nord SK 7207 Manual

Intelligent Drivesystems, Worldwide Services
B1050
Operating and Maintenance Instructions for
Industrial Gear Units SK 7207 - SK 15507
GB
DRIVESYSTEMS

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Contents
1. Notes.............................................................................................................................. 4
1.1 General information........................................................................................................ 4
1.2 Safety and information symbols ..................................................................................... 4
1.3 Correct use..................................................................................................................... 4
1.4 Safety information........................................................................................................... 5
1.5 Other documents............................................................................................................ 5
1.6 Disposal.......................................................................................................................... 5
2. Description of gear units.............................................................................................. 6
2.1 Type designations and gear unit types........................................................................... 6
2.2 Name plate ..................................................................................................................... 7
3. Storage, transport, preparation, installation.............................................................. 8
3.1 Storing the gear unit ....................................................................................................... 8
3.2 Long-term storage .......................................................................................................... 8
3.3 Transporting the gear unit .............................................................................................. 9
3.4 Preparing for installation............................................................................................... 12
3.5 Installing the gear unit .................................................................................................. 12
3.6 Fitting hubs on the gear shafts..................................................................................... 13
3.7 Fitting push-on gear units............................................................................................. 14
3.8 Torque support ............................................................................................................. 16
3.9 Fitting shrink discs........................................................................................................ 16
3.10 Fitting the covers ........................................................................................................ 17
3.11 Fitting a standard motor.............................................................................................. 17
3.12 Fitting the cooling coil to the cooling system.............................................................. 19
3.13 Mounting the external cooling system (cooling unit) .................................................. 19
3.14 Retrospective paintwork............................................................................................. 20
4. Commissioning........................................................................................................... 21
4.1 Checking the oil level.................................................................................................... 21
4.2 Lubricant cooling with internal water cooler ................................................................. 21
4.3 Lubricant cooling with external oil/water cooler (cooling system) ................................ 21
4.4 Lubricant cooling with external oil/water cooler (cooling system) ................................ 22
4.5 Gear unit cooling with a fan.......................................................................................... 22
4.6 Checking the Taconite seals ........................................................................................ 23
4.7 Pressure safeguard ...................................................................................................... 23
4.8 Checklist....................................................................................................................... 24
5. Service and maintenance........................................................................................... 25
5.1 Service and maintenance intervals............................................................................... 25
5.2 Service and maintenance work .................................................................................... 25
6. Appendix...................................................................................................................... 29
6.1 Versions and maintenance........................................................................................... 29
6.2 Lubricant quantities....................................................................................................... 31
6.3 Lubricants..................................................................................................................... 33
6.4 Bolt torque values......................................................................................................... 35
6.5 Troubleshooting............................................................................................................ 36

1. Notes
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1. Notes
1.1 General information
Read the Operating Manual carefully prior to performing any work on or putting the gear unit into
operation. Strict compliance with the instructions in this Operating Manual is essential.
Getriebebau NORD accepts no liability for damage to persons, materials or assets as a result of
the non-observance of this Operating Manual, operating errors or incorrect use. General wearing
parts, e.g. radial seals are excluded from the warranty.
If additional components are attached to or installed in the gear unit (e.g. motor, cooling
system, pressure sensor etc.) or components (e.g. cooling system) are supplied with the
order, the operating instructions for these components must be observed.
If you do not understand the contents of this Operating Manual or additional operating
instructions, please consult Getriebebau NORD!
1.2 Safety and information symbols
Please always observe the following safety and information symbols!
Danger!
Risk of fatalities and injury
Attention!
Machine may be damaged
Note!
Useful information
1.3 Correct use
These gear units generate a rotational movement and are intended for use in commercial
systems. The gear unit must only be used according to the information in the technical
documentation from Getriebebau NORD.
Danger!
Use in explosion hazard areas is prohibited.
Strict compliance with the technical data on the rating plate is essential.
The documentation must be observed.
Appropriate safety measures must be taken for applications where failure of a gear unit or
geared motor may result in injury.

1. Notes
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1.4 Safety information
All work including transportation, storage, installation, electrical connection, commissioning,
servicing, maintenance and repair must be performed only by qualified specialist personnel.
It is recommended that repairs to NORD Products are carried out by the NORD Service
department.
Danger!
Installation and maintenance work must only be performed when gear units are at a standstill
and have cooled down. The drive must be isolated and secured to prevent accidental start-up.
Tighten the drive elements or secure the parallel key before switching on.
Observe all safety information, including that provided in the individual sections of this
Operating Manual. All national and other regulations on safety and accident prevention must
also be observed.
Danger!
Serious physical and property damage may result from inappropriate installation, non-
designated use, incorrect operation, non-compliance with safety information, unauthorised
removal of housing components or safety covers and structural modifications to the gear unit.
All rotating components must be provided with guards. In standard cases, covers are fitted by
NORD . The covers must always be used if contact protection is not provided by other methods.
1.5 Other documents
Further information may be obtained from the following documents:
- Gear Unit Catalogue (G1050)
- Operating and maintenance instructions for the electric motor
- If applicable, operating instructions for attached or supplied options
1.6 Disposal
Observe the current local regulations. In particular, lubricants must be collected and disposed of
correctly.
Gear unit components: Material:
Toothed wheels, shafts, rolling bearings,
parallel keys, locking rings, … Steel
Gear unit housing, housing components, … Grey cast iron
Light alloy gear unit housing, light alloy gear unit
housing components, … Aluminium
Worm gears, bushes, ... Bronze
Radial seals, sealing caps, rubber components,… Elastomers with steel
Coupling components Plastic with steel
Flat seals Asbestos-free sealing material
Gear oil Additive mineral oil
Synthetic gear oil (rating plate code: CLP PG) Polyglycol-based lubricants
Cooling spiral, screw fittings Copper, epoxy, yellow brass

2. Description of Gear Unit
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2. Description of gear units
2.1 Type designations and gear unit types
Helical gear units
SK 7207, SK 8207, SK 9207, SK 10207
SK 11207, SK 12207, SK 13207, SK 15207
(2-stage)
SK 7307, SK 8307, SK 9307, SK 10307
SK 11307, SK 12307, SK 13307, SK 15307
(3-stage)
Bevel helical gear units
SK 7407, SK 8407, SK 9407, SK 10407
SK 11407, SK 12407, SK 13407, SK 15407
(3-stage)
SK 7507, SK 8507, SK 9507, SK 10507
SK 11507, SK 12507, SK 13507, SK 15507
(4-stage)
V
ersions / Options
- Foot mounting with solid shaft
A Hollow shaft version
B Fixing element
CC Integrated cooling coil
CS1 Cooling system oil / water
CS2 Cooling system oil / air
D Torque support
EA Hollow shaft with internal spline
ED Elastic torque support
EV Solid shaft with internal spline
EW Drive shaft with internal spline
F Block flange
FAN Fan
FK Collar flange
F1 Drive flange
H Covering cap as contact guard
IEC Standard IEC motor attachment
L Solid shaft both sides
LC Lubricant circulation
MC Motor bracket
MF.. Motor base frame
…B with brake
…K with elastic coupling
…T with hydrodynamic coupling
MS.. Motor swing base
…B with brake
…K with elastic coupling
…T with hydrodynamic coupling
MT Motor mount
NEMA Standard NEMA motor attachment
OA Oil expansion vessel
OH Oil heater
OT Oil level tank
R Back stop
S Shrink disc
V Solid shaft
VL Reinforced bearings
VL2 Agitator version
VL3 Drywell agitator version
W Free input shaft
W2 Two drive shaft journals
W3 Three drive shaft journals
WX Auxiliary drive unit
Double gear units consist of two single gear units. They are to be treated as per the instructions
in this Manual, i.e. as two individual gear units. Type designation of double gear units:
e.g. SK 13307/7282 (consisting of single gears SK 13307 and SK 7282)

2. Description of Gear Unit
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2.2 Name plate
Example of a gear unit name plate.
Explanation of the name plate
1 Matrix – Barcode
2 NORD gear unit type
3 Operating mode
4 Year of manufacture
5 Serial number
6 Rated torque of gear unit output shaft
7 Drive power
8 Weight according to ordered version
9 Overall gear unit ratio
10 Installation orientation
11 Rated speed of gear unit output shaft
12 Lubricant type, viscosity and quantity
13 Customer’s part number
14 Operating factor

3. Storage, Transport,
Preparation, Installation
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3. Storage, transport, preparation, installation
Please observe all of the general safety information in Section 1.4, 1.3 and in the individual
sections.
3.1 Storing the gear unit
For short-term storage before commissioning, please observe the following:
Store in the fitting position (see Section 6.1) and secure gear units against falling
Lightly grease bare metal housing surfaces and shafts
Store in dry rooms
Temperature in the range from –5 oC to +50 oC without large fluctuations
Relative humidity less than 60%
No direct exposure to sunlight or UV light
No aggressive, corrosive substances (contaminated air, ozone, gases, solvents, acids,
alkalis, salts, radioactivity etc.) in the immediate vicinity
No vibration or oscillation
3.2 Long-term storage
Note!
For storage or standstill periods in excess of 9 months, Getriebebau NORD recommends the
long-term storage option. With the long-term storage option and the use of the measures
listed below, storage for up to 2 years is possible. As the actual influences on the unit greatly
depend on the local conditions, these times should only be regarded as guide values.
Conditions of the gear unit and storage area for long-term storage prior to
commissioning:
Store in the fitting position (see Section 6.1) and secure gear units against falling
Transportation damage to the external paint must be repaired. Check that a suitable rust
inhibitor is applied to the flange bearing surfaces. If necessary apply a suitable rust inhibitor
to the surfaces.
Gear units with the long-term storage option are completely filled with lubricant or have VCI
corrosion protection agents added to the gear oil. (See label on gear unit)
The sealing band in the vent plug must not be removed during storage. The gear unit must
remain sealed tight.
Store in a dry place.
In tropical regions, the drive unit must be protected against damage by insects
Temperature in the range from –5 oC to +40 oC without large fluctuations
Relative humidity less than 60%
No direct exposure to sunlight or UV light
No aggressive, corrosive substances (contaminated air, ozone, gases, solvents, acids,
alkalis, salts, radioactivity etc.) in the immediate vicinity
No vibration or oscillation
Measures during storage or standstill periods
If the relative humidity is <50% the gear unit can be stored for up to 3 years.
Measures before commissioning
If the storage or standstill period exceeds 2 years or the temperature during short-term
storage greatly deviates from the standard range, the lubricant in the gear unit must be
replaced before commissioning.
If the gear unit is completely filled, the oil level must be reduced before commissioning.

3.Storage, Transport,
Preparation, Installation
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3.3 Transporting the gear unit
Danger!
To prevent injury, the danger area must be generously cordoned off. Standing under the
gear unit during transport is extremely dangerous.
Attention!
Avoid damage to the gear unit. Impacts to the free ends of the shafts may cause internal
damage to the gear unit.
Use adequately dimensioned and suitable means of transportation. Lifting tackle must be
designed for the weight of the gear unit. The weight of the gear unit can be obtained from the
dispatch documents.
The gear unit should remain on the transport packaging during transportation. It must be
transported without oil. Only the four ring bolts (1) provided may be used for transporting the
gear unit. For additional drive units and components, an additional lifting point may be
necessary. The ends of the shafts must not be used for transportation, as this may seriously
damage the gear unit. The ring bolts screwed into the gear unit must be used for transportation.
If geared motors have an additional eyebolt attached to the motor, this must not be used. When
lifting with the ring bolts, there must be no oblique force.
Figure 3-1: Gear unit lifting points
For additional drive units and components, an additional lifting point may be necessary.

3. Storage, Transport,
Preparation, Installation
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Gear units with motor adapter
Gear units with a motor adapter may only be transported with lifting ropes (2) and chains or
lifting straps (1) at an angle of 90° to 70° to the horizontal. The ring bolts on the motor must not
be used for transportation.
Figure 3-2: Transport of gear unit with motor
Drive units with V-belt drive
Gear units with V-belt drive must only be transported with lifting straps (1) and lifting ropes (2) at
an angle of 90° (vertical). The ring bolts on the motor must not be used for transportation.
Figure 3-3: Transport of gear unit with V-belt drive

3.Storage, Transport,
Preparation, Installation
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Gear units on motor swing base or base frame
Gear units on a motor swing base or base frame must only be transported with vertically
tensioned lifting ropes (1) or chains.
Figure 3-4: Transport of gear unit with motor swing base or base frame

3. Storage, Transport,
Preparation, Installation
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3.4 Preparing for installation
The drive unit must be inspected and may only be installed if no damage is apparent. In
particular the radial seals and the sealing caps must be inspected for damage.
All bare metal surfaces and shafts of the gear unit are protected against corrosion with oil,
grease or corrosion protection agents before shipping.
Thoroughly remove all oil, grease or corrosion protection agents and any dirt from the shafts and
flange surfaces before assembly.
In applications where an incorrect rotational direction may result in damage or potential risk, the
correct rotational direction of the drive shaft is to be established by test running the drive when
uncoupled and guaranteeing such for subsequent operation.
Gears with integrated return stops are marked with arrows on the driven/driving sides. The
arrows point in the rotation direction of the gear unit. It must be ensured, when connecting the
motor and during motor control, that the gear unit can only operate in the rotation direction, e.g.
by means of a rotary field test.
Attention!
With gear units with an integrated back stop, switching the drive motor to the blocked rotation
direction, i.e. incorrect rotation direction, can lead to gear damage.
Ensure that no aggressive or corrosive substances are present in the area surrounding the
installation site or are subsequently expected during operation, which attack metal, lubricants or
elastomers. In case of doubt, please contact Getriebebau NORD and take the recommended
action.
Oil expansion tanks (Option OA) must be fitted in accordance with the attached works standard
WN 0-530 04.
Oil expansion tanks (Option OA) must be fitted in accordance with the attached works standard
WN 0-521 30.
3.5 Installing the gear unit
The base or flange to which the gear unit is fitted should be vibration-free, torsionally rigid and
flat. The smoothness of the mating surface on the base or flange must be according to tolerance
class K of DIN ISO 2768-2. All contamination to the bolting surfaces of gear unit and base or
flange must be thoroughly removed.
The base must be designed according to the weight and torque, taking into account the forces
acting on the gear unit. Bases which are insufficiently rigid may lead to radial and axial
displacement during operation, which is not measurable when the unit is stopped.
When attaching the gear unit to a concrete base using masonry bolts or base blocks, appropriate
recesses must be provided in the base. Tensioning bars must be cast into the concrete base in
their aligned state.
The gear unit must be precisely aligned with the drive shaft of the machine in order to prevent
additional forces from being imposed on the gear unit due to distortion.
Note!
The service life of shafts, bearings and couplings depends on the precision of alignment of the
shaft. Therefore, zero deviation should always be aimed for in alignment. For this, e.g. the
requirements for the coupling should be obtained from the special operating instructions.
The tolerances of the shaft ends and the flange connections should be obtained from the
dimension sheet.

3.Storage, Transport,
Preparation, Installation
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Welding of the gear unit is prohibited. The gear unit must not be used as the earth connection for
welding work, as this may cause damage to the bearings and gear wheels.
The gear unit must be installed in the correct orientation (see Section 6.1). All gear unit feet
on each side or all flange screws must be used. Bolts must have a minimum quality of 8.8. The
bolts must be tightened to the correct torques (refer to Section 6.4 for torque values). Tension-
free bolting must be ensured, particularly for gear units with a foot and flange.
Danger!
To ensure that the gearbox does not get too hot and to avoid injury to persons, observe
the following during installation:
The surfaces of gear units or geared motors may become hot during or shortly after
operation. Attention: danger of burns!! Protection against accidental contact may need to
be installed.
With geared motors, the cooling air of the motor fan must be able to flow unobstructed
onto the gear unit.
3.6 Fitting hubs on the gear shafts
Attention!
Do not subject the gear unit to harmful axial forces when fitting the hubs.
Drive and driven elements, e.g. coupling and chain-wheel hubs must be mounted onto the drive
and driven shaft of the gear unit using suitable pullers that will not apply damaging axial forces
onto the gear unit. In particular, do not hit the hubs with a hammer.
Use the end thread of the shafts for pulling. Fitting can be aided by coating the hub with lubricant
or heating it up to approx. 100oC beforehand.
Figure 3-5: Example of a simple pulling device
Danger!
Drive and driven elements, such as belt drives, chain drives and couplings must be fitted
with contact protection.
Drive and driven elements may only subject the drive unit to the maximum radial forces
and axial forces FAspecified in the catalogue. Observe the correct tension, particularly on
belts and chains. Additional loads due to unbalanced hubs are not permitted. The radial force
must be applied to the gear unit as closely as possible.

3. Storage, Transport,
Preparation, Installation
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3.7 Fitting push-on gear units
Achtung!
The bearings, gear wheels, shafts and housing may be damaged by incorrect fitting.
The push-on gear unit must be fitted onto the shaft using a suitable puller, which will not exert
damaging axial forces on the gear unit. In particular, do not hit the gear unit with a hammer.
Assembly and subsequent dismantling is aided by applying an anti-corrosive lubricant to the
shaft before fitting.
Figure 3-6: Applying lubricant to the shaft and the hub
Note!
The gear unit can be fitted to shafts with and without a shoulder using the fastening element
(Option B). Tighten the bolt of the fastening element to the correct torque. (See Chapter 6.4 for
tightening torque values)
Figure 3-7: Assembly

3.Storage, Transport,
Preparation, Installation
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Figure 3-8: Securing
Figure 3-9: Dismantling
1 Fastening element
2 Securing ring
3 Assembly – threaded rod
4 Assembly – threaded nut
6 Protective cover
7 Disassembly of threaded rod
8 Disassembly element
9 Disassembly – threaded nut
When assembling push-on gears with torque supports, the support must not be distorted.
Distortion-free assembly is made easier if an elastic element (Option DG) is used.

3. Storage, Transport,
Preparation, Installation
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3.8 Torque support
The length of the torque support can be adjusted within a certain range. The torque support
consists of a fork head with a bolt (1), a threaded bolt (2), a maintenance-free joint head (3) and
a fork plate with a bolt (4).
Assembly should be carried out from the side of the machine, in order to reduce the bending
moment on the machine shaft. Tension and pressure and installation upwards or downwards are
not permissible.
Distortion of the torque support during assembly or operation must be avoided, as otherwise the
service life of the output shaft bearings may be reduced. Torque supports are not suitable for the
transfer of radial forces, therefore they may only be used in combination with motor mounts or
couplings which do not transfer radial forces.
For helical gear units with motor mounts, the torque support is located opposite to the motor
mount.
The gear unit is aligned horizontally with the threaded bolt and the nuts of the torque support
and must be secured with lock-nuts.
Figure 3-10: Permissible installation deviations of the torque support
3.9 Fitting shrink discs
Attention!
The operating instructions for the shrink disc must be observed.

3.Storage, Transport,
Preparation, Installation
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3.10 Fitting the covers
Danger!
Shrink discs and exposed rotating shaft ends require contact guards in order to prevent
injuries. A cover (Option H) can be used as a guard. If this does not achieve sufficient
protection against contact according to the required protection type, the machinery and plant
constructor must ensure this be means of special attached components.
All fixing screws must be used and tightened to the correct torque. (See Chapter 6.4 for torque
values)
3.11 Fitting a standard motor
The maximum permitted motor weights indicated in the table below must not be exceeded when
attaching the motor to an IEC- / NEMA adapter:
Maximum permitted motor weights
IEC motor size 63 71 80 90 100 112 132
NEMA motor
size 56C 143T 145T 182T 184T 210T
max. Maximum
motor weight
[kg] 25 30 40 50 60 80 100
IEC motor size 160 180 200 225 250 280 315
NEMA motor
size 250T 280T 324T 326T 365T
max. Maximum
motor weight
[kg] 200 250 350 500 700 1000 1500
Transnorm 315 355 400 450
max. Maximum
motor weight
[kg] 1500 2200 3200 4400

3. Storage, Transport,
Preparation, Installation
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Assembly procedure to attach a standard motor to the IEC adapter (Option IEC)/NEMA adapter
1. Clean motor shaft and flange surfaces of motor and adapter and check for damage.
Mounting dimensions and tolerances of the motor must conform to DIN EN 50347/NEMA
MG1 Part 4.
2. Push the coupling sleeve onto the motor shaft so that the motor parallel key engages into
the groove in the sleeve on tightening.
3. Pull the coupling sleeve onto the motor shaft according to the instructions of the motor
manufacturer. The shaft end of the motor must be adjusted so that it is parallel with the face
of the coupling. (See Figure 3-11)
4. Secure the coupling half with the threaded pin. The threaded pin must be coated prior to use
with a securing lubricant e.g. Loctite 242, Loxeal 54-03 and tightened to the correct torque.
(See Chapter 6.4 for torque values)
5. Sealing of the flange surfaces of the motor and the adapter is recommended if the motor is
installed outdoors or in a humid environment. The flange surfaces of motor and adapter
must be completely coated with surface sealant Loctite 574 or Loxeal 58-14 prior to
mounting so that the flange seals after mounting.
6. Mount the motor to the adapter; do not forget to fit the gear rim or the sleeve.
7. Tighten the adapter bolts to the correct torque. (See Chapter 6.4 for torque values)
Figure 3-11: Fitting the coupling to the motor shaft
Attention!
The operating instructions for the coupling must be observed.

3.Storage, Transport,
Preparation, Installation
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3.12 Fitting the cooling coil to the cooling system
For the inlet and outlet of cooling fluid, connections with G ½ pipe thread are located in the
casing cover for the fitting of pipes or hoses. Remove the drain plug from the screw
connectors prior to assembly to avoid any contamination of the cooling system.The
screw connectors should be connected with the coolant circuit, which must be provided by the
operator. The flow direction of the coolant is irrelevant.
Attention!
Make sure not to twist the screw connectors during or after assembly as this may
damage the cooling coil (see Item 3, Fig. 3-12). Ensure that no external forces act on the
cooling coil.
If a volume regulator is fitted upstream of the cooling coil, the connection is extended
accordingly. The cooling water must be inlet via the volume regulator. Observe the operating
instructions of the volume regulator.
Figure 3-12: Cooling cover with cooling coil fitted
3.13 Mounting the external cooling system (cooling unit)
Attention!
The separate manufacturer’s documentation must be observed for assembly.
Connect the cooling system according to Fig. 3-14. Other connection plans can be agreed upon
during consultation with NORD.
Pos.3

3. Storage, Transport,
Preparation, Installation
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Attention!
With circulation lubrication (LC) use the connection diagram included by NORD.
Figure 3-13: Industrial gear unit with CS1 and CS2 cooling systems
Figure 3-14: Hydraulic diagram of the industrial gear unit with CS1 and CS2 cooling systems
3.14 Retrospective paintwork
Attention!
For retrospective painting of the gear unit, the radial seals, rubber elements, pressure venting
valves, hoses, type plates, adhesive labels and motor coupling components must not come
into contact with paints, lacquers or solvents, as otherwise components may be damaged or
made illegible.
(1) Gear unit intake connection
(2) Pump / cooling system intake connection
(3) Cooling system pressure connection
(4) Gear unit pressure connection
(
5
)
Tem
p
erature monitorin
g
(
o
p
tional
)

4. Commissioning
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4. Commissioning
4.1 Checking the oil level
The oil level must be checked prior to commissioning. See Section 5.2.
4.2 Lubricant cooling with internal water cooler
Caution!
The drive may only be commissioned after the cooling coil has been connected to the cooling
circuit, and the cooling circuit has been put into operation.
The coolant must have a similar thermal capacity as water (specific thermal capacity at 20°C
c=4.18 kJ/kgK). Industrial water without any air bubbles or sediments is recommended as a
coolant. The water hardness must be between 1° dH and 15° dH, and the pH value must be
between pH 7.4 and pH 9.5. No aggressive liquids should be added to the coolant!
The coolant pressure must not exceed 8 bar. The required quantity of coolant is 10
litres/minute, and the coolant inlet temperature should not exceed 40°C; we recommend
10°C.
We also recommend fitting a pressure reducer at the coolant inlet to avoid any damage due to
excessive pressure.
If there is a danger of frost the operator should add a suitable anti-freeze solution to the cooling
water.
The temperature of the cooling water and the cooling water flow rate must be supervised
and ensured by the operator.
Note!
With a thermostat in the cooling water inlet, the volume of cooling water can be adjusted to
the actual requirements.
4.3 Lubricant cooling with external oil/water cooler (cooling system)
Attention!
The operating instructions for the cooling system must be observed.
The oil / water cooler consists of at least a motor pump, a filter and a flat plate heat exchanger. In
addition, a pressure switch is usual in order to monitor the pump and therefore the lubrication.
Caution!
The drive unit may only be put into operation after the cooling coil has been connected and
put into operation.