Bevel Gear Units

Contents Bevel Gear Units

Today, the ZZ-Antriebe Company is proud of its 90 years of experience in the fi eld of drive system ZZ-Universal-Line® engineering, combined with intensive innovation and progress. We are devoted to the development, Sizes ...... 2 planning, construction and production of custom-designed products according to latest technical Gear Construction ...... 4 standards. Selection Criteria ...... 5 Operating Factors ...... 6 ZZ products can be found in all areas of machine and plant construction both inland and overseas, Intermittent Operation ...... 7 throughout the world. Our objectives of manufacturing high quality products take top priority in our company policy. Our system of quality control, according to DIN EN ISO 9001:2000, conforms to Additional Shaft Loading ...... 8 international requirements. The product range covers individual types of high-quality gear wheels and Assembly - Shapes ...... 9 indexing units on to complete, manufactured, ZZ-gears. State-of-the-art methods are used in production Power and Torque Ratings and construction, including CNC-controlled machine tools in manufacturing and CAD/CAM systems in – K080 and K110 ...... 12 the development stage. – K140 and K170 ...... 13 – K210 and K260 ...... 14 We have maintained fl exibility in order to offer individual and custom-made system solutions. Our – K330 and K440 ...... 15 highest aim is the satisfaction of our clients and a continous improvement in our performance to Dimensions meet the requirements of our customers, today and in the future. We consider ourselves a competent, – K080 to K330 ...... 16 innovative partner to both our customers and suppliers. – HK080 to HK330 ...... 17 – Ratio’s for high-speed K080 to K330 ...... 18 – Bevel Gear Units LK and WK ...... 19 – K440 and HK440 ...... 20 – Bevel Gear Units with centring fl ange ...... 22 Shaft Layout and Direction of Rotation ...... 23 Grease, Splash and Pressure Circulating Lubrication ...... 25 Types of Lubrication, Heat Build-up, Power Restriction ...... 26 Selection of Lubricant ...... 27 Weights, Oil Capacities, Commissioning ...... 28 Location of Oil Supply Elements ...... 29

ZZ-Precision-Line® Product Overview, Accuracy Details ...... 30

ZZ-Servoline® Product Overview ...... 31 Power Ratings, Dimensions Tables ...... 32 Dimensions, Shapes ...... 33

ATEX Explosions Protection for Non-electrical Units ...... 34

Special Customer Requirements Addresses and further information: Use of Special Materials ...... 35 www.zz-antriebe.de Customer Applications ...... 35 Conditions of Sale and Delivery Our “General Conditions for the Supply of Gear Units and Drive Elements” shall apply. All dimensions and illustrations are without obligation. • Palloid, Zyklo-Palloid, HPG-S We reserve the right to effect changes or modiﬁ cations to the construction, sizes, weights, technical speciﬁ cations, etc., without prior notice. Gearing Valid 08/2005 Process Description ...... 36

1 ZZ-Bevel Gear Unit Program Standard Types Sizes • Standard Types • Construction ZZ-Universal-Line® • ZZ-Precision-Line®

8 Sizes K080 K110 K140 K170 K210 K260 K330 K440 The modular system provides numerous variations in the construction of different types of gear models. In addition to the standard structural shapes shown here, further standard types are illustrated on pages 6 Standard forms K with free shaft ends 23 and 24. HK with continuous hollow-shaft LK with toe-plate mountings WK with angle mountings ZK with ﬂ ange mounting (output)

> Standard gear ratio 1:1 1,5:1 2:1 2,5:1 3:1 4:1 5:1 n1/n2 1 -Ratio’s for speed increase (max. unto 1:2) n /n <1 1 2 Features • Power ratings unto 500 kW • Torque unto 7000 Nm • Speeds unto 3000 rpm

Construction • Bevel gears of case-hardened steel with Klingelnberg-Palloid spiral toothing • Gearwheels lapped in pairs, optimum loading face, smooth running properties, effi ciency > 95% • Gear housing, bearing fl ange and cover, of high-quality grey cast iron • Square housing, all faces machine-fi nished with 4 threaded holes on each face for mounting the gears in any optional position • Cylindrical outer surface of bearing cover and fl ange bearing with fi t for centralising the gear • Single- or double-ended shafts, in one or more levels • Shaft ends with threaded centering, according to DIN 332, Form D • Spline according to DIN 6885, sheet 1, Form A • Primed housing and fl ange, shaft ends with short-term, active corrosion protection • Oil supply holes are incorporated, according to type, construction, mounting position and speed • Supplied without oil-fi lling (standard version)

Properties • Compact • Accurate • Quiet-running • Efﬁ cient • Low-maintenance

Accuracy classes • ZZ-Universal-Line®: - with standard accuracies for bevel gear sets, sub-assemblies and bearings - speciﬁ ed for general drive techniques • ZZ-Precision-Line®: - with HPG-S accurate bevel gear sets - bearing with increased accuracy - for applications with high demands on torsional backlash, smooth and even running All variations can be described by the different versions of the output shaft (hollow-shaft, solid shaft ATEX single- or double-ended) and the various number and position of the pinion shaft. The rotation direction • Explosion protection for non-electric equipment, according to Ex II 2 G/D ck T4/135° of individual shafts is determined by the internal construction of the gears. With multi-shaft drives, due • EEC recommendation 94/9/EG to their construction, attention must be paid to the minimum permissible ratio’s (see page 24), in order that the gears can rotate correctly.

2 3 Gear Construction Designing a ZZ Bevel Gear Unit ZZ-Universal-Line® • ZZ-Precision-Line® Selection Criteria

The complete gear program is constructed as a modular system and by reusing parts, allows the assembly For selecting a bevel gear unit the performance tables (page 12 on..), are used that provide details of of different variations and combinations. the maximum permissible drive power and output torque in the speed range between 50 rpm and 3000 rpm for the 7 standard gear ratio’s. All details apply to splash lubrication with mineral oil. At high The dimensions of the output shaft at ratio’s of i > 1 and all shaft arrangements, is constant. For ratio’s speeds, the transferred power is limited by the thermal load limit of the gear. Here, the load limit of the i < 1 (speed increase), the dimensions of the output shaft are different, due to the conditions of the gearing is below the heat limit of power. By using a suitable heat transfer (e.g. circulating lubrication), construction. The input shaft (pinion shaft), has different dimensions, depending on the gear ratio, in the the transfer of power can be increased in the upper speed range. region of the ﬂ ange and at the shaft ends. The details in the performance tables apply to the following operating conditions: The output shaft can be chosen as a single- or double-ended solid shaft or as a hollow shaft, within the • Smooth operation of the drive machine (prime mover) framework of standardised gear components. In multi-shaft gear units, the pinion shaft sub-assembly • Daily operation of 8 hours at the input side, is used repeatedly according to the construction and shaft arrangement required, and • A maximum of 20 starts per hour mounted on the preferred side of the housing. Refer to the notes on page 24. • Maximum ambient temperature of 20°C

The relevant gear components, are: The performance tables also give details of the transferable output torque for intermittent operation.

Here, M2max is the maximum permissible output torque that can be reached during intermittent operation (max. 5 seconds, and a maximum of 10-times per hour).

At the operating conditions speciﬁ ed and the observance of regular prescribed maintenance, a nominal serviceable life of the gears of approximately 10 000 operating hours can be expected.

Bevel gear If there are any deviations in the operating conditions, they must be corrected by applying an operating Housing factor, “b”. In such a case, the available drive power of the prime mover and the output torque must be multiplied by the operating factor.

For determining the gear size, the drive power required is then given by: P = P • b Output shaft bearing (b) and the output torque by:

• M(b) = M b Bearing cover where: P(b) = Selected drive power for the gear

M(b) = Operating torque for which the gear was selected Drive shaft bearing P, M = Available drive power of the prime mover or available output torque of the work machine.

Then, a correct selection of the gear, is given by: < < P(b) = P1 sowie M(b) = M2

P1, M2 = permissible drive power and permissible drive torque of the selected gear, according to the list.

The operating factor, “b” is mainly inﬂ uenced by the mode of operation of the prime mover or work

machine (single factor b1), the ambient temperature (single factor b2) and the On-time of the gear (single Flange bearing Pinion shaft Output shaft factor b3). • b1 b2 Shaft sealing ring The operating factor is deﬁ ned as: b = b3

4 5 Designing a ZZ Bevel Gear Unit Designing a ZZ Bevel Gear Unit Operating Factors • Shock Load Factor Intermittent Operation • Additional Shaft Loading Ambient Temperature

Single factor b1 for the operating mode of the prime mover and work machine, according to Single factor b3 for intermittent operation NIEMANN. The single factor b is used with intermittent operation. Factor b is dependent of the relative switch-on Type of prime mover 3 3 period, referred to an operating time of 60 minutes. Shock- load factor Electromotor Turbine, hydraulic motor Single-cylinder piston of work Run-time per hour, under load [min] machine On-time [h] / day On-time [h] / day On-time [h] / day Run-time RT = • 100% < 2 < 8 > 8 < 2 < 8 > 8 < 2 < 8 > 8 60 [min] I 0.8 1.0 1.25 1.0 1.25 1.5 1.25 1.5 1.75 Thus, if the unit is continually run under load for 60 minutes or more, the run-time is equal to 100 % II 1.0 1.25 1.5 1.25 1.5 1.75 1.5 1.75 2.0 RT. III 1.5 1.75 2.0 1.75 2 2.25 2.0 2.25 2.5 This statement does not apply to larger gear units where time is necessary before reaching the operating temperature. In such cases, the calculations must be modiﬁ ed. Depending on the number of start-ups, the above factor b1 should be multiplied by the following factor: Run-time, RT 100% 80% 60% 40% 20% Starts per hour < 20 20 - 60 > 60 - 120 >120 Factor b3 1.0 1.2 1.4 1.6 1.8 Factor b 1.0 1.05 1.1 1.2 11 The maximum torque determined by reference to this table, must not exceed M2max.

Examples of the shock-load factor of the work machine: Additional loading on the shaft journals If the input and output journals are loaded by additional Light shocks Generators, conveyor belts, apron conveyor, screw conveyors, ventilators, radial and/or axial forces, a check must be made whether SHOCK-LOAD agitators and mixers for uniform densities, ﬁ lling and packing stations, these forces can be borne by the shaft or bearings of a FACTOR I gear wheel pumps, feed servos of machine tools. standard type of gear unit. For checking purposes, details Medium shocks Lifts, swing gear on cranes, pit ventilators, agitators and mixers for un- must be provided of the magnitude and form (pulsating or SHOCK-LOAD equal densities, piston pumps, timber processing machines, paper alternating) of the loading applied to the shaft journals or, FACTOR II processing machines, winches, auxiliary drives in ships, textile machines. the permissible radial loading can be determined, referring to the diagram. The details for Fr1 are dependent on the

Heavy shocks Punches, shears, rolling and smelting machines, heavy-duty centrifuges, gear ratio; the values for Fr2 apply for all ratio’s. SHOCK-LOAD heavy-duty supply pumps, edge runners, vibrating machines, cutting FACTOR III machines, brickworks machines, heavy-duty lifts. The shaft diameter is reduced for gear ratio’s for “speed increase”. The additional radial loadings given in the table, are therefore up to 30% less. For individual cases, if in

Single factor b2 for higher ambient temperatures doubt, consult the manufacturer.

If bevel gear units are continually operated in ambient temperatures above 20°C, the single factor b2 must be applied. Shock loading The resultant radial loading can be determined as Drive via: factor follows: Ambient temperature 10°C 20°C 30°C 40°C 50°C 60°C Sprocket wheel fr = 1,0 The selection is correct, when:

Factor b2 0.9 1.0 1.2 1.4 1.8 2.5 Spur gear fr = 1,25 • • 2000 M2 2000 M1 F = • f F = • f r2 D r r1 D r V-belt pulley fr = 1,5 2 1 Depending on the gear ratio and size of the gear, factor b2 can in some instances, be reduced. If in any doubt, contact your supplier and provide details of the operating and temperature conditions. Flat belt pulley f = 2,5 r < < Fr1 Frz1 and Fr2 Frz2 Frz = additional radial load 6 7 Designing a ZZ Bevel Gear Unit Assembly - Shapes Additional Radial Loading on Input and Output Shafts

Additional radial loading on the input shaft journals (d ) Basically, the bevel gear units can be prepared for 1 5 almost any mounting position. To comply with the Gear unit size O assembly and lubrication conditions that depend on K080 K110 K140 K170 K210 K260 K330 K440 the mounting position, the necessary requirements Gear ratio with respect to accessibility, fi xing side face, visible 4 side of the oil supply elements must be specifi ed 1:1 1:1 3:1 1:1 3:1 1:1 3:1 1:1 3:1 1:1 3:1 1:1 3:1 1:1 3:1 2 L according to the application. Various types are ------H 4:1 2:1 5:1 2:1 5:1 2:1 5:1 2:1 5:1 2:1 5:1 2:1 5:1 2:1 5:1 available, depending on the assembly shape. (Example: Assembly shape K01A) Additional radial force Frz1 [N] 400 1200 1000 1800 1500 2500 2100 3400 3000 4600 4100 6300 5700 8900 7800 Symbols: V R 3 1 Ventilation Explanation: Ventilation with angle-piece The permissible radial force for d1 is dependent on the individual operating conditions of the gear unit. This means that the values given in the table above can only be regarded as guidelines. Exact loading U values can be calculated for individual cases when details of speed, operating conditions, the direction Ventilation with oil dipstick of force and service life, are known. 6 Oil gauge glass Additional radial loading on the output shaft journals (d ) 2 The shafts and gear faces identifi ed by numbers Oil drain plug and letters, shown in the diagrammes below should assist in clarifi cation for more complex Additional plug applications. for single-ended output shaft

Assembly - Shapes A B C D E

K01

K02

K03

8 9 Assembly - Shapes Assembly - Shapes

As standard, the oil supply elements are located according to the type of gear and the mounting As standard, the oil supply elements are located according to the type of gear and the mounting location. location. The assembly shapes illustrated here, for the more common applications, show the position of The assembly shapes illustrated here, for the more common applications, show the position of ventilation, ventilation, oil gauge glass and drainage. Any deviation from the illustrations, will require a separate oil gauge glass and drainage. Any deviation from the illustrations, will require a separate check and check and adaptation. adaptation.

Assembly - Shapes A B C D E Assembly - Shapes A B C D E

K04 K10

K05 K11

K06 K12

K07 K13

K08 K14

K09 K15

10 11 Power and Torque Ratings Power and Torque Ratings K080 and K110 K140 und K170

K080 K110 K140 K170

1 1 1 Continuous running Continuous running Continuous running 1 Continuous running

100% RT 100% RT 100% RT ] 100% RT [rpm] [rpm] [rpm] [rpm] [rpm] [rpm] 2 2 2 [rpm] 2 [rpm] max [Nm] max [Nm] max [Nm] max [Nm] n n n n 2 2 2 2 speed, n speed, n speed, n operation operation operation speed, n operation P [kW] M [Nm] P [kW] M [Nm] P [kW] M [Nm] Intermittent Intermittent

P [kW] M [Nm] Intermittent Intermittent Gear ratio, i Gear ratio, i Gear ratio, i

Gear ratio, i 1 2 1 2

1 2 M M M Drive (input) Drive (input) 1 2 Drive (input) M Drive (input) Output speed, Output speed, Output speed, Output speed, 3000 3000 5,00 15 42 3000 3000 10,5 32 88 3000 3000 18,0 55 150 2000 2000 25,0 115 240 1500 1500 5,00 30 48 1500 1500 10,5 64 105 1500 1500 18,0 110 170 1500 1500 24,5 150 240 1000 1000 4,10 38 56 1000 1000 8,90 82 125 1000 1000 15,8 145 220 1000 1000 24,0 220 330 750 750 3,40 42 62 750 750 7,60 93 135 750 750 13,7 168 250 750 750 23,3 285 420 1:1 1:1 1:1 1:1 500 500 2,50 46 64 500 500 5,80 107 150 500 500 10,8 198 280 500 500 19,1 350 490 250 250 1,40 53 70 250 250 3,40 125 165 250 250 6,40 235 310 250 250 11,9 435 570 100 100 0,70 64 76 100 100 1,60 150 180 100 100 3,10 280 340 100 100 5,80 535 640 50 50 0,38 69 80 50 50 0,90 165 190 50 50 1,70 305 350 50 50 3,20 590 680 3000 2000 2,40 11 20 3000 2000 8,70 40 68 3000 2000 14,6 67 115 2000 1333 24,7 170 280 1500 1000 1,70 16 24 1500 1000 5,60 51 82 1500 1000 9,80 90 140 1500 1000 21,8 200 310 1000 667 1,30 18 28 1000 667 4,40 61 95 1000 667 7,30 101 160 1000 667 17,5 240 360 750 500 1,00 19 28 750 500 3,70 68 100 750 500 6,10 112 170 750 500 15,3 280 410 1,5:1 1,5:1 1,5:1 1,5:1 500 333 0,75 21 30 500 333 2,80 76 110 500 333 4,70 128 180 500 333 11,8 325 460 250 167 0,44 24 32 250 167 1,60 88 115 250 167 2,80 153 200 250 167 7,10 390 510 100 67 0,21 29 36 100 67 0,75 105 125 100 67 1,30 183 220 100 67 3,30 450 540 50 33 0,11 31 36 50 33 0,42 115 135 50 33 0,75 200 230 50 33 1,80 490 560 3000 1500 3,30 20 34 3000 1500 6,10 37 64 3000 1500 11,8 72 125 2000 1000 19,6 180 290 1500 750 2,10 26 42 1500 750 4,00 49 78 1500 750 8,20 100 160 1500 750 16,8 205 320 1000 500 1,60 29 44 1000 500 3,30 60 90 1000 500 6,30 115 180 1000 500 13,4 245 370 750 375 1,20 31 46 750 375 2,70 65 95 750 375 5,10 125 190 750 375 11,5 280 410 2:1 2:1 2:1 2:1 500 250 0,90 34 48 500 250 2,00 73 105 500 250 3,80 140 200 500 250 9,00 330 460 250 125 0,50 39 52 250 125 1,10 84 110 250 125 2,20 163 220 250 125 5,30 390 510 100 50 0,25 46 56 100 50 0,55 101 125 100 50 1,00 192 230 100 50 2,40 440 530 50 25 0,14 50 58 50 25 0,30 110 130 50 25 0,55 210 240 50 25 1,30 470 540 3000 1200 1,30 10 18 3000 1200 4,70 36 62 3000 1200 7,60 58 100 2000 800 10,9 125 200 1500 600 0,95 15 24 1500 600 3,10 48 76 1500 600 5,40 83 130 1500 600 9,50 145 230 1000 400 0,70 17 26 1000 400 2,50 58 86 1000 400 4,20 97 145 1000 400 7,20 165 250 750 300 0,60 18 28 750 300 2,00 63 95 750 300 3,50 106 160 750 300 5,90 180 270 2,5:1 2,5:1 2,5:1 2,5:1 500 200 0,44 20 28 500 200 1,50 70 100 500 200 2,60 118 170 500 200 4,40 200 280 250 100 0,25 23 30 250 100 0,90 81 105 250 100 1,50 134 180 250 100 2,60 235 310 100 40 0,12 28 34 100 40 0,42 96 115 100 40 0,70 158 190 100 40 1,20 270 330 50 20 0,07 30 36 50 20 0,23 105 120 50 20 0,37 170 200 50 20 0,65 290 340 3000 1000 1,30 12 22 3000 1000 3,70 34 58 3000 1000 7,60 70 120 2000 667 10,9 150 240 1500 500 0,90 17 26 1500 500 2,40 44 70 1500 500 5,10 94 145 1500 500 9,50 175 270 1000 333 0,65 19 28 1000 333 1,90 53 80 1000 333 3,90 107 160 1000 333 7,30 200 300 750 250 0,55 20 30 750 250 1,60 58 86 750 250 3,10 115 170 750 250 6,00 220 320 3:1 3:1 3:1 3:1 500 167 0,40 22 32 500 167 1,20 65 95 500 167 2,40 130 190 500 167 4,50 245 350 250 83 0,23 25 34 250 83 0,70 76 100 250 83 1,30 148 200 250 83 2,50 280 370 100 33 0,11 30 36 100 33 0,33 91 110 100 33 0,60 170 210 100 33 1,20 320 390 50 17 0,06 33 38 50 17 0,18 100 115 50 17 0,34 185 220 50 17 0,65 350 400 3000 750 0,75 9 16 3000 750 1,80 22 38 3000 750 4,90 60 105 2000 500 7,40 135 220 1500 375 0,55 14 22 1500 375 1,10 28 46 1500 375 3,10 77 120 1500 375 6,30 155 240 1000 250 0,42 16 24 1000 250 0,95 34 52 1000 250 2,40 88 135 1000 250 4,90 180 270 750 188 0,35 17 26 750 188 0,75 38 56 750 188 2,00 97 145 750 188 4,10 200 290 4:1 4:1 4:1 4:1 500 125 0,26 19 28 500 125 0,55 42 60 500 125 1,50 108 160 500 125 3,10 225 320 250 63 0,15 22 30 250 63 0,34 50 66 250 63 0,85 122 160 250 63 1,80 260 340 100 25 0,07 26 32 100 25 0,16 60 72 100 25 0,36 133 160 100 25 0,80 300 360 50 13 0,04 28 32 50 13 0,09 65 76 50 13 0,19 140 160 50 13 0,45 330 380 3000 600 3000 600 1,40 21 24 3000 600 3,90 60 105 2000 400 5,70 130 210 1500 300 1500 300 0,90 28 34 1500 300 2,50 77 120 1500 300 4,90 150 240 1000 200 1000 200 0,70 33 38 1000 200 1,90 88 135 1000 200 3,80 175 270 750 150 ratio i = 5:1 750 150 0,60 36 42 750 150 1,60 96 140 750 150 3,10 190 280 5:1 not available 5:1 5:1 5:1 500 100 500 100 0,44 40 46 500 100 1,10 105 150 500 100 2,30 215 300 250 50 250 50 0,25 45 52 250 50 0,65 120 160 250 50 1,40 255 340 100 20 100 20 0,11 52 60 100 20 0,28 130 160 100 20 0,60 280 340 50 10 50 10 0,06 55 64 50 10 0,15 135 160 50 10 0,32 290 340 values for torque, power and not integer output speeds P1 = input power , M2 = output torque values for torque, power and not integer output speeds P1 = input power , M2 = output torque

(e.g. n1=50, i=3:1, n2=16,66, n2≈17) rounded bold print values: oil cooling recommended (e.g. n1=50, i=3:1, n2=16,66, n2≈17) rounded bold print values: oil cooling recommended 12 13 Power and Torque Ratings Power and Torque Ratings K210 und K260 K330 und K440

K210 K260 K330 K440 ] ] ] ]

1 Continuous running 1 Continuous running 1 Continuous running

1 Continuous running 100% RT 100% RT 100% RT 100% RT [rpm] [rpm] [rpm] [rpm] [rpm] [rpm] [rpm] 2 2 2 [rpm] 2 max [Nm max [Nm max [Nm max [Nm n n n n 2 2 2 2 speed, n speed, n speed, n operation operation operation speed, n operation

P [kW] M [Nm] P [kW] M [Nm] P [kW] M [Nm] ntermittent

P [kW] M [Nm] Intermittent Intermittent Intermittent Gear ratio, i Gear ratio, i Gear ratio, i

Gear ratio, i 1 2 1 2 1 2 M M M 1 2 Drive (input) Drive (input) Drive (input) M Drive (input) Output speed, Output speed, Output speed, Output speed, 1500 1500 47,0 290 630 1200 1200 73 560 1200 1200 1200 140 1070 2260 1200 1200 421 3220 6800 1250 1250 47,0 350 630 1000 1000 73 670 1200 1000 1000 140 1300 2280 1000 1000 372 3450 6050 1000 1000 47,0 430 650 800 800 72 830 1220 800 800 135 1550 2300 750 750 315 3850 5700 750 750 42,5 520 760 600 600 71 1080 1540 600 600 124 1900 2700 500 500 235 4300 6150 1:1 1:1 1:1 1:1 500 500 35,5 650 910 400 400 59 1350 1840 400 400 107 2450 3340 250 250 135 4950 6750 250 250 22,4 820 1070 200 200 38 1720 2150 200 200 69 3150 3940 150 150 89 5410 6800 100 100 10,9 1000 1190 100 100 21 1950 2330 100 100 39 3600 4300 100 100 62 5700 6800 50 50 6,0 1100 1260 50 50 12 2150 2460 50 50 21 3900 4460 50 50 33 6050 6900 1800 1200 38,0 290 460 1800 1200 65 500 780 1500 1000 115 1050 1620 1500 1000 382 3500 5400 1500 1000 34,4 320 490 1500 1000 59 540 840 1200 800 105 1200 1840 1200 800 327 3750 5700 1000 667 28,0 390 580 1000 667 48 660 990 1000 667 98 1350 2020 1000 667 287 3950 5900 750 500 24,0 440 640 750 500 42 770 1120 750 500 85 1550 2260 750 500 235 4300 6250 1,5:1 1,5:1 1,5:1 1,5:1 500 333 19,2 528 740 500 333 34 920 1280 500 333 65 1800 2520 500 333 176 4850 6750 250 167 11,6 640 840 250 167 21 1160 1510 250 167 39 2150 2800 250 167 100 5500 7150 100 67 5,7 790 950 100 67 11 1450 1730 100 67 19 2600 3100 100 67 46 6250 7450 50 33 3,2 870 1000 50 33 6 1610 1840 50 33 10 2850 3260 50 33 24 6650 7600 2000 1000 30,5 280 450 2000 1000 54 495 800 2000 1000 104 950 1520 1500 750 290 3550 5700 1500 750 27,8 340 530 1500 750 53 650 1010 1500 750 91 1110 1720 1200 600 249 3800 5900 1000 500 22,4 410 620 1000 500 43 790 1180 1000 500 74 1350 2020 1000 500 215 3950 5900 750 375 19,2 470 690 750 375 38 920 1340 750 375 61 1500 2180 750 375 172 4200 6100 2:1 2:1 2:1 2:1 500 250 14,7 540 760 500 250 30 1100 1530 500 250 46 1700 2380 500 250 127 4650 6500 250 125 8,9 650 850 250 125 18 1340 1750 250 125 27 2000 2600 250 125 76 5600 7300 100 50 4,3 780 930 100 50 8,8 1610 1920 100 50 13 2400 2860 100 50 35 6380 7600 50 25 2,3 850 970 50 25 4,8 1750 2000 50 25 7,4 2700 3080 50 25 18 6670 7650 2000 800 20,1 230 370 2000 800 45 510 820 2000 800 79 900 1440 1500 600 245 3750 6000 1500 600 17,0 260 410 1500 600 39 590 910 1500 600 69 1050 1620 1200 480 207 3950 6100 1000 400 13,5 310 470 1000 400 30 690 1030 1000 400 55 1250 1880 1000 400 179 4100 6150 750 300 11,8 360 530 750 300 26 790 1150 750 300 46 1400 2040 750 300 144 4400 6400 2,5:1 2,5:1 2,5:1 2,5:1 500 200 8,9 410 570 500 200 20 910 1270 500 200 35 1600 2240 500 200 105 4800 6700 250 100 5,3 490 640 250 100 12 1050 1370 250 100 21 1950 2540 250 100 60 5500 7150 100 40 2,5 570 680 100 40 5,3 1210 1440 100 40 11 2450 2920 100 40 27 6150 7350 50 20 1,3 610 700 50 20 2,9 1310 1500 50 20 6 2750 3140 50 20 14 6400 7300 2000 667 23,3 320 520 2000 667 41 560 900 2000 667 60 830 1340 1500 500 180 3300 5300 1500 500 20,2 370 570 1500 500 36 660 1020 1500 500 52 950 1480 1200 400 159 3650 5650 1000 333 16,0 440 660 1000 333 28 770 1150 1000 333 40 1100 1640 1000 333 144 3950 5900 750 250 13,6 500 730 750 250 24 870 1270 750 250 33 1200 1740 750 250 121 4450 6500 3:1 3:1 3:1 3:1 500 167 10,4 570 800 500 167 18 990 1380 500 167 26 1450 2020 500 167 92 5050 7050 250 83 6,1 670 880 250 83 11 1160 1510 250 83 17 1850 2420 250 83 54 5950 7750 100 33 2,8 770 920 100 33 4,9 1360 1620 100 33 8,5 2350 2800 100 33 24 6600 7900 50 17 1,5 820 940 50 17 2,7 1470 1680 50 17 4,7 2600 2980 50 17 13 7050 8050 2000 500 15,3 280 450 2000 500 30 540 870 2000 500 44 800 1280 1500 375 188 4600 7400 1500 375 12,7 310 480 1500 375 25 620 960 1500 375 37 900 1400 1200 300 157 4800 7400 1000 250 9,8 360 540 1000 250 21 750 1120 1000 250 30 1100 1640 1000 250 135 4950 7400 750 188 8,2 400 580 750 188 17 830 1210 750 188 26 1250 1820 750 188 105 5150 7500 4:1 4:1 4:1 4:1 500 125 6,3 460 640 500 125 13 950 1330 500 125 20 1450 2020 500 125 74 5450 7600 250 63 3,7 550 720 250 63 7,4 1090 1420 250 63 12 1750 2280 250 63 40 5900 7700 100 25 1,7 620 740 100 25 3,4 1250 1490 100 25 5,7 2100 2500 100 25 17 6350 7600 50 13 0,9 650 750 50 13 1,8 1350 1540 50 13 3,2 2350 2680 50 13 9 6550 7500 2000 400 11,8 270 440 2000 400 22 490 800 2000 400 31 700 1120 1500 300 147 4500 7200 1500 300 10,1 310 480 1500 300 20 580 930 1500 300 26 800 1240 1200 240 119 4550 7050 1000 200 7,7 350 530 1000 200 15 690 1050 1000 200 21 950 1420 1000 200 100 4600 6900 750 150 6,4 390 570 750 150 12 760 1110 750 150 18 1100 1600 750 150 77 4700 6850 5:1 5:1 5:1 5:1 500 100 4,9 450 630 500 100 9,5 870 1210 500 100 14 1300 1820 500 100 53 4850 6750 250 50 2,9 540 710 250 50 5,3 980 1280 250 50 8,7 1600 2080 250 50 28 5100 6650 100 20 1,3 610 730 100 20 2,4 1100 1310 100 20 4,4 2000 2380 100 20 12 5300 6350 50 10 0,7 630 720 50 10 1,3 1180 1350 50 10 2,4 2200 2520 50 10 6 5400 6200 values for torque, power and not integer output speeds P1 = input power , M2 = output torque values for torque, power and not integer output speeds P1 = input power , M2 = output torque

(e.g. n1=50, i=3:1, n2=16,66, n2≈17) rounded bold print values: oil cooling recommended (e.g. n1=50, i=3:1, n2=16,66, n2≈17) rounded bold print values: pressurised oil circulation system necessary 14 15 Dimensions • K080 to K330 Dimensions • K080 to K330 Standard-Type K Standard-Type HK

Front view Side view Front view Side view Thread M x t Thread M x t Thread M x t Thread M x t

�

Top view Top view

Thread M x t Standard type S L Thread M x t Standard type S L

i = n /n ; i = 1:1 to i = 5:1 1 2 i = n1 /n2; i = 1:1 to i = 5:1

n high-speed 1 n1 high-speed n slow-speed 2 n2 slow-speed �

Special type L S � Special type L S

i = n1 /n2; max i = 1:2 n1 slow-speed

n2 high-speed n1 slow-speed n2 high-speed Not possible for types with hollow shafts Refer to page 18 for shaft dimensions.

Thread Lkr. The oil supply holes are specifi ed after Thread H7 The oil supply holes are specifi ed after Gear size k g a Ød l ØD h2 q2 m2 Oil hole“ Ød Gear size k g a Ød H7 ØD l h q m Oil hole Ød Lkr. ±0,2 2 2 h8 Mxt 2max. ±0,2 mounting position and the gear fi xings 2 h8 2 2 2 2 Mxt 2max mounting position and the gear fi xings K080 80 100 60 14 30 74 7 57 88.5 M6x9 R3/8“ 20 84.9 K080 80 100 60 12 74 30 7 57 58.5 M6x9 R3/8“ 12 84.9 k6 k6 are known. are known

K110 110 130 82 22k6 35 102 9 74 111 M8x12 R3/8“ 30k6 116.0 K110 110 130 82 22 102 35 9 74 76 M8x12 R3/8“ 22 116.0

K140 140 160 105 32k6 45 130 10 90 137 M10x15 R3/8“ 42k6 148.5 Spline dimensions, according to DIN K140 140 160 105 28 130 45 10 90 92 M10x15 R3/8“ 32 148.5 Spline dimensions, according to DIN K170 170 195 130 35 160 60 12 109.5 112 M12x18 R1/2“ 42 183.9 K170 170 195 130 42k6 60 160 12 109.5 172 M12x18 R1/2“ 55m6 183.9 6885 Sheet 1 6885 Sheet 1 K210 210 240 160 45 195 85 13 133 135 M16x24 R1/2“ 55 226.3 K210 210 240 160 55m6 85 195 13 133 220 M16x24 R1/2“ 70m6 226.3 Shafts with centralised thread, K260 260 300 200 55 245 100 17 167 170 M16x32 R3/4“ 65 282.8 Shafts with centralised thread, K260 260 300 200 65m6 100 245 17 167 270 M16x32 R3/4“ 70m6 282.8 according to DIN 332, Form D K330 330 380 260 60 310 120 27 217 220 M20x40 R3/4“ 60 367.7 according to DIN 332, Form D K330 330 380 260 75m6 120 310 27 217 340 M20x40 R3/4“ 75m6 367.7

i=1:1; 1,5:1 i=2:1; 2,5:1 i=3:1 i=4:1 i=5:1 i=1:1; 1,5:1 i=2:1; 2,5:1 i=3:1 i=4:1 i=5:1 Gear size Gear size Ød Øe h l m q Ød Øe h l m q Ød Øe h l m q Ød Øe h l m q Ød Øe h l m q 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Ød1 Øe1 h1 l1 m1 q1 Ød1 Øe1 h1 l1 m1 q1 Ød1 Øe1 h1 l1 m1 q1 Ød1 Øe1 h1 l1 m1 q1 Ød1 Øe1 h1 l1 m1 q1 K080 14 52 8 30 110 79 14 52 8 30 110 79 12 52 8 25 105 79 9 47 8 20 100 79 ------k6 k6 k6 k6 K080 14k6 52 8 30 110 79 14k6 52 8 30 110 79 12k6 52 8 25 105 79 9k6 47 8 20 100 79 ------

K110 22k6 72 8 35 135 99 22k6 72 8 35 135 99 22k6 72 8 35 135 99 16k6 72 8 30 130 99 12k6 60 8 22 122 99 K110 22k6 72 8 35 135 99 22k6 72 8 35 135 99 22k6 72 8 35 135 99 16k6 72 8 30 130 99 12k6 60 8 22 122 99

K140 32k6 90 9 45 165 119 32k6 90 9 45 165 119 32k6 90 9 45 165 119 20k6 80 9 32 152 119 16k6 75 9 30 150 119 K140 32k6 90 9 45 165 119 32k6 90 9 45 165 119 32k6 90 9 45 165 119 20k6 80 9 32 152 119 16k6 75 9 30 150 119

K170 42k6 115 12 60 210 149 42k6 115 12 60 210 149 36k6 115 12 55 205 149 26k6 100 12 45 200 154 22k6 95 12 40 195 154 K170 42k6 115 12 60 210 149 42k6 115 12 60 210 149 36k6 115 12 55 205 149 26k6 100 12 45 200 154 22k6 95 12 40 195 154 K210 55 125 15 85 275 188 55 125 15 85 275 188 38 125 15 65 255 188 32 110 15 45 235 188 26 100 15 45 235 188 K210 55m6 125 15 85 275 188 55m6 125 15 85 275 188 38k6 125 15 65 255 188 32k6 110 15 45 235 188 26k6 100 15 45 235 188 m6 m6 k6 k6 k6 K260 65 160 20 100 340 237 65 160 20 100 340 237 55 145 20 85 325 237 42 115 20 70 310 237 32 110 20 58 298 237 K260 65m6 160 20 100 340 237 65m6 160 20 100 340 237 55m6 145 20 85 325 237 42k6 115 20 70 310 237 32k6 110 20 58 298 237 m6 m6 m6 k6 k6 K330 75 230 22 120 435 312 75 230 22 120 435 312 55 190 22 85 400 312 50 190 22 75 390 312 42 190 22 70 385 312 K330 75m6 230 22 120 435 312 75m6 230 22 120 435 312 55m6 190 22 85 400 312 50k6 190 22 75 390 312 42k6 190 22 70 385 312 m6 m6 m6 k6 k6

Dimensions and illustrations without obligation; changes may be made without prior notice Dimensions and illustrations without obligation; changes may be made without prior notice

16 17 Dimensions • K080 - K330 Dimensions ZZ Bevel Gear Units Ratio’s for high-speed with toe-plate mountings LK, with angle mountings, WK

Up to a gear ratio of i = 1:2, bevel gear units with shafts d1 (n1) can be ﬁ tted with a speed increasing LK Front view Side view ratio of d2 (n2). Because of the smaller bevel gear ﬁ tted to the output shaft, the diameter d2 of the shaft Thread M x t Thread M x t is also reduced. Therefore, the transferred torque and power is also reduced. The tables on pages 12-15 cannot be used for speed increasing ratio’s.

Possible special gear ratio’s L S: (n1/n2 = i < 1) • i = 1:1,25 • i = 1:1,5 • i = 1:2,0 Reference should be made to the table of dimensions and the exemplary illustrated positions of bevel gear and pinion shaft. The gearing section with the larger diameter (greater number of teeth), rests on The toe-plates can be fi xed to any free housing surface the fl y shaft (d1, n1). In versions with speed increasing ratio’s, only the shaft arrangements 211, 311, 321 Gear size b c f h m m i Øs Mxt and 421 are possible. Dimensions for housings and fl anges that are omitted, correspond to the table of 2 K080 110 12 125 52 40 88.5 92 6.6 M6x9 dimensions on page 16. K110 140 16 160 71 50 111 126 9 M8x12 K140 175 20 200 90 70 137 160 11 M10x15 K170 210 20 235 105 70 172 190 14 M12x18 K210 260 25 290 130 90 220 235 18 M16x24 K260 310 32 340 162 100 270 292 18 M16x32 K330 380 35 430 197 100 340 362 22 M20x40

WK Front view Side view

Thread M x t Thread M x t

Speed increasing version L S

i= n1 /n2

n1 slow-speed

n2 high-speed

i=1:1,25; i=1:1,5 i=1:2 The toe-plates can be ﬁ xed to any free housing surface Gear size

Ød2 l2 m2 Ød1 Øe1 l1 m1 q1 Ød2 l2 m2 Ød1 Øe1 l1 m1 q1

Gear size b c f g h m1 m2 o p r Ø s Mxt K080 14k6 30 88.5 14k6 52 30 110 79 12k6 25 83.5 14k6 52 30 110 79 K080 125 8 140 100 60 35 88.5 60 80 28.5 6.6 M6x9 K110 22k6 35 111 22k6 72 35 135 99 16k6 30 106 22k6 72 35 135 99 K110 175 12 200 130 80 45 111 82 110 31 9 M8x12 K140 32k6 45 137 32k6 90 45 165 119 24k6 42 134 32k6 90 45 165 119 K140 224 16 250 160 100 55 137 105 140 37 11 M10x15 K170 42 60 172 42 115 60 210 149 28 50 162 42 115 60 210 149 k6 k6 k6 k6 K170 265 20 300 195 125 65 172 130 170 47 14 M12x18 K210 55 85 220 55 125 85 275 188 38 60 195 55 125 85 275 188 m6 m6 k6 m6 K210 335 25 375 240 140 82 220 160 210 80 18 M16x24

K260 65m6 100 270 65m6 160 100 340 237 50k6 80 250 65m6 160 100 340 237 K260 400 30 450 300 170 95 270 200 260 100 18 M16x32

K330 75m6 120 340 75m6 230 120 435 312 60m6 100 320 75m6 230 120 435 312 K330 510 30 570 380 220 120 340 260 330 120 22 M20x40

Dimensions and illustrations without obligation; changes may be made without prior notice Dimensions and illustrations without obligation; changes may be made without prior notice For dimensions omitted, refer to pages 16-18

18 19 Dimensions • K440 Dimensions • K440 Standard-Type K - LK Standard-Type HK

Front view Side view Front view Side view

Thread M x t Thread M x t Thread M x t Thread M x t

Top view

Top view Thread M x t Standard type S L Standard type S L

Thread M x t i = n1 /n2; i = 1:1 to i = 5:1 i = n1 /n2; i = 1:1 to i = 5:1

n1 high-speed n1 high-speed

n2 slow-speed n2 slow-speed

Special type L S Special type L S

i = n1/n2; max i = 1:2 n1 slow-speed

n2 high-speed

n1 slow-speed

n2 high-speed Not possible for types with hollow shafts Refer to page 21 for shaft dimensions

i Ø d1 Ød2 Ød2V l1 l2 l2V m1 m2 m2V e1

1:1 90m6 90m6 110m6 160 160 180 570 410 430 250

1,5:1 90m6 90m6 110m6 160 160 180 570 410 430 250

2:1 90m6 90m6 110m6 160 160 180 570 410 430 250

2,5:1 75m6 90m6 110m6 120 160 180 530 410 430 210

3:1 75m6 90m6 110m6 120 160 180 530 410 430 210

4:1 70m6 90m6 110m6 120 160 180 530 410 430 210

5:1 60m6 90m6 110m6 110 160 180 520 410 430 210

Following dimensions apply only to shapes K and LK (not HK)

i Ø d1 Ød2 Ød2V l1 l2 l2V m1 m2 m2V e1

1:1,5 90m6 90m6 - 160 160 - 570 410 - 250

1:2 90m6 80m6 - 160 130 - 570 380 - 250

20 21 Dimensions • Flanges B5 and B14 Shaft Layout and Direction of Rotation Shape ZK Design Identiﬁ cation (ID)

Flange B 5 The design identiﬁ cation number speciﬁ es the number of shafts, the shaft rotation direction and thus, the Front view Side view arrangement of the bevel gears. The illustrations below represent the top view level.

With a vertical straight-through shaft 2 - 3 , shaft end 3 should be regarded as being on top. Thread M x t Explanation of the design identiﬁ cation number

Example: 321/1 Number of shaft ends Direction of rotation Number of shaft planes

Number of ﬂ y shafts

Flange B 14 Standard, for all K-types Top view Side view

Thread M x t

For dimensions omitted, refer to pages 16-18

Flange B5 Flange B14 Gear size Gear size Thread Øb ØR Lkr. f c g Øs k g ØD h h 2h8 2 ±0,2 2 2 2 2 Mxt h8 1 2 K080 80 125 110 3.5 10 60 6.6 M6x9 K080 80 100 74 8 7 K110 110 160 140 3.5 11 76 9 M8x12 K110 110 130 102 8 9 K140 140 212 180 4 12 92 11 M10x15 K140 140 160 130 9 10 K170 170 236 212 4 14 112 14 M12x18 K170 170 195 160 15 12 K210 210 300 265 4 15 135 18 M16x24 K210 210 240 195 15 13 K260 260 355 315 5 18 168 18 M16x32 K260 260 300 245 20 17 K330 330 440 400 5 28 218 22 M20x40 K330 330 380 310 22 27

Dimensions and illustrations without obligation; changes may be made without prior notice

22 23 Shaft Layout and Direction of Rotation Grease, Splash and Pressure Circulating Lubrication Multi-shaft Gears Rotation Speed • Limit Values

Ausführungs-Kennziffer The values given in the chart, apply for a permissible gear temperature between 80° and 100°C. With peripheral speeds < 3m/s, grease or splash lubrication can be used. The average peripheral speed, v of the gears, is the decisive factor for determining the method of lubrication necessary. The values of peripheral speed at the transition levels from grease to splash lubrication and from splash to pressure circulating lubrication, should only be regarded as guide values. They cannot be stated as exact, ﬁ xed limits, since the ambient conditions and the run-time of the gears, are also determining factors. Design Design

Design Design

Important note for the shaft arrangement: The multi-shaft gears illustrated above, have “2” as the third digit. This indicates the 2 possible shaft planes. These design versions are possible only with a gear ratio of at least 1.25:1 or larger (e.g. 1.5:1, 2: 1), whereby the ﬂ y shaft 1 must always have the smaller number of teeth.

24 25 Types of Lubrication Lubricants Heat Build-up • Power Restriction Selection Criteria

General Selected lubricant: Semifl uid grease In addition to using the gear in a correct functional application to ensure operational safety and a • For an intended grease lubrication system, a synthetic semifl uid grease (viscous oil) is used in the long service life of the gear, the selection of a suitable form of lubrication and lubricant, are also very factory, consistency class 00 with a polyglycol base. important factors. Poor or inadequate lubrication reduce the loading capacity and the functional safety of the bevel gear unit. The lubricant prevents the direct contact of metal surfaces on the tooth edges, lubricates the bearings and shaft sealing rings and performs a cooling function by dissipating heat from Selected lubricant: Oil lubricant the contact surfaces (gears, bearings, shaft seal seating). The temperature of the oil should be kept as • A suitable lubricant (CLP lubricant according to DIN 51517, Pt. 3), should be selected according low as possible. to the lubricant base preferred, the ambient temperature and the operating speed of the gear. The principal range of operating speeds (range L or S) is specifi ed according to the speed determined for Depending on individual applications, the following forms of lubrication are used: the high-speed shaft. 1. Oil as Splash Lubrication For reasons connected with the transport, all gear units are delivered without an oil fi lling. All Average operating speed [rpm] of the high-speed shaft bearings and the bevel gears are automatically lubricated from the oil sump. The prescribed Speed range quantity of lubricant is dependent on operating speed and mounting position and can be checked K080 K110 K140 K170 K210 K260 K330 K440 at an oil gauge glass or oil gauge pipe. This form of lubrication is suitable for the majority of S > 2000 > 2000 > 2000 > 1500 > 1000 > 1000 >800 > 600 applications. The lubricant is selected according to the table on page 27. L < 2000 < 2000 < 2000 < 1500 < 1000 < 1000 < 800 < 600 2. Oil as Pressure Circulating Lubrication With a good lubrication and an effi cient dissipation of heat, the gears can be used beyond the restrictions of heat limits up to the limiting power of the gears. The difference between the power Viscosity according to ambient temperature, Oil type, Speed range of the gears and the heat dissipation limit of the gear is the determining factor in designing an Mineral oil Polyglycol oil PAO/HC oil Selected oil cooling aggregate. speed range +10°C -15°C +10°C -30°C +10°C -40°C The design of an additional cooling system is a rather complex task and requires knowledge of all ------the criteria relevant to the drive system. +45°C +15°C +90°C +15°C +80°C +15°C L VG 220 VG 150 VG 150 VG 100 VG 150 VG 100 3. Grease Lubrication If required, the gears can be supplied with a grease fi lling undertaken at the factory before S VG 150 VG 100 VG 100 VG 100 delivery. A semifl uid grease is suitable only for slow-running gear applications (see page 25) and should be used only with applications where the speed is not critical. For servicing, only grease types approved by the manufacturer may be used. Recommended oil-change intervals, for various ambient conditions

Heat Build-up and Power Restriction Oil-change intervals [h] at various oil operating temperatures Type of lubricant The power and torque values given in the tables and diagrammes, illustrate the range of applications of 70° C 80° C 90° C 100° C 110° C 120° C the ZZ bevel gear units without additional or external cooling. At low speeds, the mechanical properties of the gears is a limiting factor, whereas at higher speeds, the permissible input (drive) power is restricted Mineral oil 10000 7000 4000 2500 - - by the thermal limit of the gears. Synthetic PAO oil 18000 14000 10000 6000 2500 1500 Higher speeds always result in a greater build-up of heat. The thermal limit of power is then reached Synthetic PG oil 25000 18000 12000 7000 3500 1800 when the heat generated internally is of the same magnitude as the maximum possible dissipation of heat from surface of the gear housing. If the input (drive) power is greater than the thermal limit of • If the operating hours given above are not reached, mineral oil should be changed at the latest, every power, then an additional cooling system is necessary, because the resultant extra power losses cannot 3 years; synthetic oils, every 5 years. be dissipated. The permissible power of the gear is usually greater than the thermal limit of power. Thus, the gear can transfer a higher power if suitable cooling is installed or measures are taken to improve the dissipation of Caution! heat. The latter can be greatly improved if the gear unit is mounted on a steel plate with a large radiating Lubricating oils with a polyglycol base (PG) must never be mixed with mineral oils and polyalphaolefi n surface or fi tted with cooling fi ns. Satisfactory and effective heat dissipation and cooling is provided by (PAO) oils. These types are incompatible and a mixing will cause decomposition. using a pressure circulating lubrication system. It is also not recommended to mix synthetic PAO oils with mineral oils.

26 27 Weights, Oil Capacities Location of Oil Supply Elements Commissioning • Maintenance

Weight Measurements for horizontally mounted drive shaft When ventilation is required, bear in mind the location of the wheels in the gear unit. The values given are only intended as a guide and will vary according to construction shape and Ventilation (alternative) version. In models with a downwards ﬂ ange bearing, the oil level for all gear ratio’s corresponds to dimension Gear K080 K110 K140 K170 K210 K260 K330 K440 “U”, dimension “V” on request.

Weight [kg] 5 10 19 36 65 135 180 430 Oil drain (alternative) Oil drain (alternative)

U Oil drain Gear Ventilation 1:2 2,5:1 3,5:1 X Y Z Oil Capacity Oil level to to to The values given are only intended as a guide. The actual amount required is given by the visible centre 2:1 3:1 5:1 oil level at the oil gauge glass. K080 G3/8“ 34 34 34 30 16 16 K110 G3/8“ 40 40 50 45 20 20 Gear K080 K110 K140 K170 K210 K260 K330 K440 K140 G3/8“ 50 50 60 57 22 22 Oil drain (alternative) K170 G1/2“ 60 60 70 70 25 25 Volume [ltr] 0.2 0.3 0.6 1.5 1.8 2.5 7.0 20 K210 G1/2“ 70 80 90 85 25 25 K260 G3/4“ 85 85 105 95 30 30 K330 G3/4“ 100 115 130 125 32 32 The quantity of semiﬂ uid grease required is ﬁ lled at-works. K440 G1“ by agreement Gear K080 K110 K140 K170 K210 K260 K330 K440

Volume [dm3] 0.3 0.4 0.9 2.0 2.4 3.8 9.0 30 Q Oil drain Gear Ventilation 1:2 2,5:1 3,5:1 R S T Commissioning and Maintenance Oil level to to to 2:1 3:1 5:1 For reasons connected with the transport, all gear units are delivered without an oil fi lling. The correct K080 G3/8“ 50 50 50 26 26 26 type of oil is selected according to speed and power, referring to the table of lubricants. The viscosity K110 G3/8“ 55 65 65 33 33 33 given for the oil required is only approximate and applies only to normal operating conditions. For K140 G3/8“ 65 75 75 70 35 35 critical or unusual applications, a selection of oil should be made after consulting our service department K170 G1/2“ 75 80 90 85 40 40 or a suitable lubricants supplier. K210 G1/2“ 95 105 110 105 48 48 The oil must be fi lled to the middle of the oil level indicator; ideally, using a hair-sieve. After a short K260 G3/4“ 105 125 135 130 56 56 running time, the oil level should be re-checked and topped up or drained off, as necessary. Under no K330 G3/4“ 150 165 180 165 66 66 Measurements for vertically mounted drive shaft K440 G1“ by agreement circumstances, must the oil level be above than the upper edge of the oil level indicator (temperature increase due to splash losses) or below the lower edge (insuffi cient lubrication). The gear bearings are normally lubricated from the oil sump. In some models however, a correct Standard: lubrication of individual roller bearings cannot be guaranteed. In such cases, the relevant bearing is E = Filling and Ventilation greased separately and must be repeated after approximately 3000 to 5000 hours of operating. Due to S = Oil gauge glass its better temperature stability, if possible, lithium saponifi ed grease should be used. A = Drain plug Ew= Filling and Ventilation with angle piece After commissioning, it is advisable to operate each ZZ bevel gear unit for a few hours before applying (not standard) a load then, for a longer period, with a partial load applied. After this “running-in” period, the loading on the gear should be gradually increased up to its full operating load. A careful and correct running-in At high speeds and/or temperatures, the oil level period is very important to ensure a good, maximum, service life of the gear unit. can deviate from the values in the table. The fi rst oil change should be completed after the running-in period of about 500 hours of operating. With a semifl uid grease fi lling, under normal It is recommended to drain the oil when the gear unit is up to operating temperature. Oil changes are conditions, a supply hole is not present. The dependent on operating conditions and the ambient temperature, according to the details given on dimensions for a semifl uid grease fi lling do not page 27. apply. Side view Top view Dimensions and illustrations without obligation. Changes may be Full operating and maintenance instructions are supplied together with each gear unit. made without prior notice 28 29 ZZ-Precision-Line® • K110 to K440 ZZ-Servoline® Bevel Gear Units – Precision Model Product Overview KN-Series

For applications with high demands on transfer and gearing quality, the ZZ-Universal-Line bevel gear ZZ-Servoline® KN has been designed as a bevel gear unit especially for high-dynamic servo drives in units in the K110 - K440 series, can be fi nished with high-precision HPG-S bevel gear wheels. The gears automation techniques. With the hypoid gearing, gear ratio’s of up to i = 15:1 can be covered in one are optimised for a perfect running response, minimum torsional backlash and excellent balance. Detailed stage. The design of the gear takes into account a weighting according to requirements, between pitting, information for bevel gear wheels will be found on page 36. fatigue fracture, the loading capacity on the root of the gear tooth and gear scuffi ng. The gear unit is suitable for operating in any optional mounting position. The output shaft can be in the form of a single or double-ended solid shaft, or as an extended hollow shaft with external taper lock Features: assembly. The various combinations of shafts and fl anges, provide facilities for all commonly used servo • Identical in size to the ZZ-Universal-Line series (see Dimensions, pages 16-17) motors. • Power and torque transfer advantages compared to the standard K-series (see Power Tables, pages 12-15) • Gearwheel quality = 6, according to DIN 3965 • Torsional backlash < 4 arc min. • Case-hardened HPG-S gearing • High-grade smooth running uniformity • Minimum pitch errors • Minimum pitch spread • Optimum bearing face • Selected components • Bearings with improved accuracy • Quiet running • High effi ciency • Long service life

The gearing is measured and documented. Test records showing the relevant test criteria, are available on request. The torsional backlash and the gear bearing face are adapted, according to the operating conditions, in the same way as the initial tension of the bearings and the lubricant. The gears are prepared to an optimum for the particular application.

All bevel gear units are adjusted according to size, speed and gearing ratio, and achieve on average, the following values of torsional backlash (guide values only). Some adjustments may be necessary for special operating conditions.

Precision model, average torsional backlash [arc min] • 6 Sizes of gear units • up to 1400 Nm Size 1 2 3 4 5 • up to 8000 rpm K110 • 8 Gear ratio’s • Hypoid bevel gear sets K140 • Minimum backlash K170 • High power density K210 • High gear rigidity • Gear ratio’s 3:1 to 15:1 K260 • Amply dimensioned bearings K330 • Various ﬂ ange combinations K440 • Maintenance-free lifetime lubrication

30 31 ZZ-Servoline® KN-Series Dimensions for Power Ratings • Dimensions ZZ-Servoline® KN-Series • Size KN035 – KN1400

Feature / Size Units i KN035 KN070 KN140 KN260 KN700 KN1400 3:1 35 70 140 260 700 1400 4:1 34 68 136 255 690 1350 5:1 33 65 131 250 660 1280 6:1 32 61 124 240 620 1200 Nominal output torque 1) Nm 8:1 30 56 115 220 570 1100 10:1 28 51 105 200 500 980 12:1 24 45 95 180 430 850 15:1 20 40 80 160 350 700 max. Acceleration torque 2) Nm - = 1,5 * Nominal output torque 3-6 60 120 240 480 1200 2500 Emergency Off torque 3) Nm 8-10 50 100 200 400 900 2000 12-15 40 80 150 300 700 1500 max. Drive speed rpm - 8000 8000 7000 6000 5000 4000 Nominal drive speed rpm - 6000 6000 5000 4000 3000 2500 arc min - < 6 < 6 < 5 < 5 < 4 < 4 Torsional backlash arc min - reduced torsional backlash, by request 3-8 > 94 > 94 > 94 > 94 > 94 > 94 Efﬁ ciency 4) % 10-15 > 91 > 91 > 91 > 91 > 91 > 91 Weight kg - 3 6 9 15 30 55 Lubrication - - Synthetic hypoid oil Surface protection - - Housing primed, shafts with corrosion protection Mounting position - - Optional Permissible gear temperature °C - -10°C to +90 °C Protection class - - IP54 Service life hrs - > 25.000 ATEX conformity - - Ex II 2 G/D ck T4/135° (on request)

1) Cyclic operating, S5 2) max 1000 cycles per hour 3) max 1000 x during service life of gear 4) at the nominal torque

Housing dimensions Gear size

k g ØDg6 h1 v a b d4 Thread 1 c Ød1 k6 l1 m1 h2 KN035 60 90 89 13.5 9 39 22 6.6 M6 8 20 35 80 1.5 KN070 80 115 105 8.5 14 49 27 9 M8 10 24 40 90 1.5 KN140 100 140 125 8 18 59 33 11 M10 11 32 50 110 2 KN260 120 170 150 8 23 72 40 14 M12 13 40 60 130 2 KN700 146 215 195 10 32 91 52 17.5 M16 15 55 90 175 2 KN1400 196 260 245 10 42 112 70 17.5 M16 17 70 110 220 2 Construction shape (pinion shaft on top)

Hollow shaft Motor ﬂ ange Gear size H7 Ød5 f7 Ød6 l4 m3 Ød2 l2 e1 x m2 Lkr. d3 Thread 2 l3 KN035 24 20 23 71.5 9 / 11 / 14 23 / 26 / 30 55x130 / 90x143 / 75x140 Hole diameter, KN070 30 25 25 79.5 11 / 14 / 19 26 / 30 / 40 75x168 / 90x168 / 90x180 Centre diameter, KN140 36 30 29 93 14 / 19 / 24 30 / 40 / 50 90x191 / 115x191 / 115x201 Thread and centre depth KN260 50 40 33 107 19 / 24 / 32 40 / 50 / 60 115x220 / 140x220 / 140x235 according to the motor dimension sheets KN700 68 55 37 127 24 / 32 / 38 50 / 60 / 80 140x260 / 190x265 / 190x280 KN1400 80 70 40 159 32 / 38 / 48 60 / 80 / 80 190x335 / 260x345 M1 M2 M3 M4 M5

Dimensions and illustrations without obligation; changes may be made without prior notice More motorﬂ anges on request Dimensions and illustrations without obligation; changes may be made without prior notice

32 33 ATEX Conformity Special Customer Requirements Customer Applications

The basic requirements of mechanical design, construction, test and identifi cation of non-electrical In addition to the series program, bevel gear units in the ZZ-Universal-Line® and ZZ-Precision-Line® equipment that is intended for use in areas where there is a danger of explosion (such as air, gases, series, can be manufactured from other materials, with particular gear ratio’s or with special heat vapours, mist chambers and dust), are specifi ed in the EC guideline 94/9/EG (ATEX 100a) with the inclusion treatments, to comply with the requirements of a particular applications task. of European standards (e.g. EN13463-1, EN13463-5 and EN13463-8 “Non-electrical equipment for use in explosive areas”). The standards apply to normal environments, i.e. pressures from 0.8 to 1.1 bar and • Gears for the food industry temperatures from -20°C to +60°C. • Gears fi nished in stainless (rust-resistant) materials • Input and output shafts of stainless steel The guidelines defi ne the required standards of equipment, depending on the type of application and the • Gears with nickel-plated housings and fl anges environment. • Gears with housings and fl anges of aluminium • etc.

ZZ-gears according to ATEX, satisfy the following requirements: Special gear teeth and gear ratio’s • Supplementary to the standard series of ratio’s, all gears can be fi tted with specially Equipment category: 2: Equipment is intended for use in areas where there is a possibility calculated ratio’s (e.g. 1.33:1). Case-hardened or nitrifi ed steel gear teeth are recommended. of an occasional build-up of an explosive atmosphere. The explosion Manufacturing methods using palloid, cyclo-palloid or HPG-S are available. protection relevant to the equipment in this category, in cases of frequent equipment failure or fault conditions that are normally taken into account, must provide ample safety. Special gear units: If a suitable gear unit cannot be found in the large selection of our ZZ bevel gear products, or if your Explosion group: II: Equipment for use in areas where there is a danger of explosion, requirements cannot be fully covered with constructive adaptation, new gear units can be designed, with the exception of mining works where fi redamp may be constructed and manufactured according to the details provided by the customer. present.

Zone: G1: Explosive atmospheres, caused by gases, vapours or mists.

Zone: D21: Explosive atmospheres, caused by dust.

Maximum surface temperature: T4 (135°C)

Type of protection: c: Constructive safety K: Liquid encapsulation

Basically, all ZZ bevel gear units (ZZ-Univeral-Line®, ZZ-Precision-Line® and ZZ-Servoline®), can be supplied as ATEX models, within the framework conditions of “Ex II G/D ck T4/135°”. It should be borne in mind that in designing the gears to adhere to these ATEX conformity provisions, the torque and the speed in comparison to normal versions, may have to be limited. The usual applications and operating speeds are covered. The materials for the gears are selected according to the requirements. Oil is always used for lubrication in ATEX gear units.

This declaration of conformity, applies only to the ZZ-series program.

For custom-made gears and special applications, measurements, examinations and tests are necessary to ZZ-bevel gear units with an axle angle of 135°, HPG-S gear teeth, special housing, extended pinion ensure that the product model conforms to the guidelines and the standards that must be observed. shafts, hollow shaft without groove for friction-locked clamping device.

34 35 Spiral Toothing Spiral Toothing

The technical development from straight to spiral The advantage of palloid toothed bevel gears is tions in the geometry of the toothing and also, in toothed bevel gears, began in the 1920’s. the larger contact ratio compared with straight- the meshing characteristics of the gear wheels. The basic principle is that, using a suitably con- toothed bevel gears. Palloid toothing is par- Due to the increased demands with respect to structed machine, the wheel bodies are meshed ticularly indifferent to changes in the meshing speed, transfer accuracy and smooth-running, it on a geometric curve with a conical gear hobbing (changes in the bearing face). Restrictions are is necessary to remove the distortion that was mill. From this method of manufacture, the bevel present in the selection of the angle of the spiral, introduced, by heat treatment. This meant that a gears produced are called palloid toothed bevel that should be between 35° and 45°. machining process was necessary, after the gear gears. wheels were hardened. The sliding movement is the result of the meshing Left: Production of a palloid gear wheel, using the hobbing The design and calculation of spiral bevel gear of two countermoving tooth edges which produc- process. Now, a new technology is available for hardened sets requires the inclusion of a great number of es smooth running compared to straight-toothed gears – the “HPG-S” process (High-Power-Gear- infl uencing variables and marginal conditions to bevel gears. The greater number of meshed teeth Right: Production of a cylo-palloid gear wheel, using the uper). The HPG-S process functions on the basis milling head process. S achieve optimum results. in palloid toothed bevel gears, also produces a of cyclo-palloid toothed gears using special bo- For this purpose, special software is available in greater loading capacity. ron-nitrite tools, to remove the distortion from the ZZ computer system that guarantees fast and Cyclo-palloid toothed bevel gears satisfy the the gear wheels, produced as a result of the heat sure processing. By way of a powerful state-of- Special features: majority of requirements for optimum running, treatment. The machining process works within the-art CAD system using various programmes, - Constant tooth height along the width of the since both the length and position of the gear an area of µ-millimetres. the results are immediately transformed into tooth bearing face can be calculated. The “soft” metal technical drawings. - Very accurate gearing due to a continual hob- gear cutting (rough- and fi nishing cut), is usu- HPG-S toothed spiral bevel gear sets satisfy bing process ally followed by surface hardening using different the increased demands: Quality Control – Test Chart - Smoothly variable tooth crowning processes. The fi nal stage of production, as with - Unchallenged quality gearing Modern computer-aided test equipment is avail- - Specifi c infl uence on the position and size of palloid toothed bevel gears, is lapping the gears - Up to 30 % increase in the loading capacity of able in an air-conditioned test laboratory, for in- the bearing face. in pairs and drawing the gearing on special lap- the tooth fl anks termediate and fi nal control of the spiral toothed ping machines. - Considerable improvement in smooth-running bevel gears. Within the scope of a tangential - Accurately reproducible processes, means that error test, various measurement parameters can Cyclo-palloid toothing If required, test records are available. The versa- the pairing of gear sets is no longer necessary be examined and entered in a test chart (to DIN The most variable ZZ-gearing tility of cyclo-palloid toothed gearing is in the - Specifi c shaping of gear bearing faces 3965 standards): Production range continuity of the gear bearing face even with the - Tangential tooth-to-tooth composite error - Module selectable between 1.35 and 6.5 production of large quantities, the wide module - Tangential composite error - Bevel gear diameter up to approx. 500 mm range and the possibility of producing offset spi- - Pitch deviation - Further data, by request ral bevel gear sets. Left: Adjustable facing head. For the HPG-S process, the - Individual pitch deviation hardened toothed wheels are dressed with special boron- Hardened tooth gearing nitrite tools. Complete Offer – Customer Service The principle of cyclo-palloid toothing is based The most accurate ZZ-gearing Right: Quality control: In the tangential tooth-to-tooth The sum of all technical possibilities that is avail- on two eccentric groups of milling heads on Production range composite test, the quality of the gear teeth is checked in able at ZZ, for an optimum design and advice, one facing head, that have different radii of - Module selectable between 1.35 and 6.5 the mounting position and documented. guarantees custom-made offers and support curvature. This produces the required crowned - Quality 3 to 6 according to DIN 3965 even after the equipment has been delivered. shape on the concave or convex fl ank. - Profi le of tooth surface in ground quality

- Rt <= 2 µm In contrast to the palloid process, several - Further data, by request Palloid toothed system parameters can be changed in the cyclo-palloid The most economically efﬁ cient process. The angle of the spiral and module, can ZZ-gearing Production range be chosen as almost any value between 0° and The previous production processes, in particular - Module 1,0 to 7,0, bevel gear diameter 90°. for hardened spiral bevel gears, lead to distor- - up to approx. 500 mm tion due to the hardening that introduces devia-

36 37 Our Production Program

ZZ Bevel Gear Units ZZ Spiral Bevel Gears up to 7000 Nm nominal torque with - palloid gear tooth system or 500 kW power. ZZ Servoline® series - Cyclo-palloid gear tooth system for high-dynamic drives - HPG-S gear tooth system

ZZ Screw Jack Units ZZ Cams with trapezoidal or as - Globoid cams ball screw spindle - Axial cams for loading up to 1000 kN - Radial cams

ZZ Indexing Units as globoid, cylinder- or ZZ Special Gear Units radial cam gear units for versatile use in many with pendular or stepping function different types of application

ZZ-Antriebe GmbH An der Tagweide 12 76139 Karlsruhe Germany Telefon +(49) 7 21.62 05-0 Telefax +(49) 7 21.62 05-10 [email protected] www.zz-antriebe.de