Flender Gearboxes

KMP, KMPS, KMPP
FLENDER Gear Units

Vertical-mill gear unit
9180en
Operating Instructions
Edition 10/2016
siemens.com
30.11.2016 16:47
V1.01
Introduction 1
Safety instructions 2
Description 3
Application planning 4
FLENDER Gear Units
9180en 5
Assembly
Commissioning 6
Operating Instructions
Operation 7
Servicing 8
Service & Support 9
Disposal 10
Spare parts 11
Quality documents A
KMP, KMPS, KMPP
Technical data B
Edition 10/2016
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property
damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified
personnel are those who, based on their training and experience, are capable of identifying risks and avoiding
potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended or
approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described.
Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in
this publication is reviewed regularly and any necessary corrections are included in subsequent editions.
Siemens AG Document order number: Copyright © Siemens AG 2016.

Process Industries and Drives Ⓟ 11/2016 Subject to change All rights reserved
Postfach 48 48
90026 NÜRNBERG
GERMANY
Table of contents
1 Introduction...................................................................................................................................................9
1.1 General information..................................................................................................................9
1.2 Lubricants...............................................................................................................................10
2 Safety instructions......................................................................................................................................11
2.1 Security notes........................................................................................................................11
2.2 The five safety rules...............................................................................................................11
2.3 General information................................................................................................................12
2.4 General warnings and symbols..............................................................................................13
2.5 Special types of danger and personal protective equipment.................................................14
2.6 Intended use..........................................................................................................................16
3 Description..................................................................................................................................................19
3.1 General description................................................................................................................19
3.2 Housing..................................................................................................................................19
3.3 Delivered state of the gear unit..............................................................................................21
3.4 Oil supply to the gear unit......................................................................................................21
3.4.1 Hydrodynamic lubrication of tilting pad thrust bearings..........................................................22
3.4.2 Hydrodynamic lubrication of tilting pad thrust bearings on gear units with hydrostatic
starting aid..............................................................................................................................22
3.4.3 Hydrostatic lubrication of tilting pad thrust bearings with radial piston pump.........................22
3.5 Shaft seals.............................................................................................................................23
3.5.1 Labyrinth seals.......................................................................................................................23
3.6 Couplings...............................................................................................................................24
3.7 Heating...................................................................................................................................24
3.8 Oil level indicator....................................................................................................................25
3.9 Oil temperature monitoring.....................................................................................................26
4 Application planning...................................................................................................................................27
4.1 Scope of delivery....................................................................................................................27
4.2 Transport................................................................................................................................27
4.3 Attachment points..................................................................................................................29
4.4 Special aspects of gear unit lubrication and preservation......................................................32
4.4.1 Oil filling and oil drain.............................................................................................................32
4.4.2 Filling with oil..........................................................................................................................32
4.4.3 Draining oil.............................................................................................................................33
4.4.4 Checking the oil level.............................................................................................................34
Vertical-mill gear unit 9180en

Operating Instructions 10/2016 5
Table of contents
4.4.5 Taking oil samples.................................................................................................................34

4.4.6 Preservation...........................................................................................................................34
4.4.6.1 Special aspects of extending the durability of the interior preservation.................................35
4.4.6.2 Sealing cap............................................................................................................................36
4.4.6.3 Extending the durability of the interior preservation by operating the oil supply system........37
5 Assembly....................................................................................................................................................39
5.1 General assembly instructions...............................................................................................39
5.2 Unpacking the gear unit.........................................................................................................40
5.3 Gear unit assembly................................................................................................................41
5.3.1 Foundation.............................................................................................................................41
5.3.2 Description of assembly work................................................................................................42
5.4 Couplings...............................................................................................................................45
5.4.1 Assembling the coupling........................................................................................................45
5.4.2 Aligning the coupling..............................................................................................................47
5.5 Mounting the pipes.................................................................................................................48
5.5.1 Procedure...............................................................................................................................48
5.5.2 Pickling after adaptation.........................................................................................................49
5.6 Installing the motor.................................................................................................................50
5.7 Welding work on the mill........................................................................................................51
5.8 Connecting components........................................................................................................51
5.8.1 Installing further mounted components supplied as separate items......................................51
5.8.2 Making terminal box connections for pre-wired gear units.....................................................52
5.8.3 Gear units with mounted components....................................................................................52
5.8.4 Installing a separate oil supply system...................................................................................53
5.8.5 Electrical connections............................................................................................................53
5.9 Tightening procedure.............................................................................................................54
5.9.1 Introduction............................................................................................................................54
5.9.2 Bolt connection classes..........................................................................................................55
5.9.3 Tightening torques and preload forces...................................................................................55
5.10 Final work...............................................................................................................................57
6 Commissioning...........................................................................................................................................59
6.1 Measures prior to commissioning..........................................................................................59
6.1.1 Rinsing before first commissioning........................................................................................60
6.1.2 Gear unit with oil supply system.............................................................................................60
6.1.3 Checking procedure...............................................................................................................61
6.2 Measures during commissioning............................................................................................62
6.2.1 Initial test run..........................................................................................................................63
6.2.2 Gear units with heating..........................................................................................................63
7 Operation....................................................................................................................................................65
7.1 Operating data.......................................................................................................................65
7.2 Irregularities in operation........................................................................................................65
7.3 Taking the unit out of service.................................................................................................66

6 Operating Instructions 10/2016
Table of contents
8 Servicing.....................................................................................................................................................69
8.1 General maintenance information..........................................................................................69
8.2 Maintenance schedule...........................................................................................................69
8.3 Maintenance and servicing work............................................................................................70
8.3.1 Contamination limits...............................................................................................................71
8.3.2 Servicing................................................................................................................................71
8.3.3 Checking the oil temperature.................................................................................................72
8.3.4 Measuring the vibration levels................................................................................................73
8.3.5 Cleaning the gear unit............................................................................................................74
8.3.6 Cleaning the air filter and replacing the air filter element.......................................................75
8.3.6.1 Cleaning the air filter..............................................................................................................75
8.3.6.2 Replacing the air filter element...............................................................................................75
8.3.7 Cleaning the double change-over filter..................................................................................75
8.3.8 Welding work on the mill........................................................................................................76
8.3.9 General inspection of the gear unit........................................................................................76
8.3.10 Check that all of the fastening bolts are tight.........................................................................76
8.3.11 Final work...............................................................................................................................77
8.4 Possible faults........................................................................................................................77
9 Service & Support.......................................................................................................................................83
10 Disposal......................................................................................................................................................85
11 Spare parts.................................................................................................................................................87
A Quality documents......................................................................................................................................89
A.1 Declaration of Incorporation...................................................................................................89
B Technical data............................................................................................................................................91
B.1 General technical data...........................................................................................................91
B.2 Ambient temperature..............................................................................................................92
B.3 Weights..................................................................................................................................92
B.4 Enveloping surface sound pressure level..............................................................................93
Index...........................................................................................................................................................95
Tables
Table 2-1 Symbols and markings................................................................................................................12

Table 2-2 General warnings........................................................................................................................13
Table 3-1 Information about the specific heat output..................................................................................25
Table 5-1 Information on tightening fastening bolts.....................................................................................55
Table 5-2 Preload forces and tightening torques.........................................................................................56
Table 7-1 Operating data.............................................................................................................................65
Table 8-1 Maintenance and servicing work.................................................................................................69
Table 8-2 Possible faults and their rectification...........................................................................................78

Table of contents
Figures
Figure 3-1 Gear unit preservation equipment...............................................................................................20

Figure 3-2 Arrangement of round cord hollow profile and rotary shaft sealing ring......................................21
Figure 3-3 Labyrinth seal..............................................................................................................................23
Figure 4-1 Transport symbols.......................................................................................................................29
Figure 4-2 Position of the attachment points on a type KMP gear unit.........................................................30
Figure 4-3 Position of alternative attachment points on a type KMP gear unit.............................................30
Figure 4-4 Oil filling locations and oil drain locations....................................................................................32
Figure 5-1 Possible displacements...............................................................................................................47
Figure 5-2 Alignment process based on the example of a flexible coupling.................................................48
Figure 8-1 Measuring points for vibration measurements............................................................................73

Introduction 1
1.1 General information
Purpose of the operating instructions

These operating instructions describe the gear unit and provide information about handling it
- from assembly to maintenance.
Please keep these operating instructions for later use. Please read these operating instructions
prior to handling the gear unit and follow the information in them.
Note
Disclaimer
Please make sure that every person who is commissioned to work on the gear unit has read
and understood these operating instructions prior to handling the gear unit and adheres to all
of the points. Failure to observe these operating instructions can cause product or property
damage or personal injury.
Siemens does not accept any liability for damage or operating failures which are due to non-
adherence to these operating instructions.
The gear unit described in these instructions reflects the state of technical development at the
time these operating instructions went to print.
In the interest of technical advancements, Siemens AG reserves the right to make changes to
the individual components and accessories which are considered necessary for improving their
performance and safety, while maintaining their essential features.
Basic knowledge required

In order to understand these operating instructions, you will need the following general
knowledge about gear units. You will also need a basic understanding of the following topics:
● Application planning
● Assembly
● Commissioning
● Maintenance
Documentation landscape
These operating instructions form part of the delivery of your gear unit.

Introduction
1.2 Lubricants
These operating instructions form part of the complete documentation supplied with the gear
unit. The complete documentation encompasses other documents, including:
● Data sheet
● List of equipment
● Dimension drawing
● Operating instructions for gear unit lubrication and preservation BA 7300
● Operating instructions for mounted components
● Operating instructions for third-party vendor devices
Copyright
The copyright for these operating instructions is held by Siemens AG.
Without the authorisation of Siemens AG, these operating instructions may not be used wholly
or in parts for competitors’ purposes or be given to third parties.
If you have any technical queries, please contact one of our Customer Services addresses
(Page 83).
1.2 Lubricants
The oil used must meet the quality requirements specified in the separately enclosed operating
instructions BA 7300 or else the warranty issued by Siemens will be invalidated. Siemens
strongly recommends use of one of the oils listed in BA 7300 as these have been properly
tested and meet the relevant quality requirements.
In order to avoid any misunderstandings, Siemens wishes to point out that this
recommendation does not constitute an approval in the sense of a guarantee for the quality
of the lubricant obtained from a supplier. Every lubricant manufacturer is required to guarantee
the quality of his/her products.
Information such as oil type, oil viscosity and required oil quantity can be found on the rating
plate of the gear unit and in the documentation supplied with the gear unit.
The oil quantity specified on the rating plate is an approximate value. The actual quantity of
oil required is determined by the marking on the oil dipstick or oil sight glass.
The operating instructions for the current lubricant recommendations of Siemens AG can also
be viewed in the Internet (http://support.automation.siemens.com/WW/view/de/44231658).
The oils listed there undergo continuous testing. As a result, the recommended oil types might
in future be removed from the list or replaced by more advanced oils.
Siemens therefore advises users to check this list regularly to ascertain whether the selected
lubricating oil is still recommended by Siemens. If it is not, another brand of oil should be
selected instead.

Safety instructions 2
2.1 Security notes
Siemens offers products and solutions with industrial security functions, which support the safe
and secure operation of plants, systems, machines and networks.
In order to safeguard plants, systems, machines and networks against cyber threats it is
necessary to implement (and continually maintain) a holistic industrial security concept that
corresponds to the current state of the art. Siemens products and solutions undergo continuous
development in this respect.
Customers are responsible for preventing unauthorised access to their plants, systems,
machines and networks. Systems, machines and components shall only be connected to the
company network or the Internet when and as far as this is absolutely necessary and
appropriate protective measures (e.g. use of firewalls and network segmentation) shall be
taken.
In addition the recommendations of Siemens regarding appropriate protective measures shall
be observed. You can find further information about industrial security at
http://www.siemens.com/industrialsecurity.
Siemens products and solutions undergo continuous development in order to make them even
safer. Siemens expressly recommends that you regularly carry out any updates as soon as
they are available and that you only use the current product versions. Use of older or no longer
supported versions can increase the risk of cyber threats.
To keep yourselves informed of any updates to our products you can register for the Siemens
Industrial Security RSS Feed at:
http://www.siemens.com/industrialsecurity
2.2 The five safety rules

In order to protect yourself and prevent any damage to property, always observe the safety
relevant information and the following five safety rules (as per EN 50110-1 "Working on isolated
equipment") when working on electrical components of the plant.
Prior to starting work on the machine, follow the safety rules listed below:
1. Disconnect
Also disconnect auxiliary circuits such as the anti-condensation heater
2. Safeguard against restart
3. Ensure that the system is de-energised
4. Earth and short circuit
5. Cover or cordon off adjacent live parts
When all the work is complete, cancel the safety measures in the reverse sequence.

Safety instructions
Introduction
All work on the gear unit should be performed with care and only by qualified personnel.
Symbols on the gear unit

The following symbols apply to the gear unit; some of which are found as coloured markings
on the gear unit:
Table 2-1 Symbols and markings
Points labelled on the gear unit Symbol Coloured markings

Earth connection point
Air relief point yellow
Oil filling point yellow
Oil draining point white
Oil level indicator red
Oil level measurement red
Oil overflow
Connection point for vibration monitoring
Lubrication point red
Apply grease
Lifting eye
Eye bolt
Do not unscrew

Safety instructions
2.4 General warnings and symbols
Points labelled on the gear unit Symbol Coloured markings

Alignment surface, horizontal
Alignment surface, vertical
These symbols indicate the oil level check‐

ing procedure using the oil dipstick.
These symbols indicate that the oil dip‐

stick must be firmly screwed in.
2.4 General warnings and symbols

The following table contains general warnings and their associated symbols.
Table 2-2 General warnings
ISO ANSI Warning

Warning - hazardous electrical voltage
Warning - explosive substances
--- Warning - entanglement hazard
--- Warning - hot surfaces
--- Warning - substances that can irritate or which are hazardous to health
--- Warning - caustic substances
--- Warning - suspended load
--- Warning - hand injuries
ATEX certification

Safety instructions
2.5 Special types of danger and personal protective equipment
Requirements
Fulfil the following requirements before commencing work on the gear unit:
● Ensure that the oil pressure lines are depressurised.
● Only perform work on the gear unit when it is not in operation.
● Disconnect electrical systems from the power supply.
DANGER
Electric shock
Live parts can cause electric shock.
Ensure that the entire plant is de-energised before starting electrical installation work.
Protective equipment
Wear the following personal protective equipment when handling the gear unit:
● Safety shoes
● Overalls
● Helmet
● Safety gloves
● Safety goggles
WARNING
Risk of eye injury
Small foreign particles such as sand or dust can enter the cover plates of the rotating parts
and be hurled back by them.
Wear safety goggles.
Dangers during operation

Damage to the gear unit is possible.

Safety instructions
Switch the gear unit to standstill immediately if inexplicable changes are noticed during
operation. Such changes may include unusual gear unit noise or a significant increase in
operating temperature.
WARNING
Risk of falling
There is an increased risk of falling when standing or walking on the gear unit during operation.
Only walk or stand on the gear unit and its mounted components for maintenance and repair
work when it is at a standstill. Do not walk or stand on shaft ends, protection covers, mounted
components or pipes.
WARNING
Danger to life through rotating or moving parts
There is danger that rotating or moving parts may catch hold of you or pull you in.
Secure rotating and/or moving parts against contact using safeguards.
Surface temperature
The surface temperatures of the gear unit can become very extreme depending on the
operating conditions.
WARNING
Risk of burns
Possible risk of serious burn injury from hot surfaces (> 55 °C).
Wear suitable protective gloves and protective clothing.
WARNING
Risk of scalding
Risk of serious injury possible through escaping hot operating media when these are being
changed.
Wear suitable protective gloves, safety goggles and protective clothing.
WARNING
Danger due to low temperatures
Possible risk of serious injuries due to frost (pain, numbness, frostbite) on cold surfaces
(< 0 °C).

Safety instructions
2.6 Intended use
Chemical substances
Injuries can be sustained when using chemical substances.
WARNING
Risk of chemical burns due to chemical substances
There is a risk of chemical burns when handling aggressive cleaning agents.
Please observe the manufacturer's guidelines on how to handle cleaning agents and solvents.
Wear suitable protective equipment (gloves, safety goggles). Please use binding agents to
immediately clear up any spilt solvent.
CAUTION
Risk of injury due to chemically aggressive operating materials
There is a risk of injury to eyes and hands when handling chemically aggressive operating
materials.
Please observe the safety instructions in the data sheets of the oil used. Wear suitable
protective equipment (gloves, safety goggles). Use an oil-binding agent to immediately clean
up spilt oil.
Danger of explosion
An explosion may occur in a potentially explosive atmosphere.
DANGER
Danger of explosion through ignition of a potentially explosive atmosphere
Danger to life through ignition of a potentially explosive atmosphere possible when operating
the gear unit
Do not use the gear unit in potentially explosive atmospheres.
2.6 Intended use

Only use the gear unit according to the conditions specified in the service and delivery contract
and the technical data in the annex (Page 91). Deviating operating conditions are considered
improper use. The user or owner of the machine or plant is solely liable for any resulting
damage.

Safety instructions
2.6 Intended use
When using the gear unit please specifically observe the following:
● Do not make any modifications to the gear unit which go beyond the permissible handling
described in these operating instructions. This also applies to safety features designed to
prevent accidental contact.
● Only ever use original spare parts.
Other spare parts are not tested and approved by Siemens. Non-approved spare parts may
possibly change the design characteristics of the gear unit and thus impair its active or
passive safety.
Siemens will accept no liability or warranty whatsoever for damage occurring as a result of
the use of non-approved spare parts. The same applies to any accessories which were not
supplied by Siemens.
If you have any queries, please contact Customer Services (Page 83).
WARNING
Risk of falling
Risk of possible serious injury through falling.
Only walk or stand on the gear unit for maintenance and repair work when it is at a standstill.
Do not walk or stand on shaft ends, protection covers, mounted components or pipes.
Gear unit use

When using the gear unit, please observe the following basic rules:
● Ensure that the gear unit is operationally safe.
● The gear unit should only be operated, maintained or repaired by authorised, trained and
suitably qualified personnel.
● The relevant work safety and environmental protection regulations must be complied with
at all times during transport, assembly, dismantling, operation, maintenance and servicing.
● The outside of the gear unit must not be cleaned using high-pressure cleaning equipment
or water.
● No welding work must be performed on the gear unit or on parts connected to it. The gear
unit and any parts connected to it must not be used as an earthing point for electric-welding
operations. Gearing and rolling-contact bearings might be irreparably damaged by welding.
● Perform potential equalisation in accordance with the applicable regulations and guidelines.
If no threaded holes are available on the gear unit for an earth connection, please take
suitable measures. This work must always be done by specialist electricians.
● In the case of gear units that are operated in combination with electrical machines that
generate current or through which current flows (e.g. motors and generators), take
measures to ensure that no current can flow through the gear unit.
Current flowing through the gear unit can result in irreparable damage to rolling-contact
bearings and gearing. Short circuits, voltage flashovers and deposits of conductive dust,
for example, can all allow current to flow.
Use insulators and earth the gear unit properly.
When operating the main motor with frequency converter, please pay attention to the
special measures specified in the operating instructions of the frequency converter.

Safety instructions
2.6 Intended use
● When removing any protective devices, retain their fixings safely.

● Removed protective devices must be re-fitted prior to starting up.
● Pay attention to the notices attached to the gear unit such as the rating plate, direction
arrow symbol etc. Notices must not be concealed by paint or dirt. Replace any missing,
illegible or damaged plates.
● Bolts which have been damaged during assembly or disassembly work must be replaced
with new ones of the same strength class and type.
DANGER
Danger to life due to live system
Death or serious injury will occur.
Always shut down the gear unit and any oil supply system (whether separate or mounted on
the gear unit) before you carry out any work. Secure the drive unit against being operated
accidentally as follows:
● Turn off the key-operated switch.
● Remove the fuses in the power supply.
● Attach a notice to the start switch, clearly stating that work is being carried out on the gear
unit.
Ensure that the entire unit is load-free so that no danger is posed when you start to dismantle
components.
Reactivating the gear unit

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

Description 3
3.1 General description
The FLENDER® vertical mill gear unit (referred to below simply as "gear unit") described in
these operating instructions has been developed to drive a vertical mill.
The vertical mill gear units of types KMP/KMPS/KMPP are either bevel helical planetary gear
units or bevel planetary gear units.
The axial and radial forces generated by the crushing process are transferred to the foundation
via the gear unit housing.
NOTICE
Destruction of the gear unit or parts of the gear unit due to incorrect direction of rotation
The gear unit has been approved for only one direction of rotation.
Pay attention to the direction of rotation arrows on the gear unit.
Further information
Further information and a detailed illustrated description of the gear unit can be found in the
drawings in the complete documentation of the gear unit.
3.2 Housing
Introduction
The housing is made of cast iron or steel.
The gear unit housing has the following features:
● Attachment points for moving the gear unit
● Inspection and assembly cover for inspection
● Oil filling point for refilling with oil
● Oil level indicator for checking the oil level
● Oil drain screw or oil drain valve for changing the oil
● Air filter or wet-air filter for ventilation and bleeding

Description
3.2 Housing
Further information
Gear unit equipment

The following diagram shows possible equipment for preservation of the gear unit:
① Sealing cap (depending on the order) ④ Pressure pipe (gear unit)

② Round cord hollow profile ⑤ Suction pipe (gear unit)
③ Pressure pipe (pad bearing compartment)
Figure 3-1 Gear unit preservation equipment
The pipes can be of different design depending on the order. The precise design is specified
in the drawings in the complete documentation of the gear unit.
Further information

Description
3.4 Oil supply to the gear unit
3.3 Delivered state of the gear unit

The following diagram shows sketches of the arrangement of the round cord hollow profile and
the rotary shaft sealing ring.
① Rotary shaft sealing ring ② Round cord hollow profile
Figure 3-2 Arrangement of round cord hollow profile and rotary shaft sealing ring
The input shaft of the gear unit is fitted with a concealed rotary shaft sealing ring that effectively
seals the interior of the delivered gear unit air-tight for the specified preservation period. It is
not necessary to remove the rotary shaft sealing ring when the gear unit is commissioned. The
reliability of the shaft seal will not be affected if the rotary shaft seal is no longer capable of
fulfilling its sealing function after the unit has been commissioned.
A round cord hollow profile is used to provide a seal between the gear unit housing and the
output flange. The round cord hollow profile also acts to seal the interior of the gear unit air-
tight for the specified preservation period.
Opening the gear unit

If you open the gear unit, you must commission it within one week or take measures to restore
its preservation.
The gear unit is deemed to have been opened if one of the following actions is taken:
● Removal of the adhesive tape at the labyrinth seal of the input shaft or the output flange
● Removal of the round cord hollow profile
● Opening of a cover
● Opening of a screw plug

Lubrication and cooling are performed by constant oil circulation by a separate oil supply
system. Expansion joints are fitted in the piping system to suppress vibration and compensate
for thermal expansion.
The lubrication method is specified in the list of equipment drawn up specifically for the order,
in the lubrication diagram and in the separate data sheet.

Description
Toothed components and rolling-contact bearings are forced-lubricated and cooled via the low-
pressure lubrication circuit.
Further information
Additional information and a detailed illustrated description of the gear unit and the oil supply
system can be found in the drawings in the complete gear unit documentation.
Additional information about the oil supply system can be found in the separate data sheet, in
the list of equipment and in the oil supply system operating instructions provided in the
complete gear unit documentation.
3.4.1 Hydrodynamic lubrication of tilting pad thrust bearings

The oil needs to be preheated when ambient temperatures are low. If contractually agreed,
immersion heaters are integrated in the gear unit housing or in the oil tank, or a separate
heating circuit is provided.
The oil is sucked in by the oil pump, cleansed in the double change-over filter (equipped with
visual and electrical contamination indicator), cooled in the cooler and then transferred to the
lubrication points. The oil flow is distributed through valves or orifices to lubricate the gear
wheels and the pad bearing.
The volumetric flow, pressure and temperature are continuously monitored.
3.4.2 Hydrodynamic lubrication of tilting pad thrust bearings on gear units with
hydrostatic starting aid
In addition to hydrodynamic lubrication, part of the oil is fed to the high-pressure pump via a
pipe that branches off directly downstream of the cooler.
The high-pressure pump is a radial piston pump and delivers a constant volume of oil at every
oil connection port. The oil is transferred to four pads distributed around the circumference of
the thrust bearing. Before the mill is started, the oil is pumped between the pads and the race
where it immediately forms a supporting oil film. After a 2-minute period at operating speed,
the high-pressure pump can be shut down.
This operating phase is monitored by pressure switches or pressure transmitters.
3.4.3 Hydrostatic lubrication of tilting pad thrust bearings with radial piston pump
In addition to hydrodynamic lubrication, part of the oil is fed to the high-pressure pumps via a
pipe that branches off directly downstream of the cooler.
To ensure that the high-pressure pumps are running and no pipe is defective, the oil flows are
monitored for minimum and maximum pressure. The pressure depends on the pressing force
actually exerted by the grinding rolls.

Description
3.5 Shaft seals
If the pressure or flow rate in a component subject to pressure or flow monitoring falls below
the minimum value, the main drive is shut down. If the pressure exceeds the maximum limit,
an alarm is issued or the main drive is shut down.
3.5 Shaft seals

Depending on requirements, shaft seals prevent oil from escaping from the gear unit or dirt
from entering the gear unit.
The input shaft and the output flange are sealed by labyrinth seals. Air filters are provided on
the housing to provide pressure equalization.
3.5.1 Labyrinth seals

Labyrinth seals as non-contact seals prevent shaft wear. They do not require any maintenance
and improve the temperature behaviour of the gear unit.
A labyrinth seal is illustrated in the diagram below:
① Labyrinth seal at output flange ② Labyrinth seal at input shaft
Figure 3-3 Labyrinth seal
To work reliably, labyrinth seals must be installed in stationary, horizontal positions without
dirty water or any substantial amount of dust. Overfilling the gear unit can result in leaks, the
same applies to oil with a high foam content.

Description
3.7 Heating
NOTICE
Sparking, inadmissible temperature rise and shaft seal wear due to insufficient gap dimension
An insufficient gap dimension can cause sparking, inadmissible temperature rise and shaft
seal wear.
Ensure that the set gap dimension at the labyrinth seal is not changed when the input and
output elements (e.g. coupling parts) are mounted. Rotating and stationary parts must not
touch.
3.6 Couplings
Flexible couplings are used at the input end of the gear unit.
Further information
You will find further information on the coupling in the operating instructions for the coupling.
3.7 Heating
Introduction
At low ambient temperatures it may be necessary to preheat the gear unit oil before switching
on the drive or while it is in operation.
Heating elements
Heating elements can be used for these applications, for example. Heating elements convert
electricity into heat and transfer this to the oil in which they are immersed. The heating inserts
of the heating elements are installed in protective tubes in the housing so that they can be
replaced without draining off the oil first.

Description
3.8 Oil level indicator
Make sure that the heating elements are fully immersed in the oil bath by mounting the gear
unit in the correct position as shown in the drawings in the complete documentation, and by
keeping the oil topped up to the minimum level.
WARNING
Explosion and fire hazard
Exposed heating elements pose a fire hazard.
Do not switch on the heating elements unless you have checked that they are completely
immersed in the oil bath.
If heating elements are retrofitted, the heat output at the outer surface of the heating element
must not exceed the maximum values stated in the table below.
The following table contains information about the specific heat output PHO as a function of
ambient temperature:
Table 3-1 Information about the specific heat output
PHO in W/cm2 Ambient temperature in °C

0.9 10 to 0
0.8 0 to -25
0.7 -25 to -50
Heating element control

The heating elements can be controlled by a temperature monitor or an Oil temperature
monitoring (Page 26). The temperature monitor provides a signal to be amplified when the
minimum and maximum temperatures are reached.
Further information
Further information about the position of the mounted components and a detailed illustration
of the gear unit can be found in the drawing in the complete documentation of the gear unit.
Further information about heating elements can be found in the separate data sheet, in the list
of equipment and in the heating element operating instructions in the complete documentation
for the gear unit.
Further information about the temperature monitor as well as control instructions can be found
in the list of equipment and the temperature monitor operating instructions in the complete
documentation for the gear unit.
3.8 Oil level indicator

For visual monitoring of the oil level, oil level indicators are mounted on the gear unit.
Check the oil level when the gear unit is stationary and the oil pump of the low-pressure
lubrication circuit of the oil supply system is running.

Description
3.9 Oil temperature monitoring
Further information
You will find further information about the oil level indicator in the operating instructions
BA 7300, which are part of the complete documentation of the gear unit.
Further information and a detailed illustration of the gear unit and the position of the mounted
components can be found in the drawings in the complete documentation of the gear unit.
3.9 Oil temperature monitoring

Depending on the order specification, the gear unit can be fitted with a Pt 100 resistance
thermometer or a temperature monitor for measuring the oil temperature in the oil sump.
To measure temperatures or temperature differences, connect the Pt 100 resistance
thermometer or the temperature monitor to an evaluation unit (to be supplied by the customer).
Further information
Further information and a detailed illustration of the gear unit and the position of the mounted
components can be found in the drawings in the complete documentation of the gear unit.
Further information about oil temperature monitoring (such as control instructions) and the
technical data can be found in the operating instructions for the oil temperature monitor and
in the list of equipment in the complete documentation for the gear unit.

Application planning 4
4.1 Scope of delivery
The scope of delivery is specified in the packing list. Immediately upon receiving the gear unit,
check the completeness of the delivery. The packaging is not allowed to be opened for
checking. Report any damage to the packaging and any missing packages to Customer
Services (Page 83) immediately.
Opening the packaging is considered as changing the packaging and has an effect on the
durability period of the preservation. Follow the instructions in BA 7300 in this regard.
WARNING
Serious injury through defective product
Serious injury may occur.
If the gearbox exhibits any visible damage, you should not put it into operation.
4.2 Transport
General information
The gear unit is delivered fully assembled. Additional items such as shrink disks, couplings,
oil coolers, pipework and valves may be delivered separately packaged, as necessary.
When transporting the gear unit, observe the following instructions to avoid damaging the gear
unit:
● Always use suitable equipment to transport the gear unit.
● Transport the gear unit without oil filling and leave it in the transport packaging.
● Do not use impermissible attachment points. The person responsible for transporting the
unit is also responsible for ensuring that appropriate lifting equipment is selected and
properly used.
The threads in the end faces of the shaft ends may not be used for attaching lifting
equipment.
The output flange of the gear unit must not be lifted.
● Do not use the pipes for moving the gear unit.
● Ensure that the lifting equipment is adequately designed to accommodate the weight of the
gear unit.
● Insert wooden blocks as protectors at points where the transport rope is pulled tight against
the unit to protect the housing, output flange and pipes against damage.

Application planning
4.2 Transport
WARNING
Risk of crushing
There is a risk of being crushed by a component that becomes detached because the hoisting
gear and load suspension device are not suitable for handling it.
When lifting, please observe the load distribution information on the packaging.
When the product is in a raised position, transport it slowly and carefully to avoid injury to
persons or damage to the gear unit.
Attaching the gear unit

To transport the gear unit, only attach slings to the marked attachment points that are provided
for this purpose.
Please observe the following when attaching slings to the load or raising, lowering or moving
it:
● Do not exceed the specified load limits
● If you are using a load suspension device with several load hooks, make sure that the load
is evenly distributed between them
● Note the eccentric centre of gravity
● Make sure that the lifting equipment is securely attached
● Keep your speed down when moving the load
● Do not allow the load to sway and do not attach the load to objects or structures inside the
building
● Loads must not be suspended from the tip of a load hook
● Always place the products down on a level, non-slip and stable base
DANGER
Falling load
There is a risk of fatal injury from falling loads if these have not been securely attached to the
lifting equipment.
Never stand or sit under suspended loads. Do not exceed the load limits of the lifting
equipment.
Packaging
The gear unit is delivered fully assembled. Additional equipment is also delivered separately
packaged, as necessary.
The gear unit may be packed in various forms, depending on the size of the unit and method
of transport.

4.3 Attachment points
Please adhere to the symbols applied on the packaging.
7KLVZD\XS )UDJLOH .HHS .HHS &HQWUHRI 'RQRW $WWDFKKHUH

GU\ FRRO JUDYLW\ XVHKDQGKRRNV
Figure 4-1 Transport symbols
Lifting eyes
Lifting eyes are fitted to the gear unit to assist with its transportation during manufacture and
installation.
Carefully ensure that the angle of the vertical load at the gear units lifting eyes does not exceed
45°.
Transport shackles
Transport shackles are a type of lifting equipment used to lift and connect loads. The transport
shackles are designed to be connected to lifting eyes.
Position of attachment points

If the gear unit foot does not have a lifting lug, use the marked lifting eyes in the ribs.
The diagram below shows the position of the attachment points on a type KMP gear unit as
an example:

Figure 4-2 Position of the attachment points on a type KMP gear unit
The diagram below shows the position of the alternative attachment points on a type KMP
gear unit as an example:

① Wooden block
Figure 4-3 Position of alternative attachment points on a type KMP gear unit

NOTICE
Damage to gear unit due to failure to deflect transport rope
Damage can be caused to the gear unit during transportation if the wrong lifting equipment
is used.
If the gear unit head does not have rope deflectors, insert wooden blocks between the unit
and the rope to prevent damage.
Drive units with additional components mounted on the gear unit (such as drive motor,
coupling, etc.) may require an extra attachment point owing to the displacement in the centre
of gravity caused by the mounted components.
Further information
Further information, a detailed illustration of the gear unit and the position of the attachment
points can be found in the dimension and transport drawings in the complete documentation
of the gear unit.

4.4 Special aspects of gear unit lubrication and preservation
4.4.1 Oil filling and oil drain
The diagram below shows the oil filling points and the oil draining points for the gear unit:

① Venting point (sealing cap) ⑤ Oil level indicator (gear unit)

② Oil drain (pad bearing compartment) ⑥ Oil drain (gear unit)
③ Oil level indicator (pad bearing compartment) ⑦ Venting point (gear unit)
④ Venting point (pad bearing compartment) ⑧ Oil drain (sealing cap)
Figure 4-4 Oil filling locations and oil drain locations
Further information
4.4.2 Filling with oil

Follow the instructions in BA 7300.
Shut down the gear unit and the oil supply system.
Filter the oil to be filled before or during filling with a 25 µm filter.

Fill the oil pumps and all oil filling holes identified with special labels with oil before you start
up the gear unit. Fill the oil in through an oil filling hole provided on the oil pump or pressure
pipe or identified by a label. Close the oil filling holes tight so that the oil pump does not suck
in air and no oil escapes.
Fill the oil circuit of the oil cooling systems with oil. Follow the operating instructions of the oil
supply system.
Fill the gear unit with oil as instructed below depending on how the oil supply system is
equipped:
● If the oil supply system is equipped with three-way valves, use these valves to fill the gear
unit with oil. Alternatively, you can fill the gear unit with oil via the oil drain valve of the pad
bearing compartment.
● If the oil supply system is not equipped with three-way valves, use the oil drain valve of the
pad bearing compartment to fill the gear unit with oil.
● If the oil supply system is equipped with a tank, you can also use this tank to fill the gear
unit with oil. To do this, start the low-pressure pump of the oil supply system temporarily to
ensure that the pad bearing compartment is also filled with oil.
● Fill as much oil into the gear unit as is needed to reach the specified oil level (Page 34).
The approximate oil quantity is indicated in the following places:
– If the oil supply system and the pipes are not included in the scope of delivery, then the
quantity of operating oil required for the gear unit is specified on the rating plate and in
the technical data. For determining the overall quantity of operating oil, please consider
additionally the quantity of oil required for the oil supply system and the pipes.
– If the oil supply system and the pipes are included in the scope of delivery, then the
overall quantity of operating oil required for the gear unit is specified in the layout diagram
and in the technical data in the complete documentation of the gear unit.
When the oil supply system is switched off, its oil level is often higher than when it is switched
on because oil can flow back out of the pipes and hoses. Switch the oil supply system on
and off repeatedly until the oil level is correct.
Further information
4.4.3 Draining oil

In addition to the oil draining points given in chapter Oil filling and oil drain (Page 32), use the
existing residual oil draining plugs. You can find them in the drawings, which are part of the
complete documentation of the gear unit.
If the oil supply system is equipped with three-way valves, you can use these valves as an
alternative method of draining oil out of the gear unit. Drain off the remaining oil through the
oil drainage valves. If necessary, use new screw plugs.

Further information
4.4.4 Checking the oil level

Check the oil level when the gear unit is stationary and the oil pump of the low-pressure
lubrication circuit of the oil supply system is running.
The correct oil level is indicated by minimum and maximum markings on the oil level indicator
of the main gear unit, the pad bearing compartment and on the oil supply system (on systems
with tank). Hot oil can easily exceed the MAX mark on the oil level indicator.
Further information
Further information can be found in the oil supply system operating instructions in the complete
Further information about checking the oil level can be found in the operating instructions
BA 7300 in the complete documentation for the gear unit.
4.4.5 Taking oil samples

As an alternative to changing the oil (Page 69) at fixed intervals, you can arrange for the
technical services of the oil manufacturer to examine an oil sample regularly every 3 months,
and approve the oil for further use. In this case the oil manufacturer guarantees that the
properties of the oil will comply with Siemens’ specifications.
4.4.6 Preservation
Introduction
The operating instructions BA 7300 describe the standard procedures for preserving gear units
and oil supply systems. Follow these instructions whenever you take measures to preserve
the gear unit.
As an alternative, you can also extend the durability of the interior preservation of the gear unit
by operating the oil supply system (Page 37).
Special aspects of and deviations from the standard preservation procedures are described
in this chapter.

4.4.6.1 Special aspects of extending the durability of the interior preservation
Introduction
Please observe the special aspects and deviations from the instructions in BA 7300 with
respect to extending the durability of the interior preservation.
Improper use can damage the gear unit. Be sure to take the following precautions:
● Remove the coupling if necessary.
● Use a sealing cap (Page 36) to seal the input shaft.
● Use dummy flanges to seal the pressure, suction and return pipes.
● Use a screw plug to seal the oil drain valve at the pad bearing compartment.
● Seal the gear unit by means of a round cord hollow profile between the gear unit housing
and the output flange and tape over the labyrinth seal to seal it air-tight.
The round cord hollow profile can be purchased from Siemens.
Procedure for extending the durability of the interior preservation through oil filling
To extend the durability of the interior preservation through oil filling, proceed as follows:
1. Use a screw plug to seal the lower oil drain of the sealing cap.
2. If necessary, replace the air filter at the venting point of the gear unit by a screw plug. The
air filter will be required when the unit is restarted.
3. If necessary, remove the screw plug from the venting point at the pad bearing compartment.
4. Fill the sealing cap with oil via the venting point at the cap.
Filter the oil before or during filling with a 25 µm filter.
5. When closing the venting point at the sealing cap, note the following:
– If oil escapes from the venting point as the gear unit is being filled, close the venting
point.
– If no oil escapes from the venting point as the gear unit is being filled, do not close the
venting point until the gear unit has been filled with oil.
6. Remove the screw plug from the lower oil drain valve of the gear unit if necessary.
7. Using a pump, fill the gear unit with oil via the lower oil drain valve on the unit until the oil
level indicator at the pad bearing compartment is full of oil.
Filter the oil before or during filling with a 25 µm filter.
8. Use a screw plug to seal the venting point at the pad bearing compartment. Remove the
air filter beforehand if necessary. The air filter will be required when the unit is restarted.
9. Use a screw plug to seal the lower oil drain valve of the gear unit.

Procedure for extending the durability of the interior preservation using Castrol Corrosion Inhibitor N
213
To extend the durability of the interior preservation using Castrol Corrosion Inhibitor N 213,
proceed as follows:
1. Use screw plugs to seal the oil drain and the venting point of the sealing cap.
2. Seal the lower oil drain valve of the gear unit.
3. Remove the screw plugs or air filters from the venting points of the gear unit and pad bearing
compartment.
4. Fill the gear unit via the venting points on the gear unit and the pad bearing compartment
with Castrol Corrosion Inhibitor N 213. The required quantity of Castrol Corrosion
Inhibitor N 213 is specified in operating instructions BA 7300. Fill one half of this quantity
into the gear unit, and the other half into the pad bearing compartment.
5. Use screw plugs to seal the venting points on the gear unit and pad bearing compartment.
The air filters will be required when the unit is restarted.
NOTICE
Damage to the gear unit
Damage to the gear unit is possible due to impaired corrosion protection as a result of turning
the input shaft.
Do not turn the input shaft of the gear unit
Result
The durability period of the interior preservation of the gear unit is extended.
The precise durability period is stated in operating instructions BA 7300.
4.4.6.2 Sealing cap

The sealing cap is designed to seal the input shaft while preservative is filled into the interior
of the gear unit and is mounted on the gear unit. The sealing cap is not included in the scope
of delivery as standard but can be purchased from Siemens depending on the order.
The sealing cap has the following ports:
● Venting point
● Oil drain

4.4.6.3 Extending the durability of the interior preservation by operating the oil supply system
Requirements
The following requirements must be fulfilled in order to extend the durability of the interior
preservation by operating the oil supply system:
● The gear unit is installed in the mill.
● The gear unit is connected to the oil supply system.
Preservative oil
You can use the following preservative oils in order to extend the interior preservation by
operating the oil supply system:
● Castrol Alpha SP 220 S
● Castrol Optigear Synthetic 1390/220 (formerly Castrol Tribol 1390/220)
Procedure
To extend the durability of the interior preservation by operating the oil supply system, proceed
as follows:
1. If necessary, drain off old preservative or operating oil.
2. Fill the gear unit with the preservative oil.
3. Ensure that the oil reaches the specified level (Page 34).
4. Switch on the oil supply system and turn the gear unit under no load (at least one rotation
at the output).
5. Drain off the preservative oil.
6. Seal the gear unit and the oil supply system so that they are air-tight.
7. Replace the air filters with screw plugs and seal the plugs. The air filters will be required
when the unit is restarted.
8. Seal the gear unit by means of a round cord hollow profile between the gear unit housing
and the output flange.
The round cord hollow profile can be purchased from Siemens.
9. Tape over the labyrinth seals at the input shaft and the output flange to make them air-tight
within one hour.
Result
The durability period of the interior preservation of the gear unit is extended.
The precise durability period is stated in operating instructions BA 7300.

Further information
Additional information about the oil supply system can be found in the separate data sheet, in
the list of equipment and in the oil supply system operating instructions provided in the
complete gear unit documentation.
Further information about preservation can be found in the operating instructions BA 7300 in
the complete documentation for the gear unit.

Assembly 5
5.1 General assembly instructions
The assembly work must be performed very carefully by authorised, trained and suitably
instructed personnel. Liability will be disclaimed for damage caused by the incorrect
performance of this work.
Requirements
● Protect the gear unit against falling objects and from becoming covered over.
● Do not perform any welding work anywhere on the drive.
● Do not use the gear unit as an earthing point for electric-welding operations.
● Use all of the fastening points fitted to the particular unit design.
● Replace any bolts that are no longer fit for use by new bolts of the same strength class and
type.
● Make sure that sufficient hoisting gear is available.
● When installing the gear unit in the vertical mill, follow the special instructions of the mill
manufacturer.
● Do not remove the adhesive tapes from the labyrinth seals and the round cord hollow profile
between the gear unit housing and the output flange until shortly before commissioning.
Mounting position and attachment points

During the actual planning phase, be sure to allow for sufficient space around the gear unit to
enable subsequent upkeep and maintenance work. It must be possible to inspect the internal
components through the inspection cover openings. Take suitable measures to ensure that
unhindered convection across the housing surface is possible so that the gear unit does not
overheat.
Do not use impermissible attachment points (Page 29). The position of the attachment points
can be found in the dimension and transport drawings in the complete documentation of the
gear unit. To ensure that the unit is properly lubricated during operation, please observe the
mounting position specified in the dimension drawing.

Assembly
5.2 Unpacking the gear unit
NOTICE
Heating of the gear unit by external heat sources
The gear unit must not be heated by external heat sources (exposure to direct sunlight, for
example) while it is in operation and measures must be taken where necessary to protect it.
You can take the following measures to protect the gear unit against this hazard:
● A sun shield
● An additional cooling device
● A temperature monitoring device with trip function in the oil sump
If you use a sun shield, this may cause a build-up of heat.

If you use a temperature monitoring device, it must be capable of issuing an alarm when the
maximum permissible oil sump temperature is reached. It must also be capable of tripping the
drive when the maximum permissible oil sump temperature is exceeded. The operator's
process might be interrupted when the drive is shut down.
WARNING
Ignition of vapours emitted from solvents.
There is a risk of injury due to ignition of vapours emitted from solvents when carrying out
cleaning work.
Please note the following:
● Ensure adequate ventilation.
● Do not smoke.
● Keep the solvents away from ignition sources.
5.2 Unpacking the gear unit
Introduction
The scope of delivery is listed in the shipping documents.
WARNING
Risk of serious injury due to defective product
A defective gear unit can result in serious injury.
Do not put the gear unit into operation if any damage is visible.
Contact Customer Services (Page 83).

Assembly
5.3 Gear unit assembly
Requirements
Check that everything has been delivered immediately upon receipt.
NOTICE
Damage to the gear unit due to corrosion
Exposing the gear unit to moisture can result in damage from corrosion.
Do not damage or open the packaging prematurely if the packaging is designed to preserve
the unit.
Procedure
To unpack and use the gear unit, proceed as follows:
1. Remove packaging and transport devices in accordance with regulations.
2. Perform a visual inspection for damage and accumulations of dirt.
3. Immediately report any damaged and/or missing parts to Customer Services (Page 83).
4. Dispose of packaging material and transport devices in accordance with regulations.
5.3.1 Foundation
Properties of the foundation

The foundation must have the following properties:
● Flat
● Secure
● Free of vibration
● Rigid
Requirements of the foundation

The foundation must meet the following requirements:
● Construct the foundation in such a way that it does not generate any resonance vibrations
and that it is isolated against the transmission of vibrations from adjacent foundations.
● Design the foundation according to the relevant weight and torque, taking into account the
forces acting on the gear unit.

Assembly
● Align the foundation carefully with the equipment installed on the input and output sides of
the gear unit.
● Take into account any elastic deformation that may be caused by operating forces.
● Install lateral stops to prevent displacement if external forces are acting on the gear unit.
NOTICE
Poor stability
Damage to the gear unit is possible if it is not mounted on a stable foundation.
Make sure that the foundation on which the gear unit is mounted is flat, stable, vibration-free
and rigid.
It is particularly important that the surface on which the gear unit is mounted is level because
this determines the contact pattern of the teeth as well as the contact pattern of the tilting pad
thrust bearings, and so has an influence on the service life of the gear unit. Clean the mounting
surfaces of the gear unit and foundation.
All points on the gear unit mounting surface must lie between two imaginary parallel planes
that are 0.1 mm per 500 mm apart. The permissible deviation of the gear unit mounting surface
from the horizontal plane is 0.2 mm per 1000 mm.
Document the levelness of the installed baseplate (gear unit mounting surface) before installing
the gear unit.
Keep the report in a safe place together with these operating instructions.
The mill manufacturer is responsible for the foundation structure and the bolted connections
between the gear unit and foundation.
Further information
Further information about dimensions, space requirements and arrangement of supply
connections can be found in the drawings in the complete documentation of the gear unit.
5.3.2 Description of assembly work
Measures to be taken prior to assembly
CAUTION
There is a risk of chemical burns when handling aggressive cleaning agents.
Please observe the manufacturer's guidelines on how to handle cleaning agents and solvents.
Wear suitable protective equipment (gloves, safety goggles). Please use binding agents to
immediately clear up any spilt solvent.

Assembly
● Use a suitable cleaning agent to remove the corrosion protection from the shafts and
mounting surfaces.
● Do not allow the cleaning agent to come into contact with the shaft-sealing rings.
● Use an assembly fixture (retractor) if required to mount the input elements (e.g. coupling
components) onto the shafts and lock them securely. See chapter Couplings (Page 45).
● Use suitable hoisting gear to place the gear unit in position.
Further information
Further information about removing the corrosion protection can be found in the operating
instructions BA 7300 in the complete documentation for the gear unit.
Additional information on how gear units should be attached which, as a result of their weight,
require a crane or lifting gear, is provided in chapter Application planning (Page 27).
If the gear unit is to be transported with mounted parts and components, then it may be
necessary to use additional attachment points. The position of these attachment points can
be found in the dimensional and transport drawings in the complete documentation of the gear
unit.
Requirement
Follow the special instructions issued by the mill manufacturer when installing the gear unit in
the vertical mill.
Procedure
To install the gear unit on a foundation, proceed as follows:
1. Fit the foot fastening bolts in accordance with the mill manufacturer's instructions.
Note the separate operating instructions if you are using clamping nuts.
2. Tighten the foot fastening bolts with the specified tightening torque (Page 54).
If necessary, install stops to prevent displacement.
3. Align the gear unit precisely with the input and output equipment.
4. Mount the specified pins (if provided).
5. Record the alignment dimensions.
6. Keep the report in a safe place together with these operating instructions.

Assembly
NOTICE
Destruction of the gear unit or parts of the gear unit due to incorrect direction of rotation
The gear unit or parts of the gear unit can sustain irreparable damage if the gear unit is rotated
in the wrong direction.
The gear unit has been approved for only one direction of rotation.
Ensure that the direction of rotation of the motor matches the direction of rotation arrow
marked on the input shaft of the gear unit.
NOTICE
Damage to the plain bearings
The plain bearings can sustain damage.
The input shaft of the gear unit may be turned by a maximum of 1 rotation at the output for
positioning purposes during assembly of the gear unit if the pad bearing compartment is filled
with oil up to the level required for normal operation.

Assembly
5.4 Couplings
5.4 Couplings
Introduction
● If necessary, carry out the following preparatory work in accordance with the operating
instructions for the coupling:
– Machine the finished bore
– Mill the parallel keyway
– Fit the axial locking element
– Balance
● Align the individual components precisely with one another.
● Refer to the operating instructions for the coupling for instructions on how to install, maintain
and operate the coupling.
WARNING
Danger of injury due to coupling rupture
Flying fragments can cause fatal injury.
Observe the operating instructions for the couplings.
NOTICE
Serious or irreparable damage to the gear unit and coupling caused by inaccurate or
incorrect alignment
Failure to accurately or correctly align the gear unit and coupling may result in serious or
irreparable damage to both components.
Align the individual components precisely with one another when installing the drives.
Make sure that the maximum permissible displacement values are not exceeded during
operation.
Further information
Further information about the coupling can be found in the operating instructions for the
coupling in the complete documentation for the gear unit.
5.4.1 Assembling the coupling
Introduction
The method used to assemble the coupling varies according to type. The procedure described
in these operating instructions is general rather than specific to one type of coupling.

Assembly
5.4 Couplings
Assemble the coupling as described in the operating instructions for the specific coupling.
● Do not use force (hammer blows, etc.) to fit the coupling parts as this can cause internal
damage to the gear unit.
● Take care not to damage the shaft sealing rings or shaft running surfaces when fitting the
coupling parts.
Procedure
To fit the coupling, proceed as follows:
1. Carefully clean the shaft ends and the coupling parts.
2. Use a suitable fixture to mount the coupling parts on the shaft ends.
3. Lock the coupling parts to prevent axial displacement.
4. Move the machines to be coupled close to one another and thenalign them (Page 47).
5. Join the coupling parts together.
Heating coupling parts prior to mounting

Depending on the order specification, it may be necessary to heat the coupling parts before
mounting them.
WARNING
Risk of burns
Possible risk of serious burn injury from hot surfaces (> 55 °C).
● The required joining temperatures can be found in the dimension drawings in the operating
instructions for the coupling
● Unless otherwise instructed, heat the coupling parts by an induction heater, with a torch or
in an oven.
● Use heat shields designed to protect against radiant heat in order to safeguard the shaft
sealing rings against damage or heating to above 100 °C.
● Quickly fit the coupling parts on the shafts. The mounting dimensions can be found in the
dimension drawings in the operating instructions for the coupling.
Further information
Further information about the coupling can be found in the operating instructions for the
coupling in the complete documentation for the gear unit.

Assembly
5.4 Couplings
5.4.2 Aligning the coupling
Introduction
The coupling parts might become misaligned as a result of:
● Failure to accurately align the parts during assembly
● During operation:
– Due to thermal expansion
– Due to shaft deflection
– Due to machine frames that are too soft
Improper use can damage the gear unit or the coupling. Be sure to take the following
precautions:
● Make sure that the maximum permissible displacement values are not exceeded during
operation.
– If you are using couplings supplied by Siemens, you will find the maximum permissible
displacement values in the operating instructions for the coupling.
– If you are using couplings supplied by other manufacturers, contact them and ask them
for the maximum permissible displacement values, making sure that you specify the
potential radial loads for your application. Keep the operating instructions for the
coupling together with these operating instructions.
● Angular and radial displacement might occur simultaneously.
Make sure that the total value of both displacements does not exceed the maximum
permissible angular or radial displacement value.
The diagram below illustrates the potential displacements:
˂.D
˂.Z
˂.U
$[LDOGLVSODFHPHQW $QJXODUGLVSODFHPHQW 5DGLDOGLVSODFHPHQW

˂.D ˂.Z ˂.U
Figure 5-1 Possible displacements
Alignment
Align the individual components in two mutually perpendicular axial planes. The following can
be used as alignment tools:
● Ruler (radial displacement)
● Feeler gauge (angular displacement)
● Spirit level

Assembly
5.5 Mounting the pipes
● Dial gauge
● Laser alignment system
You will achieve a greater degree of alignment accuracy by using a dial gauge or laser
alignment system.
The diagram below shows the alignment process based on the example of a flexible coupling:

① Ruler ③ Measuring points

② Feeler gauge
Figure 5-2 Alignment process based on the example of a flexible coupling
Further information
Further information about the permissible alignment errors can be found in the coupling
operating instructions in the complete documentation for the gear unit, or contact the
manufacturer in question.
5.5.1 Procedure
To mount the pipes, proceed as follows:
1. Inspect the pipes for damage and soiling.
2. Carefully clean the piping and purge the piping using low viscosity oil.
3. Remove the dummy flange and plugs.
4. Screw on the pipes according to the layout diagram.
The pipe glands seal metallically. Use the appropriate seals for the flanges.

Assembly
NOTICE
Tensioning the pipes
The gear unit can be damaged if the pipes are installed so that they are under tension.
Make sure that the pipes are installed free of mechanical stress. Support the pipes on supports
as shown in the layout diagram included in the complete documentation of the gear unit.
5.5.2 Pickling after adaptation
Introduction
If the pipes are adapted on site, you must pickle the pipes carefully after welding.
Procedure
CAUTION
There is a risk of chemical burns when handling acids.
Carefully observe the manufacturer's information when handling acids. Wear suitable
protective clothing. Clean up any spilt acid immediately with a binding agent.
Proceed as follows to pickle the pipes after adaptation:

1. Close and seal off the lower end of the pipes using a suitable plug.
2. To prepare the picking solution, dilute HCl (33 % HCl) with the same quantity of water (H2O).
3. Fill the pipes with the pickling solution.
Allow the pickling solution to work for 1 hour. Make sure that no air bubbles form inside the
pipes.
4. Drain all of the pickling solution out of the pipes and dispose of it in accordance with
regulations.
5. Then flush out the pipes using an adequate amount of water.
6. After you have emptied the pipes, you must fill them with a neutralisation solution (3 % to
5 % NaOH).
The neutralisation solution should act for 15 minutes.
7. Then flush out the pipes again using water.
8. Then thoroughly flush out the pipes using flushing oil through a 25 μm (0.001 inch) filter.

Assembly
5.6 Installing the motor
Note
Preserving the pipes
If the pipes are not mounted immediately, preserve them thoroughly.
5.6 Installing the motor
DANGER
Risk of fatal injury from flying fragments
Failure to align the unit with the required degree of accuracy can cause the shaft to rupture.
A ruptured shaft can result in serious or even fatal injuries.
Align the gear unit exactly so that it conforms to the specified alignment values.
Damage to the gear unit or its components or mounted parts is possible.
The accuracy of the alignment between the shaft axes largely determines the service life of
the shafts, rolling-contact bearings and couplings. As a consequence, always try to achieve
a zero deviation. In this context, please also refer to the relevant operating instructions for
further information about, for example, the requirements of couplings.
Procedure
To install the motor, proceed as follows:
1. Follow the motor manufacturer's operating instructions.
2. Align the drive motor together with the coupling along the centre axis of the gear unit input
shaft and secure the motor in position.
3. Record the alignment dimensions.
4. Keep the report in a safe place together with these operating instructions.

Assembly
5.8 Connecting components
5.7 Welding work on the mill

Siemens provides no warranty for damage to the gear unit originally caused by welding work
on the mill.
DANGER
Risk of injury due to electric shock
Injuries as a result of electric shock can occur when welding equipment is used.
Perform potential equalisation in accordance with the applicable regulations and guidelines
before any welding work is carried out on the mill.
The gear unit and any parts connected to it must not be used as an earthing point for electric-
welding operations.
The pad bearing compartment can be optionally fitted with an earth cable that must be
connected to the output flange. Connect the earth cable to the tapped holes on the side of
the output flange. When the welding work is complete, detach the earth cable from the output
flange.
If no tapped holes are available on the gear unit for an earth connection, please take suitable
alternative measures. This work must always be done by specialist electricians.
When electric welding is carried out anywhere on the mill, the welding current must not be
conducted through the gear unit. For this reason, the welding current return cable must always
be directly connected to the component to be welded.
5.8.1 Installing further mounted components supplied as separate items
Procedure
To install further mounted components that are supplied as separate items, proceed as follows:
1. Seal all loose parts having a threaded connection with liquid sealant.
2. Install any pipe fittings supplied as separate items whose tapped holes are sealed with
sealing plugs as shown in the drawings supplied.
3. Connect electrical monitoring devices as shown in the terminal diagrams, lists of equipment
and special operating instructions.

Assembly
NOTICE
Potential damage to the gear unit due to incompatibility of operating oil and sealant.
Ensure that no sealant can get into the gear unit.
Further information
You will find further information on the electrical monitoring devices in the operating instructions
for the electrical monitoring devices, which are part of the complete documentation of the gear
unit.
You will find further information and technical data for the mounted components in the list of
equipment drawn up specifically for the order, which is part of the complete documentation of
the gear unit.
You will find further information, terminal diagrams and lists of equipment, which are part of
the complete documentation of the gear unit.
5.8.2 Making terminal box connections for pre-wired gear units

Connect up all pre-wired gear units as shown on the circuit diagram in the terminal box.
WARNING
Explosion and fire hazard
Exposed heating elements pose a fire hazard.
Do not put heating elements into service until you have checked that they are completely
Further information
You can find further information about pre-wired gear units in the order-specific list of
equipment in the complete gear unit documentation.
5.8.3 Gear units with mounted components

Depending on the order specification, the gear unit can be equipped with various components.
Connect the closed-loop control and open-loop control electrical devices corresponding to the
specifications of the device supplier.

Assembly
Further information
You can find additional information on operation and maintenance in the associated operating
instructions, provided in the complete gear unit documentation.
You can find the technical data of the mounted components in the contract-list of equipment
provided in the complete gear unit documentation.
5.8.4 Installing a separate oil supply system
Procedure
To connect the oil supply system to the gear unit, proceed as follows:
1. Remove the dummy flange from the suction and delivery line before connecting the system.
2. Connect the system to the gear unit as shown in the layout diagram in the complete
documentation and install the system separately.
3. When installing the system, make sure that the pipework is not subjected to mechanical
stresses.
Further information
Further information about the oil supply system can be found in the oil supply system operating
instructions in the complete documentation for the gear unit.
5.8.5 Electrical connections
Requirements
Do not use any motor that exceeds the specified speeds of the gear unit as otherwise the gear
unit may become damaged. The speeds are displayed on the rating plate.
● Before connecting the motor, determine the phase sequence of the three-phase power
system using a phase-sequence indicator.
● Connect the motor corresponding to the predefined direction of rotation.

Assembly
5.9 Tightening procedure
Procedure
DANGER
Electric shock
Live parts can cause electric shock.
Ensure that the entire plant is de-energised before starting electrical installation work.
Carefully observe the five safety rules (Page 11).
To connect the motors and monitoring devices, proceed as follows:

1. Ensure that the connections of the motors and monitoring devices are not damaged.
2. Connect up the motors and monitoring devices according to the terminal diagram and the
relevant operating instructions.
3. Insulate all cable entry points (glands) at electrical equipment as required for the
environment in which the equipment will operate.
Further information
You can find additional information about the electrical connections in the terminal diagrams
and equipment lists provided in the complete gear unit documentation.
5.9.1 Introduction
Bolts
The bolts must have the following properties:
● Made of steel (as per the specified strength class)
● Black-annealed or phosphatised
● Lightly oiled (do not add additional oil)
Note
Replacing bolts
Replace any bolts that are no longer fit for use by bolts of the same type and strength class.

Assembly
Mating threads
The mating threads must have the following properties:
● Made of steel or cast iron
● Dry, cut threads
Note
Using a lubricant
As a rule, lubricants may not be used, because this can result in the bolt connection becoming
overloaded.
5.9.2 Bolt connection classes

In order to affix fastening bolts, note the information in the following table:
Table 5-1 Information on tightening fastening bolts
Mounting Bolt connection Scatter of the tor‐ Tightening procedure

class que emitted on the
tool
D ± 10 % to ± 20 % ● Torque-controlled tightening with
mechanical screwdriver
Inspection cover E ± 20 % to ± 50 % ● Tightening with pulse
Protection cover screwdriver or impact wrench,
without adjustment checking
device
● Tightening by hand, using a
wrench without torque
measuring device
Further information
You can find additional information about tightening torques when mounting motor and brake
in the operating instructions from the particular manufacturer.
5.9.3 Tightening torques and preload forces

If the drawings do not specify any tightening torques or preload forces, refer to the following
table for the tightening torques. Comply with the tightening torques specifically mentioned in
the production and assembly drawing when carrying out the servicing work.
The tightening torques apply to friction values of μtotal = 0.14.

Assembly
The following table lists the preload forces and tightening torques for bolt connections, strength
classes 8.8; 10.9; 12.9:
Table 5-2 Preload forces and tightening torques
Nominal Bolt Preload force for bolt connection Tightening torque for bolt connection
thread di‐ strength classes from the table in chapter classes from the table in chapter Bolt
ameter class Bolt connection classes (Page 55) connection classes (Page 55)
d C D E C D E
mm FM min. MA
N Nm
M10 8.8 18 000 11 500 7 200 44.6 38.4 34.3
10.9 26 400 16 900 10 600 65.4 56.4 50.4
12.9 30 900 19 800 12 400 76.5 66.0 58.9
M12 8.8 26 300 16 800 10 500 76.7 66.1 59.0
10.9 38 600 24 700 15 400 113 97.1 86.6
12.9 45 100 28 900 18 100 132 114 101
M16 8.8 49 300 31 600 19 800 186 160 143
10.9 72 500 46 400 29 000 273 235 210
12.9 85 000 54 400 34 000 320 276 246
M20 8.8 77 000 49 200 30 800 364 313 280
10.9 110 000 70 400 44 000 520 450 400
12.9 129 000 82 400 51 500 609 525 468
M24 8.8 109 000 69 600 43 500 614 530 470
10.9 155 000 99 200 62 000 875 755 675
12.9 181 000 116 000 72 500 1 020 880 790
M30 8.8 170 000 109 000 68 000 1 210 1 040 930
10.9 243 000 155 000 97 000 1 720 1 480 1 330
12.9 284 000 182 000 114 000 2 010 1 740 1 550
M36 8.8 246 000 157 000 98 300 2 080 1 790 1 600
10.9 350 000 224 000 140 000 2 960 2 550 2 280
12.9 409 000 262 000 164 000 3 460 2 980 2 670
M42 8.8 331 000 212 000 132 000 3 260 2 810 2 510
10.9 471 000 301 000 188 000 4 640 4 000 3 750
12.9 551 000 352 000 220 000 5 430 4 680 4 180
M48 8.8 421 000 269 000 168 000 4 750 4 090 3 650
10.9 599 000 383 000 240 000 6 760 5 820 5 200
12.9 700 000 448 000 280 000 7 900 6 810 6 080
M56 8.8 568 000 363 000 227 000 7 430 6 400 5 710
10.9 806 000 516 000 323 000 10 500 9 090 8 120
12.9 944 000 604 000 378 000 12 300 10 600 9 500
M64 8.8 744 000 476 000 298 000 11 000 9 480 8 460
10.9 1 060 000 676 000 423 000 15 600 13 500 12 000
12.9 1 240 000 792 000 495 000 18 300 15 800 14 100

Assembly
5.10 Final work
Nominal Bolt Preload force for bolt connection Tightening torque for bolt connection
thread di‐ strength classes from the table in chapter classes from the table in chapter Bolt
ameter class Bolt connection classes (Page 55) connection classes (Page 55)
d C D E C D E
mm FM min. MA
N Nm
M72x6 8.8 944 000 604 000 378 000 15 500 13 400 11 900
10.9 1 340 000 856 000 535 000 22 000 18 900 16 900
12.9 1 570 000 1 000 000 628 000 25 800 22 200 19 800
M80x6 8.8 1 190 000 760 000 475 000 21 500 18 500 16 500
10.9 1 690 000 1 100 000 675 000 30 500 26 400 23 400
12.9 1 980 000 1 360 000 790 000 35 700 31 400 27 400
M90x6 8.8 1 510 000 968 000 605 000 30 600 26 300 23 500
10.9 2 150 000 1 380 000 860 000 43 500 37 500 33 400
12.9 2 520 000 1 600 000 1 010 000 51 000 43 800 39 200
M100x6 8.8 1 880 000 1 200 000 750 000 42 100 36 200 32 300
10.9 2 670 000 1 710 000 1 070 000 60 000 51 600 46 100
12.9 3 130 000 2 000 000 1 250 000 70 000 60 400 53 900
5.10 Final work
Measures
Once all the elements have been assembled or connected, perform the following final work:
● Check whether all devices dismantled for transportation have been reassembled.
● Check all bolt connections for tightness after installation of the gear unit has been
completed.
● Check the alignment after tightening the fastening elements. The alignment must not have
changed in any way.
● Lock the oil drain valves against accidental opening.
● Protect the gear unit against falling objects.
● Check that the guards over rotating parts are securely fastened.
Contact (accidental or deliberate) with rotating parts is not permitted.
● Perform potential equalisation in accordance with the applicable regulations and guidelines.
If no threaded holes are available on the gear unit for an earth connection, please take
suitable alternative measures. This work must always be done by specialist electricians.
● Protect the cable entries against penetrating moisture.

Assembly
5.10 Final work
Further information
You will find further information about the gear unit and all mounted or separately supplied
components in the operating instructions of the relevant components included in the complete
You can find additional technical specifications in the separate data sheet in the complete gear
unit documentation.

Commissioning 6
Introduction
The precondition for the warranty is first commissioning by specialists from Siemens or by
skilled persons who have been appropriately trained and are authorised by Siemens.
Siemens urgently recommends that the vertical mill is first driven by the gear unit under the
supervision of these specialists or skilled persons.
Follow the operating instructions, particularly with regard to maintenance work on the vertical
mill, during which the mill rotates and the gear unit rotates with it.
NOTICE
Every time the drive is set in motion represents a commissioning process. Do not commission
the gear unit without having the operating instructions at hand.
During commissioning, start up the gear unit in the load-free condition and without milled
material or roller pressure.
Adjust the sealing air seal if one is fitted.
6.1 Measures prior to commissioning

Take the following measures before commissioning the gear unit:
● Read and observe the operating instructions.
● Follow the checking procedure (Page 61).
● Replace the screw plugs with the air filters. Follow the instructions in BA 7300.
● Fill the gear unit with oil.
● Gear unit with oil supply system: Check that the oil supply system is working properly.
● Check the oil level.
● Check the gear unit for leaks.
● Gear unit with oil supply system: Follow the instructions in Measures prior to commissioning
with oil supply system (Page 60).
● Ensure that all pipes and components are filled with oil.
● Restart: Make sure that the drive cannot be restarted after safety equipment has responded
unless the restarting lockout is cancelled.

Commissioning
Further information
Further information about oil can be found in the operating instructions BA 7300 in the complete
documentation of the gear unit.
Further information about individual components can be found in the operating instructions for
the components in the complete documentation for the gear unit.
6.1.1 Rinsing before first commissioning

Filter the flushing oil before or during the flushing operation in the bypass flow with a 25 µm
filter.
The flushing oil can be reused for a maximum of 6 flushing operations.
Start up the oil pump of the low-pressure lubrication circuit and allow it to run for at least 6
hours for flushing. If the system has a high-pressure lubrication circuit, switch this on 2 minutes
later.
6.1.2 Gear unit with oil supply system

Take the following measures before commissioning a gear unit with an oil supply system:
● Make sure that the pressure in the oil supply system components does not exceed the
maximum permissible pressure.
● Make sure that the temperature of the oil supply system components does not exceed the
maximum permissible temperature.
● Using the oil supply system, lubricate the gear unit for 30 minutes in a pre-lubrication phase.
During this time, the rolling-contact bearings, tilting pad thrust bearings and gearing are
supplied with sufficient oil for starting.
On the oil supply system, make sure that the low-pressure lubrication is switched on first
and the high-pressure lubrication only after 2 minutes. This time is necessary to achieve
pressure equalisation in the oil circuit.
Switch on the high-pressure pumps no later than 5 minutes before starting the auxiliary or
main motor.
Further information
You will find information on the oil supply system in the data sheet, in the list of equipment and
in the operating instructions for the oil supply system, which are part of the complete
documentation of the gear unit.

Commissioning
6.1.3 Checking procedure

Check all drive components after completion of assembly and before the first cold trial run.
Remove all material residue, tools and assembly equipment.
If the oil supply system was supplied by Siemens, it has already been function-tested. Before
the trial run of the mill, test the electrical interlocking between the oil supply system and the
drive motors.
To perform the checking procedure, inspect the following items:
● Correct implementation of the foundation
● Foundation bolts tightened as specified
● The gear unit is properly fixed to the foundation
● The grinding table is properly installed
● The directions of rotation of the motor and gear unit match (see rotation direction arrow)
● The adhesive tapes have been removed from the labyrinth seals
● The round cord hollow profile between the housing and the output flange has been removed
● All air filters are installed
● Mounting and cleaning of all pipes as prescribed in the assembly instructions
● The coupling and motor are correctly aligned
● The correct configuration of the pipes and hoses
● Tightness of the pipe and hose connections
● Signs of oil foaming in the oil reservoir (tank for oil supply system and gear unit) during
operation
If signs of oil foaming are visible, check all of the suction pipe connections. Contact the oil
manufacturer if necessary.
● The tank for the oil supply system, the gear unit and the pad bearing compartment of the
gear unit are full of oil
Carry out the inspection when the oil system is running and the gear unit is stationary.
● The oil level is between the minimum and maximum markings
● Connection of all the monitoring devices as shown in the terminal diagram
● The oil supply system has been function-tested
● The electrical interlocking between the gear unit, the oil supply system and the drive motor
Document the results of the inspections for the following:

● The interlocking system is functioning as per the interlocking instructions
● Adjustment and correct operation of flow monitors or flow transmitters, pressure switches
or pressure transmitters, temperature sensors and level monitors
● Cooling water inlet open (for oil supply systems with water-oil cooler)
● Adequate air supply to fans (for air-cooled oil supply system)

Commissioning
6.2 Measures during commissioning
● Has the alignment between the gear unit and adjacent components been checked, recorded
and documented?
● Levelness of the foundation
You will find further checking procedures in the operating instructions of the following
components:
● Coupling
● Motor
● Oil supply system
● Vertical mill

Please observe the following measures to commission the gear unit and document these:
● For gear units with oil supply system: Check that the oil supply system is working properly.
● Check the oil level.
● Measure the oil sump temperature (Page 72) after the gear unit has run in.
● Check the tightness of the shaft seal on the gear unit (Page 23).
● Check that no contact with rotating parts is possible.
● Check whether the shutoff valves are open.
– Check that all of the oil drain valves are closed.
– Ensure that all of the other shutoff valves are open.
● Check all the connection lines are securely tightened and leak-free.
● Measure the vibration levels at the gear unit (Page 73) following commissioning and
continuous operation in order to create initial and comparison values.
Further information
You can find additional information on the topic of oil in the operating instructions BA 7300,
Further information about the oil supply system can be found in the oil supply system operating

Commissioning
6.2.1 Initial test run
Requirements
Meet the following requirements before the initial test run:
● Follow the operating instructions.
● Start up the gear unit.
Procedure
To perform the initial test run, proceed as follows:
1. Run the gear unit for several hours at partial load (50 % to 70 %), if possible. If a test run
under partial load is not possible, you can operate the gear unit under no-load with the
rollers lifted.
2. If no faults occur, gradually increase the load at suitable time intervals up to full load while
constantly monitoring the gear unit.
3. During this time, pay attention to the following items:
– Noise
During this time, listen for anomalous noises at various points on the gear unit using a
suitable device.
– Foaming
Check whether the oil in the oil reservoir (tank for oil supply system and gear unit) is
exhibiting low levels of surface foam. Surface foam up to approximately 10 mm is
acceptable. If foaming is found, contact the oil manufacturer if necessary. Foaming will
decrease as the temperature rises.
– Vibration measurement
For more information, refer to chapter Measuring the vibration levels (Page 73).
– Oil leaks
Check the screw connections for oil leaks. If necessary, provide extra sealing.
After the first run, the oil level sinks. As the gear unit warms up, the oil level rises to the
height of the marking for the operating oil level.
4. Communicate the date of first commissioning in writing to Siemens within 4 weeks.
6.2.2 Gear units with heating

Please observe the following measures to commission the gear unit with heating:
● Ensure that the heating elements are not exposed.
● Check the switching points of the temperature monitor.

Commissioning
WARNING
The oil sump can catch fire
The oil sump can catch fire if exposed heating elements are switched on.
Never switch on the heating elements until you have checked that they are completely
Further information
Further information about heating elements can be found in the heating element operating

Operation 7
7.1 Operating data
Introduction
To ensure correct, trouble-free operation of the system, observe the operating data of the gear
unit and, depending on the order specification, the data in the operating instructions for the oil
supply system.
The valid operating data can be found in the annex Technical data (Page 91).
The following operating data apply to the oil:
Table 7-1 Operating data
Inlet oil temperature 50 °C
You can find the critical values for the inlet oil temperature in the lubrication diagram and in
the list of equipment in the complete gear unit documentation.
You will find information about the oil pressure in the data sheet, in the list of equipment or in
the drawings in the complete documentation of the gear unit.
Further information
Further information about the technical data of the gear unit can be found in the data sheet
and the list of equipment in the complete documentation for the gear unit.
7.2 Irregularities in operation
Introduction
Switch off the drive assembly immediately if it exhibits irregular behaviour during operation.
A few irregularities are listed below as examples:
● Oil temperature exceeds the maximum permissible value
● Alarm tripped by the pressure monitor in the oil cooling system or oil supply system
● Unusual operating noise
● Changes in the flow volumes

Operation
7.3 Taking the unit out of service
Document continuous changes in the operating performance of the gear unit by recording
trends.
NOTICE
Faults can cause damage to the gear unit
The gear unit might sustain damage if it is not shut down when a fault occurs.
Switch off the drive assembly immediately if any fault condition develops.
Rectifying irregularities in operation

Proceed as follows to rectify any irregularities in operation:
1. Switch off the drive assembly if it exhibits irregular behaviour during operation.
2. Refer to the Fault information (Page 77) to find the cause of the fault.
3. If you still cannot determine the fault cause, contact Siemens Customer Services
(Page 83).
Introduction
After the gear unit has been shut down, it is protected against internal corrosion by the
operating oil for 7 days.
You have to take various measures depending on the time for which the gear unit will remain
out of service.

Operation
Taking the unit out of service

● Switch off the drive assembly.
● During short interruptions: Continue to run the complete oil supply system.
● During long interruptions:
– Continue to run the oil supply system for approx. 60 minutes to avoid heat accumulation.
However, damage can be ruled out due to a sudden stoppage, e.g. due to power failure.
When shutting down an oil supply system with high-pressure lubrication circuit, ensure
that the high-pressure pumps are shut down before the low-pressure pumps.
– If gear units are operated in saline environments or in close proximity to salt water, the
oil supply system should always operate continuously in order to prevent corrosion
damage. In addition, the gear unit must be turned every two weeks via the auxiliary drive
or the main motor (at least one rotation at the output flange).
If this is not possible, take measures to preserve the gear unit.
– When the gear unit is taken out of service for a period in excess of 7 days, start up the
oil supply system once a week and allow it to run for one hour. At the same time, make
sure that the gear unit is turned every 2 weeks (at least one rotation at the output flange).
If it is not possible to start up the lubrication system once a week and to turn the gear
unit every 2 weeks, take measures to preserve the gear unit.
– Close the shutoff valves for the cooling water inlet and drain lines in case of gear units
with water/oil cooler. Drain the water from the water/oil cooler if there is a risk of frost
and remove residual water with compressed air.
– Follow the preservation procedure described in operating instructions BA 7300.
WARNING
Risk of eye injury from compressed air
Water residue and dirt particles can cause damage to eyes.
Wear suitable safety goggles.

Operation

Servicing 8
8.1 General maintenance information
The operator must ensure compliance with the stipulated time limits. This also applies if the
maintenance activities are included in the operator’s internal maintenance schedules.
The gear unit could be damaged if the stipulated time limits for maintenance and servicing are
not observed.
The time limits stipulated in the maintenance schedule are largely dependent on the conditions
of use of the gear unit. For this reason, it is only possible to state average time limits here.
WARNING
Danger to life due to live system
Working on a gear unit while it is in operation is hazardous and can result in potentially fatal
injuries.
Always shut down the gear unit and any oil supply system (whether separate or mounted on
the gear unit) before you carry out any work. Take measures to prevent the accidental
restarting of the drive assembly. Display a warning notice that clearly states that work is being
carried out on the gear unit.
8.2 Maintenance schedule
Maintenance and servicing work

The following table provides an overview of all maintenance and servicing work which you are
required to perform continuously or at regular intervals.
Table 8-1 Maintenance and servicing work
Intervals and time limits Measures

As required Clean the air filter
Replace the air filter element
Clean the gear unit
Replace the oil filter
Weekly Check for leaks
Check the oil level
Check the oil temperature
Check for changes in the gear unit noise
Inspect the protection devices

Servicing
8.3 Maintenance and servicing work
Intervals and time limits Measures

Every 4 weeks Visually inspect the gear unit for cracks, leaks and
damage
Inspect the oil supply system for dirt
Inspect instruments installed in situ (temperatures, oil
pressures)
1 000 operating hours after commissioning Analyse the oil
Change the oil (or depending on results of the oil sam‐
ple test (Page 34))
Every 3 months Clean the oil filter
Clean the air filter
Check that the foot fastening bolts are tight
Every 6 months Inspect mounted components (couplings, auxiliary
drive)
Every 12 months Visually inspect the tooth flanks for damage
Inspect the hose lines
Replace the air filter element
Analyse the oil
Every 10 000 operating hours, at least every Change the oil (or depending on results of the oil sam‐
18 months ple test (Page 34))
Check the air‐oil cooler (the same time as you change
the oil)
Check the water‐oil cooler (the same time as you
change the oil)
Every 2 years Carry out a general inspection of the gear unit
Clean the gear unit
6 years after the specified date of manufacture Change the hoses
Further information
Further information about additional maintenance and servicing work can be found in the
separate data sheet in the complete documentation for the gear unit.
Further information about installed components can be found in the operating instructions for
the components in the complete documentation for the gear unit.
Introduction
You can find maintenance and servicing measures relating to gear unit lubrication and
preservation, which are not provided in this chapter, in BA 7300 in the complete gear unit
documentation.

Servicing
8.3.1 Contamination limits

The following table contains the material-specific contamination values of the oil:
Material Limit proportion [mg/kg] Possible source

Iron (Fe) 40 Wheel rim with internal teeth, gear teeth, rolling-
contact bearing cages
Chromium (Cr) +4 Plain and rolling-contact bearings, gear teeth
Aluminium (Al) +4 Oil pump bearings
Copper (Cu) +4 Rolling-contact bearing cages
Lead (Pb) +6 Thrust bearings, pump bearings
Tin (Sn) +2 Thrust bearings, pump bearings
Nickel (Ni) +2 Gear teeth
Zinc (Zn) + 10 Zinc-based primer (sometimes used as an addi‐
tive). In this case, contact Siemens.
Silicon (Si) +5 Cement dust or other environmental influences,
some oils may contain silicon
Water (H2O) 0.03 % Condensation, water/oil cooler defective (mineral
oil)
The values preceded by "+" refer to the reference sample of the fresh oil.
Note that the deviation in the viscosity of the oil sample from the viscosity of the oil specified
in the technical data should not exceed 10 %.
NOTICE
The gear unit may be damaged by dirty operating oil and mixing different oil grades.
Replace the oil if the contamination limits stated in the table or the purity class -/19/16
according to ISO 4406 is exceeded.
When changing the oil, fill the gear unit with the oil grade that was previously used. Do not
mix oils of different grades or manufacturers.
8.3.2 Servicing
Preparatory measures
Maintenance encompasses all of the measures required to keep and restore the reference
state as well as to identify and assess the actual state of technical equipment of a system.
Attach and secure the individual components and large assemblies to the lifting equipment
carefully during replacement.

Servicing
8.3.3 Checking the oil temperature
Damage to the gear unit due to excessively high oil sump temperatures.
The gear unit can sustain damage due to inadequate lubrication if you allow it to operate at oil
sump temperatures above the maximum permissible temperature.
Do not operate the gear unit above the maximum permissible oil sump temperature.
Procedure
Proceed as follows to check the oil temperature:
1. Allow the gear unit to reach its normal operating temperature.
2. Operate the gear unit with the maximum driven machine power.
3. Measure the temperature of the oil in the oil sump.
4. Compare the measured value with the maximum permissible oil temperature.
Depending on the order, you can find the maximum permissible oil temperature in the
lubrication diagram and in the list of equipment in the complete gear unit documentation.
5. Immediately stop the gear unit if the maximum permissible oil temperature is exceeded.
Contact Siemens Customer Services.

Servicing
8.3.4 Measuring the vibration levels
For KMP type, the diagram below shows the measuring points for portable vibration
measurements as an example:
$
9 9 $ + + +$ + 9 9 +
+$ + + + +
V Vertical measuring point H Horizontal measuring point
Figure 8-1 Measuring points for vibration measurements
(Measuring points 1 and 2 are positioned at the motor bearing points.)

You can contact Customer Services (Page 83) for the precise layout drawing for portable
vibration measurement for types KMP, KMPS and KMPP depending on the order.
WARNING
Risk of becoming entangled in rotating parts
There is danger that rotating parts may catch hold of you or pull you in.
If you are taking a vibration measurement at a gear unit while it is in operation, make sure
that you do not take the measurement in immediate proximity to rotating parts to avoid
accidental contact with them.
The points shown in the diagram are standard measuring points. All gear units of this type in
the field can be measured at these points. This enables you to make a direct comparison with
other gear units of the same type or size.
Arrange for the vibration measurements to be carried out and evaluated by or in close
cooperation with Siemens personnel. It will then be possible to apply experience from previous
measurements on comparable gear units to the measurement process and to the evaluation
of the measurement results.

Servicing
When taking vibration measurements, please note the following general points:
● Take measurements only at those points shown in the diagram.
● Do not take measurements at resonating bodies such as ribs, inspection covers, pipes, etc.
● Document the motor power at the time the measurement was taken. Power fluctuations
can cause variations in the measurement result.
In order to record the vibration profile of the gear unit, take a base measurement after the
whole system has been commissioned and been in continuous operation. This will form the
basis for a trend analysis if further measurements are taken at monthly intervals.
The gear unit is a Class III driven machine when assessed according to ISO 10816. As regards
this assessment, it must be noted that the axial forces generated by the crushing process are
transferred to the foundation via the gear unit housing. The possibility that vibrations are
attributable to the grinding process rather than the operation of the gear unit cannot therefore
be precluded. For this reason, the extent to which the standard ISO 10816 can be applied to
this type of gear unit is limited.
Further information
More information about diagnosing vibration can be found on the Internet (http://
www.industry.siemens.com/drives/global/de/getriebe/service).
8.3.5 Cleaning the gear unit
Introduction
Layers of dust may affect the dissipation of heat through the surface of the gear unit, resulting
in overheating. Depending on the operating conditions, it may therefore be necessary to clean
the gear unit more frequently than stated in the maintenance schedule.
Procedure
To clean the gear unit, proceed as follows:
1. Use a hard brush to remove any stubborn dirt from the gear unit. Never use a high-pressure
cleaning device or water.
2. Remove any spots of corrosion.

Servicing
8.3.6 Cleaning the air filter and replacing the air filter element
8.3.6.1 Cleaning the air filter

NOTICE
Damage to the gear unit due to penetration of foreign bodies
Damage to the gear unit due to penetration of foreign bodies is possible due to the ambient
conditions of the mill.
Do not allow foreign bodies to enter the gear unit.
8.3.6.2 Replacing the air filter element
Introduction
The paper filter cannot be cleaned.
Procedure
Proceed as follows to replace the air filter element:
1. Remove the air filter cap
2. Replace the filter element.
3. Mount the air filter cap.
8.3.7 Cleaning the double change-over filter
Procedure
To clean the double change-over filter, proceed as follows:
1. Inspect the double change-over filter.
2. Follow the operating instructions for the double change-over filter.
Further information
You can find additional information about the double change-over filter in the double change-
over filter operating instructions provided in the complete gear unit documentation.
You can find additional technical data in the separate data sheet and in the list of equipment

Servicing
8.3.8 Welding work on the mill

Siemens provides no warranty for damage to the gear unit originally caused by welding work
on the mill.
DANGER
Risk of injury due to electric shock
Injuries as a result of electric shock can occur when welding equipment is used.
Perform potential equalisation in accordance with the applicable regulations and guidelines
before any welding work is carried out on the mill.
The gear unit and any parts connected to it must not be used as an earthing point for electric-
welding operations.
The pad bearing compartment can be optionally fitted with an earth cable that must be
connected to the output flange. Connect the earth cable to the tapped holes on the side of
the output flange. When the welding work is complete, detach the earth cable from the output
flange.
If no tapped holes are available on the gear unit for an earth connection, please take suitable
alternative measures. This work must always be done by specialist electricians.
When electric welding is carried out anywhere on the mill, the welding current must not be
conducted through the gear unit. For this reason, the welding current return cable must always
be directly connected to the component to be welded.
8.3.9 General inspection of the gear unit

Arrange for Siemens Customer Services to perform a general inspection on the gear unit.
Thanks to their experience, these engineers are best placed to assess which gear unit
components need to be replaced.
8.3.10 Check that all of the fastening bolts are tight

Note the following points when checking that the fastening bolts are tight:
● Observe the data regarding connection classes (Page 55), preload forces and tightening
torques (Page 55).
● Tighten the foot fastening bolts with the prescribed preload force or to the required torque.
The relevant information can be found in the dimension drawing in the complete
● Note the separate operating instructions if you are using clamping nuts.
● Replace any bolts that are no longer fit for use by bolts of the same strength class and type.

Servicing
8.4 Possible faults
8.3.11 Final work

After you have finished all the work listed in the maintenance schedule, replace any bolts that
are no longer fit for use by bolts of the same strength class and type.
8.4 Possible faults

The faults listed below are only intended as a troubleshooting guide.
If any faults occur while the unit is still under warranty, do not allow anyone except Siemens
Customer Services to attempt a repair.
Even after the warranty period has expired, you should still arrange for faults to be rectified by
Siemens Customer Services.
Note
Loss of warranty
You will invalidate the warranty for the gear unit if you modify it in any way without seeking the
approval of Siemens beforehand, or if you do not use original spare parts.
Only use original spare parts from Siemens. Always arrange for Siemens Customer Services
to repair any faults that develop while the unit is still under warranty.

Servicing
8.4 Possible faults
Possible faults and their rectification

The following table provides you with an overview of possible faults and indicates how they
can be rectified.
Table 8-2 Possible faults and their rectification
Possible faults Causes Possible remedies

Pressure switch trig‐ Oil pressure has dropped below ● Check the oil level at room temperature
gers alarm minimum value ● Top up with oil if necessary
● Check the operating temperature
● Check the oil pump
● If required, replace the oil pump
● Check the oil filter
● Clean or replace the oil filter if necessary
● Inspect the pressure switch and replace if necessary
● Check the pipes, and replace or seal if necessary
● Check the flow
Noise Damage to the gear teeth ● Contact Customer Services
● Inspect the toothed components
● If necessary, replace damaged components
The bearing play is excessive or re‐ ● Contact Customer Services
duced ● Adjust bearing play
Defective plain or rolling-contact ● Contact Customer Services
bearings ● Replace the defective plain or rolling-contact bearings
Gear unit fastening has worked ● Tighten bolts and nuts to the specified tightening torque
loose ● Replace damaged bolts and nuts
Leakage Labyrinth seals soiled with oil, incor‐ ● Check oil filling
rect transport position ● Clean the labyrinths
Inadequate sealing of the housing ● Check the seals and replace if necessary
cover or joints ● Seal housing cover or joints
Oil level in the gear unit housing too ● Check the oil level
high ● Correct the oil level if necessary
Leaks in the input shaft ● Check the oil level
● Correct the oil level if necessary
Wet-air filter is severe‐ Wet-air filter is spent ● Replace the wet-air filter
ly discoloured
Wet-air filter is becom‐ Water in the oil ● Take test tube sample to examine oil condition for water
ing discoloured from penetration
the top downwards
● Have the oil examined by a chemical lab
● Change the oil if necessary

Servicing
8.4 Possible faults

Oil is foaming in the Preservation agent not completely ● Change the oil
gear unit drained off
Oil supply system left in operation ● Switch off the oil supply system
for too long at low temperatures ● Degas the oil
Gear unit too cold in operation ● Switch off the gear unit
● Degas the oil
● Start up without cooling water during cold restart
Water in the oil ● Take test tube sample to examine oil condition for water
penetration
Oil defoamer has run out ● Examine the oil
Unsuitable mixture of oils ● Examine the oil
The fast-running bevel gear swirls ● Check the oil level
up the oil ● Correct the oil level if necessary
Oil escaping from the Inadequate sealing of the housing ● Check the seals and replace if necessary
gear unit cover or joints ● Seal housing cover or joints
● Check the compression seals and retighten screws if
necessary
Leaking pipes ● Check the pipes, and replace or seal if necessary
Oil supply system mal‐ - ● Follow the operating instructions for the oil supply system
function

Servicing
8.4 Possible faults

Elevated temperature Oil level in the gear unit housing too ● Check the oil level
during operation low or too high ● Correct the oil level if necessary
Oil is too old ● Find out when the last oil change was done
Oil is severely contaminated ● Change the oil
Oil supply system defective ● Inspect the oil supply system
● Replace defective components if necessary
● Follow the operating instructions for the oil supply system
Gear unit with water-oil cooler: Cool‐ ● Adjust the valves at the supply and return lines
ant flow too low or too high ● Check the water-oil cooler for free flow
Gear unit with air-oil cooler: Inade‐ ● Clean the air-oil cooler
quate air flow
Gear unit with air-oil cooler: Cooler ● Clean the cooler block
block soiled
Gear unit with oil cooling system: ● Check the oil filter
Inadequate oil flow through the oil ● Clean or replace the oil filter if necessary
cooler
Coolant temperature is too high ● Check the temperature; correct if necessary
Defective oil pump ● Check the oil pump function
● If required, repair or replace the oil pump
Electrical equipment defective ● Check the electrical equipment and replace if necessary
Elevated temperature Oil filter contaminated ● Check the oil filter
at temperature sensor ● Clean or replace the oil filter if necessary
in pad bearing
Quantity of oil supplied to the pad ● Check the setting of the control valves
bearing too small
Monitoring devices defective ● Check the monitoring devices and replace if necessary
Changed grinding parameters at mill ● Examine and check the grinding parameters
Elevated temperature Oil level in the gear unit housing too ● Check the oil level at room temperature
at bearing points low or too high ● Correct the oil level if necessary
Oil is too old ● Find out when the last oil change was done
Oil supply system defective ● Inspect the oil supply system
Defective plain or rolling-contact ● Contact Customer Services
bearings ● Check the plain or rolling-contact bearings and replace if
necessary
Defective oil pump ● Check the oil pump function
● If required, repair or replace the oil pump

Servicing
8.4 Possible faults

Increased vibration Defective plain or rolling-contact ● Contact Customer Services
amplitude at the bear‐ bearings ● Check the plain or rolling-contact bearings and replace if
ing points
necessary
Gear wheels defective ● Contact Customer Services
● Inspect the gear wheels and replace if necessary
Contamination indica‐ Double change-over filter clogged ● Change over the double change-over filter corresponding
tor of the double to the separate operating instructions
change-over filter trig‐
● Clean the filter element
gers an alarm
Volume flowmeter trig‐ Oil too cold ● Warm the oil
gers alarm Oil filter contaminated ● Check the oil filter
● Clean or replace the oil filter if necessary
Leaking pipes ● Check the pipes, and replace or seal if necessary
Volume flowmeter defective ● Inspect the volume flowmeter and replace if necessary
Water in the oil Oil supply system defective ● Inspect the oil supply system
Cooler leaking ● Inspect the cooler and replace if necessary
Engine room fan is blowing cold air ● Install suitable thermal insulation to protect gear unit
onto gear unit: Water condenses housing
● Close the air outlet or change the direction of the air outlet
using structural measures.
Climatic conditions ● Contact Customer Services
● Use wet-air filter if necessary
Oil foams in the oil sump ● Take test tube sample to examine oil condition for water
penetration

Servicing
8.4 Possible faults

Service & Support 9
Contact
When ordering spare parts, requesting a customer service technician or in the case of technical
queries, please contact our factory or one of our customer service addresses:
Siemens Ltd.
309/2, 'A' Block 100, Chettipedu Village
Thandalam Post
602105 Chennai
India
Tel.: +91 (44) 37174000

Service & Support

Disposal 10
Disposal of the gear unit
When disposing of the gear unit after its useful life, please observe the following measures:
● Remove operating oil, preservative agents and coolant from the gear unit and dispose of
it according to regulations.
● Dispose of the gear unit parts according to applicable national regulations or recycle them.
Environmental protection
Observe the following environmental protection measures for disposal:
● Dispose of or recycle packaging material according to applicable national regulations.
● When changing the oil, collect the used oil in suitable containers. Use oil-binding agents to
clean up any oil spillages immediately.
● Store preservative agents separately from used oil.
● Dispose of used oil, preservative agents, oil binding agents and oil-soaked cloths according
to the applicable environmental protection regulations.

Disposal

Spare parts 11
By stocking the most important spare parts at the installation site you can ensure that the gear
unit is ready for use at any time.
Note
Damage to the gear unit due to use of unsuitable spare parts
Only use original spare parts from Siemens. Siemens shall not accept any warranty claims for
spare parts that are not supplied by Siemens.
Other spare parts are not tested and approved by Siemens. Non-approved spare parts may
possibly change the design characteristics of the gear unit and thus impair its active or passive
safety.
Siemens will accept no liability or warranty whatsoever for damage occurring as a result of the
use of non-approved spare parts. The same applies to any accessories which were not
supplied by Siemens.
The contact address of Siemens Customer Services can be found under Service & Support
(Page 83).
Information required when ordering spare parts

To order spare parts, refer to the spare-parts list. Only use spare parts that are supplied by
Siemens.
When ordering spare parts, please provide the following information:
● Order number with item
● Type and size
● Part number
● Quantity

Spare parts

Quality documents A
A.1 Declaration of Incorporation

Quality documents
A.1 Declaration of Incorporation
Declaration of incorporation
Company name and full address of the manufacturer:

Siemens Aktiengesellschaft
Am Industriepark 2
46562 Voerde
Deutschland – Germany
Name and address of the person, authorised to compile the relevant technical documentation:
Mark Zundel
Am Industriepark 2
46562 Voerde
Deutschland – Germany
Description and identification of the partly completed machinery:
KMP, KMPS, KMPP
for driving machines
The following "Essential health and safety requirements" are applied and are met:
– Directive 2006/42/EC Official Journal L 157, 9.6.2006, pages 24-86, annex I.
1.1, 1.1.2, 1.1.3, 1.1.5; 1.2.4.4, 1.2.6; 1.3.1 ‐ 1.3.4, 1.3.6 ‐ 1.3.8.1; 1.4.1, 1.4.2.1;
1.5.1, 1.5.2, 1.5.4 1.5.11, 1.5.13, 1.6.1, 1.6.2; 1.7.1, 1.7.1.1, 1.7.2, 1.7.4 ‐ 1.7.4.3
The special technical documents described in Annex VII part B have been prepared.
The manufacturer undertakes, in response to a reasoned request by national authorities, to
transmit in electronic form relevant information about the partly completed machinery.
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 to be in conformity with the provisions of Directive 2006/42/EC, as appropriate.
Voerde, 2016‐03‐23 i.V.

Mark Zundel, Head of PD MD AP VOE
Voerde, 2016‐03‐23 i.V.

Björn Podewski, Head of PD MD AP VOE BA
Translation of the original declaration of incorporation

Technical data B
B.1 General technical data
Rating plate
The gear unit rating plate contains the most important technical data.

① Company logo ⑧ Speed n2

② Serial no.: Plant code / order no. - Item - Serial ⑨ Oil data: Oil type, oil viscosity, oil quantity
no. / Year of manufacture
③ Total weight in kg ⑩ Numbers of operating instructions
④ For special information ⑪ For special information
⑤ Type, size ⑫ Manufacturer and place of manufacture
⑥ Power rating P2 in kW or torque T2 in Nm ⑬ Country of origin
⑦ Speed n1
The limits of the intended use of the gear unit are defined on the basis of these data and the
contractual agreements concerning the gear unit concluded between Siemens and the
customer.
Further information
Further information about these technical data can be found in the separate data sheet and
Further information about all major accessories including their technical data and control
instructions can be found in the order-specific list of equipment in the complete documentation
for the gear unit.

Technical data
B.3 Weights
Example code
The following is an example of the code printed in line 5 of the rating plate and explains the
meaning of the individual letters and numbers.
. 0 3 6
6L]H

'HVLJQ
3 3ODQHWDU\VWDJH
6 +HOLFDOJHDUVWDJH
'HVLJQ
3 3ODQHWDU\VWDJH
$SSOLFDWLRQ
0 9HUWLFDOPLOO
*HDUXQLWW\SH
. %HYHOJHDUXQLW
Further information
You can find additional information on the weights and the enveloping surface sound pressure
levels in chapters Weights (Page 92) and Enveloping surface sound pressure level (Page 93).
Further information about these technical data can be found in the separate data sheet and
B.2 Ambient temperature

Unless otherwise contractually agreed, the gear unit must not be exposed to any harmful
atmospheres or substances such as aggressive chemical products. By applying various
suitable measures, the gear unit can be used in the ambient temperature range extending from
-40 °C up to 60 °C. However, this must always be authorised by Siemens and specified in the
order text.
B.3 Weights
The precise weights are specified in the drawings in the complete documentation or on the
rating plate.
All weight specifications refer to units without oil filling or mounted components.

Technical data
B.4 Enveloping surface sound pressure level

It is not possible to specify an enveloping surface sound pressure level for a gear unit in
operation because the unit is operated under no load on the Siemens test stand during the
trial run.

Technical data

Index
Final work, 57
A
Air filter, 75
G
Air filter element, 75 Gear unit equipment, 20
Attachment points, 39 Gear unit housing, 19
Gear unit markings, 12
General inspection of the gear unit, 76
C
Checking procedure, 61
Coloured markings, 12
H
Contact, 83 Heating
Contamination limits, 71 Commissioning, 63
Cooling, 21 Function, 24
Copyright, 10 Heating elements, 24
Coupling, 24, 45 Temperature monitor, 25
Customer Services, 83
I
D Initial test run, 63
Danger of explosion, 16 Interval, 69
Delivered state, 21 Irregularities in operation, 65
Direction of rotation, 19
Disclaimer, 9
Disposal, 85 L
Documentation landscape, 9
Labyrinth seal, 23
Double change-over filter
Lubricant, 10
Cleaning, 75
M
E
Maintenance activities, 69
Environmental protection, 85
Maintenance information, 69
Equipment features, 19
Maintenance schedule, 69
Measures
Checking procedure, 61
F during commissioning, 62
Fastening bolts Prior to commissioning, 59
Bolt connection class, 55 Mounted components
Bolts, 54 Mounting, 51
Checking for tightness, 76 Mounting position, 39
Mating threads, 55
Preload force, 55
Tightening procedure, 55 N
Tightening torque, 55
Note about assembly, 39
Fault, 77
Fault rectification, 78
Filling with oil, 32

Index
Troubleshooting, 77
Types of danger, 14
O
Oil, 10
Contamination limits, 71
U
Oil drain, 33 Unpacking, 40
Oil level indicator, 25 Used oil, 85
Oil supply, 21 Using the gear unit, 17
Oil supply system
Commissioning, 60
Oil temperature W
Checking, 72
Warning symbols, 13
Oil temperature monitoring, 26
Operating data
Compliance with, 65
Oil, 65
Ordering spare parts, 83, 87
P
Packing list, 27
Preservation, 34
Protective equipment, 14
R
Rating plate, 91
Example of type and size, 92
Reactivating, 18
Resistance thermometer, 26
Rinsing, 60
Rotary shaft sealing ring, 21
Round cord hollow profile, 21
S
Safety rules, 11
Scope of delivery, 27
Sealing cap, 36
Servicing, 71
Servicing activities, 69
Shaft seal, 23
T
Taking oil samples, 34
Taking the unit out of service, 66
Technical data, 91
Transport information, 27
Transport symbols, 28

AA 9180_en_EBE
Siemens AG
Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
www.siemens.com/drives

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Vertical-mill gear unit 9180en

4.4.5 Taking oil samples.................................................................................................................34

Vertical-mill gear unit 9180en

Table 2-1 Symbols and markings................................................................................................................12

Vertical-mill gear unit 9180en

Figure 3-1 Gear unit preservation equipment...............................................................................................20

Vertical-mill gear unit 9180en

Purpose of the operating instructions

Basic knowledge required

Vertical-mill gear unit 9180en

Vertical-mill gear unit 9180en

2.2 The five safety rules

Vertical-mill gear unit 9180en

2.3 General information

Symbols on the gear unit

Table 2-1 Symbols and markings

Points labelled on the gear unit Symbol Coloured markings

Air relief point yellow

Oil filling point yellow

Oil draining point white

Oil level indicator red

Oil level measurement red

Connection point for vibration monitoring

Lubrication point red

Vertical-mill gear unit 9180en

Points labelled on the gear unit Symbol Coloured markings

Alignment surface, vertical

These symbols indicate the oil level check‐

These symbols indicate that the oil dip‐

2.4 General warnings and symbols

Table 2-2 General warnings

ISO ANSI Warning

Warning - explosive substances

--- Warning - entanglement hazard

--- Warning - hot surfaces

--- Warning - caustic substances

--- Warning - suspended load

--- Warning - hand injuries

Vertical-mill gear unit 9180en

2.5 Special types of danger and personal protective equipment

Dangers during operation

Vertical-mill gear unit 9180en

Vertical-mill gear unit 9180en

2.6 Intended use

Vertical-mill gear unit 9180en

Gear unit use

Vertical-mill gear unit 9180en

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

Reactivating the gear unit

Vertical-mill gear unit 9180en

Vertical-mill gear unit 9180en

Gear unit equipment

① Sealing cap (depending on the order) ④ Pressure pipe (gear unit)

Figure 3-1 Gear unit preservation equipment

Vertical-mill gear unit 9180en