Graessner PowerGear P54 User manual

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Spiral bevel gear
P
Po ow we er rG Ge ea ar r
Installation and operating instructions
PowerGear P54 to P450
X54 to X280
S90 to S170
Issue 2015-01
Ident-No. BA 21P00030 EN

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Table of contents
1. General notes
1.1 Use of the operating instructions
1.2 Significance of the warning notes
1.3 Exclusion of liability
1.4 Copyright
4
4
4
4
4
2. Intended use of MS-Graessner Gear Units
5
3. Conversions and alterations / Modifications of the product
5
4. Set-up of gear unit / Technical data
4.1 Set-up of gear unit
4.2 Type designations
4.3 Performance tables PowerGear
4.4 Technical data PowerGear
4.5 Type plate
5
5
6
7
8
8
5. Safety notes
5.1 Basic duties
5.2 Qualified personnel
5.3 Environmental protection
9
9
9
9
6. Transport, storage and long term storage
6.1 Transport
6.2 Storage conditions
6.3 Long-term storage
6.4 To be noted before commissioning
10
10
10
10
10
7. Installation
7.1 General installation instructions
7.2 Gear unit installation in plant
7.3 Installation positions
7.4 Fitting of motors
7.5 Installation of the other fitted components
7.6 Finishing work
11
11
11
11
12
12
13
8. Commissioning
14
9. Operation of the PowerGear gear units
9.1 General notes on operation
9.2 To be watched out for during operation
9.3 Irregularities
15
15
15
15

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10. Faults, causes, remedy
10.1 General fault indications
10.2 Possible faults
16
16
16
11. Inspection and maintenance
11.1 General notes
11.2 Service intervals
11.3 Oil service life
11.4 Oil change
11.5 Checking gear unit condition
17
17
17
17
17
18
12. Replacement parts, replacement part stocks, service
12.1 Replacement parts
12.2 Replacement part stocks
12.3 Service department
18
18
18
18
13. Index (alphabetic)
19

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1. General notes
1.1 Use of the operating instructions
These operating instructions are an integral part of the product and must be carefully studied before use and
kept in a safe place for later consultation.
It comprises important notes on the operation and service of the PowerGear series of gear units. These operat-
ing instructions are intended for all persons carrying out assembly, installation, commissioning and service work
on gear units from this series of gear units.
The gear units of the PowerGear series are components for installation in machines and exclusively intended for
guiding, distributing and multiplying torques and only designed for the area of use described in Chapter 2 "Tech-
nical Data".
Other operational uses and conditions must be agreed with MS-Graessner GmbH & Co.KG and contractually
regulated.
The gear units are manufactured according to the latest technical state of the art and delivered such that they
are safe to operate. They meet the current state of the description as contained in these operating instructions.
We reserve all rights to implement technical modifications on components, whilst retaining performance capabil-
ity and safety of the gear units.
1.2 Significance of the warning notes
The warning notes appear in the context in which a hazard may occur and refer to the same. They refer to haz-
ards and possible consequences if such hazards are not remedied. The notes on personal safety are highlighted
by warning triangles indicating the hazard types. Depending on the hazard level the warning notes are shown as
follows:
Note
Useful note or information
Attention:
Material damage may occur on the drive system or the environment!
Caution:
Risk of bodily injury!
(Here risk of burns)
Warning:
Possible hazardous situation - death or serious bodily injury may occur!
(Here risk of crushing)
Danger:
Immediate danger with death or serious bodily injury as consequences!
(Here risk of crushing for bodies)
1.3 Exclusion of liability
MS-Graessner GmbH & Co. KG does not assume any liability for damage and operating malfunctions resulting
from non-compliance with these instructions .
1.4 Copyright
The copyright relating to these instructions is retained by MS-Graessner GmbH & Co. KG, all rights reserved
These installation and operating instructions are available on our website www.graessner.de as a
download .

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With regard to all technical queries please contact our product management or our service department:
MS-Graessner GmbH & Co. KG
THE GEAR COMPANY
Kuchenaecker 11
D-72135 Dettenhausen
Service Department
Product management
Tel.: [phone]
Fax: [phone]
Fax: [phone]
[email protected]
www.graessner.de
These operating instructions must be read carefully before use
Keep in a safe place for later reference
If these operating instructions are not complied with, damage to the gear unit,
operating faults, material damage and personal injury may occur.
MS-Graessner GmbH & Co. KG does not accept any liability for any resulting
damage and faults.
2. Intended use of MS-Graessner Gear Units
PowerGear gear units are components for machine installation and intended exclusively for guiding, distributing
and multiplying torques within the speed range up to 3500 min-1.
They comply with the machine directives (EN 292) and EMC directives to the extent they are applicable..
PowerGear gear units must only be used in the application cases provided for in the catalogue and the associ-
ated technical specifications.
Any other use and/or any use exceeding those cases described in the catalogue and/or associated technical
specifications is deemed not compliant with the intended use.
The manufacturer does not accept any liability whatsoever for any damage resulting therefrom. This risk shall be
solely borne by users.
PowerGear gear units can be used in a wide range of different areas; therefore, responsibility for the specific
application passes to users upon commencement of such use..
3. Conversions and alterations / Modifications of the product
PowerGear gear units must not be changed in terms of design or technical safety without our prior agreement.
Any unauthorized modification within the meaning of this provision excludes any liability on our part.
4. Set-up of gear unit / Technical data
4.1 Set-up of gear unit
PowerGear are angular gear units with case-hardened spiral bevel gear pairs, with gearing according to the
Gleason system, for installation in machines and plant.
The gear unit housings are machined on all sides and feature threaded bores for attachment on all sides via 3
spigot fits with standard tolerances. The mounting of the shafts by tapered roller bearings in a cantilevered sup-
port (drive) and fork mounting (output), shaft seal rings with dust lip, flange seals by lamella sealing discs. Math-
ematically exact ratios from 1.00:1 to 5.00:1. Gear unit in full shaft or hollow shaft design, for coupling transmis-
sion or direct attachment of the motor.
PowerGear gear units are intended for guiding, distributing and multiplying torques within the speed range up to
3500 min-1 (nominal), see also the current catalogue edition "PowerGear" in this regard.

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PowerGear gear units are in full compliance with the machine directives (EN 292) and EMC directives to the ex-
tent they are applicable.
4.2 Type designations
PowerGear P54 to P280
P version with type series L, H, FL, FH,
X version, reinforced, with type series L and H
Type series L
shown in ratio 2:1 and in Wa.2 (WA = shaft arrangement)
with 2 shaft ends on the output shaft. Additional shaft ar-
rangements are Wa.1 and Wa.3.
Fits on the shaft ends in k6
Type series H
shown in ratio 1:1, in Wa.2 (WA = shaft arrangement) with
fits in H7 at both shaft ends of the output shaft.
Fit on the drive shaft end in k6.
The bearings are provided as tapered roller bearings. The drive pinions are shrunk into the driven pinion gears on the shaft.
In the case of the reinforced X version the drive shafts are provided as pinion shafts.
PowerGear P360 to P450
P version with type series L and H
Type series L
Shown in ratio 1:1
The two bevel gears are connected to the shafts via feather
Type series L
Shown in ratio 3:1 (analogously 4:1 and 5:1)
complete with bevel gear on hub and pinion shaft.

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key, in addition there is a light shrink fitting.
For the ratio 2:1 the pinion is shrunk onto the drive shaft.
The bevel gear is screwed and bolted with the hub, this sits
in a feather key connection on the output shaft.

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PowerGear HS S90 to S170
S version with type series L and KH
Type series L
Shown in ratio 1:1
Drive and output with solid shaft. Output (here) on both
sides, or on one side left or right.
Type series KH
Shown in ratio 1:1
Drive with coupling and lantern, output with hollow shaft
and key groove.
Shaft bearings with angular contact ball bearings, lubrication with synthetic gear oil ISO VG 150
4.3 Performance tables
PowerGear P Standard
Nominal torque
on output T2N
(Nm) at
P54
P75
P90
P110
P140
P170
P210
P240
P280
P360
P450
I=1:1
15
45
78
150
360
585
1300
2150
3200
3750
6600
I=1.5
15
45
78
150
360
585
1300
2150
3200
3550
7000
I=2:1
12
42
68
150
330
544
1220
2010
3050
3500
7000
I=3:1
12
33
54
120
270
450
1020
1650
2850
3350
7000
I=4:1
28
52
100
224
376
860
1410
2300
2900
6600
I=5:1
25
40
85
196
320
740
1210
2000
2600
6000
PowerGear X reinforced version
Nominal torque
on output T2N
(Nm) at
X54
X75
X90
X110
X140
X170
X210
X240
X280
I=1:1
24
87
135
290
625
1020
2050
3350
5200
PowerGear HS High Speed
Nominal torque
on output T2N
(Nm) at
S90
S110
S140
S170
I=1:1
45
78
150
360
I=1.5:1
45
78
150
360
I=2:1
42
68
150
330

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The braking as well as the emergency stop moments are shown in the performance table in the catalogue, down-
load at www.graessner.de. There you will also find the moments for the reinforced gear unit versions X54 to X280
as well as for the high speed versions S90 to S170.
4.4 Technical data
PowerGear P
P54
P75
P90
P110
P140
P170
P210
P240
P280
P360
P450
Running noise
at 1500min-1
Partial load in
dB(A)
70
70
74
76
77
78
80
82
83
85
85
Weight kg
1.8
4.5
8.0
13.0
22.0
38.5
71.0
103.5
155.0
240
400
Lubrication
Synthetic gear oil ISO VG 150, up to size P140 with filling
Average oil
quantity in l
0.05
0.10
0.20
0.30
0.40
1.00
2.20
2.60
3.0
9.0
22.0
PowerGear X
X54
X75
X90
X110
X140
X170
X210
X240
X280
Running noise
at 1500 min-1
Partial load in
dB(A)
70
70
74
76
77
78
80
82
83
Weight in kg
1.9
5.0
8.5
13.5
22.5
39.0
71.5
104.0
155.5
Lubrication
Synthetic gear oil ISO VG 150, up to size P140 with filling
Average oil
quantity in l
0.05
0.10
0.20
0.30
0.40
1.00
2.20
2.60
3.00
PowerGear HS
S90
S110
S140
S170
Running noise at 1500 min-1
Partial load in dB(A)
< 70
< 74
< 76
< 77
Weight in kg
4.5
8.0
13.0
22.0
Lubrication
Synth. gear oil ISO VG 150
Average oil quantity in l
0.20
0.30
0.40
1.00
Operating temperatures PowerGear P and X respectively -30 to +90°C, PowerGear HS -30 to +100°C
Further technical data is shown in the catalogue
"PowerGear", download at www.graessner.de.
4.5 Type plate
The type plate comprises (example):
The exact type designation P140L, the ratio 1.00:1 and
the shaft arrangement Wa.13 (output on sides 1 and 3)
the article number of the gear unit
21140P000007
the serial number of the gear unit
S-N.3109634

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Details on explosion protection area of operation / zones

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5. Safety notes
5.1 Basic duties
The safety notes listed here are used to avoid personal injury and material damage, and must always be com-
plied with and observed.
For this purpose persons with responsibility for the plant as well as qualified personnel working on the gear unit
under its own responsibility must have read and fully understood these operating instructions, in order
- to prevent any hazards for life and limb of users and any third parties.
- to provide for the operational safety of the gear unit.
- to exclude downtime and environmental damage as a result of incorrect handling.
5.2 Qualified personnel
means persons having relevant education and training and a professional qualification who are able to detect
risks in the handling of these products and avoid possible hazards.
Specialists within the meaning of these operating instructions are persons who are familiar with the set-up, me-
chanical installation, fault removal and maintenance of the gear units and have the following qualifications:
Training in the field of mechanics with successfully completed professional training ( mechanic, machine fit-
ter, mechatronics engineer, toolmaker)
Knowledge of these operating instructions
All specialists must wear protective clothing appropriate to their activity.
5.3 Environmental protection
All existing packaging material must be disposed of in accordance with regulations or recycled.
When changing the oil, the used oil must be caught in suitable vessels. Any pooled oil spills must be removed
immediately by means of a binding agent.
Any pooled oil spills must be removed immediately by means of a binding agent.
Used oil, oil binding agent or oil-contaminated cleaning cloths must be disposed of in accordance with the rele-
vant environmental protection regulations.
Disposal of the gear unit following the end of its service life:
Drain oil and preservation agents completely from the gear unit and dispose of as waste oil in accordance
with the applicable national regulations
Housing parts, shafts, roller bearings and geared parts must be disposed of or recycled in accordance with
applicable national regulations, depending on the relevant provisions also separately.
Serious personal injury and material damage due to
incorrect use of the gear unit
incorrect installation or operation
Risk to life due to operational plant
When working on the gear unit, the gear unit must always be shut down.
The drive must have been secured against unintentional activation. (Keyswitch or removal
of fuses). At the point of switch-on, an information sign must be affixed indicating the shut-
down. The drive must have been secured against unintentional activation. (Keyswitch or
removal of fuses). At the point of switch-on, an information sign must be affixed indicating
the shutdown.
The drive must have been secured against unintentional activation. (Keyswitch or removal
of fuses). At the point of switch-on, an information sign must be affixed indicating the shut-

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down.
Serious personal injury and material damage due to
non-permissible removal of the necessary protective covers!
6. Transport, storage and long term storage
6.1 Transport
Any work regarding transportation, storage, siting, installation, commissioning, operation, service and mainte-
nance must be carried out by qualified personnel only.
Any damage identified after delivery must be communicated immediately to the transport company, if appropri-
ate, commissioning / activation must be excluded.
The transportation of the gear unit must be effected such that personal injury and damage to the gear unit are
avoided.
Danger:
Immediate danger with serious bodily injury as a consequence!
(Here risk of crushing for bodies or body parts)
Transportation must only be effected by means of suitable means of transportation intended for this purpose.
When attaching to eye bolts this must only be carried out at the bores provided for this purpose with approved
and sufficiently dimensioned means of attachment. No diagonal pull must arise.
Plant-specific provisions and requirements must be complied with.
Relevant national and regional regulations for safety, accident prevention and environmental protection must be
complied with.
6.2 Storage conditions
PowerGear - gear units must only be stored in a closed condition, in a dry, dust-free and low vibration (avoiding
damage due to bearing shutdown) environment without any sun radiation at temperatures between -25
and +50°C.
Series gear units can thus be stored for up to 1 year.
Always check the oil level before taking the gear unit into service.
6.3 Long-term storage
If storage is intended to extend for more than 1 year, the version "for long term storage" is recommended.
These gear units can be stored for a period of up to 5 years maximum.
External preservation is carried out by applying a permanent preserving agent.
Internal preservation is carried out by applying a synthetic gear oil based on PAO.
It is recommended to turn the gear units at regular intervals to ensure that the bearings do not become stuck
(seize up); rotating the gear units in this way also counteracts the possible occurrence of any standstill markings
and the shaft seal rings do not stick and/or become brittle.
6.4 Commissioning
Before commissioning, drain the oil and replenish with fresh oil. If taken into service before the expiry of the 5
years, the function of the gear unit is assured.
If commissioned at a date later than 5 years after being put into storage, the roller bearings, sealing elements
and gear oil must all be replaced.

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7. Installation
7.1 General installation instructions
The installation must only be effected by qualified, authorized and trained personnel.
The safety notes in Section 3 must be complied with.
When transporting the gear unit the notes in Section 6 must be complied with.
Suitable crane tackle and lifting gear must be provided.
Before commissioning
- fill the gear unit to the correct oil level, unless the gear unit is provided with lubrication for life.
- before commissioning check the correct attachment of the transmission parts
- do not deactivate monitoring and protection devices, not even during test operation
If oil level indicators or inspection glasses exist, then the markings on these, or the centre of the oil inspection
glass, are to be taken as minimum markings.
Oil inspection
glass,
Oil level centre
Oil check screw:
The oil level affects
the thread in the
housing bore
Oil quantities (dependent on ratio, speed, shaft arrangement and installation position)
Build size
P54
P75 /
X75
P90 /
X90
P110 /
X110
P140 /
X140
P170 /
X170
P210 /
X210
P240 /
X240
P280 /
X280
P360
P450
average oil quantity
0.05
0.1 l
0.2 l
0.3 l
0.4 l
1.0 l
2.2 l
2.6 l
3.0 l
9.0
22.0
max. oil quantity
-
-
-
0.35 l
0.6 l
1.2 l
2.5 l
3.5 l
5.0 l
15.0
32.0
7.2 Gear unit installation in plant
During installation or assembly ensure the following:
- an even support on a level, vibration-dampened and torsion-free substructure, stress and strain in the housing
must be avoided.
- Perfect lubrication and ventilation are only assured with an installation in accordance with the drawings and
build type.
- tension-free assembly with combined flange or insertion mount attachment
- exact alignment of the gear unit for direct coupling, comply with manufacturer's details
7.3 Installation positions (MP = mounting position)

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7.4 Fitting of motors
The gear unit types FL and FH are equipped at the drive end with a hollow shaft complete with key groove, the
bore fitting is provided of H7 quality. The motor shaft must always be positioned and fitted such that it is in
alignment with the gear shaft. Coat shafts with assembly paste, then join up motor to the gear shaft.
Do not use a hammer to drive in motor, but use the suitable bores and threads on gear unit and motor to pull the
same with mounting bolts up to the flange surfaces until the motor is in close contact.
If there is stress on the bearings, the motor will spring back easily, repeat process until motor and gear unit are
in stress-free contact with the flanges and the shafts can be rotated easily.
Attention damage to gear unit:
If the motor is driven on by the hammer, gear unit damage may occur.
Any stress and tension on the bearings may cause them to overheat and cause
bearing damage with ensuing blockage.
Drive with lantern and coupling
a. Preparation
The surfaces of the coupling bores and the shaft ends must be free from dirt, above all from grease and oil.
b. Installation of the coupling
The radially located clamp screw of the coupling half to be fitted is turned to the left, until the screw head is in
contact with the cross pin fitted in the depression. By continuing to rotate the screw the coupling bore is elastical-
ly expanded, so that the coupling can be slid easily onto the shaft. For disassembly, proceed analogously.
Clamp screw and cross
pin.
Turn screw to the left until
the head of the screw is in
contact with the cross pin. If
you then continue to turn
the screw further to the left,
the coupling will be ex-
panded.
ATTENTION: Expand only
to such an extent that the
coupling can be fitted, oth-
erwise there is a risk of
fracture.
Coupling expanded for
fitting.
Coupling bores must be
free from dirt and
grease.
After installation the
clamp screw must be
tightened with the neces-
sary tightening torque
Tightening torques of the clamp screws
Screws: DIN 912, 10.9, galvanized
M4
M5
M6
M8
M10
5 Nm
10 Nm
14 Nm
35 Nm
65 Nm
7.5 Installation of the other fitted components
The drive and output elements (gears, belt wheels, jointed shafts etc.):
- must have been balanced with G 6.3,
- must only be fitted using suitable fitting and withdrawal devices,
- must be axially secured even if they have been shrunk on,
When using suitable tensioning elements the tightening torques must be taken into account.
The components must be mounted onto the shaft as far as is specified in the article-related dimension sheet.
In the case of a belt drive the correct belt tension must be assured, comply with the manufacturer's instructions
in this regard. The permissible transversal forces for the shaft must not be exceeded (see catalogue).
Drive and output elements must be covered by contact protection.

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7.6 Finishing work
- Before fitting protective covers check again the correct oil level in the gear unit.
- Check for even running free from strains, stresses and any faults.
- Fit protective covers.
- Carefully clear away all tools as well as any parts not fitted.
Attention:
Due to incorrect installation the gear unit can be damaged and become unusa-
ble. Such damage may be caused by falling objects, dumping, welding work or
insufficient attachment.
Due to incorrect installation the gear unit can be damaged and become unusable.
Such damage may be caused by falling objects, dumping, welding work or insuf-
ficient attachment.
The operator must ensure:
The gear unit must be protected against any falling objects and dumping.
Welding work must not be carried lout on any part of the drive.
The gear unit must not be used as a ground point for electric welding work.
All mounting options assigned to the build type must be used.
Any screws that have become unusable during assembly and disassembly must be
replaced by new ones featuring the same design and strength class.
Attention damage to gear unit:
Impacts or shocks during the mounting of the coupling may cause damage inside
the gear unit.
Fit couplings with pull-on devices.
The shaft seal rings and the running surfaces of the shafts must not be damaged
when fitting the coupling parts.

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8. Commissioning
- The commissioning (taking up operation in accordance with the intended use) of the PowerGear gear unit is
prohibited until it has been determined that the machine or plant complies with the provisions of the EU machine
directive.
- Before commissioning check the correct attachment of the transmission parts.
- Check oil level
- Do not deactivate monitoring and protection devices, not even during test operation.
- The use of an aeration and ventilation filter is not necessary for gear units up to P110 / X110 , for gear
units from P140 / X140 we recommend its use, as soon as the gear units exceed an operating tempera-
ture of 60°C.
The first start-ups must be carried out without load and at low speeds, until it is ensured that all roller bearings,
bevel gears and shaft seals are wetted with oil, then increase speed to approx. 500 min-1
After approx. 30 min. slowly increase speeds until operational speed is reached, running-in time at idle approx.
90 minutes.
- During start-up and run-up pay attention to running noise and temperature development, in particular at the
bearing points. In the case of unusual running noise, shut down machine and identify fault.
See Section 10: "Faults, causes and remedies."
Apparent leakage at the shaft seal rings
Grease emerging from the lubrication in the shaft seal rings does not represent an oil leak. This is an apparent
leakage, until the remaining lubricant has become regulated.
Wipe off any such apparent leakage and continue to observe.
Attention damage to gear unit:
If the new gear unit is started up too rapidly, this may cause bearings to overheat,
as well as cause insufficient lubrication on the gear flanks!
It is necessary to allow the gear unit to run-in in stages!
Warning:
Risk of burns!
Serious burns possible on hot surfaces (>55°C).
Wear suitable gloves and protective clothing.

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9. Operation of Power Gear
9.1 General notes on operation
The notes at item 1 "General safety notes", item 10 "Faults, causes and remedies", and item 11 "Inspection and
maintenance" must be complied with.
In order to achieve a perfect trouble-free operation of the gear unit, the operating factors defined in the "Tech-
nical Data" must be complied with.
9.2 During operation monitor the following:
Operating temperature
When using mineral gear oils (CLP) the operating temperature should not exceed 80°C or only exceed this
limit for a short temporary time period. When using synthetic gear oils (CLP) an operating temperature - in
connection with sealing rings made of FKM (fluorinated rubber, viton) - of temporarily 110°C is permissible.
Changing gear unit noises, vibrations
Oil leakage on the housing and on the shaft seal rings
Oil level –for oil level checking the gear unit must be shut down.
Check oil levels only with the gear unit in a cooled down condition:
If an oil inspection glass is available, the oil level shown must be at the centre of the oil inspection
glass
Without oil inspection glass, the check is performed at the screw plug of a vertically positioned hous-
ing surface. The oil level must be in contact with then thread in the housing (see page 11, Section
7.1)
Attention:
Insufficient lubrication caused by an excessively low oil level may cause damage
to the geared parts and the bearings!
Carry out a regular oil level check
Warning:
Serious burns possible on hot surfaces (>55°C)
Wear suitable gloves and protective clothing
9.3 Irregularities
In the event of any changes in relation to standard operation, e.g. increased temperatures, noises, vibrations, the
gear unit must be shut down in any case of doubt so that the cause of such changes can be determined.
See Section 10: "Faults, causes, remedy."
If necessary, contact our service department for consultations.

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10. Faults, causes, remedy
10.1 General fault indications
The Sections 5 "Safety notes" and 11 "Service and Maintenance" are to be complied with!
Faults occurring during the warranty period, which necessitate a repair of the gear unit, must only be removed by
service department employees of MS-Graessner.
If, on expiry of the warranty period, faults should occur whose cause cannot be clearly recognized, contact the
service department at MS-Graessner.
10.2 Possible faults
Faults
Causes
Remedy
Changed operating noise
Damage to gearings
Bearing play is increased.
Bearing is defective
Check geared components; if necessary, re-
place any damaged components, adjust bear-
ing play, contact service department
Replace defective bearing, contact service
department
Increased temperature at
the bearing points
Oil level in the housing is too low or too
high
Oil is too old
Bearing is defective
Check oil level at room temperature, if neces-
sary replenish or drain oil.
Check when the last oil change has been car-
ried out.
If necessary, change the oil
Check bearing condition; replace, if neces-
sary; contact service department
Gear unit is oily on the out-
side
Insufficient sealing of the bearing flang-
es and gear unit covers
Seal bearing flanges and gear unit covers
Oil leak at the ventilation fil-
ter
Oil foams
Oil level in the gear unit is too high
Incorrect execution of the ventilation
See fault "Oil foams in gear unit"
Decrease oil level in gear unit to the pre-
specified level
Prevent any direct oil injection by attaching
suitable extensions or angle pieces
Oil leaks from gear unit
Insufficient sealing of the bearing flang-
es and gear unit covers
Radial shaft seal rings are defective
Check seals, replace if necessary
Check radial shaft seal rings, replace if nec-
essary.
Oil foams in gear unit
Water in oil
Oil too old (De-foaming agent used up).
Unsuitable oils mixed up
Examine oil condition for water ingress by
means of a test tube sample.
Have the oil sample analysed, change oil.
Examine oil, change oil
Examine oil, change oil
Water in oil
Water condensates in the gear unit by
external climatic conditions, sun, wind,
cold: Ambient temperatures change a
great deal.
Protect gear unit against temperature influ-
ences
Increased operating tem-
perature
Oil level in the gear unit is too high.
Oil is too old
Oil is highly contaminated
Check oil level Correct if necessary.
Check when the most recent oil change was
carried out, change oil
Have the oil sample analysed, change oil.

gmb / BA PowerGear_EN as of May 2015 / 29.10.2015 Page 19 of 23
11. Inspection and maintenance
11.1 General notes
All service and maintenance work must only be carried out by qualified personnel.
See "Safety Notes 3.2" in this regard.
For carrying out service and maintenance tasks the gear unit must always be shut down.
The drive unit must be secured against any unintentional start-up (key switch, lock) and an information sign must
be affixed with the information that work is being carried out on the gear unit.
Warning:
Major risk of injury due to accidental start-up of the drive unit!
Before commencing any maintenance work, secure gear unit against any start-up!
Warning:
Major risk of injury due to disassembly of transmission parts (couplings, jointed
shafts, belts, etc.) whilst torsional forces are still acting on the gear shafts!
Secure gear shafts against torsional forces and disassembly transmission ele-
ments.
11.2 Service intervals
If service intervals are not complied with, major damage may be caused to the gear unit and within the plant.
Therefore it must be ensured that these service intervals are observed.
Measures
Service intervals
Remarks
Check running noise for any
changes
daily
Check gear unit for leakage
daily
Check oil level
monthly
Carry out first oil change
500 operating hours after commissioning
Chapter 11.3
Carry out additional oil changes
mineral oil filling
Every 24 months or 10000 operating hours
Chapter 11.3
Carry out additional oil changes
Synthetic oils
Every 4 years or 20000 operating hours
Chapter 11.3
Check gear unit condition
Every 2 years
Chapter 11.4
11.3 Oil service life
The oil service life at 80°C mean oil temperature in the gear unit without any serious change in the oil qualities
are specified by the oil manufacturers as minimum values:
For mineral oils, biodegradable oils and physiologically harmless oils 2 years or 10,000 operating hours
For synthetic oils (polyalphaolefins and polyglycols) 4 years or 20,000 operating hours
Note on oil service life
The actual relevant oil service life may be longer, but also shorter for operating temperatures in excess of
80°C. Here, the rule applies that a temperature increase by 10°C approximately halves the service life of the
oil.
11.4 Oil change
Oil should be drained directly after shutdown whilst the oil is still warm.

gmb / BA PowerGear_EN as of May 2015 / 29.10.2015 Page 20 of 23
Caution:
There is a risk of burns on the hot gear unit,
and a risk of scalding when draining the oil!
Provide for suitable protection measures!
Screw off aeration and ventilation filter or remove top screw plug on one side of the housing, open oil drain plug
and catch oil in suitable vessel.
Fit drain plug with new copper seal and screw back into housing.
Fill gear unit with oil, see also Chapter 8.
Replace oil filler plug or aeration and ventilation filter.
Material damage
Possible damage to the gear unit by defective lubrication due to incorrect or mixed
oils.
When carrying out an oil change always refill with the oil type previously used!
It is not permitted to mix different makes or mineral and synthetic oils, in particular
hydrocarbon oils must not be mixed with polyglycols. The mixtures may become
resinous or agglutinate and then precipitate into the gear unit.
11.5 Checking gear unit condition
This check must only be carried out by qualified operating personnel or the MS-Graessner service department.
Here it must be possible to assess reliably what exactly needs to be replaced on the gear unit, or it must be de-
termined that all gear unit components are in order.
12. Replacement parts, replacement part stocks, service
12.1 Replacement parts
Wear part packs and replacement parts complete with replacement or repair instructions are available from our
service department.
The designation and positioning of the individual parts are shown in the associated dimension sheets and re-
placement part drawings.
12.2 Replacement part stocks
We recommend keeping a stock of the most important replacement parts and wear parts in the vicinity of the
place of use of the gear unit, so as to ensure the operational readiness of the gear unit in this way.
The parts are shown in the replacement part drawings
12.3 Service
Should you require help from our service department please provide the following details:
- Gear unit type and size
- All data printed on the type plate (see photograph on page 7).
If the type plate is missing, you will find the serial number stamped into the housing.
- Type and scope of the fault
- Suspected cause
- Photographs of any damage (digital)
Note
Contact to Customer Service see pages 4, 8 and 20 (bottom)