EN / / 2.0 Page 19

21 Output shaft as a hollow shaft with keyway The hollow shaft is fitted with a keyway in accordance with DIN 6885/T1. The endplate for securing the plug-in shaft and the anchoring screws are included in delivery. The protection hood mounted as standard is dust-proof. Therefore, standard sealing systems for the bearing are always used on the protection hood side Output shaft as a hollow shaft with shrink-fit ring No feather key is necessary for hollow shafts with a shrink-fit ring. The shrink-fit ring is always located across from the machine shaft. The standard protection hood is dust-proof. Therefore, standard sealing systems for the bearing are always used on the protection hood side Sealing systems There are many different types of sealing systems in use that prevent the oil from being discharged at the shaft openings or contaminations from penetrating the gear unit "Advanced Protective Sealing" For very high dust exposure, the "Advanced Protective Sealing" series is used, with a labyrinth sealing and re-greasing. Leak tightness for vertical output shaft can be achieved with "Protective Sealing". In combination with the "Active Lubricant System", operating costs are reduced, due to less oil usage. ADDITIONAL DOCUMENTS More detailed information about the sealing systems used can be found in the order-specific documents Lubricant types Splash lubrication is used as standard for horizontal mounting position. In this case, the oil level is low and the gearing and positioning are immersed into the oil or are lubricated by splashed oil. For immersion, the gear unit is nearly completely filled with oil and all gear components are immersed in oil. For pressure equalising, an oil compensation container is always mounted. This type of lubrication is used for: - Pivoted mounting positions depending on tilt angle. - Vertical mounting position - Upright mounting position Separate operating instructions must be observed for these mounting positions. Only a low oil level is needed for pressure lubrication. The oil is distributed to the corresponding points of lubrication by means of a pump and lubrication lines. Pressure lubrication is used if: - Immersion lubrication is neither possible nor desirable. - Thermal conditions do not allow for immersion lubrication. - For high drive rpm and if the rpm limit was exceeded for another type of lubrication - If a drywell design is necessary for a vertical output shaft Please observe the separate operating instruction for pumps and the separate start-up conditions if using pressure lubrication. ADDITIONAL DOCUMENTS More detailed information about the lubrication type used can be found in the order-specific documents Lubricating the shaft seals The sealing systems that may be re-greased are fitted with a lubricant nipple on the gear cover in accordance with DIN71412 A R1/8 and are marked with the corresponding symbols. Re-greasing should be performed at regular intervals. If the re-greasing nipples are difficult to access, the lubricant points can be moved to the top side of the gear unit. 3P0144-EN / / 2.0 Page 20

22 3.13 Accessories for oil control Control of oil level The gear units are equipped with an oil inspection glass as standard for monitoring the oil level. For some mounting positions, an oil dip stick is necessary. This can optionally be fitted into a horizontal mounting position. Electronic sensors for continuous oil level monitoring are also available upon request Bleeding Pressure accumulates in the inside of the gear unit because of temperature increase. To prevent the accumulation of impermissibly high pressure, all gear units are equipped with a bleeding filter with a filter unit Oil drainage The gear unit is equipped with a magnetic oil drainage plug as standard. An oil drainage tap with a hose connection is also available as an option. This makes a trouble-free oil change possible, even in inconvenient mounting positions Oil level control elements Labelling on the gear unit: Oil level control element Oil level screw plug Oil inspection glass Oil level indicator Oil dip stick Correct fill level Bottom-edge threaded hole Middle inspection glass Red marking Middle marking NOTE The drive system must be shut down in order to check the oil level Lubricant symbols Lubricant symbols Bleeding Oil drainage Oil filling Re-greasing Labelling on the gear unit: 3P0144-EN / / 2.0 Page 21

23 Assembly positions 1 Oil drainage plug (optional: oil drainage tap) 2 Bleeding screws (optional: filter or valve) 3 Oil level screw 4 Optional: oil dip stick 4. Safety information for use in hazardous locations Potentially explosive gas mixtures or dust concentrations in connection with hot, electrically-live or moving parts in the gear unit/geared motor can cause serious injuries or fatality. Only specially-trained qualified personnel are permitted to carry out installation, connection and start-up, as well as maintenance/repair work on the gear unit/geared motor as well as on auxiliary electrical equipment while taking into consideration: these operating instructions the motor operating instructions the warning and information signs/plates on the gear unit/geared motor all other project documentation, start-up instructions and circuit diagrams belonging to the drive unit the system-specific regulations and requirements the currently applicable national/regional regulations the regulations of the employer's liability insurance association The gear units/geared motors are intended for use in industrial systems and may only be used as recommended in the Premium Stephan technical documentation and in accordance with the specifications on the type identification plate. They correspond to applicable standards and regulations and comply with the requirements of the directive 94/9 EC. A motor connected to the gear unit may be controlled at the frequency converter only in compliance with the data on the type identification plate of the gear unit and only if such operation is permitted by the type approval of the motor! Failure to observe the above requirements will invalidate the ATEX approval. 3P0144-EN / / 2.0 Page 22

24 4.1 Check lists Prior to start-up This checklist defines all activities that must be performed prior to starting-up a gear unit in accordance with ATEX 100a in a hazardous location. Immediately check the delivery on receipt for any transport damage. Inform the freight carrier immediately of any damage. If necessary, take steps to ensure the drive unit is not installed or placed into operation. Do the following data on the type identification plate of the gear unit agree with the operational requirements for the hazardous location? Device group Ex-category Operational zone Temperature class Maximum surface temperature See section /4.2 Have steps been taken to ensure that there is no potentially explosive atmosphere while installing the gear unit in the system? 4.3 Does the lubricant viscosity match the ambient temperature on site? 3.2/10.0 Have steps been taken to ensure that the gear units are sufficiently ventilated and there are no sources of external heat input? Does the mounting position correspond to that specified on the type identification plate of the gear unit? 4.3/ Is the position-dependent oil level correct? 8.5 Do all drive and output elements to be mounted have ATEX approval and are they mounted correctly in accordance with regulations? During start-up This checklist defines all activities that must be performed during start-up of the gear unit in accordance with ATEX 100a in a hazardous location. See section Measure surface temperature after 4 h of operation. The temperature must not exceed a maximum of 90 C. If this temperature is exceeded, the drive unit must be shut down immediately. The system operator must contact Premium Stephan During operation This checklist defines the activities that must be performed during operation of a gear unit in accordance with ATEX 100a in a hazardous location. See section Check oil level 4.5 Check seals and rotary shaft seals for leaks 4.5 Check surfaces for damage to the paintwork and corrosion 4.5 3P0144-EN / / 2.0 Page 23

25 4.2 ATEX symbol The ATEX symbol is defined in accordance with DIN EN The following tables provide an informative overview. Group I (mining, mine or pit gas and/or combustible dust) Group II (potentially explosive atmosphere consisting of gas/air or dust/air mixtures, mist or vapours) Category M Category 1 Category 2 Category G (Gas) (Zone 0) D (Dust) (Zone 20) G (Gas) (Zone 1) D (Dust) (Zone 21) G (Gas) (Zone 2) D (Dust) (Zone 22) Very high degree of safety High degree of safety Very high degree of safety High degree of safety Standard degree of safety Type of protection Meaning Temperature class Maximum surface temperature ( C) fr Vapour-resistant housing T1 450 d Pressure-proof enclosure T2 300 c Design safety T3 200 b Ignition source monitoring T4 135 p Pressurised enclosure T5 100 k Fluid enclosure T6 85 g Intrinsic safety Example: II 2 G c k T4 Group II Use in a potentially explosive atmosphere consisting of gas/air or dust/air mixtures, mist or vapours. Category 2 For devices that ensure a high degree of safety. Suitable for applications where potentially explosive atmospheres are expected. G Gas (zone 1) c k Design safety Fluid enclosure T4 Maximum surface temperature 135 C 3P0144-EN / / 2.0 Page 24

26 4.3 Installation Before you begin The drive unit may be installed only if: The data on the type identification plate of the gear unit/geared motor agree with the permissible exapplication on site The drive unit is intact, i.e. not damaged There are no potentially explosive atmospheres, oils, acids, gasses, vapours etc. in the area during installation The lubricant viscosity agrees with the ambient temperature on site Steps have been taken to ensure that the drive unit is sufficiently ventilated and that there are no sources of external heat input General conditions The drive units must be installed or attached free of vibration or mounted on a flat, rigid and solid frame or foundation in order to avoid vibration. NOTE The drive units must be aligned with the utmost care! Stress and strain in the housing must be avoided. To align the gear unit, place it on the 3 mounting points and use shims to match the other point to an accuracy of less than 0.2 mm. After the gear unit has been aligned correctly and after all the shims have been fitted, the gear unit must be firmly screwed down to the foundation. Screw class 8.8 in accordance with DIN 267. see dimensioned drawings. The screws must be tightened to the torque requirements as specified by the manufacturer. Trouble-free lubrication and ventilation are ensured only when the gear unit is mounted in the correct position. It is necessary to correct the amount of lubricant and the position of the bleeding screw if the mounting position of the gear unit is changed. It is essential to consult Premium Stephan. Otherwise the ATEX approval will be invalid. Before start-up, check the position-dependent oil level at the oil inspection window on the drive unit. Intermediate inserts or pads made of plastic must be used if there is a risk of electrochemical corrosion between the gear unit and system. Earth the gear unit housing. The cooling air intake of the motor must not be obstructed Installation of transfer elements Only drive and output elements with an ATEX approval must be used. Observe the operating instructions provided with the power transmission elements. Flexible couplings are to be used on the direct power transmission from the gear unit to the machine and, in case of risk of jamming, friction couplings are required. Only use rigid couplings in connection with unsupported or overhanging shafts (e.g. with agitators or fan drives). Due to the radial forces produced, power transmission elements, such as flat belts or V-belts, gearwheels and sprockets, cranks, eccentric cams etc., are to be arranged as close to the gear unit as possible. The bearings and drive shaft are then subject to the lowest possible load. Refer to our technical sales documentation for the maximum permissible load values. The protective coating on the end of the shaft must be removed by suitable means prior to mounting the transmission elements. Great care must be taken while fitting power transmission elements to the ground output shaft of the gear unit; this action can be performed using the threaded hole provided for this purpose on the end face of the shaft. Preferably, the power transmission element should be heated to a temperature of approx. 100 degrees C. The hole is to be dimensioned in accordance with ISO H7. All parts must be thoroughly de-burred, cleaned and the fit locations lightly greased. Avoid all knocks and impacts on the end of the shaft. The same procedure applies for transmitting the drive power to the gear unit in connection with a free drive shaft. 3P0144-EN / / 2.0 Page 25

27 4.3.3 Mounting coupling on output shaft Only output elements with an ATEX approval must be used. Observe the operating instructions provided by the coupling manufacturer. Accurate alignment and regular inspection are necessary. The maximum permissible shaft extensions for the coupling used must be observed and checked. Maintain the specified distance between the coupling halves. Only adjust the radial offset after the angle offset and the distance between the shaft ends have been checked. Recheck the angle offset after correcting the radial offset Mounting coupling on output shaft If the gear unit is equipped with an I-lantern, particular care must be taken while fitting the motor to ensure the correct distance between the coupling halves and to guarantee flush alignment of the motor shaft with respect to the input shaft of the gear unit. Particular care must be taken when aligning the motor and mounting the coupling half supplied together with the gear unit to ensure that the following conditions (see graphic) are maintained as specified by the manufacturer. Avoid all impacts and knocks during the mounting procedure. Failure to observe the installation instructions will invalidate the ATEX approval. Aligning the coupling halves on the motor and gear unit Mounting IEC D flange motor on gear unit with coupling lantern (U-Lantern) If the unit is equipped with a U-lantern and without a motor, care must be taken while mounting the flange motor to ensure that the coupling half is fitted correctly. The connecting screws must be tightened to the torque specified by the screw manufacturer. Screw strength class 8.8 in accordance with DIN 267. Particular care must be taken when mounting the coupling half supplied with the gear unit on the motor shaft to ensure that the distance "X" is maintained. The coupling seat is to be checked by opening the screw plug. After the visual inspection, the screw plug must be securely re-tightened. Avoid all impacts and knocks during the mounting procedure. Failure to observe the installation instructions will invalidate the ATEX approval. 4.4 Start-up Controls The specified position-dependent oil level must be checked prior to start-up by visually inspection at the oil inspection glass. The oil inspection and drain plugs as well as the bleeding screws and valves must be freely accessible. Check direction of rotation, especially in connection with backstops. Check seating of protective cover fitted at the customer. In case of ATEX approval GD and D also check the seating is dust-proof. Check all mountings. The check must be performed with the drive unit in the original mounting position. Screw plugs must be replaced by the bleeding valves supplied at the positions determined by installation requirements. 3P0144-EN / / 2.0 Page 26

28 4.4.2 Motor DANGER, RISK OF ELECTRIC SHOCK Observe the motor operating instructions! Electrical connection The cable type and cross sections must comply with regulations. The rated power and the connection method are specified on the motor rating plate. A circuit diagram is provided in the motor terminal box. Installation must be performed in compliance with EN Cable fitting All cable entry fittings must be firmly secured. Power supply cables must be connected to the terminal box and secured with a nut and spring lock washer. The wiring must be connected by a qualified electrician. Earthing of the electrical system must comply with applicable safety regulations. With regard to motor protection, reference is made to the applicable regulations in accordance with DIN EN or IEC 34, VDE 0105 or IEC 364. Particular care must be taken when closing the terminal box to ensure that the seal is fitted correctly. Screwed cable glands that are not required must be securely closed off Measuring surface temperatures The maximum surface temperature specified on the type identification plate is based on measurements conducted under normal ambient and installation conditions. Even the slightest changes to these conditions (e.g. poor ventilation) can have a considerable effect on the temperature. During the start-up phase for the gear unit it is necessary to measure the surface temperature under operating conditions. Determine the surface temperature at the transition from the gear unit to the motor (motor end plate) where the terminal block obstructs ventilation by the motor fan. The operating temperature is reached after about 4 hours and must not exceed a maximum value of 90 C. If the maximum temperature is exceeded, immediately shut down the drive unit and contact Premium Stephan. Failure to observe this requirement will invalidate the ATEX approval. 4.5 Oil level and leak tightness DANGER, RISK OF ELECTRIC SHOCK The power supply to the motor must be disconnected before starting routine maintenance, cleaning or servicing work.! The oil level and all seals should be checked at regular intervals every 2000 hours of operation or at least every 6 months with the drive unit stationary. If the oil level is not correct, then top it up with the same type of oil or change the oil or alternatively drain some out. In the event of a leak, the seals must be changed. The oil level is only allowed to differ from the middle of the oil inspection glass in reference to the chart figures. You must keep the maximum allowed deviation regarding chapter 9.3., if an oil level indicator is attached. Frame size CK..J. CK..K CK..L CK..M Deviation from centre of oil inspection glass ± 2 mm ± 3 mm ± 5 mm ± 5 mm All surfaces are to be regularly checked for damage to the paintwork and corrosion every 2000 hours of operation and at least every 6 months. Any damage must be repaired and the protective paintwork replaced. STOP If there are visible leaks, the drive unit should be shut down, even if the specified maintenance intervals are not reached, and the corresponding seals replaced. 3P0144-EN / / 2.0 Page 27

29 4.6 Connecting the earthing wire EARTHING WIRE Earthing must be done at the specified and ladled position. The earthing cross-section view of the machine must concur with assembly specification, e.g. in accordance with DIN EN IEC When connecting, it is important that the connection surface is clean and protected against corrosion by a suitable substance, such as acid-free Vaseline. 4.7 ATEX Inspection and maintenance plan Time interval Test/measures Daily Visual inspection of seals for oil leakage Test housing temperature max. 90 C permissible Weekly Check gearbox for changes in noise ( operating noise of gearing and roller bearing ) Visual inspection of seals for oil leakage Check oil tap for leakage ( oil tap is secured against unintentional opening by a screw plug ) Check oil level during stand still Visual inspection of seals for oil leakage Monthly After 500 operating hours Remove accumulated dust Check Pro Cool System for contaminants and clean if necessary. In case of damage or functional restrictions to the cooling system, switch off immediately. For example: Broken fan blade Clogged protective grid Restricted air flow Oil change after initial start of operation Every 2000 operating hours Check paint and repair if necessary Every 6 months or every 3000 operating hours After 6000 operating hours Check oil condition, oil change if necessary Check coupling elements, replace if necessary Check fixing screws for tightness Perform oil change Clean or replace bleeder screw Clean ventilation unit and gearbox surface Based on usage and environmental conditions Repair paint Check coupling elements Check functionality of add-on assemblies (oil cooler, heating) and replace if necessary 3P0144-EN / / 2.0 Page 28

30 5. Assembly options and additional designs 5.1 Torque arm Optional for hollow shaft gear units. Design and dimensions are determined according to customer requirements. Dimensions and exact design are based on the fixing possibilities. 10 Gear unit 20 Hollow shaft 30 High speed shaft 40 Torque arm 50 Rubber bumper The torque arm absorbs the force in hollow shaft gear units. Depending on conditions of use and requirements, the torque arm can be fitted onto mounting surfaces F1 to F6. Premium Stephan offers a customised solution for your individual usage needs. Thrust bearing and necessary elastic elements can also be offered if needed. 5.2 Rotation lock ADDITIONAL DOCUMENTS More detailed information about the torque arm used can be found in the order-specific documents. In order to facilitate operation in only one rotation direction, a rotation lock can be mounted on the high speed shaft. In these cases, the permitted rotation direction is marked with arrows on the low speed shaft and on the high speed shaft. The rotation direction is defined from the perspective of looking at the low speed shaft. CW Right (Clock Wise) CCW Left (Counter Clock Wise) 5.3 Fan For start-up, ensure that the drive motor starts in the required rotation direction. The gear units can be designed with a ProCool system for discharging large amounts of heat or with high surrounding temperatures. The fan mounted on the Input shaft supplies the necessary air volume. The optimised airflow system "ProCool" directs the air flow over the housing surfaces. This includes the side surfaces as cooling surfaces. "ProCool" System: The air flow created by the fan blade is directed over the entire housing surface by means of air baffles. Intensive cooling of the gear unit leads to less construction volume Customer advantages: Less space, light weight, smaller amounts of oil, less maintenance costs Two-part fan hood, for example, made of GFK Air flow over the entire length of the housing surface Smooth surface of the fan hood, no dust accumulation Optimal noise reduction For some designs, the rotation direction must be carefully observed. The air intake slits must be kept free and cleaned at regular intervals. 3P0144-EN / / 2.0 Page 29

31 5.4 Water cooling To increase the thermal performance limit, the gear unit can be equipped with a water cooling cartridge. The cooling cartridge is located directly in the oil sump. An optimal cooling of the gear unit is achieved by the direct heat transfer from the oil to the cooling cartridge. The cooling capacity is dependent on the water temperature at the intake and the flow volume. One or two cooling cartridges can be mounted, depending on the required thermal performance limit and gear unit size. Water cooling can also be combined with fan cooling. The water cooling cartridge is positioned in the oil sump. The water connection takes place on sit by G1/2" threaded bores Cooling capacity is dependent on the intake temperature and flow volume. Reference values are 11 litre/min., at a maximum of 30 C. The cooling coil is made of ribbed pipe. Due to the large surface area, only a small amount of water is needed. Displacement-safe connections ensure a trouble-free installation of the water supply line, ADDITIONAL DOCUMENTS More detailed information about the cooling / heating system used can be found in the order-specific documents. If no purified water is available, a consultation is required. 5.5 Oil-water cooler with pump For intensive cooling of the gear unit, a heat exchanger as an oil-air or oil-water cooler is available. The assembly can be connected directly to the gear unit or be assembled separately. Please ensure that the cooling assembly is filled with oil. The oil-water cooler with motorised pump are designed for gear units with splash lubrication. The cooling unit is completely assembled and is installed separately. The pipe lines and electrical installation are not a part of the delivery package. 5.6 Heating In order to maintain lubrication for a cold start, an oil heating unit is required Water heating The cooling cartridge can also handle warm water flow (max. 80 C) and can then serve as heating. A start-up with cold oil should be avoided by means of installed thermostats and thermostat valves. 3P0144-EN / / 2.0 Page 30

32 5.6.2 Electronic heating An electronic heat rod with an integrated thermostat can also be installed for oil heating. By means of separately installed temperature sensors, it must be ensured that a start-up is only performed after the gear unit has been heated to the temperature listed in the operating instructions. The electronic heat rod is completely immersed in the oil sump and installed instead of a cooling cartridge. Control is done by a thermostat. The standard connection voltage for the heating elements is 230V/50/60Hz. ADDITIONAL DOCUMENTS More detailed information about the cooling / heating system used can be found in the order-specific documents. 5.7 Motor mounting For mounting motors with a B5 flange, the gear unit can be delivered optionally with a motor lantern. The required claw coupling is included in delivery. The motor lantern is also available in combination with a fan and the ProCool System. The illustration shows the mounting principles for the motor lantern (without fan). The following motor adapters are available for mounting standard IEC motors with B5 flange: IEC motor J K L M 180 X X 200 X X X X 225 X X X X 250 X X X X 280 X X X X 315 X X X X 355 X X Size Further motor sizes or flange dimensions in accordance with NEMA if requested. The weight of the motor may not exceed the weight of the gear unit. For heavy motors, please consult Premium Stephan and inform us of the exact motor dimensions and weight. 3P0144-EN / / 2.0 Page 31

33 6. Installation / Assembly The most important technical information can be found on the name plate. Further information can be found in the enclosed information documents. The assembly and anchoring of the gear units may only be done in specific mounting positions. The assembly area must be even and torsion-resistant. There should be no tension between the housing feet and the flange. All oil control screws, oil drainage and filling screws must be easily accessible. Drive elements on both the input and output shaft must be secured against loosening. Direct sunlight should be avoided. The cooling may not be impaired by any possibly installed awnings (avoid heat accumulation). Airflow must be ensured for gear units with fans. 6.1 Required tools and accessories Accessories and tools for the installation or assembly of drive units are not included in the Premium Stephan delivery. 6.2 Starting torque of the mounting screws Screws that are used must generally have the clamping class 8.8 and may not be lubricated during assembly. The following starting torques are necessary: Warning! Screws / bolts Starting torque /Nm) M6 11 M8 25 M10 48 M12 86 M M M M M M M Screws must not be lubricated during assembly! 6.3 Preparation Check the completeness of the delivery and compare the information stated on the name plate and the information in the enclosed documents. Inspect the gear unit for transport damages. Damage must be reported to the transport company. Remove the conservation agents from the shafts and flanges and other mounting surfaces. Observe the information from the solvent manufacturer when doing so. Warning! Solvents can damage the sealing rings and plastic materials. Protect these elements from contact with solvents. It the gear unit was stored or put out of operation for a long period of time (>1 year), control the storage lubricants and remove them with conservation oil if necessary. If the gear unit was put out of operation for a long period of time (>1 year), a consultation with Premium Stephan is required. 3P0144-EN / / 2.0 Page 32

34 6.4 Foot mounting Steel constructions for mounting gear units must be sufficiently stable, and be able to absorb the force initiated by the torque. Vibrations and oscillations are to be avoided. All maintenance and control elements must be easily accessible. Used oil must be collected when changing the oil. Dimensions and positioning of the supply connections can be found in the documentation and illustrations. Input and output shafts are to be balanced together. Imprecisely balanced shafts can shorten their lifespan or even lead to shaft breakage. Please observe the coupling manufacturer indications. The base must be horizontal and even. Under all circumstances, gear unit tension must always be avoided Mounting screws for foot mounting: Gear unit size Quantity Screws / bolts J 6 M30 K 6 M30 L 6 M36 M 6 M Low speed shaft (LSS) Dimensions Size Ød2 l2 u2 t2 DIN332 D.M.. W J 140 m M K 150 m M L 160 m M M 170 m M Drive elements may only be mounted with appropriate tightening equipment. Under no circumstances may the be tightened with hammer blows. All transfer elements must be balanced. Belts must be tightened according to the manufacturer's specifications. All rotating shafts and transfer elements are to be fitted with appropriate contact protection prior to operation start-up. NOTE You can facilitate assembly by applying a lubricant to the output element and/or heating it to 80 C. The dimension diagrams and specific configuration of your product are applicable. 3P0144-EN / / 2.0 Page 33

35 6.5.2 Mounting coupling on output shaft STOP When mounting couplings, the following mounting tolerances can occur: Please observe the corresponding manufacturer's specifications to achieve a long life span. Aligning the coupling halves on the motor and gear unit 6.6 Hollow shaft with feather key connection Dimensions Fig. 1 Size ØD3 U3 T3 W O J 130 H , K 140 H , L 150 H , M 160 H , The shaft provided by the customer must have adequate dimensions. Premium Stephan is not responsible for the correct design of the shaft. Information about shaft design is available from Premium Stephan. The necessary mounting components are included in the standard delivery. An assembly and mounting kit is optionally available. Mounting 6 Fixing bolt 6a Washer 7 Fixing washer 8 Retaining ring (*) An O-ring is recommended to provide increased protection against moisture. ADDITIONAL DOCUMENTS More detailed information about the feather keys used can be found in the order-specific documents. The feather key is always to be positioned symmetrically in the hollow shaft. NOTE The shaft provided by the customer must be adequately dimensioned. Premium Stephan is not responsible for the correct design of the shaft. The dimension diagrams and specific configuration of your product apply. 3P0144-EN / / 2.0 Page 34

36 6.6.2 Assembly for gear units with hollow shafts The fixing washer and corresponding screws are included in delivery. Not included are nuts and threaded rods as well as tools for disassembly. You can facilitate assembly by applying a lubricant to the machine shaft, nuts and threaded rods. The gear unit is mounted directly on the drive shaft of the machine. The transport of the drive shaft is done by means of feather keys. After assembly, the machine shaft axle must be secured. Only use appropriate tools for disassembly. Tools are optionally available as a Premium Stephan assembly/disassembly kit. Mount all protective elements before start-up. 6.7 Hollow shaft with shrink-fit ring Dimensions Fig. 2 Size ØD4 ØD5 O4 W O J 130 H K 140 H L 150 H M 160 H The torque transfer is done by means of a friction-locked connection of the shrink-fit ring. A mounting ring (7) and screw (6) must be fitted if the axial load is not taken up by the shoulder of the machine shaft. (*) An O-ring is recommended to provide increased protection against moisture Assembly of machine shaft Clean and lubricate gear unit and machine shaft and grease the hollow shaft Grease the machine shaft near the bushing. The clamp area of the shrink-fit ring must be kept free of lubricant. Tighten the gear unit using the endplate and threaded rod and nut until the shaft shoulder of the machine shaft is resting on the hollow shaft. Install shrink-fit ring. Do not disassemble the shrink-fit ring. Remove all transport safety devices. Do not mount the shrink-fit ring without a retracted machine shaft. The hollow shaft can be deformed. Position the shrink-fit ring on the hollow shaft in accordance with the following table: Tighten the tension bolts by hand. Ensure that the inner and outer ring are positioned parallel. The tensions bolts should be carefully tightened in sequence (not crossover) until the inner and outer ring are aligned. Mount all protective elements before start-up. The dimension diagrams and specific configuration of your product are applicable. 3P0144-EN / / 2.0 Page 35

37 6.8 Torque arm The torque arm is not included in standard delivery. The arm can be ordered as a complete kit from Premium Stephan. In order to avoid bending moments, always mount the torque arm on the side of the machine. 11 Gear unit 21 Hollow shaft 31 High speed shaft 41 Torque arm 50 Rubber bumper Fig. 6.8 Schematic diagram ADDITIONAL DOCUMENTS More detailed information about the torque arm used can be found in the order-specific documents. Warning! Tension caused by improper assembly of the torque arm will negatively affect the storage life span and can lead to machine shaft breakage. 6.8 Motor lantern for D-flange in accordance with IEC (B5) A standard 3-phase motor with a B5 flange can be installed above the optional motor lantern, The gear unit and motor form a compact unit. Motor lanterns for mounting on NEMA motors are optionally available Permissible motor weights STOP 1. For gear units with foot mounting, the weight of the motor may not exceed the weight of the gear unit. 2. For gear units with a modular design, only half the gear unit weight may be installed above the motor lantern. For gear units with foot mounting, the motor weight may not exceed the gear unit weight. For gear units with a modular design, only half the gear unit weight may be installed above the motor lantern. For use as a traction drive, please consult with Premium Stephan. 3. Depending on motor size and the centroidal distance X, further restrictions must be observed. The lesser motor weight based on 1) or 2) always applies Installation of the motor 1. Put the feather key onto the motor shaft. 2. Fit the clutch hub to the motor shaft. - in order to facilitate tightening, the clutch hub may be heated to a max. of 80 C. 3. Set the clutch hub to the correct position on the motor shaft. - Adhere precisely to the measurements. 4. Secure the clutch hub: - tighten threaded pin - adhere to starting torque of the screws 5. Insert the ring gear into the cam section of a hub. 6. Seal the connection between motor and motor lantern: - Use a liquid surface sealant, e.g. Loctite Observe the manufacturer's processing instructions. 7. Screw together the motor and gear unit. 8. Open the inspection opening on the clutch housing: - Remove the screw plug. 9. Visual inspection: - Are all clutch components correctly installed? 10. Carefully insert the screw plug. 3P0144-EN / / 2.0 Page 36

38 6.10 Cooling / heating Convection cooling The wastage generated is discharged across the surface of the gear unit. The gear unit surface must be cleaned regularly and kept free of dust and dirt accumulation. Direct sunlight should be avoided. If installing an awning, take care that no heat accumulation can occur. The gear unit surface can get very hot. This is normal, and the seals and lubricants are designed for such temperatures Fan In order to increase the thermal performance limit of the gear unit, a fan can be mounted on the high speed shaft. The fan hood must be protected from damages. Adequate space must be left between the fan hood and other protective devices, in order to avoid hindering air intake. If the fan should be damaged, the drive should be shut down. Air intake and discharge openings must be cleaned regularly. NOTE A fan can be retrofitted on the high speed shaft if needed. Please contact Premium Stephan Water cooling One or two cooling cartridges can be installed. The flow direction is arbitrary. If two cooling cartridges are installed, they must be switched parallel. The cooling water temperature may not exceed 15 C at a maximum of 6 bar pressure and a minimum flow volume of 4 l/min. After extended stand still or frost, the cooling water must be completely drained and residue blown out with compressed air. ADDITIONAL DOCUMENTS More detailed information about the cooling type used can be found in the order-specific documents Mechanical connection Install the cooling unit vibration-free near the gear unit. Connect the oil circulation to the connections on the gear unit. Do not confuse inlet and outlet. Connect the water connections to the cooling water. Do not reduce the inner diameter of any pipes Electrical Connection Connect the pump and temperature switch according to local regulations. Warning! Ensure the correct rotation direction of the pump. Observe the enclosed circuit diagrams. 3P0144-EN / / 2.0 Page 37

39 Cooling water If using brackish or salt water, special materials must be used. In these cases, consult with Premium Stephan. The quality of the cooling medium has a large impact on the lifespan and the maintenance intervals. Water, water or glycol-based cooling fluids, or HFC pressure fluids are permissible. Cooling water temperature may not exceed 20 C. Observe the enclosed documentation from the manufacturer. ADDITIONAL DOCUMENTS More detailed information about the cooling type used can be found in the order-specific documents Heating Electronic heating The heating is controlled by a thermostat on the gear unit. The mounting position varies according to installation position of the gear unit. The heating cartridge must be completely immersed in oil. Connecting without proper oil filling can lead to the destruction of the heating cartridge. ADDITIONAL DOCUMENTS More detailed information about the heating type used can be found in the order-specific documents. 3P0144-EN / / 2.0 Page 38

40 7. Start-Up 7.1 General Information Check that all mounting bolts are tightened with the correct torque. Observe the safety information in this document, in the manufacturer's documents for the additional components and in the order-specific documents. The gear unit may not be operated in explosion-prone environments. Ensure the correct oil level. This amount is listed on the name plate. Control the oil level with the oil inspection glass or with the oil dip stick. Install appropriate safety devices on all rotating components. For gear units with fans, ensure free air intake. For gear units with cooling cartridges or cooling units, ensure proper feed of the cooling agent. If operating at low temperatures, maintain the minimum oil temperatures. Observe the heat-up period of integrated heating elements. 7.2 Warm-up time Premium Stephan recommends letting the gear units warm up over a period of 10 hours. The load, and, if possible, speed should be increased in 2-4 steps from idling full throttle. - Pay attention to oscillations. - Is the gear unit leak tight, or is oil leaking somewhere else? - Are the auxiliary devices functioning properly (water cooling, fan)? - Has the load exceeded the information listed on the gear unit or motor name plates? NOTE 7.3 Rotation lock Further information and notices about emergency maintenance can be found in emergency maintenance section. The permissible rotation direction is marked on the gear housing near the input and output shafts. Ensure the correct rotation direction before starting the motor. Start-up in the wrong rotation direction can destroy the gear unit. Check if the rotation direction of the output shaft corresponds to the rotation direction of the machine. 7.4 Start up in extremely low ambient temperatures The gear unit may only be put into operation above a minimum oil temperature. The table shows the lower temperature limits. For gear units with electronic heating cartridges, the oil temperature must be at least at the temperature without heating prior to start-up. Oil Design ISO VG320 ISO VG220 ISO VG150 Without heating -10 C -15 C -20 C Mineral oil element 1 heating cartridge -28 C -33 C -40 C 2 heating cartridges -40 C -40 C -40 C Without heating -35 C -40 C -40 C Synthetic oil element 1 heating cartridge -40 C -40 C -40 C 2 heating cartridges -40 C -40 C -40 C These are reference values. Observe any contradicting information in your order-specific documents. 3P0144-EN / / 2.0 Page 39

41 7.5 Information about operation with electronic heating ADDITIONAL DOCUMENTS More detailed information can be found in the order-specific documents. 7.6 Taking out of operation Switch the drive motor off. For systems with brake motors, secure the system against backwards rotation. Ensure that the drive cannot be switched back on accidentally (key switch, remove fuse, very obvious signage). Drain the water from gear units with water cooling. In case of frost risk, remove the residual water by blowing out the water lines. In the case of stand still for an extended period of time, the gear unit should be started up every 2-3 weeks. For a stand still of more than 6 months, special conservation measures must be taken. Please contact Premium Stephan. 8. Inspection and maintenance 8.1 Note: RISK OF BURNING Allow the gear unit to cool sufficiently after switching off. There is a risk of burning. Observe the safety information in the individual sections. Procedures may only be performed on the gear unit when the system is switched off, and secured against accidental switch-on. Maintenance intervals must be observed. Non-observance will result in loss of guarantee claim. The starting torque of all screws and nuts is to be maintained. Before disconnecting shaft connections, the load ratio must be checked. (No torsional moments may be encountered). Only use original spare parts as listed in the enclosed documentation. During all maintenance procedures, the penetration of foreign bodies into the gear unit must be prevented. Do not clean the gear unit surface with a pressure washer. This will cause potential damage to the sealing rings. Check all safety devices after concluding maintenance procedures and perform a function test. 3P0144-EN / / 2.0 Page 40

42 8.2 Maintenance intervals Daily Monthly After 500 operating hours Time interval Every 6 months or every 3000 hours Every 12 months, under difficult operating conditions sooner Every 3 years, under difficult operating conditions sooner Every 5 years, under difficult operating conditions sooner Depending on use and surrounding conditions Testing/measures Check housing temperature 90 with mineral oil 100 with synthetic oil Check oil level Examine gear unit for leakage Oil change after initial start-up Re-greasing Re-greasing depositories Re-greasing sealing systems Check oil condition Clean existing filters Control air intake, clean if necessary Control the fixing bolts for secure seating Change mineral oil Change synthetic oil Clean or replace bleeding screw Clean fan and gear unit surface Repair paint Control function of installed components (oil cooler, heating) and replace if necessary 8.3 Lubricant change intervals The number of hours of operation is dependent on the oil temperature. Under difficult operating conditions, the oil change intervals should be shortened. CLP mineral lubricants or PAO-based synthetic lubricants are used. The proper oil quality and oil level is listed on the name plate and in the enclosed documents. If a different oil should be used, consult with Premium Stephan. After 1 hour of operation 2 oil sump constant temperature We recommend regular control of the oil quality by performing an oil analysis to reduce your operating costs. 8.4 Control and monitoring of oil condition Take an oil sample from the drain plugs at regular intervals (1000h). Analyse the oil condition: Check the oil for water content, contamination by solid matter and viscosity. The lubricant supplier will give you support in your oil sample analyses. In case of heavy contamination, perform an oil change, even if it is not the normal change interval. If the oil was contaminated unusually quickly, please contact Premium Stephan. 3P0144-EN / / 2.0 Page 41

43 8.5 Check oil level For gear units with an oil inspection glass, the oil level must be in the middle of the inspection glass. For gear units with an oil dip stick, the oil level must be between the min/max marks. To control, screw and pull the dip stick out, clean the stick, and put it back in place. Turn the oil dip stick back out and control the oil level. For gear units with an oil level glass, the oil level must be between the min/max marks. Correct the oil level if necessary. After the first initial filling, the oil level should be checked again after waiting for 20 min. The positioning of the oil control elements, bleeding screw and oil drainage plug depends on the constructional design. Please observe the information in these operating instructions and the symbols on the gear box housing. Only control the oil level on gear units that are switched off, and wait until the gear unit has cooled off. Should it be necessary to correct the oil level, different types of synthetic lubricants may not be mixed, and also not mixed with mineral lubricants. 8.6 Oil change This amount listed on the name plate is to be understood as an approximate value. The correct oil level on the oil control elements is most important. Prior to re-filling, the gear unit must be thoroughly rinsed, so that oil sludge, abraded material, and old oil residue are removed. The same oil type should be used for rinsing as is also used for operation. Viscous oils should be warmed. Not until all residue is removed may the fresh oil be refilled. In general, the same oil should be used as was previously in the gear unit. Mixing various types of synthetic oils or manufacturers is not allowed. Under no circumstances should synthetic oils be mixed with mineral oils. When changing to another oil quality or type, the gear unit must be thoroughly rinsed with the new oil type. In this case, consult with Premium Stephan Procedure Switch the gear unit off. For gear units with cooling systems: shut off coolant flow and drainage lines. Drain the oil immediately after switching off, when the gear unit is still warm. Use appropriate oil catch containers. Unscrew the bleeding screw on the top side of the gear unit. Unscrew the oil drainage plug and let the oil drain into the container. If any oil is spilled, use a bonding agent to remove it. Clean the gear unit housing as described above. Check sealing ring in the oil drainage plug, and replace if necessary. Thoroughly clean the magnet on the oil drainage plug. Reinsert the oil drainage plug. Fill lubricant. Hot oil! Risk of burning! Wear protective gloves. Dispose of the used oil in accordance with local regulations. 8.7 Clean bleeding screw In case of dirt accumulation, unscrew the bleeding screw and clean it with appropriate cleaning agents. For extreme amounts of dust, the bleeding screw should be cleaned at shorter intervals. No foreign objects may penetrate the gear unit. 3P0144-EN / / 2.0 Page 42

44 8.8 Check and lubricate seals All seals on rotating shafts and static seals on coverings and the housing must be examined visually. If there is any sign of leakage, all seals should be replaced by original spare parts. Ring elements that require greasing should be lubricated at regular intervals on the marked points. For this purpose, Lithium soap grease should be used. Old grease is pushed out together with contaminants and must be removed and disposed of immediately. 8.9 Grease bearings Bearings that are fitted with a re-greasing device must be re-greased between maintenance intervals Fan Air intake and discharge openings should be controlled regularly for unrestricted airflow. The openings must be free of dust and fibre accumulation. If necessary, disassemble and clean the fan hood. The system must be switched off prior to performing any procedures to the fan system. Ensure that the protective devices are correctly installed before switching the system back on. The fan may not have contact with any surrounding components Water cooling The cooling cartridge must be demounted in order to be examined for damages. This requires that the oil be completely drained. Therefore, always examine the cooling cartridge when performing an oil change. Shut of the supply and drain taps for the cooling cartridge and disconnect the feed and return from the cooling cartridge. Drain the oil completely. Disassemble and examine the cooling cartridge. Light contaminations can be removed with a cleaning agent. Do not use scrapers or metal brushes. Heavy contamination can lead to a reduction of cooling capacity. Calciferous cooling water can clog the cooling cartridge. Control the unrestricted flow of water. If heavily contaminated, replace the cooling cartridge with original spare parts. After cleaning or replacement, re-install the cooling cartridge (check old seals and if necessary replace) and re-connect to the water connection. Switch the drive motor off. Continue to cool until the gear unit is adequately cooled Oil-water cooler with pump ADDITIONAL DOCUMENTS Please observe the special information in the documents about the gear unit and the operating and maintenance instructions for the oil-water cooler Heating The heating cartridge must be demounted in order to be examined for damages. This requires that the oil be completely drained. Therefore, always examine the heating cartridge when making an oil change. Pinch off the electrical line to the heating cartridge. Secure the system against being accidentally switched back on. Drain the oil completely as described in Fehler! Verweisquelle konnte nicht gefunden werden.. Disassemble and examine the heating cartridge. Light contaminations can be removed with a cleaning agent. Do not use scrapers or metal brushes. Heavy contamination can lead to a reduction of heating capacity or destroy the heating element. If heavily contaminated, replace the heating cartridge with original spare parts. After cleaning or replacement, re-install the heating cartridge (check old seals and if necessary replace) and re-connect to the electrical connection. Switch the drive motor off. Continue to cool until the gear unit is adequately cooled. 3P0144-EN / / 2.0 Page 43

45 9. Exploded Views 9.1 CK Three-stage Page

46 3P0144-EN / / 2.0 Page 45

47 9.2 CK Four-stage 3P0144-EN / / 2.0 Page 46

48 3P0144-EN / / 2.0 Page 47

49 9.3 CK Five-stage 3P0144-EN / / 2.0 Page 48

50 3P0144-EN / / 2.0 Page 49

51 9.4 CK Input Shaft 3P0144-EN / / 2.0 Page 50

52 9.5 CK Intermediate Shaft Three-stage 3P0144-EN / / 2.0 Page 51

53 9.6 CK Intermediate Shaft Four- and Five-stage 3P0144-EN / / 2.0 Page 52

54 9.7 Intermediate Shaft IMS 3P0144-EN / / 2.0 Page 53

55 9.8 CK Input Shaft 3P0144-EN / / 2.0 Page 54

56 9.9 Ck Oil Pump 3P0144-EN / / 2.0 Page 55

57 9.10 Lantern 3P0144-EN / / 2.0 Page 56

58 9.11 CK Pro Cool 3P0144-EN / / 2.0 Page 57

59 10. Parts list item numbers Item no. Part description Item no. Part description 6010 gear housing 6120 bearings 6015 cover 6121 bearings 6016 cover 6125 spacer ring (spacer bush) 6017 cover 6126 spacer ring (spacer bush) 6020 flange 6135 back rotation lock 6025 BGR. hub 6136 outer ring 6030 hub 6137 inner ring 6034 coupling 6138 cage clamp body 6035 coupling 6140 key 6036 screw 6141 key 6037 screw 6142 key 6038 screw 6143 key 6039 nut 6144 key 6040 disk 6145 support ring 6041 disk 6146 support ring 6042 locking wire 6147 support ring 6045 adapter 6148 support ring 6060 o-ring / round cord 6149 support ring 6061 o-ring / round cord 6150 shim 6062 o-ring / round cord 6151 shim 6063 o-ring / round cord 6152 shim 6070 screw 6153 shim 6071 screw 6154 shim 6072 screw 6155 retaining ring 6073 screw 6156 retaining ring 6075 parallel pin 6157 retaining ring 6076 parallel pin 6158 retaining ring 6077 parallel pin 6159 retaining ring 6080 locking cap 6160 retaining ring 6081 locking cap 6161 retaining ring 6082 locking cap 6162 retaining ring 6083 locking cap 6163 retaining ring 6085 locking cap 6170 shaft nut 6086 locking cap 6173 screw 6087 locking cap 6183 o-ring 6088 locking cap 6190 locking cap 6090 specification plate 6191 locking cap 6091 rivet, name plate 6210 intermediate shaft 6097 screw 6215 pinion 6098 ring nut 6216 gear 6099 eyebolt 6220 bearings 6110 high speed shaft 6221 bearings 6111 bevel gear set 6225 spacer ring (spacer bush) 6112 bevel pinion 6226 spacer ring (spacer bush) 6115 pinion 6240 key 6241 key 6242 key 6243 key

60 Item no. Part description Item no. Part description 6244 key 6356 retaining ring 6245 support ring 6357 retaining ring 6246 support ring 6358 retaining ring 6247 support ring 6359 retaining ring 6248 support ring 6360 retaining ring 6249 support ring 6361 retaining ring 6250 shim 6362 retaining ring 6251 shim 6363 retaining ring 6252 shim 6390 locking cap 6253 shim 6391 locking cap 6254 shim 6410 intermediate shaft 6255 retaining ring 6415 pinion 6256 retaining ring 6416 gear 6257 retaining ring 6420 bearings 6258 retaining ring 6421 bearings 6259 retaining ring 6425 spacer ring (spacer bush) 6260 retaining ring 6426 spacer ring (spacer bush) 6261 retaining ring 6440 key 6262 retaining ring 6441 key 6263 retaining ring 6442 key 6270 shaft nut 6443 key 6290 locking cap 6444 key 6291 locking cap 6445 spacer 6310 intermediate shaft IMS spacer 6312 bevel wheel 6447 spacer 6315 pinion 6448 spacer 6316 gear 6449 spacer 6320 bearings 6450 shim ring 6321 bearings 6451 shim ring 6325 spacer ring (spacer bush) 6452 shim ring 6326 spacer ring (spacer bush) 6453 shim ring 6340 key 6454 shim ring 6341 key 6455 retaining ring 6342 key 6456 retaining ring 6343 key 6457 retaining ring 6344 key 6458 retaining ring 6345 spacer 6459 retaining ring 6346 spacer 6460 retaining ring 6347 spacer 6461 retaining ring 6348 spacer 6462 retaining ring 6349 spacer 6463 retaining ring 6350 shim ring 6490 locking cap 6351 shim ring 6491 locking cap 6352 shim ring 6510 intermediate shaft 6353 shim ring 6515 pinion 6354 shim ring 6516 gear 6355 retaining ring 6520 bearings 6525 spacer ring (spacer bush) 6521 bearings 6526 spacer ring (spacer bush) 6540 key 3P0144-EN / / 2.0 Page 59

61 Item no. Part description Item no. Part description 6541 key 6653 shim ring 6542 key 6654 shim ring 6543 key 6655 circlip 6544 key 6656 circlip 6545 spacer 6657 circlip 6546 spacer 6658 circlip 6547 spacer 6659 Circlip 6548 spacer 6660 circlip 6549 spacer 6661 circlip 6550 shim ring 6662 circlip 6551 shim ring 6663 circlip 6552 shim ring 6672 screw / fixation disk 6553 shim ring 6673 screw / hollow shaft protector 6554 shim ring 6674 disk / for fixation disk 6555 retaining ring 6675 composite bush 6556 retaining ring 6676 shrink disc 6557 retaining ring 6690 locking cap 6558 retaining ring 6691 locking cap 6559 circlip 6695 v-ring 6560 circlip 6696 o-ring 6561 circlip 6697 o-ring / round cord 6562 circlip 6700 cover HSS 6563 circlip 6701 labyrinth HSS 6590 locking cap 6702 labyrinth seal HSS 6591 locking cap 6703 gap seal HSS 6610 low speed shaft 6704 ground bush 6615 pinion 6705 oil seal 6616 gear 6706 oil seal 6620 bearings 6707 o-ring 6621 bearings 6708 lubricating nipple 6625 spacer ring (spacer bush) 6709 oil plug 6626 spacer ring (spacer bush) 6710 cover HSS 6632 fixing washer 6711 labyrinth HSS 6635 BGR. hollow shaft protector 6712 labyrinth seal HSS 6636 hollow shaft protector 6713 gap seal HSS 6637 bracket 6714 ground bush 6640 key 6715 oil seal 6641 key 6716 oil seal 6642 key 6717 o-ring 6643 key 6718 lubricating nipple 6644 key 6719 oil plug 6645 spacer 6720 cover HSS 6646 spacer 6721 labyrinth HSS 6647 spacer 6722 labyrinth seal HSS 6648 spacer 6723 gap seal HSS 6649 spacer 6724 ground bush 6650 shim ring 6725 oil seal 6651 shim ring 6726 oil seal 6652 shim ring 6727 o-ring 3P0144-EN / / 2.0 Page 60

62 Item no. Part description Item no. Part description 6728 lubricating nipple 6786 screw connection 6729 oil plug 6787 screw connection 6730 cover LSS 6788 screw connection 6731 labyrinth LSS 6789 screw connection 6732 labyrinth seal LSS 6790 oil plug 6733 gap seal LSS 6791 oil plug 6734 ground bush 6792 oil plug 6735 oil seal 6793 oil plug 6736 oil seal 6794 oil plug 6737 o-ring 6795 screw plug 6738 lubricating nipple 6810 gear oil 6739 oil plug 6820 BGR. re-greasing line 6740 cover LSS 6821 pipe 6741 labyrinth LSS 6822 hose clip 6742 labyrinth seal LSS 6823 lubricating nipple 6743 gap seal LSS 6824 screw plug 6744 ground bush 6825 pipe fittings 6745 oil seal 6826 female connector 6746 oil seal 6827 sealing plug 6747 o-ring 6828 screw 6748 lubricating nipple 6835 BGR bleeding 6749 oil plug 6845 oil inspection window 6750 BGR. sealing system, w oil inspection window 6751 BGR. sealing system, w reducing adaptor 6752 BGR. sealing system, w reducing adaptor 6753 BGR. sealing system, w reducing adaptor 6754 BGR. sealing system, w male connector 6755 threaded rod 6853 pipe 6756 threaded rod 6855 tap extension 6757 threaded rod 6860 oil plug 6758 threaded rod 6861 oil plug 6759 threaded rod 6862 oil plug 6762 screw 6863 oil plug 6763 screw 6864 oil dip stick 6764 screw 6870 oil plug 6765 screw 6871 oil plug 6766 screw 6872 male connector 6770 lubrication line HSS 6873 male connector 6771 pipe bracket / fitting 6874 oil plug 6772 sealing plug 6875 oil plug 6775 lubrication line LSS 6876 hose barb 6776 pipe bracket / fitting 6877 fan filter 6777 sealing plug 6878 oil dip stick 6780 screw connection 6879 drain tap 6781 screw connection 6880 oil plug 6782 screw connection 6881 oil plug 6783 screw connection 6882 oil plug 6784 screw connection 6883 oil plug 6785 screw connection 6884 oil plug 3P0144-EN / / 2.0 Page 61

63 Item no. Part description Item no. Part description 6885 oil plug 6886 oil plug 6887 oil plug 7111 adapter 6888 oil plug 7112 flow switch 6889 oil plug 7113 oil filter 6890 oil plug 7135 suction line pipe oil plug 7142 pressure line pipe oil plug 7143 pressure line pipe oil plug 7144 pressure line pipe oil plug 7145 pressure line pipe oil plug 7155 o-ring 6896 oil plug 7159 pipe fittings 6897 oil plug 7160 pipe fittings 6910 cover paint 7161 pipe fittings 6912 primer paint 7175 pipe fittings -t 6914 hardener 7185 reducer 6916 thinner 7190 screw 7000 pro cool 7195 key 7010 protective cover, complete 7250 thread connector with thermostat 7011 outer cover 7296 cable 7012 protective grid 7297 cable lug 7013 spacer bush / air baffle sp 7298 terminal box 7015 inner cover 7299 pipe fittings 7020 air baffle, complete 7401 oil level glass 7021 baffle 7900 motor 7022 guide web short 9200 BGR. support 7023 guide web short 9210 support 7029 sealing 9260 screw 7030 fan blade 9300 BGR lantern SP 7035 spacer 9305 BRR lantern SK 7041 sleeve 9310 lantern 7042 key 9315 adapter 7043 circlip / belt drive 9320 coupling kit 7050 BGR. cooling cartridge 9321 motor coupling half 7051 cooling cartridge 9322 gear coupling half 7052 screw 9323 flexible element 7053 o-ring 9324 coupling cover 7054 sealing disk 9325 threaded rod 7065 screw 9326 screw 7066 screw 9360 protective cover for coupling 7067 screw 9361 protective cover for coupling 7068 screw 9365 screw 7069 screw 9366 screw 7070 screw 9367 screw 7080 sponge rubber 9368 screw 7081 flat seal 9369 screw 7101 BGR oil pump 9370 screw 7102 BGR oil pump 9371 screw 7110 oil pump 9372 screw 9373 screw 9374 screw 3P0144-EN / / 2.0 Page 62

64 Item no. Part description Item no. Part description 9375 nut 9388 disk 9376 nut 9389 disk 9377 nut 9400 auxiliary drive 9378 nut 9410 supporting ring 9379 nut 9420 disk 9380 parallel pin 9450 oil seal 9381 stay bolt 9455 circlip 9385 disk 9460 o-ring 9386 disk 9470 screw 9387 disk 3P0144-EN / / 2.0 Page 63

65 11 Malfunctions Information regarding malfunction If there is a malfunction during the warranty period, notify Premium Stephan at once by using the service hotline. If anything is done to the gear unit the warranty becomes invalid. We also recommend using our customer service also after the warranty period in the case of malfunctions that are not clearly localised. If you would like to take advantage of our customer service, we require the following information: Complete name plate information with serial number. Exact description of malfunction Time and conditions under which the malfunction occurred Probable cause In some cases, digital photos of the gear unit and the system 11.2 Possible malfunctions and causes Malfunction Possible Cause Remedy Noise development near the gear unit anchoring Increased operation temperature Oil discharge on the bleeding screw Abnormal and irregular running noises Gear unit anchoring has come loose Oil level in the gear unit is too high Oil is heavily contaminated or too old Surrounding temperature is too high Oil level too high Drive used in the wrong mounting position Foreign objects in the oil Tighten screws and nuts with the prescribed torque. Replace damaged anchoring elements Control oil level and correct if necessary Perform oil change acc. to instructions Protect gear unit from external heat exposure Correct oil level Mount bleeding screw in the correct position and correct the oil level for that position Control oil filling. Switch drive off and contact Premium Stephan. 3P0144-EN / / 2.0 Page 64

66 12. Lubricant type and quantity 12.1 Information about lubricant types The oil viscosity and the oil type are determined by Premium Stephan according to the conditions of use and recorded on the name plate and on the order confirmation. A consultation with Premium Stephan is required, should another lubricant be used. Before start-up, ensure that the oil quantity and quality correspond to the information on the name plate. The lubricant quantity only applies to the listed mounting position. For any other installation, consultation with Premium Stephan is absolutely necessary. Each lubricant manufacturer is responsible for the quality of its own products. Therefore, the following listed lubricant recommendations do not represent a guarantee as to their quality. Different types of synthetic lubricants may not be mixed, and also not mixed with mineral lubricants. Use only lubricants with purity class Iso / 17 / 14 STOP Should the conditions for use no longer be the same as the project planning, Premium Stephan must be consulted to select the correct oil quality. The filling quantities listed are guideline values and dependent on the number of gears and transmission ratio. Always fill up to the marking on the corresponding oil control elements. Take the lubricant table legend below into account when choosing a lubricant. CLP CLP HC Mineral oil Synthetic polyalphaolefin oil 3P0144-EN / / 2.0 Page 65

67 GUIDELINE : Binding is the order specific selection and name plate information!! Temperature Range min max DIN (ISO) ISO VG class Standard C 35 C VG 320 Degol BG 320 plus BP Energol GR-XP 320 Alpha SP 320 Optigear BM 320 Tribol 1100/320 Renolin CLP 320 plus Klüber GEM 1-320N Mobilgear 600 XP320 Goya NT 320 Shell Omala F320 Standard CLP -5 C 40 C VG 460 Degol BG 460 plus BP Energol GR-XP 460 Alpha SP 460 Optigear BM 460 Tribol 1100/460 Renolin CLP 460 plus Klüber GEM 1-460N Mobilgear 600 XP460 Goya NT 460 Shell Omala F460 Sonder Special C 45 C VG 320 CLP HC Degol PAS 320 BP Enersyn EP-XF 320 Optigear Symthetik X320 Renolin Unisyn CLP 320 Klüber GEM 4-320N Mobil SHC Gear 320 Mobil SHC 632 ELGreco 320 Shell Omala HD320 Sonder Special C 50 C VG 460 Degol PAS 460 BP Enersyn EP-XF 460 Optigear Symthetik X460 Renolin Unisyn CLP 460 Klüber GEM 4-460N Mobil SHC Gear 460 Mobil SHC 634 ELGreco 460 Shell Omala HD460 Roller Wälzlager bearing -25 C Getriebe gear unit 60 C Grease as per DIN VG 2-3 Page