HANSEN P4 - Hansen Industrial Transmissions

HANSEN P4 - Hansen Industrial Transmissions
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HANSEN P4
Standardized gear units
Service manual
GELEVERD
SHIPPED
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ISO 9001
ISO 9001
LIVRE
SANS
HUILE
FRANÇAIS : voir pages 41...78
ENGLISH : see pages 4...40
: DANGER
: DANGER
: WARNING
: AVERTISSEMENT
: MAINTENANCE
: ENTRETIEN
CONTENTS
Page
Page
QUICK REFERENCE
MAINTENANCE TABLE
4-7
7
3-6
1
2
3
SCOPE
GENERAL
SHIPPING
8
8-12
13
4
STORAGE
5
6
7
8
9
10
11
12
13
HANDLING
INSTALLATION
LUBRICATION
VENTILATION
COOLING
BACKSTOPS
START UP
MAINTENANCE
GREASE QUANTITIES
Grease quantity for bearings
Grease quantity for labyrinth seal
14 LUBRICANTS
Mineral oils and greases
Polyalpha-olefine based synthetic oils and
suitable grease
INDEX
Page
POINTS DE REFERENCE
TABLEAU DES TRAVAUX D'ENTRETIEN
41-44
44
7 1
7 - 11 2
12 3
OBJET
GENERALITES
LIVRAISON
45
44-49
50
13-14
12 - 13 4
ENTREPOSAGE
50-51
15-17
17-26
26-30
30
30-31
31-32
32-33
33-35
14 - 16 5
MANUTENTION
INSTALLATION
LUBRIFICATION
AERATION
REFROIDISSEMENT
ANTIDEVIREURS
MISE EN MARCHE
ENTRETIEN
QUANTITE DE GRAISSE
Quantité de graisse pour roulements
Quantité de graisse pour garniture à labyrinthe
LUBRIFIANTS
52-54
54-63
63-67
67
68-69
69
69-70
70-73
36-37
38
39-40
39
40
6
16 - 25 6
25 - 29 7
29 8
29 - 30 9
30 - 31 10
31 - 32 11
32 - 34 12
13
35 - 36
37
14
77-75
76
77-78
38
Huiles et graisses minérales
77
39
Huiles synthétiques du type polyalpha-olefine et
graisse appropriée
78
WORLDWIDE TRANSMISSION SERVICE
ORGANISATION INTERNATIONALE DE VENTE
See:
Voir:
www.hansenindustrialgearboxes.com
Hansen Industrial Transmissions nv
Leonardo da Vincilaan 1
BE-2650 Edegem
Belgium
Hansen Industrial Gearboxes Services
Leonardo da Vincilaan 1
BE-2650 Edegem
Belgium
Tel.: + 32 3 450 12 11
Fax: + 32 3 450 12 20
E-mail: [email protected]
Tel.: +32 (0)3 450 12 34
Fax: +32 (0)3 450 15 99
E-mail: [email protected]
Every
has been
taken
tothe
ensure
theof
accuracy
of the contained
information
Every
carecare
has been
taken to
ensure
accuracy
the information
in this
but,
due to a policy
of continuous
incontained
this publication,
but,publication,
due to a policy
of continuous
development
and imdevelopment
and
improvement
the
right
is
reserved
to
supply
provement the right is reserved to supply products which may differ slightly
products
which may
slightly
those illustrated and described
from
those illustrated
anddiffer
described
in thisfrom
publication.
in this
publication.
Please
contact
Hansen Industrial Transmissions nv for information on any
Please
Hansen Industrial
nv for information
on
aspects
of contact
storage, installation,
operating,Transmissions
lubrication and maintenance
that
anyclarifying.
aspects of storage, installation, operating, lubrication and
need
maintenance that need clarifying.
2
Toutes les précautions ont été prises pour assurer l'exactitude de
l’information contenue dans cette publication, mais en raison d'une
politique de développement et d'amélioration continus le droit est
réserve de fournir des produits qui peuvent différer légèrement de ceux
illustrés et décrits dans la présente publication.
Contacter Hansen Industrial Transmissions nv pour obtenir des
renseignements concernant les aspects de stockage, d'installation,
d'exploitation, de lubrification et d'entretien qui nécessitent une
clarification.
2
ENGLISH
QUICK REFERENCE
PRECAUTIONS TO TAKE ...
... upon reception and during storage
Take care of...
Possible damage if neglected
• Damaged packaging
• Unpackaged
- Check the protection of machined surfaces
and shaft ends.
- Provide the entire drive group with an
adequate protection for the planned
storage period.
• Corrosion of machined surfaces and shaft
ends
• Corrosion of gear unit parts and
components
• Damage to shafts, gears and bearings
• Store the gear unit in his original packing.
• Long term storage: see chapter 4.
• Corrosion of gear unit parts and
components
• Condensation not possible in the repository
• Corrosion of gear unit parts and
components
• Don’t store the gear unit near vibrating
machines.
• Damage to gears and bearings
... during installation
Take care of...
Possible damage if neglected
• Alignment of:
- Gear unit -> Motor
- Gear unit -> Machine shaft
• Overload on high speed shaft & low speed
shaft couplings, bearings and shafts
• Vibrations: damage to shafts, gears,
bearings and couplings
• Balancing of couplings
• Vibrations: damage to shafts, gears,
bearings and couplings
• Correct positioning of mounting feet on
bedplate by shimming
• Rupture of mounting feet
• Distortion of gear unit
• Correct tightening of fixation & motor bolts
• Retorque after 50 to 100 hours of first
operation.
• Loosening of bolts and displacement of the
gear unit -> misalignment -> ...
• Smooth mounting of couplings and brakes
onto shafts, never use impact.
• Damage to bearings
• Lift and handle gear unit by special lifting
eyes.
Never lift it by the shafts.
• Damage to bearings
Note: This quick reference for handling the gear unit is not exhaustive.
The obligation to read the complete service manual remains.
4
3
ENGLISH
... during installation, continuation
Take care of...
Possible damage if neglected
• Check before filling oil that no pipes are
damaged during transport or installation.
Replace damaged pipes.
• Insufficient lubrication -> damage to gear
unit parts and components
• Installation: After installation of the gear unit,
lubricate immediately the complete drive.
• Accidental start up of the drive group with
insufficient lubrication -> damage to gear
unit parts and components
• Oil level glasses should be calibrated with the
dipstick of the gear unit. Apply indelible
marks on the oil level glass.
• Check and compare the oil level indication
on the other oil level markings with the
dipstick of the gear unit. Calibrate the other
oil level indications if necessary.
• Oil level too low -> damage to gears and
bearings
• Oil level too high -> leakage, increased oil
temperature
• Check the direction of rotation of the low
speed shaft (built in backstop): refer to the
dimensional drawing.
• Wrong direction of rotation -> damage to
the backstop and other parts
• Test run of the gear unit: follow up all
instructions of chapter 11: “Starting-up”.
• Damage to gear unit parts and components
• Long periods of standstill of the gear unit
after installation and before starting-up:
• Corrosion of gear unit parts and
components
- follow up all instructions of paragraph 12.6
“Extended periods of standstill”,
• Damage to gear unit parts and components
- always protect the drive group against
possible corrosion.
4
Note: This quick reference for handling the gear unit is not exhaustive.
The obligation to read the complete service manual remains.
5
ENGLISH
... during start up
Take care of...
Possible damage if neglected
• Check the internal components of the gear
unit for corrosion.
• Damage to gears and bearings
• Fill gear unit up to correct level.
• Oil level too low -> damage to gears and
bearings
• Oil level too high -> leakage, increased oil
temperature
• Use required oil and correct viscosity.
• Viscosity too high (thick oil) -> lubrication is
unsatisfactory with very low starting
temperature.
• Viscosity too low (very fluid oil) -> too thin
oil film: bearing damage and pitting or
scuffing on gears
• Use clean oil and fill oil trough prefiltered
unit (avoid abrasive particles and water).
• Abrasive wear of bearings and gears due to
foreign particles in oil
• Correct tightening of fixation bolts
• Retorque after 50 to 100 hours of first
operation.
• Loosening of bolts and displacement of
the gear unit -> misalignment -> ...
• Correct functioning of control equipment
• No alarm in case of malfunctioning
Damage to bearings and gears
• Install and connect correctly lubrication group
and control switches.
• No lubrication -> damage to gears and
bearings.
• Check the direction of rotation of the low
speed shaft (built in backstop): refer to the
dimensional drawing.
• Wrong direction of rotation -> damage to
the backstop and other parts
... during normal operation
Take care of...
Possible damage if neglected
• First oil change after 100 hours, max 800
hours to take out small wear particles due to
running in.
• Premature damage to gears and bearings
(Final impact - long term effect)
• Regular oil change when oil has lost its
lubrication capacity.
• If oil has lost its capacities, anti-scuffing and
anti corrosion are unsatisfactory ->
damage to gears and bearings
• Avoid entering of sand, water, cement,...
• Damage to gears and bearings
• Check breather.
• Obstructed breather -> leakages
-> too low oil level
-> damage to bearings and gears.
Note: This quick reference for handling the gear unit is not exhaustive.
The obligation to read the complete service manual remains.
6
5
ENGLISH
MAINTENANCE ISSUES
Refer to chapter 12: Maintenance
Maintenance table
Periodical inspections as stated below will increase the reliability and lifetime.
Minimum
After first
run
Fixation of the gear
unit
Monthly
6-Monthly
Yearly
*
*
Corrosion (1)
*
Alignment
*
Oil leaks
*
Lubrication
*
*
*
*
Cleanliness
*
Abnormal noise and
vibrations
*
*
Oil level
*
*
Oil sample analysis
Greasing
*
*
Check the proper
functioning of the
backstop
Couplings - elastic
elements
Refer to the
appropriate service
manual
* (Or biennial)
*
(1) Check the internal components of the gear unit for corrosion before start up.
Repeat this check after each extended period of standstill (refer to section 12.6).
The result of this inspection must be documented and made available on request.
Any evidence of corrosion on internal components of the gear unit must be reported to
Hansen Industrial Transmissions nv.
6
Note: This quick reference for handling the gear unit is not exhaustive.
The obligation to read the complete service manual remains.
7
ENGLISH
1. SCOPE
This service manual contains the storage, installation, operating, lubrication and maintenance instructions for the
Hansen P4 standardized gear units.
The Hansen P4 gear unit is a component of a machine to decrease or to increase the input speed and
respectively to increase or to decrease the transmitted torque.
Additional information can be obtained by contacting one of the Hansen Industrial Transmissions nv sales centres
worldwide (p. 2).
All handling, storage, installation, start-up, inspection and maintenance of the equipment shall be
done by personnel qualified in matters of industrial mechanical and - where applicable - electrical
equipment.
2. GENERAL
2.1. GENERAL INSTRUCTIONS
Carefully read this manual before installing the gear unit.
Compliance with the instructions is required for long and troublefree operation of the gear unit.
The equipment should be checked against shipping papers and inspected for apparent damage caused during
transport. Any shortage, discrepancy or damage must immediately be reported to Hansen Industrial
Transmissions nv.
2.1.1. Warranty
The warranty clause of the "General Conditions of Sale" applies to gear units installed and maintained as per
instructions contained in this manual and in any additional instruction leaflets supplied with the gear unit insofar
as the gear unit operates within the service and rating conditions put forward in the "Order Acknowledgement"
and on the certified drawings.
Non compliance with these instructions, injudicious choice of lubricant or a lack of maintenance will render
warranty agreement invalid.
This warranty clause applies to all parts of the gear unit with the exception of these parts which are subject to
wear.
2.1.2. Security
Before starting activities it is essential to consult and study attentively the certified drawing of the gear
unit.
The certified drawing contains the information which makes it possible to work in safe conditions and
to avoid risks, damage and injury.
2.1.2.1. Application
It is not allowed to use the gear unit for other applications or in other operating conditions than those for which it
was ordered.
The application, the operating conditions and the conditions of use are described in the "Order
Acknowledgement".
In the absence of information or in case of doubt, refer to Hansen Industrial Transmissions nv.
2.1.2.2. Storage and packing
Read carefully the chapters “Shipping” and “Storage” to follow up the necessary instructions.
To protect the gear units from corrosion, they are treated with anti-corrosive products.
It is strongly recommended to carry out the unpacking and the inspection in a roomy, dry and aired workshop.
8
7
ENGLISH
2.1.2.3. Handling
The Hansen P4 gear units are easy to handle.
Use the suitable lifting equipment.
Use the appropriate lifting points at the gear unit housing (integral oval lifting eyes, lifting eye nuts with bolts or
integral rods.
The other components of the gear unit cannot be used for lifting.
Before handling the gear unit, the state of the lifting points must be inspected for:
- signs of fatigue
- cracks
- deformation
- signs of rupture
- corrosion
- locking of the lifting eye bolts and the lifting eye nuts
Take care of a good load distribution and a horizontal handling of the gear unit.
2.1.2.4. Installation
The user shall be responsible for the proper installation of the complete equipment and the supply of
protection guards and other safety equipment in accordance with the European Directives 2006/42/EG
and the local safety regulations.
Sufficient space and protections must be provided, in such way that a person walking by cannot injure
himself.
The gear unit contains rotating parts.
Before beginning the installation of the gear unit, it is necessary to check that involuntary starting up of
the drive is impossible.
Heaters, coolers, electrical alarms and other safety or monitoring devices supplied by Hansen Industrial
Transmissions nv separately or together with the gear unit, must be installed and connected by the user as
indicated on the relative documents.
After installation and before starting up the gear unit, it is necessary to check that:
- the rotating external parts are provided with adequate protections,
- the gear unit is lubricated,
- the lubricating system , the measuring-, safety- and control instruments, are connected and are
functioning,
- the operating and control instruments, the tubes and the flexible pipes are protected against
harmful external influences,
- the direction of rotation for the gear unit shafts and motor shaft are correct if the gear unit has
a backstop. Refer to the dimensional drawing and paragraph 11.2 “Gear units equipped with a
backstop”.
2.1.2.5. Temperature and heat
- Temperature
The temperature of the gear unit and the lubricants can be high.
Before approaching the gear unit or carrying out activities, it is strongly recommended to check that the
temperature of the gear unit is equal to the ambient temperature.
If this safety directive cannot be followed, approaching the gear unit is only allowed if the temperature is lower
than the value necessary to cause burns.
In addition the personnel must wear heat resistent clothing and gloves.
Suitable equipment will be necessary to protect the face and the eyes against possible oil splash.
8
9
ENGLISH
- Heat
The gear unit produces heat due to losses. Sufficient space must be provided around the gear unit allowing the
gear unit and the cooling system to exchange heat with the environment.
The gear unit as well as the cooling system must remain clean to assure the heat transfer with the environment.
An inadequate heat transfer leads to high temperatures and damaging of the gear unit parts. It might lead to a
faulty operation of the gear unit.
2.1.2.6. Fire
Gear units with burning marks cannot be restarted. Only after revision and repair carried out by Hansen
Industrial Transmissions nv, the gear units can be started safely.
Burning of lubricants and sealing
- Lubricants: oil and grease
Other chemical substances emerge from burning of oils and greases, which are harmful for human
and environment.
Refer to the lubricant supplier to know:
- possible dangers and consequences,
- safety specifications to follow up.
- Sealing
Some seals in a gear unit can contain FKM1 material (trade names e.g. Viton® 2 and Fluorel® 3).
If seals, made out of FKM material, have been exposed to high temperatures (e.g. in case of a fire or
when a bearing very close to the seal has experienced massive damage), highly corrosive organic
fluorides may have been generated and contact with the skin must be avoided at all time.
Since it is not always clear whether the used material is in fact FKM, it is strongly recommended to
handle every seal that has been exposed to high temperatures with extreme care and to take the
necessary precautions (*).
1: FKM is short for Fluoroelastomer
2: Viton® is a registered trademark of Dupont-Dow
3: Fluorel® is a registered trademark of Dyneon (3M)
* Exctraction from 'handling precautions for Viton® and related chemicals', technical information
from Dupont-Dow:
Precaution in the event of fire.
Highly toxic products (**) of combustion can be generated in a fire involving Viton®. Personnel fighting such a fire
must wear facemasks and a self-contained breathing apparatus. All unprotected personnel must leave the area
immediately. Anyone exposed to fumes from the fire should be moved to fresh air at once and treated by a
physician.
Anyone handling residues of Viton polymer or parts of Viton® that have been involved in a fire must wear
Neoprene gloves to avoid skin contact with these possibly highly corrosive residues, which likely include hydrogen
fluoride. (Polyvinylchloride [PVC] gloves may be used if the temperature of the residue is below the melting point
of the gloves.) Such residues should be decontaminated by washing in lime water (calcium hydroxide solution)
and disposed of in the same manner as Viton® polymer. To dispose of Viton®, landfill is preferred. The disposal
method must be conform to national, state and local regulations.
Burning of Viton® is not recommended, unless conducted by an approved, licensed incineration process. In this
case, the gaseous products should be treated by alkaline scrubbing. The gloves must be discarded after use.
(**) Combustion products of Vulcanizates of Viton®
Carbon Monoxide (CO)
Fluoroform (CHF3)
Carbon Dioxide (CO2)
Vinilidene Fluoride (H2CCF2)
Hydrogen Fluoride (HF)
Hexafluoropropylene (C3F6)
Carbonyl Fluoride (COF3)
Low molecular weight fluocarbon fragments
10
9
ENGLISH
2.1.2.7. Electricity
Before starting maintenance activities on the gear unit, it is necessary to disconnect the drive from the
electric grid.
The electric switch must be locked so that electric supply to the drive is impossible.
Earthing the gear unit as an independent element is highly recommended.
The gear unit must never be part of an earthing circuit of other electric machines.
Leaks of electric current can damage the gears and the bearings of the gear unit compromising the reliability and
the good performance of the gear unit.
2.1.2.8. Noice and vibrations
The drive group and its components cause vibrations and noise.
As limited as its emissions may be, it might be necessary, in conformity to the national or local directives, to use
envelopes, separating walls and vibration (shock) absorbers to reduce the emission values of noise and vibration
to a level lower than the values mentioned in the directives.
If the above mentioned directives can not be fulfilled, all personnel working nearby the drive groups must get the
necessary protective equipment and use it to reduce the noise and vibration nuisance to an acceptable level.
2.1.2.9. The gear unit or drive as component of a machine
The gear unit or the drive is a machine component.
Always refer to the service manual of the machine to follow the safety and installation instructions
which belong to the machine.
2.1.2.10. Maintenance
- Lighting:
Before starting maintenance activities on the gear unit, it is necessary to ensure sufficient lighting of the drive
group to work in fully safe conditions.
- Maintenance during the warranty period:
• Maintenance activities like:
- dis-assembly of the gear unit and its parts,
- assembly of the gear unit and its parts,
- replacement of parts by spare parts,
will be done by qualified personnel that is authorized by Hansen Industrial Transmissions nv.
• The maintenance which is limited to:
- the checking of the good performance of the instruments of operation and control,
- the control of cleanliness of the installation,
- the oil draining and oil filling of the gear unit, regreasing of the bearings and labyrinth seals,
- the checking of the drive group alignment,
- the checking for wear of the components of the drive group,
- the maintenance of the lubrication system,
will be carried out according to the description and the directives mentioned in this service manual.
The maintenance shall be done by personnel qualified in matters of industrial mechanical and - where
applicable -electrical equipment.
- Maintenance outside the warranty period:
The maintenance shall be done by personnel qualified in matters of industrial mechanical and - where applicable
- electrical equipment.
The disassembly and the assembly of a gear unit and its parts require a qualification and a particular
knowledge. It is strongly recommended to entrust this task to qualified personnel authorized by Hansen Industrial
Transmissions nv.
Original parts of Hansen Industrial Transmissions nv should be used to replace the existing parts.
10
11
ENGLISH
- After installation and before starting up the gear unit, it is necessary to check that:
- the rotating external parts are provided with adequate protections,
- the gear unit is lubricated,
- the lubricating system , the measuring-, safety- and control instruments, are connected and are
functioning properly,
- the operating and control instruments, the tubes and the flexible pipes are protected against the
harmful external influences,
- the direction of rotation for the gear unit shafts and motor shaft are correct if the gear unit has a
backstop. Refer to the dimensional drawing and paragraph 11.2 “Gear units equipped with a
backstop”.
2.2. GENERAL SPECIFICATIONS
For general specifications such as dimensions, weight, connecting diagrams: refer to the certified drawing of the
gear unit and/or to the Hansen P4 standardized gear unit catalogues.
2.3. IDENTIFICATION
Inquiries concerning a gear unit should always specify the unit's complete type code and manufacturing number,
which can be found on the nameplate.
This information is essential to identify the unit supplied by Hansen Industrial Transmissions nv.
The nameplate, which is fitted on each gear unit, also contains information about ratings and/or torque, speed
and lubrication.
Nameplate
*
Key to symbols
Type
Type specification of the gear unit (serial number and code)
N°
Gear unit production number
PNOM
Nominal power rating (kW) at high speed shaft of the gear unit
TNOM
Nominal torque rating (kNm) at low speed shaft of the gear unit
SF
Service Factor
min-1
Input and output speed (speeds)
EP GEAR OIL ISO 3448
Gear oil according to ISO 3448
VG
Oil viscosity for a specified ambient temperature range
*
(possible) Indication of the use of synthetic oil ("Synthetic Oil")
Grease
Grease lubrication: grease quantity (indication of grease type
"Q." and brand name, refer to the chapters 12 and 13)
Nipples
Number of grease points (nipples)
12
11
ENGLISH
3. SHIPPING
Each gear unit is inspected and approved by the QUALITY CONTROL DEPARTMENT before shipment. The inspection is carried out based on the order specification. The approval of the gear unit is granted after no load test
of several hours, in normal operating position and at the speed indicated on the nameplate.
3.1. SHIPPING CONDITIONS
Unless otherwise specified, gear units are shipped in unpacked condition and depending on necessity, fixed on
wooden pallets with open crating protection. Sometimes parts, such as spare filter elements, are separately
packed. In such case, the end-user must take care of the assembly.
The Hansen P4 gear unit is shipped without oil.
All grease lubrication points are factory filled.
In case the gear unit, after arrival of the shipment from Hansen Industrial Transmissions nv (H.I.T.), has
to be transported further, H.I.T. advises to avoid transport by train. If the gear units are nevertheless to
be transported by train anyhow, then the necessary precautions must be taken by the forwarder to
avoid false Brinelling damage on gears and bearings.
3.2. PAINTING
Unless otherwise specified, the standard external paint for Hansen Industrial gearboxes is an epoxy primer with
high solids content, corresponding to the German Standard RAL 5021, water blue.
The paint system is designed for gear units installed indoors only and not exposed to humidity or aggressive
chemicals.
The painting system is suitable to be applied in the atmospheric-corrosivity category “C1” according to ISO
12944-2.
Durability range according to ISO 12944-1: at least L, 2 to 5 years
The durability range is NOT a “guarantee time”. Durability is a technical consideration that can help the owner
set up a maintenance programme.
Overcoating is possible with most paints based on alkyd-, epoxy or polyurethane resins.
3.3. PRESERVATION
The inner parts of the gear units are sprayed with rust preventing mineral oil. The breather plug (standard, dustproof, anti-humidity) is neither removed nor sealed.
The shaft extensions are protected with a rust preventing grease. The hollow shafts and all unpainted machined
surfaces are coated with an anti-oxidizing waxy varnish.
This standard system offers corrosion protection during transport and/or short term storage for up to one year indoors.
4. STORAGE
Always store gear units in their original packaging.
Gear units should not be stored near vibrating machines in order to avoid damage to bearings.
The changes in relative air humidity and in temperature must be such that no condensation can occur in the
storage room.
4.1. SHORT TERM STORAGE - INDOORS
A standard preservation of the internal parts of the gear unit is provided for storage up to one year indoors in a
dry, ventilated and sheltered area. The sheltered area must be protected against environmental influences.
Let the applied means of protection intact.
12
13
ENGLISH
4.2. LONG TERM STORAGE
Upon request, the Hansen Industrial gearboxes can be treated in the factory for:
- a protection up to five years after delivery ex works and with storage in a dry, ventilated and
sheltered area,
- a protection up to two years after delivery ex works and for storage outdoors.
INDOORS
Up to five years indoors in a dry, ventilated and sheltered area. The sheltered area must be protected against
environmental influences. The gear unit has to be hermetically sealed. The gear unit has to be packed in a
hermetically sealed envelope.
In case the units are stored for a period up to 5 years in a dry, ventilated sheltered area, the units have to be refilled every two years with the small amount of mineral oil containing a volatile corrosion protective additive
(always read the information on the sticker on the gear unit). Consult your oil supplier about life time,
compatibility with the actual oil and about the volume concentration.
The corrosion protection of the shaft extensions has to be checked and possibly corrected. At these occasions the
high speed shaft must be turned until the low speed shaft has made 2 complete revolutions. The duration of the
operation is limited to a strict minimum. The gear unit must be hermetically resealed immediately.
OUTDOORS
Up to 2 years outdoors, in a hermetically sealed envelope and enclosed in a seaworthy packing case.
Leave the hermetically sealed envelope and the seaworthy packing case intact during the storage period of
maximum 2 years starting from the date of delivery ex works Hansen Industrial Transmissions.
This warranty expires if the package is damaged or opened.
NOTES
The gear unit will be mounted, started up and in operation before the end of the specified storage
period.
All gear units treated and packed for long term storage have the following sticker with caution and instructions.
CAUTION
This gear unit contains .... litres volatile corrosion inhibitor oil.
Type and brand name of the volatile corrosion inhibitor oil: refer to Hansen Industrial
Transmissions nv.
STORE IN SHIPPING POSITION AND KEEP HERMETICALLY CLOSED TO PREVENT VAPOURS
OR OIL FROM ESCAPING UNTIL PUTTING INTO OPERATION.
BEFORE PUTTING INTO OPERATION
- Replace the red plugs by the dipstick and breather (filter or plug).
- Drain the protective oil and fill the gear unit with the exact quantity of the prescribed gear oil
(see also maintenance manual).
It is recommended to rinse the gear unit with the selected oil before starting up. In case of doubt: refer to Hansen
Industrial Transmissions nv.
See paragraph 7.5, page 29:
28 The first oil filling.
See chapter 11, page 32:
31 Starting Up.
Handle any lubricant or oil with care and according to the handling and safety instructions to be supplied by the lubricant supplier on customer's request. These instructions have to be handed over to any
personnel performing installation, maintenance or repair of the gear unit.
Do not open the gear unit near flames, sparks or hot objects and take preventive measures to protect
people against the volatile corrosion protective substance.
14
13
ENGLISH
5. HANDLING
The Hansen P4 gear units are easy to handle and to install. Make use of integral oval lifting eyes (horizontal
mount) and lifting eye nuts with bolts or integral rods (vertical mount).
For equal load sharing make use of all available lifting points (4 lifting points), fixed to the gear unit, and use adequate tools.
Never use the lifting eye bolts of components mounted to the gear unit (eg.: motor, coupling, brake, lubrication
system, etc.)
Make use of attached lifting eye nuts or mount the appropriate eye nuts (with bolt) to the lifting points
of the housing.
Eye nuts (with bolt) must be fixed and secured before lifting the gear unit.
Never lift units with slings wrapped around the shafts or motor lantern.
5.1. LIFTING EYE NUTS WITH BOLTS ATTACHED TO THE GEAR UNIT
Max. force on the eye nut
(kN)
45°
M16 M20 M22 M24 M27 M30 M33 M36
7
12
15
18
26
36
36
51
4
7
8,7
10
15
20
20
28
Horizontal mount
- Single stage gear units (type QHP.1)
Use only the integral lifting eye and appropriate lifting eye nuts with bolts in housing feet
Gear unit size
Bolt size
Grade 8.8
ISO
Low speed shaft side
C
D
E
F
G
M22
M27
M27
M33
M33
High speed shaft side
Use only the integral lifting eye
- Multi stage gear units (type QH...)
Use only integral oval lifting eyes
Vertical mount
- Two stage gear units (type QV..2)
Gear unit size
Bolt size
Grade 8.8
ISO
C
D
E
F
Low speed shaft side
M16
M16
M20
M24
High speed shaft side
M20
M24
M24
M30
G
H
Use only the
integral rods
- Three and four stage gear units (type QV..3 and QV..4 )
C
D
E
F
G
H
Low speed shaft side
M16
M16
M20
M24
M30
M30
High speed shaft side
M16
M20
M24
M24
M30
M30
Gear unit size
Bolt size
Grade 8.8
14
ISO
15
ENGLISH
- For gear units (type QV...), sizes J up to T
Use only the integral rods
Note:
For handling of gear units equipped with a lubrication system caution is necessary.
Particular circumstances might dictate the temporary removal of thermostat(s), pressure gauge(s) and/or part of
the oil feed piping. After removal of the latter elements, one should take special care to avoid ingress of
moisture, etc... into the lubrication system of subject gear unit(s).
5.2. DIRECTION OF LIFTING FORCE FOR EYE NUTS (WITH BOLTS)
Lifting eye nuts (with bolts) must be fully engaged before lifting!
max. 45°
0°
If the condition for direction of lifting force for eye bolts cannot be satisfied, bow (anchor) shackles, rotating eye
bolts or movable eye bolts can be applied. Refer to your supplier for the appropriate selection of lifting tools.
Functioning and security conditions of the selected lifting tools must always be satisfied.
5.3. LIFTING OF THE GEAR UNIT PROVIDED WITH FOUR LIFTING POINTS
30°
(max.
45°)
30°
(max. 45°)
16
15
ENGLISH
The gear unit can only be lifted with lifting cables or lifting chains fixed to the mounted lifting eye bolts or
integral rods.
The weight of the gear unit (or drive) and other instructions are mentioned on the dimensional drawing.
Always refer to the dimensional drawing before starting handling and transport activities.
The length of lifting cables or lifting chains must be chosen in such way that the angle between lifting cables or
lifting chains is smaller than 45°.
If the gear unit is part of a drive package, the lifting points of the gear unit may not be used to lift the complete
drive package. Refer to the dimensional drawing of the drive package to determine and use the appropriate
lifting points.
Note
Proceed with caution for handling of gear units equipped with external components.
Pay attention that the external components will not be damaged when handling or transporting the gear unit.
6. INSTALLATION
6.1. FITTING OF ACCESSORIES
The metric shaft extensions are equipped with keyways according to DIN 6885 "Blatt 1 - Form N1 or N3".
Threaded centre holes in these shafts are according to DIN 332 Teil 2 Form D.
Couplings should be mounted on the shafts with fit according to specifications. Refer to the certified drawing of
the gear unit and the dimensional drawing of the coupling. In case of doubt please refer to Hansen Industrial
Transmissions nv.
Remove the protection from the shaft extensions and check the key fit and the keyway height in the component to
be mounted onto the shaft. Heating the component to 80-100°C (175-210°F) will be helpful in case of
interference fit. The threaded centre hole in the shaft may be used to assist in mounting the components onto the
shaft.
Never mount components by hammering as this may cause damage to the bearings.
Never use rigid couplings except on free end machine shafts (e.g. mixers, aerators) or in executions
with a torque arm.
6.2. COUPLINGS MOUNTED ON THE SHAFT ENDS OF THE GEAR UNIT – CORROSION PROTECTION
The coupling hubs are mounted on the shaft ends so that the front surfaces are flush or the front surface of the
shaft end remains for a minimum length within the bore of the coupling hub.
If necessary, a spacer between shaft shoulder and coupling hub is mounted.
Where applicable, the coupling hub is secured on the shaft end with thrust washer and fixation bolt.
Refer to the certified drawing.
The assembly of coupling hub, spacer, thrust washer and fixation bolt must be corrosion resistant in accordance
with the application and the atmospheric corrosion class (referring to ISO 12944) determined and mentioned by
the customer.
For the cases where coupling hub, spacer, thrust washer and fixation bolt are supplied and mounted by Hansen
Industrial Transmissions nv, all measures are taken to get a corrosion-resistant assembly in accordance with the
application and the atmospheric corrosion class (ISO 12944) as mentioned in the “Order Acknowledgement”.
If the coupling hub, spacer, thrust washer and fixation bolt are provided and mounted by the customer, he
ensures that the assembly will be corrosion-resistant in accordance with the selected atmospheric corrosion class
according to ISO 12944.
Preservation – sealing paste and painting - recommendation
Degrease and clean all components. Only the bore in the coupling hub may be slightly greased to facilitate
mounting on the shaft end. All other contact surfaces must remain clean and free of grease. Coat all contact
surfaces (A, B, C, and D - see figure at next page) between shaft shoulder, spacer, coupling hub, thrust washer
16
17
ENGLISH
and fixation bolt with an appropriate sealing paste. Remove the excess sealing paste after assembly. Check
carefully if the air gaps between the various components are properly sealed.
After assembly and sealing, a paint system that matches the selected atmospheric corrosion class according to
ISO 12944 will be applied. Refer to the “Order Acknowledgement”.
Protect the oil seals of the gear unit against paint and harmful external influences.
Recommended sealing paste: refer to your supplier. In case of doubt, refer to Hansen Industrial Transmissions nv.
A
B
C
D
6.3. EXTERNAL LOADS
If external loads act on the gear unit, thrust blocks must be installed against the unit's feet, to prevent the gear
unit from shifting.
Components transmitting radial load to the shaft should be mounted as close as possible to the housing.
Avoid exaggerated tension in transmission belts mounted on input or output shafts. On gear units with built-on
motor and V-belt drive, tension has been factory set. Tension should be rechecked after 24 hours of operations.
Chain transmissions must be mounted without preliminary tension.
In case a pinion is mounted on the shaft extension of the gear unit, care should be taken to have normal required
backlash between pinion and gear and good contact pattern must be assured.
6.4. ERECTION
6.4.1. Levelling
Always mount gear unit in the position for which it was ordered.
Before altering this mounting position of the gear unit, please consult Hansen Industrial Transmissions nv. It may
be necessary to adapt the lubrication system.
6.4.2. Alignment
Align the gear unit as accurately as possible.
Install the gear unit horizontal, taking into account a max. inclination equal to 5 mm per 1 m (5/32 inch per 3
feet or 5 mrad or 17 arc minutes) or a max. indicated on the outline drawing for positions other than horizontal.
Use three fixation points of the gear unit for alignment. Adjust the other fixation points by shimming to 0,1mm
(0.004 inch).
6.4.2.1. Connection gear unit - machine: allowable misalignment at the low speed shaft (except for
single stage gear units)
The misalignment must be minimized to improve the steadiness of bearing and coupling life span. Ensure that
the alignment remain unchanged at all operating conditions. The unavoidable misalignments may not exceed the
values mentioned in the service manual of the coupling, unless otherwise stated on the certified drawing. These
instructions apply for couplings provided by Hansen Industrial Transmissions NV and listed on the dimensional
drawing.
For couplings NOT delivered by Hansen industrial Transmissions nv (H.I.T.), H.I.T. must be consulted. An
evaluation of external factors which act on the gear unit (maximum admissible misalignment, overhung load on
shaft ends, etc.) allows to check and to guarantee the good functioning of the gear unit.
18
17
ENGLISH
Combination of angular and radial misalignment
Angular and radial misalignment can occur simultaneously. The sum of the misalignments must satisfy the
following condition:
dr
Δr
: measured radial misalignment
: allowable radial misalignment
dr
dα
Δr + Δα ≤
da : measured angular misalignment
Δa : allowable angular misalignment
1
6.4.2.2. Connection motor - gear unit : allowable misalignment at the high speed shaft (including all
shaft ends of single stage gear units)
Speed
(min-1)
Allowable misalignment
Metric (mm)
Inch (mils)
Allowable
Excellent
Allowable
Excellent
Short “flexible” coupling
750
0,19
0,09
7,5
3,5
Radial misalignment
900
0,15
0,08
6,0
3,0
1000
0,12
0,08
4,8
3,0
1200
0,10
0,06
4,0
2,5
1500
0,09
0,06
3,5
2,4
1800
0,08
0,05
3,0
2,0
750
0,13
0,09
13,0
9,0
900
0,10
0,07
10,0
7,0
1000
0,096
0,06
9,6
6,0
1200
0,08
0,05
8,0
5,0
1500
0,07
0,05
7,0
5,0
1800
0,05
0,03
5,0
3,0
750
0,25
0,15
2,5
1,5
900
0,20
0,12
2,0
1,2
1000
0,18
0,11
1,8
1,1
1200
0,15
0,09
1,5
0,9
1500
0,12
0,07
1,2
0,7
1800
0,10
0,06
1,0
0,6
Angular misalignment (*)
Spacer shaft and
membrane (disk) coupling
Radial misalignment (**)
(*) : Angular misalignment for coupling with a diameter of 100 mm or 10 inch
(**) : Radial misalignment for a spacer length of 100 mm or 1 inch
6.4.2.3
Alignment when mounting flexible gear couplings
When flexible gear couplings are mounted, the minimum allowable misalignment for the coupling may differ
from the values listed in the table of permissible misalignment (see above).
Refer to Hansen Industrial Transmissions nv to get the appropriate alignment instructions and service manual of
the gear coupling.
18
19
ENGLISH
6.5. SECURING OF SOLID SHAFT GEAR UNITS
The gear unit must be mounted onto a rigid and stable bedplate or foundation in order to avoid vibrations and
possible overload of the housing fixation pads.
Use the fixation holes indicated on the dimensional drawing.
After correct alignment and shimming of all the points, fix the gear unit solidly onto its foundation with the
appropriate size steel bolts, grade 8.8 according to DIN 267 or SAE grade 5 for steel bolts 1 1/2" and smaller,
ASTM.A-354 grade BC for steel bolts larger than 1 1/2", and grade 80 according to DIN 267 for stainless steel
bolts. Dimensions and tightening torques: see tables.
Note: for some horizontal executions with parallel shaft and fans, the protection hood of the fan must be
removed to enable tightening of the bolts. Remount the protection hood afterwards.
6.5.1. Tightening torques for steel bolts grade 8.8
Horizontal mount
- Single stage gear units (type QHP.1)
Gear unit size
C
D
E
F
G
M30
Bolt size
Grade 8.8
ISO
M20
M24
M24
M30
Tightening torque
Nm
335
675
675
1350 1350
Bolt size
Grade 5
UNC
3/4"
7/8"
1"
1 1/8" 1 1/4"
Tightening torque
lbf.in
2950 4850 6000 10300 12000
- Multi stage gear units (type QH...)
Gear unit size
A
B
C
D
E-F
G-H-J-K
L-M
N-P-Q
R-S-T
Bolt size
Grade 8.8
ISO
M16
M20
M24
M24
M30
M36
M42
M48
M56
Tightening torque
Nm
180
335
675
675
1350
2350
3800
5700
9150
Bolt size
UNC
Grade 5 /Grade BC
5/8"
3/4"
7/8"
1"
1 1/4"
1 1/2"
1 3/4"
2"
2 1/4"
Tightening torque
1550 2950 4850 6000 12000
21000
33650 50750
lbf.in
81050
Vertical mount
- Multi stage gear units (type QV...)
Gear unit size
A
B
C
D
E
F-G(1) G(2)-H-J-K L-M-N-P-Q
R-S-T
Bolt size
Grade 8.8
ISO
M16
M20
M24
M30
M30
M36
M42
M48
M56
Tightening torque
Nm
180
335
675
1350 1350
2350
3800
5700
9150
Bolt size
UNC
Grade 5 /Grade BC
5/8"
3/4"
1"
1 1/8" 1 1/4" 1 1/2"
1 3/4"
2"
2 1/4"
Tightening torque
1550 2950 6000 10300 12000 21000
33650
50750
81050
lbf.in
(1) size G : 2-stage unit
(2) size G : 3- and 4-stage unit
20
19
ENGLISH
6.5.2. Tightening torques for stainless steel bolts grade 80
Horizontal mount
- Single stage gear units (type QHP.1)
Gear unit size
C
D
E
F
G
M24
M24
M30
M30
Bolt size
Grade 80
ISO
M20
Tightening torque
Nm
340
Bolt size
Grade 5
UNC
3/4"
Tightening torque
lbf.in
3000
Upon request
7/8"
1"
1 1/8" 1 1/4"
Upon request
- Multi stage gear units (type QH...)
Gear unit size
A
B
C
D
E-F
G-H-J-K
L-M
N-P-Q
R-S-T
M24
M24
M30
M36
M42
M48
M56
2"
2 1/4"
Bolt size
Grade 80
ISO
M16
M20
Tightening torque
Nm
185
340
Bolt size
UNC
Grade 5 /Grade BC
5/8"
3/4"
Tightening torque
1650 3000
lbf.in
Upon request
7/8"
1"
1 1/4"
1 1/2"
1 3/4"
Upon request
Vertical mount
- Multi stage gear units (type QV...)
Gear unit size
A
B
C
D
E
M24
M30
M30
Bolt size
Grade 80
ISO
M16
M20
Tightening torque
Nm
185
340
Bolt size
UNC
Grade 5 /Grade BC
5/8"
3/4"
Tightening torque
1650 3000
lbf.in
F-G(1) G(2)-H-J-K L-M-N-P-Q
M36
M42
R-S-T
M48
M56
2"
2 1/4"
Upon request
1"
1 1/8" 1 1/4" 1 1/2"
1 3/4"
Upon request
(1) size G : 2-stage unit
(2) size G : 3- and 4-stage unit
The alignment of the complete drive packages mounted on a bedplate has been carefully checked before
shipment.
It is nevertheless required to check that the bedplate has not been deformed during transport or installation.
Therefore check again alignment of couplings or other elements after final installation.
20
21
ENGLISH
6.6. SECURING OF HOLLOW SHAFT GEAR UNITS
6.6.1. Hollow shaft gear unit with shrink disc connection
The Hansen Industrial Transmissions nv supplied shrink disc is ready to be installed.
Do not dismantle shrink disc prior to first mounting.
The two-part shrink disc is used as standard (fig. 1c).
Another execution is available on request. Always refer to the dimensional drawing and the appropriate service
manual of the shrink disc.
Mounting (fig. 1a)
- Clean and degrease contact surfaces (a) and (b).
- Smear surface (b) - and not surface (a) - with "Molykote D321R" or similar.
- After the applied coating has hardened, slide the O-ring (c) onto the shaft.
- Draw the gear unit onto the shaft of the machine using threaded rod (e), nut (f) and distance ring (g) until faces
(h) and (i) make contact.
- Fit shrink disc (s). A locating groove on the shaft indicates the position of the shrink disc. Tighten bolts (ZS) with
a torque wrench. The required tightening torque for the two-part shrink disc is indicated in table 1 and on the
name plate (p).
Tightening bolts are prestressed to the right level when outer ring (o) and inner ring (n) are flush (optical check).
Tighten bolts (ZS) in indicated sequence (q) one by one, progressively over several rounds, until required
tightening torque (TA) is reached.
Do not tighten bolts crosswise.
Mount protection hood.
NOTE:
Never tighten bolts when shrink disc is unmounted.
b
c
a
p
•
o
n
e
f
g
•
h
i
MOUNTING
s
q
1
2
3
ZS
4
FIG.1a
9
5
ZY
6
•
r
n
•
FIG.1b
g
l
FIG.1c
a
8
7
ZS
DISMOUNTING
22
21
ENGLISH
Securing in case of axial load
If the axial load is not absorbed by the shoulder of the machine shaft, a distance ring (g) must be included (see
23
fig. 2b, page 24).
Dismounting (fig. 1b)
- Loosen all tightening bolts (ZS) (fig.1c) uniformly, one by one in a continuous sequence, about a quarter of
a turn per round.
- Should outer and inner ring of the shrink disc not release themselves, one can remove some tightening bolts
and install them in tapped holes (r) (fig. 1c), in the inner ring, to trigger separation of both rings.
- Remove shrink disc from hollow shaft.
- Mount the distance ring (g) on the hollow shaft by means of bolts (ZY) (dimensions of ZY: see dimensional
drawing).
- Place the disassembly bolt (l) into the central hole in the distance ring (g).
- Remove the gear unit from the shaft by tightening the disassembly bolt (l).
Note
The parts e,f,g,l and ZY are not included as standard. They can be supplied upon special request.
For technical data, refer to catalogue or certified drawing.
Cleaning and greasing
Dismounted shrink discs do not have to be taken apart for cleaning and regreasing prior to reinstallation, unless
they have been used in a very dirty environment.
After cleaning, recoat the tapered surfaces using a solid lubricant with a friction coefficient of 0,04 , e.g. Molykote
D321R or similar.
Table 1: tightening torque TA (Nm) for bolts ZS of the two-part shrink disc
Gear unit
size
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
S
T
22
H.I.T.
part number
113-H11082Q
113-H12582Q
113-H14082Q
113-H16581Q
113-H18581Q
113-H22082Q
113-H24082Q
113-H26082Q
113-H28082Q
113-H32082Q
113-H34081Q
113-H36082Q
113-H39081Q
113-H42082Q
113-H44082Q
113-H48082Q
113-H50081Q
113-H53081Q
Stüwe
two-part
shrink disc
121
121
193
295
295
570
570
570
570
980
980
980
1450
1450
1450
1970
1970
1970
Ringfeder
two-part
shrink disc
120
120
190
290
290
570
570
570
570
1000
1000
1000
1450
1450
1450
1970
1970
-
Ringspann
two-part
shrink disc
The required
tightening
torque is
reached
when inner
ring (n) and
outer ring (o)
are flush, see
fig.1c.
Tas Schäfer
two-part
shrink disc
120
120
290
570
570
570
570
980
980
980
1450
1450
1450
1450
1450
-
23
ENGLISH
6.6.2. Hollow shaft gear unit with keyway connection
Mounting (fig. 2a)
- Coat mating faces (b) of the machine shaft with mounting compound.
- Slide the O-ring (c) onto the machine shaft.
- Place supplied mounting key (d) into keyway of machine shaft, with the boss against the shaft face.
- Place the gear unit into position on the machine shaft. Make sure that the keyways are correctly positioned.
- Press the gear unit on the shaft, using a threaded rod (e), a nut (f), and a distance ring (g) until the mounting
key (d) and the distance ring (g) make contact.
- Remove the nut (f), the distance ring (g) and the mounting key (d).
- Ensure that key (m) (fig. 2b) has sufficient clearance on top.
- Fit the key (m) into the shaft (≠ mounting key).
- Remount the distance ring (g) and the nut (f).
- Draw the gear unit further onto the shaft until the faces (h) and (i) make contact.
- Remove the nut (f), the distance ring (g) and the threaded rod (e).
Securing (fig. 2b)
- Mount the distance ring (g) again on the machine shaft using correct fixation bolts (J).
- Install the protection cover (k).
In case of external axial loads on the shaft, please refer to specific instructions on the outline drawing.
Dismounting (fig. 2c)
- Remove the protection cover (k) and the fixation bolts (J) (fig. 2b).
- Mount the distance ring (g) on the hollow shaft by means of bolts (ZY) (dimensions of ZY: see dimensional
drawing).
- Place the disassembly bolt (l) into the central hole in the distance ring (g).
- Remove the gear unit from the shaft by tightening the disassembly bolt (l).
Note
The parts e,f,l and ZY are not included as standard, but can be supplied upon special request.
For technical data, refer to catalogue or certified drawing.
d
c
•
FIG.2a
e
f
g
•
h
b
i
MOUNTING
k
•
J
m
FIG.2b
g
•
SECURING
ZY
•
m
FIG.2c
g
•
l
DISMOUNTING
24
23
ENGLISH
6.6.3. Mounting of the torque arm
After fitting and securing the gear unit to the driven shaft (see par. 6.6.1 or 6.6.2), fix unit by means of the
optionally supplied torque arm to a fixed torque reaction point. Refer to the certified drawing or catalogue for
torque arm location on gear unit.
The connection between torque arm and reaction point must remain flexible and resilient. This is achieved by
preloading the disc springs of the torque arm.
The preload of the disc springs (A) will be adjusted as follows:
- Determine the spacing S (fig. 3a), this is the spacing of the disk springs in unloaded and unmounted condition.
- Screw the inner nut until spacing S1 (spacing between gear unit and fixed point) is reached,
where S1 = S - ΔS (fig. 3b, 3c, 3d).
ΔS = spacing obtained after compression of the disk springs (table 2, 3 and 4) due to the weight of the gear
unit and tightening of the inner nut.
- When the prescribed spacing S1 is obtained, lock the inner nut by tightening outer nut against it.
A
FIG.3a
S
S1 = S -
FIG.3b
D
S
PR
PT
Table 2
Gear unit
size
QH.A2
QH.B2
QH.C2
QH.D2
QH.E2
QH.F2
QH.G2
QH.H2
D
±5
35
35
45
45
60
60
60
60
PT
M16
M20
M24
M24
M30
M30
M36
M36
PR max
mm
inch
40
1.57
50
1.97
60
2.36
60
2.36
75
2.95
75
2.95
90
3.54
90
3.54
ΔS
mm
0,7
0,7
0,9
0,9
1,0
1,0
1,0
1,0
inch
0.028
0.028
0.035
0.035
0.039
0.039
0.039
0.039
Q*
2x2
2x2
2x2
2x3
2x3
2x3
2x4
2x4
A
DIN 2093
A 80
A 80
A 100
A 100
A 125
A 125
A 125
A 125
Q*: number of disc springs
FIG.3c
S1 = S -
D
S
PR
PT
24
25
ENGLISH
Table 3
Gear unit
size
QH.C3
QH.D3 - QH.D4
QH.E3 - QH.E4
QH.F3 - QH.F4
QH.G3 - QH.G4
QH.H3 - QH.H4
D
±5
35
45
45
60
60
60
PT
M20
M24
M24
M30
M36
M36
PR max
mm
inch
50
1.97
60
2.36
60
2.36
75
2.95
90
3.54
90
3.54
ΔS
mm
0,7
0,9
0,9
1,0
1,0
1,0
inch
0.028
0.035
0.035
0.039
0.039
0.039
Q*
2x3
2x2
2x3
2x2
2x3
2x3
A
DIN 2093
A 80
A 100
A 100
A 125
A 125
A 125
Q*: number of disc springs
FIG.3d
S1 = S -
D
S
PR
PT
Table 4
Gear unit
size
QH.J3 - QH.J4
QH.K3 - QH.K4
QH.L3 - QH.L4
QH.M3 - QH.M4
D
±5
PT
80
80
80
80
M42
M42
M48
M48
ΔS
PR max
mm
inch
mm
105
105
120
120
1,4
1,4
1,4
1,4
4.1
4.1
4.7
4.7
inch
Q*
A
DIN 2093
0.055 2 x 3
A 160
0.055 2 x 3
A 160
0.055 2 x 4
A 160
0.055 2 x 4
A 160
Q*: number of disc springs
6.7. LUBRICATION AFTER INSTALLATION
After levelling, alignment and securing, the gear unit must be lubricated. All instructions mentioned in
chapter 7 "LUBRICATION" must be followed up.
If a long period of standstill is expected before starting up the gear unit, the instructions mentioned in
paragraph 12.6 "EXTENDED PERIODES OF STANDSTILL" must be followed up.
7. LUBRICATION
Lubrication serves four main functions :
- prevents metal to metal contact in gears and bearings
- reduces friction losses
- dissipates the generated heat from gears and bearings
- prevents corrosion
Different lubrication systems can be used, depending on
- gear velocity
- gear unit mounting position
- operating conditions
Hansen Industrial Gearboxes use one of following systems :
- splash lubrication
- forced feed lubrication: - circulation lubrication
- pressure lubrication
These systems can be completed with auxiliary cooling in different forms (see chapter 9: "COOLING").
26
25
ENGLISH
7.1. SPLASH LUBRICATION
Splash lubrication is standard for horizontal shaft gear units with one, two and three stages and for speeds
between 750 min-1 and 1800 min-1 at the high speed shaft.
Splash lubrication is standard for horizontal shaft gear units with four stages and for speeds between 1000
min-1 and 1800 min-1 at the high speed shaft.
All gears and output shaft bearings are lubricated by immersion in the oil bath. Oil splash from gears fill oil
pockets in the housing, assuring gravity circulation lubrication of the bearings via channels in housing and
covers.
For other speeds at the high speed shaft, refer to Hansen Industrial Transmissions nv.
7.2. FORCED FEED LUBRICATION
All rotating elements above oil bath level are lubricated by a gear pump forcing the oil through pressure lines.
Pumps can be either of the integral type, driven by one of the gear unit shafts, or a motorpump.
The integral type pumps are always provided with a built-in reversing device for operation in both directions.
Built-on pumps reach their normal operating capacity already after a few seconds.
In case of motorpumps the direction of rotation is always indicated.
Motorpumps should be switched on at least one minute before starting the gear unit.
7.2.1. Circulation lubrication
- With integrated pump (fig.4).
The circulation lubrication system consists of
- a pump P
- a filter F with bypass (standard from gear unit size G onwards)
- a flow switch Mf (standard from gear unit size G onwards)
Mf
••
•
•
F
FIG. 4
P
Flow switch must be wired in a circuit to automatically stop the main drive motor when oil flow drops
below alarm setting.
However, in order to avoid unwanted alarms during the start-up period, in operation or due to irregularities of
the oil flow, we recommend retarding the alarm signal; the alarm should be triggered only after the oil flow has
been interrupted for a continuous period of 5 seconds.
- With motorpump
The service manual of the lubrication and cooling system gives detailed information about the circulation
lubrication system with motorpump.
7.2.2. Pressure lubrication
The service manual of the lubrication and cooling system gives detailed information about the pressure
lubrication system.
26
27
ENGLISH
7.2.3. Instrumentation and settings, if applicable
For detailed information on lubrication system, instrumentation and settings, refer to the certified drawing, the
service manual of the lubrication and cooling system and/or separate leaflets on instrumentation, supplied with
this manual.
Settings stated on the certified drawing have been set during testrun by Hansen Industrial
Transmissions nv and should not be altered without written authorisation.
Presettings, if stated, are recommended values set by Hansen Industrial Transmissions nv, but may be altered
according to local conditions.
7.3. OIL SELECTION
Always use oil with type and viscosity as indicated on the gear unit's nameplate.
38 of this service manual, listing mineral oils and
The oil must be selected from the table at page 39
greases recommended by their respective brand name owners.
The viscosity has been selected according to operating conditions specified in the “Order Acknowledgement”.
The ISO viscosity class VG is mentioned on the nameplate and on the dimensional drawing.
For conversion from ISO viscosity class VG to other viscosity units see table of corresponding lubricants p. 39.
38
The oil suppliers are responsible for the selection and composition of their products.
Synthetic oils may be used only after written authorisation from the Engineering Department of Hansen
Industrial Transmissions nv.
The use of synthetic oil is mentioned on the nameplate.
In that event, only synthetic oils specified by Hansen Industrial Transmissions nv with brand and prod39 These synthetic oils shall be of the polyalpha-oleuct name may be used, refer to the table at page 40.
fine type (SHF-type, Synthetic Hydrocarbon Fluid).
To improve the steadiness of the bearing life time, it is highly recommended to use oil that has an initial oil
cleanliness of -/15/12 (or better) according to ISO 4406.
Refer to the oil supplier to obtain this oil quality.
Handle any lubricant or oil with care and according to the handling and safety instructions to be supplied by the lubricant supplier on customer's request. These instructions have to be handed over to any
personnel performing installation, maintenance or repair of the gear unit.
7.4. OIL QUANTITY
28
The oil level is determined by min. and max. markings on the dipstick (see fig. 5, page 29).
The oil level will always be checked with the gear unit dipstick.
Possible other oil level markings are only indicative. Refer to the dimensional drawing.
An oil sight glass or an oil level switch is optionally available.
THREADED DIPSTICKS SHOULD BE CHECKED IN PLUGGED POSITION.
The oil level must be checked when the gear unit is not running.
On systems with filters and coolers, the oil level must be checked with the lubrication and cooling
system filled with oil and after short test run.
The cooling system is automatically utilized when the oil bath temperature rises above 60°C (140°F).
If oil filling is required to take place earlier, the air must be released from the cooler whilst the pump is in
operation.
The oil quantity mentioned on the nameplate of the gear unit is an approximate value given only for procurement
purposes.
28
27
ENGLISH
FIG. 5
- Single stage gear units
- Multi-stage gear units
(1) see section
29
7.8, page 30
Position of oil filling plug, dipstick, oil draining plug, breather plug
Always refer to the certified dimensional drawing and stickers on the gear unit.
Dipstick
Oil
draining
Oil
filling
Ventilation Condensation
Grease
draining
lubrication
point
Grease lubrication
point
for bearings
Grease lubrication
point for labyrinth
seal
7.5. THE FIRST OIL FILLING (see fig. 5)
Fill units only after final installation, especially gear units with vertical downwards shafts, to prevent oil splashing
over drywell during handling.
Fill the gear unit exclusively through the oil filling opening which is provided in the inspection cover for
that purpose. In that way, all bearings are lubricated with fresh oil before start up.
Note :
- Additional oil filling of the bearing housing.
4-stage horizontal gear units with right angle shafts (QHR.4) and 3- and 4-stage vertical gear units
with right angle shafts (QVR.3 + QVR.4) require also an additional oil filling of the bearing housing.
See special sticker on gear unit. The additional oil quantity is mentioned on the certified drawing and
on the sticker.
- Oil filling of a gear unit with M1 or M3 motor base.
For gear units with horizontal shafts (QH ..) equipped with a motorbase M1 or M3 an additional small quantity
of oil must be added through the inspection cover located in the top face of the gear unit (see special
sticker on gear unit).
If easy access to the oil filler plug is prevented due to lack of space between the motor base and the gear unit
upper face, the motor base should be raised after removal of the belt.
The position of the oil filling plug is indicated by a sticker on the gear unit. Refer to to the certified dimensional
drawing.
28
29
ENGLISH
- If the gear unit is filled with storage oil, it has to be drained and it is strongly advised to rinse the gear unit with
the selected oil before starting up. Check with the oil supplier.
- To improve the steadiness of the bearing life span, it is highly recommended to use oil that has an initial oil
cleanliness of -/15/12 (or better) according to ISO 4406. Refer to the oil supplier to obtain this oil quality.
7.6. GREASE SELECTION (see table page 39)
38
If the gear unit is equiped with parts that need grease lubrication, and unless indicated otherwise on the gear
unit's name plate or in the special technical manual of the specific gear unit (if existing), the grease must be
selected from the table at page 39
38 of this service manual, listing mineral oils and greases recommended by their
respective brand name owners.
Use only high quality greases with consistency NLGI-Grade 3.
Greases with consistency NLGI-Grade 2 may be used for regreasable labyrinth type seals and grease lubricated
lower bearing of the low speed shaft.
The lubricant suppliers are responsible for the selection and composition of their products.
7.7. GREASE LUBRICATION POINTS (see fig. 5)
All greasing points for bearings which are not oil lubricated and for labyrinth seals are equipped with nipples according to DIN 71412 and have been filled before shipment.
The total number of nipples is indicated on the nameplate.
7.8. OIL DRAINING (see fig. 5)
Drain the oil while the gear unit is still warm. Be careful while draining the hot oil. Use an appropriate
hot oil recipient, heat resistent clothing and gloves to avoid burns.
To facilitate oil draining, remove the dipstick. Units having a large oil volume can be drained easier through the
drain plug when using a portable pump. With some executions a small quantity of oil remains beneath the high
28
speed bearings. This oil can be drained by means of a second drain plug (1), see fig. 5 page 29.
8. VENTILATION (see fig. 5)
To prevent pressure build-up, the gear unit is provided with a breather which is integrated in the dipstick or with a
separate breather (normal, anti-dust or anti-humidity breather).
Take care and check regularly that this breather does not become clogged.
9. COOLING
Heat generated in the gear unit due to friction and churning of the oil, must be dissipated through the housing into the environment. It is important not to decrease the heath dissipation capacity of the housing.
Regularly clean the surface of the housing.
The temperature of the oilbath will rise with increased load. Continuous operating temperature of 80 to 85°C
(175 to 185°F) is allowable for a standard gear unit filled with mineral oil.
Occasional operating temperatures of up to 95°C (200°F) are acceptable.
9.1. ADDITIONAL AIR COOLING
9.1.1. Fans
One or two fans may be mounted on gear unit shafts.
Warning
Do not run the gear unit without appropriate protection covers.
Check regularly that the air inlet and the air outlet are not obstructed.
Fans need no special maintenance, except occasional cleaning.
30
29
ENGLISH
9.1.2. Oil-to-air coolers
The service manual of the lubrication and cooling system gives detailed information about the oil-to-air cooler.
9.2. ADDITIONAL WATER COOLING
All water cooling systems must be connected to a non-calcareous water supply. See also the service manual on
lubrication and cooling system and/or technical leaflets on specific instrumentation. The use of seawater must be
specified with the order; coolers suited for use of seawater are available.
When the gear unit is not operating and freezing temperatures may occur, the water must be drained from the
cooling system. Drain facilities have to be provided by the end user.
Unless otherwise stipulated, the water flow indicated on the dimensional drawing is the required rate for water at
20°C (70°F).
Depending on the load, the ambient temperature and the water temperature a lower rate can suffice. Adjust the
water flow to obtain an oil temperature during operation between 60 and 80°C (140 and 180°F).
9.2.1. Oil-to-water coolers
Refer to the certified drawing for the connection of the oil-to-water cooler to the coolant supply system.
The service manual of the lubrication and cooling system gives detailed information about the oil-to-water
coolers.
9.2.2. Cooling coils
The direction of the waterflow is optional.
The cooling coils are suited for fresh as well as for seawater.
Maximum allowable water pressure : 0,8 MPa (8 bar, 116 psi).
Connection of the cooling coil to the water supply.
cooling coil
FIG. 6
Warning: In order to avoid torsioning of the cooling coil, hold the premounted connection with a suitable
wrench as shown in fig. 6.
10. BACKSTOPS
Backstops are subject to wear and must be inspected or replaced at intervals depending on operating conditions.
The customer must take all necessary precautions to prevent that failure of the backstop could cause physical
injury and/or severe damage to the drive and/or application.
The time span between two checks of functioning depends on the operating conditions and the activation
frequency, but should never exceed two years. These inspections are preferably carried out by qualified personnel
authorized by Hansen Industrial Transmissions nv.
In case the backstop is part of a hoist drive which is subject to a periodical safety inspection, the check of the backstop
must be included in the inspection procedure.
In case of transport of people: the user has to follow the local legislation re. the inspection of safety devices.
30
31
ENGLISH
An inspection or replacement of the backstop is also required in the following circumstances:
- in case of disassembly of the gear unit or one of its components
- in the event that abnormal wear or material break-out of gears, bearings or any other component or
pollution of the oil has been detected in the gear unit, since this may have affected the condition of the sprags
and raceways of the backstop.
The outcome of the periodical inspection is to be reported in a log book.
Never loosen any part of the backstop while the gear unit is loaded: loosening the backstop may
cause reversal of the drive and running back of the load. Check if the gear unit is not loaded before
loosening the backstop and secure the drive against unintentional movement.
STANDARD BACKSTOP INTEGRATED IN THE GEAR UNIT:
These backstops are lubricated by the oil bath of the gear unit and require, apart from the regular inspections
indicated above, no further maintenance.
Alteration of the direction of rotation of a backstop may only be carried out by qualified personnel
authorized by Hansen Industrial Transmissions nv.
11. START UP
11.1. ALL GEAR UNITS
Check the internal components of the gear unit for corrosion before starting up the gear unit.
Repeat this check after each extended period of standstill (refer to section 12.6).
The result of this inspection must be documented and made available on request.
Any evidence of corrosion on internal components of the gear unit must be reported to Hansen Industrial
Transmissions nv.
Before start up, check the oil level with the dipstick and make sure that all grease lubricating points are
filled.
Although all greasing points have been greased before delivery, it is advisable to give a few shots with a grease
gun before start up.
Check all fixation points between gear unit and foundation. They may require retightening after some running
time.
Make sure that protection hoods and air guiding plates, if any, are properly fitted.
Gear units can rotate in both directions except when direction of rotation is indicated.
Always refer to the stickers on the gear unit and to the certified drawing.
Direction of rotation: clockwise (CW)
Direction of rotation: counter-clockwise (CCW)
11.2. GEAR UNITS EQUIPPED WITH A BACKSTOP
The customer has to check the good functioning of the backstop.
On gear units equipped with a backstop, check whether the direction of rotation of the motor
corresponds to the backstop freewheeling direction, before coupling the motor to the gear unit.
In case of complete drive groups, the direction of rotation of the motor has to be checked by means of a phase
meter.
Rotation of the gear unit in reverse direction, even momentarily, may damage the backstop, and is
therefore not allowed.
32
31
ENGLISH
11.3. GEAR UNITS EQUIPPED WITH HEATERS
Gear units equipped with heaters must not be started before the oil temperature is above 5°C (40°F). Heaters
have to be switched off automatically when the oil temperature is above 15°C (60°F).
11.4. GEAR UNITS WITH FORCED FEED LUBRICATION
For the different parts of the lubrication system, refer to the service manual of the lubrication and cooling equipment
and/or the technical leaflets concerning the specific components.
11.5. GEAR UNIT DRIVEN BY A TWO SPEED MOTOR
When switching from the higher to the lower speed, first decelerate to below the lower speed so that the motor
has to accelerate when switched on at the lower speed. In this way high synchronisation peak torques can be
avoided.
12. MAINTENANCE
Refer to the MAINTENANCE TABLE on page 6
7.
Read carefully all paragraphs of chapter 12.
Read also the
points in the other paragraphs.
12.1. INSPECTION AND MAINTENANCE
Rotating parts may cause injuries and damage.
For inspection and maintenance always de-energize the drive and make sure that the gear unit and
the drive are externally secured against unintentional switch-on or movement.
12.2. OIL CHANGE AND REGREASING THE LUBRICATION POINTS
12.2.1. General directives
Handle any lubricant or oil with care and according to the handling and safety instructions to be supplied by the lubricant supplier on customer's request. These instructions have to be handed over to any
personnel performing installation, maintenance or repair of the gear unit.
Use clean oil from clean barrels. Avoid any penetration of abrasive particles and water. The water content should
be no higher than 0.05% (derived following titration method accepted by the oil manufacturer).
To improve the steadiness of the bearing life time, it is highly recommended to use oil that has an initial oil
cleanliness of -/15/12 (or better) according to ISO 4406.
Refer to the oil supplier to obtain this oil quality.
It is recommended to change the oil before summertime, hence running with fresh oil in the most
critical period when thermal load is higher.
If the gear unit is provided with a heater, disconnect the heater from the electric supply before draining
the oil.
Drain the oil while the gear unit is still warm. Be careful while draining the hot oil. Use an appropriate hot oil
recipient, heat resistent clothing and gloves to avoid burns.
Every time the lubricant is changed, it is recommended to flush the gear unit and the corresponding lubrication
and cooling system with fresh oil. Check to make sure that the gear unit, the lubrication and cooling system items
are well drained after flushing .
Don't forget to renew the filter cartridge.
Operating procedure and specifications are mentioned in the service manual of the lubrication and cooling
equipment and / or the technical leaflets for the specific instrumentation.
Disposable filter cartridges can not be cleaned.
External dipsticks and sight glasses must be periodically checked against the gear unit dipstick.
32
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12.2.2. Oil change and regreasing
The first oil change
After 100 hours and not later than 800 hours of service:
- First regrease the lubrication points, if present.
The lubrication points have to be regreased while the gear unit is warm.
- Change the oil. Use new oil or reuse the removed oil after filtering. Don't use the filter of the lubrication
system (if available).
Filter the removed oil volume at least 10 times. Use a 10 μm filter or smaller with a beta ratio of 200 or
higher. The filter must be compatible with the used oil.
- After changing the oil, replace the filter cartridge of the lubrication system of the gear unit, if present.
Filter (if present)
Replace the filter cartridge after every 800 hours of operation unless the filter has a contamination indicator.
Before replacing the filter cartridge, run the gear unit a while after regreasing if this applies.
Grease lubrication (if lubrication points are present)
- Bearings: regrease all lubrication points after every 800 hours of operation.
- Labyrinth seals: regrease all lubrication points after every 3000 hours of operation. The lubrication interval
should eventually be reduced depending on the application and the working conditions. In any case, the
outer grease chamber may never be dry.
For longer lubrication intervals: consult Hansen Industrial Transmissions nv.
29 for the greases to be used
See paragraph 7.6 (page 30)
Grease quantity for bearings: see page 36
35
Grease quantity for labyrinth seal: see page 38
37
Subsequent oil changes
After 4000 to 8000 hours or max. 18 months of operation depending on working conditions:
- First regrease the lubrication points (if present) while the gear unit is warm.
- Change the oil. Use clean oil from clean barrels. Avoid any penetration of abrasive particles and water.
- Replace the filter cartridge, if present.
12.3. OIL SAMPLE
When the oil sump temperature is frequently 80° to 95°C (175° to 200°F), or in the event of a dusty or humid
atmosphere, it is recommended to have an oil analysis performed (by a laboratory acknowledged) by the oil
brand name owner after every 4000 hours of service in order to determine the expected lifetime of the oil.
Oil sump temperature must never be higher than 95°C (200°F), since oil then will degenerate very fast.
A representative oil sample should be taken directly out of the oil sump. Drain a certain amount of oil
(recommended oil volume 2 litres) before taking the oil sample. Make sure to use only appropriate and clean
sample bottles. For the characteristics, the chemical properties and the grade of cleanliness of the sample bottle:
refer to the laboratory acknowledged by the oil brand name owner.
Be careful while draining the hot oil. Use an appropriate hot oil recipient, heat resistent clothing and
gloves to avoid burns.
Before start up, check the oil level with the dipstick and add oil when required.
12.4. CLEAN THE HEATER
If the gear unit is provided with a heater, it is recommended to clean regularly (at every oil change) the heater
and to eliminate the deposition, in order to improve the life span of the heater.
12.5. OIL-LOCKTM
OIL-GUARDTM (as an option)
Oil-LockTM
The high speed shaft is equipped as standard with an OIL-LOCKTM system.
For the Hansen P4 single stage gear units also the low speed shaft is equipped with an OIL-LOCKTM system.
This oil seal is wear resistant and maintenance free due to its centrifugal operating principle. The dual purpose
labyrinth seal also prevents the entrance of dirt and moisture.
Disassembly of the OIL-LOCKTM seal should only be carried out by qualified personnel.
34
33
ENGLISH
Oil-GuardTM as an option
The high speed shaft may be equipped as option with an OIL-GUARDTM system.
During operation, even in submerged conditions, the OIL-GUARDTMsystem ensures leak free running conditions.
Disassembly of the OIL-GUARDTM system should only be carried out by qualified personnel.
12.6. EXTENDED PERIODS OF STANDSTILL
When gear units are at standstill for an extended period, the protective oil film containing anti corrosion additives
gradually disappears and the unprotected internal parts become subject to corrosion. Adverse ambient conditions such as humid, marine, tropical and chemically aggressive environments will accelerate the process.
A periodic visual inspection through the inspection cover is required.
Corrosion of the internals can be avoided by running the gear unit for a few minutes every two weeks (depending
on the ambient conditions) thus allowing the formation of a new oil film.
Install a special breather (marked with the label shown below) to prevent moisture from entering the gear unit.
If it is not possible to run the gear unit regularly and the risk for corrosion is imminent, during extended periods
of standstill the gear unit must be protected as follows :
- an oil soluble concentrate including corrosion inhibitors which are active both in the liquid and in the vapour
phase has to be added. A 2% volume concentration is considered to be normal. Consult your oil supplier
about lifetime, compatibility with the actual oil and about volume concentration.
- seal all gear unit openings (dipstick, breather etc.) hermetically .
Before starting-up: read chapters 11 and 12. Replace the hermetical seals by the originally mounted
equipment.
12.7. SERVICE AFTER SALES
For technical assistance or additional information, the Hansen Industrial Transmissions nv sales centres are at
your disposal. When you contact them, please specify the complete type code and the manufacturing number
mentioned on the gear unit's nameplate.
12.8. REPAIRS
Any repair should only be carried out by qualified personnel.
Only original Hansen Industrial Transmissions nv spare parts should be used.
No products or substances may be used in the gear unit that could bring foreign ingredients
(particularly solid or friction reducing additives amongst) in the oil.
34
35
ENGLISH
13. GREASE QUANTITIES FOR REGREASING
Grease quantity (Type Q.) in grams for bearings by regreasing
The type Q. is indicated on the nameplate (see page 12)
11
Greases, NLGI-Grade 3, recommended by the oil suppliers: see page 39
38
Sticker on the gear unit
Figures: see page 37
36
Bearings without grease nipple are oil lubricated.
Gear unit
size
Z
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
S
T
Gear unit
size
Z
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
S
T
Type Q1
Type Q2
Type Q3
Fig. 7
Fig. 7
Fig. 7
B1
B1
B1
50
60
90
120
170
180
220
260
320
340
380
470
490
500
600
620
60
80
110
150
200
230
280
320
400
410
380
470
490
500
600
620
50
60
90
120
170
180
220
260
320
340
290
350
360
380
440
470
Type Q4
Type Q5
Fig. 8
B1
10
20
30
Fig. 9
B2
20
20
30
B1
10
20
30
Type Q6
Type Q7
Type Q8
Type Q9
Fig. 7
Fig. 7
Fig. 7
Fig. 10
B1
B1
B1
100
130
180
220
280
320
320
410
370
120
170
220
320
400
410
500
590
700
100
130
180
240
B1
B2
20
20
30
B2
B3
B4
B5
50
60
90
120
30
40
50
80
20
30
40
50
10
20
20
30
180
220
260
320
340
290
350
360
36
35
ENGLISH
FIG. 7
B1
FIG. 8
FIG. 9
B1
B1
B2
B2
FIG. 10
B2
B1
36
B3
B4
X-X
X
B5
X
B2
B3
B4
B5
30° - 45°
B1
37
ENGLISH
Grease quantity in g for labyrinth seal by regreasing
Greases, NLGI-Grade 2, recommended by the oil suppliers: see page 38
39
Sticker on the gear unit
On low speed shaft
Single stage gear units
Gear unit
g
Gear unit
Type
g
Gear unit
Type
QHRC1Z-..N
75
QHRD1Z-..N
75
QHRF1Z-..N
45
g
Type
QHPC1
QHPD1
QHPE1
QHPF1
QHPG1
10
10
15
25
35
QVPZ1
10
QVPB1
10
Multi stage gear units
Gear unit
..N
..D / ..K
Gear unit
Type
Size
g
g
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
S
T
25
35
55
60
75
60
60
130
135
145
215
230
240
255
25
25
30
65
65
120
130
145
155
160
g
QVRZ2
QVRZ2L
QVRA2
QVRA2L
QVRB2
QVRB2L
50
30
70
40
50
55
..N: gear unit with solid low speed shaft
..D / ..K: gear unit with hollow low speed shaft
On high speed shaft
Single stage gear units
Gear unit
g
Type
QHPC1
QHPD1
QHPE1
QHPF1
QHPG1
10
10
20
30
40
Multi stage gear units
QHP..
Gear unit
QHR..
QVP..
QVR..
Size
QHP.2
QHP.3
QHR.2
QHR.3
QHR.4
QVP.2
QVP.3
QVR.2
QVR.3
QVR.4
Z
A ./. H
J ./. T
10
20
10
20
10
20
10
20
10
20
10
20
10
20
10
10
20
10
20
10
20
38
37
ENGLISH
14.
LUBRICANTS
14.1. MINERAL OILS AND GREASES
For Hansen P4 standardized gear units
Unless indicated otherwise on the gear unit's name plate, the oils and lubricants must be selected from the tables below,
containing oils and greases recommended by the respective brand name owners. The required viscosity grade of the oil is mentioned on the name plate.
If nothing is mentioned on the gear unit's name plate, only mineral oils and greases have to be used.
mm2/s
40°C
ISO
VG150 (1)
ISO
VG220
ISO
VG320
ISO
VG460
Bearing grease
AGMA
4 EP
5 EP
6 EP
7 EP
Graisse pour
roulement
cSt/50°C
90
126
184
230
Wälzlagerfett
Lagervet
E/50°C
11,9
16,6
24,3
30,4
SUS/100°F
690
1100
1600
2300
(2)
BP
Energol GR-XP 150
Formulation L04021PBA
Energol GR-XP 220 Formulation L04022PBA
Energol GR-XP 320
Formulation L04023PBA
Energol GR-XP 460
Formulation L04024PBA
Energrease LS-EP 2
Energrease LS-EP 3
CASTROL
Alpha SP 150
Formulation L02045PBA
Alpha SP 220
Formulation L02046PBA
Alpha SP 320
Formulation L02047PBA
Alpha SP 460
Formulation L02048PBA
Spheerol EPL
FUCHS EUROPE
SCHMIERSTOFFE
Renolin CLP 150
Formulation 3110247
Renolin CLP 220
Formulation 3110248
Renolin CLP 320
Formulation 3110249
Renolin CLP 460
Formulation 3110250
Renolit FEP 3 /
Renolit FEP 2 (2)
KLÜBER
Klüberoil GEM 1-150 N
Klüberoil GEM 1-220 N
Klüberoil GEM 1-320 N
Klüberoil GEM 1-460 N
Centoplex 2EP (2)
(EXXON)MOBIL
Mobilgear XMP 150
Mobilgear XMP 220
Mobilgear XMP 320
Mobilgear XMP 320
Formula(tion) RL001893E Formula(tion) RL001893F Formula(tion) RL001893H Formula(tion) RL001893J
(EXXON)MOBIL
Mobilgear 600 XP 150
Mobilgear 600 XP 220
Mobilgear 600 XP 320
Mobilgear 600 XP 460
SHELL
Omala F 150
Formulation 1996 (3)
Omala F 220
Formulation 1996 (3)
Omala F 320
Formulation 1996 (3)
Omala F 420
Formulation 1996 (3)
STATOIL
LoadWay EP 150
LoadWay EP 220
LoadWay EP 320
LoadWay EP 460
Formulation SL970307-150 Formulation SL970307-220 Formulation SL970307-320 Formulation SL970307-460
(2)
Mobilux EP 3
Mobilux EP 3
Alvania EP 2
(2)
Uniway Li 62 (2)
TOTAL
Carter XEP 220
Formulation I31293
Carter XEP 320
Formulation I31293
Carter XEP 460
Formulation I31293
Multis EP 3
TOTAL
Carter EP 220
Formulation I31238
Carter EP 320
Formulation I31238
Carter EP 460
Formulation I31238
Multis EP 3
(1) Only for low ambient temperatures, see nameplate of the gear unit.
(2) Use only high quality greases, with EP-additives and consistency NLGI-Grade 3. Greases with EP-additives and consistency NLGI-Grade 2
may be used for regreasable labyrinth type seals and grease lubricated lower bearing of the low speed shaft.
(3) Composition formulation of the product designated by the year of its market introduction.
General notes
• If the gear unit is filled with storage oil, it has to be drained and it may in some instances be necessary to rince the gear unit with the
selected oil before starting up. Check with the oil supplier.
• Oil and lubricant manufacturers can change product compositions.
• The lubricating oils with the composition formulations mentioned in the above tables have to be used.
• The greases mentioned in the above table have to be of a product composition formulation of before January 10th 2005; a confirmation
from the grease or oil supplier is essential.
• Hansen Industrial Transmissions nv is not responsible nor liable for composition changes.
The oil and lubricant suppliers are responsible for the selection and composition of their products.
• If the customer does not wish to follow Hansen Industrial Transmissions nv' oil and grease prescriptions, the customer assumes responsibility
for the technical suitability of the lubricant used.
• If the customer would like to use another oil in the gear unit than the oil he last filled in the gear unit, he has to consult the oil supplier
regarding the compatibility of the two oils and the measures that possibly should be taken for reliable operation of the gear unit with the
new oil and the possible residues and/or components of the old oil that could be present in the gear unit.
• Any oil and lubricant shall be handled with care and according to the handling and safety instructions to be supplied by the lubricant
supplier on customer's request.
These instructions have to be handed over to any personnel performing installation, maintenance or repair of the gear unit.
38
39
ENGLISH
14.
LUBRICANTS
14.2. POLYALPHA-OLEFINE BASED SYNTHETIC OILS AND SUITABLE GREASE
For Hansen P4 standardized gear units
Unless indicated otherwise on the gear unit's name plate, the oils and lubricants must be selected from the tables below, containing
oils and greases recommended by the respective brand name owners. The required viscosity grade of the oil is mentioned on the
name plate.
If nothing is mentioned on the gear unit's name plate, only mineral oils and greases have to be used.
Synthetic oils may be used only after written authorisation from the Engineering Department of Hansen Industrial Transmissions nv.
mm2/s
40°C
ISO
VG150 (1)
ISO
VG220
ISO
VG320
ISO
VG460
Bearing grease
AGMA
4 EP
5 EP
6 EP
7 EP
Graisse pour
roulement
cSt/50°C
90
126
184
230
Wälzlagerfett
E/50°C
11,9
16,6
24,3
30,4
Lagervet
SUS/100°F
690
1100
1600
2300
(2)
BP
Enersyn EP-XF 150
Formulation L04025PBA
Enersyn EP-XF 220
Formulation L04026PBA
Enersyn EP-XF 320
Formulation L04027PBA
Enersyn EP-XF 460
Formulation L04028PBA
FAG Arcanol VIB3
CASTROL
Alphasyn EP 150
Formulation L98120PBA
Alphasyn EP 220
Formulation L98115PBA
Alphasyn EP 320
Formulation L98111PBA
Alphasyn EP 460
Formulation L98113PBA
FAG Arcanol VIB3
KLÜBER
Klübersynth GEM
4-150 N
Klübersynth GEM
4-220 N
Klübersynth GEM
4-320 N
Klübersynth GEM
4-460 N
FAG Arcanol VIB3
(EXXON) MOBIL
Mobilgear SHC XMP 150 Mobilgear SHC XMP 220 Mobilgear SHC XMP 320 Mobilgear SHC XMP 460
Formulation RL001983E Formulation RL001983F Formulation RL001983H Formulation RL001983J
FAG Arcanol VIB3
(EXXON) MOBIL
Mobil SHC Gear Series
150
Mobil SHC Gear Series
220
Mobil SHC Gear Series
320
Mobil SHC Gear Series
460
FAG Arcanol VIB3
SHELL
Omala HD 150
=
Omala S4 GX 150
Formulation 2007 (3)
Omala HD 220
=
Omala S4 GX 220
Formulation 2007 (3)
Omala HD 320
=
Omala S4 GX 320
Formulation 2007 (3)
Omala HD 460
=
Omala S4 GX 460
Formulation 2007 (3)
FAG Arcanol VIB3
Carter SH 220
Formulation I31219
Carter SH 320
Formulation I31219
Carter SH 460
Formulation I31219
FAG Arcanol VIB3
TOTAL
(1) Only for low ambient temperatures, see nameplate of the gear unit.
(2) Use only high quality greases, with EP-additives and consistency NLGI-Grade 3. Greases with EP-additives and consistency NLGI-Grade 2
may be used for regreasable labyrinth type seals and grease lubricated lower bearing of the low speed shaft.
(3) Composition formulation of the product designated by the year of its market introduction.
General notes
• If the gear unit is filled with storage oil, it has to be drained and it may in some instances be necessary to rince the gear unit with the
selected oil before starting up. Check with the oil supplier.
• Oil and lubricant manufacturers can change product compositions.
• The lubricating oils with the composition formulations mentioned in the above tables have to be used.
• The greases mentioned in the above table have to be of a product composition formulation of before January 10th 2005; a confirmation
from the grease or oil supplier is essential.
• Hansen Industrial Transmissions nv is not responsible nor liable for composition changes.
The oil and lubricant suppliers are responsible for the selection and composition of their products.
• If the customer does not wish to follow Hansen Industrial Transmissions nv' oil and grease prescriptions, the customer assumes responsibility
for the technical suitability of the lubricant used.
• If the customer would like to use another oil in the gear unit than the oil he last filled in the gear unit, he has to consult the oil supplier
regarding the compatibility of the two oils and the measures that possibly should be taken for reliable operation of the gear unit with the
new oil and the possible residues and/or components of the old oil that could be present in the gear unit.
• Any oil and lubricant shall be handled with care and according to the handling and safety instructions to be supplied by the lubricant
supplier on customer's request.
These instructions have to be handed over to any personnel performing installation, maintenance or repair of the gear unit.
40
39
See our worldwide
sales & service network at
www.hansenindustrialgearboxes.com
Leonardo da Vincilaan 1
B-2650 Edegem - Belgium
T. +32(0)3 450 12 11
F. +32(0)3 450 12 20
E. [email protected]
www.hansenindustrialgearboxes.com
DOC-SMM405E/0412
Hansen Industrial Transmissions nv
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