Wittenstein Alpha LK Series User manual

2022
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D026817
01
a
2022-D026817 Revision: 01a
LK+/LPK+
Operating Manual

LK+/LPK+
2022-D026817 Revision: 01a
Revision history
Revision Date Comment Chapter
124.05.07 New version All
1a 11.02.09 WITTENSTEIN Layout All
Service
In case you have technical questions,
please contact:
WITTENSTEIN alpha GmbH
Customer Service
Walter-Wittenstein-Straße 1
D-97999 Igersheim
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
© WITTENSTEIN alpha GmbH 2008
This documentation is copyright protected.
WITTENSTEIN alpha GmbH reserves all the rights to photo-mechanical reproduction,
copying, and the distribution by special processes (such as computers, file media, data
networks), even in parts.
Subject to technical and content changes without notice.

LK+/LPK+
Revision: 01 2022-D026817 en-1
Contents
1 On this manual .....................................................................................................2
1.1 Signal words ........................................................................................................2
1.2 Safety symbols.....................................................................................................2
1.3 Information symbols.............................................................................................3
2 Safety.....................................................................................................................4
2.1 EC – Machinery directive .....................................................................................4
2.2 Dangers ...............................................................................................................4
2.3 Personnel.............................................................................................................4
2.4 Intended use ........................................................................................................4
2.5 Guarantee and Liability ........................................................................................4
2.6 General safety instructions ..................................................................................5
3 Description of the gearhead................................................................................6
3.1 General information .............................................................................................6
3.2 Type plate ............................................................................................................6
3.3 Ordering code ......................................................................................................7
3.4 Performance statistics..........................................................................................7
3.5 Weight..................................................................................................................7
4 Transport and storage .........................................................................................8
4.1 Scope of delivery .................................................................................................8
4.2 Packaging ............................................................................................................8
4.3 Transport..............................................................................................................8
4.4 Storage ................................................................................................................8
5 Assembly ..............................................................................................................9
5.1 Preparations.........................................................................................................9
5.2 Mounting the motor to the gearhead..................................................................10
5.3 Mounting the gearhead onto a machine ............................................................11
5.4 Mounting on the gear output side ......................................................................11
6 Startup and operation ........................................................................................12
7 Maintenance and disposal.................................................................................13
7.1 Maintenance work..............................................................................................13
7.1.1 Visual inspection ...........................................................................................13
7.1.2 Checking the tightening torques....................................................................13
7.2 Startup after maintenance work .........................................................................13
7.3 Maintenance schedule .......................................................................................13
7.4 Notes on the lubricant used ...............................................................................14
7.5 Supplementary information ................................................................................14
8 Malfunctions .......................................................................................................15
9 Appendix .............................................................................................................16
9.1 Information on mounting onto a motor ...............................................................16
9.2 Information on mounting onto a machine...........................................................16
9.3 Tightening torques for common thread sizes in general mechanics..................17

On this manual LK+/LPK+
en-2 2022-D026817 Revision: 01
1 On this manual
This operating manual contains necessary information for the safe operation of the right-angle
gearhead LK+/LPK+, referred to as gearhead in the following.
The operator must make sure that this operating manual is read through by all persons assigned to
install, operate, or maintain the gearhead, and that they understand it.
Store the operating manual within reach near the gearhead.
1.1 Signal words
The following signal words are used to bring your attention to dangers, prohibitions, and important
information:
1.2 Safety symbols
The following safety symbols are used to bring your attention to dangers, prohibitions, and
important information:
This signal word points out to an immanent danger that can cause
serious injuries and even death.
This signal word points out to a possible danger that can cause
serious injuries and even death.
This signal word points out to a possible danger that can cause slight
to serious injuries.
This signal word (without warning symbol) points out to a possible
danger that can cause material damage.
This signal word draws your attention to application tips or especially
important information when handling the gearhead.
General danger Hot surface Suspended loads Danger of pull-in
Environment
protection
Information

LK+/LPK+On this manual
Revision: 01 2022-D026817 en-3
1.3 Information symbols
The following information symbols are used:
zrequires you to carry out an action
Âindicates the results of an action
Lprovides additional information on handling

Safety LK+/LPK+
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2 Safety
This operating manual, especially the safety instructions and the rules and regulations valid for the
operating site, must be observed by all persons working with the gearhead.
In addition to the safety specifications mentioned in the operating manual, the general and also the
local regulations on the prevention of accidents and on environmental protection should be
observed.
2.1 EC – Machinery directive
Within terms of the EC - machinery directive 2006/42/EC, the gearhead is not considered as an
autonomous machine, but as a “component to install in machines”.
Operation is prohibited within the area of validity of the EC directive until it has been determined
that the machine in which this gearhead is installed corresponds to the regulations within this
directive.
2.2 Dangers
The gearhead has been constructed according to current technological standards and accepted
safety regulations. To avoid danger to the operator or damage to the machine, the gearhead may
be put to use only for its intended usage (see chapter 2.4 "Intended use") and in a technically
flawless and safe state.
2.3 Personnel
Only persons who have read and understood this operating manual may carry out work on the
gearhead.
2.4 Intended use
The gearhead is suitable for all industrial applications that do not come under article 2 of the EC
directive 2002/95/EC (usage restriction of certain dangerous materials in electrical and electronic
equipment).
The gearhead is specified for installment on motors that:
- correspond to the design B5 (for any divergences, please consult our Customer Service
Department [Technical Customer Service]).
- show a radial and axial runout tolerance of at least “N” according to DIN 42955 and
- have a smooth shaft.
2.5 Guarantee and Liability
Guarantee and liability claims are excluded for personal injury and material damage if the claims
derive from one or more of the following causes:
- improper use
- improper assembly/disassembly or improper operation
- operation of the gearhead when safety devices and equipment are defective
- operation of a heavily soiled gearhead
- non-observance of information on transport and storage
- modifications or reconstructions that have been carried out without the written authorisation of
alpha getriebebau GmbH
- improper or neglected maintenance and repair

LK+/LPK+Safety
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2.6 General safety instructions
Objects flung out by rotating components can cause serious injuries.
zRemove objects and tools from the gearhead before putting it into
operation.
Rotating components on the gearhead can pull in parts of the body
and cause serious injuries and even death.
zKeep a sufficient distance to rotating machinery while the gearhead is
running.
Hot gearhead housing can cause serious burns.
zTouch the gearhead housing only when wearing protective gloves or
after the gearhead has been idle for some time.
Solvents can pollute soil and water.
zUse and dispose of cleaning solvents appropriately.

Description of the gearhead LK+/LPK+
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3 Description of the gearhead
3.1 General information
The gearhead is a single- or multistage, low-backlash right angle gearhead that is manufactured
standard in the «M» version (motor attachment). The output shaft bearing is designed to absorb
high tilting moments and axial forces.
The motor is centred using the clamping hub and not with the adapter plate. The motor can thus be
mounted without radial distortion.
It can be adapted to various motors using an adapter plate and a spacer sleeve.
3.2 Type plate
The identification plate is attached to the gearhead housing.
Designation
A Ordering code (see Chapter 3.3
«Ordering code»)
BRatio
C Serial number
D Lubrication note
Tbl-1: Type plate (example)
The ratio (e.g. i = 10) can also be found on a label on the plug socket. The
spacer sleeve is properly aligned when the slit points to the label.
10

LK+/LPK+Description of the gearhead
Revision: 01 2022-D026817 en-7
3.3 Ordering code
3.4 Performance statistics
Please refer to our catalogue or our Internet page at http://www.alphagetriebe.de for the maximum
permitted speeds and torques.
3.5 Weight
You will find the weights of the gearhead with medium-sized adapter plate in Table "Tbl-2". If
another adapter plate is mounted, the actual weight can deviate by up to 10%.
Please consult our service department if your gearhead is older than a year.
You will then receive the valid performance data.
Gearhead size LK+ 050 070 090 120 155
1–stage [kg] 0,7 1,9 3,2 8,9 18,9
Gearhead size LPK+ 050 070 090 120 155
2–stage [kg] 1,4 3,8 6,9 16,8 34,7
3–stage [kg] 1,6 4,2 7,9 19,2 38,7
Tbl-2: Weight
Size
LK+/LPK+ 050/070/090/120/155
Type code
Special gear
S = Standard
X=
Gearhead versions
Motor-mounted gearhead
M=
Gearhead type
nStandard desigO=
Stage number
1 = 1-stage
2 = 2-stage
3 = 3-stage
Ratio i
Type of output shaft
0 = Smooth shaft
1 = Feather key DIN6885 type A
Clearance specification
1 = Standard
Bore diameters of the
clamping hub
See catalogue
LPK 090S-MO3-100-1G1/ Motor
Motor designation
(manufacturer type)

Transport and storage LK+/LPK+
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4 Transport and storage
4.1 Scope of delivery
zCheck the completeness of the delivery against the delivery note.
LMissing parts or damage must be notified immediately in writing to the carrier the insurance, or
alpha getriebebau GmbH.
4.2 Packaging
The gearhead is delivered packed in foil and cardboard boxes.
zDispose of the packaging materials at the recycling sites intended for this purpose. Observe
the locally valid regulations for disposals.
4.3 Transport
No special transport mode is prescribed to transport the gearhead.
For specifications on the weights see Chapter 3.5 "Weights".
4.4 Storage
Store the gearhead in horizontal position and dry surroundings at a temperature of 0 °C to +30 °C
in the original packaging. Store the gearhead for a maximum of 2 years.
For storage logistics we recommend the “first in – first out” principle.
Impacts caused for instance by dropping or setting down too quickly
may damage the gearhead.
zUse only hoisting equipment and transportation devices with sufficient
capacity.
zThe permitted lifting weight of a hoist may not be exceeded.
zLower the gearhead slowly.
Suspended loads may fall and cause serious injuries and even death.
zDo not stand under suspended loads.
The plastic lid on the gearhead may come off.
zNever transport the gearhead by the plastic lid.

LK+/LPK+Assembly
Revision: 01 2022-D026817 en-9
5 Assembly
5.1 Preparations
zClean / de-grease the following gearhead components with a clean and lint-free cloth and a fat
dissolving but non-aggressive cleanser:
- all fitting surfaces to neighbouring components
- centring
- the motor shaft
- the inner diameter of the plug receptacle
- the spacer sleeve inside and outside
zCheck the fitting surface also for damages and impurities.
Loose or overloaded screw connections can damage the gearhead.
zUse a calibrated torque wrench to tighten and check all screw
connections for which a tightening torque has been specified.
Intensive distortions when assembling the motor (e.g. for motors with
shaft shoulder, extensive chamfer radius or longer shafts than
permitted for the gearhead) can damage the gearhead and the motor.
zCheck the interfering edges by measuring, or by a measurement check
based on our catalogue specifications and the information of the motor
manufacturer.
zContact our Customer Service Department.
Pressurised air can damage the sealing of the gearhead.
zDo not use pressurised air to clean the gearhead.

Assembly LK+/LPK+
en-10 2022-D026817 Revision: 01
5.2 Mounting the motor to the gearhead
zSmear screw-bonding agent (for example Loctite 243) onto the four bolts (E).
zAttach the motor (C) to the adapter plate (D) using the four screws (E).
zTighten the threaded pin (B) of the socket (A).
LFor screw sizes, prescribed tightening torques and maximum axial force, refer to Chapter
9.1 «Specifications for mounting onto a motor», table "Tbl-7".
zPress the enclosed stopper plugs up to the stop of the stopper plug in the mounting bores of
the adapter plate (D).
zIf the motor shaft has a feather key, remove it.
LIf recommended by the manufacturer, apply a half wedge.
zTurn the plug receptacle (A) so that the threaded pin (B) can be
reached through the mounting holes.
zPush the motor shaft into the socket of the gearhead.
LThe motor shaft needs to slide in easily. If this is not the
case, then the threaded pin needs to be loosened some
more.
LThe slot of the spacer sleeve has to be aligned with the
groove (if existing) of the motor shaft and be turned by 90°
towards the threaded pin, see table "Tbl-3".
LThere may be no gap between the motor (C) and the
adapter plate (D).
Designation
A Plug receptacle
B Threaded pin
F Spacer sleeve
G Smooth shaft
H Grooved shaft
Tbl-3: Arrangement of motor shaft, socket and spacer sleeve
A
B
C
E
D
B
G
F
A
H

LK+/LPK+Assembly
Revision: 01 2022-D026817 en-11
5.3 Mounting the gearhead onto a machine
5.4 Mounting on the gear output side
zSmear screw-bonding agent (for example Loctite 243) onto the
fastening bolts.
zMount the gearhead using the fastening bolts to the machine
only by the threaded bores (K).
LMount the gearhead in such a way that the type plate
remains legible.
LDo not use washers (e.g. plain washers, tooth lock
washers).
LFor prescribed screw sizes and tightening torques, refer to
Chapter 9.2 «Specifications for mounting onto a machine «,
tables «Tbl-8» and «Tbl-9».
Distortions during mounting operations can damage the gearhead.
zMount gearwheels and toothed belt pulleys onto the output shaft without
forcing.
zDo not on any account attempt an assembly by force or hammering.
zOnly use suitable tools and equipment for the assembly.
zWhen shrink-fitting or pulling on a gear onto the output shaft make sure
that the maximum static axial forces of the output bearing (table «Tbl-4»)
are not exceeded.
Gearhead size LK+050 070 090 120 155
F2AMAX [N] 100 200 450 750 1000
Gearhead size LPK+050 070 090 120 155
F2AMAX [N] 700 1550 1900 4000 6000
Tbl-4: Maximum permitted static axial forces at static load rating (s0) = 1.8 and radial force (FR) = 0
K
K

Startup and operation LK+/LPK+
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6 Startup and operation
Operational conditions and requirements for the surroundings:
- Because of the factory-filled lubricant, the ambient temperature may not lie under 0 °C, or over
+40 °C. Operating temperature may not exceed +90 °C.
LFor other conditions of use, please consult our Customer Service Department.
- Only use the gearhead up to its maximum limit values, see chapter 3.5 “Performance
statistics”.
- Only use the gearhead in a clean, dust-free and dry environment.
Objects flung out by rotating components can cause serious injuries.
zRemove objects and tools from the gearhead before putting it into
operation.
Rotating components on the gearhead can pull in parts of the body
and cause serious injuries and even death.
zKeep a sufficient distance to rotating machinery while the gearhead is
running.
Hot gearhead housing can cause serious burns.
zTouch the gearhead housing only when wearing protective gloves or
after the gearhead has been idle for some time.

LK+/LPK+Maintenance and disposal
Revision: 01 2022-D026817 en-13
7 Maintenance and disposal
7.1 Maintenance work
7.1.1 Visual inspection
zCheck the entire gearhead for exterior damage.
zThe radial shaft seals are subject to wear. Therefore also check the gearhead for leakage
during each visual inspection.
LYou can find more general information on radial shaft seals on our partner's Internet site at
http://www.simrit.de.
LCheck the mounting position, so that no foreign medium (e.g. oil) has collected on the
output shaft.
7.1.2 Checking the tightening torques
zCheck the tightening torque of the fastening bolts on the gear unit housing.
LFor prescribed tightening torques, refer to Chapter 9.2 «Specifications for mounting onto a
machine « tables "Tbl-8" and "Tbl-9".
zCheck the tightening torque of the threaded pin on the motor attachment.
LFor prescribed tightening torques, refer to Chapter «Specifications for mounting onto a
motor», table «Tbl-7».
7.2 Startup after maintenance work
zClean the outside of the gearhead.
zAssemble all safety devices.
zDo a trial run before releasing the gearhead again for operation.
7.3 Maintenance schedule
Hot gearhead housing can cause serious burns.
zTouch the gearhead housing only when wearing protective gloves or
after the gearhead has been idle for some time.
Rotating components on the gearhead can pull in parts of the body
and cause serious injuries and even death.
zDisconnect the machine from the mains before starting maintenance
work.
zSecure the motor against restarting during maintenance work.
Maintenance work At start-up After 500
operating hours
or 3 months
Every 3
months
Yearly
Visual inspection XXX
Checking the
tightening torques
XX X
Tbl-5: Maintenance schedule

Maintenance and disposal LK+/LPK+
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7.4 Notes on the lubricant used
You can obtain further information on the lubricant from our Customer Service.
7.5 Supplementary information
Consult our Customer Service Department for supplementary information on exchanging the
adaptor plate, on disassembly and on disposal of the gearhead.
zDispose of the gearhead at the recycling sites intended for this purpose.
LObserve the locally valid regulations for disposal.
All gearheads are lubricated for their entire working life.

LK+/LPK+Malfunctions
Revision: 01 2022-D026817 en-15
8 Malfunctions
Changed operational behaviour can be an indication of existing
damage to the gearhead, or cause damage to the gearhead.
zDo not put the gearhead back into operation until the cause of the
malfunction has been rectified.
Fault Possible cause Solution
Increased operating
temperature
The gearhead is not suited
for the task.
Check the technical
specifications.
Motor is heating the
gearhead.
Check the wiring of the motor.
Ensure adequate cooling.
Change the motor.
Ambient temperature too
high.
Ensure adequate cooling.
Increased noise during
operation
Distortion in motor mounting. Please consult our Customer
Service Department.
Damaged bearings.
Damaged gear teeth.
Loss of lubricant Lubricant quantity too high. Wipe off discharged lubricant
and continue to watch the
gearhead. Lubricant
discharge must stop after a
short time.
Seals not tight. Please consult our Customer
Service Department.
Tbl-6: Malfunctions

Appendix LK+/LPK+
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9 Appendix
9.1 Information on mounting onto a motor
9.2 Information on mounting onto a machine
Gearhead size
LK+/LPK+Width across flats
[mm]
Tightening torque
[Nm]
Max. axial force
[N]
050 35,645
070 49,580
090 5 23 100
120 6 45 150
155, 1–stage 8 78 180
155, 2–stage 6 45 150
Tbl-7: Information on mounting onto a motor
Gearhead
size LK+Bore Ø
[mm]
Screw size /
property
class
Tightening
torque
[Nm]
050 44 M4 / 8.8 2,8
070 62 M5 / 8.8 5,6
090 80 M6 / 8.8 9,5
120 108 M8 / 8.8 23
155 140 M10 / 8.8 45
Tbl-8: Threaded bores in the gear unit housing LK+
Gearhead
size LPK+Bore Ø
[mm]
Screw size /
property
class
Tightening
torque
[Nm]
050 44 M4 / 12.9 4,95
070 62 M5 / 12.9 9,7
090 80 M6 / 12.9 16,5
120 108 M8 / 12.9 40
155 140 M10 / 12.9 81
Tbl-9: Threaded bores in the gear unit housing LPK+

LK+/LPK+Appendix
Revision: 01 2022-D026817 en-17
9.3 Tightening torques for common thread sizes in general mechanics
Tightening torques [Nm] for threads
Property
class
M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24
8.8 1,28 2,9 5,75 9,9 24 48 83 132 200 275 390 530 675
10.9 1,8 4,1 8,1 14 34 67 117 185 285 390 550 745 950
12.9 2,15 4,95 9,7 16,5 40 81 140 220 340 470 660 890 1140
Tbl-10: Tightening torques for common thread sizes

2022
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D026817
:
01
a
enAC: XXXXXXXX 2022-D026817 Revision: 01a
WITTENSTEIN alpha GmbH
Walter-Wittenstein-Straße 1
97999 Igersheim
WITTENSTEIN - being one with the future
www.wittenstein.de