General information and
1
___________________
safety notes
2
___________________
Technical description
SIMOGEAR
Electric-monorail-gearboxes
BA 2535
Operating Instructions
Incoming goods, transport,
3
___________________
and storage
___________________
4
Assembly
5
___________________
Commissioning
___________________
6
Operation
___________________
7
Faults, causes and remedies
___________________
8
Service and maintenance
___________________
9
Disposal
___________________
10
Technical specifications
___________________
11
Spare parts
___________________
12
Declaration of Incorporation
Translation of the original instructions
02/2017
A5E37106353A/RS-AC
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E37106353A/RS-AC
Ⓟ 04/2017 Subject to change
Copyright © Siemens AG 2016 - 2017.
All rights reserved
Table of contents
1
2
3
4
5
General information and safety notes ...................................................................................................... 7
1.1
General information .................................................................................................................. 7
1.2
Copyright ................................................................................................................................... 8
1.3
Use for the intended purpose ................................................................................................... 9
1.4
Obligations of the user .............................................................................................................. 9
1.5
Particular types of hazards .....................................................................................................11
Technical description ............................................................................................................................ 13
2.1
General technical description .................................................................................................13
2.2
Cooling ....................................................................................................................................14
2.3
Clutch ......................................................................................................................................14
2.4
Rating plate .............................................................................................................................14
2.5
2.5.1
2.5.2
2.5.3
Surface treatment ...................................................................................................................15
General information on surface treatment ..............................................................................15
Painted version .......................................................................................................................15
Primed version ........................................................................................................................17
Incoming goods, transport, and storage................................................................................................. 19
3.1
Incoming goods .......................................................................................................................19
3.2
3.2.1
3.2.2
Transport .................................................................................................................................19
General information on transport ............................................................................................19
Fastening for suspended transport .........................................................................................20
3.3
3.3.1
3.3.2
3.3.2.1
3.3.2.2
3.3.2.3
Storage ...................................................................................................................................21
General information for storage ..............................................................................................21
Storage up to 36 months with long-term preservation (optional) ............................................21
General notes for storage up to 36 months ............................................................................21
Gearbox filled with operating oil and anti-corrosive agent ......................................................22
Gearbox completely filled with oil ...........................................................................................22
Assembly .............................................................................................................................................. 23
4.1
Unpacking ...............................................................................................................................23
4.2
General information concerning the installation .....................................................................23
4.3
Thread sizes and tightening torques for fastening bolts .........................................................25
4.4
Mounting an input or output element on the gearbox shaft ....................................................25
4.5
Mounting the clutch lever ........................................................................................................28
Commissioning ..................................................................................................................................... 29
5.1
General information for commissioning ..................................................................................29
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Table of contents
5.2
6
Checking the oil level prior to commissioning ........................................................................ 29
Operation .............................................................................................................................................. 31
6.1
General information about operation ..................................................................................... 31
6.2
Operating the clutch ............................................................................................................... 31
7
Faults, causes and remedies................................................................................................................. 33
8
Service and maintenance ...................................................................................................................... 37
8.1
General notes about maintenance work ................................................................................ 37
8.2
8.2.1
8.2.2
8.2.3
8.2.4
8.2.5
8.2.5.1
8.2.5.2
8.2.5.3
8.2.5.4
8.2.6
8.2.7
8.2.8
8.2.9
Checking and changing lubricants ......................................................................................... 39
General safety instructions .................................................................................................... 39
Checking the oil level ............................................................................................................. 40
Checking the oil level using the oil sight glass (optional) ...................................................... 41
Checking the oil quality .......................................................................................................... 41
Changing the oil ..................................................................................................................... 42
General safety notes for changing the oil .............................................................................. 42
Draining the oil ....................................................................................................................... 43
Flushing the gearbox when changing between incompatible oils .......................................... 43
Filling in oil ............................................................................................................................. 45
Topping up with oil ................................................................................................................. 46
Change the roller bearing grease .......................................................................................... 46
Service life of the lubricants ................................................................................................... 47
Recommended lubricants ...................................................................................................... 49
8.3
Replace bearings ................................................................................................................... 50
8.4
Checking the gearbox for leaks ............................................................................................. 50
8.5
Replacing the vent valve ........................................................................................................ 51
8.6
Cleaning the gearbox ............................................................................................................. 51
8.7
Checking the tightness of fastening bolts .............................................................................. 52
8.8
Inspecting the gearbox ........................................................................................................... 52
9
Disposal................................................................................................................................................ 53
10
Technical specifications ........................................................................................................................ 55
11
12
10.1
Type designation .................................................................................................................... 55
10.2
General technical data ........................................................................................................... 55
10.3
Weight .................................................................................................................................... 57
10.4
Sound energy level ................................................................................................................ 58
10.5
Mounting positions and oil quantities ..................................................................................... 58
Spare parts ........................................................................................................................................... 61
11.1
Stocking of spare parts .......................................................................................................... 61
11.2
11.2.1
11.2.2
Spare parts lists ..................................................................................................................... 62
Electric-monorail-gearboxes BHZ29, BH39, BHZ39.............................................................. 62
Electric-monorail-gearboxes KHF 49 - 79 .............................................................................. 64
Declaration of Incorporation .................................................................................................................. 67
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General information and safety notes
1.1
General information
Note
Siemens AG does not accept any liability for damage and failures that result from the nonobservance of these operating instructions.
These operating instructions are supplied as standard with the gearbox. Store the operating
instructions near the gearbox. Please read the operating instructions prior to handling the
gearbox and observe the information they contain. This is how you secure safe and
disturbance-free function.
These operating instructions apply to the standard version of
SIMOGEAR electric-monorail-gearboxes BHZ 29 - 39, BH39 and KHF 49 - 79.
For a description of the precise designation, see Type designation (Page 55).
Table 1- 1
Article number code
SIMOGEAR gearbox
Electric-monorail-gearboxes BH, KH
Article number position
1
2
3
4
5
2
K
J
3
8
Note
In addition to these operating instructions, special contractual agreements and technical
documentation apply to a special gearbox design and the associated supplementary
equipment.
Please refer to the other operating instructions supplied with the product.
The described gearboxes correspond to the state-of-the-art at the time these operating
instructions were printed.
Siemens AG reserves the right to change individual components and accessory parts in the
interest of further development. The changes serve to improve the performance and safety.
The significant features are retained. The operating instructions are updated regularly with
new contents.
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General information and safety notes
1.2 Copyright
The latest versions of the operating instructions, the declaration of incorporation and the
declarations of conformity are available in electronic form in the Industry Online Support
(https://support.industry.siemens.com/cs/ww/de/ps/13424/man).
You can find technical configuration data, spare parts lists and certificates of compliance on
the Intranet at Once Delivered (https://c0p.siemens.com:8443/sie/1nce_delivered).
You can find the contact data of your Technical Support in the Database of contacts at
Siemens AG (www.siemens.com/yourcontact).
If you have any technical questions, please contact Technical Support
(https://support.industry.siemens.com/cs/ww/en/sc/2090).
Europe and Africa
Telephone: +49 911 895 7222; support.automation@siemens.com
America
Telephone: +1 800 333 7421; support.america.automation@siemens.com
Asia / Australia / Pacific
Telephone: +86 400 810 4288; support.asia.automation@siemens.com
Valid operating instructions for SIMOGEAR
● BA 2030 - operating instructions for SIMOGEAR gearboxes
● BA 2031 - operating instructions for permissible mounting position deviations of
SIMOGEAR gearboxes
● KA 2032 - compact operating instructions for SIMOGEAR worm geared motor S
● BA 2039 - operating instructions for adapters for mounting on SIMOGEAR gearboxes
● BA 2330 - operating instructions for motors LA/LE/LESfor mounting on SIMOGEAR
gearboxes
● BA 2535 - operating instructions for SIMOGEAR electric-monorail-gearboxes
● BA 2730 - operating instructions for SIMOGEAR geared motors with encoder for safetyrelevant applications
1.2
Copyright
The copyright to these operating instructions is held by Siemens AG.
These operating instructions must not be wholly or partly reproduced for competitive
purposes, used in any unauthorized way or made available to third parties without
agreement of Siemens AG.
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General information and safety notes
1.3 Use for the intended purpose
1.3
Use for the intended purpose
The SIMOGEAR gearboxes described in these Operating Instructions have been developed
for use as travel drives in monorail conveyors.
Unless otherwise agreed, the gearboxes have been designed for use in plants and
equipment in industrial environments.
They are used to transport goods in roofed over industrial applications. They can be used
outdoors if the necessary contractual arrangements are made.
The gearboxes have been built using state-of-the-art technology and are shipped in an
operationally reliable condition. Changes made by users could affect this operational
reliability and are forbidden.
Note
The performance data assumes an ambient temperature of -20° C to +40° C and an
installation altitude of up to 2000 m above sea level.
In the case of other ambient temperatures and installation altitudes, please contact Technical
Support.
The gearboxes have been designed solely for the application described in the Technical data
(Page 55). Do not operate the gearbox outside the specified power limit. Other operating
conditions must be contractually agreed.
Do not climb on the gearbox. Do not place any objects on the gearbox.
1.4
Obligations of the user
The operator must ensure that all persons assigned to work on the geared motor have read
and understood these operating instructions and that they follow them in all points in order
to:
● Eliminate the risk to life and limb of users and other persons.
● Ensure the operational safety of the geared motor.
● Avoid disruptions and environmental damage through incorrect use.
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General information and safety notes
1.4 Obligations of the user
Note the following safety information:
Shut down the geared motors and disconnect the power before you carry out any work on
them.
Make sure that the drive unit cannot be turned on accidentally, e.g. lock the key-operated
switch. Place a warning notice at the drive connection point which clearly indicates that work
is in progress on the geared motor.
Carry out all work with great care and with due regard to "safety".
For all work, observe the relevant regulations for work safety and environment protection.
Read the instructions on the rating plates attached to the geared motor. The rating plates
must be kept free from paint and dirt at all times. Replace any missing rating plates.
In the event of changes during operation, switch off the drive unit immediately.
Take appropriate protective measures to prevent accidental contact with rotating drive parts,
such as couplings, gear wheels or belt drives.
Take appropriate protective measures to prevent accidental contact with parts and
equipment that heat up to over +70 °C during operation.
When removing protective equipment, keep fasteners in a safe place. Re-attach removed
protective equipment before commissioning.
Collect and dispose of used oil in accordance with regulations. Remove oil spillages
immediately with an oil-binding agent in compliance with environmental requirements.
Do not carry out any welding work on the geared motor. Do not use the geared motor as a
grounding point for welding operations.
Carry out equipotential bonding in accordance with applicable regulations and directives by
electrotechnology specialists.
Do not use high-pressure cleaning equipment or sharp-edged tools to clean the geared
motor.
Observe the permissible tightening torque of the fastening bolts.
Replace damaged bolts with new bolts of the same type and strength class.
Siemens AG accepts the warranty only for original spare parts.
The manufacturer who installs the geared motors in a plant must include the regulations
contained in the operating instructions in its own operating instructions.
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General information and safety notes
1.5 Particular types of hazards
1.5
Particular types of hazards
WARNING
Extreme surface temperatures
Hot surfaces over +55 °C pose a burn risk.
Cold surfaces below 0 °C pose a risk of damage due to freezing.
Do not touch the gearbox without protection.
WARNING
Hot, escaping oil
Before starting any work wait until the oil has cooled down to below +30 °C.
WARNING
Poisonous vapors when working with solvents
Avoid breathing in vapors when working with solvents.
Ensure adequate ventilation.
WARNING
Risk of explosion when working with solvents
Ensure adequate ventilation.
Do not smoke!
WARNING
Risk of eye injury
Rotating parts can throw off small foreign particles such as sand or dust.
Wear protective eyewear!
In addition to the prescribed personal protection gear, also wear suitable protective gloves
and safety glasses.
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General information and safety notes
1.5 Particular types of hazards
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Technical description
2.1
2
General technical description
The BH gearbox is supplied with two transmission stages; the KH gearbox is supplied with
three transmission stages. The gearbox is equipped with a mechanical clutch. The clutch
separates the power flow between the drive and the conveyor system.
The gearbox is suitable for various mounting positions. Observe the correct oil level.
Gearbox housing
The housing is made of cast iron.
Geared components
The geared components are hardened and ground.
The bevel gear stage of the bevel gearbox is lapped in pairs.
Lubrication
The geared components are supplied with adequate lubricant by means of splash
lubrication.
Shaft bearings
All shafts are mounted in roller bearings. The roller bearings are lubricated using splash
lubrication or oil-spray lubrication. Bearings that are not supplied with lubricant are closed
and grease-lubricated.
Shaft seals
The shaft sealing rings on the output side prevent lubricant from escaping from the housing
at the shaft outlet and prevent pollution from entering the housing.
The optimum use of the seals depends on the ambient conditions and the lubricant being
used.
Radial shaft sealing ring
A high-quality radial shaft sealing ring is used as a standard seal. The ring is provided with
an additional dust lip to protect against contaminants from outside.
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Technical description
2.2 Cooling
2.2
Cooling
NOTICE
Dust deposits prevent heat radiation
Dust deposits prevent heat radiation and cause a high housing temperature.
Keep the gearbox free from dirt, dust, etc.
The gearbox does not normally require additional cooling. The generously dimensioned
housing surface is sufficient for dissipating heat losses where there is free convection. If the
housing temperature exceeds a value of +80 °C, please contact Technical Support.
2.3
Clutch
Actuation of the clutch lever interrupts the force flow in the positive claw coupling on the
output shaft. The output shaft can then freely rotate while the motor is stopped or in no-load
operation.
2.4
Rating plate
The rating plate on the gearbox or geared motor is of coated aluminum foil. The rating plate
is glued using a special masking film. The film ensures permanent resistance to UV radiation
and media of all kinds, such as oils, greases, salt water and cleaning agents.
The adhesive and the material ensure firm adhesion and long-term legibility within the
operating temperature range from -40 °C to +155 °C.
The edges of the rating plate are paint-finished to match the color of the gearbox or motor to
which it is affixed.
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Technical description
2.5 Surface treatment
2.5
Surface treatment
2.5.1
General information on surface treatment
All paint finishes are sprayed on.
NOTICE
Failure of the exterior protection
If the paint finish is damaged, the geared motor may corrode.
Do not damage the paint finish.
Note
Information about the ability to be repainted does not guarantee the quality of the paint
product supplied by your supplier.
Only the paint manufacturer is liable for quality and compatibility.
2.5.2
Painted version
The corrosion protection system is classified according to the corrosiveness categories in
DIN EN ISO 12944-2.
Table 2- 1
Paint according to corrosiveness categories
Paint system
Description
Corrosiveness category C1, unpainted for gearbox and motor housings made of aluminum
-
•
Indoor installation
•
Heated buildings with neutral atmospheres
•
Resistance to greases and some resistance to
mineral oils, aliphatic solvents
•
Standard
Corrosiveness category C1 for normal environmental stress
1-component hydro paint, top coat
•
Indoor installation
•
Heated buildings with neutral atmospheres
•
Resistance to greases and some resistance to
mineral oils, aliphatic solvents
•
Standard paint for gearbox housings made of cast
iron
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Technical description
2.5 Surface treatment
Paint system
Description
Corrosiveness category C2 for low environmental stress
2-component polyurethane base coat,
2-component polyurethane top coat
•
Indoor and outdoor installation
•
Unheated buildings with condensation, production
areas with low humidity, e.g. warehouses and sports
facilities
•
Atmospheres with little contamination, mostly rural
areas
•
Resistance to greases, mineral oils and sulfuric
acid (10 %), caustic soda (10 %) and some
resistance to aliphatic solvents
Corrosiveness category C3 for medium environmental stress
2-component polyurethane base coat,
2-component polyurethane top coat
•
Indoor and outdoor installation
•
Production areas with high humidity and some air
contamination, e.g. food production areas, dairies,
breweries and laundries
•
Urban and industrial atmospheres, moderate
contamination from sulfur dioxide, coastal areas with
low salt levels
•
Resistance to greases, mineral oils, aliphatic
solvents, sulfuric acid (10 %), caustic soda (10 %)
Corrosiveness category C4 for high environmental stress
2-component epoxy zinc phosphate base
coat,
2-component polyurethane top coat
•
Indoor and outdoor installation
•
Chemical plants, swimming pools, wastewater
treatment plants, electroplating shops, and
boathouses above seawater
•
Industrial areas and coastal areas with moderate salt
levels
•
Resistance to greases, mineral oils, aliphatic
solvents, sulfuric acid (10 %), caustic soda (10 %)
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Technical description
2.5 Surface treatment
Paint system
Description
Corrosiveness category C5 for very high environmental stress
2-component epoxy zinc phosphate base
coat,
2-component epoxy iron mica
intermediate coat,
2-component polyurethane top coat
•
Indoor and outdoor installation
•
Buildings and areas with almost constant
condensation and high contamination, e.g. malt
factories and aseptic areas
•
Industrial areas with high humidity and aggressive
atmosphere, coastal areas and offshore
environments with high salt levels
•
Resistance to greases, mineral oils, aliphatic
solvents, sulfuric acid (10 %), caustic soda (20 %)
In case of corrosiveness category C1, overpainting with a 1-component hydrosystem after
prior rubbing down is possible.
In case of corrosiveness categories C2 to C5, overpainting with 2-component polyurethane
paint, 2-component epoxide paint and 2-component acrylic paint after prior rubbing down is
possible.
2.5.3
Primed version
Table 2- 2
Primer according to corrosiveness category
Paint system
Can be overpainted with
Unpainted corrosiveness category C1
Cast iron parts immersion primed,
steel parts primed or zinc-plated,
aluminum and plastic parts untreated
•
Synthetic paint, synthetic resin paint, oil paint
•
2-component polyurethane paint
•
2-component epoxy paint
•
2-component polyurethane paint
•
2-component epoxy paint
•
2-component acrylic paint
•
Acid-hardening paint
Primed according to corrosiveness category C2 G
2-component metal primer,
desired coat thickness 60 μm
Primed according to corrosiveness category C4 G
2-component epoxide zinc phosphate,
desired coat thickness 120 μm
•
2-component polyurethane paint
•
2-component epoxy paint
•
2-component acrylic paint
•
Acid-hardening paint
A paint-protective film must be applied to the rating plate and the masking film for the primed
or unpainted variant. They can be repainted without further preparation, e.g. masking with
adhesive tape.
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Technical description
2.5 Surface treatment
Peeling off the paint-protective film
The paint coat must have fully hardened before the paint-protective film is peeled off (be at
least "touch-proof").
①
②
③
④
⑤
Company logo
Masking film
Rating plate
Paint-protective film
Peeling tab
Figure 2-1
Rating plate with paint-protective film
Procedure
1. Pull the peeling tab ⑤ up.
2. Carefully peel the paint-protective film ④ off diagonally from one corner (not parallel to
the plate).
3. Blow any paint fragments away or wipe them off with a clean cloth.
You have now removed the paint-protective film.
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Incoming goods, transport, and storage
3.1
3
Incoming goods
NOTICE
Transport damage impairs correct functioning
Do not commission faulty gearboxes or geared motors.
Note
Do not open or damage parts of the packaging that preserve the product.
Note
Check that the technical specifications are in accordance with the purchase order.
Inspect the delivery immediately on arrival for completeness and any transport damage.
Notify the freight company of any damage caused during transport immediately (this is the
only way to have damage rectified free of charge). Siemens AG will not accept any claims
relating to items missing from the delivery and which are submitted at a later date.
The gearbox or geared motor is delivered in a fully assembled condition. Additional items are
sometimes delivered packaged separately.
The products supplied are listed in the dispatch papers.
3.2
Transport
3.2.1
General information on transport
NOTICE
The use of force will damage the gearbox or geared motor
Transport the gearbox or geared motor carefully. Avoid knocks.
Before putting the drive into operation, remove any transport fixtures and keep them safe or
render them ineffective. You can then use them again for transporting further items or you
can apply them again.
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Incoming goods, transport, and storage
3.2 Transport
Different forms of packaging may be used, depending on the size of the gearbox or geared
motor and the method of transport. Unless contractually agreed otherwise, the seaworthy
packaging complies with HPE Packaging Guidelines (Bundesverband Holzpackmittel
Paletten Exportverpackungen e.V., the German Federal Association for wooden packaging,
pallets, and export packaging).
Note the symbols which appear on the packaging. These have the following meanings:
This way up
Center of gravity
Fragile
Do not use hand hook
Keep dry
Attach here
Keep cool
3.2.2
Fastening for suspended transport
WARNING
Inadequately secured gearboxes or geared motors can break loose
Use only the transport eye of the gearbox to transport the gearbox or geared motor. The
transport eye is only designed to hold the weight of the gearbox or geared motor, and it is
not permissible to add additional loads.
Do not rig eyebolts to the front threads at the shaft ends for transportation purposes.
Do not use the integrally cast lifting eyes on the motor for transport because of the risk of
breaking.
If necessary, use additional, suitable lifting accessories for transport or during installation.
When attaching by a number of chains and ropes just two strands must be sufficient to bear
the entire load. Secure lifting equipment so that it cannot slip.
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Incoming goods, transport, and storage
3.3 Storage
3.3
Storage
3.3.1
General information for storage
WARNING
Danger of serious injuries caused by falling objects
Danger of damage to the gearbox when stacked
Do not stack gearboxes or geared motors on each other.
NOTICE
Failure of the external protection
Mechanical damage, chemical damage and thermal damage, such as scratches, acids,
alkalis, sparks, welding beads and heat cause corrosion.
Do not damage the paint finish.
Unless contractually agreed otherwise, the guarantee period for the standard preservative
lasts 6 months from the date of delivery.
In the case of storage in transit over 6 months, special arrangements must be made for
preservation. Please contact Technical Support.
Store the gearbox or geared motor in dry, dust-free rooms that are maintained at a constant
temperature.
The storage location must be vibration- and shock-free.
The free shaft ends, sealing elements and flange surfaces must have a protective coating.
3.3.2
Storage up to 36 months with long-term preservation (optional)
3.3.2.1
General notes for storage up to 36 months
Store the gearbox or geared motor in dry, dust-free rooms that are maintained at a constant
temperature. Special packing is then not necessary.
If such premises are not available, pack the gearbox or the geared motor in plastic film or airtight sealed film and materials. The films and materials must be able to accept moisture.
Cover them to provide protection against heat, direct sunlight and rain.
The permissible ambient temperature is -25 °C to +50 °C.
The life of the corrosion protection is 36 months from delivery.
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Incoming goods, transport, and storage
3.3 Storage
3.3.2.2
Gearbox filled with operating oil and anti-corrosive agent
NOTICE
Damage to the gearbox caused by incorrect oil quantities
Check the oil level before commissioning.
Observe the information and procedures for Checking the oil level (Page 39).
The gearbox is filled with oil corresponding to the mounting position so that it is ready for
operation, and is sealed airtight using a screw plug or with a pressure breather valve with
transport fixture.
For storage up to 36 months, a VCI anti-corrosion agent (Volatile Corrosion Inhibitor) is
added.
3.3.2.3
Gearbox completely filled with oil
NOTICE
Damage to the gearbox caused by incorrect oil quantities
Prior to commissioning, remove excessive oil until it has the correct oil level.
Observe the information and procedures for Correcting the oil level (Page 39).
When biodegradable oils or oils for the food-processing sector are used, the gearbox is filled
completely with operating oil. The gearbox is closed air-tight with a sealing plug or a
pressure venting with transport fixture.
Do not lower the oil level during short-time commissioning for 10 minutes in no-load
operation.
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4
Assembly
4.1
Unpacking
NOTICE
Transport damage impairs the correct function of the gearbox
Never commission faulty gearboxes.
Check the gearbox for completeness and for damage. Report any missing parts or damage
immediately.
Remove and dispose of the packaging material and transport equipment in compliance with
regulations.
4.2
General information concerning the installation
WARNING
Assembly work with the system under load
Under load, the system can start or reverse in an uncontrolled fashion.
The entire system must be load-free so that there is no danger during this work.
NOTICE
Destruction caused by welding
Welding destroys the geared parts and bearings.
Do not weld on the gearbox. The gearbox must not be used as a grounding point for
welding operations.
NOTICE
Overheating caused by solar radiation
Overheating of the gearbox due to exposure to direct sunlight.
Provide suitable protective equipment such as covers or roofs. Prevent heat accumulation.
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Assembly
4.2 General information concerning the installation
NOTICE
Malfunction resulting from foreign objects
The operator must ensure that no foreign objects impair the function of the gearbox.
NOTICE
Damaged components impair the correct function of the gearbox
If any components are damaged, the correct function of the gearbox will no longer be
ensured.
Do not install any damaged gearbox components.
NOTICE
Violation of the maximum permissible oil sump temperature
The oil sump temperature may be exceeded if the temperature monitoring equipment is
incorrectly set.
A warning must be given when the maximum permissible oil sump temperature is reached.
The geared motor must be switched off when the maximum permissible temperature is
exceeded. If the geared motor is shut down, then this can cause the machine to come to a
stop.
Exercise particular care during mounting and installation. The manufacturer cannot be held
liable for damage caused by incorrect mounting and installation.
Make sure that there is sufficient space around the gearbox or geared motor for mounting,
maintenance and repair.
On geared motors with a fan, leave sufficient free space for the entry of air. Observe the
installation conditions for the geared motor.
Provide sufficient lifting gear at the start of mounting and fitting work.
Observe the mounting position specified on the rating plate. This ensures that it will be
provided with the correct quantity of lubricant.
Use all the fastening means that have been assigned to the particular mounting position and
mounting type.
Cap bolts cannot be used in some cases due to a lack of space. In such cases, please
contact Technical Support quoting the type of gearbox.
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Assembly
4.3 Thread sizes and tightening torques for fastening bolts
4.3
Thread sizes and tightening torques for fastening bolts
The general tolerance for the tightening torque is 10 %. The tightening torque is based on a
friction coefficient of μ = 0.14.
Table 4- 1
Tightening torques for fastening bolts
Thread size
4.4
Tightening torque for strength class
8.8
10.9
12.9
[Nm]
[Nm]
[Nm]
M4
3
4
5
M5
6
9
10
M6
10
15
18
M8
25
35
41
M10
50
70
85
M12
90
120
145
M16
210
295
355
M20
450
580
690
M24
750
1 000
1 200
M30
1 500
2 000
2 400
M36
2 500
3 600
4 200
Mounting an input or output element on the gearbox shaft
WARNING
Risk of burns caused by hot parts
Do not touch the gearbox without protection.
NOTICE
Damage to shaft sealing rings caused by solvent
Avoid any contact of solvent or benzine with the shaft sealing rings.
NOTICE
Damage to shaft sealing rings caused by heating
Use thermal shields to protect shaft sealing rings from heating above 100 °C due to radiant
heat.
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Assembly
4.4 Mounting an input or output element on the gearbox shaft
NOTICE
Premature wear or material damage due to misalignment
Misalignment caused by excessive angular or axis displacement to the connecting shaft
ends.
Ensure precise alignment of the individual components.
NOTICE
Damage caused by improper handling
Bearings, housing, shaft and locking rings are damaged due to improper handling.
Do not use impacts or knocks to force the input and output elements to be mounted onto
the shaft.
Note
Deburr the parts of elements to be fitted in the area of the hole or keyways.
Recommendation: 0.2 x 45°
Where couplings are to be fitted in a heated condition, observe the specific operating
instructions for the coupling. Unless otherwise specified, apply the heat inductively using a
torch or in a furnace.
Use the center holes in the shaft end faces.
Use a fitting device to fit the input or output elements.
Figure 4-1
Example of a fitting device
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Assembly
4.4 Mounting an input or output element on the gearbox shaft
Observe the correct mounting arrangement to minimize stress on shafts and bearings due to
lateral forces.
Correct
a
Hub
F
Force
Figure 4-2
Incorrect
Mounting arrangement for low stress on shafts and bearings
Procedure
1. Use either benzine or solvent to remove the anti-corrosion protection from the shaft ends
and flanges or remove the applied protective skin.
2. Fit the drive input and output elements to the shafts. Fasten the elements when
necessary.
You have now fitted the input or output element.
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Assembly
4.5 Mounting the clutch lever
4.5
Mounting the clutch lever
1190 Clutch lever
①
②
Nut
Contact arm
Figure 4-3
Mounting the clutch lever
Mount the separately supplied clutch lever on gearbox types BH29 and BH39.
Procedure
1. Fit the nut ① onto the clutch lever 1190.
2. Screw the clutch lever 1190 into the contact arm ②.
3. Tighten the M12 nut ① to a torque of 40 Nm.
You have now mounted the clutch lever.
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5
Commissioning
5.1
General information for commissioning
WARNING
Unintentional starting of the drive unit
Secure the drive unit to prevent it from being started up unintentionally.
Attach a warning notice to the start switch.
WARNING
Risk of slipping on oil
Remove any oil spillage immediately with an oil-binding agent in compliance with
environmental requirements.
Checking the pressure breather valve
Check that the breather valve is activated.
If the breather valve has a transport fixture, it must be removed before commissioning.
Figure 5-1
Pressure breather valve with securing clip
Remove the transport fixture by pulling the securing clip ① in the direction of the arrow.
5.2
Checking the oil level prior to commissioning
Please observe Checking and changing lubricants (Page 39).
Check the oil level before commissioning. Adjust the oil level if necessary.
Siemens AG recommends a complete oil change after a storage time longer than 24 months:
● For gearboxes with long-term preservation.
● For gearboxes supplied completely filled with oil.
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Commissioning
5.2 Checking the oil level prior to commissioning
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Operation
6.1
General information about operation
CAUTION
Malfunctions can cause injuries or gearbox damage
In the event of changes during operation, the drive unit must be switched off immediately.
Determine the cause of the fault using the fault table (Page 33). Remedy faults or have
faults remedied.
Check the gear unit during operation for:
● Excessive operating temperature
● Changes in gear noise
● Possible oil leakage at the housing and shaft seals
6.2
Operating the clutch
WARNING
Unintentional movement of the travelling gear
Once the clutch is disengaged, the motor brake is inoperative and no power transmission is
possible.
Lock the travel drive so that it cannot move unintentionally.
NOTICE
Damage to gearboxes caused by impact of acceleration
Avoid impact of acceleration when engaging the clutch.
Engage the clutch when the motor is at standstill or at low speed.
The gearbox can be disengaged during operation under load.
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Operation
6.2 Operating the clutch
The clutch can be engaged when:
● The motor and output shaft are stationary.
● The output speed and weights are low.
● Low speed differentials before and after shifting.
E.g. when extending and retracting at low speed into a chain-pulled conveyor when the
clutch is shifted via the shifting guides.
Figure 6-1
Position of the clutch lever for BH. 29 - 39
To disengage the clutch: Move the clutch lever from position ① to position ②.
To engage the clutch: Move the clutch lever from position ① to position ②.
1197 End stop bolt
Figure 6-2
Position of the clutch lever for KHF 49 - 79
To disengage the clutch: Move the clutch lever from position ① to position ② or ③.
To engage the clutch: Move the clutch lever from position ② or ③ to position ①.
The end stop bolt position 1197 limits the operating travels from position ① to ② or from
position ① to ③. Changing the thread position changes the operating travel. The position of
the operating travel is specified with the order.
Shift force needed on clutch lever
The specified shift forces F apply at standstill. The values provided in the following table are
reference values. If a torque is transferred to the output shaft as the clutch is shifted, the
required shift forces may increase by a multiple.
Gearbox type
BHZ29
BH.39
KHF 49
KHF 69
KHF 79
F [N]
70
90
120
140
150
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7
Faults, causes and remedies
Note
Faults and malfunctions that occur during the warranty period and requiring repair work on
the gearbox must be remedied only by Technical Support. If faults occur without a clearly
identifiable cause, Siemens AG recommends the services of the Technical Support even
after the warranty period has elapsed.
If you need the help from the Technical Support, please have the following information
ready:
• Rating plate data
• Nature and extent of the fault
• Suspected cause
Table 7- 1
Faults, causes and remedies
Faults
Causes
Remedy
Unusual noise on
the gearbox.
Oil level too low.
Check the oil level (Page 39).
Foreign objects in the oil (irregular
noise).
Checking the oil quality (Page 41).
Cleaning the gearbox (Page 51).
Change the oil (Page 39).
Excessive bearing play and / or
bearing defective.
Check the bearing and replace if
necessary.
Defective gearing.
Check the gearing and replace if
necessary.
Fastening bolts loose.
Checking the tightness of fastening
bolts (Page 52).
Excessive external load on the drive
input and output.
Check the load against rated data (you
might need to correct the belt tension,
for example).
Transport damage.
Check the gearbox for damage in
transit.
Damage due to blockage during
commissioning.
Call Technical Support.
Drive unit bearing not lubricated
(motor size 160 and higher).
Regrease the bearings, see BA 2039
Operating Instructions.
Excessive bearing play and / or
bearing defective.
Check the bearing and replace if
necessary.
Fastening bolts loose.
Checking the tightness of fastening
bolts (Page 52).
Unusual noise from
the drive unit.
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Faults, causes and remedies
Faults
Causes
Remedy
Unusual motor
noise.
Excessive bearing play and / or
bearing defective.
Check the bearing and replace if
necessary.
Motor brake is rubbing.
Check air gap and adjust if necessary.
Inverter parameterization.
Correct the parameterization.
Incorrect oil level for the mounting
position being used.
Check the mounting position (Page 58)
and the oil level (Page 39).
Gearbox leaks.
Checking the gearbox for leaks
(Page 50).
Overpressure due to lack of venting.
Mount the venting as appropriate for
the mounting position (Page 58).
Overpressure due to soiled venting.
Clean the venting (Page 51).
Shaft sealing rings defective.
Replace the shaft sealing rings.
Cover / flange bolts loose.
Checking the tightness of fastening
bolts (Page 52). Continue to monitor
the gearbox.
Surface sealing defective (e.g. on
cover, flange).
Reseal.
Damage in transit (e.g. hairline
cracks).
Check the gearbox for damage in
transit.
Incorrect oil level for the mounting
position used and / or incorrect
venting position.
Check the venting position, the
mounting position (Page 58) and the oil
level (Page 39).
Oil escapes.
Oil leak at the
gearbox vent.
Frequent cold starts during which the Call Technical Support.
oil foams up.
Gearbox overheats.
Motor fan cover and / or gearbox
very dirty.
Clean the fan cover and surface of the
geared motor (Page 51).
Incorrect oil level for the mounting
position being used.
Check the mounting position (Page 58)
and the oil level (Page 39).
Incorrect oil being used (e.g.
incorrect viscosity).
Checking the oil quality (Page 41).
Oil is too old.
Check the date of last oil change. If
required, change the oil (Page 39).
Excessive bearing play and / or
bearing defective.
Check the bearing and replace if
necessary.
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Faults, causes and remedies
Faults
Causes
Output shaft does
not turn when the
motor is running.
Force flow interrupted by breakage in Call Technical Support.
gearbox.
Remedy
Geared motor only
starts with difficulty
or not at all.
Incorrect oil level for the mounting
position being used.
Check the mounting position (Page 58)
and the oil level (Page 39).
Incorrect oil being used (e.g.
incorrect viscosity).
Checking the oil quality (Page 41).
Excessive external load on the drive
input and output.
Check the load against rated data (you
might need to correct the belt tension,
for example).
Motor brake is not released.
Check circuit / connection of brake.
Check brake for wear and readjust if
necessary.
Geared motor runs against backstop. Change the direction of motor or
backstop rotation.
Excessive play at
drive input and
output.
Flexible elements worn (e.g. on
couplings).
Replace flexible elements.
Positive connection disrupted by
overload.
Call Technical Support.
Increased play at
clutch lever.
Clutch lever has become loose.
Tighten fastening nut at clutch lever.
After engagement, the clutch is out of Turn the output shaft until the clutch
mesh.
engages.
After actuating the
Clutch has been displaced.
clutch lever, the
clutch does not
disengage / engage.
Call Technical Support. Clutch must be
readjusted or serviced.
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Faults, causes and remedies
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8
Service and maintenance
8.1
General notes about maintenance work
WARNING
Unintentional starting of the drive unit
Secure the drive unit to prevent it from being started up unintentionally.
Attach a warning notice to the start switch.
NOTICE
Improper maintenance
Only authorized qualified personnel may perform the maintenance and servicing. Only
original parts supplied by Siemens AG may be installed.
Only qualified personnel may perform the inspection, maintenance and servicing work.
Please observe the General information and safety notes (Page 7).
Table 8- 1
Maintenance measures
Remedy
Interval
Description of work
Monitor and check the geared
motor for unusual noise,
vibrations, and changes.
Daily; if possible, more
frequently during operation.
Operation (Page 31)
Check the housing temperature. After 3 hours, on the first day,
thereafter monthly.
Check the oil level.
After the first day, and then
every 3 000 operating hours, or
at the latest after 6 months.
Checking and changing
lubricants (Page 39)
Check the oil quality.
Every 6 months.
Checking the oil quality
(Page 41)
First oil change after
commissioning.
After approximately
Checking and changing
10 000 operating hours or at the lubricants (Page 39)
latest after 2 years.
Subsequent oil changes.
Every 2 years or
10 000 operating hours 1).
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Service and maintenance
8.1 General notes about maintenance work
Remedy
Interval
Description of work
Visual inspection of the
gearbox and shaft sealing ring
for leaks.
After the first day, thereafter
monthly.
Checking the gearbox for leaks
(Page 50)
When required, replace the
breather valve.
Once a year.
Replacing the vent valve
(Page 51)
Clean the gearbox.
Depending on degree of soiling,
at least every 6 months.
Cleaning the gearbox (Page 51)
Carry out a complete inspection
of the geared motor.
Every 12 months.
Inspecting the gearbox
(Page 52)
Check that fastening bolts on
After 3 hours, and then every 2
gearboxes and add-on elements years.
are securely tightened. Check
that covers and plugs are
securely fastened.
Checking the tightness of
fastening bolts (Page 52)
Change the roller bearing
grease.
When the oil is changed.
Change the roller bearing
grease (Page 46)
Replace the bearing.
-
Replace bearings (Page 50)
1)
When using synthetic oils, the intervals can be doubled. The data specified is valid for an oil
temperature of +80° C. See the figure titled "Guide values for oil change intervals" for the intervals
for other temperatures.
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Service and maintenance
8.2 Checking and changing lubricants
8.2
Checking and changing lubricants
8.2.1
General safety instructions
WARNING
Danger of scalding from escaping hot oil
Before starting any work wait until the oil has cooled down to below +30 °C.
WARNING
Risk of slipping on oil
Remove any oil spillage immediately with an oil-binding agent in compliance with
environmental requirements.
NOTICE
Damage to the gearbox caused by incorrect oil quantities
The oil quantity and the position of the sealing elements are determined by the mounting
position.
After removing the oil level screw, the oil level may not be below the specified fill level.
NOTICE
Damage to the gearbox due to open oil holes
Close the gearbox immediately after checking the oil level or changing the oil. Dirt and
harmful substances in the atmosphere can penetrate through open oil holes.
Note
Information about oil
Refer to the rating plate for the type of oil, oil viscosity and quantity of oil required.
For oil compatibility, see Recommended lubricants (Page 49).
Note
Gearbox sizes 29 and 39
Gearbox sizes 29 and 39 are lubricated for life. An oil change is not required.
Mounting positions M2 and M4 are equipped with a breather valve. There is no opening to
check the oil level.
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Service and maintenance
8.2 Checking and changing lubricants
8.2.2
Checking the oil level
NOTICE
The volume of gearbox oil changes with temperature
If the temperature rises, the volume increases. Where temperature differences and filling
quantities are significant, the volume difference can amount to several liters.
The oil level must therefore be checked while still slightly warm, approximately 30 minutes
after switching off the drive unit.
①
②
③
Specified oil level
Maximum oil level
Minimum oil level
Figure 8-1
Oil level in the gearbox housing
Table 8- 2
Minimum and maximum fill levels x
Oil level hole
∅d2
Fill level x
Tightening torque
[mm]
[mm]
[Nm]
G 1/8"
14
2.5
10
G 1/4"
18
3
10
G 3/8"
22
4
25
G 3/4"
32
7
50
Procedure
1. Switch off the power supply to the drive unit.
2. Unscrew the oil level screw, see Mounting positions and oil quantities (Page 58). Oil
escapes if the maximum fill level is above the plug hole.
3. Check the oil level. Observe the fill level x.
4. Top up the oil level if necessary and check it again.
5. Check the state of the sealing ring on the sealing element. If the sealing ring is damaged,
replace the sealing element with a new one.
6. After checking, seal the gearbox immediately using the sealing element.
You have now checked the oil level in the gearbox housing.
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Service and maintenance
8.2 Checking and changing lubricants
8.2.3
Checking the oil level using the oil sight glass (optional)
If there is an oil sight glass to check the oil level ①, the oil must be visible in the center of
the sight glass when the oil is cool. When the oil is hot, the oil level ① is above the center of
the sight glass. The oil level ① of cold oil is below the center of the sight glass.
Figure 8-2
Oil level in the oil sight glass
Top up the oil level ① if necessary, and check it again.
8.2.4
Checking the oil quality
Visible signs show effects on the oil. Fresh oil is clear to the eye, and has a typical smell and
a specific product color. Clouding or a flocculent appearance indicates water and / or
contamination. A dark or black color indicates residue, serious thermal decomposition or
contamination.
Observe the symbols in the diagrams of the Mounting positions and oil quantities (Page 58):
Venting
Oil level
Procedure
1. Allow the geared motor to run for a short time. Wear and contaminant particles are visible
in the oil shortly after shutting down.
2. Switch off the power supply to the drive unit.
3. Unscrew the sealing element at one of the points marked with the symbols listed above.
4. Remove some oil, using a suction pump and a flexible hose, for example.
5. Check the state of the sealing ring on the sealing element. When required, replace the
sealing ring.
6. Seal the gearbox with the sealing element.
7. Check the oil for abnormalities. Change the oil immediately if you determine any
abnormalities, see Changing the oil (Page 42).
You have now checked the oil quality.
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Service and maintenance
8.2 Checking and changing lubricants
8.2.5
Changing the oil
8.2.5.1
General safety notes for changing the oil
NOTICE
Impermissible mixing of oils leads to damage
Impermissible mixing of oils leads to:
• Darkening
• Sediment
• Foam formation
• Change of the viscosity or reduced corrosion protection
• Wear protection.
When changing oil of the same type, the residual volume of oil in the gearbox should be
kept as low as possible. Generally speaking, a small residual volume will cause no
particular problems.
Gear oils of different types and by different manufacturers must not be mixed. Have the
manufacturer confirm that the new oil is compatible with the remaining volume of used oil.
If very different types of oil or oils with very different additives are changed, always flush out
the gearbox with the new oil. When changing from mineral oil to polyglycol oil (PG) or vice
versa, it is vital to flush the gearbox twice. All traces of old oil must be completely removed
from the gearbox.
NOTICE
Contaminations of the oil impair the lubricity
Do not mix the gearbox oil with other substances.
Do not flush with paraffin or other solvents, as traces of these substances will always
remain inside the gearbox.
Note
The oil must be warm because insufficient viscosity caused by oil that is too cold impairs
correct emptying.
If necessary, run the gearbox for 15 to 30 minutes to become warm.
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Service and maintenance
8.2 Checking and changing lubricants
8.2.5.2
Draining the oil
Observe the symbols in the diagrams of the Mounting positions and oil quantities (Page 58):
Venting
Oil level
Oil drain
Procedure
1. Switch off the power supply to the drive unit.
2. Unscrew the vent plug.
3. Place a suitable and sufficiently large receptacle underneath the oil drain plug.
4. Remove the oil drain plug. Drain all the oil into the receptacle.
5. Check the state of the sealing ring on the sealing element. If the sealing ring is damaged,
replace the sealing element with a new one.
6. After draining the oil, seal the gearbox immediately using the sealing element.
You have now drained the oil from the gearbox.
8.2.5.3
Flushing the gearbox when changing between incompatible oils
WARNING
Impermissible mixing of oils leads to damage
Residual quantities of original oil can impair the specific properties of the new oil.
A flushing process is required with biodegradable and physiologically safe oils.
The residual corrosion protection oil must amount to no more than 1% of the operating oil
volume.
Note
Polyglycol oil has a higher density than mineral oil. Therefore, it sinks down towards the oil
drain and the mineral oil floats on top.
This makes the required complete draining of mineral oil from the gearbox extremely difficult.
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Service and maintenance
8.2 Checking and changing lubricants
Note
After the second flush, we recommend that an appropriate analysis institute checks the
quality of the flushed fluid.
Observe the symbols in the diagrams of the Mounting positions and oil quantities (Page 58):
Venting
Oil drain
Procedure
1. After the oil has been drained, wipe the gearbox clean of any remaining mineral oil using
a cloth.
2. Unscrew the vent plug.
3. Fill the gearbox with a flushing oil, using a filter (filter mesh max. 25 μm). For the flushing
oil, use either the new oil or one that is compatible with the new oil and is less expensive.
4. Operate the gearbox for 15 to 30 minutes under a low load.
5. Place a suitable and sufficiently large receptacle underneath the oil drain plug.
6. Remove the oil drain plug. Drain all the oil into the receptacle.
7. After flushing, immediately seal the gearbox using the sealing element.
8. Repeat this step for the second flushing.
You have now flushed the gearbox twice and can pour in the new oil.
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Service and maintenance
8.2 Checking and changing lubricants
8.2.5.4
Filling in oil
NOTICE
Mixing of different oils impairs the lubricity
When adding oil, use the same oil type and viscosity. If changing mutually incompatible
oils, see Flushing the gearbox (Page 43).
Observe the symbols in the diagrams of the Mounting positions and oil quantities (Page 58):
Venting
Procedure
1. Unscrew the vent plug.
2. Fill the gearbox with fresh oil. Use a filler filter with mesh of max. 25 μm.
3. Check the oil level.
4. Top up the oil level if necessary and check it again.
5. Check the state of the sealing ring on the sealing element. If the sealing ring is damaged,
replace the sealing element with a new one.
6. After filling with oil, seal the gearbox immediately using the sealing element.
You have now filled up the gearbox with oil.
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Service and maintenance
8.2 Checking and changing lubricants
8.2.6
Topping up with oil
If the mounting position of the gearbox is changed or oil lost because of leakage, check the
oil level. If you notice oil escaping, locate the leak and seal the affected area. Top up and
check the oil level.
At the time of going to print, the following types of oil are being used when the gearbox is
filled for the first time:
CLP ISO VG220: Castrol Alpha SP 220
CLP ISO PG VG220: Castrol Tribol / Optigear Synthetic 1300/220
CLP ISO PG VG460: Castrol Tribol / Optigear Synthetic 1300/460
CLP ISO PAO VG68: Addinol Eco Gear 68S-T
CLP ISO PAO VG220: Addinol Eco Gear 220S
CLP ISO E VG220: Fuchs Plantogear Bio 220S
CLP ISO H1 VG100: Klüber Klübersynth UH1 6 100
CLP ISO H1 VG460: Castrol Tribol Foodproof / Optileb GT 1800/460
If, following agreement, the gearbox is filled at the factory with special lubricant for the
special applications referred to above, the lubricant must be shown on the rating plate.
8.2.7
Change the roller bearing grease
The roller bearings are lubricated in the factory with the greases listed in the table.
Renew the grease quantify for grease-lubricated bearings with each oil change.
Clean the bearing before filling it with fresh lubricant.
In the case of bearings on the output shaft or intermediate shafts, the grease quantity must
fill 2/3, and in the case of bearings on the input side, 1/3 of the space between the rolling
elements.
Table 8- 3
Roller-bearing and shaft-sealing-ring grease
Fields of application
Ambient temperature
Manufacturer
Type
Standard
-40 °C to +80 °C
Klüber
Petamo GHY 133 N
Foodstuff-compatible for the
food industry
-30 °C to +40 °C
Castrol
Optileb GR UF 1 NSF H1
Biologically degradable, for
agriculture, forestry and
water
industries
-35 °C to +40 °C
BP
Biogrease EP 2
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8.2 Checking and changing lubricants
8.2.8
Service life of the lubricants
Note
In case of ambient conditions deviating from normal conditions, e.g. high ambient
temperatures, high relative humidity, aggressive ambient media, the intervals between
changes should be shorter. In such cases, contact Technical Support for assistance in
determining the individual lubricant change interval.
Note
Oil sump temperatures above +80 °C can reduce service life. A temperature increase
by 10 K halves the service life by the amount as shown in the figure titled "Guide values for
oil change intervals".
For a +80 °C oil sump temperature, the following service life can be expected when
observing the properties specified by Siemens AG:
Table 8- 4
Service life of the oils
Type of oil
Service life
Mineral oil
10 000 operating hours or 2 years
Biodegradable oil
Physiologically safe oil according to USDA-H1/-H2
Synthetic oil
20 000 operating hours or 4 years
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8.2 Checking and changing lubricants
①
②
Mineral oil
T
Oil-bath steady-state temperature [°C]
I
Oil change interval in operating hours [h]
Synthetic oil
Figure 8-3
Guide values for oil change intervals
Grease service life of roller bearing greases
Roller bearings and the clearance in front are filled with sufficient grease.
Under approved operating conditions and ambient temperatures, no regreasing is required.
We recommend that the grease in the bearings is also renewed when the oil or shaft sealing
rings are replaced.
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8.2 Checking and changing lubricants
8.2.9
Recommended lubricants
The released and recommended lubricants are listed in the table T 7300
(http://support.automation.siemens.com/WW/view/en/44231658).
DANGER
Used lubricants only have conditional approval
The used lubricants are not or only conditionally approved for use in the foodstuff or
pharmaceutical industry.
Use only lubricants with USDA (United States Department of Agriculture) H1 / H2 approval
for deployment in the foodstuff or pharmaceutical industry.
NOTICE
Incorrect operating temperatures impair lubricity of the gearbox oil
Operating temperatures outside the permitted range impair the lubricating property of the
gearbox oil.
Maximum permissible temperature for:
• Mineral oil +90 °C, for brief periods +100 °C
• Polyglycols and polyalphaolefins +100 °C, for brief periods +110 °C
• Synthetic esters +90 °C
The minimum permissible temperature for initial filling corresponds to the lowest ambient
temperature specified on the rating plate.
The oil used must be approved for use in the ambient temperature range given on the
rating plate.
When changing the oil, please observe the operating temperature range of the new oil as
specified by the oil manufacturer.
Note
As standard, the lubricants and shaft seals are harmonized and coordinated with one
another corresponding to the prevailing operating conditions.
Contact Technical Support for:
• Change of the operating conditions
• Change in oil grade
• Deployment of new shaft seals.
Note
The lubricants used are not at all or only conditionally biodegradable. If biologically
degradable lubricants are required, use only gearbox lubricants with the appropriate
classification listed in the T 7300 table.
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Service and maintenance
8.3 Replace bearings
Note
These recommendations are not a guarantee of the lubricant quality provided by your
supplier. All lubricant manufacturers are responsible for the quality of their own products.
The oil viscosity is decisive for the oil selection (ISO VG class). The viscosity is specified on
the rating plate of the gearbox. The viscosity class indicated applies for the contractually
agreed operating conditions.
In the case of different operating conditions, please contact Technical Support.
If, following agreement, the gearbox is filled at the factory with special lubricant for the
special applications referred to above, the lubricant is shown on the rating plate.
The oil quality must meet the gearbox lubricant requirements specified in the T 7300 table.
The Siemens warranty is otherwise null and void. We recommend the use of one of these
gearbox lubricants. These gearbox oils are subject to constant testing and meet the specified
requirements. It is possible that the recommended oils are removed or replaced by oils that
have been further developed at a later point in time. We recommend that you regularly check
as to whether the selected lubricating oil is still recommended by Siemens. Otherwise
change the product.
8.3
Replace bearings
The bearing service life depends greatly on the operating conditions and so cannot be
calculated reliably. In the operating conditions specified by the operator, bearing life can be
calculated and indicated on the rating plate. If no information is given, changes in vibration
and noise pattern can serve as an indicator that an immediate bearing replacement is
necessary.
8.4
Checking the gearbox for leaks
Note
Due to the inherent principle of operation, oil mist can escape from a breather valve or
labyrinth seal.
Oil or grease escaping in small quantities from the shaft sealing ring should be regarded as
normal during the running-in phase of 24 hours operating time.
If the quantities escaping are significant or leaking continues after the running-in phase, the
shaft sealing ring must be replaced to prevent consequential damage.
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8.5 Replacing the vent valve
Table 8- 5
8.5
Description and measures
Status
Description
Measures
Notes
Film of moisture
on the shaft
sealing ring
Film of moisture as a
result of the inherent
principle of operation
(apparent leakage)
Remove using a clean
cloth and continue to
observe.
This does not represent a
fault; frequently, in the
course of operation, the
sealing ring dries off.
Leakage at the
shaft sealing ring
Identifiable small trickle,
formation of drops, also
after the running-in
phase
Replace the sealing
ring, determine the
possible cause of the
sealing ring failure and
rectify.
During the run-in period, the
shaft sealing ring beds into
the shaft. A visible track can
be seen on the shaft.
Optimum preconditions for a
perfect seal are obtained
after the run-in period.
Replacing the vent valve
To ensure correct functioning, renew the breather valve yearly.
When replacing, prevent dirt and damaging atmospheres from entering the gearbox.
If too much oil is contained in the gearbox, oil will escape from the breather valve. Correct
the oil quantity and replace the breather valve.
8.6
Cleaning the gearbox
NOTICE
Dust deposits cause higher housing temperatures
Dust deposits prevent heat radiation.
Keep the geared motor free from dirt and dust.
NOTICE
Cleaning with a high-pressure cleaning appliance
Water can penetrate into the geared motor. Seals can become damaged.
Do not use a high-pressure cleaning appliance to clean the geared motor.
Do not use tools with sharp edges.
Switch off the power supply to the drive unit before cleaning it.
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8.7 Checking the tightness of fastening bolts
8.7
Checking the tightness of fastening bolts
Note
Replace damaged headless bolts with new bolts of the same type and strength class.
Switch off the power supply to the drive unit. Check all fastening bolts for tightness using a
torque wrench.
The general tolerance for the tightening torque is 10 %. The tightening torque is based on a
friction coefficient of μ = 0.14.
Table 8- 6
Thread size
8.8
Tightening torques for fastening bolts
Tightening torque for strength class
8.8
10.9
12.9
[Nm]
[Nm]
[Nm]
M4
3
4
5
M5
6
9
10
M6
10
15
18
M8
25
35
41
M10
50
70
85
M12
90
120
145
M16
210
295
355
M20
450
580
690
M24
750
1 000
1 200
M30
1 500
2 000
2 400
M36
2 500
3 600
4 200
Inspecting the gearbox
Carry out a scheduled inspection of the gearbox once a year in accordance with the possible
criteria listed in General notes about maintenance work (Page 37).
Check the gearbox in accordance with the criteria set out in General information and safety
notes (Page 7).
Touch up damaged paintwork carefully.
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Disposal
WARNING
Old oil disposal
Incorrect disposal of used oil is a threat to the environment and health.
After use, oil must be taken to a used oil collection point. The addition of foreign substances
such as solvents, brake and cooling fluid is prohibited.
Avoid prolonged contact with the skin.
Empty the used oil from the gearbox. The used oil must be collected, stored, transported and
disposed of in accordance with regulations. Do not mix polyglycols with mineral oil. Dispose
of polyglycols separately.
Please observe country-specific laws. Under German law, to allow optimal treatment of the
oil (§4 VI Used Oil), oils with different disposal codes must not be mixed with one another.
Collect and dispose of used oil in accordance with regulations.
Remove oil spillages immediately with an oil-binding agent in compliance with environmental
requirements.
Dispose of the housing parts, gears, shafts, and roller bearings of the geared motor as scrap
metal.
Dispose of packaging material in accordance with regulations.
Table 9- 1
Disposal codes for gear oils
Type of oil
Designation
Disposal code
Mineral oil
CLP ISO VG220
13 02 05
Polyglycols
CLP ISO PG VG220,
CLP ISO PG VG460,
CLP ISO H1 VG100,
CLP ISO H1 VG460
13 02 08
Poly-Alpha-Olefines
CLP ISO PAO VG68,
CLP ISO PAO VG220
13 02 06
Biologically degradable oils
CLP ISO E VG220
13 02 07
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Technical specifications
10.1
Type designation
Table 10- 1
Example of the type designation structure
Example:
Main gearbox
BH
Gearbox type
Z
Fixing
Z
Size
Table 10- 2
39
BH
39
Type designation code
Gearbox type
BH
Electric-monorail-gearboxes, bevel gearboxes, two-stage
KH
Electric-monorail-gearboxes, bevel gearboxes, three-stage
Fixing
10.2
(-)
Foot-mounted design
Z
Housing flange (C type)
F
Flange-mounted design (A type)
General technical data
The most important technical data appears on the rating plate of the gearboxes and geared
motors.
This data, together with the contractual agreements for the geared motors, determines the
limits of intended use.
In the case of geared motors, a rating plate attached to the motor usually indicates the data
for the entire drive.
In certain cases separate rating plates are mounted on the gearbox and the motor.
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10.2 General technical data
Figure 10-1
Example of a SIMOGEAR rating plate
1
Data matrix code
2
Applied standard
3
Serial number
FDU = Siemens AG, Bahnhofstr. 40, 72072 Tübingen, Germany
4
CE marking or other marking, if required
5
Article number
6
Type designation
7
Mounting position
8
Degree of protection acc. to IEC 60034-5
9
Weight m [kg]
10
Ambient temperature
11
Customer ID
12
Oil quantity [l] main gearbox / intermediate gearbox
13
Type of oil
14
Oil viscosity ISO VG class according to DIN 51519 / ISO 3448
15
Total transmission ratio i
Frequency 1
16
Rated frequency f [Hz]
17
Gearbox output speed n2 [rpm]
18
Geared motor output torque T2 [Nm]
19
Service factor fB
Frequency 2
20
Rated frequency f [Hz]
21
Gearbox output speed n2 [rpm]
22
Geared motor output torque T2 [Nm]
23
Service factor fB
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10.3 Weight
Motor and brake data
24
Phase number and type of current for the motor
25
Temperature class Th. Cl.
26
Symbols (IEC 60617-2):
27
Rated braking torque TBr [Nm]
28
Brake supply voltage U [V]
= brake
Frequency 1
29
Rated frequency f [Hz]
30
Rated voltage / range U [V]
31
Circuit, graphical symbols according to DIN EN 60617 Part 6 / IEC 60617-6
32
Rated current I N [A]
33
Power factor cos φ
34
Rated output PN [kW]
35
Duty type
36
Efficiency class marking according to IEC 60034-30
37
Rated speed n N [rpm]
Frequency 2
10.3
38
Rated frequency f [Hz]
39
Rated voltage / range U [V]
40
Circuit, graphic symbols according to DIN EN 60617 Part 6 / IEC 60617-6
41
Rated current IN [A]
42
Power factor cos φ
43
Rated output PN [kW]
44
Duty type
45
Efficiency class marking according to IEC 60034-30
46
Rated speed n N [rpm]
47
Motor series
48
Motor designation
Weight
The weight of the entire geared motor is given in the shipping papers.
If the weight exceeds 30 kg, the weight of the entire geared motor is indicated on the rating
plate of the gearbox or geared motor.
Where there are several rating plates on one geared motor, the specification on the main
gearbox is decisive.
The weight specification refers only to the product in the delivery state.
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Technical specifications
10.4 Sound energy level
10.4
Sound energy level
SIMOGEAR geared motors have noise levels below the permissible noise levels defined for
gearboxes in VDI guideline 2159 and for motors in IEC 60034-9. In conjunction with
gearboxes, the motor noise values LpfA or LWA increase on average by 3 dB (A).
The circumferential velocity of the motor pinion has a significant influence on the additional
gearbox noise. As a consequence, higher speeds or lower ratios result in higher noise.
External noise
Noise not generated by the gearbox but emitted from it are not taken into consideration.
Noise emitted by the drive and driven machines or the base are also not taken into
consideration. Even when the noise from the gearbox have been transferred there.
10.5
Mounting positions and oil quantities
Only operate the gearbox in the mounting position specified on the rating plate. This ensures
that it will be provided with the correct quantity of lubricant.
Note
Gearbox sizes 29 and 39
Gearbox sizes 29 and 39 are lubricated for life. An oil change is not required.
Mounting positions M2 and M4 are equipped with a breather valve. There is no opening to
check the oil level.
Description of the symbols:
Venting
①
②
③
Oil level
Oil drain
Engaged
Disengaged
Disengaged
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Technical specifications
10.5 Mounting positions and oil quantities
Figure 10-2
Mounting positions for electric-monorail-gearboxes BHZ29, BH39, BHZ39
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10.5 Mounting positions and oil quantities
Figure 10-3
Mounting positions for electric-monorail-gearboxes KHF 49 - 79
NOTICE
Damage to the gearbox caused by incorrect oil quantities
The oil quantities listed in the tables are guide values for changing the oil. They serve, for
example, for lubricant storage and procurement.
The precise values depend on the number of stages and transmission ratio of the gearbox.
The specified oil quantities are valid for the standard mounting position.
Table 10- 3
Type
Oil quantities [l] for BH. 29 - 39, KHF 49 - 79
Mounting position
M1
M2
M3
M4
M5
M6
BH29
0.4
0.65
0.85
1.2
0.8
0.4
BH.39
0.6
0.95
1.1
1.6
0.9
0.75
KHF49
1.5
2.2
1.9
2.2
-
-
KHF69
2.4
3
2.9
3.4
-
-
KHF79
2.8
3.5
3.1
3.8
-
-
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Spare parts
11.1
Stocking of spare parts
By stocking the most important spare and wearing parts on site, you can ensure that the
gearbox or geared motor is ready for use at any time.
NOTICE
Safety impairment caused by inferior products
The installation and / or use of inferior products can have a negative impact on the design
characteristics of the geared motor and might consequently impair the active and / or
passive safety features of the machine.
Siemens AG states explicitly that only spare parts and accessories supplied by Siemens
have been tested and approved by Siemens.
If you do not use original spare parts and original accessories, Siemens AG excludes every
liability and warranty.
Siemens AG accepts the warranty only for original spare parts.
Note that special manufacturing and delivery specifications often apply to individual
components. All spare parts offered by Siemens AG are state-of-the-art and conform to the
latest legal regulations.
Please state the following data when ordering spare parts:
● Serial number shown on the rating plate ③
● Type designation shown on the rating plate ⑥
● Part number
– 4-digit item number from the spare parts list
– 6-digit object number
– 7-digit article number
– 14-digit material number
● Quantity
Figure 11-1
Example of a SIMOGEAR rating plate
For motors with their own rating plate, the spare parts documentation in the original
operating instructions applies.
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11.2 Spare parts lists
11.2
Spare parts lists
11.2.1
Electric-monorail-gearboxes BHZ29, BH39, BHZ39
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11.2 Spare parts lists
1001 Gearbox housing
1301 Plug-in pinion
1020 Bearings
1305 Spur gear
1027 Locking ring / nut
1306 Parallel key
1030 Bearings
1320 Bevel gear pair
1031 Supporting disk
1401 Screw plug
1035 Locking ring
1420 Vent filter
1037 Locking ring
1600 Lubricants
1050 Housing cover
1601 Lubricants
1051 Bolt
1631 Shim
1055 Seal
1632 Shim
1101 Output shaft
1633 Shim
1105 Parallel key
1641 Shim
1118 Plug / sealing cap
1642 Shim
1129 Supporting disk
1643 Shim
1130 Bearings
1646 Shim
1132 Supporting disk / shim
1647 Shim
1135 Locking ring
1648 Shim
1139 Supporting disk
1140 Bearings
1142 Bushing
1146 Locking ring
1160 Shaft sealing ring
1161 Shaft sealing ring
1173 Coupling
1174 Compression spring
1182 Contact arm
1184 O ring
1185 O ring
1186 Supporting disk
1187 Locking ring
1190 Clutch lever
1210 Bolt
1211 Screw retainer
1212 Nut
1225 Seal
Figure 11-2
Electric-monorail-gearboxes BHZ29, BH39, BHZ39
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11.2 Spare parts lists
11.2.2
Electric-monorail-gearboxes KHF 49 - 79
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Spare parts
11.2 Spare parts lists
1001 Gearbox housing
1182 Cam part
1020 Bearing
1184 O ring
1022 Supporting disk / shim
1186 Supporting disk / shim
1030 Bearing
1187 Locking ring
1032 Shim
1190 Clutch lever
1040 Output flange
1191 Bolt
1045 Bolt
1192 Pin
1050 Housing cover
1193 Threaded bolt
1051 Bolt
1194 Bushing
1055 Seal
1195 Nut
1057 Supporting disk
1196 Locking ring
1060 Bearing
1197 Bolt
1061 Supporting disk
1198 Nut
1063 NILOS ring
1199 Plug
1066 Locking ring
1210 Bolt
1067 Locking ring
1212 Nut
1068 Bearing
1225 Seal
1070 Sealing cap
1301 Plug-in pinion
1101 Output shaft
1305 Helical
1105 Feather key
1306 Feather key
1130 Bearing
1312 Disk
1132 Bushing
1313 Bolt
1140 Bearing
1314 Bolt retainer
1141 Supporting disk / shim
1320 Bevel gear pair
1146 Locking ring
1331 Feather key
1160 Shaft sealing ring
1340 Pinion shaft
1162 O ring
1345 Spur wheel
1165 Seal
1401 Bolt plug
1173 Coupling
1420 Vent filter
1174 Compression spring
1600 Lubricants
1175 Feather key / pin
1646 Supporting disk / shim
1176 Pressure pin
1647 Shim
1180 Cover
1648 Shim
1181 Bolt
1649 Shim
Figure 11-3
Electric-monorail-gearboxes KHF 49 - 79
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11.2 Spare parts lists
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Declaration of Incorporation
Document No. A5E36963968AC
Declaration of Incorporation according to Directive 2006/42/EC Annex II 1 B.
Manufacturer:
Siemens AG
Division Digital Factory DF MC
Address:
Bahnhofstraße 40, 72072 Tübingen, Germany
Product designation:
SIMOGEAR gearboxes with adapter K
• Electric-monorail-gearboxes BH. 29 - 39, KHF 49 - 79
The designated product is an incomplete machine in the sense of Article 2 g of
Directive 2006/42/EC. It is designed exclusively for incorporation into another machine or for
assembly with one or more other machines.
The following essential safety and health requirements of Directive 2006/42/EC, Annex I are
relevant for the incomplete machine specified above and are applied. The risks not relevant
for the product are not listed.
•
1.1, 1.1.2, 1.1.3, 1.1.5
•
1.2.4.4, 1.2.6
•
1.4.1, 1.4.2, 1.4.2.1
•
1.5.1, 1.5.2, 1.5.4, 1.5.5, 1.5.6, 1.5.8, 1.5.9, 1.5.10, 1.5.11, 1.5.13, 1.5.15
•
1.6.1, 1.6.2
•
1.7.1, 1.7.1.1, 1.7.2, 1.7.3, 1.7.4, 1.7.4.1, 1.7.4.2, 1.7.4.3
•
1.3.1, 1.3.2, 1.3.3, 1.3.4, 1.3.6, 1.3.8.1
When developing and manufacturing the above designated product, the following standards
and specifications were applied: EN ISO 12100-1: 2011
The special technical documents according to Annex VII, B of the Directive 2006/42/EC were
generated and will be provided to the appropriate authorities when justifiably requested in an
electronic form.
The named person for compiling the technical documents:
Georg Böing, Head of Research & Development
Before the final product is commissioned, in which the incomplete machine described here is
to be incorporated, it must be ensured that this is in conformance with Directive 2006/42/EC.
Tübingen, November 1, 2016
Georg Böing
Head of Research & Development
Florian Hanisch
Head of Leadfactory SIMOGEAR
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Declaration of Incorporation
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