Sumitomo Hansen P4 Maintenance Manual
Maintenance manual
405
Standardized gear units
Hansen Industrial Transmissions nv
MM_405
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. Hansen Industrial
Transmissions NV reserves the right to revise the content of this document from time to time
without the obligation of Hansen Industrial Transmissions NV to notify any person of such revision
or change.
Details and values given in this document are average values and have been compiled with care.
They are not binding, however, and Hansen Industrial Transmissions NV disclaims any liability for
damage or detriments suffered as a result of reliance on the information given herein or the use of
products, processes or equipment to which this document refers. No warranty is made that the use
of the information or of the products, processes or equipment to which this document refers will not
infringe any third party's patents or rights. The information given does not release the user from
making their own experiments and tests.
Contact data
www.sumitomodrive.com
Hansen Industrial Gearbox Services
Terelststraat 208
BE-2650 Edegem
Belgium
E-mail: hit.info@shi-g.com
24/7 SERVICE HOTLINE
Tel.: +32 3 450 12 34
2
Contents
Contents
1 Customer data sheet................................................................................6
2 Manual Disclaimer................................................................................... 8
3 About this document................................................................................ 9
3.1 Function of the document............................................................................................................ 9
3.2 Language.....................................................................................................................................9
3.3 Illustrations...................................................................................................................................9
3.4 Use of steps, lists and titles in this document.............................................................................. 9
3.5 How to use this document............................................................................................................9
3.6 Warnings, cautions and notes used in the document.................................................................. 9
3.7 Related documents....................................................................................................................10
3.8 Storage of this document and the related documents............................................................... 11
3.9 Abbreviations............................................................................................................................. 11
3.10 Customer support...................................................................................................................... 11
4 Description............................................................................................. 12
4.1 Intended use.............................................................................................................................. 12
4.2 Type plate.................................................................................................................................. 12
4.2.1 Type plate.................................................................................................................. 12
4.3 Signs in the documentation and on the gear unit.......................................................................13
4.4 Description of the lubrication of the gear unit.............................................................................16
4.4.1 Function of lubrication................................................................................................16
4.4.2 Splash lubrication.......................................................................................................17
4.4.3 Force-feed lubrication................................................................................................ 17
4.5 Breather plug............................................................................................................................. 17
4.6 Cooling system.......................................................................................................................... 17
4.7 Direction of rotation of the shafts............................................................................................... 18
5 Safety.....................................................................................................19
5.1 Restrictions................................................................................................................................ 19
5.2 Approved maintenance engineer...............................................................................................19
5.3 General safety instructions........................................................................................................ 19
5.4 Safety instructions for maintenance...........................................................................................20
5.5 Special safety instructions (backstop)........................................................................................20
5.6 Partly completed machine..........................................................................................................20
5.7 Instructions in case of a fire....................................................................................................... 20
5.8 Warranty.................................................................................................................................... 20
6 Maintenance.......................................................................................... 21
6.1 General maintenance instructions............................................................................................. 21
6.1.1 Limits..........................................................................................................................21
6.1.2 Not approved work.....................................................................................................21
6.1.3 Instructions (water cooling)........................................................................................21
6.2 Maintenance schedule (all gear units)....................................................................................... 21
6.3 Special maintenance (belt drives)..............................................................................................22
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3
Contents
6.4 Special maintenance (grease lubrication points)....................................................................... 22
6.5 Special maintenance (lubrication points for bearings)............................................................... 22
6.6 Special maintenance (lubrication points for labyrinth seals)......................................................23
6.7 Special maintenance (backstop)................................................................................................23
6.8 Change the oil............................................................................................................................23
6.9 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 Do a check on the breather plug................................................................................................25
6.13 Do a check on the fixation of the gear unit.................................................................................25
6.14 Do a check on the position of the gear unit................................................................................26
6.15 Replace the oil filter cartridge (if applicable)..............................................................................27
6.16 Clean the gear unit.....................................................................................................................27
6.17 Do a check on the backstop.......................................................................................................28
6.18 Install the torque arm................................................................................................................. 28
6.19 Fill the gear unit with gear oil..................................................................................................... 29
6.20 Add grease to the lubrication points for grease......................................................................... 30
6.21 Do a check for corrosion of internal parts of the gear unit......................................................... 31
6.22 Do a check on the V-belt drive...................................................................................................31
6.13.1 Do a check on the fixation of the gear unit (solid shafts)........................................... 25
6.13.2 Do a check on the fixation of the gear unit (hollow shafts)........................................ 25
6.13.3 Do a check on the fixation of the gear unit (shrink disk, other than 2-part)................26
6.13.4 Do a check on the fixation of the gear unit (2-part shrink disk)..................................26
6.14.1 General instructions................................................................................................... 26
6.14.2 Measure the position of the LSS and the HSS (single stage)....................................26
6.14.3 Measure the position of the LSS (multi stage)........................................................... 27
6.14.4 Measure the position of the HSS (multi-stage).......................................................... 27
Install the torque arm..................................................................................................................28
Prestress the disk springs of the torque arm..............................................................................28
6.19.1 Select the gear oil...................................................................................................... 29
6.19.2 Measure the gear oil level..........................................................................................29
6.19.3 Add gear oil (all gear units)........................................................................................ 29
6.19.4 Drain gear oil..............................................................................................................30
6.20.1 General procedure..................................................................................................... 30
6.20.2 Select the grease type............................................................................................... 30
6.20.3 Add grease.................................................................................................................31
7 Technical data........................................................................................32
7.1 Dimensions and mass................................................................................................................32
7.2 Materials of the gear unit........................................................................................................... 32
7.3 Torque seal specification........................................................................................................... 32
7.4 Paint specification......................................................................................................................32
7.5 Corrosion protection by H.I.T.....................................................................................................32
7.6 Position of the gear unit............................................................................................................. 33
7.7 Ambient conditions for storage.................................................................................................. 33
7.8 Misalignment of the LSS............................................................................................................33
7.9 Misalignment of the HSS (couplings).........................................................................................33
7.10 Bolt specifications (gear units with solid shafts).........................................................................34
7.10.1 Bolt specifications (single-stage, horizontal LSS)...................................................... 34
7.10.2 Bolt specifications (multi-stage, horizontal LSS)........................................................35
7.10.3 Bolt specifications (multi-stage, vertical LSS)............................................................ 37
7.11 Torque values for oil drain screw...............................................................................................38
7.12 Shrink disk specifications (2-part shrink disk)............................................................................38
7.12.1 Lubrication................................................................................................................. 38
7.12.2 Torque specifications................................................................................................. 39
7.13 Prestress specifications for the torque arm (hollow shaft)......................................................... 40
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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
7.15.2 Grease quantity types Q1, Q2, Q3, Q6, Q7 and Q8.................................................. 45
7.15.3 Grease quantity type Q4............................................................................................ 46
7.15.4 Grease quantity type Q5............................................................................................ 46
7.15.5 Grease quantity type Q9............................................................................................ 47
7.16 Grease quantity for lubrication points at labyrinth seals (LSS).................................................. 48
7.16.1 Grease quantity type..................................................................................................48
7.16.2 Grease quantity (single-stage)...................................................................................48
7.16.3 Grease quantity (multi-stage).....................................................................................48
7.17 Grease quantity for lubrication points at labyrinth seals (HSS)..................................................49
7.17.1 Grease quantity type..................................................................................................49
7.17.2 Grease quantity (single-stage)...................................................................................49
7.17.3 Grease quantity (multi-stage).....................................................................................50
7.18 Cooling water specifications...................................................................................................... 50
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Customer data sheet
1
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
Motor Power [kW]
Motor Torque [kNm]
Service Factor on Motor Power
Absorbed Power [kW]
Absorbed Torque [kNm]
Service Factor on Absorbed Power
Direction of Rotation (low speed shaft)
Mass of the gear unit1 [kg]
ATEX Specifications
ATEX marking Gear unit
ATEX marking electrical system
Calculated minimum bearing lifetime [Hrs]
Paint
Corrosion category according to ISO12944-2
Colour
Lubrication
Type of gear oil
Oil viscosity grade [ISO VG]
Minimum temperature for the
oil bath for start-up [ºC]
1
Estimated value, without gear oil, without drive package components
6
MM_405_002_EN
Lubrication
Maximum ambient temperature
[ºC]
Maximum continuous temperature of the gear oil in the oil
bath, during operation [ºC]
Maximum peak temperature of
the gear oil in the oil bath, during operation, [ºC]
Grease type
Storage and protection
The gearbox is adequately treated for storage and corrosion protection up to
1 year indoors
2 years outdoors
Customer data sheet
2
5 years indoors
2
The applicable value is marked with X
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Manual Disclaimer
2
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. Users must be aware that
updates and amendments will be made from time to time to the Manual. It is the user’s
responsibility to determine whether there have been any such updates or amendments.
Neither Hansen Industrial Transmissions nv nor any of its directors, officers, employees
or agents shall be liable in contract, tort or in any other manner whatsoever to any person
for any loss, damage, injury, liability, cost or expense of any nature, including without
limitation incidental, special, direct or consequential damages arising out of or in
connection with the use of the Manual. The user and/or purchaser bears all risks. Should
further information be desired or should particular problems arise which are not covered
sufficiently for the users’ and/or purchaser’s purposes, the matter should be referred to in
writing to Hansen Industrial Transmissions nv.
Warning: Read and understand all instructions and information prior to any
handling including maintenance, installing or starting the gear unit. Failure to
follow instructions could lead to damage, serious injury, or death.
• Only qualified and trained personnel should be involved with the storage (including
transport), commissioning, operation, installation (including removal), inspection,
maintenance and repairs of this gear unit.
• Make sure all your personnel, operators of this gear unit have been professionally and
adequately trained for safe working practices.
• Operators must wear adequate personal protective equipment.
• Ensure all international, EU, national and local safety regulations and codes are
followed when handling, maintaining, installing (including all related actions) the gear
unit.
• Verify the compatibility of the gear unit with the installation it is meant for.
8
MM_405_002_EN
About this document
3
3.1
3.2
3.3
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.
Language
The original instructions of this document are in English. All other language versions are
translations of the original instructions.
If there is any doubt, the English version of the document is binding.
Illustrations
It is not always possible to show the configuration of your gear unit as in the certified
drawing. The illustrations in this document show a typical setup. They are for instruction
or description only.
3.4
3.5
3.6
Use of steps, lists and titles in this document
• The steps in procedures have numbers (123) if the sequence is important.
• The lists and steps with bullets (•) are used if the sequence is not important.
• The lists with letters (abc) are used if the sequence is important.
• In titles of sections, the part between brackets () shows to which type of gear unit or
component of the gear unit the section applies.
How to use this document
Procedure
1. Make sure that you know the structure and the contents of the related documents.
2. Read the safety chapter and make sure that you know all the instructions.
3. Do the steps in the procedures fully and in the correct sequence.
Warnings, cautions and notes used in the document
Type
Warning If you do not obey the instruc-
Description Icon
tion, this can cause injury.
MM_405_002_EN
Caution If you do not obey the instruc-
tion, this can cause damage to
the gear unit, to equipment or
to property.
9
About this document
Type Description Icon
Note A note gives more data.
3.7
Related documents
Document name Document code Target audience
General conditions of sale -
Order acknowledgement OA_
Certified drawing
Installation manual IM_
Maintenance manual MM_
Logbook
Spare parts drawing
Service manual of the lubrication and cooling system
D_
• All personnel
• Approved installation engineers
• Approved installation engineers
• Approved installation engineers
• Approved maintenance engineers
• Approved installation engineers
• Approved maintenance engineers
• Approved maintenance engineers
• Approved installation engineers
• Approved maintenance engineers
10
MM_405_002_EN
About this document
Document name Document code Target audience
Drive package documentation
• Approved installation engineers
• Approved maintenance engineers
3.8
3.9
3.10
Storage of this document and the related documents
This document and the related documents are a part of the gear unit.
• Make sure that you keep the document and the related documents in a dry and clean
location.
• Make sure that the document and the related documents are available to all
personnel.
Abbreviations
Abbreviation
H.I.T. Hansen Industrial Transmissions NV
LSS Low-Speed Shaft
HSS High-Speed Shaft
Description
Customer support
Procedure
1. If more information is necessary, speak to H.I.T.
2. Give the manufacturing number and gear unit type to H.I.T. Refer to the type plate.
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11
Description
4
4.1
4.2
4.2.1
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. The responsibility for the vibration analysis which
includes the total system of driver, gearbox, driven equipment, couplings, mounting
conditions and sources of excitation rests with the owner of the installation. H.I.T. is not
responsible for system dynamics and related damage.
Type plate
Type plate
The type plate gives information about the gear unit.
12
A Manufacturing number
B Gear unit type
C Production number
D Nominal power rating at the HSS
E Nominal torque rating at the LSS
F Service factor
G Exact ratio (R: reduction, M: multiplication)
H Mass of the gear unit, without gear oil
I Input speed n1 (output speed n2)
Input speeds n1/n1' (output speeds n2/n2')
MM_405_002_EN
Description
Variable input speed n1-n1' (variable output speed n2-n2')
J Type of gear oil
K Viscosity of the gear oil
L Minimum temperature for the oil bath for startup
M Maximum ambient temperature for which the viscosity of the gear oil is applicable
N Quantity of gear oil
O Grease quantity type
P Number of lubrication points
Q Grease type
Z Remarks
Note: The certified drawing shows more data:
• illustration of the gear unit type
• connection diagrams
• dimensions
4.3
Signs in the documentation and on the gear unit
Sign
Description
Risk of hot surface
Protective clothing is mandatory.
Hearing protection is mandatory.
Read and understand the installation and maintenance manual before
any handling.
Dipstick
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Oil drain
13
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
14
Direction of rotation: counterclockwise
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Sign Description
P
C
Breather plug to prevent ingress of moisture
Level indicator
Gauge glass
Overflow
Inspection opening
Description
Pump lubrication
Filter
Filter with mechanical contamination indicator
Filter with electrical contamination indicator
Temperature indicator
Temperature transmitter
Level switch
Flow switch
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15
bar
Description
Sign Description
Pressure switch
Pressure transmitter
Pressure indicator
Pressure relief valve
Built-in backstop
4.4
Heater
Protection cap for bolt or nut
Hole for vibration sensor
Ground connection
ATEX
Description of the lubrication of the gear unit
4.4.1
16
Function of lubrication
Lubrication is necessary for these functions:
• To prevent metal-to-metal contact in gears and bearings
• To decrease friction losses
• To dissipate generated heat from the gears and the bearings
• To prevent corrosion
MM_405_002_EN
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