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FLENDER Gear UnitsGear-rim system5150.1en

Hardware Installation Manual

Edition 09/2016

DMG2 18, 22, 25.4, 30

30.11.2016 15:24V1.00

Gear-rim system

FLENDER Gear Units5150.1en

Hardware Installation Manual

DMG2 18, 22, 25.4, 30

Edition 09/2016

Introduction 1

Safety instructions 2

Description 3

Application planning 4

Assembly 5

Commissioning 6

Operation 7

Maintenance 8

Service & Support 9

Disposal 10

Spare parts 11

Technical data A

Legal informationWarning 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.

DANGERindicates that death or severe personal injury will result if proper precautions are not taken.

WARNINGindicates that death or severe personal injury may result if proper precautions are not taken.

CAUTIONindicates that minor personal injury can result if proper precautions are not taken.

NOTICEindicates 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 PersonnelThe 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 productsNote the following:

WARNINGSiemens 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.

TrademarksAll 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 LiabilityWe 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 AGProcess Industries and DrivesPostfach 48 4890026 NÜRNBERGGERMANY

Document order number: Ⓟ 11/2016 Subject to change

Copyright © Siemens AG 2016.All rights reserved

Table of contents

1 Introduction...................................................................................................................................................9

1.1 General information..................................................................................................................9

1.2 Lubricants...............................................................................................................................10

2 Safety instructions......................................................................................................................................11

2.1 Security notes........................................................................................................................11

2.2 The five safety rules...............................................................................................................11

2.3 General information................................................................................................................12

2.4 General warnings and symbols..............................................................................................13

2.5 Special types of danger and personal protective equipment.................................................14

2.6 Intended use..........................................................................................................................16

3 Description..................................................................................................................................................19

3.1 General description................................................................................................................19

3.2 Girth gear...............................................................................................................................20

3.3 Girth gear protective cover.....................................................................................................20

3.4 Sealing system.......................................................................................................................213.4.1 Oil seal...................................................................................................................................223.4.2 Dust protection lip..................................................................................................................22

4 Application planning...................................................................................................................................23

4.1 Scope of delivery....................................................................................................................23

4.2 Transport................................................................................................................................23

4.3 Storing the girth gear system.................................................................................................25

5 Assembly....................................................................................................................................................27

5.1 General assembly instructions...............................................................................................27

5.2 Unpacking..............................................................................................................................29

5.3 Assembling the two section girth gear...................................................................................305.3.1 Preparing the tube mill flange................................................................................................305.3.2 Preparing the girth gear.........................................................................................................315.3.3 Assembling the first girth gear half.........................................................................................315.3.4 Assembling the second girth gear half...................................................................................325.3.5 Tighten the connecting elements at the surfaces of the girth gear........................................325.3.6 Adjusting the girth gear .........................................................................................................345.3.7 Tightening procedure.............................................................................................................365.3.7.1 Introduction............................................................................................................................365.3.7.2 Bolt connection classes..........................................................................................................375.3.7.3 Tightening torques and preload forces...................................................................................37

Gear-rim system 5150.1enHardware Installation Manual 09/2016 5

5.4 Mounting and adjusting the gear unit.....................................................................................38

5.5 Mounting the girth gear protective cover................................................................................395.5.1 Checking the dimensions.......................................................................................................395.5.2 Assembling the lower foot segments.....................................................................................395.5.3 Mounting the girth gear protective cover segments...............................................................41

5.6 Attaching the sealing system.................................................................................................445.6.1 Attaching the oil seal and dust protection lip..........................................................................445.6.2 Mounting the outer protective sheet steel panels...................................................................455.6.3 Attaching the seal between the girth gear protective cover and gear unit.............................46

6 Commissioning...........................................................................................................................................49

7 Operation....................................................................................................................................................51

7.1 Operating data.......................................................................................................................51

7.2 Irregularities in operation........................................................................................................51

8 Maintenance...............................................................................................................................................53

8.1 General maintenance information..........................................................................................53

8.2 Maintenance schedule...........................................................................................................53

8.3 Possible faults........................................................................................................................54

9 Service & Support.......................................................................................................................................57

10 Disposal......................................................................................................................................................59

11 Spare parts.................................................................................................................................................61

A Technical data............................................................................................................................................63

A.1 General technical data...........................................................................................................63

A.2 Ambient temperature..............................................................................................................63

A.3 Weights..................................................................................................................................63

A.4 Enveloping surface sound pressure level..............................................................................63

Glossary.....................................................................................................................................................65

Index...........................................................................................................................................................67

Tables

Table 2-1 Symbols and markings................................................................................................................12Table 2-2 General warnings........................................................................................................................13Table 5-1 Preload forces and tightening torques for SUPERBOLT tensioners...........................................33Table 5-2 Permissible runout and axial eccentricity of girth gears..............................................................34Table 5-3 Information on tightening fastening bolts.....................................................................................37Table 5-4 Preload forces and tightening torques.........................................................................................38Table 5-5 Hole size for various rag bolt sizes..............................................................................................40Table 7-1 Operating data.............................................................................................................................51

Table of contents

Gear-rim system 5150.1en6 Hardware Installation Manual 09/2016

Table 8-1 Maintenance and servicing work.................................................................................................54Table 8-2 Possible faults and their rectification...........................................................................................55

Figures

Figure 3-1 Representation of the girth gear system with segment numbers................................................19Figure 3-2 Schematic cross-section of a girth gear protective cover segment.............................................21Figure 3-3 Components of the sealing system.............................................................................................22Figure 4-1 Transport symbols.......................................................................................................................25Figure 5-1 Positioning the dial gauges (A, B ) on the mill flange..................................................................31Figure 5-2 Tightening sequence of the SUPERBOLT tensioners.................................................................34Figure 5-3 Positioning the dial gauges (A, B, C) on the girth gear...............................................................35Figure 5-4 Rag bolt.......................................................................................................................................40Figure 5-5 Numbering of the girth gear protective cover segments..............................................................42Figure 5-6 Clamping device..........................................................................................................................42Figure 5-7 Components of the sealing system.............................................................................................44Figure 5-8 Sheet steel strips.........................................................................................................................46

Table of contents


Table of contents


Introduction 11.1 General information

Purpose of the assembly instructionsThese assembly instructions describe the girth gear system and provide information about handling it - from assembly to maintenance.

Please keep these assembly instructions for later use. Please read these assembly instructions prior to handling the girth gear system and follow the instructions provided in them.

NoteDisclaimer

Please make sure that every person who has been deployed to work on the girth gear system has read and understood these assembly instructions prior to handling the girth gear system and adheres to all of the points. Failure to observe these assembly instructions can cause product or property damage or personal injury.

Siemens does not accept any liability for damage or operating failures which are due to non-adherence to these assembly instructions.

The girth gear system described in these instructions reflects the state of technical development at the time these assembly instructions went to print.

In the interest of technical advancements, Siemens AG reserves the right to make changes to the individual components and accessories which are considered necessary for improving their performance and safety, while maintaining their essential features.

Basic knowledge requiredIn order to understand these assembly instructions, you will need the following general knowledge about gear units. You will also need a basic understanding of the following topics:

● Application planning

● Assembly

● Commissioning

● Maintenance

Documentation landscapeThese assembly instructions form part of the delivery of your girth gear system.


These assembly instructions form part of the complete documentation supplied with the girth gear system. The complete documentation encompasses other documents, including:

● Data sheet

● List of equipment

● Dimension drawing

● Operating instructions for gear unit lubrication and preservation BA 7300

● Operating instructions for mounted components

● Operating instructions for third-party vendor devices

CopyrightThe copyright for these assembly instructions is held by Siemens AG.

Without the authorisation of Siemens AG, these assembly instructions may not be used wholly or in parts for competitors’ purposes or be given to third parties.

If you have any technical queries, please contact one of our Customer Services addresses (Page 57).

1.2 LubricantsThe oil used must meet the quality requirements specified in the separately enclosed operating instructions BA 7300 or else the warranty issued by Siemens will be invalidated. Siemens strongly recommends use of one of the oils listed in BA 7300 as these have been properly tested and meet the relevant quality requirements.

In order to avoid any misunderstandings, Siemens wishes to point out that this recommendation does not constitute an approval in the sense of a guarantee for the quality of the lubricant obtained from a supplier. Every lubricant manufacturer is required to guarantee the quality of his/her products.

Information such as oil type, oil viscosity and required oil quantity can be found on the rating plate of the gear unit and in the documentation supplied with the gear unit.

The oil quantity specified on the rating plate is an approximate value. The actual quantity of oil required is determined by the marking on the oil dipstick or oil sight glass.

The operating instructions for the lubricants currently recommended by Siemens AG can also be viewed on the Internet (http://support.automation.siemens.com/WW/view/de/44231658).

The oils listed there undergo continuous testing. As a result, the recommended oil types might in future be removed from the list or replaced by more advanced oils.

Siemens therefore advises users to check this list regularly to ascertain whether the selected lubricating oil is still recommended by Siemens. If it is not, another brand of oil should be selected instead.

Introduction1.2 Lubricants


http://support.automation.siemens.com/WW/view/de/44231658

Safety instructions 22.1 Security notes

Siemens offers products and solutions with industrial security functions, which support the safe and secure operation of plants, systems, machines and networks.

In order to safeguard plants, systems, machines and networks against cyber threats it is necessary to implement (and continually maintain) a holistic industrial security concept that corresponds to the current state of the art. Siemens products and solutions undergo continuous development in this respect.

Customers are responsible for preventing unauthorised access to their plants, systems, machines and networks. Systems, machines and components shall only be connected to the company network or the Internet when and as far as this is absolutely necessary and appropriate protective measures (e.g. use of firewalls and network segmentation) shall be taken.

In addition the recommendations of Siemens regarding appropriate protective measures shall be observed. You can find further information about industrial security at http://www.siemens.com/industrialsecurity.

Siemens products and solutions undergo continuous development in order to make them even safer. Siemens expressly recommends that you regularly carry out any updates as soon as they are available and that you only use the current product versions. Use of older or no longer supported versions can increase the risk of cyber threats.

To keep yourselves informed of any updates to our products you can register for the Siemens Industrial Security RSS Feed at:http://www.siemens.com/industrialsecurity

2.2 The five safety rulesIn order to protect yourself and prevent any damage to property, always observe the safety relevant information and the following five safety rules (as per EN 50110-1 "Working on isolated equipment") when working on electrical components of the plant.

Prior to starting work on the machine, follow the safety rules listed below:

1. DisconnectAlso disconnect auxiliary circuits such as the anti-condensation heater

2. Safeguard against restart

3. Ensure that the system is de-energised

4. Earth and short circuit

5. Cover or cordon off adjacent live parts

When all the work is complete, cancel the safety measures in the reverse sequence.


2.3 General information

IntroductionAll work carried out on the girth gear system must be performed carefully and by qualified personnel only.

Symbols on the gear unitThe following symbols apply to the gear unit; some of which are found as coloured markings on the gear unit:

Table 2-1 Symbols and markings

Points labelled on the gear unit Symbol Coloured markingsEarth connection point

Air relief point yellow

Oil filling point yellow

Oil draining point white

Oil level indicator red

Oil level measurement red

Oil overflow

Connection point for vibration monitoring

Lubrication point red

Apply grease

Lifting eye

Eye bolt

Safety instructions2.3 General information


Points labelled on the gear unit Symbol Coloured markingsDo not unscrew

Alignment surface, horizontal

Alignment surface, vertical

These symbols indicate the oil level check‐ing procedure using the oil dipstick.

These symbols indicate that the oil dip‐stick must be firmly screwed in.

2.4 General warnings and symbolsThe following table contains general warnings and their associated symbols.

Table 2-2 General warnings

ISO ANSI WarningWarning - hazardous electrical voltage

Warning - explosive substances

--- Warning - entanglement hazard

--- Warning - hot surfaces

--- Warning - substances that can irritate or which are hazardous to health

--- Warning - caustic substances

--- Warning - suspended load

--- Warning - hand injuries

Safety instructions2.4 General warnings and symbols


2.5 Special types of danger and personal protective equipment

RequirementsFulfil the following requirements before commencing any work on the girth gear system:

● Ensure that the oil pressure lines are depressurised.

● Only perform work on the girth gear system when it is at an absolute standstill.

● Disconnect electrical systems from the power supply.

DANGER

Electric shock

Live parts can cause electric shock.

Ensure that the entire plant is de-energised before starting electrical installation work.

Protective equipmentWear the following personal protective equipment when handling the girth gear system:

● Safety shoes

● Overalls

● Helmet

● Safety gloves

● Safety goggles

WARNING

Risk of eye injury

Small foreign particles such as sand or dust can enter the cover plates of the rotating parts and be hurled back by them.

Wear safety goggles.

Dangers during operationDamage to the girth gear system and the gear unit are possible.

Safety instructions2.5 Special types of danger and personal protective equipment


Switch the gear unit to standstill immediately if inexplicable changes are noticed during operation. Such changes may include unusual gear unit noise or a significant increase in operating temperature.

WARNING

Risk of falling

There is an increased risk of falling when standing or walking on the girth gear system and gear unit during operation.

Only walk or stand on the girth gear system, gear unit or its mounted components for maintenance and repair work when the gear unit is at an absolute standstill. Do not walk or stand on shaft ends, protection covers, mounted components or pipes.

WARNING

Danger to life through rotating or moving parts

There is danger that rotating or moving parts may catch hold of you or pull you in.

Secure rotating and/or moving parts against contact using safeguards.

Surface temperatureThe surface temperatures of the girth gear system can become extremely hot depending on the operating conditions.

WARNING

Risk of burns

Possible risk of serious burn injury from hot surfaces (> 55 °C).

Wear suitable protective gloves and protective clothing.

WARNING

Risk of scalding

Risk of serious injury possible through escaping hot operating media when these are being changed.

Wear suitable protective gloves, safety goggles and protective clothing.

WARNING

Danger due to low temperatures

Possible risk of serious injuries due to frost (pain, numbness, frostbite) on cold surfaces (< 0 °C).

Wear suitable protective gloves and protective clothing.

Safety instructions2.5 Special types of danger and personal protective equipment


Chemical substancesInjuries can be sustained when using chemical substances.

WARNING

Risk of chemical burns due to chemical substances

There is a risk of chemical burns when handling aggressive cleaning agents.

Please observe the manufacturer's guidelines on how to handle cleaning agents and solvents. Wear suitable protective equipment (gloves, safety goggles). Please use binding agents to immediately clear up any spilt solvent.

CAUTION

Risk of injury due to chemically aggressive operating materials

There is a risk of injury to eyes and hands when handling chemically aggressive operating materials.

Please observe the safety instructions in the data sheets of the oil used. Wear suitable protective equipment (gloves, safety goggles). Use an oil-binding agent to immediately clean up spilt oil.

Danger of explosionAn explosion may occur in a potentially explosive atmosphere.

DANGER

Danger of explosion through ignition of a potentially explosive atmosphere

Danger to life though ignition of a potentially explosive atmosphere possible when operating the girth gear system

Do not use the girth gear system in potentially explosive atmospheres (hazardous zones).

2.6 Intended useOnly use the girth gear system according to the conditions specified in the service and delivery contract and the technical data in the annex (Page 63). Deviating operating conditions are considered improper use. The user or owner of the machine or plant is solely liable for any resulting damage.

Safety instructions2.6 Intended use


When using the girth gear system please specifically observe the following:

● Do not make any modifications to the girth gear system that go beyond the permissible handling described in these assembly instructions. This also applies to safety features designed to prevent accidental contact.

● Only ever use original spare parts.Other spare parts are not tested and approved by Siemens. Non-approved spare parts may possibly change the design characteristics of the girth gear system and thus impair its active or passive safety.Siemens will accept no liability or warranty whatsoever for damage occurring as a result of the use of non-approved spare parts. The same applies to any accessories which were not supplied by Siemens.

If you have any queries, please contact Customer Services (Page 57).

WARNING

Risk of falling

Risk of possible serious injury through falling.

Only walk or stand on the girth gear system, gear unit or its mounted components for maintenance and repair work when the gear unit is at an absolute standstill. Do not walk or stand on shaft ends, protection covers, mounted components or pipes.

Using the girth gear system When using the girth gear system, please observe the following basic rules:

● Ensure that the girth gear system is operationally safe.

● The girth gear system should only be operated, maintained or repaired by authorised, trained and suitably qualified personnel.

● The relevant work safety and environmental protection regulations must be complied with at all times during transport, assembly, dismantling, operation, maintenance and servicing.

● It is not permissible to clean the outside of the girth gear system using high-pressure cleaning equipment.

● No welding work must be performed on the girth gear system or on parts connected to it. The girth gear system and any parts connected to it must not be used as an grounding point for electric-welding operations. Gearing and rolling-contact bearings might be irreparably damaged by welding.

● Perform potential equalisation in accordance with the applicable regulations and guidelines. If no threaded holes are available on the girth gear system for a ground connection, please take suitable measures. This work must always be done by specialist electricians.

● In the case of gear units that are operated in combination with electrical machines that generate current or through which current flows (e.g. motors and generators), take measures to ensure that no current can flow through the gear unit.Current flowing through the gear unit can result in irreparable damage to rolling-contact bearings and gearing. Short circuits, voltage flashovers and deposits of conductive dust, for example, can all allow current to flow.Use insulators and earth the gear unit properly.



● When removing any protective devices, retain their fixings safely.

● Removed protective devices must be re-fitted prior to starting up.

● Pay attention to the notices attached to the gear unit such as the rating plate, direction arrow symbol etc. Notices must not be concealed by paint or dirt. Replace missing plates.

● Bolts which have been damaged during assembly or disassembly work must be replaced with new ones of the same strength class and type.

DANGER

Danger to life due to live system

Death or serious injury will occur.

Always shut down the girth gear system and any oil supply system (whether separate or mounted on the gear unit) before you carry out any work. Secure the drive unit against being operated accidentally as follows:● Turn off the key-operated switch.● Remove the fuses in the power supply.● Attach a notice to the start switch, clearly stating that work is being carried out on the girth

gear system and on the gear unit.

Ensure that the entire unit is load-free so that no danger is posed when you start to dismantle components.

Reactivating the girth gear system When installing the girth gear unit in machines or systems, the machine or system manufacturers must ensure that the regulations, notes and descriptions contained in these assembly instructions are incorporated in their own operating instructions.



Description 33.1 General description

The girth gear system described in these assembly instructions has been developed to protect the girth gear and to distribute the oil from the gear unit around the girth gear in an oil tight fashion. Potential applications for this girth gear system include, for example, the cement and ore processing industries.

The following diagram shows the girth gear system with segment numbers

Figure 3-1 Representation of the girth gear system with segment numbers

The girth gear system completes a tube mill that is driven using a "DMG2" gear unit.


Elements of the girth gear systemThe girth gear system comprises three individual systems:

● Girth gear

● Girth gear protective cover

● Sealing system

3.2 Girth gearThe girth gear is flanged to the tube mill. The DMG2 girth gear unit drives the tube mill via this flanged connection.

Sealing surfaces are provided on the girth gear for the sealing system mounted on the girth gear protective cover. A thrower ring, which is welded to the girth gear, protects the double lip seal against oil flowing downward.

Further informationFor more information about assembling the girth gear, refer to chapter Assembling the two section girth gear (Page 30).

3.3 Girth gear protective cover

IntroductionThe girth gear protective cover described in these assembly instructions is part of the tube mill drive. The girth gear protective cover has been designed for use with a FLENDER® DMG2 girth gear unit, and is intended to fulfil the following tasks:

● Provides protection against inadvertently coming into contact with the girth gear around the circumference of the mill.

● Guarantees that the system is oil-tight, controls the flow of oil in the pressurized oil lubricated gear unit as well as that of the girth gear.The oil is fed back to the oil supply system.

● The complete system is sealed using seals.

The girth gear protective cover stands on feet, and is connected to the gear unit through an elastic seal.

Design of the girth gear protective cover segmentsThe girth gear protective cover segments comprise three individual parts:

● A lower part (is also subsequently called "sump")

● Two side parts

Description3.3 Girth gear protective cover


The following diagram shows the schematic cross-section of a girth gear protective cover segment:

① Side part ② Lower part (sump)

Figure 3-2 Schematic cross-section of a girth gear protective cover segment

Use a sealing paste to establish the seal between the individual segments.

Further informationFor more information about assembling the girth gear protective cover, refer to chapter Mounting the girth gear protective cover (Page 39).

3.4 Sealing system

Design of the sealing systemThe sealing system comprises two elements:

● Oil seal

● Dust protection lip

The diagram below shows the various parts of the sealing system:

Description3.4 Sealing system


① U profile ⑤ Laminated sheet steel assembly② Double lip seal ⑥ Dust protection lip③ Intermediate ring ⑦ Threaded rod with nut④ Laminated sheet steel assembly

Figure 3-3 Components of the sealing system

Further informationFor more information about assembling the sealing system, refer to chapter Attaching the sealing system (Page 44).

3.4.1 Oil sealThe double lip seal prevents oil escaping from the girth gear protective cover - and prevents the ingress of dust. The double lip seal can be axially moved using an intermediate ring.

The sealing system can be radially moved using a U profile. The U profile presses on the laminated sheet steel assembly of the sealing system, and is fixed in place using a threaded rod and a nut.

3.4.2 Dust protection lipThe dust protection lip prevents dust from entering the girth gear protective cover.

The dust protection lip is axially coupled to the sealing system, and can be radially moved using a U profile. The U profile presses on the laminated sheet steel assembly of the dust protection lip, and is fixed in place using a threaded rod and a nut.

Description3.4 Sealing system


Application planning 44.1 Scope of delivery

The scope of delivery is listed in the shipping documents. Immediately upon receiving the girth gear system, check that everything has been delivered. Report any damaged and/or missing parts to Customer Services (Page 57) immediately.

WARNING

Serious injury through defective product

Serious injury may occur.

If the girth gear system exhibits any visible damage, you should not commission it.

4.2 Transport

General informationThe girth gear system is shipped, broken down into individual parts. Additional equipment is also delivered separately packaged where appropriate.

Carefully observe the following points when transporting the girth gear system to avoid damaging it:

● Always use suitable equipment to transport the girth gear system.

● Transport the girth gear system without any oil in it - and leave it in the transport packaging.

● Do not use incorrect attachment points.

● Do not use the pipework to move the girth gear system.

● Ensure that the lifting equipment is adequately designed to accommodate the weight of the girth gear system.

● If the girth gear protective cover segments receive blows, this can cause dents, which in operation come into contact with the girth gear thus leading to damage.


WARNING

Risk of crushing

There is a risk of being crushed by a component that becomes detached because the hoisting gear and load suspension device are not suitable for handling it.

When lifting, please observe the load distribution information on the packaging.

When the product is in a raised position, transport it slowly and carefully to avoid injury to persons or damage to the girth gear system.

Attaching the gear unitTo transport the girth gear system, only attach slings to the marked attachment points that are provided for this purpose.

Please observe the following when attaching slings to the load or raising, lowering or moving it:

● Do not exceed the specified load limits

● If you are using a load suspension device with several load hooks, make sure that the load is evenly distributed between them

● Note the eccentric centre of gravity

● Make sure that the lifting equipment is securely attached

● Keep your speed down when moving the load

● Do not allow the load to sway and do not attach the load to objects or structures inside the building

● Loads must not be suspended from the tip of a load hook

● Always place the products down on a level, non-slip and stable base

DANGER

Falling load

There is a risk of fatal injury from falling loads if these have not been securely attached to the lifting equipment.

Never stand or sit under suspended loads. Do not exceed the load limits of the lifting equipment.

PackagingThe girth gear system is shipped, broken down into individual parts. Additional equipment is also delivered separately packaged, as necessary.

The girth gear system may be packed in various forms, depending on its size and method of transport.

Application planning4.2 Transport


Please adhere to the symbols applied on the packaging.

Figure 4-1 Transport symbols

Further informationFurther information, a detailed illustration of the girth gear system and the position of the attachment points can be found in the dimension drawings in the complete documentation for the girth gear system.

4.3 Storing the girth gear system

Preservation stateThe girth gear system has a coating of protective preservation agent.

The properties for exterior coating depend on the environmental conditions for the transport route and location specified in the order.

NOTICE

Risk of corrosion if there is no top coat

The girth gear system may be damaged by corrosion if no top coat has been applied. The undercoat does not by itself offer any durable corrosion protection.

It can be contractually agreed on a case-by-case basis that the girth gear system is shipped only with the undercoat applied.

In this case a top coat in accordance with the guidelines relevant to the application must be applied shortly after the delivery.

Note that signs, connections, monitoring devices and similar accessories as well as shaft seals may not be coated with top coat when this is being applied.

StorageWhen making the inquiry and placing the purchase order with Siemens AG, agree special environmental conditions during transport and storage. Special environmental conditions for example include tropical climate or marine transport. The girth gear system may be damaged by corrosion if it is packaged or stored incorrectly.

Storage must take place in the position of the original packaging or in the position of use.

Application planning4.3 Storing the girth gear system


Prevent the corrosion protection layers from becoming damaged during storage.

WARNING

Danger to life through falling parts

Persons are at risk of being crushed or struck by falling parts.

Never stack the segments or parts of a girth gear system.

With indoor storage the rule is:

● Select a dry room with vibration-free base.

● Cover the girth gear system.

With outdoor storage the rule is:

● Select a vibration-free and dry base.

● Store the girth gear system in a location which is protected against the weather.

● Cover the girth gear system very carefully.

● Ensure that the girth gear system surface is wiped clean of any moisture or foreign bodies.

● Avoid waterlogging.

The following regulations apply to your incoming goods control where marine transport packaging has been applied and the girth gear system is not scheduled to be used straight away:

● Only open the outer part of the packaging where possible, and check the condition of the film.

● Keep the film open for no longer than 10 minutes.

● Do not remove any corrosion protection materials such as VCI products and desiccants.

● Reseal the film making it airtight.

NOTICE

Damage caused by external sources

The girth gear system could be damaged if exposed to harmful effects such as aggressive chemical products.

Do not expose the girth gear system to harmful environmental factors such as chemically aggressive products.

Application planning4.3 Storing the girth gear system


Assembly 55.1 General assembly instructions

The assembly work must be performed very carefully by authorised, trained and suitably instructed personnel. Liability will be disclaimed for damage caused by the incorrect performance of this work.

RequirementsImproper use can damage the girth gear system. Be sure to take the following precautions:

● Protect the girth gear protective cover system against falling objects and from becoming covered over.

● Do not perform any welding work anywhere on the girth gear protective cover system.

● Do not use the girth gear protective cover system as an earthing point for electric-welding operations.

● Use all of the fastening points fitted to the particular unit design.

● Replace any bolts that are no longer fit for use by new bolts of the same strength class and type.

● Make sure that sufficient hoisting gear is available.

Mounting position and attachment pointsDuring the actual planning phase, be sure to allow for sufficient space around the girth gear protective cover to enable subsequent upkeep and maintenance work.

The positions of the attachment points are shown in the dimension drawing. To ensure that the unit is properly lubricated during operation, please observe the mounting position specified in the dimension drawings.

Further informationWhen mounting, carefully observe the information in the dimension drawing, the foundation and layout diagrams and in these assembly instructions for the girth gear system.


NOTICE

Increase in temperature of the girth gear system due to external sources of heat

The gear unit must not be heated by external heat sources (exposure to direct sunlight, for example) while it is in operation and measures must be taken where necessary to protect it.

You can take the following measures to prevent an excessive rise in temperature of the girth gear system:● A sun shield● An additional cooling device

If you use a sun shield, this may cause a build-up of heat.

WARNING

Ignition of vapours emitted from solvents.

There is a risk of injury due to ignition of vapours emitted from solvents when carrying out cleaning work.

Please note the following:● Ensure adequate ventilation.● Do not smoke.

Tools required for assemblyThe assembly technician provides the following tools:

● Mechanical engineer's spirit level

● 3 dial gauges with magnetic attachment with an accuracy of a hundredth of a millimetre

● One set of feeler gauges

● One set of U-shaped shims/filler plates

● One mallet (500 g)

● Solvent to remove corrosion protection

● Hydraulic wrench (adapted to the size of the bolts of the girth gear flange)

● Torque wrench (150 Nm, with reinforced sleeve)

● Reinforced sleeves for wrench or hydraulic wrench (adapted to the size of the bolts to be tightened)

● Set of open-ended wrenches and a socket wrench

● Set of sockets with accessories and ratchet

● Sealing paste

● Cyanoacrylate adhesive, type "Loctite 495"

Assembly5.1 General assembly instructions


● Loctite 5910

● Loctite 401

5.2 Unpacking

Introduction The scope of delivery is listed in the shipping documents.

WARNING

Risk of serious injury due to defective product

A defective girth gear system can result in serious injury.

Do not commission the girth gear system if there is any visible damage.

Contact Customer Services (Page 57).

RequirementCheck that everything has been delivered immediately upon receipt.

NOTICE

Damage to the girth gear system due to corrosion

Exposing the girth gear system to moisture can result in damage from corrosion.

Do not damage or open the packaging prematurely if the packaging is designed to preserve the unit.

ProcedureTo unpack and use the girth gear system, proceed as follows:

1. Remove packaging and transport devices in accordance with regulations.

2. Perform a visual inspection for damage and accumulations of dirt.

3. Immediately report any damaged and/or missing parts to Customer Services (Page 57).

4. Dispose of packaging material and transport devices in accordance with regulations.

Assembly5.2 Unpacking


5.3 Assembling the two section girth gear

Measures prior to assembling the girth gearEnsure that the following measures are carried out before assembling the girth gear:

● Provide the required work materials and resources.The list of materials required is provided in the complete documentation for the girth gear system.

● Ensure that the two girth gear halves are correctly paired up.Carefully observe the markings at the connection positions indicating the unique assignment.

WARNING

Risk of chemical burns due to chemical substances

There is a risk of chemical burns when handling aggressive cleaning agents.

Please observe the manufacturer's guidelines on how to handle cleaning agents and solvents. Wear suitable protective equipment (gloves, safety goggles). Please use binding agents to immediately clear up any spilt solvent.

5.3.1 Preparing the tube mill flange

ProcedureProceed as follows to prepare the mill flange before assembling the girth gear:

1. Clean the mill flange using solvent.

2. Position the two dial gauges as shown in the following diagram.

3. Ensure that pressure is applied to the hydrostatic bearings.

4. Rotate the tube mill using a winch. Use a winch with reverse locking in order to avoid the tube mill recoiling.

5. Measure and document the axial eccentricity. The procedure is described in the measurement report for the mill flange.

6. If the measured values deviate from the recommended values, then immediately stop all work and contact Siemens.

The following diagram shows how the dial gauges are positioned on the mill flange:

Assembly5.3 Assembling the two section girth gear


Figure 5-1 Positioning the dial gauges (A, B ) on the mill flange

5.3.2 Preparing the girth gear

ProcedureProceed as follows to prepare the girth gear before assembly:

1. Using solvent, completely remove the corrosion protection from the girth gear and from the holes. Carefully observe the manufacturer's information on how to handle solvents.

2. Remove any possible signs of impact on the contact surfaces and through holes for the fitted bolts using a very soft file.

5.3.3 Assembling the first girth gear half

ProcedureProceed as follows to assemble the first girth gear half:

1. Wedge the tube mill to avoid any undesirable rotation of the girth gear during the assembly process.

2. Lower the first half of the girth gear onto the tube mill from the top.

3. Fix the first half of the girth gear using four uniformly distributed bolts and lock these using a wrench hammer.



5.3.4 Assembling the second girth gear half

ProcedureProceed as follows to assemble the second girth gear half:


2. Remove the wedge used to fix the tube mill. Use a winch with reverse locking in order to avoid the tube mill recoiling.

3. Rotate the tube mill using a winch so that the first half of the girth gear is located at the lower part of the tube mill.

4. Wedge the tube mill to avoid any undesirable rotation of the girth gear during the assembly process.

5. Lower the second half of the girth gear onto the tube mill from the top. Ensure that both halves of the girth gear are correctly aligned.

6. Fix the second half of the girth gear using every second bolt.

5.3.5 Tighten the connecting elements at the surfaces of the girth gear

RequirementsObtain the bolts required to connect the two girth gear halves. Use SUPERBOLT tensioners as clamping nuts.

PreparationEnsure that the following measures are taken prior to tightening the SUPERBOLT tensioners:

● Carefully clean the threads and the contact surfaces.

● Ensure that the jack bolts do not protrude and are well lubricated.

● If required, lubricate the thread of the jack bolts using special graphite grease (without molybdenum bisulfide).

● Tighten the nuts by hand until the washers lock.

● After having tightened the nuts by hand, unscrew them again by about 1/2 revolutions. Leave a play of about 1 to 3 mm between the washer and the nut body of the SUPERBOLT.



Preload forces and tightening torques for SUPERBOLT tensionersThe table below contains the preload forces and the tightening torques for SUPERBOLT tensioners:

Table 5-1 Preload forces and tightening torques for SUPERBOLT tensioners

Part No. Preload force Tightening torqueNominal F1 in kN Maximum F2 in kN Nominal M1 in Nm Maximum M2 in Nm

MT-M36x4/W 343 457 72 96MT-M39x4/W 457 610 72 96MT-M42x4.5/W 457 610 72 96MT-M45x4.5/W 700 935 131 175MT-M48x5/W 700 935 131 175MT-M52x5/W 700 935 131 175MT-M56x5.5/W-P 875 1 160 131 175MT-M60x5.5/W 875 1 160 131 175MT-M64x6/W 1 270 1 690 315 420

ProcedureProceed as follows to tighten SUPERBOLT tensioners:

1. Tighten the four jack bolts by hand (tightening sequence for steps 1, 2, and 3 in the following diagram) diagonally offset so that the main thread is centred and any possible play is eliminated.

2. Tighten the bolts tightened in the 1st step diagonally with 50% of the specified tightening torque.

3. Tighten the bolts tightened in the 2nd step diagonally with 100% of the specified tightening torque.

4. Tighten all jack bolts (tightening sequence for step 4 in the following diagram) clockwise with 100 % of the specified tightening torque.

5. Repeat the 4th step until all of the jack bolts are uniformly and evenly tightened (less than 20° remaining angular movement).Generally, between 2 and 3 iterations are sufficient; correspondingly more for long bolts.

6. Using a feeler gauge, check that the thickness/size of the contacts around the joint face is 0.05 mm.The joint faces must be in contact. In the warm state, it is permissible for the joint surfaces to open by 0.10 mm (measured at the tooth base), with a maximum temperature difference between the gearing and the mounting flange of the girth gear on the mill of 20 °C.The two girth gear halves are now a single rigid part, which can be easily adjusted.

7. Using a wrench hammer, lock the screws of the second girth gear half to the mill flange.



Tightening sequence of the SUPERBOLT tensionersThe following diagram shows the sequence in which the SUPERBOLT tensioners are tightened:

A Tightening sequence for steps 1, 2 and 3 B Tightening sequence for step 4

Figure 5-2 Tightening sequence of the SUPERBOLT tensioners

5.3.6 Adjusting the girth gear

IntroductionIt is not permissible for the runout and axial eccentricity of the girth gear to exceed the maximum permissible values. You must realign the girth gear if any of the maximum permissible values are exceeded.

The permissible runout and axial eccentricity values for girth gears are listed in the following table.

Table 5-2 Permissible runout and axial eccentricity of girth gears

Tip circle diameter of the girth gear in m

Permissible runout in mm Permissible axial eccentricity in mm

≤ 5.0 0.8 0.8> 5.0 1.0 1.0

The following diagram shows how the dial gauges are positioned on the girth gear:



Figure 5-3 Positioning the dial gauges (A, B, C) on the girth gear

ProcedureProceed as follows to adjust the girth gear:

1. Attach three dial gauges to the girth gear. Carefully observe the position of the dial gauges on the girth gear.


3. Rotate the tube mill using a winch. Use a winch with reverse locking in order to avoid the tube mill recoiling.

4. Measure the runout and axial eccentricity. The procedure is described in the measurement report for the girth gear. Only document the final state (after all of the bolts have been tightened). A deviation higher than 0.2 mm between two consecutive measuring points is not permissible (e.g. between measuring points 4 and 5).

5. To adjust the girth gear at the locations to be corrected, place U-shaped shims around the bolts between the girth gear flange and the mill flange. Add shims and measure the runout and axial eccentricity until the permissible values are achieved.

6. Finally, tighten the bolts that connect the girth gear to the mill flange using a torque wrench, complying with the following tightening sequence and the specified tightening torque (Page 36):

– each 8th bolt

– each 4th bolt

– all remaining bolts

7. Check that all of the bolts are firmly seated.

8. Then measure the runout and axial eccentricity of the girth gear, and record the results in a measurement report.You must realign the girth gear if any of the maximum permissible values are exceeded.



5.3.7 Tightening procedure

5.3.7.1 Introduction

BoltsThe bolts must have the following properties:

● Made of steel

● Black-annealed or phosphatised

● Lightly oiled (do not add additional oil)

NoteReplacing bolts

Replace any bolts that are no longer fit for use by bolts of the same type and strength class.

Mating threadsThe mating threads must have the following properties:

● Made of steel or cast iron

● Dry, cut threads

NoteUsing a lubricant

As a rule, lubricants may not be used, because this can result in the bolt connection becoming overloaded.



5.3.7.2 Bolt connection classesIn order to affix fastening bolts, note the information in the following table:

Table 5-3 Information on tightening fastening bolts

Mounting Bolt connection class

Scatter of the tor‐que emitted on the tool

Tightening procedure

Gear unitMotorBrake

C ± 5 % to ± 10 % ● Hydraulic tightening with mechanical screwdriver

● Torque-controlled tightening with a torque wrench or a signal-emitting torque wrench

● Tightening with a precision mechanical screwdriver with dynamic torque measurement

D ± 10 % to ± 20 % ● Torque-controlled tightening with mechanical screwdriver

Protection coverSun shield

E ± 20 % to ± 50 % ● Tightening with pulse screwdriver or impact wrench, without adjustment checking device

● Tightening by hand, using a wrench without torque measuring device

Further informationYou can find additional information about tightening torques when mounting motor and brake in the operating instructions from the particular manufacturer.

5.3.7.3 Tightening torques and preload forcesThe specified bolted connections must be tightened to the torques stated in the table below:

The tightening torques apply to friction values of μtotal = 0.14.



The following table lists the preload forces and tightening torques for bolt connections, strength classes 8.8; 10.9; 12.9:

Table 5-4 Preload forces and tightening torques

Nominal thread di‐ameter

Bolt strength class

Preload force for bolt connection classes from the table in chapter Bolt connection classes (Page 37).

Tightening torque for bolt connection classes from the table in chapter Bolt connection classes (Page 37)

dmm

C D E C D EFM min.

NMA

NmM12 8.8 26 300 16 800 10 500 76.7 66.1 59.0

10.9 38 600 24 700 15 400 113 97.1 86.612.9 45 100 28 900 18 100 132 114 101

M36 8.8 246 000 157 000 98 300 2 080 1 790 1 60010.9 350 000 224 000 140 000 2 960 2 550 2 28012.9 409 000 262 000 164 000 3 460 2 980 2 670

M42 8.8 331 000 212 000 132 000 3 260 2 810 2 51010.9 471 000 301 000 188 000 4 640 4 000 3 75012.9 551 000 352 000 220 000 5 430 4 680 4 180

M48 8.8 421 000 269 000 168 000 4 750 4 090 3 65010.9 599 000 383 000 240 000 6 760 5 820 5 20012.9 700 000 448 000 280 000 7 900 6 810 6 080

M56 8.8 568 000 363 000 227 000 7 430 6 400 5 71010.9 806 000 516 000 323 000 10 500 9 090 8 12012.9 944 000 604 000 378 000 12 300 10 600 9 500

M64 8.8 744 000 476 000 298 000 11 000 9 480 8 46010.9 1 060 000 676 000 423 000 15 600 13 500 12 00012.9 1 240 000 792 000 495 000 18 300 15 800 14 100

5.4 Mounting and adjusting the gear unitAfter the girth gear has been assembled, the gear unit must be mounted and adjusted. Only qualified personnel, trained and authorised by Siemens AG may mount and adjust the gear unit.

Assembly5.4 Mounting and adjusting the gear unit


5.5 Mounting the girth gear protective cover

5.5.1 Checking the dimensions

ProcedureProceed as follows to check the dimensions:

1. Check the height between the baseplates at the floor and the horizontal mill axis.

2. Check the distances between the feet between the various shaped baseplates at the foundation.

Further informationYou can find additional information and the precise dimensions of the girth gear protective cover in the dimension drawing, which is part of the complete documentation of the girth gear system.

5.5.2 Assembling the lower foot segments

IntroductionThe foot segments of the girth gear system comprise the following two parts:

● Lower part

● Upper part

RequirementsBe sure to take the following precautions:

● Position the lower sections of the foot segments before you start to assemble the girth gear protective cover segments.

● Construct the foundation for the foot segments 50 mm lower for subsequent grouting. Construct the foundation out of reinforced concrete and embed the foundations firmly in the ground.

● Rag bolts are used to anchor the foot segments to the ground. There must be one hole for each rag bolt. Refer to the following table for the appropriate hole size.

The following diagram shows a rag bolt:

Assembly5.5 Mounting the girth gear protective cover


① Filling compound ③ Height of the completed foundation② Height of the prepared foundation 3) The depth of the hole in foundation l1 should

be selected the same as bolt length l.

Figure 5-4 Rag bolt

Hole dimension for rag bolt sizesThe following table lists hole sizes for various rag bolt sizes.

Table 5-5 Hole size for various rag bolt sizes

Rag bolts Installation dimension/hole dimension

Rag bolts Installation dimension/hole dimension

d x l v x v x l1 d x l v x v x l1M8 x 125 35 x 35 x 125 M20 x 250 60 x 60 x 250M10 x 160 40 x 40 x 160 M20 x 400 60 x 60 x 400M12 x 200 40 x 40 x 200 M24 x 500 70 x 70 x 500M16 x 250 50 x 50 x 250 M30 x 500 90 x 90 x 500M16 x 400 50 x 50 x 400 M30 x 630 90 x 90 x 630

ProcedureProceed as follows to mount the lower foot segments:

1. Place the lower section of the foot segment on the ground.

2. Insert the rag bolt through the hole in the foot.

3. Screw on the nut by hand up to approximately the centre of the rag bolt thread.

4. Grout the hole together with the rag bolt.

5. Repeat the operation for each rag bolt.



6. Mount the girth gear protective cover and align this as described in ChapterMounting the girth gear protective cover segments ().

7. Check that the filling compound of the prepared foundation has hardened completely.

8. Cast the missing 50 mm of the foundation.

5.5.3 Mounting the girth gear protective cover segments

RequirementsEnsure that the following measures are carried out when mounting the girth gear protective cover segments:

● Mount the girth gear protective cover from the bottom towards the top, as described in the procedure.

● Mount the girth gear protective cover segments with precisely the same arrangement as for the trial design.The girth gear protective cover segments are marked so that they can be uniquely assigned to their specific mounting location.

● Using positioning pins, align all of the elements with respect to one another.

● Apply sealant when joining two flange surfaces.

● After you have completely bolted the flange surfaces, using a clamp, additionally pull the flange surfaces together at their lateral lugs.

● You can adjust the baseplates using rag bolts to adjust the height of the feet. It is also possible to insert spacer plates between the two foot segments.

The following diagram shows the numbering of the girth gear protective cover segments:



① Upper part of the foot segment ② Lower part of the foot segment

Figure 5-5 Numbering of the girth gear protective cover segments

The following diagram shows the clamping device:

Figure 5-6 Clamping device



ProcedureProceed as follows to mount the girth gear protective cover segments:

1. On the ground, bolt the three lower sump segments together (segments 1, 2 and 8) and lower these down as an assembly onto the lower foot segments using a forklift truck.Only use lifting gear and load suspension devices with sufficient load bearing capacity during transport.

2. Bolt the side parts to the sump segments mounted in step 1 (segments 1, 2 and 8). This results in the substructure of the girth gear protective cover.

3. Mount the two-part segment 3. The gear unit is connected to segment 3 at a later point in time. Using a crane, assemble the two parts at the side around the girth gear and mount these to the lower sump segments as well as the foot segments provided for the purpose. Fix all of the segments using positioning pins at the flange surfaces and bolt them tight.

4. Mount segment 7. First attach the sump to the associated foot. Fix the sump using the positioning pins to the flange surface of segment 8 and bolt this tight. Then mount the two side parts.

5. On the ground, bolt the three upper sump segments (segments 4, 5 and 6) and then lower these down as an assembly on the flange surface of cover segments 3 and 7 using a crane. Fix the segments using positioning pins and bolt them tight. Mount the associated side parts to the sump segments. Attach the seal between the gear unit and the girth gear protective cover, as described in Chapter Attaching the seal between the girth gear protective cover and gear unit (Page 46).



5.6 Attaching the sealing system

IntroductionThe diagram below shows the various parts of the sealing system:

① U profile ⑤ Laminated sheet steel assembly② Double lip seal ⑥ Dust protection lip③ Intermediate ring ⑦ Threaded rod with nut④ Laminated sheet steel assembly

Figure 5-7 Components of the sealing system

5.6.1 Attaching the oil seal and dust protection lip

ProcedureProceed as follows to attach the oil seal and dust protection lip:

1. After the girth gear protective cover has been mounted, screw the threaded rods into the nuts provided at the panel of the girth gear protective cover.

2. Place the double lip seal with inserted springs around the sealing surface at the panel of the girth gear protective cover.

3. Insert a laminated sheet steel assembly in the U-shaped groove at the neck of the double lip seal.

4. To initially fix, place the small U profile through the threaded rod and fix it with a nut.

5. Align the double lip seal to the sealing surface. Repeat this procedure until the oil seal is completely aligned around the circumference.

Assembly5.6 Attaching the sealing system


6. Place the dust protection lip on the laminated sheet steel assembly of the double lip seal and fix this using the larger U profile.

7. At the centre, cut open 300 mm of the dust protection lip at the lowest location so that dirt inside can escape.

5.6.2 Mounting the outer protective sheet steel panels

ProcedureProceed as follows to mount the outer protective sheet steel panels:

1. Attach the protective sheet steel panel at the intended location in the upper area of the girth gear protective cover and bolt it tight.

2. Repeat the procedure for the other protective sheet steel panels.You must mount the seven identical protective sheet steel panels on each side in the upper area of the girth gear protective cover (position: 8:00 to 4:00).



5.6.3 Attaching the seal between the girth gear protective cover and gear unit

Sheet steel stripsThe following diagram shows the sheet steel strips:

① Sheet steel strips

Figure 5-8 Sheet steel strips



ProcedureTo attach the seal between the girth gear protective cover and gear unit, proceed as follows:

1. Place the sealing strip around the two sealing surfaces of the gear unit and the girth gear protective cover segment 3.Ensure that the holes in the sealing strip are aligned with those of the two sealing surfaces. Also ensure that the seal strap on the upper side completely overlaps over two layers.

2. Place the sheet metal strips one after the other on the sealing strip and screw these together.

3. To adjust the girth gear at the locations to be corrected, place U-shaped shims around the bolts between the girth gear flange and the mill flange. Add shims and measure the runout and axial eccentricity until the permissible values are achieved.



Commissioning 6Introduction

The precondition for the warranty is first commissioning by specialists from Siemens or by skilled persons who have been appropriately trained and are authorised by Siemens.

Siemens urgently recommends that the tube mill is first driven by the main drive under the supervision of the nominated specialists or skilled persons.

Follow the operating instructions, particularly with regard to maintenance work on the tube mill, during which the mill rotates and the gear unit rotates with it.

NOTICE

Damage to the girth gear system

Every time the drive is set in motion represents a commissioning process. Do not commission the girth gear system without the required assembly instructions being available.


Commissioning


Operation 77.1 Operating data

IntroductionTo ensure correct, trouble-free operation of the system, observe the operating data of the gear unit and, depending on the order specification, the data in the operating instructions for the oil supply system.

The operating values specified in the technical data of the complete gear unit documentation apply.

The following operating data apply to the oil:

Table 7-1 Operating data

Average inlet oil temperature 40 - 45 °C

Maximum inlet oil temperature 55 °C is applicable for mineral oil, API groups I or II and saturated synthetic ester

60 °C is applicable for semi-synthetic oils, API group III, PAO and PG oils

In operation, filter the lubricating oil in the lubricating circuit using a filter with 25 μm nominal filter mesh size.

Further informationFurther information about the technical data of the gear unit can be found in the data sheet and the list of equipment in the complete documentation for the gear unit.

7.2 Irregularities in operation

IntroductionSwitch off the drive assembly immediately if it exhibits irregular behaviour during operation.

A few irregularities are listed below as examples:

● Oil temperature exceeds the maximum permissible value

● Alarm tripped by the pressure monitor in the oil cooling system or oil supply system

● Unusual operating noise


NOTICE

Faults can damage the girth gear system

The girth gear system might sustain damage if it is not shut down when a fault occurs.

Switch off the drive assembly immediately if any fault condition develops.

Rectifying irregularities in operationProceed as follows to rectify any irregularities in operation:

1. Switch off the drive assembly if it exhibits irregular behaviour during operation.

2. Refer to the Fault information (Page 54) to find the cause of the fault.

3. If you still cannot determine the fault cause, contact Siemens Customer Services (Page 57).

Operation7.2 Irregularities in operation


Maintenance 88.1 General maintenance information

Maintenance encompasses all of the measures required to keep and restore the reference state as well as to identify and assess the actual state of technical equipment of a system.

In this sense, maintenance is a comprehensive term which can be subdivided into inspection and service including lubrication and repair.

Measures before starting work on a girth gear systemEnsure that the following measures are carried out before starting maintenance work, repairs or other work:

● Ensure that the drive motors (main and auxiliary drive motor) are locked out so that they cannot be accidentally switched on.

● The tube mill must have settled and be stationary.

● Lock the tube mill using the holding brake.

● Protect the girth gear system against falling objects.

● Check that the guards over rotating parts are securely fastened. Contact (accidental or deliberate) with rotating parts is not permitted.

Further informationFurther information about operation and maintenance can be found in the separate data sheet, in the list of equipment and the dimension drawings in the complete documentation for the girth gear system.

8.2 Maintenance scheduleThe operator must ensure compliance with the stipulated time limits. This also applies if the maintenance activities are included in the operator’s internal maintenance schedules.

The girth gear system could be damaged if the stipulated time limits for maintenance and servicing are not observed.


Maintenance and servicing workThe following table provides an overview of all maintenance and servicing work which you are required to perform continuously or at regular intervals.

Table 8-1 Maintenance and servicing work

Intervals and time limits Measures8 operating hours after commissioning Check that the housing seals seal effectivelyDaily Check the oil quantity in the side mounted tanksWeekly Clean the external oil holes100 operating hours after commissioning Check the assembly bolts of the housing and tighten if

necessaryEvery 100 operating hours Check that the housing seals seal effectivelyEvery 4 weeks Check the girth gear system for abnormal noise, tem‐

perature and protective devicesCheck the girth gear and main gear unit

1 000 operating hours after commissioning Analyse the oilChange the oil (or depending on results of the oil sam‐ple test)

Annually Check that the housing seals seal effectivelyCheck the assembly bolts of the housing and tighten if necessary

Further informationFurther information about additional maintenance and servicing work can be found in the separate data sheet in the complete documentation for the gear unit.

Further information about installed components can be found in the operating instructions for the components in the complete documentation for the gear unit.

8.3 Possible faultsThe faults listed below are only intended as a troubleshooting guide.

If any faults occur while the unit is still under warranty, do not allow anyone except Siemens Customer Services to attempt a repair.

Even after the warranty period has expired, you should still arrange for faults to be rectified by Siemens Customer Services.

NoteLoss of warranty

You will invalidate the warranty for the girth gear system if you modify it in any way without seeking the approval of Siemens beforehand, or if you do not use original spare parts.

Only use original spare parts from Siemens. Always arrange for Siemens Customer Services to repair any faults that develop while the unit is still under warranty.

Maintenance8.3 Possible faults


Possible faults and their rectificationThe following table provides you with an overview of possible faults and indicates how they can be rectified.

Table 8-2 Possible faults and their rectification

Possible faults Causes Possible remediesNoise

Damage to the gear teeth ● Contact Customer Services● Inspect the toothed components● If necessary, replace damaged components

The girth gear protective cover comes into contact with the girth gear itself

● Remove possible housing damage (e.g. dents)● Measure the runout and axial eccentricity of the girth gear

Oil foams in the girth gear protective cover

Oil is severely contaminated ● Change the oilOil supply system left in operation for too long at low temperatures

● Switch off the oil supply system● Degas the oil

Gear unit too cold in operation ● Switch off the gear unit● Degas the oil● Start up without cooling water during cold restart

Water in the oil ● Take test tube sample to examine oil condition for water penetration

● Have the oil examined by a chemical lab● Change the oil if necessary

Oil escapes from the girth gear protective cover

Defective seals ● Check the seals and if necessary, readjustFormation of running tracks on the sealing surface

● Axially reposition the seals using the intermediate ring

Oil escapes from the outer oil pipe

Outer oil distribution holes blocked ● Clean the oil distribution holes

Increased vibration lev‐els

Foot fastening bolts have become loose

● Retighten the foot fastening bolt to its specified torque

Foundation damage ● Contact Customer Services● Have the foundation repaired

Oil supply system mal‐function

- ● Follow the operating instructions for the oil supply system



Possible faults Causes Possible remediesElevated temperature during operation

Oil is too old ● Find out when the last oil change was done● Change the oil if necessary

Oil is severely contaminated ● Change the oilOil supply system defective ● Inspect the oil supply system

● Replace defective components if necessary ● Follow the operating instructions for the oil supply system

Gear unit with water-oil cooler: Cool‐ant flow too low or too high

● Adjust the valves at the supply and return lines● Check the water-oil cooler for free flow

Gear unit with oil cooling system: Inadequate oil flow through the oil cooler

● Check the oil filter and coarse filter● If required, replace the oil filter or clean the coarse filter

Coolant temperature is too high ● Check the temperature; correct if necessaryDefective oil pump ● Check the oil pump function

● If required, repair or replace the oil pumpElectrical equipment defective ● Check the electrical equipment and replace if necessary



Service & Support 9Contact

When ordering spare parts, requesting a customer service technician or in the case of technical queries, please contact our factory or one of our customer service addresses:

Siemens AG

Am Industriepark 2

46562 Voerde

Germany

Tel.: +49 (0)2871 / 92‐0

Fax: +49 (0)2871 / 92‐1544


Service & Support


Disposal 10Disposal of the girth gear system

When disposing of the girth gear system after its useful life, please observe the following measures:

● Remove operating oil, preservation agents and coolant from the girth gear system and dispose of it according to regulations.

● Dispose of the various parts of the girth gear system according to applicable national regulations or recycle them.

Environmental protectionObserve the following environmental protection measures for disposal:

● Dispose of or recycle packaging material according to applicable national regulations.

● When changing the oil, collect the used oil in suitable containers. Use oil-binding agents to clean up any oil spillages immediately.

● Store preservative agents separately from used oil.

● Dispose of used oil, preservative agents, oil binding agents and oil-soaked cloths according to the applicable environmental protection regulations.


Disposal


Spare parts 11By stocking the most important spare parts at the installation site you can ensure that the girth gear system is ready for use at any time.

NoteDamage to the girth gear system due to incorrect the spare parts

Only use original spare parts from Siemens. Siemens shall not accept any warranty claims for spare parts that are not supplied by Siemens.

Other spare parts are not tested and approved by Siemens. Non-approved spare parts may possibly change the design characteristics of the girth gear system and thus impair its active or passive safety.

Siemens will accept no liability or warranty whatsoever for damage occurring as a result of the use of non-approved spare parts. The same applies to any accessories which were not supplied by Siemens.

The contact address of Siemens Customer Services can be found under Service & Support (Page 57).

Information required when ordering spare partsTo order spare parts, refer to the spare-parts list. Only use spare parts that are supplied by Siemens.

When ordering spare parts, please provide the following information:

● Order number with item

● Type and size

● Part number

● Quantity


Spare parts


Technical data AA.1 General technical data

Further information about these technical data can be found in the separate data sheet and the dimension drawings in the complete documentation for the girth gear system.

A.2 Ambient temperatureUnless otherwise contractually agreed, the girth gear system must not be exposed to any harmful atmospheres or substances such as aggressive chemical products. By applying various suitable measures, the girth gear system can be used in the ambient temperature range extending from 0 °C up to 40 °C. However, this must always be authorised by Siemens and specified in the order text.

A.3 WeightsThe weights of the individual parts vary between 2 000 and 40 000 kg.

The precise weights are specified in the dimension drawings in the complete documentation for the girth gear system or gear units.

All stated weights refer to units without any oil in them, without oil supply system and without mounted components.

A.4 Enveloping surface sound pressure levelIt is not possible to specify an enveloping surface sound pressure level for a gear unit in operation because the unit is operated under no load on the Siemens test stand during the trial run - and therefore there is no meshing with the girth gear.


Technical dataA.4 Enveloping surface sound pressure level


Glossary

APIAmerican Petroleum Institute

EDDuty cycle

LoctiteLoctite is an adhesive for locking cylindrical fastening elements.

PAOPoly-alpha-olefin is a synthetic paraffin and naphthenic base oil.

PG/PAGPolyglycol is a synthetic, common water soluble polymer-based base oil.


Glossary


Index

AAttachment points, 27

CColoured markings, 12Contact, 57Copyright, 10Customer Services, 57

DDanger of explosion, 16Disclaimer, 9Disposal, 59Documentation landscape, 9Double lip seal, 22Dust protection lip, 22

EEnvironmental protection, 59

FFastening bolts

Bolt connection class, 37Bolts, 36Mating threads, 36Preload force, 37Tightening procedure, 37Tightening torque, 37

Fault, 54Fault rectification, 55

GGear unit markings, 12Girth gear, 20Girth gear protective cover, 20Girth gear system, 19

IInterval, 54Irregularities in operation, 51

LLubricant, 10

MMaintenance activities, 54Maintenance schedule, 54Mounting position, 27

NNote about assembly, 27

OOil, 10Oil seal, 22Operating data

Compliance with, 51Oil, 51

Ordering spare parts, 57, 61

PPackaging, 25Preservation

Delivered state, 25Protective equipment, 14

RReactivating, 18

SSafety rules, 11Scope of delivery, 23Sealing system, 21


Servicing activities, 54Shipping documents, 23Storage

Indoor storage, 25Outdoor storage, 25

TTransport information, 23Transport symbols, 24Troubleshooting, 54Types of danger, 14

UUnpacking, 29Used oil, 59Using the girth gear system, 17

WWarning symbols, 13

Index


Siemens AGProcess Industries and DrivesPostfach 48 4890026 NÜRNBERGGERMANY

www.siemens.com/drives

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