Gearbox installation


Gearbox Installation process:

1. Checking that there are no damages at the gear unit.
2. Checking that the gear unit and the motor name plate, matches the requirements of the machine the unit is to
be installed into.
3. Thoroughly cleaning the gearbox mounting surfaces that are to be used and the shafts of paint and anti-corrosion
agents, using a commercially available solvent. Ensure solvent does not make contact with the oil seals.
4. Fitting of components to either the unit input or output shaft.

The input or output shaft extension diameter tolerance is to ISO tolerance j6 (for shaft diameter =40 mm) and k6
(for shaft diameter >40 mm). Fitted components should be to ISO tolerance K7.
1. cleaning shaft extensions, bores & keys.
2. Items (such as gears, sprockets, couplings etc.) should not be hammered onto these shafts since this would damage
the shaft support bearings.
3. Items being fitted may be heated to 80/100°C to aid assembly.
The gear motor must never be lifted by the lifting eye on the motor alone.

Foot mounted or flange mounted units
1. The base foundation mounting surface is flat1, vibration absorbing and torsionally rigid.
Mounted on the same bedplate as the prime mover.
2. If a chain sprocket is fitted to the output shaft, the direction of pull should be chosen so that the gear housing is pressed
against the foundation.
3. Align unit: It is important to ensure when aligning unit on baseplate that all machined mounting points are supported over
their full area.
If steel packings are used, these should be placed either side of the foundation bolt as close as possible.
During final bolting ensure the unit or baseplate is not distorted as this would cause strains in the gear case resulting in
errors of alignment of shafts and gearing. All mounting points are fully supported and adjust if necessary by using steel packings.
4. Secure unit, or baseplate if fitted, to a rigid foundation using heavy duty bolts to ISO grade 8.8 minimum or Class 8.
1) Maximum permissible flatness error for mounting surface is 0.12 mm.

Screw size:
M4 - 2.8 Nm = 25
M5 - 5.5 Nm = 49
M6 - 10 Nm = 89
M8 - 25 Nm = 221
M10 - 50 Nm = 442
M12 - 85 Nm = 752
M16 - 200 Nm = 1770

The gear housing for BS40-BS71 with a vertical secondary shaft will have separate feet.
When fitting the angle feet for BS40-BS71, locking washers (DIN 6797) must be fitted to the bolts between
the gear housing and the angle feet. When tightened, the gear housing should be pressed against the mating
surface of the feet.

Flange Mounting
When installing with a secondary flange, no stress is exerted on the gear unit when the flange mounting bolts are tightened.

Following the mounting procedure below:
1. Fit the flange or flange adaptor without tightening the bolts.
2. Fit the locking ring for the extra bearing on the shaft.
3. Fix the bearing on the shaft with Loctite 641 or an equivalent before sliding it up against the locking ring.
4. Fit the keys and all locking rings except the outermost locking ring on the shaft.
5. Lubricate the shaft with Molykote BR2 corrosion inhibitor or equivalent before mounting.
6. Fit in the rear locking ring and tighten the bolts to the correct torque.
fit shims between the flange and gear housing. Alignment tolerances must comply with DIN 42955.
7. Fit the connecting ring, if used.

Could you please suggest me that I'm the right way to install the Worm Gearbox Installation process?

Any better idea would be highly appreciated.