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Operating Manual STRÖTER Gear drives

03.2013

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Contents

1. Information 1.1 General advice 1.2 Safety and labeling 1.3 Intended use 1.4 Safety advice 1.5 Pre-delivery 1.6 Transport 1.7 Disposal 1.8 Customer service 1.9 Further documentation 1.10 Technical changes 2. Model description and types of drives 2.1 Bevel gear drives 2.1 Mechanical variable gear drives 2.1 Bevel gear variable drives 2.1 Spur gear drives 3. Storing, preparation, installing 3.1 Storing the gear drive 3.2 Long term storage 3.3 Subsequent coating 3.4 Checking the gear drive 3.5 Checking the identification plate data 3.6 Checking the mounting design 3.7 Preparing the installation 3.8 Installing the gear drive 3.9 Assembling the hubs and gear shafts 3.11 Assembling gears with hollow shafts and keys (parallel key) 3.12 Assembling gears with shrink discs 3.13 Assembling covers 3.14 Assembly: Toothed steel - motor coupling K- gear drives 3.15 Assembly: Toothed plastic motor coupling K…gear drives 3.16 Coupling sizes and variations K…gear drives 3.17 Assembly: Toothed steel – motor coupling A… gear drives 4. Initial operation 4.1 Checking oil level 4.2 Controlling the gear drive 4.3 Checklist 5. Service and maintenance 5.1 Service and maintenance intervals 5.2 Service and maintenance work 5.3 Oil change 5.4 General overhaul 5.5 Operating faults 6. Design and mounting position 6.1 Bevel gear drives 6.2 Mechanical variable drives 6.3 Bevel gear variable drives 6.4 Spur gear drives 7. Lubricants 7.1 Information 7.2 Lubrication chart

8. Address contacts

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1. Information 1.1 General advice The operating manual is an integral part of the product and contains important advice for operation and service. The operating manual must remain in a readable state and kept in an accessible place. Read this operating manual carefully before working on or putting the gear drive into operation. The instructions of this operating manual are to be strictly followed. The STRÖTER Antriebstechnik GmbH is not responsible for any resulting personal injury, property and financial losses due to failure to observe the operating instructions, user errors or improper use. General consumable parts such as shaft seals are not covered under the warranty. Additionally the operating manual of the drive gears’ motor is to be followed. In case of not understanding any part of this operating manual, please contact STRÖTER Antriebstechnik GmbH (Service Tel. +49 (0) 211/95600-99). 1.2 Safety and labelling

Please observe the following safety and labeling information!

Danger ! (Danger of death or injury)

Warning ! (can cause damage)

Advice ! (useful Information)

1.3 Intended use These gear drives are used to generate rotational movement and are intended for industrial applications. The gear drive is considered to be „partly completed machinery“, and therefore not subject to the EC Directive for Machine 2006/42/EC. Commissioning of the unit is not permitted until the end product conforms to provisions of the EC machinery Directive 2006/42/EC.

Gefahr! Use in hazardous areas is prohibited, unless specifically provided for this purpose. The specifications on the name plate must be followed. The content of the documentation must be observed. Appropriate safety measures are to be taken in the event of failure of the transmission or motor, which could cause personal injury.

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1.4 Safety advice These safety instructions are to be kept safe

Warning It is assumed that the basic planning of the gear drive as well as transportation, installation, commissioning, maintenance and repairs will be undertaken by qualified personnel. On carrying work out on the gear drive it must be assured that no voltage is present and that it cannot be switched back on. It is recommended that repairs are carried out on STRÖTER gear drives by STRÖTER personnel. Warning Changes in comparison to normal operation (higher current, temperature, vibrations noises etc. or activation of monitoring devices) assume that the gear drives function is impaired. To reduce failures which could result in personal injury or damage, the responsible service person must be Informed immediately. If in doubt, the equipment should be shut down immediately!

Electrical connection - Motor connection shall be undertaken according to the wiring schematic - Ensure that the local voltage and frequency corresponds to that on the nameplate - Ensure a secure ground connection is made - If necessary correct the rotational direction by swapping 2 phases. - Unused cable connection openings and the connection box are to be sealed against dust and water - Overload and phase failure to be prevented by implementing a circuit protector - Adjusting the circuit breaker to the rated current - Before switching on fit a drive element or secure the key

Commissioning - Remove the cap before use (overpressure!) and install the breather valve. For further information see Chap. 7 Lubricants 7.1 Advice - Normal first filling: see lubrication chart - Air cooled motors are designed for ambient temperatures from - 20°C to +40°C as well as altitudes of up to

1000 m above sea level

Take into account all safety instructions, also those in the individual chapters of this operating manual. Also all national, international and other regulations for safety precaution should be made aware of.

Serious personal injury and damage can occur due to unprofessional installation, not intended use, wrong operation, disregard for safety notices, unpermitted removal of housing parts or safety covers and structural changes to the gear drive.

Rotating parts can lead to injuries. It has to be checked that no parts or tools are found on or around the gear drive before putting into operation.

Loose or overloaded screw connections can cause damage. Checking all screw connections is to be carried out using a calibrated torque wrench. Never use gear drives or motors as steps, climbing aids or fixing points.

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1.5 Pre-delivery All STRÖTER Gear drives and order details are checked at final control before dispatch. The gear drives are coated with grey paint RAL 7031 and filled with oil, so long as not otherwise stated. The operating guide, the breather valves and the coupling (only those without motors) are delivered loose. Ströter gear drives may not be opened during the guarantee period without our express permission, otherwise all claims will be invalidated.

1.6 Transport Please check the delivery immediately after receiving for transport damage and that it is complete. If damage is found inform the courier immediately and make a damage report. Where necessary, use sufficiently suitable handling methods. Remove any transport fixings before commissioning. 1.7 Disposal Dispose of the gear drives in accordance with local regulations for example as

Gear parts: Material: Gears, shafts, roller bearings, keys, securing rings.....

Steel

Gear housings, housing parts, .... Cast iron

Light metal housings, light metal housing parts,.... Aluminium

Worm gears, bushings,...

Bronze

Shaft seals, stoppers, rubber elements, .... Elastomer with steel

Couplings Plastic or steel

Gearbox oil additives Mineral oil

Gearbox oil synthetic (Label: CLP PAO) Synthetic oil CLP PAO (Poly--Olefin)

Collect used oil and dispose of according to local regulations. 1.8 Customer service If you should require our customer service please give the following details: - Name plate information - Gearbox number (if not available the number is stamped into the housing) - Type and result of the failure - Time and conditions of the failure - Suspected cause - Delivery date - Operating time - Installation date

1.9 Further documentation Further information is readily available: - in all STRÖTER Antriebstechnik GmbH gear drive catalogues. - Operating and maintenance manuals for the motors - Operating manuals for built in options 1.10 Technical changes STRÖTER Antriebstechnik GmbH reserves the right to make technical changes and improvements.

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2. Model descriptions and types of drives

2.1 Bevel gear drives

Model description:

K062 ; K152 ; K252 ; K452 ; K652 (3-step)

Variations:

/MA ; /MB ; /MAB Foot mounting /MAF ; /MBF Flange mounting /MH Hollow shaft version /MHF Hollow shaft flange version /MHS Shrink disc version /WA ; /WB ; /WAB with free input shaft – Foot mounting /WAF ; /WBF with free input shaft – Flange mounting /WH with free input shaft – Hollow shaft version /WHF with free input shaft – Hollow shaft version /WHS with free input shaft – Shrink disc version /IEC Standard motor version

Model description:

KS063 ; KS080 ; KS112 (2-step)

/MA ; /MB ; /MAB Foot mounting /MAF ; /MBF Flange mounting /MH Hollow shaft version /MHF Hollow shaft flange version /MHS Shrink disc version /WA ; /WB ; /WAB with free input shaft – Foot mounting /WAF ; /WBF with free input shaft – Flange mounting /WH with free input shaft – Hollow shaft version /WHF with free input shaft – Hollow shaft version /WHS with free input shaft – Shrink disc version /IEC Standard motor version

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2.2 mechanical variable gear drive

Model description:

A012 ; A025 ; A05 ; A1 ; A2 (1-step)

A012/I ; A025/I ; A05/I ; A1/I (2-step)

Variations:

AM …/… with Motor AW …/… free input shaft A(M)…/… for IEC – standard motor mounting

A.. … F Flange mount

(1,5) Model with more powerful motor

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2.3 Bevel gear variable speed gear drive

Model description:

A 012 ; A025 ; A05 ; A1

Variations:

AM …/… with motor AW …/… free input shaft A(M)…/… for IEC – standard motor mount

A…./MA ; /MB ; /MAB Foot mounting A…./MAF ; /MBF Flange mounting …./MH Hollow shaft version A…./MHF Hollow shaft mount flange version A…./MHS Shrink disc version

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2.4 Spur gear drive

Model description:

G 00 , G 11 ; G 22 ; G 33 ; G 44 ; G 55 ; G 66 (2-step)

Model description:

G 220 ; G 330 ; G 440 (3-step)

Model description:

G 26-00 ; G 33-00 ; G 44-11 G 44-22 ; G 55-22 ; G 55-26 G 55-33 ; G 66-22 ; G 66-26 G 66-33 (4-step)

Variations:

G … with Motor DSG free input shaft G… for IEC – Standard motor mounting

G … Foot mounting G … F Flange mounting

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3. Storing, preparation, installing

3.1 Storing the gear drives During storage the following should be observed: - The gear drive must be stored in its mounting position (see name plate). - Lightly oil exposed housing areas and shafts. - The gear drive must be stored in a dry area. - The store temperature may not be allowed to go below -5°C and over 40°C. - The relative humidity may not exceed 60%. - The gear drive may not be left out in exposed sunlight or UV light. - The storage air may not contain corrosive or aggressive gases (ozone, cleaning fluids, acids, alkalis, salts,

radio activity, etc.). - During storage the gear drive may not be exposed to constant vibration or shock.

3.2 Long term storage

Hint! During long storage or down times longer than 9 months we recommend using the long term Storage option. By using the long term storage option it is possible using the above steps to achieve a storage time of approx. 2 years. This storage time is strongly influenced by local conditions and can only be used as a guide. Conditions for gear drives and storage areas for long term storage before commissioning:

- The gear drive must be stored in its’ mounting position (see name plate). - Re-paint transport damage to the outer coating. Check that adequate rust protection is applied to flange areas and shaft ends. - The gear drive with is completely filled with lubricant.

- The gearbox must be sealed (do not install breather valve). - Store in a dry area. - Protect the gear drive from insect feed in tropical regions. - The storage temperature may not be allowed to go below -5°C and over 40°C. - The relative humidity may not exceed 60%

- The gear drive may not be left out in exposed sunlight or UV light. - The storage air may not contain corrosive or aggressive gases (ozone, cleaning fluids, acids, alkalis, salts,

radio activity, etc.). - During storage the gear drive may not be exposed to constant vibration or shock.

Procedures during storage or down time - If the relative humidity remains <50% then the gear drive can be stored for up to 3 years. Procedures before commissioning

- The lubricant should be replaced if the storage or down time exceeds 2 years, or the temperature deviates greatly from the norm. - The oil level has to be filled according to the mounting position before commissioning.

3.3 Subsequent painting

Warning When re-coating the gear drive it is important that the paint does not come into contact with shaft seals, Breather valves, hoses, name plates, labels and motor coupling parts, otherwise the parts can become damaged or unreadable.

3.4 Checking the gear drive The gear drive can only be installed if: - No damage can be seen which may have occurred during storage or transport. Shaft seals and stoppers especially should be checked for damage. - No leaks are present. - No corrosion or signs of damp storage are present. - The packing material and transport fixings are completely removed.

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3.5 Checking the name plate identification It is recommended to check and confirm that the gear drive model and its technical information is crosschecked with the information from the equipment. It is important that the electric motor has a name plate.

Explanation of the name plate: 1 Input speed (min-1) 2 Drive power 3 Mount type / Mounting position 4 Output speed (Mech. Variable speed gear drives output speed range) 5 Output torque 6 Type designation 7 Type of oil 8 Gear number (Year Month Number) 3.6 Checking the mount type The gear drive can only be operated in the given mounting position. The permissible mounting position is stated on the name plate. It should be checked that the version and mounting position on the name plate correspond to the actual Operational position and has not been changed. 3.7 Preparation for the installation To avoid damage the rotational direction of the gear drive must be tested and eventually changed before Installing. It must be ensured that no aggressive chemicals or corrosive elements are in the installation area that can attack the metals, lubricants and seals. If in doubt please contact STRÖTER Antriebstechnik GmbH for further eventual safety measures. By some gearboxes it is necessary to replace the filler cap with a breather valve. The location of the cap is indicated by a label on the gear box.

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3.8 Installing the drive gear The safety instructions in chapter 1.1 are to be observed. When installing the STRÖER gear drive it should be observed that the supplied oil fittings such as breather valve, control and drain are freely accessible The gear drive must be installed and mounted in the supplied condition according to the name plate, only then is a trouble free lubrication and venting ensured. The base or flange on which the gear drive is fixed must be vibration free, rigid and level. The level of the fixing surface must correspond to the tolerance class DIN ISO 2768-2. Eventual soiling of the fixing surface of the gear drive base or flange must be thoroughly removed. The gear drive has to align properly to the driven machine shaft to avoid unnecessary force or tension in the gear drive. NO welding work is permitted on the gear drive. The gear box may not be used as an earthling point for welding work otherwise bearings and gears will become damaged. The gear drive is to be installed in the correct mounting position. Changing the mounting position requires adapting the bleed valve and oil level.. All mounting points from the gear drives’ feet or flange are to be used. The minimal quality of the fixing screws should be 8.8. The screws are to be tightened with appropriate torque. It must be ensured that gear drives with foot and flange fixings use tension free bolts.

Danger! So that the gear drive does not become too warm and lead to personal injury the following should be

observed during the installation: - Gear boxes and motors can have hot surfaces during or shortly after operation Warning danger of burns! A safety cover should be provided. - Furthermore an adequate amount of ventilation for the cooling fan is to be observed and the air flow around the

gear drive may not be obstructed.

3.9 Assembling the hubs and gear drive shafts

The gear drive and motor may only be fitted onto a vibration free and rigid base in the given mounting position. Do not tighten housing feet and flange against each other. Please observe permissible horizontal and axial Force! Flange gear drives can be directly fixed to the driven machine. To equalize small assembly deviations it is recommended to use an elastic coupling. Screws with quality 8.8

are to be used to fix the gear drive motors. - Use tapped holes (DIN 332) to fasten connecting elements on to the shafts - Avoid beating the shafts (bearing damage!) - Before switching on fix drive elements and secure keyways.

Preliminary work Completely remove corrosion inhibitor, soiling or similar from drive shafts and flange areas (use commercial Cleaning fluids).

Do not allow cleaning fluids into the sealing lips of the shaft seals. Component damage!

Assembling drive elements The diagram depicts an example of a puller device for mounting couplings or hubs onto gear drives or motor shafts. It may not be necessary to use an axial Bearing in the process.

Shaft end Axial bearing

Coupling hub

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The diagram depicts the correct mounting assembly of a gear or chain sprocket to reduce un-allowed transverse forces. • Assemble drive elements only with a puller device. Use the central tapped bore on the shaft end to

attach. • Attached drive elements should be balanced and not be allowed to cause radial or axial force.

• On no account should pulley wheels, couplings, gears etc. be fitted onto the shaft end with hammer blows (damage to bearings, housing and shaft). • Observe the correct tension for belts and chains (Manufacturer guide).

Hint: The assembly is made easier with the use of a lubricant or warming the drive element

shortly beforehand (to a max. of 80-100 °C). Drive elements such as pulleys, sprockets and couplings should be provided

with a safety cover. 3.10 Coupling assembly

When assembling a coupling the following manufacturer’s instructions are to be taken into consideration: a) Maximum and minimum gap b) Axial misalignment c) Angle misalignment

Drive elements such as pulleys, sprockets and couplings should be provided with a safety cover.

Hub Hub

incorrect correct

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3.11 Assembling gear drives with hollow shafts and keyways Hollow shaft gear drives can be directly connected to the shaft of the machine to be driven. Establishing the correct axis is achieved by the use of an end disc and screw. It should be observed that the fixing surface is at the correct angle to the axle of the machine to be driven. Otherwise the gear drive bearings can become over loaded and fail. The torque and corresponding reaction torque can be intercepted with a STRÖTER torque arm. To avoid bending stresses the torque arm is always arranged on the machine side (Use rubber buffers with the torque arm). Preliminary work Completely remove corrosion inhibitor, soiling or similar from the hollow shaft (use commercial Cleaning fluids).

Do not allow cleaning fluids into the seal lips of the shaft seals. Component damage!

Check the hollow and machine shafts for burring or edge damage. Re work the machine shaft with a suitable

tool and clean again. Hint : To reduce fretting on the contact surfaces apply a suitable lubricant, i.e. Paste ZLE 1, Manufacturer Molyduval.

Fitting Improper installation can cause damage to the bearings, gears, shafts and Housing. Mounting the gear drive onto the shaft should be carried out with the appropriate pulling device. Pull on the drive by using a nut and threaded shaft or hexagonal screw. Support using the hollow shaft.

To do this the hollow shaft and machine shaft must be correctly aligned so that the possibility of damage is eliminated. With flange drives the hollow shaft axial and radial may not be put under tension, otherwise the bearings will become overloaded and fail.

Threaded spindle, nut, washer and securing ring are not part of the delivery Secure Hollow shaft axial to the machine shaft (i.e. securing ring, washer, hexagonal screw).

Hollow shaft Machine shaft disc

Key securing ring washers

nut

Threaded spindle

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With gear types..

KS 063 ; KS 080 ; K 062 ; K 152 ; K 252 ; K 452 ; K 652 ; AM 025/M ; AM 05/M ; AM 1/M It is possible to protect the hollow shaft against damp with the use of an O-ring (4). Fixing elements can be ordered separately.

Typ / Type

Maße / Dimensions ØDH7 A B B1 Ød K L max. L min. S Pos.5

AM025/M 25 98 5 20 40 115 80 75 M12 M8 x 60

KS 063 25 96 5 14 45 110 80 75

M12 M8 x 60

K 062 30 M16 M10 x 60

AM05/M und

25 107 5 21 45 124 89 83

M12 M8 x 60

K 152 30 M16 M10 x 60

KS 080 35

115 5 21 45 130 96 93 M16 M12 x 70

40 M20 M16 x 70

AM1/M und

35 129 5 21 55 144 110 100

M16 M12 x 70

K 252 40 M20 M16 x 70

K 452 40

139 5 21 65 154 120 105 M20 M16 x 70 45

K 652 45

186 5 24 75 206 160 135 M20 M16 x 100 50

1 Hollow shaft 4 O-Ring 7 Set collar DIN 705* 2 Threaded ring 5 Cylindrical screw DIN 6912 8 Hexagonal screw DIN 933 3 Securing ring 6 Spacer disc * not Standard

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Dismantling

An adequate and suitable form of support is required to fix the gear drive before Dismantling and removing the machine shaft. The traction

- remove the hollow shafts axial fixing. - In the event of rust on the surface area it is advisable to use a rust remover to aid removing the gear drive. - Remove from the machine shaft by using a washer and threaded rod with pin. Allow the rust remover to take effect before removing the gear drive using a suitable pulling device.

It is important to ensure that tilting is avoided during removal. Washer, Threaded piece with pin, securing ring and threaded rod are not part of the delivery.

Washer

2x Nut

Threaded rod

Threaded piece

Pin

Securing ring

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3.12 Assembling hollow shafts with a shrink disc Assembly – de-assembly and maintenance hints

Improper de-assembly of the shrink disc can cause injury

Assembly steps: 1. Remove the transport safety between the flange, if available. 2. Tighten the tension screws (lightly by hand) until the play

between the flange and inner ring is eliminated. The inner ring has to be able to turn easily. 3. Grease the bore of the inner ring to ease assembly of the

Shrink disc to the gears hollow shaft. 4. Insert the gear drives hollow shaft into the machine shaft.

Do not tighten tension screws without fully inserting the shaft! The machine shaft and hollow shaft must be free of grease in the shrink disc mounting area.

The machine shaft should be greased in the area of the bronze bushing before inserting. Avoid grease on the bronze bushing getting onto the shrink disc mounting position.

5. By gently tightening the tension screws the tension flange positions itself automatically. 6. Tighten the tension screws one after the other in an anti-clockwise direction several times. Do not cross over

– 1/4 to 1/2 screw turns per revolution. Tighten the tension screws with a torque wrench to the torque shown in the dimensions table.

7. There must be an equal gap between the tension flanges. If this is not the case the gear must be dismantled and the shrink disc coupling checked for exactness.

8. Mark the hollow shaft and machine shaft, so that any possible slippage through load can be recognized.

De-assembly steps: 1. Untighten the tension screws one after the other several times, 1/4 turn per revolution. Do not remove the

tension screws from the thread. Risk of accident!! 2. Loosen the tension flange from the cones of the inner ring. 3. Remove the gear drive from the machine solid shaft.

Maintenance of the shrink disc: An installed shrink disc is maintenance free. If the shrink disc was in operation for a long period and dismantled, it should be taken apart and cleaned before re-using. After cleaning lubricate the cone surface of the tension flange with Molykote G-Rapid Plus or a similar grease. Grease the screws and threads with normal grease or Molykote.

Safety advice - Installation and commissioning may only be under taken by trained personnel. Repairs may only be carried out

by the manufacturer or authorized dealers. - If a malfunction is suspected, the product or the machine in which it is installed must be taken out of operation

immediately and STRÖTER Antriebstechnik GmbH or the dealer informed. - The operating manual is valid for the safety component canal tension element. - All aspects of this operating manual are to be followed carefully. - Not following this can lead to a failure of the tension element. - Risk of death because of un-controlled operating conditions of the machine or equipment is possible.

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3.13 Installing covers Danger! Shrink discs and free turning shafts require contact protection to reduce injuries. A cover plate can be used as contact protection. If the cover protection is not adequate for the required safety class then the machine manufacturer has to guarantee this by installing special attachments. All fixing screws are to be tightened by applying the necessary torque.

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3.14 Assembly: toothed Steel – Motor coupling K… Gear drive

Types : KS063 ; KS080 ; KS112

K062 ; K152 ; K252 ; K452 ; K652

O=open motor shaft - keyway

Cleaning the motor shaft.

Warning: Coupling types and variations (see page 20 and 21) Observe key height, remove if necessary.

Heat the coupling to a maximum of 80°C (Steel) Assembling without heating leads to bearing damage in the motor

Assemble the coupling only with protective gloves (danger of injury)

Slide the coupling onto the motor shaft to the end of the collar on motor shaft.

Assemble the motor to the housing.

A suitable liquid grease is included in the delivery and is loose packed. Warning : Do not completely fill the drive shaft with liquid grease (see diagram)

Warning : The key in the coupling is integrated with coupling ST-N31-19 (Head circle diameter 24.8mm) and motor shaft Ø19mm, therefore the keyway must be open at the shaft.

* The intermediate flange is 13,5 mm wide and the couplings 12,5mm wide with K062 intermediate flange and coupling ST-N32-___ ( Head circle diameter 37,7 mm).

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3.15 Assembly: toothed plastic – motor coupling K… Gears Type : K062 ; K152 ; K252

Clean the motor shaft.

Warning: Coupling types and variations (see page 20 & 21) check key height, eventually remove the key.

Heat the coupling to a maximum of 60°C (plastic) Assembling the coupling without heating can lead to bearing damage in the motor.

Handle the coupling with gloves (Risk of injury)

Slide the coupling fully onto the motor shaft to the end collar of the motor shaft.

Assemble the motor to the housing. 3.16 Coupling size and variations K… Gears

Warning : The key in the coupling is integrated with coupling ST-N31-19 (Head circle diameter 24.8mm) and motor shaft Ø19mm, therefore the keyway must be open at the shaft.

* The intermediate flange is 13,5 mm wide and the couplings 12,5mm wide with K062 intermediate flange and coupling ST-N32-___ ( Head circle diameter 37,7 mm).

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X = Without altering the key O = Open motor shaft -keyway F = Flat-key (Check keyway of the coupling ) A = Remove key Z = With motor intermediate ring D = Coupling and spacer ring Special coupling (additional price)

Type

Ratio i = … : 1

Motor shaft Coupling

max. revolution [ min-1 ] 3000 3000 1500 1500

Ø max. - length ST-N31

d = 24,8

ST-N32

d = 37,7

ST-N33

d = 51,7

ST-N34

d = 59,7 K 062 180,0 – 36,2 9 – 14 30 X

15 – 18 40 F

19 40 O

27,8 – 7,0 9 – 14 32 X

15 – 18 40 F

19 40 O

19 40 X

24 50 Z ; F ; A

K 152 178,8 – 144,0 9 – 14 30 X

118,9 – 44,8 9 – 14 30 X X

15 – 18 40 F X

19 40 O X

24 50 F ; Z

38,0 – 8,8 14 – 19 40 X

24 50 F ; Z

28 60 Z ; F ; A

K 252 174,3 – 144,2 9 – 14 30 X

15 – 18 30 F

19 30 O

117,4 – 6,9 9 – 19 40 X

24 50 F

28 60 Z ; F

K 452 179,3 – 90,1 and 45,22

14 – 19 40 X

24 50 F

28 60 Z ; F

30 – 35 50 F

30 – 35 60 F ; Z

71,0 – 28,64 not 45,22

14 – 19 40 X

24 50 F

28 60 F

30 – 35 60 F

22,5 – 8,2 24 – 28 60 X

30 – 35 60 F

38 80 Z ; F ; A

K 652 171,3 – 138,1

14 – 19 40 X

24 50 Z ; F

112,2 – 46,2 14 – 19 40 X

24 50 F

28 60 Z ; F

30 – 35 60 F

38 80 Z ; F ; A

35,4 – 13,9 24 – 28 60 X

30 – 35 60 F

38 80 Z ; F ; A

KS 063 36,6 – 3,7 11 – 19 40 X

24 50 Z ; F ; A ; D

28 33 Z ; F ; A ; D

KS 080 39,0 – 3,8 14 – 19 40 X

24 – 28 50 F

38 80 Z ; F ; A

KS 112 39,0 – 5,0 24 – 28 60 X ; Z

38 80 Z ; A

42 110 Z ; F ; A ; D

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3.17 Assembly: toothed Steel – Motor coupling A… Gears

Typen : AM 012 /…. - AM 1 / ….. From gear nr. 100.000 Seal the contact areas of mechanical variable speed gear drives with a suitable sealant. Motor version always oil tight (with Radial-shaft seal)

Clean the motor shaft.

Warning: Check key height (AM 1 Motor shaft Ø24)

Heat the coupling to a maximum of 80°C (Steel) Assembling the coupling without heating can lead to bearing damage in the motor. Handle the coupling with gloves on (Risk of injury)

Slide the coupling fully onto the motor shaft to the end collar of the motor shaft.

Assemble the motor to the housing.

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4. Initial operation

4.1 Check oil level Control the oil level in the show glass before putting into operation (mechanical variable speed gear drives). The mounting position must correspond to that on the name plate. The oil level should reach the middle of the sight glass when the gear drive is stationary. With double gear boxes both the gear boxes oil levels should be checked. Gear boxes without show glasses do not require checking. Gear boxes which were not filled in the factory should be filled before checking the oil level. In case the oil level is not correct, fill or empty according to the oil type on the name plate.

4.2 Checking the gear drive The gear drive is to be checked under full load for: - unusual noises such as grinding, knocking or scraping -unusual vibrations or rocking - Steam or smoke After the test run the gear drive is to be checked for:

- leaks - slippage with shrink discs. Check the marking as shown in chapter 3.9 -Point 8 for any deviation. The gear drive must be switched off and contact made with STRÖTER Antriebstechnik GmbH, if any of the above control points are shown as conspicuous.

4.3 Check list

Subject for testing

(checked)

Is transport or damage recognizable?

Does the information on the name plate correspond to the application?

Does the mounting position on the name plate correspond to that of the gear mounting position?

Is the breather valve (if necessary) screwed in?

Are the exterior gear shaft loads permissible?

Is the oil level checked according to the mounting position?

Has the gear drive been checked by a test run?

Has the shrink disc been checked for slippage?

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5. Service and maintenance 5.1 Service and maintenance intervals Service and maintenance intervals and maintenance information

Shorten the lubrication interval in extreme conditions (high humidity, aggressive environment or high temperature swings)

5.2 Service and maintenance work Maintenance work may only be carried out by trained personnel. Assembly and maintenance work may only be carried out when the gear drive is stationary. The gear drive must be free of voltage and secured against accidental switching on. Visual control The gear drive is to be checked for leaks. Additionally check the gear drive externally for damage, such as split hoses, hose connections and rubber buffers. If leaks from oil or coolant, splits or damage is detected, it must be repaired. Please contact STRÖTER Antriebstechnik GmbH.

Shaft sealing rings are rubbing seals and have sealing lips made from an elastomer material. These sealing lips are lubricated with a special grease at the factory. This reduces the wear due to their function and ensures a long service life. An oil film in the region of the rubbing sealing lip is therefore normal and is not due to leakage.

Check running noises If unusual running noises or vibrations occur from the gear drive, it could mean or lead to damage. The gear drive should be taken out of service and generally overhauled. Check the oil level The mounting positions are represented in chapter 6.1 and the corresponding oil level shown. Gear drives with double gear boxes require both gear boxes oil levels to be checked. The breather valve must be in the position as shown in chapter 6.1. Gear drives without oil level screws do not require the oil level to be checked.

Gear drive types that do not require oil filling from the factory should be filled with oil before checking. (see „Oil changing“)

Service interval Lubrication after : General overhaul

Spur gear drives

Typ: G.. ; DSG..

Bevel gear drives

Typ: K.. ;

At least every 6 months

- visual control

- check for running noises

- check oil level

10.000 operating hours / min. every 2 years

with Mineral oil filling CLP

20.000 operating hours / min.every 4 years

with Synthetic oil filling CLP PAO

At least every 10 years

Mechanical variable speed gear drives and bevel gear variable gear drives

Typ A…

At least every 3 months

- visual control

- check for running noises

- check oil level

2.000 operating hours / min. every year

With mineral oil filling CLP

4.000 operating hours / min. every 2 years with Synthetic oil filling CLP PAO

5.000 operating hours / min. every 3 years with traction fluid Variotrac 68

At least every 5 years

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5.3 Oil changing In the diagrams in chapter 6.1 the oil drain screw, the oil level screw and the breather valve screw if necessary are shown corresponding to the mounting position. 1. Place a drip tray under the oil drain screw.. 2. Completely unscrew the oil drain screw

Warning danger of hot oil! 3. Allow the oil to drain from the gear drive. 4. If the thread from the drain screw is damaged, replace with a new one. Always use a new seal. 5. Fit the sealing ring. Tighten the drain screw with the corresponding amount of torque! 6. Pour in the correct amount (see the oil quantity chart) and same type of oil through the filler bore The oil level for mechanical variable speed gear drives to be checked when stationary. The sight glass

should be filled with oil to the middle by the correct mounting position of the gear drive. Check the oil level again after approx. 1/2 hour running.

5.4 General overhaul

The gear drive is to be fully dismantled. The following work is to be carried out - all gear parts are to be cleaned - all gear parts are to be inspected for damage and wear - all damaged or worn parts are to be replaced - all roller bearings are to be replaced - all seals, radial shaft seals and rings are to be replaced - Plastic and Elastomer parts are to be replaced The general overhaul must be carried out in a suitable workshop using suitable equipment by trained personnel. We recommend that the general overhaul is carried out by STRÖTER Antriebstechnik GmbH.

5.5 Operating faults

Gear drive fault

Gear drive fault Possible reason

Unusual noises, rocking Not enough oil, Bearing damage, Gear tooth damage

Consult Ströter Antriebstechnik GmbH

Oil escaping from the gear box or motor

Seal defect Consult Ströter Antriebstechnik GmbH

Oil escaping from the breather valve

Wrong oil level, wrong or dirty oil, poor operating condition

Change oil

Gear drive is too warm Poor installation conditions, gear drive damage


Schlag beim Einschalten, Vibrationen

Motor coupling defective, gear fixing loose

Consult Ströter Antriebstechnik GmbH, Tighten motor and Gear fixings

Drive shaft does not turn, although the motor turns

Break in the gear, motor coupling defective, shrink disc slipping


Warning: The drive is to be turned off in the event of any failure!

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6. Design / Mounting position 6.1 Bevel gear drive

The mounting position is determined by the underside laying gear drive side A - F

Oil amount ( l ) Typ D (B3) A (B6) B (B7) C (B8) E (V5) F (V6)

KS 063 0,5 0,5 0,5 0,5 0,8 0,6

KS 080* 1,2 1,2 1,2 1,2 1,4 1,3

KS 112 3,1 3,1 3,1 3,1 2,6 3,1

K 062 0,7 0,8 0,8 0,8 0,9 0,8

K 152 1,5 1,7 1,5 1,0 1,7 1,5

K 252 2,2 2,4 1,7 2,0 2,6 2,2

K 452 3,5 3,0 3,0 3,2 4,0 3,0

K 652 7,0 5,0 5,0 6,0 9,0 5,5

* Motor size 132 (Motor shaft 38 mm) Oil level on request

shown : Connection box side A

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6.2 mechanical variable speed gear drive

Foot mounting Flange mounting

* maximum motor / drive revolutions in this design 1500 min-1

E : Breather

Oil amount [ l ] Type B 3 B 5 B 6 B 7 B 8 V 1 V 3 V 5 V 6

AM 012* 0,25 0,25 0,35 0,35 0,4 0,5 0,5 0,5 0,5

AM 012/I* 0,4 0,4 0,4 0,4 0,45 0,68 0,75 0,68 0,75

AM 025* 0,9 0,9 1,0 1,0 0,8 1,2 1,2 1,2 1,2

AM 025/I* 1,1 1,1 1,2 1,2 0,9 1,8 1,8 1,8 1,8

AM 05* 1,2 1,2 1,1 1,1 1,0 2,2 2,1 2,2 2,1

AM 05/I* 1,8 1,8 1,5 1,5 1,2 2,9 2,7 2,9 2,7

AM 1* 1,8 1,8 1,8 1,8 1,2 3,3 2,8 3,3 2,8

AM 1/I* 2,5 2,5 2,5 2,5 1,7 4,5 4,2 4,5 4,2

AM 2* 1,5 1,5 1,1 1,1 1,0 3,0 2,75 3,0 2,75

*Control oil level when stationary. When the gear drive is in the correct mounting position, the oil level has to be at the middle of the sight glass.

shown : Hand wheel side A

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6.3 Bevel gear variable speed drive Fußausführung Foot mounting

Flanschausführung gezeichnet : Seite A Flange mounting showing : side A

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Determining the version of STRÖTER – Variable speed gear drives AM012 to AM 1

With built on bevel gear box K062/M_ to K652/M_

a) Mounting position A – F

b) Position of regulating gearbox to bevel gearbox 1 – 4

obere Reihe gezeichnet : Handradseite A ; Abtriebsseite A top row showing : hand wheel A ; output side A

untere Reihe gezeichnet : Handradseite B ; Abtriebsseite A bottom row showing : hand wheel B ; output side A

Beispiele / Example :

Oil amount [ l ]

Type B 3 B 5 B 6 B 7 B 8 V 1 V 3 V 5 V 6

AM 025/K...* 1,2 1,2 1,3 1,3 1,1 1,9 1,6 1,9 1,6

AM 05/K...* 1,85 1,85 1,7 1,7 1,65 3,0 2,6 3,0 2,6

AM 1/K...* 2,5 2,5 2,5 2,5 2,25 5,0 4,7 5,0 4,7

* Control oil level when stationary, When the gear drive is in the correct mounting position, the oil level has to be at the middle of the sight glass.

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6.4 Spur gear drive

Design The gearbox / motors are available in different designs. The breather and drain bores positions are dependent on the mounting position.

The breather valve has to be installed at the correct position before operating the gear drive. This position is shown in the table below and is marked with a label on delivery.

Foot mounting Flange mounting

B3

B5

B6

B5/6

B7

B5/7

B8

B5/8

V5

V1

V6

V3

Breather - screw Oil drain - screw

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Oil amount [ l ] Type B 3 B 5 B 6 B 7 B 8 V 1 V 3 V 5 V 6

(DS) G 00 0,12 0,1 0,1 0,1 0,1 0,15 0,23 0,25 0,25

(DS) G 11 0,3 0,2 0,3 0,3 0,3 0,35 0,3 0,5 0,4

(DS) G 22 0,5 0,3 0,5 0,5 0,5 0,65 0,65 1,1 0,8

(DS) G 26 0,8 0,5 0,8 0,8 0,8 1,25 1,1 1,7 1,4

(DS) G 33 1,3 0,9 1,3 1,3 1,3 2,0 2,5 3,0 2,5

(DS) G 44 3,6 3,6 3,6 3,6 2,0 4,4 4,0 7,5 4,0

(DS) G 55 4,7 4,7 4,7 4,7 3,0 7,0 6,0 10,5 6,0

(DS) G 66 9,0 9,0 9,0 9,0 4,0 12,0 8,5 18,0 8,5

G 220 0,8 0,6 0,5 0,5 0,5 1,0 1,1 1,45 1,1

G 260 1,3 1,0 0,85 0,85 1,0 1,85 1,85 2,4 1,85

G 330 2,0 1,7 1,6 1,6 2,0 2,7 3,2 4,1 3,2

G 440 6,2 4,0 4,1 4,1 3,4 7,1 6,1 10,4 6,5

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7. Lubricants 7.1 Hints Gear drives are delivered generally filled with oil.

Spur gear drive Type : G... und DSG.... Mineral oil CLP 220

Synthetic CLP PAO 150 (Poly--Olefin)

Bevel gear drive Type : K ... Synthetic CLP PAO 150 (Poly--Olefin)

Mech. Variable speed Type : A ... Mineral oil CLP 68 Care has to be taken when commissioning that: - The mounting position corresponds to that on the name plate. - The plastic stoppers screwed in for transport are replaced by the breather valves. The oil level in mech. Variable speed gear drives is controlled when stationary, whereby the oil level is at the middle of the sight glass of the gear box when in the correct mounting position. - Breather valves are not used in bevel gear drives type K .. to prevent condensation and damp entering.

Oil types : Three different types of oil are shown in the lubricants chart:

Mineral oil CLP

Synthetic oil CLP PAO (Poly--Olefin)

physiologically safe oil CLP HC (USDA H1)

Gear oils have to have the following quality requirements:

Compatibility with the radial shaft seals

Compatibility with seals between bolting areas

Compatibility with the gears interior coatings

Using gear oils that do not conform to the quality requirements / not in the lubrication table can render our guarantee as void. We expressly recommend that the oil manufacturer / supplier is responsible for product

Synthetic oil CLP PG (Polyglycol) is not used because of its intolerance to radial shaft seals.

Bio-degradable oils on request!

Oil change : Type : Oil type : Viscosity by

40°C in mm2/s Oil change after :

Spur gear drive G...

DSG....

TR 320

Mineral oil CLP 220 2 years / 10.000 operating hours

Synthetic oil CLP PAO 150 4 years / 20.000 operating hours

Physiologically safe oils CLP HC 220 2 years / 10.000 operating hours

Bevel gear drive K ...

BK ....

Mineral oil CLP 220 2 years / 10.000 operating hours

Synthetic CLP PAO (Poly--Olefin) 150 4 years / 20.000 operating hours

Physiologically safe oils CLP HC 220 2 years / 10.000 operating hours

Mech. Variable speed gear drive

A ...

Mineral oil CLP 68 2.000 operating hours

Synthetic oil CLP PAO 68 4.000 operating hours

Physiologically safe oils CLP HC 68 2.000 operating hours Traction Fluid 68 5.000 operating hours

The actual life expectancy can be higher, but also lower with oil temperatures over 80°C. Here the rule applies that a raise in temperature by 10°C lowers the life expectancy by half.

The purity of the oil influences the operating safety and life expectancy of the oil and gearbox. It must therefore be ensured that clean oil is in the gearbox. When changing the oil it is necessary to have as little old oil in the gearbox as possible. This does not necessarily lead to Problems, but because of compatibility oil types from different manufacturers may not be mixed with each other. In such cases it is necessary to rinse out the gearbox with clean oil. All old oil must be removed from the gearbox.

Warning : The gear oil may not be mixed with other liquids. Rinsing with petroleum or other cleaning

fluids is not allowed because deposits can be left in the gearbox.

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7.2 Lubricants table

Oil type Amb. Temp. (°C)

Viscosity at 40°C 2

Spur gear drives

Gear types :

G… DSG…. TR 320

CLP 0 +40

220 Degol BG 220

Energol GR-XP 220

Klüberoil GEM1-220 N

Mobilgear 600 XP 220

Renolin CLP 220/Plus

Optigear BM 220

Goya 220 Omala S2 G 220

Carter EP 220

CLP 150

CLP PAO

-20 +60

150 Degol PAS 150

Enersyn HTX 150


Mobil SHC Gear 150

Renolin Unisyn CLP 150

Optigear Synthetic X 150

Schumann 150

Omala S4 GX 150

Carter SH 150

Syntholube 150

CLP

HC1

0 +40

150 Klüberoil 4 UH1-150 N

Mobil SHC Cibus 150

Geralyn SF 150

Optileb GT 150

Cassida GL 150

Nevastane SL 150

Syntholube A 150 LM

220 Eural Gear

220 Klüberoil

4 UH1-220 N Mobil SHC Cibus 220

Geralyn SF 220

Optileb GT 220

Cassida GL 220

Nevastane SL 220

Syntholube A 220 LM

Bevel gear drives

Gear types :

K… BK….

CLP 0 +40

220 Degol BG 220

Energol GR-XP 220


Mobilgear 600 XP 220

Renolin CLP 220/Plus

Optigear

BM 220 Goya 220 Omala

S2 G 220 Carter EP 220

CLP 220

CLP PAO

-20 +60

150 Degol PAS 150

Enersyn HTX 150


Mobil SHC Gear 150

Renolin Unisyn CLP 150

Optigear Synthetic X 150

Schumann 150

Omala S4 GX 150

Carter SH 150

Syntholube 150

CLP

HC1

0 +40

150 Klüberoil 4 UH1-150 N

Mobil SHC Cibus 150

Geralyn SF 150

Optileb GT 150

Cassida GL 150

Nevastane SL 150

Syntholube A 150 LM

220 Eural Gear

220 Klüberoil

4 UH1-220 N Mobil SHC Cibus 220

Geralyn SF 220

Optileb GT 220

Cassida GL 220

Nevastane SL 220

Syntholube A 220 LM

Mech.

Variable

CLP 0 +40

68 Degol BG 68

Energol GR-XP 68

Klüberoil GEM 1-68 N

Mobilgear 600 XP 68

Renolin B 20 VG 68 Renolin CLP 68

Optigear

BM 68

Goya 68 Omala S2 G 68

Carter EP 68

CLP 68

speed gears

CLP PAO

0 +40

68 Klüberoil GEM 4-68 N

SHC 626 Renolin Unisyn CLP 68

Schumann 68

Spirax S4 G 75W-90

Syntholube 68

Gear types :

A…

CLP

HC1

0 +40

68 Eural Hyd 68 Klüberoil 4 UH1-68 N

Mobil SHC Cibus 68

Geralyn SF 68

Optileb

HY 68

Cassida HF 68

Nevastane SL 68

Syntholube A 68 LM

Traction Fluid

0 +40

68 Variotrac 68

1 full synthetic gearbox oil, physiologically safe USDA H1. 2 in mm2/s

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8. Address directory

national

STRÖTER Antriebstechnik GmbH Krefelder Str. 117 40549 Düsseldorf Tel.: 0211/95600-0 Service Tel.: 0211/95600-99 Fax.: 0211/504415 E-Mail: [email protected] Internet : www.stroeter.com

International

Belgium BEGE Aandrijftechniek BVBA Puttestraat 73 B-2940 Stabroek Tel: 0032-3/605.1.605 Fax: 0032-3/605.3.605 E-Mail : [email protected] Internet:www.bege.be

Denmark BRD. KLEE A/S GADAGERVEJ 11 2620 ALBERTSLUND Tel. 0045-43 86 83 33 Fax: 0045-43 86 83 88 E-Mail: [email protected] Internet: www.klee.dk

France A.T.M. Serge Steinmetz 19, rue du Fossé F-68330 Huningue Tel: 0033-609/153297 Fax: 0033-389/898684 E-Mail: [email protected]

Great Britain STROETER U.K. 266 Harrogate Road GB-Bradford BD2 3RH Tel: 0044-1274/637638 Fax: 0044-1274/626683 E-Mail: [email protected]

Israel Liranco Foreign Trade Ltd. Harwix Building, 7, Ha´Arad Street Ramat Ha´Chayal, TelAviv, 69710 Tel. : + 972 3 7 662 666 Fax : + 972 3 7 662 662 E-Mail : [email protected] Internet : www.liranco.com

Netherlands BEGE Aandrijftechniek BV Anton Philipsweg 30 NL-2170 AC Sassenheim Tel: 0031-2522/20220 Fax: 0031-2522/18484 E-Mail: [email protected] Internet:www.bege.nl

Norway BRD. KLEE A/S GADAGERVEJ 11 2620 ALBERTSLUND Tel. 0045-43 86 83 33 Fax: 0045-43 86 83 88 E-Mail: [email protected] Internet: www.klee.dk

Poland GLOBALEX sp.z.o.o. ul. Wiece 12 PL-60-638 Poznan Tel: 0048-618/411253 Fax: 0048-618/224747 E-Mail: [email protected] Internet: www.globalex.com.pl

Sweden AB Benzlers Box 922 S-25109 Helsingborg Tel: 0046-42/186800 Fax: 0046-42/31493

Switzerland Max Müller AG Hagmattstr. 19 CH-4123 Allschwil Tel.: 0041-61/4879285 Fax: 0041-61/4879299 E-Mail: [email protected] Internet: www.maxmuellerag.ch

Spain Hijos de a Ferrer Dalmau S.A. C/ Rosalia de Castro 21 E-08025 Barcelona Tel: 0034-93/4874015 Fax: 0034-93/4875037 E-Mail: [email protected] internet:www.ferrer-dalmau.com

Thailand Interdrive System Co. Ltd. 144/39 Ramkamhang 24 Huamark Bangkok 10240 Tel: 0066-2/4342, 719-00 7509 Fax: 0066-2/3004395 [email protected]

Czechoslovakia Elektropohony spol.s.r.o Závodi 234 74401 Frenstat pod Radhostem Tel: 0042 0556/880611 Fax: 0042 0556/880698 E-Mail: [email protected] Internet: www.epo.cz

USA STROETER INC. P.O. Box # 6 USA-Mount Carroll, IL 61053 Tel: +1-815-244-2100 Fax: +1-815-244-2102 E-Mail: [email protected] Internet : www.stroter.com

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