Maintenance Manual en 2020 01

Installation and Maintenance
Helical and Bevel Helical Gearboxes
KUMERA POWER TRANSMISSION GROUP

Gearbox installation and maintenance 84 80 27F_EN
Helical and bevel helical gearboxes
KUMERA DRIVES OY KUMERA ANTRIEBSTECHNIK GMBH

Kumerankatu 2 Raiffeisenstrasse 38-40
FI-11100 Riihimäki A-8010 Graz
FINLAND AUSTRIA
Tel. +358 20 755 4200 Tel. +43 316 471 524 0
Fax +358 20 755 4220 Fax +43 316 462 550
E-mail [email protected] E-mail [email protected]
[email protected]
24h service +358 400 300 644
KUMERA AS KUMERA (CHINA) CO, LTD.

P.O. Box 2043 168 Meifeng Road,
N-3202 Sandefjord Kunshan 215300, Jiangsu
NORWAY CHINA
Tel. +47 33 48 54 54 Tel. +86 512 503 61701
Fax +47 33 48 54 55 Fax +86 512 503 61710
E-mail [email protected] E-mail [email protected]
© Kumera Drives 2020

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Introduction Symbols
These are general instructions for persons To be observed during operation and
installing, operating or maintaining helical and maintenance.
bevel helical gearboxes made by Kumera
Drives Oy. They should read and understand
the contents of these instructions. An important issue to be observed
during installation, operation, and
Kumera Drives Oy is not liable for any maintenance.
damages caused by not following these
instructions.
The gearboxes described in the instructions are

similar to the gearboxes being manufactured at
the time of writing.
Translation of the original instructions.
Copyright:
These instructions are © Kumera Drives Oy. The instructions must not be used for commercial or competitive
purposes without the permission of Kumera Drives Oy.

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Contents
1 Safety........................................................... 4 5 Lubrication.................................................. 21
1.1 Gear noise pressure levels.......................... 5 5.1 Lubrication basics...................................... 21
1.2 Screw tightening torques.............................. 6 5.2 Oil and grease quantities........................... 21
2 Technical Information................................... 7 5.3 Oil change.................................................. 21
2.1 Type plate..................................................... 7 5.4 Cleanliness of oil........................................ 22
2.2 Type code..................................................... 8 5.5 Oil preheating............................................. 22
3 Storage......................................................... 9 5.6 Oil cooling.................................................. 22
3.1 Normal protection, 0 to 12 months............... 9 5.7 Synthetic lubricants.................................... 23
3.2. Long-term protection, 5.8 Breather plug.............................................. 23

longer than 12 months................................. 9
5.9 Recommended lubricants.......................... 24
4 Installation and Start-up............................. 10
6 Gearbox Design......................................... 25
4.1 Lifting.......................................................... 10
6.1 Housing...................................................... 25
4.2 Gearbox start-up........................................ 10
6.2 Toothed parts............................................. 25
4.3 Gearbox alignment..................................... 10
6.3 Bearings..................................................... 25
4.4 Installing of a foot-mounted gearbox.......... 10

6.4 Sealing....................................................... 26
4.5 Mounting a coupling................................... 12

7 Gearbox Accessories................................. 29
4.6 Installing of a shaft-mounted gearbox 7.1 Backstop.................................................... 29

with a keyway............................................. 14
7.2 Lubrication pumps...................................... 30
4.7 Installing of a shaft-mounted gearbox
with a shrink disc........................................ 15 7.3 Pressure lubrication unit............................. 31
4.8 Installing a torque arm................................ 16 7.4 Gearbox cooling methods.......................... 32
4.9 Installing of a motor to the gearbox............ 17 7.5 Heating the gearbox oil.............................. 33
4.10 Installing of a V-belt drive........................... 18 7.6 Vibration measurement adapter................. 33
4.11 Installing of a tooth-belt drive..................... 19 7.7 Temperature sensor PT-100....................... 33
4.12 Installing of a chain drive............................ 20 8 Scheduled Maintenance............................. 34
4.13 Filling lubrication oil.................................... 20 9 Troubleshooting.......................................... 35
4.14 Installing of the breather plug..................... 20 10 Disposal..................................................... 35

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1 Safety
In order to prevent any damages, transportation, Helical and bevel helical gearboxes may
unpacking, installation and setup shall be generate noise pressure levels in excess of the
performed by professional personnel in permissible noise pressure level, depending
accordance with the instructions of Kumera on the output power level of the gearbox.
Drives Oy. Persons working near the gearbox must use the
appropriate protection.
A gearbox must not be installed in a place or
used in a way it was not designed for. Gearboxes The gearboxes may warm up to the extent that
are delivered to the customer in accordance their surface becomes hot. Avoid touching the
with the information supplied to Kumera Drives gear surface during operation.
Oy, and this information must not be deviated
from when installing the gearbox. Gearboxes The gearbox was packed at the Kumera
must not be subjected to extra application of Drives Oy factory according to the terms of
load due to installation. delivery, in such a way that it withstands normal
transportation.
Pay attention to safe operation when installing
the gearbox. Protect places dangerous to the When lifting the gearbox, use its lifting eyes.
operator. Do not make any changes to the See the machine plate for the weight of the
structure and guards of our gearboxes. Kumera gearbox. The gearbox lifting eyes are only for
Drives Oy is not liable for structural changes or lifting the gearbox, not for accessories such as
changes to the guards made by another party. an electric motor. Do not use the shafts when
lifting. Report any damage during transportation
Do not remove the safety devices while the immediately to Kumera Drives Oy.
gearbox is in use. Perform any maintenance
operations while the gearbox is standing still.
When opening inspection covers, make sure
that no foreign objects or impurities can enter
the gearbox.

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1.1 Gear noise pressure levels
Table 1 lists the noise level behaviour of helical According to the ISO 4871 standard, the
and bevel helical gearboxes in accordance with emission sound pressure level is to be measured
the power class of the gear. The table values at a distance of 1 metre from the outer surface
are calculated and indicative, and they can be of the gearbox. Noise level variations due to
used for comparison with the noise level of the accessories are not taken into account in the
gearbox during operation. table.
One fan increases the noise level by approx.

3 dB(A). Major deviations from the values must
be examined in order to establish the cause of
the unusually loud noise.
TABLE 1. Output power / emission sound pressure levels of helical and bevel helical gearboxes
Helical gearboxes Bevel helical gearboxes
Unit output Noise level Unit output Noise level

(kW) (dBA) (kW) (dBA)
5 54 5 56
10 58 10 60
20 61 20 63
40 65 40 67
60 67 60 69
80 69 80 71
100 70 100 72
150 72 150 74
200 74 200 76
250 75 250 77
300 76 300 78
400 77 400 79
500 79 500 81
700 80 700 82
900 82 900 84
1200 83 1200 85
1500 84 1500 86
2000 86
2500 87
3000 88
3500 89
4000 90
4500 90
5000 91

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1.2 Screw tightening torques
All the screw connections mentioned in the We recommend greasing the screws before
instructions must be tightened according to installation. The table provides values for dry
Table 2, unless otherwise mentioned in the and greased (friction coefficient 0.10) screws.
installation instructions.
TABLE 2. Screw tightening torques
Grade 8.8 Grade 10.9 Grade 12.9

Thread
size Dry Greased Dry Greased Dry Greased
(Nm) (Nm) (Nm) (Nm) (Nm) (Nm)
M 10 49 40 69 59 79 71
M 12 86 69 120 100 136 120
M 16 210 170 295 250 333 265
M 20 410 340 580 490 649 580
M 24 710 590 1000 840 1120 1000
M 30 1450 1200 2000 1700 2210 2000
M 36 2530 2070 3560 2990 3850 3500

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2 Technical Information
2.1 Type plate
A type plate is installed during packing onto all the gearboxes supplied by us. The plate contains the
required identification information and lubrication recommendations of the gearbox.
Example of the gearbox type plate:
Type: Gearbox type (see page 8)
Serial No.: Gearbox serial number
Year: Manufacturing year
Gear ratio: Exact gear ratio
Weight: Weight without oil
Lubricant: Recommended viscosity of lubrication oil
Oil qty: Indicative oil capacity, to be checked using the oil sight glass, the oil level
sight glass or the dipstick.
P1N (n1): Nominal power of the gearbox
Ksf : Selection factor
ATEX: Note: If the gearbox is ATEX certified, the ATEX mark and class are
marked in the bottom left corner.

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2.2 Type code
R F B M – 3 180 H1 J – 56 – L B S 4 – 42F300 – E1
Model
L Foot mounted, helical gearbox
T Shaft mounted, helical gearbox
K Foot mounted, bevel gearbox
R Shaft mounted, bevel gearbox
S Mixer gearbox
Range
AFGDX
Foot
ABCD/LTKR
Motor adapter
Number of reduction stages
12345
Gearbox size
Output shaft, options
H1 Hollow shaft, normal
H2 Hollow shaft, stepped
H3 Hollow shaft, shrink disc
Additional equipment
J Backstop
T Fan
V Water cooling coil
Z Pressure lubrication unit
P Lubrication oil pump
K Centralized lubrication system
Ratio
Shaft arrangement
L Output shaft to the left
R Output shaft to the right
V Input and output shaft to the left
H Input and output shaft to the right
Mounting positions
A Horizontal
B Vertical, output horizontal at bottom
C Vertical, output horizontal at top
D Output shaft vertical at left
E Output shaft vertical at right
Foot positions
N Underneath
P Above
S On the same side as the output shaft
O On the opposite side from the output shaft
Rotation directions of shafts
1 Output shaft clockwise
2 Output shaft counter-clockwise
3 Output shaft clockwise, input shaft clockwise
4 Output shaft counter-clockwise, input shaft clockwise
5 Output shaft clockwise, input shaft counter-clockwise
6 Output shaft counter-clockwise, input shaft counter-clockwise
IEC code for flange of the electric motor
Code of special construction

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3 Storage
3.1 Normal protection, 0 to 12 months 3.2 Long-term protection, longer than 12

months
THE GEARBOX IS
DELIVERED WITHOUT The long-term protection is to be agreed
LUBRICANTS! separately when ordering. The long-term
storage provides protection to the gearbox in
The gearboxes have been treated as follows dry indoor spaces with an even temperature.
before delivery: Store the gearbox on a vibration free base.
The shaft ends and other machined surfaces The shaft ends and other machined surfaces
outside the gearboxes are treated with anti- outside the gearboxes are treated with anti-
corrosive agent. Remove the anti-corrosive corrosive agent. Remove the anti-corrosive
agent with solvent before start-up. agent with solvent before start-up.
The internal parts of the gearbox are protected 3.2.1 Rust proofing with anti-corrosive
by oil that spreads to their surfaces during the agent
test run. Gear oil is used in the test run.
Repeat internal rust proofing of the gearbox
Anti-corrosive agent is also sprayed inside every 12 months using anti-corrosive agent.
the gearbox. The gearbox is made airtight by You need not remove the anti-corrosive agent
replacing the breather plug with a pipe plug. The during start-up.
effect of the agent is based on slow evaporation
and accumulation on the metal surfaces. An During storage, use the gearbox every 12
invisible layer is formed on the metal surfaces months manually so that all the shafts rotate at
and prevents corrosion by passivating the least half a turn. Replace the pipe plug with the
metal. Replace the pipe plug with the breather breather before start-up.
before start-up.
3.2.2 Rust proofing with oil fill
In gearboxes with a labyrinth sealing, the gas
can escape, in which case the gearbox is Alternatively, you can fill the gearbox with oil.
enclosed in airtight plastic that prevents the
agent from escaping. When filling the gearbox with oil, use the
quantity indicated in the type plate. At the same
This provides protection for storage for up to time, replace the breather with a pipe plug. In
12 months in dry indoor spaces with an even addition to rust proofing, the oil protects the
temperature. Store the gearbox on a vibration bearings from pitting during transportation.
free base. During storage, use the gearbox every 2
months manually so that all the shafts rotate at
least half a turn. This spreads the oil onto the
gear surfaces. Replace the pipe plug with the
breather before start-up.
THE NORMAL PROTECTION 3.2.3 Rust proofing with full oil fill
OR LONG-TERM
PROTECTION TREATMENT In case it is not possible to operate the gearbox
DOES NOT PROTECT or rotate the shafts during storage, fill the
THE GEARBOX DURING gearbox completely with oil. Change the oil
TRANSPORT BY SEA. during start-up. Replace the pipe plug with the
breather before start-up.

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4 Installation and Start-up
THE GEARBOX IS DELIVERED During operation, pay attention to the operating

WITHOUT LUBRICANTS! sound, warm-up, vibration and oil circulation.
Overheating, for example, is often caused by

4.1 Lifting an excessive amount of oil in the gearbox.
For gearbox operation, the recommended
For lifting, the gearboxes have been maximum temperature is +90 °C. In higher
provided with one or several lifting eyes. temperatures, use special lubricants and/or
Lifting must be done simultaneously and additional cooling. The oil change interval is
symmetrically by all lifting eyes. The load shorter in high temperatures.
suspension angle shall not exceed 45°. The
lifting eyes must not be used for any other Stray current shall be prevented from entering
purpose except lifting the gearbox. the bearings and toothings of the gear unit. In
case there is a possibility of stray currents, it is
Do not use the shafts for lifting the gearbox. If recommended to make necessary stray current
the shaft and its bearings are subjected to even measurements during commissioning, in order
a slight load in the wrong direction, the shaft for the supplier of the whole equipment to be
bearings may be damaged. able to take the necessary actions to prevent
stray currents.
4.3 Gearbox alignment
The gearbox must be installed to the designed

mounting position according to the tolerances of
the Figure 2.
FIGURE 1. Maximum lifting angles of the gearbox FIGURE 2.
4.2 Gearbox start-up 4.4 Installing of a foot-mounted gearbox
All gearboxes are test-run prior to delivery from A requirement for faultless operation of the
the factory. However, the test run does not gearbox is an even and sturdy foundation. The
correspond to actual load conditions: for this installation foundation of the gearbox must
reason, you should at first operate the gearbox be designed to withstand unit loads without
at a partial load. During the running-in, monitor distorting.
the operating sound, running smoothness,
temperature, lubrication and oil tightness of Distortion of the foundation during operation
the gearbox. If you notice something abnormal may cause distortion of the gear housing and
during running-in, detect and eliminate the incorrect tooth contact. This may result in
cause of the problem before the final start-up. breakdown of the teeth, bearings or housing.

10/36
The foundation must not resonate as a result

of gear running, and any resonance caused by
nearby equipment must not be allowed to affect
the foundation.
Small gearboxes with mounting feet can be

mounted directly onto a concrete foundation
with foundation bolts. Use shims between the
concrete foundation and the bedplate when
using foundation bolts. When the grout of the
foundation bolts is dry, check that the foundation
is straight. Correct any faults with shims. Then,
tighten the foundation bolts.
FIGURE 4. Gearbox installed on mounting columns
1. Nut 5. Adjustment screw

2. Shim (1…1.5 mm) 6. Grout
3. Stud bolt and T-slot nut 7. Mounting plate
4. Mounting column 8. Foundation
The mounting screws and nuts must be

tightened to the correct torque without
exceeding the maximum values determined by
the screw grade. The required torque depends
on the diameter, number and grade of the bolts.
The minimum tensile strength of the bolts,
mounting columns and beams is 350 N/mm2.
The foundation must be reinforced so that

its strength is at least the same as that of the
gearbox mounting screws. It acts also as the
FIGURE 3. Gearbox installed with foundation bolts dowel-bar reinforcement for grouting.
1. Nut 5. Foundation bolt Grouting is performed after the gearbox has been
2 Shim (1…1.5 mm) 6. Grout of foundation bolts placed in position. Leave the grouting below the
3. Steel plate 7. Beam T slot of the mounting column. Its compressive
4. Nut 8. Foundation strength must be at least 20 N/mm2. When the
grout is dry, check the alignment of the gearbox.
The base must be horizontal and even (max.
For mounting large gearboxes (shaft distance deviation 0.01 mm/100 mm).
>250 mm), we recommend either mounting
columns made of cast iron or steel, or machined Before installation, check that the oil drain and
steel foundations. filling plugs are easily accessible for oil change.
Do not weld the gearbox, its housing

or any part! When performing other
welding, do not attach the earthing
cable to the gearbox or its parts.

11/36
4.5 Mounting a coupling
To mount a coupling onto the shaft, heat the 4.5.2 Measuring angular displacement (∆Kw)
coupling halves to approximately +100 °C or
draw them onto the shaft using the tapped holes Angular displacement is usually measured with
at the ends of the shafts. a dial gauge. Place the dial gauge on top of one
of the coupling halves. Make both halves rotate
together while checking that the tip of the dial
4.5.1 Measuring radial displacement (∆Kr) gauge does not move on the measuring surface
(top of the coupling half).
You can measure the radial displacement with a
dial gauge or another appropriate device. Place The installation tolerances of flexible couplings
the dial gauge on top of one of the coupling are specified in Table 3 on the next page. For
halves. Make both halves rotate together while other couplings, follow the manufacturer’s
checking that the tip of the dial gauge does instructions.
not move on the measuring surface (top of the
coupling half). Divide the variance indicated
by the dial gauge to acquire the value of radial
displacement.
The installation tolerances of flexible couplings

are specified in Table 3 on the next page. For
other couplings, follow the manufacturer’s
instructions.
FIGURE 6. Measuring angular displacement
FIGURE 5. Measuring radial displacement

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TABLE 3. Installation tolerance of flexible couplings
Axial Radial Angular

Coupling Dimensions displacement displacement
offset
size [mm] ΔKr [mm] ΔKw [°]
Δka [mm] Speed of rotation [rpm]
L E b s 1500 1500
14 35 13 10 1.5 1.0 0.16 1.2
15 28 8 6 1.0 1.0 0.16 1.2
19 66 16 12 2.0 1.2 0.20 1.2
21 78 18 14 2.0 1.4 0.22 0.9
28 90 20 15 2.5 1.5 0.25 0.9
38 114 24 18 3.0 1.8 0.28 1.0
42 126 26 20 3.0 2.0 0.32 1.0
48 140 28 21 3.5 2.1 0.36 1.1
55 160 30 22 4.0 2.2 0.38 1.1
65 185 35 26 4.5 2.6 0.42 1.2
75 210 40 30 5.0 3.0 0.48 1.2
90 245 45 34 5.5 3.4 0.50 1.2
100 270 50 38 6.0 3.8 0.52 1.2
110 295 55 42 6.5 4.2 0.55 1.3
125 340 60 46 7.0 4.6 0.60 1.3

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4.6 Installing a shaft-mounted gearbox with a keyway
4.6.1 Installation 4.6.3 Locking
To install a shaft-mounted gearbox onto the Lock the shaft-mounted gearbox to the shaft
shaft, drive a screw into the centre hole thread with a screw as shown in Figure 9. Leave a
on the shaft end and then tighten the nut on the space of approx. 5-10 mm between the shaft-
screw as Figure 7 shows. Before installation, mounted gearbox and the bearing housing of
grease should be applied to the shaft to ease the nearest driven machine.
future removal.
The screw diameter must be smaller

than the diameter of the tapped hole
of the thrust plate and equivalent to
the diameter of the tapped hole of the shaft end.
FIGURE 9. Locking the shaft-mounted gearbox
When installing and removing the shaft-

mounted gearbox, you can use hydraulic pulling
1. Gap or pushing devices instead of mechanical
2. Thread screws. They provide higher assembly and
disassembly force.
FIGURE 7. Installing a shaft-mounted gearbox onto
the driven shaft with a key
4.6.2 Removal
To remove a shaft-mounted gearbox,

use the screw and the thread of the
gearbox’s thrust plate. The thread
corresponds to the thread of the thrust plate
hole, and the end is unthreaded. Do not damage
the shaft end thread.
1. Thread
2. Unthreaded
FIGURE 8. Removing a shaft-mounted gearbox from

the driven shaft with a key

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4.7 Installing a shaft-mounted gearbox with a shrink disc
Shrink discs are delivered ready for 5. Install the shaft of the driven machine inside
installation. Do not disassemble them the output shaft on the gearbox.
before they have been tightened for the
first time. 6. Tighten all the clamping screws evenly in a
circle, as shown in Figure 11.
Do not tighten the clamping screws

before the output shaft of the
gearbox has been installed!
1. Inner ring
2. Outer ring
3. Screw FIGURE 11. Tightening order of shrink disc screws
4. Shaft
5. Output shaft
! GREASE-FREE Tighten the screws equally, maximum ¼ to ½
turns at a time, until their tightening torques
FIGURE 10. Structure of a shrink disc are the same. You must tighten the screws in
several rounds. The outer rings must remain
4.7.1 Installation parallel.
1. Remove any spacers that may have Check the tightening torques with a torque
been installed between the outer rings for wrench. See Table 4 for the correct screw
transportation reasons. tightening torques. The values are for screws
greased with MoS2 grease.
2. Tighten the three clamping screws so that
you can still rotate the inner ring. The three
tightened screws must form the tips of an TABLE 4. Tightening torques of shrink disc screws
equilateral triangle. Measure the gap between
the outer rings at different points to ensure that Screws Tightening Tolerance
the outer rings are parallel. (grade 10.9) torque ±5%
(Nm) (Nm)
3. Push the shrink disc onto the output shaft of
M5 4 ±0,2
the gearbox. To make installation easier, you
can grease the outer surface of the output M6 12 ±0,6
shaft of the gearbox at the place where the M8 30 ±1,5
shrink disc is located. M10 59 ±3,0
M12 100 ±5,0
4. Use solvent to remove grease from the inner
M16 250 ±12,5
surface of the output shaft and the shaft of the
driven machine that will be installed to it. M20 490 ±25,0

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4.7.2 Removal 4.8 Installing a torque arm
1. Remove the clamping screws evenly, by When installing, pay attention to the position
loosening them in the opposite order to that of of the torque arm as shown in Figure 12. The
tightening. Initially, loosen each clamping screw torque arm must always be equipped with
only ¼ of a round. In this way, you can avoid two joints that allow movement of the point of
distortion of the outer ring. Never unscrew the support due to thermal expansion. If there is
clamping screws. eccentricity at the end of the driven machine’s
shaft, the torque arm must be equipped with two
2. Remove the shaft of the driven machine from ball joints.
the output shaft of the gearbox. Remove any
corrosion that has formed between the shafts. The torque arm can take compression or tensile
load. With compression load, the arm rod must
3. Remove the shrink disc from the output shaft be designed to be sufficiently strong so that
of the gearbox. there is no buckling. We recommend installing
the gearbox so that compression load is applied
to the arm rod. With compression load, the
support reaction caused by torque lessens the
load of the shaft end and bearing of the driven
4.7.3 Cleaning and lubrication machine.
You need not detach the removed shrink discs

from each other or lubricate them again before
tightening them again. However, clean and
lubricate dirty shrink discs. Grease the clamping
screws with multi-purpose grease and replace
damaged seal rings. When replacing the inner
ring, the bevel surfaces must be greased (e.g.
MoS2).
FIGURE 12. Position of the torque arm

16/36
4.9 Installing a motor to the gearbox
In flange mountings, the installation space 3. A flange motor at the end of a shaft-mounted
between the gearbox shaft and the motor bevel gearbox
shaft must be at least 3 mm. There must
be a gap between the shaft ends.
Instructions on the weight ratio of the motor and

gearbox:
Motor weight ≤ 1.0 x gearbox weight
1. A foot motor on a bracket on a shaft-mounted 4. A flange motor connected to the side of a

helical gearbox shaft-mounted helical gearbox
Motor weight ≤ 1.5 x gearbox weight Motor weight ≤ 0.4 x gearbox weight
2. A flange motor vertically on a gearbox 5. A flange motor connected to the side of a foot-
mounted helical gearbox
The limits can be exceeded only by the

permission of Kumera Drives Oy after a
more specific review of each case.

17/36
4.10 Installain a V-belt drive
1. Mount the motor to its bracket.
2. Attach the back-plate of the guard to the

gearbox and the motor bracket with clamps.
3. Install the belt pulley to the gearbox input

shaft with a suitable tool. Alternatively, you can
use belt pulleys with conic sleeves. Install the
belt pulleys onto the motor and gearbox shafts
axially at the same distance. Install the belt
pulleys as close as possible to the motor and
gearbox bearings. The shafts must be installed
parallel to each other. The maximum permitted FIGURE 13. Belt force
angle error of the belt pulleys is 0.5 degrees.
4. Install the V-belts onto the pulleys and tighten Example:

them with the adjustment screws of the motor
bracket. Tighten the belts according to Table 5. 1. CC = 1.2 m;
When checking the belt tightness, measure the dL = 10 mm;
length of the belt span and the perpendicular
bending force that causes the belt to bend 10 in which case CC x dL
mm (dL) for each 1,000 mm of the belt span = 1.2 m x 10 mm/m
(CC). = 12 mm
Do not over-tighten the belts. Excessively 2. Measure the perpendicular

tight belts increase the load on the shaft ends bending force F with a belt
and considerably shorten the lifetime of the tightness gauge.
bearings.
3. Compare the bending force
5. Tighten the mounting screws of the back with the values in Table 5.
plate of the guard and attach the guard cover The belt bending force should
with a hexagon screw. be within the indicated range.

18/36
TABLE 5. V-belt tightness
Belt Ø of smaller Force needed

profile pulley (mm) to bend the belt
1 mm/100 mm (N)
56-71 7-8
75-80 9-13
SPZ 85-95 10-15
100-125 12-17
132-180 13-19
80-95 12-16
100-125 14-21
SPA
132-200 19-28
212-250 20-30
112-150 23-36 FIGURE 14. A belt drive in a gearbox without a guard
160-200 29-44
SPB
212-280 36-50
300-400 38-58
180-236 40-60 4.11 Installing a tooth-belt drive
SPC 250-355 51-75
The tooth-belt drive pulleys are installed onto
375-530 60-90
the shafts in a manner similar to the V-belt drive,
60-63 8-13 see section 4.10.
67-71 9-14
75-80 10-15 Position the tooth belt onto the belt pulleys
XPZ
85-95 11-16 slack. Tighten the belt to the correct tightness
100-125 13-19 with the adjustment screws of the motor
bracket. According to the formula, the tightness
132-180 16-24
of the tooth-belt depends on the power to be
80-125 18-27
XPA transferred as well as the peripheral velocity.
132-200 22-31 Perform other steps as in section 4.10.
112-118 24-36
125-140 27-41
150-170 30-47 Pretension force: min.:
XPB
180-200 36-53
212-280 38-55
300-400 41-64
max.:
180-236 50-75
XPC 250-355 65-95
375-530 80-110 in which P = power to be transferred, kW
V = belt velocity, m/s

19/36
4.12 Installing of a chain drive 4.13 Filling lubrication oil
A chain wheel is normally installed to the THE GEARBOX IS DELIVERED

slow shaft of the gearbox by heating it to a WITHOUT LUBRICANTS!
temperature of +80 - +120 °C. Small chain
wheels can be installed with a suitable pulling
tool, using the threaded centre holes of the shaft 1. Before start-up, the gearbox must be
ends. filled with oil specified in the type plate of the
gearbox or according to the included lubrication
Install the chain wheels onto the gearbox and recommendation.
driven machine shafts axially at the same
distance. Install the chain as close as possible 2. To check the correct oil level:
to the bearings, so that the bending moment at
the shaft ends remains as low as possible. This • With the oil sight glass: fill the gearbox
also minimizes the bearing loads. with oil up to the middle of the oil sight
glass.
Install the shafts parallel to each other in order
to balance the load on the chain and chain • With the oil level sight glass: fill the
wheels. The maximum angular and parallel gearbox with oil up to between the marks.
misalignment error is ±1/300. The allowed
angle error between the shafts depends on the • With the oil plug: add oil to the gearbox
distance between the shafts. until it leaks out of the opened overflow
hole.
At a distance of less than 1 metre, the allowed
error is ±1 mm. At 1-10 m, the error is calculated • With the dipstick: fill the gearbox with
with the formula (distance between shafts oil up to the area between the dipstick
[mm])/1,000. At a distance of more than 10 marks.
metres, the allowed error is ±10 mm.
3. Check the oil level when the gearbox is at a
When selecting chain drives, make sure that the standstill and the oil has cooled. Avoid overfilling
allowed loads of the gearbox shaft ends are not when adding oil. Too much oil may cause the
exceeded. gearbox to heat up above the allowed limit.
For more information on lubrication and

lubricating oils, see Chapter 5.
4.14 Installing the breather plug
Before starting up the gearbox, make sure that

the breather plug is in place and operational.

20/36
5 Lubrication
THE GEARBOX IS DELIVERED

WITHOUT LUBRICANTS!
5.1 Lubrication basics 5.2 Oil and grease quantities
Depending on the gearbox and operating An indicative quantity of oil is specified in the
conditions, four different lubrication methods gearbox type plate.
are used.
The amount is always indicative. Check
5.1.1 Splash lubrication the exact amount of oil with an oil sight
glass, oil level sight glass, oil level plug or
Splash lubrication is used for gearboxes with dipstick.
peripheral velocities of 2-14 m/s. In this case,
it is essential to ensure that the amount of oil In a grease-lubricated gearbox, the amount of
in the gearbox is correct. Too low an amount grease is specified in the type plate.
causes insufficient lubrication of the gearbox,
and too high an amount may cause the gearbox
to overheat over the allowed limit. 5.3 Oil change
5.1.2 Pressure lubrication 5.3.1 First oil change
Pressure lubrication is used for gearboxes with The first oil change must be performed
peripheral velocities higher than 14 m/s. Utmost after approx. 300 to 500 operating hours
care should be taken to ensure a continuous after the gearbox’s start-up.
flow of oil onto the mesh point of the gear.
Pressure lubrication can also be used for 5.3.2 Oil change interval
gearboxes with slower velocities, if required by
the gearbox. The gearbox oil must be changed every 12
months when using mineral oil, and every 24
5.1.3 Oil bath lubrication months when using synthetic oil. In grease
lubrication, the change must be performed
Oil bath lubrication can be used in slow speed approx. every 8,000 operating hours. In
gearboxes with peripheral velocities slower special cases and when using special oils,
than 4 m/s. This method provides efficient please discuss the change intervals with a
lubrication of the bearings and gears. Due to representative of the oil company or our factory.
the low peripheral velocity, no harmful warming
of the lubricant occurs in the gearbox. The breather plug must be replaced when the oil
is changed. A clogged breather plug generates
5.1.4 Grease lubrication pressure that causes oil leaks in the seals. If the
system has a filter, it must always be replaced
Grease lubrication is used in gearboxes with when the oil is changed.
peripheral velocities slower than 5 m/s. Grease
lubrication is especially suitable for gearboxes 5.3.3 Bearing lubrication
in occasional operation undergoing frequent
starts. The grease remains on the tooth surface If the gearbox is equipped with grease nipples
and in the bearings during stoppages. to lubricate the bearings, add approx. 10-20 g
of new bearing grease into each bearing nipple
every 6 months.

21/36
5.4 Cleanliness of oil
The cleanliness of oil is crucial for the service In splash lubrication, heating is required only if
life of the bearings and gears of the gearbox. the temperature falls below the pour point of the
oil.
There are two kinds of impurities: solid and
liquid. In pressure lubrication, heating is required if the
temperature falls below the following values:
Solid impurities are dust entering the gearbox
from its surroundings, metal particles caused TABLE 6. Oil heating
by wear in the gearbox, carbon from possible
Temperature limits without
overheating and dirt caused by external factors
in the lubrication system (e.g. a container used heating elements
for oil change).
Oil viscosity Splash or bath lubrication Pressure
class lubrication
Liquid impurities are water and chemicals that
have ended up in the gearbox due to processes,
Synthetic Mineral and
washing of the gearbox or condensation. Mineral oil oil synthetic oil
The mechanical cleanliness of oil is determined ISO VG 150 -20 °C -40 °C +6 °C

by the standard ISO 4406. The standard divides ISO VG 220 -18 °C -40 °C +10 °C
the oil cleanliness grade into three parts. The
ISO VG 320 -15 °C -35 °C +15 °C
cleanliness grade of a 100 ml oil sample is
calculated in three parts: particles over 4 µm, ISO VG 460 -12 °C -30 °C +20 °C
over 6 µm and over 14 µm, the amounts of
which are always included in the preceding one. Set the upper limit of the thermostat so that
it switches heating off at a temperature that
The customer is responsible for the cleanliness is approx. +10 °C higher than the above
of the oil. With long oil change intervals, inspect temperature.
the cleanliness of the oil with an oil sample in
order to ensure proper lubrication.
5.6 Oil cooling
Required cleanliness level ISO 4406
• splash and oil bath lubrication -/19/16 Oil cooling may be required due to, for example,
• pressure lubrication -/17/14 a high ambient temperature. When the oil
temperature exceeds +80 °C, oil cooling is
necessary. With synthetic oil, temperatures up
to +90 °C can be allowed. At high temperatures,
ensure the heat resistance of the sealing
5.5 Oil preheating material and sufficient clearance of the bearings.
If the gearbox is installed in a cold environment Cooling of a gearbox can be arranged as

and is equipped with pressure lubrication, oil follows:
preheating is often required. The oil is heated
with a heating element installed in the oil • Install a fan to the input shaft of the
sump of the gearbox. A separate thermostat is gearbox. Also several fans can be used.
installed for controlling the heating element.
• Install a water cooling coil in the oil sump.

22/36
5.7 Synthetic lubricants
Gearboxes with pressure lubrication can be Synthetic lubricants can be used in gearboxes
cooled as follows: that are operating in very low or high
temperatures and when the oil change interval
• Install a water-cooled heat should be extended. When using other than the
exchanger into the oil circulating system. synthetic lubricants specified below, check the
suitability of the sealing materials.
• Install an air-cooled heat exchanger into
the oil circulating system.
For more details, see section 7.3. 5.8 Breather plug
The breather plug is supplied detached. Install it

when filling with oil. The breather plug must be
replaced when the oil is changed.
A clogged air filter generates pressure that

causes oil leaks in the seals.

23/36
5.9 Recommended lubricants

Recommended viscosity for lubricant
Splash or bath lubrication Pressure lubrication
Oil sump Max. ambient Oil sump Max. ambient
Mineral oil Synthetic oil Mineral oil Synthetic oil
temperature temperature temperature temperature
< 60 °C < 25 °C 220 220 < 60 °C < 25 °C 150 150
61-80 °C 26-45 °C 320 320 61-80 °C 26-45 °C 220 220
81-95 °C 46-60 °C - 460 81-95 °C 46-60 °C - 320
Lubrication unit with additional cooling
Lubrication unit without additional cooling
NOTE. Proper lubrication oil viscosity class is selected by Kumera and marked on gearbox type plate.
Mineral oils DIN 51517-CLP, EP (extreme pressure) oil

ISO VG 150 220 320 460
AGMA 4 EP 5 EP 6 EP 7 EP
ARAL Degol BG 150 Plus Degol BG 220 Plus Degol BG 320 Plus Degol BG 460 Plus
BP Energol GR-XP 150 Energol GR-XP 220 EnergolGR-XP 320 Energol GR-XP 460
CASTROL Optigear BM 150 Optigear BM 220 Optigear BM 320 Optigear BM 460
FUCHS Renolin CLP 150 Renolin CLP 220 Renolin CLP 320 Renolin CLP 460
KLÜBER Klüberoil GEM 1-150 N Klüberoi lGEM 1-220 N Klüberoil GEM 1-320 N Klüberoil GEM 1-460 N
604 Almasol Vari- 607 Almasol Vari- 605 Almasol Vari- 608 Almasol Vari-
LE
Purpose Gear Lub Purpose Gear Lub Purpose Gear Lub Purpose Gear Lub
LUKOIL Steelo 150 Steelo 220 Steelo 320 Steelo 460
MOBIL Mobilgear 600 XP 150 Mobilgear 600 XP 220 Mobilgear 600 XP 320 Mobilgear 600 XP 460
NESTE Vaihteisto 150 EP Vaihteisto 220 EP Vaihteisto 320 EP Vaihteisto 460 EP
SHELL Shell Omala S2 G 150 Shell Omala S2 G 220 Shell Omala S2 G 320 Shell Omala S2 G 460
TEBOIL Pressure Oil 150 Pressure Oil 220 Pressure Oil 320 Pressure Oil 460
TEXACO Meropa 150 Meropa 220 Meropa 320 Meropa 460
TOTAL Carter XEP 150 Carter XEP 220 Carter XEP 320 Carter XEP 460
Q8 OILS Q8 Goya NT 150 Q8 Goya NT 220 Q8 Goya NT 320 Q8 Goya NT 460
Synthetic lubricants
Synthetic lubricants can be used in gearboxes that are the mineral oil otherwise used in the same conditions.
operating in very low or high temperatures or when the When using other than the synthetic lubricants
oil change period should be longer than usual. The specified below, check the suitability of the sealing
viscosity of synthetic oil must be the same as that of materials.
Synthetic oils DIN 51517-CLP, EP (extreme pressure) oil

ISO VG 150 220 320 460
AGMA 4 EP 5 EP 6 EP 7 EP
BP Enersyn HTX-150 Enersyn HTX-220 Enersyn HTX-320 Enersyn HTX-460
CASTROL Optigear synth X 150 Optigear synth X 220 Optigear synth X 320 Optigear synth X 460
FUCHS Renolin Unisyn CLP 150 Renolin Unisyn CLP 220 Renolin Unisyn CLP 320 Renolin Unisyn CLP 460
Klübersynth GEM Klübersynth GEM Klübersynth GEM Klübersynth GEM
KLÜBER
4-150 N 4-220 N 4-320 N 4-460 N
NESTE Vaihteisto S 150 EP Vaihteisto S 220 EP Vaihteisto S 320 EP Vaihteisto S 460 EP
MOBIL Mobil SHC GEAR 150 Mobil SHC GEAR 220 Mobil SHC GEAR 320 Mobil SHC GEAR 460
SHELL Omala S4 GX 150 Omala S4 GX 220 Omala S4 GX 320 Omala S4 GX 460
TEBOIL Sypres 150 Sypres 220 Sypres 320 Sypres 460
TOTAL Carter SH 150 Carter SH 220 Carter SH 320 Carter SH 460
Lubricant greases Grease lubricated gearboxes Grease lubricated bearings

ARAL Aralub FDP 0 Aralub HL2
BP Energrease LS EP 0 Energrease LS EP 2
CASTROL Longtime PD 0 Longtime PD 2
MOBIL Mobilux EP 0 Mobilux EP 2
SHELL Alvania Grease GC 00 Alvania Grease RL 2
TEBOIL Universal CLS Multipurpose EP

24/36
6 Gearbox Design
6.1 Housing 6.3 Bearings
The housings are made of grey cast iron. If All the shafts of the gearbox are equipped with
necessary, nodular cast iron or a welded steel roller bearings. The bearings are self-lubricated,
structure is used. The division planes of the pressure-lubricated or splash-lubricated.
housings are sealed with elastic compound.
With splash lubrication, it is important to ensure
6.2 Toothed parts that the oil level of the gearbox is correct. If
necessary, you can monitor the condition of
The helical teeth are case-hardened and the bearings with vibration measuring adapters
ground, and calculated according to the that can be used for measuring vibrations or for
standard ISO 6336. The bevel gears are case- listening to bearing sounds.
hardened and lapped, and calculated according
to the standard AGMA 2003-B97.
FIGURE 15. A basic diagram of a helical gearbox
1 Housing half I 12 Inspection cover 31 Distance ring 52 Breather plug 69 Bearing

2 Housing half II 19 Gear 34 Distance ring 56 Eye bolt 70 Bearing
4 Bearing cover 20 Gear 35 Distance ring 57 Helical pin 75 Shaft oil seal
6 Bearing cover 21 Input shaft 40 Counter plate 61 Rectangular key 77 Shaft oil seal
7 Bearing cover 23 Intermediate shaft 41 Cover 62 Rectangular key 78 Shaft oil seal
8 Sealing housing 24 Intermediate shaft 44 Pin 63 Rectangular key 81 Snap ring
9 Bearing housing 25 Output shaft 45 Washer 65 Bearing 311 Ball valve
11 Inspection cover 30 Distance ring 47 Distance ring 68 Bearing

25/36
6.4 Sealing
Ensure that the oil seals of the shafts are in In lip seals, where the above-mentioned VITON
good condition in order to prevent impurities properties are not needed, nitrile rubber seals
from entering the bearing housing and (NBR) are used.
lubricant. At the same time, this prevents
lubricant from leaking from the gearbox. Try
to prevent dirt from entering the seal. The
shaft seals do not tolerate pressure washing.
6.4.1 Lip sealing
Lip sealing is used in the gearboxes as a

standard and in applications where there are no
special requirements for sealing.
Lip sealing may consist of one or several seals.

The outermost lip seal always has a dust lip.
The lip seals of the gearboxes are made of FIGURE 16. Lip sealing
Viton (FPM) or nitrile rubber (NBR).
VITON sealing material is often used in the

following cases:
6.4.2 Labyrinth seal
- if the shaft diameter is 100 mm or less
In good conditions, a labyrinth seal with no
- on the high speed shaft of gearboxes wearing surfaces can be used on the shafts of
high speed single-stage gearboxes.
- in single-step bevel and helical gearboxes
- if the ambient temperature exceeds +50 °C
- if the operating temperature of the gear unit

exceeds +60 °C
- if the peripheral velocity of the shaft exceeds

the velocity allowed for nitrile rubber.
Note that the frost resistance of a VITON seal

is -40 °C and the maximum allowed peripheral
velocity is 15 m/s.
FIGURE 17. Labyrinth seal

26/36
6.4.3 Taconite seal 6.4.5 V-ring
Taconite seals are used in very dusty The V-ring is usually used together with other
environments. Add grease periodically to a sealing types to prevent fine dust from entering
Taconite seal according to its size. The seal the actual seal.
housing is equipped with a grease nipple for
adding grease.
FIGURE 18. Taconite seal
6.4.4 Lip seal and washing cover
A washing cover is used if the gearbox must

tolerate powerful pressure washing. It prevents
water and dirt from entering the seals.
FIGURE 19. Lip seal and washing cover

27/36
6.4.6 Dry well and grease-lubrcated bearing
A dry well is used in a vertical-mixer gearbox TABLE 7. Grease amounts for G series mixer
operating in an application where no oil is gearboxes
allowed to leak through a seal into the process.
Post
The bearings and shaft seals in a dry well are Gearbox -lubrication, First fill,
grease-lubricated. size amount of amount of
grease, g grease, g
A dry well can be equipped with a control pipe G-225 50 100
for checking, whether oil has entered the well.
G-250 60 120
G-280 70 140
G-315 90 180
G-355 110 210
G-400 140 270
G-450 180 360
Bearing is pre-filled with grease at the factory.
FIGURE 20. Dry well and grease lubrication
FIGURE 21. Greasing interval depends on the

rotation speed of the output shaft.
Seals lubricated separately with grease must be

lubricated according to Table 8.
TABLE 8. Seal lubrication
Seal size, Amount of grease,

D = outer diameter g per 6 months
D < 180 mm 20
D > 180 mm 40

28/36
7 Gearbox Accessories
7.1 Backstop
The purpose of a backstop is to prevent

the driven machine from unexpectedly or
unintentionally running backwards. A backstop
allows the gearbox to rotate only in one
direction.
Backstops are installed by Kumera Drives Oy.

The required direction of rotation of the output
shaft must be informed while ordering the
gearbox. The customer must check
the correct direction of rotation of
the electric motor before starting it. FIGURE 23. Backstop, F series for centre distances
An incorrect direction of the motor rotation may 160 mm, 180 mm, 200 mm
break down the backstop. A temporary oversize
torque may also break the backstop.
In case of a shutdown, the reverse torque must

not exceed the rated load torque of the gearbox.
Figures 22-24 show different backstops.
FIGURE 24. Backstop, G and D series
FIGURE 22. Backstop, F series for centre

distances <140 mm

29/36
7.2 Lubrication pumps
FIGURE 25. Gear pump FIGURE 26. Specially designed lubrication pump
A gear pump is used in lubrication units driven A specially designed gear pump is used in a
by electric motors. The pumps are available in shaft-driven lubrication system. Its pumping
several sizes. The correct pump model depends direction stays the same regardless of the
on the cooling demand and the required direction of rotation. The flange of the pump is
circulation amount of oil. mounted to the gearbox housing and the pump
connected to the shaft. When installing the
The pump with an electric motor must pump, make sure that the oil inlet and outlet of
always be started before the gearbox, and the pump are the right way around.
it can be shut down only after the gearbox
has come to a complete stop. Deaerating of Lubricating pumps
After a refill or oil-change of the lubricating oil

of the gearbox equipped with a shaft-mounted
oil pump, one must make sure that the oil
circulation starts immediately at the start-up of
the unit. This is especially necessary if the oil
inlet hole of the pump (suction side) resides
above the oil surface inside the gearbox as the
air in the pipeline might block the flow to the
pump. Therefore the system must be deaerated
before start-up.
The pump can be deaerated by filling the pump

and pipeline with oil after a refill or oil-change.
This is done by opening the hose or pipe fitting
from the inlet side (suction) of the pump and by
pouring oil into the system and the pump. The
unit is then deaerated and ready for service.
Notice!
Deaeration of the lubricating pump is
absolutely necessary to avoid breakdown
or damage of the gearbox due to a lack of
lubricating oil during start-up.

30/36
7.3 Pressure lubrication unit 7.3.3 Flow switch (part 3)
Before starting up a pressure lubrication unit, A flow switch can be used instead of a pressure
connect the measuring sensors to the control switch. Both can be used, if required. If the oil
system. The cause of an alarm must be flow drops below the set point, immediately stop
determined immediately. the unit and repair the lubrication malfunction.
An example of the lubrication diagram of a 7.3.4 Oil filter (part 4)

pressure lubrication unit:
The oil filter removes any impurities from the
oil. The filter is equipped with a by-pass valve
that opens at a pressure difference of 2.5 bar.
The oil is not filtered after the by-pass valve has
opened.
If the visual clogging indicator of the oil filter

shows red, the filter must be replaced. The oil
filter can also be equipped with an electronic
clogging indicator. The filter element must be
replaced in connection with an oil change at
least once a year.
7.3.5 Pressure gauge (part 5)
The pressure gauge indicates the pressure of

the oil entering the gearbox.
7.3.6 Thermometer (part 6)
The thermometer indicates the temperature of

the oil entering the gearbox.
FIGURE 27. Pressure lubrication unit diagram
7.3.7 Thermo switch (part 7)
7.3.1 Pump unit (part 1)
A thermo switch is used for monitoring the
The lubrication pump has a built-in safety temperature of the oil entering the gearbox. If
valve that protects the system from excessive the temperature exceeds the allowed limit, the
pressure increase in case of a malfunction. The control system gives an alarm.
opening pressure is 8 bar. If the safety valve
is continuously open, the gearbox is not being 7.3.8 Thermostatic water valve (part 8)
lubricated as designed.
If the pressure lubrication unit has a water-
7.3.2 Pressure switch (part 2) cooled cooling unit, the water flow is controlled
with a thermostat valve. The valve opens
The pressure switch is used to control the when the oil temperature exceeds the preset
lubrication of the gearbox. The set point of the temperature.
pressure switch has been set at the factory to
0.3-0.5 bar. If the pressure drops below the set
point, immediately stop the unit and repair the
lubrication malfunction.

31/36
7.3.9 Heat exchanger (part 9) 7.3.10 Placement of the lubrication unit
If necessary, the pressure lubrication unit can - max 0.5 m above the gearbox from the
be equipped with a heat exchanger that cools mounting plane
the lubricant. The heat exchanger can be - max 2 m below the gearbox from the
cooled with water or air. mounting plane
- permissible length of the hoses max 3 m
Water-cooled pressure lubrication unit
The placement of the lubrication unit according
The unit components are designed for a to these instructions unless otherwise agreed.
freshwater environment where the water pH
value is higher than 6. If necessary, the cooling
water must be pre-treated and filtered (100 µm)
before the heat exchanger. The temperature of 7.4 Gearbox cooling methods
the cooling water of a water-cooled pressure
lubrication system must be +4 to +30 °C. The Depending on the conditions, the gearbox may
water flow can be controlled with the thermostat warm up so much that separate cooling of the
valve. gearbox is necessary. Three different cooling
solutions are used for improving the thermal
output of the gearbox.
An oil cooler connected to the pressure

lubrication unit was discussed in the previous
chapter. Alternatively, a fan or a water cooling
coil can be used. The cooling solutions are
selected according to the operating conditions
of the unit and the required cooling performance.
FIGURE 28. Water-cooled pressure lubrication unit

7.4.1 Fan
Air-cooled pressure lubrication unit If the operating conditions of the gearbox are
dust-free with good ventilation, a fan or several
The ambient temperature range of an air-cooled fans can be used for cooling the unit. The fan is
pressure lubrication unit is -10 to +40 °C. installed permanently to the gearbox shaft. The
fan and its cover must be cleaned of any dirt
during a stoppage or as soon as it gets dirty.
FIGURE 29. Air-cooled pressure lubrication unit FIGURE 30. Fan in a gearbox

32/36
7.4.2 Water cooling coil 7.6 Vibration measurement adapter
The water cooling coil is installed inside the Vibration measurement adapters can be
gearbox in the oil sump. The coil is then installed for monitoring the condition of the
connected to the water system that circulates bearings. The adapters can be installed in
water through the coil. If the gearbox has a water the gearbox housing next to the appropriate
cooling coil, the accessories required for cooling bearings.
or circulating water are not included in the
delivery. The water circulation can be controlled
with a thermostat valve, which opens after the
oil temperature has reached the desired level.
FIGURE 33. Vibration measurement adapter and

sensor
When measuring the vibration measurement

level, first remove the adapter cap and make
FIGURE 31. Water cooling coils sure that the adapter is clean and properly
tightened. Then connect the vibration
measurement sensor to the adapter.
7.5 Heating the gearbox oil 7.7 Temperature sensor PT-100
If the temperature of the gearbox’s operating A PT-100-type temperature sensor can be used
environment is low, the gearbox oil can be for measuring the temperature of the gearbox
heated with a heating element. The maximum oil.
allowed surface power of the heating element
is 1 W/cm2. Output signal 2…20 mA (2-pole)
Protection class IP65 (standard)
Voltage ranges 230/400 V or 400/690 V.
When using a heating element, make sure that

it is completely immersed in oil!
The heating element can be controlled with a

thermostat or, if the load current of the element
exceeds the nominal current of the thermostat,
with a separate contactor control.
FIGURE 34. Temperature sensor
FIGURE 32. Heating element

33/36
8 Scheduled Maintenance
Kumera’s recommendation for periodic inspections and maintenance of industrial gearboxes

according to the table below. Bearing and sealing replacements and renewals of geared parts are
recommended to be done by Kumera’s specialist.
Recommended maintenance period plan for industrial gearboxes

Every Every 3 Annual Every 2 Every 5 Every 10
Service object week months Maintenance years years years
Oil level inspection x
Temperature measurement x
Drive train visual and noise inspection x
Vibration measurement x
Grease change (see page 28) x
Oil change (Mineral oils) x
Air breather change x
Oil analysis x
Oil filter change x
Visual inspection of geared parts x
Cleaning of the cooling fan x
Drive train inspection (couplings, belt drive) x
Oil change (Synthetic oils) x
Endoscopy inspection (bearings) x
Change of sealings x
Change of bearings x
Change of backstop and oil pump x
Change of geared parts x
Timely maintenance increases the life of the gearboxes and operational reliability. If abnormalities
in the operation of the gearbox are detected, they must be corrected immediately. An internal gear
inspection (endoscope inspection) can extend the change intervals for bearings and gearing parts.
The first oil change must be performed after approx. 300 to 500 operating hours after the gearbox’s
start-up. Oil condition can be examined by oil analysis. Based on the analysis, the oil change
interval can be extended if desired.
When opening the inspection covers and SAE flanges of the gearbox, clean the sealing
surfaces carefully and apply new sealing compound on the sealing surfaces before closing
the covers.

34/36
9 Troubleshooting
Problem Possible cause(s) Prevention/correction
Damaged seals Normal wear Grind the sealing surface and

improve lubrication
Wear due to dust Replace the dust lip seals
Hardening due to heat Replace the Viton seals
Damaged bearings Insufficient lubrication Improve lubrication, increase the

amount of oil or its viscosity
Wear due to impurities Improve filtering and/or shorten

the oil change intervals
Broken shaft Fatigue breakdown due to Check the alignment of the

external load couplings
Check the tightness of the belt

drive
Fretting in connections Overload, alternating stress, Select a tighter fit for connections
trembling, vibration
Damaged tooth surfaces Pitting (Overload) Upgrade the lubricant
Scuffing (Overload) Use a higher viscosity lubricant
Scratching Filter the lubricant oil
Broken tooth (Overload) Repair installation errors
10 Disposal
• Recycle or dispose of packaging material according to applicable national regulations.

• Before disposing of the gearbox after its service life, remove any lubricants from it. Disassemble
components of different materials and recycle or dispose of them according to applicable
regulations.
• Dispose of the used lubricants in accordance with applicable environmental protection
regulations.

35/36
Notes

36/36

KUMERA DRIVES OY
Kumerankatu 2
FI-11100 RIIHIMÄKI, FINLAND
Tel. +358 20 755 4200
Fax: +358 20 755 4220
E-mail: [email protected]
www.kumera.com
www.power-plaza.com

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Installation and Maintenance

Helical and Bevel Helical Gearboxes

KUMERA POWER TRANSMISSION GROUP

KUMERA DRIVES OY KUMERA ANTRIEBSTECHNIK GMBH

KUMERA AS KUMERA (CHINA) CO, LTD.

© Kumera Drives 2020

The gearboxes described in the instructions are

Translation of the original instructions.

© Kumera Drives 2020

1.1 Gear noise pressure levels.......................... 5 5.1 Lubrication basics...................................... 21

1.2 Screw tightening torques.............................. 6 5.2 Oil and grease quantities........................... 21

2 Technical Information................................... 7 5.3 Oil change.................................................. 21

2.1 Type plate..................................................... 7 5.4 Cleanliness of oil........................................ 22

2.2 Type code..................................................... 8 5.5 Oil preheating............................................. 22

3 Storage......................................................... 9 5.6 Oil cooling.................................................. 22

3.1 Normal protection, 0 to 12 months............... 9 5.7 Synthetic lubricants.................................... 23

3.2. Long-term protection, 5.8 Breather plug.............................................. 23

4.4 Installing of a foot-mounted gearbox.......... 10

4.5 Mounting a coupling................................... 12

4.6 Installing of a shaft-mounted gearbox 7.1 Backstop.................................................... 29

4.8 Installing a torque arm................................ 16 7.4 Gearbox cooling methods.......................... 32

4.10 Installing of a V-belt drive........................... 18 7.6 Vibration measurement adapter................. 33

4.11 Installing of a tooth-belt drive..................... 19 7.7 Temperature sensor PT-100....................... 33

4.12 Installing of a chain drive............................ 20 8 Scheduled Maintenance............................. 34

4.13 Filling lubrication oil.................................... 20 9 Troubleshooting.......................................... 35

4.14 Installing of the breather plug..................... 20 10 Disposal..................................................... 35

© Kumera Drives 2020

© Kumera Drives 2020

1.1 Gear noise pressure levels

One fan increases the noise level by approx.

Helical gearboxes Bevel helical gearboxes

Unit output Noise level Unit output Noise level

© Kumera Drives 2020

1.2 Screw tightening torques

TABLE 2. Screw tightening torques

Grade 8.8 Grade 10.9 Grade 12.9

© Kumera Drives 2020

2.1 Type plate

Example of the gearbox type plate:

Type: Gearbox type (see page 8)

Serial No.: Gearbox serial number

Year: Manufacturing year

Gear ratio: Exact gear ratio

Weight: Weight without oil

Lubricant: Recommended viscosity of lubrication oil

P1N (n1): Nominal power of the gearbox

Ksf : Selection factor

© Kumera Drives 2020

2.2 Type code

© Kumera Drives 2020

3.1 Normal protection, 0 to 12 months 3.2 Long-term protection, longer than 12

© Kumera Drives 2020

4 Installation and Start-up

THE GEARBOX IS DELIVERED During operation, pay attention to the operating

Overheating, for example, is often caused by

4.3 Gearbox alignment

The gearbox must be installed to the designed

FIGURE 1. Maximum lifting angles of the gearbox FIGURE 2.

4.2 Gearbox start-up 4.4 Installing of a foot-mounted gearbox

© Kumera Drives 2020