This document describes the operating manual for Neugart gearboxes, which are designed for various applications, including economy, precision, and application-specific uses. The manual provides comprehensive information on the function, technical specifications, usage, and maintenance of these gearboxes.
Function Description
Neugart gearboxes are mechanical transmission elements that transfer speeds and torques from an input shaft to an output shaft. They are designed to accommodate external loads and are available in partially closed or closed housing configurations, with the drive and output shafts typically being freely accessible. The gearboxes are available in planetary and right-angle designs, offering flexibility for different application requirements. They are used in various industrial settings for power transmission and motion control.
Important Technical Specifications
The technical specifications of Neugart gearboxes are crucial for their proper selection and operation. These specifications include:
- Gearbox Types: The manual lists various gearbox series, including PLE, PLQE, PLPE, PLHE, PLFE, PFHE, WPLE, WPLQE, WPLPE, WPLFE, WPLHE, WPLFE, NGV, PSBN, PSN, PLN, PSFN, PLFN, WPLN, WPSFN, and WGN. Each series is designed for specific performance characteristics and applications.
- Nameplate Data: Each gearbox is equipped with a nameplate that provides essential identification data, including the product code, data matrix code, serial number, article number, and production date. This information is vital for traceability and maintenance.
- Lubrication: The gearboxes are lubricated with a low-temperature lubricant, and performance data related to lubricant life is provided in a diagram. The lubricant life is dependent on the gearbox temperature during operation.
- Radial and Axial Run-out Tolerance: Detailed tables specify the radial run-out tolerance for different nominal motor shaft diameters and the axial run-out and coaxiality tolerance for various flange sizes. These tolerances are critical for ensuring smooth operation and preventing premature wear.
- Radial Run-out Tolerance [mm] for Nominal Motor Shaft Diameter:
- 0 – ≤ 10: 0.03 (PLE, PLQE, PLPE, PLHE, PLFE, PFHE, WPLE, WPLQE, WPLPE, WPLFE, WPLHE, NGV) / 0.015 (PSBN, PSN, PLN, PSFN, PLFN, WPLN, WPSFN, WGN)
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10 – ≤ 30: 0.04 / 0.020
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30 – ≤ 50: 0.05 / 0.025
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50 – ≤ 80: 0.06 / 0.030
- Axial Run-out and Coaxiality Tolerance [mm] for Flange Size/Square Measure:
- 0 – ≤ 40: 0.06 (PLE, PLQE, PLPE, PLHE, PLFE, PFHE, WPLE, WPLQE, WPLPE, WPLFE, WPLHE, NGV) / 0.03 (PSBN, PSN, PLN, PSFN, PLFN, WPLN, WPSFN, WGN)
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40 – ≤ 100: 0.08 / 0.04
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100 – ≤ 230: 0.10 / 0.05
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230 – ≤ 450: 0.13 / 0.06
- Mounting Bolt Specifications: The manual provides guidelines for selecting and tightening mounting bolts, including strength class and tightening torques for different bolt sizes (M3 to M16).
- Tightening Torques for Application-side Mounting Bolts [Nm]:
- Strength class 10.9: M3 (1.6), M4 (3.8), M5 (7.5), M6 (12.9), M8 (31), M10 (61), M12 (105), M16 (257)
- Strength class 12.9: M3 (1.9), M4 (4.4), M5 (8.7), M6 (15.1), M8 (36), M10 (72), M12 (123), M16 (300)
- General conditions for establishing the tightening torques include design of bolted connection in accordance with VDI 2230, total coefficient of friction for thread and head support is µtotal=0.1, and up to 90% of the bolt yield strength is used. The maximum permissible tightening torque must satisfy DIN EN ISO 6789-1 Type II A at a minimum.
- Modified Gearboxes: For painted gearboxes, the use of washers for application-side attachment on steel or aluminum is recommended to protect the paint layer.
Usage Features
The proper usage of Neugart gearboxes involves several key aspects to ensure safety, performance, and longevity:
- Personnel Qualification: Only qualified personnel with training and experience in mechanics and drive technology should work with the gearboxes. They must be able to assess risks and implement preventive measures.
- Intended Use: The gearboxes are designed for converting or transmitting torques, speeds, and for absorbing radial or axial loads in accordance with their technical specifications. They are intended for commercial and industrial reutilization.
- Reasonably Foreseeable Misuse: The manual highlights several scenarios of foreseeable misuse, such as operation without connecting elements, without monitoring protective devices, outside the temperature range, without considering lubricant service life, in potentially explosive atmospheres, and outside performance data. These misuses can lead to hazards and should be avoided.
- Storage and Transport:
- Storage: Improper storage can damage the gearbox. It must be stored in a dry location to avoid corrosion. The long-term storage temperature should be between 0 °C and +40 °C. Direct sunlight or UV radiation accelerates aging of seals and results in premature wear. To ensure lubricant serviceability, the storage period must not exceed 1 year.
- Transport: When lifting and moving the gearbox, there is a risk of it falling if not properly secured. The gearbox must be lifted by suitable lifting aids that wrap directly around the gearbox housing. Keep the gearbox weight and dimensions listed in its technical specifications in mind.
- Mounting:
- Attaching the Motor: The gearbox is prepared for mounting a motor by means of a clamping system or a drive pinion. Incorrect mounting can lead to unacceptable deviation from radial run-out and axial run-out tolerances, causing damage to the gearbox. The permissible motor weight or bending moment must be observed. The mounting instructions for motor and drive pinion mounting must be followed. Radial and axial run-out tolerances must be ensured. A suitable torque tool with minimum accuracy to DIN EN ISO 6789-1 Type II A must be used for tightening. Bolts must be secured against self-loosening using threadlocker.
- Clamping System: Insufficient cleaning of friction-locked components or insufficient tightening torque of the clamping screw can lead to slippage. The clamping system must be protected against plastic deformation. Components must be clean and free of residues.
- Drive Shaft: Faulty mounting of the drive shaft can cause breakage of torque-transmitting gearbox components or slippage. The permissible motor weight or bending moment must be observed. The design of the connection between the motor shaft and the drive pinion must ensure performance data.
- Installing the Gearbox in the Application: Incorrect attachment can lead to misalignment or slippage, causing breakage or slippage of components. Observe the strength class of application-side mounting bolts and use washers. Observe the tightening torques for application-side mounting bolts. Select a suitable torque tool. Bolts must be secured against self-loosening. Non-positive connections must be made with suitable clamping sets. Clean the component surfaces. The application-side flange geometry must be free of damage and residues. Uncontrolled introduction of external forces can lead to damage.
- Commissioning and Operation:
- Initial Operation: The direction of rotation of the gearbox can be the same or opposite. Failure to note the direction of rotation may result in an unexpected starting direction.
- Warning! For the intended use, a gearbox has at least one freely accessible shaft through which pulling is possible. Only operate the gearbox with appropriate technical safeguards. Protective devices must be used. When operating with an exposed feather key, the key can be thrown off at high centrifugal forces. Do not operate the gearbox with the feather key exposed. Secure or remove the feather key.
- Torque-transmitting Gearbox Components: Due to kinetic energy, the motor can cause torque-transmitting gearbox components to break in non-stationary operation. The maximum motor bending moment must be observed.
- Exceeding Performance Data: Exceeding performance data can cause gearbox components to break. Check for possible faults and malfunctions (increased current consumption, vibration, temperature, deposits, sluggishness, noise, uncontrolled introduction of external forces and torques).
- External Forces and Torques: Uncontrolled introduction of external forces and torques can lead to breakage of gears, shafts, failure of gearbox bearings, and leakage.
- Gearbox Surface Temperature: The gearbox surface may heat up during operation. Allow the gearbox to cool down sufficiently after shutdown.
- Low Temperatures: Unusually low temperatures can cause sealing elements to freeze, leading to leakage. The gearbox may only be operated within its technical specifications. Ensure environmental conditions prevent sealing elements from freezing.
- Rotary Shaft Seals: Rotary shaft seals with a dust lip are initially greased. Harmless apparent leakage may occur during the first few hours of operation.
- Lubricant Service Life: The expected service life of the lubricant depends on the gearbox temperature. Determine the surface temperature in the thermally steady state. Check the surface temperature at several locations. Determine the lubricant temperature by adding 5 °C to the highest surface temperature. Define the expected or desired operating time at the respective lubricant temperature. Check the lubricant as listed in the technical specifications.
- Operation: Exceeding performance data can cause gearbox components to break. Changing operating parameters may be possible only within the limits of maximum values. Check for possible defects and malfunctions. In the event of contamination or deposits, the gearbox can no longer fully meet warranted performance characteristics. The gearbox must be protected against accumulation of dust and contamination, especially on the gearbox housing (heat buildup) and in the area of the seals (abrasive wear and leakage). Continuous loss of lubricant due to leakage can cause a gear component to break. Check for leakage. Replace the gearbox if you notice a continuous loss of lubricant.
Maintenance Features
Regular inspection and maintenance are essential for the long-term reliability and performance of Neugart gearboxes.
- Remedying Operational Malfunctions: The manual provides a table of fault states, possible causes, and potential solutions.
- High Operating Temperature:
- Fault state: Gearbox unsuitable for load. Possible cause: Compare the load with the technical specifications.
- Fault state: High ambient temperature. Possible cause: Ensure sufficient cooling by convection or forced-air ventilation. Optimize heat conduction in the application.
- Fault state: Insufficient convection, heat conduction. Possible cause: Optimize heat conduction in the application.
- Fault state: Motor is heating the gearbox. Possible cause: Check load on the motor.
- Fault state: Deposits on the gearbox surface. Possible cause: Clean the gearbox surface.
- Fault state: Gearbox too close to a heat source. Possible cause: Shield the gearbox or relocate heat source.
- Fault state: Gearbox unsuitable for load. Possible cause: Compare the load with the technical specifications.
- Loud Noise During Operation:
- Fault state: Gearbox damage (bearings, gearing, lubricant used up). Possible cause: Contact our customer service.
- Fault state: Motor attachment or radial/axial run-out of the motor out of tolerance. Possible cause: Check radial/axial run-out of motor and remount motor.
- Leakage:
- Fault state: Leaking from initial lubrication. Possible cause: Monitor leakage. If lubricant leakage does not stop, contact customer service.
- Fault state: Leakage due to excessively greased bearing. Possible cause: Check whether foreign medium is responsible for leakage.
- Fault state: Supposed leakage due to foreign medium. Possible cause: Contact customer service for inspection or maintenance.
- Fault state: Leakage due to worn seal (end of service life reached). Possible cause: Order new product.
- Fault state: Seal type unsuitable for load. Possible cause: Contact our customer service.
- Fault state: Gearbox damage (damaged seal). Possible cause: Compare the load with the technical specifications.
- Fault state: Gearbox unsuitable for load. Possible cause: See potential remedy for fault condition "High operating temperature". Contact customer service.
- No Power Transmission / Blockage:
- Fault state: Operating temperature too high. Possible cause: See potential remedy for fault condition "High operating temperature". Contact customer service.
- Inspection Intervals and Measures:
- During commissioning: Check for impurities, foreign bodies or foreign media, noise during operation, leakage, temperature. Check the non-positive and positive connections.
- 10 h after commissioning: Check for impurities, foreign bodies or foreign media, noise during operation, leakage, temperature. Check the non-positive and positive connections.
- Every 3 months: Check for impurities, foreign bodies or foreign media, noise during operation, leakage, temperature.
- Contamination, foreign bodies or media are to be expected under ambient conditions; the regular inspection intervals must be shortened accordingly.
- Maintenance Operations: The gearbox is maintenance-free during its expected service life. A rotary shaft seal installed on the gearbox is a wearing part and may need to be replaced. Sealing elements must be protected from compressed air and aggressive cleaning agents. For cleaning, use cold cleaning agents based on a gasoline hydrocarbon. Only clean the gearbox when it is at a standstill. Have shaft seals changed by customer service. Opening the gearbox for maintenance purposes is not permitted.
- Safety Data Sheets: The corresponding safety data sheet can be obtained from customer service or at www.neugart.com.
Disposal
The gearbox is made mainly of steel and aluminum materials. If possible, dispose of the gearbox lubricant separately, observing the relevant safety data sheet referenced in 5.4.3. If steel and aluminum components are not materially bonded, dispose of these materials separately if possible. Contact customer service if you have any questions regarding disposal.
For any queries, please contact Neugart Service. Details for the nameplate are provided. For optimal handling of service, contact the location from which the gearbox was purchased. Service requests are available at www.neugart.com.
- Address for Return Shipments:
- Neugart GmbH, Plant 2, Customer service, Keltenstraße 18, 77971 Kippenheim, Germany.
- Email: service@neugart.com
- Phone: +49 7825 847 - 3535
- Fax: +49 7825 847 - 433535
- Internet: www.neugart.com
- Locations in the USA and China: If you have purchased a gearbox through companies in the USA or China, you are also welcome to contact them for pre-authorized service requests.
- Neugart USA Corp.
- 14325 South Lakes Drive, Charlotte, NC 28273, United States
- Email: sales@neugartusa.com
- Phone: +1 980 299-9800
- Fax: +1 980 299-9799
- Neugart Planetary Gearboxes (Shenyang) Co., Ltd.
- No. 152, 22nd road, E&T Development Zone Shenyang, PC 110143, PR China
- Email: sales@neugart.net.cn
- Phone: +86 024 25195797
- Fax: +86 024 25372552
- Manufacturer (company name and address):
- Neugart GmbH, Keltenstraße 16, 77971 Kippenheim, Germany
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