Winsmith Engineering Service Bulletin

Installation,
Operation,
andLubrication SEENCORE
Instructions
WORM
GEAR
SPEED
REDUCER
I. SELECTION
The selectionof the appropriatespeedreducerfor a
given applicationrequiresthat allfactorsaffectingthe
operationof the reducerbe givencarefulconsideration.
Servicefacto.smustbe applied[o catalogratings
dependingon the type of primemoverused,the
severityof the application,and durationof dailyservice.
N4any
applicationand St Encoreworm gearspeed
reducerselectioncriteriaare discussedin the SE Encore
catalogthat is availableat www.WlNSMlTH.com.
For
personalassistance,pleasespeakwith a localWinsmith
salesrepresentative
whosecontactinformationis also
availableon the website.
D. Vibrationtendsto loosenfastenersevenif theyare
initiallytight.Afterthe firstweekor two of
operation,
allfastenerswithinthe driveassembly
shouldbe retightened.
Dowelingthe motorand
speedreducerto the baseplatewill helpmaintain
alignment.
E. Excessive
thrustor overhungloadson the input
or outputshaftsof a gearreducermaycause
premature
failuresof the bearingsand/orshafts.
gears,
pulleysand sprocketsas closeto the
l\,4ount
housingas possibleto minimizesuchloads.Do not
exceedcatalogloads.
2. Mounting Positions
il. titsTALLATtOl{
1, Shaft Alignment and Loading
A. Guardagainstunusualstressesand overloadsby
accuratelyaligningthe variousdrivemembers
(motor,speedreducer,coupling,sprocket,sheave,
gear,erc.).
B. Flexiblecouplingsare recommended
if a prime
movershaftis to be directlyconnectedto the input
shaftor if the outputshaftis directlyconnectedto
the drivenshaft.Note: Flexiblecouplingshavea
limitedcapacityfor misalignment.
Ensurethat shaft
alignmentsare withinthe limitsrecommended
by
the couplingmanufacturer
at installation.Even
slightmisalignments
in a rigid mountingsystem
may bringaboutbinding,largevibrationforces,or
excessiveoverhungloading;eachin itself
promotinqprematurebear,ng.shaft.or speed
reducerfailure.Do not excessively
forcecouplings
or otherconnectiondevicesonto eitherinputor
outputshafts;the resultmay be permanentbearing
damage.Ensureall shaftkeysare captiveand
securedbeforeoperation.
C. A commonbaseplatesupportingthe motorand
reducerwill helppreserve
the originalalignment
betweenthe reducerandthe motorshaft.lf a
strLrctural
steelbaseis used,the plateshouldbe at
leastequal n thicknessto the dlameterof the base
platedlasteningbolts.In addition,the structure
supportingthe baseplatemustbe suffcientlyrigid
that it preventsexcessive
flexingdur ng normal
operatron,
A. Single Reduction Speed Reducers and
Helical Gear Ratio Multipliers
All SE Encoresinglereductionspeedreducersand
all helicalgearratiomutipliersare filledwith
lubricantat Winsmithand can be mountedin any
of the positlonsidentlfiedin Figure3. Grease
frttngs (notshownin F gure3)areusedto lubrcate
beanngswhenthe motorspeedis below1160RPNI.
PleasereferenceSectionlll of this documeni,
"Lubrication& l,4aintenance.
for detailsrelatedto v
Properlubricatronlevels.
B, Double Reduclion Speed Reducers
Worm/Wormand HelicalMorm Double
Reduction
TheSE Encoredoublereductionspeedreducers
are designedto be mountedin any of the
"Standard"positionsshownin Figure4. These
unitsare factoryfilledwith lubricantto a level
that is appropriatefor thesestandardmounting
positions.Standardmodelshavean oil leve that is
commonto both housings.Greasefittings(not
shownin Figure4) are usedto lubricaiebearings
whenthe motorspeedis below 1160RPNy'.
lf an
position
additionalmounting
not shownin Figure4
is required,pleasespeakwith a localWinsmith
salesrepresentatlve
whosecontactinformationis
available
on thewebsite,
www.WlNSMlTH.com.
3. Mounting Considerations
It
The recommended
mountingfor a hollowshaft
reducerIncorporates
a torquearrn.The recommended
mountingof a reducerwith a flange/bracket
mounting
on a conveyorheadshaftusesa pillowblockor flange
bearingon the oppositeside of the conveyorfromthe
speedreduceras a supportbearing.This provides
threebearingsfor alignmentpurposes_
lt is difficultto
maintainand aligna systemwith a rigidlymounted
bearingcloseto a rigidlymountedspeedreducer_
lt
is extremelyimportantto "customalign"and "custom
shim"all componentspriorto tighteningmountingbolts
whenusinga rigidmountrng
approach.
Thisminimizes
misalignment
that is causedby excessiveloads.Select
an appropriatekey whenusinga bushingin the output
boreof any hollowoutputshaftspeedreducer.
4. C Face Motor Mounting Procedures
A. C FacelQuillMotor Mounting
v
3. Determinethe assembledshah clearanceby
measuringthe distancefrom the C Faceto the
reducershaftend and subtractingthe motor
shaftlength.N4ount
and securethe motorshaft
side of the couplingsuchthat the spider-endof
the couplingis locatedone halfof the clearance
distancebeyondthe motorshaft.Mountthe
redrrcercouplinghalf and couplingspideronto
the reducershaftin its approximateposjtion,
but do not secure.
4. Locatethe motorconduitbox in the desired
positionand securethe motorto the reducer
inputadaptorusingthe fastenersprovided.
Tightento 200 tbf-in.
5. Usingthe accessholein the inputaclaptor,
slidethe couplingtogetherand tightenthe
1. Checkthe motorand reducermountingregisters 5. Speed Reducer Assembly/Disassembty
for nicksthat couldinterferewith assembly;remove
Instructions
if necessary
ContactWinsmithor a localsalesrepresentative
2. Removeprotectiveplasticfrom the reducerinput
for detailedassembly/disassembly
instructions.
shaft.The bore has beencoatedwith an anti-seize
compound.
6. Sealed vs. Vented Speed Reducel
3. Alignthe motorshaftand key with keywayin bore
and slidemotorup inputadaptor.
4. Positionthe motorconduitbox as desired.
v
on eachshaftto obtainproperengagement.
Thefollowingdescribesa methodfor doingthis:
5. Securethe motorto the reducerusingthe
suppliedfasteners.Ensurepropermotorseating
beforetighteningthe fasteners.lf the mororooes
not readilyseat itself,checkfor axialmovement
of the motorshaftkey as this can cause
interference.
Stakingthe keywayadjacentto the
motorkey will helppreventaxialmovementof the
key duringthe mountingprocedure.Drawdown
evenlyon the fastenersto avoidbendingthe
motorshaftand tighten[o 200 Jbfin maximum.
B. C Face CouplingMotor Mounting
1. Checkthe motorand reducermounting
registersfor nicksthat could interferewith
assembly.Removeif necessary
2. Whenassemblingthe motorand coupling,
the couplinghalvesshouldbe evenlyspaced
Operation
All SE Encoreseriesspeedreducersare designedto
operatesealedor vented. Decidingwhethera speed
reducershoujdoperatesealedor ventedrequiresan
understanding
of the application,the environment,
the
operationof radialshaftseals,and a reviewof the
fundamentals
of thermodynamics
that governthe
temperature
and pressurerelationship
rnthe speed
reducer,
Any significantincreasein pressurein a sealedspeed
reducerdecreasesthe operationalservicelife of the
radial lip seals.A pressurechangeof only S psi may
reducethe seallife by as muchas one third.Thereare
two importantphenomenathat causean increaseIn
the internalpressureof a sealedspeedreducerFirst,
the changeof internalpressuae
duringoperatjonis
proportiona'to the changeof internaltemperature
that occursduringnormaloperation.The relationship
followsthe combinedgas law expressedas
PlV1 / T1= P2V2/T2
Secondly,radiallip sealscan ingestor "pump"air nto
a speedreducerregardless
of whetherit is operating
sealedor vented. Whilethe rateof ingestionis highly
variableand dependanton runningtime and speed,
undercontinuousoperatingconditionsthe net effect
of "purrped air to lhe totalpressJrei'lcreaseis
signficant.Venting.or the use of a breathervent. s
the onlv absolutemethodof eiiminatno the oressure
i,lcreasein a soeedreducercaJsedAy bAl1pllop
and thermalexpansion.
contarnination
causesa greaterreductionrn overall
speedreducerservicelifethanthe negatve impact
of the internalpressureincrease.The machinebuilder
or the endequipment
usershoulddetermine
whether
seaing or ventingthe speedreduceris the bestchoice
for a specificapplicationas this decison hasa direct
impacton the sealservicelife.A moredetailed
discussionof the factorsinfluencing
sealwearand seal
servicelife follows.
In someapplications,
the duty cyc e of the speed
reduceris ntermittent,
the run timesshort,and the
temperature
rncrease
modest.Whilesealngthe reducer
du'i19 operaro1 sLbsaqLe'ltlyrrc'easeslhe pressur.ir
theseapplicatrons,
the ncreasemay be verysrnalland
thereforehaveminimalimpacton the sealservce ife.
Additionaliy,
operatinga sealedspeedreducermay be
the best choicein applicationswhereexternalalrborne
InternalTemperatureand PressureIncreaseIn a
SealedSpeed Reducer
A speedredLrcer
experencesa signf cant rnternal
lemperaturencreasedue to operatingoads. The
:
changein temperatLrre
of an operatingspeedreducer
(fromstatrcambientternperature
to rnaxtmumoperating
temperature)
oftenexceeds130'Fahrenherr.
In a
sealedspeedreducer,ihe increasingtemperature
PBESSURE
IIICREASE
II{ A SEALED
SPEED
REDUCER
ilr
.1
A:
6p
;h
g rF
E':
*4e;'
a. .=
FIGUREl. Change in Speed ReducerOperatingTemperature(F)
' Assumes60% lubricanland 40oloairiill
' Asslmes reducerstartingpressureof 14,7psiat each starting
* L,sescoefiicientof thermalexpansionlor Mobil Glygoyle460lubicant
-*
10otSlarlTempefalure
l iiii't StanTemperalure
!
circulatesthe lubncantresidingclosestto the
sealback insidethe speedreducerand away
Contam
nants
from the externalenvironment.
The pumpiog
actionof the sealpreventsthe lubricantfrorn
seeprngout and is necessaryfor proper
operation.Unfortunately,
a correctly
functioningradialshaftseaialsocausesan
unintendedand unavoidable
sideeffect.Tests
confirmthat microscopicair bubblesand
contaminants
fromthe externalenvironment
are entrainedin the lubricant.The actively
pumpingsealsweepsthem jnwardwith the
inducedlubricantflow and once inside.they
FIGURE2. Ingestionof Air and
escapeintothe speedreducer.With
Contaminanlby a BadialSeal
continuousoperation,the air bubblesaccumulateinside
Couftesyof Parket Hannifin Cotporation
th. reducercavitv.Thesealis acttngas an ai. pu.tp.
caLrsing
air ingesttonthat increasesthe internalpressure
resultsin a corresponding
pressureincreaseas
of
a
sealed
speedreducer.Winsmith'sextensivetesting
describedby the combned gas law:
has verifiedthat the increasedinternalpressureof the
speedreducerand the rateof pressurizatton
are
P1V1/T1= P2V2/ T2
dependenton manyvariablesincludingoperatingtime,
ln a closedsystem(e.9.sealedreducer),any changein linearveloc/tyof the shaftunderthe seal,temperature,
sealmateral, and sealand shaftmanufactur
ng
lernperature
from one stateof equilibriumto the next
tolerances.
stateof equilibnumresultsln a corresponding
changein
both oil volumeand interlal p.assu,e.I\,4oreover,
the
In summary,a significantlylargepercentageof sealed
thermalexpanstonof the lubricantin the reducercan
speedreducersdevelopan internalpressureof 5 psi or
havea considerable
effecton the pressure,temperature,morewhenoperatedon a continuousduty cycle.This
and volumerelationship.The influenceof the lubricant'sphenomenon
canoccurevenwhenthereis no change
ihermalexpansrondependson the percentvotume
n temperaturebecausethe radia ltp seas ingestair into
occupiedby the lubricantcomparedto that of the air
the reducer(seeFigure2 - seetop of page q.
Typically,
the volumeinsidethe reduceris about60%
Conversely,
test ng indicatesthat whena reducer
lubncantand 407oair. Thethermalexpansionof the
operatesin an intermittentmanner(e,g.5 minutesof run
lubricantalonelncreasesthe internalpressurein the
time every30 rninutesof dwell);the internalpressure
reducerby approxmately1.5 psi whenthe changein
build-upis verysmall.
temperature
is 130'F.
The Effectsof Temperatureand pressureon Seal
Figure1 (seepage 4) showsthe total mpactof the
OperatingLife
nrarnaltemperatLro
and associaledpressurencrease
Thespecfic failuremechantsms
of sealsvary dependng
at drl{erentambientstartingtemperatures
In a seateo
on
the
seal
matena
.
However,
the
normal.,wearout,'
speedreducer.Pressu.eincreasesg,eaterthan 5 ps
butadtene
can resulttrom the combinedeffeciof the lubrcant,s failuremodeof an NBRrubber(Acrylonitrile
"nitrile")dynamicradialshaftsealis relatedto time
or
thermalexpansionand the rnternaltemperature
change.
and temperature
and oftentermed..embrittiement.,,
pressure
Seal "Pumping" Effects on Increased
In an Overtime undersomereiativeelevattonof temperature,
OperatingSpeed Reducer
nitrilesealslooseelasticity,developmicrocracksthat
cause
an abradedsealingsurfacethat can no longer
Correctlyoperatingradialshaftlip sealsare oynamtc
properly
containthe speedreducerlubrcant.The
and requirethe presenceof a microscopically
thin flln
embrittlement
rateof NBRmaterialsbeglnsto
of iubricantdirectlyunderthe sealinglip. The seallip
accelerate
at lip opefatingternperatures
between
imposesshearforceson the fim as the shan rorates
180'F
,,pumping
and
200'F.
beneatht. Thiscreatesa seal
ac|on', that
5
SealLip
rt
t
Lubricant
and pressurein a
The impactof increasingtemperature
sealedspeedreduceron the servicelife of an NBFIseal
has beenassessedby numerousseal manufactureG,
Whilethe resultsof thesetestsvarydependingon
they
variablessuchas the actualseallip temperature,
psi
pressure
as
small
as
5
can
indicatethat a changein
reducethe expectedsealservicelife by one third. This
is becausea oositiveinternaloressuredifferentialin a
speedreducercausesthe shaftlip sealsto exerta
higherradralforceon the shatt.Underdynamic
conditions.this forceincreasesthe liDsealcontactarea
on the shaft,increasingthe friction,and therebycreating
highertemperaturebetweenthe shaft
a correspondingly
and the lip seal. This increaseis directlyproportionalto
the amountof radialforceon the sealand to the speed
of the shaftat the seal interfaceand causesa decrease
in the seal life.
All SE Encorespeedreducerswith a quill inputadaptor
rubber)
niti e butadiene
LlsespecialHNBR(hydrogenated
(aka
or fluoroelastomer Vitong materialson all input
shaftsbecausethesematerialsare tolerantof higher
Thetypicalfailuremodeof
lip operatingtemperatures.
HNBRmaterialis blisteringat the sealsurface.
Pedormancelssues with Bladdersand
ExDansionChambers
Variousspeedreducerdesignapproachesaimed
the internalpressureincreasehave
at eliminating
incorporatedinternalcollapsiblediaphragmsor
bladders.Eliminatinglhe pressureincreaserequires
that the bladderor diaphragmcollapseat very low
pressuresand havea volumethat sufficiently
the expansionof the air and the
accommodates
lubricant.In a reducerwith a two inchcenterdistance,
the internalvolumeis between30 in3 and 40 in3.
Assumingthe volumeis 60% lubricantand 40oloair
and applyingthe previouslydiscussedcombinedgas
law overa temperaturechangeof 130'F (70"Fstart,
200"Ffinal),the sizeof an internaldiaphragmor
bladderrequiredto preventa pressureincreasernust
be between3.9 in3 and 5.2 in3. In mosttypicalspeed
reducers.thereis insufficientinternalsDacefor sucha
whilesomeinternalexpansion
largebladder.Moreover,
chambersare effectivein limting or reducinginternal
pressurerisedue to temperature
changes,noneare
comoletelveffectivein avoidinothe pressurebuilduo
relatedto sealair oumpingactionassooatedwith
continuousdutv cvcleaoplications.
6
ApplicationsDetermineWhen Sealinga Speed
Reduceris Preferredto Venting
As coveredin the precedingdiscussion,sealinga
V
reducercan increasethe internalpressurewhichresults
in decreasedsealservicelife.This is especially
prevalentwhenoperatingundercontinuousduty
conditions.However,thereare certainapplications
wherethe speedreducerduty cycle is highly
intermittent,
and run timesare shortwith lightaverage
duty loads.Testingand field experienceindicatethat
smallinternalpressureincreases(1 - 2 psi)havea
minimaleffecton the sealsewicelife.
Anotherapplicationdependentsituationwheresealed
reduceroperationis oreferredoccurswhenthe external 'l
air environment
is extremelycontaminated
with material
that, if drawnintothe reducerthrougha vent,can
rapidlyreduceseal,bearing,or worm gearlife.In these
applications,
the increasedp€ssureresultingfrom
operatinga sealedreducercan still havea significantly
negat,veeffecton seal'ire and.in thesecases,require
morefreouentsealreolacement.
Howevetthe reducer
life may be lengthenedby operatingsealedratherthan
operatingwith an openvent in thesetypesof harsh
environments.Further,the machinebuilderor
V
equipmentoperatormightdetermrnethat the
convenience
of operatinga sealedspeedreducer
outweighsthe negativeresultof reducedsealservicelife.
The Winsmith two (2) year warranly on defects in
parts and wo*manship remains unatfected whether
an SE Encore wotm gear speed rcducet opeates
with or without a vent since the ventlsealed decision
only affects the service life of the speed reducer
wear comDonents.
!
ln conclusion,therearethreefundamentalfactorsthat
governthe speedreducerseal/ventdecision.First,as
the temperatureincreasesin a sealedreducer,so will
the pressure.Second,the radialshaftsealsare
designed
to -pump lubricant
backintothe speed
reducer.This pumpingactionalso causesan ingestion
of air that increasesthe internalpressure.Any increase
of pressurecausesdecreaseddynamicradialseallife.
Ventingis the mostcost effectivemethodof eliminating
the pressure.Finally,whenextremeenvironmental
conditionscausecorrponenIor sealwearin excess
of that causedby an increasedinternalpressure,
v
J
v
t
sealinga speedreduceris the best likelyalternative.
However,undertheseconditions,sealwearis apt
to take placeat higherthan predictedrates.
SE EncoreVentingSoluiion is a StandardFeature
NOTE:HelicalGear Ratio Multipliersare factory
filled with Mobilgear600 XP 220 tubricant.The
use of other lubricantsmay result in substantially
Iower torque capacity and is nol recommendedby
Winsmith.lf other lubricantsare used, a thorough
tlushing procedureis rcquired.
The SE Encoreworm gearspeedreducerseriescan
satisfactoriry
operatesealedor vented.Eacnreoucer
is suppliedwith an optional"open-closedvent"that
can be installedby the equipmentbuilderor the
equipmentuser.ThisexclusiveWinsmithvent is made
from blackDuPontrM
Zltel@Nylonwith UV protection. l. FactoryFillingand UniversalMounting
The vent'sdesignincorporates
a labyrinthwtth a
dust/splashcap that minimizescontaminateand
water incirrsionfrom the externalenvironment
created
www.wr NSMr TH.coM 07/08
by general,harsh,and outdoorapplications.
The
reducerhousrngoffersmultiplelocationsfor vent
E17
[' DNS
30
LR
installation
dependng on the final reducermounting
( ' ) , l l l 9{) 9
positionon the equipmentTurningthe top cap to the
0 66
5S6
closedpositionensuresthat no oil drainswhilethe
:l
L i \l :')\l l
,-.
) .CTJ ElZMDN52lOONEK
equipmentis in transitto the operatinglocatton.
Turningthe top cap counterclockwise,by hand,
opensthe vent priorto runningthe speedreducerA
Size \lodel
I l'h Positi',n
specialscrewdriverslot moldedinto the cap allows
t) = Slrndrrd
easyactuationwhenaccessis limtted.Thevent
\ = \ou-Standard
shouldbe installedin the highestpipeplug location
availablebasedon the actualmounttngorientationof
the speedreduceron the operatingequipment.
NOTE:All SE Encore[4DNSand N,4DSS
standard
Additionally,
a brightyellowplastictag is provided
modelsarefiled withlubricant
by Wnsmith.The
with the ventthat reads:
lubricantlevelin thesereducersmay be slightlyabove
the appropriatelevelplug in someorientations.
This
smallamountof additionallubricationis normatand
\MPORTANT- VENTPEQUIRES
ACTIVATION
accePtable.
THIS UNIT HAS BEENSHIPPEDTO YOU WITH THE
All SE Encore|\,4DNS
VENTIN THE CLOSEDPOSITION- IT IS
and I\,4DSS
non-standardmodets
IMPORTANTTO OPENTHE VENTBY MAKINGA
arefilledwith lubricantby Winsmithto a leveldictated
by the specifiedorientation.
ONE QUARTERTURNCOUNTERCLOCKWISE"
Thesefill levelsare
shownin Figure3.
m
ilt. LUBR|CAT|O]{&
MAINTENANCE
NOTE:SE Encoreworm gear speed reducers
are factory filled with Mobil Glygoyle460 (PAG)
lubricant.The use ol other lubricantsmay result
in substantiallylower torque capacily and is
not recommendedby Winsmith,lf other
lubricantsarc used, a thoroughflushing
Procedureis required.
W I NSMI T H
The 1lth characterin the part numberon the reducer
nameplatedesignatesa standardor non-sraoaro
reducer.A "0" in the 11thpositionindicates
"Standard"
andan "X" in the 11thpositionindicates
"Non-Standard."
2. Ambient Temperature
lf the ambienttemperaturedLrringoperations outside
of -18 to 130 degreesE pleasecontactWinsmith.
3. InitialStart-Up
FtcURE3
Priorto start up, the lubricant
ill levels
T1eproperlubricant
reducer
dependent
onthespeed
durinqooerarion.
fhe
orientario.r
, ^nr
nr i r i 6
fill
d/rin
.n ^
.,"
fl i F. ' i-o4
Il9j
ts
, ( 'r - 'J
]"@ff
,liq . U ;
A.
f:llo
\#
l' . t:
i
|
\----
"l
r
--i
-,H
| . ,i
L
'
;
- 1 ,-
rJriq
tc8s
t--*iJl
,
isb e l o1w1 6 0
the.not or
s peed
l;
nountng
rpm.l'an altp.nate
position,
3
notshownin Figures
l-
4
-iH-!t
- ..
& 4, is required,pleasecontacta
tocatsatesrepresenrave or
Winsmithfor assistance.
Theoil levelshouldbe checked,
andadjustedif necessaryp orlo
operalion
usingtheoil levelplug
provided
andwhilethe reduceris
position.
orientedin its operating
460or
OnlyMobilGlygoyle
shouldbe
compatiblelubricant
containing
worm
usedlor reducers
gears.TheHelicalGearRatio
Muhipliers
shoulduseMobilgear
600XP220lubricant.
lfii
F'T f
r.
,:
,ru1
l"
+iJ
-Y
tll
fl
,J_
ffil
F
l6 vo l
plug locationsfor
ior a varietyof
modelsand orientationsare shown
in Figures3 & 4. Greasefittings,
not shownin Figures3 & 4, are
usedro lubricatebearingswhen
-.L_hAe
l;
+f
t -lT,
-.:i
i.;.[
E-
l' :i_
.l
XDLS
Duringthe in tial start-upoperation,
a breakin periodis lecessary
beforethe reducerreaches
xsFS
maximumoperatingefficiency.
Winsmithrecommendsa gradual
applicatior
o' loaddunngthe'irct
severalhoursafterstart-up,The
reducermay run hot duringthis initialbreak-inper od.
This is normal.A few dropsof oil may weepfromthe lip
sealsduringthe break-instage.Aftera shortperiodof
operation,cleanoff any excessoil aroundthe shaft
sealsand recheckthe oil level;adjust f necessary.
4. Oil ChangeInstructions
Whenchangingthe oil for any reason,use only I/obil
Glygoyle460 or othercompatiblePAG(Polyalkyl,.ne
8
.
.;
,DN- _
^
glycol)syntheticlubricants.lf anoiheroil type is used
(PAO,N4ineral
musi be drained
Oil,etc.),the housing(s)
and thoroughlyflushedwith a lightf ushng oil priorto
refilling.Do not mix differentlubricantsin the reducer.
Lubricantincompatibility
manyresultin premature
failure.Note: Whenchangingoil, carefullylnspectused
oil to be surethereare no meta shavings,fragments
and othersignsof excessivewear.
Theo I levelshouldbe checkedaftera shonpe-od o'
operationand adjustedif necessary.
Eachhousingof a
-
FIGURE4 l
LroutsLE
FEDUoIoN
\r,oRr,/r1r\ioBfr
i
STANDAFDAIOU NTI NG
:
_
\
DoLTBLE
FEDucrta^ I
HELtcAL,wo;;
STANNARNM
'-a\DAoDvorOI\'r|\
] N T I' N G
,
d_
:;11 A'"=-fiF
.X;;
tr--fF"f.1_
"",
.;i;
mfl
"tii' -r-rrii
:1P Tlf"
:3-
I
f J,-{
1
^7_
il:'
doublereductionmodelshouldbe drainedand fi ed
t3l^
'
i i l 1-* |
r T+
a
f -__l.rr_
'
flTlbF
"a,t:"1
{,g-lj/
i : - : '
I
t:
lJ +
lL_J]]
\]L
"
I,l*
"
ffiH
";
j :l.131
,
:5s
- W-
_rrr
i'5-#
'"1 ffi.
*4i
'o
-
ffi
-rt+rr
-i!.+-]J
Undersevere
(rapid
conditions
temperature
changes,
'noist,dirty.or corrosive
environme.ts)
it .naybe
necessary
to changetheoil at intervats
of 1-3months.
periodicexamination
of oil samples
takenfromthe
,
reducerwitthetDestabtisl.the appropriateirtervat.
-
O *-_ l
-. ---,1 {r-L
dt:TlF_
__rF -. 't
"" ..,)*-!f
rrr-L
: l
frhm"
r
trl_j_.ll "-t
t-_; 1-.!
^ t r5
I '
F:-H
.e.f,,.Ler
i= =
,1,
i l-.n
l-.n
#fffi
gsJ
d _V_ -
_
-
tt
=.
i
f;T'
.
l hr
_u
-."
;n
thi- qEll
tl^l
tl
2. Doublereducridnsize E35and E43moddtsaG suppriedw lh s6a* I ftinqs Dn
the inpurshafiroe^s!rcbe ns r! bdc.iionroral mounrinq
postioB.
3 Conractw nsmth whei nputsp€edsaretessrhr|60Dmloensue
A
FIGUBE3 & 4 CHANTKEY
reducer
lifeof 25.ooo
hourswrthout
everchanging
the
' -' ' "
inAGN4A
6034.Be2
is hishty
apptication
dependent.
In
1I
*;
t\,4obrl
lle ot |\,4obrl
|Ie
ctygoyte460,s
Glygoyle
460,sextended
pointwhere
extended
to the point
wher(
i reducer
rc.r,,.ar.,n
r^rth6
a.^,A <na.{,6^
a
canoperare
tor
tf,e
-Normat.
-N,^.--,.
AOI\,4A
spec
freo
^na,ia
Winsmtths 100yearsof experience.we havefoundthat
the actualservicelife of manyof.ourreducersexceeds
25,000hoursby severalrnultiples
"ffi
ljl
In nany
manylight
tightduty.
duty,relativelycleanambienr
ambientconditrons.
conditions,rhe
tl
lubncant.
lubricant.
.Normat,,reducer
Note:The -Normat.
redJcFrtifeof 25,OOO
25.OOO
hoursspecified
specitrF
T]-h'
i. 1 |l
_ll!?fL
l:l
i
independenllywhen changing the oil. Visit our website,
wwwWlNSN,4lTH.com,
for a detailed flushing procedure.
procedu.e
Theoilchange
fora SEEncore
speed
reducers
pruss
ojt.t:. drain.
andievet
are
: "'T]]:r-Ih:."ppr.p^,i:te
please
tdenttfied
in Figures
3 & 4.
notethat theselocations
areuniquefor eachoperating
position
shown.After
draining
theoldtubricant,
newtubricant
shouJd
beadded
to the app'opnate level pl,rg shown.
Mounting position and Lubricant Levelstor Singleand
Doubre
Beduction
Moders
Op|mat tubricantevetinformationfor singeand double
reductionmodelsis shown
w lrn
r r rFigures
rgures o
3 dand
u 4
4.. LLubricant
U o r ca n r
'evplsare
'evpls
properoperation
are crit,cal
crit,calto the
the proper
operationof atlsppeo
sppeo
reduce.s.
tf a soeedreducer
wasorderedanosupptied
ror a spectttcmountingposition.it shouldnot be changed
without coniacltng
wtTTOUt
contacting Winsmiih.
Wtnsmtth,
Attering
A teringthe
the rlountrng
mounting
positionfrorr that wh ch was spec:fiedmav resuttin
inaoequateluoricatron.
ContactWinsmithor a ocal sates
reoresentative
wirh ouestionsreqardingproperlubricant
selectronand level.
5. Long Term Storageor InfrequentOperation
lf a speedreduceris to standidlefor an extendedperiodof
time,eitherpriorto installation
or duringuse,the housrng
shouldbe completely
filledwith oil.Thiswi protectthe
Intenorcomponents
fromcorrosiondue to internal
condensation.
Be sureto drainthe orlto the properlevel
priorto placingthe reducerintoservice.ContactWinsmith
or a localsalesrepresentative
withquestionson long
termstorage.
I
6. GreaseFittings
Somespeedreducermodelsare equippedwith grease
fittingsto lubricatebearingsthat are not adequately
lubricatedby the oil splash.Thesefittingsmust
be lubricatedevery3 6 monthsdependingon the
operatingconditions.WinsmithusesMobilithSHC220
or equivalent(NLGI#2).Cautionshouldbe usedwhen
greasingbecauseexcessivegreasemay reducethe
performance
of the lubricantinsidethe speedreducer.
7. Low InputSpeeds(Under1160RPM)
grease
Wheninputspeedsare lessthan 1160RPIV1,
fittingswiil be requiredto lubricateany bearingsnot
partiallycoveredby the normaloil level.lf a low speed
operatingconditionexistsand the reducersare without
the appropriategreasefittings,pleasecontactWinsmith
or a localSalesRepresentative.
8. Oil Temperature
Speedreducersin normaloperationcan generate
temperatures
of up to 200 degreesF dependingon the
type of the reducerand the severityof the application
(loading,durationof service,ambienttemperatures).
may be the resultof one or
Excessiveoil temperatures
moreof the followingfactors:
A. Overloads
Overloadsmay be due to the originalmodelbeing
too smallfor the application.Overloadscan also
occur if the speedreduceris properlysizedfor the
applicationand higherthananticipatedloadsare
Alwayscheckthe reducerrating
experienced.
when increasingdrivenloadsor whenincreasing
the horsepowerratingof the motoror other
primemover.
B. Overfillingor Underfilling
lf a speedreduceris overfilledwith oil, the energy
used in churningthe excessiveoil can resultin
lf overfillingoccurs,shut downthe
overheatlng.
drive,removethe oil levelplug,and allowoil to drain
frornthe levelholeuntil it stops.Reinstallthe level
plugand restartthe drive.
lf the speedreduceris underfilled,the resultant
and possible
frictioncan causeoverheating
damage.lf this occurs,the reducershouldbe
disassembled
and inspectedfor excessivewear.
'10
Replacedamagedcomponents,reassemble
the
reducer,and fill with lubricantto the appropriate
levelfill hole.
C. lnadequateCooling
In orderto dissipateinternallygeneratedheat,the
speedreducermust be installedin sucha way
that air can circLrlate
freely.Tightlyconfinedareas,
(insidecabinets,etc.)shouldbe avoided.if this is
not possible,use a separateblowerto provide
forcedair cooling.
9. Oil Sealsand Wear Components
Variousnormalwearcomponentssuchas seals,
bearingsand gearsmay needmorefrequent
replacementin severeapplications,
Gearreducershaftlip sealsare all subjectto weat
Experience
indlcatesthat theirusefullife is extremely
variable,and basedpr mafiy on the operaing
temperature.
Otheroperatingfactorsthat rnfluence
seal life are highinputshaftspeedsand envrronmental
factorssuchas air-bornabrasiveparticulates.
Inspectingthe gearreducerregularlyand repacingthe
shaftsealsat the first sign that theyare beyondtheir
usefullife is the only methodof ensuringno lubricant
leakage.This mightbe as frequentlyas 2 yearsor less
in someapplications;in othersit can be as long as 10
yearsor more.
Winsmithuseshighqualityoil sealsand precisron
groundshafts.However,it is possiblethat damage
duringshipment
or rnstalation
cancauseoil seal
leakage.Whenreplacinga shaftoil seal,the following
suggestionswill helpensureleakfreeoperationand
longseallife:
A. Wheninstallinga new seal,coverthe keyrvayand
with smooth
any othershaftsurfacediscontinuities
protect
tape to
the seal lip from beingdamaged.
B. Usea sealantbetweenthe OD of the sealand the
lD of the boreinto whichthe seal is beinginstalled.
The sealboreshouldalso be freeof any burrs,nicks,
or scratches.
C. Be surethat the sealis not cockedin the sealbore.
The outerface of the sealshouldbe flushwith the
outersurfaceof the reducer.
DuPontrt^,Zytelb,and l4ton@are registeredtrademarks
of E. L du Pont de Nemoursand Company.
WARNIIIGS
ANDGAUTIONS:
ta
Winsm
th produclsandassocatedequpmenlandmaclrneryarc nlendod
for
seecton
andusebylran€d
andsk edp€6ons
capab
e oldelerm
n n9iher
siab iyjorihespsifcappicaionoruse.
Properselecion,lnsialaion,
operation
andmaintenance.
incudng nrplementation
oi ad4uate
saiety
precaulions
aretheresponsb
lityol lh-"purchassor userfte fo owngsaf€iy
precauiions
precaut
aswe asaddl onalsaiely
onsthatmayberequredlofthe
spec
licappcalion
oruse,ae lherespom
biltyol lhepurchaser
orusl
FALURE
TOOBSERVE
REOUIBED
SCFFIY
PFECAUTIONS
COULO
RESULT
IN
SEBOUS
INJUFYTO
PEFSONSOR
PFOPERTY
OFOTHEF
LOSS.
Lock-ouftaq-out.
r s EXTFEMELY
|MPOF|ANTlhat
equpment
ormach
nery
y stai. Toprevenl
doesnotunexpected
llris po$ib rty,a e ectncaorother
npuipower
sources
musibeiumed
olf,andproperyiocked
outTagou1
pmcedures
muslbelollowedbetorelvorking
onornearthereducef
orany
Ns a1€d
elupmenlLoads
onlheinputandoulput
shafls
should
be
prorio working
disconnecied
onanyrelucer Falureio obseflethese
precaut
onsmayresut ins€rious
bodiy injuryand/orproperly
damaqe.
grounded
Besurellleunlandassocialed
Grcundino.
equpnrenl
arcpropedy
andolhe|wse
nstaedinaccodancewlhai
e€clicalcoderequircmenls
Nota s{oood siructure.A speedredLrcef
muslneverbeusedasan ntegra
componenl
01arnach
nesup€rslruclue
orsuppon
irame
thalwoud sublect
1lo
addllonal@dsotherihanpropery raledloadsl ransnr11ed
thouqhthestufts.
gearreducer
Mountino
Posilion.
Your
Wlnsmlh
should
bemounled
n oneof
positonsshown
themountng
nthecalaog.
Dfle€ntmounlngposliom
shouldnolbeusedwithoutconlactngirymsm
lh asih s mayrcsultin mpbper
poslionsmay
Ovetnead
Mounlinc.Mounling
ol a sp€edreducer
moverhead
b€hazardous
Useoi enemasupport
la s orstructLrre
s stmngy
recommerted
loranyoveheadnrount
ng.
povidedonth€g€arreducs
LiltingEvebolts.
Any fi ngsupporrs
oreyebolts
arcsupplied
withlhepurpose
to verlicay linth€g€arrcducer
ony,wthoutany
other
atachmenis
ormoio6.lnspecisuch
supportsandbols
belore
eacnuse.
Propedv
SecrrEilounling8olts.Prcpermouningb0rsandpropertorques
muslbeappil€d
andmantaned10nsurc
thegear€ducer
isscuelymounted
10lhedesircd
machinery
Inspeclreguadym maclrnev bralionmayoosen
PrulecliveGuadino / LooseClothino.elc.Awaysnsu'€thercis proper
prolmtveguading
padsNever
overallrctain!
ormovng
a lowloose
cloihng,
lrrrcadlockinoCoinoound.
Poperihrcadockngcompound
shourd
be
partsor
y apped10lhec €an€dihreadsoi allmounling boltsconneclhgor
hair,leweryandthe keto beworninllrevicnly of rolalingormoving
appopriale
y ngwitha applicable secur
mach
n€ryThepdchaseror
us isresponslble
lorcomp
ngthespeed
reducer
lo equipmenl
andanydrve,accessoies,
orbrake
saretycodes.Faurcto dosomayrcsuliins€rious
bodly injuryand/ordamag€ components
altached
10lhesp€edreducerf ai any1meaiternstaatona
lacldy s pp edassem
by orconslruclion
bolt s €nroved,
caremuslbelaken
y c eanoflllreoldlhreadl@kngmmpound
lo llrorouqh
anda n€wappropr
al€
Selection& lnslallalion.
Ths reducer
andassocialed
equipment
muslbe
lhrcadockn9compound
mustbeappliedFaiiure
lo prcpedy
applynewtlr€ad
selecled,
insta€d,adiusled
andmaintaned
byqualed peBonne
wlroaE
ockngcompound
onalmountng
orr€ducef
conslruct
onbolsmayresu
1n
knowed9eabe iegarding
all€qu pmentn lhesystem
andlhepolentiaha.zard
s
sedo0sniuryordealhlromlalingm€chanical
componenls
Reducer
Sudacels Hot.Opera1
n99s rcdlceEgmeraieheat Surrace
ConsultCataloo
Ralinas.
Load,lorque
andotlrer
requ
rements
rnustnol
lemperalu€s
maybecome
hotenoughlo
causo
sev€r€
burnsProperpeGona
prolmtveequpmenl
exc*dlhepubslredElings
nihecurentcataogand/oronlhespeedreducer
should
beused.
nameplate,
andih€reducef
seecledmustbeconsslentwiiha seruceracloB
forlheappcalon SeeWnenlhcalaogsanduwwWNSM
TH.com
nqg€arrenuceB
maygen€rate
highnois€evels.UseappEprate
llqise Operat
h€arngprolecionandavoidexlended
exposu'e
to highnoi* evels
Bnke ToruueLoads.Whenever
a bmkeoranyollrerstoppngrorces nvoived
inanapplicalion,
braking
lorque
loadsmposed
onlhegearreducsnuslnol
LubdcadsHotaldude4lelsqq Thetemperature
of u$ canlsnsidea
gearreducer
exceed
thea rowab
e oad€lircs
maybeveryhgh.Tlrereducer
shouldbeallow€d
to coollo
ambentlemperature
beiorcremovaofanyvenl.dran, evelorlill plugs,and
Nota 8Eke.Speed
redrss sh.uC.e€,be6ed lo povdethelunclonofa
beloreremovn! seas orbeadnq
covers.
Geafreducers
withoula pfessurc
venl
iars ai€bm k eora .a $ -d s ' o .(.!c e !c e So e erc
muslnever
be
mayalsobeunder
n d u cen
Eealntsnapre$ue.Sowyloosnih€ubrcanllillplug
y.
usedlo replace
a DG{.r.r:.:.a ..ak^g3ip catonfunclion
abovelhelubricant
levelo ventanyniemalpr€ssure
belorctunnerd sassemb
Bcess Oy€fillnoLoads.Ercessveoveriungoadsonlheinpuiorouipul
shaftsofa gearrcducaroy €u* premalurc
iatguelaiu€s oflhebeatings
and/orshails.Mounlgea pulleys
andspmkeisasc oseio lhehousing
as
poslibe'or - - ?es-(r oadsDo.ole(eedcaaloq?r-qe.
Lub cantContact.Contacl
withlubdcants
cM presenl
salelyconcems.
Prcp€t
pereonal
prot€civeequlpment
shouldbeusedwhenever
handngsp€edreducer
ubcanls.Consuit
thelubicant
MSDS
sh*i whch s ofls available
onthe
ubfcalonmanufaclurer's
w€bsle.
Excess
Thrust
Loads.
Ex.ess!elhrusl
oadsonthe
npuioroutpul
shalls
ol a
premature
geafreducer
ria! cause
farureotbearngs.Donotexceed
calaog
FDA.USDI,and
NSFApolietions.
Factorysupplied
ubrcanls
maynoib-"
prcduc1s.
sulableorsaleforappcatons
invovng
iood,drugs
andsmilar
Ths
ncludes
applications
subleclroFDA.
USDA,
NSFororhef
requlalory
dion
iudsd
Consullhe
ub cantNpptrorWnsmlhloracceplabelubrcanls
power
P.operr!
Alionme.lt,
a qnanynputandoutpul
tmnsfer
e emenis
conn{led1olhespeed
rcducer
Even
sightmisalignmenls
n a fgidmounling
slstenia! calsee nding,large
v bratonforces
orex€essive
ovehung
oads
ead.9to prematue
b€ar
ng,slraft,
orspeed
reducfl
fairc. Useoflexble
coupnls lhaialowlhereducerand
connecied
transi-ar
elemenls
io sel a !n
dunng
operat
onw I compensaie
formnormsagnments.
InsoectionandLub
geafreducerloensure
calion.Feqularyinspeclthe
l6
propedy
operatn9,andfo owa manlenance
operaionandlubicalion