Wittenstein Alpha TP+ Series User manual

2022-D063062 Revision: 01
Replacing the adapter plate /
Rear centering TP+/DP+/RP+
Instruction Sheet

Instruction Sheet
2022-D063062 Revision: 01
WITTENSTEIN alpha GmbH
Walter-Wittenstein-Straße 1
D-97999 Igersheim
Germany
Customer Service department
Deutschland WITTENSTEIN alpha GmbH [email protected] [phone]
Benelux WITTENSTEIN BVBA [email protected] [phone]
Brasil WITTENSTEIN do Brasil [email protected] [phone]
[email protected] [phone]
Österreich WITTENSTEIN GmbH offi[email protected] [phone]
Danmark WITTENSTEIN AB [email protected] [phone]
France WITTENSTEIN sarl [email protected] [phone]
Great Britain WITTENSTEIN Ltd. [email protected] [phone]
Italia WITTENSTEIN S.P.A. [email protected] [phone]
[email protected] [phone]
North America WITTENSTEIN holding Corp. [email protected] [phone]
España WITTENSTEIN S.L.U. [email protected] [phone]
Sverige WITTENSTEIN AB [email protected] [phone]
Schweiz WITTENSTEIN AG Schweiz [email protected] [phone]
[email protected] [phone]
Türkiye WITTENSTEIN Güç Aktarma
Sistemleri Tic. Ltd. Şti. [email protected] [phone]
© WITTENSTEIN alpha GmbH 2019
Subject to technical and content changes without notice.

Instruction Sheet
Revision: 01 2022-D063062 en-1
Table of Contents
1 About this manual ................................................................................................2
2 Safety.....................................................................................................................2
2.1 Personnel.............................................................................................................2
3 Disassembly / replacement .................................................................................2
3.1 Disassembling the adapter plate..........................................................................2
4 Assembly ..............................................................................................................3
4.1 Preparations.........................................................................................................3
4.2 Attaching gearboxes with rear centering to a machine ........................................4
4.2.1 Mounting with through-holes ...........................................................................4
4.2.2 Mounting with slotted holes ............................................................................4
4.3 Mounting the adapter plate ..................................................................................5
5 Appendix ...............................................................................................................6
5.1 Name plate...........................................................................................................6
5.2 Ordering code ......................................................................................................6
5.3 Information for mounting the adapter plate ..........................................................6
5.3.1 DP+ / HG+ / RP+ / SP+ / TP+ / XP+..................................................................7
5.3.2 NP / NPL / NPR / NPS / NPT ..........................................................................8
5.3.3 CP/CPS ...........................................................................................................8
5.4 Tightening torques for common thread sizes in general
mechanical engineering .......................................................................................9
5.5 Disposal ...............................................................................................................9
5.6 Supplementary information ..................................................................................9

About this manual Instruction Sheet
en-2 2022-D063062 Revision: 01
1 About this manual
The operator must ensure that all persons assigned to install, operate, or maintain the gearbox have
read and understand these instructions in full.
Store these instructions within reach of the gearbox.
These safety instructions should be shared with colleagues working in the vicinity of the device
to ensure individual safety.
The original instructions were prepared in German; all other language versions are translations of
these instructions.
The signal words, safety symbols, and information symbols are explained in the standard manual.
2 Safety
These instructions, especially the safety instructions and the rules and regulations valid for the
operating site, must be observed by all persons working with the gearbox.
In addition to the safety instructions in this manual and in the standard manual, also observe any
(legal and otherwise) applicable environmental and accident prevention rules and regulations (e.g.
personal safety equipment).
2.1 Personnel
Only technicians who have read and understood this operating manual may perform work on the
gearbox. Based on their training and experience, technicians must be able to evaluate the tasks
assigned to them, in order to recognize and avoid risks.
3 Disassembly / replacement
Before motor-side installation on a machine, the adapter plate must be disassembled
depending on the product type and gearbox size.
3.1 Disassembling the adapter plate
The fastening screws of the adapter plate can also hold the gearbox housing together.
When reusing the adapter plate, mark its position.
Clamp the gearbox vertically (with the adapter plate [B] upwards).
These instructions describe the replacement of the adapter plate
on the gearbox as well as the motor-side installation of a gearbox
with rear centering [M] on a machine. It is an amendment to the
standard operating manual. Contradictory specifications in the
standard manual thereby become void.
Also observe all instructions in the standard manual.
M

Instruction Sheet Assembly
Revision: 01 2022-D063062 en-3
4 Assembly
4.1 Preparations
Clean/degrease and dry the following components using a clean and lint-free cloth and a
grease-dissolving, non-aggressive cleaning agent:
- All fitting surfaces to neighboring components
- Adapter plate
- Fastening screws
Dry all fitting surfaces to neighboring components in order to achieve the proper friction values
for the screw connections.
In addition, check the fitting surfaces for damage and impurities.
Loosen the fastening screws [B2] in the adapter plate [B]
and remove it.
Remove adhesive residue from the threaded bores for the
fastening screws.
Use a suitable thread cutter.
If you only want to replace the adapter plate, please
observe the instructions for installation of the new adapter
plate in chapter 4.3 "Mounting the adapter plate".
Also observe all instructions in the standard manual.
Observe the safety and processing instructions for the threadlocker to be
used.
Pressurized air can damage the gearbox seals.
Do not use pressurized air to clean the gearbox.
Directly sprayed cleaning agents can alter the frictional values of the
clamping hub.
Only spray cleaning agents onto a cloth for wiping off the clamping hub.
Operation without an adapter plate might lead to damage.
Only install your own adapter plate or replace an adapter plate according
to the specifications of WITTENSTEIN alpha GmbH.
Operation without an adapter plate is prohibited.
In rare cases, a grease lubricated gearbox may show a small leak at
the input (sweating).
To prevent seeping, we recommend to seal the surfaces between
- adapter plate and drive housing (gearbox), as well as between
- adapter plate and motor,
using a surface sealing adhesive (e.g. Loctite® 573 or 574).
B
H
B2
E3
J

Assembly Instruction Sheet
en-4 2022-D063062 Revision: 01
4.2 Attaching gearboxes with rear centering to a machine
This section is only valid for TP+/DP+/RP+ gearboxes with rear centering.
Center the gearbox in the machine bed.
Apply threadlocker (e.g. Loctite®243) to the fastening screws.
Mount the gearbox so that the identification plate can still be read.
The specified screw sizes and tightening torques can be found in the standard manual.
4.2.1 Mounting with through-holes
4.2.2 Mounting with slotted holes
Use only the washers included within the scope of delivery for fastening the gearbox to a
machine.
We recommend doing without washers as long as the
material of the screw surface features sufficient interface
pressure.
Fasten the gearbox on the machine with the fastening screws
through the through-holes [M].
The gearbox can be optionally equipped with an output pinion [P1].
The gearing backlash between output pinion and toothed rack/
counter-wheel can be adjusted using the slotted holes [M] and the
lateral guides. An additional adjustment mechanism is no longer
necessary.
Detailed information on the design of the gearbox interface is
available on request.
For the proper setting of the gearing backlash, you will find
further information in the "alpha rack and pinion system" manual
(doc. no. 2022–D001333). The manual will be provided by our
Sales / Customer Service department on request. Please always
provide the serial number.
Operating the gearbox without a motor (e.g. using a hand wheel) is
permitted for setting / aligning the output pinion on the toothed rack.
When doing so, ensure never to tilt / bend the clamping hub.
Slide the washers onto the fastening screws.
Fasten the gearbox to the machine with the
fastening screws through the slotted holes [M].
Carry out the pinning of the gearbox according
to the standard manual.
M
P
1
MM
M

Instruction Sheet Assembly
Revision: 01 2022-D063062 en-5
4.3 Mounting the adapter plate
When attaching a new adapter plate, only use new screws (DIN EN ISO 4762) and clamping
washers (DIN 6796).
Only use adapter plates approved by WITTENSTEIN alpha GmbH.
Notes on the disposal of components no longer in use can be found in chapter 5.5
"Disposal".
Operation without an adapter plate might lead to damage.
Only install your own adapter plate or replace an adapter plate according
to the specifications of WITTENSTEIN alpha GmbH.
Operation without an adapter plate is prohibited.
Position the adapter plate on the drive side [E3].
Select the correct fastening screws (see chapter 5.3
"Information for mounting the adapter plate").
Place the clamping washers on the fastening screws [B2].
Coat the fastening screws with a threadlocker (e.g.
Loctite®243).
Install the fastening screws and tighten them in a criss-
cross pattern using a torque wrench.
For the specified tightening torque, see chapter 5.4
"Tightening torques for common thread sizes in general
mechanical engineering".
Carry out any further tasks according to the standard
manual.
B
H
B2
E3
J

Appendix Instruction Sheet
en-6 2022-D063062 Revision: 01
5 Appendix
5.1 Name plate
The identification plate is attached to the gear housing or the input flange.
5.2 Ordering code
More information is available in our catalog or at www.wittenstein-alpha.de.
5.3 Information for mounting the adapter plate
Designation
A Ordering code
(see Chapter 5.2 "Ordering code")
BRatioi
C Customer material number (optional)
D Serial number
E Lubricant
F Production date
G Data matrix code (optional)
Tbl-1: Identification plate (sample values)
Product type overview
Product type CP/CPS CPK/CPSK CVH/CVS DP+DPK+HDP+/HDV
see table "Tbl-5" x* x* "Tbl-3" x* x*
Product type HG+LK+/LPK+/
LPBK+LP+/LPB+NPK/NPLK/ NPSK/
NPRK/NPTK
NP/NPL/
NPS/NPR/
NPT
NVH/NVS
see table x* x* x* x* "Tbl-4" x*
Product type PKF RP+RPC+/
RPK+SC+/SPC+SK+/SPK+SP+
see table x* "Tbl-3" x* x* x* "Tbl-3"
Product type TK+/TPK+TP+TPC+VH+/VS+/VT+XP+XPC+/XPK+
see table x* "Tbl-3" x* x* "Tbl-3" x*
x*: upon request
Tbl-2: Product type overview
A B
C
G D E F G
WITTENSTEIN alpha GmbH-Walter-Wittenstein-Str.1-97999 Igersheim
xxxxxxx xxx
Mat. No.: 23456789
SN: 1234567
Lubrication: xxx
i= xx
DMF: 10/18
Made in Germany
Product type
Characteristic
Gearbox variant
Gearbox model
Number of stages
Ratio
optional
Motor connection
Generation
Backlash
Clamping hub diameter
Output shape
xxxxxxx x - x x x - xxxxx - x x x - x x xxxxx

Instruction Sheet Appendix
Revision: 01 2022-D063062 en-7
5.3.1 DP+ / HG+ / RP+ / SP+ / TP+ / XP+
Fastening screws (DIN EN ISO 4762) for adapter plate**,
Property class 12.9, Screw size x Length [ ]x[mm]
Gearbox
size
Number
of stages
Code letter (.)*
B C E G / H I / K M N O
DP+ 004
SP+ 060
TP+ 004
XP+ 010
1 M3x25M4x20-----
2M3x16M3x45------
DP+ 010
SP+ 075
TP+ 010
XP+ 020
1-M4x30M5x18----
2 M3x16M4x55-----
3-M3x16------
DP+ 025
RP+ 030
SP+ 100
TP+ 025
XP+ 030
1 - - M5x35 M6x25 - - -
2-M4x20M5x70----
3--M4x20-----
DP+ 050
RP+ 040
SP+ 140
TP+ 050
XP+ 040
1 - - - M6x45 M8x30 - -
2 - - M5x20 M6x90 - - -
3 ---M5x20- - - -
RP+ 050
SP+ 180
TP+ 110
XP+ 050
1 - - - - M8x50 -
2 - - - M6x25 M8x105 - -
3 ----M6x25- - -
RP+ 060
TP+ 300
1 ---- - -M10x35-
2 ---- -M8x30- -
3 ----M6x25- - -
RP+ 080
TP+ 500
1 ---- - - -M12x40
2 ---- -M8x30- -
3 ----M8x105- - -
SP+ 210 1 ---- - -M10x40-
2 ---- -M8x30- -
SP+ 240 1 ---- - - -M12x45
2 ---- -M8x30- -
* Ordering code: xxxxxxxx-xxx-xxxxx-x(.)*x-xx (see chapter 5.1 "Name plate")
** The value for the tightening torque can be found in chapter 5.4 "Tightening torques for common
thread sizes in general mechanical engineering".
Tbl-3: Fastening screws (DIN EN ISO 4762) for adapter plate DP+ / RP+ / SP+ / TP+ / XP+

Appendix Instruction Sheet
en-8 2022-D063062 Revision: 01
5.3.2 NP / NPL / NPR / NPS / NPT
5.3.3 CP/CPS
Fastening screws (DIN EN ISO 4762) for adapter plate**,
Property class 10.9, Screw size x Length [ ]x[mm]
Gearbox
size
Number
of stages
Code letter (.)*
Z A B C D E G / H I / K
NPx005 1 M3x20 M3x10----
2 M3x20 M3x10----
NPx015 1 - M3x20 M4x16 -
2 M3x20 M3x35----
NPx025 1 - - - M4x30 M5x16 -
2 - M3x20 M4x50 - -
NPx035 1 - - - - - M5x30 M6x22
2 - - - M4x30 M5x55 -
NPx045 1 - - - - M8x50 M6x45
2----- M5x30M6x75
* Ordering code: xxxxxxxx-xxx-xxxxx-x(.)*x-xx (see chapter 5.1 "Name plate")
** The value for the tightening torque can be found in chapter 5.4 "Tightening torques for common
thread sizes in general mechanical engineering".
Tbl-4: Fastening screws (DIN EN ISO 4762) for adapter plate NP / NPL / NPS / NPR / NPT
Fastening screws (DIN EN ISO 4762) for adapter plate**,
Screw size x Length [ ]x[mm]
Gearbox
size
Number
of
stages
Code letter (.)*
B C E G / H I / K
Property class 8.8 Property class 10.9
CP005 1M3x20 ----
2M3x20 ----
CPx015 1 - M3x25 M4x22 - -
2 - M3x25*** M4x22 - -
CPx025 1 - - M4x30 M6x25 -
2 - - M4x30*** M6x25 -
CPx035 1 - - - M6x45 M6x30
2 - - - M6x45*** M6x30
CP045 1 - ---M6x45
2 - - M5x30 M6x75
* Ordering code: xxxxxxxx-xxx-xxxxx-x(.)*x-xx (see chapter 5.1 "Name plate")
** The value for the tightening torque can be found in chapter 5.4 "Tightening torques for common
thread sizes in general mechanical engineering".
*** The following only applies to gearboxes with ratio i=32, 64: Deviating screw length;
measure the correct screw length.
Tbl-5: Fastening screws (DIN EN ISO 4762) for adapter plate CP / CPS

Instruction Sheet Appendix
Revision: 01 2022-D063062 en-9
5.4 Tightening torques for common thread sizes in general mechanical engineering
The specified tightening torques for set screws and nuts are calculated values and are based on
the following conditions:
- Calculation in accordance with VDI 2230 (February 2003 version)
- Friction value for thread and contact surfaces µ=0.10
- Utilization of the yield stress 90%
- Torque tools type II classes A and D in accordance with ISO 6789
The settings are values rounded to usual commercial scale gradations or setting possibilities.
Use the exact values in this table to set your tools.
5.5 Disposal
Dispose any components no longer in use at the disposal centers intended for this purpose.
Please observe the valid national regulations for waste disposal.
5.6 Supplementary information
For further information, please visit our website at www.wittenstein-alpha.de. Or contact our
Customer Service department at [email protected]
Tightening torque [Nm] with thread
Property
class
screw / nut
M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24
8.8 / 8 1.15 2.64 5.2 9.0 21.5 42.5 73.5 118 180 258 362 495 625
10.9 / 10 1.68 3.88 7.6 13.2 32.0 62.5 108 173 264 368 520 700 890
12.9 / 12 1.97 4.55 9.0 15.4 37.5 73.5 126 202 310 430 605 820 1040
Tbl-6: Tightening torques for set screws and nuts
WITTENSTEIN alpha GmbH
Customer Service department
Walter-Wittenstein-Straße 1
D-97999 Igersheim, Germany
Tel.: [phone] © WITTENSTEIN alpha GmbH 2019

Instruction Sheet
Revision: 01 2022-D063062
Revision history
Revision Date Comment Chapter
01 16.10.19 New version
draft
All

AC: XXXXXXXX 2022-D063062 Revision: 01
WITTENSTEIN alpha GmbH · Walter-Wittenstein-Straße 1 · 97999 Igersheim · Germany
Tel. [phone] · [e-mail]
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www.wittenstein-alpha.de