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Summary of Contents for Sumitomo Hansen P4
- Page 1 Maintenance manual Standardized gear units Hansen Industrial Transmissions nv MM_405...
- Page 2 Copyright and contact data Copyright Hansen Industrial Transmissions NV This document or parts thereof may not be reproduced, stored in a retrieval system, nor transmitted, in any form nor by any means, electronic, mechanical, photocopying, recording, nor otherwise, without the prior written permission of Hansen Industrial Transmissions NV. This document could contain technical inaccuracies or typographical errors.
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Page 3: Table Of Contents
Contents Contents Customer data sheet................6 Manual Disclaimer................... 8 About this document................9 Function of the document......................9 Language.............................9 Illustrations...........................9 Use of steps, lists and titles in this document................9 How to use this document......................9 Warnings, cautions and notes used in the document..............9 Related documents........................10 Storage of this document and the related documents............... - Page 4 Contents Special maintenance (grease lubrication points)............... 22 Special maintenance (lubrication points for bearings)............... 22 Special maintenance (lubrication points for labyrinth seals)............23 Special maintenance (backstop)....................23 Change the oil..........................23 Do a check for oil leaks......................24 6.10 Do a check for unexpected noise and vibrations............... 24 6.11 Do a check on the quality of the gear oil..................24 6.12...
- Page 5 Contents 7.14 Lubricants..........................41 7.14.1 General specifications for lubricants................41 7.14.2 Gear oil filter specifications..................41 7.14.3 Additional gear oil specifications (heater)..............42 7.14.4 Mineral gear oil and related grease................42 7.14.5 Synthetic gear oil and related grease................ 43 7.15 Grease quantity at lubrication points for bearings..............44 7.15.1 Grease quantity type....................44...
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Page 6: Customer Data Sheet
Customer data sheet Customer data sheet Customer References Name Project Application Hansen Industrial Transmissions References Manufacturing Number Order Gear Unit Type Technical Specifications AGMA Power Rating [kW] AGMA Torque Rating [kNm] Exact Ratio Input Speed(s) constant [RPM] Input Speed(s) variable [RPM] Output Speed(s) constant [RPM] Output Speed(s) variable [RPM] Shaft Arrangement... - Page 7 Customer data sheet Lubrication Maximum ambient temperature [ºC] Maximum continuous tempera- ture of the gear oil in the oil bath, during operation [ºC] Maximum peak temperature of the gear oil in the oil bath, dur- ing operation, [ºC] Grease type Storage and protection The gearbox is adequately treated for storage and corrosion protection up to 1 year indoors...
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Page 8: Manual Disclaimer
Manual Disclaimer Manual Disclaimer This Manual and its instructions and information do not purport to cover all details or variations in the gear unit and do not claim to provide for every possible contingency met in connection with handling, installation, operation, or maintenance. Hansen Industrial Transmissions nv does not make any representations, warranties or guarantees, express or implied, as to the accuracy or completeness of the Manual. -
Page 9: About This Document
About this document Function of the document The document is only applicable for the "Hansen P4" gear unit, from here on in the document referred to as the gear unit. The document is for approved maintenance engineers and gives the information that is necessary to do maintenance on the gear unit. -
Page 10: Related Documents
About this document Type Description Icon Note A note gives more data. Related documents Document name Document code Target audience General conditions of sale • All personnel Order acknowledgement • Approved installation engi- neers Certified drawing • Approved installation engi- neers Installation manual •... -
Page 11: Storage Of This Document And The Related Documents
About this document Document name Document code Target audience Drive package documentation • Approved installation engi- neers • Approved maintenance en- gineers Storage of this document and the related documents This document and the related documents are a part of the gear unit. •... -
Page 12: Description
Description Description Intended use The gear unit is a part of a machine. Only use the gear unit for the application, ambient conditions, operation conditions and other conditions of use shown in the order acknowledgement. Resonant vibrations may cause severe overloads on components which may be several times higher than the nominal load. -
Page 13: Signs In The Documentation And On The Gear Unit
Description Variable input speed n1-n1' (variable output speed n2-n2') Type of gear oil Viscosity of the gear oil Minimum temperature for the oil bath for startup Maximum ambient temperature for which the viscosity of the gear oil is applicable Quantity of gear oil Grease quantity type Number of lubrication points Grease type... - Page 14 Description Sign Description Magnetic Drain valve with hose coupling Oil fill plug Breather plug Anti-humidity Condensation drain Lubrication point for grease Lubrication point for grease at bearing Lubrication point for grease at labyrinth seal Direction of rotation: clockwise Direction of rotation: counterclockwise MM_405_002_EN...
- Page 15 Description Sign Description Breather plug to prevent ingress of moisture Level indicator Gauge glass Overflow Inspection opening Pump lubrication Filter Filter with mechanical contamination indicator Filter with electrical contamination indicator Temperature indicator Temperature transmitter Level switch Flow switch MM_405_002_EN...
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Page 16: Description Of The Lubrication Of The Gear Unit
Description Sign Description Pressure switch Pressure transmitter Pressure indicator Pressure relief valve Built-in backstop Heater Protection cap for bolt or nut Hole for vibration sensor Ground connection ATEX Description of the lubrication of the gear unit Function of lubrication 4.4.1 Lubrication is necessary for these functions: •... -
Page 17: Splash Lubrication
Description These parameters have an effect on the type of lubrication system for the gear unit: • Gear speed • Mounting position of the gear unit • Operation conditions The certified drawing shows the lubrication system that is used for your gear unit. Splash lubrication 4.4.2 Splash lubrication is the standard for gear units with horizontal LSS of these types:... -
Page 18: Direction Of Rotation Of The Shafts
Description Direction of rotation of the shafts As a standard, the shafts of the gear unit can turn in two directions. If the shafts of the gear unit can only turn in one direction, a sign on the gear unit and the certified drawing shows this. -
Page 19: Safety
Safety Safety Restrictions Warning: Use of the gear unit in ways other than described in the related documents may result in injury, death, or property and equipment damage. Use the gear unit only as described in the related documents. H.I.T. cannot be held responsible for injuries or damages resulting from non-standard, unintended use of the gear unit. -
Page 20: Safety Instructions For Maintenance
Safety Safety instructions for maintenance • Obey the European Directives 2006/42/EG and the local safety regulations and install guards and other safety equipment. • Make sure that the motor that operates the gear unit is de-energized. Make sure that the motor cannot be energized unwantedly during maintenance. •... -
Page 21: Maintenance
Maintenance Maintenance General maintenance instructions Limits 6.1.1 Each maintenance interval also contains the maintenance task of the interval(s) before. For example, the maintenance after 1 week also contains the maintenance after 1 day. Procedure Read also the maintenance tasks in the drive package documentation. Refer to Related documents section on page 10... -
Page 22: Special Maintenance (Belt Drives)
Maintenance Task Limit Instruction Do a check on Do a check on the breather plug. 6 months Section the breather plug page 25 Do a check on Do a check on the fixation of the gear unit. 1 year Section the fixation of the gear unit on page 25... -
Page 23: Special Maintenance (Lubrication Points For Labyrinth Seals)
Maintenance Special maintenance (lubrication points for labyrinth seals) Task Limit Instruction Add grease to Add grease for labyrinth seals. 3000 hours of opera- Section the lubrication points tion or 1 year for grease on page 30 Special maintenance (backstop) Task Limit Instruction Do a check on... -
Page 24: Do A Check For Oil Leaks
Maintenance Procedure Add grease to the lubrication Add grease to all lubrication points for grease. Refer to points for grease on page 30. Make sure that the gear unit operates for minimum one hour. Stop the gear unit. Drain gear oil Remove all the gear oil from the gear unit. -
Page 25: Do A Check On The Breather Plug
Maintenance Note: For the test parameters and the specifications of the test container, refer to the supplier of your gear oil. Procedure Drain 2 liters of gear oil. Refer to section Drain gear oil on page 30. At the oil drain, get an oil sample. Use a clean test container. Make sure that a test is done on the sample. -
Page 26: Do A Check On The Fixation Of The Gear Unit (Shrink Disk, Other Than 2-Part)
Maintenance Do a check on the fixation of the gear unit (shrink disk, other than 2-part) 6.13.3 Procedure Measure the torque of the bolts of the shrink disk. Compare the torque with the specification in the drive package documentation. If the torque is not correct, tighten the bolts. For the correct torque, refer to the drive package documentation. -
Page 27: Measure The Position Of The Lss (Multi Stage)
Maintenance Measure the position of the LSS (multi stage) 6.14.3 Procedure Measure the misalignment of the coupling. Compare the misalignment with the specifications. Refer to the specification of the couplings. Calculate the result of the angular and the radial misalignment. Refer to section Misalignment of the LSS on page 33. -
Page 28: Do A Check On The Backstop
Maintenance Do a check on the backstop 6.17 Warning: • Do not loosen a part of the backstop when there is load on the gear unit. In this condition, the gear unit can turn in the incorrect direction. • Make sure that a failure of a backstop cannot cause injury or damage to the system. -
Page 29: Fill The Gear Unit With Gear Oil
Maintenance Fill the gear unit with gear oil 6.19 Select the gear oil 6.19.1 Caution: • Only use the gear oil that agrees with the type plate and with section Lubricants on page 41. Do not use another type of gear oil. •... -
Page 30: Drain Gear Oil
Maintenance Procedure Open the gear unit at the oil fill plug. Refer to the sign on the gear unit. Add gear oil. If the gear unit has a motor pump, make sure that the pump goes on for minimum 3 minutes. -
Page 31: Add Grease
Maintenance Add grease 6.20.3 Caution: Before you use a different type of grease that is in the gear unit, speak to the supplier of the grease. Not all greases are compatible with each other. The supplier of the grease gives instructions. Obey these instructions. Note: •... -
Page 32: Technical Data
Technical data Technical data Dimensions and mass Refer to the certified drawing. Materials of the gear unit • Gear oil • Grease • FKM (a type of fluoroelastomer) • Copper • Aluminium • Polycarbonate (solid) • Polypropylene (with embedded glass fibre or with carbon) •... -
Page 33: Position Of The Gear Unit
Technical data Position of the gear unit Parameter Specification Inclination Maximum 5 mm per 1 m (5/32 inch per 3 feet or 5 mrad or 17 arc minutes) Accuracy of the vertical position from the fourth 0.1 (0.004) connection point [mm] ([inch]) Ambient conditions for storage Parameter Specification... -
Page 34: Bolt Specifications (Gear Units With Solid Shafts)
Technical data Type of coupling Speed of the HSS [1/min ] Maximum permitted misalign- ment [mm] ([mils]) 0.25 (2.5) Radial misalignment for the spacer shaft and membrane 0.20 (2.0) (disk) coupling, spacer length 1000 0.18 (1.8) 100 mm (1 inch) 1200 0.15 (1.5) 1500... -
Page 35: Bolt Specifications (Multi-Stage, Horizontal Lss)
Technical data Bolt specifications (multi-stage, horizontal LSS) 7.10.2 Table for bolts according to DIN 267 bolt quality grade 8.8 Gear unit type Gear unit size Bolt dimension [ISO] Torque [Nm] QH... 1350 1350 2350 2350 2350 2350 3800 3800 5700 5700 5700 9150... - Page 36 Technical data Table for bolts according to SAE bolt quality grade 5 Gear unit type Gear unit size Bolt dimension [UNC] Torque [lbf.in] QH... 5/8" 1550 3/4" 2950 7/8" 4850 1" 6000 1 1/4" 12000 1 1/4" 12000 1 1/2" 21000 1 1/2"...
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Page 37: Bolt Specifications (Multi-Stage, Vertical Lss)
Technical data Bolt specifications (multi-stage, vertical LSS) 7.10.3 Table for bolts according to DIN 267 bolt quality grade 8.8 Gear unit type Gear unit size Bolt dimension [ISO] Torque [Nm] QV... 1350 1350 2350 G, 2-stage 2350 G, 3-stage and 4-stage M42 3800 3800 3800... -
Page 38: Torque Values For Oil Drain Screw
Technical data Table for bolts according to SAE bolt quality grade 5 Gear unit type Gear unit size Bolt dimension [UNC] Torque [lbf.in] 5/8" 1550 3/4" 2950 1" 6000 1 1/8" 10300 1 1/4" 12000 1 1/2" 21000 G, 2-stage 1 1/2"... -
Page 39: Torque Specifications
901-SDA2D320001 901-SDA2D340001 901-SDA2D360001 901-SDA2D390001 1480 901-SDA2D420001 1480 901-SDA2D440001 1480 901-SDA2D480001 1980 901-SDA2D500001 1980 901-SDA2D530001 1980 Torque values only valid for 'Sumitomo Drive Technologies' branded shrink disc. For other brands, obey the mounting instructions and torque values of the manufacturer. MM_405_002_EN... -
Page 40: Prestress Specifications For The Torque Arm (Hollow Shaft)
Technical data Prestress specifications for the torque arm (hollow shaft) 7.13 Note: (Y) is the difference between distance without load and the distance when the disk springs are prestressed. Gear unit type [mm] [inch] QH.A2 0.028 QH.B2 0.0.28 QH.C2 0.035 QH.D2 0.035 QH.E2... -
Page 41: Lubricants
Technical data Gear unit type [mm] [inch] QH.K3 0.055 QH.K4 0.055 QH.L3 0.055 QH.L4 0.055 QH.M3 0.055 QH.M4 0.055 Lubricants 7.14 General specifications for lubricants 7.14.1 Parameter Specification Initial gear oil cleanliness -/15/12 (or better) according to ISO 4406 Gear oil: maximum allowable water content 0,05 (Karl Fischer) [%] NLGI-Grade of grease... -
Page 42: Additional Gear Oil Specifications (Heater)
Technical data Additional gear oil specifications (heater) 7.14.3 Parameter Specification Minimum gear oil temperature for startup Refer to the type plate Gear oil temperature at which the heater must 15 (60), unless the certified drawing shows an- stop [°C] ([°F]) other specification. -
Page 43: Synthetic Gear Oil And Related Grease
Technical data Supplier Related grease, NLGI grade 2 Related grease, NLGI grade 3 SHELL Gadus S2 V220 2 Gadus S2 V220 3 STATOIL Uniway Li 62 TOTAL Multis EP 3 ADDINOL Multi-grade grease LM 2 EP Multi-grade grease LM 3 EP Synthetic gear oil and related grease 7.14.5 The synthetic oil must be of the poly-alpha-olefin type (SHF-type, Synthetic Hydrocarbon... -
Page 44: Grease Quantity At Lubrication Points For Bearings
Technical data Supplier ISO VG150 ISO VG220 ISO VG320 ISO VG460 PETRO-CANADA ENDURATEX ENDURATEX ENDURATEX Synthetic EP 220 Synthetic EP 320 Synthetic EP 460 Q8 Oils Q8 Galilei 150 Q8 Galilei 220 Q8 Galilei 320 Q8 Galilei 460 REPSOL SUPER TAURO SUPER TAURO SUPER TAURO SINTETICO 220... -
Page 45: Grease Quantity Types Q1, Q2, Q3, Q6, Q7 And Q8
Technical data Grease quantity types Q1, Q2, Q3, Q6, Q7 and Q8 7.15.2 Lubrication point Gear unit Grease quantity type size Q1 [g] Q2 [g] Q3 [g] Q6 [g] Q7 [g] Q8 [g] MM_405_002_EN... -
Page 46: Grease Quantity Type Q4
Technical data Grease quantity type Q4 7.15.3 Lubrication point Lubrication point Gear unit size Lubrication point A [g] B [g] Grease quantity type Q5 7.15.4 Lubrication point Lubrication point Gear unit size Lubrication point A [g] B [g] MM_405_002_EN... -
Page 47: Grease Quantity Type Q9
Technical data Gear unit size Lubrication point A [g] B [g] Grease quantity type Q9 7.15.5 B - C - D - E 30°- 45° Lubrication point at the lower side Lubrication point at the upper side Lubrication point at the upper side Lubrication point at the upper side Lubrication point at the upper side Gear unit size... -
Page 48: Grease Quantity For Lubrication Points At Labyrinth Seals (Lss)
Technical data Grease quantity for lubrication points at labyrinth seals (LSS) 7.16 Grease quantity type 7.16.1 The grease quantities only apply to the lubrication points that are indicated on the gear unit with the sign for lubrication point for grease at labyrinth seals. Grease quantity (single-stage) 7.16.2 Gear unit type... -
Page 49: Grease Quantity For Lubrication Points At Labyrinth Seals (Hss)
Technical data Gear unit type Grease quanitty [g] Gear unit size LSS type Solid Hollow Solid Hollow Solid Hollow Solid Hollow Solid Hollow Solid Hollow Solid Hollow Solid Hollow Solid Solid Solid Solid Grease quantity for lubrication points at labyrinth seals (HSS) 7.17 Grease quantity type 7.17.1... -
Page 50: Grease Quantity (Multi-Stage)
Technical data Grease quantity (multi-stage) 7.17.3 Gear unit type Grease quantity [g] A to H J to T Cooling water specifications 7.18 Parameter Specification [MPa] [bar] [psi] Maximum water pres- sure on the cooling coils Quality Fresh water or salt water MM_405_002_EN... - Page 51 Technical data MM_405_002_EN...
- Page 52 Leonardo Da Vincilaan 1 B-2650 Edegem | Antwerp | Belgium Phone: +32 3 45012-11 | Fax: +32 3 45012-20 info@hansenindustrialgearboxes.com Sumitomo (SHI) Cyclo Drive Germany GmbH CycloStraße 92 | 85229 Markt Indersdorf | Germany Phone: +49 8136 66-0 | Fax: +49 8136 5771 marktind@sce-cyclo.com...
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