Wittenstein Alpha LK+ User manual
2022
-
D026817
07
2022-D026817 Revision: 07
LK+/LPK+/LPBK+
Operating Manual
LK+/LPK+/LPBK+
2022-D026817 Revision: 07
Revision history
Revision Date Comment Chapter
01 24.05.07 New version All
01a 11.02.09 WITTENSTEIN Layout All
02 01.08.09 Machinery Directive 1, 2, 3, 4, 6
03 09.03.10 LPBK+All
03a 26.07.10 Technical Data 5.4.1
04 01.09.10 Technical Data 5.4, 9.1
05 11.03.15 LPBK+ 3 stage, safety;
clamping hub
2.1, 2.5, 3.5, 5.3, 9.1
06 13.02.17 Mounting the motor 5.3
07 31.05.19 Adapter plate 5.1
Service
In case you have technical questions,
please contact:
WITTENSTEIN alpha GmbH
Customer Service
Walter-Wittenstein-Straße 1
D-97999 Igersheim
Tel.: +49 7931 493-12900
Fax: +49 7931 493-10903
E-mail: [email protected]
© WITTENSTEIN alpha GmbH 2019
This documentation is copyright protected.
WITTENSTEIN alpha GmbH reserves all the rights to photo-mechanical reproduction,
copying, and the distribution by special processes (such as computers, file media, data
networks), even in parts.
Subject to technical and content changes without notice.
LK+/LPK+/LPBK+
Revision: 07 2022-D026817 en-1
Contents
1 About this manual ................................................................................................2
1.1 Signal words ........................................................................................................2
1.2 Safety symbols.....................................................................................................2
1.3 Design of the safety instructions ..........................................................................3
1.4 Information symbols.............................................................................................3
2 Safety.....................................................................................................................3
2.1 EC directives........................................................................................................3
2.1.1 Machinery directive .........................................................................................3
2.1.2 RoHS...............................................................................................................3
2.2 Dangers ...............................................................................................................4
2.3 Personnel.............................................................................................................4
2.4 Intended use ........................................................................................................4
2.5 Reasonably foreseeable misuse..........................................................................4
2.6 Guarantee and liability .........................................................................................4
2.7 General safety instructions ..................................................................................4
3 Description of the gearhead................................................................................6
3.1 Overview of the gearhead components ...............................................................6
3.1.1 Overview of the gearhead components LK+/LPK+..........................................6
3.1.2 Overview of the gearhead components LPBK+...............................................6
3.2 Identification plate ................................................................................................7
3.3 Ordering code ......................................................................................................7
3.4 Performance data ................................................................................................7
3.5 Weight..................................................................................................................7
3.6 Noise emission.....................................................................................................8
4 Transport and storage .........................................................................................8
4.1 Scope of delivery .................................................................................................8
4.2 Packaging ............................................................................................................8
4.3 Transport..............................................................................................................8
4.4 Storage ................................................................................................................8
5 Assembly ..............................................................................................................9
5.1 Preparations.........................................................................................................9
5.2 Mounting the gearhead to a machine (LPBK+ only)...........................................10
5.3 Mounting the motor on the gearhead.................................................................12
5.4 Components mounted on the output side ..........................................................13
5.4.1 Mountings on the output flange (LPBK+ only) ...............................................14
5.5 Mounting the gearhead to a machine (LK+/LPK+ only).....................................15
6 Startup and operation ........................................................................................15
7 Maintenance and disposal.................................................................................16
7.1 Maintenance work..............................................................................................16
7.1.1 Visual inspection ...........................................................................................16
7.1.2 Checking the tightening torques....................................................................16
7.2 Startup after maintenance work .........................................................................16
7.3 Maintenance schedule .......................................................................................16
7.4 Notes on the lubricant used ...............................................................................17
7.5 Disposal .............................................................................................................17
8 Malfunctions .......................................................................................................17
9 Appendix .............................................................................................................18
9.1 Specifications for mounting onto a motor...........................................................18
9.2 Specifications for mounting on a machine .........................................................18
9.3 Tightening torques for common thread sizes in general
mechanical engineering .....................................................................................19
About this manual LK+/LPK+/LPBK+
en-2 2022-D026817 Revision: 07
1 About this manual
These instructions contain necessary information for the safe operation of the right-angle gearhead
LK+/LPK+/LPBK+, referred to as gearhead in the following.
If this manual is supplied with an amendment (e.g. for special applications), then the information in
the amendment is valid. Contradictory specifications in this manual thereby become obsolete.
The operator must ensure that these instructions are read through by all persons assigned to install,
operate, or maintain the gearhead, and that they fully comprehend them.
Store these instructions within reach of the gearhead.
These safety instructions should be shared with colleagues working in the vicinity of the device
to ensure individual safety.
The original instructions were prepared in German; all other language versions are translations of
these instructions.
1.1 Signal words
The following signal words are used to bring your attention to dangers, prohibitions, and important
information:
1.2 Safety symbols
The following safety symbols are used to bring your attention to dangers, prohibitions, and
important information:
This signal word points to an imminent danger that can cause serious
injuries and even death.
This signal word points to a possible danger that can cause serious
injuries and even death.
This signal word points to a possible danger that can cause slight to
serious injuries.
This signal word points to a possible danger that can cause material
damage.
A note without signal word draws your attention to application tips or
especially important information when handling the gearhead.
General danger Hot surface Suspended loads Danger of being
pulled in
Environment
protection
Information
LK+/LPK+/LPBK+Safety
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1.3 Design of the safety instructions
The safety instructions of these instructions are designed according to the following pattern:
1.4 Information symbols
The following information symbols are used:
Indicates an action to be performed
Indicates the results of an action
Provides additional information on handling
2 Safety
These instructions, especially the safety instructions and the rules and regulations valid for the
operating site, must be observed by all persons working with the gearhead.
In addition to the safety instructions in this manual, also observe any (legal and otherwise)
applicable environmental and accident prevention rules and regulations (e.g. personal safety
equipment).
2.1 EC directives
2.1.1 Machinery directive
The gearhead is considered a "machine component" and is therefore not subject to the
EC Machinery Directive 2006/42/EC.
Operation is prohibited within the area of validity of the EC directive until it has been determined
that the machine in which this gearhead is installed corresponds to the regulations within this
directive.
2.1.2 RoHS
The homogeneous materials used in the gearhead fall below the amounts of hazardous materials
limited by directive 2011/65/EU Annex II.
- Lead (0.1%)
- Mercury (0.1%)
- Cadmium (0.01%)
- Hexavalent chromium (0.1%)
- Polybrominated biphenyls (PBB) (0.1%)
- Polybrominated diphenyl ether (PBDE) (0.1%)
A = Safety symbol (see Chapter 1.2 "Safety symbols")
B = Signal word (see Chapter 1.1 "Signal words")
C = Type and consequence of the danger
D = Prevention of the danger
Safety LK+/LPK+/LPBK+
en-4 2022-D026817 Revision: 07
Installation of the gearhead therefore has no effect on the restriction of using certain hazardous
materials in electrical and electronic equipment as required in the directive.
2.2 Dangers
The gearhead has been constructed according to current technological standards and accepted
safety regulations.
To avoid danger to the operator or damage to the machine, the gearhead may be put to use only
for its intended usage (see chapter 2.4 "Intended use") and in a technically flawless and safe state.
Read the general safety instructions before beginning work (see Chapter 2.7 "General safety
instructions").
2.3 Personnel
Only persons who have read and understood these instructions may carry out work on the
gearhead.
2.4 Intended use
The gearhead serves to convert torques and speeds. It is suitable for all industrial applications.
The gearhead may not be operated in areas with explosion hazards. In food processing, the
gearhead may be used only next to or under the foodstuff area.
The gearhead is intended for installation on motors that:
- Correspond to the design B5 (in the event of deviations, consult our Customer Service
department [technical Customer Service department]).
- Have a radial and axial runout tolerance according to DIN EN 50347.
- Have a cylindrical shaft end with tolerance class h6 to k6.
2.5 Reasonably foreseeable misuse
Any usage that exceeds the maximum permitted speeds, torques and temperature is considered a
misuse and is therefore prohibited.
Co-riding the gearhead on the drive axle is prohibited. Exceptions require a written approval and
technical statement from WITTENSTEIN alpha GmbH.
2.6 Guarantee and liability
Guarantee and liability claims are excluded for personal injury and material damage in case of
- Ignoring the information on transport and storage
- Improper use (misuse)
- Improper or neglected maintenance and repair
- Improper assembly / disassembly or improper operation (e.g. test run without secure
attachment)
- Operation of the gearhead when safety devices and equipment are defective
- Operation of the gearhead without lubricant
- Operation of a heavily soiled gearhead
- Modifications or reconstructions that have been carried out without the approval of
WITTENSTEIN alpha GmbH
2.7 General safety instructions
Objects flung out by rotating components can cause serious injuries.
Remove objects and tools from the gearhead before putting it into
operation.
Remove/Secure the shaft key (if available) if the gearhead is operated
without attachments on the output/drive side.
LK+/LPK+/LPBK+Safety
Revision: 07 2022-D026817 en-5
Rotating components on the gearhead can pull in parts of the body
and cause serious injuries and even death.
Keep a sufficient distance to rotating machinery while the gearhead is
running.
Secure the machine against restarting and unintentional movements
during assembly and maintenance work (e.g. uncontrolled lowering of
lifting axes).
A damaged gearhead can cause accidents and injury.
Never use a gearhead that has been overloaded to due misuse or a
machine crash (see chapter 2.5 "Reasonably foreseeable misuse").
Replace the affected gearhead, even if no external damage is visible.
Hot gearhead housing can cause serious burns.
Touch the gearhead housing only when wearing protective gloves or
after the gearhead has been at standstill for some time.
Loose or overloaded screw connections can damage the gearhead.
Use a calibrated torque wrench to tighten and check all screw
connections for which a tightening torque has been specified.
Lubricants are flammable.
Do not spray with water to extinguish.
Suitable extinguishing agents are powder, foam, water mist, and carbon
dioxide.
Observe the safety instructions of the lubricant manufacturer
(see Chapter 7.4 "Notes on the lubricant used").
Solvents and lubricants can cause skin irritations.
Avoid direct skin contact.
Solvents and lubricants can pollute soil and water.
Use and dispose of cleaning solvents and lubricants properly.
Description of the gearhead LK+/LPK+/LPBK+
en-6 2022-D026817 Revision: 07
3 Description of the gearhead
The gearhead is a single- or multi-stage angle gear, that is manufactured as standard in the "M"
version (motor installation). The output shaft bearing is designed to withstand high tilting moments
and axial forces.
For applications with special safety requirements (e.g. vertical axes, distorted gear inputs) we
recommend employing exclusively our products alpheno®, RP+, SP+, TP+, TP+ HIGH TORQUE or
consulting with WITTENSTEIN alpha GmbH .
The motor centering is realized via the held receptacle for tabs, and not via the adapter plate. Radial
clamping of the motor is avoided.
An adaptation to various motors is realized via an adapter plate and a bushing.
The optional LPBK+ has an output flange instead of an output shaft. This provides the option of
mounting a toothed belt pulley.
3.1 Overview of the gearhead components
3.1.1 Overview of the gearhead components LK+/LPK+
3.1.2 Overview of the gearhead components LPBK+
Gearhead components LK+/LPK+
A Gearhead housing
B Output shaft
C Adapter plate
Tbl-1: Overview of the gearhead components
Gearhead components LPBK+
A Gearhead housing
B Output flange
C Adapter plate
D Mountable flange
Tbl-2: Overview of the gearhead components
A
B
C
A
B
C
A
B
C
D
LK+/LPK+/LPBK+Description of the gearhead
Revision: 07 2022-D026817 en-7
3.2 Identification plate
The identification plate is attached to the gearhead housing.
3.3 Ordering code
3.4 Performance data
For the maximum permitted speeds and torques, refer to
- our catalog,
- our website www.wittenstein-alpha.de,
- the respective customer-specific performance data (X093–D...).
3.5 Weight
The table "Tbl-4" specifies the gearhead weights with a medium-sized adapter plate. If a different
adapter plate is mounted, the actual weight can deviate by up to 10 %.
Designation
A Ordering code
(see Chapter 3.3 "Ordering code")
BRatio
C Serial number
D Lubricant information
E Production date
Tbl-3: Identification plate (sample values)
Consult our Customer Service department if the gearhead is older
than a year. You will then receive the valid performance data.
Gearhead size LK+050 070 090 120 155
1–stage [kg] 0.7 1.9 3.2 8.9 19
Gearhead size LPK+050 070 090 120 155
2–stage [kg] 1.4 3.8 6.9 17 35
3–stage [kg] 1.6 4.2 7.9 19 39
Gearhead size LPBK+—070 090 120 —
2–stage [kg] —3.46.216 —
3–stage [kg] —3.86.917 —
Tbl-4: Weight
WITTENSTEIN alpha GmbH - Walter-Wittenstein-Str.1 - 97999 Igersheim
LPK 090-MO3-100-111
SN: 1234567
DMF: 24/08
Lubrication: For Lifetime
Made in Germany
A
CDB
E
i = 100
Gearhead type
LK+/LPK+ 050/070/090/120/155
LPBK+070/090/120
Gearhead variations
Gearhead model
Number of stages
Backlash
Clamping hub bore hole
diameter
Output shaft shape
Ratios i
LPK 090 -MO3 -100 -111
Transport and storage LK+/LPK+/LPBK+
en-8 2022-D026817 Revision: 07
3.6 Noise emission
Depending on the gearhead type and product size, the continuous sound pressure level is up to
78 dB(A).
For specifications on your particular product, refer to our catalogue or our Internet page at
http://www.wittenstein-alpha.de or contact our Customer Service department.
Observe the total noise pressure level of the machine.
4 Transport and storage
4.1 Scope of delivery
Check the completeness of the delivery against the delivery note.
Immediately notify the carrier, the insurance company, or WITTENSTEIN alpha GmbH in
writing of any missing parts or damage.
4.2 Packaging
The gearhead is delivered packed in foil and cardboard boxes.
Dispose of the packaging materials at recycling sites intended for that. Observe the locally
valid regulations for disposals.
4.3 Transport
No special transport mode is prescribed to transport the gearhead.
For specifications on the weights see Chapter 3.5 "Weight".
4.4 Storage
Store the gearhead in horizontal position and dry surroundings at a temperature of 0 °C to +40 °C
in the original packaging. Store the gearhead for a maximum of 2 years. Consult our Customer
Service department if the conditions are different.
For storage logistics, we recommend the "first in –first out" method.
Hard knocks, because of falling or hard dropping, can damage the
gearhead.
Use only hoisting equipment and transportation devices with sufficient
capacity.
The permitted lifting weight of a hoist may not be exceeded.
Lower the gearhead slowly.
Suspended loads may fall and cause serious injuries and even death.
Do not stand under suspended loads.
The plastic lid on the gearhead may come off.
Never transport the gearhead by the plastic lid.
This manual suits for next models
2
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