Installation and Maintenance Manual Atex Gearboxes RE GB (UK)
Contents
1. 5 2 4 Pendular design Fasten the reaction arm to the gearbox with screws with a minimum resistance class of 8 8 tightened to a torque corresponding to 70 of their yielding load Clean and degrease the shafts coupling surfaces Apply a thin layer of lubrication to the outer surface of the joint then fit it on the gearbox shaft Tighten an initial group of 3 screws Couple the gearbox with the shaft to be controlled Tighten the screws gradually proceeding in a circular direction and tightening several times to ensure all the screws are tightened to the torque stated in table 4 depending on the type of joint gearbox See drawing FIG 7 Note Do not tighten diametrically opposed screws in a row FIG 7 UN See table 4 7 Z Z 4 Z Z 4 Z 4 Z Z 2 a am Z 59 Table 4 Sizes 110 210 240 310 51060 810 1020 1520 2000 Screw M Me m MB m M8 M Mie M16 Quantity Class 109 109 109 109 109 109 109 109 109 Tightening torque Sizes TT 2520 3000 3510 4800 6000 8000 12010 16000 Screw M6 Me Mme Mme M16 M6 M20 M20 Quantity Class __ 109 109 109 109 109 109 109 109 Tightening torque Sizes __ 21000 26000 31000 40000 45000 53000 61000 85000 M20 M20 M20 M24 M24 M24 M24 M24 Quanti2. 71 5 SUPPORT ANDOSERVICING ices nay unan 2 Siino a MUR ME IDA MUI E PN RDUM KM PUER MY 12 8 1 ROUTINE SERVICING uuu asasusakassashussasusshiasqaspusassusawaqasashusqasashakkasqsswssasuasakqapaspusQqasashuankasqshwssasasuakaspasbussqapushuashkask 73 8 2 SUPPLEMENTARY SERVICING uuu a asqa uqauaqaakawpaqaqukasaqaasqqupaqpaqqhuqqaskaypaqpquiqasaqqaqqakaspaqqisaaaakaypaspuakayaqkaaakaq 74 8 3 OIL REPLACEMEN Mf e NEON E ON 74 93 1 Oailreplacememnt proc edure uuu T m T T 74 8 4 GREASE REPLACE NUGENT gm Y 75 9 BREAKDOWNS AND SOLUTIONS 5 2 7 5 2924220922945 oriali ricada 76 10 DISMANTLING AND DISPOSA D su acnscexsacasctubd estu pu Oer TL SU Rd ERU IDEA PR RARE RD T ANNEX 1 AMOUNTS OF OIL AND WEIGHTIS a aassssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssssa ANNEX 2 TIGHTENING TORQUES FOR LARGE PITCH SCREWS AND CAPS cette ANNEX 3 NEGATIVE HYDRAULIC MULTI DISK BRAKES eeeeeeeeeeeeeenenen eene enne enne nennen eene nennen Revisions The revision index of this manual can be found on the last page p 135 The most up to date versions of Dinamic Oil S p A catalogues and manuals are available at www dinamicoil com 41 1 GENERAL INFORMATION The instructions contained in this manual are an integral part of the planetary gearboxes range
3. Manuale Installazione Uso e Manutenzione Riduttori Epicicloidali Installation Operation and Service Manual Planetary Gearboxes Handbuch f r installation betrieb und wartung Planetengetriebe x A TEX includea INDEX L GENERAL INEORMNIA TION greve rei 42 1 1 TERMSAND SYMBOLS c 42 1 2 SUPPLY qe M M Q 43 2 SAPETYINPORNATION c 44 2 1 GENERAL SAFETY WARNINGS i u uu usaasasaspuska asssashawspupus assaksasaspusapassaaishussbusaqasshaskayashusaqaasussshusshukaq aska kasa 44 2 2 SAFETY WARNINGS FOR HANDLING WHEN UNPACKING AND TRANSPORTING 45 2 5 SAFETY WARNINGS FOR USE AND OPERATIONN 45 2 4 SAFETY WARNINGS FOR INSTALLATION AND ASSEMBL Y 45 2 5 SAFETY WARNINGS REGARDING ENVIRONMENTAL IMPACI 45 2 6 SAFELY ANDINBORMATION NOTICES eroosioon aena 45 2 7 CONSTRUCTOR EEA RUDY uuu i uiaaspatussskhap kuaspakupuwakusasaqapakukauphassiuqspakupuwakusaupaaqakssaqphasqiypapakupuwakupayakapabskaskihassh 45 2 8 BS ADD ISI e 46 2 9 REASONABLY EXPECTED INCORRECT USES uuuuuuuauakasauskapabakuskpqaqkunapakwassikhusauakakokakus
4. Incorrect use of the partly completed machinery is defined as a use different from that described in the instructions of this manual and the data sheets but which is reasonably expected human behaviour e Negligence on the part of the operator to follow the instructions in this manual e Instinctive reactions of the operator e Lack of concentration or carelessness during installation or servicing e Behaviour resulting from the pressure to keep the machine running under any circumstance 46 3 TECHNICAL INFORMATION 3 1 GENERAL DESCRIPTION OF THE MACHINE DINAMIC OIL S p A gearboxes have been designed and built to be incorporated into and powered by an electric or hydraulic motor in finished devices or systems for use in industrial sectors such as construction chemical mechanical agri foodstuff transport naval etc once the constructor has resolved all problems relating to the safety of final regulations in accordance with Directive 2006 42 EC on machinery and other community directives e g ATEX For certain applications and to satisfy specific requirements the gearbox may be supplied in various structural forms and configurations including a range of accessories and optional modifications For all the technical and information and descriptions about these see the relevant sales catalogue It is the user s responsibility to use the gearbox in a correct manner adhering to the warnings given in this manual Gearboxes approved for
5. 5 1 DIRECTION OF ROTATION When making the connection check the direction of the shafts depending on the input attached and using the figures below for reference Dl In line 54 O Installing gearboxes compliant with Directive 94 9 EC Category 2D gearboxes must be installed according to EN 1127 1 and EN 50281 1 2 standards and the installer must therefore have complete mastery of these The installer must know the ATEX classification of the installation zone as well as the risks of a potentially explosive atmosphere in the environment with particular emphasis on explosion and fire hazards so that the relevant protection measures are taken All servicing fitting and dismantling must be performed away from the area at risk of explosion by qualified and authorised personnel Check that accessory parts cables joints cable glands heat exchangers etc are also compliant with the essential safety requirements of the ATEX directive They must be handled with extreme care so they are not altered in any way Remove the screws from the threaded seat if they are required to fasten the gearbox Do not damage the coupling surfaces When installing gearboxes equipped with a reaction arm prevent friction from being produced between the moving metal parts when operational If required install non metal anti friction parts compliant with 94 9 EC Do not attach any object to the unit with elec
6. d Filtering To guarantee reliable motor operation and a long working life for the unit it is extremely important that the hydraulic circuit is equipped with a filtering capacity that is able to ensure a degree of oil cleanliness that complies with the following standards Grade 9 NAS 1638 Grade 6 SAE Grade 18 15 SO DIS 4406 5 6 FITTING ACCESSORIES 5 6 1 Pinion flange smooth bushing To fit accessories onto the grooved shaft proceed as follows e Apply a thin layer of anti seize lubricant or grease to the groove e Push the accessory into the output shaft until the stopping point on the shaft is reached e Insert the retainer plate and tighten the fastening screws 65 5 7 SLEWING GEARBOX INSTALLATION To carry out the installation correctly check that the centerings and support surfaces on the reducer and the structure to which it must be fastened are clean and free of dents Also make sure that the structure is rigid and perpendicular to the axis of operation These checks are important in order to obtain a correct meshing between the reducer pinion and the fifth wheel The latter generally has a mark with three coloured teeth on the point of greatest for slewing bearing with external gear or least for slewing bearing with external gear ovalisation of the pitch which is the point in which the reducer pinion will be positioned If it is not indicated contact the manufacturer 5 7 1 Eccentric suppo
7. if it is at the correct level This operation requires special attention and the level must be checked again after a few minutes of operation 7 2 SELECTING AN OIL Any mechanical transmission oil with EP additives in viscosity classes ISO VG220 to ISO VG320 under ISO 3448 can be used In special cases oils with different viscosities may be used In this case contact the DINAMIC OIL S p A technical assistance service The oil viscosity must be chosen to suit the room temperature and the gearbox s real operating temperature If the gearboxes must operate at very high ambient temperatures or with very large temperature excursions synthetic oil is recommended In gearboxes with vertical fitting and continuous operation oil may suddenly overheat In these cases it is necessary to provide an external tank which DINAMIC OIL S p A can supply to allow the oil to expand as it heats up If the delivered gearbox is already filled with oil the lock cap used for delivery needs to be replaced with the vent cap supplied safety data sheets Do not release used oil into the environment Collect it and send it to authorised bodies for disposal in Lubricants are potentially harmful toxic substances to health always refer to the manufacturer s i accordance with legislative provisions in force Recommended viscosity ISO OPERATING TEMPERATURE C i VG 3448 20 10 o 10 20 30 40 50 60 70 80 90 100 69
8. All required information for purchasers and engineers is included on the dimensional drawings and data sheets provided in the proposal In the absence of such information the data provided in the catalogue should be considered correct In addition to adhering to rules of best practice in construction this information should be carefully read and stringently applied If in any doubt contact the DINAMIC OIL S p A technical assistance service These installation instructions have been designed for the safety of all persons carrying out assembly transport handling installation start up and support on planetary gearboxes however any other technical or specific documentation from the order must also be followed There may be attachments to this manual The manual is relevant to the following units e Planetary gearboxes To comply with their intended use they must be operated as described in this manual and in accordance with the other technical documents data sheets catalogues etc The manufacturer has designed these units for industrial uses Any use application and or installation beyond those described in this manual and other technical documents data sheets catalogues etc must be agreed approved by the DINAMIC OIL S p A technical assistance service For the purposes of Directive 2006 42 EC on machinery the gearbox is considered partly completed machinery which will be fitted onto other machines and or installations The gearb
9. Constructor DINAMIC OIL S p A N A Oil fill breather Oil level Oil drain 42 Instructions given next to the Ex symbol only apply to equipment compliant with the 94 9 EC ATEX directive Activities referenced by this symbol must only be performed by professionally qualified and authorised personnel with specific training on safety issues relating to areas with potentially explosive atmospheres Failure to adhere to these instructions can pose serious risks to the safety of persons animals and objects Instructions given next to the Ex symbol should be interpreted as additional instructions to those provided for installation use and servicing of standard gearboxes and not as a replacement 1 2 SUPPLY Upon receipt of the gearbox check that it has not been damaged and that the item supplied KI matches the one ordered If any of these conditions is not fulfilled contact the DINAMIC OIL S p A sales technical assistance service immediately DINAMIC OIL S p A gearboxes are delivered in cases pallets carton pallets or simple cardboard boxes which are carefully organised to prevent movement The packaging material should be disposed of according to the national and international environmental standards in force A Take the utmost care when unpacking The gearboxes are supplied as follows e Arranged for installation in the assembly position stated when the order was placed e Without lubrication oil unle
10. must be performed with the power supply disconnected and the gearbox taken level so as not to burn the operators The instructions given in this paragraph must be followed ensuring the gearbox is operational and that required levels of safety are met Only use original spare parts refer to the Spare Parts List for the gearbox in question Use lubricants that are recommended by the manufacturer After any servicing work always replace the seal washers and any lubricating oil Carry out the routine servicing work as set out by the manufacturer Use additional lighting if carrying out servicing work in dimly lit areas to ensure that it is performed safely Take relevant precautions if carrying out servicing work in enclosed spaces to ensure that it is performed safely DINAMIC OIL S p A will not be held liable for damage caused to persons animals or objects if non original spare parts are used SERVICING Adhere to the routine inspection and servicing intervals to ensure correct working order and explosion proofing are maintained Before carrying out servicing or repair on any part of the gearbox wait for it to cool completely to avoid a risk of burns from parts that are still hot After servicing ensure that all safety measures are fully and correctly reinstated Arrange for the gearbox to be cleaned once the servicing repair phase is complete After servicing refit the vent loading and level caps using the appropriate tighte
11. use in a potentially explosive atmosphere must be labelled with the appropriate identification plate and are protected and manufactured to comply with the Essential Safety Requirements ESR in Annex II of the 94 9 EC ATEX directive They comply with the following Equipment group Il Category Gas 2G Dust 2D Zone Gas 1 Dust 21 Maximum surface temperature temperature class T4 for 2G and 130 C for 2D 3 2 CONDITIONS AND RESTRICTIONS OF USE PIN The recommended ambient temperature for use of standard gearboxes is min 15 C max 40 C The gearbox may only be installed in the position indicated on the identification plate Any change to its installation position must be authorised by DINAMIC OIL S p A Using the gearbox in aggressive environments in water or other liquids is not permitted unless agreed during the planning stage Unless duly marked ATEX plate it is not permitted to use the gearbox in potentially explosive atmospheres or where explosion proof equipment is required If it does not have a plate the gearbox is not permitted to be used on machinery operated in potentially explosive atmospheres If it is liability for improper use or any harm to persons objects or animals rests with the customer Values for maximum surface temperatures relate to measurements in standard environmental conditions and a standard installation Variations to these conditions however small including narrowed openin
12. 16 M18 M18 M24 M24 129 129 129 129 129 129 129 129 88 88 M2 M27 M30 M30 M30 M36 M36 M36 88 88 88 88 88 88 88 88 Sizes 1000 130000H 150000H 2500 235000H Screw M2 M2 M2 M2 M2 Quantity Class 88 88 88 88 88 Tightening torque For transmission torques greater or equal to those given in the table and with frequent motion inversions use screws with a resistance class of at least 10 9 37 5 2 2 Female grooved shaft design Ensure that the gearbox and the driven shaft are aligned and that the latter is not exposed to bending during operation See drawing FIG 5 FIG 5 See table j Table 3 Sizes Screw Quantity 8 j 8 8 172 12 172 16 16 16 Class Tightening torque Quantity 36 36 360 36 36 36 Tightening torque 1 202 1 282 1 202 2 240 2 240 2 240 36 36 36 36 36 36 Maximum torque tolerated by screws 512 633 512 633 512 633 940 487 940 487 940 487 For transmission torques greater or equal to those given in the table and with frequent motion inversions use screws with at least class 10 9 resistance 58 5 2 3 Design with feet These gearboxes must be fastened to a suitably sturdy base worked with a machine tool and with a maximum planarity error of 0 3 mm 0 8 mm See drawing FIG 6 FIG 6
13. 42 EC Description Remarks a Ameri Correct and non hazardous 19 i 1 3 4 i Risks posed by surfaces edges or angles i positioning is the responsibility of Protection of the operator from potential risks related to moving parts is the responsibility of the Protection of the operator from i Choice of protection against risks arising from potential risks related to moving moving parts parts is the responsibility of the The choice of requirements for guards and protective devices is 26 1424 Fixed guards T any ee guargs Is tne x nn _ uan responsibility of the customer _ i Fitting any adjustable guards 28 1 4 2 3 Adjustable guards restricting access restricting access is the The choice of special requirements 29 1 4 3 Special requirements for protective devices for protective devices is the x i responsibility of the customer I I x 22 x 1 3 7 x Risks related to moving parts 23 1 3 8 General requirements for guards and a Lasi protective devices 2 9 REASONABLY EXPECTED INCORRECT USES
14. 59 5 3 CONNEC TIONS sssrini E EE 60 5 4 INPUT CONNEC TIONS scriniis EENE EE E 6l 5 4 1 Connection to hydraulic motori iero ia ir pira 61 5 4 2 Connection to electric niotF iii a arri 62 JM EO REC alta 63 Sdad Connection to Prakt c 63 5 5 GEARBOX MOTOR INSLALUI A T ION SL u u u ssn a S 64 5 6 PITTING ACC ESSOR IE Y uu aapalawasaQaQusshakkiasqaqakususaakusassaqhuqasspakkiauuasasutusaqkuaawsaqhaqasspalkiaaua sa sutusaakuuawsaqhaqussaakskasas 65 S SEEWING GEARBOX INSTALLAT ION itisssesicesssek eee na aya riena nN ail ili 66 EE ESSE LUN S do DO TESTING cerere 67 b LUBRICALION m r 69 7 1 TYPEOF LUBRICATION ecc 69 7 2 SELEC TING AN Oll remm cro cc toenasseceusicnatteusnasacsavcaactseneshecsusicacttcunsancasuscanctsenwaics 69 Tad BRAKE LUBRICATION wcicseivcasccusscniccessensccesscuicteuecercccuscustexeecucceuseeltteusccutceusicistieuveavaceubeuittanseasiceascusbissauatecenseuiteasrecies 70 7 4 OIL FILLING AND LEV EL CHE CRIN G iisscasscdssesaacenssnasadicessastunenasadaseaancenssnsbadacessustunsaabecastaancens ashadaseseustuncxabadaseneass 70 lo Azores 70 yr ME Cun Iri err TT TT 70 LS FILLING PROCEDURE uuu aw m 71 7 5 1 Filling procedure with expansion chamber a a 71 7 6 AMOUNT OF 67 Pee
15. Lubricants for general use Mineral oil PARAL J DeglBG ego GS BP Energol GR XP_ EnersynEPX Enersyn HTX DEA FalconChP PO 0 Glycolube FNA JGima G P Mellano j TelsiaOl OPTIMOL Ura 0 Q8 Goya JElGeo JElGreco Lubricants for the food industry Manufacturer AGIP Rocol Foodlube Hi Torque ESSO Gear Oil FM KL BER Kl beroil 4 HU1 N MOBIL DTE FM SHELL Cassida Fluid GL 7 3 BRAKE LUBRICATION Negative hydraulic brakes with multiple discs and a lubrication chamber are already lubricated 7 4 OIL FILLING AND LEVEL CHECKING Every gearbox is equipped with level vent filling and draining caps for oil in a configuration that varies depending on the structural form see point 3 7 4 1 Horizontal fitting For horizontal fitting the lubricating oil level is located on the middle section of the gearbox 7 4 2 Vertical fitting For vertical fitting both linear and at right angle the lubricating oil level is located on the top section of the gearbox to ensure the upper bearing is lubricated 70 7 5 FILLING PROCEDURE n When being filled the gearbox must be in the exact position that it will be in when operating A Ensure the power supply is disconnected when filling e Unscrew and remove the loading and level caps see point 3 5 e Feed the oil through the
16. OL Jejdepe uonoeuuoo iolol 6 SINdNI ud IA JOJOW EWQIO S JOjOUJ uo sid jelpey p JOJOW uo sid eIxy AOJOW EWNGIO Z JOJOW 9IN99 I SUOLON SINYOH IVUNLIIONAHIS VE 3 5 DESIGN FORMS INLINE GEARBOXES RIGHT ANGLE GEARBOXES pos 1 STANDARD 110 510 1020 235000 50 4 TRANSPORT HANDLING AND STORAGE Handling trained personnel trained must ensure the required safety conditions are enforced for e lI themselves and for persons in the vicinity The cases only have load bearing structure on the bottom with the other sides for coverage only Those structures must therefore not be loaded 41 HANDLING OF PACKAGING Before handling the packaging prepare an appropriate marked out area with paving and a flat surface for unloading and placing the packages on the ground When moving the package use appropriate methods e g forklift trucks cranes or transpallets for the type of packaging all in perfect working order taking into consideration the packaging s size weight and centre of gravity Keep the packages level to prevent them from tipping over during handling A Use accessories that comply with the directive on machinery and which are suitable for the weight to be lifted the package Bj The weight gripping points and centre of gravity of the package to be handled are shown on 42 HANDLING OF EQUIPMENT Befo
17. al laws on safety and safe working practices e Incorrect installation inadequate or incorrect observance of the instructions given in this manual e Electrical or hydraulic power supply failure for motor gears e Alteration or tampering e Operations performed by untrained unqualified or unauthorised personnel e Use applications or installations beyond the instructions given the data sheets or this manual that have not been approved by DINAMIC OIL S p A The safety of the gearbox also relies upon strict observance of the instructions given in this manual and in particular e The gearbox must only be operated within its limitations of use see data sheets catalogues etc e Diligent routine servicing must always be carried out e Operators assigned to inspection and servicing must be sufficiently trained e Only original spare parts must be used e The configurations shown on the dimensional drawings and their instructions in the catalogue are the only ones permitted e Do not attempt to use the gearbox in any other way than indicated by the provided instructions e The instructions given in this manual are supplementary to and do not replace obligations in legislation on safety standards in force 45 2 8 RESIDUAL RISKS Residual risks are potential hazards which cannot be eliminated or can only be partially eliminated and which can harm the operator if incorrect methods or working practices are used Directive Note 2006
18. ceeds the limits stop the gearbox immediately and do not use the machine Notify the Dinamic Oil S p A technical assistance service immediately Dinamic Oil will not be held liable for damage to persons animals or objects if these tests are not carried out and documented Provided that the gearbox has passed all the checks specified above and any other instructions supplied in this manual have been followed correctly and precisely the gearbox will be ready to be incorporated in the customer s machinery Any other accessory fitted onto the gearbox and consequently any drives must be ATEX certified to at least the same degree of protection in order for the customer s machinery to be compliant with Directive 94 9 EC The customer s complete system and or machinery including the gearbox itself is only compliant with the directive on machinery once risk analysis has been carried out and any resulting risks are resolved and once the technical dossier and any other documentation required by Directive 2006 42 EC on machinery has been submitted see the General Information section of this manual 7 LUBRICATION All DINAMIC OIL S p A gearboxes are supplied without lubricating oil The user is required to ensure the units are filled with the correct lubricants before putting the machine to use 7 1 TYPE OF LUBRICATION Gearboxes are oil bath lubricated Before putting the gearbox to use fill it with oil looking through the level cap to see
19. chnical assistance service Lack of pressure Check the hydraulic circuit Internal problem Contact the DINAMIC OIL S p A technical assistance service Residual pressure in brake Check the hydraulic circuit Worn plate Contact the DINAMIC OIL S p A technical assistance service 76 10 DISMANTLING AND DISPOSAL Before scrapping the gearbox it needs to be rendered unusable and emptied of lubricant remembering that used oil has a serious impact on the environment The gearbox must be dismantled by expert operators adhering to the applicable laws on occupational health and safety and environmental protection Non biodegradable products must not be disposed of into the environment under any circumstances Disassembled and disused gearboxes produce the following waste iron aluminium cast iron lubricant plastic copper and bronze The gearbox parts must be disposed of according to the selective sorting standards in force in the country where the disposal takes place For countries in the European Community with the issue of Commission decision 2000 532 EC subsequently amended by decisions 2001 118 EC and 2001 19 EC from the Commission and 2001 573 EC from the Council new community provisions have been introduced regarding waste classification Do not attempt to reuse parts or components which may seem to be complete after they have undergone checks and tests and or replacements by specialist personnel and declared no longer fit fo
20. cts Filling and topping up must be performed by expert and authorised personnel away from the area at risk of explosion For the initial oil filling and any top ups only the recommended oils should be used 53 5 INSTALLATION AND ASSEMBLY ji Gearboxes must be installed carefully and professionally by suitably suitably trained and technically skilled authorised personnel guaranteed for both workers and third parties and that the gearbox operates correctly and All the installation operations must be performed to ensure maximum safety levels are A safely Before installing the gearbox check that it is in the correct assembly position e Tampering with the gearbox and any of the accessories fitted during production is strictly prohibited e When any lifting and handling manoeuvres are carried out care must be taken to ensure the end of the shaft does not hit anything The relative hoisting straps and or eyebolts must be used suitably arranged and with hoisting means whose capacity is sufficient for the job e Welding operations on gearboxes are strictly prohibited without suitable protection e Any installation work or servicing must be carried out with the gearbox stationary therefore it is recommended that you ensure the gearbox cannot be switched on accidentally e In the event of connections involving the use of rotary parts such as shafts joint or pulleys with belts suitable accident prevention gear must be provided
21. efore starting up the unit we recommend you replace the washers of the static and rotary seals For storage for over 6 months fill the gearbox with the same type of oil as the oil that is planned to be used when operational placing the vent cap in the upper part of the gearbox Before starting up fill the gearbox with the right amount of oil The static and rotary seals will begin to deteriorate after 6 months SAFETY PRECAUTIONS WHEN RESTORING THE GEARBOX AFTER STORAGE All surfaces contaminated with lubricants protection solvents dust or other potentially flammable material must be carefully cleaned commercial solvents This operation must be performed away from the area with the explosion hazard The solvent must not come into contact with the seal rings avoiding damage to the equipment and compromising its functionality Grease used for the bearings must strictly be synthetic in nature When filling with lubricating oil check the amount of oil required for each gearbox size Annex 1 of this manual Place the gearbox in the assembly position indicated on the plate and check the right amount of oil using the level caps Once filled wait 15 30 minutes for the oil to stabilise and top up if necessary When testing check that the oil level in the gearbox is correct and top up if necessary When topping up ensure the gearbox is taken out of service and take care with hot surfaces to avoid serious harm to persons animals or obje
22. forming the various operations personnel must also adhere to national and international standards on safety and safe working practices e Installing and operating damaged units can pose serious safety risks e Serious harm can be caused to persons animals or objects as a result of gt Improper use gt Incorrect installation or use gt Unauthorised removal of protection systems e The following risks arise during and after gearbox operation Overheated parts Moving parts Parts under pressure Before carrying out any task personnel responsible for installation use and servicing in areas with potentially explosive atmospheres must carry out all necessary environmental safety measures e g degassing or removal of residual dust etc 44 2 2 SAFETY WARNINGS FOR HANDLING WHEN UNPACKING AND TRANSPORTING see point 4 Transport handling and storage 2 3 SAFETY WARNINGS FOR USE AND OPERATION Adhere to the information in the data sheet 2 4 SAFETY WARNINGS FOR INSTALLATION AND ASSEMBLY Adhere to the information in the data sheet 2 5 SAFETY WARNINGS REGARDING ENVIRONMENTAL IMPACT Units must be disposed of according to the environmental standards in force 2 6 SAFETY AND INFORMATION NOTICES Manufacturers carrying the CE mark are responsible for applying safety and information notices 2 7 CONSTRUCTOR LIABILITY The constructor will not be held liable in the event of e Gearbox being used contrary to nation
23. gs external heat sources areas exposed to solar radiation etc can have considerable effects on the build up of heat Any modification to the structural form or installation position can pose potentially serious hazards to the safety of persons animals or objects If these modifications are not approved and authorised by Dinamic Oil S p A the ATEX certification is rendered void and all liability rests with the customer 47 333 TECHNICAL DATA The gearboxes are equipped with identification plates containing the unit s main technical and manufacturing information To interpret the product description A refer to the sales catalogue A Product description customer code B Serial number week year identifying number C Product code The product description may be replaced by a code supplied by the customer Gearbox plate with ATEX option DINAMIC OIL C BOMPORTO MO ITALY N N Agenc Do D Mount Pmax kW max om mlO m x 2 GD ck O Number registration body Permitted assembly position Reduction ratio Maximum applicable power in kW with mechanical yield 0 97 for each reduction stage input speed 1500 rpm ambient temperature 20 C altitude 0 500 m Maximum input revolutions allowed for the connected electric motor in revs minute Maximum transmissible applicable output torque in Nm Mark of conformity accordi
24. haqaskuaspakapusakasasalapekakssshassh 46 3 TECHNICA INDPORMATION E 47 3 1 GENERAL DESCRIPTION OF THE MACHINE spsssssstssssasncussessdssssinnanassiisasaassinasnadaiiesadssasensaaassiesaassssannnadiiessdssasawsnaans 47 3 2 CONDITIONS AND RESTRIC TIONS OF USE iii 47 3 3 FECHNICAL DA I m 48 3 4 STRUCPRURALFORMS rrr 49 3 5 DESIGN TORM Sila 50 4 TRANSPORT HANDLING AND STORAGE nennen eene e eene nenne eene e tese eese eene eene enne dil 4 1 HANDLING OF e eT Cm 51 4 2 HANDLINGOFEQUIPNIEENT scici iero icicnri dslencnionicniicvslenoiivzicnni dslencicvnlonii dvslunsiina inni dslizoi iva beg Us i62 Liz E crisis SI 4 3 VJEOILT VC UM 53 5 INSTALLATION AND ASSEMBL Y 54 5 1 DIRECTION OF RO VATION 53 dcticssietis S victhvsn ies v3 eidbu sp iaso icona disaisniaia lesi Cid d 2E doo eM RO 1200020 1612 C62 iaoeia ankaii 54 5 2 SERIES RE GB GEARBOX DESIGNS i u a excvacetecsuncsnctcvasansasveusieasvasaiiasvasensdavasensasteastaceiisacdasuasensdancanesasns 56 SMe PFlapgcd CCS Re 7 56 5 2 2 Female grooved shaft design r ness esse nnn neris ss nnn nns 58 USO MW PIECE EE 59 5 2 4 Pendular design NONO
25. ication that all the instructions in the following manual and specified above have been correctly observed if a gearbox motor compliant with Directive 94 9 EC is desired the motor to be fitted must have equal or greater ATEX protection to that of the gearbox Dinamic OilS p A will not be held liable for any risks in fitting the gearbox motor unless the entirety is directly supplied 5 4 1 Connection to hydraulic motor Remove the protective cap version F1 F2 only There are two types of set up for hydraulic motors 1 MO F5 F6 F8 F9 and ST MU PAM versions the oil seal is guaranteed by the ring fitted on the joint on the motor you will simply need to apply a thin layer of oil to the driving shaft 2 F1 F2 version fit the O Ring which guarantees the seal between the motor and the brake taking care to fit it correctly in its seat without damaging it See drawing FIG 8 FIG 8 Use screw minimum resistamce class 8 8 Apply graese film before fitting F5 F6 F9 ST PAM F8 MU PAM 61 5 4 2 Connection to electric motor If the motor in question is a particularly high power motor ME 225 and above use B3 B5 motors with suitable supports See drawing FIG 9 N B The motors must always be perfectly aligned whether the motor and the gearbox shaft are coupled with a joint or and especially if they are coupled directly Incorrect positioning can cause damage to the bearings on both the
26. loading hole until it flows out of the level hole e Refit the caps using the appropriate tightening torques see Annex 2 7 5 1 Filling procedure with expansion chamber In vertical fitting and cases where the gearbox needs to be completely filled use of an expansion chamber is recommended This accessory ensures that all the gearbox s components are lubricated as well as serving as a reservoir for the oil which increases in volume as the temperature rises e Unscrew cap C located on the upper part of the gearbox to prevent an air bubble from forming at the upper rotary seal e Unscrew loading cap A and start filling When the oil flows out of the hole in cap C close it using the appropriate tightening torques see Annex 2 and fill up to level B e Refit cap A using the appropriate tightening torques see Annex 2 ay Z SJ 7 6 AMOUNT OF OIL Indicative oil amounts are given in Annex 1 of this manual These values are only indicative and the level cap on the middle section of the gearbox itself must therefore be referred to 71 8 SUPPORT AND SERVICING ji Servicing must be performed by expert authorised personnel adhering to the work and environmental safety standards in force out of service to prevent it from being switched on accidentally The oil temperature must be at a safe Servicing on the gearbox
27. motor and the motor set up See drawing FIG 9 FIG 9 Use screw minimum resistamce class 8 8 Clean the mating surfaces LL p IZ zal D dia m PSA 62 5 4 3 Connection to fast shaft Clean all the mechanisms before connection In the event that pulleys for belt drives or toothed pinions for chain gearing are fitted the shafts must be parallel and the pulleys aligned Do not tighten the belts more than necessary as excessive tension could damage the bearings If the connection is made with a rigid joint a compensation system must be added to recover any phase displacement between the fast shaft and the gearbox fastening See drawing FIG 10 FIG 10 5 4 4 Connection to brake For gearboxes arranged for hydraulic motors and complete with brakes when installing connect to the hydraulic control hole on the brake body with a suitable hydraulic circuit pipe See drawing FIG 11 FIG 11 Draining Oil input For further information about Dinamic Oil brakes please refer to annex 3 of this manual 63 5 5 GEARBOX MOTOR INSTALLATION 5 5 1 With an electric motor If the complete gearbox motor set is supplied follow the instructions given previously for its installation The electrical connection types are stamped inside the terminal cover The conventional clockwise rotation direction is obtained by connecting terminals U1 V1 W1 respectively to
28. nd the air ventilation pathways to ensure correct heat dispersal e Check the screws are all tight and tighten them where required It is worth checking for the vibration noise and temperature of the gearbox while it is in operation When repaired the right amount of oil must be restored For installations in zone 21 and 22 a scheduled routine cleaning plan must be provided and implemented by the customer for surfaces and areas of accumulation to prevent dust deposits from exceeding a thickness of 3 5 mm After every 1000 hours of operation or after 6 months Check the surface temperature of the gearbox The maximum temperature must not exceed the value shown on the plate Check the lubricating oil levels with the relevant caps Check for any leaks in the seals After every 5000 hours of operation Replace the lubricating oil Replace the seal rings General inspection of the gearbox Replace the seals bearings and any worn mechanical parts If anomalies are found identify the cause and commence repairs Restore the correct level of lubrication before putting the gearbox back into operation 73 8 2 SUPPLEMENTARY SERVICING If agreed with the customer DINAMIC OIL S p A can supply suitable servicing procedures on a case by case basis DINAMIC OIL S p A prohibits the gearbox from being opened for any operations which are not defined as routine servicing DINAMIC OIL S p A will accept no liability for harm to object
29. ng counterflanges on the unit or system on which they are to be installed The surfaces where the gearboxes will be coupled with the flange must be flat and worked with a machine tool Connect the output shaft to the mechanism to be controlled following the instructions given in the drawings below FIG 1 FIG 2 and FIG 3 FIG 1 DIN 5480 e8 DIN 5482 e9 DIN 5480 H9 DIN 5482 H10 DIN 5480 H9 _DIN 5482 H10 DIN 5480 e8 DIN 5482 e9 Recommended tolerances Coupling with interference Hollow shaft FIG 3 See table 1 Table 1 Sizes ON 110T OTR 11071 T10TRT 210N 210T 210TR Screw Mio Mio Mio M12 MI2 mio mio Mio Quantity NB 100 10 10 10 8 10 10 Class 88 88 88 88 88 88 88 88 Sizes 201 210TR1 2401 240TR 310N 310T 310TL 510 610N Screw j M2 M2 M2 MO M2 M2 M2 M2 Class 1 j 88 88 88 88 88 88 88 88 Sizes 510 610T 510 610TL 810N 810T 1020T 15207 2000T Screw M2 M12_ M M4 M6 Mie M Class 1 Jj 88 88 88 88 88 88 88 For transmission torques greater or equal to those given in the table and with frequent motion inversions use screws with a resistance class of at least 10 9 FIG 4 See table 2 M16 Mte M16 M16 M16 M
30. ng to Directive 94 9 EC Ensure the identification plate is kept clean and clearly visible If even one item of information on it is no longer legible request a copy from the manufacturer and replace it 48 or L 3 nm iA 4eqweyo uoisuedx3 py d3 18 d pu3 ep NO ASIP YUNUS ZY uu Jeq pe ooJo Ly uS3 Buiusnq euoBexeH or Sgu USNA peA ooJs GE u 13 BUL ge ad UOlUlg JE SHINOSSHDOV yeys indino jeoupuljAo euu j oe peys indino jeuoBexeH s peys indino p Aoo1 B euu jJ ve yeys 1ndino p Aoo1o ec yeys indino jeoupui A Ze ON HOddns indino LE id Hoddns jndino oF Ha HOddns jndjno ez 4 1L Moddns jndino 87 wl Hoddns indino 2Z aLa Hoddns jndjno 97 da 4oddns ndino sz Na Hoddns jndjno 7 SLHVHS INdLNO NV SLYOddAS uononpei Be s aly Z uononpal ebe s 1no4J zz uononpei eBejs uu LZ uononpa 1 eBeis jqnoq 0Z uononpal abeys ejDBuis 64 JeoB anagq JUNOW p d gL SHOVIS NOILOQQSH Jejdepe eBue l dN LL Jejdepe abueji ZN OL oDue J piepueis G4 u64 84 94 S4 eXe1q eAnebeN HL w CAs bau 94e4q eAneBeN Jejdepe ioloui elio aq ZL Jeydepe JOIOW 9117981 PAA LL yeys jsey
31. ning torques see Annex 1 At the end of any servicing operation the original state of the seals must be restored using the appropriate sealant In gearboxes where double ring seals are supplied the chamber must be filled between the two rings with Fluorocarbon gel 880 ITP synthetic grease or similar in terms of properties and field of use When replacing a seal ring in any type of gearbox a thin layer of Fluorocarbon gel 880 ITP synthetic grease or similar in terms of its properties and field of use must be applied to the lip of the gearbox before fitting Only use original spare parts for repairs 72 8 1 ROUTINE SERVICING Scheduled routine servicing work is carried out on DINAMIC OIL S p A gearboxes by the operator n Proper servicing improves performance longevity and safety After the first 150 hours of operation e Check there are no metal residues of abnormal size in the magnetic caps on the gearboxes e Clean the surfaces of the gearbox body and the air ventilation pathways to ensure correct heat dispersal e Change the lubricating oil see point 8 2 e Check the screws are all tight and tighten them where required After every 500 hours of operation e Check the oil levels with the relevant caps e Check for any leaks in the seals e Check the screws are all tight and tighten them where required After every 2000 hours of operation or at least every 12 months e Clean the surfaces of the gearbox body a
32. nt 7 5 74 8 4 GREASE REPLACEMENT The bearings of some gearboxes are lubricated with grease performed in the factory Replace the lubricating grease according to the schedule set out in the following table Average operating duration according to grease type Grease type 5 000 hours 10 000 hours n DINAMIC OIL S p A recommends replacement at every oil change For the type and quantity refer to the gearbox data sheet 45 9 BREAKDOWNS AND SOLUTIONS Excessive and or Internal problem Contact the DINAMIC OIL S p A technical abnormal noise assistance service Excessive vibration Seeping of lubricant from seals Excessive heat With the motor switched on the slow shaft of the gearbox does not turn Parking brake will not release Parking brake will not apply Gearbox not installed correctly Check the fastening Weak coupling structure Strengthen the structure Internal problem Contact the DINAMIC OIL S p A technical assistance service Seals worn or damaged Contact the DINAMIC OIL S p A technical assistance service Seals stiffened after prolonged time in storage Clean the area and check for seeping after a few hours of operation Lack of lubricating oil Apply lubricating oil assistance service assistance service Motor not fitted correctly Check the coupling between the motor and the gearbox Jammed brake Check the hydraulic circuit Internal problem Contact the DINAMIC OIL S p A te
33. ox must not be incorporated into them and used until all safety issues have been resolved and it is not permitted to start up the final product for its intended use until it has been verified as compliant with Directive 2006 42 EC on machinery The customer must accept responsibility for compliance with the Directive 2006 42 EC on machinery and any other community directive relating to safety of machinery Planetary gearboxes can pose hazards to persons animals and material goods For this reason all handling transport fitting installation start up and support operations must only be carried out by personnel who are trained qualified and authorised to carry out the task and who are aware of the potential hazards Personnel must have the required qualifications for the task to be carried out and have attested experience in handling transporting fitting installing starting up and supporting planetary gearboxes see point 2 1 1 TERMS AND SYMBOLS Warning A Precautionary measures to be followed to ensure the safety of the operator and persons present in the working area animals and objects Specialist authorised personnel Operations which must only be performed by specialist authorised personnel Information Important information or procedures Customer Manufacturer of final machinery Manufacturer of final machinery Person fitting the partly completed machinery gearbox onto the final machinery Manufacturer
34. r use 71
35. re taking the gearbox out of its packaging prepare the relevant lifting accessories e g chains bands grills eyebolts etc or handle it using a pallet as a resting platform Take the utmost care when unpacking Use accessories that comply with the directive on machinery and which are suitable for the weight to be lifted 31 Lift the gearbox taking care not to unbalance the load while moving m Move and lay down the gearbox in the area prepared for unloading Refrain from making abrupt movements and perform an initial slow manoeuvre to ensure that the load is balanced Examples are given below of the lifting points for the main DINAMIC OIL S p A gearbox designs n The weight of the equipment to be lifted can be found in Annex 1 52 4 3 STORAGE For correct storage of the units the following steps must be taken For storage for over 2 months protect the coupling surfaces such as the flanges shafts and joints with a very thin layer of grease and or protective anti corrosion fluids Store in a dry place with temperatures of between 5 C and 30 C e Always place wooden planks or a platform made of other materials between the unit and the floor to prevent direct contact Do not stack the packages Check the internal gears regularly by rotating the input shaft manually If the unit is fitted with negative lamellar brakes release the brake with a hydraulic pump or suchlike B
36. rt If the gearbox has an eccentric support to adjust the clearance between the fifth wheel and the pinion the support will have a notch at the minimum point of eccentricity indicating the minimum obtainable meshing clearance between the fifth wheel and the pinion This applies to gearboxes positioned both inside or outside of the fifth wheel This applies to gearboxes positioned both inside or outside of the fifth wheel SLEWING RING PAINTED TEETH SLEWING RING PAINTED TEETH MAX BACKLASH _ w O a LOW ECCENTRICITY POINT LOW ECCENTRICITY POINT The amount of clearance between the sides of the teeth between the pinion and the fifth wheel is obtained by multiplying the module m of the toothing by two fixed values given in the table below 0 1 0 2 0 3 04 0 4 0 8 The resulting values provide a range that the clearance between the teeth must lie within to allow perfect meshing A Grease the teeth before use 66 6 START UP AND TESTING A Improper start up can damage the gearbox At the factory the gearbox s seals are checked for leaks and a vacuum test is performed Check the following before start up e That the machinery incorporating the gearbox is compliant with Directive 2006 42 EC on machinery and any other applicable safety standards in force e That all rotating parts are sufficiently protected in compliance with Directive 2006 42 EC on machinery e That any risks to the safety of persons animals or objects are re
37. s Further important operational information is given in the dimensional drawings data sheets or in any specific documentation for the order Before start up the machinery must undergo a functional documented test checking the following Temperature noise any abnormal events braking torque working order of accessories DINAMIC OIL S p A will not be held liable for damage caused to persons animals or objects if these tests are not carried out 67 Measuring the surface temperature of the gearbox e The maximum temperature of the gearbox surfaces varies depending on the number of revolutions the gear ratio and the structural form but must never exceed 108 C for temperature class T4 Values on the plate for maximum surface temperatures relate to measurements in standard environmental conditions and a correct installation Variations to these conditions however small including narrowed openings can have considerable effects on the build up of heat When starting up the surface temperature of the gearbox must be measured in the same operating conditions as those planned for operation The surface temperature must be measured in the connecting area between the gearbox and motor in the parts that are most shielded from ventilation generated by the motor IMPORTANT Perform a test in operating conditions for a sufficient time period to reach thermal equilibrium and measure the temperature reached If the temperature ex
38. s or persons caused by operations carried out which do not fall within routine servicing and have not been agreed with the customer KI If in need of assistance contact the DINAMIC OIL S p A technical sales office 83 OIL REPLACEMENT Replace the lubricating oil according to the schedule set out in the following table or at least every 2 years Average operating duration according to oil type Oil type Operating temperature Do inerte Synthetic oil To make it easier to empty the gearbox it is recommended that oil be changed when the gearbox is warm Internal parts must be washed with a suitable liquid before filling with new oil Oils with different viscosity or different brands of oil should not be mixed In particular synthetic and mineral oils must never be mixed together Once the machine is in operation periodically check lubricant level and top up if necessary Do not release used oil into the environment Collect it and send it to authorised bodies for disposal in accordance with legislative provisions in force Empty the oil when the gearbox is warm but at a temperature not exceeding 40 45 C to prevent the risk 4 k of burns 8 3 1 Oil replacement procedure e Place areceptacle of sufficient size underneath the draining cap e Unscrew the gearbox s loading and draining caps and allow the oil to completely drain e Die inneren Teile des Getriebes mit geeigneten Fl ssigkeiten sp len e Refill the gearbox with oil see poi
39. solved e That the assembly position is the same as the one shown and required on the identification plate e That the oil level is correct see point 7 4 e That there is no leakage of lubricant from the caps or washers e That the vent cap is not obstructed by dirt or paint e That once the gearbox is installed the fastening screws are seated correctly and the preload is as shown in the table see Annex 2 e That appropriate supply systems are used and that they are in good working order e That accessories are correctly fitted The following must be verified and guaranteed before start up The gearbox must not be fitted in an atmosphere at risk of explosion oils acids gases vapours or radiation and dust must not accumulate to a depth of than more than 3 5 mm When in operation the gearbox must be adequately ventilated and there must be no significant heat radiation from outside When in operation the temperature of the cooling air must not exceed 40 C The caps for checking and draining oil and the vent valves must all be freely accessible Any accessories of any type fitted onto the gearbox must be ATEX certified Gearboxes with a hollow shaft with or without an attraction joint must be correctly fitted Arrange for the gearbox to be cleaned once the installation phase is complete Check the effectiveness of all devices made to prevent accidental contact between operators and the rotating units and or the gearbox seal ring
40. ss otherwise provided for by contractual arrangement e Painted externally with a red water based anti oxidising undercoat unless otherwise provided for by contract This protective coating is suitable for normal industrial environments even outdoors and allows further finishing coats of synthetic paint to be applied e The external machined parts of the gearbox such as the outside of the shafts the resting surfaces and centring units as well as the internal kinematic mechanisms require protection with anti oxidising oil 43 2 SAFETY INFORMATION KI Follow the simple instructions given in the relevant parts of the manual to reduce or eliminate risk situations 2 1 GENERAL SAFETY WARNINGS e These safety warnings apply to all types of gearbox gears and other Dinamic Oil S p A products e Safety warnings contained in the other chapters of this manual must also be adhered to e The safety warnings must be adhered to at every stage of the product life cycles described in this manual transport handling packaging storage installation fitting start up operation servicing dismantling disposal e Failure to adhere to the safety warnings can pose serious health risks and harm to objects and animals e fin any doubt about the safety warnings contact the Dinamic Oil technical assistance service e The personnel that this manual is addressed to must have attested experience and be authorised to carry out the operations e While per
41. the direct power mains supply triplet R S T See drawing FIG 12 FIG 12 5 5 2 With hydraulic motor In addition to the regulations concerning the installation of the gearbox it is recommended that you follow the rules below for the installation of the hydraulic motor a Connection to the hydraulic circuit The motors can be connected in either open or closed loop circuits If itis an open loop circuit the solenoid valve or control distributor can be of either a closed or open centre type The branch of the circuit corresponding to the hydraulic motor delivery side or the flanged side of the motor must always have a maximum pressure valve fitted calibrated to a value not exceeding the value piu internal pressure admitted for the hydraulic motor See drawing FIG 13 FIG 13 Open loop circuit Closed loop circuit b Connection to drainage hole For counter pressure gt 15 bar with continuous operation and gt 30 bar with intermittent operation the drain must always be connected unless the the hydraulic motor has reinforced seals for operating without drainage If the motor connected to the F1 and F2 brakes is an OMSU motor the drain is machined into the brake body and must always be connected See drawing FIG 14 64 FIG 14 ORBITAL MOTOR c Hydraulic oil type Mineral hydraulic oil with viscosity level ISO VG 46 46 cSt at 40 C is recommended
42. trical resistance greater than 10 Q Take relevant measures to prevent hazardous dust liquid from accumulating near the seals of the protruding shafts and to protect the machinery If the gearbox motor is installed vertically downwards the electric motor must be equipped with a protective cover The axes between the output shaft and any pulleys or other transmission units must be completely parallel The gearbox must only be installed in the structural form and assembly position specified in the order If the gearbox was originally supplied without lubricant it must be installed as such and only filled with lubricant afterwards Secure the gearbox to a flat vibration damping surface which is sufficiently resistant to torsion Take care not to deform the contact surfaces feet and or assembly flanges by over tightening the screws When fastening gearboxes screws of at least grade 8 8 quality must be used Ensure that no loads are placed on the gearbox greater than those given in the data sheets The vent caps and level check caps for the oil must be freely accessible and readily serviceable Arrange for the gearbox to be cleaned once the installation phase is complete Arrange for the gearbox to be earthed to avoid a build up of static charge 239 5 2 SERIES RE GB GEARBOX DESIGNS n General information unless otherwise indicated on the relevant data sheets 5 2 1 Flanged design SIZES UP TO RE2000 Prepare the coupli
43. ty Class 2109 109 109 109 109 109 109 109 Tightening torque A To prevent abnormal loads on the gearbox bearings if the motor is coupled directly it must be integral to and therefore pendulate with the gearbox 5 3 CONNECTIONS Fasten the input and output mechanisms connecting to the gearbox without striking them with hammers or suchlike Use the service screws and the threaded holes on the shafts for inserting the mechanisms Before fitting the connecting mechanisms remember to clean the shafts to remove any traces of grease and or protective treatments To meet the requirements of areas at risk of explosion between coupled areas with friction hazards and therefore flashing hazards material must be used to avoid this rubber pastes rubber or teflon inserts sealant It is the responsibility of the customer to apply such measures Use a suitable quantity of sealant as Loctite 510 or suchlike for the gearbox input couplings with the motor and the output drivers to the customer s machine This sealant must be compatible with the ATEX installation area to avoid dust and foreign bodies from entering 60 5 4 INPUT CONNECTIONS After verif
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