ELECTRA-GEAR SM-3 Rev. E 2002 - Beeler Industries

1 SM-3 Rev. E2002 WORM REDUCERINSTALLATION, MAINTENANCEAND SERVICE MANUALELECTRA-GEARA REGAL-BELOIT Company1110 N. Anaheim Blvd. Anaheim, California 92801 Telephone: (800) 877-4327 (714) 535-6061 Fax: (714) Email: Today, with more than 100,000 square feet, over 100 employees and a worldclass manufacturing operation, ELECTRA-GEAR is a leading producer of mechanicaland electrical motion control products serving a broad array of ELECTRA-GEAR team prides itself on consistent, fast delivery of quality productswhich meet the customers specific needs. Our products are at the heart of whatdrives your worldand you will find them used in food processing, material handling, chemical process and waste treatment, marine and health holds the distinction in our industry to offer several firsts: First to offer reducers, gearmotors and electric motors using aluminumcastings First to utilize rolled worm technology, a highly automated method of producing a worm First to introduce the modifiable worm gear drive providing customers theultimate in mounting flexibilityWhat distinguishes ELECTRA-GEAR from its many competitors?

2 Aluminum Construction(Reducers and Motors)uNo RustuLight Weight, High StrengthuExcellent Heat DissipationuNon-corrosive Surface Finish(Platinum Finish)uNo PaintuBright, shiny aesthetically attractiveuOptional polymer washdown finish (Platinum Plus) Short Lead TimesuGuaranteed Same Day/Next Day ServiceuAggressive VIPS ervice for Critical SituationsTABLE OF Shaft Shaft Term Fill Filling In Change Check Points - Trouble / Noise / By Step Parts EvaluationVBEARING REMOVAL AND Bearings and Bearing Part Numbers and Mfg. Part NumbersVIGEAR REMOVAL AND 20 VIISEAL REMOVAL AND By Step and Manufacturer Seal Part NumbersVIIIASSEMBLY Required (Change of Bearings or Gearset) Shaft Shaft Complete - Final AssemblyIXSERVICE TIPS - MULTIPLE REDUCTION UNITSAND 25 XASSEMBLY AND MOUNTING / NUT TORQUE 30 XIIPARTS - INSTALLATIONI mproper installation of the gear reducer may cause injury to personnel, gear reducer failure, or damage to driven equipment.

3 Load conditionsmust be within the published catalog ratings with the recommended factors properly equipment is potentially dangerous and should be properly guarded. The user is responsible for checking all applicable safety codesin his area and providing suitable reducer should be mounted on a flat surface on the machine or foundation, securely bolted down and accurately aligned. Shims under the mounting base should be used when required to provide a level mounting Shaft MountingThe output shaft can be connected to the load by flexible coupling, sprocketand chain, sheave and V belt, or pinion. Check to insure proper alignment andtension of all components. If sprocket, sheave, or pinion is used, mount as closeto gear housing as possible to minimize bearing load and shaft load must be checked to make certain it does not exceed couplings, sheaves, sprockets, or pinions are mounted, it is importantthat extreme care be used.

4 It is quite easy to damage internal parts by heavyblows used in trying to drive one of these parts on the shaft. It is recommendedthat a bore be selected to give a light driving fit. If a press fit is required, it is suggested that the external element be heated to assure an easy beyond 250 degrees F. (121 C.) is not recommended, as heat conductedalong the shaft, may damage the shaft Shaft MountingThe torque arm of the shaft mounted worm gear reducer must not be mounted too rigidly. If the torque arm is held down without any flexibility, shafteccentricity, which is usually present, can overload the bearings of the gear reducer. The flexible grommet provided with all torque arms must be retained, orsome other suitable means provided to allow the torque arm to be mounted withsome flexibility. The torque arm should be mounted in tension (based on directionof rotation). Term Storage (6 months and up)Units should be stored in a protected area (preferably indoors).

5 If storedoutdoors, they should be covered to be protected from rain and snow. Whereverstored, units should be filled completely with oil. The input shaft should be rotated so that the output shaft makes at least one revolution per month. The inputand output shafts should be covered with grease to protect from corrosion andrust. At start up time, completely drain storage oil and fill to proper oil level withthe correct - LUBRICATIONAll ELECTRA-GEAR worm reducers and gearmotors are shipped with oilunlessspecified LubricantsAmbient & Lubricant NameRange (F.)RatingGetty - Veedol Asreslube 98+100to+1508 EPGetty - Veedol Asreslube 95+50to+1057 EPGetty - Veedol Asreslube 90+40to+1006 EPGetty - Veedol Asreslube 86+25to+905 EPLubr. Eng. - Almasol 609+45to+1258 Lubr. Eng. - Almasol 608+32to+1057 Lubr. Eng. - Almasol 607+15to+705 Mobil - Mobil Extra Hecla Super+50to+1258 Mobil - Mobil Cylinder 600W+32to+1007 Shell - Omala J-460+40to+1157 EPShell - Valvata J-460+40to+1057 Texaco - Meropa 680+45to+1208 EPTexaco - Meropa 460+32to+1007 EPTexaco - Meropa 220+15to+755EP Special Wide Temperature Range Lubricants Kendall - Three Star-10to+1007 Mobil - Mobil SHC 6340to+1357 EPMobil - Mobil SHC 629-25to+1005 EPMobil - Mobil SHC 626-40to+403EP Special Cold Duty Lubricants Conoco - Polar Start 600-40to+10 Lubr.

6 Eng. - Almasol 606-10to+403 EPMobil - Mobil SHC 624-55to0 Shell - Donax T-6-55to+54 Ambient temperature range is based on service factor. Lubricants (listedon page 3) are compounded for use in worm gear reducers. Some contain non-corrosive, extreme pressure additives. Do not use lubricants that containmaterials that are toxic. Avoid use of such lubes that bring harmful effects. If indoubt, consult your local lubricant supplier. Use only rated worm Fill CapacitiesDue to the numerous shaft, base, and mounting configurations of ELECTRA-GEAR worm reducers, it is impossible to pin-point the exact amount of oil to beused in each unit. Please use the following chart as a guide only for ordering SizeContinuous DutyIntermittent (or 350) DutyContinuous duty is defined as running more than 30 minutes in an hour. If theunit is going to be run on a continuous basis (more than half the time), it shouldbe filled to the continuous duty (low) level.

7 See diagram next DutyIntermittent Duty is defined as running less than 30 minutes in an hour, or withan input speed of 800 RPM or less. All double reduction worm reducers shouldhave the secondary box filled to the intermittent (high) Level and Mounting Positions for ELECTRA-GEAR Worm Filling ProceduresElectra- gear Worm gear reducers are easily filled to the proper level by following these pressure relief valve or proper oil plug for oil level lubricant through breather plug oil into unit until oil runs out of hole where oil level plug was.*These positions are not recommended, because the high speed oil seal must support the full head of gearcase double reduction worm gear reducers have two oilreservoirs. Fill both to proper level before operating. Use preceding page andbelow as a reducers have many plugs on them designed to be an aid in oilfilling and removal and breather location. Your mounting position and duty cyclewill have an oil plug that corresponds to it.

8 The breather should be located at thehighest position MOUNTINGB reather LocationIntermittent Oil LevelContinuous Oil LevelOil Drain7 III - In PeriodThe maximum efficiency of ELECTRA-GEAR worm gear reducers is obtained aftera run in period. The length of time required will depend on the load applied andwill be 8 to 12 hours at rated load, and considerably longer at light run in , higher than normal motor currents, lower efficiency, and loweroutput torque can be expected. Overloading will not decrease run in time, but may cause Change Timetable1)Standard Mobil 600W LubeDrain and refill oil after first 100 hours of operation. Under normal condi-tions, change oil every 2000 hours of operation or 6 months, whichevercomes first. Check ambient temperature limits of your oil to make sure itmatches ambient )Synthetic Lubricants such as Mobil SHC 600 SeriesUnder normal conditions, change oil every 4000 hours of operation orevery year, whichever comes Check Points - Trouble Shooting1)Oil LeaksThere are several possible places for oil to leak out of worm gear reducers:a)Oil Fill and Drain Plugs - when oil is changed, plug threads should becoated with non-hardening pipe thread sealing compound.

9 Check fortightness on these )If oil is leaking at pressure relief valve or location - Is pressure relief valve or breather at highestlocation? oil level - overfilling (to intermittent level in a continuous oper-ation) will cause oil to foam oil type - the wrong type of oil will foam excessively. Refer tolubrication )Input Bearing Caps and Output Sideplates - output sideplates and inputbearing caps should be tight against reducer housing (check bolts) andshould have a bead of silastic around inside machined fit where cap fitsto reducer housing. See Final Assembly Procedures for more details.(Page 24)CAUTION8If sideplate or bearing cap bolts are working loose repeatedly in operation, thewhole drive system should be checked over in detail for: overhung load, shockcomponents, faulty drive components, overloading, and be reevaluated ac-cordingly. Consult ELECTRA-GEAR Service or Application Engineering Departmentsfor additional places to look for oil Seals See seal removal and installation section, page actual oil bath temperature after running (or during).

10 Oil bath tempera-ture should not be over 200 degrees. Generally the oil bath temperature will riseapproximately 100 degrees over ambient temperature (based upon a servicefactor, continuous duty). Excessive oil bath temperature after run in period maybe a signal of lubricant breakdown, excessive loading, high ambient temperature,or other internal gear reducer lubricant and internals of the reducer. Check to see if heat is localized(around a particular bearing or bearings). If so, disassemble and evaluate allparts, change bearings and observe while levelIf noise level all drive system components. Check for proper alignment andtension. Check for noise coming from components themselves, orsomewhere else in the noise is coming from gear reducer, try to identify location and fre-quency of frequency (high speed) noises indicate input (worm shaft) input coupling area (alignment and fit.) to input bearings (through stethoscope or screw driver.)