DOCUMENTATION - INSTALLATION _ MAINTENANCE

Transcription

1 Bevel gears DOKUMENTATION BETRIEBS_ UND WARTUNGSANLEITUNG DOCUMENTATION - INSTALLATION _ MAINTENANCE FOR BEVEL GEARS 1

2 Bevel gears Radial forces Permissible radial load (stress) on input (d 1 ) and output (d 2 )shafts F k d 1...d 2 Size Journal of shaft d 1 d 2 d 1 d 2 d 1 d 2 d 1 d 2 d 1 d 2 F k n 1 = n 1 = max [N] n 1 = Size Journal of shaft d 1 d 2 d 1 d 2 d 1 d 2 d 1 d 2 d 1 d 2 F k n 1 = n 1 = max [N] n 1 = Size Journal of shaft d 1 d 2 d 1 d 2 d 1 d 2 F k n 1 = n 1 = n 1 = max [N] For additionally occuring axial forces the possible values of F K (value from table) have to be multiplied by the actor,5. 4

3 Lubricants for bevel gears For a faultless use of the bevel gears, lubrication is necessary. Slowly rotary gears, with peripheral speed of the bevel wheels until 4 m/s and on special operating conditions until 8 m/s, synthetic operating life grease are used. If the peripheral speed is faster, splash lubrication necessary. Consult our engineers for further information. The position and configuration of the oil fittings are determining in according to costumers. Mineral oils: Degol BG 1 Energol GR-XP 1 Alpha SP 1 Spartan EP 1 Mobilgear 627 Omala F 1 Degol BG 15 Energol GR-XF 15 Alpha SP 15 Spartan EP 15 Mobilgear 629 Omala F 15 Degol BG 22 Energol GR-XF 22 Alpha SP 22 Spartan EP 22 Mobilgear 63 Omala F 22 Degol BG 68 Energol GR-XF 68 Alpha SP 68 Spartan EP 68 Mobilgear 636 Omala F 68 Synthetic oils: Degol GS 22 Energol SGR-XP 22 Glygoyle HE22 Tivela WB Mobil SHC 629 Mobil SHC 63 Mineral grease: Fett FDP Energrease Getriebefließfett Mobilux EP 4 Retinax G HT-EP Synthetic grease: Glygoyle Grease Tivela Compound A Gearbox size G Forced lubrication Oil lubrication Output speed x1 [rpm] Ordering example Bevel gear BG 14 / 2:1 / 1.1 / II / C; D / C / B / 144 Size Transmission ratio = flange shaft : through shaft Structural shape of the gear Gear design Side to be installed Installation position (below side) Side with oil fittings Speed on flange (input) r To avoid mistakes, it is necessary to be precise when ordering. e 11

4 EXECUTION and POSITION DEF.

5 General Instructions for the Operating and Maintenance of Gears Contents Page. Contents 1 1. General Information 1 2. Transport 1 3. Assembly General Information 3.2. Foundation 3.3. Alignment 4. Starting Oil filling 5. Maintenance Deadlines for Oil Exchange 5.2. Lubrication 5.3. Cleaning 6. Lubricants 2 7. Corrosion Protection and Storage of the Gear 2 before Starting 7.1. Preservation 7.2. Storage 1. General Information This operating instruction does not contain any remarks concerning industrial safety. Respective documents are part of the documentation, presented by the final manufacturer of the unit. (The relevant required safety-technical cover of the gear in the unit is known to the manufacturer.) The final manufacturer is bound by law to cover the rotating shaft end s and the components fixed on to them during the use of the gear. The gears have to be set up so that they are protected against chemical substances and extreme environmental effects ( e. g. water, chemical steams, acids, extreme temperatures). In the case of non-compliance, or breach of these instructions, or unauthorised interference, the gear manufacturer s guarantee will not apply. Any demand for compensation resulting from this case will be refused. For additional axial and radial forces on the shaft s end, a consultation with the manufacturer is necessary. 2. Transport The gears contain oil. The gears may only be transported if the ventilation (oil dipstick) is adjusted upwards. The gears have to be stored on even planes and not on top of one another. They have to be secured against contact damages. 3. Assembly 3.1. General Information The installation or dismantling of gears has to be carried out by trained workers. Before installation, the gears have to be cleaned of corrosion protection and foreign elements. All polished surfaces have t o be greased slightly Foundation Gear foundations have to be safeguarded against dislocation; vibrations on neighbouring foundations and resonance must not occur. Steel constructions on which the gear will be installed have to be safeguarded against distortion. The fixing means and the steel constructions have to correspond to the weight and the torque of the gear. Energies occurring additionally from outside must be transferred to the gearbox, so that the operational security of the gear is ensured. The manufacturer is not responsible for damages caused by dislocation of the foundation Alignment During the set down and the alignment of the gearbox on the foundation, special attention has to be paid to the evenness of the bearing surfaces so that a warping of the gearbox during the tightening of the screws is not possible. For the fixing of the gears screws of the quality 8.8 are necessary. If additional axial and radial forces for the ends of the shafts have been allowed, the material quality of the screws has to correspond to the contractual agreements. The gears have to be aligned horizontally if there is no divergent inclination given in the instructions. The highest deviation must not be more than 2mm per 1m. During the alignment of the shaft ends to the connected machines, the allowed tolerances of the installed couplings have to be maintained. Inhibitions of the shaft ends in the mountings must not occur. During the operations special attention has to be paid to the dislocation of the shafts, caused by cog pressure, the effects of temperature etc.. 4. Starting 4.1. Oil Filling During standstill of the gear, the oil level has to be in the middle of the oil gauge. The information about the oil level on the machine sign is only an approximate value. The oil must not be topped up during operation. The gear may only be operated if the temperature of the oil lies within the given operational temperature limits. 5. Maintenance The maintenance of the gears involves the control of the temperature of the mountings, the control of the oil level (measurement and top up during standstill of the gear only), the control of the oil exchange, the control of the noise development, the control of the oil leakage, and the keeping clean of the ventilator / ventilator drillings.

6 5.1. Deadlines for Oil Exchange The first oil change after start -up has to take place after 5 service hours. Subsequent oil changes may apply after 1, service hours. The oil should be drained while it is still warm. The gear unit has to be flushed well, and the flushing oil has to correspond with the oil beforehand. Fresh oil may be filled-in only, if sludge, particles, oil residue, and rinsing oil was removed. During the re-charge, a fine meshed strainer has to be used to guaranty best cleanliness. (For oil filling see point 4.1) If the gear unit are filled with synthetic lifetime lubricants by the manufacturer, this procedure does not apply. However, the lifetime lubricants should be replaced after 5 to 7 years of service. Grease lubricated components have to be disassembled and parts have to be cleaned. When re-charging grease purged components, the gear unit has to be de-aired. When synthetic oil is used, the same procedure as for mineral oil may apply Lubrication The gear units are lubricated by splash lubrication. With this lubrication the rolling bearings are also supplied with oil. The interiors of the gearbox are ventilated by a ventilator on the uppermost point of the case. If the gears are installed in the free atmosphere or in places where there are extreme changes of temperature, control of the condensation is necessary, in addition of the control of the oil level, so that corrosion of inside parts of the gear during a longer standstill can be avoided. If the gears are not used for a longer period, an effective treatment with corrosion protection oil according to the standard instructions of the manufacturer is recommended. Before restarting, the corrosion protection has to be removed totally if it does not correspond to the used lubrication oil Cleaning The gears are to be cleaned only with solutions which will not damage the sealing elements. Generally using jet pressure cleaning devices are forbidden. In the case of entrance of water or cleaning solution in the gear frame, the guarantee will immediately be invalid. 6. Lubricants Mainly, the following gear oils can be used: (see also to points in your documentation by the final manufacturer) Shell ARAL Mobil Oil BP ESSO Castrol Omala Oil 1 Degol BG 1 Mobil Gear 627 Energol GR-XP 1 Spartan EP 1 Alpha ZN 1 Omala Oil 22 Degol BG 22 Energol GR-XP 22 Spartan EP 22 Omala Oil 68 Degol GB 68 Spartan EP 68 Tivela- Compound A Spezial-getriebefett H Mobil SHC 626 Sulphur alloyed oils must not be used because of the incompatibility with the shaft sealing rings. The usage of other alloyed oils of the same quality is allowed. 7. Corrosion Protection and Storage of the Gear before Usage 7.1. Preservation During a storage according to the rules, the gear manufacturer gives a guarantee period of 12 months on the gear preservation, and a guarantee of 6 months on the preservation of the protruding shaft journal. The guarantee period starts on the day of the gear delivery. The most important condition for every corrosion protection is the cleanness of the ventilator so that the gear can breathe Storage The gears have to be stored covered and on a support. Condensation and foreign elements must not accumulate in the cone space of the sealing rings (outside). The treads of the sealing rings have to be kept functioning by lubricating. In case of damage caused by wrong storage, the manufacturer s guarantee will not apply.