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FI ESO 2018 08
30.01.2019
Worm Gear Drive Units (3C/4C)
Test procedure to check feather key connection between motor
and gearbox
thyssenkrupp Fahrtreppen GmbH FI 3C 4C maintenance instruction | 30.01.2019 | Rev. 03 | page 2
Disclaimer
Copyright © by thyssenkrupp Fahrtreppen GmbH, Kolumbusstraße 8, 22113 Hamburg, Germany. thyssenkrupp Fahrtreppen GmbH is the copyright holder. All rights are reserved. This manual is protected by copyright and contains confidential information on the products of the thyssenkrupp Fahrtreppen GmbH. According to copyright laws, this manual may not be copied without the express written consent of thyssenkrupp Fahrtreppen GmbH except for the purpose of normal use or data backup. This exception does not include the making of copies for other users. According to the law, the term copy includes translation into other language or reproduction in a different format. thyssenkrupp Fahrtreppen GmbH reserves the right to make modifications in its products in line with new technical developments. These modifications are not necessarily documents in each individual case. Illustrations in this document aid the general understanding and may differ from the actual design. We waive a gender-specific differentiation because of an easier readability. Terms apply equally to both genders within the meaning of equal treatment.
thyssenkrupp Fahrtreppen GmbH FI 3C 4C maintenance instruction | 30.01.2019 | Rev. 03 | page 3
Content
1 Purpose of this manual ............................................................................................... 4
2 Time frame of initial and repetitive maintenance inspections ............................................ 5
3 Description of components .......................................................................................... 5
4 Preparation ................................................................................................................ 6
4.1 Tools and material needed ....................................................................................... 6
4.2 Safety ................................................................................................................... 6
5 Separate motor and gearbox ....................................................................................... 7
5.1 Prepare for disconnecting motor and gearbox ............................................................ 7
5.2 Lift the motor ......................................................................................................... 8
5.3 Remove dirt and possible corrosion ........................................................................ 10
5.4 Check for mechanical damages .............................................................................. 11
5.5 Burr on gear flange ............................................................................................... 13
5.6 Lubricate feather key connection ............................................................................ 13
6 Re-assemble motor and gearbox ................................................................................ 14
7 Replacement of 3C drive unit ..................................................................................... 15
8 Reporting ................................................................................................................ 17
9 Factory contact ........................................................................................................ 18
thyssenkrupp Fahrtreppen GmbH FI 3C 4C maintenance instruction | 30.01.2019 | Rev. 03 | page 4
1 Purpose of this manual
This manual describes how to maintain the connection between motor and gearbox of escalators and inclined moving walks to avoid unsafe situations caused by damaged feather keys.
Depending on the detected condition, further steps may be required as described in the following chapters
based on these scenarios:
Figure 1: Motor type label indicating series 3C or 4C
3C or 4C drive unit
Separation of motor from gear
box possible?
No Yes
Replace drive unit
Selection of new drive unit according to table 2
Operation of old unit allowed for another max. 6 weeks
Report to factory
Yes No Motor shaft or hollow shaft or
feather key damaged?
Clean shafts and feather key
Grease shafts and feather key
Re-assemble motor on gearbox
Repeat maintenance in 2 years
Report to factory
Replace drive unit
Selection of new drive unit
according to table 2
No further operation of old unit is allowed
Report to factory
Burr on gear
or motor flange?
No
Yes
Replace drive unit
Selection of new drive unit according to table 2
Operation of old unit allowed for another max. 6 weeks
Report to factory
thyssenkrupp Fahrtreppen GmbH FI 3C 4C maintenance instruction | 30.01.2019 | Rev. 03 | page 5
2 Time frame of initial and repetitive maintenance inspections
This initial maintenance procedure shall be carried out as soon as possible on all drive units of this type according to local timetables.
Regular maintenance inspections of the feather key connections shall be carried out every two years after the
initial inspection.
3 Description of components
The connection between motor and SOG - FTS 125/160 (3C and 4C) worm gear is made with a rigid feather key connection. The driving torque of the motor shaft is transferred to the hollow shaft of the gear via feather
key connection. It is used for escalators and moving walks with chain transmission and spur gear transmission.
New drive units (5C, start of production September 2017) are connected with a flexible coupling and do not
require this maintenance procedure.
Figure 2: Drive unit
1 Motor 2 Motor shaft
3 Feather key 4 Gear hollow shaft
5 Gearbox SOG - FTS worm gear (by the example of chain transmission)
1
2 3
4
5
thyssenkrupp Fahrtreppen GmbH FI 3C 4C maintenance instruction | 30.01.2019 | Rev. 03 | page 6
4 Preparation
4.1 Tools and material needed
Standard tool box
Torque wrench 85-190 Nm
Load ring M12 standard 3,4kN, tkE mat.number 300000132600
Load ring M12 reinforced 19,6kN, tkE mat.number 300000127700
Lifting equipment
3 chisels
Sponge or rough cloth for cleaning
Cleaning detergent (e.g. Caramba Eisrostlöser tkE mat.number: 300000201600*, Liqui moli 1611, WD44004, Nigrin 72271)
Grease (Fuchs Lubritech - Gleitmo805K, tkE mat.number: 300000202700* or Fuchs Lubritech - Gleitmo805)
*The last digit of the part number might differ for different packaging sizes
4.2 Safety
Consider the Maintenance Instructions MF8-00-17 (Instructions for accident prevention) and MF8-00-18 (Accident prevention instructions).
DANGER
Danger of rotating machine parts!
Do not reach into machine. Keep sufficient distance to rotating parts. Wear tight-fitting clothes. Make sure long hair does not get into rotating parts.
CAUTION
Hot surface!
Wear appropriate protective gloves.
√ The unit is shut off (set safety barriers and warning signs at the landings).
√ The main switch is switched off and secured against restarting. LOTO
√ The unit is disconnected from power source.
thyssenkrupp Fahrtreppen GmbH FI 3C 4C maintenance instruction | 30.01.2019 | Rev. 03 | page 7
5 Separate motor and gearbox
5.1 Prepare for disconnecting motor and gearbox
Figure 3: Disconnect motor and gearbox
1 Brake magnet 2 Brake monitoring
3 Motor power cable 4 Motor
5 Gearbox 6 Bolts and nuts to connect motor and gearbox
1
3
2
6
5
4
thyssenkrupp Fahrtreppen GmbH FI 3C 4C maintenance instruction | 30.01.2019 | Rev. 03 | page 8
5.2 Lift the motor
WARNING
Suspended load! Never stay under suspended loads!
There is a danger of falling loads, which could result in severe injuries.
Never work under a suspended load.
Figure 4: Lift motor
1 Load ring 2 Appropriate lifting device
3 Appropriate lifting rope 4 Disconnecting point
5 Recesses for separation 6 Nuts
2
3
4
1
5
FL
6
thyssenkrupp Fahrtreppen GmbH FI 3C 4C maintenance instruction | 30.01.2019 | Rev. 03 | page 9
To lift the motor proceed as follows:
1. Screw a load ring into the motor shaft at top. 2. Install the lifting device above the drive shaft vertically. 3. Remove the nuts (6). Make sure that all connections are separated. 4. Pay attention to cable connections, loose cable ties if necessary. 5. Lift motor slowly and carefully (see figure 4).
The vertical lifting FL force must not exceed 3,4 kN if a standard load ring is used. The vertical lifting FL force must not exceed 19,6 kN if a reinforced load ring is used. Higher
loads than that are not allowed. If it is not possible to lift the motor from the gearbox with the lifting device, proceed as follows:
6. Drift the chisels from several sides evenly into the gap between the motor and the gearbox (pos. 5 in
fig.4, positions of the recesses are different for different gearbox sizes), while the lifting device is still loaded. Please consider that not all versions of the gearbox have these recesses.
a. Use a steel hammer with a maximum weight of 500 g. b. Hit the chisel with the hammer from a distance of approximately 30cm two times. If the space
is not available reduce the distance accordingly. c. Then use the next recess again with two hits. d. Repeat this until each recess has been used two times.
If the motor can not be disconnected still, proceed as follows:
7. Fix the nuts (6) again. Bring the escalator into operation again. See chapter 6 also. 8. Order a replacement drive unit and exchange it within the next 6 weeks.
Figure 5: Disconnecting of motor and gear box
1 Disconnecting jointing 2 Chisel 3 Hammer (max 500 g)
1
2
3
thyssenkrupp Fahrtreppen GmbH FI 3C 4C maintenance instruction | 30.01.2019 | Rev. 03 | page 10
5.3 Remove dirt and possible corrosion
Figure 6: Corroded motor shaft
Figure 7: Corroded gear hollow shaft
Figure 8: Cleaned motor shaft
Figure 9: Cleaned hollow shaft
To remove dirt and possible corrosion, proceed as follows:
1. Remove dirt and possible corrosion from the drive shaft and the gearbox hollow shaft with a rough
cloth or sponge and rust solvent Caramba Eisrostlöser or others listed above. 2. Ensure that no dirt falls into the gearbox.
3. Clean all surfaces
thyssenkrupp Fahrtreppen GmbH FI 3C 4C maintenance instruction | 30.01.2019 | Rev. 03 | page 11
5.4 Check for mechanical damages
To check the feather key connection for mechanical damages, proceed as follows:
1. Check the motor shaft, gearbox hollow shaft and the feather key connection for mechanical damages. 2. If there are damaged or worn parts (as in fig. 11 to 13) or rust accumulations (as in fig. 14 and 15),
then:
Change the complete drive unit.
Take the escalator/moving walk out of operation if no spare drive unit is available.
Examples for damages:
Figure 10: Damaged motor shaft
Figure 11: Damaged hollow shaft of gearbox in cross section view
Damaged
hollow shaft
Gear hollow shaft
Motor shaft
Feather key
thyssenkrupp Fahrtreppen GmbH FI 3C 4C maintenance instruction | 30.01.2019 | Rev. 03 | page 12
Figure 12: Damages on feather key Figure 13: Damages on feather key
Figure 14: Rust accumulation in feather key groove Figure 15: Rust accumulation close to hollow shaft of gear box
IMPORTANT
It is unsafe to operate the unit with any of these damages.
The unit must not be operated until a new drive unit is installed.
Ensure that the escalator / moving walk is not accessible to passengers for the out of operation time
(use suitable barriers, brakes must be engaged, power switched off).
thyssenkrupp Fahrtreppen GmbH FI 3C 4C maintenance instruction | 30.01.2019 | Rev. 03 | page 13
5.5 Burr on gear flange
1. Check the machined surface of the gear flange for burrs which protrude vertically. These burrs do not
allow a proper alignment of motor and gear shafts. 2. If there are burrs or other foreign parts on the flange, then:
Change the complete drive unit.
The escalator/moving walk may be operated for another 6 weeks from detection of this fault if no damage on the motor shaft, gear shaft or feather key is visible.
Figure 16: Burr on gear flange Figure 17: Burr on gear flange
Remark: A corroded flange surface is an indicator for a burr or other obstacle between motor and gear flange.
5.6 Lubricate feather key connection
Figure 18: Treated motor shaft (Gleitmo805K)
Figure 19: Treated gear hollow shaft (Gleitmo805)
To treat the parts with lubrication, proceed as follows:
1. Clean surfaces with rust solvent e.g. Caramba Eisrostlöser or others listed above. 2. Lubricate the drive shaft, gearbox hollow shaft and the feather key connection with high-performance
lubricating paste Fuchs Lubritech- Gleitmo805K or Gleitmo805. Other type of lubrication is not permitted.
IMPORTANT
The replacement must be completed within 6 weeks after the detection of this problem. During this
limited period of time the escalator / moving walk may be operated if no other damages are present.
thyssenkrupp Fahrtreppen GmbH FI 3C 4C maintenance instruction | 30.01.2019 | Rev. 03 | page 14
6 Re-assemble motor and gearbox
Figure 20: Connect motor and gearbox
1 Load ring 2 Appropriate lifting device
3 Appropriate lifting rope
To connect drive and gearbox, proceed as follows:
1. Place the drive shaft vertically exactly above the gearbox hollow shaft.
Pay attention to a correct alignment of the feather key on the motor drive shaft to the feather key slot on the gearbox hollow shaft and the motor drive shaft to the gearbox hollow shaft.
2. Let the drive slowly down till it is fitted flush in the gearbox.
3. Apply the fixing screw for drive and gearbox with washers and nuts.
Tighten with tightening torque as shown in Table 1: Tightening torque. 4. Remove the load ring from the motor shaft.
5. Connect the cable connections if necessary.
6. Carry out a test run. 7. Only re-start the unit when safety is ensured.
8. Close the unit and remove safety precautions.
Table 1: Tightening torque gearbox - motor
Design size Screws Tightening torque
SOG - FTS 125 4 x M12 8.8 85 Nm
SOG - FTS 160 4 x M16 8.8 190 Nm
1
2
3
thyssenkrupp Fahrtreppen GmbH FI 3C 4C maintenance instruction | 30.01.2019 | Rev. 03 | page 15
7 Replacement of 3C drive unit
In case the 3C drive unit can’t be used anymore a replacement is needed. The succeeding model is 5C which uses the same design as 3C but has an elastic coupling between motor and gearbox. Due to the coupling the height of 5C is bigger than of 3C. Therefore not all variants of 3C can be replaced by 5C. Table 2 gives an
overview about the limitations. In case 5C is not suitable 2M (OMS gearbox with EMOD motor) shall be used.
Motor size and brake type are indicated on the type label of the motor, the inertia is stamped on the fly wheel.
In case one drive of a twin drive is damaged and needs replacement, the other drive has to be replaced with the same type of drive. A combination of a 2 M or 5 C and a 3C is not allowed.
In case of twin chain drive the machinery support needs special attention as the positions might differ
depending on many design aspects. Please contact the factory for clarification.
For final order of replacement drive units please contact the factory to ensure that project specific
modifications are considered, as this table reflects the standard only.
thyssenkrupp Fahrtreppen GmbH FI 3C 4C maintenance instruction | 30.01.2019 | Rev. 03 | page 16
Table 2: 5C replacement limitations to replace 3C (4C can be replaced by 4C only)
4 C drive units (Velino compact) can be replaced by 4C only. The regular maintenance procedure has to be followed in the same way as for 3C.
thyssenkrupp Fahrtreppen GmbH FI 3C 4C maintenance instruction | 30.01.2019 | Rev. 03 | page 17
8 Reporting
Please report to the factory about the result of each maintenance inspection with the following information and add pictures form the shaft with feather key and the hollow shaft before cleaning:
Please use the online web tool to report about the condition of the units you inspected. The link to the tool will
be shared separately. In case you have no internet access, please use the format below.
Escalator/Moving walk fabrication number:
Number on motor type plate:
Place of installation:
Date of inspection:
Inspection performed by (Name):
Results Please mark
Motor could be removed from gear box Yes No
Feather key damaged Yes No
Motor shaft damaged Yes No
Hollow shaft damaged Yes No
Burr on gear flange Yes No
Rust could be removed Yes No
Re-assembly without problems Yes No
Escalator/moving walk put back in operation with original drive unit
Yes No
Escalator/moving walk put back in operation with replacement drive unit
Yes No
Escalator/moving put out of operation until new drive unit will be available
Yes No
Notes:
thyssenkrupp Fahrtreppen GmbH FI 3C 4C maintenance instruction | 30.01.2019 | Rev. 03 | page 18
9 Factory contact
In case you need any support please contact the factory which delivered the escalator or moving walk.
tk Fahrtreppen in Hamburg, Germany: [email protected]
tk Norte in Mieres, Spain: [email protected]
thyssenkrupp Fahrtreppen GmbH
Thomas Zimmer
Kolumbusstraße 8
22113 Hamburg
Postfach 74 06 23
22096 Hamburg, Germany
Telefon: +49 (0) 40 73 117-537
Telefax: +49 (0) 40 73 117-439
thyssenkrupp Norte, S.A.
Javier Álvarez-Buylla Escobar
Pol. Ind. La Pereda s/n. 33682 Mieres (Asturias), Spain
Phone: +34 98 544 6804
Mobile : +34 662 600 654
E-mail: [email protected]