WEG CESTARI Worm Gearbox line User manual

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Worm Gearbox line | Instruction Manual

2 | Worm Gearbox line
1General Considerations ..............................................................................Erro! Indicador não definido.
1.1Safety and information indications ...........................................................Erro! Indicador não definido.
1.2General information.............................................................................Erro! Indicador não definido.
1.3Exclusion of liability .............................................................................Erro! Indicador não definido.
1.4Copyright and Protection Rights..........................................................Erro! Indicador não definido.
2General safety ..............................................................................................Erro! Indicador não definido.
3Transport ................................................................................................................................................. 7
3.1Moviment.............................................................................................Erro! Indicador não definido.
4Storage..........................................................................................................Erro! Indicador não definido.
4.1Period without operation......................................................................Erro! Indicador não definido.
4.2Long Term Storage .............................................................................Erro! Indicador não definido.
4.3Storage Preparation ............................................................................Erro! Indicador não definido.
4.4Operation after Storage.......................................................................Erro! Indicador não definido.
5Installation ............................................................................................................................................. 10
5.1Example of Working Position ..............................................................Erro! Indicador não definido.
5.2Minimum permissible diameter for the drive element mounted on the shaftErro! Indicador não
definido.
5.3Mounting position of notched hub .......................................................Erro! Indicador não definido.
5.4Axial clearance for bearing mounting ............................................................................................... 13
6Lubrication ...................................................................................................Erro! Indicador não definido.
6.1Operating temperature and oil temperature ........................................Erro! Indicador não definido.
6.2Quantity of lubricant Magma M Line................................................................................................. 16
6.3Lubricant quantity Alumag line ......................................................................................................... 16
6.4Quantity of lubricant Magma K Line ................................................................................................. 16
6.5Quantity of lubricant 1st stage of the duplex gearboxes Magma K line .......................................... 17
6.6Recommended synthetic lubricants ................................................................................................. 17
6.7Recommended mineral lubricants.................................................................................................... 17
6.8Check list - Installation and assembly of gearboxes ........................................................................ 18
7Operation ......................................................................................................Erro! Indicador não definido.
8Maintenance .................................................................................................Erro! Indicador não definido.
8.1Maintenance Task List ........................................................................Erro! Indicador não definido.
8.2Gearbox faults .....................................................................................Erro! Indicador não definido.
9Repairs..........................................................................................................Erro! Indicador não definido.
9.1Compact Single Input Assembly ...................................................................................................... 23
9.2Compact single entry list .................................................................................................................. 24
9.3Compact Dual Input Assembly ......................................................................................................... 25
9.4Compact dual entry list...................................................................................................................... 26
9.5Single input Assembly ...................................................................................................................... 27
9.6Simple Input List............................................................................................................................... 28
9.7Dual Input Assembly ........................................................................................................................ 29

Worm Gearbox line
9.8Dual entry list.......................................................................................Erro! Indicador não definido.
9.9Adaptation Accessories.................................................................................................................... 31
9.10List Adaptation Accessories .............................................................Erro! Indicador não definido.
9.11Compact input assembly............................................................................................................... 33
9.12Compact Input List ........................................................................................................................ 34
9.13Adaptations Alumag accessories .................................................................................................. 35
9.14List Adaptations Alumag Accessories ...........................................................................................36
10Warranty term...............................................................................................Erro! Indicador não definido.
11Environmental guidelines ...........................................................................Erro! Indicador não definido.

4 | Worm Gearbox line
1 General Considerations
The purpose of this manual is to provide important information that must be observed when transporting,
storing, installing, operating and maintaining WEG-CESTARI products (gear units, gear motors, parts, and
parts) and we, therefore, recommend that you carefully read the instructions contained herein. Failure to
observe the instructions in this manual, in the motor manual (if supplied), voids the product warranty and may
result in serious personal injury and property damage.
In the case of geared motors supplied with a WEG motor, the Motor Installation, Operation and Maintenance
Manual is attached to this manual and must also carefully observe.
The gearboxes supplied with a nameplate (Fig.1) and the geared motors supplied with two nameplates, one
from the gearbox (Fig..1) and one from the motor (according to the manufacturer's standard). The nameplates
contain symbols and values that determine the characteristics of the gearbox and the motor. They fixed in an
easily visible place; they made of weather-resistant material.
The data on the gearbox nameplate are:
Code: Gearbox or geared motor code.
Serial: Serial number.
P1: Motor or gearbox power (kW).
rpm: Gearbox output speed.
M2: Output torque (Nm).
sf: Service factor.
i: Total reduction.
Weight: Weight of the gearbox without motor
(kg).
Oil: Type and viscosity of the oil at 40ºC.
P: Working position and Year of manufacture.
TAG: Information Space
Figura 1
.
The geared motors and gearboxes supplied painted with WEG-CESTARI standard synthetic enamel or
according to specific customer requirements.

Worm Gearbox line
1.1 Safety instructions and information
1.2 General information
This documentation is an integral part of the product and must be read carefully. The information is intended
for all people involved in the assembly, installation, operation, and maintenance of the product and must be
followed.
We do not accept any liability for damage or interruptions of operation resulting from non-compliance with this
documentation.
In the interest of future development, we reserve the right to make modifications and adjustments to this
document without prior notice.
If you have any questions or would like further information, please contact WEG-CESTARI Redutores e Motor
reducutores S.A.
Intended use:
Geared motors are exclusively designed to generate a defined rotary motion in machines and equipment.
Any use other than this is considered unintended use.
The user/operator of the machine or equipment is solely responsible for damage resulting from this.
The details of this manual, the nameplate, and other technical documentation must be considered and
observed.
Intended use for motors:
The motors are designed for operation with power and also in combination with frequency inverters.
Standard motors are designed for use in:
Ambient temperatures from -20°C to +40°C
Altitudes ≤1000 m above sea level.
All safety and warning instructions must be followed without exception!
WARNING!
Warning of electrical or mechanical danger.
ATTENTION!
Important instructions for safe and trouble-free operation.

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This information can also be found on the motor nameplate
.
1.3 Exclusion of liability
The information contained in this Instruction Manual must be followed to ensure the safe and flawless
operation of the Geared motor and to achieve the specified product characteristics and performance
requirements.
WEG-CESTARI assume no responsibility for damage to persons, equipment or property resulting from non-
compliance with this instruction manual. In these cases, any liability for defects is excluded.
1.4 Copyright and protection rights
Todos os documentos técnicos são protegidos de acordo com a lei de direitos autorais. O processamento,
reprodução e divulgação deles, mesmo que em partes, assim como outra utilização não é permitida, salvo
com concessão expressa por escrito.
2 General safety
The customer is responsible for installing the unit following good engineering practice.
The instructions in these Operating Instructions must be followed to achieve the characteristics of the drive
units and to ensure approval in case of warranty claims.
Make sure that no damaged products are put into operation!
Read these Operating Instructions carefully before starting any adjustment, installation or maintenance.
Installation, commissioning, maintenance, and repair of the Geared motor and electrical accessories may
only be carried out by qualified personnel under the following items:
Operating Instructions
Information labels/labels on the Geared motor
All other project documents, installation manuals, and operation manuals
Geared motor specifications and requirements belonging to the Geared motor
The applicable regional and national safety and accident prevention regulations..
WARNING!
Work is only allowed:
With the drive stopped,
When disconnected and prevented from being turned on again.

Worm Gearbox line
The protection around rotating parts must be observed in the installation project of the equipment to be
actuated to protect people and prevent accidents.
The operation of the drive unit by means of a frequency inverter may only take place if the specifications
shown on the motor nameplate are observed.
3 Transport
We recommend that when you receive our product (gearbox, geared motor and/or parts and accessories), you
check that it is in good condition and that it corresponds to your specifications.
If any damage has been found to the product, we request immediate formal communication of the fact to the
shipping company and WEG-CESTARI.
No installation work should be started before the problem encountered is resolved.
3.1 Movement
Use appropriate ropes, cables, belts and suspension equipment when moving the gearboxes/geared motors
so as not to endanger human lives and the equipment itself..
The gearboxes must be moved using the suspension screw (Fig.2A) and, when it is a geared motor, it must
be moved together with the motor eyebolt (Fig.2B) respecting the maximum angle of 60º between the cables.
Never suspend the equipment only through the motor.
Figure 2A Figure 2B
60º

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Before fully lifting the gearboxes/geared motor make sure that the load is properly balanced. All handling of
the gearbox/geared motor must be carried out in a gentle manner to avoid impacts and damage especially
to the shaft ends.
4 Storage
WEG-CESTARI products (gearboxes, geared motors, parts, and parts) must be stored in their original
packaging in a closed environment (not directly exposed to sunlight or UV rays), dry, protected against insects,
free of dust, air humidity below 60%, free of gases, fungi, corrosive agents (contaminated air, ozone, gases,
solvents, acids, alkaline, salts, radioactivity, etc) and ambient temperature between -5ºC to +40ºC.
WEG-CESTARI gearboxes must be stored in the specified and supplied working position, on a flat surface on
platforms or appropriate shelves (not in direct contact with the floor) and not in a place with vibration and
oscillations.
4.1 No operation period
WEG-CESTARI gearboxes/motors leave the factory and must be put into operation within a maximum
period of 6 months.
For periods of 6 months to 9 months without operation, it is recommended to fill the entire interior of the gear
unit with appropriate lubricants (see chapter Lubricants). Fill the reducer with oil up to the top (just below the
vent), thus ensuring that all its gears and bearings are immersed in oil. The input shaft of the reducer must
be rotated at least two complete turns and this procedure must be repeated at least once every 2 months.
NOTE:
For the appropriate lubricant volume, refer to chapter "Lubrication".
Protect the retainers externally with grease and apply a thin layer of grease to the external surface to prevent
drying out. The grease should be removed before starting operation (recommended grease NLGI#2EP
Texaco Multifak EP2 or similar).
4.2 Long-term Storage
The following are guidelines for cases of long-term storage or shutdown, i.e., more than 9 months without
operation. These guidelines are recommended for the storage of up to 2 years. If the relative humidity of
the air is less than 50%, the WEG-CESTARI product can be stored for up to 3 years.
Since there may be influences on the gearbox depending on local conditions, the time indications may vary
from those mentioned above.
If in doubt, contact WEG-CESTARI.

Worm Gearbox line
4.1 Preparation for Storage:
a) Remove all moisture from the gearbox;
b) Check the oil level and complete if necessary with the lubricant recommended in the product
manuals;
c) On gearboxes supplied with lubricating oil, add VCI (Volatile Corrosion Inhibitor) anticorrosive agent
to the lubricant to the extent of 2% of the lubricating capacity.
d) In the case of gear geraboxes supplied without oil, mix 10% of the total volume of the lubricant
recommended in the manuals with 2% of this total volume of VCI and fill the reducer. VCI additive
reference MV OIL 1061 (http:// www.vcibrasil.com.br).
Mineral oil already with VCI (Castrol Alpha SP 150 S or Castrol Alpha SP 220 S);
e) Seal the gerabox completely by hermetically closing the air holes (vents) and the area around the
level dipstick with an adhesive tape (if level dipstick is present);
f) Place grease around the shafts near the retainers and then wrap the shaft areas near the retainers
with an adhesive tape leaving the shaft flush with the retainers;
g) For external fastening surfaces (shafts and flange faces) they are Factory protected; inspect and
protect these surfaces if necessary (in case of film loss) with appropriate corrosion protection (Castrol
Safecoat DW 801 Corrosion Protection Oil or similar layer of approximately 50 μm). Any damage
caused by transport must be corrected.
h) If the gearbox is stored outdoors, place it on blocks. Make a frame around it (if possible) and cover it
with tarpaulin (cotton wax is recommended). Leave the bottom open to receive ventilation.
4.2 Operation after Storage:
If the storage or stop time exceeds 2 years or the ambient temperature deviates from the normal range
during storage, the gear unit lubricant must be replaced before commissioning.
Since they have been properly lubricated, the retainers must be replaced after 2 (two) years.
a) Remove any tape used in preparation for storage;
b) Remove any moisture that may have accumulated in the gearbox, clean the gearbox and inspect for
damage;
c) The VCI corrosion protection agent is soluble in recommended lubricating oils and does not need to
be removed from the gearbox;
d) Check this manual for recommended lubricants and installation, maintenance and operating
instructions;
e) In case the gear reducer is filled with oil, the amount of oil must be reduced to the recommended
amount before commissioning. See chapter "Mounting positions and lubricant quantities".
If required, gearbox prepared for "long-term storage" can be supplied. In this case, WEG-CESTARI must be
informed during the quotation and purchase process.
For storage periods longer than 9 months, the gearboxes/geared motors may only be put into operation if
the above procedures have been followed.

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5 Installation
For geared motors supplied with a rubber-sealed vent valve for transportation, before operating the geared
motor/gearbox, completely remove the protective rubber installed in the valve (as shown below):
After this procedure the vent valve is ready to operate.
The shaft ends are protected with a thin layer of anti-corrosion oil. This oil should be removed before
installation using normal solvents (varsol, turpentine or similar).
Attention !
The solvent must not reach the retainers and never use sandpaper to remove the varnish.
Geared motors / gearboxes must be installed in the correct working position (as stated in the Commercial
Proposal) on a flat, rigid base (to avoid additional stresses and strains), allowing easy access to the
lubrication devices.
5.1 Example of Working Position
Position-1
Position-4
Position-2 Position-5