field information fi eso 2018 08 · we waive a gender-specific differentiation because of an easier...

Field Information

FI ESO 2018 08

30.01.2019

Worm Gear Drive Units (3C/4C)

Test procedure to check feather key connection between motor

and gearbox

thyssenkrupp Fahrtreppen GmbH FI 3C 4C maintenance instruction | 30.01.2019 | Rev. 03 | page 2

Disclaimer

Copyright © by thyssenkrupp Fahrtreppen GmbH, Kolumbusstraße 8, 22113 Hamburg, Germany. thyssenkrupp Fahrtreppen GmbH is the copyright holder. All rights are reserved. This manual is protected by copyright and contains confidential information on the products of the thyssenkrupp Fahrtreppen GmbH. According to copyright laws, this manual may not be copied without the express written consent of thyssenkrupp Fahrtreppen GmbH except for the purpose of normal use or data backup. This exception does not include the making of copies for other users. According to the law, the term copy includes translation into other language or reproduction in a different format. thyssenkrupp Fahrtreppen GmbH reserves the right to make modifications in its products in line with new technical developments. These modifications are not necessarily documents in each individual case. Illustrations in this document aid the general understanding and may differ from the actual design. We waive a gender-specific differentiation because of an easier readability. Terms apply equally to both genders within the meaning of equal treatment.


Content

1 Purpose of this manual ............................................................................................... 4

2 Time frame of initial and repetitive maintenance inspections ............................................ 5

3 Description of components .......................................................................................... 5

4 Preparation ................................................................................................................ 6

4.1 Tools and material needed ....................................................................................... 6

4.2 Safety ................................................................................................................... 6

5 Separate motor and gearbox ....................................................................................... 7

5.1 Prepare for disconnecting motor and gearbox ............................................................ 7

5.2 Lift the motor ......................................................................................................... 8

5.3 Remove dirt and possible corrosion ........................................................................ 10

5.4 Check for mechanical damages .............................................................................. 11

5.5 Burr on gear flange ............................................................................................... 13

5.6 Lubricate feather key connection ............................................................................ 13

6 Re-assemble motor and gearbox ................................................................................ 14

7 Replacement of 3C drive unit ..................................................................................... 15

8 Reporting ................................................................................................................ 17

9 Factory contact ........................................................................................................ 18


1 Purpose of this manual

This manual describes how to maintain the connection between motor and gearbox of escalators and inclined moving walks to avoid unsafe situations caused by damaged feather keys.

Depending on the detected condition, further steps may be required as described in the following chapters

based on these scenarios:

Figure 1: Motor type label indicating series 3C or 4C

3C or 4C drive unit

Separation of motor from gear

box possible?

No Yes

Replace drive unit

Selection of new drive unit according to table 2

Operation of old unit allowed for another max. 6 weeks

Report to factory

Yes No Motor shaft or hollow shaft or

feather key damaged?

Clean shafts and feather key

Grease shafts and feather key

Re-assemble motor on gearbox

Repeat maintenance in 2 years

Report to factory

Replace drive unit

Selection of new drive unit

according to table 2

No further operation of old unit is allowed

Report to factory

Burr on gear

or motor flange?

No

Yes

Replace drive unit

Selection of new drive unit according to table 2

Operation of old unit allowed for another max. 6 weeks

Report to factory


2 Time frame of initial and repetitive maintenance inspections

This initial maintenance procedure shall be carried out as soon as possible on all drive units of this type according to local timetables.

Regular maintenance inspections of the feather key connections shall be carried out every two years after the

initial inspection.

3 Description of components

The connection between motor and SOG - FTS 125/160 (3C and 4C) worm gear is made with a rigid feather key connection. The driving torque of the motor shaft is transferred to the hollow shaft of the gear via feather

key connection. It is used for escalators and moving walks with chain transmission and spur gear transmission.

New drive units (5C, start of production September 2017) are connected with a flexible coupling and do not

require this maintenance procedure.

Figure 2: Drive unit

1 Motor 2 Motor shaft

3 Feather key 4 Gear hollow shaft

5 Gearbox SOG - FTS worm gear (by the example of chain transmission)

1

2 3

4

5


4 Preparation

4.1 Tools and material needed

Standard tool box

Torque wrench 85-190 Nm

Load ring M12 standard 3,4kN, tkE mat.number 300000132600

Load ring M12 reinforced 19,6kN, tkE mat.number 300000127700

Lifting equipment

3 chisels

Sponge or rough cloth for cleaning

Cleaning detergent (e.g. Caramba Eisrostlöser tkE mat.number: 300000201600*, Liqui moli 1611, WD44004, Nigrin 72271)

Grease (Fuchs Lubritech - Gleitmo805K, tkE mat.number: 300000202700* or Fuchs Lubritech - Gleitmo805)

*The last digit of the part number might differ for different packaging sizes

4.2 Safety

Consider the Maintenance Instructions MF8-00-17 (Instructions for accident prevention) and MF8-00-18 (Accident prevention instructions).

DANGER

Danger of rotating machine parts!

Do not reach into machine. Keep sufficient distance to rotating parts. Wear tight-fitting clothes. Make sure long hair does not get into rotating parts.

CAUTION

Hot surface!

Wear appropriate protective gloves.

√ The unit is shut off (set safety barriers and warning signs at the landings).

√ The main switch is switched off and secured against restarting. LOTO

√ The unit is disconnected from power source.


5 Separate motor and gearbox

5.1 Prepare for disconnecting motor and gearbox

Figure 3: Disconnect motor and gearbox

1 Brake magnet 2 Brake monitoring

3 Motor power cable 4 Motor

5 Gearbox 6 Bolts and nuts to connect motor and gearbox

1

3

2

6

5

4


5.2 Lift the motor

WARNING

Suspended load! Never stay under suspended loads!

There is a danger of falling loads, which could result in severe injuries.

Never work under a suspended load.

Figure 4: Lift motor

1 Load ring 2 Appropriate lifting device

3 Appropriate lifting rope 4 Disconnecting point

5 Recesses for separation 6 Nuts

2

3

4

1

5

FL

6


To lift the motor proceed as follows:

1. Screw a load ring into the motor shaft at top. 2. Install the lifting device above the drive shaft vertically. 3. Remove the nuts (6). Make sure that all connections are separated. 4. Pay attention to cable connections, loose cable ties if necessary. 5. Lift motor slowly and carefully (see figure 4).

The vertical lifting FL force must not exceed 3,4 kN if a standard load ring is used. The vertical lifting FL force must not exceed 19,6 kN if a reinforced load ring is used. Higher

loads than that are not allowed. If it is not possible to lift the motor from the gearbox with the lifting device, proceed as follows:

6. Drift the chisels from several sides evenly into the gap between the motor and the gearbox (pos. 5 in

fig.4, positions of the recesses are different for different gearbox sizes), while the lifting device is still loaded. Please consider that not all versions of the gearbox have these recesses.

a. Use a steel hammer with a maximum weight of 500 g. b. Hit the chisel with the hammer from a distance of approximately 30cm two times. If the space

is not available reduce the distance accordingly. c. Then use the next recess again with two hits. d. Repeat this until each recess has been used two times.

If the motor can not be disconnected still, proceed as follows:

7. Fix the nuts (6) again. Bring the escalator into operation again. See chapter 6 also. 8. Order a replacement drive unit and exchange it within the next 6 weeks.

Figure 5: Disconnecting of motor and gear box

1 Disconnecting jointing 2 Chisel 3 Hammer (max 500 g)

1

2

3


5.3 Remove dirt and possible corrosion

Figure 6: Corroded motor shaft

Figure 7: Corroded gear hollow shaft

Figure 8: Cleaned motor shaft

Figure 9: Cleaned hollow shaft

To remove dirt and possible corrosion, proceed as follows:

1. Remove dirt and possible corrosion from the drive shaft and the gearbox hollow shaft with a rough

cloth or sponge and rust solvent Caramba Eisrostlöser or others listed above. 2. Ensure that no dirt falls into the gearbox.

3. Clean all surfaces


5.4 Check for mechanical damages

To check the feather key connection for mechanical damages, proceed as follows:

1. Check the motor shaft, gearbox hollow shaft and the feather key connection for mechanical damages. 2. If there are damaged or worn parts (as in fig. 11 to 13) or rust accumulations (as in fig. 14 and 15),

then:

Change the complete drive unit.

Take the escalator/moving walk out of operation if no spare drive unit is available.

Examples for damages:

Figure 10: Damaged motor shaft

Figure 11: Damaged hollow shaft of gearbox in cross section view

Damaged

hollow shaft

Gear hollow shaft

Motor shaft

Feather key


Figure 12: Damages on feather key Figure 13: Damages on feather key

Figure 14: Rust accumulation in feather key groove Figure 15: Rust accumulation close to hollow shaft of gear box

IMPORTANT

It is unsafe to operate the unit with any of these damages.

The unit must not be operated until a new drive unit is installed.

Ensure that the escalator / moving walk is not accessible to passengers for the out of operation time

(use suitable barriers, brakes must be engaged, power switched off).


5.5 Burr on gear flange

1. Check the machined surface of the gear flange for burrs which protrude vertically. These burrs do not

allow a proper alignment of motor and gear shafts. 2. If there are burrs or other foreign parts on the flange, then:

Change the complete drive unit.

The escalator/moving walk may be operated for another 6 weeks from detection of this fault if no damage on the motor shaft, gear shaft or feather key is visible.

Figure 16: Burr on gear flange Figure 17: Burr on gear flange

Remark: A corroded flange surface is an indicator for a burr or other obstacle between motor and gear flange.

5.6 Lubricate feather key connection

Figure 18: Treated motor shaft (Gleitmo805K)

Figure 19: Treated gear hollow shaft (Gleitmo805)

To treat the parts with lubrication, proceed as follows:

1. Clean surfaces with rust solvent e.g. Caramba Eisrostlöser or others listed above. 2. Lubricate the drive shaft, gearbox hollow shaft and the feather key connection with high-performance

lubricating paste Fuchs Lubritech- Gleitmo805K or Gleitmo805. Other type of lubrication is not permitted.

IMPORTANT

The replacement must be completed within 6 weeks after the detection of this problem. During this

limited period of time the escalator / moving walk may be operated if no other damages are present.


6 Re-assemble motor and gearbox

Figure 20: Connect motor and gearbox

1 Load ring 2 Appropriate lifting device

3 Appropriate lifting rope

To connect drive and gearbox, proceed as follows:

1. Place the drive shaft vertically exactly above the gearbox hollow shaft.

Pay attention to a correct alignment of the feather key on the motor drive shaft to the feather key slot on the gearbox hollow shaft and the motor drive shaft to the gearbox hollow shaft.

2. Let the drive slowly down till it is fitted flush in the gearbox.

3. Apply the fixing screw for drive and gearbox with washers and nuts.

Tighten with tightening torque as shown in Table 1: Tightening torque. 4. Remove the load ring from the motor shaft.

5. Connect the cable connections if necessary.

6. Carry out a test run. 7. Only re-start the unit when safety is ensured.

8. Close the unit and remove safety precautions.

Table 1: Tightening torque gearbox - motor

Design size Screws Tightening torque

SOG - FTS 125 4 x M12 8.8 85 Nm

SOG - FTS 160 4 x M16 8.8 190 Nm

1

2

3


7 Replacement of 3C drive unit

In case the 3C drive unit can’t be used anymore a replacement is needed. The succeeding model is 5C which uses the same design as 3C but has an elastic coupling between motor and gearbox. Due to the coupling the height of 5C is bigger than of 3C. Therefore not all variants of 3C can be replaced by 5C. Table 2 gives an

overview about the limitations. In case 5C is not suitable 2M (OMS gearbox with EMOD motor) shall be used.

Motor size and brake type are indicated on the type label of the motor, the inertia is stamped on the fly wheel.

In case one drive of a twin drive is damaged and needs replacement, the other drive has to be replaced with the same type of drive. A combination of a 2 M or 5 C and a 3C is not allowed.

In case of twin chain drive the machinery support needs special attention as the positions might differ

depending on many design aspects. Please contact the factory for clarification.

For final order of replacement drive units please contact the factory to ensure that project specific

modifications are considered, as this table reflects the standard only.


Table 2: 5C replacement limitations to replace 3C (4C can be replaced by 4C only)

4 C drive units (Velino compact) can be replaced by 4C only. The regular maintenance procedure has to be followed in the same way as for 3C.


8 Reporting

Please report to the factory about the result of each maintenance inspection with the following information and add pictures form the shaft with feather key and the hollow shaft before cleaning:

Please use the online web tool to report about the condition of the units you inspected. The link to the tool will

be shared separately. In case you have no internet access, please use the format below.

Escalator/Moving walk fabrication number:

Number on motor type plate:

Place of installation:

Date of inspection:

Inspection performed by (Name):

Results Please mark

Motor could be removed from gear box Yes No

Feather key damaged Yes No

Motor shaft damaged Yes No

Hollow shaft damaged Yes No

Burr on gear flange Yes No

Rust could be removed Yes No

Re-assembly without problems Yes No

Escalator/moving walk put back in operation with original drive unit

Yes No

Escalator/moving walk put back in operation with replacement drive unit

Yes No

Escalator/moving put out of operation until new drive unit will be available

Yes No

Notes:


9 Factory contact

In case you need any support please contact the factory which delivered the escalator or moving walk.

tk Fahrtreppen in Hamburg, Germany: [email protected]

tk Norte in Mieres, Spain: [email protected]

thyssenkrupp Fahrtreppen GmbH

Thomas Zimmer

Kolumbusstraße 8

22113 Hamburg

Postfach 74 06 23

22096 Hamburg, Germany

Telefon: +49 (0) 40 73 117-537

Telefax: +49 (0) 40 73 117-439

thyssenkrupp Norte, S.A.

Javier Álvarez-Buylla Escobar

Pol. Ind. La Pereda s/n. 33682 Mieres (Asturias), Spain

Phone: +34 98 544 6804

Mobile : +34 662 600 654

E-mail: [email protected]

mailto:[email protected]



field information fi eso 2018 08 · we waive a gender-specific differentiation because of an easier...

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