Gearbox Handbook
Contents
1. 5 5 In case of disposal we suggest you take the reduction gear to an authorized disposal centre or contact the nearest INTERPUMP GROUP Authorized Service Centre IMPORTANT The reduction gear shall not be tampered with for any reason and or used for any A purpose other than the use it has been designed for In case of tampering the manufacturer disclaims all responsibility as to the reduction gear functioning and safety 6 WARRANTY CONDITIONS 6 1 The period and conditions of warranty are specified in the purchase contract 6 2 Warranty is voided in case the reduction gear is used for improper purposes used at higher performances than the rated ones repaired with non original spare parts or if it turns out to be damaged due to the non compliance with the operating instructions or to unauthorized tampering Copyright The content of these operating instructions is property of Interpump Group The instructions contain technical descriptions and illustrations that cannot be copied and or reproduced entirely or in part nor distributed to third parties in any form and without in any case authorized written consent of the owner Offenders will be prosecuted according to the laws in force and proper legal actions will be instituted against them The information contained in this document may be modified without notice DICHIARAZIONE DI INCORPORAZIONE Ai sensi dell allegato II della Direttiva Europea 2006 42 CE Il produ2. Interpump Group high pressure pumps It must be used in connection with other mechanical units components in order to create a system with a definite function 1 2 Since the RS500 reduction gear is used within a complete system installation and use must be suited to the type of system used and comply with the safety Regulations in force in the Country where the reduction gear is used 1 3 Before using the reduction gear make sure that the system the reduction gear is used with is certified to comply with the relevant Directives and or Regulations 1 4 Before installing and using the reduction gear for the first time we suggest you check that it is undamaged and make sure that the rated features correspond to the required ones If this is not the case do not use the reduction gear and contact the after sales service of Interpump Group for information 1 5 In order to install the reduction gear correctly follow the instructions for the assembly and for the connections with pump and engine as stated in this instruction manual and or on the reduction gear itself 1 6 Assembly and installation must be made by qualified staff only who must have the necessary mechanical and technical skills and be informed of the operating and safety instructions contained in this document 1 7 In view of a correct functioning of the reduction gear and in particular of the pump it is coupled to the rating of the engine used must be suited to the p
3. 5931 AUT 8 8 Z VITE TCEI M8x30 UNI5929 ANELLO 40 UNI 7435 ALA ATALA A A ae oo 99308400 VITE TCE M8x30 UNI5931 8 8 Z 90168000 ANELLO RADIALE 40x55x7 AiLOi TECHNICAL FEATURES ENGINE SHAFT DIAMETER A 25 4mm 1 28 6mm 1 1 8 MAX GEAR DRIVE POWER 18 5 kW max 25 HP A See power curve for continuous duty in view of the choice of the engine NA ISO 3046 ICXN CURVE type ENGINE FLANGE SAE J609 A B GEAR DRIVE RATIO reduction i 2 2 3100 1425 rpm OIL CAPACITY 0 28 L 9 47 fl oz LUBRICATING OIL See paragraph LUBRICATING OIL WEIGHT without oil 4 20 kg 9 26 Ib INTERPUMP GROUP PUMPS SERIES 47 all 1450 rpm versions SERIES 66 all 1450 rpm versions Translated from original instructions THIS DOCUMENT PROVIDES THE INSTRUCTIONS FOR THE INSTALLATION USE AND MAINTENANCE OF THE REDUCTION GEAR THEREFORE IT IS AN INTEGRAL PART OF IT AND MUST BE READ CAREFULLY BEFORE ANY USE AND KEPT WITH CARE STRICTLY COMPLY WITH THE INSTRUCTIONS CONTAINED IN THIS DOCUMENT IN VIEW OF A SAFE AND EFFECTIVE USE OF THE REDUCTION GEAR FAILURE TO COMPLY WITH THESE INSTRUCTIONS MIGHT CAUSE EARLY FAULTS AND RESULT IN SITUATIONS OF DANGER IN ADDITION TO VOIDING ANY WARRANTY 1 GENERAL INFORMATION 1 1 The RS500 reduction gear is designed to be operated by a gasoline or diesel engine and to be coupled to the
4. 8 6 H7 0 0 021 0257 0 02 0 041 028 6 f7 0 02 0 041 3 2 5 Fix the reduction gear pump assembly to the engine by means of the four screws pos 6 or 7 see engine flange of the washer pos 3 and the washer pos 4 or 5 and tighten torque wrench setting as stated in the exploded view IMPORTANT The pump must be fixed to the A reduction gear only therefore it must be 4 LUBRICATING OIL suspended during working 4 1 For the inside lubrication use gear drive oils with cSt 40 C 2180 viscosity better if containing addition agents in order to grant an excellent level of protection against wear against foaming and to provide high oxidation and corrosion strength We suggest you use ISO VG 220 DIN 51519 quality oils or with 80W 90 SAE degree 4 2 These oil types are valid for room temperatures between and 30 In case of different temperatures pl ease contact the after sales service of Interpump Group 4 3 Oil change 4 3 1 The oil change must be carried out when the reduction gear is at a working temperature 4 3 2 Place a container under the drain plug pos 20 4 3 3 Remove the oil dipstick cap pos 8 and then the drain plug pos 20 4 3 4 Wait until all the oil has been drained then screw back the drain plug pos 20 torque wrench setting as stated in the exploded view 4 3 5 Fill with fresh oil up to the middle of the oil window cap pos 1 and screw back the oil dipstick cap pos 8 IMPORTANT Th
5. RIDUTTORE PER MOTORI ENDOTERMICI REDUCTION GEAR FOR GASOLINE amp DIESEL ENGINES REDUCTEUR POUR MOTEURS A COMBUSTION INTERNE UNTERSETZUNGSGETRIEBE FUR VERBRENNUNGSMOTOREN ae gt MOTORE MAK ly A 20 ENGINE CNN mes A e Nw MOTOR MOTEUR p Y 4 ISTRUZIONI D USO OPERATING INSTRUCTIONS MODE D EMPLOI BEDIENUNGSANLEITUNG oo N 6 FORI Kk lt q s f A lt N A 7 Ber x Bell GAN SIN RZ Hy lim ZA d i ZA LN lt E E LU Ti NL sis 146 05 Fs 10 043 Pos PIGNONE Z 17 A B C D 007 0 028 28 3 0 0 15 6 4 0 02 71 5 40 15 0 cod 10031255 25 H7 0 021 0 28 2 0 1 0 7 D10 0 098 0 040 71 5 0 15 0 cod 10027155 28 6 H7 0 02 0 31 5 0 0 1 6 4 0 02 72 5 0 15 0 20Nm 5 16 30Nm 3 8 SPIA LIVELLO OLIO G3 4x11 5 SCATOLA RIDUTTORE RS500 ROSETTA D 8 4x15x1 5 ZINC RONDELLA ELASTICA D 8 RONDELLA ELASTICA D 10 5 VITE TCEI 5 16 24x1 ANSI B18 2 1 Z flangia SAE J609 A VITE TCEI 3 18 16x1 ANSI B18 2 1 Z flangia SAE J609 B TAPPO CON ASTA G3 8x64 CUSCINETTO 40x80x18 6208 ANELLO 80 UNI 7437 PIGNONE 2 17 i25 4 PIGNONE Z 17 2125 PIGNONE Z 17 2128 6 CORONA 2 37 OR D 152 07x2 62 3600 COPERCHIO RIDUTTORE RS500 OR D 56 82x2 62 3225 VITE TCEI M8x30 UNI
6. a redigere la dichiarazione L amministratore delegato Ing Paolo Marinsek 1 Reggio Emilia 6 05 2010 Firma DECLARATION OF INCORPORATION According to annex II of European Directive 2006 42 EC The manufacturer INTERPUMP GROUP S p A Via E Fermi 25 42049 S D ENZA RE Italy DECLARE that the device identified and described as follows Description Reduction gear Type Reduction gear for gasoline and diesel engines Trademark INTERPUMP GROUP Model RS500 Complies with the requirements of the below listed directives and following updates Directive 2006 42 EC Machinery Directive 2002 95 EC Reduction of hazardous substances RoHS Directive 85 374 EC Liability for defective products UNI EN ISO 12100 1 2005 UNI EN ISO 12100 2 2005 The above mentioned reduction gear complies with all the essential requirements of safety and health protection listed in annex I point 1 of the Machinery Directive and the relevant technical documents are compiled in accordance with annex VII B Moreover in response to a reasoned request the manufacturer and their mandatory undertake to transmit copy of the technical documents on the reduction gear within the terms and in the ways to be determined The reduction gear must not be put into service until the system into which the reduction gear is to be incorporated has been declared in conformity with the provisions of the relevant directives and or norms Person authorized to com
7. ar so as to make the mesh and the coupling easier 3 1 11 Fix the reduction gear casing pos 2 to the reduction gear cover pos 14 by means of the nine screws pos 21 and tighten torque wrench setting 20 Nm 3 1 12 Screw down the oil drain cap pos 20 torque wrench setting 40 Nm into the lower port of the reduction gear casing pos 2 3 1 13 Make the first oil filling by the oil dipstick cap hole pos 8 up to the middle of the oil window cap pos 1 Approximately 0 28 litres are needed See paragraph LUBRICATING OIL 3 1 14 Screw down the oil dipstick cap pos 8 3 2 Coupling to the engine 3 2 1 Lubricate the engine shaft with grease in order to make the assembly easier and prevent contact oxidation 3 2 2 Center and couple the reduction gear pump assembly to the engine by means of the flange taking care that the shaft and the hole are correctly aligned See table of TECHNICAL FEATURES in order to choose the flange to be used with the engine Make sure that the feather key is present on the engine shaft 3 2 3 Do not force and or damage the coupling of the engine shaft to the reduction gear pinion hole due to incorrect actions 3 2 4 In order to obtain a good centering and a correct functioning we suggest you use engine shafts with the following machining tolerances for the shaft end P n 10023355 025 4 G7 0 007 0 028 25 4 f7 0 02 0 041 P n 10031255 25 H7 0 0 021 P n 10027155 02
8. e exhausted oil must be gathered in N containers and disposed of contacting the authorized centres as established by the laws in force The oil must not be dispersed in the environment for any reason 5 MAINTENANCE 5 1 Maintenance and repair must be carried out by qualified and authorized staff only Before any operation make sure that the engine reduction gear pump assembly is shut down and made unusable 5 2 A correct maintenance helps extend the working life and grants a better performance of the reduction gear 5 3 Scheduled maintenance 5 3 1 After 50 working hours Change the oil after 50 working hours from the first use Afterwards the oil must be changed every 1000 working hours or once a year See paragraph Oil change 5 3 2 Every 500 hours Check the oil window pos 1 to verify the oil level If necessary add the oil up to the middle of the oil window In case of a substantial decrease in the oil level check that there are no leakages or drippings caused by an excessive wear or by breakings 5 4 Replace the reduction gear parts with original spare parts only Use only oil types as stated in the above paragraph IMPORTANT After maintenance we suggest you change the lubricating oil Moreover make sure that A the reduction gear is re assembled correctly and that the initial conditions are restored If necessary comply with the instructions contained in the above paragraph ASSEMBLY AND INSTALLATION
9. ose the pumps to be used 3 1 2 Lubricate the O ring pos 15 and place it in the seat obtained on the outside end of the reduction gear cover pos 14 by the hole provided for the pump shaft 3 1 3 Center the reduction gear cover pos 14 on the case side cover shaft outlet end of the pump taking care that the O ring pos 15 stays in place correctly 3 1 4 Fix the reduction gear cover pos 14 to the pump by means of the four screws pos 16 and tighten torque wrench setting 20 Nm Check that the O rings pos 23 are present under the screws head 3 1 5 IMPORTANT Place the reduction gear cover pos 14 horizontally taking care that when the reduction gear is assembled the oil dipstick cap pos 8 is positioned upwards 3 1 6 Lubricate the pump shaft with grease in order to make the assembly easier and prevent contact oxidation 3 1 7 Fit the crown gear pos 12 to the pump shaft up to limit stop Make sure that the feather key is present on the shaft 3 1 8 Fix the crown gear pos 12 to the pump shaft by tightening the screw pos 17 with 542 Loctite torque wrench setting 14 Nm 3 1 9 Lubricate the O ring pos 13 and place it into the seat of the reduction gear casing pos 2 3 1 10 Join the two parts of the reduction gear matching the reduction gear casing pos 2 with the reduction gear cover pos 14 Take care that the O ring pos 13 stays in place correctly Position the toothing of the crown gear and of the pinion ge
10. pile the technical documents Name Maurizio Novelli Address INTERPUMP GROUP S p A Via E Fermi 25 S Ilario d Enza RE Italy Person empowered to draw up the declaration Ing Paolo Marinsek Managing Director 1 Reggio Emilia 6 05 2010 Signature sd
11. ttore INTERPUMP GROUP S p A Via E Fermi 25 42049 S D ENZA RE Italia DICHIARA che l attrezzatura identificata e descritta come segue Denominazione Riduttore Tipo Riduttore per motori endotermici Marchio di fabbrica INTERPUMP GROUP Modello RS500 Risulta essere conforme ai requisiti delle sotto elencate direttive e successivi aggiornamenti Direttiva Macchine 2006 42 CE Direttiva sulla restrizione dell uso di determinate sostanze pericolose 2002 95 CE RoHS Direttiva sulla responsabilit del produttore 85 374 CE UNI EN ISO 12100 1 2005 UNI EN ISO 12100 2 2005 Il riduttore sopra identificato rispetta tutti i requisiti essenziali di sicurezza e di tutela della salute elencati nel punto 1 dell allegato I della Direttiva Macchine e la relativa documentazione tecnica stata compilata in conformit dell allegato VII B Inoltre il produttore e il suo mandatario si impegnano a rendere disponibile a seguito di una richiesta adeguatamente motivata copia della documentazione tecnica pertinente il riduttore nei modi e nei termini da definire Il riduttore non deve essere messo in servizio finch l impianto al quale il riduttore deve essere incorporato stato dichiarato conforme alle disposizioni delle relative direttive e o norme Persona autorizzata a costituire il fascicolo tecnico Nome Maurizio Novelli Indirizzo INTERPUMP GROUP S p A Via E Fermi 25 S Ilario Enza RE Italy Persona autorizzata
12. ump performance In any case the engine power must not exceed 18 5 kW 25HP In case of doubts do not hesitate to contact the A after sales service of Interpump Group ji 1 8 The installer must provide the ultimate consumer with the proper instructions for the correct use of the engine reduction gear pump assembly and if necessary of the system the assembly is used in connection with 2 PACKAGE 2 1 Packages must be handled in compliance with the instructions stated on the packages themselves and or provided by the manufacturer 2 2 In case the reduction gear is not used immediately it must be stored in its integral package and placed in areas which are not exposed to the weather and protected from excessive humidity and from direct sunlight Moreover it is advisable to place wooden pallets or other types of pallets between the package and the floor in order to prevent the direct contact with the ground 2 3 The package components must be disposed of in compliance with the relevant laws in force 3 ASSEMBLY AND INSTALLATION The positions mentioned in the following instructions refer to the exploded view Carefully clean all the driving parts surfaces of the reduction gear of the pump and of the engine 3 1 Coupling to the pump 3 1 1 Unscrew and remove the 4 screws fixing the case side cover shaft outlet end of the pump the reduction gear must be coupled to See table of TECHNICAL FEATURES in order to cho
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