Instruction Manual cardan shafts — seit 1935 — Preamble This isa instruction manual according the Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery and amending Directive 95/16/EC (fecast). The instruction does apply to the regulation for parly completed machinery and accordingly machine pars. Safety regulations are not summarised in a separate chapter, but described in the chapters ofthe specific agenda items. Attention: Read the instruction manual before installation and start of operation! The cardan shafts are ready for operation. Under normal Circumstances no extra greasing before slat is needed. Cardan flange faces have to be clean and blank before assembling! Installation, ‘ismanting ané maintenance have to be executed by qualified skilled workers only! Contacts ‘Engineering office:phone+49(0)40.2263201-30.e-mail: h@w-sass.de sinternet: www.w-sass.de «24hService:phone +49-(0}40-2263301-0 Contents 01 Flange boting 02 Installation 03 Dismanting 04 Transport and Storage 05 Maintenance and Lubrication 06 EU Declaration of Conformity 01 Flange bolting Use the high-strength cardan bolts ofthe quality grade 10.9, or hexagon bolts DIN 960-10.9 only. By using of bolts according DIN 931-10.9 accordingly DIN 933-10.9 at companion langes with lap holes, consider th cifferent bolt and nut torque moment. Use the selLlocking hexagon ruts DIN 880-10 ll meta) only. By using standard nuts secure the nut. By using companion flanges wih tp holes secure the bolls by locking, Itis not every time possible to insert the bolts from the cardan shaft lange side. The normal procedure by Boling of cardan shat flanges is 10 inset the bol from the companion lange side in the hole and screw the nut fom the eardan flange side on the bot. This i the stand of all our cardan shafts nol diferent aranged. We delver our cardan shafts normally wathout bolting, As a malter of course we shall Supply 00 customer request together with the cardan shafts the corresponding sets of cardan bolting. The bolts shall bein a lightly olled condition, but ever put to much oil of any kind of grease on it. The locking of securing bolls or nuls wil be destroyed by lighten and loosening. Therefore ater tighten and loosening a bolt or nut, secure and lock it again. Boting for DN tanges at ‘Accor ISO 7648 s Cardon bats o he quay grade 10.9 a y Hoxagon bot equal DIN 980-109 (EM Hexagon nut DIN 080-10 HH e/ we sie 114 M0416 i gorl ur loos] ram Sehranber Bos or 11 | 002) Flansch | — eg —T sw] EW] Lz | | We sie [amo | oe | on | nom |S se] «| es[reom | moms [2 fosfas[ s | 2 es[ 5 [oo [rom | woz [wo [nal «|e | « 75| 6 | oo [rice | woz [waa] «|e | « vo | @ [oe [rom | wens [1 [wal sa] e | 26 of 2 [os [ruce@ | wanes [1 [alsa] e | 26 2 wemao_ fs faa psa] | ae 20) 70 03 6) a 2 ee = % companion ange cardan Nange 150 | 12 | O12 | FL-04(10) | M12x1.5x40 | 19 | 21.1 | 7.5 | 12 | 120 bi 7 ao is | ros(12) | treet | 22 | 245 ee | i | io Bia] Flas @) [Mrz sas | Te] zt] 75 | | 20 to] 4 | Ota | FLo¥ a0) | treet sas | 22 | 243] 8 | a | io0 16 | F.o5(12) | hroet se | 24 | 258 | 40 | 1 | 300 FLas(a) [wrzetss0 | Te] zt] 75] 12 | 120 225 | 18 | O16 | F1-05(12) | migxt5x50 | 24 | 268 | 10 | 16 | 300 Fat | Ta] Oe | FL 09 @) | Miext-seo [a7 [soz] 75 | Ae | 450 a5 | 20 | 020 | F050) | wastes | 20 [330 | 25] 20 | ozo a5 [22 oa [roa a) aaatse7s [aa ase) | 14 [22 [eo aso | 25 [oo [FLos top| watsws [ae [ase | 4 | 2 | a0 S50 | 26 [24 [FL06 (| waset es [ae 40 | io | 2a | Hi00 was oz [oor [roe io | weratsms [at bese | zr | roo Bolting SAE flanges sue According ISO 7647 Cardan bots ofthe quality grade 10.9 Hexagon bolts DIN 960-10.9 Hexagon nut DIN 980-10 Version:17.06.2010.part 9800026 00-Betriebsanleitung-En DOC page: 1 of 4 ea re)Instruction Manual cardan shafts — seit 1935 — o1| sae | L1 | 903 | Flansch a peteaseen teat mmm | Type | mm | mm | tango’ | M2 | sw| ew | x2 [aa] ie met Wiebe + so | roofs | oe [rem | Me [as [rsa [ss] «| a6 a Trroxta9 96 | 1200 | 7 | Sag [vw | serene [7 [re9 [ea [ro] 70 312 2a Sad0 aie rao | 2 | 2% Pretty [METS | to [ana [75 [12 120 aia Wier Sut 7 150 1600] 2 | 2, [rove | Mtoe | a2 [ass [ee | 14 | 12 a oe Seniesa v5 re00 | 10 | 2 [ria | MO | a7 [aso [ea] 10] 70 Waa], | Om | Aaa w | was 203} sa00 | 1 | ost | Fu14 (ay | zreexi sie | 1 | 21-1 | 79 | 12 | 120 ns [roo S| Ors LFL-9@) | Wied oso | oe [oes Lo |e | a0 1900 ize 5x80 2x0 | 12? | 10 [ora | rita aay | MIZE | 19 [zn [75 | 12 | 120 wre | ooo |e | ore [FP | Mion Soo | oe [oee [10 |e [ooo Bolting for KV /XS (x-serration) flange According ISO 12667 and 1SO 8667, all KVIXS flanges are equipped with 4 bolts, cardan bolts ofthe qualty grade 10.9, hexagon bolts equal DIN 960-10.9, hexagon nut DIN 980-10 ou, sor Too Sceesber oa ao (921 3 | 002 | ae — Sei ee Pe etre ee eta ee br ne ee Lory 420 | 74 [ori |_Mioxiao [7 | ies [ oa] 10 | 70 8|-H-E 150 | 16 [oro | Mize suas [19 211] 75] 12] 120, aul 02 Installation ‘First remove possible transport lock before start of instalation ‘Check the position of the slip unit male and female pars. The marking of the female unit and the male unit shall bain in. ‘* Ensure a tho slip unt, thatthe sip range ofthe length compensation is free off any coating, when painting the cardan shaft ‘Use bolts and nuts inthe right quality and size according o our above bolting tables only. one ‘The installation of the cardan shaft has to be caried out so that no dit or water shall run ino the sip unit paris. Moisture and water shal be able to flow orto dip fom the cardan shaft L ‘Tighten the bolts always via cross. Use torque spanner only. OS + Clean the surface ofthe flanges from dit, crease, ol paint and ant corrosion protection before boting. By { Never interchange the sip unit or any other parts ofthe cardan shaft wih pars ofan other cardan shaft. ‘\ ‘Otherwise the cardan shaft will be never more in balance and vibrate in operation. ‘Ifitis necessary to remove bot slip unit parts, make sure, that by assembling the markings of both parts are in ine. ‘= Never remove or change balancing plates or any other parts of the cardan shaft, or redesign and modify the cardan shaft Itwll malfunction the cardan shaft and our waranty will be invalid. ‘*Eneure that the slip range ofthe length compensation i free lo both sides. Make sure, that he slpunit can) ‘+ For gearboxes, bearings or similar machinery parts with cardan shafts on both sides: The flange bolting of the driving cardan shaft and the driven cardan shaft shal be attached 90" shitted to each other ‘© Do not tum the cardan joints with pinch bar o pipe because this may damage the sealing system and grease nipples. ‘= Check the companion flanges. Type, size and design shall be the same as the cardan flanges. * Installation of cardan shafts wih centred double joints: Secure the double joints against ato wide delaction angle or hanging. Othervise the centred bearing can be damaged. ‘* Take measurements, which ensure, that no other machinery or plant unit isin the range of the rotation radios and sp area of the cardan shaft. ‘¢ Read first the instructions of your plant or vehicle manufacturer. { Secure allather machinery of plant unit in the area ofthe cardan shaft by frames, guards etc. In case of damage atthe cardan shaft, other units shall be no affected. «= Before stat of operalon: Read greasing instructions, Version:17.06.2010.part 9800026 00-Betriebsanleltung-En DOC page:2 of 4 ea re) eoInstruction Manual cardan shafts — seit 1935 — Additional information for the installation of drive lines ‘* Normally we deliver the intermadiato shafts and drive lines complete assembled withthe intermediate bearing. Install ‘the midship bearing every Ume together with the whole dive line. Never dismantle the intermediate bearing frm the lve line. Therefore fx together wih the whole dive line. ‘Never tighten 0° loase the securing bls) or securing nut of the intermediate bearing unit. Otherwise lock will be damaged. ‘Read before installation ofthe drive ine the instruction manual of the vehicle or machine manufacturer. Use only the specified ‘mounting place and bolting according the instruction manual ofthe vehicle or machine manufacturer. ‘Tighten the intermediate bearing frame bolts only afer bolting the flanges of the driveline. Install the intermediate bearing unstressed. ‘By installation work often large torque can appear onthe drive line joints. Secure the joints against ato wide deflection angle or hanging. ‘there th ants and the mgship bearing san be damaged. =~ hee « Ista the interests arg ony nthe igh angi 0 ew the inlermediata shaft or dive SSP hey fut ‘* Ensure that the slip range of the length compensation is free (RF pa IE {oath sides, Make sure, that he spun can compensate the | lengh between the rhaximum and minimum operation fongh of tho dive ne. “teeters ‘+The basic frame of the vehicle or machine shal be strong enough to compensate all forces coming from the intermediate bearing, ‘+The installation of the cardan shaft has to be caried out go that ne dit or water shal run int the slip unit parts. Moisture and water shall be ‘able to flow oro dip fom the drive ine 03 Dismantling «Secure the slip unit against sipping out and fang {1"the marking on the Both sip unit parts fs never more visible, make new marking before you dismantle bath part 1 Always: safely fist. Secure the joints and slip uit against hanging down and fang. By dismantling under the vehicle or plant secure the ‘whole cardan shaft against fling ‘s Never exchange part ofthe dismantled cardan shaft with pats of an ther cardan shalt, 04 Transport and Storage ‘All transpoct shal be carried out in horizontal postin, / y anspor with th forklift put imber between fork and cardan tube. {Never transport or store cardan shafts with stres or load onthe slip uni. ‘= By iting wih ropes use text or synthetic material ony 1 Store the cardan shafts only in the dey. ‘Secure the cardan shafts in the store room and by transportation with wedges, prism or cradles against rong «Take the grease nipple in consideration. Square timbers and iting ropes shall not destroy the grease nipples. ‘© Transport and storage of cardan shafts with centred double joints: Secure the double joints agains ato wide deflection angle or hanging ‘Otherwise the centred bearing can be damaged. ‘Storage conditions for cardan shafts and plow block bearings Allitams shal be stored inthe original packing. ‘The storing and the storeroom shal be clean, dry, dust fre, without any chemical vapor and in resting postion without any vibration. The maximum data for the environment of the storeraom f for te temperature -6°C to 25°C, fore the temperature diference between day and night 8°C and for the relative humidity of air 65%. By observation of these regulations the stored cardan shafts and pliow biock bearings can be slored up to § years. Fr al parts longer stored as 1 year: Change by comple greasing al the ‘ld grease agains the new one before intial operation. 05 Maintenance and Greasing Greasing and inspection of the cardan shaft can be caried out by the normal maintenance and inspection intervals of the vehicle or the machine. As a matter of course all our information about greasing and inspection intervals are just guideline data, because only the operation Conditions are accountable forthe interval schedule. Therefore only the operator can determinate the greasing and inspection intervals. Greasing and inspection intervals (guideline) oes asaiog | — errand | —rapocton —] — ora ae 7 all. after all after areal vicos ed i Asan Ta a el a nan and all similar used vehicles 80 000 kr 12 month 100 000 12 months mora ois Ud payor onan Oa ‘Stoner vanes Usdin ate 2s000%m | monte | s00c0Km | 12 months ‘Seal ina ued ven, Busse uso ang darcy Vac Sooo — | — eas —| ooo |e Baas estan oa S000 | — sans —[ So ooo | — oa Sire vies an bua maces wseT Ov weET Trot intl vnlo, taee, ila veNdes” resookm | Seact | as0008m | monte and all similar used vehicles” " river crossing sip engies TOF Sn 15007 mA Sr gga al pans a TT SOOT Sn SOF cen Vata ar Dea aa a rae SST ST Verson.17.08 2070901 8600028 Oo-Berebsnltung En DOC page: 9 of 4 ee et) ea Telefon re)Instruction Manual cardan shafts — seit 1935 — Cleaning of cardan shatt Don't clean the cardan shaft with a high pressure cleaning machine or with a steam cleaner. If it should happen ance: grease immediately according to our above instructions so long as the new grease appears. Greasing Clean the grease nipple and the grease channels before start of greasing. Grease always gentle, Don't use to much pressure. We recommend about § bar. Slop greasing after trash grease appear on the seals. The slip unt grease only with 2-3 grease gun strokes per maintenance Interval. Grease with feeling, Watch every time the seals. Lubricant ‘We always deliver all cardan shalts in greased condition. For cardan shaft in storage of ut of operation longer than 6 months: Grease before putting into operation again! Use ithium complex grease only. We recommend Microlube GL_262 as standard lubicant and Kldberplex BEM. 34-132 as high performance and high temperature lubricant of Klueber Lubrication, Munich, Germany. This lubricants are special complex ‘grease on a mineral hydrocarbon base. Allemalive lubricant brands for our standard grease are: BP Energraase LS 2, Esso ~ Beacon EP 2, Shell Aiania EP 2, Mobil Mobilx 2. Do not use sodium grease, Molykote paste or lubricant with MoSz additives! if your cardan shaft is ‘equipped with special low or high temperature universal joint, use only the special low or high temperature greasa! The greasing nipples of our cardan shafts correspond to the standard DIN 71412, if the drawing not comments a different type. All greasing nipples DIN 71412 are ‘equipped with plastic it covers. BBut you can use any other lubricant that matches folowing performance data Operation temperature range: -25°C 10 140°C (high performance lubricant -45'), consistence class: 2 (DIN 51818, NLGI), penetration: approx. 265.295 (DIN ISO 2137), drop point: > 220-280°C (DIN ISO 2176). densify: approx. 0.9 g/cm (DIN 51757 at 20"), water resistance: ‘approx. 1 ~ 90 (DIN 51807 ~ 3h/90°C), flow pressure: approx. 1400 mbar (DIN 51805 -25°C), coresion protection behaviour. 1 (DIN 51802 Emcor test), speed factor: approx. 300 000 (dm xn). Check list for inspection (can be carried out with the cardan shalt on site) ‘Proof the ightening ofthe flange bolting. Important, ighten the bots withthe right torque according to the above lists * Check the ups ofthe universal oint bearing. The snap rings have to sit onthe right place (7). a Control te colour a form of the Univeral joint Bearing cups the normal metalic colour oe frm has Re ahh changed, may bo the Bearing Is damaged duo o excessive heat (7). Change the whole universal jan. fF Srey «+ Prof the cups ofthe universal joint bearing. If you See grooves or tuning marks in the area of the snap - ‘ings, the cup then revolves inthe hol. The damaged part with the hole (lange or frk) has tobe changed. BD + Check the seals of the boring cups (1) [sa Seal damaged or worn out, change the whole bearing cup. ¥ 1 Proof whether the balance plates are in place, not damaged and not loose (8). By damaged. lst or loose ‘balance plates: The cardan shaft has to be balanced. ‘* Check the sip unt. Seal of the profile protection and synthetic coating (Rlsan) have to be without damages (14348). If there are damages, change the sip unit ‘= Control al the greasing nipples (2+4) and the dt caps. it necessary clean the grease nipple and the grease channals. ‘Take the load ffom the cardan shaft by iting it abit. Try to tum the Sip unl andthe universal joints (6). I the part moves, itis to much play in the unit. ‘© Control the tube and the protile protection whether there are bumps or scratches on il. Check also all other parts and lines of weld whether there are cuts or broken pars. If part or line of weld is defective, the cardan shall has to be overhauled, «By inlarmediata shafts and drive lines consider ‘There shall be no noise from the bearing by running of the cardan shaft I necessary change the beating of the intermediate shatt. By Elastic. Midship Bearings: Check the elastic inlay, whether there are cracks or Cuts. The cushion or elastic inlay has to sit nis place in the frame or bracket. The ball or roller bearing shail sit in its right place, without any play in the seal. Check the fastening bolts. If necessary, tighten the bolls with the night torque according to our above lst. The ball or roller beering shall run smooth and without any play or nolee. Proot the intermediate bearing flanges: The flange shall st ight on the key seat of the shaft. There has to be no tuming or horizontal play. Loose dirt overs can be a sign for loose flanges. Securing bolts or nuts shall sit tight. If necessary, tighten the bolts withthe right torque according o our above ist By ighton or loose the securing bal(s) or securing nut ofthe intermediate bearing unit, lock will be damaged. By any kind of tighten ‘lovee of securing balls or nuts: You have to secure the bolts or nuts again 06 EU Declaration of Conformity according EU Machinery Directive 2006/42/EC Product: Cardan shafts type: GW-500 to GW-599 We hereby deciare that the cardan shafts described above confirms to the relevant fundamental safety and health requtements of the Appropriate EU Directives and relevant Standards, both inits basic design and construction as well as in the version marketed by us. This ‘daclaation will cease to be valid i any modification is made to the cardan shalt without our express approval. Appropriate internal measures have Been taken to ensure that series production units conform at al mes to the requirements of current EU Directives and relevant Standards. intial operation of this machine partis. prohibit, so long as the machine, where this machine part is embedded, i not conform in all items withthe requirements of curent EC Directives and relevant standards ‘The signatory is authorized to act on behalf ofthe company management Stapelfold, 15.01.2010 fal Gelerkwellenfabrk Withelm Sass KG, Brookstrasse 14, 0-22146 Stapetfld, Commercial Register HRA 2151 Place Of Jursidiction / Reinbek - Germany Version:17.06.2010-part 9800026 00-Botriabsanleitung-En.DOC page: 4 of 4 ee et) ea re eo