Nidec EvoGear L User manual

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Page 1 of 22
Servo Angular Gears
EVOGEAR
EvoGear L / LSV
EG55 to EG115
EvoGear PLS
EG55 to EG115
EvoGear PLT
EG55 to EG115
Installation and Operating Instructions
Issue 2021-07

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Table of Contents
1. General Information
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 Nidec Graessner Gearboxes
5
3. Conversions and Changes / Modification of the Product
5
4. Gearbox Design / Technical Data
4.1 Gearbox Design
4.2 Type Designations
4.3 EvoGear Performance Tables
4.4 EvoGear Technical Data
4.5 EvoGear Technical Data with Planetary Gear Stage
4.6 Type Plate and Designations
6
6
6
8
8
9
9
5. Safety Information
5.1 Fundamental Obligations
5.2 Qualified Personnel
5.3 Environmental Protection
10
10
10
10
6. Transport, Storage and Long-Term Storage
6.1 Transport
6.2 Storage Conditions
6.3 Long-Term Storage
6.4 Commissioning after Long-Term Storage
11
11
11
11
11
7. Installation
7.1 General Installation Instructions
7.2 Gearbox Installation in the Plant
7.3 Attachment of Motors
7.4 Installation of the other Add-on Components
7.5 Final Work
12
12
12
12
15
15
8. Commissioning
16
9. Operation of the EvoGear Gearbox
9.1 General Information on Operation
9.2 During operation monitor the following
9.3 Irregularities
16
16
17
17

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10. Faults, Causes and Remedies
10.1 General Fault Indications
10.2 Possible Faults
17
17
18
11. Inspection and Maintenance
11.1 General Information
11.2 Maintenance Periods
11.3 Oil Service Life
11.4 Oil Change
11.5 Checking the Gearbox Condition
19
19
19
19
20
20
12. Replacement Parts, Stocking of Replacement Parts, Service
12.1 Replacement Parts
12.2 Stocking of Replacement Parts
12.3 Service Department
20
20
20
20
13. Keyword Index (alphabetical)
21

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1. General Information
1.1 Use of the Operating Instructions
These operating instructions are an integral part of the product and must be carefully read through before use
and kept in a safe place for subsequent consultation.
They contain important information on the operation and servicing of the EvoGear gearbox range. These
operating instructions are intended for all individuals who carry out assembly, installation, commissioning and
service work on gearboxes from this gearbox range.
The gearboxes in the EvoGear range are components for installation in machines and are intended exclusively
for the deflection, distribution and multiplication of torques.
EvoGear gearboxes are only designed for the field of application described in Section 2 “Technical Data”.
Other conditions of use must be agreed with Nidec Graessner GmbH & Co. KG and contractually regulated.
The gearboxes are manufactured according to the latest technical standards and delivered in a condition in
which they are safe to operate. They conform to the current status of the description as contained in these
operating instructions.
We reserve the right to make technical changes to components while maintaining the performance
characteristics and safety of the gearboxes.
1.2 Significance of the Warning Notes
The warning notes are mentioned within the context in which a hazard may occur and refer to the same. They
refer to the hazards and the possible consequences if the 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 and comprise:
Note
Useful note or information
Attention:
Material damage may occur to 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: crushing hazard)
Danger:
Immediate danger of death or serious bodily injury as a consequence
(Here: crushing hazard for the body)
1.3 Exclusion of Liability
For damage and malfunctions resulting from non-compliance with the instructions,
Nidec Graessner GmbH & Co. KG does not accept any liability.
1.4 Copyright
The copyright to these instructions remains with Nidec Graessner GmbH & Co. KG –all rights reserved

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These instructions are available on our website
www.graessner.de
as a download.
For all technical questions, please contact our Product Management or Service Department:
Nidec Graessner GmbH & Co. KG
THE GEAR COMPANY
Kuchenaecker 11
D-72135 Dettenhausen
Product Management
Department
Service Department
Tel.: [phone]
Fax: [phone]
Fax: [phone]
[email protected]
www.graessner.de
These operating instructions must be read carefully before use.
Damage to the gearbox, malfunctions, damage to property and personal injury
are possible if these instructions are not observed.
Nidec Graessner GmbH & Co. KG does not accept any liability for damage and/or
malfunctions resulting from this.
2. Intended Use of Nidec Graessner Gearboxes
EvoGear gearboxes are components which are intended for incorporation into machines and are to be used
exclusively for the deflection, distribution and multiplication of torques.
They comply with the Machinery Directives (EN ISO 12100) and EMC Directives, to the extent that these are
applicable.
EvoGear gearboxes may only be used for the applications provided for in the catalogue and in the associated
technical specifications.
Any other use or use that goes beyond the above is considered to be contrary to their intended use.
The manufacturer does not accept liability for any damage resulting from this. This risk shall be borne by the
user alone.
EvoGear gearboxes can be used in a wide range of different areas; for this reason, responsibility for the specific
application is transferred to the user in such cases.
3. Conversions and Changes / Modification of the Product
EvoGear gearboxes must not be changed with respect to their design or safety-related aspects without our prior
agreement. Any unauthorized modification within this meaning shall exclude any liability on our part.

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4. Gearbox Design / Technical Data
4.1 Gearbox Design
EvoGear are angular gears with case-hardened bevel gear pairs with Gleason hypoid toothing for incorporation
into machines and systems. The EvoGear is performance-matched to all common servo motors and can be
variably adapted by means of the flange and coupling.
The gearboxes offer optimum centring on the input (motor flange/lantern) and on the output (mounting side 1 of
the housing).
The shafts are supported by tapered roller bearings in a cantilever bearing arrangement (input) and a fork
bearing arrangement (output), shaft seals by shaft seal rings made of NBR (nitrile rubber “Perbunan”) and FKM
(fluorocarbon rubber “Viton”); flange seals by laminated sealing washers. The ratios are mathematically
accurate from 3.00:1 to 100:1 in the standard version. Gearbox in a full shaft or hollow shaft design, for coupling
transmission or direct mounting of the motor.
EvoGear complies with the Machine Directives (EN ISO 12100) and EMC Directives to the extent that these are
applicable.
4.2 Type Designations
EvoGear EG55 to EG115
Output in full shaft (build types L) and hollow shaft design LSV with motor lantern and coupling
L range (full shaft)
Shown in the single-stage version and 1L shaft
arrangement, with 1 output shaft on side 1, with motor
lantern and metal bellow-type coupling on the drive side.
H range (hollow shaft)
Shown in the single-stage version and 1LSV shaft
arrangement, with motor lantern and metal bellow-type
coupling on the drive side.

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EvoGear PLS
Output in full shafts with planetary gear stage
Shown: PLS range with full shaft
and planetary gear stage, with motor lantern and metal bellow-
type coupling on the drive side.
Shown: PLS range for mounting on side 1.
EvoGear PLT
Output with planetary gear stage and robot flange
Shown: PLT range with robot flange, with motor lantern and
metal bellow-type coupling on the drive side.
Shown: PLT range for mounting on side 1.

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4.3 EvoGear Performance Tables
EvoGear performance tables without planetary drive
Nominal torque at output T2N (Nm) for
EG55
EG75
EG90
EG115
3:1
35
70
140
260
4:1
35
70
140
260
5:1
35
70
140
260
6:1
35
70
140
260
8:1
35
70
140
260
10:1
35
70
140
260
12:1
25
50
95
180
15:1
25
50
95
180
EvoGear performance tables with planetary drive on the output
Nominal torque at output T2N
(Nm) for
EG55
EG75
EG90
EG115
i=16
80
200
380
850
i=20
86
220
410
910
i=25
106
280
590
1100
i=28/35/40/50/70
118
280
590
1300
i=100
88
220
440
930
For the max. acceleration torques and the emergency stop torques, please refer to the performance
tables in the catalogue, which can be downloaded at www.graessner.de.
4.4 Technical Data
EvoGear Technical Data
EG55
EG75
EG90
EG115
Running noise at 3000 min-1
Partial load in dB(A)
<66
<66
<68
<68
Weight in kg
2.9
4.8
8.6
13.3
Average oil quantity in l
0.05
0.08
0.06
0.08
0.12
0.15
0.3
0.4
Service life LH (h)
Lubrication:
Installation positions:
Operating temperature:
Paint finish:
Ex-Protection:
Protection class:
>30,000 S5 load spectrum as design basis
synthetic gear oil POA base, ISO –VG 150
any
-10°C to +90°C
Primer RAL 9005 –matt black
Explosion-proof gearboxes available on request
IP 64

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4.5 Technical Data
EvoGear Technical Data with Planetary Gear Stage on the Output
EG55
EG75
EG90
EG115
Running noise at 3000 min-1
Partial load in dB(A)
<68
<68
<70
<70
Approx. weight in kg
5.0
9.9
19.5
38.0
Average oil quantity in l
0.06
0.08
0.12
0.15
0.3
0.4
0.55
0.75
Service life LH (h)
Lubrication:
Installation positions:
Operating temperature:
Paint finish:
Ex-Protection:
Protection class:
>20,000 S5 load spectrum as design basis
synthetic gear oil POA base, ISO –VG 150
any
-10°C to +90°C
Primer RAL 9005 –black + silver
Explosion-proof gearboxes available on request
IP 64
4.6 Type Plate and Designations
The type plate contains (example):
•Gearbox range
•Type designation: EG055
•Ratio: 10.00:1
•Shaft arrangement: 1LSV
•the article number: EVO000079
•the serial number: 3189769
For further technical information, please refer to the “EvoGear”catalogue,
which can be downloaded at www.graessner.de,
or which is available as a printed version from our Product Management and
Service Department.

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5. Safety Information
5.1 Fundamental Obligations
The safety information provided here is intended to prevent personal injury and damage to property and must be
observed and complied with without fail.
For this purpose, individuals are responsible for the plant, as well as qualified personnel who work on the
gearbox on their own responsibility must have read and fully understood these operating instructions.
- in order to avert any hazards to life and limb of the user and third parties.
- in order to ensure the operational safety of the gearbox.
- in order to exclude any loss of use and environmental damage resulting from incorrect handling.
5.2 Qualified Personnel
are individuals who have relevant training and a professional qualification and who are skilled at recognising
risks and avoiding possible hazards when dealing with these products.
Skilled personnel within the meaning of these operating instructions are individuals who are familiar with the
structure, mechanical installation, troubleshooting and maintenance of the gearboxes and who have the
following qualifications:
•Training in the field of mechanics with successfully completed vocational training (mechanic, machine fitter,
mechatronics engineer)
•Knowledge of these operating instructions
All specialists must wear protective clothing that is appropriate to their work.
5.3 Environmental Protection
* All existing packaging material must be disposed of in accordance with the regulations or recycled.
* When the oil is changed, the waste oil must be collected in suitable containers. Oil spills must be removed
immediately using oil-binding agents.
* Waste oil, oil-binding agents or oil-contaminated cleaning cloths must be disposed of in accordance with the
relevant environmental protection regulations.
* Disposal of the gearbox at the end of its service life:
•Drain oil and preservatives completely from the gearbox and dispose of as waste oil in accordance with the
applicable national regulations.
•Housing parts, shafts, roller bearings and geared parts are to be disposed of or recycled in accordance with
the applicable national regulations –also separately depending on the applicable provision.
Serious personal injury and damage to property due to
•improper use of the gearbox
•incorrect installation or operation
Risk to life due to operational plant
When work is carried out on the gearbox, the gearbox must always be shut down. The
input must be secured against unintentional switch-on (key switch or removal of the
fuses). A sign indicating that the gearbox has been shut down must be attached at the
switch-on point.
Serious personal injury and damage to property due to
non-permissible removal of the necessary protective covers

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6. Transport, Storage and Long-Term Storage
6.1 Transport
Any work regarding transport, storage, siting, installation, commissioning, operation, service and maintenance
must be carried out by qualified personnel only.
Any damage identified after delivery must be communicated IMMEDIATELY to the transport company, if
appropriate, commissioning / activation must be excluded.
The gearbox must be transported in such a way that personal injuries and damage to the gearbox 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 eyebolts, this may only be carried out at the bores provided with approved and sufficiently
dimensioned lifting gear. 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
EvoGear gearboxes may only be put into storage in a closed condition, in a dry, dust-free and low-vibration
environment (avoidance of standstill damage) without sunlight at temperatures between -25°C and +50°C.
Serial gearboxes can be stored for up to 1 year in this manner.
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 gearboxes can be stored for a maximum period of 5 years.
External preservation is carried out by applying a permanent preserving agent.
Internal preservation is carried out with a PAO-based synthetic gear oil.
It is recommended to turn the gearboxes at regular intervals to ensure that the bearings do not become stuck
(seize up); rotating the gearboxes 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 after Long-Term Storage
If commissioning is carried out before the expiry of the 5 years, the function of the gearbox is assured.
If commissioning is carried out later than 5 years after being put into storage, the roller bearings, sealing
elements and gear oil must all be replaced.
For this purpose it is probably best if you return the gearbox to our Service Department.

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7. Installation
7.1 General Installation Instructions
The installation must only be effected by qualified, authorized and trained personnel.
When transporting the gearbox the notes in Section 6 must be complied with.
Suitable crane tackle and lifting gear must be provided.
Before Commissioning
•Before commissioning, check the correct attachment of the transmission parts
•Do not deactivate monitoring and protection devices, not even during test operation
Oil quantities (dependent on ratio, speed, shaft arrangement and installation position)
See EvoGear Technical Data under Section 4.4 (page 8)
EvoGear Technical Data PLS and PLT under Section 4.5 (page 9)
7.2 Gearbox Installation in the Plant
During installation or assembly ensure the following:
•uniform support on a level, vibration-damped and torsion-free surface
substructure, stresses and strains in the housing must be avoided
•tension-free assembly with combined flange or push-on attachment
•exact alignment of the gearbox for direct coupling –comply with the manufacturer's instructions
7.3 Attachment of Motors
7.3.1 Input with Motor Flange/Lantern and Coupling
a. 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
elastically expanded, so that the coupling can be slid easily onto the shaft. For disassembly, proceed
analogously.
Clamp screw and
cross pin.
Turn the screw to the
left until the screw head
is in contact with the
cross pin. If you then
continue to turn the
screw further to the left,
the coupling will be
expanded.
ATTENTION: Expand
only to such an extent
that the coupling can be
fitted, as otherwise
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 necessary
tightening torque

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The drive shaft end must be free
from dirt, oil and grease
Fit the coupling and prepare as
described above. If specified, set the
mounting dimension of the coupling
in accordance with the dimension
sheet. Tighten clamp screw.
Install lantern and tighten
screw(s).
The coupling can be tightened on
the motor side through the bore at
the top. It is recommended to turn
the lantern such that this bore is
located on the side of the terminal
box of the motor.
The mounting dimension of the coupling to the gearbox is stated in the corresponding dimension sheet. If
nothing to the contrary has been stated there, push the coupling onto the shaft until it rests against the shaft
shoulder.
After tightening the coupling, place the motor lantern in position and screw it tight, ensuring that the bores
provided for tightening the clamp screws on the coupling are located on the same side as those on the motor.
Tightening torques of the clamp screws on the couplings
Screws: DIN 912, 10.9, galvanised, black
M4
M5
M6
M8
M10
5 Nm
8.5 Nm
14 Nm
35 Nm
69 Nm
b. Mounting the Motor
Preferred installation in the vertical position. Always position the motor shaft with the gear shaft such that it is in
alignment with the coupling. The metal bellows of the coupling must be neither bent nor axially compressed
during assembly. Do not drive in the motor with a hammer, but use suitable bores and threads on the gearbox
and motor to allow it to slide into position with assembly screws into the centring seat until the motor is in close
contact; then tighten the coupling on the motor side.
There must be no distortion of the bearings or coupling.
After tightening the clamp screws, insert plug into the bore.
Attention gearbox damage:
Due to incorrect assembly the coupling can become compressed or bent!
Due to the bearings becoming distorted, overheating of the same may occur
which then causes damage to the bearings ending in blockage.
The shaft seal rings and the running surfaces of the shafts must not be damaged
when fitting the coupling parts. Otherwise leakages may occur!
Other coupling types and versions can also be installed on request!
As a matter of principle, we refer to the assembly and operating instructions of the respective coupling
manufacturer!

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7.3.2 Input via Clamping Hub and Clamping Ring Screw (Example: EvoGear PLT)
Clean the clamping hub, bore and
flange surface of the planetary gear
stage so that it is free of dirt and
grease and then do the same on the
motor shaft and motor flange.
Position the clamping hub with the
clamp screw, then open the same.
Preferred mounting position: Gearbox
and motor vertical. Insert the motor
into the gearbox from below.
The motor must be in tension-free
contact with the gearbox flange, then
screw in screws using screw locking
paste and tighten crosswise to the
prescribed tightening torque.
Tightening torques for screws on flanges, lanterns and motors DIN 912, 8.8
M5
M6
M8
M10
M12
6 Nm
10 Nm
25 Nm
50 Nm
86 Nm
Tightening torques of the clamp screws on the clamping hubs
Gearbox
EG55
EG75
EG90
EG115
Tightening
torque of the
clamp screw MA
(Nm)
6
9
9
up to Ø 14 - 11 Nm
from Ø 19 - 20 Nm
Width across
flats Allen key
(mm)
4
4
4
5
Tighten the tensioning screw in
the clamping hub with a
suitable MA,
fit plug.

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7.4 Installation of the other Add-on Components
The drive and output elements (gears, belt wheels, cardan 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 and the manufacturer's instructions must be
complied with. The permissible transversal forces for the shaft must not be exceeded (see catalogue).
Drive and output elements must be covered by contact protection.
7.5 Final Work
•Before fitting protective covers, check the correct oil level in the gearbox, if possible.
•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 gearbox can be damaged and become
unusable, e.g. due to falling objects, spillage, welding work or insufficient
fastening.
The operator must ensure:
•The gearbox must be protected against any falling objects and spillage
•Welding work must not be carried out on any part of the input
•The gearbox must not be used as a grounding point for electric welding work
•All mounting options assigned to the build type must be used.
•Any screws that have become unusable during assembly or disassembly must be
replaced by new ones featuring the same design and strength class.

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8. Commissioning
The commissioning (start of operation in accordance with the intended use) of the EvoGear gearbox is
prohibited until it has been determined that the machine or plant complies with the provisions of the EU
Machinery Directive.
Before commissioning, check the correct attachment of the transmission parts.
If possible, check the oil level.
Do not deactivate monitoring and protection devices, not even during test operation.
With EvoGear gearboxes, the use of an aeration and ventilation filter is not provided for. In special
cases, with very high operating temperatures, an aeration and ventilation filter may help in S1 operation
to decrease the temperature and avoid leakages. Please contact our Product Management in this
regard.
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 the 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 min.
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 settled.
Wipe off any such apparent leakage and continue to observe.
Attention gearbox damage:
If the new gearbox is started up too rapidly, this may cause bearings to overheat,
as well as causing insufficient lubrication on the gear flanks.
It is necessary to allow the gearbox to run-in in stages
Warning:
Risk of burns
Serious burns possible on hot surfaces (>55°C)
Wear suitable gloves and protective clothing
9. Operation of the EvoGear Gearbox
9.1 General Information on Operation
The notes under item 1 “General safety information”, 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 gearbox, the operating factors defined in the
“Technical Data”must be complied with.

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9.2 During operation monitor the following:
- Operating temperature
When using mineral gear oils (CLP) the operating temperature should not exceed 90°C or only exceed this limit
for a short period of time. When using synthetic gear oils (CLP), an operating temperature of 110°C for a short
period of time is permissible if all sealing rings are made of FKM (fluorocarbon rubber, “Viton”), whereby it must
be ensured that the shaft seals on the drive shafts are already FKM as standard.
See also Section 11.3 Oil Service Life
- Changing gearbox noises, vibrations.
- Oil leakage on the housing and on the shaft seal rings.
- Oil level –for oil level checking, the gearbox must be shut down.
Check oil levels only with the gearbox 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 an oil inspection glass, the check is carried out on the screw plug, if present, of a vertical
housing surface. The oil level must be in contact with the thread in the housing.
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 additional protective clothing
9.3 Irregularities
In the event of any changes in relation to standard operation, e.g. increased temperatures, noises, vibrations,
the gearbox 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.
10. Faults, Causes and Remedies
10.1 General Fault Indications
Sections 5 “Safety Information” and 11 “Inspection and Maintenance” must be observed!
Faults occurring during the warranty period which necessitate a repair of the gearbox must only be corrected by
Service Department employees of Nidec Graessner.
The Nidec Graessner Service Department should also be contacted after the warranty period has expired if
faults occur whose cause cannot be clearly identified.

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10.2 Possible Faults
Faults
Causes
Remedy
•Changed operating
noise
•Damage to gearings
•Bearing clearance is increased.
•Bearing is defective
•Check geared components; if
necessary, replace any damaged
components
•Adjust the bearing clearance, contact
the Service Department
•Replace defective bearing, contact
the Service Department
•Increased
temperature at the
bearing points
•Oil level in the gearbox housing
is too low or too high
•Oil is too old
•Bearing is defective
•Check oil level at room temperature,
if necessary replenish or drain oil.
•Check when the last oil change has
been carried out.
•If necessary, change the oil
•Check the bearing condition; replace
if necessary; contact the Service
Department
•Gearbox is oily on
the outside
•Insufficient sealing of the
bearing flanges and gearbox
covers
•Check seals, replace if necessary
•Seal the bearing flanges and gearbox
covers
•Oil leakage at the
ventilation filter
•Oil foams
•Oil level in the gearbox too high
•Incorrect design of the
ventilation
•See fault “Oil foams in gearbox”
•Decrease oil level in gearbox to the
specified level
•Prevent any direct oil injection by
attaching suitable extensions or
angle pieces
•Oil leakage from
the shafts
•Radial shaft seal rings or seal
seat defective or pressed out of
its seat
•Check radial shaft seal rings, replace
if necessary.
•Oil foams in the
gearbox
•Water in the 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 the oil
•Examine oil, change oil
•Examine oil, change oil
•Water in the oil
•Water condenses in the
gearbox due to external climatic
conditions, sun, wind, cold:
Ambient temperatures change
to a large extent
•Protect gearbox against temperature
influences
•Increased
operating
temperature
•Oil level in the gearbox too high.
•Oil is too old
Oil is highly contaminated
•Check the oil level. Correct if
necessary.
•Check when the last oil change was
carried out, change the oil
•Have the oil sample analysed,
change the oil

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11. Inspection and Maintenance
11.1 General Information
All service and maintenance work must only be carried out by qualified personnel.
See Section 3.Conversions and Changes.
When carrying out service and maintenance tasks, the gearbox must always be shut down.
The input 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 gearbox.
Warning
Major risk of injury due to accidental start-up of the input unit.
Before starting any maintenance work, secure the gearbox against any start-up.
Warning
Major risk of injury from disassembly of transmission parts (couplings, cardan
shafts, belts, etc.) as long as torsional forces are still acting on the gear shafts.
Secure gear shafts against torsional forces and disassembly transmission
elements.
11.2 Maintenance Periods
If maintenance periods are not complied with, major damage may be caused to the gearbox and within the
plant. Therefore it must be ensured that these maintenance periods are observed.
Measures
Maintenance Periods
Remarks
Check running noise for any
changes
daily
Check the gearbox for leakage
daily
Check oil level
monthly
Only if an oil inspection
glass is present
Carry out first oil change
500 operating hours after commissioning
Section 11.3
Carry out additional oil changes
mineral oil filling
Every 24 months or 10,000 operating hours
Section 11.3
Carry out additional oil changes
synthetic oils
Every 4 years or 20,000 operating hours
Section 11.3
Checking the gearbox condition
Every 2 years
Section 11.4
11.3 Oil Service Life
The oil service lives at a mean oil temperature of 80°C in the gearbox 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 lives 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.

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11.4 Oil Change
Oil should be drained directly after shutdown whilst the oil is still warm.
Caution
There is a risk of burns on the hot gearbox and a risk of scalding when
draining the oil!
Provide for suitable protection measures.
•Unscrew the aeration and ventilation filter or remove the upper screw plug on one side of the housing.
•If present, open the oil drain plug and collect the oil with a suitable container.
•Fit drain plug with new copper seal and screw back into housing.
•Fill the gearbox with oil.
•Replace the oil filler plug or aeration and ventilation filter.
Note: EvoGear gearboxes have no oil bore as standard. An oil change can only be carried out by trained
specialist personnel or by the manufacturer.
Material Damage
Possible damage to the gearbox by inadequate 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 gearbox.
11.5 Checking Gearbox Condition
This check may only be carried out by qualified operating personnel or by the Nidec Graessner Service
Department. Here, it must be possible to assess reliably what exactly needs to be replaced on the gearbox.
Or it must be determined that all gear components are in order.
12. Replacement Parts, Stocking of Replacement Parts, 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
replacement part drawings.
12.2 Stocking of Replacement Parts
We recommend keeping a stock of the most important replacement parts and wear parts in the vicinity of the
place of use of the gearbox in order to ensure the operational readiness of the gearbox in this way.
The parts are shown in the replacement part drawings.
12.3 Service Department
Should you require help from our Service Department, please provide the following details:
- Gearbox type and size.
- All data printed on the type plate (see Section 4.6).
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).