SEW-Eurodrive M Series User manual

Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services
Industrial Gear Units of the M.. Series
M.P../M.R.. Horizontal Gear Units
O perating Instructions
D6.C00
Edition 07/2004
11279028 / EN

SEW-EURODRIVE – Driving the world

Contents
Operating Instructions – Industrial Gear Units of the M.. Series M.P../M.R.. Horizontal Gear Units
3
1 Important Notes................................................................................................. 4
2 Safety Notes ...................................................................................................... 5
2.1 Transport of industrial gear units .............................................................. 6
2.2 Corrosion protection and storage conditions .......................................... 10
3 Gear Unit Design............................................................................................. 12
3.1 Basic design of the M..P.. series............................................................. 12
3.2 Basic design of the M..R.. series ............................................................ 13
3.3 Unit designation / nameplates................................................................. 14
3.4 Mounting positions, shaft positions and directions of rotation................. 16
3.5 Lubrication of industrial gear units.......................................................... 21
4 Mechanical Installation................................................................................... 22
4.1 Required tools / resources...................................................................... 22
4.2 Before you begin..................................................................................... 22
4.3 Preliminary work ..................................................................................... 22
4.4 Gear unit foundation ............................................................................... 23
4.5 Mounting of solid shaft gear units........................................................... 26
4.6 Mounting / removing hollow shaft gear units with keyed connection...... 28
4.7 Mounting / removing hollow shaft gear units with shrink disc................. 31
4.8 Mounting a motor with motor adapter..................................................... 36
5 Mechanical Installation Options .................................................................... 37
5.1 Important installation instructions............................................................ 37
5.2 Mounting of couplings............................................................................. 40
5.3 Backstop ................................................................................................ 48
5.4 Installation with steel frame..................................................................... 49
5.5 Torque arm ............................................................................................. 50
5.6 Mounting of V-belt drive.......................................................................... 53
5.7 Oil heater ................................................................................................ 55
5.8 Temperature sensor PT100.................................................................... 60
5.9 SPM adapter........................................................................................... 61
5.10 Fan.......................................................................................................... 65
5.11 Cooling coil ............................................................................................ 67
6 Pressure Lubrication...................................................................................... 68
6.1 Shaft end pump ...................................................................................... 68
6.2 Motor pump ............................................................................................ 70
6.3 External cooling system.......................................................................... 70
6.4 Customer supplied external cooling and lubrication systems................. 71
7 Startup.............................................................................................................. 75
7.1 Startup of M gear units............................................................................ 75
7.2 Startup of M gear units with backstop..................................................... 76
7.3 Taking M gear units out of operation ...................................................... 76
8 Inspection and Maintenance.......................................................................... 77
8.1 Inspection and maintenance intervals..................................................... 77
8.2 Lubricant change intervals...................................................................... 78
8.3 Inspection and maintenance of the gear unit.......................................... 79
9 Malfunctions.................................................................................................... 82
9.1 Gear unit malfunctions............................................................................ 82
10 Symbols and Mounting Positions ................................................................. 83
10.1 Symbols used ......................................................................................... 83
10.2 Symbols and Mounting Positions of M.P.. gear units.............................. 84
10.3 Symbols and mounting positions of M.R.. gear units.............................. 84
11 Lubricants........................................................................................................ 85
11.1 Guideline for oil and grease selection..................................................... 85
11.2 Overview of lubricants for M.. industrial gear units................................. 89
11.3 Sealing grease........................................................................................ 94
11.4 Lubricant fill quantities ............................................................................ 95

1
4
Operating Instructions – Industrial Gear Units of the M.. Series Horizontal Gear Units M.P../M.R..
Important Notes
1 Important Notes
Safety and
warning
instructions
Always follow the safety and warning instructions in this publication!
A requirement of fault-free operation and fulfillment of any rights to claim under
guarantee is that you adhere to the information in the operating instructions.
Consequently, read the operating instructions before you start working with the gear
unit!
The operating instructions contain important information about servicing; as a result,
they should be kept in the vicinity of the gear unit.
Waste disposal Follow the current instructions:
• Housing parts, gears, shafts and anti-friction bearings of the gear units must be
disposed of as steel scrap. The same applies to gray cast iron castings unless there
are separate collection arrangements.
• Collect waste oil and dispose of it correctly.
Electrical hazard
Possible consequences: Severe or fatal injuries.
Hazard
Possible consequences: Severe or fatal injuries.
Hazardous situation
Possible consequences: Slight or minor injuries.
Harmful situation
Possible consequences: Damage to the drive and the environment.
Important information about explosion protection.
Tips and useful information.
•It is essential to contact SEW-EURODRIVE regarding a subsequent change of
mounting position!
•The industrial gear units of the M.. series are delivered without oil fill. Refer to
the information on the nameplate!
•Refer to the instructions in the sections "Mechanical Installation" and
"Startup"!

Operating Instructions – Industrial Gear Units of the M.. Series Horizontal Gear Units M.P../M.R..
5
2
Safety Notes
2 Safety Notes
Preliminary
remarks
The following safety notes are concerned with the use of industrial gear units of the M
series. If gear units of the R, F, K, S series or motors of the DR/DT/DV series are used,
also refer to the safety notes for motors and gear units in the corresponding operating
instructions.
Also take account of the supplementary safety notes in the individual sections of
these operating instructions.
General
information
During and after operation, industrial gear units and motors have live and moving parts
and their surfaces may be hot.
All work related to transport, storage, setting up/mounting, connection, startup,
maintenance and repair may only be performed by trained personnel observing
• the corresponding detailed operating instruction(s) and wiring diagrams,
• the warning and safety signs on the industrial gear unit,
• the specific regulations and requirements for the system and
• national/regional regulations governing safety and the prevention of accidents.
Designated use Industrial gear units are intended for industrial systems. They correspond to the
applicable standards and regulations. The technical data and the information about
permitted conditions are provided on the nameplate and in the documentation.
It is essential to observe all specified information!
Transport Inspect the delivery for any damage in transit as soon as you receive the delivery.
Inform the transport company immediately. It may be necessary to preclude
startup.
Startup/operation Check that the direction of rotation is correct in decoupled status (also listen for unusual
grinding noises as the shaft rotates).
Secure the shaft keys for test mode without drive components. Do not render monitoring
and protection equipment inoperative even for test mode.
Switch off the main motor if in doubt whenever changes occur in relation to normal
operation (e.g. increased temperature, noise, vibration). Determine the cause; contact
SEW-EURODRIVE if necessary.
Inspection /
maintenance
Refer to the instructions in Sec. "Inspection and Maintenance."
Severe injuries and damage to property may result from
• incorrect use,
• incorrect installation or operation,
• removal of required protective covers or the housing when this is not permitted.

2
6
Operating Instructions – Industrial Gear Units of the M.. Series Horizontal Gear Units M.P../M.R..
Transport of industrial gear units
Safety Notes
2.1 Transport of industrial gear units
Transport
eyebolts
Tighten screwed in transport eyebolts [1] firmly. They are only designed for the weight
of the industrial gear unit including the motor connected via motor adapter; do not attach
any additional loads.
•The main gear unit must only be lifted using lifting ropes or chains on the two
screwed in transport eyebolts on the main gear unit. The weight of the gear unit
is indicated on the nameplate or the dimension sheet. The loads and regula-
tions specified on the nameplate must always be observed.
•The length of the lifting chains or ropes must be dimensioned in such a way
that the angle between the chains or ropes does not exceed 45°.
•Eyebolts on the motor, auxiliary gear unit or primary gear unit must not be
used for transport (→ following figures)!
•Use suitable, sufficiently rated handling equipment if necessary. Before
startup, remove securing devices used for transport.
53744AXX
Figure 1: Positions of transport eyebolts
53359AXX
Figure 2: Do not use eyebolts on the motor for transport
[1]

Operating Instructions – Industrial Gear Units of the M.. Series Horizontal Gear Units M.P../M.R..
7
2
Transport of industrial gear units
Safety Notes
Transport of M..
industrial gear
units with motor
adapter
Industrial gear units of the M.P.. / M.R.. series with motor adapter (→following figure)
must only be transported using lifting ropes/chains [2] or lifting belts [1] at an angle
of 90° (vertically) to 70°.
53385AXX
Figure 3: Transport of industrial gear unit with motor adapter – Do not use eyebolts on the motor for transport
90°-70°
[1] [2]
<70°
[1]
[2]

2
8
Operating Instructions – Industrial Gear Units of the M.. Series Horizontal Gear Units M.P../M.R..
Transport of industrial gear units
Safety Notes
Transport of M..
industrial gear
units on a base
plate
Industrial gear units of the Mseries on a base plate (→following figure) must only be
transported with the lifting ropes [1] or chains (angle 90°) vertically to the base plate:
Transport of M..
industrial gear
units on a swing
base
Industrial gear units of the Mseries on a swing base (→following figures) must only
be transported using lifting belts [1] and lifting ropes [2] at an angle of 90°
(vertically) to 70°.
53387AXX
Figure 4: Transport of M.. industrial gears unit on a base plate
90°
90°
[1] [1]
53390AXX
Figure 5: Transport of M.. industrial gear unit on a swing base
[2]
90°-70°
[1] [2] [1]

Operating Instructions – Industrial Gear Units of the M.. Series Horizontal Gear Units M.P../M.R..
9
2
Transport of industrial gear units
Safety Notes
Transport of M..
industrial gear
units with V-belt
drive
Industrial gear units of the Mseries with V-belt drive (with motors up to IEC size 200)
must only be transported using lifting ropes [2]. The eyebolts on the motor must not
be used for transport.
Industrial gear units of the Mseries with V-belt drive (with motors of IEC sizes 225 to
315) must only be transported using lifting belts [1] and lifting ropes [2] at an angle
of 90° (vertically). The eyebolts on the motor must not be used for transport.
53394AXX
Figure 6: Transport of M.. with V-belt drive (with motors up to IEC size 200)
52111AXX
Figure 7: Transport of M.. with V-belt drive (with motors of IEC sizes 225 to 315)
[1] [1]
90°
90°
[1] [1]
[2]
[2]

2
10
Operating Instructions – Industrial Gear Units of the M.. Series Horizontal Gear Units M.P../M.R..
Corrosion protection and storage conditions
Safety Notes
2.2 Corrosion protection and storage conditions
Overview Industrial gear units of the M.. series are delivered without oil fill. Observe the corrosion
protection required for the various storage periods listed in the following table:
Standard
protection
• The gear unit is delivered on a pallet without cover.
• Protection of the inside of the gear unit: Gear units of the M series undergo a test run
with protection oil.
• Oil seals and seal surfaces are protected through bearing grease.
• SEW-EURODRIVE applies a protective coating to unpainted surfaces, including
spare parts. Before assembly or before other equipment is mounted to such
surfaces, the protective coating must be removed. To do so, clean the surface with
solvent.
• Small spare parts and loose pieces, such as screws, nuts, etc., are supplied in
corrosion protected plastic bags (VCI corrosion protection bag).
• Threaded holes and blind holes are covered by plastic plugs.
• The corrosion protection is not intended for long-term storage or for humid
conditions. The operator is responsible for keeping the gear unit in corrosion-free
condition.
• The breather plug (Position →Sec. "Mounting Positions") is delivered in a separate
bag and has to be mounted before start-up.
Storage period Storage conditions
Outdoors, under roof Indoors (dry, warm air, heated if
required)
6 months Standard protection Standard protection
12 months Consult with SEW-EURODRIVE Standard protection
24 months Long-term protection Long-term protection
36 months Consult with SEW-EURODRIVE Long-term protection
Sea transport,
storage in
areas close to
the sea
Consult with SEW-EURODRIVE Long-term protection

Operating Instructions – Industrial Gear Units of the M.. Series Horizontal Gear Units M.P../M.R..
11
2
Corrosion protection and storage conditions
Safety Notes
Long-term
protection
• The gear unit is packaged in a seaworthy plywood box and is delivered on a pallet.
This way, the gear unit is protected from humidity and shock. SEW-EURODRIVE
recommends a seaworthy package if the gear unit will be stored for an extended
period of time or if protection against salty air is required.
• Protection of the inside of the gear unit apart from standard protection: A solvent in
the form of a vapor phase inhibitor (VPI = Vapor Phase Inhibitor) is sprayed through
the oil filling hole (recommended value: 0.5 liters in a 10 % solvent per m3). Inhibitors
are volatile, fixed substances that saturate the ambient air with their vapor in closed
rooms. If the inside of the gear unit is subjected to such an atmosphere, then an
invisible VPI film forms on the components inside the gear unit. This film serves as
corrosion protection. After this protection treatment, the solvent vapors (methanol,
ethanol) should have evaporated before closing the gear unit. The breather plug
(Position →Sec. "Mounting Positions") is replaced with a screw plug. The screw plug
must be screwed into the gear unit again before startup. Repeat the long-term
protection treatment after 24 or 36 months (→Overview of corrosion protection
conditions).
• SEW-EURODRIVE applies a protective coating to unpainted surfaces, including
spare parts. Before assembly or before other equipment is mounted to such
surfaces, the protective coating must be removed. To do so, clean the surface with
solvent.
• Small spare parts and loose pieces, such as screws and nuts are supplied in
corrosion protected plastic bags (VCI corrosion protection bag).
• Threaded holes and blind holes are covered by plastic plugs.
•Never open the gear unit near open flames, sparks and hot objects because the
solvent vapors might be ignited.
•Take preventive measures to protect people from solvent vapors. It is
absolutely crucial that open flames are avoided when the solvent is applied
and when the solvent evaporates.

3
12
Operating Instructions – Industrial Gear Units of the M.. Series Horizontal Gear Units M.P../M.R..
Basic design of the M..P.. series
Gear Unit Design
3 Gear Unit Design
3.1 Basic design of the M..P.. series
The following illustrations serve to explain the general design. Their only purpose is to
facilitate the assignment of components to the spare parts lists. Discrepancies are
possible depending on gear unit size and version!
53741AXX
Figure 8: Basic design of the M..P.. series
[1] Housing [45] Cover [199] Gear wheel [310] Bearing
[10] Cover [70] Inspection cover [201] Pinion [399] Gear wheel
[15] Cover [100] LSS shaft [210] Bearing [401] Pinion shaft
[25] Cover [110] Bearing [299] Gear wheel [410] Bearing
[35] Cover [162] Retaining ring [301] Pinion [454] Retaining ring
[40] Cover
[10]
[101]
[110] [162]
[35]
[25]
[454]
[410]
[210]
[40]
[162]
[110]
[15]
[199]
[299]
[1]
[1]
[35]
[25]
[201]
[310]
[310]
[410]
[10]
[301]
[401]
[399]
[210]
[45]

Operating Instructions – Industrial Gear Units of the M.. Series Horizontal Gear Units M.P../M.R..
13
3
Basic design of the M..R.. series
Gear Unit Design
3.2 Basic design of the M..R.. series
53382AXX
Figure 9: Basic design of the M..R.. series
[1] Housing [40] Cover [199] Gear wheel [399] Bevel wheel
[10] Cover [70] Inspection cover [201] Pinion [401] Bevel pinion
[15] Cover [100] LSS shaft [210] Bearing [410] Bearing
[25] Cover [110] Bearing [299] Gear wheel [411] Bearing
[35] Cover [162] Retaining ring [301] Pinion [449] Bushing
[10]
[162]
[110]
[210]
[399]
[301] [1]
[445]
[35]
[401]
[310]
[201]
[35]
[25]
[410]
[411] [80]
[40]
[15]
[310]
[210]
[10]
[25]
[162]
[110]
[299]
[199]
[1]
[101]

3
14
Operating Instructions – Industrial Gear Units of the M.. Series Horizontal Gear Units M.P../M.R..
Unit designation / nameplates
Gear Unit Design
3.3 Unit designation / nameplates
Sample unit designation
M 3 R S F 80 Size:
Horizontal 50 ... 90
Vertical 10 ... 90
Gear unit mounting:
F = Foot mounting
T = Torque arm
Low speed shaft type (LSS):
S = Solid shaft
H = Hollow shaft (key or shrink disc connection)
Mounting position:
no designation: Horizontal
V = Vertical
Gear unit type:
R = Bevel-helical gear unit
P = Helical gear unit
Number of gear stages:
2 = Two stages
3 = Three stages
4 = Four stages
5 = Five stages
Industrial gear unit series

Operating Instructions – Industrial Gear Units of the M.. Series Horizontal Gear Units M.P../M.R..
15
3
Unit designation / nameplates
Gear Unit Design
Example: Nameplate of the M series industrial gear unit, SEW-EURODRIVE
54006AXX
Figure 10: Nameplate
Type Unit designation
Nr. 1 Serial number 1
Nr. 2 Serial number 2
Pe[kW] Absorbed power on the output shaft
MN2 [kNm] Rated torque of the gear unit
FSService factor
i Exact gear unit reduction ratio
n [r/min] Input/output speed
kg [kg] Weight
Lubricant Oil grade and viscosity class / oil volume
Year Year of manufacture
Number of
greasing points [pcs] Number of points that require regreasing
M3PSF80
01.3115835301.0001.02
234
22100
1:40.093 2004
1480/36,9
ISO VG460 Miner.Oil/ca. 160 liter
Year
MN2 kNm
Nr. 2
Made by SEW
Number of greasing points:
Lubricant
kg
i 1:
n r/min
Fs
Pe kW
Nr. 1
Typ
Bruchsal/Germany
1332 359 8.12
119
T09558

3
16
Operating Instructions – Industrial Gear Units of the M.. Series Horizontal Gear Units M.P../M.R..
Mounting positions, shaft positions and directions of rotation
Gear Unit Design
3.4 Mounting positions, shaft positions and directions of rotation
The following mounting positions (for a detailed overview, see →Sec. "Mounting
Positions") and shaft positions (0, 1, 2, 3, 4) are possible:
Mounting
position, shaft
positions M.P..
Mounting
position, shaft
positions M.R..
The shaft positions (0, 1, 2, 3, 4) and directions of rotation shown in the following figures
apply to output shafts (LSS) of the types solid shaft and hollow shaft. For other shaft
positions or gear units with backstop, contact SEW-EURODRIVE.
M.PS.. M.PH..
53867AXX
Figure 11: Mounting positions and shaft positions M.P..
1
4
3
2
1
3
2
4
M.RS.. M.RH..
53868AXX
Figure 12: Mounting positions and shaft positions M.R..
4
3
0
4
3
0

Operating Instructions – Industrial Gear Units of the M.. Series Horizontal Gear Units M.P../M.R..
17
3
Mounting positions, shaft positions and directions of rotation
Gear Unit Design
Directions of
rotation
The directions of rotation of the outputs shaft (LSS) are defined as follows:
Direction of
rotation
Gear unit version
M.PS..
M.RS.. M.PH.. M.RH..
Clockwise
(CW)
53219AXX 53260AXX
Direction of
rotation
Gear unit version
M.PS..
M.RS.. M.PH.. M.RH..
Counterclock-
wise (CCW)
53265AXX 53266AXX

3
18
Operating Instructions – Industrial Gear Units of the M.. Series Horizontal Gear Units M.P../M.R..
Mounting positions, shaft positions and directions of rotation
Gear Unit Design
Shaft positions
and correspond-
ing directions of
rotation of M2P..
industrial gear
units
The following figures show shaft positions and corresponding directions of rotation for
industrial gear units of the M2P.. series.
Shaft positions
and correspond-
ing directions of
rotation of M3P..
industrial gear
units
The following figures show shaft positions and corresponding directions of rotation for
industrial gear units of the M3P.. series.
Two stages
53224AXX
53225AXX
1-4 2-4
CW
CCW
CCW CW
CCW
CW
CCW
CW
CW
CCW
2-3
CCW
CW
1-3
CW
CW
CCW
CCW
Three stages
53226AXX
53227AXX
1-4 2-4
CW CCW
CCW
CW
CCW
CW
CCW
CW
CCW
CW
1-3
CW
CW CCW
CCW
CCW
CW
2-3

Operating Instructions – Industrial Gear Units of the M.. Series Horizontal Gear Units M.P../M.R..
19
3
Mounting positions, shaft positions and directions of rotation
Gear Unit Design
Shaft positions
and correspond-
ing directions of
rotation of M4P..
industrial gear
units
The following figures show shaft positions and corresponding directions of rotation for
industrial gear units of the M4P.. series.
Shaft positions
and correspond-
ing directions of
rotation of M3R..
industrial gear
units
The following figures show shaft positions and corresponding directions of rotation for
industrial gear units of the M3R.. three stage series.
Other directions of rotation are possible. Please refer to the order-specific drawing.
Four stages
53234AXX
53236AXX
1-4 2-4
CCW
CW CC
W
CW
CCW
CW
CW CCW
CCW
CW
1-3
CW
CW
CCW
CCW
CCW
CW
2-3
Three stages
53240AXX
53241AXX
0-4
CCW
CCW
CW
CW
CCW
CW
CCW
CW
0-3
CW
CCW CCW
CW
CCW
CW CCW
CW

3
20
Operating Instructions – Industrial Gear Units of the M.. Series Horizontal Gear Units M.P../M.R..
Mounting positions, shaft positions and directions of rotation
Gear Unit Design
Shaft positions
and correspond-
ing directions of
rotation of M4R..
industrial gear
units
The following figures show shaft positions and corresponding directions of rotation for
industrial gear units of the M4R.. four stage series.
Shaft positions
and correspond-
ing directions of
rotation of M5R..
industrial gear
units
The following figures show shaft positions and corresponding directions of rotation for
industrial gear units of the M5R.. five stage series.
Other directions of rotation are possible. Please refer to the order-specific drawing.
Four stages
53244AXX
53245AXX
0-4
CCW
CCW CW
CW
CCW
CW
CCW
CW
CCW
CW
CCW
CW
0-3
CW
CCW
CW
CCW
Five stages
53246AXX
53247AXX
0-4
CCW
CCW
CW
CW
CCW
CW
CCW
CW
0-3
CW
CCW
CW
CCW
CW
CCW
CW
CCW