Wittenstein Alpha SP Series User manual

2022
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2022-D012825 Revision: 06
SP+
Operating Manual

SP+
2022-D012825 Revision: 06
Revision history
Revision Date Comment Chapter
101.12.03 New version All
2 13.07.04 Do not release adaptor
plate
Oil types
3.4.3, 4.3, 9.0
3 10.03.06 ISO 3864 All
418.01.07 Product sizes 210 -
240,
bipartite plug
receptacles,
ANSI, Layout 07
All
5 26.11.07 Technical Data
updated 9
6 01.07.08 Layout WITTENSTEIN 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.

SP+
Revision: 06 2022-D012825 en-1
Contents
1 On this manual .................................................................................................... 2
1.1 Signal words ....................................................................................................... 2
1.2 Safety symbols.................................................................................................... 2
1.3 Information symbols............................................................................................ 2
2 Safety.................................................................................................................... 3
2.1 EC – Machinery directive.................................................................................... 3
2.2 Dangers .............................................................................................................. 3
2.3 Personnel............................................................................................................ 3
2.4 Intended use....................................................................................................... 3
2.5 Guarantee and Liability....................................................................................... 3
2.6 General safety instructions ................................................................................. 4
3 Description of the gearhead............................................................................... 5
3.1 General Information ............................................................................................ 5
3.2 Overview of the gearhead components .............................................................. 5
3.3 Type plate ........................................................................................................... 5
3.4 Ordering key ....................................................................................................... 6
3.5 Performance statistics......................................................................................... 6
3.6 Weight................................................................................................................. 6
4 Transport and storage........................................................................................ 7
4.1 Scope of delivery ................................................................................................ 7
4.2 Packaging ........................................................................................................... 7
4.3 Transport............................................................................................................. 7
4.3.1 Transport of gearheads up to and including size SP+140 ............................ 7
4.3.2 Transport of gearheads as of size SP+180 ................................................... 7
4.4 Storage ............................................................................................................... 7
5 Assembly ............................................................................................................. 8
5.1 Preparation ......................................................................................................... 8
5.2 Mounting the motor onto the gearhead............................................................... 9
5.3 Mounting gearhead on a machine .................................................................... 10
5.4 Mounting on the output side.............................................................................. 10
6 Startup and operation....................................................................................... 11
7 Maintenance and disposal................................................................................ 12
7.1 Maintenance work............................................................................................. 12
7.1.1 Visual inspection .......................................................................................... 12
7.1.2 Checking the tightening torques................................................................... 12
7.2 Startup after maintenance work........................................................................ 12
7.3 Maintenance schedule...................................................................................... 12
7.4 Notes on the lubricant used.............................................................................. 13
7.5 Supplementary information............................................................................... 13
8 Malfunctions...................................................................................................... 14
9 Appendix............................................................................................................ 15
9.1 Specifications on mounting onto a motor.......................................................... 15
9.2 Specifications on mounting onto a machine ..................................................... 16
9.3 Tightening torques for common thread sizes in general mechanics................. 16

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1 On this manual
This operating manual contains necessary information for the safe operation of the planetary
gearhead SP+, referred to as gearhead in the following.
The operator must make sure that this operatingmanual 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:
1.3 Information symbols
The following information symbols are used:
zrequires you to carry out an action
<indicates the results of an action
Lprovides additional information on handling
DANGER This signal word points out to an immanent danger that
can cause serious injuries and even death.
WARNING This signal word points out to a possible danger that can
cause serious injuries and even death.
CAUTION This signal word points out to a possible danger that can
cause slight to serious injuries.
CAUTION This signal word (without warning symbol) points out to a
possible danger that can cause material damage.
INFORMATION Thissignalworddrawsyourattentiontoapplicationtipsor
especially important information when handling the
gearhead.
General danger Hot surface Suspended loads Danger of pull-in
Environment
protection Information

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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 the gearhead without lubricant
- 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
WITTENSTEIN alpha GmbH
- improper or neglected maintenance and repair

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2.6 General safety instructions
WARNING
Objects flung out by rotating components can cause serious injuries.
zRemove objects and tools from the gearhead before putting it into
operation.
WARNING
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.
CAUTION
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.
INFORMATION
Solvents can pollute soil and water.
zUse and dispose of cleaning solvents appropriately.
zObserve the locally valid regulations for disposals.

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3 Description of the gearhead
3.1 General Information
The gearhead is a one- or multistage, low-backlash planetary gearhead, which is manufactured as
standard in the “M” version (motor installation). The output shaft bearing is designed to receive high
tilting moments and axial forces.
Motor centring is performed:
- up to gearhead size SP+100 and a motor shaft diameter of 24 mm of through the clamping
hub and coupling
- from gearhead size SP+140 and a motor shaft diameter of > 24 mm through the centring
collar of the motor
Avoid a radial distortion of the motor.
Adaptation to various motors is done through an adaptor plate and a spacer sleeve.
The gearhead can be optionally constructed with a coupling to compensate for thermal linear
expansion.
3.2 Overview of the gearhead components
3.3 Type plate
The type plate is attached to the gearhead housing.
Gearhead components
AGearhead housing
B Output bearing
C Output shaft
DRadial shaft sealing ring
E Planetary gear stage
F Radial shaft sealing ring
GAdaptor plate
H Spacer sleeve
I Clamping hub and coupling
JDrive bearing arrangement
K Drive housing
Tbl-1: Overview of the gearhead components
Designation
AOrdering key (see chapter 3.4
“Ordering key”)
BRatio
C Series number
DLubricant
Tbl-2: Type plate (sample values)
AB
C
D
E
F
G
H
I
JK
A
BCD

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3.4 Ordering key
3.5 Performance statistics
Please refer to our catalogue or our Internet page at http://www.wittenstein-alpha.de for the
maximum permitted speeds and torques.
3.6 Weight
The table “Tbl-3” specifies the gearhead dimensions with medium-sized adaptor plate. If another
adaptor plate is mounted, the actual dimensions can deviate by up to 10%.
INFORMATION
Please consult our service department if your gearhead is older than a year.
You will then receive the valid performance data.
Gearhead size SP+060 075 100 140 180 210 240
1-stage [kg] 1.9 3.9 7.7 17.2 34.0 57.0 79.0
2-stage [kg] 2.0 3.6 7.9 17.0 36.4 on demand on demand
Tbl-3: Weight
SP140 S-M F 1-10-0 K 1-2 K
Gearhead type
SP 060/075/100/140/180/210/
240
Motor-mounted
K = Coupling
S = plug receptacle
Design code
S = Standard
V = incl. pinion on gear output
X = Special gearhead
Generation
Backlash
0 = Reduced
1 = Standard
Gearhead versions
M = motor-mounted gearhead Borediametersoftheclamping
hub
See catalogue
Gearhead design
F = Cyclic duty S5
C = Continuous duty S1 Form of output shaft
0 = Smooth shaft
1 = Key DIN 6885 Form A
2 = Involute: DIN 5480
Stage number
1 = 1 stage
2 = 2 stage
Ratio i

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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 WITTENSTEIN alpha 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
Specifications on the weights, refer to chapter 3.6 “Weight”.
4.3.1 Transport of gearheads up to and including size SP+140
No special transport mode is prescribed for transporting the gearhead.
4.3.2 Transport of gearheads as of size SP+180
For gearheads as of size SP+180 a support bore (A) is provided for a ring screw
(e.g. acc. to DIN 580). The ring screw is used for secure attachment to hoisting equipment.
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.
CAUTION
Hard knocks, for instance because of falling or hard dropping, can
damage the gearhead.
zOnly use hoisting equipment and transports with sufficient capacity.
zThe maximum permitted lift capacity of a hoist may not be exceeded.
zLower the gearhead slowly.
WARNING
Suspended loads can fall and can cause serious injuries and even
death.
zDo not stand under suspended loads.
Gearhead size SP+Support bore (A) [Ø]
180 M8
210 M10
240 M12
Tbl-4: Support bore on the gearhead

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5 Assembly
5.1 Preparation
zClean/de-grease the following gearhead components with a clean and lint-free cloth and
grease-dissolving, non-aggressive detergent:
- all fitting surfaces to neighbouring components
-centring
- the motor shaft
- only the inside diameter of the clamping hub
- the spacer sleeve (if provided) inside and out
zCheck the fitting surfaces in addition for damage and foreign bodies.
CAUTION
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.
CAUTION
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.
CAUTION
Pressurised air can damage the gearhead seals.
zDo not use pressurised air to clean the gearhead.
CAUTION
Directly sprayed cleaning agents can alter the frictional values of the
clamping hub.
zOnly spray cleaning agents onto a cloth, with which you can then clean
the clamping hub.

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5.2 Mounting the motor onto the gearhead
zApply screw-bonding agent to the four screws (G) (e.g. Loctite 243).
zFasten the motor (E) onto the adaptor plate (B) with the four screws (G).
zTighten the clamping bolt (C) of the clamping hub (D).
LFor screw sizes and specified torques refer to chapter 9.1 "Specifications on mounting onto
a motor", table "Tbl-10".
zScrew in plug (A) of the adaptor plate (B).
LFor screw sizes and specified torques refer to table "Tbl-6".
zIf the motor shaft has a feather key, remove the
feather key.
LIf recommended by the motor manufacturer, apply
a half wedge.
zRemove the plug (A) from the mounting bore in the
adaptor plate (B).
zTurn the clamping hub (D) until the clamping bolt (C)
can be reached over the mounting bore.
zRelease the clamping bolt (C) of the clamping hub (D)
with one revolution.
zPush the motor shaft into the clamping hub of the
gearhead.
LThe motor shaft should slip in easily. If this is not
the case, the clamping bolt must be loosened
more.
LA slotted spacer sleeve has to be installed extra
for certain motor shaft diameters and applications.
LThe slot of the spacer sleeve (if provided) and
clamping hub have to be flush with the groove (if
provided) of the motor shaft, see table "Tbl-5".
LNo gap is premitted between motor (E) and the
adaptor plate (B).
Designation
HClamping bolt
I Clamping hub
J Spacer sleeve
KGrooved shaft
L Smooth shaft
Tbl-5: Arrangement of motor shaft, clamping hub and spacer sleeve
Width across flats [mm] 5 8 10 12
Tightening torque [Nm] 10 35 50 70
Tbl-6: Torques for the plugs
E
G
B
A
F
D
C
I
K
J
H
L

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5.3 Mounting gearhead on a machine
5.4 Mounting on the output side
zSmear screw-bonding agent (e.g. Loctite 243) onto
the fastening bolts.
zFasten the gearhead on the machine with the bolts
through the holes (A).
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 screw sizes and specified torques refer to
chapter 9.2 "Specifications on mounting onto a
machine", table "Tbl-11".
CAUTION
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 assembly.
zIf you pull on or shrink-fit a gearwheel onto the output shaft you must
make sure that the maximum permitted static axial forces of the output
bearing (see table "Tbl-7") are not exceeded.
Gearhead size SP+060 075 100 140 180 210 240
Fa max[N] 9250 10750 18500 31250 49750 83250 97750
Tbl-7: Maximum permitted static axial forces at static bearing statistic (s0) = 1.8 and radial force (Fr) = 0
A

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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.
- For 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.
WARNING
Objects flung out by rotating components can cause serious injuries.
zRemove objects and tools from the gearhead before putting it into
operation.
WARNING
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.
CAUTION
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.

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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 gearhead housing.
LYou can find the prescribed tightening torques in chapter 9.2 “Specifications on mounting
onto a machine”, table “Tbl-11”.
zCheck the tightening torque of the clamping bolt on the motor mounting.
LYou can find the prescribed tightening torques in chapter 9.1 “Specifications on mounting
onto a motor”, table “Tbl-10”.
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
CAUTION
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.
WARNING
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 X X X
Checking the tightening
torques XX X
Tbl-8: Maintenance schedule

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7.4 Notes on the lubricant used
You can receive further information on the lubricants directly from the manufacturer:
Castrol Industrie GmbH, Mönchengladbach
Tel.: + 49 (0) 21 61/9 09 - 30
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.
INFORMATION
All gearheads are permanently lubricated by the manufacturer with
synthetic gear oil (polyglycols) of viscosity class ISO VG 220 or with a high-
performance lubricant (see type plate).

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8 Malfunctions
CAUTION
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.
Lubricantdischargemuststop
after a short time.
Seals not tight. Please consult our Customer
Service Department.
Tbl-9: Malfunctions

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9 Appendix
9.1 Specifications on mounting onto a motor
Gearhead size SP+Clamping
hubinsideØ
“x” [mm]
Clamping
bolt DIN
912-12.9
Width
across
flats
[mm]
Tighte-
ning
torque
[Nm]
max. axial force [N]
Clamping
hub Coupling
060
1 stage x ≤ 11
11 < x ≤ 14
14 < x ≤ 19
M4
M5
M6
3
4
5
4.1
9.5
16 100 10
2 stage x ≤ 11
11 < x ≤ 14 M4 M5 3 44.1 9.5 80 5
075
1 stage x ≤ 14 14 < x ≤ 19
19 < x ≤ 24
M5
M6
M8
4
5
6
9.5
16
39 120 20
2 stage x ≤ 11
11 < x ≤ 14
14 < x ≤ 19
M4
M5
M6
3
4
5
4.1
9.5
16 100 10
100
1 stage x ≤ 19 19 < x ≤ 24
24 < x ≤ 38
M6
M8
M10
5
6
8
16
39
79 150 30
2 stage x ≤ 14 14 < x ≤ 19
19 < x ≤ 24
M5
M6
M8
4
5
6
9.5
16
39 120 20
140
1 stage x ≤ 24
24 < x ≤ 38
38 < x ≤ 48
M8
M10
M12
6
8
10
39
79
135 200 50
2 stage x ≤ 19 19 < x ≤ 24
24 < x ≤ 38
M6
M8
M10
5
6
8
16
39
79 150 30
180
1 stage x ≤ 38
38 < x ≤ 48 M10 M12 8 10 79 135 250 200
2 stage x ≤ 24
24 < x ≤ 38 M8 M10 6 839 79 200 50
210 1 stage 48 < x ≤ 55 M12 10 135 300 -
2 stage 38 < x ≤ 48 M12 10 135 250 200
240 1 stage 48 < x ≤ 60 M16 14 330 300 -
2 stage 38 < x ≤ 48 M12 10 135 250 200
Tbl-10: Specifications on mounting onto a motor

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9.2 Specifications on mounting onto a machine
9.3 Tightening torques for common thread sizes in general mechanics
Gearhead size SP+Bore Ø
[mm] Bore Ø [mm] Screw size/
property class Tightening torque
[Nm]
060 68 5.5 M5/12.9 9.7
075 85 6.6 M6/12.9 16.5
100 120 9.0 M8/12.9 40
140 165 11.0 M10/12.9 81
180 215 13.0 M12/12.9 140
210 250 17.0 M16/12.9 340
240 290 17.0 M16/12.9 340
Tbl-11: Specifications on mounting onto a machine
Tightening torque [Nm] for threads
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-12: Tightening torques for common thread sizes
Property
class
M3
M4
M5
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24