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Hansen P4 Installation Manual
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Table for bolts according to SAE bolt quality grade 5
Gear unit type
Gear unit size
Bolt dimension [UNC]
Torque [lbf.in]
QH...
A
5/8"
1550
B
3/4"
2950
C
7/8"
4850
D
1"
6000
E
1 1/4"
12000
F
1 1/4"
12000
G
1 1/2"
21000
H
1 1/2"
21000
J
1 1/2"
21000
K
1 1/2"
21000
L
1 3/4"
33650
M
1 3/4"
33650
N
2"
50750
P
2"
50750
Q
2"
50750
R
2 1/4"
81050
S
2 1/4"
81050
T
2 1/4"
81050
Technical data
56
IM_405_002_EN
55
57
Table of Contents
Default Chapter
3
Table of Contents
3
1 Customer Data Sheet
7
2 Manual Disclaimer
9
3 About this Document
10
Function of the Document
10
Language
10
Illustrations
10
Use of Steps, Lists and Titles in this Document
10
How to Use this Document
10
Warnings, Cautions and Notes Used in the Document
10
Related Documents
11
Storage of this Document and the Related Documents
12
Abbreviations
12
Customer Support
12
4 Description
13
Intended Use
13
Type Plate
13
Signs in the Documentation and on the Gear Unit
14
Description of the Lubrication of the Gear Unit
17
Function of Lubrication
17
Splash Lubrication
18
Force-Feed Lubrication
18
Breather Plug
18
Cooling System
18
Direction of Rotation of the Shafts
19
5 Safety
20
Restrictions
20
Approved Installation Engineer
20
General Safety Instructions
20
Safety Instructions for Installation
21
Special Safety Instructions (Backstop)
21
Noise and Vibrations
21
Partly Completed Machine
21
Instructions in Case of a Fire
21
Warranty
22
6 Transport
23
Off-Site Transport
23
On-Site Transport
23
Lift the Gear Unit
23
7 Storage
26
General Storage Instructions
26
Indoor Storage for Maximum 1 Year
26
Extended Storage Outdoors for Maximum 2 Years (Extended Outdoor Storage)
26
Extended Storage Indoors for Maximum 5 Years (Extended Indoor Storage)
27
8 Installation
28
Maximum Time between Installation and Commissioning
28
Remove the Packaging Material
28
Installation Instructions for Parts that Are Not Part of the Gear Unit
28
Do a Check for Corrosion of Internal Parts of the Gear Unit
28
Install the Couplings
28
Prepare
29
Apply the Sealing Paste
29
Install the Coupling Hubs
29
Remove Unwanted Sealing Paste and Apply Paint
30
Install Parts that Give External Loads to the Gear Unit
30
Install Gear Units with a Backstop
30
Align the Gear Unit
31
Align the Gear Unit in the Horizontal Plane
31
Align the LSS (Multi-Stage)
31
Align the LSS (Single Stage)
31
Align the HSS
32
Attach the Gear Unit with the Bolts (Solid Shafts)
32
Attach the Gear Unit
32
Install the Safety Cover
32
Attach the Gear Unit (Hollow Shafts)
32
Install the Shrink Disk
32
Install the Shaft with Keyway Connection
34
Install the Torque Arm
37
Install a Ground Connection
38
Install the Lubrication System
38
General Instructions for the Lubrication System
38
Instructions for Force-Feed Lubrication (Integrated Pump)
39
Instructions for Force-Feed Lubrication (Pump with a Motor)
39
Instructions for Force-Feed Lubrication (Pressure Lubrication)
39
Fill the Gear Unit with Gear Oil
39
Select the Gear Oil
39
Add Gear Oil (Gear Unit with Motor Base)
40
Add Gear Oil (QHR.4, QVR.3 and QVR.4)
40
Measure the Gear Oil Level
40
Add Gear Oil (All Gear Units)
41
Drain Gear Oil
41
Add Grease to the Lubrication Points for Grease
41
Select the Grease Type
41
Add Grease
41
Install the Oil-To-Air Cooler
42
Install the Water Cooling
42
Install the Oil-To-Water Cooler
42
Install the Cooling Coils
43
Installation Instructions (Heater)
43
9 Commissioning
44
Maximum Time between Commissioning and Operation
44
Do a Check on the Gear Unit
44
Start Instructions (Backstop)
44
Start Instructions (Heater)
44
Start Instructions (Force-Feed Lubrication, Pump with a Motor)
44
Start Instructions (Force-Feed Lubrication, Integrated Pump)
45
Start Instructions (Drive Group with a 2-Speed Motor)
45
Instructions after Commissioning
45
10 Instructions for Operation
46
General Instructions for Operation
46
Instructions (Force-Feed Lubrication, Pump with a Motor)
46
Instructions (Water Cooling)
46
Instructions (Drive Group with a 2-Speed Motor)
46
Instructions if the Gear Unit Does Not Operate more than 2 Weeks
46
Operate the Gear Unit for 5 Minutes each 2 Weeks
47
Protect the Gear Unit with a Volatile Corrosion Inhibitor
47
11 Removal of the Gear Unit
48
General Instructions for Removal of the Gear Unit
48
Remove the Gear Unit (Solid Shafts, Couplings)
48
Remove the Gear Unit (Hollow Shafts)
48
Disconnect the Gear Unit from the Torque Reaction Point
48
Remove the Shrink Disk
48
Disconnect the Keyway Connection
49
12 Care for the Environment
51
13 Technical Data
52
Dimensions and Mass
52
Materials of the Gear Unit
52
Torque Seal Specification
52
Paint Specification
52
Corrosion Protection by H.I.T
52
Position of the Gear Unit
53
Ambient Conditions for Storage
53
Misalignment of the LSS
53
Misalignment of the HSS (Couplings)
53
Bolt Specifications (Gear Units with Solid Shafts)
54
Bolt Specifications (Single-Stage, Horizontal LSS)
54
Bolt Specifications (Multi-Stage, Horizontal LSS)
55
Bolt Specifications (Multi-Stage, Vertical LSS)
57
Torque Values for Oil Drain Screw
58
Shrink Disk Specifications (2-Part Shrink Disk)
58
Lubrication
58
Torque Specifications
59
Prestress Specifications for the Torque Arm (Hollow Shaft)
60
Lubricants
61
General Specifications for Lubricants
61
Additional Gear Oil Specifications (Heater)
61
Mineral Gear Oil and Related Grease
62
Synthetic Gear Oil and Related Grease
63
Grease Quantity at Lubrication Points for Bearings
64
Grease Quantity Type
64
Grease Quantity Types Q1, Q2, Q3, Q6, Q7 and Q8
65
Grease Quantity Type Q4
66
Grease Quantity Type Q5
66
Grease Quantity Type Q9
67
Grease Quantity for Lubrication Points at Labyrinth Seals (LSS)
68
Grease Quantity Type
68
Grease Quantity (Single-Stage)
68
Grease Quantity (Multi-Stage)
68
Grease Quantity for Lubrication Points at Labyrinth Seals (HSS)
69
Grease Quantity Type
69
Grease Quantity (Single-Stage)
69
Grease Quantity (Multi-Stage)
70
Cooling Water Specifications
70
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Hansen P4 Specifications
General
Brand
Hansen
Model
P4
Category
Industrial Equipment
Language
English
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