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HANSEN P4 - Hansen Industrial Transmissions

1. NU Patented US5680793 P0648317 O Hansen ELE IN182162 JP2860164 KR187555 FI TYPE N Prou Tou SF EP GEAR OIL ISO 3448 Ratio m min vG Grease Nipples Q Key to symbols Type specification of the gear unit serial number and code Gear unit production number Nominal power rating kW at high speed shaft of the gear unit Nominal torque rating kNm at low speed shaft of the gear unit SF Service Factor min Input and output speed speeds EP GEAR OIL ISO 3448 Gear oil according to ISO 3448 VG Oil viscosity for a specified ambient temperature range possible Indication of the use of synthetic oil Synthetic Oil Grease Grease lubrication grease quantity indication of grease type Q and brand name refer to the chapters 12 and 13 Nipples Number of grease points nipples Hansen Hansen P4 industrial gearboxes 3 SHIPPING Each gear unit is inspected and approved by the QUALITY CONTROL DEPARTMENT before shipment The in spection is carried out based on the order specification The approval of the gear unit is granted after no load test of several hours in normal operating position and at the speed indicated on the nameplate 3 1 SHIPPING CONDITIONS Unless otherwise specified gear units are shippe
2. A B D E F G H J K L M N P Q R S T Hansen P4 industrial gearboxes 6 6 2 Hollow shaft gear unit with keyway connection Mounting fig 20 Coat mating faces b of the machine shaft with mounting compound Slide the O ring c onto the machine shaft Place supplied mounting key d into keyway of machine shaft with the boss against the shaft face Place the gear unit into position on the machine shaft Make sure that the keyways are correctly positioned Press the gear unit on the shaft using a threaded rod e a nut f and a distance ring g until the mounting key d and the distance ring g make contact Remove the nut f the distance ring g and the mounting key d Ensure that key m fig 2b has sufficient clearance on top Fit the key m into the shaft mounting key Remount the distance ring g and the nut f Draw the gear unit further onto the shaft until the faces h and i make contact Remove the nut f the distance ring g and the threaded rod e Securing fig 2b Mount the distance ring g again on the machine shaft using correct fixation bolts J Install the protection cover k In case of external loads on the shaft please refer to specific instructions the outline drawing Dismounting fig 2c Remove the protection cov
3. Direction of rotation clockwise CW Direction of rotation counter clockwise CCW 11 2 GEAR UNITS EQUIPPED WITH A BACKSTOP The customer has to check the good functioning of the backstop On gear units equipped with a backstop check whether the direction of rotation of the motor corresponds to the backstop freewheeling direction before coupling the motor to the gear unit In case of complete drive groups the direction of rotation of the motor has to be checked by means of a phase meter Rotation of the gear unit in reverse direction even momentarily may damage the backstop and is therefore not allowed 31 Hansen P4 industrial gearboxes 11 3 GEAR UNITS EQUIPPED WITH HEATERS e Gear units equipped with heaters must not be started before the oil temperature is above 5 C 40 F Heaters have to be switched off automatically when the oil temperature is above 15 C 60 F 11 4 GEAR UNITS WITH FORCED FEED LUBRICATION For the different parts of the lubrication system refer to the service manual of the lubrication and cooling equipment and or the technical leaflets concerning the specific components 11 5 GEAR UNIT DRIVEN BY A TWO SPEED MOTOR When switching from the higher to the lower speed first decelerate to below the lower speed so that the motor has to accelerate when switched on at the lower speed In this way high synchronisation peak torques can be avoided
4. Hansen dustrial gearboxes Sumitomo Drive Technologies Always on the Move Hansen industrial gearboxes Hansen Industrial Transmissions nv Leonardo da Vincilaan 1 B 2650 Edegem Belgium T 32 0 3 450 12 11 32 0 3 450 12 20 E info hansenindustrialgearboxes com www hansenindustrialgearboxes com DOC SMM405E 0412 See our worldwide sales amp service network at www hansenindustrialgearboxes com
5. 12 Refer to the MAINTENANCE TABLE on page 6 Read carefully all paragraphs of chapter 12 Read also the v points in the other paragraphs 12 1 INSPECTION AND MAINTENANCE A Rotating parts may cause injuries and damage For inspection and maintenance always de energize the drive and make sure that the gear unit and the drive are externally secured against unintentional switch on or movement 12 2 OIL CHANGE AND REGREASING THE LUBRICATION POINTS 12 2 1 General directives A Handle any lubricant or oil with care and according to the handling and safety instructions to be sup plied by the lubricant supplier on customer s request These instructions have to be handed over to any personnel performing installation maintenance or repair of the gear unit Use clean oil from clean barrels Avoid any penetration of abrasive particles and water The water content should be no higher than 0 0596 derived following titration method accepted by the oil manufacturer To improve the steadiness of the bearing life time it is highly recommended to use oil that has an initial oil cleanliness of 15 12 or better according to ISO 4406 Refer to the oil supplier to obtain this oil quality It is recommended to change the oil before summertime hence running with fresh oil in the most critical period when thermal load is higher If the gear unit is provided with a heater disconnect the heater from the electric sup
6. Draw the gear unit onto the shaft of the machine using threaded rod e nut f and distance ring g until faces h and i make contact Fit shrink disc s A locating groove on the shaft indicates the position of the shrink disc Tighten bolts ZS with a torque wrench The required tightening torque for the two part shrink disc is indicated in table 1 and on the name plate p Tightening bolts are prestressed to the right level when outer ring o and inner ring n are flush optical check Tighten bolts ZS in indicated sequence 9 one by one progressively over several rounds until required tightening torque TA is reached Do not tighten bolts crosswise Mount protection hood Q NOTE Never tighten bolts when shrink disc is unmounted TE eZ 7 lt h um i MOUNTING FIG la a T DISMOUNTING 21 22 QHansen Hansen P4 industrial gearboxes Securing in case of axial load If the axial load is not absorbed by the shoulder of the machine shaft a distance ring g must be included see fig 2b page 23 Dismounting fig 1b Loosen all tightening bolts ZS fig 1c uniformly one by one in a continuous sequence about a quarter of a turn per round Should outer and inner ring of the shrink disc not release themselves one can remove some tightening bolts and install them in tapped
7. prevents metal to metal contact in gears and bearings reduces friction losses dissipates the generated heat from gears and bearings prevents corrosion Different lubrication systems can be used depending on gear velocity gear unit mounting position operating conditions Hansen Industrial Gearboxes use one of following systems splash lubrication forced feed lubrication circulation lubrication pressure lubrication These systems can be completed with auxiliary cooling in different forms see chapter 9 COOLING 25 Hansen Hansen P4 industrial gearboxes 7 1 SPLASH LUBRICATION Splash lubrication is standard for horizontal shaft gear units with one two and three stages and for speeds between 750 min 1 and 1800 min at the high speed shaft Splash lubrication is standard for horizontal shaft gear units with four stages and for speeds between 1000 min and 1800 min at the high speed shaft All gears and output shaft bearings are lubricated by immersion in the oil bath Oil splash from gears fill oil pockets in the housing assuring gravity circulation lubrication of the bearings via channels in housing and covers For other speeds at the high speed shaft refer to Hansen Industrial Transmissions nv 7 2 FORCED FEED LUBRICATION All rotating elements above oil bath level are lubricated by a gear pump forcing the oil through pressure lines Pumps can be either of the integral type driven by one of the gear u
8. and lifting eye nuts with bolts or integral rods vertical mount For equal load sharing make use of all available lifting points 4 lifting points fixed to the gear unit and use ad e equate tools Never use the lifting eye bolts of components mounted to the gear unit eg motor coupling brake lubrication system etc AMS use of attached lifting eye nuts or mount the appropriate eye nuts with bolt to the lifting points of the housing Eye nuts with bolt must be fixed and secured before lifting the gear unit Never lift units with slings wrapped around the shafts or motor lantern 5 1 LIFTING EYE NUTS WITH BOLTS ATTACHED TO THE GEAR UNIT Max force on the eye nut kN M16 Horizontal mount Single stage gear units type QHP 1 Use only the integral lifting eye and appropriate lifting eye nuts with bolts in housing feet Bolt size Low speed shaft side Grade 8 8 High speed shaft side Use only the integral lifting eye Multi stage gear units type QH Use only integral oval lifting eyes Vertical mount Two stage gear units type QV 2 Bolt size Low speed shaft side Use only the Grade 8 8 High speed shaft side integral rods Three and four stage gear units type QV 3 and QV 4 Bolt size Low speed shaft side Grade 8 8 High speed shaft side QHansen Hansen P4 industrial gearboxes For gear units type QV sizes J up to T Use only the integral
9. safety and control instruments are connected and are functioning the operating and control instruments the tubes and the flexible pipes are protected against harmful external influences the direction of rotation for the gear unit shafts and motor shaft are correct if the gear unit has a backstop Refer to the dimensional drawing and paragraph 11 2 Gear units equipped with a backstop 2 1 2 5 Temperature and heat Temperature The temperature of the gear unit and the lubricants can be high Before approaching the gear unit or carrying out activities it is strongly recommended to check that the temperature of the gear unit is equal to the ambient temperature If this safety directive cannot be followed approaching the gear unit is only allowed if the temperature is lower than the value necessary to cause burns In addition the personnel must wear heat resistent clothing and gloves Suitable equipment will be necessary to protect the face and the eyes against possible oil splash Hansen Hansen P4 industrial gearboxes Q Heat The gear unit produces heat due to losses Sufficient space must be provided around the gear unit allowing the gear unit and the cooling system to exchange heat with the environment The gear unit as well as the cooling system must remain clean to assure the heat transfer with the environment An inadequate heat transfer leads to high temperatures and damaging of the gear unit parts It migh
10. 1 2 7 Electricity Before starting maintenance activities on the gear unit it is necessary to disconnect the drive from the electric grid The electric switch must be locked so that electric supply to the drive is impossible Earthing the gear unit as an independent element is highly recommended The gear unit must never be part of an earthing circuit of other electric machines Leaks of electric current can damage the gears and the bearings of the gear unit compromising the reliability and the good performance of the gear unit 2 1 2 8 Noice and vibrations The drive group and its components cause vibrations and noise As limited as its emissions may be it might be necessary in conformity to the national or local directives to use envelopes separating walls and vibration shock absorbers to reduce the emission values of noise and vibration to a level lower than the values mentioned in the directives If the above mentioned directives can not be fulfilled all personnel working nearby the drive groups must get the necessary protective equipment and use it to reduce the noise and vibration nuisance to an acceptable level 2 1 2 9 The gear unit or drive as component of a machine The gear unit or the drive is a machine component Always refer to the service manual of the machine to follow the safety and installation instructions which belong to the machine Q 2 1 2 10 Maintenance Lighting Before starting maintenance activitie
11. an oil analysis performed by a laboratory acknowledged by the oil brand name owner after every 4000 hours of service in order to determine the expected lifetime of the oil Oil sump temperature must never be higher than 95 C 200 F since oil then will degenerate very fast A representative oil sample should be taken directly out of the oil sump Drain a certain amount of oil recommended oil volume 2 litres before taking the oil sample Make sure to use only appropriate and clean sample bottles For the characteristics the chemical properties and the grade of cleanliness of the sample bottle refer to the laboratory acknowledged by the oil brand name owner Be careful while draining the hot oil Use an appropriate hot oil recipient heat resistent clothing and gloves to avoid burns Before start up check the oil level with the dipstick and add oil when required 12 4 CLEAN THE HEATER If the gear unit is provided with a heater it is recommended to clean regularly at every oil change the heater and to eliminate the deposition in order to improve the life span of the heater 12 5 OIL LOCK OIL GUARD as an option Oil Lock The high speed shaft is equipped as standard with an OIL LOCK system For the Hansen P4 single stage gear units also the low speed shaft is equipped with an OIL LOCK system This oil seal is wear resistant and maintenance free due to its centrifugal operating principle The dual purpose labyrinth s
12. gt lubrication is unsatisfactory with very low starting temperature Viscosity too low very fluid oil gt too thin oil film bearing damage and pitting or scuffing on gears Use clean oil and fill oil trough prefiltered unit avoid abrasive particles and water Abrasive wear of bearings and gears due to foreign particles in oil Correct tightening of fixation bolts Retorque after 50 to 100 hours of first operation Loosening of bolts and displacement of the gear unit gt misalignment gt Correct functioning of control equipment No alarm in case of malfunctioning Damage to bearings and gears Install and connect correctly lubrication group and control switches No lubrication gt damage to gears and bearings Check the direction of rotation of the low speed shaft built in backstop refer to the dimensional drawing during normal operation Wrong direction of rotation gt damage to the backstop and other parts Take care of Possible damage if neglected First oil change after 100 hours max 800 hours to take out small wear particles due to running in Premature damage to gears and bearings Final impact long term effect Regular oil change when oil has lost its lubrication capacity If oil has lost its capacities anti scuffing and anti corrosion are unsatisfactory gt damage to gears and bearings e Avoid entering of sand water cement Dam
13. holes r fig 1c in the inner ring to trigger separation of both rings Remove shrink disc from hollow shaft Mount the distance ring g on the hollow shaft by means of bolts ZY dimensions of ZY see dimensional drawing Place the disassembly bolt I into the central hole in the distance ring g Remove the gear unit from the shaft by tightening the disassembly bolt I Note The parts e f g l and ZY are not included as standard They can be supplied upon special request For technical data refer to catalogue or certified drawing Cleaning and greasing Dismounted shrink discs do not have to be taken apart for cleaning and regreasing prior to reinstallation unless they have been used in a very dirty environment After cleaning recoat the tapered surfaces using a solid lubricant with a friction coefficient of 0 04 e g Molykote D321R or similar Table 1 tightening torque TA Nm for bolts ZS of the two part shrink disc St we Ringfeder Ringspann Tas Sch fer two part two part two part two part shrink disc shrink disc shrink disc shrink disc Gear unit H I T size part number 113 H11082Q 113 H12582Q 113 H14082Q 113 H16581Q 113 H18581Q 113 H22082Q The required 113 H24082Q tightening 113 H26082Q torque is 113 H28082Q ju 8 113 H32082Q anai and 113 H34081Q outer ring o 113 H36082Q are flush see 113 H39081Q fig 1c 113 H42082Q 113 H44082Q 113 H48082Q 113 H50081Q 113 H53081Q
14. motor and V belt drive tension has been factory set Tension should be rechecked after 24 hours of operations Chain transmissions must be mounted without preliminary tension In case a pinion is mounted on the shaft extension of the gear unit care should be taken to have normal required backlash between pinion and gear and good contact pattern must be assured 6 4 ERECTION 6 4 1 Levelling Always mount gear unit in the position for which it was ordered Before altering this mounting position of the gear unit please consult Hansen Industrial Transmissions nv It may be necessary to adapt the lubrication system 6 4 2 Alignment Align the gear unit as accurately as possible Install the gear unit horizontal taking into account a max inclination equal to 5 mm per 1 m 5 32 inch per 3 feet or 5 mrad or 17 arc minutes or a max indicated on the outline drawing for positions other than horizontal Use three fixation points of the gear unit for alignment Adjust the other fixation points by shimming to 0 1mm 0 004 inch 6 4 2 1 Connection gear unit machine allowable misalignment at the low speed shaft except for single stage gear units The misalignment must be minimized to improve the steadiness of bearing and coupling life span Ensure that the alignment remain unchanged at all operating conditions The unavoidable misalignments may not exceed the values mentioned in the service manual of the coupling unless otherwise stated o
15. onto the shaft Never mount components by hammering as this may cause damage to the bearings Never use rigid couplings except on free end machine shafts e g mixers aerators or in executions with a torque arm 6 2 COUPLINGS MOUNTED ON THE SHAFT ENDS OF THE GEAR UNIT CORROSION PROTECTION The coupling hubs are mounted on the shaft ends so that the front surfaces are flush or the front surface of the shaft end remains for a minimum length within the bore of the coupling hub If necessary a spacer between shaft shoulder and coupling hub is mounted Where applicable the coupling hub is secured on the shaft end with thrust washer and fixation bolt Refer to the certified drawing The assembly of coupling hub spacer thrust washer and fixation bolt must be corrosion resistant in accordance with the application and the atmospheric corrosion class referring to ISO 12944 determined and mentioned by the customer For the cases where coupling hub spacer thrust washer and fixation bolt are supplied and mounted by Hansen Industrial Transmissions nv all measures are taken to get a corrosion resistant assembly in accordance with the application and the atmospheric corrosion class ISO 12944 as mentioned in the Order Acknowledgement If the coupling hub spacer thrust washer and fixation bolt are provided and mounted by the customer he ensures that the assembly will be corrosion resistant in accordance with the selected atmospheric co
16. prevent pressure build up the gear unit is provided with a breather which is integrated in the dipstick or with a separate breather normal anti dust or anti humidity breather Take care and check regularly that this breather does not become clogged 9 COOLING Heat generated in the gear unit due to friction and churning of the oil must be dissipated through the housing in to the environment It is important not to decrease the heath dissipation capacity of the housing v Regularly clean the surface of the housing The temperature of the oilbath will rise with increased load Continuous operating temperature of 80 to 85 C 175 to 185 F is allowable for a standard gear unit filled with mineral oil Occasional operating temperatures of up to 95 C 200 F are acceptable 9 1 ADDITIONAL AIR COOLING 9 1 1 Fans One or two fans may be mounted on gear unit shafts famine Do not run the gear unit without appropriate protection covers v Check regularly that the air inlet and the air outlet are not obstructed Fans need no special maintenance except occasional cleaning 29 Hansen Hansen P4 industrial gearboxes 9 1 2 Oil to air coolers The service manual of the lubrication and cooling system gives detailed information about the oil to air cooler 9 2 ADDITIONAL WATER COOLING All water cooling systems must be connected to a non calcareous water supply See also the service manual on lubrication and cooling system and or tech
17. rods Note For handling of gear units equipped with a lubrication system caution is necessary Particular circumstances might dictate the temporary removal of thermostat s pressure gauge s and or part of the oil feed piping After removal of the latter elements one should take special care to avoid ingress of moisture etc into the lubrication system of subject gear unit s 5 2 DIRECTION OF LIFTING FORCE FOR EYE NUTS WITH BOLTS Lifting eye nuts with bolts must be fully engaged before lifting If the condition for direction of lifting force for eye bolts cannot be satisfied bow anchor shackles rotating eye bolts or movable eye bolts can be applied Refer to your supplier for the appropriate selection of lifting tools Functioning and security conditions of the selected lifting tools must always be satisfied 5 3 LIFTING OF THE GEAR UNIT PROVIDED WITH FOUR LIFTING POINTS Hansen P4 industrial gearboxes The gear unit can only be lifted with lifting cables or lifting chains fixed to the mounted lifting eye bolts or integral rods The weight of the gear unit or drive and other instructions are mentioned on the dimensional drawing Always r
18. spacer length of 100 mm or 1 inch 6 4 2 3 Alignment when mounting flexible gear couplings When flexible gear couplings are mounted the minimum allowable misalignment for the coupling may differ from the values listed in the table of permissible misalignment see above Refer to Hansen Industrial Transmissions nv to get the appropriate alignment instructions and service manual of the gear coupling Hansen Hansen P4 industrial gearboxes 6 5 SECURING OF SOLID SHAFT GEAR UNITS The gear unit must be mounted onto a rigid and stable bedplate or foundation in order to avoid vibrations and possible overload of the housing fixation pads Use the fixation holes indicated on the dimensional drawing After correct alignment and shimming of all the points fix the gear unit solidly onto its foundation with the appropriate size steel bolts grade 8 8 according to DIN 267 or SAE grade 5 for steel bolts 1 1 2 and smaller ASTM A 354 grade BC for steel bolts larger than 1 1 2 and grade 80 according to DIN 267 for stainless steel bolts Dimensions and tightening torques see tables Note for some horizontal executions with parallel shaft and fans the protection hood of the fan must be removed to enable tightening of the bolts Remount the protection hood afterwards 6 5 1 Tightening torques for steel bolts grade 8 8 Horizontal mount Single stage gear units type QHP 1 emm Bolt size Grade 8 8 M24 M24 M30 M30 Tightening
19. the drive against unintentional movement STANDARD BACKSTOP INTEGRATED IN THE GEAR UNIT These backstops are lubricated by the oil bath of the gear unit and require apart from the regular inspections indicated above no further maintenance Alteration of the direction of rotation of a backstop may only be carried out by qualified personnel authorized by Hansen Industrial Transmissions nv 11 START UP Q 11 1 ALL GEAR UNITS Check the internal components of the gear unit for corrosion before starting up the gear unit Repeat this check after each extended period of standstill refer to section 12 6 The result of this inspection must be documented and made available on request Any evidence of corrosion on internal components of the gear unit must be reported to Hansen Industrial Transmissions nv Before start up check the oil level with the dipstick and make sure that all grease lubricating points are filled Although all greasing points have been greased before delivery it is advisable to give a few shots with a grease gun before start up Check all fixation points between gear unit and foundation They may require retightening after some running time Make sure that protection hoods and air guiding plates if any are properly fitted Gear units can rotate in both directions except when direction of rotation is indicated Always refer to the stickers on the gear unit and to the certified drawing m
20. the right is reserved to supply products which may differ slightly from those illustrated and described in this publication Please contact Hansen Industrial Transmissions nv for information on any aspects of storage installation operating lubrication and maintenance that need clarifying Hansen industrial gearboxes QUICK REFERENCE PRECAUTIONS TO TAKE upon reception and during storage Hansen P4 Take care of Possible damage if neglected Damaged packaging Unpackaged Check the protection of machined surfaces and shaft ends Provide the entire drive group with an adequate protection for the planned storage period Corrosion of machined surfaces and shaft ends Corrosion of gear unit parts and components Damage to shafts gears and bearings Store the gear unit in his original packing Long term storage see chapter 4 Corrosion of gear unit parts and components Condensation not possible in the repository Corrosion of gear unit parts and components Don t store the gear unit near vibrating machines during installation Damage to gears and bearings Take care of Possible damage if neglected Alignment of Gear unit gt Motor Gear unit gt Machine shaft Overload on high speed shaft amp low speed shaft couplings bearings and shafts Vibrations damage to shafts gears bearings and couplings Balancing of couplings Vibration
21. torque Nm 675 675 1350 1350 Bolt size Grade 5 7 8 1 1 1 8 1 1 4 Tightening torque Ibf in 2950 4850 6000 10300 12000 Multi stage gear units type QH em A Te Te e S T Bolt size M20 M24 N24 M30 M36 M42 M56 Grade 8 8 Na 335 675 675 1350 2350 3800 5700 9150 Bolt size Grade 5 Grade BC UNC 5 8 3 4 7 8 11 4 11 2 13 4 2 2 1 4 Tightening torque Ibf in 1550 2950 4850 6000 12000 21000 33650 50750 81050 Vertical mount Multi stage gear units type QV C Bolt size M20 M24 M30 M30 M36 M42 M48 M56 Grade 8 8 Tightening torque 335 675 1350 1350 2350 3800 5700 9150 Bolt size u u u u u u u u es de 1 netur 1 3 4 2 2 1 4 Tighfenimgdorqus IBE 2950 6000 10300112000 21000 33650 50750 81050 1 size G 2 stage unit 2 size G 3 and 4 stage unit 19 QHansen Hansen P4 industrial gearboxes 6 5 2 Tightening torques for stainless steel bolts grade 80 Horizontal mount Single stage gear units type QHP 1 Bolt size Grade 80 M24 M24 M30 M30 Tightening torque Nm Upon request Bolt size Grade 5 MN 1 94 Tightening torque Ibf in Upon request Multi stage gear units type QH Gear unit size Bolt size Grade 80 Tightening torque Nm 185 Bolt size Grade 5 Grade BC UNC 5 8 Tight
22. 405 Ef HANSEN P4 Standardized gear units Service manual SHIPPED A WITHOUT OIL Carefully read this manual before installing the gear unit Sumitomo Drive Technologies Q Hansen Always on the Move industrial gearboxes Hansen industrial gearboxes A DANGER e WARNING v MAINTENANCE CONTENTS QUICK REFERENCE MAINTENANCE TABLE SCOPE GENERAL SHIPPING STORAGE HANDLING INSTALLATION LUBRICATION VENTILATION COOLING BACKSTOPS START UP MAINTENANCE GREASE QUANTITIES Grease quantity for bearings WN m WN Grease quantity for labyrinth seal 14 LUBRICANTS Mineral oils and greases Polyalpha olefine based synthetic oils and suitable grease WORLDWIDE TRANSMISSION SERVICE See 12 13 14 16 16 25 25 29 29 29 30 30 31 31 32 32 34 35 36 37 38 39 Hansen P4 Hansen Industrial Transmissions nv Leonardo da Vincilaan 1 BE 2650 Edegem Belgium Tel 32 3 450 1211 Fax 323 450 12 20 E mail info hansenindustrialgearboxes com www hansenindustrialgearboxes com Hansen Industrial Gearboxes Services Leonardo da Vincilaan 1 BE 2650 Edegem Belgium Tel 32 0 3 450 12 34 Fax 32 0 3 450 15 99 E mail services hansenindustrialgearboxes com Every care has been taken to ensure the accuracy of the information contained in this publication but due to a policy of continuous development and im provement
23. N gear unit with solid low speed shaft D K gear unit with hollow low speed shaft ZT On high speed shaft Single stage gear units Gear unit Type Multi stage gear units 55 Gear unit QHP QHR QVP Size QHP 2 QHP 3 QHR 2 QHR 3 QHR 4 QVP 2 QVP 3 QVR 2 10 10 10 10 10 10 20 20 20 20 20 Hansen P4 37 38 Hansen P4 industrial gearboxes 14 LUBRICANTS 14 1 MINERAL OILS AND GREASES For Hansen P4 standardized gear units Unless indicated otherwise on the gear unit s name plate the oils and lubricants must be selected from the tables below containing oils and greases recommended by the respective brand name owners The required viscosity grade of the oil is mentio ned on the name plate If nothing is mentioned on the gear unit s name plate only mineral oils and greases have to be used ISO VG150 1 4 EP 90 11 9 690 Energol GR XP 150 Formulation LO4021PBA Alpha SP 150 Formulation LO2045PBA Renolin CLP 150 Formulation 3110247 mm 2 s 40 C AGMA cSt 50 C E 50 C SUS 100 F Bearing grease Graisse pour roulement W lzlagerfett Lagervet 2 Energrease LS EP 2 Energrease LS EP 3 2 Renolit FEP 3 Renolit FEP2 2 Centoplex 2EP 2 Energol GR XP 220 For mulation LO4022PBA Alpha SP 220 Fo
24. TION The inner parts of the gear units are sprayed with rust preventing mineral oil The breather plug standard dust proof anti humidity is neither removed nor sealed The shaft extensions are protected with a rust preventing grease The hollow shafts and all unpainted machined surfaces are coated with an anti oxidizing waxy varnish This standard system offers corrosion protection during transport and or short term storage for up to one year in doors 4 STORAGE Always store gear units in their original packaging Gear units should not be stored near vibrating machines in order to avoid damage to bearings The changes in relative air humidity and in temperature must be such that no condensation can occur in the storage room 4 1 SHORT TERM STORAGE INDOORS A standard preservation of the internal parts of the gear unit is provided for storage up to one year indoors in a dry ventilated and sheltered area The sheltered area must be protected against environmental influences Let the applied means of protection intact Hansen Hansen P4 industrial gearboxes 4 2 LONG TERM STORAGE Upon request the Hansen Industrial gearboxes can be treated in the factory for a protection up to five years after delivery ex works and with storage in a dry ventilated and sheltered area a protection up to two years after delivery ex works and for storage outdoors INDOORS Up to five years indoors in a dry ventilated and sheltered are
25. a The sheltered area must be protected against environmental influences The gear unit has to be hermetically sealed The gear unit has to be packed in a hermetically sealed envelope In case the units are stored for a period up to 5 years in a dry ventilated sheltered area the units have to be re filled every two years with the small amount of mineral oil containing a volatile corrosion protective additive always read the information on the sticker on the gear unit Consult your oil supplier about life time compatibility with the actual oil and about the volume concentration The corrosion protection of the shaft extensions has to be checked and possibly corrected At these occasions the high speed shaft must be turned until the low speed shaft has made 2 complete revolutions The duration of the operation is limited to a strict minimum The gear unit must be hermetically resealed immediately OUTDOORS Up to 2 years outdoors in a hermetically sealed envelope and enclosed in a seaworthy packing case Leave the hermetically sealed envelope and the seaworthy packing case intact during the storage period of maximum 2 years starting from the date of delivery ex works Hansen Industrial Transmissions This warranty expires if the package is damaged or opened NOTES The gear unit will be mounted started up and in operation before the end of the specified storage period All gear units treated and packed for long term storage have the following s
26. age to gears and bearings Check breather Obstructed breather gt leakages gt too low oil level gt damage to bearings and gears Note This quick reference for handling the gear unit is not exhaustive The obligation to read the complete service manual remains Hansen P4 industrial gearboxes MAINTENANCE ISSUES Refer to chapter 12 Maintenance v Maintenance table Periodical inspections as stated below will increase the reliability and lifetime After first rum Monthly 6 Monthly Fixation of the gear unit Corrosion 1 Alignment Oil leaks Lubrication Cleanliness Abnormal noise and vibrations Oil level Oil sample analysis Greasing Check the proper functioning of the Or biennial backstop Couplings elastic elements Refer to the appropriate service manual 1 Check the internal components of the gear unit for corrosion before start up Repeat this check after each extended period of standstill refer to section 12 6 The result of this inspection must be documented and made available on request Any evidence of corrosion on internal components of the gear unit must be reported to Hansen Industrial Transmissions nv Note This quick reference for handling the gear unit is not exhaustive The obligation to read the complete service manual remains Hansen Hansen P4 indust
27. and or components of the old oil that could be present in the gear unit Any oil and lubricant shall be handled with care and according to the handling and safety instructions to be supplied by the lubricant supplier on customer s request These instructions have to be handed over to any personnel performing installation maintenance or repair of the gear unit 39 Hansen dustrial gearboxes Hansen dustrial gearboxes Hansen dustrial gearboxes
28. as to consult the oil supplier regarding the compatibility of the two oils and the measures that possibly should be taken for reliable operation of the gear unit with the new oil and the possible residues and or components of the old oil that could be present in the gear unit Any oil and lubricant shall be handled with care and according to the handling and safety instructions to be supplied by the lubricant supplier on customer s request These instructions have to be handed over to any personnel performing installation maintenance or repair of the gear unit Hansen industrial gearboxes 14 LUBRICANTS Hansen P4 14 2 POLYALPHA OLEFINE BASED SYNTHETIC OILS AND SUITABLE GREASE For Hansen P4 standardized gear units Unless indicated otherwise on the gear unit s name plate the oils and lubricants must be selected from the tables below containing oils and greases recommended by the respective brand name owners The required viscosity grade of the oil is mentioned on the name plate If nothing is mentioned on the gear unit s name plate only mineral oils and greases have to be used Synthetic oils may be used only after written authorisation from the Engineering Department of Hansen Industrial Transmissions nv mm2 s 40 C ISO VG150 1 AGMA 4 EP cSt 50 C 90 E 50 C 11 9 SUS 100 F BP 690 Enersyn EP XF 150 Formulation L04025PBA Enersyn EP XF 220 Formulation 104026 Ener
29. certified drawings Non compliance with these instructions injudicious choice of lubricant or a lack of maintenance will render warranty agreement invalid This warranty clause applies to all parts of the gear unit with the exception of these parts which are subject to wear Q 2 1 2 Security Before starting activities it is essential to consult and study attentively the certified drawing of the gear unit The certified drawing contains the information which makes it possible to work in safe conditions and to avoid risks damage and injury 2 1 2 1 Application It is not allowed to use the gear unit for other applications or in other operating conditions than those for which it was ordered The application the operating conditions and the conditions of use are described in the Order Acknowledgement In the absence of information or in case of doubt refer to Hansen Industrial Transmissions nv 2 1 2 2 Storage and packing Read carefully the chapters Shipping and Storage to follow up the necessary instructions To protect the gear units from corrosion they are treated with anti corrosive products It is strongly recommended to carry out the unpacking and the inspection in a roomy dry and aired workshop QHansen Hansen P4 industrial gearboxes 2 1 2 3 Handling The Hansen P4 gear units are easy to handle Use the suitable lifting equipment Use the appropriate lifting points at the gear unit housing integral oval lif
30. d in unpacked condition and depending on necessity fixed on wooden pallets with open crating protection Sometimes parts such as spare filter elements are separately packed In such case the end user must take care of the assembly The Hansen P4 gear unit is shipped without oil All grease lubrication points are factory filled In case the gear unit after arrival of the shipment from Hansen Industrial Transmissions nv H I T has to be transported further H I T advises to avoid transport by train If the gear units are nevertheless to be transported by train anyhow then the necessary precautions must be taken by the forwarder to avoid false Brinelling damage on gears and bearings 3 2 PAINTING Unless otherwise specified the standard external paint for Hansen Industrial gearboxes is an epoxy primer with high solids content corresponding to the German Standard RAL 5021 water blue The paint system is designed for gear units installed indoors only and not exposed to humidity or aggressive chemicals The painting system is suitable to be applied in the atmospheric corrosivity category C1 according to ISO 12944 2 Durability range according to ISO 12944 1 at least L 2 to 5 years The durability range is NOT a guarantee time Durability is a technical consideration that can help the owner set up a maintenance programme Overcoating is possible with most paints based on alkyd epoxy or polyurethane resins 3 3 PRESERVA
31. ducts of combustion can be generated in a fire involving Viton Personnel fighting such a fire must wear facemasks and a self contained breathing apparatus All unprotected personnel must leave the area immediately Anyone exposed to fumes from the fire should be moved to fresh air at once and treated by a physician Anyone handling residues of Viton polymer or parts of Viton that have been involved in a fire must wear Neoprene gloves to avoid skin contact with these possibly highly corrosive residues which likely include hydrogen fluoride Polyvinylchloride PVC gloves may be used if the temperature of the residue is below the melting point of the gloves Such residues should be decontaminated by washing in lime water calcium hydroxide solution and disposed of in the same manner as Viton polymer To dispose of Viton landfill is preferred The disposal method must be conform to national state and local regulations Burning of Viton is not recommended unless conducted by an approved licensed incineration process In this case the gaseous products should be treated by alkaline scrubbing The gloves must be discarded after use Combustion products of Vulcanizates of Viton Carbon Monoxide CO Fluoroform CHF3 Carbon Dioxide CO Vinilidene Fluoride H2CCF Hydrogen Fluoride HF Hexafluoropropylene C3F6 Carbonyl Fluoride COF3 Low molecular weight fluocarbon fragments QHansen Hansen P4 industrial gearboxes 2
32. eal also prevents the entrance of dirt and moisture Disassembly of the OIL LOCK seal should only be carried out by qualified personnel 33 34 Hansen Hansen P4 industrial gearboxes Oil Guard an option The high speed shaft may be equipped as option with an OIL GUAR system During operation even in submerged conditions the OIL GUARD system ensures leak free running conditions Disassembly of the OIL GUARD system should only be carried out by qualified personnel 12 6 EXTENDED PERIODS OF STANDSTILL When gear units are at standstill for an extended period the protective oil film containing anti corrosion additives gradually disappears and the unprotected internal parts become subject to corrosion Adverse ambient condi tions such as humid marine tropical and chemically aggressive environments will accelerate the process A periodic visual inspection through the inspection cover is required Corrosion of the internals can be avoided by running the gear unit for a few minutes every two weeks depending on the ambient conditions thus allowing the formation of a new oil film Install a special breather marked with the label shown below to prevent moisture from entering the gear unit Py 4 le ie vee NT EE If it is not possible to run the gear unit regularly and the risk for corrosion is imminent d
33. efer to the dimensional drawing before starting handling and transport activities The length of lifting cables or lifting chains must be chosen in such way that the angle between lifting cables or lifting chains is smaller than 45 If the gear unit is part of a drive package the lifting points of the gear unit may not be used to lift the complete drive package Refer to the dimensional drawing of the drive package to determine and use the appropriate lifting points Note Proceed with caution for handling of gear units equipped with external components Pay attention that the external components will not be damaged when handling or transporting the gear unit 6 INSTALLATION 6 1 FITTING OF ACCESSORIES The metric shaft extensions are equipped with keyways according to DIN 6885 Blatt 1 Form 1 Threaded centre holes in these shafts are according to DIN 332 Teil 2 Form D Couplings should be mounted on the shafts with fit according to specifications Refer to the certified drawing of the gear unit and the dimensional drawing of the coupling In case of doubt please refer to Hansen Industrial Transmissions nv Remove the protection from the shaft extensions and check the key fit and the keyway height in the component to be mounted onto the shaft Heating the component to 80 100 C 175 210 F will be helpful in case of interference fit The threaded centre hole in the shaft may be used to assist in mounting the components
34. ening torque Ibf in 1650 Upon request Vertical mount Multi stage gear units type QV GORE M42 M48 M56 Bolt size Grade 80 ISO M16 M20 M24 M30 M30 M36 Tightening torque Nm 185 Bolt size Grade 5 Grade BC UNE USES Tightening torque Ibf in 1650 1 size G 2 stage unit 2 size G 3 and 4 stage unit 340 Upon request 3 4 1 1 4 1 1 2 3 4 3000 Upon request The alignment of the complete drive packages mounted on a bedplate has been carefully checked before shipment It is nevertheless required to check that the bedplate has not been deformed during transport or installation Therefore check again alignment of couplings or other elements after final installation 20 Hansen P4 industrial gearboxes 6 6 SECURING OF HOLLOW SHAFT GEAR UNITS 6 6 1 Hollow shaft gear unit with shrink disc connection The Hansen Industrial Transmissions nv supplied shrink disc is ready to be installed Do not dismantle shrink disc prior to first mounting The two part shrink disc is used as standard fig 1c Another execution is available on request Always refer to the dimensional drawing and the appropriate service manual of the shrink disc Mounting fig 1a Clean and degrease contact surfaces a and b e Smear surface b and not surface a with Molykote D321R or similar After the applied coating has hardened slide the O ring c onto the shaft
35. er k and the fixation bolts J fig 2b Mount the distance ring g on the hollow shaft by means of bolts ZY dimensions of ZY see dimensional drawing Place the disassembly bolt I into the central hole in the distance ring 9 Remove the gear unit from the shaft by tightening the disassembly bolt I Note The parts e f and ZY are not included as standard but can be supplied upon special request For technical data refer to catalogue or certified drawing FIG 2a FIG 2b SECURING FIG 2 1 B ENS NE DISMOUNTING 23 QHansen Hansen P4 industrial gearboxes 6 6 3 Mounting of the torque arm After fitting and securing the gear unit to the driven shaft see par 6 6 1 or 6 6 2 fix unit by means of the optionally supplied torque arm to a fixed torque reaction point Refer to the certified drawing or catalogue for torque arm location on gear unit The connection between torque arm and reaction point must remain flexible and resilient This is achieved by preloading the disc springs of the torque arm The preload of the disc springs A will be adjusted as follows Determine the spacing S fig this is the spacing of the disk springs in unloaded and unmounted condition Screw the inner nut until spacing S1 spacing between gear unit and fixed point is reached
36. er changing the oil replace the filter cartridge of the lubrication system of the gear unit if present Filter if present Replace the filter cartridge after every 800 hours of operation unless the filter has a contamination indicator Before replacing the filter cartridge run the gear unit a while after regreasing if this applies Grease lubrication if lubrication points are present Bearings regrease all lubrication points after every 800 hours of operation Labyrinth seals regrease all lubrication points after every 3000 hours of operation The lubrication interval should eventually be reduced depending on the application and the working conditions In any case the outer grease chamber may never be dry For longer lubrication intervals consult Hansen Industrial Transmissions nv See paragraph 7 6 page 29 for the greases to be used Grease quantity for bearings see page 35 Grease quantity for labyrinth seal see page 37 Subsequent oil changes After 4000 to 8000 hours or max 18 months of operation depending on working conditions First regrease the lubrication points if present while the gear unit is warm Change the oil Use clean oil from clean barrels Avoid any penetration of abrasive particles and water Replace the filter cartridge if present 12 3 OIL SAMPLE When the oil sump temperature is frequently 80 to 95 C 175 to 200 F or in the event of a dusty or humid atmosphere it is recommended to have
37. gear unit Figures see page 36 Bearings without grease nipple are oil lubricated Type Q1 Type Q2 Type Q3 Type Q4 Type Q5 Gear unit size Fig 7 Fig 7 Fig 7 Fig 8 Fig 9 BI B1 B1 B1 B2 B1 B2 10 20 10 20 20 20 20 20 nm ONW PN Type Q6 Type Q7 Type Q8 Type Q9 Gear unit size Fig 7 Fig 7 Fig 7 Fig 10 B1 B1 B1 B1 B2 B3 B4 B5 ol ZIE TA EO nm ONW PN 35 Hansen Hansen P4 FIG 8 FIG 9 Hansen industrial gearboxes Grease quantity in g for labyrinth seal by regreasing Greases NLGI Grade 2 recommended by the oil suppliers see page 38 Sticker on the gear unit On low speed shaft Single stage gear units Gear unit Type QHRC1Z N 75 Gear unit Type Gear unit Type QHRD1Z N 75 QHRF1Z N 45 25 35 Multi stage gear units Gear unit D K Size g QVRZ2 10 QVPZ1 10 19 10 15 Gear unit Type 50 QVRZ2L 30 QVRA2 70 QVRA2L 40 QVRB2 50 QVRB2L
38. ial Transmissions nv Original parts of Hansen Industrial Transmissions nv should be used to replace the existing parts Hansen industrial gearboxes Hansen P4 After installation and before starting up the gear unit it is necessary to check that the rotating external parts are provided with adequate protections the gear unit is lubricated the lubricating system the measuring safety and control instruments are connected and are functioning properly the operating and control instruments the tubes and the flexible pipes are protected against the harmful external influences the direction of rotation for the gear unit shafts and motor shaft are correct if the gear unit has a backstop Refer to the dimensional drawing and paragraph 11 2 Gear units equipped with a backstop 2 2 GENERAL SPECIFICATIONS For general specifications such as dimensions weight connecting diagrams refer to the certified drawing of the gear unit and or to the Hansen P4 standardized gear unit catalogues 2 3 IDENTIFICATION Inquiries concerning a gear unit should always specify the unit s complete type code and manufacturing number which can be found on the nameplate This information is essential to identify the unit supplied by Hansen Industrial Transmissions nv The nameplate which is fitted on each gear unit also contains information about ratings and or torque speed and lubrication Nameplate
39. l Transmissions nv with brand and prod uct name may be used refer to the table at page 39 These synthetic oils shall be of the polyalpha ole fine type SHF type Synthetic Hydrocarbon Fluid To improve the steadiness of the bearing life time it is highly recommended to use oil that has an initial oil cleanliness of 15 12 or better according to ISO 4406 Refer to the oil supplier to obtain this oil quality poe any lubricant or oil with care and according to the handling and safety instructions to be sup plied by the lubricant supplier on customer s request These instructions have to be handed over to any personnel performing installation maintenance or repair of the gear unit 7 4 OIL QUANTITY The oil level is determined by min and max markings on the dipstick see fig 5 page 28 The oil level will always be checked with the gear unit dipstick Possible other oil level markings are only indicative Refer to the dimensional drawing An oil sight glass or an oil level switch is optionally available THREADED DIPSTICKS SHOULD BE CHECKED IN PLUGGED POSITION The oil level must be checked when the gear unit is not running On systems with filters and coolers the oil level must be checked with the lubrication and cooling system filled with oil and after short test run The cooling system is automatically utilized when the oil bath temperature rises above 60 C 140 F If oil filling is required to take place earlier
40. licable For detailed information on lubrication system instrumentation and settings refer to the certified drawing the service manual of the lubrication and cooling system and or separate leaflets on instrumentation supplied with this manual Settings stated on the certified drawing have been set during testrun by Hansen Industrial Transmissions nv and should not be altered without written authorisation Presettings if stated are recommended values set by Hansen Industrial Transmissions nv but may be altered according to local conditions 7 3 OIL SELECTION Always use oil with type and viscosity as indicated on the gear unit s nameplate The oil must be selected from the table at page 38 of this service manual listing mineral oils and greases recommended by their respective brand name owners The viscosity has been selected according to operating conditions specified in the Order Acknowledgement The ISO viscosity class VG is mentioned on the nameplate and on the dimensional drawing For conversion from ISO viscosity class VG to other viscosity units see table of corresponding lubricants p 38 The oil suppliers are responsible for the selection and composition of their products Synthetic oils may be used only after written authorisation from the Engineering Department of Hansen Industrial Transmissions nv The use of synthetic oil is mentioned on the nameplate In that event only synthetic oils specified by Hansen Industria
41. lubrication and unless indicated otherwise on the gear units name plate or in the special technical manual of the specific gear unit if existing the grease must be selected from the table at page 38 of this service manual listing mineral oils and greases recommended by their respective brand name owners Use only high quality greases with consistency NLGI Grade 3 Greases with consistency NLGI Grade 2 may be used for regreasable labyrinth type seals and grease lubricated lower bearing of the low speed shaft The lubricant suppliers are responsible for the selection and composition of their products 7 7 GREASE LUBRICATION POINTS see fig 5 All greasing points for bearings which are not oil lubricated and for labyrinth seals are equipped with nipples ac cording to DIN 71412 and have been filled before shipment The total number of nipples is indicated on the nameplate v 7 8 OIL DRAINING see fig 5 the oil while the gear unit is still warm Be careful while draining the hot oil Use an appropriate hot oil recipient heat resistent clothing and gloves to avoid burns To facilitate oil draining remove the dipstick Units having a large oil volume can be drained easier through the drain plug when using a portable pump With some executions a small quantity of oil remains beneath the high speed bearings This oil can be drained by means of a second drain plug 1 see fig 5 page 28 v 8 VENTILATION see fig 5 To
42. n the certified drawing These instructions apply for couplings provided by Hansen Industrial Transmissions NV and listed on the dimensional drawing For couplings NOT delivered by Hansen industrial Transmissions nv H I T H l T must be consulted An evaluation of external factors which act on the gear unit maximum admissible misalignment overhung load on shaft ends etc allows to check and to guarantee the good functioning of the gear unit QHansen Hansen P4 industrial gearboxes Combination of angular and radial misalignment Angular and radial misalignment can occur simultaneously The sum of the misalignments must satisfy the following condition dr measured radial misalignment Ar allowable radial misalignment dr doa da measured angular misalignment Ar Aat Aa allowable angular misalignment lt 1 6 4 2 2 Connection motor gear unit allowable misalignment at the high speed shaft including all shaft ends of single stage gear units Allowable misalignment Metric mm Inch mils Allowable Excellent Allowable Excellent Short flexible coupling Radial misalignment iw Angular misalignment Spacer shaft and membrane disk coupling Radial misalignment Angular misalignment for coupling with a diameter of 100 mm 10 inch Radial misalignment for a
43. nical leaflets on specific instrumentation The use of seawater must be specified with the order coolers suited for use of seawater are available e When the gear unit is not operating and freezing temperatures may occur the water must be drained from the cooling system Drain facilities have to be provided by the end user Unless otherwise stipulated the water flow indicated on the dimensional drawing is the required rate for water at 20 C 70 F Depending on the load the ambient temperature and the water temperature a lower rate can suffice Adjust the water flow to obtain an oil temperature during operation between 60 and 80 C 140 and 180 F 9 2 1 Oil to water coolers Refer to the certified drawing for the connection of the oil to water cooler to the coolant supply system The service manual of the lubrication and cooling system gives detailed information about the oil to water coolers 9 2 2 Cooling coils The direction of the waterflow is optional The cooling coils are suited for fresh as well as for seawater Maximum allowable water pressure 0 8 MPa 8 bar 116 psi Connection of the cooling coil to the water supply p cooling coil FIG 6 Q Warning In order to avoid torsioning of the cooling coil hold the premounted connection with a suitable wrench as shown in fig 6 10 BACKSTOPS y odia are subject to wear and must be inspected or replaced at intervals depending on operating conditions The customer mus
44. nit shafts or a motorpump The integral type pumps are always provided with a built in reversing device for operation in both directions Built on pumps reach their normal operating capacity already after a few seconds In case of motorpumps the direction of rotation is always indicated Motorpumps should be switched on at least one minute before starting the gear unit 26 7 2 1 Circulation lubrication With integrated pump fig 4 The circulation lubrication system consists of a pump P a filter F with bypass standard from gear unit size G onwards aflow switch Mf standard from gear unit size G onwards FIG 4 Flow switch must be wired in a circuit to automatically stop the main drive motor when oil flow drops below alarm setting However in order to avoid unwanted alarms during the start up period in operation or due to irregularities of the oil flow we recommend retarding the alarm signal the alarm should be triggered only after the oil flow has been interrupted for a continuous period of 5 seconds With motorpump The service manual of the lubrication and cooling system gives detailed information about the circulation lubrication system with motorpump 7 2 2 Pressure lubrication The service manual of the lubrication and cooling system gives detailed information about the pressure lubrication system Hansen Hansen P4 industrial gearboxes 7 2 3 Instrumentation and settings if app
45. or regreasable labyrinth type seals and grease lubricated lower bearing of the low speed shaft 3 Composition formulation of the product designated by the year of its market introduction General notes Ifthe gear unit is filled with storage oil it has to be drained and it may in some instances be necessary to the gear unit with the selected oil before starting up Check with the oil supplier Oil and lubricant manufacturers can change product compositions The lubricating oils with the composition formulations mentioned in the above tables have to be used The greases mentioned in the above table have to be of a product composition formulation of before January 10th 2005 a confirmation from the grease or oil supplier is essential Hansen Industrial Transmissions nv is not responsible nor liable for composition changes The oil and lubricant suppliers are responsible for the selection and composition of their products f the customer does not wish to follow Hansen Industrial Transmissions oil and grease prescriptions the customer assumes responsibility for the technical suitability of the lubricant used f the customer would like to use another oil in the gear unit than the oil he last filled in the gear unit he has to consult the oil supplier regarding the compatibility of the two oils and the measures that possibly should be taken for reliable operation of the gear unit with the new oil and the possible residues
46. ply before draining the oil Drain the oil while the gear unit is still warm Be careful while draining the hot oil Use an appropriate hot oil recipient heat resistent clothing and gloves to avoid burns Every time the lubricant is changed it is recommended to flush the gear unit and the corresponding lubrication and cooling system with fresh oil Check to make sure that the gear unit the lubrication and cooling system items are well drained after flushing Dont forget to renew the filter cartridge Operating procedure and specifications are mentioned in the service manual of the lubrication and cooling equipment and or the technical leaflets for the specific instrumentation Disposable filter cartridges can not be cleaned External dipsticks and sight glasses must be periodically checked against the gear unit dipstick 32 v v A v Hansen Hansen P4 industrial gearboxes 12 2 2 Oil change and regreasing The first oil change After 100 hours and not later than 800 hours of service First regrease the lubrication points if present The lubrication points have to be regreased while the gear unit is warm Change the oil Use new oil or reuse the removed oil after filtering Don t use the filter of the lubrication system if available Filter the removed oil volume at least 10 times Use a 10 um filter or smaller with a beta ratio of 200 or higher The filter must be compatible with the used oil Aft
47. rial gearboxes 1 SCOPE This service manual contains the storage installation operating lubrication and maintenance instructions for the Hansen P4 standardized gear units The Hansen P4 gear unit is a component of a machine to decrease or to increase the input speed and respectively to increase or to decrease the transmitted torque Additional information can be obtained by contacting one of the Hansen Industrial Transmissions nv sales centres worldwide p 2 All handling storage installation start up inspection and maintenance of the equipment shall be done by personnel qualified in matters of industrial mechanical and where applicable electrical equipment 2 GENERAL 2 1 GENERAL INSTRUCTIONS Carefully read this manual before installing the gear unit Compliance with the instructions is required for long and troublefree operation of the gear unit The equipment should be checked against shipping papers and inspected for apparent damage caused during transport Any shortage discrepancy or damage must immediately be reported to Hansen Industrial Transmissions nv 2 1 1 Warranty The warranty clause of the General Conditions of Sale applies to gear units installed and maintained as per instructions contained in this manual and in any additional instruction leaflets supplied with the gear unit insofar as the gear unit operates within the service and rating conditions put forward in the Order Acknowledgement and on the
48. rmulation LO2046PBA Renolin CLP 220 Formulation 3110248 Energol GR XP 320 Energol GR XP 460 Formulation LO4023PBA Formulation LO4024PBA Alpha SP 320 Alpha SP 460 Formulation 102047 Formulation LO2048PBA Renolin CLP 320 Renolin CLP 460 Formulation 3110249 Formulation 3110250 BP CASTROL Spheerol EPL FUCHS EUROPE SCHMIERSTOFFE KL BER Kl beroil GEM 1 150 N Kl beroil GEM 1 220 N Kl beroil GEM 1 320 N Kl beroil GEM 1 460 N Mobilgear XMP 150 Mobilgear XMP 220 Formula tion RLOO1893E Formula tion RLO01893F Mobilgear XMP 320 Formula tion RLOO1893H Mobilgear XMP 320 EXXON MOBIL Formula tion RLOO1893J Mobilux EP 3 EXXON MOBIL Mobilgear 600 XP 150 Mobilgear 600 XP 220 Mobilgear 600 XP 320 Mobilgear 600 XP 460 Mobilux EP 3 Omala F 150 Formulation 1996 Formulation 1996 LoadWay EP 150 LoadWay EP 220 Formulation SL970307 150 Formulation SL970307 220 Omala F 220 Omala F 320 Formulation 1996 LoadWay EP 320 Formulation SL970307 320 Omala F 420 Formulation 1996 LoadWay EP 460 Formulation SL970307 460 SHELL Alvania EP 2 2 3 3 3 3 STATOIL Uniway 162 2 TOTAL Carter XEP 220 Formulation 131293 Carter XEP 320 Formulation 131293 Carter XEP 460 Formulation 131293 Multis EP 3 TOTAL Carter EP 220 Formulation 131238 Carter EP 320 Formulation 131238 Carter EP 460 Formulation 131238 Multis EP 3 1 Only for low ambient
49. rrosion class according to ISO 12944 Preservation sealing paste and painting recommendation Degrease and clean all components Only the bore in the coupling hub may be slightly greased to facilitate mounting on the shaft end All other contact surfaces must remain clean and free of grease Coat all contact surfaces A B C and D see figure at next page between shaft shoulder spacer coupling hub thrust washer Hansen Hansen P4 industrial gearboxes and fixation bolt with an appropriate sealing paste Remove the excess sealing paste after assembly Check carefully if the air gaps between the various components are properly sealed After assembly and sealing a paint system that matches the selected atmospheric corrosion class according to ISO 12944 will be applied Refer to the Order Acknowledgement Protect the oil seals of the gear unit against paint and harmful external influences Recommended sealing paste refer to your supplier In case of doubt refer to Hansen Industrial Transmissions nv 6 3 EXTERNAL LOADS If external loads act on the gear unit thrust blocks must be installed against the unit s feet to prevent the gear unit from shifting Components transmitting radial load to the shaft should be mounted as close as possible to the housing Avoid exaggerated tension in transmission belts mounted on input or output shafts On gear units with built on
50. s damage to shafts gears bearings and couplings Correct positioning of mounting feet on bedplate by shimming Rupture of mounting feet Distortion of gear unit Correct tightening of fixation amp motor bolts Retorque after 50 to 100 hours of first operation Loosening of bolts and displacement of the gear unit gt misalignment gt Smooth mounting of couplings and brakes onto shafts never use impact Damage to bearings Lift and handle gear unit by special lifting eyes Never lift it by the shafts Damage to bearings Note This quick reference for handling the gear unit is not exhaustive The obligation to read the complete service manual remains Hansen industrial gearboxes during installation continuation Hansen P4 Take care of Possible damage if neglected Check before filling oil that no pipes are damaged during transport or installation Replace damaged pipes Insufficient lubrication gt damage to gear unit parts and components Installation After installation of the gear unit lubricate immediately the complete drive Accidental start up of the drive group with insufficient lubrication gt damage to gear unit parts and components Oil level glasses should be calibrated with the dipstick of the gear unit Apply indelible marks on the oil level glass Check and compare the oil level indication on the other oil level markings wi
51. s on the gear unit it is necessary to ensure sufficient lighting of the drive group to work in fully safe conditions Maintenance during the warranty period Maintenance activities like dis assembly of the gear unit and its parts assembly of the gear unit and its parts replacement of parts by spare parts will be done by qualified personnel that is authorized by Hansen Industrial Transmissions nv The maintenance which is limited to the checking of the good performance of the instruments of operation and control the control of cleanliness of the installation the oil draining and oil filling of the gear unit regreasing of the bearings and labyrinth seals the checking of the drive group alignment the checking for wear of the components of the drive group the maintenance of the lubrication system will be carried out according to the description and the directives mentioned in this service manual The maintenance shall be done by personnel qualified in matters of industrial mechanical and where applicable electrical equipment Maintenance outside the warranty period The maintenance shall be done by personnel qualified in matters of industrial mechanical and where applicable electrical equipment The disassembly and the assembly of a gear unit and its parts require a qualification and a particular knowledge It is strongly recommended to entrust this task to qualified personnel authorized by Hansen Industr
52. shafts QHR 4 and 3 and 4 stage vertical gear units with right angle shafts QVR 3 QVR 4 require also an additional oil filling of the bearing housing See special sticker on gear unit The additional oil quantity is mentioned on the certified drawing and on the sticker Oil filling of a gear unit with M1 or M3 motor base For gear units with horizontal shafts QH equipped with a motorbase M1 or M3 an additional small quantity of oil must be added through the inspection cover located in the top face of the gear unit see special sticker on gear unit If easy access to the oil filler plug is prevented due to lack of space between the motor base and the gear unit upper face the motor base should be raised after removal of the belt The position of the oil filling plug is indicated by a sticker on the gear unit Refer to to the certified dimensional drawing 28 QHansen Hansen P4 industrial gearboxes If the gear unit is filled with storage oil it has to be drained and it is strongly advised to rinse the gear unit with the selected oil before starting up Check with the oil supplier To improve the steadiness of the bearing life span it is highly recommended to use oil that has an initial oil cleanliness of 15 12 or better according to ISO 4406 Refer to the oil supplier to obtain this oil quality v 7 6 GREASE SELECTION see table page 38 If the gear unit is equiped with parts that need grease
53. syn EP XF 320 Formulation LO4027PBA Enersyn EP XF 460 Formulation LO4028PBA Bearing grease Graisse pour roulement W lzlagerfett Lagervet 2 FAG Arcano CASTROL Alphasyn EP 150 Formulation L98120PBA Alphasyn EP 220 Formulation L98115PBA Alphasyn EP 320 Formulation L98111PBA Alphasyn EP 460 Formulation L98113PBA FAG Arcano KL BER Kl bersynth GEM 4 150 N Kl bersynth GEM 4 220N Kl bersynth GEM 4 320 N Kl bersynth GEM 4 460 N FAG Arcano EXXON MOBIL Mobilgear SHC XMP 150 Formulation RLOO1983E Mobilgear SHC XMP 220 Formulation RLOO1983F Mobilgear SHC XMP 320 Formulation RLOO1983H Mobilgear SHC XMP 460 Formulation RLOO1983J FAG Arcano EXXON MOBIL Mobil SHC Gear Series 150 Mobil SHC Gear Series 220 Mobil SHC Gear Series 320 Mobil SHC Gear Series 460 FAG Arcano Omala HD 150 Omala 4 GX 150 Formulation 2007 3 Omala HD 220 Omala S4 GX 220 Formulation 2007 3 Omala HD 320 Omala 54 GX 320 Formulation 2007 3 Omala HD 460 Omala S4 GX 460 Formulation 2007 3 FAG Arcano 1 Only for low ambient temperatures see nameplate of the gear unit Carter SH 220 Formulation I31219 Carter SH 320 Formulation I31219 Carter SH 460 Formulation I31219 FAG Arcano 2 Use only high quality greases with EP additives and consistency NLGI Grade 3 Greases with EP additives and consistency NLGI Grade 2 may be used f
54. t lead to a faulty operation of the gear unit Q 2 1 2 6 Fire Gear units with burning marks cannot be restarted Only after revision and repair carried out by Hansen Industrial Transmissions nv the gear units can be started safely Burning of lubricants and sealing Lubricants oil and grease Other chemical substances emerge from burning of oils and greases which are harmful for human and environment Refer to the lubricant supplier to know possible dangers and consequences safety specifications to follow up Sealing Some seals in a gear unit can contain FKM material trade names e g Viton 2 and Fluorel 3 If seals made out of FKM material have been exposed to high temperatures e g in case of a fire or when a bearing very close to the seal has experienced massive damage highly corrosive organic fluorides may have been generated and contact with the skin must be avoided at all time Since it is not always clear whether the used material is in fact FKM it is strongly recommended to handle every seal that has been exposed to high temperatures with extreme care and to take the necessary precautions 1 FKM is short for Fluoroelastomer 2 Viton is a registered trademark of Dupont Dow 3 Fluorel is a registered trademark of Dyneon 3M Exctraction from handling precautions for Viton and related chemicals technical information from Dupont Dow Precaution in the event of fire Highly toxic pro
55. t take all necessary precautions to prevent that failure of the backstop could cause physical injury and or severe damage to the drive and or application The time span between two checks of functioning depends on the operating conditions and the activation frequency but should never exceed two years These inspections are preferably carried out by qualified personnel authorized by Hansen Industrial Transmissions nv In case the backstop is part of a hoist drive which is subject to a periodical safety inspection the check of the backstop must be included in the inspection procedure A In case of transport of people the user has to follow the local legislation re the inspection of safety devices 30 QHansen Hansen P4 industrial gearboxes An inspection or replacement of the backstop is also required in the following circumstances in case of disassembly of the gear unit or one of its components in the event that abnormal wear or material break out of gears bearings or any other component or pollution of the oil has been detected in the gear unit since this may have affected the condition of the sprags and raceways of the backstop The outcome of the periodical inspection is to be reported in a log book JA Ne loosen any part of the backstop while the gear unit is loaded loosening the backstop may cause reversal of the drive and running back of the load Check if the gear unit is not loaded before loosening the backstop and secure
56. temperatures see nameplate of the gear unit 2 Use only high quality greases with EP additives and consistency NLGI Grade 3 Greases with EP additives and consistency NLGI Grade 2 may be used for regreasable labyrinth type seals and grease lubricated lower bearing of the low speed shaft 3 Composition formulation of the product designated by the year of its market introduction General notes If the gear unit is filled with storage oil it has to be drained and it may in some instances be necessary to the gear unit with the selected oil before starting up Check with the oil supplier Oil and lubricant manufacturers can change product compositions The lubricating oils with the composition formulations mentioned in the above tables have to be used The greases mentioned in the above table have to be of a product composition formulation of before January 10th 2005 a confirmation from the grease or oil supplier is essential Hansen Industrial Transmissions nv is not responsible nor liable for composition changes The oil and lubricant suppliers are responsible for the selection and composition of their products f the customer does not wish to follow Hansen Industrial Transmissions oil and grease prescriptions the customer assumes responsibility for the technical suitability of the lubricant used the customer would like to use another oil in the gear unit than the oil he last filled in the gear unit he h
57. th the dipstick of the gear unit Calibrate the other oil level indications if necessary Oil level too low gt damage to gears and bearings Oil level too high gt leakage increased oil temperature Check the direction of rotation of the low speed shaft built in backstop refer to the dimensional drawing Wrong direction of rotation gt damage to the backstop and other parts Test run of the gear unit follow up all instructions of chapter 11 Starting up Damage to gear unit parts and components Long periods of standstill of the gear unit after installation and before starting up follow up all instructions of paragraph 12 6 Extended periods of standstill always protect the drive group against possible corrosion Corrosion of gear unit parts and components Damage to gear unit parts and components Note This quick reference for handling the gear unit is not exhaustive The obligation to read the complete service manual remains Hansen industrial gearboxes during start up Take care of Check the internal components of the gear unit for corrosion Hansen P4 Possible damage if neglected Damage to gears and bearings Fill gear unit up to correct level Oil level too low gt damage to gears and bearings Oil level too high gt leakage increased oil temperature Use required oil and correct viscosity Viscosity too high thick oil
58. the air must be released from the cooler whilst the pump is in operation The oil quantity mentioned on the nameplate of the gear unit is an approximate value given only for procurement purposes 27 Hansen industrial gearboxes FIG 5 Hansen P4 Single stage gear units Multi stage gear units Position of oil filling plug dipstick oil draining plug breather plug Always refer to the certified dimensional drawing and stickers on the gear unit see section 7 8 page 29 Dipstick Oil Oil Ventilation draining filling Condensation Grease draining lubrication int rests un pen Grease lubrication Grease lubrication point point for labyrinth for bearings seal M 7 5 THE FIRST OIL FILLING see fig 5 Fill units only after final installation especially gear units with vertical downwards shafts to prevent oil splashing over drywell during handling Fill the gear unit exclusively through the oil filling opening which is provided in the inspection cover for that purpose In that way all bearings are lubricated with fresh oil before start up Q Note Additional oil filling of the bearing housing 4 stage horizontal gear units with right angle
59. ticker with caution and in structions Q CAUTION This gear unit contains litres volatile corrosion inhibitor oil Type and brand name of the volatile corrosion inhibitor oil refer to Hansen Industrial Transmissions nv STORE IN SHIPPING POSITION AND KEEP HERMETICALLY CLOSED TO PREVENT VAPOURS OR OIL FROM ESCAPING UNTIL PUTTING INTO OPERATION BEFORE PUTTING INTO OPERATION Replace the red plugs by the dipstick and breather filter or plug Drain the protective oil and fill the gear unit with the exact quantity of the prescribed gear oil see also maintenance manual It is recommended to rinse the gear unit with the selected oil before starting up In case of doubt refer to Hansen Industrial Transmissions nv See paragraph 7 5 page 28 The first oil filling See chapter 11 page 31 Starting Up Jn any lubricant or oil with care and according to the handling and safety instructions to be sup plied by the lubricant supplier on customer s request These instructions have to be handed over to any personnel performing installation maintenance or repair of the gear unit not open the gear unit near flames sparks or hot objects and take preventive measures to protect people against the volatile corrosion protective substance Hansen P4 industrial gearboxes 5 HANDLING The Hansen P4 gear units are easy to handle and to install Make use of integral oval lifting eyes horizontal mount
60. ting eyes lifting eye nuts with bolts or integral rods The other components of the gear unit cannot be used for lifting Before handling the gear unit the state of the lifting points must be inspected for signs of fatigue cracks deformation signs of rupture Corrosion locking of the lifting eye bolts and the lifting eye nuts Take care of a good load distribution and a horizontal handling of the gear unit 2 1 2 4 Installation The user shall be responsible for the proper installation of the complete equipment and the supply of protection guards and other safety equipment in accordance with the European Directives 2006 42 EG and the local safety regulations Sufficient space and protections must be provided in such way that a person walking by cannot injure himself The gear unit contains rotating parts A Before beginning the installation of the gear unit it is necessary to check that involuntary starting up of A the drive is impossible Heaters coolers electrical alarms and other safety or monitoring devices supplied by Hansen Industrial Transmissions nv separately or together with the gear unit must be installed and connected by the user as indicated on the relative documents After installation and before starting up the gear unit it is necessary to check that the rotating external parts are provided with adequate protections the gear unit is lubricated the lubricating system the measuring
61. uring extended periods of standstill the gear unit must be protected as follows an oil soluble concentrate including corrosion inhibitors which are active both in the liquid and in the vapour phase has to be added A 296 volume concentration is considered to be normal Consult your oil supplier about lifetime compatibility with the actual oil and about volume concentration seal all gear unit openings dipstick breather etc hermetically Before starting up read chapters 11 and 12 Replace the hermetical seals by the originally mounted equipment 12 7 SERVICE AFTER SALES For technical assistance or additional information the Hansen Industrial Transmissions nv sales centres are at your disposal When you contact them please specify the complete type code and the manufacturing number mentioned on the gear unit s nameplate 12 8 REPAIRS Any repair should only be carried out by qualified personnel Only original Hansen Industrial Transmissions nv spare parts should be used No products or substances may be used in the gear unit that could bring foreign ingredients particularly solid or friction reducing additives amongst in the oil Hansen P4 industrial gearboxes 13 GREASE QUANTITIES FOR REGREASING Grease quantity Type Q in grams for bearings by regreasing The type Q is indicated on the nameplate see page 11 Greases NLGI Grade 3 recommended by the oil suppliers see page 38 Sticker on the
62. where S1 S AS fig AS spacing obtained after compression of the disk springs table 2 3 and 4 due to the weight of the gear unit and tightening of the inner nut When the prescribed spacing S1 is obtained lock the inner nut by tightening outer nut against it FIG 3a AT s FIG 3b Table 2 40 50 60 60 75 75 90 90 Q number of disc springs FIG 3c ZD 24 QHansen Hansen P4 industrial gearboxes Table 3 Gear unit PT PRmax AS A size mm inch mm inch Q DIN 2093 QH C3 50 0 7 QH D3 QH DA 60 0 9 QH E3 QH E4 60 0 9 QH F3 QH F4 75 1 0 QH G3 QH G4 90 1 0 QH H3 QH H4 90 Q number of disc springs FIG 3d Table 4 QH J3 QH J4 105 QH K3 QH K4 105 QH L3 QH L4 120 QH M3 QH M4 120 Q number of disc springs 6 7 LUBRICATION AFTER INSTALLATION After levelling alignment and securing the gear unit must be lubricated All instructions mentioned in chapter 7 LUBRICATION must be followed up If a long period of standstill is expected before starting up the gear unit the instructions mentioned in paragraph 12 6 EXTENDED PERIODES OF STANDSTILL must be followed up 7 LUBRICATION Lubrication serves four main functions

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