Bosch Rexroth GTM Series Technical manual

R911297321
Edition 01
Rexroth GTM
Planetary Gearboxes
Project Planning Manual
Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Mobile
Hydraulics

About this Documentation Planetary Gearboxes
DOK-GEAR**-GTM********-PR01-EN-P
Rexroth GTM
Planetary Gearboxes
Project Planning
DOK-GEAR**-GTM********-PR01-EN-P
120-1200-B303-01/EN
This documentation
•describes the product attributes, the applications and conditions for
use
•includes technical data of the available gearboxes
•gives notes to product selection, handling and operation
Description Release
Date Notes
DOK-GEAR**-GTM********-PR01-EN-P 10/2003 First edition
2003 Bosch Rexroth AG
Copying this document, giving it to others and the use or communication
of the contents thereof without express authority, are forbidden. Offenders
are liable for the payment of damages. All rights are reserved in the event
of the grant of a patent or the registration of a utility model or design
(DIN 34-1).
The specified data is for product description purposes only and may not
be deemed to be guaranteed unless expressly confirmed in the contract.
All rights are reserved with respect to the content of this documentation
and the availability of the product.
Bosch Rexroth AG
Bgm.-Dr.-Nebel-Str. 2 •D-97816 Lohr a. Main
Telephone [phone] •Tx 68 94 21 •Fax [phone]
http://www.boschrexroth.com/
Dept. BRC/EDM (MH)
This document has been printed on chlorine-free bleached paper.
Title
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Internal File Reference
Purpose of Documentation
Record of Revisions
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Note

Planetary Gearboxes Content I
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Content
1 Introduction to the Product 1-1
1.1 About this Documentation............................................................................................................. 1-3
2 Important Instructions on Use 2-1
2.1 Intended Use ................................................................................................................................ 2-1
Introduction.............................................................................................................................. 2-1
Fields of Use and Application.................................................................................................. 2-2
2.2 Non-Intended Use......................................................................................................................... 2-2
3 Safety Instructions for Electric Drives and Controls 3-1
3.1 Introduction................................................................................................................................... 3-1
3.2 Explanations................................................................................................................................. 3-1
3.3 Hazards by Improper Use............................................................................................................. 3-2
3.4 General Information...................................................................................................................... 3-3
3.5 Protection Against Contact with Electrical Parts........................................................................... 3-5
3.6 Protection Against Electric Shock by Protective Low Voltage (PELV)......................................... 3-6
3.7 Protection Against Dangerous Movements.................................................................................. 3-7
3.8 Protection Against Magnetic and Electromagnetic Fields During Operation and
Mounting....................................................................................................................................... 3-9
3.9 Protection Against Contact with Hot Parts.................................................................................. 3-10
3.10 Protection During Handling and Mounting.................................................................................. 3-10
3.11 Battery Safety ............................................................................................................................. 3-11
3.12 Protection Against Pressurized Systems.................................................................................... 3-11
4 Dimensioning and selection 4-1
4.1 Dimensioning................................................................................................................................ 4-1
4.2 Selection....................................................................................................................................... 4-3
5 Notes Regarding Application 5-1
5.1 Conditions for Use........................................................................................................................ 5-1
Operation S5 (intermittent operation)...................................................................................... 5-2
Continuous Operation (S1)...................................................................................................... 5-3
5.2 Mechanical features...................................................................................................................... 5-4
5.3 Combination possibilities of GTM planetary gearboxes with AC-motors ..................................... 5-6
6 Technical Data 6-1
6.1 Technical data for intermittent and continuous operation............................................................. 6-1
6.2 Technical data for increased lifetime............................................................................................ 6-4

II Content Planetary Gearboxes
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6.3 Permittable shaft loading.............................................................................................................. 6-5
GTM060................................................................................................................................... 6-6
GTM075................................................................................................................................... 6-7
GTM100................................................................................................................................... 6-8
GTM140................................................................................................................................... 6-9
GTM180................................................................................................................................. 6-10
GTM240................................................................................................................................. 6-11
7 Dimensional Details 7-1
7.1 GTM060........................................................................................................................................ 7-1
7.2 GTM075........................................................................................................................................ 7-2
7.3 GTM100........................................................................................................................................ 7-3
7.4 GTM140........................................................................................................................................ 7-4
7.5 GTM180........................................................................................................................................ 7-6
7.6 GTM240........................................................................................................................................ 7-8
8 Type codes 8-1
8.1 Type codes for the GTM060......................................................................................................... 8-1
8.2 Type codes for the GTM075......................................................................................................... 8-2
8.3 Type codes for the GTM100......................................................................................................... 8-3
8.4 Type codes for the GTM140......................................................................................................... 8-4
8.5 Type codes for the GTM180......................................................................................................... 8-5
8.6 Type codes for the GTM240......................................................................................................... 8-6
9 Handling, transport and storage 9-1
9.1 Handling........................................................................................................................................ 9-1
Identifying the Goods............................................................................................................... 9-1
Name plates............................................................................................................................. 9-1
9.2 Transport ...................................................................................................................................... 9-2
9.3 Storage ......................................................................................................................................... 9-4
10 Assembly 10-1
10.1 Skilled Technical Personnel........................................................................................................ 10-1
10.2 Mounting to the motor................................................................................................................. 10-1
10.2.1 Motor connection........................................................................................................ 10-2
10.2.2 Mounting procedure.................................................................................................... 10-3
10.3 Gearbox mounting...................................................................................................................... 10-7
11 Startup, Operation, and Maintenance 11-1
11.1 Commissioning ........................................................................................................................... 11-1
Preparation............................................................................................................................ 11-1
Execution............................................................................................................................... 11-1
11.2 Deactivation................................................................................................................................ 11-2
11.3 Dismantling................................................................................................................................. 11-2
11.4 Maintenance ............................................................................................................................... 11-3
Measures............................................................................................................................... 11-3

Planetary Gearboxes Content III
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11.5 Troubleshooting.......................................................................................................................... 11-3
Excess Temperature of Gearbox Housing ............................................................................ 11-4
Gearbox-motor unit generates vibrations.............................................................................. 11-4
Specified position is not attained........................................................................................... 11-4
12 How to order 12-1
13 Service & Support 13-1
13.1 Helpdesk..................................................................................................................................... 13-1
13.2 Service-Hotline ........................................................................................................................... 13-1
13.3 Internet........................................................................................................................................ 13-1
13.4 Vor der Kontaktaufnahme... - Before contacting us... ................................................................ 13-1
13.5 Kundenbetreuungsstellen - Sales & Service Facilities............................................................... 13-1
14 Appendix 14-1
14.1 List of Standards......................................................................................................................... 14-1

IV Content Planetary Gearboxes
DOK-GEAR**-GTM********-PR01-EN-P

Planetary Gearboxes Introduction to the Product 1-1
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1 Introduction to the Product
MG000001v01_NN.jpg
Fig. 1-1: Mounting example: GTM Planetary gearbox on an MKD motor
In combination with the drive and control systems of BOSCH REXROTH,
GTM planetary gearboxes, provide a low-cost automation system for
various sectors of industry.
They are well-suited for use with gear racks or toothed belts in handling
systems with high speed and accelerations (e.g.: loaders, robots).
The low-backlash, ground and matched gearing permits the execution of
exact positioning tasks. Furthermore, the gearboxes are suited for S1-
operation-required for use in printing sector.
345710 20 50
GTM060
GTM075
GTM100
GTM140
GTM180
GTM240
0
250
500
750
1000
1250
1500
1750
2000
2250
2500
2750
3000
Gear ratio
Gearbox output rated torque in Nm
GL000001v01_en.EPS
Fig. 1-2: Nominal torque gradation of the GTM planetary gearboxes.
Fields of application
Gradation

1-2 Introduction to the Product Planetary Gearboxes
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The GTM series of planetary gearboxes offers a coaxial input and output.
The output shaft of the motor is connected to the sun gear with a
compression clamp coupling. This sun gear drives the planetary gears,
which revolve within the ring gear. The planetary gears are fixed in the
planetary carrier, which acts as the output. By dividing the load among the
planetary gears, a balanced force splitting occurs. This allows for a very
compact gearbox with a high power density.
•Maintenance-free operation through lifetime lubrication
•Use under adverse environmental conditions is possible thanks to the
completely enclosed IP65 design.
•Viton seals on the input and output provide safe and effective
protection.
•Hermetically sealed housing
•Power transfer free from backlash-free torque transmission via the
compression coupling.
•High accuracy through use of ground, gears and low backlash.
•High torsional rigidity by optimized planetary gears supported on both
sides with stabile needle bearings.
•High efficiency, low temperature and minimum power loss made
possible by using the smallest possible seal diameters.
•Low running noise by optimized gear profiles.
•High emergency stop torque made possible by internal transferred
power.
•High dynamic because of low inertia
•Low weight through to compact design
•The high radial-load capability and tilt resistance makes it possible to
directly mount a pinion or pulley.
•The design of the output shaft with a solid shaft shoulder makes axial
tightening of output elements simple.
•The gearbox can be mounted in any position due to the bearing design
and its pumping action, a sufficient lubrication supply is always
ensured.
•Flange mounting is permitted in all installation positions because of the
B05 design (EN 60034-7:1996-06).
•The output elements can be mounted in two different ways:
•Compression fitting on the smooth shaft (standard), or
•Connection by means of an output shaft with keyway
Mode of functioning
High operational reliability
High power
Easy to mount to machine

Planetary Gearboxes Introduction to the Product 1-3
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1.1 About this Documentation
This document contains safety regulations, technical data, and operating
instructions for gearboxes. The individual chapters can be subdivided into
the following focal points:
Chapter Title Content
1 Introduction to the Product General information
2 Important Instructions on Use
3 Safety Notes Safety
4 Dimensioning and Selection
5 Notes Application
6 Technical Data
7 Dimensional Details
8 Type Codes
Product description
(for planners and machine
constructors)
9 Handling, Transport and Storage
10 Assembly
11 Startup, Operation, and Maintenance
12 Ordering Data
Practical
(for operating and
maintenance personnel)
13 Appendix
14 Service and Support
15 Index
General information
Fig. 1-3: Document structure

1-4 Introduction to the Product Planetary Gearboxes
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Standards
This documentation refers to German, European and international
technical standards. Documents and sheets on standards are subject to
copyright protection and may therefore not be passed on to third parties
by Bosch Rexroth. If necessary, please contact your local authorized
sales outlet or, in Germany, contact:
BEUTH Verlag GmbH
Burggrafenstrasse 6
10787 Berlin
Phone [phone], Fax [phone]
Internet: http://www.din.de/beuth
E-mail: postm[email protected]
Feedback
Your experiences are an essential part of the process of improving both
product and documentation.
Please do not hesitate to inform us of any mistakes you detect in this
documentation or of any modifications you might desire. We would
appreciate your feedback.
Please send your remarks to:
Bosch Rexroth AG
Dept. BRC/EDM
Bgm.-Dr.-Nebel-Str. 2, 97816 Lohr a. Main
Fax +49 93 52 / 40-43 80

Planetary Gearboxes Important Instructions on Use 2-1
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2 Important Instructions on Use
2.1 Intended Use
Introduction
Bosch Rexroth products are designed and manufactured using state-of-
the-art technology. Before they are delivered, they are checked for their
operationally safety.
The products may only be used as intended. If they are not used as
intended, situations may arise resulting in injuries to property and
persons.
Note: For damage caused by products not being used as intended,
Bosch Rexroth gives no warranty, assumes no liability, and will
not pay for any damages. Any risks resulting from the products
not being used as intended are the sole responsibility of the
user.
Before using Bosch Rexroth products, the following requirements must be
fulfilled so as to ensure that they are used as intended:
•Anyone handling one of the products in any manner must read and
understand the appropriate safety instructions and the intended use.
•Regarding hardware components, the product concerned must be left
in its original state, i.e. it is not permitted to modify it structurally.
Software products may not be decompiled; their source codes may not
be altered.
•Damaged or defective products may not be installed or put into
operation.
•It must be ensured that the products are installed according to the
instructions mentioned in the documentation.

2-2 Important Instructions on Use Planetary Gearboxes
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Fields of Use and Application
Typical application ranges of the GTM planetary gearboxes are:
•Handling and mounting systems,
•Packaging and food-processing machines,
•Printing and paper-processing machines and
•Machine tools
Controlling and monitoring of the motor/-gearbox combination may require
connection of additional sensors and actuators.
Note: The gearboxes may only be used with the accessories
specified in the documentation. Components which are not
expressly named may neither be mounted nor connected.
The motors may be operated only in the expressly specified
component configurations and combinations and with the
software and firmware specified in the appropriate functional
description.
Any drive controller must be programmed before startup, in order to
ensure that the motor executes the functions specific to the particular
application.
The gearboxes may only be operated under the assembly, mounting and
installation conditions, in the position of use, and under the environmental
conditions (temperature, degree of protection, humidity, EMC) specified in
this documentation.
2.2 Non-Intended Use
Any use of the planetary gearboxes outside of the fields of application
mentioned above or under operating conditions and technical data other
than those specified in this documentation is considered to be “non-
intended use”.
Planetary gearboxes may not be used if . . .
•they are subjected to operating conditions which do not comply with
the environmental conditions described above (e.g. operation under
water, under extreme variations in temperature or extreme maximum
temperatures is not permitted),
•the intended application is not explicitly released by Bosch Rexroth.
Please be absolutely sure to also observe the statements made in the
general safety instructions.

Planetary Gearboxes Safety Instructions for Electric Drives and Controls 3-1
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3 Safety Instructions for Electric Drives and Controls
3.1 Introduction
Read these instructions before the initial startup of the equipment in order
to eliminate the risk of bodily harm or material damage. Follow these
safety instructions at all times.
Do not attempt to install or start up this equipment without first reading all
documentation provided with the product. Read and understand these
safety instructions and all user documentation of the equipment prior to
working with the equipment at any time. If you do not have the user
documentation for your equipment, contact your local Bosch Rexroth
representative to send this documentation immediately to the person or
persons responsible for the safe operation of this equipment.
If the equipment is resold, rented or transferred or passed on to others,
then these safety instructions must be delivered with the equipment.
WARNING
Improper use of this equipment, failure to follow
the safety instructions in this document or
tampering with the product, including disabling
of safety devices, may result in material
damage, bodily harm, electric shock or even
death!
3.2 Explanations
The safety instructions describe the following degrees of hazard
seriousness in compliance with ANSI Z535. The degree of hazard
seriousness informs about the consequences resulting from non-
compliance with the safety instructions.
Warning symbol with signal
word Degree of hazard seriousness according to ANSI
DANGER
Death or severe bodily harm will occur.
WARNING
Death or severe bodily harm may occur.
CAUTION
Bodily harm or material damage may occur.
Fig. 3-1: Hazard classification (according to ANSI Z535)

3-2 Safety Instructions for Electric Drives and Controls Planetary Gearboxes
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3.3 Hazards by Improper Use
DANGER
High voltage and high discharge current!
Danger to life or severe bodily harm by electric
shock!
DANGER
Dangerous movements! Danger to life, severe
bodily harm or material damage by
unintentional motor movements!
WARNING
High electrical voltage due to wrong
connections! Danger to life or bodily harm by
electric shock!
WARNING
Health hazard for persons with heart
pacemakers, metal implants and hearing aids in
proximity to electrical equipment!
CAUTION
Surface of machine housing could be extremely
hot! Danger of injury! Danger of burns!
CAUTION
Risk of injury due to improper handling! Bodily
harm caused by crushing, shearing, cutting and
mechanical shock or incorrect handling of
pressurized systems!
CAUTION
Risk of injury due to incorrect handling of
batteries!

Planetary Gearboxes Safety Instructions for Electric Drives and Controls 3-3
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3.4 General Information
•Bosch Rexroth AG is not liable for damages resulting from failure to
observe the warnings provided in this documentation.
•Read the operating, maintenance and safety instructions in your
language before starting up the machine. If you find that you cannot
completely understand the documentation for your product, please ask
your supplier to clarify.
•Proper and correct transport, storage, assembly and installation as
well as care in operation and maintenance are prerequisites for
optimal and safe operation of this equipment.
•Only persons who are trained and qualified for the use and operation
of the equipment may work on this equipment or within its proximity.
•The persons are qualified if they have sufficient knowledge of the
assembly, installation and operation of the equipment as well as an
understanding of all warnings and precautionary measures noted in
these instructions.
•Furthermore, they must be trained, instructed and qualified to
switch electrical circuits and equipment on and off in accordance
with technical safety regulations, to ground them and to mark them
according to the requirements of safe work practices. They must
have adequate safety equipment and be trained in first aid.
•Only use spare parts and accessories approved by the manufacturer.
•Follow all safety regulations and requirements for the specific
application as practiced in the country of use.
•The equipment is designed for installation in industrial machinery.
•The ambient conditions given in the product documentation must be
observed.
•Use only safety features and applications that are clearly and explicitly
approved in the Project Planning Manual.
For example, the following areas of use are not permitted: construction
cranes, elevators used for people or freight, devices and vehicles to
transport people, medical applications, refinery plants, transport of
hazardous goods, nuclear applications, applications sensitive to high
frequency, mining, food processing, control of protection equipment
(also in a machine).
•The information given in the documentation of the product with regard
to the use of the delivered components contains only examples of
applications and suggestions.
The machine and installation manufacturer must
•make sure that the delivered components are suited for his
individual application and check the information given in this
documentation with regard to the use of the components,
•make sure that his application complies with the applicable safety
regulations and standards and carry out the required measures,
modifications and complements.
•Startup of the delivered components is only permitted once it is sure
that the machine or installation in which they are installed complies
with the national regulations, safety specifications and standards of the
application.

3-4 Safety Instructions for Electric Drives and Controls Planetary Gearboxes
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•Operation is only permitted if the national EMC regulations for the
application are met.
The instructions for installation in accordance with EMC requirements
can be found in the documentation "EMC in Drive and Control
Systems".
The machine or installation manufacturer is responsible for
compliance with the limiting values as prescribed in the national
regulations.
•Technical data, connections and operational conditions are specified in
the product documentation and must be followed at all times.

Planetary Gearboxes Safety Instructions for Electric Drives and Controls 3-5
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3.5 Protection Against Contact with Electrical Parts
Note: This section refers to equipment and drive components with
voltages above 50 Volts.
Touching live parts with voltages of 50 Volts and more with bare hands or
conductive tools or touching ungrounded housings can be dangerous and
cause electric shock. In order to operate electrical equipment, certain
parts must unavoidably have dangerous voltages applied to them.
DANGER
High electrical voltage! Danger to life, severe
bodily harm by electric shock!
⇒Only those trained and qualified to work with or on
electrical equipment are permitted to operate, maintain
or repair this equipment.
⇒Follow general construction and safety regulations when
working on high voltage installations.
⇒Before switching on power the ground wire must be
permanently connected to all electrical units according
to the connection diagram.
⇒Do not operate electrical equipment at any time, even
for brief measurements or tests, if the ground wire is not
permanently connected to the points of the components
provided for this purpose.
⇒Before working with electrical parts with voltage higher
than 50 V, the equipment must be disconnected from
the mains voltage or power supply. Make sure the
equipment cannot be switched on again unintended.
⇒The following should be observed with electrical drive
and filter components:
⇒Wait five (5) minutes after switching off power to allow
capacitors to discharge before beginning to work.
Measure the voltage on the capacitors before beginning
to work to make sure that the equipment is safe to
touch.
⇒Never touch the electrical connection points of a
component while power is turned on.
⇒Install the covers and guards provided with the
equipment properly before switching the equipment on.
Prevent contact with live parts at any time.
⇒A residual-current-operated protective device (RCD)
must not be used on electric drives! Indirect contact
must be prevented by other means, for example, by an
overcurrent protective device.
⇒Electrical components with exposed live parts and
uncovered high voltage terminals must be installed in a
protective housing, for example, in a control cabinet.

3-6 Safety Instructions for Electric Drives and Controls Planetary Gearboxes
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To be observed with electrical drive and filter components:
DANGER
High electrical voltage on the housing!
High leakage current! Danger to life, danger of
injury by electric shock!
⇒Connect the electrical equipment, the housings of all
electrical units and motors permanently with the safety
conductor at the ground points before power is
switched on. Look at the connection diagram. This is
even necessary for brief tests.
⇒Connect the safety conductor of the electrical
equipment always permanently and firmly to the
supply mains. Leakage current exceeds 3.5 mA in
normal operation.
⇒Use a copper conductor with at least 10 mm²cross
section over its entire course for this safety conductor
connection!
⇒Prior to startups, even for brief tests, always connect
the protective conductor or connect with ground wire.
Otherwise, high voltages can occur on the housing
that lead to electric shock.
3.6 Protection Against Electric Shock by Protective Low
Voltage (PELV)
All connections and terminals with voltages between 0 and 50 Volts on
Rexroth products are protective low voltages designed in accordance with
international standards on electrical safety.
WARNING
High electrical voltage due to wrong
connections! Danger to life, bodily harm by
electric shock!
⇒Only connect equipment, electrical components and
cables of the protective low voltage type (PELV =
Protective Extra Low Voltage) to all terminals and
clamps with voltages of 0 to 50 Volts.
⇒Only electrical circuits may be connected which are
safely isolated against high voltage circuits. Safe
isolation is achieved, for example, with an isolating
transformer, an opto-electronic coupler or when
battery-operated.

Planetary Gearboxes Safety Instructions for Electric Drives and Controls 3-7
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3.7 Protection Against Dangerous Movements
Dangerous movements can be caused by faulty control of the connected
motors. Some common examples are:
•improper or wrong wiring of cable connections
•incorrect operation of the equipment components
•wrong input of parameters before operation
•malfunction of sensors, encoders and monitoring devices
•defective components
•software or firmware errors
Dangerous movements can occur immediately after equipment is
switched on or even after an unspecified time of trouble-free operation.
The monitoring in the drive components will normally be sufficient to avoid
faulty operation in the connected drives. Regarding personal safety,
especially the danger of bodily injury and material damage, this alone
cannot be relied upon to ensure complete safety. Until the integrated
monitoring functions become effective, it must be assumed in any case
that faulty drive movements will occur. The extent of faulty drive
movements depends upon the type of control and the state of operation.

3-8 Safety Instructions for Electric Drives and Controls Planetary Gearboxes
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DANGER
Dangerous movements! Danger to life, risk of
injury, severe bodily harm or material damage!
⇒Ensure personal safety by means of qualified and
tested higher-level monitoring devices or measures
integrated in the installation. Unintended machine
motion is possible if monitoring devices are disabled,
bypassed or not activated.
⇒Pay attention to unintended machine motion or other
malfunction in any mode of operation.
⇒Keep free and clear of the machine’s range of motion
and moving parts. Possible measures to prevent
people from accidentally entering the machine’s range
of motion:
- use safety fences
- use safety guards
- use protective coverings
- install light curtains or light barriers
⇒Fences and coverings must be strong enough to
resist maximum possible momentum, especially if
there is a possibility of loose parts flying off.
⇒Mount the emergency stop switch in the immediate
reach of the operator. Verify that the emergency stop
works before startup. Don’t operate the machine if the
emergency stop is not working.
⇒Isolate the drive power connection by means of an
emergency stop circuit or use a starting lockout to
prevent unintentional start.
⇒Make sure that the drives are brought to a safe
standstill before accessing or entering the danger
zone. Safe standstill can be achieved by switching off
the power supply contactor or by safe mechanical
locking of moving parts.
⇒Secure vertical axes against falling or dropping after
switching off the motor power by, for example:
- mechanically securing the vertical axes
- adding an external braking/ arrester/ clamping
mechanism
- ensuring sufficient equilibration of the vertical axes
The standard equipment motor brake or an external
brake controlled directly by the drive controller are
not sufficient to guarantee personal safety!
⇒Disconnect electrical power to the equipment using a
master switch and secure the switch against
reconnection for:
- maintenance and repair work
- cleaning of equipment
- long periods of discontinued equipment use
⇒Prevent the operation of high-frequency, remote
control and radio equipment near electronics circuits
and supply leads. If the use of such equipment cannot
be avoided, verify the system and the installation for
possible malfunctions in all possible positions of
normal use before initial startup. If necessary, perform
a special electromagnetic compatibility (EMC) test on
the installation.