Verticalmill gear unit

KMP

Sizes 180 to 450 Assembly and operating instructions BA 9138 EN 12/2010

FLENDER gear units

Technical data

1 2 3 4 5 6 7 8 9 10 11 12

Verticalmill gear unit

KMP

General notes Safety instructions Transport and storage Technical description Fitting Startup Operation Faults, causes and remedy Maintenance and repair Spare parts, customer service Declarations

Sizes 180 to 450

Assembly and operating instructions

Translation of the original assembly and operating instructions

BA 9138 EN 12/2010 2 / 44

Notes and symbols in these assembly and operating instructions

Note: The term "Assembly and operating instructions" will in the following also be shortened to "instructions" or "manual".

Legal notes Warning note concept

This manual comprises notes which must be observed for your personal safety and for preventing material damage. Notes for your personal safety are marked with a warning triangle or an "Ex" symbol (when applying Directive 94/9/EC), those only for preventing material damage with a "STOP" sign. WARNING! Imminent explosion! The notes indicated by this symbol are given to prevent explosion damage. Disregarding these notes may result in serious injury or death. WARNING! Imminent personal injury! The notes indicated by this symbol are given to prevent personal injury. Disregarding these notes may result in serious injury or death. WARNING! Imminent damage to the product! The notes indicated by this symbol are given to prevent damage to the product. Disregarding these notes may result in material damage. NOTE! The notes indicated by this symbol must be treated as general operating information. Disregarding these notes may result in undesirable results or conditions. WARNING! Hot surfaces! The notes indicated by this symbol are made to prevent risk of burns due to hot surfaces and must always be observed. Disregarding these notes may result in light or serious injury. Where there is more than one hazard, the warning note for whichever hazard is the most serious is always used. If in a warning note a warning triangle is used to warn of possible personal injury, a warning of material damage may be added to the same warning note.

Qualified personnel
The product or system to which these instructions relate may be handled only by persons qualified for the work concerned and in accordance with the instructions relating to the work concerned, particularly the safety and warning notes contained in those instructions. Qualified personnel must be specially trained and have the experience necessary to recognise risks associated with these products or systems and to avoid possible hazards.

BA 9138 EN 12/2010 3 / 44

Intended use of Siemens products

Observe also the following: Siemens products must be used only for the applications provided for in the catalogue and the relevant technical documentation. If products and components of other makes are used, they must be recommended or approved by Siemens. The faultfree, safe operation of the products calls for proper transport, proper storage, erection, assembly, installation, startup, operation and maintenance. The permissible ambient conditions must be adhered to. Notes in the relevant documentations must be observed.

Trademarks
All designations indicated with the registered industrial property mark are registered trademarks of Siemens AG. Other designations used in these instructions may be trademarks the use of which by third parties for their own purposes may infringe holders rights.

Exclusion of liability
We have checked the content of the instructions for compliance with the hard and software described. Nevertheless, variances may occur, and so we can offer no warranty for complete agreement. The information given in these instructions is regularly checked, and any necessary corrections are included in subsequent editions.

Symbols
Earth connection point Air relief point yellow

Oilfilling point

yellow

Oildraining point

white

Oil level

red

Oil level Connection for vibrationmonitoring device Apply grease

red

Oil level

red

Lubrication point

red

Lifting eye

Eye bolt

Do not unscrew

Alignment surface, horizontal

Alignment surface, vertical

These symbols indicate the oillevel checking procedure using the oil dipstick. These symbols indicate that the oil dipstick must always be firmly screwed in.

BA 9138 EN 12/2010 4 / 44

Contents
1.
1.1 1.2

Technical data, rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measuringsurface soundpressure level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7
7 7

2.
2.1 2.2

General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8
8 8

3.
3.1 3.2 3.3

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Obligations of the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special dangers and personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9
9 10 10

4.
4.1 4.2 4.3 4.3.1 4.3.2 4.3.2.1 4.3.2.2 4.3.2.3

Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storing the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preservation (preservation time < 24 months) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Longterm preservation (preservation time > 24 months) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparatory work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filling with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Durability of the internal gear unit preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11
11 11 12 13 13 13 14 15

5.
5.1 5.2 5.2.1 5.2.2 5.2.2.1 5.3 5.4

Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrodynamic lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrodynamic lubrication and hydrostatic starting aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic lubrication system with radial piston pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16
16 16 16 17 17 17 17

6.
6.1 6.2 6.2.1 6.2.2 6.3 6.3.1 6.3.2 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11

Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General information on fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lifting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparatory measures for gear unit installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintaining preservation if the gear unit has been opened in the meanwhile . . . . . . . . . . . . . . . . . Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearunit installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the pipework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pickling of adapted pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting addon parts delivered loosely with the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welding work on the mill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Final work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18
18 18 18 18 19 19 19 20 21 21 21 21 22 22 22

BA 9138 EN 12/2010 5 / 44

7.
7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.4.1 7.1.4.2 7.1.5 7.1.6 7.2 7.2.1 7.2.2 7.2.3 7.3 7.3.1 7.3.1.1 7.3.1.2 7.3.1.3 7.3.2 7.3.2.1

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure before startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Depreservation of the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flushing before initial startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil quantity for flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil quantity for initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oilsupply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checks before startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prelubrication phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal from service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preservation during longer periods of nonuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interior preservation with preservative agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interiorpreservation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interior preservation by oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exterior preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exteriorpreservation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23
23 23 23 24 25 25 25 25 25 26 26 27 27 28 28 28 29 29 29 29

8.
8.1 8.2

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Irregularities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30
30 30

9.
9.1 9.2

Faults, causes and remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General information on faults and malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Possible faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31
31 31

10.
10.1 10.2 10.3 10.3.1 10.4 10.5 10.6 10.7 10.7.1 10.7.2 10.7.3 10.8 10.9 10.10 10.11 10.12

Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General notes on maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the gearunit surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the airfilter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Examine water content of oil / conducting oil analyses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Change oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking tightness of the foundation bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General inspection of the gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Welding work on the mill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vibration measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34
34 34 34 34 35 35 36 37 38 38 40 40 40 40 41 41

11.
11.1 11.2

Spare parts, customerservice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stocking spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare parts and customerservice addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42
42 42

12.
12.1

Declarations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Declaration of incorporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43
43

BA 9138 EN 12/2010 6 / 44

1.
1.1

Technical data, rating plate

General technical data The most important technical data are shown on the rating plate. These data and the contractual agreements between Siemens and the customer for the gear unit determine the limits of its correct use.

Fig. 1:
Rating plate gear unit

Company logo Order number, item, sequence number, year built Total weight in kg Special information Type, size *) Power rating P2 in kW or torque T2 in Nm Speed n1

Speed n2 Oil data (oil type, oil viscosity, oil quantity) Instructions number(s) Special information Manufacturer and place of manufacture Country of origin

*) Example

K M P

180 Size . . . . . . . . . . . . . . . . . . . . . . 180 ... 425

Types . . . . . . . . . . . . . . . . . . . . . P = Planetary stage Application . . . . . . . . . . . . . . . . Vertical mill Type . . . . . . . . . . . . . . . . . . . . . . Bevelgear unit

For details regarding weight and further technical data, please refer to the drawings in the gearunit documentation and the orderspecific data sheet. 1.2 Measuringsurface soundpressure level A measuringsurface soundpressure level cannot be specified, as during the test run the gear unit is operated on the Siemens test rig without load.

BA 9138 EN 12/2010 7 / 44

2.
2.1

General notes
Introduction These instructions are an integral part of the gear unit supplied and must be kept in its vicinity for reference at all times. All persons carrying out work on the gear unit must have read and understood these instructions and must adhere to them. Siemens accepts no responsibility for damage or disruption caused by disregard of these instructions. The "FLENDER verticalmill gear unit" described in these Instructions has been designed for driving a mud pump. The gear unit is designed only for the application specified in section 1, "Technical data". Other operating conditions must be contractually agreed. The gear unit has been manufactured in accordance with the state of the art and is delivered in a condition for safe and reliable use. The gear unit must be used and operated strictly in accordance with the conditions laid down in the contract governing performance and supply agreed by Siemens and the customer. The gear unit described in these instructions reflects the state of technical development at the time these instructions went to print. In the interest of technical progress we reserve the right to make changes to the individual assemblies and accessories which we regard as necessary to preserve their essential characteristics and improve their efficiency and safety.

2.2

Copyright The copyright to these instructions is held by Siemens AG. These instructions must not be wholly or partly reproduced for competitive purposes, used in any unauthorised way or made available to third parties without our agreement. Technical enquiries should be addressed to the following works or to one of our customer services:

Siemens AG Am Industriepark 2 46562 Voerde Tel.: +49 (0)2871 / 920 Fax: +49 (0)2871 / 921544 Email: heavy.duty.aud@siemens.com

BA 9138 EN 12/2010 8 / 44

3.

Safety instructions
Entry to the gear unit and its added components is not permitted during operation! Entry for maintenance and repair work is only permitted when the gear unit is at a standstill! Caution! Risk of falling! Any changes on the part of the user are not permitted. This applies equally to safety features designed to prevent accidental contact.

3.1

Obligations of the user The operator must ensure that everyone carrying out work on the gear unit has read and understood these instructions and is adhering to them in every point in order to: avoid injury or damage. ensure the safety and reliability of the unit. avoid disruptions and environmental damage through incorrect use. During transport, assembly, installation, dismantling, operation and maintenance of the unit, the relevant safety and environmental regulations must be complied with at all times. The gear unit may only be operated, maintained and/or repaired by persons qualified for the work concerned (see "Qualified personnel" on page 3 of this manual). The outside of the gear unit must not be cleaned with highpressure cleaning equipment. All work must be carried out with great care and with due regard to safety. All work on the gear unit must be carried out only when it is not in operation. The drive unit must be secured against being switched on accidentally (e.g. by locking the key switch or removing the fuses from the power supply). A notice should be attached to the start switch stating clearly that work is in progress. No electrical welding work must be done at all on the drive. The drives must not be used as an earthing point for welding operations. Toothed parts and bearings may be irreparably damaged by welding. A potential equalisation in accordance with the applying regulations and directives must be carried out! If no threaded holes for earth connection are available on the gear unit, other appropriate measures must be taken. This work must always be done by specialist electricians. If any inexplicable changes are noticed during operation of the gear unit, such as an important increase in temperature or unusual noises, the drive assembly must be switched off immediately. Rotating and/or movable drive components must be fitted with suitable safeguards to prevent contact. When the gear unit is incorporated in plant or machinery, the manufacturer of such plant or machinery must ensure that the contents of these instructions are incorporated in his own instructions.

BA 9138 EN 12/2010 9 / 44

 3.2

Removed safety equipment must be reinstalled prior to starting up. Notices attached to the gear unit, e.g. rating plate, direction arrows etc., must always be observed. They must be kept free from dirt and paint at all times. Missing plates must be replaced. Screws which have been damaged during assembly or disassembly work must be replaced with new ones of the same strength class and type. Spare parts should always be obtained from Siemens (refer also to section 11).

Environmental protection Dispose of any packing material in accordance with regulations or separate it for recycling. When changing oil, the used oil must be collected in suitable containers. Any pools of oil which may have collected should be removed at once with an oilbinding agent. Preservative agents should be stored separately from used oil. Used oil, preservative agents, oilbinding agents and oilsoaked cloths must be disposed of in accordance with environmental legislation. Disposal of the gear unit after its useful life: Drain all the operating oil, preservative agent and/or cooling agent from the gear unit and dispose of in accordance with regulations. Depending on national regulations, gearunit components and/or addon parts may have to be disposed of or sent for recycling separately.

3.3

Special dangers and personal protective equipment Depending on operating conditions, the surface of the gear unit may heat up or cool down to extreme temperatures. In case of hot surfaces (> 55 C) there is a risk of burns! In case of cold surfaces (< 0 C) there is a risk of frost injury (pain, numbness, frostbite)! During oil changes there is a risk of scalding from escaping oil! Small foreign matter such as sand, dust, etc. can get into the cover plates of the rotating parts and be thrown back by these. Risk of eye injury! In addition to any generally prescribed personal safety equipment (such as safety shoes, safety clothing, helmet) handling the gear unit requires wearing suitable safety gloves and suitable safety glasses! The gear unit is not suitable for operation in explosion hazard locations. It must under no circumstances be used in such locations because of the risk to life and limb. When handling oils and/or preservative agents, protective gloves and safety glasses must always be worn! The oil must not come into contact with the skin (e.g. the operators hands). The safety notes on the data sheets for the oil used must be observed here!

BA 9138 EN 12/2010 10 / 44

4.

Transport and storage

Observe the instructions in section 3, "Safety instructions"!

4.1

Scope of supply The products supplied are listed in the despatch papers. Check immediately on receipt to ensure that all the products listed have actually been delivered. Parts damaged and/or missing parts must be reported to Siemens in writing immediately. If there is any visible damage, the gear unit must not be put into operation.

4.2

Transport When transporting our products, use only lifting and handling equipment of sufficient loadbearing capacity! Observe the notes regarding load distribution on the packing. The gear unit is delivered in the fully assembled condition and without oil filling. Additional items (e.g. pipes and fittings) can be delivered separately packaged. Different forms of packaging may be used, depending on the size of the unit and method of transport. Unless otherwise agreed, the packaging complies with the HPE Packaging Guidelines. The symbols marked on the packing must be observed at all times. These have the following meanings:

Top

Fragile

Keep dry

Keep cool

Centre of gravity

Use no hand hook

Attach here

Fig. 2:

Transport symbols Transport of the gear unit must be carried out so as to avoid personal damage and damage to the gear unit. If, for example, the free shaft ends are knocked, this may damage the gear unit. Gear units provided with pipework must be transported with especial care. The gear unit must be transported using suitable equipment only. During transport the gear unit should be left without oil filling and on the transport packing. Use only the eyes provided to attach lifting equipment to the unit. Attach slings with shackles to the eyebolts. Slinging and lifting gear must be adequate for the weight of the gear unit. To prevent the housing, output flange and pipework from being damaged by the deflection of the transport rope, wooden blocks must be placed under the rope. The output flange of the gear unit must never be lifted.

BA 9138 EN 12/2010 11 / 44

Fig. 3:
1

Attachment points

Wooden block For a detailed illustration of the gear unit and the position of the attachment points, please refer to the drawings of the orderspecific gearunit documentation.

4.3

Storing the gear unit The gear unit must be stored in a sheltered place in the position of the original packaging or in the position of use, placed on a vibrationfree, dry base, and covered over. When temporarily storing the gear unit and any single components supplied with it, the preservative agent should be left on them. It must not be damaged, otherwise there is a risk of corrosion. Do not stack gear units on top of one another. If the gear unit is being stored out of doors, it must be particularly carefully covered, and care must be taken that neither moisture nor foreign material can collect on the unit. Unless otherwise agreed by contract, the gear unit must not be exposed to harmful environmental factors such as chemical products. Provision for special environmental conditions during transport (e.g. transport by ship) and storage (climate, termites, etc.) must be contractually agreed.

BA 9138 EN 12/2010 12 / 44

4.3.1

Preservation (preservation time < 24 months) The gear unit is provided with an interior preservative agent; the free shaft end is painted for protection. The properties of the outer paint coat are as follows: Resistant to acids, weak alkalis, solvents, atmospheric action, temperatures up to 120 C / 248 F (briefly up to 140 C / 284 F), and to tropical conditions. Corrosion prevention times depend on the kind of packing and the place of installation and/or storage (see item 4.3.2.3). If the corrosion prevention time is exceeded, the internal and external preservation must be renewed (see section 7, "Startup"). The labyrinth seals on the input shaft and output flange are additionally sealed with adhesive tape. The adhesive tape on the labyrinth seals must not be removed until just before the machine is started up.

4.3.2

Longterm preservation (preservation time > 24 months) One possible longtime preservation method to be recommended is to completely fill the gear unit with preservative oil (here Siemens must be consulted).

4.3.2.1 Preparatory work To seal the labyrinth seal on the input shaft, a sealing cap must be fitted to the gear unit and sealed. The oil drain of the sealing cap must be sealed with a screw plug. The breather in the sealing cap must remain open during the oil filling (see item 4.3.2.2) until the oil runs over. Then this too must be sealed. The lower drain cock on the gear unit must be fitted and sealed with a screw plug. The pressure and suction lines mst be sealed with blank flanges.
6 10

8 5

Fig. 4:
1 2 3 4 5

Gearunit features for preservation measures 6 7 8 9 10 Oil drain (tilting pad thrust bearing chamber) Oil drain (gear unit) Pressure line (gear unit) Pressure line (tilting pad thrust bearing chamber) Indication of oil level (tilting pad thrust bearing chamber)

Breather of sealing cap Oil drain of sealing cap Sealing cap Indication of oil level (gear unit) Suction line (gear unit)

The air filter for the gear unit must be replaced and sealed with a screw plug. The air filter on the tiltingpad thrust bearing chamber serves for ventilation during the oil filling. If the air filter has been replaced with a screw plug, the screw plug must be removed in any case. When the filling operation has finished, the air filter must be replaced with a screw plug or the tapped hole sealed with a screw plug.

BA 9138 EN 12/2010 13 / 44

4.3.2.2 Filling with oil The oil to be put in must be filtered beforehand with a 25 m (0.0010 inch) filter gauge. The service oil of the gear unit with the corresponding high viscosity (see rating plate) can also be used as a preservative oil. For easier filling, it is recommended to use an oil of lower viscosity, although this is not suitable for later operation of the gear unit and so must be completely drained off. In both cases of oil grade and/or viscosity selection (high or low viscosity) reuse and preparation after a correspondingly long preservation or storage period (> 24 months) must be clarified with the oil manufacturer. The gear unit must be filled with oil via the oildrain cock of the tiltingpad thrust bearing. During filling care must be taken that the breather of the sealing cap on the input shaft is not sealed until oil emerges from it. After sealing the oil filling can be continued. If oil emerges from the labyrinth seal of the tiltingpad thrust bearing chamber, the oil flow quantity must be reduced. The gear unit is not completely filled until during filling oil alone (without air) escapes from the upper air vent of the tilting pad thrust bearing chamber. After complete filling the upper oildrain cock (tiltingpad thrust bearing chamber) must be closed and sealed with a screw plug. Remove any oil spillage immediately with an oilbinding agent! Oil leaks occurring during filling must be stopped immediately! The local environmental protection requirements of the country concerned must be observed. The longtime preservation with oil filling is suitable for a period of 10 years. After 10 years the oil filling must be completely renewed. The gear unit must be inspected for leaks at regular intervals. Before starting up the gear unit the oil must be drained off at the oil drain on the tiltingpad thrust bearing chamber and the oil drain on the gear unit base. Then installation and startup must be carried out in accordance with these operating instructions.

BA 9138 EN 12/2010 14 / 44

4.3.2.3 Durability of the internal gear-unit preservation The following table shows the durability of the internal gear-unit preservation, depending on the packing and the place of installation or storage. If the unit is stored out of doors without packing, item 4.3 in particular must be observed. For internal gear-unit preservative agent, see technical data. Table 1: Durability of the internal gear-unit preservation
Minimum measures Internal gearunit preservative agent Climatic zone Duration of at the place of protection installation or storage Kind of transport on the for the gear unit packing A1 A up to 6 months A B Tribol 1390/220 A up to 12 months B A up to 24 months B not including sea transport A1 including sea transport not including sea transport including sea transport not including sea transport including sea transport not including sea transport including sea transport not including sea transport including sea transport not including sea transport including sea transport A1 A1 A1 A2 A2 A2 A2 A2 B2 or B3 B2 B2 B2 B3 B3 B2 B3 B3 C1 C2 C2 C2 C2 C2 C3 C3 C3 at the place of installation or storage C2

North pole 90 N Arctic Circle 66.5 N A Northern Tropic 23.5 N B A Antarctic Circle 66.5 S South pole 90 S Equator 0 Southern Tropic 23.5 S

Table 2:

Packaging and Place of installation or storage

Packing no B1 packaging. Place of installation/ storage unprotected C1 out of doors. covered over C2 or covered.
C3 in enclosed space.

Measures on the gear unit no special measures A1 (gear unit in normal assembled condition). Close gear unit (as A A2 1, but close breathers, seal labyrinths).

Special measures Specification by agreement (statement about protection times in agreement with the customer D1 under precisely stipulated conditions. Description in the Siemens order confirmation)

B2

plain transport packing.. seaworthy packing..

B3
1)

1)

On reception of the goods the seaworthy packing must be inspected for damage. If damaged, the packing must be restored to its seaworthy condition.

The higher the numbers affixed to the letters of the subitems are, the better the corrosion prevention.

BA 9138 EN 12/2010 15 / 44

5.

Technical description
Observe the instructions in section 3, "Safety instructions"!

5.1

General description The KMP type verticalmill gear unit is a bevelgear planetary gear unit for driving a vertical mill. The axial forces resulting from the grinding process are conducted via the gearunit housing to the foundation. A detailed view of the gear unit can be obtained from the drawings in the gearunit documentation. For operation and maintenance, always observe the operating instructions indicated in the orderspecific appendix. For technical data, refer to the orderspecific documents.

5.2

Lubrication Lubrication and cooling is provided by continuous oil circulation from a separate oilsupply system. The technical data on the oilsupply system are specified in the list of equipment of the oilsupply system. When operating and servicing the components of the oilsupply system, observe the operating instructions of the oilsupply system. The type of lubrication is specified in the orderspecific list of equipment. Toothed parts and rolling bearings are forcelubricated and cooled via the lowforced lubrication circuit.

5.2.1

Hydrodynamic lubrication If ambient temperatures are low, the oil must be prewarmed. If contractually agreed, immersion heaters will be fitted in the gearunit housing or the oil tank, or a separate heating circuit will be provided. The oil is drawn in by the oil pump, cleaned in the doublechangeover filter, which is fitted with an optical and electrical contamination indicator, then cooled in the cooler and conducted to the lubricating points. The oil flow is divided by valves or orifice plates for the lubrication of the gears and tiltingpad thrust bearing. Volumetric flow, pressure and temperature are constantly monitored by monitoring equipment. To prevent vibration and compensate for heat expansion, compensators are provided for in the pipe system.

BA 9138 EN 12/2010 16 / 44

5.2.2

Hydrodynamic lubrication and hydrostatic starting aid In addition to the hydrodynamic lubrication, part of the oil is fed immediately downstream of the cooler to the highpressure pumps via a branch circuit. The pumps are radialpiston pumps and deliver a constant oil quantity at each connection. The oil is conducted to four axial thrust bearing segments distributed around the circumference. Before the mill is started, the oil is pumped between the pads and the race. A bearing oil film will form immediately. After 2 minutes' operation at operating speed the highpressure pump can be turned off. Pressure switches monitor this operating phase and the nonreturn valves built into the pads prevent the oil from backing up during normal operation.

5.2.2.1 Hydrostatic lubrication system with radial piston pump In addition to the hydrodynamic lubrication, part of the oil is fed immediately downstream of the cooler to the highpressure pumps via a branch circuit. The pumps are radialpiston pumps and deliver a constant oil quantity at each connection. The same oil quantity is supplied to each bearing pad independently of the counterpressure. The oil connections are distributed so that no two adjacent pads are supplied by one pump. In this way the drive can be bypassed while the failed pump is being replaced. To ensure that the pumps are operating and no oil line is defective, the oil flows are monitored for minimum pressure. The pressure at the pressure gauge is adjusted by the pressure actually exerted by the grinding rollers. If the minimum setting of a pressure or flowmonitored component is fallen below, the main drive is switched off. The nonreturn valves built into the pads prevent the oil from backing up during normal operation. 5.3 Sealing The input shaft and output flange are sealed with labyrinth seals. Air filters are provided on the housing to regulate the pressure. 5.4 Drive coupling A flexible coupling is to be provided for the gear unit drive. For maintenance and operation of the coupling, refer to the operating instructions for the coupling.

BA 9138 EN 12/2010 17 / 44

6.

Fitting
Observe the instructions in section 3, "Safety instructions"!

6.1

General information on fitting When transporting the gear unit observe the notes in section 4. Adequate lifting equipment must be available before beginning the fitting work. Fitting to the mill must be undertaken under the supervision of Siemens specialists or by suitably trained specialists authorised by Siemens. No liability can be accepted for damage resulting from incorrect installation by nonFLENDER staff. The operator should ensure that no foreign bodies affect the proper function of the gear unit (e.g. falling objects or heaping over). When fitting in the vertical mill, the mill manufacturer's special instructions must be observed.

6.2

Installation conditions As early as during the planning phase, sufficient space must be allowed around the gear unit for later mounting, care and maintenance work. Care must be taken that the oil can be drained and an adequate air supply is provided. It must be possible to check the internal parts through the holes in the inspection hole covers. Machines located up and downstream are to be arranged accordingly. If the pipes connecting the gear unit and oilsupply system are included in the Siemens delivery, the installation plan is enclosed with the documentation. All the fastening points provided by the design of the unit must be used. Screws which have been damaged during assembly or disassembly work must be replaced with new ones of the same strength class and type.

6.2.1

Dimensions and weights For details regarding weight and further technical data, please refer to the drawings in the gearunit documentation and the orderspecific data sheet.

6.2.2

Lifting device Adequate lifting equipment must be available before beginning the fitting work. The loadbearing capacity of the lifting gear to be installed and used must correspond at least to the weight of the gear unit (for details see section 1, "Technical data"). Refer to section 4 for notes regarding transport.

BA 9138 EN 12/2010 18 / 44

6.3

Preparatory measures for gear unit installation The packing must be removed before the gear unit is installed in the vertical mill. The adhesive tape on the labyrinths must not be removed until the gear unit is started up. Opening the gear unit (e.g. removing the adhesive tape on the input shaft or on the output flange, or opening a cover) reduces the guaranteed life of the preservative (see item 6.3.1). If the gear unit is opened (e.g. the adhesive tape on the labyrinth seal of the input shaft and/or the output flange or a cover or a screw plug is opened), the gear unit must be started up within a week. The input shaft of the gear unit must be rotated for positioning during installation only when the tiltingpad thrust bearing chamber is filled with oil up to the specified level. The gear unit must be cleaned on the outside and all preserved surfaces washed down with a solvent, e.g. benzine. To ensure function (coefficient of friction), the contact surfaces of the gear unit and foundation must be cleaned. Ensure adequate ventilation. Do not smoke! Danger of explosion! If startup is delayed, special measures are necessary to maintain preservation (see item 6.3.1).

6.3.1

Maintaining preservation if the gear unit has been opened in the meanwhile If a gear unit which has been opened in the meanwhile is left standing without transport packing in an unprotected, but covered environment for longer than a week and the gear unit cannot be flushed out for one hour and turned for 15 minutes every 2 days, the preservation can partly be maintained by proceeding as follows: If the gear unit has not not been flushed out, it must be closed airtight (covering the labyrinth seal of the input shaft and the output flange with adhesive tape; replacing air filters with screw plugs; if applicable, closing pipe holes airtight).

The following preservation times can then be guaranteed: Zone A (see item 4.3.2.3) six months corrosion prevention (starting from the date at which the gear unit was first opened). Zone B (see item 4.3.2.3) four months corrosion prevention (starting from the date at which the gear unit was first opened). The maximum durability of the gear-unit preservation (see item 4.3.2.3) must not be exceeded, even if the gear unit has been resealed. 6.3.2 Foundation The gear unit must be installed on a level, secure, vibrationfree and rigid foundation. The levelness of the gear unit standing surface is especially important, as the contact pattern of the teeth and the carrying portion of the axial thrust bearing depend on it and the service life of the gear unit is affected by it. All points on the gear unit standing surface must lie between two imaginary parallel planes 0.1 mm per 1 m (0.012 inch per 1 ft) apart. The permissible deviation of the gear unit standing surface from the horizontal plane is 0.2 mm per 1 m (0.024 inch per 1 ft).

BA 9138 EN 12/2010 19 / 44

6.4

Gearunit installation The gear unit must be installed under the vertical mill in accordance with the mill manufacturer's instructions. The input shaft of the gear unit must be rotated for positioning during installation only when the tiltingpad thrust bearing chamber is filled with oil up to the specified level. The gear unit must be fastened down with the foundation bolts provided for in the parts list. For pretensioning and tightening torque values for foundation bolts of strength class 8.8 to DIN 267, please see table 3. Table 3: Initial tension, tightening torque, initialtensioning tool Initialtensioning force
[N]
M 20 M 24 M 30 M 36 M 42 M 48 M 56 M 64 M 72 x 6 M 80 x 6 M 90 x 6 M 100 x 6 114000 164000 262000 382000 526000 693000 959000 1268000 1600000 1950000 2550000 3200000

Thread size

Tightening torque
[ Nm ]
410 710 1450 2530 4070 6140 9840 14300 20800 28900 41650 57800

Initial tensioning tool phydraulic

[ bar ]

[ lft x104 ]
25.7 36.9 58.9 85.9 118.4 155.9 215.8 285.3 360.0 438.8 573.8 720.0

[ ft lbs ]
303 524 1070 1867 3004 4531 7262 10553 15350 21328 30738 42730

Operating instructions of the manufacturer of the hydraulic initialtensioning tool

For Superbolt nuts the separate instructions of the manufacturer apply (see item "Other operating instructions" in the gearunit documentation). After the gear unit has been aligned, the pins specified in the dimensioned drawing must be fitted. Lateral stops can also be fitted to prevent the gear unit from shifting. The gear unit is approved for one direction of rotation only. The direction of rotation of the motor must correspond to the direction indicated by the arrow on the gearunit input shaft. Gear units which are used out of doors or under other very unfavourable environmental conditions e.g. dirt, dust, heat or water spray must be protected against these by suitable means. However, the free movement of air over the surface of the housing must not be obstructed. Screws which have been damaged during assembly or disassembly work must be replaced with new ones of the same strength class and type.

BA 9138 EN 12/2010 20 / 44

6.5

Installing the pipework The pipework must be carefully cleaned and flushed through with a lowviscosity oil. The pipework must be screwed on in accordance with the specifications on the drawings. Blank flanges and plugs must be removed beforehand. The screw connections seal metallically, while the associated seals must be used for the flanges. The pipework must not be overstressed. The pipework must be supported with struts as indicated in the drawings in the gearunit documentation. If the pipework is adapted on site, the pipes must be carefully pickled after welding.

6.6

Pickling of adapted pipes Personal protective equipment (gloves, safety glasses) must be worn during this process. Risk of corrosion burns. The lower end of each pipe must be sealed with a plug. Pickling solution: 33 % hydrochloric acid (HCl) diluted with the same quantity of water (H2O). Air bubbles must not under any circumstances be allowed to form on the inside of the pipes. The pipes must be filled with the pickling solution. Acting time: 1 hour. Flush pipes out well with water (H2O). When the pipes are empty, they must be filled with a neutralising solution (sodium lye 3 % to 5 % NaOH). Neutralisation time: 15 minutes. Then flush the pipes out once more with water (H2O). The pipes must then be flushed out thoroughly with flushing oil via a 10 m (0.0004 inch) filter. If the pipes are not fitted straightaway, they must be carefully preserved.

6.7

Installing the couplings When installing the couplings, the related operating instructions for the couplings must be observed. Before beginning installation, the shaft ends and the coupling parts must be carefully cleaned. Couplings must be hoisted with the aid of the thread centring hole at the shaft ends. The couplings must be secured to prevent them from being shifted axially. The parts must not be driven on by abrupt force, as this may damage the gear unit.

6.8

Installing the motor The drive motor must be aligned precisely with the central axis of the input shaft of the gear unit and fixed in position. Record alignment dimensions. When installing the motor, the specific operating instructions for the motor must be observed. The precise alignment of the shafts one with the other is of fundamental importance for the service life of the shafts, bearings and couplings.

BA 9138 EN 12/2010 21 / 44

6.9

Fitting addon parts delivered loosely with the unit All loose parts with a thread connection must be sealed with fluid seals. No sealing agent must get into the gear unit. Any loose fittings the tapped holes of which are sealed with plugs must be fitted in accordance with the drawings supplied with them. Electrical monitoring instruments must be connected in accordance with terminal diagrams, lists of equipment and specific operating instructions.

6.10

Welding work on the mill Siemens will assume no liability for damage caused to the gear unit by welding work carried out on the mill. The gear unit must not be used as an earthing point for welding operations. Before welding work is carried out on the mill, the gear unit must be properly earthed! When carrying out electric welding anywhere on the mill the welding current must not be conducted through the gear unit. The welding current return wire must therefore always be connected direct to the component to be welded.

6.11

Final work After installation of the gear unit check all screw connections for tight fit. Check the alignment after tightening the fastening elements (the alignment must not have been changed). Check that all the devices which have been demounted for transport reasons have been refitted. For this refer to the details in the data sheet, the list of equipment and the associated drawings. Oildrain cocks, if any, must be secured against accidental opening. If an oilsight glass is used for monitoring the oil level, it must be protected against damage. The gear unit must be protected against falling objects. Protective devices for rotating parts must be checked for correct seating. Contact with rotating parts is not permitted. A potential equalisation in accordance with the applying regulations and directives must be carried out! If no threaded holes for earth connection are available on the gear unit, other appropriate measures must be taken. This work must always be done by specialist electricians. Cable entries should be protected against moisture. Check that protective measures have been taken!

BA 9138 EN 12/2010 22 / 44

7.

Startup
Observe the instructions in section 3, "Safety instructions"! The gear unit must not be started up, if the required instructions are not available. During startup the initial run of the gear unit is loadfree, that is, without grinding material and roller pressure.

7.1

Procedure before startup A precondition of the warranty is initial startup by Siemens specialists or suitably trained specialists authorised by Siemens. Any setting of the drive in motion represents a startup! For this reason the operating instructions must be adhered to, particularly if maintenance work is carried out on the mill during which this is rotated and the gear unit along with it.

7.1.1

Depreservation of the gear unit When depreserving the gear unit, all the preservative paint coats must be removed with a suitable cleanser (e.g. benzine). Preserving and/or runningin oil residues must be drained off via the oildrain cocks on the gear unit and then the gear unit flushed out. Remove any oil spillage immediately with an oilbinding agent. The following additional work is necessary: Insert air filter in accordance with the dimensioned drawing in the gear unit documentation. Remove the adhesive tape on the labyrinth seal of the input shaft and the output flange.

7.1.2

Flushing before initial startup In all cases a distinction must be made between "flushing" during the initial startup and "flushing" before and after repairs and overhauls (see item 10.4, "Flushing"). Flushing before initial startup serves to minimise residues from previous lubricating oils or preservative agents. Flushing should be carried out with the selected service lubricating oil. Other viscosities of oil of the same grade and make as that used as service lubricating oil may also be used as flushing oil. Put in flushing oil. For flushing, the gear unit and/or the tank of the oilsupply system must be filled with sufficient oil for the oil pump of the oilsupply system to be able to be operated for flushing. Flushing times: For flushing, operate the oil pump of the lowpressure lubricating circuit for at least 6 hours. After flushing the oil must be carefully drained off via the oildrain cocks on the gear unit and the oilsupply system. It may be reused only as flushing oil. The flushing oil must be cleaned before reuse. The flushing oil can be reused for a maximum of six flushing operations.

BA 9138 EN 12/2010 23 / 44

7.1.3

Oil filling The gear unit must be filled with oil after flushing and before initial start-up of the gear unit, once parts such as pressure gauges, thermometers, pipework, etc. which have been delivered separately or removed for transport have been fitted. The quality of the oil used must meet the requirements of the separately supplied BA 7300 EN operating instructions, otherwise the guarantee given by Siemens will lapse. We urgently recommend using one of the oils listed in BA 7300 EN, because they have been tested and meet the requirements. Information on the type, quantity and viscosity of the oil is given on the rating plate on the gear unit. In case of gear units with oil cooling system the oil circuit must additionally be topped up. For this, the operating instructions of the oilsupply system must be observed. Only the oil level marks of the oillevel indicators on the gear unit and/or the oilsupply system (in the case of the version with tank) are decisive for the oil quantity to be put in. Quantities indicated on the rating plate of the gear unit are only guide values. Oil pumps and all parts the oil filling holes of which are identified by a special information sign must be filled with oil before starting up the gear unit. This is done by way of:

an oilfilling hole on the oil pump of the lubricating system or an oil-filling hole on the pressure line or an oil-filling hole marked with an instruction plate
These oilfilling holes must be tightly closed to prevent the pump from drawing in air and/or oil from escaping.

Fig. 5:
1 2 3

Oil level, oil drain and breather 4 5 6 Oil level Tilting pad thrust bearing Air filter Gear unit Air filter Tilting pad thrust bearing

Oil drain Gear unit Oil drain Tilting pad thrust bearing Oil level Gear unit

A detailed view of the gear unit can be obtained from the drawings in the gearunit documentation.

BA 9138 EN 12/2010 24 / 44

The gear unit can be filled with oil in different ways, depending on the equipment of the oilsupply system. The oil to be put in must be filtered beforehand with a 25 m (0.0010 inch) filter gauge. If the oilsupply system is fitted with threeway cocks, the gear unit can be filled either via the threeway cocks of the oilsupply system or via the oildrain cock of the tiltingpad thrust bearing of the gear unit. If the oilsupply system is not fitted with threeway cocks, the gear unit is filled via the oildrain cock of the tiltingpad thrust bearing. If the oilsupply system is fitted with a tank, the gear unit can be also filled with oil via the oil tank of the oilsupply system. For this, it is necessary in the meantime to start the lowpressure pump of the oilsupply system in order to also fill the tiltingpad thrust bearing chamber of the gear unit with oil.

7.1.4

Oil quantity

7.1.4.1 Oil quantity for flushing For flushing, the gear unit and/or the tank of the oilsupply system must be filled with sufficient oil for the oil pump of the oilsupply system to be able to be operated for flushing. The flushingoil quantity may be between 50 % and 100 % of the total oil filling (see technical data), depending on the design of the gear unit. 7.1.4.2 Oil quantity for initial start-up Sufficient oil must be put in to reach the specified oil level on the oillevel indicators of the gear unit (see dimensioned drawing of gear unit) and/or on the oilsupply system (in the case of version with tank) while the gear unit is stationary and the oil pumps (low and highpressure circuit) are operating. 7.1.5 Oilsupply system The main gear unit is supplied with lubricating and cooling oil by the oilsupply system (see operating instructions for the oilsupply system). 7.1.6 Checks before startup When the installation has been completed and before the first cold test run, all the drive parts must be inspected and all material residues, tools and installation aids removed. If no shutoff equipment for the cooling water supply has been installed by Siemens, it must be provided by the customer. The entire drive must also be checked against the following check list:

Has the foundation been correctly constructed? Are all the foundation bolts tightened to specification? Has the gear unit been correctly fastened in place? Has the grinding bowl been correctly installed? Are the direction of rotation of the motor and that of the gear unit identical (see direction of rotation arrow)? Has the adhesive tape on the labyrinth seals been removed? Has all the pipework been fitted and cleaned in accordance with the installation instructions? Especial care must be taken to ensure that the oilconducting pipework is clean, since any dirt in it would be conducted through the gear unit before it could be filtered out at the filter of the oilsupply system!

BA 9138 EN 12/2010 25 / 44

Are the coupling and the motor correctly aligned? Have the pipework and the hoses been correctly fitted? Have the pipe and hose connections been checked for leaks? Especial attention must be given to the flange connections on the suction line. If air gets into it, the oil tends to foam. Is the oil in the oil reservoir (tank of oilsupply system and/or gear unit) lowfoaming on the surface during operation? If there is foam, check all the suction line connections. If necessary, also contact the oil manufacturer. Have the tank of the oilsupply system and/or the gear unit and the tilting pad thrust bearing chamber been fllled with oil up to the mark? The oil level must be checked while the oilsupply system is running and the gear unit is stationary. Has all the monitoring equipment been connected up in accordance with the terminal diagram? Has the electric interlock between the gear unit, oil supply and mill drive motor been checked?

Have the following checks been recorded?

Function of the interlock according to interlock specifications. Adjustment and function of flow monitor, pressure switch and temperature sensor. Coolingwater supply opened, on oilsupply systems with water oilcooler.

For further checks, see the operating instructions for the couplings, motors, oilsupply system and vertical mill. 7.2 7.2.1 Startup Prelubrication phase Prior to each startup, the gear unit must always be prelubricated for approx. 30 minutes by means of the oilsupply system. During this time rolling bearings, axial tiltingpad thrust bearings and teeth for the initial start are supplied with lubricating oil. Care must be taken in the case of gear units with highforced lubrication that the lowforced lubrication system is started first and then after 2 minutes the highforced lubrication system. This time is necessary to ensure the pressure balance in the oil circuit. The highpressure pumps which may have been installed must be started no later than 5 minutes before the auxiliary or main motor is started.

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7.2.2

Initial startup After due observance of the relevant operating instructions, the gear unit can be put into operation. If possible, the gear unit should run for several hours on part load (50 % to 70 %). If part load is not possible, the gear unit can also be run without load and with the rolls and/or rollers lifted. If no faults are indicated, the load can be gradually increased to full load at suitable intervals under continuous observation. During this time, in particular the following points have to be observed: a) Noise. If possible, during this time the gear unit must be listened to for unusual noises at various points with a suitable instrument (e.g.a stethoscope). b) Foam formation Is the oil in the oil reservoir (tank of oilsupply system and/or gear unit) lowfoaming on the surface? If there is foam, check all the suction line connections. If necessary, also contact the oil manufacturer. c) Vibration measurement (for this see section 10, "Maintenance and repair", item 10.10) d) Oil leakages All the screw connections in the oil lines must be monitored for oil leaks and, if necessary, resealed! The date of initial startup must be notified to Siemens within 4 weeks.

7.2.3

Checking procedure The following visual checks must be conducted and recorded when starting up:

Oil level Leaktightness of the oilcooling or oilsupply lines Opening condition of the shutoff valves Effectiveness of the shaft seals Freedom of the rotating parts from contact. The document must be kept with the operating instructions.

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7.3

Removal from service Switch motors off. Secure the drive unit to prevent it from being started up unintentionally. Attach a warning notice to the start switch! Our recommendation is that during short interruptions the complete oilsupply system be kept operating. If the unit is stationary for longer periods, we recommend that the oilsupply system be kept running for approx. 60 minutes to prevent heat from building up. If there is a sudden stoppage, like that caused by a power failure, however, no damage will result. It should be noted that, when oilsupply systems with a highpressure lubricating circuit are shut off, the highpressure pumps must be shut down at first. During longer stoppages the shutoff valves in the coolant inlet and outlet lines must be closed. If a water oilcooler is used, the water must be drained off to prevent damage from freezing at possible subzero temperatures. If gear units are operated in a saline environment or in the vicinity of bodies of saline water, the oilsupply system must be run through its cycle to prevent damage from corrosion. Additionally, the gear unit must be turned over with the auxiliary drive or main motor for 15 minutes every week (see item 7.2). If taken out of service for longer periods, the gear unit must be flushed through for one hour and rotated for 15 minutes every 7 days. The prerun time for the oilsupply system of 30 minutes before the vertical mill is set in motion must be adhered to. If the gear unit cannot be regularly set in motion, it must be preserved (see item 7.3.1).

7.3.1

Preservation during longer periods of nonuse

7.3.1.1 Interior preservation with preservative agent Before a longer period of storage the gear unit must be run without load with the preservative agent listed in table 4. Table 4: Preservative agent Preservative agent Special measures after running with preservative
Close gear unit. Put an airtight seal on the labyrinth on the input shaft and on the output flange. Replace breather screw and/or air filter with a (yellow) plug screw (replace the original parts before startup).

Duration of protection

Depending on the correct use of the preservation agent. Up to 36 months

Tribol 1390 / 220

After internal reservation the gear unit must be closed airtight (see item 7.3.1.2) (see also "Special measures" in table 4).

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7.3.1.2 Interiorpreservation procedure Switch the gear unit off and drain the oil as described in section 10, "Maintenance and repair". Pour preservative agent in through the ventilation hole and/or the hole in the inspection cover up to the upper mark on the oillevel indicators. Close the venting hole and/or the opening in the inspection cover. Start oilsupply system (low and highpressure circuit). Running time of the oilsupply system for preservation: at least 1 hour. Start the gear unit and allow it to idle briefly. The gear unit must start once. If this is not possible, the gear unit must be rotated for at least one revolution on the output flange. This can be done by rotating the input shaft by hand. Observe direction of rotation of the gear unit! Unscrew the oildrain plug and allow the preservative to drain into a suitable container and dispose of it according to regulation. There is a risk of scalding from the hot preservative agent draining from the gear unit. Wear protective gloves. Screw in the oildrain plug. Seal labyrinth seals on the input shaft and output flange with adhesive tape.

7.3.1.3 Interior preservation by oil filling Alternatively the gear unit can also be filled with operating oil. Observe details at item 4.3.2. Contact Siemens. 7.3.2 Exterior preservation Table 5: Exterior preservation of shaft ends and other bright machined surfaces Preservative agent Layer thickness Remarks
Longterm waxbased preservative agent, resistant to sea water and tropical conditions (soluble with CH compounds). The Duration of protecton depends on the conditions of storage.

Duration of protection

min. 12 months

Tectyl 846 K19

approx. 50 m

7.3.2.1 Exteriorpreservation procedure Clean the surfaces. Apply preservative agent.

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8.

Operation
Observe the instructions in section 3, "Safety instructions", in section 9, "Faults, causes and remedy", and in section 10, "Maintenance and repair"!

8.1

General During operation the gear unit must be monitored for: Oil temperature The gear unit is designed for a oil-feed temperature of 50 C (122 F) in continuous operation. If the oil-feed temperature reaches critical values (see lubrication plan and equipment list), the gear unit must be shut down immediately and Siemens consulted.

Changes in gear noise. Possible oil leakage at the housing and shaft seals. Bearing vibrations with present measuring instrument Correct oil level (see section 7, "Startup"). To check the oil level, the gear unit must be taken out of operation and the oil level checked while the oil pump of the lowforced lubrication circuit of the oilsupply system is running. The oil level should be between the two marks of the oillevel indicator. If the oil falls below the lower mark of the oillevel indicator, the oil must be topped up. If the oil level in the gear unit rises above the upper mark, the oil may foam more, because the highspeed bevel gear churns up the oil. If the oil level is too high, leaks may also develop on the input shaft. If necessary, the oil level must be adjusted. 8.2 Irregularities The drive unit must be switched off at once, if irregularities are found during the operation or if the pressure monitoring device in the oilcooling system triggers alarm (only with correspondingly equipped gear units). Determine the cause of the fault, using table 6, "Faults, causes and remedy" (see item 9.2). Table 6, "Faults, causes and remedy", contains a list of possible faults, their causes and suggested remedies. If the cause cannot be found, a specialist from one of our customerservice centres should be called in (see section 2). Continuous changes in the operating behaviour of the gear unit must be recorded with the aid of trend records.

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9.

Faults, causes and remedy

Observe the instructions in section 3, "Safety instructions", and in section 10, "Maintenance and repair"!

9.1

General information on faults and malfunctions Faults and malfunctions occurring during the guarantee period and requiring repair work on the gear unit must be carried out only by Siemens customer service. In the case of faults and malfunctions occurring after the guarantee period and whose cause cannot be precisely identified, we advise our customers to contact our customer service. Siemens will not be bound by the terms of the guarantee or otherwise be responsible in cases of improper use of the gear unit, modifications carried out without Siemens agreement or use of spare parts not supplied by Siemens. To remedy faults and malfunctions, the gear unit must always be taken out of service. Secure the drive unit to prevent it from being started up unintentionally. Attach a warning notice to the start switch!

9.2

Possible faults Table 6: Faults, causes and remedy Faults

Changes in gearunit noise.

Possible causes
Damage to gear teeth.

Remedy
Contact Customer Service. Check all toothed components and replace any damaged parts. Contact Customer Service. Adjust bearing backlash. Contact Customer Service. Replace defective bearings.

Bearing backlash too high or too low. Bearing defective. Increased temperature at the bearing points.

Oil level in gearunit housing too low Check the oil level at room or too high. temperature and, if necessary, adjust oil level. Oil too old. Mechanical oil pump defective. Contact Customer Service. Check date of last oil change. Contact Customer Service. Check that oil pump is working correctly. Repair or replace oil pump. Contact Customer Service. Check and, if necessary, replace bearings. Check and, if necessary, replace sealings. Seal joints. Check oil level and, if necessary, adjust.

Bearing defective.

Oil leakage from the gear unit.

Inadequate sealing of housing covers and/or joints. Oil level in housing too high.

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Faults
Volumetricflow meter triggers alarm.

Possible causes
Oil too cold. Oil filter dirty. Heat oil.

Remedy

Clean oil filter. Consult operating instructions for oilsupply system. Check and, if necessary replace pipes. Check oil level and, if necessary, top up oil. Check and, if necessary, replace oil pump. See Faults "Operating temperature too high". Clean the oil filter. Consult operating instructions for oilsupply system. Check and, if necessary replace pipes. Check oil level and, if necessary, adjust. Contact Customer Service. Check date of last oil change. Contact Customer Service. Change oil. Check and, if necessary, replace oil pump. Consult operating instructions for oilsupply system. Clean the oil filter. Consult operating instructions for oilsupply system. Check and, if necessary, replace cooler. Observe operating instructions for cooler. Check coolingwater feed and/or coolingair feed. Observe operating instructions for cooler. Check oil filter for dirt. Consult operating instructions for oilsupply system. Check setting of the control valves. Check all monitoring devices. Observe operating instructions to monitoring devices. Analyse and check milling parameters.

Pipes leaky. Pressure monitor triggers alarm. Oil level too low. Oil pump defective. Operating temperature too high. Oil filter dirty.

Increased operating temperature.

Pipes leaky. Oil level in housing too high. Oil too old. Oil badly contaminated. Oil pump defective.

Oil filter dirty.

Cooler defective (dirty).

Coolingwater feed and/or coolingair feed defective. Excessive temperature on temperature sensor in tilting pad thrust bearing. Oil filter dirty.

Oil quantity to tilting pad thrust bearing too small. Monitoring devices defective.

may also be connected with altered grinding parameters, e.g. raising of the temperature of the gas in the vertical mill.

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Faults
The oil foams.

Possible causes
Water in oil. Oil too old (defoaming agent used up). Unsuitable oils mixed up. Cooler leaky. Water condensing.

Remedy
Test the oil, change oil if necessary. Test the oil, change oil if necessary. Test the oil, change oil if necessary. Replace cooler. Change oil. Reduce water content by heating the oil. Consult operating instructions for oilsupply system.

Water in oil.

Fault in oilsupply system.

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10.

Maintenance and repair

Observe the instructions in section 3, "Safety instructions", and in section 9, "Faults, causes and remedy"! Once the maintenance and repair work is completed, the information in section 7, "Startup" should be noted.

10.1

General notes on maintenance Maintenance comprises all measures for preserving and restoring the required condition and for ascertaining and assessing the actual condition of the technical means of a system. In this context maintenance is a comprehensive generic concept which can be subdivided into three areas: Inspection. Maintenance (including lubrication). Repair. All maintenance and repair work must be done with care and by duly trained and qualified personnel only. Before carrying out maintenance work, repairs or other work on the gear unit, the operator of the system must ensure that the drive motor is secured against unintentional starting. We also refer to the relevant accident prevention regulations at the place of installation. The gear unit must be protected against falling objects. Protective devices for rotating parts must be checked for correct seating. Contact with rotating parts is not permitted. For operation and maintenance the information given in the orderspecific gearunit documentation must be observed.

10.2

Cleaning the gearunit surface To prevent the buildup of dust on the gear unit, cleaning must be done in accordance with operating conditions. The gear unit must not be cleaned with highpressure cleaning equipment.

10.3

Clean the air filter Every 12 weeks or when the air filter (breathing filter) is very contaminated. Unscrew the filter and clean it with benzine or similar cleaning agents. Be especially careful when cleaning with compressed air. Wear protective glasses! Screw in again dry air filter.

10.3.1 Replacing the airfilter cartridge Every 12 weeks or when the air filter is very contaminated. Remove the airfilter cover and replace the filter element (the paper filter cannot be cleaned).

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10.4

Flushing In all cases a distinction must be made between "flushing" during the initial startup and "flushing" before and after repairs and overhauls. Flushing before and after repairs and overhauls serves to remove impurities (e.g. carbon deposits, oil foam, abraded material). The flushing action can be improved by using e.g OPTIMOL Detergen System Cleaner, to dissolve residues or reduce coagulated substances. Flushing should be carried out with the selected service lubricating oil. Other viscosities of oil of the same grade and make as that used as service lubricating oil may also be used as flushing oil. For flushingoil quantity see item 7.1.4.1. Flushing times: For flushing, operate the oil pump of the lowpressure lubricating circuit for at least 6 hours. After flushing the oil must be carefully drained off via the oildrain cocks on the gear unit and the oilsupply system. It may be reused only as flushing oil. The flushing oil must be cleaned before reuse. The flushing oil must be filtered beforehand or during filling using a nominal filter gauge of 25 m (0.0010 inch). The flushing oil can be reused for a maximum of six flushing operations.

10.5

Oil filling After flushing and before the initial run of the gear unit the gear unit must be filled with oil. Information on the type, quantity and viscosity of the oil is given in the orderspecific gearunit documentation. For oil grades which can be used, see the recommended lubricants in the operating instructions BA 7300 EN (see item 10.12, "Lubricants").

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10.6

Inspection The inspection comprises all measures for ascertaining and assessing the actual condition. The measures must be recorded. Table 7: Inspection measures Measures
General visual check for cracks, leaks and damage Visual check of the toothflank condition for damage Check oil filters of the oilsupply system for contamination Check of the instruments installed on site (temperatures, oil pressures) Inspection of the oilconducting lines for leaks Oil level check at the oillevel indicators on the gear unit and, if necessary, on the oilsupply system (version with tank) Check unusual noises, temperature, safety equipment. Check of the addon parts such as couplings, possibly auxiliary drive

Periods
Every 4 weeks Every 4 weeks Every 4 weeks Every 4 weeks Weekly Weekly

Remarks

Visual indication, see also operating instructions oilsupply system.

See also operating instructions oilsupply system.

Every 4 weeks

Yearly

See operating instructions individual components.

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10.7

Maintenance Maintenance comprises all measures for preserving the required condition. Table 8: Maintenance measures Measures
Cleaning the filter elements Test oil for water content

Periods
Every 4 weeks or when the filters are dirty After approx. 400 operating hours, thereafter at least once per year After approx. 1000 operating hours or depending on the results of the oil analysis carried out Every 1000 operating hours Depending on the oilanalysis results; (without oil analysis: every 18 months and/or 5000 operating hours) Every 12 weeks Every 12 weeks Every 12 weeks Every 2 years See also operating instructions oilsupply system. Every 26 weeks

Remarks
See operating instructions for the individual components See item 10.7.1

First oil change after startup

See item 10.7.2

Oil analyses Subsequent oil changes

See item 10.7.1 See item 10.7.2

Cleaning the air filter (breathing filter) Replacing the airfilter cartridge Checking tightness of the foundation bolts Carrying out complete inspection of gear unit Maintenance work on the oilsupply system Check couplings

see item 10.3 see item 10.3.1 See item 10.7.3 see item 10.8 See also operating instructions oilsupply system. See operating instructions individual components

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10.7.1 Examine water content of oil / conducting oil analyses More information about examining the oil for water content or conducting oil analyses is obtainable from your lubricant manufacturer or our customer service. For reference purposes, a fresh sample of the operating lubricating oil used must be sent with the used oil sample to the analysing institute for analysis. The oil sample must be taken downstream of the filter of the oilsupply system while the gear unit is running. A suitable connection point is normally located upstream of the gear unit input (e.g. oildrain cock in the pressure line). A special sample container should be filled with the specified quantity of oil. If there is no such sample container available, at least one litre of oil must be put in a clean, transportworthy, sealable vessel. The viscosity of the oil sample may not deviate by more than 10% from that specified in the technical data. The oil purity should be between 15/13/10 (high availability) and 17/15/12 (normal availability) to ISO 4406. Limit values for oil contamination. Materialrelated contamination limit values of the oil Limit content [ mg/kg ]
40 4 4 4 6 2 2 10 20 0.10 %

Table 9:

Material
Iron (Fe)

Possible source
Gear rim with internal teeth, teeth, bearing cage Rolling bearing, teeth Oilpump bearing Cage of bearing Plain thrust bearings, pump bearings Plain thrust bearings, pump bearings Teeth Zincbased primer (is sometimes used as additive). In this case please contact Siemens. Cement dust or other environmental factors Water condensation; wateroil cooler defective

Chromium (Cr) Aluminium (Al) Copper Lead Tin Nickel Zinc Silicon Water (Cu) (Pb) (Sn) (Ni) (Zn) (Si) (H2O)

10.7.2 Change oil When changing the oil, always refill the gear unit with the same type of oil. Never mix different types of oil and/or oils made by different manufacturers. Polyglycolbased synthetic oils in particular must not be mixed with PAObased synthetic oils or mineral oils. If changing to a different grade or make of oil, the gear unit must, if necessary, be flushed out with the new oil grade. Flushing is not necessary, if the new service oil is fully compatible with the old service oil in all respects. Compatibility must be confirmed by the oil supplier. If there is a change to another oil grade or make, Siemens recommends flushing out the gear unit with the new grade of service oil. When changing the oil, the housing and, where present, the oil cooling system must also be cleaned thoroughly by flushing with oil to remove oil sludge, abraded particles and residues of old oil. Use the same type of oil as is used for normal operation. Highviscosity oils must be heated beforehand. Ensure that all residues have been removed before filling with fresh oil.

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The oil change should be carried out immediately after the shut down of the gear unit while the oil is still warm. Stop the gear unit by switching off the drive unit. Secure the drive assembly to prevent it from being started up accidentally. Attach a warning notice to the start switch. A suitable container should be placed under the oildrain cock of the gearunit housing and the tilting pad thrust bearing chamber. Unscrew the screw plugs of the oildrain cocks and allow the oil to drain into the container. There is a danger of scalding from the hot oil emerging from the housing. Wear protective gloves. Remove any oil spillage immediately with an oilbinding agent. Dispose of the old oil according to the environmental protection regulations. If the oilsupply system is fitted with threeway cocks, the gear unit can be emptied via these. The remaining residual oil must then be drained off via the oildrain cocks.

Fig. 6:
1 2 3

Oil level, oil drain and breather 4 5 6 Oil level Tilting pad thrust bearing Air filter Gear unit Air filter Tilting pad thrust bearing

Oil drain Gear unit Oil drain Tilting pad thrust bearing Oil level Gear unit

Screw in screw plugs into the oildrain cocks again. Check the condition of the sealing ring (the sealing ring is vulcanised onto the screw plug); if necessary, use a new screw plug. For data such as oil grade, oil viscosity and oil quantity required, refer to the technical data. For oil grades which can be used, see the recommended lubricants in the operating instructions (see information in item 10.12, "Lubricants"). For filling oil into the gear unit the information given in items 7.1.3 and 7.1.4 must be observed.

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10.7.3 Checking tightness of the foundation bolts Foundation bolts of strength class 8.8 to DIN 267 must be tightened in accordance with the values (pretension, tightening torque) given in table 3 (see item 6.4). Damaged bolts must be replaced with new bolts of the same type and strength class. 10.8 General inspection of the gear unit The general inspection of the gear unit should be carried out by the Siemens Customer Service, as our engineers have the experience and training necessary to identify any components requiring replacement. 10.9 Welding work on the mill Siemens will assume no liability for damage caused to the gear unit by welding work carried out on the mill. The gear unit must not be used as an earthing point for welding operations. Before welding work is carried out on the mill, the gear unit must be properly earthed! When carrying out electric welding anywhere on the mill the welding current must not be conducted through the gear unit. The welding current return wire must therefore always be connected direct to the component to be welded. 10.10 Vibration measurements If vibration is measured on a gear unit while it is in operation, care must be taken not to carry out the measurement in the immediate vicinity of rotating parts to avoid accidentally touching the rotating parts.
3V 4V 5H 7H 6H 8H 3V 4V 6H

3H 4H

4H

5H

Fig. 7:
V

Measuring points H Horizontal measuring point

Vertical measuring point

(The measuring points 1 and 2 are located at the bearing points on the motor.). The measuring points specified in figure 7 are standard measuring points. All the gear units of this type in the field are measured at these measuring points. This enables direct comparison with other gear units of the same type and size. A detailed view of the gear unit can be obtained from the drawings in the gearunit documentation. Vibration measurements and their evaluation should be conducted by Siemens personnel and/or in close collaboration with Siemens personnel. In this way experience gained from measurements conducted on comparable bevelgear planetary gear units can be incorporated into the measurement and the evaluation of its results.

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Generally, when measuring vibration, the following should be observed: a) Measure only at the measuring points indicated in the diagram shown above. b) Do not measure on resonance cavities (e.g. fins, inspection covers, pipes, etc.). c) The motor output should also be recorded at the time of measurement, as output fluctuations may result in different measurements. After startup and continuous operation of the entire system a initial measurement should be carried out to obtain the vibration profile of the gear unit. Subsequent measurements at monthly intervals will then enable a trend analysis to be carried out. For assessing the gear unit to DIN ISO 10816 the classification III applies to this machine. With this assessment, however, it must be noted that the axial forces arising from the grinding process are conducted to the foundation via the gearunit housing so that it cannot be ruled out that vibrations are due to the grinding process and are not generated by the gear unit. For this reason DIN ISO 10816 has only limited application for this type of gear unit. Further information about vibration diagnosis is obtainable from: http://www.automation.siemens.com/mcms/mechanical-drives/en/gear-units/service 10.11 Repair Repair comprises all measures for restoring the required condition after faults. When carrying out repair work, especial care must be taken that, when doing electric welding work at any point on the unit, the welding current is not conducted through rolling bearings or other movable connections and measuring equipment. The welding current return wire must therefore be connected direct to the part to be welded. When replacing individual components and other subassemblies, these must be carefully fastened to lifting gear and secured to prevent hazards. Use only suitable, technically faultfree lifting gear and loadbearing equipment with sufficient carrying capacity! Do not stand or work under suspended loads! 10.12 Lubricants The quality of the oil used must meet the requirements of the separately supplied BA 7300 EN operating instructions, otherwise the guarantee given by Siemens will lapse. We urgently recommend using one of the oils listed in BA 7300 EN, because they have been tested and meet the requirements. To avoid misunderstandings, we should like to point out that this recommendation is in no way intended as a guarantee of the quality of the lubricant supplied. Each lubricant manufacturer is responsible for the quality of his own product. Information on the type, quantity and viscosity of the oil is given on the rating plate on the gear unit and/or in the supplied documentation. The quantity of oil indicated on the rating plate is an approximation only. The marks on the oil dipstick or oilsight glass are decisive for the amount of oil to be filled in. The manual containing the current lubricants recommended by Siemens can also be consulted on the internet (see back cover). The oils listed there are subjected to continuous tests. Under certain circumstances the oils recommended there may therefore later be removed from the range or replaced with further developed oils. We recommend regularly checking whether the selected lubricating oil is still recommended by Siemens. If it is not, the brand of oil should be changed.

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11.
11.1

Spare parts, customerservice

Stocking spare parts By stocking the most important spare and wearing parts on site you can ensure that the gear unit is ready for use at any time. To order spare parts, refer to the spareparts list. For further information refer to the spareparts drawing stated in the spare parts list. We guarantee only the original spare parts supplied by us. Nonoriginal spare parts have not been tested or approved by us. They may alter technical characteristics of the gear unit, thereby posing an active or passive risk to safety. Siemens will assume no liability or guarantee for damage caused by spare parts not supplied by Siemens. The same applies to any accessories not supplied by Siemens. Please note that certain components often have special production and supply specifications and that we supply you with spare parts which comply fully with the current state of technical development as well as current legislation. When ordering spare parts, always state the following: Order number, item Type, size Part number Quantity

11.2

Spare parts and customerservice addresses When ordering spare parts or requesting a service specialist, please contact Siemens first (see section 2).

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12.
12.1

Declarations
Declaration of incorporation

Declaration of incorporation
in accordance with Directive 2006/42/EC, Annex II 1 B The manufacturer, Siemens AG, D 46393 Bocholt, declares with regard to the partly completed machinery

Verticalmill gear unit

KMP Sizes 180 to 450
for driving a vertical mill: The special technical documents described in Annex VII B have been prepared. The following basic health and safety requirements set out in Directive 2006/42/EC, Annex I, are applied and are satisfied: 1.1, 1.1.2, 1.1.3, 1.1.5; 1.2.4.4, 1.2.5, 1.2.6; 1.3.1 1.3.4, 1.3.6 1.3.8.1, 1.3.8.2; 1.4.1, 1.4.2.1; 1.5.1, 1.5.2, 1.5.4 - 1.5.11, 1.5.13, 1.5.15, 1.5.16; 1.6.1 1.6.3; 1.7.1 - 1.7.2, 1.7.3 1.7.4.3 The partly completed machinery must not be put into service until it has been established that the machinery into which the partly completed machinery is to be incorporated has been declared in conformity with the provisions of Directive 2006/42/EC, as appropriate. The manufacturer undertakes, in response to a reasoned request by the national authorities, to transmit in electronic form relevant information about the partly completed machinery. The person authorised to compile the relevant technical documentation is: Dr. Nico van de Sandt (Head of Engineering DAE)

Voerde, 20101202 Dr. Nico van de Sandt (Head of Engineering DAE)

Voerde, 20101202

Dr. Bernhard Hoffmann (VicePresident Business Subsegment DA)

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Siemens AG Industry Sector Mechanical Drives Alfred-Flender-Strae 77 46395 Bocholt GERMANY

Subject to modifications Siemens AG 2010

www.siemens.com/drivetechnology