1009944 imo wd h maintenance

Upload: taytaytaytay

Post on 04-Jun-2018

220 views

Category:

Documents


0 download

TRANSCRIPT

  • 8/14/2019 1009944 IMO WD H Maintenance

    1/19

    IMO Industrie Antriebseinheit Stoll & Ru GmbH

    Bechhofer Strae 2291350 Gremsdorf / Germany

    Mounting - and maintenance instructions for drive units Revision

    4

    - 1 -

    Mounting- and maintenance

    instructions for slew drives

    series WD-H

  • 8/14/2019 1009944 IMO WD H Maintenance

    2/19

    IMO Industrie Antriebseinheit Stoll & Ru GmbH

    Bechhofer Strae 2291350 Gremsdorf / Germany

    Mounting - and maintenance instructions for drive units Revision

    4

    - 2 -

    Mounting- and maintenance instructions for drive units

    Preface:The following instruction offers you all information you need, to mount- and maintenance an IMO drive unit

    correctly.

    Please also observe any supplement sheets, that may change- or substitute for procedures included in this

    instruction.We oblige you and your customers to follow these instructions, if there are obscure points, please contact us

    immediately.

    We are not liable in case of :

    1. incorrect mounting

    2. improper maintenance or

    3. omitting of passing on of this instructions to your customers and / or to a third party that needs this

    instructions to built in, or maintenance our drive units correctly, or in case of falsification of the text of this

    instruction.

    All relevant information concerning mounting and maintenance are included in this instructions, this instruction

    and possible supplement sheets are always authoritative in their newest number of revision.Our staff would naturally like to answer you any questions you may have about mounting and maintenance.

    Every instruction issued by our firm about mounting and maintenance belose its validity, from now on the number

    of revision, included at the end of the index of this instructions, decides about the validity of the instruction.

    This instruction is meant to be given to your customer, please also refer to it in possible existing machinery

    instructions, but give this instructions in any case with any machine to your customer and / or maintenance

    contractors, subcontractors or resembling.

    All working steps described in this instruction have to be performed by qualified staff, also consider the quality of

    the supporting surfaces the drive unit is fixed on to ( as described below ), this can affect function and durability

    of the drive unit substantially.

    Symbols in this instruction :

    = Information relevant for safety

    Information's marked by this sign have to be followed exactly.

    If this instructions are not followed exactly, this might lead to endangering of :

    - staff

    - the drive unit

    - the machinery or parts of the equipment.

    = Working proceedings are marked by this symbol. They have to be considered as a whole.

    All working steps have to be performed, all information's have to be put into consideration.

    = Working steps are marked by a number in a circle.

    This working steps have to be performed in the order indicated.

    = Mounting- and shaping proceedings are marked by this symbol.

    = Measurement proceedings are marked by this symbol.

  • 8/14/2019 1009944 IMO WD H Maintenance

    3/19

    IMO Industrie Antriebseinheit Stoll & Ru GmbH

    Bechhofer Strae 2291350 Gremsdorf / Germany

    Mounting - and maintenance instructions for drive units Revision

    4

    - 3 -

    = Calculation proceedings are marked by this symbol.

    Index :

    0. Transport- handling- and storage instructions

    0.1 Transport- and handling instructions

    0.2 Storage instructions

    1. Fitting

    1.1 Preparation for fitting

    1.1.1 Normal conditions of usage

    1.1.2 Cleaning of the fixing surface of the drive unit and of the supporting structure

    1.1.3 Determination of the permissible plane deviation P, angular deviation Wand the permissibledeformation of the fixing surface of the supporting structure v

    1.1.4 Initial lubrication of the drive unit, respectively control of the oil level

    1.1.5 Choice of the fixing screws

    1.1.6 Choice of the tightening torque of the screws

    1.2 Installation of the drive unit

    1.2.1 Positioning of the drive unit

    1.2.2 Fixing of the drive unit

    1.2.3 Determination of the actual tilting clearance

    1.2.4 Determination of the actual rotation clearance

    1.2.5 Connecting the hydraulic system and the motor1.2.6 Functional testing of the drive unit

    1.2.6 Permissible revolving speed and permissible revolutions

    1.2.7 Varnishing of the drive unit and the surrounding structure

    2. Maintenance / safety checks and lubrication

    2.1 Check of the fixing screws

    2.2 Checking of the tilting clearance

    2.3 Checking of the rotation clearance

    2.4 Checking of the seals

    2.5 Lubrication of oil filled drive units

    2.6 Lubrication of drive units, filled with grease

    2.7 Lubrication intervals for grease - respectively oil - filled drive units

    3. Removal of a worn - out drive unit

    4. Appendix

    4.1 Grease and oil list

  • 8/14/2019 1009944 IMO WD H Maintenance

    4/19

    IMO Industrie Antriebseinheit Stoll & Ru GmbH

    Bechhofer Strae 2291350 Gremsdorf / Germany

    Mounting - and maintenance instructions for drive units Revision

    4

    - 4 -

    0. Transport- handling- and storage instructions

    0.1 Transport- and handling instructions

    Transports of drive units have to be performed in a horizontal position.

    Pay attention to the fact, that a drive unit may not be exposed to hard impacts during handling procedures.

    Handling procedures have to be performed with working gloves, to avoid injuries.

    Eye screws can be screwed into the tapping holes of a drive unit, this enables a save handling on a hitch.

    - The drive unit has to be suspended at least at 3, better on 4 points, a spreading angle of

    the ropes suspended on the eye screws of more than 120 is not permissible.

    - Make sure, the eye screws are screwed in on their full lengths and that the ropes and the

    eye screws are in faultless condition and are proved for the designated loads.

    - Make also sure, that the tapping holes are in faultless, not corroded condition.

    0.2 Storage instructions

    Drive units have to be stored horizontally, if they are piled up, with a layer of wooden planks between each drive

    unit.

    The corrosion protection, applied by our firm will last for 1 week in covered storage places.

    If you want to store a drive unit for a longer time, a long term corrosion protection has to be applied.

    - Uncovered storage places are not suitable for drive units.

    1. Fitting

    1.1 Preparation for fitting

    1.1.1 Normal conditions of usage

    Concerning the permissible static- and dynamic loads, the permissible revolving moment and the quality of the

    fixing screws, as well as the permissible number of revolutions, see at the technical data of the respective drive

    unit. For advice and choice of the type, consult our technical staff.The temperature of usage is -20 to +80. If deviations occur, please consult our technical staff.

    1.1.2 Cleaning of the fixing surface of the drive unit and of the supporting structure

    The fixing surfaces have to be absolutely clean. Also remove any corrosion protection.

    - By no means cleaning agents may enter the housing of the drive unit.

    - Observe any important instructions concerning the cleaning agents ( for instance

    manufacturer specifications, health and security instructions, environmental protection

    instructions )

    - Do not use any aggressive cleaning agents or solvents, that could harm the rubber of the

  • 8/14/2019 1009944 IMO WD H Maintenance

    5/19

    IMO Industrie Antriebseinheit Stoll & Ru GmbH

    Bechhofer Strae 2291350 Gremsdorf / Germany

    Mounting - and maintenance instructions for drive units Revision

    4

    - 5 -

    seals.

    Common detergents : cold detergents ( for instance washing gas, diesel, Katryl KEV etc. )

    Cleaning procedure of the fixing surfaces of the drive unit and of the supporting structure

    Remove alien material from the connection surfaces ( including dry paint and welding beads )

    Remove corrosion protection from the drive unit utilizing a fuzz free cloth, dry the connecting

    surfaces of the drive unit and the supporting structure.

    1.1.3 Determination of the permissible plane deviation P, angular deviation W and the permissible

    deformation of the fixing surface of the supporting structure v

    Chart 1 : permissible plane- including angular deviation for drive units in standard designType of the unit 86 136 146 220 300 360 373 490 645

    Plane including angular deviation 0,08 0,08 0,09 0,09 0,10 0,10 0,11 0,12 0,13

    for each connecting surface

    (mm)

    If the actual type of the unit is between 2 charted values, take the smaller value.

    For bigger units, take the value listed at 3000 mm.

    The maximum permissible angular deviation Wis calculated for a flange that corresponds to the flange of the

    respective drive unit. It may only be reached once at half of the circumference of the drive unit.

    The curve of the plane deviation has to lock similar to a sinus curve, increasing and decreasing slowly. It may be

    possible to equalize unevenness with toughened washers. Talk to our technical staff for this possibility.

    Sketch 1: plane- and angular deviation at the supporting structure

    Sketch 2 : Deformation of the fixing surfaces

    The drive unit has to be supported on it's whole

    fixing surface by a surrounding construction that is

    completely not deformable.

    A deformation under load

    is not permissible

    Fixing

    surfaces

    Drive unit

  • 8/14/2019 1009944 IMO WD H Maintenance

    6/19

    IMO Industrie Antriebseinheit Stoll & Ru GmbH

    Bechhofer Strae 2291350 Gremsdorf / Germany

    Mounting - and maintenance instructions for drive units Revision

    4

    - 6 -

    1.1.4 Initial lubrication of the drive unit respectively control of the oil level

    Drive units are delivered greased with longlife grease. The drive unit has to be regreased before the initialoperation.

    Utilize water-repellent lithium-soap-grease according to DIN 51 825 TI of NLGI-class 2 DIN 51 818 for the

    raceway.

    See chart 7 for greases fit for use.

    Lubrication of the housing ( for units, filled with grease )

    Press grease into all grease nipples of the drive unit while revolving the drive unit in the mean

    time, until a continuos grease collar forms under the open seal.

    Apply a small amount of grease beyond the seal lip of the close seal, utilizing for instance a

    brush, to enable a wear resistant run of the seal.

    Control and refilling of the oil level ( for units, filled with oil )

    Apply a small amount of grease beyond both of the seal lips, utilizing for instance a brush, to

    enable a wear resistant run of the seal.

    Open the oil inlet screw to check the oil level

    If the drive unit is not filled with oil completely to the edge of the inlet drilling, fill oil into the unit, until

    the edge of the inlet drilling.

    When the unit is filled completely, close the inlet screw.

    - Use this bore as inlet bore, that occupies the highest position, relative to the planed fitting

    position.

    1.1.5 Choice of the fixing screws

    Only the prescribed screws may be utilized to fix a drive unit to the supporting structure.

    The prescribed size, number and quality of the screws has to be observed.

    - The function and durability of the drive unit is determined substantially by the durability of

    the screw connection.

    - If washers are utilized, to equalize unevenness, the maximum admissible surface stress

    may not be exceeded.

    - Toughened washers have to be used any time, screws of the quality 10.9 or 12.9 are

    utilized.

    - The clamp lengths ( clamp lengths referring to the diameter of the screw ) has to be 5.

    If differences occur, please talk to our technical staff.

    Chart 3 : Maximum admissible surface stress for different parts and materials

  • 8/14/2019 1009944 IMO WD H Maintenance

    7/19

    IMO Industrie Antriebseinheit Stoll & Ru GmbH

    Bechhofer Strae 2291350 Gremsdorf / Germany

    Mounting - and maintenance instructions for drive units Revision

    4

    - 7 -

    Material Maximum admissible surface stress in N/mm

    Drive unit / revolving part ( GGG70 ) 440

    Drive unit / fixed part ( GS60 ) 300

    Fixing surface St 37 260

    Fixing surface St 52 420

    - Use only new screws, nuts and washers any time a drive unit is mounted or replaced.

    1.1.5 Choice of the tightening torque of the screws

    Under normal conditions the screws are secured sufficiently against loosen, by correct preloading.

    - Additional retention of the screws is possibly necessary, if shock loads or vibrations

    happen regularly.

    - Lock-washers, spring-washers or resembling may never be used.

    Chart 4 : tightening torque's for different sizes and qualities of screws, resembling VDI guideline 2230 K = 0,14

    G = 0,125

    Screw- tightening torque's in Nm for qualities

    size 8.8 10.9 12.9

    M 8 22,5 32,4 38,7

    M 10 45 63 75,6

    M 12 77,4 109 131

    M 16 194 270 324

    M 20 369 522 630

    If the aggrieving factors named above ( shock loads or vibrations ) are in effect screw retention has to be utilized.Utilization of screw retention, for example Loctite-270 :

    The surface roughness of the surfaces to be connected shall not exceed Rz 65.

    The enclosed instructions of the manufacturer have to be observed carefully.

    Additional information concerning screw retention can be taken from DIN 25 201 or DIN 25 203, especially

    information concerning the anchoring utilization of screw retention.

    For special information known manufacturers of screw retention ( for instance Loctite ) have to be contacted.

    1.2 Installation of the drive unit

    1.2.1 Positioning of the drive unit

    The drive unit has to be placed on the supporting surface.

    Test if the drive unit is supported by the supporting surface on the whole circumference and

    width. Utilize feeler gauges for this test.

    If this is not the case, unevenness may be equalized by toughened washers. Please discuss this

    with our technical staff.

  • 8/14/2019 1009944 IMO WD H Maintenance

    8/19

    IMO Industrie Antriebseinheit Stoll & Ru GmbH

    Bechhofer Strae 2291350 Gremsdorf / Germany

    Mounting - and maintenance instructions for drive units Revision

    4

    - 8 -

    1.2.2 Fixing of the drive unit

    - Drive units may only be fixed to a surface utilizing the designated screw holes.

    It is, in no way, permissible to weld them to the supporting structure, or to perform welding

    procedures in the surrounding of the supporting structure, because this may lead to an

    irreparable distortion in the housing and because of that to an early breakdown.

    When mounting a drive unit to the supporting structure, mount the housing first and then the revolving part. This

    mounting procedure has to be performed, free of external loads.

    In all connections parallel screw axes against each other in a load free condition and parallel screw axes to the

    separation gaps standards are assumed.

    Furthermore the fixing holes of the base - and the revolving part of the drive unit and the supporting structure have

    to resemble each other exactly, in any other case the drive unit will be preloaded.

    - To avoid intolerable deviations between torque moments of the screws stick to the

    following procedure.

    Screwing

    Screw the base part of the drive unit to the surrounding structure first.

    Apply a small amount of oil to the screws to ensure a constant friction coefficient ( not if screw

    retention is utilized ).

    If screw retention is used, stick to the instruction of these products.

    Tighten the screws, possibly with washers, loose.

    Tighten the screws at the loose screwed base part in an over cross pattern.

    Preload the screws step by step up to the stipulated value.

    Now fix the revolving part of the drive unit by repeating the procedure above.

    - If a hydraulically tightening device is used the preload may not exceed 90 % of the elastically

    values.

    The tighten torque moment ( according to chart 3 ) is determined by many factors, especially by the friction

    value of the thread and can vary heavily in practice.

    1.2.3 Determination of the actual tilting clearance

    The tilting clearance increases when the drive unit is built-in.

    To determine the increase of the tilting clearance, the tilting clearance has to be measured at the built-in, not yet

    operated drive unit.

    - Mark the measurement point ( for instance with a taped ) in the main load direction at

    both base - and revolving part, to have a fixed measurement point for subsequent checks.

    - Note and archive all measured values.

  • 8/14/2019 1009944 IMO WD H Maintenance

    9/19

    IMO Industrie Antriebseinheit Stoll & Ru GmbH

    Bechhofer Strae 2291350 Gremsdorf / Germany

    Mounting - and maintenance instructions for drive units Revision

    4

    - 9 -

    Checking of tilting clearance

    Determine and mark the measurement point, if possible, in the main load direction at the base

    part and at the revolving part.

    Check the distance between base part and revolving part, as shown in sketch 3

    First, fix a dial gauge with a measurement arm at point "A" of the sketch. The feeler of the dial

    gauge must lay at point "B" of the sketch.

    The revolving part has to be tilted in the "1" direction of the sketch, utilizing a determined force.

    Nil the dial gauge.

    Now create a tilting moment into the 2 direction of the sketch by a determined force.

    The value now shown on the dial gauge is equal to the tilting clearance.

    - All further checking procedures have to be performed at the same measurement point with

    the same loads, with the same position of base - and revolving part against each other, by

    utilizing the measurement method indicated.

    - Note and archive the measured values for further checks as reference values.

    Sketch 3 measurement of tilting clearance

    The presently measured tilting

    clearance is seen as a reverence

    value for later checks, in case of

    later checks, the procedure above

    has to be utilized.

    1.2.4 Determining the actual rotation clearance

    In order to determine the increase of the rotation clearance, the rotation clearance has to be measured at a

    mounted, not yet operating drive unit.

    - Mark the measurement point at the base- and at the revolving part respectively at the structure

    ( for instance with tap numbers ), to have a fixed measurement point for later checks.

    - Note and archive all measured values.

    Initial determination of the rotation clearance

    Determine and mark the measurement point at the base- and at the revolving part.

    The measurement point has to be at the external diameter of the revolving part.

    A dial gauge has to be fixed to the base part utilizing a measurement arm, as shown in sketch 4.

    A

    B 1

    2point of

    measurement

  • 8/14/2019 1009944 IMO WD H Maintenance

    10/19

    IMO Industrie Antriebseinheit Stoll & Ru GmbH

    Bechhofer Strae 2291350 Gremsdorf / Germany

    Mounting - and maintenance instructions for drive units Revision

    4

    - 10 -

    First rotate base- and revolving part counter clockwise against each other, utilizing a determined

    force

    Nil the dial gauge.

    Now rotate base- and revolving part clockwise against each other, utilizing a determined force.

    The value, now shown on the dial gauge, is equal to the rotation clearance.

    - All subsequent checks have to be performed at the same measurement point with the same

    loads, the same position of base part and revolving part against each other and by utilizing the

    same measurement method

    - Note the measured values for further measurements, and archive them as reference values for

    further checks.

    Sketch 4 : measurement of the rotation

    clearance

    The presently measured rotation clearance

    is seen as a reference value

    for further checks, further checks have to

    stick to the same procedure.

    1.2.5 Connecting the hydraulic system and the motor.

    If the drive unit has to be delivered without motor, the motor has to be connected now. After that the hydraulic

    system has to be connected.

    Depending on the construction, the drive unit can be also equipped with 2 motors.

    In this case connect both motors, and connect both hydraulic systems of the motors.

    Stick closely to the instructions of the motor- and hydraulic manufacturers.

    - It is not permissible to operate a drive unit, that is constructed to be driven by two motors with

    just one motor.

    1.2.6 Functional testing of the drive unit

    Structure

    rotation

    clearance

    measurement arm

    dial gauge

    measurement point

  • 8/14/2019 1009944 IMO WD H Maintenance

    11/19

    IMO Industrie Antriebseinheit Stoll & Ru GmbH

    Bechhofer Strae 2291350 Gremsdorf / Germany

    Mounting - and maintenance instructions for drive units Revision

    4

    - 11 -

    It now has to be possible to revolve the drive unit with correctly bolted base part, revolving part and motor

    constantly by hydraulic means.

    The influence of loads and possible deviations at the connection surfaces above and beyond the drive unit can

    increase the rotation resistance.

    In case of a rotation resistance, that exceeds the specifications, the drive unit has to be disconnected from the

    surrounding structure, and the rotation resistance has to be measured in a not connected condition.

    Functional testing

    Revolve the mounted drive unit a few times.

    Check if the drive unit runs smoothly and even.

    Perform further testing runs under full load.

    - After the test run, check the drive unit again. If it is necessary retighten the screws up to the

    described values.

    1.2.7 Permissible revolving speed and permissible revolutions

    - Depending on type, and kind of lubrication of the drive unit, different numbers of revolutions are

    permissible. This is described further in our offer. In case of units that are delivered without

    motor, contact to our technical department.

    Depending on constructive base, drive units are not suited as continuos running devices.

    1.2.8 Varnishing the drive unit and the surrounding structure

    - Connection surfaces may not be varnished.

    - No paint may spill on the seal or the connecting surface of the seal, this can corrode the seal,

    or stick the seal lip to the connecting surface.

    This surfaces have to be covered with adhesive tape before the painting procedure.

    2. Maintenance / safety checks and lubrication

    2.1. Check of the fixing screws

    The tightening screws have to be checked every 700 operating hours or at least every 6 months. This time

    schedule has to be adjusted ( lowered ), if special working conditions apply.

    - The tightening moments of the fixing screws have to be checked after the first 100 operating

    hours, but at least after the first month in service in order to equalize possible settling effects

    and the screws have to be retighten to the values indicated in chart 3

    - After this initial test retighten the tightening screws every 700 operating hours respectively after

    the appropriate adjusted ( shorter ) time schedule, this test has to be performed at least every 6months, depending what time is reached earlier.

    If this is not performed, personal and installations can be endangered.

  • 8/14/2019 1009944 IMO WD H Maintenance

    12/19

    IMO Industrie Antriebseinheit Stoll & Ru GmbH

    Bechhofer Strae 2291350 Gremsdorf / Germany

    Mounting - and maintenance instructions for drive units Revision

    4

    - 12 -

    Checking of detachment, replacing the screws

    Relief the screws of any external load.

    Check the tightening value utilizing a torque wrench and adjust them to the values in chart 3.

    Replace loosened screws.

    - Only new screws and washers are suited to replace single loose screws, respectively to

    replace the drive unit.

    2.2 Checking of the tilting clearance

    Wear in the raceway system leads to an increase in the tilting clearance.

    Because of that, the tilting clearance has to be checked in certain, regular, intervals.

    - Check the tilting clearance after 700 service hours, but at least after 6 months

    Failure to do this may endanger personal and installations.

    Checking of the increase of the tilting clearance K , if the tilting clearance can be measured directly

    at the diameter of the borecircle of the worm wheel.

    For the procedure of checking the tilting clearance look at page 7, point 1.2.3 .

    The value measured first, at the installation of the drive unit ( m1) serves as a base value for the checking

    measurements ( mx). The value of the initial measurement is subtracted from the value of al subsequent

    measurements. This value may not exceed the removal clearance.

    K= mx- m1

    Chart 4 : Removal clearance ( increase in tilting clearance )

    Type of drive unit = diameter of the

    borecircle of the worm wheel

    86 136 146 220 300 360 373 490 645

    Removal clearance K ( mm ) 0,3 0,3 0,4 0,4 0,4 0,4 0,5 0,5 0,5

    If the actual size of the type is between 2 given sizes, take the value of the smaller unit. For units, bigger than

    type 645, take the value from type 645.

    If it is impossible to measure the tilting clearance directly at the diameter of the holes in the worm wheel, convert

    the measured value by to the following formula.

    Checking of the increase of the tilting clearance K,if the tilting clearance can not be measured

    directly at the diameter of the borecircle of the worm wheel.

    Calculate the increase of the tilting clearance Kafter every measurement ( after the initial measurement )

    according to the following formula.

    m= mx- m1

    ADSK= m

    ADS+ 2a

  • 8/14/2019 1009944 IMO WD H Maintenance

    13/19

    IMO Industrie Antriebseinheit Stoll & Ru GmbH

    Bechhofer Strae 2291350 Gremsdorf / Germany

    Mounting - and maintenance instructions for drive units Revision

    4

    - 13 -

    ADS= Diameter of the fixing surface of the worm wheel, a = Distance of the measurement point from the

    diameter of the borecircle of the worm wheel.

    For the maximum permissible increase of the tilting clearance ( removal clearance ) see chart 4.

    - If the increase of the tilting clearance equals 75% of the maximum permissible increase, the

    inspection interval has to be lowered to 200 service hours.

    - After an increase of more than 75% of the maximum permissible increase of the tilting

    clearance, the inspection interval has to be lowered further ( to 50 - 100 service hours ).

    - If the removal clearance is exceeded, the machine has to be shut down and the drive unit has

    to be exchanged.

    2.3 Checking of the rotation clearance

    Wear of the teeth, as well of the spring elements leads to a change in the rotation clearance.

    The rotation clearance has to be checked in regular intervals therefore.

    - Check the rotation clearance after 700 service hours or at least after 6 months.

    If this is not performed, personal and installations can be endangered.

    Checking of the increase of the rotation clearance D , if the rotation clearance can be measured

    directly at the diameter of the borecircle of the worm wheel.

    For the procedure of checking the rotation clearance look at page 9, sketch 4.

    The initial measurement of the rotation clearance, measured at the installation of the drive unit ( m 1) serves as a

    basis value for the subsequent checking measurements. ( mx). The value of the initial measurement is

    subtracted from the value of the subsequent measurements. This value may not exceed the removal clearance.

    D= mx- m1

    Chart 5 : Removal clearances ( enlargement of rotation clearance )

    Type of the unit = diameter of the

    borecircle of the worm wheel

    86 136 146 220 300 360 373 490 645

    Removal clearances D ( mm ) 0,5 0,5 0,8 0,8 0,8 0,8 1,3 1,3 1,3

    In case of types that are between two given type-sizes, take the value for the smaller type. For sizes bigger than

    type 645, take the value of type 645.

    Checking of the increase of the rotation clearance D,if the rotation clearance can not be measureddirectly at the diameter of the borecircle of the worm wheel.

    Calculate the increase of the rotation clearance Dafter every measurement ( after the initial measurement )

    according to the following formula.

    m= mx- m1

    ADS

    K= mADS+ 2a

    ADS= Diameter of the fixing surface of the worm wheel, a = Distance of the measurement point from thediameter of the borecircle of the worm wheel.

    For the maximum permissible increase of the rotation clearance ( removal clearance ) see chart 5.

  • 8/14/2019 1009944 IMO WD H Maintenance

    14/19

    IMO Industrie Antriebseinheit Stoll & Ru GmbH

    Bechhofer Strae 2291350 Gremsdorf / Germany

    Mounting - and maintenance instructions for drive units Revision

    4

    - 14 -

    - If the actual increase of the rotation clearance equals 75% of the maximum permissible

    increase, the inspection interval has to be decreased to 200 service hours

    - After an increase of more than 75% of the maximum permissible increase, the inspection

    interval has to be lowered even further ( to 50 - 100 service hours ).

    - If the removal clearance of the rotation clearance is exceeded, the machine has to be shut

    down and the drive unit has to be exchanged.

    2.4 Checking of the seals

    If a seal fails, because of wear, mechanical, respectively chemical influence it has to be renewed. Seals have tobe checked at every control of the screwing.

    The seal can be purchased from our house as piece goods together with glue and fitting instructions.

    2.5 Lubrication of oil filled drive units

    Use the same product for the lubrication of the interior of the housing.

    Use Polyalphaolefin oils for lubrication of the housing, if there are no contradictory instructions on any

    supplement sheets. Check chart 8 for greases, suited for service.

    - All legal - and manufacturer instructions for the usage of lubricants have to be put into

    consideration.

    - Take the bore that occupies the highest position, relative to the planed installation position, as

    inlet bore.

    - Always take the bore, that occupies, relative to the planed installation position, the lowest

    position as oil run - out bore

    - Waste oil may only be disposed by qualified firms

    Maintenance :

    Take, for instance, a brush to put a small amount of grease beyond the lip of both of the seals,

    to ensure a low - wear run.

    Screw the oil - inlet - screw open and check the oil level.

    If the drive unit was not filled with oil completely, fill in new oil up to the edge of the inlet bore

    After the unit is filled completely, close the inlet screw again.

    If more than an appropriate amount of oil is missing, check all seals for a possible leak.

    Oil change :

  • 8/14/2019 1009944 IMO WD H Maintenance

    15/19

    IMO Industrie Antriebseinheit Stoll & Ru GmbH

    Bechhofer Strae 2291350 Gremsdorf / Germany

    Mounting - and maintenance instructions for drive units Revision

    4

    - 15 -

    Take, for instance, a brush to put a small amount of grease beyond the lip of both of the seals,

    to ensure a low - wear run.

    Screw open the oil inlet bore, as well as the oil run out bore and let the waste oil flow into a

    suitable tank.

    Close the oil run out bore again.

    Now fill the unit up to the edge of the inlet bore with fresh oil.

    Close the inlet screw again after filling the unit completely.

    If more than an appropriate amount of oil is missing, check all seals for a possible leak.

    2.6 Lubrication of drive units, filled with grease

    Use the same product for the relubrication of the housing interior any time.

    Use for the lubrication water - repellent Lithiumsoapgreases according to DIN 51 825 of the NLGI - class 2 DIN

    51 818 only. Also check chart 7.

    - All legal - and manufacturer regulations for the usage of lubricants have to be observed.

    - Waste grease may only be disposed by qualified firms.

    Relubrication of the housing

    Clean all grease nipples.

    Press grease into all grease nipples, until a continuos collar of fresh grease has formed beyond the

    opening seal lip.

    Rotate the drive unit a few times meanwhile.

    Ensure that old grease can flow out without problems.

    Put a small amount of grease, i. e. utilizing a brush beyond the seal lip of the seal, that is not

    opening, to ensure a low - wear run.

    Change of the grease

    Clean all grease nipples.

    Press grease into all grease nipples, until the old ( darker ) grease has escaped completely from

    the opening seal.

    Rotate the drive unit a few times meanwhile.

    Continue the lubrication, until only new ( lighter ) grease escapes undiluted from the opening

    seal.

    Make sure, that old grease can flow out without problems.

    Put a small amount of grease, i. e. utilizing a brush beyond the seal lip of the seal, that is notopening, to ensure a low - wear run.

  • 8/14/2019 1009944 IMO WD H Maintenance

    16/19

    IMO Industrie Antriebseinheit Stoll & Ru GmbH

    Bechhofer Strae 2291350 Gremsdorf / Germany

    Mounting - and maintenance instructions for drive units Revision

    4

    - 16 -

    2.7 Lubrication intervals for grease - respectively oil - filled drive units

    Lubrication intervals mainly depend on the kind of lubrication, the working conditions, the environmental

    conditions, the type of the drive unit and the number of operating hours.

    Exact relubrication intervals can only be determined through testing under realistic conditions.

    If no comparable test results are present, the following chart can be taken as estimated data.

    Oil filled units are filled with a polyalphaolefin oil, if no contradictory information is noted on a supplement sheet.

    This kind of lubrication has the advantage of increased stand times, higher possible rotation speed and lower

    wear.

    Because of that changed data applies :

    Chart 6 : Lubrication intervals for drive units

    Working conditions drive units filled with oil drive units filled with grease

    maintenance

    intervals

    oil change

    intervals

    relubrication

    intervals

    grease change

    intervals

    Dry and clean plant - building (turn tables / robots or similar )

    Difficult conditions in open terrain (

    cranes / excavators or similar )

    every 400operating hours,

    but at least every 6

    months

    every 2500operating hours,

    but at least every

    36 months

    every 300operating hours,

    but at least every 6

    months

    every 2000operating hours,

    but at least every

    36 months

    Aggressive climatic conditions

    sea- / desert - / arcticclimates /

    Extremely dirty condition / more

    than 70 operating hours per week

    every 200

    operating hours,

    but at least every 4

    months

    every 2000

    operating hours,

    but at least every

    36 months

    every 150

    operating hours,

    but at least every 4

    months

    every 1500

    operating hours,

    but at least every

    36 months

    Extreme conditions ( tunneldrilling

    machinery / steelworks )

    every 70 operating

    hours, but at least

    every 2 months

    every 1500

    operating hours,

    but at least every

    36 months

    every 50 operating

    hours, but at least

    every 2 months

    every 1000

    operating hours,

    but at least every

    36 months

    The values in chart 6 apply only under the following reservations :

    - Working temperature at the unit

  • 8/14/2019 1009944 IMO WD H Maintenance

    17/19

    IMO Industrie Antriebseinheit Stoll & Ru GmbH

    Bechhofer Strae 2291350 Gremsdorf / Germany

    Mounting - and maintenance instructions for drive units Revision

    4

    - 17 -

    4. Appendix

    4.1 Grease - and oil - lists

    Chart 7

    Manufacturer Name of product Temperature of usage C

    Bechem RHUS LT 2 EP - 20 + 120

    Aral Aralub HLP 2 - 25 + 130

    BP Energreasel LS 2 - 25 + 130

    Castrol Speerol EPL 2 - 20 + 120

    DEA Glissando FT 2 - 30 + 120

    Elf Elf EP 2 - 25 + 130

    Esso Beacon 2 - 25 + 130

    Fina Marson EPL 2 - 25 + 130

    Klber Centroplex 2 - 35 + 130

    Mobil Mobilux 2 - 35 + 130Reiner Stabyl LEP 2 - 20 + 120

    Shell Alvania Fett R2 - 30 + 130

    Names of local suppliers and products may differ.

    Chart 8

    Manufacturer Name of product Temperature of usage C

    Bechem Berusynth GP generally between - 30 and + 150 C.

    BP Olex SG-XPA Data, specific for a manufacturer, has to be

    Castrol Alphasyn T inquired.DEA Intor HCLP

    Mobil Mobilgear SHC

    Optimol Optigear HT

    ICI Tribol Tribol 1510

    Names of local suppliers and products may differ.

    Viscosity

    Viscosity has to be between 320 and 680 according to ISO VG. When choosing the viscosity please also

    consider the lowest possible temperature of usage because, in case of increasing viscosity, the liquidity

    decreases and, because of that, power losses increase.

    In case of general questions concerning the viscosity values please talk to our technical department. In case of

    more specific questions, please talk to the manufacturer directly.

  • 8/14/2019 1009944 IMO WD H Maintenance

    18/19

    IMO Industrie Antriebseinheit Stoll & Ru GmbH

    Bechhofer Strae 2291350 Gremsdorf / Germany

    Mounting - and maintenance instructions for drive units Revision

    4

    - 18 -

    Revision 4 / 27.04.1998

  • 8/14/2019 1009944 IMO WD H Maintenance

    19/19

    IMO Industrie Antriebseinheit Stoll & Ru GmbH

    Bechhofer Strae 2291350 Gremsdorf / Germany

    Mounting - and maintenance instructions for drive units Revision

    4

    - 19 -

    This mounting and maintenance instructions substitute for all instructions before the no. of revision / date named

    above.

    Please also consider possible supplement sheets.