ELECTRA-GEAR® - Beeler Industries
Contents
1. 57 35150 56 ELECTRA PART NO MANUFACTURER S NO 57 35150 81 57 35150 07 57 30223 85 CR 15542 CR 13739 CR 24954 NOK AD4020 EO NAT 473215 NAT 470605 1 9 16 X 2 3 8 X 5 16 1 3 8 X 2 3 8 X 5 16 2 1 2 X 3 3 8 X 3 8 3 3 4 X 5 X 1 2 DIMENSIONS 57 35150 81 57 35150 07 57 30223 90 57 35150 56 ELECTRA PART NO CR 15542 CR 13739 CR 27269 NOK AD4020 EO MANUFACTURER S NO NAT 473215 NAT 416664 1 9 16 X 2 3 8 X 5 16 1 3 8 X 2 3 8 X 5 16 2 3 4 X 3 1 2 X 3 8 3 3 4 X 5 X 1 2 DIMENSIONS FOR KEYED INPUT SHAFT REDUCER USE 57 35150 07 NAT P N 473215 DIM 1 3 8 X 2 3 8 X 5 16 FOR INCH AND ABOVE BORE SIZE USE 57 35150 55 NOK AD7856 EO DIM 4 1 4 X 5 1 2 X 1 2 NOTE WHEN ORDERING PARTS YOU MUST GIVE THE PARTS LIST NUMBER ITEM NUMBER PART DESCRIPTION H P PHASE HERTZ VOLTS R P M AND THE COMPLETE FRAME AND MODEL NUMBER THIS WILL INSURE THAT THE CORRECT PART IS ORDERED All dimensions designs prices and specifications are subject to change without notice ASSEMBLY PROCEDURES These procedures are to be followed when you have complete worm shaft and gear shaft sub assemblies ready to go into gear reducer A Shimming Required These instructions should be followed when any bearings worm shaft or gear have been replaced If either assembly has had no parts changes the shim packs can remain and the assemblies can be installed as under the procedures in B Proper operation of the gear reduce2. BEARINGS CROSS REFERENCE CHART STANDARD REDUCERS OR GEARENDS C Bearing Part Numbers and Mfg Part Numbers Input Input Brg Output Output Brg Gear Mfg Solid Hollow Mfg Size Bearing Bearing ID Bearing Bearing ID PL 1 4b PL 1 4a PL 1 17 56 30330 30 56 32220 12 EGO 56 32220 12 56 30221 02 EGO 13 6203NR 6203 NTN 56 31221 02 N A 6203 L44610 Brg Sz 203 Brg Sz 203 L44643 T 56 32220 18 56 32220 18 EGO 56 30221 02 56 30221 12 EGO 17 6304 6304 NTN 56 31221 02 56 31221 12 L44610 LM29710 Brg Sz 304 Brg Sz 304 L44643 LM29749 T 56 32220 20 56 32220 47 EGO 56 30221 05 56 30221 11 EGO 21 6305 6204 NTN 56 31221 05 56 31221 11 LM67010 LM806610 Brg Sz 305 Brg Sz 204 LM67048 LM806649 T 56 32220 21 56 32220 85 EGO 56 30221 06 56 30221 09 EGO 26 6306 6205 NTN 56 31221 06 56 31221 09 LM48510 382 Brg Sz 306 Brg Sz 205 LM48548 3874 T 56 30221 45 56 30221 45 EGO 56 30221 46 56 30221 10 EGO 30 56 31221 45 56 31221 45 56 31221 46 56 31221 10 M86610 M86610 LM102910 34478 M86644 M86644 T LM102949 34306 T 56 30221 45 56 30221 45 EGO 56 30221 46 56 30221 10 EGO 35 56 31221 45 56 31221 45 56 31221 46 56 31221 10 M86610 M86610 LM102910 34478 M86610 M86610 T LM102949 34306 T 56 30221 07 56 30221 28 EGO 56 30221 27 56 30221 29 EGO 400 56 31221 07 56 31221 28 56 31221 27 56 31221 29 8941 HM8941 3720 HM218210 89443 89443 3775 2789 56 30221 20
3. 56 34338 01 EGO 56 30221 33 56 30221 35 EGO 56 31221 20 56 31221 33 56 31221 35 500 NU308 NTN 44348 N A 3920 42584 44162 Brg Sz 308 T 3982 42381 T 56 30221 36 56 34338 02 EGO 56 30221 34 56 30221 35 EGO 56 31221 36 56 31221 34 56 31221 35 600 NU309 NTN 903210 N A JM612910 42584 HM903247 Brg Sz 309 T JM612949 42381 T All tapered bearings are sold as a cup and cone set only Both part numbers must be used Refer to Parts List number PL 1 for item number and information EGO Electra Gear Operations Part Number T Timken NTN NTN 19 VI GEAR REMOVAL AND INSTALLATION Gears should be pressed off output shafts as shown in bearing section pages 16 amp 17 Be careful not to lose the key Press gear squarely against shaft shoulder VII SEAL REMOVAL AND INSTALLATION A Step by Step Procedures 1 2 3 4 Pry seal out of bearing cap or sideplate with screwdriver Clean all silastic out of seal housing cavity Apply small bead 1 32 of silastic in the seal bore Press or gently tap seal in seal bore using a squared off piece of tubing with O D smaller than O D of seal Be careful to press seal squarely into cavity Lack of silastic or improper pressing will cause oil leak around back of seal 20 SEALS CROSS REFERENCE CHART STANDARD PRODUCT REDUCERS OR GEARENDS INPUT OUTPUT MOTOR OR PULLEY END FAN OR BLIND END SOLID SHAFT HOL
4. box Terminal box Terminal box cover Klixon T M Klixon retainer Rotary switch Bearing fan end Bearing output end Spring washer Air baffle fan end Air baffle output end Stationary switch Insulation stationary switch 85 Spacer stationary switch 86 End cap fan end opposite drive end 87 Grease fitting not std only spl units 88 Fan 89 Fan shroud 90 Shoulder screw 91 Brake mount for T E F C 92 mount of T E N V 93 Brake specify as to torque NEMA design Volts hz 94 Key rotor 95a Rotor Shaft assembly keyed output 95b Rotor Shaft assembly splined output 96 Bearing retainer 97 or 47 or 44a or 44b End Cap output end must specify as to type and size etc 33 IMPORTANT INFORMATION Please Read Carefully The following and information is supplied to you for your protection and to provide you with many years of trouble free and safe operation of your Electra Gear product Read ALL instructions prior to operating reducer Injury to personnel or reducer failure may be caused by improper installation maintenance or operation MWARNING Written authorization from Electra Gear is required to operate or use reducers in man lift or people moving devices Check to make certain application does not exceed the allowable load capacities published in the current catalog Buyer shall be solely responsible for determining the adequacy of the product for any and all uses to
5. no liability to Buyer for consequential damages Resellers Buyers agree to also include this entire document including the warnings and cautions above in a conspicuous place and in a conspicuous manner in writing to instruct users on the safe usage of the product This information should be read together with all other printed information supplied by Electra Gear 34 NOTES 35 ELECTRA GEAR WARRANTY PROCEDURE Units returned under warranty must be accompanied by a Return Goods Authorization or RGA number and should be shipped freight prepaid to Electra Gear or an authorized service center Valid warranty items will be repaired or replaced at Electra Gear s option on a no charge basis and shipped back to customer freight allowed Warranty is limited to parts and labor involved in our product only Charge backs for customers to perform warranty work will not be accepted Warranty will not be extended by virtue of having been repaired during warranty period RETURNS Annual Restocking Distributors are entitled to one annual return in an unlimited amount No restocking charge will be assessed if an order of equal value is placed to offset credit Returned products must be unused less than eighteen 18 months old and current saleable merchandise Restocking Minimum charge is 3596 of price on all products except annual restocking and prototy
6. removing as these may damage the input seal a Loosen and remove bolts from fan end bearing cap The end opposite input shaft b Tap worm shaft on the input shaft end until bearing cap is loose Remove fan end bearing cap Tap the worm shaft out of reducer housing Be sure to keep shims with bearing cap removed 11 Electra Gear worm gear reducers have four different worm shaft assembly designs You will have one of them 1 Ball bearing design Frame Sizes 13 17 21 26 Keyed input shaft Snap Ring gt Worm threads Input bearing Fan end bearing Splined input shaft 2 Tapered roller bearing design Frame Sizes 30 35 400 Splined Input Shaft gt f Keyed Input Shaft lum r Input Bearing _ sg Worm Threads Fan End Bearing monem w W I Qm APAPA Shaft Extension for Fan 12 3 Double tapered roller bearing design Frame Sizes 500 amp 600 Fan Extension Worm Threads Roller Bearing Inner Race _ __ Roller Bearing Outer Race Keyed Input Shaft Splined Input Shaft 4 Swallow shaft design available on Frame Sizes 13 17 21 26 30 35 400 Fan End Bearing Swallow Coupling When replacing a swallow shaft worm the worm coupling assembly has to be ordered as a unit 13 Typical output shaft assemblies Double Extended H
7. which Buyer shall apply the product The application by Buyer shall not be subject to any implied war ranty of fitness for a particular purpose For safety Buyer or User should provide protective guards over all shaft extensions and any moving apparatus mounted thereon The User is responsible for checking all applicable safety codes in his area and providing suitable guards Failure to do so may result in bodily injury and or damage to equipment Hot oil and reducers can cause severe burns Use extreme care when removing lubrication plugs and vents Make certain that the power supply is disconnected before attempting to service or remove any components Lock out the power supply and tag it to prevent unexpected application of power Reducers are not to be considered fail safe or self locking devices If these features are required a properly sized independent holding device should be utilized Reducers should not be used as a brake Any brakes that are used in conjunction with a reducer must be sized or positioned in such a way so as to not subject the reducer to loads beyond the catalog rating Lifting supports including eyebolts are to be used for vertically lifting the gearbox only and no other associated attachments or motors Use of anoil with an EP additive on units with backstops may prevent proper operation of the backstop Injury to personnel damage to the reducer or other equipment may result Overhung loads s
8. A D flange specify as to motor frame size Flexible coupling assembly Rubber insert flex coupling Motor adapter specify as to motor frame size Roll pin Solid coupling 17 tooth Solid coupling 19 tooth Double worm adapter to secondary gear box Double worm reducers or gearmotors use the same basic parts in the primary or secondary reduction unit Single or Double Worm Parts Group STANDARD PRODUCT PARTS LIST Planetary Gear housing Spacer washer Helical gear specify gear ratio Retain in washer Retain in bolt Bearing input Bearing input Input shaft pinion gear keyed Input shaft pinion gear splined Seal input End plate helical All dimensions designs prices and specifications are subject to change without notice 32 MOTOR PARTS LIST To Reducer he Refer to page 2 NOTE WHEN ORDERING PARTS PLEASE PROVIDE THE PARTS LIST NUMBER ITEM NUMBER PART DESCRIPTION H P PHASE HERTZ VOLTS R P M AND THE COMPLETE FRAME AND MODEL NUMBER THIS WILL INSURE THAT THE CORRECT PART IS ORDERED All dimensions designs prices and specifications are subject to change without notice MOTOR PARTS LIST FOR FOOT MOUNTED FACE MOUNTED OR 3 4 MOTOR END GEARMOTOR SINGLE PHASE OR THREE PHASE 70 71 72 73 74 75 76 77 78 79 80a 80b 81 82a 82b 83 84 Wound stator assembly specify as to with or without feet Cover capacitor Capacitor Stud motor Mounting pad terminal
9. ELECTRA GEAR n E WORM REDUCER INSTALLATION MAINTENANCE AND SERVICE MANUAL ELECTRA GEAH A REGAL BELOIT Company 1110 N Anaheim Blvd Anaheim California 92801 Telephone 800 877 4327 714 535 6061 Fax 714 535 2489 www electragear com Email sales electragear com Today with more than 100 000 square feet over 100 employees and a world class manufacturing operation Electra Gear is a leading producer of mechanical and electrical motion control products serving a broad array of markets The Electra Gear team prides itself on consistent fast delivery of quality products which meet the customers specific needs Our products are at the heart of what drives your world and you will find them used in food processing material handling chemical process and waste treatment marine and health equipment Electra Gear holds the distinction in our industry to offer several firsts First to offer reducers gearmotors and electric motors using aluminum castings First to utilize rolled worm technology a highly automated method of producing a worm First to introduce the modifiable worm gear drive providing customers the ultimate in mounting flexibility What distinguishes Electra Gear from its many competitors Aluminum Construction Reducers and Motors No Rust Light Weight High Strength Excellent Heat Dissipation Non corrosive Surface Finis
10. LOW SHAFT SLEEVELESS SLEEVELESS SLEEVELESS SLEEVELESS DESIGN DESIGN DESIGN DESIGN 57 35150 60 57 35150 65 ELECTRA PART NO AD 0723 FO N A MANUFACTURER S NO 667 X 1 379 X 2 55 CR 6580 656 X 1 575 X 250 57 35150 26 57 35150 58 ELECTRA PART NO NOK 79Y 7101R NAT 473438 MANUFACTURER S NO 21 57 35150 27 NOK 79Y 7100R 785 X 1 3 8 X 1 4 57 35150 27 NOK 79Y 7100R 785 X 1 3 8 X 1 4 57 30223 02 NAT 471267 7 8 X 1 1 2 X 5 16 57 35150 25 NOK 79Y 7094R 1 1 8 X 1 3 4 X 1 4 57 38292 84 NAT 470774 1 15 82 X 2 3 8 X 3 8 57 38296 49 NAT 472924 2 X 2 7 8 X 1 2 57 30223 09 NAT 471272 DIMENSIONS ELECTRA PART NO MANUFACTURER S NO DIMENSIONS ELECTRA PART NO MANUFACTURER S NO 7 8 X 1 3 8 X 5 16 57 30223 98 57 30223 98 57 35150 33 57 35150 38 ELECTRA PART NO NAT 252277 NAT 252277 NOK AD7796 EO NOK AD3664 EO MANUFACTURER S NO 1 X 1 3 8 X 1 4 1 X 1 3 8 X 1 4 1 3 4 X 2 5 8 X 5 16 3 X4 X 7 16 DIMENSIONS 1 3 8 X 2 1 16 X 7 16 2 1 8 X 3 X 3 8 DIMENSIONS 57 30223 98 57 30223 98 57 35150 33 57 35150 38 ELECTRA PART NO NAT 252277 NAT 252277 NOK AD7796 EO NOK AD3664 EO MANUFACTURER S NO 1 X 1 3 8 X 1 4 1 X 1 3 8 X 1 4 1 3 4 X 2 5 8 X 5 16 3 X4 X 7 16 DIMENSIONS 57 35150 25 57 35150 25 57 35150 34 57 35150 37 ELECTRA PART NO NOK 79Y 7094R NOK 79Y 7094R NOK AD7799 EO NOK AD7943 EO MANUFACTURER S NO 1 1 8 X 1 3 4 X 1 4 1 1 8 X 1 3 4 X 1 4 1 7 8 X 2 3 4 X 5 16 3 1 2 X 4 5 8 X 1 2 DIMENSIONS
11. aft of the primary is connected to the input shaft of the secondary by means of a splined coupling Heat puller or press may be needed to disassemble or assemble Ss C Worm planetary units WP17A WP177A R etc Planetary units are on the output end of our 17 worm reducers or helical gear cases The output sideplate of the 17 is the adapter between the two gear units 26 The majority of Electra Gear worm reducers are used with motors as an integral design To disassemble for servicing the gear reducer Remove motor brake fan guard and fan if present Remove long through bolts Tap end cap with soft hammer to loosen and remove Tap gear housing while holding stator housing assembly and remove Pry rotor shaft assembly loose from splined coupling Use wood blocks and be careful not to break adapter 27 X ASSEMBLY AND MOUNTING CHANGES Assembly positions are easily changed on Electra Gear worm gear speed reducers A Changing output shaft protrusion Right to left or Left to right 2 7 Remove sideplate being careful to leave all shims with sideplate Remove output shaft gear assembly You will have to remove both sideplates on 500 and 600 units Remove opposite sideplate keep shims with it Clean excess silastic off housing and sideplates Apply silastic to both sideplates before reassembling Reassemble in reverse order and r
12. arings In extreme cases heat may be used to facilitate but should be used with extreme care so as not to damage new bearings a Always press on the inner race only b Use a length of steel tubing with squared ends which is large enough in I D to fit over the shaft and small enough in O D to fit the inner race c Press bearings squarely all the way to shaft shoulder gear or snap ring Failure to do this can result in improper adjustment of endplay when unit is assembled causing bearing or worm gear failure B Bearing Cups With the exception of the 500 and 600 worm assemblies all bearing cups in Electra Gear worm reducers are pressed into bearing caps input or sideplates output 500 and 600 have one bearing cup loose at fan end To remove see next page 17 o cx 1 Heat area around bearing cup Don t overheat 2 Tap sideplate or bearing cap on table until cup falls out 3 Repeat step 1 until step 2 is accomplished AWWARNING Handle with care severe burns can occur Heat resistant gloves are recommended 4 The new bearing cup is easily installed while bearing cap or sideplate is hot Drop bearing cup into hot sideplate Make sure cup bottoms out in sideplate 5 Alternate to step 4 Press bearing cup into bearing cap sideplate Be careful not to brinnell cup s wearing surface See chart next page for Electra Gear and Manufacturers bearing part numbers 18
13. assembly into housing and through input bearing cap Repeat steps in 2 for fan end bearing cap Repeat steps in Z2 for blank output sideplate NOTE This step is for single output shaft extensions on size 400 and below For hollow shaft double extended shaft 500 and 600 proceed to step 6 Insert output gear shaft assembly into gear reducer Align with worm Repeat steps in Z2 for open sideplates Tighten all input bearing cap bolts and all output sideplate bolts Refer to page 30 for proper bolt nut torques Referto installation and lubrication instructions before pages 1 6 putting unit into service 24 AND GEARMOTORS Electra Gear multiple reduction reducers are as easy to service as single reduction units Helical worm double worm and worm planetary are two gear reducers connected A Helical worm reducers are built so that the back end of the helical gearcase becomes the input bearing cap for the secondary worm reducer This part should be treated as such for shimming procedures etc The helical gearcase itself is serviced as the worm gear reducer is with bearing end play tolerances etc all important 25 B Double worm reducers are built so that the adapter circled is the output side plate for the primary unit and the input bearing cap for the secondary unit If reshimming the unit use this piece and shim units separately before final assembly The output sh
14. ect worm bearings Check for noise feel of rotation They should spin smoothly Check bearing cups for signs of distress brinelling fretting overhung load uneven wear etc 4 Inspect output bearings as above 5 Inspect seals Are springs intact Is seal lip cut Show signs of wear After the inspection of all parts determine which parts need replacing If worm or gear show that they need replacing both should be replaced As was noted earlier worms and gears are available as a set only Undetectable wear on one member of the set will shorten the service life of the replaced part If gearset is replaced it is a good idea to replace bearings and seals as well V BEARING REMOVAL AND INSTALLATION A Ball Bearings and Bearing Cones All ball bearings and bearing cones are a press fit on worm and gear shafts Bearings may be removed by press puller or heat 1 Removal Guidelines a Be careful to remove snap rings or locknuts on worm shafts before removal of bearings b Be careful to get good contact with inner race when pressing or pulling bearing cones as the cages will quickly deform if pressed or pulled against 16 c When removing output shaft bearings with press it is easier to remove gear and press gear back on than to attempt to grab inner race of bearing on gear side opposite shaft shoulder 2 Installation Guidelines A press should be used when installing bearing cones or ball be
15. ed completely with oil The input shaft should be rotated so that the output shaft makes at least one revolution per month The input and output shafts should be covered with grease to protect from corrosion and rust At start up time completely drain storage oil and fill to proper oil level with the correct lubricant Il LUBRICATION All Electra Gear worm reducers and gearmotors are shipped with oil unless specified otherwise A Recommended Lubricants Ambient Temp Manufacturer amp Lubricant Name Range F Getty Veedol Asreslube 98 100 to 150 Getty Veedol Asreslube 95 50 to 105 Getty Veedol Asreslube 90 40 to 100 Getty Veedol Asreslube 86 25 to 90 Lubr Eng Almasol 609 45 to 125 Lubr Eng Almasol 608 32 to 105 Lubr Eng Almasol 607 15 to 70 Mobil Mobil Extra Hecla Super 50 to 125 Mobil Mobil Cylinder 600W 32 to 100 Shell Omala J 460 40 to 115 Shell Valvata J 460 40 to 105 Texaco Meropa 680 45 to 120 Texaco Meropa 460 32 to 100 Texaco Meropa 220 15 to 75 Special Wide Temperature Range Lubricants Kendall Three Star 10 to 100 Mobil Mobil SHC 634 0 to 135 Mobil Mobil SHC 629 25 to 100 Mobil Mobil SHC 626 40 to 40 Special Cold Duty Lubricants Conoco Polar Start 600 40 to 10 Lubr Eng Almasol 606 10 to 40 Mobil Mobil SHC 624 55 to 0 Shell Donax A T F T 6 55 to 5 A G M A Rating 8EP 7EP 5EP 3EP 3EP Ambien
16. es securely Check axial end play Adjust to limits shown in table by removal or addition of shims b Runthe unit without oil in both directions for several output shaft revo lutions Apply slight holding pressure to output shaft to assist the marking of the gear To prevent cuts from the keyway or key hold output shaft clo Remove assembly and align the gear with the worm by moving shims from one side to the other to get desired pattern Move gear this sa way Move gear ths map way Correct Marking to get desired pattern to get desired pattern Refer to next section before putting unit into service B No Shimming Required Shimming Complete Final Assembly If no parts have been changed or just seals the reducer will not have to be re shimmed Careful disassembly should have left shim packs with the bearing caps and sideplates as originally assembled Follow these steps when assembling without shimming or when shimming is complete 23 Clean off excess silastic around bearing caps sideplates shims and reducer housing Take remove input shaft end bearing cap first and follow these steps a Grease lip of seal generously with Chevron SRI Grease 2 or equiva lent The cavity between lips on seal and where spring is should be full of grease b Apply a small bead of silastic approximately 1 16 diameter on inside edge of shims on the edge where the cap fits up to housing Slide worm shaft
17. evel Continuous Cil Level Breather Intermittent Breather Level Intermittant Oil Level Continuous Oil Level 2 These positions are not recommended because the high speed oil seal must support the full head of gearcase oil E Oil Filling Procedures Electra Gear Worm Gear reducers are easily filled to the proper level by following these steps 1 Remove pressure relief valve or breather 2 Remove proper oil plug for oil level desired 3 Insert lubricant through breather plug hole 4 Pump oil into unit until oil runs out of hole where oil level plug was Electra Gear reducers have many plugs on them designed to be an aid in oil filling and removal and breather location Your mounting position and duty cycle will have an oil plug that corresponds to it The breather should be located at the highest position possible HORIZONTAL MOUNTING Breather Location Intermittent Oil Level C Continuous Oil Level Oil Drain CAUTION Electra Gear double reduction worm gear reducers have two oil reservoirs Fill both to proper level before operating Use preceding page and below as a guide DOUBLE WORM REDUCER Intermittent Oil Level Oil Level for Intermittent or Input Continuous RPM 800 or Less Oil Level Continuous Oil Level PRIMARY GEARBOX SECONDARY GEARBOX HELICAL WORM REDUCER Breather Breather Intermittent Oil Level Oil Level for Intermit
18. everse position of disassembly Make sure shims stay with the sideplate they came off with this will maintain centering of the gear Change breather location if necessary B Base change Reducer feet angle brackets etc may be moved from one side to another using tapped holes in housing Ring bases should be changed as described in Output Shaft section above In both cases be sure to change breather to proper location C Double Worm Reducers There are many possible configurations for these units The primary may be rotated in 90 degree increments in relation to the secondary unit This is done by simply loosening the adapter bolts and rotating the unit to the position desired Study the assembly position you want carefully Most changes however complicated they appear are usually accomplished by one or two simple procedures 28 D Convertible MAKING THE CONVERSION lt q 4 1 An Electra Gear Convertible 2 Slipping the reducer coupling 3 Tighten the set screw The Worm Reducer can be quickly half onto the input shaft and nextstepisto and easily converted from a locate on the shaft according to standard configuration reducer to the dimensions on the dimension NEMA reducer by sheets then tel tals 4 Remove the four bolts holding 5 Replaced by longer bolts 6 Slip the NEMA C flange the bearing cap in place without which are included
19. g Required Change of Bearings or Gearset 1 Worm Shaft Assembly 2 Gear Shaft Assembly B Shimming Complete Final Assembly SERVICE TIPS MULTIPLE REDUCTION UNITS AND GEARMOTORS ks tau PE RE Fa Eu RIA REIR DIR Dd KR ASSEMBLY AND MOUNTING 5 A Output Shaft B Adaptable Base C Double Worm D Convertibles BOLT NUT TORQUE SPECIFICATIONS PARIS LIST aod reete PAGE 20 PAGE 20 PAGE 22 PAGE 25 PAGE 28 PAGE 30 PAGE 31 I INSTALLATION Improper installation of the gear reducer may cause injury to personnel gear reducer failure or damage to driven equipment Load conditions must be within the published catalog ratings with the recommended A G M A service factors properly applied SAFETY Rotating equipment is potentially dangerous and should be properly guarded The user is responsible for checking all applicable safety codes in his area and providing suitable guards A General The reducer should be mounted on a flat surface on the machine or foundation securely bolted down and accurately aligned Shims under the mounting base should be used when required to provide a level mounting surface B Solid Shaft Mounting The output shaft can be connected to the load by flexible coupling sprocket and chain sheave and V belt or pinion Check to insure proper alignment and tension of all com
20. h Platinum Finish No Paint Bright shiny aesthetically attractive Optional polymer washdown finish Platinum Plus Short Lead Times Guaranteed Same Day Next Day Service Aggressive VIP Service for Critical Situations VI VII VIII XI XII TABLE OF CONTENTS INSTALLATION Me A General Provisions B Solid Shaft Mounting C Hollow Shaft Mounting D Long Term Storage LUBRICATION 25 ied onde be mb Gio ven Recommended Lubricants Oil Fill Capacities Continuous Duty Intermittent Duty Oil Filling Procedures 2 35 sakkqs Run In Period Oil Change Timetable Maintenance Check Points Trouble Shooting 1 Oil Leaks 2 Temperature 3 Vibration Noise Level 4 Dirt Contaminants 5 General gt moomn gt DISASSEMBLY PROCEDURES A Step By Step Procedures B Internal Parts Evaluation BEARING REMOVAL AND INSTALLATION A Ball Bearings and Bearing Cones B Bearing Cups C Bearing Part Numbers and Mfg Part Numbers GEAR REMOVAL AND INSTALLATION SEAL REMOVAL AND INSTALLATION A Step By Step Procedures B Electra Gear and Manufacturer Seal Part Numbers ASSEMBLY PROCEDURES RO M dU tid a A Shimmin
21. in the adapter into place and removing the bearing cap The Convertible Kit four bolts removed are tel tals 7 Tighten the bolts This com 8 The mounting of a NEMA C 9 A worm gearmotor has been pletes the conversion which face motor In just these few assembled allows AERE minutes XI BOLT NUT TORQUE SPECS Grade of Bolt Nut Thread 2 5 8 84 Size Ft Lbs of Torque 10 24 2 3 4 5 1 4 20 7 10 14 16 5 16 18 14 21 30 33 3 8 16 24 37 52 59 7 16 14 39 60 84 95 1 2 13 59 90 128 145 Cil Fill Drain Plugs Thread Size Square Head Socket Head 1 8 Pipe 6 5 1 4 Pipe 10 9 3 8 Pipe 20 15 1 2 Pipe 25 20 Note 1 Above torque specs in ft Ibs 2 Assemble all bolts nuts and pipe plugs with an anti seize compound Grade I D System Grade 8 2 5 8 e Hex Head Bolts Socket flat and button head cap screws 30 NOTE WHEN ORDERING PARTS PLEASE PROVIDE THE PARTS LIST NUMBER ITEM NUMBER PART DESCRIPTION H P PHASE HERTZ VOLTS R P M AND THE COMPLETE FRAME AND MODEL NUMBER THIS WILL INSURE THAT THE CORRECT PART IS ORDERED Helical Parts Group To C Face ES Motor P d Refer to page 4 gt T Pi Motor End tRefer page 4 aoro ADAPTER PARTS GROUP The gear bronze and the worm shaft are sold as a set only Worm Reducer o
22. internals of the reducer Check to see if heat is localized around a particular bearing or bearings If so disassemble and evaluate all parts change bearings and observe while operating 3 Vibration Noise level If noise level changes a Check all drive system components Check for proper alignment and tension Check for noise coming from components themselves or somewhere else in the machinery b If noise is coming from gear reducer try to identify location and fre quency of noise 1 High frequency high speed noises indicate input worm shaft problems A Check input coupling area alignment and fit B Listen to input bearings through stethoscope or screw driver 2 Low frequency low speed noises indicate output worm gear shaft problems A Check output shaft coupling sprocket or other load connection area B Listen to output bearings Constant noise at any bearing could be caused by lack of lubrica tion lubrication breakdown bronze filings from worm gear wear or other con taminants Disassemble and inspect unit as soon as possible Make certain that the power supply is disconnected before attempting to disassemble and inspect the unit Lock out the power supply and tag it to prevent unexpected application of power Intermittent or repetitive noise could be caused by a high spot on the worm gear this will usually disappear after running under load Noise could also be caused by broken particles of internal com
23. nent parts with hand wrenches a soft hammer and a screw driver Units with fans require an allen wrench for fan set screw 1 Drain unit of oil when reducer is hot preferably Hot oil or the reducer can cause severe burns Use extreme caution when removing lubrication plugs and vents 2 Remove output sideplates a Loosen and remove bolts holding sideplate to reducer housing b Pry sideplate from reducer housing This can usually be done by putting a screwdriver against an oil plug or in the case of a ring base unit gently tap the base from the housing Be careful to leave shims intact with sideplates 3 Remove output gear assembly a Pry output shaft away from worm this may have to be tapped with soft hammer b Lift output shaft assembly out of reducer On units with double extended output shafts hollow shafts and 500 and 600 units it is recommended that both output sideplates be removed before removing worm gear assembly to prevent damage to seals and bearings and to facilitate disassembly 10 4 Remove fan shield and fan If none on unit proceed to step 5 a Remove fan shield b Remove fan from worm shaft 5 Remove worm shaft assembly Be sure output gear assembly is out of reducer before attempting to remove worm shaft Serious damage to internal parts will result and worm shaft will not come out Remove all keys from input shaft before
24. ollow Shaft Single Extended B Internal Parts Evaluation and Determination NOTE All worms and gears are available as a set only both worm and gear After removing worm shaft and gear shaft assemblies clean all parts with non flammable solvent including tapered bearing cups pressed in bearing caps 1 Inspect worm gear The nature of the material and application usually make the worm gear the fuse of the unit No tooth Material left bd Unit Failed at that point y New Gear on right Badly worn teeth not much material left A good gear will have a nice even polish across the tooth face all around and have plenty of tooth material left Look for even wear across the face of the gear teeth Uneven wear may be the result of improper centering offset shimming of the gear Look for lines in teeth surface signs of heat or stress Pitting or broken teeth is evidence of shockload Pitting can indicate extreme loads and or lubrication breakdown More wear in one area of the gear than others is indication of a heavy cyclic load that occurs on each output shaft rotation 2 Inspect worm shaft Carburized oil Bronze Material on Thread Nick from Shockload 15 Check smoothness of worm threads A good worm will have smooth threads Discoloration should be noted also Bluish tint or burnt oil indicate excessive heat loading incorrect lubricant or lubrication breakdown 3 Insp
25. pe returns Rush service charges freight and all other charges are not subject to credit All returns must be accompanied by an RGA number and shipped back to Electra Gear freight prepaid Old line parts units and accessories are not returnable ELECTRA GEAR A REGAL BELOIT Company 1110 North Anaheim Blvd Anaheim California 92801 Telephone 800 877 4327 714 535 6061 Fax 714 535 2489 www electragear com E mail sales electragear com ELECTRA GEAH FOR SPEED REDUCERS PARTS AND ELECTRIC MOTORS ELECTRA GEAR A REGAL BELOIT Company 1110 North Anaheim Blvd Anaheim California 92801 Telephone 800 877 4327 714 535 6061 Fax 714 535 2489 www electragear com E mail sales electragear com Printed in U S A 3464E 1000 6 02 BP BH REV1 4180E 500 12 03 BP BH
26. ponents If sprocket sheave or pinion is used mount as close to gear housing as possible to minimize bearing load and shaft deflection Overhung load must be checked to make certain it does not exceed published capacity When couplings sheaves sprockets or pinions are mounted it is important that extreme care be used It is quite easy to damage internal parts by heavy blows used in trying to drive one of these parts on the shaft It is recommended that a bore be selected to give a light driving fit If a press fit is required it is suggested that the external element be heated to assure an easy assembly Heating beyond 250 degrees F 121 C is not recommended as heat conducted along the shaft may damage the shaft seal C Hollow Shaft Mounting The torque arm of the shaft mounted worm gear reducer must not be mounted too rigidly If the torque arm is held down without any flexibility shaft eccentricity which is usually present can overload the bearings of the gear reducer The flexible grommet provided with all torque arms must be retained or some other suitable means provided to allow the torque arm to be mounted with some flexibility The torque arm should be mounted in tension based on direction of rotation D Long Term Storage 6 months and up Units should be stored in a protected area preferably indoors If stored outdoors they should be covered to be protected from rain and snow Wherever stored units should be fill
27. ponents resulting from shockload or handling Helical worm gear reducers are often noisy in the helical high speed end A con stant whirring sound is normal and may disappear after run in If noise is excessive after run in contact Electra Gear Service Department 4 Dirt Contaminant Accumulation Excessive dirt will hamper effectiveness of reducer cooling fan and pressure relief valve or breather and may cause excessive pressure or heat in the gear reducer Be careful not to allow any contaminants to enter the gear reducer or build up on the outside 5 General CAUTION Oil should be changed more often if gear reducer is used in a severe envi ronment i e dusty humid Even if no oil leaks are evident oil levels should be checked frequently Oil condition should be noted when oil changes are made Look for foreign particles in oil and lubri cant condition These could show signs of future troubles and if suspicious the gear reducer should be thoroughly inspected at oil change time to prevent future down time A CAUTION Mounting bolts should be routinely checked to ensure that the unit is firmly anchored for proper operation A further insurance against down time is the purchase of a spare unit or spare parts The investment is usually quite small when measured against down time costs IV DISASSEMBLY PROCEDURES A Step by Step Procedures Electra Gear worm reducers are easily disassembled for inspection of compo
28. r gear end for gearmotor Parts Group single or double worm Gear housing Shim set output Worm shaft keyed for reducer only Gear bronze specify gear ratio Worm shaft splined for gearmotor only gear end Bearing output cup and cone set Key input worm shaft Seal output solid Bearing input specify as to ball taper or roller Seal output hollow Bearing input fan end specify as to ball taper or roller Side plate open Seal input Side plate closed Seal input fan end Output shaft single end keyed Shim set input Output shaft single end splined for planetary Bearing cap input or double worm specify Bearing cap input fan end Output shaft standard double end keyed Snap ring Output shaft hollow specify as to bore diameter Lock nut 500 and 600 only Key gear Fan Key output Fan shield Key inside hollow shaft Pressure relief valve Elbow or bushing 31 24 25 26 27 28 29 30 31 32 33 34 35 37 ut To Secondary Reduction Gear Box Planetary adapter Bearing cup and cone set Ring gear Dowel pin ring gear Key output shaft Planetary gear shaft assembly Gear 3 required Needle bearing 3 required Thrust washer 6 required Pin 3 required Bearing output cup and cone set Seal output Planetary gear housing Heducer Parts Group Ring mount Adaptable base 2 required Torque arm B bracket JB bracket NEMA C flange specify as to motor frame size NEM
29. r requires accurate adjustment of the worm shaft and gear shaft end play Excessive end play results in noisy opera tion while insufficient end play will pre load the bearings and result in premature failure or overload to the motor 1 Worm Shaft Installation NOTE Size 13 17 21 26 worm shafts ball bearing design cannot be adjusted for end play One bearing is clamped one is floating Install shims as they were when originally disassembled For taper bearings designs Shims Color Thickness Red 002 Green 003 Blue 005 Brown 010 Yellow 020 Install approximately 020 shims under each bearing cap Clamp gear reducer and measure end play with dial indicator Adjust end play by addition or removal of shims supplied with gear set See Table next page for allowable end play o oo 22 GEAR HEAD WORM SHAFT END PLAY OUTPUT SHAFT PRELOAD SIZE BALL BEARINGS UTILIZED NO AXIAL ADJUSTMENT REQUIRED BEARING OPPOSITE WORM INPUT END IS SHIMMED TO LOCK INTO HOUSING OTHER BEARING IF USED FLOATS NOTE The allowable end play is for normal 4 32 to 125 F ambient tempera ture only Call Electra Gear service department for proper end play for other operating temperatures or conditions 2 Output Shaft Assembly a To properly adjust output shaft end play and center the gear with worm apply bluing to gear teeth Install approximately 020 shims with each sideplate Bolt sideplat
30. t temperature range is based on 1 0 service factor Lubricants listed on page 3 are compounded for use in worm gear reducers Some contain non corrosive extreme pressure additives Do not use lubricants that contain materials that are toxic Avoid use of such lubes that bring harmful effects If in doubt consult your local lubricant supplier Use only A G M A rated worm gear lubes B Oil Fill Capacities Due to the numerous shaft base and mounting configurations of Electra Gear worm reducers it is impossible to pin point the exact amount of oil to be used in each unit Please use the following chart as a guide only for ordering oil Continuous Duty Intermittent Duty wm me mm C Continuous Duty Continuous duty is defined as running more than 30 minutes in an hour If the unit is going to be run on a continuous basis more than half the time it should be filled to the continuous duty low level See diagram next page D Intermittent Duty Intermittent Duty is defined as running less than 30 minutes in an hour or with an input speed of 800 RPM or less All double reduction worm reducers should have the secondary box filled to the intermittent high level Oil Level and Mounting Positions for Electra Gear Worm Reducers Breather Intermittent Oil Level Intermittent Oil Level Breather Continuous Continuous Oil Level Oil Levei Breather Intermittent Oil Level Continuous Oil L
31. tent or Input RPM 800 or Less Continuous Oil Level Continuous Oil Level SECONDARY GEARBOX PRIMARY GEARBOX 1 MAINTENANCE A Run In Period The maximum efficiency of Electra Gear worm gear reducers is obtained after a run in period The length of time required will depend on the load applied and will be 8 to 12 hours at rated load and considerably longer at light loads During run in higher than normal motor currents lower efficiency and lower output torque can be expected ACAUTION Overloading will not decrease run in time but may cause severe wear B Oil Change Timetable 1 Standard Mobil 600W Lube Drain and refill oil after first 100 hours of operation Under normal condi tions change oil every 2000 hours of operation or 6 months whichever comes first Check ambient temperature limits of your oil to make sure it matches ambient conditions Synthetic Lubricants such as Mobil SHC 600 Series Under normal conditions change oil every 4000 hours of operation or every year whichever comes first C Maintenance Check Points Trouble Shooting 1 Oil Leaks There are several possible places for oil to leak out of worm gear reducers a Oil Fill and Drain Plugs when oil is changed plug threads should be coated with non hardening pipe thread sealing compound Check for tightness on these fittings b If oil is leaking at pressure relief valve or breather 1 Check location Is pressure relief
32. ubject shaft bearings and shafts to stress which may cause premature bearing failure and or shaft breakage from bending fatigue if not sized properly CAUTION Test run unit to verify operation If the unit tested is a prototype that unit must be of current production f the speed reducer cannot be located in a clear and dry area with access to adequate cooling air supply then precautions must be taken to avoid the ingestion of contaminants such as water and the reduction in cooling ability due to exterior contaminants Mounting bolts should be routinely checked to ensure that the unit is firmly anchored for proper operation In the event of the resale of any of the goods in whatever form Resellers Buyers will include the following language in a conspicuous place and in a conspicuous manner in a written agreement covering such sale The manufacturer makes no warranties or representations express or implied by operation of law or otherwise as to the merchantability or fitness for a particular purpose of the goods sold hereunder Buyer acknowledges that it alone has determined that the goods purchased hereunder will suitably meet the requirements of their intended use In no event will the manufacturer be liable for consequential incidental or other damages Even if the repair or replacement remedy shall be deemed to have failed of its essential purpose under Section 2 719 of the Uniform Commercial Code the manufacturer shall have
33. valve or breather at highest location 2 Check oil level overfilling to intermittent level in a continuous oper ation will cause oil to foam through 3 Check oil type the wrong type of oil will foam excessively Refer to lubrication section c Input Bearing Caps and Output Sideplates output sideplates and input bearing caps should be tight against reducer housing check bolts and should have a bead of silastic around inside machined fit where cap fits to reducer housing See Final Assembly Procedures for more details Page 24 If sideplate or bearing cap bolts are working loose repeatedly in operation the whole drive system should be checked over in detail for overhung load shock components faulty drive components overloading and be reevaluated ac cordingly Consult Electra Gear Service or Application Engineering Departments for additional help Other places to look for oil leaks e Oil Seals See seal removal and installation section page 20 2 Temperature Check actual oil bath temperature after running or during Oil bath tempera ture should not be over 200 degrees Generally the oil bath temperature will rise approximately 100 degrees over ambient temperature based upon a 1 0 service factor continuous duty Excessive oil bath temperature after run in period may be a signal of lubricant breakdown excessive loading high ambient temperature or other internal gear reducer problems Inspect lubricant and
Download Pdf Manuals
Related Search