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Industrial - X Horizontal - Instructions

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1. gt a Ea Ke gt d 35805196 Position of the backstop Alternative backstop position depending on size and gear ratio Consult SEW EURODRIVE when using a backstop Operating Instructions Industrial Gear Units X Series Design of Basic Gear Units Direction of rotation dependencies 3 7 2 X K Standard Reverse direction of rotation Shaft position 03 04 034 Pos final gear 4 3 4 X2K V gt gt X3K _ P gt X4K y wem gt 362987915 Shaft position 03 04 043 Pos final gear 3 4 3 X2K o gt X3K n ra Fa P Ee ts X4K IR gt EE Position of the backs
2. Lebanon Sales Beirut Gabriel Acar amp Fils sarl Tel 961 1 4947 86 B P 80484 961 1 4982 72 Bourj Hammoud Beirut 961 3 2745 39 Fax 961 1 4949 71 gacar beirut com Lithuania Sales Alytus UAB Irseva Tel 370 315 79204 Naujoji 19 Fax 370 315 56175 LT 62175 Alytus info irseva lt http www sew eurodrive It Luxembourg Assembly Br ssel CARON VECTOR S A Tel 32 10 231 311 Sales Avenue Eiffel 5 Fax 32 10 231 336 Service B 1300 Wavre http www caron vector be info caron vector be Malaysia Assembly Johore SEW EURODRIVE SDN BHD Tel 60 7 3549409 Sales No 95 Jalan Seroja 39 Taman Johor Jaya Fax 60 7 3541404 Service 81000 Johor Bahru Johor sales sew eurodrive com my West Malaysia Mexico Assembly Queretaro SEW EURODRIVE MEXIKO SA DE CV Tel 52 442 1030 300 Sales SEM 981118 M93 Fax 52 442 1030 301 Service Tequisquiapan No 102 http Awww sew eurodrive com mx Parque Industrail Queretaro scmexico seweurodrive com mx C P 76220 Queretaro Mexico Morocco Sales Casablanca AT Tel 212 22618372 5 rue Emir Abdelkader Fax 212 22618351 MA 20300 Casablanca richard miekisiak premium net ma Netherlands Assembly Rotterdam VECTOR Aandrijftechniek B V Tel 31 10 4463 700 Sales Industrieweg 175 Fax 31 10 4155 552 Service NL 3044 AS Rotterdam http www vector nu Postbus 10085 info vector nu NL 3004 AB Rotterdam New Zealand Assembly Auckland SEW EURODRIVE NEW
3. 181714571 Operating Instructions Industrial Gear Units X Series 13 14 Safety Notes Transportation 2 4 4 Gear units with V belt drive Gear units with a V belt drive must only be transported using lifting straps 1 and cables 2 at an angle of 90 vertical The eyebolts on the motor may not be used for transport O O OCH HECO E go os 9 8 o D or 370067595 Operating Instructions Industrial Gear Units X Series Safety Notes 2 Coating and surface protection systems 2 5 Coating and surface protection systems SEW version S 931 2 A 0S 2 o 9S3 h Low environmental impact Medium environmental impact High environmental impact Unheated buildings where Production spaces with high Chemical processing plants Use as surface protec condensation can build up humidity levels and medium air swimming pools boat houses tion with typical ambient Atmospheres with low contamina contamination above sea water conditions tion levels mostly rural areas City and industrial atmospheres Industrial areas and coastal areas Corrosion categories medium contamination with sulfur with moderate salt load DIN EN ISO 12944 2 dioxide NPP dairies C2 low C3 moderate C4 high GE 120h 120 h 240 h Salt spray test ISO 7253 240 h 480 h NDFT on 5 d concrete ba
4. Measuring instruments Angular misalignment Axial misalignment Feeler gauge This method only achieves an accurate result when the deviation of the coupling faces is eliminated by turning both coupling halves by 180 and then calculating the average value from the difference a a2 The following illustration shows the measurement of axial misalignment using a straight edge Permissible values for axial misalignment are usually so small that the best measurement results can be achieved with a micrometer dial If you rotate one coupling half together with the micrometer dial and divide the deviation by two the deviation displayed on the micrometer dial indicates the misalignment dimension b that includes the axial misalignment of the other coupling half Micrometer dial A prerequisite for this measuring method is that there is no axial play in the shaft bearings when the shafts rotate If this condition is not fulfilled the axial play between the faces of the coupling halves must be eliminated As an alternative you can use two micrometer dials positioned on the opposite sides of the coupling to calculate the difference of the two micrometer dials when rotating the coupling The following figure shows the how to measure axial misalign ment using a more accurate measuring method as described above The coupling halves are rotated together without letting the
5. OTT O 313740683 1 Water cooling cover 2 Inflow DI Return Operating Instructions Industrial Gear Units X Series 40 4 7 4 7 1 Design of Options and Accessories Water cooling cartridge Water cooling cartridge Design The water cooling cartridge is mounted in the gear unit s oil sump and is provided with cooling water through a water connection The water connection is made on site The amount of heat that can be removed depends on the intake temperature and the volume flow of the cooling medium that flows through the unit See the technical speci fications to determine the number of water cooling cartridges required Contact SEW EURODRIVE if chemically aggressive cooling media such as brackish or salt water are used The water cooling cartridge consists of two basic parts e Cooling pipes CuNi alloy e Connection piece brass Two bores G1 2 with pipe threads are available to connect to the cooling circuit The piping is not included in the scope of delivery Gear units in the water cooling cartridge version are delivered completely assembled Gear units without water cooling cartridges may be retrofitted consult SEW EURODRIVE toL o JMO SCH 3 4 3 4 1 2 313751819 1 Cooling pipes 2 Connection piece 3 Return 4 Inflow Operating Instructions Industrial Gear
6. Gearmotors Industrial Gear Units Drive Electronics Drive Automation Services A x_n Industrial Gear Units Helical and Bevel Helical Gear Units X Series Horizontal Gear Units Edition 05 2007 11513411 EN Operating Instructions SEW EURODRIVE Driving the world Contents 1 Important Information about the Operating Instructions Een 5 1 1 Important notes and proper use 5 1 2 Explanation of SyMbOIS A 7 1 3 Operating Notes EE 7 2 SDatety NOLS caga A AE te deneoteng evesestestestesosuigecersneneecteeaeey 8 2 1 Preliminary dE 8 2 2 General information ce ceececceeeee eee eenee eter eeneee sees eaeeeeeeetaeeeeeetaeeeeere 8 2 3 Symbols on the gear unt 10 2 4 PRANSPOrAtOMN 5 2 tee ee det cede ach ade EE Eet 11 2 5 Coating and surface protection svsiems seeeseeeeiessererrsrrrrrrrssereen 15 2 6 Storage and transport Conditions 15 3 Design of Basic Gear Units 0 0 ceeceeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneeneeeenenes 18 Sr WAITCESIQN ATION ET 18 32 Nameplates cfc tea tedsets hac hese gts EE 19 3 3 Mounting POSITION 0 eect eceetee eee eeeee cette eeeeeeeeeeeeeeeeeeeeteeeaaeeeeseeaaeeees 20 3 4 Mountng eurtaces eee cette eter eeee cette aR A arbediad tka TN aeai eia 21 3 5 Shaft pOsition ees dete eet Ud ae are dee 22 3 6 Mounting position and standard mounting surface n 23 3 7 Direction of rotation dependencies
7. Safety Notes Storage and transport conditions 2 6 4 Storage conditions During storage up to startup the gear unit must be stored in a shock free manner in order to prevent damage to the anti friction bearing races The gear units are delivered without an oil fill different protection systems are required depending on storage period and storage conditions Climate zone Packaging corrosion protection Storage location Storage duration Temperate Europe USA Canada China and Russia excluding tropical zones Long term packaging Long term corrosion protection Roofed protected against rain and snow no shock loads Up to three years with regular checks of the packaging and moisture indicator Relative humidity lt 50 Standard packaging Standard corrosion protection Under roof enclosed at constant temperature and atmospheric humidity 5 C lt 3 lt 60 C 41 F lt lt 140 F relative humidity lt 50 Protected against sudden temperature fluctuations and with controlled ventilation with filter free from dust and dirt Protected against aggressive vapors and shocks One year or more with regular inspections Check for clean liness and mechanical damage during inspection Check corrosion protection Tropical Asia Africa Central and South America Australia New Zealand excluding temperate zones Long term packaging Long ter
8. 1 Joint head with bolt 2 Threaded bolt with nut 3 Joint head 4 Fork plate with bolt Operating Instructions Industrial Gear Units X Series 33 34 4 2 Design of Options and Accessories Backstop Backstop The purpose of a backstop is to prevent undesirable reverse rotation During operation the backstop permits rotation in only one specified direction of rotation The backstop functions by using centrifugal lift off sprags Once the lift off speed is reached the sprags lift off from the contact surface of the outer ring completely The backstop is lubricated with the gear unit oil 199930635 The direction of rotation is determined with a view to the output shaft LSS e CW Clockwise e CCW Counterclockwise anti clockwise The permitted direction of rotation 1 is indicated on the housing If the drive has a through going output shaft the direction of rotation of the backstop should be given as viewed towards shaft position 3 Operating Instructions Industrial Gear Units X Series Design of Options and Accessories Motor adapter 4 3 Operating Instructions Motor adapter Motor adapters 1 are available for mounting e IEC B5 motors sizes 100 to 355 e NEMA C face motors sizes 182 to 449 All motor adapters may be equipped with a fan for two and three stage gear units An elastic claw coupling is included in the scope of delivery of the motor a
9. Upright mounting position M4 separate publication with X K gear units e Standard lubrication type without oil compensator for Upright mounting position M4 with X F gear units separate publication The gear unit is equipped with a pump shaft end pump or motor pump The oil level is low and may even be reduced when compared to splash lubrication The gearing and bearing positions that are not immersed in the oil bath are sprayed by oil through lubri cation lines Pressure lubrication is used when e Splash lubrication is not possible see the relevant mounting positions and variants under Bath lubrication e Instead of bath lubrication when that is not desired or is not thermally advantageous see the relevant mounting positions and variants e A drywell version is required only with a vertical output shaft with LSS facing down separate publication e High drive speeds are present and the speed limit for the other types of lubrication is exceeded dependant on the gear unit size version and number of stages Operating Instructions Industrial Gear Units X Series 31 32 Design of Basic Gear Units Accessories 3 13 Accessories 3 366662795 1 Position of the oil dipstick optional 2 Breather 3 Oil level glass 4 Oil drain 3 13 1 Visual oil level check 3 13 2 Breather 3 13 3 Oil drain Depending on the mounting position SEW EURODRIVE offers the following
10. cccccceeeeeeeeeeeeeeeeteceeeeeeeeeees 24 3 8 HOUSING EE 26 3 9 G0earing and shafts ec eee eee eete a ea aa i airea 26 3 10 Input and output Shafts ec ececccce cee ce eee eeeeeceeecaeceeeeeeeeeeeeeeteeesensisaeeees 27 SIT SeN EE TE 29 E LUBRICATION BEE EN KEEN 32 4 Design of Options and ACCeESSOLICS ceccccceeeeeenteeeeeeeeneeeeeeeeeneeeeeeeseeeeenes 33 Ai WOPQUGs ANI EE 33 Lee EE 34 4 3 Motor adapten seberat atara a ae eatae edd dela 35 AA Drive packages on steel frame cc cccecceeeeeeeeeeeeeeeeeeeneeeeseeeneeeeeeeenaees 36 GD E GT EE 38 4 6 Water Cooling COVEN roires arrar noA rE A ENERE EAEEREN RETEA EES 39 4 7 Water cooling Cartridge sireni EE REA RAN 40 4 8 Oil water cooler with motor Dump 41 4 9 Oilheater ania hea aaa a a Bel 42 4 10 Temperature sensor POD 43 4 11 NTB temperature switch cece cette ee eeteeeeeceneaesaeeeeeeeeeeeees 43 5 Assembly Installation ccccccceseeeeeeeeeeneeeeeeeeeeeeseeeeeseeeseeeesseenseeseeseenseeeesees 44 5 1 Required tools resources ssseeseesrtnrretnsteestttttttnrrtnnttstrertternrnnnn ennnen 44 5 2 Tightening Kelte UE 44 53 Securing the gear Unib vesis ere eaea r AEAEE AEE EErEE e aai 45 D4 Tolerances a a A AA AAG A TA 45 5 5 Notes on installing the gear unt 46 5 6 Preliminary WOK eenaa parii a RN er a 47 5 7 Installing the gear unt 48 5 8 Gear units with solid ebhaft ceeeeeeeeeeeteee eee eeneeee eee eeeeeeetiaeeeerenea 49 5 9 Gear unit with hollo
11. 11 2006 1 China Production Tianjin SEW EURODRIVE Tianjin Co Ltd Tel 86 22 25322612 Assembly No 46 7th Avenue TEDA Fax 86 22 25322611 Sales Tianjin 300457 gm tianjin sew eurodrive cn Service http www sew eurodrive com cn Assembly Suzhou SEW EURODRIVE Suzhou Co Ltd Tel 86 512 62581781 Sales 333 Suhong Middle Road Fax 86 512 62581783 Service Suzhou Industrial Park suzhou sew com cn Jiangsu Province 215021 P R China Additional addresses for service in China provided on request Colombia Assembly Bogot SEW EURODRIVE COLOMBIA LTDA Tel 57 1 54750 50 Sales Calle 22 No 132 60 Fax 57 1 54750 44 Service Bodega 6 Manzana B http www sew eurodrive com co Santaf de Bogot sewcol sew eurodrive com co Croatia Sales Zagreb KOMPEKS d oo Tel 385 1 4613 158 Service PIT Erd dy 4 II Fax 385 1 4613 158 HR 10 000 Zagreb kompeks net hr Czech Republic Sales Praha SEW EURODRIVE CZ S R O Tel 420 220121234 Business Centrum Praha Fax 420 220121237 Luzna 591 http www sew eurodrive cz CZ 16000 Praha 6 Vokovice sew sew eurodrive cz Denmark Assembly Kopenhagen SEW EURODRIVEA S Tel 45 43 9585 00 Sales Geminivej 28 30 P O Box 100 Fax 45 43 9585 09 Service DK 2670 Greve http www sew eurodrive dk sew sew eurodrive dk Estonia Sales Tallin ALAS KUUL AS Tel 372 6593230 Mustam e tee 24 Fax 372 6593231 EE 10620 Tall
12. Industrial Gear Units X Series Design of Options and Accessories Drive packages on steel frame 4 4 2 Base plate For gear units in a horizontal mounting position complete preassembled drive packages on a base plate are available from SEW EURODRIVE A base plate is a steel frame 1 that accommodates the gear unit hydro coupling and motor and brake if required including protection devices such as guards etc The steel frame is supported by several foot mountings 2 Such a frame is usually used for solid shaft gear units with elastic coupling on the output shaft Example Base plate with coupling 219858571 1 Base plate 2 Foot mounting 3 Bevel helical gear unit 4 Protection cover for coupling 5 Motor Operating Instructions Industrial Gear Units X Series 37 Design of Options and Accessories Fan To raise the thermal rating or when the ambient conditions change after gear unit startup a fan may be retrofitted The direction of rotation of the gear unit does not influ ence the operation of the fan The following fan designs are available 4 5 1 SE Fan standard 1 Air intake that should be kept clear 4 5 2 X K Fan standard 1 Air intake th
13. The following ions do not have a corrosive effect under normal conditions phosphate nitrate nitrite iron manganese sodium potassium II Also observe the additional manufacturer s documentation e Operating Instructions Industrial Gear Units X Series Assembly Installation Oil heater 5 19 Oil heater In order to prevent damage it is essential that the heating elements are fully immersed in the oil bath The position of the thermostat and the temperature sensor varies with gear unit design and mounting position of the gear unit 5 19 1 Connection power The table below shows the power of the heaters that may be installed Pinst Pinst Gear unit 1 Heater 2 Heaters Size Version kW K h kW K h X2F X3K X3F X4K 1x 1 6 4 2 2x 1 6 14 ae X4F 1x 1 1 2 9 2x 1 1 9 X2F X3K X3F X4K 1x 1 6 4 1 GN X4F 1x 1 1 2 8 X2F X3K X3F X4K 1x 1 9 4 0 2x19 13 Gi X4F 1x1 3 2 7 2x1 3 9 X2F X3K X3F X4K 1x1 9 3 9 Si X4F 1x 1 3 2 6 220 X2F X3F X4F X3K X4K 1x 2 25 3 7 2x 2 25 12 230 X2F X3F X4F X3K X4K 1x 2 25 3 7 240 X2F X3F X4F X3K X4K 1x 2 25 3 1 2x 2 25 9 250 X2F X3F X4F X3K X4K 1x26 3 6 K h Heating power kelvins hour Pinst Power of the installed heater Operating Instructions Industrial Gear Units X Series 5 Assem
14. Meropa 320 CLP 320 Plus Goya NT 320 Optigear BM 320 Tribol 1100 320 Optigear Mobilgear Synthetic A 320 Shell Omala Kl ber Degol BP Enersyn Pinnacle Renolin Optigear Oil HD 320 GEM4 320N PAS 320 EP XF 320 EP 320 Unisyn CLP 320 ELGreco 320 Synthetic X 320 SHC 632 Tribol 1510 320 Tribol 1710 320 Mobilgear Shell KLUBER DegolBG BP Energol Renolin Alphamax 460 XMP460 Omala F460 GEM 1 460N 460Plus GR XF 460 Meropa 460 CLP 460Plus Goya NT 460 Optigear BM 460 Tribol 1100 460 Optigear Mobilgear Synthetic X 460 Shell Omala Kliiber BP Enersyn Pinnacle Renolin Oil HD 460 GEM4 460N EP XF 460 WM460 Unisyn CLP 460 ELGreco 460 tibol 1510 460 Sue sk Tribol 1710 460 Alpha SP 680 Mobilgear KLUBER Degol BG BP Energol Renolin XMP680 GEM 1 680N 680Plus GR XF 680 Meropa680 CLP 680Plus Goya NT 680 Optigear BM 680 Tribol 1100 680 47 0490 105 Operating Instructions Industrial Gear Units X Series 95 Lubricants Lubricant fill quantities 9 3 Lubricant fill quantities The specified fill quantities are guide values The precise values vary depending on the number of stages and gear ratios The markings on the oil level glass or dipstick are the decisive indicators for the quantity of oil used to fill the unit 9 3 1 X F X2F liter X3F liter X4F
15. The shaft positions 0 1 2 3 4 and corresponding directions of rotation shown in the following diagrams apply to solid shaft and hollow shaft version output shafts LSS For other shaft positions or gear units with backstop contact SEW EURODRIVE The following shaft positions 0 1 2 3 4 are possible 3 5 1 SE Shaft positions X FS Shaft positions X FH X FA 315325708 315325836 3 5 2 X K Shaft position X KS Shaft position X KS X KA 315328908 315329036 Operating Instructions Industrial Gear Units X Series Design of Basic Gear Units Mounting position and standard mounting surface Mounting position and standard mounting surface 3 6 A certain standard mounting surface is assigned to each mounting position The mounting position and or mounting surface may not differ from the order The gear units marked in gray are standard versions Delivery times may be longer for variants other than the standard assignment Other mounting surfaces are possible in combination with a certain mounting posi tion Refer to the order specific dimension drawing N mM SE lt SEE Ze ENG vA of SUS ra Fa Rar d Gre EE 7 Ee F6 F3 CH RA N a AX EA 2 NO KW CaN TO 3 Cp IN Ge 23 Operating Instructions Industrial Gear Units X Series Design of Basic Gear Units
16. liter X2F 180 74 X3F 180 77 X4F 180 70 X2F 190 75 X3F 190 77 X4F 190 71 X2F 200 102 X3F 200 104 X4F 200 96 X2F 210 102 X3F 210 104 X4F 210 96 X2F 220 137 X3F 220 143 X4F 220 141 X2F 230 137 X3F 230 143 X4F 230 141 X2F 240 165 X3F 240 176 X4F 240 175 X2F 250 170 X3F 250 176 X4F 250 175 9 3 2 X K X3K liter X4K liter X3K 180 74 X4K 180 77 X3K 190 75 X4K 190 71 X3K 200 104 X4K 200 96 X3K 210 104 X4K 210 96 X3K 220 143 X4K 220 141 X3K 230 143 X4K 230 141 X3K 240 176 X4K 240 175 X3K 250 176 X4K 250 175 Operating Instructions Industrial Gear Units X Series Lubricants Sealing grease 9 4 Sealing grease The following overview shows the greases recommended by SEW EURODRIVE Supplier Sealing grease Aral Aralub HLP2 BP Energrease LS EPS Castrol Spheerol EPL2 Chevron Dura Lith EP2 EI Epexa EP2 Esso Beacon EP2 Exxon Beacon EP2 Gulf Gulf crown Grease 2 Kliber Centoplex EP2 Kuwait Q8 Rembrandt EP2 Mobil Mobilux EP2 Molub Alloy BRB 572 Optimol Olista Longtime 2 Shell Alvania EP2 Texaco Multifak EP2 Total Multis EP2 Tribol Tribol 3030 2 Operating Instructions Industrial Gear Units X Series 97 10 98 Index 10 Index B Backstage dE EE Ba e platen fateh anit EE 37 Breather rsin a ee eet Cc Changing the Oil srsiredaneiiiisa daiire Checking and cleaning the breather plug Checking the oil consi
17. 1 937 440 3799 Troy Ohio 45373 cstroy seweurodrive com Dallas SEW EURODRIVE INC Tel 1 214 330 4824 3950 Platinum Way Fax 1 214 330 4724 Dallas Texas 75237 csdallas seweurodrive com Additional addresses for service in the USA provided on request Venezuela Assembly Valencia SEW EURODRIVE Venezuela S A Tel 58 241 832 9804 Sales Av Norte Sur No 3 Galpon 84 319 Fax 58 241 838 6275 Service Zona Industrial Municipal Norte http www sew eurodrive com ve Valencia Estado Carabobo sewventas cantv net sewfinanzas cantv net 11 2006 SEW EURODRIVE Driving the world EURODRIVE Gearmotors Industrial Gear Units Drive Electronics Drive Automation Services How were driving the world With people who think fast and develop the future with you ag A With a global presence that offers responsive and reliable solutions Anywhere service network that is always close at hand With drives and controls that automatically improve your productivity With innovative technology that solves tomorrow s problems today With comprehensive knowledge in virtually every branch of industry today With uncompromising quality that reduces the cost and complexity of daily operations SEW EURODRIVE Driving the world id Gm With online information and software updates via the Internet available around the clock M I VM SEW EURODRIVE GmbH am
18. 190p 3 620 130 149 320 460 5 3195 2 M36 200 4 45059 M301 X A220 36 21048 2107 210 4 3 686 133 152 370 518 5 352 5 2 5 M36 221 4 5059 M301 X A230 36 2108 2107 i 3 686 133 152 370 518 5 352 5 2 5 M36 221 4 SO Mao X A240 45 23048 2307 Z 3 778 147 170 370 562 5 400 5 25 M42 241 4 50059 M361 X A250 45 24048 2407 Aua 3 778 147 170 370 562 5 400 5 2 5 M42 252 4 Se M361 lt Dimensions not according to DIN 332 the thread depth including the counterbore is at least twice that of the thread diameter Operating Instructions Industrial Gear Units X Series 53 5 Assembly Installation Gear unit with hollow shaft keyed connection 5 9 4 Mounting the gear unit onto the machine shaft e Included in the scope of delivery Retaining screws 3 and end plate 4 e Not included in the scope of delivery Threaded rod 2 nut 5 retaining screw 6 ejector screw 8 The selection of the thread and length of the threaded rod as well as the retaining screw depends on the design of the customer s surrounding structure 1 Apply NOCO fluid to the hollow shaft 7 and the shaft end of the machine shaft 1 310347915 1 Machine shaft 7 Hollow shaft 2 Use the retaining screws 3 to attach the end plate 4 to the hollow shaft 7
19. Direction of rotation dependencies 3 7 Direction of rotation dependencies The gear unit can fundamentally be operated in both directions of rotation Gear unit versions with a backstop are an exception The following table shows the direction of rotation dependencies between the drive and output shaft The gear units as well as the position of the backstop are schematically shown as the solid shaft version 3 7 1 X F Shaft position Pos final gear X2F X3F X4F p ee OTs gt Shaft position 134 243 Pos final gear X2F X3F l pa pal X4F
20. of the product The personnel must carefully read understand and comply with the operating instruc tions in particular the safety notes section Operating Instructions Industrial Gear Units X Series Important Information about the Operating Instructions Important notes and proper use 1 1 4 Exclusion of liability You must comply with the information contained in these operating instructions to ensure safe operation of the X series gear units and to achieve the specified product characteristics and performance requirements SEW EURODRIVE GmbH amp Co KG assumes no liability for injury to persons or damage to equipment or property resulting from non observance of these operating instructions In such cases any liability for defects is excluded 1 1 5 Product names and trademarks The brands and product names in these operating instructions are trademarks or regis tered trademarks of the titleholders 1 1 6 Disposal e Housing parts gears shafts and roller bearings of the gear units must be disposed of as steel scrap This also applies to gray cast iron parts if there is no separate collection e Collect waste oil and dispose of it according to the regulations in force Operating Instructions Industrial Gear Units X Series Important Information about the Operating Instructions Explanation of symbols 1 2 Explanation of symbols The operating instructions contain important information that deals w
21. Danger of burns The gear unit must still be warm otherwise the high viscosity of excessively cold oil will make it more difficult to drain the oil correctly 3 Place a container underneath the oil drain plug 4 Remove the oil fill plug and the oil drain plug 5 Drain all the oil When changing the oil clean the gear unit housing thoroughly to remove oil residues and abrasion Use the same oil grade as for the operation of the gear unit 6 Re insert the oil drain plug 7 Fill new oil of the same type as the old oil via the oil filling plug if you want to change the oil type contact our customer service first e Use a funnel to fill the oil filter mesh max 25 um 0 00098 in e Fill the oil according to the quantity specified on the nameplate Nameplate section The oil quantity specified on the nameplate is an approximate value e Check whether the oil level is correct using the oil level glass or the oil dipstick 8 Clean the oil filter replace the filter element if necessary when using an external oil air or oil water cooling system Any dripping oil must be removed immediately with an oil binding agent Operating Instructions Industrial Gear Units X Series 87 88 Inspection and Maintenance Checking and cleaning the breather plug 7 7 Checking and cleaning the breather plug Prevent foreign bodies from entering into the gear unit during the following work 1 Remove any deposits loc
22. When connected in parallel the switching power of the thermo stat must be considered Operating Instructions Industrial Gear Units X Series Startup C vi Shutting down gear units Shutting down gear units Switch off the gear unit s drive unit Prevent the drive unit from starting up unintentionally for example by locking the keyswitch or removing the fuses from the power supply Place an information sign on the ON switch to warn that the gear unit is being worked on When working on gear units with a cooling coil or an oil water cooler close the cooling water inflow and return shutoff valves Drain the water from the cooling coil or the oil water cooler If the gear unit will not be operated for an extended period of time you must activate it regularly at intervals of approx 2 3 weeks If the gear unit will not be operated for a period longer than nine months additional corrosion protection is required e Internal corrosion protection Fill the gear unit up to the breather plug with the oil grade specified on the nameplate Set the gear unit in no load running operation for a short period of time at regular intervals If this method of corrosion protection is not possible the interior of the gear unit should be sealed and protected with a suitable corrosion protectant Consult with the respective supplier regarding the compatibility with the oil that is used and the length of corrosion p
23. chain sprockets according to illustration B A Incorrect 1 Hub B Correct e Only use a mounting device for installing input and output elements Use the center bore and the thread on the shaft end for positioning e Never force belt pulleys couplings pinions etc onto the shaft end by hitting them with a hammer This may damage the bearings housing and the shaft e When using belt pulleys make sure the belt is tensioned correctly in accor dance with the manufacturer s instructions e Input and output elements such as couplings must be equipped with a touch guard e Power transmission elements should be balanced after installation and must not give rise to excessive radial or axial forces Mounting is easier if you first apply lubricant to the output element and or heat it up briefly to 80 100 C 176 212 F Operating Instructions Industrial Gear Units X Series 49 5 Assembly Installation Gear units with solid shaft 5 8 2 Couplings Mounting tolerances When mounting couplings the following mounting tolerances may arise In order to ensure trouble free operation and long service life these should be corrected according to the manufacturer s specifications 1 Axial misalignment maximum and minimum clearance 3 357835788 Angular misalignment 2 Axial misalignment concentric running fault The following table shows various methods for measuring the differing tolerances
24. disc 5 Secure the machine shaft 1 with the retaining screw 6 see section 5 2 for tight ening torques The retaining screw should also be locked with a suitable thread locker 310510731 1 Machine shaft 6 Retaining screw Do not disassemble the shrink disc before the first installation Do not tighten the retaining screws unless the machine shaft is installed the hollow shaft could be deformed 6 Slide the shrink disc 9 with untightened screws onto the hollow shaft 7 and position the inner ring of the shrink disc 9b with measurement A 449699468 7 Hollow shaft 9a Bevel outer ring 9 Shrink disc 9b Taper bushing inner ring Gear unit size Dimension A mm in XH180 190 37 1 46 XH200 210 38 1 50 XH220 230 39 1 53 XH240 250 48 1 89 62 Operating Instructions Industrial Gear Units X Series Assembly Installation 5 Gear unit with hollow shaft and shrink disc 7 Tighten the retaining screws 10 hand tight In doing so align the bevel outer ring 9a parallel to the taper bushing inner ring 9b Successively tighten the retaining screws 10 in a clockwise direction not in a diametrically opposite sequence each with a quarter turn Do not tighten the retaining screws 10 in a diametrically opposite sequence For shrink discs with a slotted taper bushing inner ring 9b tighten the retaining screws 10 to the left and right of
25. each order This information is noted in the order confirmation and on the gear unit s nameplate You must contact SEW EURODRIVE in case of a deviation from this specifica tion Ensure that the gear unit is filled with the correct oil grade and quantity before startup You can obtain the corresponding information from the gear unit nameplate and the lubricant table in the following section The most important factors in selecting lubricants are the specified oil grade and viscosity found on the nameplate The specified viscosity and oil grade are chosen for the operation conditions agreed upon in the contract Any deviation from it makes consultation with SEW EURODRIVE essential This lubricant recommendation in no way represents a guarantee as to the quality of the lubricant delivered by each respective supplier Each lubricant manufacturer is responsible for the quality of its product Do not mix different synthetic lubricants and do not mix synthetic with mineral lubricants Operating Instructions Industrial Gear Units X Series 93 94 Lubricants Approved lubricants 9 2 Approved lubricants 9 2 1 General The lubricant table on the following page shows the permitted lubricants for gear units Please refer to the following key for the lubricant table 9 2 2 Key to the lubricant table Abbreviations used meaning of shading and notes CLP Mineral oil CLP HC Synthetic polyalphaolefin Synthetic lubrican
26. enclosed breather filter must be installed on the gear unit again before startup e Small spare parts and loose pieces such as bolts nuts etc are packed in corrosion protection plastic bags VCI corrosion protection bags e Threaded holes are covered by plastic plugs e Ifthe gear unit is stored longer than six months you must check the protective coating of unpainted areas as well as the paint coating regularly Areas where the protective coating or paint has been damaged may have to be recoated as needed e The output shaft must be rotated at least one full rotation so that the position of the roller elements in the bearings of the drive and output shafts changes This procedure must be repeated every six months until startup 2 6 3 Packaging Standard packaging The gear unit is delivered on a pallet without cover Application Land transport Long term packaging The gear unit is attached to a pallet wrapped in film and equipped with appropriate corrosion protection material in the film packaging Application Land transport and for long term storage Seaworthy packaging The gear unit is packaged in a seaworthy wooden box and is delivered on a pallet that is appropriate for sea transport The gear unit is wrapped in a film and equipped with appropriate corrosion protection material in the film packaging Application Sea transport and for long term storage 16 Operating Instructions Industrial Gear Units X Series
27. gm sew eurodrive de Central SEW EURODRIVE GmbH amp Co KG Tel 49 7251 75 1780 Electronics Ernst Blickle StraRe 42 Fax 49 7251 75 1769 D 76646 Bruchsal sc mitte e sew eurodrive de North SEW EURODRIVE GmbH amp Co KG Tel 49 5137 8798 30 Alte Ricklinger StraRe 40 42 Fax 49 5137 8798 55 D 30823 Garbsen near Hannover sc nord sew eurodrive de East SEW EURODRIVE GmbH amp Co KG Tel 49 3764 7606 0 Dankritzer Weg 1 Fax 49 3764 7606 30 D 08393 Meerane near Zwickau sc ost sew eurodrive de South SEW EURODRIVE GmbH amp Co KG Tel 49 89 909552 10 Domagkstrae 5 Fax 49 89 909552 50 D 85551 Kirchheim near M nchen sc sued sew eurodrive de West SEW EURODRIVE GmbH amp Co KG Tel 49 2173 8507 30 Siemensstrae 1 Fax 49 2173 8507 55 D 40764 Langenfeld near Dusseldorf sc west sew eurodrive de Drive Service Hotline 24 Hour Service 49 180 5 SEWHELP 49 180 5 7394357 Additional addresses for service in Germany provided on request France Production Haguenau SEW USOCOME Tel 33 3 88 73 67 00 Sales 48 54 route de Soufflenheim Fax 33 3 88 73 66 00 Service B P 20185 http www usocome com F 67506 Haguenau Cedex sew usocome com Assembly Bordeaux SEW USOCOME Tel 33 5 57 26 39 00 Sales Parc d activit s de Magellan Fax 33 5 57 26 39 09 Service 62 avenue de Magellan B P 182 F 33607 Pessac Cedex Lyon SEW USOCOME Tel 33 4 72 15 37 00 Parc d Affaires Roosevelt Fax 33 4 72 15 37 15 Rue Jacques Tati F 69120 Vaulx en Velin Paris SEW USOC
28. grade thoroughly when switching from mineral oil or when switching from synthetic oil of one basis to synthetic oil of a different basis e Refer to the lubrication table in section 9 2 to determine which oils from the various lubricant manufacturers can be used e Information such as the oil grade oil viscosity and required oil quantity is listed on the nameplate of the gear unit e The oil quantity specified on the nameplate is an approximate quantity The markings on the oil level glass or dipstick are the decisive indicators for the quantity of oil used to fill the unit e Only change the oil when the gear unit is warm e When changing the oil flush the housing thoroughly with oil to remove oil sludge oil residue and abrasion products Use the same grade of oil that is used to operate the gear unit Viscous oil must first be heated up Fill with fresh oil only after all residues have been removed e The position of the oil level and oil drain plug and the breather valve depends on the mounting position Refer to the diagrams of the mounting positions e The used oil must be collected and recycled according to the applicable regu lations Operating Instructions Industrial Gear Units X Series Inspection and Maintenance Changing the oil 7 6 2 Procedure 1 Work on the gear unit only when the machine is not in use 2 Secure the drive unit against unintentional power up Wait until the gear unit has cooled off
29. may result from Improper use Incorrect installation or operation Improper removal of the required protective covers 2 2 1 Startup operation Check that the direction of rotation is correct in decoupled condition Pay attention to unusual grinding noises as the shaft rotates Secure the keys without output elements for the test run Do not deactivate monitoring and protection equipment during the test run When in doubt switch off the main motor whenever changes in relation to normal operation occur such as increased temperatures noise oscillation Determine the cause of the fault and consult SEW EURODRIVE Work carefully and keep safety in mind Work on the gear unit and additional equipment only when the machine is not in use Prevent the drive unit from being accidentally switched on by locking the keyswitch or removing the fuses from the power supply Attach an information sign near the ON switch to warn that the gear unit is being worked on Observe the notes attached to the gear unit such as the nameplate and direction arrow They must be free of paint and dirt Replace missing signs When installing the gear unit in devices or systems the manufacturers of the device or system are obliged to include the regulations notes and descriptions from these operating instructions in their own operating instructions Purchase spare parts from SEW EURODRIVE 2 2 2 Operating environment In its normal form the gear unit is not
30. point of the micrometer dial slide onto the measuring surface The axial misalignment is obtained by dividing the deviation displayed on the micrometer dial dimension b 50 Operating Instructions Industrial Gear Units X Series Assembly Installation Gear units with solid shaft ROTEX coupling The low maintenance elastic ROTEX coupling is capable of compensating for a radial extension as well as an angular misalignment Careful and exact alignment of the shafts ensures long service life of the coupling V a CN G LG H x 2 ee 2 e z H amp SH L S i era S a gt 358469515 Mounting dimensions Set screw Coupling e A size E s Ody Thread Tightening torque mm in mm in mm in Nm in Ib 14 13 0 51 1 5 0 59 10 0 39 M4 2 4 21 19 16 0 63 2 0 08 18 0 7 M5 4 8 42 24 18 0 7 2 0 08 7 1 1 M5 4 8 42 28 20 0 79 2 5 0 10 0 1 2 M 8 3 73 38 24 0 94 3 0 1 38 1 5 M8 20 180 42 26 1 0 3 0 1 46 1 8 M8 20 180 48 28 1 1 3 5 0 14 51 2 0 M8 20 180 55 30 1 2 4 0 2 60 2 4 M10 40 350 65 35 1 4 4 5 0 18 68 2 7 M10 40 350 75 40 1 6 5 0 2 80 3 1 M10 40 350 90 45 1 8 5 5 0 22 100 3 94 M12 69 610 100 50 2 0 6 0 2 113 4 45 M12 69 610 110 55 2 2 6 5 0 26 127 5 00 M16 195 1 730 125 60 2 4
31. pour point 10 C 14 F 15 C 5 F 20 C 4 F With heater 28 C 33 C 40 C XF180 XF250 4 heater 18 F 27 F 40 F With heater 40 C 40 C 40 C 2 heaters 40 F 40 F 40 F 6 4 2 Synthetic oil Gear unit Version ISO VG320 ISO VG220 ISO VG150 Without heater e 40 C 5 J pour point 35 C 31 F 40 F 40 C 40 F XF180 XF250 sini HOSE Se I eater o o o 1 heater or 2 heaters AO EECH 40 F SE lee The temperatures specified refer to the average values of the permitted lubricants based on the lubricant table see section 9 2 In borderline cases the permitted temperature of the lubricant that is actually being used must be verified When planning the motor observe the increased starting torque at low temperatures It may be necessary to contact SEW EURODRIVE 6 4 3 Operating notes The oil heater s thermostat is factory set at the respective limit temperature The oil heater turns off when the set temperature is exceeded by 8 K to 10 K The thermostat and oil heater are installed on the gear unit and ready for operation but they must be connected to the external power supply before startup Contact SEW EURODRIVE if a differing oil viscosity class is used or if ambient temperatures fall below the identified limit temperature Depending on the switching point the resistor element may be controlled directly or through a contactor
32. suited for operation in potentially explo sive atmospheres Follow the specifications regarding contract specific ambient temperature ratings and ambient conditions Modifications require prior approval by SEW EURODRIVE Operating Instructions Industrial Gear Units X Series Safety Notes Symbols on the gear unit 2 3 Symbols on the gear unit The symbols on the gear unit must be observed They have the following meaning Symbol Meaning Bal Oil fill plug 4 Kg Oil drain Oil level glass Inspection opening Il Oil dipstick KI A i Breather plug En D Air outlet screw Le mio Water inflow 2 H 0 Water return x Direction of rotation Delivery state DELIVERED WITHOUT OIL Hot surfaces GEAR UNIT IS VPI ANTI RUST TREATED COVER AND Extended storage PLUG OF GEAR UNIT MUST NOT TO BE OPEND AND GEAR UNIT MUST NOT ROTATED BEFORE START UP BEFORE START UP THE PROTECTIVE PLUG MUST BE REMOVED AND REPLACED BY ENCLOSED AIR VALVE Operating Instructions Industrial Gear Units X Series Safety Notes Transportation 2 4 2 4 1 Transportation Notes Immediately upon delivery inspect the shipment for any damage that may have occurred during transportation Inform the shipping company immedi ately It may be necessary to preclude startup The weight of the gear unit is indicated on the
33. the slot one after another and then in several stages tighten the remaining screws at evenly spaced intervals 9a Bevel outer ring 10 Retaining screws 9b Taper bushing inner ring 8 Working around the ring in several stages evenly tighten the retaining screws 10 by quarter turns until the bevel outer ring 9a and the taper bushing inner ring 9b align on the face that holds the screws as is shown in the illustration below L1 Condition at the time of shipment preassembled 9a Bevel outer ring L2 Finished assembly ready for operation 9b Taper bushing inner ring 10 Retaining screws If the bevel outer ring and the taper bushing inner ring cannot be aligned on the face that holds the screws disassemble the shrink disc again and carefully clean lubricate it as is presented in the next section Be sure to properly attach the protection cover after completing assembly Operating Instructions Industrial Gear Units X Series 63 5 Assembly Installation Gear unit with hollow shaft and shrink disc 5 10 5 Disassembling the gear unit from the machine shaft Never completely unscrew the retaining screws because the shrink disc might jump off and cause an accident 1 Loosen the locking screws 10 by a quarter turn one after the other to avoid straining the connecting surface 419025426 9a Bevel outer ring 9b Taper bushing inner ring 10 Retaining screws
34. work Welding may destroy gearing parts and bearings Protect rotating drive parts such as couplings gears or belt drives using suitable devices that protect from contact Units installed outdoors must be protected from the sun Suitable protective devices are required such as covers or roofs When using these avoid heat accumulation The operator must ensure that foreign objects do not impair the function of the gear unit e g by falling objects or coverings Protect the gear unit from direct cold air currents Condensation may cause water to accumulate in the oil Gear units are supplied with a coating suitable for use in damp areas or in the open air Any damage to the coating e g on the breather valve must be repaired Operating Instructions Industrial Gear Units X Series Assembly Installation 5 Preliminary work 5 6 Preliminary work Check that the following conditions have been met s The information on the motor s nameplate matches the voltage supply system e The drive has not been damaged during transportation or storage e Ambient temperature according to the nameplate e The drive must not be assembled in the following ambient conditions Potentially explosive area Oils Acids Gases Vapors Radiation 5 6 1 Removing protective agents Ensure that there is sufficient ventilation when using solvents There is a risk of explosion No open flames Risk of material da
35. 3332523 Service 195220 St Petersburg Russia http Awww sew eurodrive ru sew sew eurodrive ru Senegal Sales Dakar SENEMECA Tel 221 849 47 70 M canique G n rale Km 8 Route de Rufisque B P 3251 Dakar Fax 221 849 47 71 senemeca sentoo sn Serbia and Montenegro Sales Beograd DIPAR d o o Tel 381 11 347 3244 Ustanicka 128a 381 11 288 0393 PC Kogum IV floor Fax 381 11 347 1337 SCG 11000 Beograd dipar yubc net Singapore Assembly Singapore SEW EURODRIVE PTE LTD Tel 65 68621701 Sales No 9 Tuas Drive 2 Fax 65 68612827 Service Jurong Industrial Estate http www sew eurodrive com sg Singapore 638644 sewsingapore sew eurodrive com Slovakia Sales Bratislava SEW Eurodrive SK s r o Tel 421 2 49595201 Rybnicna 40 Fax 421 2 49595200 SK 83107 Bratislava http www sew sk sew sew eurodrive sk Zilina SEW Eurodrive SK s r o Tel 421 41 700 2513 ul Vojtecha Spanyola 33 SK 010 01 Zilina Fax 421 41 700 2514 sew sew eurodrive sk Banska Bystrica SEW Eurodrive SK s r o Rudlovska cesta 85 SK 97411 Banska Bystrica Tel 421 48 414 6564 Fax 421 48 414 6566 sew sew eurodrive sk Slovenia Sales Celje Pakman Pogonska Tehnika d o o Tel 386 3 490 83 20 Service UI XIV divizije 14 Fax 386 3 490 83 21 SLO 3000 Celje pakman siol net 11 2006 South Africa Assembly Joha
36. 4 M36 M301 X H200 36 18047 181 18046 180m1 181m6 195 3 750 4 101 83 450 5 319 5 4 M36 M301 X H210 36 19047 191 19046 190m1 191m6 205 3 753 4 106 83 453 5 319 5 4 M36 M301 X H220 36 21047 2114 21095 i 211mg 230 3 830 4 118 108 497 5 352 5 5 M36 M301 X H230 36 21047 211 210g 210m1 211m6 230 3 830 118 108 497 5 352 5 5 M36 M301 X H240 45 23047 231 23046 230m1 231m6 250 3 948 4 140 108 571 5 400 5 5 m42 m36 X H250 45 24047 241 24046 24011 241me 260 3 948 4 140 108 571 5 400 5 5 M42 M361 Dimensions not according to DIN 332 the thread depth including the counterbore is at least twice that of the rated thread diameter lt Operating Instructions Industrial Gear Units X Series 59 Assembly Installation Gear unit with hollow shaft and shrink disc N 5 10 4 Mounting the gear unit onto the machine shaft e Included in the scope of delivery Retaining screws 3 and end plate 4 e Not included in the scope of delivery Threaded rod 2 nut 5 retaining screw 6 ejector screw 8 The selection of the thread and length of the threaded rod as well as the retaining screw depends on the design of the customer s surrounding structure 1 Before assembling the gear uni
37. 5 A e Cable entry M20x1 5 for cable diameter 5 to 10 mm 0 2 to 0 4 in e Enclosure IP65 according to EN 60529 Operating Instructions Industrial Gear Units X Series 75 5 Assembly Installation Temperature sensor PT100 5 20 Temperature sensor PT100 5 20 1 Dimensions ee PG9 PG11 k 35 ry H t 359154443 5 20 2 Electrical connection 359158539 5 20 3 Technical data e Sensor tolerance K 0 3 0 005 x T corresponds to DIN IEC 751 class B T Oil temperature C e Plug connector DIN 43650 PG9 IP65 e The tightening torque for the retaining screw in the back of the plug connector for electrical connection 0 25 Nm 2 2 in Ib 76 Operating Instructions Industrial Gear Units X Series Assembly Installation 5 NTB temperature switch 5 21 NTB temperature switch 5 21 1 Dimensions 60 1 366524939 5 21 2 Electrical connection To guarantee a long service life and trouble free functioning we recommend that you use a relay in the power circuit instead of a direct connection through the temperature switch 366532491 1 NC contact without vacuum 2 Grounding terminal 6 3 x 0 8 3 NO contact without vacuum 5 21 3 Technical data e Trigger temperature 70 C 80 C 90 C 100 C 5 C 158 F 176 F 194 F 212 F 9 F e Contact capacity 10 A AC 240 V e Plug connecto
38. 7 0 3 147 5 79 M16 195 1 730 140 65 2 6 7 5 0 30 165 6 50 M20 201 1 780 160 75 3 0 9 0 4 190 7 48 M20 201 1 780 180 85 3 3 10 5 0 413 220 8 66 M20 201 1 780 During assembly the shaft distance must be strictly observed dimension E to ensure axial play of the coupling Operating Instructions Industrial Gear Units X Series 51 52 Ass embly Installation Gear unit with hollow shaft keyed connection 5 9 Gear unit with hollow shaft keyed connection 5 9 1 General information The material of the machine shaft as well as the keyed connection should be dimen sioned by the customer according to the loads that will occur The shaft material should have a yield point of at least 320 N mm 46 400 Ib in The key length should be at minimum that shown in the dimension sheets section 5 9 3 If a longer key is used it should be aligned symmetrically to the hollow shaft With a through going machine shaft or axial forces SEW EURODRIVE recommends that the machine shaft be designed with a contact shoulder In order to prevent the retaining screw of the machine shaft from loosening upon a reversing load direction it should be secured with a suitable threadlocker If necessary two eccentric retaining screws may be used 5 9 2 Thread sizes tightening torques SEW EURODRIVE recommends the following thread sizes and tightening torques Recommended thread size e T
39. 7 Checking and cleaning the breather polug 88 7 8 Refilling Ee 88 LSC WEN GT EE 88 7 10 Water Cooling COVER rear e EA E A A G 89 7 11 Water Cooling cartrdge eraa E EE AAA 89 Ka E OMMC EE 90 TAS Split HOUSING deed 90 WE e de EE 91 8 1 Notes regarding gear unit malfunctions eect teeter eeeeeetttteeeeeeeeee 91 8 2 CUSLOMEr SEPVICE isiishie i an aa EENS Seege 91 8 3 Possible gear unit malfunctions ee ee cette eeeeeteeeeeeeteeeeeeeetnateeeeeeeaas 92 9 Lubrieante eege EELER EE EEEEAE NEEN ENEE 93 9 1 Selection of lubricants ssenseeeeeeoeeennt ne netnsttesttnrnnnrtnnstnssteertnnnnnn nnn 93 9 2 Approved l bricants sree aaeeei ar aea anaana aE e danaa R arkara 94 9 3 Lubricant fill quantities eee eee ee eee eee ee eeeeeaecaeceeeeeeeeeeeteneeenseaaees 96 ya lie Kei 97 le TE i aaa E ETTE pices eteedaenndesttaceneeeesaeenatcusetagees 98 Address List infos rer sg a ar aaea aaa aa E EA aaa Eaa a aE Ea EE Eai 99 Operating Instructions Industrial Gear Units X Series Important Information about the Operating Instructions Important notes and proper use Important Information about the Operating Instructions Important notes and proper use Introduction Proper use Adhering to the operating instructions is a prerequisite for fault free operation and the fulfillment of any right to claim under warranty Read the operating instructions before you start working with the unit Make sure
40. Gear unit size Recommended thread size Ejector screw IN threads in the end plate Threaded rod 2 Nut DIN934 5 Retaining screw 6 Strength class 8 8 Tightening torque Nm in Ib Retaining screw el Strength class 8 8 XH180 230 M36 M30 1450 12 830 XH240 250 M42 M36 2500 22 130 1 See the following pages Gear unit size Thread size for 6 x retaining screws 3 Tightening torque Assembly Operating status Disassembly Nm in Ib Strength class 10 9 EH XH180 190 M10x30 48 420 Apply hand pressure XH200 230 M12x30 86 760 Apply hand pressure XH240 250 M16x40 210 1860 Apply hand pressure 1 See the following pages Operating Instructions Industrial Gear Units X Series Assembly Installation 5 Gear unit with hollow shaft and shrink disc 5 10 3 Dimensions of the machine shaft C1 Lo 1 ES CH CH S wl S N FA lt A ES Hi a ZS J A a Di A Ql o ae K2 K3 418503819 C1 D5 D6 D7 D8 D9 Ce FA K K2 K3 MD el R 5 ZE X H180 36 16597 166 16546 165h1 166mg 180 3 6724 83 83 400 292 4 M36 M301 X H190 36 16547 166 165gg 165p11 166mg 180 3 6724 83 83 400 292
41. If the bevel outer ring 9a and the taper bushing inner ring 9b do not separate by themselves Take the necessary number of retaining screws and screw them into the removal bores evenly Tighten the retaining screws in several steps until the tapered bushing separates from the bevel ring 2 Pull the shrink disc off of the hollow shaft Disassemble the gear unit from the machine shaft as is described in section 5 9 5 Only use the hollow shaft for bracing during disassembly Bracing against other gear unit parts may cause damage Before re assembly the shrink disc must be cleaned and lubricated as described in the following section 64 Operating Instructions Industrial Gear Units X Series Assembly Installation Gear unit with hollow shaft and shrink disc Cleaning and lubricating the shrink disc You must perform the following steps carefully in order to ensure that the shrink disc functions perfectly Use only products that are comparable to the lubricants that are given Clean the shrink disc after removal and 1 Lubricate the retaining screw 10 on the threads and under the head with an MoS compound e g gleitmo 100 from FUCHS LUBRITECH www fuchs lubritech de 2 Apply a thin layer 0 01 0 02 mm 0 0004 0 0008 in of gleitmo 900 lubricant from FUCHS LUBRITECH www fuchs lubritech de or a comparable product from another manufacturer to the face of the bevel and surface that holds the screws
42. OME Tel 33 1 64 42 40 80 Zone industrielle Fax 33 1 64 42 40 88 2 rue Denis Papin F 77390 Verneuil l Etang Additional addresses for service in France provided on request Algeria Sales Alger R ducom Tel 213 21 8222 84 16 rue des Fr res Zaghnoun Fax 213 21 8222 84 Bellevue El Harrach 16200 Alger Argentina Assembly Buenos Aires SEW EURODRIVE ARGENTINA S A Tel 54 3327 4572 84 Sales Centro Industrial Garin Lote 35 Fax 54 3327 4572 21 Service Ruta Panamericana Km 37 5 sewar sew eurodrive com ar 11 2006 99 1 Australia Assembly Melbourne SEW EURODRIVE PTY LTD Tel 61 3 9933 1000 Sales 27 Beverage Drive Fax 61 3 9933 1003 Service Tullamarine Victoria 3043 http www sew eurodrive com au enquires sew eurodrive com au Sydney SEW EURODRIVE PTY LTD Tel 61 2 9725 9900 9 Sleigh Place Wetherill Park Fax 61 2 9725 9905 New South Wales 2164 enquires sew eurodrive com au Townsville SEW EURODRIVE PTY LTD Tel 61 7 4779 4333 12 Leyland Street Fax 61 7 4779 5333 Garbutt QLD 4814 enquires sew eurodrive com au Austria Assembly Wien SEW EURODRIVE Ges m b H Tel 43 1 617 55 00 0 Sales Richard Strauss Strasse 24 Fax 43 1 617 55 00 30 Service A 1230 Wien http sew eurodrive at sew sew eurodrive at Belgium Assembly Br ssel SEW Caron Vector S A Tel 32 10 231 311 Sales Avenue Eiffel 5 Fax 32 10 231 336 Service B 1300 Wav
43. Units X Series Design of Options and Accessories Oil water cooler with motor pump 4 8 4 8 1 Oil water cooler with motor pump Design An oil water cooling system may be used if the thermal rating of the naturally cooled gear unit or cooling using a fan on the input shaft is not sufficient The prerequisite for using an oil water cooling system is that appropriate cooling water is available on site e Contact SEW EURODRIVE if chemically aggressive cooling media such as brackish or salt water are used s The following versions apply for gear units with splash lubrication The cooling system with a motor pump only cools the gear unit oil The cooling system consists of the following e Pump with directly mounted asynchronous motor e Oil water heat exchanger e Temperature switch with two switching points for Controlled startup of the motor pump with an oil temperature of 40 C 104 F Monitoring of the cooling group i e warning or gear unit shutdown when the oil temperature reaches 90 C 194 F The cooling system is delivered as a complete unit but without electrical connections The following versions are possible e Directly mounted on the gear unit including cooling circuit piping or e On the mounting frame for separate installation but without piping 2 6 7 1 BR la a Eer 3 403806604 1 Pump with motor 5 Oil return 2 Oil wat
44. ZEALAND LTD Tel 64 9 2745627 Sales P O Box 58 428 Fax 64 9 2740165 Service 82 Greenmount drive http www sew eurodrive co nz East Tamaki Auckland sales sew eurodrive co nz Christchurch SEW EURODRIVE NEW ZEALAND LTD Tel 64 3 384 6251 10 Settlers Crescent Ferrymead Fax 64 3 384 6455 Christchurch sales sew eurodrive co nz Norway Assembly Moss SEW EURODRIVE A S Tel 47 69 241 020 Sales Solgaard skog 71 Fax 47 69 241 040 Service N 1599 Moss http www sew eurodrive no sew sew eurodrive no Peru Assembly Lima SEW DEL PERU MOTORES REDUCTORES Tel 51 1 3495280 Sales S A C Fax 51 1 3493002 Service Los Calderos 120 124 http www sew eurodrive com pe Urbanizacion Industrial Vulcano ATE Lima sewperu sew eurodrive com pe 11 2006 103 1 Poland Assembly Lodz SEW EURODRIVE Polska Sp z o 0 Tel 48 42 67710 90 Sales ul Techniczna 5 Fax 48 42 67710 99 Service PL 92 518 Lodz http Awww sew eurodrive pl sew sew eurodrive pl Portugal Assembly Coimbra SEW EURODRIVE LDA Tel 351 231 20 9670 Sales Apartado 15 Fax 351 231 20 3685 Service P 3050 901 Mealhada http Awww sew eurodrive pt infosew sew eurodrive pt Romania Sales Bucuresti Sialco Trading SRL Tel 40 21 230 1328 Service str Madrid nr 4 Fax 40 21 230 7170 011785 Bucuresti sialco sialco ro Russia Assembly St Petersburg ZAO SEW EURODRIVE Tel 7 812 3332522 7 812 5357142 Sales P O Box 36 Fax 7 812
45. asing should be carried out at regular intervals The lube points are located near the input and output shafts Example 323616395 3 11 4 Grease nipple on the top side of the gear unit option When installed in a restricted space the lube points can be relocated to the top side of the gear unit When this is done flat grease nipples according to DIN 3404 A G1 8 are used Regreasing should be carried out at regular intervals Note the following points e This option is normally used on drives with fans and motor adapters e The option applies to both input and output shafts Example 323626123 30 Operating Instructions Industrial Gear Units X Series Design of Basic Gear Units Lubrication 3 12 Lubrication 3 12 1 Type of lubrication Splash lubrication Bath lubrication Pressure lubrication The oil level is low gearing and bearing parts that are not immersed in the oil bath are lubricated by splashing oil Standard lubrication type for horizontal mounting positions M1 or M3 The gear unit is almost completely filled with oil all gearing and bearing positions are either completely or partly submerged in the oil bath e Standard lubrication type with oil compensator for Swiveling mounting positions with horizontal gear units beyond a certain incli nation angle depending on type of gear unit version and size Vertical gear units mounting position M5 separate publication
46. at should be kept clear 4 5 3 X K Advanced option When the X3K Advanced version is used the connection element e g hydraulic centrif ugal coupling can be mounted flush on the fan guard The air intake that must be kept clear is integrated into the fan guard C L tine lt a 1 Air intake that should be kept clear Operating Instructions Industrial Gear Units X Series 38 Design of Options and Accessories Water cooling cover 4 6 4 6 1 Water cooling cover Design The water cooling cover is located on the gear unit s assembly opening and is provided with cooling water through a water connection The water connection is made on site The amount of heat that can be removed depends on the intake temperature and the volume flow of the cooling medium that flows through the unit The data given in the technical specifications must be observed Contact SEW EURODRIVE if chemically aggressive cooling media such as brackish or salt water are used The water cooling cover 1 is made of a corrosion resistant aluminum alloy Two bores G1 2 with pipe threads are available to connect to the cooling circuit The piping is not included in the scope of delivery Gear units in the water cooling cover version are delivered completely assembled Gear units without water cooling covers may be retrofitted consult SEW EURODRIVE 2 1 3
47. ated near the breather plugs 2 Replace clogged breather plugs with new ones 7 8 Refilling grease Regreasable sealing systems may be refilled with lithium soap grease see section 9 3 Using moderate pressure force approx 30 g 1 1 0z grease into each lubrication point Used grease including contaminants and sand is thus pressed out of the sealing gap Used grease that has oozed out must be removed immediately and properly disposed of 7 9 Fan Check the fan s inlets and outlets regularly The opening must be kept clear clean the fan guard if necessary Before restarting the fan be sure the fan guard is mounted properly The fan may not rub against the fan guard Operating Instructions Industrial Gear Units X Series Inspection and Maintenance Water cooling cover 7 10 Water cooling cover Wait until the gear unit has cooled off Danger of burns 1 Remove the cooling water inflow and return lines from the water cooling cover 2 Check the water cooling cover for deposits Light dirt on the water cooling cover should be cleaned off using an appropriate cleaning agent This should be replaced with a new one if it is heavily soiled Consult SEW EURODRIVE 3 Re connect the water cooling inflow and return lines to the water cooling cover 7 11 Water cooling cartridge A Wait until the gear unit has cooled off Danger of burns 1 Remove the cooling water inflow and return lines from the water cool
48. bly Installation Oil heater 5 19 2 Electrical connection resistor element Examples AC single phase AC 230 V parallel connection L1 N N HU mp L e 1 Thermostat 2 Heater Mains voltage Phase voltage Resistor element voltage 400 V 230 V 230 V e AC three phase 3 x AC 400 V delta connection LU GE PE L1 L2 L3 1 i e GE e 2 kd kl kd WOU B 1 Thermostat 2 Contactor on site 3 Heater Mains voltage Phase voltage Resistor element voltage 400 V 400 V 230 V s AC three phase AC 230 400 V star connection J PE ills E 1 a ap coe 2 OUL s1 1 Thermostat 2 Contactor on site DI Heater Mains voltage Phase voltage Resistor element voltage 400 V 400 V 230 V 74 Operating Instructions Industrial Gear Units X Series Assembly Installation 5 Oil heater 5 19 3 Thermostat Electrical connection 450993035 e Connect to terminals 1 2 and 4 per wiring diagram e Connect the protective earth to terminal PE II Follow the manufacturer s safety instructions Lef Technical data e Ambient temperature 40 C to 80 C 40 F to 176 F e Scale range 20 C to 100 C 4 F to 212 F e Max switching power AC 230 V 10 10A DC 230 V 10 0 2
49. d the tightening torques of the individual gear unit sizes Tightening torque bolt nut Gear unit size Bolt nut Strength class 8 8 Nm in Ib X 180 M36 2500 22 130 X 190 X 200 X 210 M42 4000 35 400 X 220 X 230 X 240 M48 6000 53 100 X 250 The bolts must not be lubricated during assembly 5 4 Tolerances 5 4 1 Shaft ends Diameter tolerance in accordance with DIN 748 lt 50mm 2 0in ISO k6 gt 50mm 2 0in ISO m6 Center bores according to DIN 332 part 2 Type D gt 16 21 mm 0 63 0 83 in M gt 50 85 mm 2 0 3 3 in M20 gt 21 24 mm 0 83 0 94 in gt M8 o gt 85 130 mm 3 3 5 12 in M24 gt 24 30 mm 0 94 1 2 in M10 o gt 130 225 mm 5 12 8 86 in M30 o gt 30 38 mm 1 2 1 5 in M12 gt 225 320 mm 8 86 12 6 in M36 gt 38 50 mm 1 5 2 0 in gt M16 gt 320 500 mm 12 6 197 in M42 1 Dimensions not according to DIN 332 the thread depth including the counterbore is at least twice that of the rated thread diameter Keys according to DIN 6885 domed type 5 4 2 Hollow shaft Diameter tolerance ISO H7 for hollow shafts with shrink discs ISO H8 for hollow shafts with keyway 5 4 3 Mounting flange Centering shoulder tolerance ISO f7 Operating Instructions Industrial Gear Units X Series 45 46 5 5 Assembly Ins
50. dapter The diagrams below show the basic design of the motor adapter X F 1 Oo _ o fe nu X K ic we O o K qO 5 Q 3 san UJ COO Es D ei fi O Z oO i WW gl e Je 324537009 1 Motor adapter 35 Industrial Gear Units X Series 36 Design of Options and Accessories Drive packages on steel frame 4 4 Drive packages on steel frame For gear units in a horizontal mounting position complete preassembled drive packages on a steel frame swing base or base plate are available 4 4 1 Swing base A swing base is a steel frame 1 that accommodates the gear unit hydro coupling and motor and brake if required including protection devices such as a guard etc A swing base is normally used for e Hollow shaft gear units or e Solid shaft gear units with flange coupling on the output shaft The steel frame 1 is supported by a torque arm 2 Example Swing base with coupling 216568971 1 Swing base 2 Torque arm optional 3 Bevel helical gear unit 4 Coupling with protection cover 5 Motor Operating Instructions
51. dia com Technical Offices Bangalore SEW EURODRIVE India Private Limited Tel 91 80 22266565 308 Prestige Centre Point Fax 91 80 22266569 7 Edward Road salesbang seweurodriveinindia com Bangalore Ireland Sales Dublin Alperton Engineering Ltd Tel 353 1 830 6277 Service 48 Moyle Road Fax 353 1 830 6458 Dublin Industrial Estate Glasnevin Dublin 11 Israel Sales Tel Aviv Liraz Handasa Ltd Tel 972 3 5599511 Ahofer Str 34B 228 Fax 972 3 5599512 58858 Holon lirazhandasa barak online net Italy Assembly Milano SEW EURODRIVE di R Blickle amp Co s a s Tel 39 02 96 9801 Sales Via Bernini 14 Fax 39 02 96 799781 Service I 20020 Solaro Milano http Awww sew eurodrive it sewit sew eurodrive it Ivory Coast Sales Abidjan SICA Tel 225 2579 44 Ste industrielle et commerciale pour l Afrique Fax 225 2584 36 165 Bld de Marseille B P 2323 Abidjan 08 Japan Assembly Iwata SEW EURODRIVE JAPAN CO LTD Tel 81 538 373811 Sales 250 1 Shimoman no Fax 81 538 373814 Service Iwata sewjapan sew eurodrive co jp Shizuoka 438 0818 Korea Assembly Ansan City SEW EURODRIVE KOREA CO LTD Tel 82 31 492 8051 Sales B 601 4 Banweol Industrial Estate Fax 82 31 492 8056 Service Unit 1048 4 Shingil Dong http Awww sew korea co kr Ansan 425 120 master sew korea co kr Latvia Sales Riga SIA Alas Kuul Tel 371 7139253 Katlakalna 11C Fax 371 7139386 LV 1073 Riga http www alas kuul com info alas kuul com 102 11 2006
52. e lip seal with radial labyrinth seal e Normal environment e Medium dust load with e High dust lo ad with abrasive e Very high dust load with abrasive particles particles abrasive particles tA M Z Z 308250636 308250764 308250892 308251020 3 11 2 Output shaft Standard Dust proof Dust proof Radial labyrinth seal Regreasable Taconite protection lip Single lip seal with dust Single lip seal with dust protection cover not regreasable Double lip seal with dust protection cover regreasable Single lip seal with radial labyrinth seal e Normal environment Medium dust load with abrasive particles e High dust load with abrasive particles e Very high dust load with abrasive particles 308254092 308254220 308254348 308254476 Operating Instructions Industrial Gear Units X Series Design of Basic Gear Units Sealing systems 3 11 3 Greasing nipple on gear unit cover standard Taper greasing nipples according to DIN 71412 A R1 8 are normally used on the gear unit cover in regreasable sealing systems Regre
53. eleasing shaft connections be sure that there are no active torsional moments present tensions within the system If you remove the gear unit cover you must apply new sealing compound to the sealing surface Otherwise the sealing properties of the gear unit might be impaired Contact SEW EURODRIVE in this case Prevent foreign bodies from entering into the gear unit during the following work Do not clean the gear unit with a high pressure cleaning system If one is used water may enter into the gear unit and the seals may be damaged Perform safety and function tests following all maintenance and repair work Danger of burns Touching the gear unit when it has not yet cooled off may result in burns Never touch the gear unit during operation or during the cool down phase after it has been switched off Operating Instructions Industrial Gear Units X Series Inspection and Maintenance Inspection and maintenance periods 7 2 Inspection and maintenance periods Time interval What to do e Check the housing temperature e With mineral oil max 90 C 194 F Daily With synthetic oil max 100 C 212 F e Check gear unit noise Monthly e Check gear unit for signs of leakage e Check the oil level section 7 4 e After 500 hours of operation e First oil change after initial startup section 7 6 e Every 3 000 operating hours at least every 6 months e Check the oil consis
54. er heat exchanger 6 Cooling water inflow 3 Temperature switch with two switching points 7 Cooling water return 4 Oil suction Operating Instructions Industrial Gear Units X Series 41 42 Design of Options and Accessories Oil heater 4 9 Oil heater Oil heating is required to ensure lubrication during a cold gear unit startup when the ambient temperature is low 4 9 1 Design The oil heater consists of two main parts 1 Resistor in the oil bath oil heater with terminal box 2 Temperature sensor with thermostat 181714571 1 Oil heater 2 Temperature sensor with thermostat Operating Instructions Industrial Gear Units X Series Design of Options and Accessories Temperature sensor PT100 4 10 Temperature sensor PT100 The temperature sensor PT100 can be used to measure the temperature of the oil in the gear unit The temperature sensor is located in the gear unit s oil sump The exact position depends on the gear unit version and position of the shaft 4 11 NTB temperature switch A temperature switch with fixed switching temperatures of 70 C 80 C 90 C or 100 C 158 F 176 F 194 F 212 F is used for monitoring the gear unit oil temperature The temperature switch is normally used for the following functions e Early warning at 70 C 158 F or 80 C 176 F e Stopping the main motor of the gear unit at 90 C 194 F or 100 C 212 F To g
55. fans ke a Oil grade and viscosity class oil quantity Year Year of construction IM Mounting position and mounting surface Operating Instructions Industrial Gear Units X Series 19 20 3 3 Design of Basic Gear Units Mounting position Mounting position The mounting position defines the position of the gear unit housing in the space and is designated MI M The horizontal gear units described in these operating instructions normally have mounting position M1 unless otherwise indicated It is also possible to mount horizontal gear units in position M3 However when this mounting position is used the use of certain optional equipment may be limited Contact SEW EURODRIVE in this case For vertical gear units the standard mounting position is M5 for upright gear units M4 These will be described in a separate publication X F X K 315220363 Operating Instructions Industrial Gear Units X Series Design of Basic Gear Units Mounting surfaces Mounting surfaces 3 4 The mounting surface is defined as the surface of a gear unit with JD or Foot mounting X IF on which the gear unit is mounted Flange mounting X Fei Six different mounting surfaces are defined designation F1 179879691 21 Operating Instructions Industrial Gear Units X Series 22 Design of Basic Gear Units Shaft position 3 5 Shaft position
56. functions of oil air or oil water cooling system e Check the oil level correct if necessary Inspection and Maintenance section e Check when the oil was last changed change the oil if necessary Inspection and Maintenance section e Protect from external heat sources e g provide shade e Change the oil Inspection and Maintenance section e Check the air intake opening and clean if neces sary clean gear unit housing e Observe the separate operating instructions for the oil water and oil air cooling system Bearing point temperatures too high e Not enough oil e Oil too old Bearing damaged e Check the oil level correct if necessary Inspection and Maintenance section e Check when the oil was last changed change the oil if necessary Inspection and Maintenance section e Check bearing and replace if necessary contact customer service Operating temperature at backstop too high No blocking function e Damaged defective backstop e Check backstop replace if necessary e Contact customer service Oil leaking e From cover plate e From gear unit cover plate e From bearing cover e From mounting flange From drive output side oil seal Gasket on cover plate gear unit Cover bearing cover mounting flange leaks Sealing lip of the oil seal turned up e Oil seal damaged worn e Tighten the bolts on the respective cover plate and observe the gear unit If oi
57. h guards Also consider the supplementary safety notes in the individual sections of these operating instructions 2 2 General information GE Electrical connection The electrical connection may only be established by a qualified electrician General as well as local regulations should be followed especially in regard to the protective measures Connections should be made according to the included circuit diagram and or the wiring diagram in the terminal box Danger of burns Touching the gear unit when it has not yet cooled off may result in burns Never touch the gear unit during operation or during the cool down phase after it has been switched off Never install or start up damaged products In the event of damage submit a complaint to the shipping company immediately During and after operation industrial gear units primary gear units and motors have e e Live parts Moving parts Hot surfaces Only qualified personnel may carry out the following work Installation and assembly Connection Startup Maintenance Servicing Operating Instructions Industrial Gear Units X Series Safety Notes General information The following information and documents must be observed during these processes e Relevant operating instructions and wiring diagrams System specific regulations and requirements National regional safety and accident prevention regulations Serious injuries and property damage
58. hreaded rod GI Ejector screw Tat e Nut DIN934 It EEN Gear unit size z de 1 Retaining screw 6 threads in the end plate e Retaining screw 6 Strength class 8 8 Strength class 8 8 XA180 230 M36 M30 1 450 12 830 XA240 250 M42 M36 2 500 22 130 1 See the following pages Tightening torque Gear unit size 6x Ea Gil EES Disassembly Nm in Ib Strength class 10 9 DEE XA180 190 M10x30 48 420 Apply hand pressure XA200 230 M12x30 86 760 Apply hand pressure XA240 250 M16x40 210 1860 Apply hand pressure 1 See the following pages Operating Instructions Industrial Gear Units X Series Assembly Installation 5 Gear unit with hollow shaft keyed connection 5 9 3 Dimensions of the machine shaft Ci o 1 o A ES a Q wel Ki Lop Ge N S An Dm R716 R216 wT ES A el tee 2S Pat K l K3 ka Ze 412158475 Cl D2 D3 D4 FA K1 K2 K3 L14 N Rie SS Tz U2 DIN 332 D X A180 36 16548 165 7 16541 3 565 109 128 300 423 292 2 M36 174 4 A0 M301 X A190 36 16548 1657 165 3 565 109 128 300 423 292 2 M36 174 4 4059 M301 X A200 36 18048 1807 18041 3 620 130 149 320 460 5 3195 2 M36 190 4 4559 M301 X A210 36 19048 1907
59. ible Operating Instructions Industrial Gear Units X Series 91 Oe D gt Z Malfunctions oe Possible gear unit malfunctions 8 3 Possible gear unit malfunctions Problem Possible cause Remedy Unusual regular running noise e Meshing grinding noise Bearing damage e Knocking noise Irregularity in the gearing e Deformation of the housing upon tightening e Noise generation caused by insufficient rigidity of the gear unit foundation e Check the oil Inspection and Maintenance section replace bearings e Contact customer service e Check the gear unit mounting for possible deformation and correct if needed e Reinforce the gear unit foundation Unusual irregular running noise e Foreign bodies in the oil e Check the oil see section Inspection and Maintenance e Stop the drive contact customer service Unusual noise in the area of the gear unit mounting e Gear unit mounting has loosened e Tighten retaining screws and nuts to the specified torque e Replace the damaged defective retaining screws or nuts Operating temperature too high Too much oil e Oil too old e The oil is heavily contaminated e Ambient temperature is too high e Gear units with fan Air intake opening gear unit housing very dirty e For gear units with built in cooling Cooling liquid flow rate too low Cooling liquid temperature too high Deposits in the cooling system e Mal
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61. ing cartridge 2 Before disassembly drain the oil completely see section 7 6 3 Check the water cooling cartridges for deposits Lightly soiled water cooling cartridges should be cleaned using an appropriate cleaning agent if necessary These should be replaced with new ones if they are is heavily soiled Consult SEW EURODRIVE 4 Re connect the water cooling inflow and return lines to the water cooling cartridges Operating Instructions Industrial Gear Units X Series 89 7 Inspection and Maintenance Oil heater 7 12 Oil heater Remove any encrusted oil from the oil heater Remove the oil heater to clean it 1 Work on the gear unit only when the machine is not in use 2 Secure the drive unit against unintentional power up A Wait until the gear unit has cooled off Danger of burns 3 Before disassembling the oil heater drain the oil completely see section 7 6 4 Remove the oil heater 5 Clean the tubular heating elements with solvent replace defective heating elements Ensure that there is sufficient ventilation when using solvents There is a risk of explosion No open flames e Do not let the solvent come into contact with the sealing lips of the oil seals e Be careful not to damage the heating elements through scratching or scraping 6 Re install the oil heater 7 13 Split housing If the split gear unit housing is divided during maintenance be sure that e the parting lines are sealed agai
62. ith general and operational safety This information is emphasized in particular with the following symbols Hazard Possible consequences Severe or fatal injuries Electrical hazard Possible consequences Severe or fatal injuries Hazardous situation Possible consequences Slight or minor injuries gt gt amp Danger of burns Touching the gear unit when it has not yet cooled off may result in burns Harmful situation Possible consequences Damage to the drive and the environment Tips and useful information 1 3 Operating notes e The gear unit is delivered without oil fill e The nameplate of the gear unit contains the most important technical data e The gear unit may only be installed and operated within the conditions speci fied in the service and delivery contract e The mounting position may only be changed after consultation with SEW EURODRIVE The warranty will become void without prior consultation Operating Instructions Industrial Gear Units X Series re Safety Notes Preliminary remark 2 Safety Notes 2 1 Preliminary remark gt The following safety notes relate primarily to the use of X series industrial gear units If using motors please also refer to the safety notes for motors in the corre sponding operating instructions Unauthorized changes to the gear unit that impair operational safety are not permitted This also applies to protection devices that are installed as touc
63. l still leaks Contact customer service e Vent the gear unit observe the gear unit If oil still leaks Contact customer service e Check shaft end ring replace if necessary e Contact customer service Oil leaking e From oil drain plug e From breather plug Too much oil e Drive installed in incorrect mounting position e Frequent cold starts oil foams and or high oil level e Correct the oil volume see Inspection and Maintenance section e Mount the breather plug correctly and correct the oil level see nameplate Lubricants section Malfunctions of oil air or oil water cooling system e Observe the separate operating instructions for the oil water and oil air cooling system Gear unit does not reach cold start temperature e Oil heater incorrectly connected or defective e Heat dissipation too great due to unfavorable climactic conditions e Check that oil heater is connected and functioning correctly replace if needed e Protect the gear unit from cooling off during the warm up phase 1 During the run in phase 24 hour run time it is normal for small amounts of oil grease to leak from the oil seal see also DIN 3761 Operating Instructions Industrial Gear Units X Series Lubricants Selection of lubricants 9 Lubricants 9 1 Selection of lubricants The oil viscosity and type mineral synthetic that are to be used are deter mined by SEW EURODRIVE specifically for
64. livery In order to simplify the mounting of output elements such as a coupling hub the shaft has an insertion area with a reduced diameter 324237835 Operating Instructions Industrial Gear Units X Series 27 28 Design of Basic Gear Units Input and output shafts 3 10 3 Output shaft as a hollow shaft with keyway The hollow shaft is equipped with a keyway according to DIN 6885 T 1 Included in the scope of delivery End plate with retaining screws 1 and protection guard D 324297995 The protection guard is dust proof The standard sealing system is therefore normally used on the protection guard side 3 10 4 Output shaft as hollow shaft with shrink disc The shrink disc is positioned on the side opposite to the machine shafts Included in the scope of delivery End plate with retaining screws 1 shrink disc 2 protection guard 3 324304523 The protection guard is dust proof The standard sealing system is therefore normally used on the protection guard side Operating Instructions Industrial Gear Units X Series Design of Basic Gear Units Sealing systems 3 11 Sealing systems 3 11 1 Input shaft Standard Dust proof Dust proof Regreasable Radial labyrinth seal Taconite protection lip Single lip seal with dust Single lip seal with dust protection cover not regreasable Double lip seal with dust protection cover regreasable Singl
65. m corrosion protection Protected against insect damage and mildew by chemical treatment Under roof protected from rain and shocks Up to three years with regular checks of the packaging and moisture indicator Relative humidity lt 50 Standard packaging Standard corrosion protection Under roof enclosed at constant temperature and atmospheric humidity 5 C lt 3 lt 60 C 41 F lt lt 140 F relative humidity lt 50 Protected against sudden temperature fluctuations and with controlled ventilation with filter free from dust and dirt Protected against aggressive vapors and shocks Protected against insect damage One year or more with regular inspections Check for clean liness and mechanical damage during inspection Check corrosion protection Operating Instructions Industrial Gear Units X Series 17 Design of Basic Gear Units Unit designation 3 Design of Basic Gear Units 3 1 Unit designation 3 1 1 Example X 3 K S 220 IB Gear unit mounting supplement B Foot mounting T Torque arm F Flange mounting Gear unit size 180 250 Type of output shafts S Solid shaft with key R Solid shaft without key L Splined solid shaft A Hollow shaft with key H Hollow shaft with shrink disc V Splined hollow shaft Gear unit version F Helical gear unit K Bevel helical gear unit standard version Number of gea
66. mage Do not let the solvent come into contact with the sealing lips of the oil seals e You must clean the output shafts and flange surfaces thoroughly to ensure they are free of anti corrosion agents contamination or similar Use a standard solvent e Protect all oil seals against direct contact with abrasive substances such as sand dust shavings 5 6 2 Extended storage Please note The service life of the lubricant in the bearings is reduced if the unit is stored for 2 1 year only applies to bearings with grease lubrication Replace the corresponding screw plug with the enclosed breather 5 6 3 Filling with oil Fill the gear unit with the oil grade and oil volume specified on the nameplate see section 7 e Fill to volume suitable for the mounting position and lubrication type see nameplate e Check oil level using the oil level glass or the oil dipstick Operating Instructions Industrial Gear Units X Series 47 48 5 7 Assembly Installation Installing the gear unit Installing the gear unit The foundation must be level and flat the gear unit may not be deformed when the retaining screws are tightened To ensure quick and successful mounting the type of foundation should be correctly selected and the mounting carefully planned in advance Foundation drawings with all necessary construction and dimension details should be available To avoid harmful vibrations and oscillations adequate rigidity mu
67. methods for checking the oil level Mounting position Oil level check M1 Oil level glass or oil dipstick optional M3 Oil dipstick M1 M3 Two oil dipsticks When a gear unit is vented non permitted pressures which arise from heating during operation are avoided The gear units are normally equipped with a high quality breather with a filter mesh of 2 um 0 00008 in The gear unit is normally equipped with an oil drain plug An oil drain valve may be provided as an option This allows for a drain line to be easily attached when changing the gear unit oil Operating Instructions Industrial Gear Units X Series Design of Options and Accessories Torque arm 4 Design of Options and Accessories 4 1 Torque arm A torque arm is available to support the reaction torque of hollow shaft gear units in the shaft mounted version The torque arm can bear tensile stress as well as thrust loads The length of the torque arm can be adjusted within a certain range The torque arm consists of a joint head with bolt 1 threaded bolt 2 maintenance free joint head 3 and fork plate with bolt 4 The design using the joint head allows for the compensation of assembly tolerances and operational displacements Constraining forces on the output shaft are thus avoided 441732108
68. n carefully and e the screw connections are re tightened using the tightening torques given in section 5 2 90 Operating Instructions Industrial Gear Units X Series Malfunctions x A Notes regarding gear unit malfunctions lt a 8 Malfunctions 8 1 Notes regarding gear unit malfunctions e Strictly observe the safety notes in the individual sections e When eliminating malfunctions the gear unit and additional equipment must be deactivated Prevent the drive unit from starting up unintentionally for example by locking the keyswitch or removing the fuses from the power supply Place an information sign on the ON switch to warn that the gear unit is being worked on Danger of burns d Touching the gear unit when it has not yet cooled off may result in burns Never touch the gear unit during operation or during the cool down phase after it has been switched off Malfunctions that occur during the warranty period that require repair to the gear unit may only be resolved by SEW EURODRIVE After the warranty period has elapsed we recommend that our customers contact our customer service when malfunctions occur and their cause is not clear 8 2 Customer service Please have the following information available if you require customer service assistance e Complete nameplate data e Type and extent of the problem e Time the problem occurred and any accompanying circumstances e Assumed cause e Adigital photograph if poss
69. nameplate or the dimension sheet Observe the loads and specifications given on the nameplate Use suitable sufficiently rated handling equipment if necessary Remove restraining devices used for transportation prior to startup The gear unit must be transported in a manner that prevents injuries and damage to the gear unit For example impacts against exposed shaft ends can damage the gear unit Stay away from beneath the gear unit during transport Secure the danger zone For transport gear units are suspended from the points indicated in the following drawings When transporting the gear unit it may only be hoisted using the four trans port holes 1 32393707 Operating Instructions Industrial Gear Units X Series 11 2 Safety Notes Transportation 2 4 2 Gear units with motor adapters Gear units with motor adapters may only be transported using lifting cables chains 2 or lifting straps 1 at an angle from 90 vertical up to 70 from the horizontal The eyebolts on the motor may not be used for transport 4179876363 12 Operating Instructions Industrial Gear Units X Series Safety Notes Transportation 2 4 3 Gear units on swing base base plate Gear units on a swing base base plate may only be transported using vertically tensioned lifting cables 1 or chains
70. ng screw 6 into the machine shaft 1 310470027 1 Machine shaft 6 Retaining screw 56 Operating Instructions Industrial Gear Units X Series Assembly Installation Gear unit with hollow shaft keyed connection 4 To disassemble the gear unit flip the end plate 4 over and use the retaining screws 3 to reattach it to the hollow shaft 7 The retaining screws 3 should be tightened hand tight s 3 310474123 4 End plate 3 Retaining screw 7 Hollow shaft 5 Thread the ejector screw 8 into the end plate 4 to remove the gear unit from the machine shaft 1 Only use the hollow shaft for bracing during disassembly Bracing against other gear unit parts may cause damage Applying lubricant to the threaded spindle and to the threads in the end plate prior to disassembly makes the job easier 310478219 1 Machine shaft 4 End plate 8 Ejector screw Operating Instructions Industrial Gear Units X Series 57 58 Assembly Installation Gear unit with hollow shaft and shrink disc 5 10 Gear unit with hollow shaft and shrink disc 5 10 1 General The material of the machine shaft should be dimensioned by the customer according to the loads that will occur The shaft material should have a yield point of at least 320 N mm 46 400 Ib in 5 10 2 Thread sizes tightening torques SEW EURODRIVE recommends the following thread sizes and tightening torques
71. ng temperatures or longer downtimes the cooling water should be drained out of the cooling circuit Any residual amounts should be removed with compressed air 5 17 Water cooling cartridge Connect the water cooling cartridge to the available cooling circuit Refer to section 5 18 3 to determine the permitted cooling media The direction of flow does not matter Cooling water temperature max 15 C 59 F Volume flow minimum 4 I min 1 06 US gal min according to order documents The cooling water pressure may not exceed 6 bar 87 psi In case of freezing temperatures or longer downtimes the cooling water should be drained out of the cooling circuit Any residual amounts should be removed with compressed air The cooling circuit must be connected in parallel for gear units with two water cooling cartridges Connect two water cooling cartridges as shown below 370075915 lt a Inflow cold water intake t Return warm water discharge Operating Instructions Industrial Gear Units X Series 71 Assembly Installation Oil water cooler with motor pump only circulation cooling 5 18 Oil water cooler with motor pump only circulation cooling 5 18 1 Mechanical connection Observing local regulations connect the heat exchanger to the cooling circuit according to the identifying markings Avoid reducing the indicated pipe cross section when doing this Do not use tin coated screw fitting pieces i
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73. of the attached motor Wp must be linearly reduced if the distance from the center of gravity distance X is increased Wu max Cannot be increased if the distance from the center of gravity is reduced Operating Instructions Industrial Gear Units X Series Assembly Installation 5 Motor adapter 5 12 3 Attaching the motor to the motor adapter 1 Clean the motor shaft and flange surfaces of the motor and the motor adapter To avoid contact corrosion we recommend applying NOCO fluid to the motor shaft before mounting the coupling halves 2 Push the coupling half onto the motor shaft and position it When doing this observe the information in section 5 8 2 and the illustration below The coupling size and type are indicated on the coupling oe XM pp 450994699 1 Motor adapter E Mounting dimension X Distance between the coupling and the motor adapter flange surface Xw Distance between the coupling and the motor flange surface gt Xm Xa E 3 Secure the coupling halves using the setscrew 4 Install the motor onto the adapter making sure that the claws of the coupling engage each another 69 Operating Instructions Industrial Gear Units X Series 70 Assembly Installation Base plate 5 13 Base plate It is essential that 5 14 Swing base 5 15 Fan The support structure of the foot mounting is adequately dimensioned and rigid The base plate is only bolted on
74. on the taper bushing The necessary layer thickness of approx 0 01 0 02 mm 0 0004 0 0008 in is achieved when the lubricant covers the surface Operating Instructions Industrial Gear Units X Series 65 66 Assembly Installation Torque arm 5 11 Torque arm Do not deform the torque arm during installation Deformation leads to constraining forces on the output shaft which may negatively influence the service life of the output shaft bearings 1 To keep the flexural torque on the machine shaft as low as possible the torque arm must always be mounted on the same side as the machine that is driven The torque arm can be mounted on the top or bottom of the gear unit 359130891 2 Align the gear unit horizontally over the threaded bolts and the nuts of the torque arm 4 IT o D se oT wagered like AR Lacan _o A IAN Roi bk a i Lo 449931788 1 Joint head with bolt 2 Threaded bolt with nuts 3 Joint head 4 Fork plate with bolt Operating Instructions Industrial Gear Units X Series Assembly Installation Motor adapter 5 12 Motor adapter 5 12 1 Maximum motor weight depending on gear unit When selecting a motor observe the permitted motor weight the gear unit ver
75. p Co KG P O Box 3023 D 76642 Bruchsal Germany Phone 49 7251 75 0 Fax 49 7251 75 1970 sew sew eurodrive com WWW sew eurodrive com
76. r DIN 43650 PGO9 IP65 e The tightening torque for the retaining screw in the back of the plug connector for the electrical connection is 0 25 Nm 2 2 in Ib 77 Operating Instructions Industrial Gear Units X Series 6 78 Ce 6 6 1 Startup Notes on startup Startup Notes on startup Strictly observe the safety notes in the individual sections Observe section 5 5 Preliminary work The most important technical data is included on the nameplate Additional data relevant for operation is available in drawings order confirmations or any order specific documentation Ensure that the unit is not started up in a potentially explosive atmosphere Before startup check that the oil level is correct Refer to the unit s nameplate for the lubricant volumes It is essential that there is no open fire or risk of sparks when working on the gear unit After the gear unit has been installed ensure that all retaining screws are tight After tightening the mounting elements check to ensure that the alignment has not changed Ensure that rotating shafts as well as couplings are equipped with suitable protective covers Contact with rotating parts is not permitted If there are any oil drain valves ensure that they cannot be opened uninten tionally If you use an oil level glass to monitor the oil level protect it from possible damage Protect the gear unit from falling objects If the gear unit i
77. r stages 2 2 stage 3 3 stage 4 4 stage Industrial gear unit series 1 Upon request to SEW EURODRIVE 18 Operating Instructions Industrial Gear Units X Series Design of Basic Gear Units Nameplate 3 2 3 2 1 Nameplate Example SEWHEURODINIME Bruchsal Germany O Type XSFS190 B Nr 1 01 1101687801 0001 06 66 1234567812 norm min PK1 kW MK2 Nm max l Ia FS FR1 N ni A min FR2 N n 1 min FA1 IN CH Se g N N D ks Operation instruction have to be observed FA2 N Made in Germany Mass kg Qty of greasing points Fans o IM M1 F1 7 CLP HC460 Synthetic Oil 90 Itr Year GEES 418645515 Type Unit designation Nr 1 Serial number Px kW Operating power on the input shaft HSS Mx2 Nm Gear unit output torque n4 1 min Input speed HSS n2 1 min Output speed LSS norm Standard operating point min Operating point at minimum speed max Operating point at maximum speed i Exact gear unit reduction ratio Fs Service factor Fri N Actual overhung load acting on the input shaft Fro N Actual overhung load acting on the output shaft Eau N Actual axial load acting on the input shaft Fao N Actual axial load acting on the output shaft Mass kg Weight of the gear unit Qty of greasing points Number of points for regreasing Fans Number of installed
78. re http www caron vector be info caron vector be Brazil Production Sao Paulo SEW EURODRIVE Brasil Ltda Tel 55 11 6489 9133 Sales Avenida Amancio Gaiolli 50 Fax 55 11 6480 3328 Service Caixa Postal 201 07111 970 http Awww sew com br Guarulhos SP Cep 07251 250 sew sew com br Additional addresses for service in Brazil provided on request Bulgaria Sales Sofia BEVER DRIVE GmbH Tel 359 2 9151160 Bogdanovetz Str 1 Fax 359 2 9151166 BG 1606 Sofia bever fastbg net Cameroon Sales Douala Electro Services Tel 237 4322 99 Rue Drouot Akwa Fax 237 4277 03 B P 2024 Douala Canada Assembly Toronto SEW EURODRIVE CO OF CANADA LTD Tel 1 905 791 1553 Sales 210 Walker Drive Fax 1 905 791 2999 Service Bramalea Ontario L6T3W1 http www sew eurodrive ca reynolds sew eurodrive ca Vancouver SEW EURODRIVE CO OF CANADA LTD Tel 1 604 946 5535 7188 Honeyman Street Fax 1 604 946 2513 Delta B C V4G 1 E2 b wake sew eurodrive ca Montreal SEW EURODRIVE CO OF CANADA LTD Tel 1 514 367 1124 2555 Rue Leger Street Fax 1 514 367 3677 LaSalle Quebec H8N 2V9 a peluso sew eurodrive ca Additional addresses for service in Canada provided on request Chile Assembly Santiago de SEW EURODRIVE CHILE LTDA Tel 56 2 75770 00 Sales Chile Las Encinas 1295 Fax 56 2 75770 01 Service Parque Industrial Valle Grande www sew eurodrive cl LAMPA ventas sew eurodrive cl RCH Santiago de Chile P O Box Casilla 23 Correo Quilicura Santiago Chile 100
79. res refer to the Malfunctions section 6 3 Gear units with backstop The purpose of a backstop is to prevent undesirable reverse rotation During operation the backstop permits rotation in only one specified direction of rotation e Donot start up the motor in the direction that is blocked Be sure that the motor power supply is correctly attached so that the motor rotates in the required direction Operating the motor in the direction that is blocked could destroy the backstop e Consult SEW EURODRIVE if you want to change the blocking direction The direction of rotation is determined with a view to the output shaft LSS e Clockwise CW e Counterclockwise CCW The permitted direction of rotation 1 is indicated on the housing 199930635 Operating Instructions Industrial Gear Units X Series 79 Startup Starting up the gear unit at low ambient temperatures e Gu 6 4 Starting up the gear unit at low ambient temperatures The minimum permissible ambient temperature for gear unit startup depends on the pour point of the oil that is used Before startup the oil must be heated up to the temperature specified under Without heater pour point The table below shows the limit temperatures for gear unit startup with and without heater 6 4 1 Mineral oil Gear unit Version ISO VG320 ISO VG220 ISO VG150 Without heater 3 o o o o
80. rodrive com Muang District Chon Buri 20000 Tunisia Sales Tunis T M S Technic Marketing Service Tel 216 1 4340 64 1 4320 29 7 rue Ibn El Heithem Fax 216 1 4329 76 Z 1 SMMT tms tms com tn 2014 M grine Erriadh Turkey Assembly Istanbul SEW EURODRIVE Tel 90 216 4419163 164 3838014 15 Sales Hareket Sistemleri San ve Tic Ltd Sti Fax 90 216 3055867 Service Bagdat Cad Koruma Cikmazi No 3 sew sew eurodrive com tr TR 34846 Maltepe ISTANBUL Ukraine Sales Dnepropetrovsk SEW EURODRIVE Tel 380 56 370 3211 Service Str Rabochaja 23 B Office 409 Fax 380 56 372 2078 49008 Dnepropetrovsk http Awww sew eurodrive ua sew sew eurodrive ua 11 2006 105 106 1 USA Production Greenville SEW EURODRIVE INC Tel 1 864 439 7537 Assembly 1295 Old Spartanburg Highway Fax Sales 1 864 439 7830 Sales P O Box 518 Fax Manuf 1 864 439 9948 Service Lyman S C 29365 Fax Ass 1 864 439 0566 Telex 805 550 http www seweurodrive com cslyman seweurodrive com Assembly San Francisco SEW EURODRIVE INC Tel 1 510 487 3560 Sales 30599 San Antonio St Fax 1 510 487 6381 Service Hayward California 94544 7101 cshayward seweurodrive com Philadelphia PA SEW EURODRIVE INC Tel 1 856 467 2277 Pureland Ind Complex Fax 1 856 845 3179 2107 High Hill Road P O Box 481 csbridgeport seweurodrive com Bridgeport New Jersey 08014 Dayton SEW EURODRIVE INC Tel 1 937 335 0036 2001 West Main Street Fax
81. rotection for your particular gear unit version e Exterior corrosion protection Clean the surfaces Grease the shaft near the sealing lip to separate the sealing lip of the oil seal and the corrosion protectant Apply a wax based protective coating to shaft ends and unpainted surfaces as external corrosion protection Observe the notes in section 2 6 4 Refer to the Startup section before re starting the gear unit Operating Instructions Industrial Gear Units X Series 6 81 82 7 7 1 Inspection and Maintenance Notes regarding inspection and maintenance Inspection and Maintenance Notes regarding inspection and maintenance Strictly observe the safety notes in the individual sections Strict adherence to the inspection and maintenance intervals is absolutely necessary to ensure safe working conditions Observe the startup torques in section 5 2 Work on the gear unit and additional equipment only when the machine is not in use Prevent the drive unit from starting up unintentionally for example by locking the keyswitch or removing the fuses from the power supply Place an information sign on the ON switch to warn that the gear unit is being worked on When using primary gearmotors also observe the maintenance notes for motors and primary gear units in the accompanying operating instructions Use only OEM spare parts according to the delivered spare and wearing parts lists Before r
82. s equipped with a fan on the input shaft check for free air intake within the specified angle For gear units with long term protection Replace the screw plug at the loca tion indicated on the gear unit with a breather plug position see order docu ments Be sure that the external coolant supply is guaranteed for gear units with circu lation cooling water cooling covers and water cooling cartridges When operated in areas with low ambient temperatures be sure that the gear unit is not below the limit temperature given in section 6 4 upon startup Allow for sufficient warm up time Operating Instructions Industrial Gear Units X Series Startup C vi 6 Run in period 6 2 Run in period SEW EURODRIVE recommends running in the gear unit as the first phase of startup Increase the load and speed of revolutions in two to three steps up to the maximum level The running in phase takes approx 10 hours Check the following points during the run in phase e Verify the power values specified on the nameplate at startup because their level and frequency may be a decisive factor for the service life of the gear unit e Does the gear unit run smoothly s Are there vibrations or unusual running noises e Are there signs of leakage lubricants on the gear unit e Check to be sure that the additional devices such as oil pump cooler etc a func tioning properly For further information and troubleshooting measu
83. se 150 um 0 00591 in 210 um 0 00827 in 270 um 0 0106 in Color top coat RAL 7031 RAL 7031 RAL 7031 Color according to RAL Yes Yes Yes Se SEU RE Coat with hand perspiration and water repellent anticorrosion agent for external preservation 1 NDFT nominal dry film thickness standard layer thickness minimum layer thickness 80 NDFT maximum layer thickness 3x NDFT DIN EN ISO 12944 5 2 Standard color 2 6 Storage and transport conditions 2 6 1 Interior corrosion protection Standard After the test run the test oil fill is drained out of the gear unit The remaining oil film protection protects the gear unit against corrosion for a limited period of time Long term After the test run the test oil fill is drained out of the gear unit and the interior space is protection filled will a vapor phase inhibitor The breather is replaced by a screw plug and enclosed with the gear unit Operating Instructions Industrial Gear Units X Series 15 2 Safety Notes Storage and transport conditions 2 6 2 Exterior corrosion protection e Bare uncoated parts are coated with an anti rust agent Remove it only using an appropriate solvent which is not harmful to the oil seal e Sealing surfaces on radial oil seals are protected by an appropriate anti corrosion agent e When the gear unit is filled with vapor phase inhibitor the breather filter is replaced by a screw plug and enclosed with the gear unit The
84. see section 5 2 for tightening torques and screw the threaded rod 2 onto the machine shaft 1 Applying lubricant to the threaded spindle and nut prior to assembly makes the job easier 310352011 1 Machine shaft 3 Retaining screws 2 Threaded rod 4 End plate 7 Hollow shaft 54 Operating Instructions Industrial Gear Units X Series Assembly Installation 5 Gear unit with hollow shaft keyed connection 3 Tighten the machine shaft 1 with the nut 5 until the shaft end of the machine shaft 1 and the end plate 4 meet 310407307 1 Machine shaft 4 End plate 5 Nut 4 Loosen the nut 5 Screw the threaded rod 2 out 310655244 2 Threaded rod 5 Nut 5 Secure the machine shaft 1 with the retaining screw 6 see section 5 2 for tight ening torques The retaining screw should also be locked with a suitable thread locker 310415883 1 Machine shaft 6 Retaining screw Be sure to properly attach the protection cover after completing assembly Operating Instructions Industrial Gear Units X Series 55 5 Assembly Installation Gear unit with hollow shaft keyed connection 5 9 5 Disassembling the gear unit from the machine shaft 1 Loosen the retaining screw 6 310460043 6 Retaining screw 2 Remove the retaining screws 3 and the end plate 4 310464523 3 Retaining screw 4 End plate 3 To protect the center bore screw the retaini
85. sion and the type of gear unit mounting according to the following tables The table only applies to stationary applications For mobile applications e g travel drives consult SEW EURODRIVE Series gear unit version Mounting type X F X K Foot mounted version Wu lt We Wu lt We Shaft mounted version Wy lt 0 5 We Wu lt Wo Flange mounted version Wm lt 0 5 We Wu lt Wo The following applies to all tables Ww Motor weight Wae Gear unit weight Operating Instructions Industrial Gear Units X Series 67 Assembly Installation Motor adapter 5 12 2 Maximum motor weight depending on the adapter size In addition to the maximum motor weights depending on the gear unit described in section 5 12 1 the following maximum loads on the motor adapter may not be exceeded Wm 356535436 1 Center of gravity of the motor 2 Motor adapter X Distance from the center of gravity Wp Weight of the motor that is mounted Motor adapter Wm X IEC NEMA IN Ib mm in 100 112 182 184 600 135 190 7 48 132 213 215 1100 247 3 230 9 06 160 180 254 286 2200 494 6 310 12 2 200 324 2800 629 5 340 13 4 225 326 4000 899 2 420 16 5 225 280 364 405 8200 1843 480 18 9 315S L 444 449 14 500 3259 680 26 8 315 20 000 4496 740 29 1 355 25 000 5620 2 740 29 1 The maximum permitted weight
86. st be ensured when mounting the gear unit on a steel frame The foundation must be dimensioned according to the weight and torque of the gear unit taking into account the forces acting on the gear unit Tighten retaining screws or nuts to the specified torque Use the screws and tightening torques specified in section 5 3 The dimensions and layout of the supply connections are given in the illustrations included in the order documents The service life of the shafts bearings and couplings depends on the precision of the alignment of the shaft axes with each other Always try to align them so that there is zero deviation When doing so you should also consult the special operating instructions regarding the requirements of the couplings for example Failure to observe this may result in shaft breakage which could endanger the life and health of persons Operating Instructions Industrial Gear Units X Series Assembly Installation 5 Gear units with solid shaft 5 8 Gear units with solid shaft 5 8 1 Mounting input and output components The following illustrations shows a mounting device for installing couplings or hubs on gear unit or motor shaft ends It may be possible to dispense with the thrust bearing on the mounting device dl 356867979 1 Shaft end DI Coupling hub 2 Thrust bearing J nm FX1 357001227 Avoid impermissibly high overhung loads Install gear or
87. stency 0 0 0 0 eee eeeeeeeees Checking the oil level eeeeeeeeeeeeteeeeeeeeeees Coating systems Customer Service oo cee eceee ccc eeeecee ee cesseeecesaueeeeeauees D Direction of rotation dependencies Drive packages on steel frame E Exterior corrosion protection ceeeees Gearing and shafts ceceeeeeeeeceeeeeeeteeteeeetees Greasing nipple on gear unit Cover s es H ele le MET l Input shaft r acces ents ae eel ee Inspection intervals ccccccecceeeeeeeeeeeeeeeeees Installing the gear unit oo eee ee eenteeeeeeeeeee Interior corrosion protection eeeeeeeeeees L Lubricant change intervals ccceeeeeeeeee Lubricant table soere ean E E RAA LUDAGANTS a a A AA aa eens al Lubrication M Maintenance intervals aeee E tute EE Motor adapter iiis enine aiaa 35 Mounting position scireeaiies ienien aR Mounting position and standard mounting Sace or aa RTS Mounting surface N Nameplate cecceccccecceceeeeeeeeeeeeeeeneeeeeeneeees 19 NTB temperature switch 43 77 O Oil heater 2 gef uen E dn dude 42 73 90 Oil water cooler with motor pump 41 72 Outputshawt eist eles apen Edge Age 27 P alle Un E 16 R Refilling grease oo ee cceeeeeeeceeeeeeeeneeeeeeeeeeteeeeeeeaas 88 RUN IN period ecccceccccceceeeeeeeeeeseeneneeeaeeeeeees 79 S Sealing grease raan hen i R 97 Sealing sys
88. t Mineral lubricant 9 2 3 Notes on the lubricant table e The temperature ranges are to be considered guide values The decisive factor is the viscosity information on the nameplate e Contact SEW EURODRIVE if you operate the unit under extreme conditions such as cold heat or there are changes to the operating conditions since project planning Operating Instructions Industrial Gear Units X Series Lubricants Approved lubricants 9 2 4 Lubricant table Castrol DIN ISO Alpha SP 150 KLUBER Degol BG BP Energol Renolin Alphamax 150 GEM 1 150N 150Plus GR XF 150 Meropa 150 CLP150Plus Goya NT 150 Optigear BM 150 Tribol 1100 150 Optigear Mobilgear Kliiber BP Enersyn Pinnacle Renolin Synthetic X 150 VG 150 SHC XMP150 GEM4 150N EP XF 150 WM 150 Unisyn CLP 150 ELGreco 150 Tribol 1510 150 Tribol 1710 150 Alpha SP 220 Mobilgear Shell KLUBER Degol BG BP Energol Renolin Alphamax 220 XMP220 Omala F220 GEM 1 220N 220 Plus GR XF 220 Meropa 220 CLP 220 Plus Goya NT 220 Optigear BM 220 Tribol 1100 220 Optigear Synthetic A 220 Mobilgear Shell Omala Kliber BP Enersyn Pinnacle Renolin Optigear VG 220 SHC XMP220 Oil HD 220 GEM4 220N EP XF 220 WM 220 Unisyn CLP 220 ELGreco 220 Synthetic X 220 Tribol 1510 220 Tribol 1710 220 Alpha SP 320 Mobilgear Shell KLUBER Degol BG BP Energol Renolin Alphamax 320 XMP320 Omala F 320 GEM 1 320N 320 Plus GR XF 320
89. t degrease the hollow shaft 7 and the machine shaft 1 and apply some NOCO fluid to the machine shaft 1 in the socket area 11 The clamping area of the shrink disc between the machine shaft 1 and the hollow shaft 7 must remain absolutely free of any grease Thus never apply NOCO Fluid directly to the socket 11 since the paste may get into the clamping area of the shrink disc when the input shaft is put on Ensure that the dimensions of the machine shaft correspond to SEW specifica tions See previous page 1 356508044 1 Machine shaft 7 Hollow shaft 11 Socket 60 Operating Instructions Industrial Gear Units X Series Assembly Installation 5 Gear unit with hollow shaft and shrink disc 2 Use the retaining screws 3 to attach the end plate 4 to the hollow shaft 7 see section 5 2 for tightening torques and screw the threaded rod 2 onto the machine shaft 1 356508428 1 Machine shaft 3 Retaining screws 7 Hollow shaft 2 Threaded rod 4 End plate 3 Tighten the machine shaft 1 with the nut 5 until the shoulders of the machine shaft and the hollow shaft 7 meet 310501387 1 Machine shaft 7 Hollow shaft 5 Nut 4 Loosen the nut 5 Screw the threaded rod 2 out 5 Ke Vp Og 310506251 2 Threaded rod 5 Nut Operating Instructions Industrial Gear Units X Series 61 5 Assembly Installation Gear unit with hollow shaft and shrink
90. t is preferable that you use screw fittings with composite material seals 5 18 2 Electrical connection Make the electrical connections for the pump and the temperature switch according to local regulations Ensure that the pump rotates in the correct direction when making the connection The temperature switch should be integrated into the circuit in such a manner that s The motor pump of the oil water cooler is switched on at the first switching point at 40 C 104 F oil temperature e Either a warning signal is activated or the main drive is switched off at the second switching point at 90 C 194 F oil temperature 5 18 3 Cooling media Special procedures are required when sea and brackish water are used Please contact SEW EURODRIVE Note that the service life the efficiency and the maintenance intervals of the heat exchanger depend to a great degree on the quality and contents of the cooling medium Permitted e Water water glycol cooling liquids HFC refrigerants cooling media e Cooling water temperature 20 C 68 F same volume flow of oil and cooling water Dirt The quantity of suspended solids ball shaped particle size lt 0 6 mm 0 02 in should be less than 10 mg l 0 0013 oz US gal Threadlike contaminants increase the risk of pressure loss Corrosion Limit values free chlorine lt 0 5 ppm chlorine ions lt 200 ppm sulfate lt 100 ppm ammonia lt 10 ppm free CO lt 10 ppm pH 7 10
91. tallation Notes on installing the gear unit Notes on installing the gear unit Strictly observe the safety notes in the individual sections The most important technical data is included on the nameplate Additional data relevant for operation is available in drawings order confirmations or any order specific documentation Install mount the gear unit only in the specified mounting position on a level vibration damping and torsionally rigid support structure Do not deform housing legs and mounting flanges against each other Work on the gear unit only when the machine is not in use Prevent the drive unit from starting up unintentionally for example by locking the keyswitch or removing the fuses from the power supply Place an information sign near the ON switch to warn that the gear unit is being worked on The plugs for checking and draining oil and the breather valves must be freely accessible Use plastic inserts 2 to 3 mm 0 08 to 0 1 in thick if there is a risk of electro chemical corrosion between the gear unit and the driven machine connection between different metals such as cast iron and high grade steel Also fit the plugs with plastic washers Ground the housing additionally use the grounding bolts on the motor Only authorized personnel may assemble gear head units with motors and adapters Please contact SEW EURODRIVE Do not weld anywhere on the drive Do not use the drive as a ground point for welding
92. tems asissseesireesesrreeceerreesrrrrresserrneees 29 Securing the gear unit a an 45 Shaft position ceeceeeeeeeeceeeceeeeeeeeeeeteeeeenteees 22 Shutting down gear units aeee 81 Split NOUSING 90 Starting up the gear unit at low ambient temperatures c ececeseeeeeeseeeeceaeeteeeedeenesenenenaee 80 Storage conditions 15 17 Surface protection systems eeeeeeeeeeeeeeeee 15 SWING Dase ieran ETNA 36 70 T Temperature sensor PT100 aseainena 43 76 Tightening torques sasssanoosesnninoeranaeseennnnereenna 44 Ee le 45 PORQUE ANIM eir a aT cuter 33 66 Transport conditions 15 Transportation ageet ee 11 U Unit designation 18 V Visual oil level check seseessiesererreeereerrssees 32 W Water cooling cartridge cee 40 71 89 Water cooling Cover cceeeeeeeeeees 39 71 89 Operating Instructions Industrial Gear Units X Series Address List 1619 Garin Germany Headquarters Bruchsal SEW EURODRIVE GmbH amp Co KG Tel 49 7251 75 0 Production Ernst Blickle StraRe 42 Fax 49 7251 75 1970 Sales D 76646 Bruchsal http www sew eurodrive de P O Box sew sew eurodrive de Postfach 3023 D 76642 Bruchsal Service Central SEW EURODRIVE GmbH amp Co KG Tel 49 7251 75 1710 Competence Center Gear units Ernst Blickle Stra e 1 Fax 49 7251 75 1711 Motors D 76676 Graben Neudorf sc mitte
93. tency section 7 5 e Fill regreasable sealing systems with grease see section 7 8 e Depending on the operating condi tions at least every 12 months e Check whether retaining screws are tightly secured e Check the condition of the oil water cooling system e Clean oil filter replace filter element if necessary e Atleast every 3 years depending on the operating conditions see figure on next page e Change mineral oil e Atleast every 5 years depending on the operating conditions see figure on next page e Change synthetic oil e Varies depending on external factors e Check the breather plug replace if needed section 7 7 Clean the external gear unit housing and fan e Check the alignment of the input and output shaft section 5 7 e Repair or renew the surface anticorrosion coating e Check built in coolers such as water cooling covers cartridges for deposits sections 7 10 7 11 Check oil heating at same time as oil change e Are all connection cables and terminals tightened securely and free from corrosion e Clean encrusted heating elements replace if needed section 7 12 Operating Instructions Industrial Gear Units X Series 83 7 Inspection and Maintenance Lubricant change intervals 7 3 Lubricant change intervals Change the oil more frequently when using special designs subject to more severe aggressive ambient conditions Mineral CLP lubricants and syn
94. that the operating instructions are available to persons responsible for the plant and its operation as well as to persons who work independently on the unit Also observe other technical documents delivery contracts or other agreements Proper use refers to the procedure specified in the operating instructions X series industrial gear units are gear units driven by motors for industrial and commer cial systems The units may only be run at the speeds and powers shown in the technical data or on the nameplate Implementing gear unit loads other than the permitted values or operating the gear units in areas of application other than industrial and commercial systems is only permitted after consultation with SEW EURODRIVE For the purpose of EC Machinery Directive 98 37 EC X series industrial gear units are components for installation in machinery and systems In the scope of the EC directive you must not take the machinery into operation in the proper fashion until you have established that the end product complies with Machinery Directive 98 37 EC 1 1 3 Qualified personnel Gear units represent a potential hazard for persons and material assets Consequently assembly installation startup and service work may only be performed by trained personnel who are aware of the potential hazards The personnel must be appropriately qualified for the task at hand and must be familiar with the e Mounting e Installation e Startup e Operation
95. thetic polyalphaolefin based PAO lubricants are used for lubrication The synthetic lubricant CLP HC according to DIN 51502 shown in the following illustration corresponds to the PAO oils 30000 h 25000 20000 15000 1 70 80 90 100 110 C 120 1 Operating hours 2 Sustained oil bath temperature Average value per oil type at 70 C 158 F In order to optimize the oil change intervals SEW EURODRIVE recommends that the gear unit oil be analyzed regularly see section 7 5 84 Operating Instructions Industrial Gear Units X Series Inspection and Maintenance Checking the oil level 7 4 Checking the oil level e Do not mix different synthetic lubricants and do not mix synthetic with mineral lubricants e The position of the oil level plug oil drain plug and breather valve depends on the mounting position Refer to the diagrams of the mounting positions 1 Work on the gear unit only when the machine is not in use 2 Secure the drive unit against unintentional power up Wait until the gear unit has cooled off Danger of burns 3 For gear units with oil level glass e Visually check that the oil level is correct centered between Min Max mark ings correct if necessary see following illustration e When filling for the first time the oil level must be checked once again after 15 minutes equalization of level between gear unit interior and oil level glass 4 For gear uni
96. to the gear unit foundation at the mounting hole positions that are provided for that purpose That the base frame is not deformed hazard of damage to gear unit and coupling That the base frame is not deformed through incorrect alignment of the gear unit output shaft to the machine shaft It is essential that The system frame is sufficiently dimensioned to absorb the torque of the torque arm The swing base is not deformed during installation hazard of damage to gear unit and coupling When protective devices for couplings or similar are installed on gear units equipped with a fan sufficient separation distance for the cooling air intake must be provided See the dimension drawing in the catalog or the order documents for the required distance Protect the fan guard from external damage Never operate the gear unit without the protective housing Make sure that the fan air intake vents are not blocked or covered Operating Instructions Industrial Gear Units X Series Assembly Installation 5 Water cooling cover 5 16 Water cooling cover Connect the water cooling cover to the available cooling circuit Refer to section 5 18 3 to determine the permitted cooling media The direction of flow does not matter Cooling water temperature max 15 C 59 F Volume flow minimum 4 I min 1 06 US gal min according to order documents The cooling water pressure may not exceed 6 bar 87 psi In case of freezi
97. top Alternative backstop position depending on size and gear ratio Consult SEW EURODRIVE when using a backstop Operating Instructions Industrial Gear Units X Series 362996619 25 Design of Basic Gear Units Housing 3 8 Housing The gear unit housings are made of sturdy gray cast iron with either monobloc or split housings with horizontal parting lines e Monobloc housing up to size 210 441828619 e Split housing size 220 and larger 441826955 3 9 Gearing and shafts The hardened and ground gearing is made from hardened steels The output shafts are made of tough quenched and tempered steel 26 Operating Instructions Industrial Gear Units X Series Design of Basic Gear Units Input and output shafts 3 10 Input and output shafts Two types of shafts are differentiated in the catalog e High speed shaft HSS normally an input shaft e Low speed shaft LSS normally an output shaft 324029963 3 10 1 Input shaft The input shaft is provided with a closed keyway according to DIN 6885 T1 and center bore according to DIN 332 The key that fits according to DIN 6885 T1 form A is included in the scope of delivery 324038667 3 10 2 Output shaft as a solid shaft with key The output shaft is provided with a closed keyway according to DIN 6885 T1 and center bore according to DIN 332 A key according to DIN 6885 T1 form B is included in the scope of de
98. ts with oil dipstick optional e Unscrew the oil dipstick and remove it e Clean the oil dipstick and re insert it by turning it hand tight into the gear unit up to the stop e Remove dipstick again and check oil level Correct if necessary centered between Min Max markings Oil level glass Oil dipstick Oil sight glass Q WI n 5 S 460483724 460483852 460483980 1 The oil level should be within this range Operating Instructions Industrial Gear Units X Series 86 7 5 7 6 7 6 1 Inspection and Maintenance Checking the oil consistency Checking the oil consistency 1 Work on the gear unit only when the machine is not in use 2 Secure the drive unit against unintentional power up Wait until the gear unit has cooled off Danger of burns 3 Remove some oil at the oil drain plug 4 Check the oil consistency e For more detailed information on checking the oil for water content and viscosity contact your lubricant manufacturer e If you can see that the oil is heavily contaminated change the oil even if this is outside of the specified oil change intervals Changing the oil Notes e When changing the oil always refill the gear unit with the grade of oil that was used before Mixing oils of different grades or manufacturer is not permitted Especially synthetic oils may not be mixed with mineral oils or other synthetic oils Flush the gear unit with the new oil
99. uarantee a long service life and functioning under all conditions using a relay in the power circuit instead of a direct connection through the temperature switch is recom mended The temperature switch is located in the gear unit s oil sump The exact position depends on the gear unit version and position of the shaft Operating Instructions Industrial Gear Units X Series Assembly Installation Required tools resources 5 Assembly Installation 5 1 Required tools resources Not included in the scope of delivery Set of wrenches Torque wrench Mounting device Compensation elements shims spacing rings if necessary Fasteners for drive and output elements Lubricant e g NOCO fluid from SEW EURODRIVE For hollow shaft gear units aids for assembly disassembly onto the machine shaft Securing components for the gear unit base 5 2 Tightening torques Tightening torque bolt nut Strength class 8 8 Bolt nut Nm in Ib M6 11 97 M8 25 220 M10 48 420 M12 86 760 M16 210 1860 M20 410 3630 M24 710 6280 M30 1450 12 830 M36 2500 22 130 M42 4000 35 400 M48 6000 53 100 M56 9600 84 970 The bolts must not be lubricated during assembly 44 Operating Instructions Industrial Gear Units X Series Assembly Installation 5 Securing the gear unit 5 3 Securing the gear unit The following table shows the thread sizes an
100. w shaft keyed Connection 52 Operating Instructions Industrial Gear Units X Series Contents 5 10 Gear unit with hollow shaft and shrink dec rnn 58 STi Ree ANIM NEE 66 5 12 Motor adapter icc ciiadind es etaa ee a aeaa a Kaer Dat a ede uae Aaa 67 5 13 Base plate ncn ae a nies ea ees 70 D SWING PASC ees geben een ee E ies een E 70 ehr ost N Dp eae ere EE 70 5 16 Water Cooling COVER nerie ee 71 5 17 Water Cooling Cartridge cece a 71 5 18 Oil water cooler with motor pump only circulation Coolmg 72 5 19 Ol MO e 73 5 20 Temperature sensor PT100 sssssseseseesrnnrrennenesserttntrrnrrnnsnenrreerr nenne 76 5 21 NTB temperature awitch nnn 77 ET EEN 78 6 1 Notes on startupi seri le cela nies a a a E de 78 DZ RUNFIN POMOd 22 a Ee 79 6 3 Gear units with backstop 79 6 4 Starting up the gear unit at low ambient femperatures 80 6 5 Shutting down gear units 0 eee cece scene eee eeeeeaeeeeeeeeaeeeeeeeaaeeeeeeeaas 81 7 Inspection and Maintenance ecceceeeeeeeeeeeeeeeeeeeeneeeeeeeeeseeeeeeeeeeeeanes 82 7 1 Notes regarding inspection and maimtenance reene 82 7 2 Inspection and maintenance periodS sesssssssseesetirrrnretnserestrerrrrr rrn 83 7 3 Lubricant change intervals cccccceceeseeeeeececeeceeeeeeeeeeeeseteeeseesiaeeees 84 TAs Checking the oil levei a aaa aaa aa aaa a Ae 85 7 5 Checking the oil Gonsten 86 T6 Changing the Olle ctw EE 86 7

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