This document provides operating instructions for SEW-EURODRIVE Industrial Gear Units of the M-Series, specifically the M.P../M.R.. Horizontal Gear Units.
Function Description
These industrial gear units are designed for various applications, providing power transmission and speed reduction. They are available in different configurations, including horizontal and vertical designs, and can be equipped with various accessories such as motor adapters, backstops, and cooling systems. The units utilize either splash lubrication or pressure lubrication, depending on the specific model and application requirements.
Important Technical Specifications
The gear units come in various sizes (e.g., 50, 60, 70, 80, 90) and can have different numbers of stages (two, three, four, or five).
- Gear Unit Type: Bevel-helical (M.R.) or helical (M.P.) gear units.
- Low Speed Shaft Type (LSS): Solid shaft (S) or hollow shaft with key or shrink disc connection (H).
- Mounting Position: Horizontal (no designation) or vertical (V).
- Gear Unit Mounting: Foot mounting (F) or torque arm (T).
- Power: The absorbed power on the output shaft (Pe) varies by model, for example, 234 kW for M3PSF80.
- Rated Torque: The rated torque of the gear unit (MN2) varies by model, for example, 119 kNm for M3PSF80.
- Service Factor (Fs): For M3PSF80, Fs is 2.
- Exact Gear Unit Reduction Ratio (i): For M3PSF80, i is 140.093.
- Input/Output Speed (n): For M3PSF80, n is 1/min 480/36.9.
- Weight (kg): For M3PSF80, weight is 2100 kg.
- Lubricant: ISO VG460 Mineral Oil, with a capacity of approximately 160 liters for M3PSF80.
- Mounting Tolerances (Couplings): For ROTEX couplings, offset misalignment (b) and angular misalignment (a1-a2) tolerances vary with outside diameter D and speed n. For example, for D ≤ 100 mm and n < 500 min⁻¹, a1-a2 is 0.05 mm and b is 0.05 mm. For GM, GMD, and GMX couplings, tolerances also vary with coupling type and speed.
- Oil Heater: Available for various gear unit sizes (M2P.., M3R.., M3P.., M4P.., M4R.., M5R..) with power ratings from 1000 W to 2330 W, depending on the size and number of heating rods.
- Temperature Sensor PT100: Sensor tolerance ± (0.3 + 0.005 × t), where t is oil temperature. Plug connector DIN 43650 PG9 (IP65). Tightening torque for retaining screw is 15 Nm.
- SPM Adapter: Available for measuring shock pulses of gear unit bearings. Nipple sizes and positions vary by gear unit series (M2P../M3R.., M3P../M4P.., M4R.., M5R..).
- Fan: Outer diameter of the fan (FK1) varies by gear unit size (e.g., 315 mm for M2P50, 400 mm for M2P80).
Usage Features
- Transport: Industrial gear units of the M-series are delivered without oil fill. Specific instructions are provided for transporting gear units with and without motor adapters, and for units on a base plate or swing base. Lifting ropes/chains or lifting belts must be used at specific angles (e.g., 90° vertically, 70° for units with motor adapter).
- Corrosion Protection: Gear units are delivered without oil fill but with corrosion protection. For storage periods up to 6 months, outdoor storage requires standard protection. For longer periods (12, 24, 36 months), consultation with SEW-EURODRIVE is recommended for long-term protection.
- Mounting: Detailed instructions are provided for mounting the gear unit foundation, including reinforcing the concrete base, grouting, and tightening torques for foundation screws. Specific procedures are outlined for mounting solid shaft gear units and hollow shaft gear units with keyed connection or shrink disc.
- Coupling Mounting: Instructions for mounting ROTEX, Nor-Mex E, Nor-Mex G, and rigid GM, GMD, GMX couplings, including alignment procedures and tolerances for offset and angular misalignment.
- Backstop: The backstop prevents undesirable reverse rotation. It is centrifugally operated with sprags that lift off at low speeds.
- Installation with Steel Frame: Instructions for installing gear units on a steel frame, including swing base and torque arm configurations.
- V-belt Drive: Instructions for mounting V-belt drives, including alignment checks and tensioning.
- Oil Heater: Used to ensure lubrication at startup when ambient temperature is low. It consists of a resistor element, temperature sensor, and thermostat.
- SPM Adapter: Used for measuring shock pulses of gear unit bearings.
- Fan: Ensures proper cooling of the gear unit. Air intake vents must not be blocked.
- Pressure Lubrication: For units with shaft end pumps or motor pumps, detailed instructions are provided for pump suction, ensuring sufficient lubrication, and external cooling and lubrication systems.
Maintenance Features
- Safety Notes: Emphasizes electrical, general, hazardous situations, harmful situations, and explosion protection. Always follow safety and warning instructions.
- Waste Disposal: Instructions for disposing of housing parts, gears, shafts, anti-friction bearings, steel scrap, cast iron castings, waste oil, and other components.
- Inspection and Maintenance Intervals:
- Daily: Check housing temperature, gear unit noise, and gear unit for signs of leakage.
- After 500 - 800 hours of operation: First oil change after initial startup.
- After 500 hours of operation: Check oil level, refill oil.
- Every 3000 hours of operation, at least every 6 months: Change the oil (water content must not exceed 0.03%), check lubricant level, clean breather plug, check condition of oil/water cooling system, clean oil filter.
- Depending on operating conditions, at the latest every 12 months: Check whether retaining screws are tightly secured, check condition of oil/water cooling system, clean oil filter.
- Depending on operating conditions, at the latest every 3 years: Repair or renew surface/anti-corrosion coating, clean the gearcase surface and fan, check oil heater.
- Varying (depending on external factors): Check electrical connection cables and terminals, check heating element, and replace if required.
- Lubricant Change Intervals: Provides graphs (Figure 72) showing lubricant change intervals (hours of operation) based on sustained oil bath temperature for mineral CLP and synthetic CLP HC (PAO) lubricants.
- Checking Oil Level: Instructions for checking oil level using a dipstick or oil level glass.
- Changing Oil: Procedures for draining old oil and filling with new oil, including filter mesh size (max. 25 µm).
- Removing Oil Heater: Instructions for removing the oil heater and gasket, and cleaning the tubular heating elements.
- Refilling Grease: Guidelines for refilling grease, including recommended grease types (NLGI 2 EP) and quantities.
- Lubricant Selection: Detailed tables (Figures 76, 77) and lists of mineral oils and synthetic PAO (CLP HC) based lubricants from various companies, including viscosity and pour point.
- Sealing Grease: Recommended grease types for operating temperatures from –30 °C to +100 °C, including penetration and drop point.
- Lubricant Fill Quantities: Tables providing oil volume in liters for different gear unit sizes (M.P. and M.R.) and number of stages (two, three, four, five) for splash and pressure lubrication.
- Malfunctions: A troubleshooting guide (Table 9.1) listing common problems (e.g., unusual noise, high operating temperature, oil leakage), possible causes, and corresponding solutions.
Need help?
General
To Next Page