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LK+/LPK+

Supplementary information

LK+/LPK+

Revision history

Revision Date Comment Chapter1 12.11.08 New version All

ServiceIn case you have technical questions, please contact:WITTENSTEIN alpha GmbHCustomer ServiceWalter-Wittenstein-Straße 1D-97999 Igersheim

Tel.: +49 7931 493-10900

Fax: +49 7931 493-10903E-mail: service-alpha@wittenstein.de

© WITTENSTEIN alpha GmbH 2008This documentation is copyright protected.WITTENSTEIN alpha GmbH reserves all the rights to photo-mechanical reproduction, copying, and the distribution by special processes (such as computers, file media, data networks), even in parts.Subject to technical and content changes without notice.

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LK+/LPK+

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Contents1 On this manual .....................................................................................................2

1.1 Signal words ........................................................................................................21.2 Safety symbols.....................................................................................................21.3 Information symbols.............................................................................................3

2 Safety.....................................................................................................................42.1 Personnel .............................................................................................................42.2 Guarantee and Liability ........................................................................................42.3 General safety instructions ..................................................................................4

3 Dismantling...........................................................................................................53.1 Preparation ..........................................................................................................53.2 Disassembling the gearhead with the motor from the machine ...........................53.3 Disassembling the motor .....................................................................................53.4 Replacing adapter plate and spacer sleeve.........................................................6

4 Disposal ................................................................................................................85 Appendix ...............................................................................................................9

5.1 Tightening torques for common thread sizes in general mechanics....................9

On this manual LK+/LPK+

1 On this manualThese instructions contain necessary information for the safe operation of the right-angle gearhead LK+/LPK+, referred to as gearhead in the following.The operator must make sure that this operating manual is read through by all persons assigned to install, operate, or maintain the gearhead, and that they understand them.Store these instructions within reach near the gearhead.

1.1 Signal wordsThe following signal words are used to bring your attention to dangers, prohibitions, and important information:

1.2 Safety symbolsThe following safety symbols are used to bring your attention to dangers, prohibitions, and important information:

This signal word points out to an immanent danger that can cause serious injuries and even death.

This signal word points out to a possible danger that can cause serious injuries and even death.

This signal word points out to a possible danger that can cause slight to serious injuries.

This signal word (without warning symbol) points out to a possible danger that can cause material damage.

This signal word draws your attention to application tips or especially important information when handling the gearhead.

General danger Hot surface Suspended loads Danger of pull-in

Environment protection

Information

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LK+/LPK+ On this manual

1.3 Information symbolsThe following information symbols are used:

requires you to carry out an actionindicates the results of an action

provides additional information on handling

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Safety LK+/LPK+

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2 SafetyThese instructions, especially the safety instructions and the rules and regulations valid for the operating site, must be observed by all persons working with the gearhead.In addition to the safety specifications mentioned in this operating manual, the general and also the local regulations on the prevention of accidents and on environmental protection should be observed.

2.1 PersonnelOnly persons who have read and understood these disassembly instructions may carry out work on the gearhead.

2.2 Guarantee and LiabilityGuarantee and liability claims are excluded for personal injury and material damage in case of

- ignoring the information on transport and storage- improper use- improper or neglected maintenance and repair.- improper assembly / disassembly or improper operation- Operation of the gearhead when safety devices and equipment are defective- Operation of the gearhead without lubricant- Operation of a heavily soiled gearhead- Modifications or reconstructions that have been carried out without the approval of

WITTENSTEIN alpha GmbH

2.3 General safety instructions

Objects flung out by rotating components can cause serious injuries.Remove objects and tools from the gearhead before putting it into operation.

Rotating components on the gearhead can pull in parts of the body and cause serious injuries and even death.

Keep a sufficient distance to rotating machinery while the gearhead is running.

Hot gearhead housing can cause serious burns.Touch the gearhead housing only when wearing protective gloves or after the gearhead has been idle for some time.

Solvents can pollute soil and water.Use and dispose of cleaning solvents appropriately.

LK+/LPK+ Dismantling

3 Dismantling

3.1 PreparationShut down the machine that contains the gearhead.Make sure that it is possible to dismantle the gearhead without constituting a damage hazard for the whole machine.

3.2 Disassembling the gearhead with the motor from the machineDisconnect the electrical connections of the motor.Secure the gearhead and the motor so it cannot fall.Loosen the screws connecting the gearhead to the whole machine.Remove the gearhead from its position with care, so as to safeguard the gearhead and adjacent parts against damage.

3.3 Disassembling the motorFor gearheads with motors, the motor shaft and the gearhead's drive shaft were connected with a clamping hub. A slotted spacer sleeve was used extra for certain motor shaft diameters and applications.

If a load is moved by the drive, the load can fall and can cause serious injuries and even death during the disassembly of the gearhead.

Always prop up suspended loads.Do not stand under suspended loads.

Remove the plug stopper (L) from the mounting bores of the adapter plate.Turn the gearhead until the threaded pin (B) can be reached through the mounting bore.Before starting work, disconnect the machine from the mains.

DesignationA Plug receptacle

B Threaded pin

F Spacer sleeve

G Smooth shaft

H Grooved shaft

Tbl-1: Arrangement of motor shaft, plug receptacle and spacer sleeve

B

L

B

G

F

A

H

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Dismantling LK+/LPK+

3.4 Replacing adapter plate and spacer sleeve

The fastening bolts of the adapter plate can also hold the gearhead housing together.Only use new bolts (DIN EN ISO 4762) and clamping washers (DIN 6769).Use only WITTENSTEIN alpha GmbH approved adapter plates.

Distortions can damage the motor and the gearhead.Make sure that the motor is dismantled in a vertical position.

Loosen the threaded pin (B) in the plug receptacle (A).Loosen the screws (E) between motor (C) and adapter plate (D).

Make sure that the motor allows itself to be removed “easily”.

Pull the motor from the gearhead.The adapter plate and the spacer sleeve are parts of the gearhead. Should you wish to return the gearhead, please include these parts as well.

Danger of being scalded by hot lubricant!The hot gearhead is subject to overpressure.

Only dismantle the adapter plate when the gearhead has cooled down to ambient temperature.

Loose or overloaded screw connections can damage the gearhead.Use a calibrated torque wrench to tighten and check all screw connections for which a tightening torque has been specified.

A

B

C

E

D

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LK+/LPK+ Dismantling

Loosen the fastening bolts (M) in the adapter plate and remove the adapter plate.The shim rings (O) remain in the housing and may not be replaced.

Clean the plane surface of the adapter plate and the fitting surface of the gearhead housing.Make sure that the shim rings (O) lie centrally.Position the new adapter plate on the drive side (N).

No gap is permitted between the adapter plate and the housing.De-grease the new fastening bolts. Slide the new clamping washers in the proper position onto the fastening bolts.Screw in the fastening bolts into the adapter plate and tighten them in diagonal order by means of a torque wrench.

For prescribed torques, refer to Chapter 5.1 "Tightening torques for common thread sizes in general mechanics"

Replace the adapter plate (D) in vertical position (with the adapter plate to the top).Loosen the threaded pin (B) in the plug receptacle by two revolutions.Pull off the spacer sleeve (F) towards the rear.

Use an extraction tool.Clean / de-grease the new spacer sleeve (F) inside and outside.Insert the spacer sleeve into the plug receptacle.

The slit of the spacer sleeve has to be turned by 90° to the threaded pin, see table "Tbl-1".The spacer sleeve has to be aligned with the plug receptacle.

M

D

NO

F

B

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Disposal LK+/LPK+

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4 Disposal

If you have any questions regarding ecological disposal methods, please consult our technical service department.If our product is no longer of use and you wish to dispose of it, refer to the instructions here. You should pay attention to the following residual substances and materials:

Lubricants: Do not mix polyglycols with mineral oils that are meant for recycling.Metals: Iron, aluminium (e.g. adapter plate), non-ferrous heavy metal (e.g. motor winding)Composite materials: Sealing rings should be cleaned of lubricant.

Lubricants (oils and greases) can pollute soil and water.Use and dispose of lubricants appropriately.Observe the locally valid regulations for disposals.

LK+/LPK+ Appendix

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5 Appendix

5.1 Tightening torques for common thread sizes in general mechanicsThe specified tightening torques for headless screws and nuts are calculated values and are based on the following conditions:

- Calculation acc. VDI 2230 (Issue February 2003)- Friction value for thread and contact surfaces μ=0.10- Exploitation of the yield stress 90 %

Tightening torque [Nm] for threadsProperty

classBolt / nut

M3 M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24

8.8 / 8 1.15 2.64 5.24 8.99 21.7 42.7 73.5 118 180 258 363 493 625

10.9 / 10 1.68 3.88 7.69 13.2 31.9 62.7 108 173 265 368 516 702 890

12.9 / 12 1.97 4.55 9.00 15.4 37.3 73.4 126 203 310 431 604 821 1042

Tbl-2: Tightening torques for headless screws and nuts

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WITTENSTEIN alpha GmbHWalter-Wittenstein-Straße 197999 Igersheim

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