Via M. L. King, 6 - 41122 MODENA (ITALY) Tel: +39 059 415 711 Fax: +39 059 415 729 / 059 415 730 INTERNET: http://www.hansatmp.it E-MAIL: hansatmp@hansatmp.it
HT 05 / D / 109 / 0509 / E
GB 31.000
TISO 238.000 Nm Output Torque (175.500 lbf.ft)
CONTENTS
General Information Gearbox Selection Method Motor Selection Method Motor Mounting Instruction Gearbox Mounting Instruction Lubrication Motor Selection Card Gearbox Selection Card Order Code Installation Drawings Technical Characteristics - Load on Shaft Accessories Weight Table Oil Quantity Table
4-8 9 - 10 10 11 - 12 13 - 14 15 16 17 18 19 - 23 24 25 25 25
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Main features
- Flexibility in service: modular concept enables drive to be uprated in service with minimum inconvenience. - Constant torques: throughout the infinitely variable speed range. - Lower maintenance costs: modular system enables motors to be overhauled without disturbing the system. - Uniform running at low speeds: speeds at fractions of one R.P.M. can be achieved smoothly. - Excellent gear life: materials used are aimed at maximum running hours. - Modular design: plug in concept enables standard motors to be fitted from existing stock. - Complete transmission: full range gives a balanced transmission package for both automotive and general industrial drives.
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Symbol Fr2 Fa2 fs ie in kf Lmin Mt max n1 n1 x h n2 max n2 h hi p P1 P2 Pd Pt Q Tf T1 T2 Teq TISO Tcont. Tmax. Timp. TM V X m v t
SYMBOLS and UNIT of MEASURE Unit Description N Output shaft radial load N Output shaft axial load _ Service factor _ Effective reduction ratio _ Nominal ratio _ Output support life correction factor mm. Torque arm lenghts Nm Shrink disk torque n/min. Input speed n/min. x h Input duration index n/min. Max output speed n/min. Rated output speed h Working Time in hours _ Time percentage bar Pressure kW Input power kW Output power kW Dissipated power kW Thermal power lt/min. Oil flow Nm Static braking torque Nm Input torque Nm Output torque Nm Equivalent torque Nm ISO limit torque Nm Continuous torque Nm Maximum torque Nm Impulse torque Nm Max. load torque 3 Displacement cm mm. Reaction distance _ Mechanical efficiency _ Volumetric efficiency _ Total efficiency
CONVERSION TABLE
Length 1 mm. 1 in. 1 mm. 1 ft 1 kp 1N 1 kp 1 lbf 1 Nm 1 lbf.in 1 Nm 1 lbf.ft ff 1 n / min. 1 rad. / sec. 1 kW 1 HP 1 kW 1 PS 1 kW 1 kp.m / sec. 1 bar 1 kp / cm 1 bar 1 PSI 1 Mpa 1 PSI
2
= = = = Force = = = =
0,03937 in. 25,4 mm. 0,000328 ft 304,8 mm. 9,81 N p 0,102 kp 2,2046 lbf 0,4536 kp
Torque = 8,85 lbf. in = 0,1129 Nm = 0,737 lbf.ft = 1,355 Nm Angular speeed = 0,1047 rad. /sec. = 9,549 n / min. Power = 1,341 HP = 0 7457 kW 0,7457 = 1,3596 PS = 0,7355 kW = 101,972 kp.m / sec. = 0,0985 kW Pressure 0,981 0 981 kp / cm2 = 1,02 bar = 14,5 PSI = 0,0689 bar = 145 PSI = 0,00689 Mpa Capacity / Flow rate = 0,22 Imp. GPM = 4,546 lt / min. = 0,2642 US GPM = 3,785 lt / min. Volume / Displacement = = = 0,062 , in3 16,387 cm3 Temperature = 5/9 (F-32) = 32+ 9/5 C
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fs x T2 < Tcont
SERVICE FACTOR fs TYPE OF LOAD Number of start-ups per hour Hydraulic motor Electric motor <5 1.0 1.1 UNIFORM U 5-50 1,0 1,2 > 50 1,2 1,4 <5 1,0 1,2 MODERATE M 5-50 1,2 1,4 > 50 1,4 1,6 <5 1,2 1,4 HEAVY H 5-50 1,4 1,6 > 50 1,6 1,8
Reduction ratio
ie = effective reduction ratio: ratio between the input and output speed of the gearbox in = nominal ratio: Renard R 20 numbers, near the value of ie.
Correction factor kf
kf = output support lifetime correction factor: used to obtain the theoretic duration of the support for values of n2 x h different from those found in the catalogue. For all gearboxes the external load curves are calculated for: n2 x h = 100.000 for the output supports n2 x h = 1.500.000 for the input supports
Speed
n 1. = input speed: is the input speed of the gearbox. n 2 max..= maximum output speed: is the maximum output speed of the gearbox for continuous operation; values of speed near the maximum can be achieved in compatibility with the duty cycle. For further information please contact our Tech Dpt.
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Power
Pt = thermal power: maximum mechanical power that the gearbox can transmit while operating continuously, with splash lubrication without exceeding the thermal limit (oil temperature not greater than 90C). Greater powers can be transmitted by using an appropriate cooling system. The value refers to a continual operation with mechanical efficiency of 0,97 for each reduction stage, input speed of 1.500 n /min., ambient temperature 20C, altitude 0 / 500 m., application to the cover. For different conditions, the thermal power value must be multiplied by the thermal factors shown in the following table. For limited operating periods followed by rests period that are sufficiently long to guarantee an adequate cooling of the gearbox, the thermal power loses its significance and can be disregarded.
THERMAL FACTORS Room temperature 10C 20C 30C 40C 50C altitude m 0 500 1.000 1.500 2.000 working time 100% 1,2 1,0 0,8 0,7 0,5 80% 1,3 1,1 1,0 0,8 0,7 60% 1,4 1,3 1,1 1,0 0,8 input speed 400 1,2 1,2 1,1 1,1 1,1 800 1,1 1,1 1,0 1,0 1,0 1000 1,1 1,1 1,0 1,0 1,0 1500 1,0 1,0 0,9 0,9 0,9 2000 0,7 0,7 0,6 0,6 0,6 40% 1,6 1,4 1,3 1,1 1,0 20% 1,8 1,6 . 1,4 1,3 1,1
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where
Tmax = maximum torque: Value of maximum torque that the gearbox can transmit for short period of time. Tmax = 1,25 x Tcont when n2 x h = 50.000 In application with high number of cycles and a torque near the maximum, one must take into account an opportune safety factor. In this case it is recommended that our Tech. Dpt. be contacted. Timp = impulsive torque: Value of static torque or an istantaneous peak load that the gearbox can withstand: Timp = ( from 1,25 to 1,9 ) x Tcont Each coefficient is given in the life time table. when n2 x h = 50.000
Efficiency
nm = mechanical efficiency: ratio between the output power and input power. Normally it is considered to be equal to 0,97 - 0,98 per reduction stage that makes up the gearbox; it depends upon various factors, of which speed, torque, ratio, working position and lubrication.
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MECHANISM SELECTION GUIDE ACCORDING TO FEM 1.001/3 Type of appliance hoisting Hand-operated appliance Erection cranes Erection and dismantling cranes for power stations, machine shops... Stocking and reclaiming transporters Workshop cranes Overhead travelling cranes, pig-breaking cranes, scrapyard cranes Ladle cranes Soaking-pit cranes Stripper cranes, open-heath furnace-charging cranes Forge cranes Bridge cranes for unloading, bridge cranes for containers Drydock cranes, shipyard jib cranes Floating cranes and pontoon derricks for very heavy loads Deck cranes Tower cranes for building Derricks Railway cranes allowed to run on train M1 M2-M3 M2 M5-M8 M6 M8 M7-M8 M8 M8 M8 M4-M8 M5-M6 M3-M4 M4-M6 M4 M2-M3 M3-M4 M2-M3 M4-M6 M4 M6 M6 M6 M4-M6 M4-M5 M3-M4 M3-M4 M5 M1-M2 M2-M3 Type of mechanism slewing luffing M1-M2 M3-M8 M4-M5 M3-M4 M3-M4 M4 M1-M2 M2-M3 traverse M1 M1-M2 M2 M4-M7 M4 M6-M7 M4-M5 M7 M7 M5 M4-M8 M4-M5 M2-M5 M3 travel M1 M2-M3 M2 M5-M8 M5 M7-M8 M6-M7 M8 M8 M6 M4-M5 M5-M6 M3-M4 M3 -
We waives all responsability of improper use of the selection criteria mentioned above, in particular for all applications subject to special rules (for example when personnel safety is involved) and place this responsability on the application constructor. Contact our Tech. Dpt. for all technical support. HT 05 / D / 109 / 0509 / E Pag. 9
where nm is the mechanical efficiency. The necessary supply flow rate is:
where nv is the volumetric efficiency of the motor. Please use the following table as a guide for hydraulic motor selection.
HYDRAULIC MOTORS Use medium - heavy Pressure - bar Type of motor Speed - n/min. m v
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Motor Axis Vertical, shaft down. The piping, from any drain port, must be taken above the level of the motorcase to ensure good bearing lubrication. The drain line should be run above the level of the uppermost bearing. If there is a risk of syphoning then a syphon breaker should be fitted.
Motor Axis Vertical, shaft up. Specify V within the model code for extra drain port, G1/4 (BSPF). Connect this port into the main drain line downstream of a 0.35 bar check valve to ensure good bearing lubrication. The piping arrangement must not allow syphoning from the motorcase. An additional G 1/4" (BSPF) drain port is provided when V (shaft vertically upwards) designator is given after the shaft type (see Ordering Code). This additional drain should be connected into the main motor casing drain line downstream of a 0.35 bar check valve to ensure lubrication of the upper bearing (see installation diagram). Pag. 12
Additional drain port G1/4" (BSPF)
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Installation
Gearbox with flange and male shaft: The connecting surface should be flat, unpainted, machined and perpendicular to the rotation axis. The following table shows the required spigot with their representative tolerances.
Diameter Tollerance
mm mm
Gearbox with female splined shaft: The female version gearboxes are not suitable for supporting output radial loads, it is therefore extremely important to properly align between the gearbox and the driven shaft. It is also necessary to check that driven shaft does not undergo bending during the working phases.
Torque arm mounted gearbox: It is necessary to carry out an anchorage of the torque arm that is not constrained to the axis of the gearbox. The anchorage must also be suitable shock proof. In the dimension tables of each gearbox one can find the minimum torque arm lenght needed to carry out the application correctly.
Screw size M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30 M 33 M 36
Class 8.8 Torque Nm 50 85 136 213 300 430 580 730 1.080 1.470 2.000 2.550 Force N 27.000 39.500 54.500 75.000 93.500 120.000 148.000 170.000 225.000 270.000 335.000 390.000
Class 10.9 Torque Nm 70 120 195 310 420 600 810 1.000 1.500 2.050 2.750 3.500 Force N 39.000 57.000 78.000 105.000 130.000 165.000 210.000 240.000 315.000 385.000 460.000 535.000
Class 12.9 Torque Nm 85 145 230 360 495 700 965 1.200 1.800 2.450 3.300 4.500 Force N 46.000 67.000 92.000 127.000 153.000 195.000 245.000 285.000 370.000 455.000 550.000 645.000
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Paint
The supplied gearboxes are not painted. A few parts are treated with a base layer of water soluble epoxy ester red oxide. The customer must take care to carry out the surface treatment using a paint that is compatible with the base layer. O-Rings must be protected during the painting.
STORAGE
The gearboxes must not be stored in the open or in direct contact with the ground. For long time periods they must be stored full of oil, with external worked parts covered with grease and the coupling surfaces protected with anti-oxidant agents. We recommend to operate the gearboxes (a complete rotation of the output shaft is sufficient) without load at least once every two months. For further information regarding storage, please refer to the maintenance and operating manual.
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Choice of oil
Any type of oil for mechanical transmission can be used with EP additives with viscosity classes from VG 68 to VG 220 according ISO 3448 or SAE 80-90 W according SAE J 306-81. In particular cases we can use oils with different viscosities, in this event please contact our Tech. Dpt. The oil viscosity must be chosen as a function of the ambient temperature of the gearbox. For gearboxes that have to operate at high ambient temperatures or where there are strong thermal excursions, the use of synthetic based oils is recommended. In gearboxes with vertical installation and continuous operation, the oil can undergo excessive overheating ; in this case an external expansion tank is necessary to enable the oil to expand due to the thermal action.
Oil change
The oil change must be carried out after the first 150 hours of effective work, and then after the following 2000 to 4000 hours of operation, depending on the working condition and at least once a year. To facilitate the emptying of the gearbox, we advise that the oil change is carried out while the gearbox is warm. The internal parts must be washed with suitable liquid before the new oil introduction. Different oils must not be mixed together: this is particularly true for mineral and synthetic oils. After the gearbox has been operated, the oil level must be checked periodically and re-filling carried out if necessary.
Oil quantity
The oil quantities required for proper lubrication can be found in page 25.
OIL VISCOSITY OPERATING TEMPERATURE C SAE J-306-81 SAE 80W SAE 85W SAE 90W VG ISO 3448 -20 68 150 220 -10 0 10 AMBIENT TEMPERATURE C 20 30 40 50 60 70 80 90 100
Ambient Temperature Viscosity MOBIL AGIP BP CASTROL ELF ESSO IP SHELL TOTAL ISO 3448 IV min.
Mineral Oil -15C / +25C VG 100 95 MOBILGEAR 627 BLASIA 100 ENERGOL GR XP 100 ALPHA SP100 REDUCTELF SP100 SPARTAN EP100 MELLANA 100 OMALA OIL 100 CARTER EP100N
Mineral Oil -5C / +40C VG 150 95 MOBILGEAR 629 BLASIA 150 GR XP 150 ALPHA SP150 REDUCTELF SP150 SPARTAN EP150 MELLANA 150 OMALA OIL 150 CARTER EP150
Syntetic Oil -25C / +80C VG 150 - 220 165 MOBILGEAR SHC XMP 220 BLASIA SX 220 ENERSYNT HTX 220 ALPHASYNT 220 ORITIS 125 MS SPARTAN SYNT EP220 TELESIA OIL 150 OMALA OIL HD 200 CARTER SH 220
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* Intermediate displacements can be made available to special order ** At min / max. displacement *** At max. displacement
Dual Displacement Radial Piston Hydraulic Motors HPC Series (Low friction components)
Motor Model HPC 080 HPC 125 HPC 200 HPC 270 HPC 325 Displacement min/max. * cm3/n 164 - 1.600 164 - 2.048 164 - 3.087 328 - 4.588 492 - 5.326 Rated Pressure bar 250 250 250 250 250 Intermittent Pressure bar 275 275 275 275 275 Continuous Speed ** n/min. 1.000 - 270 1.000 - 190 1.000 - 175 1.000 -120 350 - 100 Continuous Power *** kW 165 202 261 278 278 Approx Weight kg 172 235 282 450 460
* Intermediate displacements can be made available to special order ** At min. / max. displacement *** At max. displacement, 250 bar, with flushing
3,43
GB 31001
4,09 5,25 6,23 16,74 21,48 25,49 27,56 32,71 38,82 66,94 85,91 87,02 101,96 111,68
GB 31002
GB 31003
130,85 134,23 159,31 172,27 204,45 242,64 238,48 278,07 310,03 356,85 397,87 438,14 506,79 569,58
GB 31004
650,38 715,56 781,71 920,45 1003,19 1166,40 1237,47 1401,92 1663,82 858,53 1013,55 1101,78 1284,67 1432,32 1632,27 1824,45 2007,30 2212,49 2550,43 2876,24 2984,00
GB 31005
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GB
3100 2
38,82 ST AA
B5
HMB
200
Gearbox GB Series
Gearbox frame size: 3100.. Motor displacement: See motor selection table Number of stages: 1 - 2 - 3 - 4 - 5 Motor type: HMB HMC HPC
Output shaft: S - Male splined shaft C - Parallel kejed shaft K - K1 - Parallel special shaft
Motor adapter configuration: FS - Female splined shaft HQ - Shrink disc shaft Radial Piston Motor
Reduction ratio: Please write the exact ratio as shown on the selection tables
Direct input: ST
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120
302
290 h7
200
M 24 N2
760 h8
870
32 N36
260 210 25
M24 N8 260 f7
175
200
283 f7
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795 GB 31005
265 1/8"G
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295 g6
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795 GB 31005
242 H7
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Gearbox type
Motor type HMB 200 HMB 270 - 325 HMB 400 HMB 700
GB 31002
For motor dimensions see specific catalogues: HMB - HMC - HPC. For different sizes and types of motors please consult our Tech. Dpt.
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A 370 475
B 132 142
C 345 375
For motor dimensions see specific catalogues: HMB - HMC - HPC. For different sizes and types of motors please consult our Tech. Dpt.
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VERSION H
A 870
B 870
C 32 (36)
D 140
E 160
F 100
G 70
H 1500
H1 2000
L 40
Shrink Disk GA
A 360
B 590
C 162
T max 522.000 Nm
* Indicative quantity
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As HANSA-TMP has a very extensive range of products and some products have a variety of applications, the information supplied may often only apply to specific situations. If the catalogue does not supply all the information required, please contact HANSA-TMP. In order to provide a comprehensive reply to queries we may require specific data regarding the proposed application. Whilst every reasonable endeavour has been made to ensure accuracy, this publication cannot be considered to represent part of any contract, whether expressed or implied. HANSA-TMP reserves the right to amend specifications at their discretion.
Via M. L. King, 6 - 41122 MODENA (ITALY) Tel: +39 059 415 711 Fax: +39 059 415 729 / 059 415 730 INTERNET: http://www.hansatmp.it E-MAIL: hansatmp@hansatmp.it