Wittenstein Alpha TK PLUS ATEX User manual

2022
-
D034859
02
a
2022-D034859 Revision: 02a
TK+ATEX
Operating Manual

TK+ATEX
2022-D034859 Revision: 02a
Revision history
Revision Date Comment Chapter
01 18.12.2009 New version All
02 31.08.2010 2-stage design 1, 3, 5, 7, 9
02a 03.12.2012 Translation corrections 2.4, 7.3
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 2012
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..

TK+ATEX
Revision: 02a 2022-D034859 en-1
Contents
1 Regarding this manual.........................................................................................3
1.1 Signal words ........................................................................................................3
1.2 Safety symbols.....................................................................................................3
1.3 Design of the safety instructions ..........................................................................4
1.4 Information symbols.............................................................................................4
2 Safety.....................................................................................................................5
2.1 EC directive for devices and protective systems in areas with
explosion hazards ................................................................................................5
2.2 Dangers ...............................................................................................................5
2.3 Personnel.............................................................................................................5
2.4 Intended use ........................................................................................................5
2.5 Reasonably predictable misuse ...........................................................................6
2.6 Guarantee and liability .........................................................................................6
2.7 General safety instructions ..................................................................................6
3 Description of the gearhead................................................................................9
3.1 Type plate ............................................................................................................9
3.1.1 Atex identification in gas atmospheres with explosion hazard ......................10
3.1.2 Atex identification in dust-air atmosphere with explosion hazard..................10
3.2 Ordering code ....................................................................................................10
3.3 Performance statistics........................................................................................10
3.4 Dimensioning .....................................................................................................11
3.4.1 Inspection ......................................................................................................11
3.5 Weight................................................................................................................11
3.6 Noise emission...................................................................................................11
4 Transport and storage.......................................................................................12
4.1 Scope of delivery ...............................................................................................12
4.2 Packaging ..........................................................................................................12
4.3 Transport............................................................................................................12
4.4 Storage ..............................................................................................................12
5 Assembly ............................................................................................................13
5.1 Preparations.......................................................................................................13
5.2 Installation conditions ........................................................................................13
5.3 Mounting the motor onto the gearhead..............................................................13
5.4 Mounting gearhead on a machine .....................................................................15
5.5 Mounting on the output side...............................................................................15
6 Startup and operation........................................................................................16
6.1 Note during startup ............................................................................................16
6.2 Inadmissible operational conditions ...................................................................17
6.3 Check running-in behavior .................................................................................17
7 Maintenance and disposal.................................................................................18
7.1 Maintenance work..............................................................................................18
7.1.1 Visual/Noise inspection .................................................................................18
7.1.2 Checking the tightening torques....................................................................18
7.1.3 Check for leakage .........................................................................................18
7.1.4 Replacing the gearhead ................................................................................18
7.2 Startup after maintenance work .........................................................................19
7.3 Maintenance schedule .......................................................................................19
7.4 Notes on the lubricant used ...............................................................................19
7.5 Disposal .............................................................................................................19
8 Malfunctions.......................................................................................................20
9 Appendix.............................................................................................................21
9.1 Specifications on mounting onto a motor...........................................................21

TK+ATEX
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9.2 Specifications on mounting onto a machine...................................................... 22
9.3 Specifications on mounting on the gear output side.......................................... 22
9.4 Tightening torques for common thread sizes in general mechanics ................. 22
9.5 Technical specifications ................................................................................... 23
9.5.1 Technical specifications for TK+004 for use in areas with
explosion hazards......................................................................................... 23
9.5.2 Technical specifications for TK+010 for use in areas with
explosion hazards......................................................................................... 25
9.5.3 Technical specifications for TK+025 for use in areas with
explosion hazards......................................................................................... 28
9.5.4 Technical specifications for TK+050 for use in areas with
explosion hazards......................................................................................... 30
9.5.5 Technical specifications for TK+110 for use in areas with
explosion hazards......................................................................................... 33
9.6 Lubricant quantity .............................................................................................. 35
9.7 Declaration of Conformity.................................................................................. 36

TK+ATEX Regarding this manual
Revision: 02a 2022-D034859 en-3
1 Regarding this manual
These instructions contain necessary information for the safe operation of the angle gear TK+in
areas with explosion hazards, 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 them.
Store these instructions within reach near the gearhead.
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.
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 imminent 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 points out to a possible danger that can cause
material damage.
A note without signal word draws your attention to application tips or
especially important information when handling the gearhead.
General danger Hot surface Suspended loads Danger of being
pulled in
Environment protection Information Explosion Electric voltage

Regarding this manual TK+ATEX
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1.3 Design of the safety instructions
The safety instructions of this operating manual are designed according to the following pattern:
1.4 Information symbols
The following information symbols are used:
requires you to carry out an action
indicates the results of an action
provides additional information on handling
A= Safety symbol (see Chapter 1.2 "Safety symbols")
B= Signal word (see Chapter 1.1 "Signal words")
C= Type and consequence of the danger
D= Prevention of the danger
An "explosion protection symbol" indicates information on handling in areas with
explosion hazards.

TK+ATEX Safety
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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 gearhead.
In addition to the safety specifications mentioned in this operating manual, the general and also the
local regulations on the prevention of accidents and on environmental protection should be
observed.
2.1 EC directive for devices and protective systems in areas with explosion hazards
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.
Be informed of the general safety instructions before beginning work. (see Chapter 2.7
"General safety instructions").
2.3 Personnel
Only persons who have read and understood these instructions may carry out work on the
gearhead.
2.4 Intended use
The gearhead serves to convert torques and speeds. It is designed for industrial applications.
Within terms of the EC machinery directive 94/9 EC, the gearhead is considered a
device that is mounted together with other devices in a machine. A declaration of
conformity for this gearhead can be found in the appendix (see Chapter 9.7
"Declaration of Conformity").
Operation is prohibited within the area of validity of the EC directive until it has been
determined that the machine in which this product is installed corresponds to the
regulations within this directive.
The gear reducer can be used in areas with explosion hazard group II, zones 1 and
2, and zones 22 and 21, thus in the device categories 2 and 3. The gearhead can be
operated in a gas atmosphere in temperature class T3. In dust atmosphere, a
maximum surface temperature of 150°C is possible.
Observe the instructions on the type plate and the appendix on the written
certificate of conformity.
The gearhead is manufactured and declared applying EN 13463 standards and the
94/9/EC directive for use in areas with explosion hazard.
It is imperative that you observe the restrictions of speeds and torques (see
Chapter 9.5 "Technical specifications").
Please consult our Customer Service Department [technical customer service] if
you have any questions or need explanations.

Safety TK+ATEX
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2.5 Reasonably predictable misuse
2.6 Guarantee and liability
Guarantee and liability claims are excluded for personal injury and material damage in case of
- Ignoring the information on transport and storage
- Improper use (misuse)
- Improper or neglected maintenance and repair
- 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
- Operating the gearhead despite leakage or unusual running noises
2.7 General safety instructions
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
- have a smooth shaft
- feature at least the same temperature class as the gearhead.
We recommend temperature class T3 and higher, because the gearhead may
not be permitted to heat up to more than 90 °C in normal conditions. The
gearhead can be heated additionally through heat connection to the motor, and
thus reach a higher housing temperature than 90 °C. The performance of our
gearhead in explosion-risk areas would therefore no longer be guaranteed.
Any use transgressing the maximum permitted speeds, torques and temperature
(especially ignoring the regulations on explosion protection) is not compliant with the
regulations, and thus prohibited.
- Operating the gearhead in an atmosphere whose ignition temperature lies under
the temperature class specified on the type plate.
- Modifications or reconstructions that have been executed without written approval
of WITTENSTEIN alpha GmbH
Operating the gearhead in areas for which it is not approved can lead
to explosions that can cause serious injuries and even death.
Make sure that the gearhead is only used in those areas for which it is
permitted according to the identification plate (see Chapter 3.1 "Type
plate").
Assembly and maintenance in areas with explosion hazards can lead
to explosions that can cause serious injuries and even death.
Be certain that there is no explosive atmosphere during assembly and
maintenance.

TK+ATEX Safety
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Table "Tbl-1" lists a summary of the possible hazards, their causes and protective
measures for areas with explosion hazards.
Dangers Possible causes Protective measures
Hot surfaces Increased friction and dissipated
power because of wear, improper
assembly, overload, or leaks.
Reduction of the torques and
speeds in comparison to standard
gears
Limiting the motor current and
maximum speed of the motor
Maintenance intervals for wear
parts and lubrication according to
maintenance schedule
Inspection of the temperature
behavior and the running-in
behavior before startup
Regular visual and acoustic
inspections
Prohibition of certain mounting
positions and conditions
Increased surface temperature
because of dust deposits.
Cleaning regulations according to
maintenance plan
Mechanically
caused sparks
Overload on shafts, moving parts
and connection elements.
Reduction of the torques and
external loads in comparison to
standard gears
Limiting the motor current of the
motor
Maximum load test before startup
Electrostatic
loading
Potential differences between
components, cleaning processes,
insulating layers
Grounding the gearhead and the
motor
Tbl-1: Summary of the hazards and protective measures for areas with explosion hazards

Safety TK+ATEX
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Objects flung out by rotating components can cause serious injuries.
Remove 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.
Keep a sufficient distance to rotating machinery while the gearhead is
running.
Secure the machine against restarting and unintentional movements
during assembly and maintenance work.
Hot gearhead housing can cause serious burns.
Touch the gearhead housing only when wearing protective gloves or
after the gearhead has been at standstill for some time.
Loose or overloaded screw connections can damage the gearhead.
Use a calibrated torque wrench to tighten and check all screw
connections for which tightening torques have been specified.
Solvents and lubricants can pollute soil and water.
Use and dispose of cleaning solvents as well as lubricants appropriately.

TK+ATEX Description of the gearhead
Revision: 02a 2022-D034859 en-9
3 Description of the gearhead
The gearhead is a single- or two-stage, low-backlash angle gear, which is manufactured as
standard in the "M" version (motor installation).
Motor centering is performed:
- up to gearhead size TP+025 and a motor shaft diameter of 28 mm by the clamping hub
(plug receptacle or coupling)
- from gearhead size TP+050 and a motor shaft diameter of > 28 mm by the centering collar of
the motor
A radial distortion of the motor is avoided.
Adaptation to various motors is done by an adapter plate and a bushing.
The gearhead is equipped with an integrated linear length compensation to compensate for the
expansion of the motor shaft when heated up.
3.1 Type plate
The type plate is attached to the gearhead housing.
There are two centering mechanisms for the output flange, in
accordance with ISO 9409.
The hollow shaft running through serves as a conduit for lines or
hoses, but does not aid in securing the load. On the back side of the
output flange, the position and/or the speed of the load can be
measured through the hollow shaft.
A Ordering code (see Chapter 3.2
"Ordering code")
F Production date
B Ratio G Maximum permitted gear output torque
T2B
C Lubricant H Maximum permitted drive speed n1Max
D Atex identification I CE identification
E Serial number J Name and address of manufacturer
Tbl-2: Type plate (sample values)
A
D
E
WITTENSTEIN alpha GmbH - Walter-Wittenstein-Str.1 - 97999 Igersheim
TK+ 025E-MF1-10 -5K1-1K00 i=10
Lubricated for Life: Oil Castrol Tribol 800/220
SN: 1234567 DMF: 34/08 Made in Germany
II 2 G c k IIC T3 X
II 2 D c k 150°C X
T : 480 Nm / n : 2500rpm
2B 1max
C
GHI
J
F
B

Description of the gearhead TK+ATEX
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3.1.1 Atex identification in gas atmospheres with explosion hazard
3.1.2 Atex identification in dust-air atmosphere with explosion hazard
3.2 Ordering code
3.3 Performance statistics
Based on test results, torques and speeds are reduced in relation to the standard gearhead. The
shaft loads are also reduced in relation to the standard gear. Refer to Chapter 9.5 "Technical
specifications".
Designation
L Group, category
M Type of ignition protection, explosion
group, temperature class
N Ambient temperature
Tbl-3: Type plate (sample values)
Designation
L Group, category
M Type of ignition protection, maximum
surface temperature
N Ambient temperature
Tbl-4: Type plate (sample values)
Deviant values can cause the loss of explosion protection.
If values are divergent, please consult our Customer Service.
L
II2GckIICT3X
MN
L
II 2 D c k 150°C X
MN
Gearhead type
TK+004/010/025/050/110
Type code
E = Explosion protected according to
94/9/EG
Gearhead variations
M = Motor-mounted gearhead
Gearhead model
F = Standard (for Cyclic duty S5)
Number of Stages
1 = 1-stage
2 = 2-stages
Backlash
1 = Standard
Bore diameters of the
clamping hub
see catalogue
Form of output flange
5 = Hollow shaft flange
Ratio i
TK+ 025E - M F 1-10-5K1

TK+ATEX Description of the gearhead
Revision: 02a 2022-D034859 en-11
3.4 Dimensioning
3.4.1 Inspection
The required protection types can be achieved for example by the following measures:
- Use surface-bonding agent between motor flange and adapter plate.
- Use sealing plates between motor flange and adapter plate to seal the through-holes of the
adapter plate.
Sealing plates are available upon request from WITTENSTEIN alpha GmbH.
3.5 Weight
The table "Tbl-5" specifies the gearhead dimensions with medium-sized adapter plate. If another
adapter plate is mounted, the actual dimensions can deviate by up to 10%.
3.6 Noise emission
Depending on the gearhead type and product size, the continuous sound pressure level is up to
68 dB(A) .
Erroneous dimensioning and inspection may lead to loss of explosion
protection.
Please observe all instructions in this chapter.
Adopt the construction according to specifications in the total catalogue, Chapter
"Information" or "Detailed construction", or contact WITTENSTEIN alpha GmbH.
Note the reduced output specifications in construction according to Chapter 9.5
"Technical specifications".
Please consult our Customer Service Department if you have any questions.
Note the instructions in Chapter 7.1.4 "Replacing the gearhead", if the calculated
bearing life is less than 20,000 h.
Prevent gearhead overloading by the motor by limiting motor current and motor
speed.
Clarify the chemical stability of the gearhead for every individual case so as to
avoid a premature failure of a shaft seal or corrosion on the gearhead.
This also includes water and steam, which can cause corrosion. Contact
WITTENSTEIN alpha GmbH about this.
Make sure that the connection of the motor to the gearhead corresponds to the
required protection types (according to DIN 40050):
- in dust atmosphere IP6x,
- in gas atmosphere IP54.
Gearhead size TK+004 010 025 050 110
1–stage [kg] 2,9 5,3 8,9 22,0 48,0
2–stage [kg] 3,2 6,1 10,6 26,0 54,0
Tbl-5: Weight
Specifications on your specific product can be found in Chapter 9.5
"Technical specifications".

Transport and storage TK+ATEX
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4 Transport and storage
4.1 Scope of delivery
Check the completeness of the delivery against the delivery note.
Missing 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.
Dispose of the packaging materials at recycling sites intended for that. Observe the locally
valid regulations for disposals.
4.3 Transport
Specifications on the weights, refer to Chapter 3.5 "Weight".
4.4 Storage
Store the gearhead in horizontal position and dry surroundings at a temperature of 0 °C to +40 °C
in the original packaging. Store the gearhead for a maximum of 2 years.
For storage logistics, we recommend the "first in – first out" method.
Hard knocks, for instance because of falling or hard dropping, can
damage the gearhead.
Only use hoisting equipment and transports with sufficient capacity.
The maximum permitted lift capacity of a hoist may not be exceeded.
Lower the gearhead slowly.
Suspended loads can fall and can cause serious injuries and even
death.
Do not stand under suspended loads.

TK+ATEX Assembly
Revision: 02a 2022-D034859 en-13
5 Assembly
Be informed of the general safety instructions before beginning work. (see Chapter 2.7
"General safety instructions").
5.1 Preparations
Clean / De-grease the following components with a clean and lint-free cloth and grease-
dissolving, non-aggressive detergent:
- All fitting surfaces to neighboring components
- Centering
- The motor shaft
- The inside diameter of the clamping hub
- The bushing inside and out
Dry all fitting surfaces to neighboring components in order to achieve the proper friction values
of the screw connections.
Check the fitting surfaces additionally for damage and impurities.
5.2 Installation conditions
5.3 Mounting the motor onto the gearhead
Ensure that the motor is mounted if possible in a vertical direction.
Pressurized air can damage the gearhead seals.
Do not use pressurized air to clean the gearhead.
Directly sprayed cleaning agents can alter the frictional values of the
clamping hub.
Only spray cleaning agents onto a cloth, with which you can then clean
the clamping hub.
Provide a metallic frame for connection of the gear reducer.
Provide a ground in the areas of the motor gear and gear-gear connection, so as
to prevent any electrostatic charge that may arise.
A damaged coupling can cause ignition dangers.
Align the shaft ends of the motor and gearhead precisely. The offset
values in table "Tbl-8" must definitely be maintained.
Observe the general information and safety instructions of the motor
manufacturer.
Observe the safety and processing instructions of the screw-bonding
agents to be used.

Assembly TK+ATEX
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Apply screw-bonding agent to the four screws (e.g. Loctite 243).
Fasten the motor (A) onto the adaptor plate (B) with the four screws.
If it concerns a single stage gearhead (MF1) , smear screw-bonding agent (for example
Loctite 243) onto the clamping bolt (H).
Tighten the clamping bolt (H) of the clamping hub (I).
For screw sizes and specified torques refer to chapter 9.1 "Specifications on mounting onto
a motor", table "Tbl-12".
Screw in plug (D) of the adaptor plate (B).
For screw sizes and specified torques refer to table "Tbl-7".
If the motor shaft has a feather key, remove the
feather key.
If recommended by the motor manufacturer,
apply a half wedge.
Remove the plug (D) from the mounting bore in the
adaptor plate (B).
Under nocircumstanceremove the plug (E) in the
housing.
Turn the clamping hub (I) until the clamping bolt (H)
can be reached over the mounting bore.
Release the clamping bolt (H) of the clamping
hub (I) with one revolution.
Push the motor shaft into the clamping hub of the
gearhead.
The motor shaft should slip in easily. If this is not
the case, the clamping bolt must be loosened
more.
A slotted spacer sleeve has to be installed extra
for certain motor shaft diameters and
applications.
The 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-6".
No gap is premitted between motor (A) and the
adaptor plate (B).
Designation
H Clamping bolt
I Clamping hub
J Spacer sleeve
K Grooved shaft
L Smooth shaft
Tbl-6: Arrangement of motor shaft, clamping hub and spacer sleeve
E

TK+ATEX Assembly
Revision: 02a 2022-D034859 en-15
5.4 Mounting gearhead on a machine
Smear screw-bonding agent (e.g. Loctite 243) onto the fastening bolts.
Fasten the gearhead on the machine with the bolts through the holes.
Mount the gearhead in such a way that the type plate remains legible.
Do not use washers (e.g. plain washers, tooth lock washers).
For screw sizes and specified torques refer to chapter 9.2 "Specifications on mounting onto
a machine", table "Tbl-13".
5.5 Mounting on the output side
For screw sizes and specified torques refer to chapter 9.3 "Specifications on mounting on the
gear output side", table "Tbl-14".
Width across flats [mm] 5 8 10
Tightening torque [Nm] 10 35 50
Tbl-7: Torques for the plugs
Gearhead size TK+004 010 025 050 110
Axial offset [mm] ± 0,25 ± 0,3 ± 0,4 ± 0,5 ± 0,6
Angle offset [°] 0,2 0,2 0,2 0,2 0,2
Tbl-8: Permissible offset of the coupling, gearhead singlestaged (MF1)
Observe the safety and processing instructions of the screw-bonding
agents to be used.
Distortions during mounting operations can damage the gearhead.
Mount gearwheels and toothed belt pulleys onto the output shaft without
forcing.
Do not on any account attempt an assembly by force or hammering!
Only use suitable tools and equipment for assembly.

Startup and operation TK+ATEX
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6 Startup and operation
Be informed of the general safety instructions before beginning work. (see Chapter 2.7
"General safety instructions").
Check the gearhead before startup for possible damage, especially the radial shaft seal on
the gear output.
6.1 Note during startup
Operating the gearhead in areas for which it is not approved can lead
to explosions that can cause serious injuries and even death.
Make sure that the gearhead is only used in those areas for which it is
permitted according to the identification plate (see Chapter 3.1 "Type
plate").
A damaged gearhead can lead to explosions that can cause serious
injuries and even death.
Never operate damaged or abnormally running or sounding gearheads
in an area of explosion hazard.
Improper use can cause damage to the gearhead and cause ignition dangers.
Make sure that
-theambient temperature does not drop below 0 °C or exceed +40 °C and
-theoperating temperature does not exceed +90 °C.
- the gearhead is mounted in the mounting positions depicted below to ensure
the lubrication of all gearhead components.
For other conditions of use and other mounting positions as those depicted below
(e.g. tilting by an axis of these mounting positions), please consult our Customer
Service Department.
Mounting position B5/V3 (output shaft horizontal, motor shaft upwards)
Mounting position V1/B5 (output shaft downwards, motor shaft
horizontal)
Mounting position V3/B5 (output shaft upwards, motor shaft horizontal)
Mounting position B5/B5 (output shaft horizontal, motor shaft
horizontal)

TK+ATEX Startup and operation
Revision: 02a 2022-D034859 en-17
6.2 Inadmissible operational conditions
6.3 Check running-in behavior
Prevent gear reducer from overloading by limiting the motor current and the
maximum motor speed. Otherwise, the drive output should be switched off in case
the motor temperature rises 10 °C above the usual operational temperature.
Use the gearhead only in a clean and dry environment. Please consult our
Customer Service Department if your gearhead is subjected to course dust or any
kind of liquids during operation.
The following operational conditions are not permitted:
- Mounting position B5/V1 (output shaft horizontal, motor shaft
downwards)
- Co-riding the gearhead on the drive axle is prohibited. Exceptions
require a written approval and technical statement from
WITTENSTEIN alpha GmbH.
- Use during permanent operation (S1 operation: power-on time
greater than 60% or longer than 20 minutes)
After 4 running hours in maximum
operating conditions, check the gearhead
for leakage between gear and motor and
on the output shaft seal.
Measure the surface temperature on the
input flange (A) and on the housing (B).
Consult our Customer Service
Department if the temperature exceeds
+90 °C.
Check the proper assembly of the
clamping hub before startup by a
maximum load test.
Increased running noises may be caused by
faulty motor mounting.
If so, mount onto motor again according to
the operating manual, or consult our
Customer Service Department.
A
B

Maintenance and disposal TK+ATEX
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7 Maintenance and disposal
Be informed of the general safety instructions before beginning work. (see Chapter 2.7
"General safety instructions").
7.1 Maintenance work
7.1.1 Visual/Noise inspection
Dust off the housing. Make sure that the deposit of dust layers on the housing never exceeds
a layer thickness of 5 mm.
Check the entire gearhead for exterior damage and corrosion.
Check the clamping hub for external damage when you inspect the tightening torques of the
clamping bolt.
Check the gearhead for unusual running noises and vibrations during operation.
Please contact our Customer Service if you have any questions regarding maintenance.
7.1.2 Checking the tightening torques
Check the tightening torque of the fastening bolts on the gearhead housing.
You can find the prescribed tightening torques in chapter 9.2 "Specifications on mounting
onto a machine", table "Tbl-13".
Check the tightening torque of the clamping bolt on the motor mounting.
You can find the prescribed tightening torques in chapter 9.1 "Specifications on mounting
onto a motor", table "Tbl-12".
7.1.3 Check for leakage
Check the gear output radial shaft seal for leakage.
Look for external emission of lubricant from the drive.
Open up the Ermeto screw connection in the adapter plate and check for any lubricant
emission inside the adapter plate.
If you detect a leak, remove the lubricant and check the inside of the adapter plate once more
after a brief operation. Lubricant discharge should stop after a short time.
In case lubricant still is emitted, shut down the gearhead and consult our Customer Service.
7.1.4 Replacing the gearhead
Replace the gearhead:
- When 90 % of the calculated life of the gear output bearing has been reached (see
"Cymex®" design or total catalogue: Chapter "Information" or "Detailed construction").
- At the latest after a total of 20,000 operating hours.
Alternatively, the gearhead can be checked by WITTENSTEIN alpha GmbH and if
necessary, released for further operation.
The following maintenance work is crucial for the explosion protection.
Perform these tasks thoroughly and diligently.
When opening up the Ermeto coupling, dust could collect on the
adapter plate and catch fire during later operation.
Make sure that no explosive dust-air mixture is present and no dust can
get into adapter plate before opening the Ermeto coupling or dismantling
the motor.