OPERATION AND MAINTENANCE MANUAL FOR TURNING GEAR WITH MOTOR NRT - 14000 AMICI errr TeTPED OTC HPOOOTOTUCTE TEC TETONTOOTT MANUAL NARACORPORATIONMANUAL mm TUTITTOTTHNTTTNTT Turning-Gear with Motor . GENERAL - TRANSPORTATION AND INSTALLATION - OPERATION . LUBRICATION . INSPECTION AND MAINTENANCE 6. DISASSEMBLY AND REASSEMBLY BF eNVe wv NARA Corporation #1500-11, Dadae-Dong, Saha-gu, Busan, Korea, Tel082-(051)-264-3100, Fax:082-(051)-264-31071, General The Turning Gears with Motor(’Turning gear” here in after) are designed, manufactured and tested in accordance with KS, AGMA or n handle it etc, and have high rigidity. Even an unskilled operator easily. However, as improper handling may cause unexpected troubles, read this manual carefully. Normal torque applied to an output shaft should be kept below the rated torque. Continuous use above normal torque may shorten the service life of gears and bearings, and sometimes cause damage to them, 2. Transportation and Installation. 2-1. Transportation When lifting Turn the top of the casing. In this case, Turning gear should be in the parallel position. The following table shows the weights of Turning gears. gear for transportation, use the eye bolt attached at Model Weight (kgf) NRT - 14000 R 2800 2-2. Installation All the Turning gears should be installed in clean, dry place. If there is any excessive dust or moisture around the Turning gears, please consult us. Install Turning gear on a rigid foundation board and fasten fitting bolts and nuts tightly. Improper installation may cause abnormal noise or vibration and shorten the service life of Turning gears and other machinery. If the Turning gear is not installed horizontally (inclined, vertical or upside-down position) lubricating problems can occur.3. Operation 3-1. Prior to initial start Check the connections whether they are still tight enough, and make sure that none of them have loosened during transportation or storage. Before starting the Turing gear, check whether the gear unit is properly filled with oil. (center of oi] gauge) 3-2. Initial start ~ Check the operation of brake and the running direction of motor. ~ When the Turning gear is started up for the first time, it should, if possible, run without load at least for two hours, checking abnormal noise, abnormal vibration and any other possible problems. If no irregularities are noticed, increase the load gradually. - As testing drive, operate it with full load for 30 minutes. meanwhile, any abnormal noise and abnormal vibration should not be noticed. Check exceeding heat of bearing(below 110T). - Turning gear out of operation for a long time should, if possible, be operated without load for a hour every 3 weeks. If it is impossible, the turning gear must be protected against corrosion. ~ If you want to make the Tuming gear run in the opposite direction, at first you should stop operating so that the turning gear is not overloaded. 4. Lubrication 4-1, Lubrication system The general lubrication method of Turning gears is oil bath system, ie. all components in the gear units are lubricated by splashed oil during ‘operation. : 4-2. Oil filling ~ Before starting up, all gear units except grease-lubricated types must be filled with oil to the correct level. ~ The gear oil should be poured into the gear unit through the oil filler plug hole. Only fresh, clean, unspoilt oil must be used.~ The selection of oil depends on oil viscosity according to the nomal operating condition with ambient temperatures between -20°C and +50T.(refer to Table ~1.) If ambient temperatures below -20°C and above +50°C or extreme fluctuations of temperatures or external heat sources, please consult us. ~ It is permissible to use the equivalent oils of others manufacturers provided in Table - T ~ Lubricant selection table (Table = 1.) Viseosity | Ambient MAKER 150-VG | iemperatore ETON (fs) | (ty | ARAL BP Hom | SHELL | FAMINE SK ant, | Aral Dogo! | BP Emrgol | Mobilgear | She Meropa | SUPER vom] = |acam — | cRxP zo | ae Onala Oi GEAR 400 | BMB 320 20 EP 30) Av Aral Degol BP Energol | Mobilgear Shell. Meropa 22) | SUPER vom | ~ .|pc2m | or-xp2m | 6 Omata Oil GEAR sat | BMB29 20 Ep 20) Model _and Quantity of oil MODEL OIL Q’TY IN REDUCER (2) NRT-14000 R 40 4-3. Oil change - It is commonly recommended to change the lubricating oil after 50 operating hours for the first time. Subsequent oil changes must be made once a year, depending on working conditions or ambient temperatures. The intervals of changing oil must be shortened if the Turning gear operates continuously above 50°C of ambient temperature. - By oil changing, the gear unit should be refilled with the same grade of oil used previousl; - The gear unit is initially filled with FAMM "Meropa 320, from the company.5. Inspection and maintenance It is recommended that a general inspection routine be established to check periodically the following items. 1) Cleanliness 2) Lubrication 3) Noise and vibration 5-1. Cleanliness ~ The exterior of the Turning gear should be kept free from such foreign materials as dirt, oil and grease, or etc. They may build up on the exterior of the Turning gear and impair oil seal, leading to oil leakage. ~ The dusty air breather(or air vent) may cause pressure rise inside of gear unit while running. It must be always cleaned and checked whether the filter of it is free of dust and pollutions. 5-2. Lubrication - Oil filling and change must be carried out in accordance with section 4-3. If it is not kept, the life of Turning gear as well as the life of bearing may be shorten. - Make sure that the oil level is at the correct height 5-3. Noise and vibration - Any excessive noise or vibration should be traced to its source and eliminated. Increase in vibration may be indication of change in balance and more commonly a change in alignment. In this case, the run out of shafts and bearing alignment must be checked. ~ Noise should be localized during operation of the Turing gear, then shutdown and check if all mechanical clearances are maintained. Note whether noise is reduced when power is removed. If possible, rotate the motor shaft extension by hand to see that it turns smoothly. - Check whether the surface of teeth is failed after unbolting the inspection covers. In case of doubt, please consult us.6. Disassembly and reassembly 6-1. Disassembly - Disassemble Turning gear after full comprehension of it’s construction in accordance with the attached assembly section drawing. Make clear the purpose of disassembly in order to minimize parts to be disassembled. If there is no match mark on a part to be disassembled, disassemble Turing gear after marking. Never strike parts strongly nor pull them by force. If problems occur during disassembly, do not continue disassembly forcibly. Repeat disassembly after careful inspection or consulting us. 6-2. Reassembly - Carry out reassembling normally in the reverse order of disassembling. - Reassemble parts after washing them carefully with cleaning oil and applying machine oil or lubrication oil. - When fitting a new bearing to the shaft, warm it in oil bath maintained of 100°C ~120 and then set. - Special care is required when fitting oil seals in order to avoid damage to the sealing lips. Damaged oil seals are the cause of leakage. When inserting an oil seal, apply grease to the shaft for smooth installation of seal. If possible, it is recommended to replace the oil seals with new ones. After reassembly, make certain whether the motor shaft can be rotated by hand smoothly and lightly.Assembly Drawing (NRT - 14000 R) a ©7. Motor 7-1. tructure PART NO. | MANE OF PARTS | PART NO. | MANE OF PARTS 1 FRAME Ly BEARING (D.E) 2 SHAFT 10 BEARING (ODE) 3 ROTOR CORE | SAFETY COVER 4 STATOR CORE 12 BAN 5 | STATOR COL B FAN CLAMP 6 | __END-RING 14 | CONDUIT BOX 7 ND SHIELD (D.E) 5B | 8 | END SHIELD (0.D.E) 16 7-2. Operation - Before operation, check correct installation, electrical connections and earthing connections with satisfactory conditions. ~ Check running direction at the initial start 7-3. Maintenance - The work required in power installation must only be carried by skilled personnel,~ Check and note results according to below chart. Periodical Maintenance Chart Interval Inspection Inspection procedure Corrective measure. | Retate the motor by hand | If abnormality is noted, investigate and check for abnomality. | the cause and repair. | Measure insulation IF insulation is deteriorate, investi- Monthly | Motor and resistance, gate the cause and repair, ‘starter Check surface Clean contaminated area. ‘Check Lerminais for loosene | Retighten loosened connection. € connection, Measure insulation Af the measurement is less than the oe Tesistance, minimum value given below dry or 3-monthly | Electire circuit | Check operation of starter other wise correct. (M8 or greater) If operation is abnormal. Apparatus and accessory apparatus. | Investigate the cause and repair. associated Repair defective or burnt part. with motor Check contact part, If necessary, replace. terminal and connections. | Retighten loosened connection. 6-monthly EEE EE SS eee 7 Check for loosened bolt or | Retighten loosened boll or nut. nut in the base mounting | Renew defective bolt or nut with a Motor part, joint cover mounting | new one id for correc Measure air gap between | Renew defective bearing with a stator and rot rt ane stalor and rotor spare pa Check for abnormality in | Clean shaft and bearing. bearing part Yearly (1) Check the number (1) Check with parts tis @) Measure insulation | (2) If insulation is deteriorated, Spare part resistance. investigate the cause and dry or otherwise correct.- The ball bearing requires replacement if it produces abnormal during operation. ~ The procedure for bearing replacement is as given belows. LD) After disassembling the motor, remove the defective bearing from the rotor shaft by use of a bearing puller. 2) Anti-rust grease on the surface of the replacement bearing should be removed with a cloth. _ 3) Install the new bearing on the rotor. ~ Replenish grease to the chain sprocket of motor shaft periodically is required. (Operate frequently : every 3 month, Operate intermittently : every 6 month) 7-4. Disassembling and reassembling ~ Caution 1) The machines of vertical types of construction should be disassembled in a horizontal position. 2) Assembly or disassembly is carried out by two or more qualified personnel. 3) Keep the place of disassembling in good order and well arranged to prevent mixed up of the parts and to improve the work efficiency. 4) Cover the disassembled parts, with cloth to protect from dust or foreign materials, ete. = Disassembly order 1) Remove all external cables connected to the motor and brake. 2) Remove the bolts connecting the motor with base plate. 3) Carry to the place of disassembly. 4) In case of vertical type motor, lay the motor down horizontally. 5) Remove the chain sprocket connecting the motor. 6) Remove the brake in accordance with the section 8-2. 7) Remove each-end shields since it may cause the damage of coil. Please handle carefully 8) Pull out the rotor from the stator, - Assembly order 1) Carry out assembling normally in the reverse order of disassembling. 2) Before assembling, thoroughly wipe off the dust, oil, etc. from the disassembling parts.8. Brake 8-1. Structure This brake is the dry disc electric magnetic type. PART NO.| NAME OF PARTS 1 MAGNET 2 MAGNET FLANGE 3 LINING 4 FLANGE, GEAR 6 SET SCREW 7_| SPRING STUD BOLT 9 SET SCREW 0 RIVET i SELF LOCKING NUT 12 HEX. BOLT. 3 SPRING WASHER ae 14 DISC FLANGE fa | SAFETY COVER (Table - 1.) STATIC CHARACTER oe | Gap TORQUE | VOLTAGE | AMPERE | RFSISTANCE wart | (oo) 29 ketm| DCsv | 0968 sean) | seaw | 05-06 8-2. Disassembly order ~ Remove all external cables connected to the brake. ~ Remove the motor cover and the fan. ~ Remove the outside self locking nut. - Remove the magnet, at this time, please take care of spring not to be lost.~ Remove the inside self locking nut. - Remove the magnet flange, the lining and the disc flange. ~ Remove the stud-bolt - Remove set screw of upper gear. - Remove the gear from motor shaft. 8-3. Assembly order ~ Carry out assembling normally in the reverse order of disassembling. - Before assembling, thoroughly wipe off the dust, oil, etc. from disassembling parts. 8-4. Gap adjustment method ~ Measure the gap with a filler gauge to see if the brake is loose. - Loosen the gap adjusting nut(inside self locking nut) and adjust the gap between the magnet and the magnet flange with the nut(use the gap gauge). - The brake is adjusted at “Table - 11.” upon release from the factory. The inspection and gap adjustment is required per 6 months at least.8-5. Manual opening method ~ When opening the brake manually, use the furnished release bolts. - Refer to the following process. 2-RELEASE BOLT ge SESE LewrencH MAGNET a GaP(C) 1) Remove the motor cover and the motor fan. 2) Using an "L-Wrench’, tighten two releai bolts until magnet flange is separated from lining.(Tighten the release bolts until the gap reaches "0".) 3) Don’t forget to remove "Release-bolt” after use it.l CAUTION ! 1. Bri ke. 1-1. Gap adjustment is required every 6 months at least. (Gap amount is shown on the "Table 1I".) 1-2. Make sure to remove "Release-bolt” after using it to loose manually. 2. Check and tension adjustment for Roller Chain. (Inspect per 6 months.) 2-1. Check of Roller Chain. 2-1-1. If the noise occurred to the roller chain, Inspect the roller chain after removing the chain cover. If a heavy noise is still not disappeared, rearrange the sprockets of motor and reducer, 2-1-2, Inspect a failure of each link of chain. 2-2. Adjustment of Roller chain. 2-2-1. Roller chain has to be tensile-loaded until chain's roller contacts to the root of teeth. 2-2-2. The amount of slack should not be exceeded 2% of the center to center distance of sprockets. p~ /o™ Model A 2%E [mml NRT=14000 15Adjustment for the looseness of chain tension. - To adjust chain tension, Release base bolts of Motor and adjust chain tension with lateral adjusting bolt. Fasten base bolts of Motor. Adjusting bolt Brake motor Base bot / € feeee welt Motor bed _// 3. Inspection of Limit Switch. ~ Before operation, Limit Switch must be adjusted as follows, kK fl Indicator. ieee = i ~ As the roller of Limit switch \ u/ fal irs = £ Tabet acess is contacted to the stopper, The indicator should be located in a / “a” position.4. Inspection of 3/2 Way Valve. ~ Before operation, 3/2 Way Valve must be adjusted as follows, 4-1. For 10 Bar. i i i i Check the below conditions - Disengaged Stage : Port @, @ should be opened. - Engaged Stage : Port @, @ should be opened.Parts list (NRT ~ 14000 R) in NAME OF PARTS aie NAME OF PARTS. al NAME OF PARTS 1 CASE vv [AST isu SHART | 6 OIL SEAL 2 [peaninc cover vo | 2% | FRONT cover | @ on sea | sap mvTENAL Gear | 2 | manic covER vin | 6 | SNAP RING a | powerin |» | mororpen | « | svar RING a1 [power rn | ai | serocker cy | oe [swap mine s_| ourpur sart | x spacer | & SNAP RING ARD VIN xs | cover piare | a | sNar RING SRD IDLE GEAR Mw 7 SPROCKET (4) oT SNAP RING: 8 | aR couar cHaN cover | 6 | SNAP RING 9 3RD CARRIER OIL GAUGE, eo ROLLER BEARING 10 | sracer | HANDLE | 7 | ROLLER BEARING ul [= KEY 0 71_[_ BALL BEARING w | arp sux cear | a | exvort.w |e | Batt BEARING w | axpcarmer | a macnertc praxe| 73. fw xeroue umanine 4 2ND PIN | REX'BOLT, W | a xD weRDHE amarNg| 5 | epwiecear | # | sexuour.w [a fisr seepie neAnInG 16 “OND COLLAR” | “50 WRENCH BOLT 6 SET SCREW v7 [exp ovrersan cean | ot | aexpout. w | 77 KEY 1 SPACER HEX'BOLT. W | 7 KEY 9 SPACER st [a KEY 2 | uND SUN GEAR | 54 5 CHAIN a | asrcaruer | os st | DRAIN PLUG 2 IST PIN o [uEXoLt, Nur wl MOTOR ws [astute cear | sv | aexpour.w | wt AIR VENT uw | asrcottar [st | nexporr, sur | st [HEXBOUT sur, w (25 | IST INTERNAL GEAR | 58 | WRENCH BOLT, W] 85 PIPE a | KEY ds wo | eve nour | si | wreycu aout, w