Brochure of Gear Box

Edition
0
Gear Units
2003
M... and CN... Series
Maintenance Operating Manual

CONTENTS
1. BASIC MODULE (GEAR UNIT) DOCUMENTS PAGE
U307M Safety instructions 1.1.1

E102 Gear unit operation and maintenance 1.2.1
F301 Gear unit foundation, foot mounted gear units 1.3.1
G302 Mounting of foot mounted gear units (solid shaft) 1.3.3
H303M Mounting of horizontal shaft mounted gear units (hollow shaft) 1.3.4
H303MV Mounting of vertical shaft mounted gear units (hollow shaft) 1.3.5
J103 Corrosion protection and storing 1.4
B201 Lubricating oils and greases 1.5.1
C202 Bath and s plash lubrication 1.5.2
U215 Greasing, M-series 1.5.3
U306 Assembly report (for mounting and commissioning) 1.6
2. MODULAR ACCESSORIES DOCUMENTS PAGE

12102 Elastic couplings NOR-MEX 2.1.2
12303 Flexible all steel coupling 2.1.6
L403 Coupling guard 2.1.7
15002 Shrink disc (2-part shrink disc) 2.1.8
12706 Back stop AA, AE, RBI 2.2.2
12701 Back stop RS/BI 2.2.3
12702 Back stop GFR F3-F4 2.2.4
12703 Back stop RIZ G3-G4 2.2.5
12705 Back stop FXM 2.2.6
15004 Torque arm, M-series 2.3
60004M Expansion tank (closed model) 2.5.3
60004M Expansion tank (closed model) 2.5.3
62004 Oilheater, sensor, thermostat 2.5.4
64001 Thermostat RT 14 2.5.5
64111 Temperature nipple (for oil sump) PT100 2.5.6
65006 SPM nipple (for bearings) 2.5.7
64006 Cooling coil, valve and thermometer 2.6
60006 Central lubrication connections 2.7
Manufacturer reservs the right to alteration.

Safety Instructions
U307MEN.doc 25.05.2000
SAFETY INSTRUCTIONS
1. Manufacturer’s warrantee and buyer’s 2.3 Protection of rotating parts
responsibility Appropriate guards must be provided in order to
In order to ensure the validity of the warrantee the ensure that rotating parts cannot be touched, as
buyer must ensure that storage, mounting, required by safety laws.
lubrication, operation and maintenance of the gear
unit is carried out according to SEW´s Mechanical guards must not be removed
instructions and operating conditions are as specified when the gear unit is running.
in the contract.
2.4 Maintenance
Transport, installation, plumbing, operation, All maintenance procedures are to be carried out
maintenance, and inspections should be handled by when the gear unit is at rest.
properly trained technicians; otherwise, injury or
damage to the machine may result. When opening the inspection cover be careful that no
contamination gets in to the gear unit.
The main contractor is responsible for the stability of
the drive system because he has control over the NOTE! The gear units are delivered without oil!
affecting factors. The system of connected rotating
parts must be compatible, free from critical speed as ATTENTION! Gear unit temperature must be at
well as torsional and other type vibrations within the ambient when completing any service work.
specified speed range.
3. Markings in instructions
SEW must be informed if a significant risk to the
environment or operating personnel may arise by
failure of the machine.
Electrical shock danger
Warrantee applies only when SEW´s instructions
are met.
Mechanical danger
2. Safety
2.1 Temperature Important instruction

The outer surface of the gear unit when running
exceeds 60°C. The maximum temperature may rise
as high as 100°C, especially in splash and bath
lubricated gear units.
2.2 Noise
The noise level varies according to mechanical power
rating and type of gear unit. A sound pressure level
based on measurements is given in tables
(next page ). The measurement is carried out acc. to
DIN 45 635 or ISO 8579 by the sound intensity
method.
1.1.1 1(2)
Safety Instructions
U307MEN.doc 25.05.2000
SEW M-SERIES
Helical gear units M.P.. Bevel - helical gear units M.R..

Sound pressure level LPA ± 2 dB(A) Sound pressure level LPA ± 2 dB(A)
PK1 Gear unit size PK1 Gear unit size
[kW] 10 20 30 40 50 60 70 80 90 [kW] 30 40 50 60 70 80 90
5 60 59 59 59 59 58 58 58 57 5 57 57 57 57 56 56 56
10 64 63 63 63 62 62 62 61 61 10 62 62 62 61 61 61 60
20 67 67 67 66 66 66 65 65 65 20 67 67 66 66 66 65 65
40 71 71 70 70 70 69 69 69 69 40 72 71 71 71 71 70 70
60 73 73 72 72 72 72 71 71 71 60 75 74 74 74 73 73 73
80 75 74 74 74 73 73 73 73 72 80 77 76 76 76 75 75 75
100 76 76 75 75 75 74 74 74 73 100 78 78 78 77 77 77 76
150 78 78 77 77 77 76 76 76 76 150 81 81 80 80 80 79 79
200 79 79 79 78 78 78 77 77 200 82 82 82 81 81
250 80 80 79 79 79 79 78 250 84 84 83 83 83
300 81 81 80 80 80 80 79 300 85 84 84 84
400 82 82 82 81 81 81 400 87 86 86 86
500 83 83 83 82 82 500 88 88 87
700 85 85 84 84 84 700 90 90 90
900 86 86 85 85
1200 88 87 87 87
1500 88 88 88
2000 90 90 89
PK1 = Running power on HSS, Input speed The values in the tables applies only in free-field
n1 = 1200..1800 r/min, conditions at one (1) meter distance from the gear
Gear unit service factor FS = 1.1 ... 2.25 unit surface. Measurement uncertainty for the sound
pressure level LPA is ± 2 dB(A).
Sound pressure level for gear unit with fan(s) is
increased: When the operating conditions differ significantly from
-2 fans +6 dB the above mentioned, please contact SEW.
-1 fan +3dB.
1.1.1 2(2)
Operating and maintenance of gear unit
E102EN.DOC 25.05.2000
OPERATING AND MAINTENANCE OF GEAR UNIT

1. Starting the gear unit 2. Maintenance
1.1 Test run The first task of maintenance is to prevent damage.
All the most important procedures for gear units are to
As the first stage of use we recommend running-in the be marked in the preventive maintenance card:
gear unit. Load and, if possible, revolutions should be
raised in 2-3 steps to maximum. This takes about 10 à Date of completion of mounting and measurement
hours. of mounting accuracy
During running in, check the functioning of the gear unit à First oil filling, grade and quantity.
for smooth running, vibration, running noise, à Start and finish of running in, and any observation
temperature, leaks and lubrication. If anything made during its course.
suspicious is found, the cause of disturbance has to be à Start of actual operation and motor power
cleared up and eliminated. verification.
à First oil change and inspection carried out in this
1.2 Verification of the loading connection.
When running in and starting the specified loadings à Next oil changes. It is extremely important that the
should be verified. Special attention should be paid to regular checks include inspection of gears and if
peak loads, because their frequency may be of decisive possible, condition of bearings, and that results are
significance for the service life of the gear unit. entered in the preventive maintenance card.
à It is important both the user and the manufacturer of
1.3 Preparatory measures the gear unit to carry out a careful inspection at the
The outside surface of the gear unit should be cleaned end of the warranty period.
of anticorrosives taking care not to damage the seals. à If there is clearly increased wear of the teeth or
As cleaning solvents it is recommended to use only damage to flanks of teeth (pitting), the cause must
aromatic free alifatic hydrocarbon solvents, which do be investigated immediately. Too short a service life
not damage rubber seals. Seal lips and surfaces should may be due to failure of the foundation, overloading,
not be cleaned mechanically by rubbing. wrong lubrication, water in the lubrication oil,
blocking of an oil pipe, or underestimation of loading
If the gear unit has been stored for up to two (2) years when selecting the gear unit.
before use, it is advisable to rotate the gear unit without
load with lubricating oil using the gear units own 2.1 Oil filling
lubricating system.
The oil grade must be as recommended, or fully
equivalent, and oil quantity must be right. Every gear
1.4 Starting and control
unit has a plate attached giving the recommended oil
Before starting pressure lubricated gear units, first grades and quantity. In addition every gear unit has an
check the functioning of the pressure-lubrication system oil level indicator, a graduated glass or a dip stick on
by test running check that the rotational direction of the which is marked the level the oil should reach when the
pump motor is correct, and the overload relay is gear unit is at rest and the pump, if fitted,
suitable and that the interlock between the main drive and pipes are full of oil. It is essential that
motor and the pump motor operates satisfactorily. oil filling is done according to the oil level
Ensure that the surveillance devices are properly indicator, the quantity given on the plate is only a
connected. As start up is the critical moment for
guideline. Note that it is often impossible to judge the
lubrication, it is important to monitor the functioning of
quantity of oil correctly when the gear unit is running.
the pressure lubrication system. Always make sure that
the pump is taking up oil and building up pressure on
2.2 Importance of correct oil quantity
the pressure side.
Make sure when starting up that the gear unit is In splash lubricated gear units whose running load is
rotating in the right direction, shown by the arrow. close to the thermal rating, the correct quantity of oil is
Make sure that rotating shafts and especially important.
couplings are properly guarded before
starting. The operating temperature may rise in certain cases
15-20°C above the normal, simply because 15% too
much oil has been added. This may cause a reduction
1.5 Mounting
in the lubricating capacity of the oil and at worst
Instructions for mounting the gear unit are given damage the gear unit. When the oil level is lower than
separately. indicated, there is a risk that the gear will not reach the
oil and splash lubrication will not operate properly.
1.2.1 1(2)
Operating and maintenance of gear unit
E102EN.DOC 25.05.2000
In case of leakage special attention must be paid to the greasing is limited. The initial greasing of the bearings
oil level and any leaks must be repaired. is done at the factory. The recommended grades of
grease are given on the plate attached to the gear unit.
2.3 Oil changes
The first oil change must be made after On parts requiring subsequent greasing, bearing
500...800 operating hours. The used oil should housings or covers, there is a grease nipple marked by
be drained off when it is still warm. If necessary a plate. Care should be taken not to use excessive
the oil sump should be rinsed out with flushing oil. The grease, as this raises the operating temperature of the
first oil may be mineral oil, even though the subsequent bearing. Subsequent greasing instructions are given
oil is synthetic (PAO). individually for each gear unit.
à Mineral oil 2.7 Cleaning outer surfaces

With mineral oils, subsequent oil changes must be The outer surface and cooling fan, if any, as well as
made at one year (1) intervals. If running electric motors must be kept clean as accumulated dirt
temperatures are higher than +80°C, measured at raises the operating temperature. If an air cooled oil
bearing housings, the oil should be changed after cooler is used, its ribbing must also be kept clean. In
3000 h. pressure washing, the water jet should not be aimed
à Synthetic (PAO) oil directly at seals or at the breather. The functioning of
With synthetic oil, subsequent oil changes must be the breather must always be checked in connection with
made at three year (3) intervals. If running oil changes.
temperatures are higher than +90°C, measured at
bearing housings, the oil should be changed after 2.8 Maintenance of oil heater
12000 h. If the oil heater becomes encrusted it should be
removed and cleaned when changing the oil. Always
If the back stop has a separate oil chamber, this oil make sure that the heater is switched off
should also be changed at one year (1) intervals. before draining oil, as the heated resistor
With large gear units where a substantial volume of oil might cause danger of oil vapour exploding.
is used, the oil change interval can also be prolonged Encrusting of the resistor and premature
using mineral oil, provided that an oil analysis is carried ageing and spoiling of the oil is effectively prevented by
out annually e.g. by the oil company, and their setting the heater to switch off at temperatures 8-10°C
statement allows the continued use of the oil. higher than the temperature at which it switches on
according to the instructions.
If the oil change interval is longer than one (1) year,
SEW recommend spot checks to be carried out by The resistor should never be switched on when the oil
the oil company to test the condition of the oil. In temperature is higher than 40°C, as the properties of
particular the water content of oils used out of doors the additives in the oil are impaired by the effect of the
and in humid conditions should be checked, so that it resistor’s surface temperature, this accelerating the
does not exceed 0.05% (500 ppm). If the water content formation of explosive gases.
rises above 0.2% (2000 ppm), the water must be
removed. 2.9 Replacing spare parts
Instructions for replacing spare parts of gear units are
2.4 Changing oil given separately.
For changing oil, we recommend using a pump unit that
also filters the oil. When the oil filling hole is opened,
make sure that no impurities get into the oil sump, as
they shorten the service life of bearings.
2.5 Minimum purity level of lubricating oil

The purity of oil for gear units is defined according to
ISO 4406. A gear unit that has been run should have an
impurity level of 21/18 or better. The oil sample is taken
from the oil sump immediately after stopping for
changing the oil.
2.6 Subsequent lubricating of grease lubricated

bearings
In grease lubricated bearings, the grease cannot
escape into the oil sump, so the need for repeated
1.2.1 2(2)
Gear unit foundation
F301EN.doc 25.05.2000
GEAR UNIT FOUNDATION, FOOT MOUNTED GEAR UNITS, HORIZONTAL OR

VERTICAL LSS
1. Type of foundation use of steel clamps or rods or steel sections embodied
In order to ensure quick and successful mounting the in the concrete. The base concrete should be clad with
type of foundation should be correctly selected and the grout as shown in figures 1, 4 and 6.
mounting carefully planned in advance, foundation The base concrete must withstand at least the same
drawings with construction details should be available. load as the weld joints of the foundation screws.
SEW recommend the foundation methods shown
in figures 1…7. A customer’s own foundation method 3. Base concrete and supporting girders
must be equally adequate. When mounting a gear unit Fastening plates with a sufficient number of anchoring
onto steel framework, special attention should be paid bolts may also be used instead of supporting girders.
to the rigidity of this framework in order to prevent Type and dimensions of the supporting girders are
destructive vibrations and/or oscillations. Within the guiding values.
actual steel construction, the mounting bed for the gear
unit must also comply with the quality requirements as
4. Grouting
for machine beds.
When grouting, it is absolutely necessary to avoid
Small gear units weight below 250 kg are mounted by tamping or vibrating the concrete, as this may have a
using foundation screws as shown in figure 1. For gear bad effect on tooth contact and could impose an
units weight 250-4000 kg SEW recommend the unnecessary stress on the gear case. By using the
foundation type in figure 3, which is equipped with recommended types of foundation the density of the
separate machined foundation brackets. For gear units grout must be equal to base concrete.
weight more than 4000 kg as well as for turbine and
high speed gear units, a bedplate of either fabricated Table. 1. Fig. 1 and 2 dimensions [mm]
steel or cast iron is recommended according to figure 6 Foundation Steel Supporting Tightening
and 7. If the foundation brackets or the bedplate are Ød screw plate girders torque
ordered from SEW, our delivery includes all the l a K Ha bxc
parts to be mounted above the supporting girders. M12 100 5 40 20 100x100 67 Nm
M16 120 5 50 20 100x100 161 Nm
2. Concrete reinforcement M20 120 6 50 20 100x100 315 Nm
Dimension JE are given in the gear unit brochure.
The concrete base for the foundations and the grout
must be adequately interlocked and reinforced by the
Fig. 1 pos. description

Gear unit (Horizontal LSS) 6010fitting plate
weight below 6012steel plate
250 kg 6014foundation screw
6018nut
6024centralizing bush
6024
6010
Tensile strength
6012 Tack welding of the supporting
6018 girders and
6014 foundation
screws (6014)
must be at least
2
350 N/mm
1.3.1 1(3)
F301EN.doc 25.05.2000
Fig. 2
Gear unit Fig. 3
(upright) weight
below Tack welding
250 kg
Fig. 4 pos. description

Gear unit 6010 fitting plate
(Horizontal LSS) 6012 foundation bracket
weight 6014 stud bolt
250-4000 kg 6016 nut
6018 foundation screw
6024 centralizing bush
6014
6016
Tack welding
6024
6010
6012
6018
Fig. 5
Gear unit
(Vertical LSS)
weight
250-4000 kg
Table 2. Fig. 3, 4 and 5 dimensions [mm]

∅d Foundation screws Foundation Supporting Tightening
bracket girders torque
s l a K f n B L Ha bxc
M12 20 100 50 31 80 120 120 100x100 67 Nm
M24 20 100 8 50 31 80 120 120 100x100 541 Nm
M30 20 140 10 70 46 120 150 140 140x140 1092 Nm
M36 30 150 10 70 41 120 150 140 140x140 1900 Nm
M42 36 180 10 90 22 150 185 180 180x180 3045 Nm
M48 36 200 10 11 34 150 185 180 180x180 4599 Nm
Tensile strength of the supporting girders and foundation screws (pos. 6018) and stud bolts (pos. 6014) must be at
2
least 350 N/mm . Dimension J and JE are given in the gear unit brochure.
1.3.1 2(3)
F301EN.doc 25.05.2000
Fig. 6
pos. description
Gear unit
6010 fitting plate
(Horizontal LSS)
6012 bed plate
weight over
6014 stud bolt
4000 kg
6016 nut
6014
6024
6010
6012
Tack welding
6016
6018
Fig. 7
Gear unit
(Vertical LSS)
weight over
4000 kg
Table 3. Fig. 3, 6 and 7 dimensions [mm]

∅Q Foundation screws Bedplate Supporting Tightening
girders torque
l a K f n B L Ha bxc
M36 160 10 80 41 J+40 E+40 160 180x180 1900 Nm

M42 180 10 90 22 J+40 E+40 180 180x180 3045 Nm
M48 200 10 110 34 J+40 E+40 180 180x180 4599 Nm
M48 200 10 110 34 J+40 E+40 180 180x180 4599 Nm
Tensile strength of the supporting girders and stud bolts (pos. 6014) and foundation screws (pos. 6018) must be at
2
least 350 N/mm . Dimensions JN , J and JE are given in the gear unit brochure.
1.3.1 3(3)
Mounting of foot mounted gear units
G302EN.doc 25.05.2000
MOUNTING OF HORIZONTAL OR VERTICAL LSS FOOT MOUNTED GEAR UNITS

1. Preparations for mounting
1.1 Checking
Prior mounting it is advisable to check the foundation dimensions with those of in the drawings.
Fig. 1
pos. description
Gear unit weight below
6010 fitting plate
250 kg (horizontal LSS)
6012 washer
6016 foundation plate
6018 6018 nut
6012 6024 centralizing bush
6024
6010
Tack welding
6016
6014
Fig. 2
Gear unit weight below
250 kg (vetical LSS)
pos. description
6010 fitting plate
6012 foundation bracket
Fig. 3
6014 stud bolt
Gear unit weight 250-4000
6016 nut
kg (horizontal LSS)
6014
6024
Tack welding
6010
6012
6016
6018
Fig. 4
Gear unit weight 250-4000
kg (vertical LSS)
1.3.3 1(3)
G302EN.doc 25.05.2000
Fig. 5
Gear unit weight over
4000 kg (horizontal LSS)
6014
Tack welding pos. description
6024
6010 fitting plate
6010 6012 bed plate
6014 stud bolt
6012 6016 nut
6016 6024 centralizing bush
6018
Fig. 6
Gear unit weight over
4000 kg (vertical LSS)
2.4 The ends of the foundation screws are first tack

2. Mounting of the gear unit welded to the supporting girders, each screw at
Details of small gear units are shown in figure 1 and three points at least. The screw should be tack
2, and of larger gear units in figures 3, 4, 5 and 6. welded in pairs on each side of the centre line of
Mounting is carried out in the following order: the gear unit, starting from the middle and from
the centre line of the gear unit in pairs. This
2.1 The parts shown in the figures 1, 3 or 5 are
makes it possible to avoid any movement due to
fastened to the gear unit. The fitting plates pos.
welding. When all screws have been tack
6010 and centralising bushes pos. 6024 are
welded, they must be welded all the way round in
used to make it possible for later adjustments
the above mentioned order. Check that the
and for instance, make mounting of a
welded foundation screws do not twist the gear
replacement gear unit easier.
unit housing by adjusting the nuts on the
2.2 The gear unit is supported at the selected
foundation screws.
position on the supporting girders by means of
2.5 Mounting to be checked and grouting to be
three maximum spaced foundation screws (two
carried out after tack welding the nuts for gear
on one side of unit, one on other side)
unit fastening screws
Alignment:
2.6 When the grouting concrete has set, the
- vertically by lifting, lowering and tilting, using
mounting must be checked and (if necessary)
the nuts of the foundation screws
finely adjusted after removing the centralizing
- horizontally by tapping the foundation screws
bushes (pos 6024) from the fastening holes of
lightly in the required direction.
the gear unit.
2.3 When the correct vertical and horizontal position
2.7 The mounting is finalized by securing with two
and shaft line of the gear unit has been reached,
tapered dowel pins. By this means, the gear unit
the nuts on the three foundation screws are
can be moved (e.g. for coupling fitting) and
locked and the other foundation screws are
refitted accurately by locating with the dowel
carefully lowered on to the girders and locked.
pins. The top end of the pins to be fitted with nut
The position of the gear unit must then be
for easy withdrawal.
rechecked in case any disturbance in the setting
has occurred. If so this must be rectified.
1.3.3 2(3)
G302EN.doc 25.05.2000
3. Mounting precision when aligning

3.1 General
Use SEW´s instructions for aligning the HSS and
LSS couplings.
3.2 Foundation plane accuracy when aligning

Ensure when aligning that the mounting accuracy
plane tolerances of the foundation do not exceed
values ymax in table 1. Use shims for levelling the
foundation base.
Table 1: Mounting accuracy plane tolerances
JE ymax
[mm] [mm]
< 400 0.035
400..799 0.060
800..1200 0.090
1200..1600 0.125
1600..2000 0.150
4. Mounting the motor to the gear unit

When using mounting flange, the assembly
clearance, at least (3..5 mm), between motor and
gear unit shaft ends must be checked by opening the
inspection cover of the flange.
When using foot mounted motor, the maximum

misalignment tolerances are given in an separate
instruction depending on the coupling type.
Fig. 4 Mounting the motor with mounting flange
1.3.3 3(3)
Mounting of hollow shaft gear units,
horizontal LSS
HM303MEN.doc 25.05.2000
MOUNTING OF HOLLOW SHAFT GEAR UNITS, HORIZONTAL LSS, M-SERIES

1. Mounting of hollow shaft gear unit, shrink disc
connection
The hollow shaft bore is provided with end plate and
1) Mount the gear unit on to the driven shaft and
the retaining ring for mounting, securing and
screw the nut (2) until shaft end and end plate
dismounting the unit.
meet.
DO NOT USE ANY GREASE ON THE 2) Mount the shrink (1) disc according to separate
SHAFT, because it reduces the friction. instructions.
MOUNTING
1 shrink disc
2 nut
3 stud bolt (not included
in standard delivery)
4 end plate
AS MOUNTED
1 shrink disc
5 shrink disc cover
6 shaft end cover
1.3.4 1(3)
horizontal LSS
HM303MEN.doc 25.05.2000
2. Dismounting of hollow shaft gear unit, shrink disc connection

Attach the screw (7) into the end plate and turn the screw in order to dismount the gear unit from the driven shaft.
DISMOUNTING
1 shrink disc
4 nut
4 end plate
7 stud bolt (not included
in standard delivery)
3. Mounting of hollow shaft gear units, key connection

The hollow shaft bore is provided with a retaining 1) Remove the protective cover of the hollow shaft.
rings and an end plate for mounting, securing and Coat the shaft end of the driven machine with a
®
dismounting the gear unit. anti-corrosive oil or grease e.g. NOCO -Fluid,
Never-seez, Molykote DX, Molykote G Rapid 2
plus, Fel-Pro C-670, Chesterton 785
2) Mount the gear unit on to the driven shaft and
screw nut (2) until shaft end and end plate (4)
meet.
3) After mounting the gear unit to the driven shaft,
fasten the fixing screws.
MOUNTING
2 nut
3 stud bolt
4 end plate
1.3.4 2(3)
horizontal LSS
HM303MEN.doc 25.05.2000
AS MOUNTED
4 end plate
6 cover
8 fixing screw
4. Dismounting of hollow shaft gear unit, key connection

Attach the screw (1) into the end plate (2) and turn the screw in order to dismount
the gear unit from the driven shaft.
1 screw
2 end plate
5. Allowed mounting tolerances
Clearance to allow lateral movement
Material GRP, welding not allowed
1.3.4 3(3)
Mounting of vertical hollow shaft
gear units
H303MVEN.doc 25.05.2000
MOUNTING OF VERTICAL HOLLOW SHAFT GEAR UNITS

1. General 1.2 Mounting of hollow shaft gear unit, key
The mounting of hollow shaft gear unit is carried out by connection
using the end plate and suitable screw (see fig. 2...5). 1. Remove the protective cover of the hollow shaft.
The size of screws required for mounting can be found Coat the shaft end of the driven machine with a
®
from the dimension drawing of the gear unit. anti-corrosive oil or grease e.g. NOCO -Fluid,
Never-seez, Molykote DX, Molykote G Rapid 2
1.1 Preparation for mounting plus, Fel-Pro C-670, Chesterton 785 when key
1. Check the diameters and tolerances of the hollow connection is used
shaft bore and the shaft end of the driven machine. 2. Lift the hollow shaft gear unit to the level of the
2. Check the dimensions and tolerances of the shaft end of the driven machine. The hollow shaft
keyways and the key. of the gear unit can be heated to between 60° and
3. Check the fitting position of the holes in the plate 70°C, using e.g. a soft flame all over the shaft hole.
and the tapped holes in the shaft end. 3. Fit the gear unit to the shaft when necessary by
means of a shaft stud bolt(s) and nut(s) which are
tightened against the end plate.
4. Fasten the protective cover
Picture 1: Mounting, Key Connection Picture 2: As mounted, Key Connection
1.3.5 1(4)
gear units
H303MVEN.doc 25.05.2000
1.3 Mounting of hollow shaft gear unit, shrink It is extremely important that the hollow
disc connection shaft bore and the driven shaft is
When shrink disc connection is used, separate thoroughly cleaned from oil or grease, in
instructions to fasten shrink discs are given. order to provide sufficient friction
between the surfaces in contact.
Picture 3: Mounting, Shrink disk Picture 4: As mounted, Shrink Disk
1.4 Dismounting of the hollow shaft gear unit 4. The dismounting is carried out by means of screws
1. Drain the oil from the gear unit. and threaded holes in the end plates (Picture 5 and
Picture 6).
2. Remove the protective cover of the hollow shaft.
5. Appropriate hydraulic devices and tools can also be
3. Fasten a lifting device to the gear unit and remove
used.
the gear unit from the anchoring rod.
1.3.5 2(4)
gear units
H303MVEN.doc 25.05.2000
Picture 5:Dismounting, key connetion Picture 6: Dismounting, Shrink Disk
2. Mounting precision when aligning

2.1 Aligning of couplings
Use SEW´s instructions for aligning the HSS and
LSS couplings.
2.2 Foundation plane accuracy when aligning

When aligning ensure that the mounting accuracy
plane deviations of the foundation do not exceed
values ymax in table 1. Use shims for levelling the
foundation base.
Table 1: Mounting accuracy plane tolerances
JE ymax
[mm] [mm]
< 400 0.035
400..799 0.060
800..1200 0.090
1200..1600 0.125
1600..2000 0.150
Picture 7: Mounting accuracy plane deviations
1.3.5 3(4)
gear units
H303MVEN.doc 25.05.2000
3. Mounting the motor on to the gear unit

When using a mounting flange, the
assembly clearance, at least (3..5 mm),
between motor and gear unit shaft ends
must be checked by opening the
inspection cover of the flange (Picture 8).
When using foot mounted motor, the maximum

misalignment tolerances are given in an separate
instruction depending on the coupling type.
Picture 8: Mounting the motor with the mounting flange
NOTE: Shaft ends must not meet, there must allways

be a gap between shaft ends.
1.3.5 4(4)
Corrosion protection and storing
J103EN.doc 25.05.2000
CORROSION PROTECTION AND STORING
Table 1: Selection of corrosion protection and packing (chapter number)

transportation storage conditions transport conditions
and outdoors under indoors in heated Land/normal Sea transportation
storage time roof conditions transportation
6 months chapter 1 chapter 4 chapter 5
separately
- chapter 2 chapter 4 -
agreeded
1. Standard protection SEW works. Solvent cleaning is required when

- interior protection: all SEW gear units are test mounting
driven without load using a protective oil (Neste - threaded holes and blind holes are sealed with
Protective oil 20W/30 ISO VG 100), which protects plastic plugs.
the gear unit interior against corrosion. The gear
unit is delivered normally without oil! - additionally, if VPI cannot be used or extra long
term protection is required SEW recommends
- oil seals and seal surfaces are protected externally the customer to fill the gear unit with oil (see
by suitable grease technical specification for oil type) as high as
- unpainted surfaces including spare parts, are possible but not higher than breather or filling
coated with protective-coating Tectyl 506EH at connection so that all rotating parts including
SEW works. Solvent cleaning is required when bearings are in oil.
mounting • filling the gear unit with oil, applies only when all
seals are lip type seals
- small spare parts and small loose parts e.g. bolts, • during filling rotate the shafts (if possible) and
nuts, etc. are delivered wrapped in plastic anti- check for any oil leaks
corrosion VCI bags
Shell vapour phase inhibitors (VPI range) are volatile
- threaded holes and blind holes are sealed with solids, which when placed in enclosed spaces saturate
plastic plugs. the surrounding air with their vapour. Gear unit internal
parts, when placed in this atmosphere are coated by an
2. Short term protection invisible film of VPI, which protects them from
- interior protection as in chapter 1 corrosion.
- unpainted surfaces including spare parts, are The Shell VPI 260 is used as powder. The powders are
sprayed with CRC400 or RostOff –anti corrosion dissolved as 10% solution in methanol or ethanol.
spray at SEW works The solvent is allowed to evaporate before the
- threaded holes and blind holes are sealed with protected gear unit is closed. In addition it must be
plastic plugs emphasized that methanol and ethanol are inflammable
and furthermore methanol is toxic. Care must therefore
- customers is fully responsible for the corrosion be taken to protect operators from the vapours and also
protection of the gear unit. to ensure that no open flames or sparks are presented
either during application or while the volatile solvent is
3. Long term protection evaporating.
- interior protection: vapour phase inhibitor solvent As a guidance one can use 0.5 l of a 10% solution per
(VPI range) is sprayed through the inspection hole one interior m³ of the gear unit.
by means of, for instance, a dye sprayer. The gear
units are delivered normally without oil! The treatment must be repeated after 36 or 24 months
(acc. to table 1).
- gear case is made as air tight as possible and free
from moisture. The breather is replaced by a plug.
The breather is tied to the gear unit with instructions
to put it back before start-up
- unpainted surfaces including spare parts, are
coated with protective-coating Tectyl 506EH at
1.4 1(2)
Corrosion protection and storing
J103EN.doc 25.05.2000
4. Standard packing 7. Prior to commissioning

- all oils used for storage purposes must be drained
away
- breather is checked and fitted
- gear unit must be thoroughly cleaned out with flushing
oil
WHEN CLEANING TECTYL FROM SHAFT
ENDS DO NOT USE SOLVENTS WHICH
INCLUDE AROMATIC INGREDIENTS, AS
AROMATICS ARE HARMFUL FOR THE OIL
SEALS. ONLY AROMATIC-FREE
ALIPHATIC SOLVENTS ARE
RECOMMENDED FOR THIS PURPOSE.
WHEN CLEANING SHAFT ENDS, DO NOT
MECHANICALLY SCRAPE LIP SEALS AND
5. Seaworthy packing SEAL SURFACES!
Seaworthy packing is recommended as mechanical - Solvents for cleaning TECTYL 506EH are for
protection and protection against moisture during example:
transport and storage. Closed plywood or plastic cover Neste LIAV 230
with wooden framework. Esso Exxsol D 60
Exxon Exxsol D 60
Shell Shellsol D 70
- visual inspection of gear unit interior must be done
whilst rotating the output shaft (LSS) one full
revolution to verify if any corrosion exists.
- fill the gear unit to specified level with correct oil
type for operating conditions when gear unit is
standing still. See Instruction B201
- check that the pressure lubrication system (if
included) functions correctly.
6. Electrical equipment
Electrical equipment are protected by packing them
wrapped in anti-corrosion plastic film or bag, including a
silicasel bag.
1.4 2(2)
Lubricating oils and greases for gear units
B201EN.doc 16.02.2001
LUBRICATING OILS AND GREASES FOR GEAR UNITS

1. Lubricating oils 3. Synthetic oils (PAO)
This instruction can be applied when following
3.1. Lubricating oil standards
conditions are valid:
- Industrial helical, bevel-helical and planetary Lubricating oils are grouped in ISO VG viscosity
applications, no classification requirements are classes according to standards ISO 3448 and DIN
presented. 51519.
- Ambient temperature is in the range of ISO VG ISO 6743-6
-30ºC…+40ºC class designation
- Only antifriction roller bearings are used (no sliding 150 ISO-L-CKT 150
bearings) 220 ISO-L-CKT 220
- The actual max. pitch line velocity is less than 35m/s 320 ISO-L-CKT 320
- All lubricating methods with oil: splash, bath and 460 ISO-L-CKT 460
pressurised lubrication Containing EP additives
In addition to the required viscosity class ISO VG, the oil 3.2. Selection of viscosity class ISO VG (40°C)
must contain anti-wear, anti-rust, anti-oxidant and anti-
Maximum operating temperature of synthetic oil is
foam additives. The FZG stage should be at least 12
90°C.
according to DIN 51354.
Table 1 indicates the required ISO VG class of the oil
The oil must also contain EP additivies. If synthetic oils and the max. lubricating temperature TL of the oil.
are selected due to operating temperatures or oil
change intervals, Metso Drives recommends 3.3. Selection of the lubricating oil
polyalfaolefin based (PAO) oil. Synthetic PAO oils (tables 3 and 3.1)
When the gear unit is located out of doors, use an oil
2. Mineral oils heater when:
2.1. Lubricating oil standards - With splash or bath lubrication the starting
temperature is less than the pour point of the oil
Lubricating oils are grouped in ISO VG viscosity
- With pressurised lubrication the starting oil
classes according to standards ISO 3448 and DIN
viscosity is greater than 2000 cSt.
51519.
ISO VG ISO 6743-6 DIN 51517-3 AGMA 4. Lubricating greases for bearings
class designation designation 9005-D94
designation 4.1. Lubricating grease standards
150 ISO-L-CKC DIN 51517- AGMA 4 EP When lubricating grease for bearings is used it is
150 CLP 150 marked on the gear unit and technical specification.
220 ISO-L-CKC DIN 51517- AGMA 5 EP
Containing EP additives. Only to be used for greasing
220 CLP 220
of bearings. Hardness class NLGI 2.
320 CLP 320 ISO 6743-9 designation DIN 51502 designation
460 CLP 460 ISO-L-XCCFB 2 DIN 51502 K2K-30
680 ISO-L-CKC DIN 51517- AGMA 8 EP Lithium soap based greases are recommended.
680 CLP 680
Containing EP additives 4.2. Selection of lubricating grease
2.2. Selection of viscosity class ISO VG (40°C) For roller bearings the greases shown in table 4 are
used. A plate with grease recommendations is attached
Maximum operating temperature of mineral oil is 80°C.
if the gear unit requires grease lubrication.
Table 1 indicates the required ISO VG class of the oil
and the max. lubricating temperature TL of the oil. 5. Slow speed gear units
2.3. Selection of the lubricating oil When the pitch line velocity of the slowest stage is
1
Mineral oils (tables 2 and 2.1) under 1 m/s (n2 < 15 /min), the gear unit operates in
When the gear unit is located out of doors, use an oil boundary lubrication area.
heater when: It is recommended to use:
- With splash or bath lubrication the starting - mineral oils with EP- and antiwear additives
temperature is less than the pour point of the oil - running viscosity should be ≥ 100 cSt
- With pressurised lubrication the starting oil - the cleanliness of the oil and the oil sump must be
viscosity is greater than 2000 cSt. ensured.
1.5.1 1(9)
B201EN.doc 16.02.2001
6. Oil selection, ISO VG (40°C) class

Table 1 Practical lubricating oil (ISO VG (40°C)) and max. lubricating temperature (TL) of the oil
1) Splash or bath 1) Pres. lub. 2) Pres. lub. 3) Pres. lub. Note
Number lubrication NO ext. cooler Ext. cooler, Ext. cooler,
of stages spray dose, oil led to
in the splash or bath gearmeshes
gear unit lubrication and bearings
ISO VG (40°C)/TL ISO VG(40°C)/TL ISO VG (40°C)/TL ISO VG (40°C)/TL
1 320/90 320/90 220/70 220/60 Synthetic oil

1 320/80 320/80 220/70 220/60 Mineral oil
2 320/90 320/90 220/70 220/60 Synthetic oil

2 320/80 320/80 220/70 220/60 Mineral oil
3 460/80 460/80 320/70 320/60 Mineral or

synthetic oil
4 460/70 460/70 460/70 320/60 ONLY mineral oil
5 460/70 460/70 460/70 320/60 ONLY mineral oil
Pres. Lub. = Pressurised lubrication or central TL = Max. lubricating temperature of the oil which
lubrication lubricates the gearmeshes and bearings (Celcius)
1) NOTE: The oil temperature TL is measured from
3) NOTE: the oil is led directly to the gearmeshes and
the oil surface.
bearings with direct piping. The oil temperature
2) NOTE: the oil temperature going into the gear unit when going into the gear unit is set in the range of
is different that lubricates the gearmeshes and 45º…55ºC.
bearings. NO direct piping to the gearmeshes and
bearings is made. The oil temperature when going
into the gear unit is set in the range of 45º…55ºC.
Fig. 1 Mineral oils Fig. 2 Synthetic PAO oils
-25-20-15-10 -7 Pour point [°C]

-40 -40 -35 -30 Pour point [°C]
3000
3000 220 460
2000
2000 150 320 Viscosity index
150 320 680 Viscosity index
VI=90...100 VI=140...180
220 460 1000 ISO VG
1000
ISO VG
500 500
200 200
150 150
100 100
40 40
Viscosity Viscosity
[cSt] [cSt]
10 10
-20 -10 0 10 20 30 40 50 60 70 80 90 100 -20 -10 0 10 20 30 40 50 60 70 80 90 100
Gear unit’s lubricating temperature of oil TL [°C] Gear unit’s lubricating temperature of oil TL [°C]
1.5.1 2(9)
B201EN.doc 16.02.2001
Mineral oils Table 2

ISO VG AGMA Company Oil Viscosity Pour point
class number cSt/40°C °C
Aral Aral Degol BG 150 150 -24
BP Energol GR-XP 150 140 -27
Castrol Alpha SP 150 150 -21
Chevron EP Industrial Oil 150 150 -15
Exxon Spartan EP 150 140 -27
Esso Spartan EP 150 140 -27
Fuchs Renolin CLP 150 Plus 148 -21
150 4EP Gulf Gulf EP Lubricant HD 150 146 -27
Klüber Klüberoil GEM 1-150 150 -15
Kuwait Q8 Goya 150 150 -27
Mobil Mobilgear 629 142 -24
Molub-Alloy MA-814 / 150 150 -23
Neste Vaihteisto 150 EP 145 -27
Nynäs Nynäs GL 150 150 -24
Optimol Optigear BM 150 150 -18
Petro Canada Ultima EP150 152 -27
Statoil Loadway EP 150 140 -27
Texaco Meropa 150 148 -24
Total Carter EP 150 150 -18
Gulf Gulf EP Lubricant HD 220 219 -15
220 5EP Mobil Mobilgear 630 209 -23
Molub-Alloy MA-90 / 220 220 -18
1.5.1 3(9)
B201EN.doc 16.02.2001

class Number cSt/40°C °C
Molub-Alloy MA-690 / 320 320 -15
Molub-Alloy MA-140 / 460 460 -15
1.5.1 4(9)
B201EN.doc 16.02.2001

Molub-Alloy MA-170W / 680 680 -12
Mineral oils for paper machine drives Table 2.1

Esso Teresstic N 220 220 -12
Mobil DTE Oil BB PM 208 -15
220 5EP Neste Paperikone 220 D 220 -12
Shell Delima Oil 220 220 -9
Shell Delima S Oil 220 -9
Texaco Paper Machine Oil Premium 220 220 -18
Texaco Paper Machine Oil Ashless(3) 220 -18
1.5.1 5(9)
B201EN.doc 16.02.2001
Synthetic polyalfaolefin-based (PAO) oils Table 3

ISO VG AGMA Company Oil Viscosity cSt Pour
class number 40 °C 100 °C point °C
Castrol Alphasyn EP 150 150 19.3 -48
Esso Spartan Synthetic EP 150 160 20.1 -42
Exxon Spartan Synthetic EP 150 160 20.1 -42
Fuchs Renolin Unisyn CLP 150 151 19.4 -39
Klüber Klübersynth GEM 4-150 150 19 -45
Neste Vaihteisto S 150 EP 155 21.5 -48
150 4EP Nynäs Mereta 150 150 20 -42
Total Carter EP/HT 150 150 19 -42
Texaco Pinnacle EP 150 150 19.8 -50
220 5EP Neste Vaihteisto S 220 EP 205 27 -45
Nynäs Mereta 220 220 26 -39
Optimol Optigear Synthetic A 220 210 23.5 -36
Nynäs Mereta 320 320 34 -39
Optimol Optigear Synthetic A 320 290 30 -36
Optimol Optigear Synthetic A 460 463 44.5 -30
Synthetic polyalfaolefin-based (PAO) oils for paper machine drives Table 3.1
class Number 40°C 100°C point°C
Esso Teresstic N Synthetic 220 220 24.7 -42
Mobil SHC PM 220 240 26.1 -39
220 5EP Neste Lamda 220 ZF 210 30.6 -45
Optimol Optisynth HT 220 220 27.4 -39
Shell Delima HT Oil 220 226 24.1 -28
Texaco Paper Machine Oil XL(2) * 220 20.5 -12
* Half-synthetic oil
1.5.1 6(9)
B201EN.doc 16.02.2001
Roller bearing greases Table 4

Operating temperature -30°C...+100°C NLGI 2 (EP)
Company Grease Penetration Drop point
°C
Aral Aralub HLP2 265/295 180
BP Energrease LS-EPS 265/295 190
Castrol Spheerol EPL 2 265/295 175
Chevron Dura-Lith EP2 265/295 185
Elf Epexa EP2 265/295 180
Esso Beacon EP2 270/280 185
Exxon Beacon EP2 270/280 185
Gulf Gulf crown Grease 2 279/290 193
Klüber Centoplex EP2 265/295 190
Kuwait Q8 Rembrandt EP2 265/295 180
Mobil Mobilux EP2 265/295 177
Molub-Alloy BRB-572 240/270 188
Neste Yleisrasva EP 2 265/295 198
Nynäs L42 265/295 190
Optimol Olista Longtime 2 265/295 180
Shell Alvania EP2 265/295 180
Statoil Uniway EP2 270/280 185
Texaco Multifak EP2 265/295 186
Total Multis EP2 265/295 190
Tribol Tribol 3030 / 100-2 265/295 180
Lubrication of hot (>80°C) running tapered roller bearings NLGI 2 (EP)

°C
Castrol LMX 265/295 260
Klüber Klüberplex BE 31-102
Molub-alloy MA-680-220-2 265/295 260
Optimol Longtime PD 2 265/295 260
Shell Albida Grease EP2 265/295 260
Tribol Tribol 4020/220-2 265/295 260
Lubrication of slow running thrust bearings NLGI 0...1 (EP)

°C
Klüber Unimoly GL 402
Molub-Alloy MA 870 (NLGI 2) 265/295 180
Optimol Optipit (NLGI 2-3) 245/275 300
Shell Albida Grease HD2 (NLGI 2) 265/295 260
Tribol Tribol 3020/1000-1 310/340 180
1.5.1 7(9)
B201EN.doc 16.02.2001
7. Additional oil types and bearing greases
Mineral Oils
class number cSt/40°C °C
1)
Mobil Mobilgear XMP 150 150 -27
2)
Shell Omala Oil 150 150 -25
150 4EP
Teboil Pressure Oil 150 150 -21
3)
Tribol Tribol 1100-150 151 -28
Lubrication Eng. LE-607 220 -23
1)
2)
220 5EP Shell Omala Oil 220 220 -18
3)
1)
2)
3)
1)
2)
3)
1)
680 8EP Shell 2)
680 -9
Omala Oil 680
3)
Synthetic polyalfaolefin-based (PAO) oil

class number 40 °C 100 °C point °C
Lubrication Eng. LE-9920 150 25 -45
1)
Mobil Mobilgear SHC XMP 150 150 21 -48
150 4EP
Teboil Teboil Sypres 150 20 -48
3)
Tribol Tribol 1710 / 150 155 18.9 -45
1)
Mobil Mobilgear SHC 2)XMP 220 220 28 -45
Shell Omala HD 220 220 26 -48
220 5EP
3)
Tribol Tribol 1710-220 220 24.7 -33
1)
320 6EP
3)
Tribol Tribol 1710-320 320 33.4 -30
1)
460 7EP
3)
Tribol Tribol 1710-460 460 42.4 -30
1)
These oils are specially designed to prevent micro pitting.
1)
The same oil type should be used during test run.
2)
Recommended only for helical and bevel-helical gear units with 1, 2 or 3 stages
3)
Recommended only for helical and bevel-helical gear units
1.5.1 8(9)
B201EN.doc 16.02.2001
Roller bearing greases

Operating temperature -30°C...+100°C NLGI 2 (EP)
°C
Lubrication Eng. LE-1275 280 232
Teboil Universal EP 280/300 180
Lubrication of hot (>80°C) running tapered roller bearings NLGI 2 (EP)

°C
Teboil Universal EPS 265/295 260
Lubrication of slow running thrust bearings NLGI 0...1 (EP)

°C
Optimol Optimol Longtime PD1 310/340 180
1.5.1 9(9)
Bath and splash lubrication
C202EN.doc 25.05.2000
BATH AND SPLASH LUBRICATION OF GEAR UNIT

1. General 3.4 Grease lubrication
Lubrication, inspection and planned maintenance are of Grease lubrication is used exclusively for bearings and
prime importance to ensure trouble free running of gear seals where the structure of the gear unit bearings
units. requires it.
4. Oil heating
2. Lubrication principles If the gear unit is to be used out doors or in unheated
The main purpose of lubrication is to provide a film of oil premises, SEW should be informed of this and of
which prevents direct metal to metal contact between the variation in temperature to be expected.
the working flanks and at the same time to lubricate the The oil heater consist of a resistor element which is
bearings and seals. Other functions of lubrications are: placed in the oil sump of the gear unit and screwed in to
the wall of the gear case. It can be removed for
- to reduce friction cleaning. The oil must always first be drained from the
- to dissipate heat from tooth contact surfaces and gear unit.
bearings The oil heater is controlled by thermostat. The
- to minimize wear thermostat must be set so that it switches the oil heater
- to remove wear particles on when the oil temperature in the gear unit falls below
- to inhibit corrosion the pour point of oil.
The upper limit of the thermostat is set so that the oil
The thickness of the oil film depends on the surface heater switches off at a temperature of 8-10°C higher
stress of the tooth, the oil viscosity and pitch line than the above-mentioned switch on temperature.
velocity. If the oil film repeatedly breaks during
operation, the working flanks of the teeth will be 5. Oil cooling
damaged. The highest permitted operating temperature for a gear
unit, measured at the bearing housing, is normally
3. Lubrication methods +90°C. In special cases a maximum temperature of
+100°C is allowed. If the mechanical running load of the
3.1 Choice of lubrication method gear unit is higher than the thermal rating, the above
The lubrication method depends in the first place on the mentioned normal temperatures will be exceeded if oil
pitch line velocity. Design, type and size of the gear unit cooling is not provided.
must also be considered. The gear unit can be cooled by:
The lubrication method depends on the pitch line - by mounting one or two fans at the input shaft of the
velocity (v) of the gear unit as follows: gear unit
- bath lubrication is normally used when v < 6 m/s - incorporating a cooling water coil in the oil sump of
- with helical gearing splash lubrication is normally the gear unit
used when v < 15 m/s
- with bevel gearing splash lubrication is normally SEW does not recommend using a fan in dusty or
used when v < 12 m/s humid conditions.
A thermostat controlled water valve must be fitted on
3.2 Bath lubrication the inlet side of the cooling water coil. The maximum
When using bath lubrication, the oil level is raised so permitted water pressure is 1MPa (10 bar). The
that contact surfaces of teeth and roller elements of the direction of flow in the cooling water coil is not
bearings are submerged in oil. important.
The amount of water flow in the cooling water coil
should be regulated so that the temperature of the oil
3.3 Splash lubrication
sump does not rise above +80°C. There is a
Splash lubrication is the most commonly used method. thermometer in the oil sump for this purpose.
The contact surfaces of teeth are lubricated by oil
splashing from the gears or oil carried by the teeth. The 6. Cold start
bearings are also lubricated by oil splashing from the
In cold start situation the starting temperature has to be
gears. Normally a pitch line velocity of v = 15 m/s sets
higher than the pour point of the lubricating oil.
the upper limit for splashing lubrication, but with special
Otherwise the alternatives are:
arrangements, higher pitch line velocities are possible.
- using different oils for summer and winter conditions
- using an oil heater
1.5.2 1(1)
Greasing the lower bearing, dry well
U215EN.doc 25.05.2000
GREASING THE LOWER BEARING, M-SERIES/ DRY WELL

The recommended grades of grease are given on the plate attached to the gear unit, as are also alternative
recommended greases. See also instruction B, lubrication oils and greases.
1. Grease amounts
Table 1: Grease amounts for standard and

re-einforced design.
Size After First filling
greasing
M..V.. [g] [g]
10 20 40
20 30 60 Oil level
30 45 90
40 55 105 Grease
50 65 130 filling
60 90 180
70 105 210
80 135 270
90 175 350 Outlet for
excessive
First filling at factory. grease,
remove
The re-greasing is recommended to perform plug
when the gear unit is warm.
Greasing when the shaft is rotating.
2. Greasing intervals
Greasing interval [h] / LSS speed [r/min]
5000
4500
4000
3500
3000
[h]
2500 Ge a r
2000 size
1500 M..V..10..30
1000 M..V..40..60
M..V..70..90
500
0
0 50 100 150 200 250 300
LSS SPEED [r/min]
3. Grease plates
The right grease type is marked in the grease plates. The amount of grease nipples is marked in the technical
specification.
1.5.3 1(1)
Assembly report
U306EN.doc 25.05.2000
ASSEMBLY REPORT
GEAR UNIT: MANUF. NUMBER:
DRIVE:
Offset misalignment HSS LSS
motor machine
shaft shaft
Angular misalignment HSS LSS

0-position
motor machine
shaft shaft
o Checked distance of coupling flanges _________ mm

o Measured assembly temperature ________°C
o Height correction of shaft centres observed
o Grease filling completed / grease quality ___________________________
o Gear unit fastened to foundation with pins
Lubrication of gear unit o Gear unit connected to central lubrication

flow _______ l/min
Oil type: o mineral o Check of oil level height
o synthetic
o VG class _______________ o Operation of pressure lubrication
_________°C _______bar
Date _______________________ Approved: _______________________________________________
1.6 1(1)
NOR-MEX elastic coupling
12102EN.doc 25.05.2000
MOUNTING OF NOR-MEX ELASTIC COUPLING, TYPE G AND E

1. General Before dismounting items 102 and 104, the relative
The Nor-Mex couplings type G and E are elastic positions should be marked, to ensure that they are
couplings, accommodating axial, angular and radial mounted in the identical positions. The couplings are
misalignments. Torque is transmitted via an elastic balanced as mounted units.
elements, with high damping properties, which is also oil When re-mounting items 102 and 104, ensure that the
and temperature resistant. mating components are oil and grease free. All screws
should be tightened equally, to the maximum torque
as per the table 3.
2. Mounting
After mounting of the coupling halves, ensure that they 2.2 Combination E
are no closer than the recommended clearances S2 and
Tighten the screws to
S1, or overall length LG or LE shown in the tables 1 and prevent movement of
2. Maximum element life will be obtained when the the coupling halves
coupling is accurately aligned acc. to chapter 3.
Fig. 2
2.1 Combination G
Tighten the screws to
prevent movement of
the coupling halves
Table 2 Nor-Mex E, dimensions

Size IE LE S1 Total
d5 max.tol. Mass
mm mm mm [mm] kg
E67 30 62.5 2.5±0.5 0.93
Table 1 Nor-Mex G, dimensions E82 40 83 3±1 1.76
Size IE IG LG S2 Total E97 50 103 3±1 3.46
d5 max.tol. Mass E112 60 123.5 3.5±1 5.0
mm mm mm mm mm kg E128 70 143.5 3.5±1 7.9
G82 40 40 92 12±1 1.85 E148 80 163.5 3.5±1 12.3
G97 50 49 113 14±1 3.8 E168 90 183.5 3.5±1.5 18.4
G112 60 58 133 15±1 5 E194 100 203.5 3.5±1.5 26.3
G128 70 68 154 16±1 7.9 E214 110 224 4±2 35.7
G148 80 78 176 18±1 12.3 E240 120 244 4±2 46.7
G168 90 87 198 21±1.5 18.3 E265 140 285.5 5.5±2.5 66.3
G194 100 97 221 24±1.5 26.7 E295 150 308 8±2.5 84.8
G214 110 107 243 26±2 35.5 E330 160 328 8±2.5 121.3
G240 120 117 267 30±2 45.6 E370 180 368 8±2.5 169.5
G265 140 137 310 33±2.5 65.7 E415 200 408 8±2.5 237
G295 150 147 334 37±2.5 83.9 E480 220 448 8±2.5 320
G330 160 156 356 40±2.5 125.5 E575 240 488 8±2.5 457
G370 180 176 399 43±2.5 177.2
G415 200 196 441 45±2.5 249.2 Table 3 Screw tightening torque
G480 220 220 485 45±2.5 352.9 Quality 8.8 Quality 10.9
G575 240 240 525 45±2.5 517.2 M6 7.9 Nm Size 330 197 Nm
M8 18 Nm M16 Size 370 216 Nm
One coupling half is supplied with a detachable collar M10 38 Nm Size 415 246 Nm
(item 102), which can be moved axially over the hub M12 74 Nm
(item 104) after removal of the allen screws. The drive M14 148 Nm M20 324 Nm
is thus disconnected and elastic elements (item 010)
may be exchanged if required.
2.1.2 1(3)
12102EN.doc 25.05.2000
3. Aligning of shafts
3.1 Mounting accuracy

Table 4 Mounting accuracies of elastic shaft couplings [mm]
-1 -1 -1
Outer n < 500 min 500 - 1500 min > 1500 min
diameter D a1 - a2 b a1 - a2 b a1 - a2 b
≤ 100 0.05 0.05 0.04 0.04 0.03 0.03
100< D ≤ 200 0.06 0.06 0.05 0.05 0.04 0.04
200< D ≤ 400 0.12 0.10 0.10 0.08 0.08 0.06
400< D ≤ 800 0.20 0.16 0.16 0.12 0.12 0.10
a1 - a2 = maximum angular misalignment b = maximum offset
Picture 1 illustrates the measurement for angular Picture 2 illustrates the measuring using a dial
misalignment (α) using a feeler gauge. When using micrometer. The same result as previous is obtained
this method, an accurate result is achieved only if the if the coupling halves are forced to rotate together so
error of the faces is eliminated by turning both that the point of the dial micrometer does not move
coupling halves 180° and then calculating the noticeably on the measuring surface.
average of the two differencies (a1 - a2). This method assumes shaft bearings which do not
allow the shafts to move axially when rotating. If this
cannot be achieved, the axial movement must be
eliminated between the end faces of the coupling
halves or two dial micrometer on opposite sides of
the coupling can be used (for calculating the
difference of the micrometers when rotating the
coupling).
2.1.2 2(3)
12102EN.doc 25.05.2000
Picture 3 illustrates the control for concentricity of Picture 4 shows a more accurate method. The
shafts, using a straightedge. Allowed values of coupling halves rotate together and the point of the
eccentricity are usually so small that sufficient micrometer does not move noticeably on the
accuracy is best achieved using a dial micrometer. By measuring surface. When the variation shown on the
rotating the coupling half together with the dial micrometer is divided by two (2), the misalignment b
micrometer, dividing the dimensional differencies by is obtained.
two (2) the misalignment b, which contains the
It is very important for gear units operation to use
misalignment of the other coupling half, is obtained
mounting accuracies mentioned in table 4.
from the variation shown on the micrometer.
3.2 The effect of the gear unit thermal

expansion
- Normally machines are mounted in ambient room
temperature (about 15...30°C).
- The running temperature of a single-, double- and
triple stage gear unit is 80°C to 90°C, causing the
raise of shaft centres and expansion of centre
distance between HSS and LSS.
- Normally the running temperature of a motor is
lower than the running temperature of a gear unit. NOTE ! The raise of LSS must be also observed at
the assembly.
- The running temperature of the driven machine
must also be considered.
4. Operating and maintenance
SEW recommends the following mounting
procedure to be considered when single-, double- During use, elastic couplings are maintenance free.
and triple stage gear units are in question:
Gear unit HSS and LSS centre height must be less

than the height of the motor and driven shaft end
centres. Due to the thermal expansion the shaft end
height difference at room temperature is
recommended to be mounted to an offset
misalignment difference b, see table 1.
2.1.2 3(3)
FLEXIBLE ALL STEEL COUPLING
12303EN 25.05.2000
1. Aligning the shafts 1.2 The maximum angular misalignment

Good shaft alignment optimizes both coupling The angular misalignment can be verified by measuring
performance and device life. Total misalignment during the flange-to-flange distance (see figure below) and
running, may arise for many reasons, e.g.: substracting the smallest reading from the largest
- accuracy in mounting reading (Y-Z). The maximum value of (Y-Z) depends on
- foundation settlement the flange diameter, therefore on the coupling size. The
following maximum values [mm] for (Y-Z) are
- changing temperatures recommended:
- deflection of the shafts (due to a high torque).
-Coupling with 4-6 bolts (Y-Z) ≤ (ØD) / 300
1.1 The maximum offset misalignment
If shafts have an offset misalignment with minimum -Coupling with 8 bolts (Y-Z) ≤ (Coupling size) / 600
angular misalignment, the following maximum values
[mm] for the offset are applicable. -Coupling with 10 bolts (Y-Z) ≤ (Coupling size) / 700
-Coupling with 4-6 bolts: Example: For ØD=380, 6 bolts (Y-Z) should not exceed
TIR ≤ ( disc pack to disc pack distance L ) / 150 380/300 = 1.27 mm.
-Coupling with 8 bolts:

TIR ≤ ( disc pack to disc pack distance L) / 300
-Coupling with 10 bolts

TIR ≤ ( disc pack to disc pack distance L) / 350
(NOTE : TIR is the Total Indicator Reading, which is

twice the shaft offset )
2.1.6 1(2)
12303EN 25.05.2000
1.3 The maximum axial misalignment Gear unit HSS and LSS centre height must be less
than the height of the motor and driven shaft end
centres. Due to the thermal expansion the shaft end
height difference at room temperature is recommended
to be mounted to an offset misalignment difference b,
see table 1.
The recommended maximum axial displacement (∆Ka)

between shafts during installation shown in the graph
below is 20% of the allowable displacement. The axial
displacement creates large stresses in the discs. For a NOTE ! The raise of LSS must be also observed
long life it is recommended that the discs are as close at the assembly.
as possible to being flat. Therefore, the possible axial
movements of the shafts as caused by thermal
2. Disc bolt tightening
expansion should be carefully considered.
2.5 Coupling Disc bolt Coupling Disc bolt Coupling Disc bolt
size non-lubricated size non-lubricated size non-lubricated
6 bolts 8 bolts ØD tightening ØD tightening ØD tightening
2 [mm] torque (Nm) [mm] torque (Nm) [mm] torque (Nm)
4 bolts
110 35 302 720 540 5000
1.5 132 35 325 720 570 6200
158 65 345 940 605 7500
∆ka 10 bolts 185 115 380 1330 635 9500
1 202 185 410 1850 675 11900
[mm] 228 275 440 2430 700 14600
0.5 255 545 475 3150 730 14600
278 545 505 4000 760 17600
0 For 6, 8, and 10 bolt discs

0 100 200 300 400 500 600 700 800
ØD [mm] 3. Operating and maintenance
During use, flexible couplings are maintenance free.

1.4 The effect of the gear unit thermal expansion
After the first running hours it is recommended to verify
- Normally machines are mounted in ambient room the alignment and the tightening torque of the screws
temperature (about 15...30°C). and nuts
- The running temperature of a single-, double- and
triple stage gear unit is 80°C to 90°C, causing the It is also recommended to disassemble and inspect the
raise of shaft centres and expansion of centre couplings after every 10000 hours or two years for any
distance between HSS and LSS. fatique crack and for verifying alignment.
- Normally the running temperature of a motor is lower
than the running temperature of a gear unit.
- The running temperature of the driven machine must
also be considered.
SEW recommends the following mounting

procedure to be considered when single-, double- and
triple stage gear units are in question.
2.1.6 2(2)
Steel Coupling Guard
L403EN.doc 25.05.2000
STEEL COUPLING GUARD

1. General 2. Materials and finish
The coupling guard is supplied as an optional The guards are made of sheet steel (s = 2 mm) and
accessory for gear units. The length of the guard is coated with epoxy powder paint. The guard is available
adjustable, which makes it suitable for use in several in RAL-1021 or TM-1310 (bright yellow).
applications. The structure of the coupling guard is
shown in Fig. 1. Holes in the guard allow a stroboscope
to be used. The guard is designed for easy disassembly
so that the equipment on the driving/driven side need
not be dismounted.
Fig. 1
Cooling vents 5
Driving / driven
Adjustable length machine
Gear unit -side

fixing flange 4
L
Gear unit shaft
(LSS, HSS)
2
3. Mounting
The guard is fastened to the gear unit using a fixing
flange. No separate feet or fixing to the motor are Table 1
required. Guard Max. Length Max.
Installation sequence (fig. 1): Size coupling shaft Ø
1. Fasten the guard flange(s) to the gear unit (1). diameter L of driving
2. Fasten the bottom section (2) to the gear unit flange. D /driven
3. Install the second bottom section (3) inside the first machine
one (2). 1 140 138 - 189 65
4. Fix the top sections in position, first the inner and 2 140 190 - 293 65
then the outer section (4 and 5). 3 230 190 - 293 105
5. Adjust the guard to correct length and tighten the 4 230 297 - 482 105
screws. 5 290 297 - 482 105
6 360 297 - 482 145
4. Sizes and adjustments 7 470 483 - 829 205
The coupling guard is available in eight standard sizes 8 570 483 - 829 205
according to maximum coupling outer diameter. For the
correct size of guard for your particular couplings, see
Table 1.
2.1.7 1(1)
Sanlo Shrink Disc
15001EN.doc 25.05.2000
SANLO - SHRINK DISC

1. General 4. Cleaning and regreasing
Sanlo shrink discs are used to join the hollow shaft of Shrink discs which have been in service should be
gear unit and the driven shaft. totally dismantled and cleaned. The bevel surfaces are
The shrink discs are supplied assembled and ready to factory-lubricated with a solid lubricant (e.g. Molycote G
mount. Only the larger units, where the weights involved Rapid). Undamaged bevel surfaces should be
make handling difficult, should be disassembled to regreased only with Molycote BR2, which should
facilitate mounting. likewise be applied to threads and screw-head bearing
surfaces.
2. Mounting If the shrink disc connection is opened, we recommend
renewing the screws before reclamation (grade 10.9).
2.1 Remove any spacers which may have been
arranged between the pressure rings as protection
during transport.
Fig. 1 Apply grease to threads
2.2 The screws should only be tightened to such a and screw heads Pressure rings
Tightening torque
degree that the inner ring can still be turned freely. for screws
Hub
2.3 Apply grease to the surface of the hollow shaft on (hollow shaft)
which the shrink disc seats.
Shaft
2.4 Push the shrink disc onto the hub of the hollow Inner ring
shaft. Attention: Do not begin tightening the screws
before the shaft is in place in the hub bore,
otherwise permanent deformation will result.
2.5 Push the hollow shaft onto the driven shaft, both
contact surfaces being ungreased.
Do not apply grease to
2.6 Make sure the shrink disc is alinged, i.e. the the hub bore or the shaft
pressure rings are in parallel planes, by tightened Apply grease to hub
seat and bevel surfaces
the screws with a short wrench.
2.7 Tighten the shrink disc by tensioning the screws

evenly one after the other in clockwise direction Table 1
(not in a "crosswise" fashion). It will be necessary Screws Tightening torque
to go round several times before all the screws are (grade 10.9)
torqued down to the recommended value. Check
with a torque wrench. Tightening torques are M8 29 Nm
shown in the table 1. The tightening torque is either M10 58 Nm
punched into material with smaller units, or is M12 100 Nm
indicated on a plate.
M16 240 Nm
3. Disassembly M20 470 Nm
3.1 Loosen the screws evenly one after the other, M24 820 Nm
again going round several times to avoid canting of M27 1250 Nm
the plates on the inner ring.
Under no circumstances whatsoever should the
screws be totally disengaged, since this could lead
to a shrink disc jumping off (think safety).
3.2 Before the driven shaft is dismantled off the hub,

any rust on the driven shaft should be removed.
3.3 Remove the shrink disc from the hollow shaft.
2.1.8 1(1)
2-Part Shrink Disc
15002EN.doc 25.05.2000
2-PART SHRINK DISC, TYPE 3171

1. General
Shrink discs are used to connect the hollow shaft of the 4. Cleaning and regreasing
gear unit and the driven shaft. Shrink Discs are Shrink discs which have been in service should be
supplied preassembled and ready for mounting. totally dismounted and cleaned. The tapered surfaces
are factory-coated with a solid lubricant (e.g. Molycote
2. Mounting G Rapid). Undamaged taper surfaces should be
2.1 Clean the hub bores and shafts free of grease regreased only with Molycote BR2, which should
before mounting likewise be applied to threads and screw-head bearing
surfaces.
2.4 Push the shrink disc onto the hub of the hollow If the shrink disc connection is opened, we recommend
shaft. Attention: Do not begin tightening the screws renewing the screws (grade 10.9).
before the shaft is in place in the hub bore,
otherwise permanent deformation will result. Place
the shrink disc towards a shaft shoulder or Outer ring Pre-assembly
bushing, for MC-series on an offset distance A as supplied
from the shaft end (see table 2). Inner ring
2.5 Push the hollow shaft onto the driven shaft, both
contact surfaces being cleaned.
Hub
2.6 Make sure the shrink disc is aligned, i.e. the inner
ring is in parallel plane with the outer ring, by
tightened the screws with a short wrench. Shaft Shaft and hub bore
clean and grease
crease free
2.7 Tighten the shrink disc by tensioning the screws
evenly one after the other in clockwise direction
(not in a "crosswise" fashion). It will be necessary Bolt
to go round several times before all the screws are
Mounted assembly *)
torqued down to the recommended value. Check
with a torque wrench. Tightening torques are
shown in the table 1. The tightening torque is
indicated on the shrink disc.
3. Dismounting Table 1
3.1 Loosen the screws evenly one after the other, Screws
again going round several times to avoid canting of Tightening torque
the plates on the inner ring. If required, bolts can (grade 10.9)
be used to disengage inner and outer rings by M8 29 Nm
means of tapped jacking holes. M10 58 Nm
Under no circumstances should the screws be
M12 100 Nm
totally disengaged, since this could lead to a shrink
disc jumping off (think safety). M16 240 Nm
M20 470 Nm
3.2 Before the driven shaft is dismounted off the hub,
M24 820 Nm
any rust on the driven shaft should be removed.
M27 1250 Nm
3.3 Remove the shrink disc from the hollow shaft.
*) After tightening the screws the front faces of the inner
and outer rings should meet.
2.1.8 1(1)
Backstop RBI, AA, AE
12706EN.doc 25.05.2000
BACKSTOP RBI, AA, AE

1. General
The purpose of backstop is to prevent undesirable
reverse rotation. Backstop will permit rotation in one
direction but immediately locks if the shaft attempts to
rotate in the reverse direction.
2. Mounting and operating

Backstops are mounted in factory. Therefore direction
of rotation for output shaft is important to specify. It is
also important for the customer to check that
electric motor is connected to rotate to
correct direction. Otherwise the peak torque
of electric motor may load the backstop in
unfavourable way.
Picture 2 Backstop RBI
Picture 1 The permitted direction of rotation is

marked on the housing of the gear unit.
3. Changing rotating direction

If a customer wishes to change the permitted
direction of rotation it can be done by flipping the
inner ring with sprags around. The inner ring and
sprags are pulled out with extractor and placed back
when flipped.
3.1 Backstop mounted on the side of the gear

unit (picture 2 and 3):
1. Remove the screws POS 4313 and retaining
ring (4319) Picture 3 Backstop AA
2. Remove the whole backstop
3. When mounting again flip the backstop around.
All the forces in assembly should be directed to
the inner ring, not to the sprag cage.
4. Flip the rotation direction signs (picture 1) on
the gear unit
5. After the mounting check that the backstop
runs smoothly.
2.2.2 1(2)
Backstop RBI, AA, AE
12706EN.doc 25.05.2000
3.2 Backstop mounted inside the gear unit

(pict. 4):
1. Remove the bearing cover 4313 (056). Be careful
with the shims and bushings between the cover
and bearings, the order must be retained when
remounting
2. Remove the whole backstop by the means of
threaded holes in the inner ring (D)
3. When remounting flip backstop around. Lock the
backstop axially by retaining ring (4319)
4. Flip the rotation direction signs (picture 4) on the
gear unit
5. After remounting check that the backstop runs
smoothly.
Picture 4 Backstop AE
4. Maintenance and lubrication

Backstops are maintenance free because they are lubricated with the same oil as gear unit.
Table 1. Tightening torques for screws.
Screw Tightening
(grade 8.8)
torque
M5 6 Nm
M6 10 Nm
M8 25 Nm
M10 48 Nm
M12 84 Nm
M16 206 Nm
M20 402 Nm
M24 696 Nm
M30 1420 Nm
2.2.2 2(2)
Backstop RS/BI F8
12701EN.doc 25.05.2000
BACKSTOP RS/BI F8
922
1. General
Backstops are optional accessories for gear units. The
926
purpose of the backstop is to prevent undesirable
reverse rotation e.g. in conveyor drives.
Backstopping is effected by anchoring one member of
the backstop between the inner and outer race so that it
will permit rotation in one direction but immediately
locks if the shaft attempts to rotate in the reverse
direction. 925
2. Structure and dimensions

RS/BI is a centrifugal lift off sprag type backstop.
When the disengaging speed is reached the sprags Fig. 1. 920 (926)
automatically disengage completely from the contact
surface of the outer race and are then contact and
wear-free. RS/BI backstops do not have bearings of
their own. Therefore the inner and outer races have to
be aligned exactly according to the permissible
squareness and concentricity tolerances.
The outer race is secured to the gear unit with screws.
Individually spring-loaded sprags are housed in a cage
which is connected to the rotating inner race by means
of retaining rings (Figure 1).
Dimensions are presented in table 1.
3. Limitations
Type RS/BI has minimum and maximum rotation speed
limits (see table 1).
Fig. 2.
Table 1.
Size Torque Overruning speed Weight
d H7 T nmin nmax D h6 D3 dmin z l l2 l3 d4
[mm] [Nm] [rpm] [rpm] [mm] [mm] [mm] [kpl] [mm] [mm] [kg]
20 120 875 14500 90 78 52 6 35 8 16 M6 1.8
25 185 825 14300 95 82 56 6 35 8 16 M6 2
30 250 780 11400 100 87 62 6 35 8 16 M6 2.2
35 300 740 10500 110 96 66 8 35 8 16 M6 2.6
40 450 720 7600 125 108 76 8 35 10 21 M8 3.4
45 510 665 6600 130 112 82 8 35 10 21 M8 3.8
50 820 610 6100 150 132 100 8 40 10 21 M8 5.3
55 880 600 5500 160 138 105 8 40 10 21 M8 6.7
60 1100 490 6100 175 155 110 8 50 12 35 M10 8.3
70 1600 480 4500 190 165 120 12 50 12 35 M10 10.5
80 2500 450 4000 210 185 140 12 60 12 35 M10 15.1
90 3300 420 3000 230 206 160 12 70 12 35 M12 20.4
100 5800 455 2700 270 240 180 12 80 15 37 M16 33
130 8500 415 2400 310 278 210 12 80 15 37 M16 41
150 16300 365 1300 400 360 280 12 80 18 44 M16 76
2.2.3 1(2)
Backstop RS/BI F8
12701EN.doc 25.05.2000
4. Assembly Table 2. Tightening torques for screws.

Check the rotation direction. To change the rotation Screw Tightening torque
direction turn the backstop around. In the older models (grade 8.8)
the chamfer of 15° had to be assembled outwards. To
M5 6 Nm
change rotation direction the sprag cage and inner race
had to be turned around. According to manufacturer M6 10 Nm
both sides of the backstop are now similar which means M8 25 Nm
the backstop can be assembled either way depending M10 48 Nm
on the freewheeling direction. Check the recommended
tolerances (h6/j6 for shaft, h6/j6 and H7/G7 for outer M12 84 Nm
race). M16 206 Nm
Attach backstop on the shaft by using key according to M20 402 Nm
DIN6885 page 1. Put the backstop on the shaft (also M24 696 Nm
outer race). All the forces in assembly should be
directed to the inner race, not to the sprag cage. Lock M30 1420 Nm
the inner race axially by retaining rings according to
DIN471 (pos.926). Secure outer ring with screws
(pos.922). Check concentricity tolerances between
shaft and outer ring and also perpendicularity from the 5. Lubrication
face of the outer race (Figure 3.) Values given by RS/BI-type backstop is uses the same oil as the gear
manufacturer have been split in half because of the EP unit and therefore doesn’t need separate lubrication.
additives used in lubrication oil. Loosen the screws and
put cover F8 on. Secure screws by using tightening
torques given in table 2.
6. Maintenance
After mounting check that the backstop runs smoothly;
No maintenance is required with RS/BI-type.
freewheeling torque value should be approximately
1/1000 of the nominal torque. When mounting or
dismounting the sprag cage by using the tapped holes
avoid screwing in too far as this can damage the
sprags and cage. Remove sprag cage rotating it slightly
at the same time in the freewheeling direction. When
mounting again turn both sprag cage and inner race
around. Lock the sprag cage to the inner race with both
retaining rings.
Backstop size:
20 - 50
60 - 90
100 - 240
Fig. 3.
2.2.3 2(2)
Back stop GFR F3-F4
12702EN.DOC 25.05.2000
BACK STOP GFR F3-F4

Table 2.
1. General Temperature (°C) 30 40 50 60
temperature factor 1 0.8 0.7 0.5
purpose of the backstop is to prevent undesirable
923
the backstop between the inner and outer race so that it 924
direction.
922
GFR is a roller type backstop. It can be directly
attached with flange to several machine elements like
gearings, gears or couplings or it can be used with 921
different cover combinations.
Backstop GFR F3-F4 is used as a separate unit 920 925
mounted on the shaft end and it has it’s own lubrication.
Backstops are self contained and sealed. An o-ring is Fig 1.
used to seal the end plate to avoid oil leakage. 160-
series ball bearings are used to centralize the inner and
outer race. L2
Outer race holds it’s position when the torque bolt of the
cover F3 is fitted into a slot in a cover of the gear unit
(see fig 1).
Dimensions are presented in the table 1.
D
F3 F4 dH7
3. Limitations
E
Type GFR has maximum rotation speed limits (see F
table 1). Rotation speed limits given in the table 1 are
C
for ambient temperatures below 30°C. If the ambient
temperature is above 30°C the speed limits given in the L3 L4
table 1 must be multiplied by the temperature factor
given in the table 2. Fig 2.
Table 1.
Size Torque Overrunning speed D L2 L3 L4 C E F Weight
d H7 [mm] T [Nm] nmin rpm nmax rpm mm mm mm mm mm mm mm kg
12 44 - 3100 62 64 10 13 10 44 59 1.4
15 100 - 2800 68 78 10 13 10 47 62 1.8
20 145 - 2400 75 82 11 15 12 54 72 2.3
25 230 - 1600 90 85 14 18 16 62 84 3.4
30 400 - 1300 100 95 14 18 16 68 92 4.5
35 580 - 1200 110 102 18 22 20 76 102 5.6
40 820 - 850 125 115 18 22 20 85 112 8.5
45 900 - 740 130 115 22 26 25 90 120 8.9
50 1700 - 580 150 123 22 26 25 102 135 12.8
55 2100 - 550 160 138 25 30 32 108 142 16.2
60 2800 - 530 170 147 25 30 32 112 145 19.3
70 4600 - 500 190 168 30 35 38 135 175 23.5
80 6800 - 480 210 178 30 35 38 145 185 32
90 11600 - 450 230 192 40 45 50 155 205 47.2
100 16000 - 350 270 217 40 45 50 180 230 76
130 25000 - 250 310 250 55 60 68 205 268 110
150 56000 - 200 400 286 55 60 68 255 325 214
2.2.4 1(2)
Back stop GFR F3-F4
12702EN.DOC 25.05.2000
4. Assembly 5. Lubrication
Check the rotation direction. To change the rotation The rust inhibitor is removed before use and backstop
direction replace covers F3 and F4 with each other and is thoroughly cleaned.
attach the back stop to the gear unit. Be careful not to
damage the seals. Check the recommended shaft The purpose of the lubricating oil is to protect rollers
tolerances h6/j6. and races against free rolling wear and to decrease free
rolling and slide torques. Lubricants containing graphite,
Backstop is bearing supported so there is no special molycote or similar additives (friction coefficient
need to ensure the parallelism of the shaft and the reducing additives) should be avoided.
housing. Although the bearings should be stress free
and the outer race has to be able to move free both In horizontally mounted gear units the right oil level is
axially and radially. The torque bolt must have a radial about 1/3 of the inside height of the backstop. Cover F4
clearance of 1-2% of the bolt's diameter and at least 2/3 has three oil plugs (one for oil inlet, one for oil outlet
of the bolt's length must be inside the slot. There has to and one for adjusting the oil level). If the backstop is
be 1mm minimum clearance at the bottom of the slot. mounted vertically backstop manufacturer must be
contacted.
Assembly is performed so that the entire backstop is
preassembled (except cover F4). Pull the inner race on Lubrication recommendations are presented in table 4.
the shaft and use the key according to DIN 6885 page
1. All forces in assembly should be directed only to the
6. Maintenance
inner race (not to the bearings or outer race because
this might damage the bearings). Lock the backstop The first oil change is done after about 100 operating
axially by using end plate and socket head cap screw hours. Next oil change is done after about 2000
(pos. 924 and 922). Oil leakage through the keyway is operating hours (in very dirty environment after about
prevented by using o-ring (pos. 921) between the cover 1000 hours). The oil change can be done at the same
and the end plate. time as for the gear unit. In any case, the oil must be
changed at least once a year.
Mount the cover F4 and use paper gasket between the
cover and the backstop. Tightening torques for the The condition and level of the oil should be checked
screws (grade 10.9) are presented in the table 3. After regularly as well as the condition of the seals. The
mounting check that the backstop runs smoothly. backstop can be flushed with thin oil if needed after
which the oil should be changed. If operating
Dismounting is performed like mounting but in reversed temperature is below -20°C or above +100°C contact
order. the lubricant supplier.
Table 3. Tightening torques for screws
Screw Torque [Nm] Screw Torque [Nm]
M5 8 M16 290
M6 14 M20 550
M8 34 M24 950
M10 68 M30 1900
M12 118
Table 4. Lubrication recommendations

AMBIENT TEMPERATURE
OIL -40°C…-15°C -15°C…+15°C +15°C…+30°C +30°C…+50°C GREASE
OPERATING TEMPERATURE
-20°C…+20°C +10°C…+50°C +40°C…+70°C +50°C…+85°C
ISO-VG/DIN
51519 mm2/s
10 22 46 100
ARAL Sumorol CM10 Sumorol CM22 Motanol HK46 Degol CL100 Aralub HL2
BP Energol HL10 Energol HL22 Energol HL46 Energol RC100 Energrease LS2
DEA Astron HL10 Astron HL22 Astron HL46 Astron HL100 Glissando 20
ESSO Nuto H10 Nuto H22 Nuto H46 Nuto H100 Beacon 2
Spinesso10 Spinesso 22 Teresso 46
FUCHS Renolin MR3 Renolin DTA22 Renolin DTA46 Renolin MR30 Renolit LZR2
KLÜBER Crucolan 10 Crucolan 22 Crucolan 46 Crucolan 100 Polylub WH2
MOBIL Velocite No 6 Velocite No 10 Vactra Vactra Mobilux 2
medium VG46 heavy VG100
SHELL Morlina 10 Morlina 22 Morlina 46 Morlina 100 Alvania G2
TOTAL Azzola ZS10 Azzola ZS22 Azzola ZS46 Azzola ZS100 Glisando multis 2
2.2.4 2(2)
Back stop RIZ G3-G4
12703EN.DOC 25.05.2000
BACK STOP RIZ G3-G4

1. General 923
purpose of the backstop is to prevent undesirable 924
the backstop between the inner and outer race so that it
direction. 922

Type RIZ is a grease lubricated centrifugal lift off sprag
type backstop.
921
When the disengaging speed is reached the sprags
automaticly disengage completely from the contact 920 925
surface of the outer race and are then contact and
wear-free.
Type RIZ G3-G4 has been sealed with labyrinth seal Fig 1.
and cover. The labyrinth seal is used to minimize the
heating of the backstop. Type RIZ G3-G4 backstop is
used as a separate unit mounted on the shaft end. 60- L
series ball bearings are used to centralize the inner and
outer race. The backstop is secured on the gear units
shaft by an end plate.
Outer race holds its position when the torque bolt of the
cover G3 is fitted into a slot in a cover of the gear unit.
(see figure 1). D
G3 G4
Dimensions are presented in table 1.
E
3. Limitations F
Type RIZ has minimum and maximum rotation speed C
limits (see table 1).
L4
dH7
L3
Fig 2.
Table 1.
Size Torque Overrunning speed Weight
d H7 T nmin nmax D L2 L3 L4 C E F
mm Nm rpm rpm mm mm mm mm mm mm mm kg
30 250 780 9000 100 95 14 18 16 68 92 4.5
35 300 740 8500 110 102 18 22 20 76 102 5.6
40 450 720 7500 125 115 18 22 20 85 112 8.5
45 510 665 6600 130 115 22 26 25 90 120 8.9
50 820 610 6000 150 123 22 26 25 102 135 12.8
55 880 600 5600 160 138 25 30 32 108 142 16.2
60 1100 490 5300 170 147 25 30 32 112 145 19.3
70 1600 480 4500 190 168 30 35 38 135 175 23.5
80 2500 450 4000 210 178 30 35 38 145 185 32
90 3300 420 3000 230 192 40 45 50 155 205 47.2
100 5800 455 2700 270 217 40 45 50 180 230 76
130 8500 415 2400 310 250 55 60 68 205 268 110
2.2.5 1(2)
Back stop RIZ G3-G4
12703EN.DOC 25.05.2000
4. Assembly 5. Lubrication
Check the rotation direction. To change the rotation Type RIZ G3-G4 back stop is grease lubricated and it is
direction replace covers G3 and G4 with each other and delivered lubricated from manufacturer. Bearings are
attach the back stop to the gear unit. Check the type 2Z, which means that they are lubricated for life
recommended shaft tolerances h6/j6. and the backstop is maintenance free. (see section 6.
maintenance).
Backstop is bearing supported so there is no special
need to ensure the parallelism of the shaft and the
housing. The bearings should be stress free and the 6. Maintenance
outer race has to be able to move free both axially and Recommended grease: Klüber Polylub WH2
radially. The torque bolt should have a radial clearance
of 1-2 % of the bolt’s diameter and at least 2/3 of the Type RIZ back stops are maintenance free but manu-
bolt's length must be inside the slot. There has to be 1 facturer recommends a lubricant change every second
mm minimum clearance at the bottom of the slot. year for back stop sizes larger than 90. Backstop is
dismounted, cleaned and relubricated. About 1/4 of the
The tightening torques for the screws (grade 10.9) are grease amount is used for each bearing and the rest is
presented in the table 2. used for the sprag surfaces, for the inner surface of the
Assembly is performed so that the entire backstop is outer race and for the outer surface of the inner race.
preassembled. Pull the inner race on the shaft and use Also a small amount of grease is pressed inside the
the key according to DIN 6885 page 1. All the forces in labyrinth seal.
assembly should be directed only to the inner race (not
to the bearings or outer race because this might
damage the bearings). Lock the back stop axially by Table 3.
using the end plate and socket head cap screw (pos. Back stop size Bearings Amount of grease (g)
924 and 922). The O-ring (pos. 921) is placed between (RIZ) Klüber Polylub WH2
the end plate and inner race. 30 6009 2Z 10
35 6010 2Z 15
After assembly check that the backstop runs smoothly
40 6011 2Z 20
to the free rolling direction. Free rolling torque (sprags
45 6012 2Z 25
dragging) should be about 1/1000 of the nominal
50 6014 2Z 35
torque.
55 6015 2Z 40
Dismounting is performed like mounting but in reversed 60 6016 2Z 75
order. 70 6018 2Z 115
80 6021 2Z 125
90 6024 2Z 175
Table 2. Tightening torques for screws. 100 6028 2Z 275
Screw 130 6032 2Z 400
Tightening torque 150 6040 2Z 500
(grade 10.9)
M5 8 Nm
M6 14 Nm
M8 34 Nm
M10 68 Nm
M12 118 Nm
M16 290 Nm
M20 550 Nm
M24 950 Nm
M30 1900 Nm
2.2.5 2(2)
Backstop FXM
12705EN.doc 27.08.1999
BACKSTOP FXM
3. Changing rotating direction
1. General If a customer wishes to change the permitted
The purpose of backstop is to prevent undesirable direction of rotation it can be done by flipping the
reverse rotation. Backstop will permit rotation in one inner ring with sprags around. The inner ring and
direction but immediately locks if the shaft attempts to sprags are pulled out with extractor and placed back
rotate in the reverse direction. when flipped. The backstop can be heated max.
100°C to ease the mounting.
RINGSPANN FXM-type backstops are centrifugal lift
off sprag type backstops. When the disengaging 3.1 Backstop mounted on the side of the gear
speed is reached the sprags automatically disengage unit (picture 2):
completely from the contact surface of the outer race
1. Empty the oil from the gear unit
and are then contact and wear-free. FXM-backstops
2. Remove the screws POS 4313
do not have bearings of their own.
3.Remove the outer ring rotating it
slightly at the same time in the freewheeling
2. Mounting and operating direction.
Backstops are mounted at factory. Therefore 4. Remove the retaining ring POS 4319, the inner
direction of rotation for output shaft is important to ring and sprag cage
specify. It is also important for the customer 5. When mounting again flip inner ring and sprags
to check that electric motor is connected to together around. All the forces in assembly
rotate to correct direction. Otherwise the should be directed to the inner ring, not to the
peak torque of electric motor may load the sprag cage. Use the threaded holes on the
backstop in unfavourable way. inner ring
6. Lock the inner ring axially by retaining ring,
When adding oil to the gear unit, check the oil level to POS 4319.
ensure the lubrication of the backstop. 7. Flip the rotation direction signs (picture 1) on
the gear unit
8. Add oil to the gear unit and check the oil level.
9. After the mounting check that the backstop
runs smoothly.
Picture 1
The permitted direction of rotation is marked on
the housing of the gear unit.
Picture 2
2.2.6 1(2)
Backstop FXM
12705EN.doc 27.08.1999
4. Maintenance and lubrication
Backstops are maintenance free because they are

lubricated with the same oil as gear unit.
For the first oil filling of the gear unit, fill the oil into the
backstop (backstop mounted on the side of the gear
unit) separately to ensure proper lubrication in the
first startup.
Table 2. Tightening torques for backstop cover screws (POS 4313, backstop mounted on the side of the gear unit).
Screw Tightening torque

(grade 8.8)
M5 6 Nm ( 53 in.-lbs)
M6 10 Nm ( 90 in.-lbs)
M8 25 Nm ( 220 in.lbs)
M10 48 Nm ( 425 in.-lbs)
M12 84 Nm ( 745 in.-lbs)
M16 206 Nm ( 1820 in.-lbs)
M20 402 Nm ( 3560 in.-lbs)
M24 696 Nm ( 6160 in.-lbs )
M30 1420 Nm ( 12570 in.-lbs)
2.2.6 2(2)
Torque arm, M-series
15004EN.doc 25.05.2000
TORQUE ARM, M-SERIES

1. Design of the torque arm Elastic washers (nylon) (pos. 705) are assembled under
Torque arm can be placed in either tension or the anchoring foot (pos. 702).
compression.
If the torque arm is of our supply it will be manufactured 2. Foundation for torque arm
according to figure 1. The torque arm will be delivered The foundation is made according to figure 1. The
with foundation screws, washers and nuts. The supporting girders are mounted horizontally in their
supporting girders are not included in our delivery, but fixed locations and embodied in the base concrete. The
recommendation for dimensioning the foundation is mounting tolerance should be 10 mm in all directions.
given in figure 1. The concrete base must be adequately reinforced and
When ordering the torque arm, dimension HA must be interlocked by the use of steel rods. The base concrete
advised. It can be freely chosen between HAmin and must withstand at least the same load as the weld joints
HAmax. If HA is to be longer than HAmax the torque arm of the foundation screws.
will be of special design. Crouting, which is laid in connection with the mounting
If customer manufactures the torque arm himself, of the torque arm, must be bonded to the base concrete
following items must be considered: with steel rods.
Tightening of nuts (pos. 704) are to be done after
à Torque arm and its foundation must be capable to
crouting has dried.
withstand the anchoring force
à In the torque arm there must be two hinges and the
construction must allow axial movement of the gear
unit because of heat expansion, run out errors of
driven shaft and other erection errors.
Gear unit sizes
500-800 pos. description
700 joint pin
701 rod
702 foot
701 703 foundation screw
704 nut
705 washer (nylon)
706 bush (nylon)
707 locking ring
707
706 Tensile strength of the
702 700 supporting girders and
705 foundation screws (pos.
704 703) must be at least
703
350 N/mm2
Positions refer only to

this instruction
Picture 1: Torque arm parts and dimensions

Table 1 Dimensions [mm]
Gear unit A B C ØD E N HAmax HAmin K L ØM O P R pcs supporting
size H8 girder, bxc
50 172 125 15 32 75 32 950 125 50 50 24 7 100 M20 4 100x260
60-90 240 180 20 45 90 45 1070 175 70 70 28 9 125 M24 4 100x320
Dimensions are not binding.
2.3 1(2)
Torque arm, M-series
15004EN.doc 25.05.2000
Clearance to allow lateral movement
Material GRP, welding not allowed
Picture 2: allowed mounting tolerances
2.3 2(2)
Belt Drive of Gear Unit
10501EN.doc 25.05.2000
V-BELT DRIVE OF GEAR UNIT

1. General 2.5 Installation of taper bushings (5210, 5212)
The V-belt drive is supplied as an optional accessory to 2.5.1 Remove the protective grease from the
gear units. For details, see Fig. 1. The V-belt drive is bushings and pulley hub. Insert the bushing in
available as follows: the hub and make sure that the holes are
- complete v-belt drive assembly (including pulleys, aligned.
V-belts tapered bushings, motor bracket and the 2.5.2 Apply grease to the fixing screws and screw
belt guard). them in position. The thread is in the pulley
hub.
- motor bracket and belt guard (including motor
2.5.3 Clean the shaft and insert the pulley and
bracket, screws and belt guard).
sleeve.
- motor supplied only when ordered.
2.5.4 Tighten the screws.
2.5.5 Knock the sleeve lightly and relighten the
All the versions (excluding V-belt guard only) will be
screws. Repeat this a couple of times.
supplied fully assembled on the gear unit.
2.5.6 Check the screws for tightness at least every
Any combination of the above options will also be
3000 hours.
supplied.
2.5.7 Fill the pull holes with grease to prevent the
ingress of dirt.
2. Installation
Installation sequence: 2.6 Draw the V-belts (5218) over the pulleys and
2.1 Mount the motor bracket (5112, 5110) to the gear. tension the belts by means of the adjustment
2.2 Mount the motor onto the bracket. screws in the motor bracket. When tightening the
2.3 Fix the belt guard rear plate (5260) to the gear unit V-belts, make sure that the pulleys are aligned
motor bracket by means of fixings (pre-tightening). accurately enough. Use a steel liner to check
When mounting the rear plate, note the desired alignment as shown in Fig. 2. Make sure that the
direction of opening of the door. See note, Fig.1 ruler makes contact at four points. The maximum
2.4 Mount the pulleys (5214, 5216) on the motor and permissible error of angle is 1mm per 1000mm
gear shafts (as close to the shoulder as possible). span of the V-belt. Tension the V-belts according
to Table 1. This is the only way to ensure
maximum power transmission efficiency and to
prevent excessive loads on the gear and motor
shafts.
V-belt tension adjustm ent
Note! If the guard upper fixing (5262) is attached to the upper plate of the motor
bracket (5110), it must be loosened before adjusting the v-belt tension.
Fig. 1 Fig. 2
2.4 1(2)
Belt Drive of Gear Unit
10501EN.doc 25.05.2000
Table 1. V-belt tightening.

V-belt Smaller Force required to displace the V- 3. Limitations
profile pulley Ø belt by 16mm per one meter of
span length The following limitations for the use of V-belt drives
d1 [mm] Newton (N) shall apply:
SPZ 56 - 95 13 - 20
100 - 140 20 - 25 3.1 V-belt speed
SPA 80 - 132 25 - 35 The V-belt speed determined by the manufacturer
140 - 200 35 - 45 of cast-iron V-belt pulleys is:
SPB 112 - 224 45 - 65
236 - 315 65 - 85 vhmax = 35 m/s
SPC 224 - 355 85 - 115
375 - 560 115 - 150 3.2 Usually, a V-belt drive requires no extra
inspections, if the ambient temperature does not
Check the V-belt tension as follows (using a V-belt exceed 70°C. V-belt drives used at temperatures
tension meter): exceeding 70°C should be checked regularly at
least every 1500 hours.
2.6.1 Measure the length of the V-belt span
(= free V-belt length).
2.6.2 Measure the perpendicular force causing a
16mm sag per one metre of V-belt.
2.6.3 Compare the measured values with those
listed in Table 1.
A new V-belt must be tensioned to the higher value

because it stretches in use. All V-belts should be
retensioned every 3000 hours.
2.7 Tighten the locking screws for the motor rack and
the belt guard rear plate.
2.8 Mount the belt guard lid using the hinge pins and
lock the pins.
2.4 2(2)
Expansion tank, M-series
60004MEN.doc 25.05.2000
EXPANSION TANK, M-SERIES, BATH LUBRICATION
WARNING
The expansion tank has
hot oil in it when the
gearbox is hot
Picture 1. Example of attachment of expansion tank
1. The filling of oil into a new (unused) gearbox 2.4 Open the oil filling plug (5) and drain the rest of
the used oil into a container and make sure that
ATTENTION! Gear Unit Temperature must be at
no foreign objects or dirt gets through the filling
ambient when checking or refilling the oil. Add
hole.
oil only into a fully cooled down gearbox
2.5 Make sure that all used oil is drained from the
1.1 Ensure oil drain valve or plug (7) is closed. gearbox.
1.2 Wipe all dust and dirt from the expansion tank (3) 2.6 Close the oil drain valve (7).
and near the oil filling plug (5). 2.7 Follow instructions: The filling of oil into a new
1.3 Open the air expression screw (8 opp. (unused) gearbox (Chapter 1.1).
side of the air pipe) and oil filling plug.
1.4 Pour oil into gearbox (5), see also dimension 3. Oil level checking and refill
drawing for oil filling positions. Make sure that the
oil-level is at the level instructed (middle of the oil ATTENTION! Gear Unit Temperature must be at
sight glas 6). ambient when checking or refilling the oil. Add
1.5 Close the air expression screw (8) and oil filling oil only into a fully cooled down gearbox
plug.
3.1 Stop the electric motor and let the gearbox cool
2. Oil change to ambient.
Oil change in connection with service. 3.2 Wipe all dust and dirt from the expansion tank (3)
WARNING! If the gear unit is hot there is and near the oil filling plug (5).
1 to 10 litres of hot oil in the expansion 3.3 Inspect the quantity of oil in the oil-sight (6).
tank (3).
2.1 Stop the electric motor. 3.4 If the oil-level is not at the appropriate level follow
instructions: The filling of oil into a new (unused)
2.2 Wipe all dust and dirt from the expansion tank (3) gearbox (Chapter 1.1). Fill the oil to the
and near the oil filling plug (5) instructed oil-level.
2.3 Open oil drain valve (7) and drain used oil into a
container (approximately 15 litres) or enough that 3.5 Start the electric motor.
air can be seen in the oil-sight glas (6).
2.5.3 1(1)
Oil Heater
62004EN.doc 25.05.2000
OIL HEATER
Picture 1: Heating element and thermostat
A B
1. Design of the heater
Material of the resistance elements is stainless
steel.
The oil heater is controlled by a thermostat.The
thermostate is an 1-hubbed change-over-contact,
position of which is depending on the temperature
of the sensor.
Surface power of the oil heater is 1 W/cm2.
Standard voltage is 230/400V.
2. Mounting
- the heater and the gasket are mounted on the C
gear unit
- the tubular heating elements must be totally
immersed in liquid at all times
- the base of the terminal box is fixed to the
immersion heater by means of a mounting ring
- check that the gasket sits properly between the
box and the element head
- the sensor of the thermostat is introduced into
the oil sump of the gear unit and the desired Picture 2 Wiring diagrams
temperature is set on the thermostat, see
chapter 2.3.
2.2 Check-list for the electrical connection
2.1 Electrical installation - verify that the mains voltage corresponds to the
voltage stamped on the rating plate.
The supply cable has to be chosen according to the
- Close the lid of the terminal box and make sure
total power of the heater, and attention must be
the seal sits properly between the lid and the
paid to its temperature rating.
base of the box.
Connection: WARNING !
- single phase supply (picture 2, A, C); terminate
Faulty connected or on the top of oil
the supply cable to terminals L1 and N in
surface working heater may cause a
accordance with diagram A (or C in case of danger of explosion. Check that there is oil in the
single heating element). Terminate the earth
gear unit before the heating element is connected
lead to the earth terminal on the base of the
to the net. The assembly is allowed to be done only
terminal box.
by a skilled worker.
- three-phase supply (picture 2, B); remove the
brown branch wire. Terminate the phase leads
of the supply cable to terminals L1, L2 and L3.
If neutral lead is available, terminate it to
terminal N. Terminate the earth lead to the
earth terminal on the base of the terminal box.
2.5.4 1(2)
Oil Heater
62004EN.doc 25.05.2000
2.3 Setting up the thermostat of the oil heater 3. Maintenance

- The thermostat must be set so that it switches The resistance element can be removed for
the oil heater on when the oil temperature in the cleaning in connection to the oil change, if
gear unit falls below temperature shown in table necessary. The cleaning of the resistance element
1 (bath or splash lubrication) or table 2 can be performed with dissolvents, but never with
(pressure lubrication). the chisel and such like of thing which damages the
- The upper limit of the thermostat is set so the resistance element.
oil heater switches off at a temperature - verify at regular intervals, e.g. once a year, that
8…10°C higher than the above mentioned the leads are tightly fastened to the terminals
switching on temperature. and that they are not oxidized.
- if the immersion heater does not function,
2.3.1 Gear units without pump (bath or splash check that the thermal cut-out device has not
lubrication) tripped (if the system has one) and that the
heating elements and the thermostat are
The minimum starting temperature in splash- and
undamaged.
bath lubricated gear units is the same as pour point
- a damaged immersion heater has to be
of the oil. If the temperature of the gear unit and the
replaced.
oil is lower than pour point, an oil heater is needed.
- check the elements. Encrusted elements must
be cleaned or replaced. The oil must always
Table 1. Pour points [°C]
first be drained from the gear unit.
ISO VG 680 460 320 220 150 100
Mineral oil -7 -10 -15 -20 -25 -28
Synthetic -30 -35 -40 -40 -45
2.3.2 Gear units with pump (pressure

lubrication)
If the temperature of the gear unit and the oil is
lower than minimum starting temperature, an oil
heater is needed. In pressure lubricated gear units
the oil viscosity in minimum starting temperature
must be lower than 2000 cSt:
Table 2. Minimum temperatures [°C]

ISO VG 680 460 320 220 150 100
Mineral oil +25 +20 +15 +10 +5
Synthetic +15 +10 +5 0 -5
2.5.4 2(2)
Thermostat RT 14
64001EN.doc 25.05.2000
THERMOSTAT RT 14
Picture 1: Setting the temperature range
Picture 2: Mains connection
Min. temperature variation rate: < 1K/15 minutes.

1. Usage Enclosure (Box): IP 66, IEC 144 or DIN 40050.
Contact load: see switch cover or picture 1.
Connect the RT14 thermostat to control the oil
heater of the gear unit. When using 3 phase
heater, two heaters or the current ratings exceed 3. Mains connection
the nominal values of the thermostat, a contactor START = make STOP = break DIFF = differential
must be used. Cable diameter: 6...14 mm.
The earth terminal (38) should be connected to
The switching temperature is set depending the oil earth. See picture 2.
type and class used in the gear unit (See
instruction D, Pressure lubrication of gear unit). 4. Fitting
The thermostat and the heaters are normally fitted
The thermostat stops the operation of the oil
to the gear unit, ready to operate, but without
heater in temperature which is the switching
electrical connections.
temperature + temperature difference (appr. 8°C).
WARNING: Connections are allowed to carry out
2. Technical data only by an electrician.
Range: -5 °C...+30 °C
Max permissible bulb temperature: +150 °C.
Absorption.
Ambient temperature: -50 °C...+70 °C (-50T70).
2.5.5 1(1)
Temperature Sensor PT100
64111EN.doc 25.05.2000
TEMPERATURE SENSOR PT100 (MBT 5250)
The Danfoss temperature sensor MBT 5250 can be used for

measurement and regulation of gear unit oil sump temperature.
Sensor tolerance is DIN IEC 751 Class B, ± (0.3 + 0.005 x t)

t = temperature of oil, normally max 90 °C
1. Dimensions
B = 150 (standard)
C = Ø8
D = R1/2
Plug DIN43650 PG9 (IP65)
2. Mounting
Electrical connections:
Not connected
2-wire, 3 terminals
Tightening torque moment for the mounting screw at the rear end of the plug for the electrical
connection: 25 Nm
2.5.6 1(1)
SPM-Nipples for M-series
65006EN.doc 25.05.2000
SPM-NIPPLES FOR BEARINGS SHOCK IMPULSE MEASUREMENT

1. Positions of SPM-nipples Note:
If not otherwise agreed there are 4...10
nipples depending on the gear unit size.
M2P..
M3R..
Nipples 1 and 2 are on both sides of the gear unit.
Nipple 3 only for bevel-helical gear units (M.R..)
M3P..
M4P..

Nipple 3 only for M4P.. gear units on both sides
M4R..
M5R..
Nipples 1, 2 and 3 are on both sides of the gear unit.
M.PV..
M.RV..
Nipples 1, 2, 3 and 4 are on one side of the gear unit.
Nipple 5 only for M.RV.. gear units
2.5.7 1(2)
SPM-Nipples for M-series
65006EN.doc 25.05.2000
2. Measuring
SPM-nipple
Shock
impulse
sensor
Picture 1: Measuring the shock impulse level of gear unit

bearings:
1. remove the protective hub of the SPM-nipple
2. ensure that the nipple is clean and properly tightened
(see picture beside)
3. fix and lock the shock impulse sensor on the SPM-
nipple.
2.5.7 2(2)
Thermostatic water valve
64006EN.doc 25.05.2000
THERMOSTATIC WATER VALVE AVTA
Fig. 2.
Forced opening
of valve
Fig. 1.
Pos.1 Knob
Pos.9 Pressure stem
Pos.12 Sensor
Pos.27 Spindle
Pos.37 Spring retainer
1. General Turning the knob in an anticlockwise direction raises

The thermostatic water valve is used to regulate the the temperature while turning it in a clockwise direction
water flow into cooler (lubrication unit) or cooling coil of lowers the temperature.
the gear unit. Install the capillary tube without sharp bends. Relieve
the capillary tube at the ends. Relief is especially
important where vibrations can occur.
2. Mounting
After mounting, rinse out the pipeline to remove any 4. Technical data
impurities and dirt. Rinsing is carried out by means of
forced opening of the valve. Insert two screwdrivers in Maximum working pressure*) 10 bar
through the two holes in the setting unit of the valve. Minimum working pressure *) 2 bar
Press the spring retainer upwards and the valve will Maximum differential pressure 7 bar
open to flow (see fig. 2).
Maximum water temperature *) 25°C (40°C)
3. Adjustement
Using the adjustment knob, the valve can be set so that
the desired temperature is obtained at the sensor. The *) when using the water valve for lubrication unit or
temperature is controlled with a themometer of the cooling coil.
lubrication unit
2.6 1(1)
Central lubrication system
60006EN.doc 25.05.2000
CENTRAL LUBRICATION SYSTEM

Recommended components and dimensioning
See drawing n:o Y0006766
1) Oil tank:
- Oil tank must be closed and equipped with an oil draining plug, an oil level indicator, a splash plate and a
breather. It is recommended to use a water absorving breather in case of moisture climate. Splash plate is
located between the oil return line and the suction line. An adequate volume of the oil tank is 5 x Qp , where Qp
is the total oil flow of the system (pump capasity).
2) Pump
3) Filter:
- filtration degree must be at least β25≥75 according to ISO 4572 (25 µm abs.)
- filter is equipped with visual or electrical contamination indicator and a by pass valve
4) Cooler, recommended max. temperature of oil is 50° C
5) Pressure gauge, temperature gauge, pressure alarm switch
6) Water separation
7) Throttle valve:
- oil flow into gear unit is controlled by throttle valve.
8) Flow meter:
- the oil flow into each gear unit must be adjusted at least once at startup according to SEW’s instructions
9) Gear unit with splash / central lubrication:
- the oil level is controlled by central lubrication connection pipe
- lubrication method and oil level are determined by SEW
10) Gear unit with pressure / central lubrication :
- no oil level in the gear unit
- lubrication method and oil level are determined by SEW
11) Central lubrication connection flange:
- delivered by SEW
- size of the connection flange and oil return pipe depends of the oil flow (see graph below)
12) Oil return line 1
- see dimensioning graph below
o
- Ød is calculated with oil class ISO VG 220 mineral and with startup temperature min. 15 C
- minimum oil level difference is 1.5 m (oil level in the gear unit and main return line)
13) Oil return line 2
14) Main oil return line:
- see dimensioning graph below
o
- ØD is calculated with oil class ISO VG 220 mineral, startup temperature min. 15 C and slope 5°.
- length of the main return line is not critical if 5° slope is maintained
Recommended oil class for central lubrication is minimum ISO VG 220 mineral. If other oil types is used, please
contact SEW.
Return pipe size / pressure lubrication Return pipe size / splash lubrication
125 125 125 125
120 120
115 115
110 110
105 105
100 100
95 95
Pipe diameter ØD [mm]
Pipe diameter ØD [mm]
90 90
D( Q ) 85 D( Q ) 85
80 80
75 75
d( Q ) d( Q ) 70
70
65 65
60 60
55 55
50 50
45 45
40 40
35 35
30 30
20 25 20 25
20 20
1 10 100 1 10 100
1 Q 100 1 Q 100
Oil flow [l/min] Oil flow [l/min]
ØD main return line ØD main return line
Ød return line Ød return line
Picture 1: Oil return pipe Ø / pressure lubrication Picture 2: Oil return pipe Ø / splash lubrication
(see drawing Y0006766 item 2) (see drawing Y0006766 item 1)

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Edition

Maintenance Operating Manual

1. BASIC MODULE (GEAR UNIT) DOCUMENTS PAGE

U307M Safety instructions 1.1.1

2. MODULAR ACCESSORIES DOCUMENTS PAGE

Manufacturer reservs the right to alteration.

2.1 Temperature Important instruction

Helical gear units M.P.. Bevel - helical gear units M.R..

OPERATING AND MAINTENANCE OF GEAR UNIT

à Mineral oil 2.7 Cleaning outer surfaces

2.5 Minimum purity level of lubricating oil

2.6 Subsequent lubricating of grease lubricated

GEAR UNIT FOUNDATION, FOOT MOUNTED GEAR UNITS, HORIZONTAL OR

Fig. 1 pos. description

Fig. 4 pos. description

Table 2. Fig. 3, 4 and 5 dimensions [mm]

Table 3. Fig. 3, 6 and 7 dimensions [mm]

M36 160 10 80 41 J+40 E+40 160 180x180 1900 Nm

MOUNTING OF HORIZONTAL OR VERTICAL LSS FOOT MOUNTED GEAR UNITS

2.4 The ends of the foundation screws are first tack

3. Mounting precision when aligning

3.2 Foundation plane accuracy when aligning

4. Mounting the motor to the gear unit

When using foot mounted motor, the maximum

Fig. 4 Mounting the motor with mounting flange

MOUNTING OF HOLLOW SHAFT GEAR UNITS, HORIZONTAL LSS, M-SERIES

2. Dismounting of hollow shaft gear unit, shrink disc connection

3. Mounting of hollow shaft gear units, key connection

4. Dismounting of hollow shaft gear unit, key connection

5. Allowed mounting tolerances

Clearance to allow lateral movement

Material GRP, welding not allowed

MOUNTING OF VERTICAL HOLLOW SHAFT GEAR UNITS

Picture 1: Mounting, Key Connection Picture 2: As mounted, Key Connection

Picture 3: Mounting, Shrink disk Picture 4: As mounted, Shrink Disk

Picture 5:Dismounting, key connetion Picture 6: Dismounting, Shrink Disk

2. Mounting precision when aligning

2.2 Foundation plane accuracy when aligning

Picture 7: Mounting accuracy plane deviations

3. Mounting the motor on to the gear unit

When using foot mounted motor, the maximum

Picture 8: Mounting the motor with the mounting flange

NOTE: Shaft ends must not meet, there must allways

CORROSION PROTECTION AND STORING

Table 1: Selection of corrosion protection and packing (chapter number)

1. Standard protection SEW works. Solvent cleaning is required when

4. Standard packing 7. Prior to commissioning

LUBRICATING OILS AND GREASES FOR GEAR UNITS

6. Oil selection, ISO VG (40°C) class

1 320/90 320/90 220/70 220/60 Synthetic oil

2 320/90 320/90 220/70 220/60 Synthetic oil

3 460/80 460/80 320/70 320/60 Mineral or

Fig. 1 Mineral oils Fig. 2 Synthetic PAO oils

-25-20-15-10 -7 Pour point [°C]

Mineral oils Table 2

Mineral oils Table 2

Mineral oils Table 2

Mineral oils for paper machine drives Table 2.1

Synthetic polyalfaolefin-based (PAO) oils Table 3

Roller bearing greases Table 4

Lubrication of hot (>80°C) running tapered roller bearings NLGI 2 (EP)

Lubrication of slow running thrust bearings NLGI 0...1 (EP)

7. Additional oil types and bearing greases

Synthetic polyalfaolefin-based (PAO) oil

Date _ Approved: _________________________