En Stoa110077 00 HP50G2

Pulper
Cartulinas CMPC
Maule
BM19 (M450VALZ)
OptiSlush Broke (HP-50G2)
COPYRIGHT NOTICE AND LIABILITY DISCLAIMER
Valmet Technologies, Inc., 2015. All rights reserved.

The following copyrighted materials are the exclusive property of Valmet
Technologies, Inc. and are protected by Finnish and international copyright
laws. Valmet Technologies, Inc. reserves all rights not expressly granted
herein to the authorized user of these copyrighted materials, and no part of
these materials may be reproduced, copied, conveyed, retransmitted or
redistributed in any form or manner without the prior written consent of
Valmet Technologies, Inc.
These copyrighted materials may be used for the sole purpose of operating
and maintaining the machinery, equipment and/or systems addressed herein.
No part of these materials may be used for any other purpose. All machine
operating and maintenance tasks shall be carried out by trained personnel
who are familiar with the machine and applicable safety regulations.
Valmet Technologies, Inc. may modify or update its products and services at
any time without prior notice. These copyrighted materials may contain
references to products or services that may no longer be available at a later
point in time or to methods, processes or procedures that may subsequently
become outdated. Valmet Technologies, Inc. hereby expressly disclaims all
liability for any direct, indirect, incidental and/or consequential damages that
may be incurred by any user of these copyrighted materials due to such
changes.
This Copyright Notice and Liability Disclaimer will be governed by and
construed and interpreted in accordance with Finnish law.
Manufacturer
PO Box 587
FI-40101 JYVSKYL
FINLAND
Tel. +358 (0)10 672 0000
Fax +358 10 672 6600
Business ID 1539180-9
Valmet (China) Co., Ltd.

688, Baofeng Road,
Xuhang Town,
Jiading District
201809 Shanghai, Jiading
P.R CHINA
Tel. +86 21 3997 5000
Fax +86 21 3997 5100
Business ID
310000400327818
machinemanual.feedback@valmet.com
http://www.valmet.com/
Valmet Paper Technology

(Xi'an) Co., Ltd.
No 4, 4th A Fang Road,
Xi'an, 710086, Shaanxi
P.R CHINA
Tel. +86 29 8436 3226
Fax +86 29 8436 3000
Business ID
610000400001423
Cartulinas CMPC
Maule BM19 (M450VALZ)
Safety Instructions
Technical Data
Design and Operating Principle
Operating Instructions
Mechanical Maintenance
5
6
7
8
Pulper
Rev.00
Service and Spare Parts
2016-01-04
Appendices
10
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1 SAFETY INSTRUCTIONS
1
GENERAL SAFETY INSTRUCTIONS ................................................................................. 1

1.1
General Safety Instructions ......................................................................... 1

1.1.1
Design Principles of the Equipment .............................................. 1
1.1.2
Ensuring Safety ............................................................................. 1
1.2
General Safety Equipment .......................................................................... 2

1.2.1
Safeguards .................................................................................... 2
Mechanical Guards ....................................................................... 2
Automation System Safety ............................................................ 3
Warnings and Guides .................................................................... 3
1.3
Working Safety ............................................................................................ 3

1.3.1
Risks that cannot be completely eliminated / Residual Risks
....................................................................................................... 3
Crushing Hazard ........................................................................... 4
Shearing Hazard ........................................................................... 4
Hazard caused by High-Pressure Fluid or Steam ......................... 4
Slipping, Tripping and Falling ......................................................... 4
Noise ............................................................................................. 5
Vibration ........................................................................................ 5
Harmful Fluids, Gases and other Discharges ............................... 5
1.4
Equipment Disassembly and Disposal of the Parts .................................... 5
SAFETY DURING INSTALLATION ....................................................................................... 7

2.1
Safety during Installation .............................................................................. 7
SAFETY DURING OPERATION ........................................................................................... 9

3.1
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Safety during Operation ............................................................................... 9

3.1.1
Procedures for Emergency Draining ............................................ 10
1 Safety Instructions
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SAFETY DURING MAINTENANCE .................................................................................... 11

4.1
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Safety during Maintenance ......................................................................... 11
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1
GENERAL SAFETY INSTRUCTIONS
1.1
General Safety Instructions
This operation and maintenance instruction includes warnings. On the
basis of the type of accident or damage that can result from the danger,
the warnings are divided into two categories:
WARNING
CAUTION
Indicates that the danger in question could result in an accident or

death.
Indicates that the product, process, or environment could suffer damage
from the event in question.
1.1.1
Design Principles of the Equipment
The equipment is designed to be as safe as possible in accordance
with the standards EN ISO 12100. Hazards have been eliminated
through design or by using guards, and they are pointed out by warning
signs and instructions. Hazards that cannot be completely eliminated
are as residual risks.
1.1.2
Ensuring Safety
This operation and maintenance instruction must be kept for the entire
lifecycle of the equipment. If the equipment is moved to another location
or sold, the person responsible for operating it and for maintenance
must ensure that the instructions are kept with the equipment. The
owner of the equipment is responsible for updating the operating and
maintenance instructions with the supplements or modifications
delivered by the manufacturer.
The following is a presentation of safety instructions designed to ensure
the safety of the personnel who operate, monitor and maintain the
machinery, as well as other persons in its immediate vicinity.
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In the interest of safety, Valmet Technologies, as the manufacturer of

the equipment, requires that:
The owner of the equipment makes the safety instructions

available to all personnel responsible for operating, monitoring
and maintaining the equipment, and ensures that the personnel
follow these instructions.
The personnel operating, maintaining and monitoring the

equipment have been trained and have acquainted themselves
carefully with the safety instructions before beginning work. The
personnel operating, maintaining and monitoring the equipment
must also read the safety instructions for other equipment and
components that come with this equipment;
The operating, maintenance and monitoring personnel possess

the basic qualifications and expertise required for their work;
The operating, maintenance and monitoring personnel comply

with these instructions, current legislation applicable at the
location of the equipment, and general occupational safety
regulations.
The owner of the equipment is responsible for supervising that

outsiders cannot operate the machine or enter the possible
danger zone.
1.2
General Safety Equipment
1.2.1
Safeguards
Mechanical Guards
Rotating or otherwise moving parts of the equipment at arms reach
have been protected.
WARNING
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The guards must not be removed while the equipment is running. If

the guards need to be removed for maintenance or repair works, make
sure that start-up of the machine has been prevented. All guards must
be attached in their original places before restarting the machine.
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Automation System Safety

For automation system interlockings, safety switches, safety limits, and
other safety devices, please consult the automation operating and
maintenance instructions.
No safety measures may be disabled or bypassed while the equipment
is running. If bypassing them becomes necessary during a shutdown,
make sure to follow the separate instructions possibly given in the
automation operating and maintenance instructions.
Before start-up the above safety devices must be returned to operational
status.
Warnings and Guides

The equipment is provided with warning and instruction signs. The
signs must not be removed. If the sign is lost or is damaged the owner
of the equipment is responsible for replacing the sign with a new one.
1.3
Working Safety
1.3.1
Risks that cannot be completely eliminated / Residual Risks
There are elements of danger related to the equipment and its operating
environment that cannot be completely eliminated due to operational
reasons.
While the equipment is running most of the hazards are outside of
arms reach. Hazards due to unexpected events are eliminated if moving
or staying in the vicinity of the equipment is avoided while the equipment
is running. If you need to enter the possible danger zone e.g. to perform
measurements, adequate personal protective equipment must be worn.
WARNING
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Strict directions must be provided for each measuring or other job and
it should be performed by a person familiar with the procedure. Hazards
during maintenance and repair work are minimized by using appropriate
personal protective equipment and by using tools and methods in
accordance with this instruction.
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Crushing Hazard
The equipment has been designed and safeguarded to minimize
crushing hazard while the machine is running. Most of the crushing
hazards occur during maintenance and repair works.
Wearing of safety shoes and gloves, usage of appropriate tools and
methods, obeying of given handling instructions and neatness of the
environment diminish the risk of accidents. Unintentional startup or
other possible rotation or movement of the machine must be prevented
during maintenance and repair works in order to eliminate crushing
hazard.
Shearing Hazard
Shearing hazard due to sharp edges is connected with the crushing
hazards, thus the same measures are applied to eliminate the hazard.
Hazard caused by High-Pressure Fluid or Steam

The high-pressure fluid can be hazardous while test running the
equipment during maintenance of the washings and washing water
shower pipes.
High-pressure steam can cause a serious burn hazard. Always before
maintaining or repairing equipment, pipes, instruments etc. under
steam, make sure the devices are depressurized and that the
temperature has dropped to a safe level.
Regular condition control of the equipment and replacement of worn
parts are also essential safety measures.
Slipping, Tripping and Falling

Water, other liquids, unnecessary tools and debris left on the floor,
walkways or stairs present a slipping and tripping hazard, or even the
risk of falling off. This is why keeping the machine clean and its vicinity
neat is of such great importance. Personnel must also wear safety
shoes whenever moving in the vicinity of the machine, and also wear
a hard hat and safety goggles inside the machine. Safety harnesses
must be worn at all times whenever the potential fall is more than one
meter.
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These hazards must be particularly considered in connection with such

maintenance procedures, during which guardrails, parts of walkways,
and other protective structures often need to be temporarily removed.
Special care, employing appropriate working procedures and
equipment, following the manufacturer's instructions, and wearing
appropriate personal protective equipment will considerably reduce
the risk of injury. Wearing a safety harness is mandatory.
Noise
Noise of the equipment can in many cases occasionally or constantly
be dangerously high. For that reason, and simply for convenience
hearing protectors must always be worn in the vicinity of the machine.
Vibration
Damaging of the rotating parts, disturbance within balancing, loosening
of joints or problems in other parts may cause vibration.
Vibration as such does not have an immediate effect on personal safety.
It is, however, a sign of abnormal operation which can create a device
failure and further cause a safety risk. This is why the reason for the
abnormal vibration has to be immediately checked and removed.
Harmful Fluids, Gases and other Discharges

During washings the worker can be exposed to the chemicals in use
or to other harmful substances present or generated in the process.
Therefore, wearing of personal protective equipment, especially of
respiration protector is essential during washings.
1.4
Equipment Disassembly and Disposal of the Parts
The equipment is made of almost entirely recyclable materials, which
makes it possible to reuse the materials of the components.
Make sure to comply with local working safety and environmental laws
and regulations when disassembling a machine and disposing of or
recycling its parts.
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Follow the manufacturers instructions for replacing parts and their

safety instructions when removing components from the equipment.
Special care must be taken during lifting and handling of heavy parts.
Safety measures applied in installation made by Valmet are a good
starting point also for safe disassembly work.
Compliance with all safety instructions and co-operation with the
manufacturer when necessary ensure the safety of the work.
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2
SAFETY DURING INSTALLATION
2.1
Safety during Installation
All installation work must be carried out in accordance with general
occupational safety regulations, and any specific requirements of plant
conditions must be taken into account.
NOTE
Lifting and transferring parts of the equipment must be performed in

accordance with general occupational safety regulations, and no parts
of the unit are to be allowed to fall. Never go under a hanging load.
The weight of the equipment or its parts is indicated in the drawing
and/or in the bill of material. Always ensure that the maximum load
marked on the lifting equipment is not exceeded. Also read the
instructions for other equipment and components that come with this
equipment.
When installing a chute section, be careful with the components sharp
edges.
Handling and disposal of substances used during transport and
installation (e.g., sealants, oils, glues, paints, chemicals) must be done
in accordance with the instructions in operational safety bulletins,
plant-specific waste disposal instructions, and current local legislation.
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3
SAFETY DURING OPERATION
3.1
Safety during Operation
Before commissioning and performing initial start-up, ensure that the
equipments motor voltage corresponds to the mains voltage.
Check regularly (at least once a year) the following fastening and joint
points:
CAUTION
NOTE
the fastening and tightness of the pipe connections
the overflow connection in order to detect any blockage
the fastening and tightness of the sealing water connections
the fastening and tightness of the instrumentations air

connections
the fastening of the rotor unit to the foundation
tightness of the gear fastenings in order to prevent possible oil

leaks and other damages
Mind the surfaces of the equipment and the connections they can
occasionally become dangerously hot.
In the case of belt-driven equipment, periodically check the tightness
of the V-belts and fastening of the belt pulley in accordance with the
separate instructions.
Dust and other dirt accumulating on the surfaces of the equipment
should be washed off periodically.
CAUTION
CAUTION
Due to noise generated by the gear, hearing protectors must be used

during operation.
The pulper hatch is operated by remote control be careful of its
automatic closure and opening functions.
When feeding the paper web into the pulper, be careful of the drop
openings in the floor.
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When working from a sampling or other hatch, be careful not to open

the shower unintentionally.
When working in the vicinity of the equipment, be careful of its standing
braces and other projections.
Keep the working environment clean. There is a risk of slipping if any
stock or lye leaks onto the floor.
3.1.1
Procedures for Emergency Draining
In an emergency, the pulper must be drained as follows:
Pulper (HP-50G2)
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Stop and lock the motor(s), the possible conveyor and turn off
the shower pipes
Start the pulpers exhaust pump
Start the ventilation
Open the manhole as soon as the stock level allows this
Enter the pulper and administer first aid to the victim. Remember
to wear protective equipment when entering the pulper
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4
SAFETY DURING MAINTENANCE
4.1
Safety during Maintenance
Maintenance work must be carried out in accordance with general
CAUTION

equipment.
Do the following before you begin maintenance:
Detach the motor from the mains in order to prevent accidental

starting during maintenance
Shut down the stock feed to the pulper
Make sure that all the hot parts of the equipment have cooled off
Follow instructions of the motor supplier when replacing the motor.
CAUTION
CAUTION
Use protective gloves and appropriate tools when handling melted or

burned O-rings that contain Viton.
When heating parts, use respiratory protection and adequate protective
clothing and ensure sufficient ventilation of the environment.
Before opening a sealing water pipe or pneumatic lubrication unit,
ensure that the system is depressurized and empty.
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CAUTION
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When performing maintenance and repair work, the pulper must be

fitted with a separate railed scaffold to prevent slipping off the chutes.
If the pulper cover hatch has been removed and taken for repair, the
pulper opening must be covered with netting or a similar covering, to
prevent falling in.
NOTE
The equipments pneumatic system must be locked in case of

pneumatic cylinder or pipe fractures.
Before cleaning the ventilation duct, ensure that the cleaning shower
hand valve is closed and locked.
If the maintenance requires entry into the pulper, in the interest of safety
ensure that:
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maintenance work inside the pulper is not allowed when the

paper-/board machine is running
the person responsible for operating the equipment has been

notified of the start of the maintenance and of its estimated
duration
signs warning of the maintenance have been placed in

appropriate places
all of the pulpers feed conveyors have been locked to prevent

start-up
the safety switch of the rotors drive motor has been locked in
STOP position and the motor locked to prevent start-up
cover openings have been blocked so that objects cannot fall

into the pulper during maintenance
the pulper hatch has been locked to prevent opening and closing
supplied lifting tools must be used when lifting parts
general lifting equipment must be appropriate, inspected and

approved
parts of the equipment are prevented from striking personnel or

pinning anyone against other structures
the hand valves on the showers and connections are closed and
locked to prevent unexpected opening
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If the maintenance requires going inside the pulper, in the interest of

safety of the persons entering inside, ensure that:
harmful chemicals and bacteria have been rinsed out of the

pulper, and the flow of fresh air into the pulper has been ensured
electric tools used during maintenance have been inspected for

defects before they enter the equipment
maintenance personnel use proper protective equipment (e.g.,

safety rope) and they have a contact person outside the tank for
the entire duration of the maintenance
maintenance personnel use personal protective equipment in

order to prevent, e.g., slipping
Once the maintenance is complete, ensure that all of the equipment's

protective covers are in the correct places and the inside of the vat is
clean.
Remove warning signs regarding maintenance.
Let the person responsible for operating the equipment know that
maintenance work is finished.
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2 TECHNICAL DATA
1
TYPE CODES ....................................................................................................................... 1

1.1
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Type Codes .................................................................................................. 1
2 Technical Data
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TYPE CODES
1.1
Type Codes
The OptiSlush product family covers all pulping applications in the
areas of recycled fibers and pulp handling in various stages of the
process and at different consistencies.
Based on the intended application and position, OptiSlush equipment
has been divided into the following product groups:
Table 1.
Product name
Pulpers:
OptiSlush Broke (HP)
OptiSlush Bale (VMi)
OptiSlush Vertical (VHi)
OptiSlush Vertical (VCi)
Couch Pit Pulper
Drum Screens:
OptiSlush Drum Screen (DS)
Typical consistencies
3,5...4,5 %
4...8 %
8...15 %
4...5,5 %
2...4 %
<2%
Example of a type code: OptiSlush Broke (HP-33G2)

Key to the code:
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HP = Horizontal Pulper
33 = Rotor diameter in inches
G = Gear Drive / B = Belt Drive
2 = Number of rotors
2 Technical Data
TECHNICAL SPECIFICATION
MPQR000790.19
Maule_BM19
Cartulinas CMPC S.A.
Jussi Ahola
19.12.2014
01.10.5 Broke collection (Area 070)
Description
Dimensioning data and

requirements
Technical data
Note
Pos. E1401
ValZone pulper
HP-50G2L, Gear drive

Agitator unit, 2 pcs
Rotor diameter 1270 mm
Screen plate with holes 360 / 15 mm
3
Vat volume, net/gross 53 m / 70 m
Valmet MPQR000790.19 01.10.5 Broke collection (Area 070) 19.12.2014
Pos. E1701
OptiSlush
Technical data
Incl. Note
[total]
Broke collection
Valzone pulper
HP-50G2L
Pulper rotor unit
X
- Rotor and screen plate
- Extraction box with discharge
connection
- V-belt drive with guard or
- Gear drive with coupling and guard
- Cord packing
- Seal water flow monitoring unit with
alarm
Manufacturing drawings
for vat, chutes, hatches (2pcs), shower

pipes and Y-pipe
Vat
X
-
- Overflow, drain and level transmitter

connections
- Manhole
- Foundation bolts
Chutes
Shower pipes
Motor
- Fastening elements
Valmet MPQR000790.19 01.10.5 Broke collection (Area 070) 19.12.2014
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3 DESIGN AND OPERATING PRINCIPLE

1
DESIGN AND PRINCIPLE OF OPERATION OF A GEAR DRIVEN HP PULPER .............. 1

1.1
CONSTRUCTION ........................................................................................ 1
1.1.1
Vat .................................................................................................. 2
1.1.2
Rotor Unit(s) ................................................................................... 2
Rotor .............................................................................................. 4
Screen / Slot Plates ........................................................................ 5
1.1.3
Drive Equipment ............................................................................. 5
Gear Drive ...................................................................................... 5
1.1.4
Chutes or Cover ............................................................................. 6
1.1.5
Shower Pipes ................................................................................. 7
1.2
PRINCIPLE OF OPERATION ...................................................................... 7
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1
DESIGN AND PRINCIPLE OF OPERATION OF A GEAR DRIVEN HP PULPER
1.1
CONSTRUCTION
Figure 1. Construction of OptiSlush Broke (HP) pulper (STOA009535)

1
2
3
4
5
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Vat
Rotor unit
Drive motor
Shower pipes
Chutes
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The main components of the HP pulper are:

1
Vat
Rotor unit(s)
Drive equipment
Essential construction components also include:

1
Chutes
Shower pipes
1.1.1
Vat
The vat of the pulper is made of a welded steel construction. The parts
of the vat that come into contact with stock are made of acid-proof
steel, and the external support structures are of structural steel. The
vat is rectangular with 4...10 feet welded to the bottom. The vat is
equipped with a hinged manhole.
The vat has standard connections for draining and surface-level
measurement. Other necessary connections are made on a
customer-specific basis.
An adjustment ring has been welded to the side of the vat to house the
rotor unit(s).
1.1.2
Rotor Unit(s)
There are two kinds of rotor units: belt-driven and gear-driven. The
rotor is attached to the bearing unit shaft in a belt-driven rotor unit, and
to the gear shaft in a gear-driven unit.
The rotor unit and vat are flexibly connected due to the O ring between
them. There are either one or two rotor units in a pulper.
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Figure 2. Gear-driven rotor unit (STOA009536)

1
2
3
4
5
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Suction box
Gear
Shaft seal
Screen plate
Rotor
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Rotor
The rotor has eight blades, four of them with additional pump blades.
The rotor is usually made of acid-resistant steel casting.
Figure 3. HP pulper rotor (STOA009537)
Figure 4. HP pulper rotor (STOA009539)

1
2
3
4
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Rotor
Pump blade
Screen plates
Slot plates
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Screen / Slot Plates

The rotor unit can be equipped with both a screen and a slot plate or
just a single screen plate. Depending on the pumping capacity, either
a 360-degree screen plate sector or a 180-degree screen plate sector
with the upper section replaced with a slot plate is used.
Figure 5. Screen / slot plates: Screen plate sector of 180 and Screen plate
sector of 360 (STOA009540)
1.1.3
Drive Equipment
The drive equipment is determined by the power required by the pulper
and the space available. Either gear drive or belt drive is used.
Gear Drive
The gear drive equipment includes the gear, coupling, and motor.
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Figure 6. Gear drive (STOA009541)

1
2
3
Gear
Coupling
Motor
In gear-driven pulpers, the rotor is mounted on the gear shaft using

bearings.
All rotating parts are equipped with mechanical protective covers.
1.1.4
Chutes or Cover
The parts of the chutes and cover that come into contact with stock
are made of acid-proof steel. The external stiffeners are made of
stainless steel.
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The cover is normally welded to the vat.

The chutes and covers are always designed and manufactured
customer-specifically and are equipped with the necessary pipe
connections.
1.1.5
Shower Pipes
The shower pipes are made of acid-proof steel. The external brackets
are made of stainless steel. The shower pipes are welded to the chutes
or to the dowel bars in the building.
1.2
PRINCIPLE OF OPERATION
OptiSlush Broke (HP) pulpers are used mainly as a broke pulper for a
paper machine or under the finishing machines.
Typical applications include:
press pulper
calander pulper
on-machine coater pulper
reel pulper
winder pulper
guillotine pulper
The purpose of pulping is to disintegrate the paper into a form ready

for pumping and to deflake the paper as well as possible. However,
the degree of deflaking depends on the paper grade and the pulping.
In addition, using a deflaker is recommended with paper grades that
are hard to disintegrate.
The paper is mixed with water so that the bonds between the fibers
can be more easily dissolved. When the fibers get wet, they become
weak and at the same time regain their original characteristics.
Due to the mixing and mechanical kneading, the fibers are separated.
Separation is induced by vigorously mixing the water/fiber suspension
with the rotor. The rotors rotation induces speed differences in the flow
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between stock layers, which further cause the turbulent flows necessary
for deflaking.
The rotor also has a mechanical deflaking effect. The rotor blades hit
the bits of paper that have not been deflaked yet, and they knead the
stock in the zone between the rotors lower surface and the screen
plate. In mechanical deflaking, the slotted plate in particular has an
important influence.
Mechanical forces are important at the beginning of pulping when stock
is fed into the pulper. At first, the rotor tears the paper into small bits,
after which hydraulic forces finish the deflaking of the stock.
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4 OPERATING INSTRUCTIONS
1
SAFETY DURING OPERATION ........................................................................................... 1

1.1
Safety during Operation ............................................................................... 1

1.1.1
Procedures for Emergency Draining .............................................. 2
OPERATING INSTRUCTIONS OF A GEAR DRIVEN OPTISLUSH HP PULPER .............. 3

2.1
Procedures before Commissioning .............................................................. 3

2.1.1
Installation Inspection ..................................................................... 3
2.1.2
Checking the Drive Equipment ...................................................... 3
2.1.3
Checking the Shaft Seal for Sealing Water .................................... 3
2.1.4
Checking the Direction of Rotation of the Rotor ............................. 4
2.1.5
Other Inspection Procedures before Commissioning .................... 5
2.1.6
Water Run ...................................................................................... 5
2.1.7
Level Height ................................................................................... 6
2.1.8
Stock Consistency .......................................................................... 6
2.1.9
Flushing Water ............................................................................... 6
2.1.10 Showers ......................................................................................... 7
2.2
Monitoring during Operation ......................................................................... 7
2.3
Restrictions on Use ...................................................................................... 8
2.4
Stopping ....................................................................................................... 9
2.4.1
Short Shutdown Period .................................................................. 9
2.4.2
Long Shutdown Period ................................................................... 9
2.5
Troubleshooting ............................................................................................ 9
Pulper (HP-50G2)
STOA110077.00.EN
4 Operating Instructions
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1
SAFETY DURING OPERATION
1.1
Safety during Operation
Before commissioning and performing initial start-up, ensure that the
equipments motor voltage corresponds to the mains voltage.
Check regularly (at least once a year) the following fastening and joint
points:
CAUTION
NOTE
the fastening and tightness of the pipe connections
the overflow connection in order to detect any blockage
the fastening and tightness of the sealing water connections
the fastening and tightness of the instrumentations air

connections
the fastening of the rotor unit to the foundation
tightness of the gear fastenings in order to prevent possible oil

leaks and other damages
Mind the surfaces of the equipment and the connections they can
occasionally become dangerously hot.
In the case of belt-driven equipment, periodically check the tightness
of the V-belts and fastening of the belt pulley in accordance with the
separate instructions.
Dust and other dirt accumulating on the surfaces of the equipment
should be washed off periodically.
CAUTION
CAUTION
Due to noise generated by the gear, hearing protectors must be used

during operation.
The pulper hatch is operated by remote control be careful of its
automatic closure and opening functions.
When feeding the paper web into the pulper, be careful of the drop
openings in the floor.
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When working from a sampling or other hatch, be careful not to open

the shower unintentionally.
When working in the vicinity of the equipment, be careful of its standing
braces and other projections.
Keep the working environment clean. There is a risk of slipping if any
stock or lye leaks onto the floor.
1.1.1
Procedures for Emergency Draining
In an emergency, the pulper must be drained as follows:
Pulper (HP-50G2)
STOA110077.00.EN
Stop and lock the motor(s), the possible conveyor and turn off
the shower pipes
Start the pulpers exhaust pump
Start the ventilation
Open the manhole as soon as the stock level allows this
Enter the pulper and administer first aid to the victim. Remember
to wear protective equipment when entering the pulper
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2
OPERATING INSTRUCTIONS OF A GEAR DRIVEN OPTISLUSH HP PULPER
2.1
Procedures before Commissioning
2.1.1
Installation Inspection
Before commissioning, perform an installation inspection and repair
any faults.
2.1.2
Checking the Drive Equipment
Ensure that
the gearbox of a gear-driven pulper has been filled with oil (see
gear manufacturer's instructions in 10. Appendices)
2.1.3
Checking the Shaft Seal for Sealing Water
Under no circumstances should the rotor rotate without sealing water.
NOTE
Pulper (HP-50G2)
STOA110077.00.EN
Flush the sealing water line to the channel so that no impurities

pass beyond the shaft seal
Connect the sealing water connection to the shaft seal
Open the sealing water line and check the connections for leaks
Adjust shaft sealing water pressure and flow (see Mechanical

Maintenance)
Ensure that the sealing water pressure exceeds the equipment

operating pressure by 100 kPa (~14,5 psi) and follow the
instructions of the seal manufacturer
Check the sealing water temperature according to the

manufacturers instruction
Set the low limit alarm for the flow
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2.1.4
Checking the Direction of Rotation of the Rotor
Sealing water must be on when checking the direction of rotation.
NOTE
Ensure the rotor can rotate freely
Run the motor for 10 seconds
Check that the rotor rotates with the thicker side of the blades
leading
Figure 1. The rotation direction of the rotor in a pulper with one rotor
(STOA009543)
Figure 2. The rotation direction of the rotors in a pulper with two rotors
(STOA009544)
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2.1.5
Other Inspection Procedures before Commissioning
Ensure that
all the guards are in place and the safety devices function
(emergency stop switches)
the shaft seal is not leaking
all fixing screws are in place and tightened
flange joints have been properly tightened
drain plugs (if any) are in place and all valves are closed
manhole is closed
the inside of the pulper is clean and all foreign objects, tools, etc.
have been removed from the pulper
the internal weld seams are in order (visual check)
the gear pressure lubrication unit functions
the level indicator has been switched on
2.1.6
Water Run
After the procedures before commissioning have been completed and
the required adjustments and modifications have been made, perform
the pulpers water run as follows:
Pulper (HP-50G2)
STOA110077.00.EN
Fill the vat with water to about 2/3 of its volume
Check the vat and the sealing between vat and rotor unit for leaks
Start the pressure lubrication unit (if any) and monitor the
pressure level
Open the sealing water line and check the flow and pressure
When the water level is correct, start the pulpers drive motor
Check that the pulper runs smoothly, and observe the sound and
the motors power intake (60...90% of the nominal value)
Observe the shaft seals performance
Also observe all external weld seams for leaks
Check and calibrate the pulper's instrumentation
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2.1.7
Level Height
A suitable pulping level has been specified separately for each pulper.
The pulper instrumentation should keep the level at the given value. It
is necessary for the pulper's operation that the level remains within the
given limits. Both too low and too high levels will weaken the deflaking
properties of the pulper. If the level is too low and a part of the rotor is
above the level, the surface current pattern of the stock is disturbed
and harmful air is mixed into the stock. If the level is too high, both the
surface flow of the stock and the sinking of the feed inside the pulper
are slowed down.
2.1.8
Stock Consistency
The optimal stock consistency for the HP pulper is 3.5...4.5%,
depending on the situation. The consistency control system ensures
that the consistency during both pulping and discharge is within the
proper limits.
Too low a consistency causes harmful turbulence, and too high a
consistency weakens the suction effect of the rotor by limiting the flow
speed of the stock in the vat. Thus, both too low and too high
consistencies impair the sinking of the material into the pulper. A
consistency appropriate to the pulper is marked on the layout drawing.
2.1.9
Flushing Water
The possible flushing water line led below the rotor keeps the rear side
of the rotor clean from stock and any impurities. The flushing water
line is usually opened periodically, three to four times a day, e.g., during
breaks.
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2.1.10
Showers
The showers are used in the pulper for the following purposes:
to wash and to prevent paper from sticking to the chute surfaces
to dampen the paper web to speed up sinking
to dilute the stock
The showers are always directed at the top surface of the paper web.
Only the flushing showers of the chutes are directed at the lower surface
of the paper web and at the chutes.
The showers used for dampening the web are either water or stock
showers. Water showers are used for paper and thin qualities in
general, but heavy qualities, such as board, require a stock shower if
they are to sink into the pulper effectively enough. The stock shower
normally has a separate connection, a so-called circulation connection,
in the suction box of the rotor unit.
The flows of different showers are adjusted in accordance with the
pulpers location in the process.
2.2
Monitoring during Operation
During operation, certain operational and mechanical parameters have
to be monitored. Most of this monitoring can be carried out by the
instruments, which sound an alarm if a deviation from the parameters
set value or operation range occurs.
Regular monitoring of certain functions ensures trouble-free operation
and low maintenance costs.
With regard to the pulpers operation, it is essential to monitor:
Condition of the shaft seal

Flow and pressure of the seal water, as well as the amount of
cord packing leakage water.
Stock surface level

Its maximum deviation is 150 mm (~5,9 in.) above or below the
specified level.
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Stock consistency
Optimal consistency of the stock is 3.5...4.5 %
Quality of the fed fiber material

Visual checks / laboratory analyses.
Rotor clearance
The clearance must be checked once a year.
Increased rotor clearance impairs the pumping out of stock from
the vat.
Rotor and screen plate condition

Wear to the rotor or screen plate impairs the deflaking properties
of the pulper.
Operation sound and vibration of the equipment
The motors power intake

The rotor condition can be observed by regular monitoring (as
the rotor becomes worn, its power consumption decreases).
Drive equipment
In a gear-driven pulper, check the oil level and temperature of
the gear (see Appendices, Separate Instructions / Gear).
Also read the instructions for other equipment or components that come
with this equipment.
2.3
Restrictions on Use
Feeding un-split paper rolls into the pulper is strictly prohibited.
NOTE
A roll stuck between the rotor and the bottom will damage the pulper
Bale wires must be cut, and metal hoops are not allowed.
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2.4
Stopping
2.4.1
Short Shutdown Period
1
Stop the rotor, stock pump, and any air exhaust fan
Close the water valves, which dilute the stock in the vat
-
shower water
rotor flushing water
Sealing water may flow.

NOTE
2.4.2
Long Shutdown Period
1
Pump the pulper as empty as possible
Dilute the remaining stock by adding water up to the overflow

connection
Pump the pulper as empty as possible again
Stop the rotor(s), stock pump, and any exhaust fan
Close the water valves (as for a short shutdown period)
2.5
Troubleshooting
Symptom: Vibration
Probable cause:
Fastening of equipment is not tight
Correction:
Tighten bolts and screws
Probable cause:
Bearings are worn
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Correction:
Replace bearings
Probable cause:
Rotor shaft is bent
Correction:
Replace shaft
Probable cause:
Rotor is balanced incorrectly (or worn)
Correction:
Replace rotor
Probable cause:
Stock level in the vat is too low
Correction:
Raise stock level
Symptom: Gear overheats
Probable cause:
Bearings are worn
Correction:
Replace bearings
Symptom: Mechanical seal leaks
Probable cause:
Seal surfaces of the mechanical seal are worn or faulty
Correction:
Seal maintenance
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Symptom: Cord packing leaks
Probable cause:
Cord packing is too loose
Correction:
Tighten cord packing
Probable cause:
Too much sealing water
Correction:
Decrease the amount of sealing water
Symptom: Cord packing overheats
Probable cause:
Cord packing is too tight
Correction:
Loosen cord packing
Probable cause:
Insufficient amount of sealing water
Correction:
Increase sealing water flow and/or check and repair sealing water
feeding equipment
Symptom: Deflaking of pulp is permanently decreased
Probable cause:
Screen plate is worn
Correction:
Replace screen plate
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Probable cause:
Rotor is worn
Correction:
Replace rotor
Symptom: Drive motor power consumption is permanently

decreased
Probable cause:
Rotor is worn
Correction:
Replace rotor
Symptom: Pumping out of stock is permanently decreased
Probable cause:
Screen plate is worn
Correction:
Replace screen plate
Probable cause:
Rotor is worn
Correction:
Replace rotor
Symptom: Drive motor overheats
Probable cause:
Cooling of motor is prevented
Correction:
Eliminate the cause
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Probable cause:
Bearings are worn
Correction:
Replace bearings
Probable cause:
Sealing rings of cord packing are worn
Correction:
Seal maintenance
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5 MECHANICAL MAINTENANCE
1
SAFETY DURING MAINTENANCE ...................................................................................... 1

1.1
TIGHTENING TORQUES .................................................................................................... 5

2.1
Safety during Maintenance ........................................................................... 1
Tightening Torques ...................................................................................... 5
MECHANICAL MAINTENANCE OF A GEAR DRIVEN HP PULPER .................................. 7

3.1
Periodical Maintenance ................................................................................ 7

3.1.1
Lubrication ...................................................................................... 7
3.1.2
Other Inspection and Maintenance Procedures ............................. 7
3.2
Maintenance and Adjustments ..................................................................... 8

3.2.1
Replacing the Rotor ....................................................................... 8
Removing the Rotor ..................................................................... 10
Installing the Rotor ....................................................................... 10
3.2.2
Replacing the Screen and Slot Plates .......................................... 11
Removing the Screen and Slot Plates ......................................... 11
Installing the Screen and Slot Plates ........................................... 11
3.2.3
Rotor Clearance ........................................................................... 12
Adjusting the Rotor Clearance ..................................................... 12
3.2.4
Shaft Seal Maintenance ............................................................... 13
Mechanical Seal ........................................................................... 13
Cord Packing ................................................................................ 15
3.2.5
Gear Drive .................................................................................... 17
Pulper (HP-50G2)
STOA110077.00.EN
5 Mechanical Maintenance
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1
SAFETY DURING MAINTENANCE
1.1
Safety during Maintenance
Maintenance work must be carried out in accordance with general
CAUTION

equipment.
Do the following before you begin maintenance:
Detach the motor from the mains in order to prevent accidental

starting during maintenance
Shut down the stock feed to the pulper
Make sure that all the hot parts of the equipment have cooled off
Follow instructions of the motor supplier when replacing the motor.
CAUTION
CAUTION
Use protective gloves and appropriate tools when handling melted or

burned O-rings that contain Viton.
When heating parts, use respiratory protection and adequate protective
clothing and ensure sufficient ventilation of the environment.
Before opening a sealing water pipe or pneumatic lubrication unit,
ensure that the system is depressurized and empty.
Pulper (HP-50G2)
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CAUTION
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When performing maintenance and repair work, the pulper must be

fitted with a separate railed scaffold to prevent slipping off the chutes.
If the pulper cover hatch has been removed and taken for repair, the
pulper opening must be covered with netting or a similar covering, to
prevent falling in.
NOTE
The equipments pneumatic system must be locked in case of

pneumatic cylinder or pipe fractures.
Before cleaning the ventilation duct, ensure that the cleaning shower
hand valve is closed and locked.
If the maintenance requires entry into the pulper, in the interest of safety
ensure that:
Pulper (HP-50G2)
STOA110077.00.EN
maintenance work inside the pulper is not allowed when the

paper-/board machine is running
the person responsible for operating the equipment has been

notified of the start of the maintenance and of its estimated
duration
signs warning of the maintenance have been placed in

appropriate places
all of the pulpers feed conveyors have been locked to prevent

start-up
the safety switch of the rotors drive motor has been locked in
STOP position and the motor locked to prevent start-up
cover openings have been blocked so that objects cannot fall

into the pulper during maintenance
the pulper hatch has been locked to prevent opening and closing
supplied lifting tools must be used when lifting parts
general lifting equipment must be appropriate, inspected and

approved
parts of the equipment are prevented from striking personnel or

pinning anyone against other structures
the hand valves on the showers and connections are closed and
locked to prevent unexpected opening
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If the maintenance requires going inside the pulper, in the interest of

safety of the persons entering inside, ensure that:
harmful chemicals and bacteria have been rinsed out of the

pulper, and the flow of fresh air into the pulper has been ensured
electric tools used during maintenance have been inspected for

defects before they enter the equipment
maintenance personnel use proper protective equipment (e.g.,

safety rope) and they have a contact person outside the tank for
the entire duration of the maintenance
maintenance personnel use personal protective equipment in

order to prevent, e.g., slipping
Once the maintenance is complete, ensure that all of the equipment's

protective covers are in the correct places and the inside of the vat is
clean.
Remove warning signs regarding maintenance.
Let the person responsible for operating the equipment know that
maintenance work is finished.
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2
TIGHTENING TORQUES
2.1
Tightening Torques
Follow the guidelines given in the following table, unless otherwise
specified in the customer-specific drawings and in separate component
instructions.
Table 1. Tightening torques
TIGHTENING TORQUES
Steel screws and nuts
EN ISO 4014, EN ISO 4017, EN ISO 3506-1, EN ISO 4762 EN ISO
4032, EN ISO 3506-2
Thread
M5
M6
M8
M 10
M 12
M 14
M 16
M 20
M 22
M 24
M 27
M 30
M 33
M 36
M 39
1)
8,8 Zne Nm 1)
5
9
24
45
85
125
200
400
525
675
980
1345
1820
2350
3000
A4-80 Nm 2)
5
8
22
42
75
115
175
350
465
600
A4-70 Nm 2)
3,7
6
16
31
55
85
130
265
348
450
795
990
1200
1385
1800
Dry
Primarily: Molycote 1000/Molycote HSC Plus

Substitute: e.g. Chesterton 785, Loctite 8155 Hirange (friction
coefficient always <0,20)
USE CALIBRATED TIGHTENING TOOL
2)
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Table 2. Tightening torques (US-units)

TIGHTENING TORQUES
Steel screws and nuts
ANSI 18.2.1, ANSI B 18.3
Thread
1/4
UNC
5 / 16
UNC
3/8
UNC
1/2
UNC
5/8
UNC
3/4
UNC
7/8
UNC
1 UNC
1 UNC
1 UNC
1)
8,8
Nm
Zne 1)
Ft-lbs
10
A4-80
Nm
10
2)
A4-70
Nm
Ft-lbs
7,5
5,2
23
17
22
15
16
11
42
30
38
28
28
21
100
73
89
65
66
48
200
145
175
130
131
97
350
260
315
230
236
172
560
410
500
365
375
273
825
1640
2850
610
1210
2100
730
540
547
1210
1680
405
895
1240
2)
Ft-lbs
Dry
Primarily: Molycote 1000/Molycote HSC Plus

Substitute: e.g. Chesterton 785, Loctite 8155 Hirange (friction
coefficient always <0,20)
2)
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3
MECHANICAL MAINTENANCE OF A GEAR DRIVEN HP PULPER
3.1
Periodical Maintenance
The inspection and maintenance procedures and lubrication points
related to maintaining the equipment are presented in the Preventive
Maintenance Jobs table, see Appendices. No daily routines performed
by the production and/or mechanical maintenance personnel are
included in this table.
3.1.1
Lubrication
See gear documentation for manufacturers instructions on the points
to be lubricated, lubrication intervals and lubrication oils and greases.
3.1.2
Other Inspection and Maintenance Procedures
Inspection and maintenance procedures related to maintaining the
equipment are presented in the Preventive Maintenance Jobs table,
see Appendices.
Instructions for performing the maintenance procedures are presented
in chapter Maintenance and Adjustments.
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3.2
Maintenance and Adjustments
3.2.1
Replacing the Rotor
Figure 1. Pulling out the rotor (STOA009547)
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2
3
4
5
6
7
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Rotor
Shaft
Jack
Flange
Threaded rods (4 pcs)
Threaded hole
Hexagonal nut
Figure 2. Detaching the rotor (STOA009548)

1
2
3
4
5
6
7
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Rotor
Seal
Flange
Shims
O-ring
Plug screw
Lifting tackle
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Removing the Rotor

Follow the equipments safety instructions.
NOTE
Remove the protective cover located in the middle of the rotor
Remove the plug screw (6) from the splash plate above the rotor
in the vat and replace it with a lifting eye screw from inside the
vat
Fasten the lifting eye screw in the thread in the outer edge of the
rotor blade and put the lifting tackle (7) between the lifting eye
screws in the rotor and the vat
Remove the flange (3), seal (2) and shims (4)
Pull the rotor out of the shaft sleeve and the shaft with a jack and
place it at the bottom of the vat with a lifting rope
Installing the Rotor
Pulper (HP-50G2)
STOA110077.00.EN
Check that the O-ring (5) on the shaft sleeve is in good condition
(replace the O-ring if necessary)
Lubricate the shaft with installation grease
Lift the rotor to the shaft and attach it to the shaft using the flange,
threaded rods, and nuts
Measure the rotor clearance
Install the appropriate number of shims
Mount the flange and seal in place and tighten the screws
Check the rotor clearance and adjust again, if necessary
Lock the screws with a locking weld and fasten the protective
cover. Also lock the screws of the protective cover by welding
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3.2.2
Replacing the Screen and Slot Plates
Removing the Screen and Slot Plates

NOTE
Remove the rotor as described under Replacing the Rotor
Loosen the tightening screws of the slot and screen plates.

Depending on the rotor size and manufacturing mode, the slot
and screen plate may consist of a maximum of three segments
Remove the plates and check the cleanliness of the suction box
behind the plates
Installing the Screen and Slot Plates
Pulper (HP-50G2)
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Mount the slot and screen plates in their places
Tighten the fastening screws carefully and lock the screws with
locking weld
Mount the rotor in place as described under Replacing the Rotor
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3.2.3
Rotor Clearance
Adjusting the Rotor Clearance
Figure 3. Adjusting the rotor clearance, gear drive (STOA016595)

1
2
3
4
5
6
7
Flange
Protective cover
O-ring
Shims
O-ring
Clearance according to Rotor Assembly drawing (see Appendices)
Gear
The rotor is fastened to the shaft with a key. The rotor clearance can
be adjusted by adding or removing shims at the end of the shaft.
Measure the rotor clearance (space between the lower surface of the
rotor vanes and screen and slot plates) from below two opposite vanes
at least.
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If the clearance is not the same as marked on the rotor assembly

drawing (see Appendices), it has to be adjusted as follows:
NOTE
Remove the protective cover (2) and the O-ring (3) under it
Loosen the locking screws, and remove the flange (1) and O-ring
(5) from the middle part of the rotor
Put block gauges corresponding to a suitable clearance between

opposite wings and screen and slot plates, and push the rotor
until the rotor touches the block gauges
Check the rotor clearance and adjust it again if necessary
Place as many shims (4) as are needed at the end of the shaft
Install the O-ring and flange in their places and fasten the screws
Lock the screws with a locking weld and fasten the protective
cover. Also lock the screws of the protective cover by welding.
3.2.4
Shaft Seal Maintenance
The pulper is equipped with a mechanical slide ring seal or cord packing
(see manufacturers instructions).
Mechanical Seal
Removing the Seal
Pulper (HP-50G2)
STOA110077.00.EN
The mechanical seal has to be replaced or repaired if the slide

rings are worn out or damaged, e.g., due to running dry
Both replacing and repairing require removing the seal
The rotor must also be removed
The seal is pulled off the shaft (pay attention to any mounting
blocks) after the sealing water lines have been removed
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Installing the Seal

1
When remounting the seal, replace the O-rings between the seal
and pulper frame as well as those between the shaft sleeve and
rotor hub
Remember also to remove any mounting blocks and connect the

sealing water lines properly
See manufacturers instructions in Appendices.

NOTE
Always remember to adjust the flow and pressure of the sealing water
line after seal maintenance.
NOTE
Adjusting the Water Flow

1
Detach the hose between the rotameter and the seal
Adjust the flow amount to 3...5 l/min (~0,80...1,3 gal/min) (= max.

flow of the worn seal) with an Allen wrench in the controller in
the rotameter
Fasten the hose between the rotameter and the seal back into
place
Adjust the pressure to appropriate level for the sealing housing

(200...400 kPa / ~29....58 psi) by tightening the screws gradually
and evenly from all directions
The sealing water should flow through the sealing (3...5 l/min /
~0,80...1,3 gal/min) and come out of the outlet hose
Initially monitor the operation and temperature of the seal.

NOTE
NOTE
Pulper (HP-50G2)
STOA110077.00.EN
See also manufacturers instructions in Appendices for the seal and

rotameter.
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Cord Packing
Tightening the Cord Packing

The packing is tightened regularly by tightening the clamping ring nuts
during machine operation.
The tightness is correct when drops of water fall continuously from the
packing into the air space. Then there is no risk of the cord packing
catching fire due to running dry.
Figure 4. Cord packing (STOA009545)

1
2
3
4
5
6
7
8
9
10
11
Pulper (HP-50G2)
STOA110077.00.EN
Tightening flange
Screw
Seal ring
Seal ring 1
Water ring
Seal ring 2
Seal ring 3
Seal ring 4
Seal ring 5
Sleeve
O-ring
2015-05-13
Cartulinas CMPC
16
Adjusting the Water Flow

1
Detach the hose between the rotameter and the seal
Adjust the flow amount to 3...5 l/min (~0,80...1,3 gal/min) (= max.

flow of the worn seal) with an Allen wrench in the controller in
the rotameter
Fasten the hose between the rotameter and the seal back into
place
Adjust the pressure to appropriate level for the sealing housing

(200...400 kPa / ~29....58 psi) by tightening the screws gradually
and evenly from all directions
The packing should slightly leak outwards (60...100 drops per

minute, for example)
Initially monitor the operation and temperature of the packing and

tighten the packing gradually.
NOTE
See manufacturers instructions in Appendices for the cord packing

and the rotameter
NOTE
Replacing Worn Cords

The cords are replaced when the tightening allowance of the tightening
flange is used up, i.e. if an excessive amount of water or, in the worst
case, stock is leaking from the packing into the air space because the
cords are damaged. Replace the packing cord rings from the air space
side by removing the tightening flange.
See Appendices, for the cord packing instruction.
Replacing a Worn Shaft Sleeve

The shaft sleeve is hard-coated and lasts for a long time in normal use.
If the packing runs dry for a long period of time, the sleeve surface will
be damaged and the sleeve must be replaced. When replacing the
shaft sleeve, you need to remove the entire sealing package. The
sealing package is removed from the rotor side, in which case the rotor
must also be removed (see "Replacing the Rotor").
Pulper (HP-50G2)
STOA110077.00.EN
2015-05-13
NOTE
Cartulinas CMPC
17
Always remember to adjust the flow and pressure of the sealing water
line after seal maintenance.
3.2.5
Gear Drive
The gear drive is integrated into the rotor unit. See more specific
information and maintenance instructions in gear manufacturer's
instructions, 10. Appendices.
Pulper (HP-50G2)
STOA110077.00.EN
1(3)
At Your Service
Finland
Jyvskyl
Raupohjankatu, Po Box 587
FI-40101 Jyvskyl, Finland
Tel. +358 10 672 0000
Fax +358 10 672 6600
24 h service number +358 400 343 651
paper.service@valmet.com
Cernay
Valmet SAS
Rue de lIndustrie 5, Z. L. Est
FR-68700 Cernay, France
Tel. +33 3 8975 3200
Fax +33 3 8975 3315
24 h service number +33 631 434 836
Jrvenp
Wrtsilnkatu 100
FI-04400 Jrvenp, Finland
Tel. +358 10 672 0000
Fax +358 10 672 7501
24 h service number +358 400 431 666
Como
Valmet S.p.A
Via Repubblica 21
IT-22070 Grandate (Como), Italy
Tel. +39 031 412 9452
Fax +39 031 396 533
valmetitaly@valmet.com
Scandinavia
Gorizia
Valmet S.p.A
Via A. Gregorcic 46
IT-34170 Gorizia, Italy
Tel. +39 0481 528 311
Fax +39 0481 220 27
valmetitaly@valmet.com
Karlstad
Valmet AB
Axel Johnsons vg 6, PO Box 1014
SE-651 15 Karlstad, Sweden
Tel .+46 54 171 000
Fax +46 54 171 241
24 h service number +46 703 177 900 (Paper),
+46 703 555 9064 (Fiber)
Sundsvall
Valmet AB
Gustaf Gidlfs vg 1
SE-851 94 Sundsvall, Sweden
Tel. +46 60 165 000
Fax +46 60 568 166
Europe
Darwen
Valmet Ltd
Waterside Business Park,
Johnson Road, Eccleshill
BB3 3BA Darwen, UK
Tel. +44 1254 819 050
Fax +44 1254 819 059
Pfungstadt
Valmet GmbH
Ostendstrasse 1
DE-64319 Pfungstadt, Germany
Tel. +46 6157 9455 0
Fax +49 6157 9455 850
24 h service number +49 6157 945 555
metsopaperger.info@valmet.com
St. Petersburg
ZAO Valmet
Business center Senator,
Chapaeva street 15
RU-197101 St. Petersburg, Russia
Tel. +7 812 332 3650
Fax +7 812 332 3651
Lisbon
Valmet Lda
Polo Recnologico de Lisboa Parque Poente
Rua Carlos Alves, 1,2o Dto.
PT-1600-515
Lisboa, Portugal
Tel. +351 21 711 2051
Fax +351 21 711 2059
Mount Edgecombe
Valmet (Pty) Ltd.
Kingfisher Office Park, 28 Siphosethu Road,
4300 Mount Edgecombe, Durban
South Africa
Tel. +27 31 539 8640
Fax +27 31 539 8645
2(3)
At Your Service
North America
Asia Pacific
Atlanta
Valmet Inc.
2900 Courtyards Drive
30071 Norcross, Georgia, USA
Tel. +1 770 263 7863
Fax +1 770 441 9652
napaper.service@valmet.com
Melbourne
Valmet Pty Ltd
14-28 South Road, Braybrook
3019 Melbourne, Victoria, Australia
Tel. +61 3 9311 8133
Fax +61 3 9311 8744
24 h service number +61 0488 316 451
Beloit
Valmet Inc.
1280 Willowbrook Road
53511 Beloit, USA
Tel. +1 608 365 3319
Fax +1 608 364 2502
Auckland
Valmet Pty Ltd
Unit 12, First Floor, Building 3,
1 William Pickering Drive, Albany
0632 Auckland, New Zealand
Tel. +64 9 920 3240
Fax +64 9 303 4919
Montreal
Valmet Ltd.
4900 Thimens Blvd.
H4R 2B2, Ville St. Laurent
Quebec, Canada
Tel. +1 514 335 5426
Fax +1 514 335 6909
24 h service number +1 514 591 9955 (Paper),
+1 514 594 7426 (Fiber)
South America
Sorocaba
Valmet Celulose Papel e Energia Ltda
Av. Independencia, 2500 Bairro Iporanga
18087-101 Sorocaba, So Paulo, Brazil
Tel. +55 15 2102 9834
Fax +55 15 2102 1673
Curitiba
Valmet Celulose Papel e Energia Ltda
R. Francisco Sobnia, 1300 CIC
81460-130 Curitiba PR
Brazil
Tel. +55 41 3341 4444
Fax +55 41 2102-4357/4358
Tokyo
Valmet K.K.
A-14F 2-4-1 Shiba-Koen, Minato-ku
105-0011 Tokyo, Japan
Tel. +81 3 6744 3001
Fax +81 3 6744 3039
paper.japan@valmet.com
Wuxi
Valmet Paper Technology (China) Co., Ltd.
2, Hanjiang Road, Wuxi New District
214028 Wuxi, Jiangsu, China
Tel. +86 510 8522 5939
Fax +86 510 8522 5940
paper.servicechina@valmet.com
Guangzhou
Valmet Paper Technology (Guangzhou) Co., Ltd.
No. 1 Mugu Road, Yonghe Economic Zone,
Guangzhou Economic & Technological
Development District
511356 Guangdong, China
Tel. +86 020 3222 5061
Fax +86 020 3222 5062
Zibo
Valmet Paper Technology (China) Co., Ltd.
43, Minxiang Road, Zibo New & Hi-tech
Industrial Development Zon
255035 Zibo, Shandong, China
Tel. +86 533 398 2331
Fax +86 533 398 2332
3(3)
At Your Service
Asia Pacific
Laem Chabang
Valmet Co., Ltd
49/24 Moo 5, Tambon Thoongsukla,
Amphoe Sriracha
20230 Chonburi, Thailand
Tel. +66 38 401 100
Fax +66 38 400 972
paper.servicethailand@valmet.com
Jakarta
PT Valmet
ANZ Tower, 9th Floor, Jl.Jend.
Sudirman Kav. 33-A
10220 Jakarta, Indonesia
Tel. +62 21 573 5034
Fax +62 21 573 1376
paper.serviceindonesia@valmet.com
Daejeon
Valmet Inc.
3rd Floor, 764, Gwanpyeong-dong,
Yuseong-gu
305-509 Daejeon, Korea
Tel. +82 42 936 4856
Fax +82 42 934 4860
paper.servicekorea@valmet.com
Gurgaon
Valmet Technologies Co. Pvt. Ltd
UG Floor, DLF Building No. 10,
Tower A, DLF Cybercity, DLF Phase II
122002 Gurgaon, Haryana, India
Tel. +91 124 330 5800
Fax +91 124 330 5841
paper.serviceindia@valmet.com
2015-05-13
Cartulinas CMPC
i
10 APPENDICES
1
APPENDICES ....................................................................................................................... 1
1.1
Drawings and Bills of Material ...................................................................... 1
1.2
Brochures - in electronic format only ............................................................ 1
1.3
Appendices ................................................................................................... 1
Pulper (HP-50G2)
STOA110077.00.EN
10 Appendices
2015-05-13
Cartulinas CMPC
1
1
APPENDICES
1.1
Drawings and Bills of Material
STOD163527
Customer Assembly
STON008327
Rotor Unit (A, B)
STOD017339
Control Unit (Drawing only)
STOM000112
Shaft Seal
1.2
Brochures - in electronic format only
Flowmeter (John Crane Safematic)
Cord Packing
Gear (Santasalo)
Coupling (Flender N-Eupex)
1.3
Appendices
Preventive Maintenance Jobs Table
Lubricant Information
Noise Level Specification
Installation Instruction
Pulper (HP-50G2)
STOA110077.00.EN
10 Appendices
Valmet
OptiSlush
2015-11-16
PM Mill Global
Item
STOD163527
This document is the exclusive intellectual property of Valmet Corporation and/or its
subsidiaries and is furnished solely for operating and maintaining the specific project. Re-use of
the document for any other project or purpose is prohibited. The document or the information
shall not be reproduced, copied or disclosed to a third party without prior written consent of the
company.
pc=piece, mm=millimeter, m=meter, m2=square meter, m3=cubic

meter, kg=kilogram, l=liter, in=inch, in2=square inch, in3=cubic
inch, lb=pound, ft=feet, R=rev., B=BOM, L=Level, S=Status
Bill of Material
INTERNAL
Rev Drawing
11 STOD163527.11
Additional information
Lev. No. Item
Description
VALZONE PULPER OPTISLUSH HP-50G2
Status
Released by
Main project title

Maule BM19 ValZone
Project search key

M450VALZ
Subtitle
AEE014
Std.
Mater.
Size
Drawing
11
STOD163527.11
Rele VALZONE PULPER OPTISLUSH HP-50G2
STOD165099
00
STOD165099.00
10500,0
pc
STON008327A
00
STON008327
Rele VAT HP-50

CUBA HP-50
Rele ROTOR UNIT HP-50G, MOVENTAS 2008
MARKING OF THE MACHINE LABEL:
* MODEL: HP-50G
* SERIAL NUMBER: STON008327A
* POS.NO:
* WEIGHT: 3650 kg
* MANUFACTURING YEAR: 2015
UNIDAD DEL ROTOR HP-50G, MOVENTAS
2008
MARCADO DE LA ETIQUETA DE
MQUINA:
* MODELO: HP-50G
* EL NMERO DE SERIE: STON008327A
* POS.NO:
* PESO: 3650 kg
* AO DE FABRICACIN: 2015
3650,0
pc
STON008327B
00
STON008327

* MODEL: HP-50G
* SERIAL NUMBER: STON008327B
* POS.NO:
* WEIGHT: 3650 kg
2008
MQUINA:
* MODELO: HP-50G
* EL NMERO DE SERIE: STON008327B
* POS.NO:
* PESO: 3650 kg
3650,0
pc
STOD165100
00
STOD165100.00
3170,0
pc
Pseudo
STOD162526
00
STOD162526
419,0
pc
Pseudo
10
STOD123325A
00
STOD123325
13,0
pc
11
STOD100149A
00
STOD100149
12
VAL0109075
13
VAL0137819
Rele CHUTES HP-50

CANALES DE DESCARGA HP-50
Rele Y-PIPE 2xDN600 / 30"
TUBERA EN "Y" 2xDN600 / 30"
Rele LUG M30/M20
OREJETA M30/M20
Rele ADJUSTMENT SCREW L=143
TORNILLO DE AJUSTE L=143
HEXAGON SCREW M30x100-8.8-tZn-ISO
10684
TORNILLO DE CABEZA EXAGONAL
M30x100-8.8-tZn-ISO 10684
PLAIN WASHER 30-200HV-A4-ISO 3506-1
PLACA DE ASIENTO 30-200HV-A4-ISO
3506-1
ISO 4017
8.8-tZn
M30x100
ISO 7089
200HV-A4
31x56x4
STOD163527.11.xls
Weight
Product
Stock preparation
STOD163527
printed: 16.11.2015
Description
Released date
Length
Width
Pcs
Qty.
Unit Info
pc
0,35
pc
0,745
pc
pc
Pseudo
page 1/2
2015-11-16
PM Mill Global
Item
STOD163527
company.

Bill of Material
INTERNAL
Rev Drawing
11 STOD163527.11
Lev. No. Item
Drawing
Description
VALZONE PULPER OPTISLUSH HP-50G2
Status
Released by
Main project title

Maule BM19 ValZone
Project search key

M450VALZ
Subtitle
AEE014
14
STOD100020A
00
STOD100020
15
STOD100020B
00
STOD100020
16
STOD100020G
00
STOD100020
20
STOD014505
01
STOD014505
21
STOD014506
01
STOD014506
30
STOA110077
00
STOA110077
40
STOA110072
00
STOA110072
printed: 16.11.2015
Description
Std.
Mater.
Rele SHIM S=0,5

CUA S=0,5
Rele SHIM S=1,0
CUA S=1,0
Rele SHIM S=0,2
CUA S=0,2
Rele SIGN VALMET
SEAL VALMET
Rele PLATE OPTISLUSH
PLACA OPTISLUSH
Rele OPERATING AND MAINTENANCE MANUAL
HP
MANUAL DE USO Y DE MANTENIMIENTO
HP
Rele QUALITY ASSURANCE PLAN HPPLAN DE ASEGURAMIENTO DE LA
CALIDAD HP-
STOD163527.11.xls
Size
Weight
Released date
Product
Stock preparation
Length
Width
Pcs
Qty.
Unit Info
16
pc
16
pc
16
pc
6,8
pc
6,8
pc
pc
pc
page 2/2
2015-11-16
PM Mill Global
Item
STON008327A
company.

Bill of Material
INTERNAL
Rev Drawing
00 STON008327
Lev. No. Item
Description
ROTOR UNIT HP-50G, MOVENTAS 2008
UNIDAD DEL ROTOR HP-50G, MOVENTAS 2008
Main project title
Maule BM19 ValZone
Status
Released by
Project search key

M450VALZ
Subtitle
AEE014
Drawing
STON008327A
00
STON008327

* MODEL: HP-50G
* SERIAL NUMBER: STON008327A
* POS.NO:
* WEIGHT: 3650 kg
2008
MQUINA:
* MODELO: HP-50G
* EL NMERO DE SERIE: STON008327A
* POS.NO:
* PESO: 3650 kg
3650,0
STOD115883A
00
STOD115883.00
1700,0
STOD100077G
03
STOD100077
STOM000170
03
STOM000170
STOD115876EA
01
STOD115876.01
STOD017339A
01
STOD017339
STOM000112B
01
STOM000112
STOD107986
00
STOD107986
VAL0001287
10
VAL0137810
Rele FRAME HP-50G, RH, D1PSF60HPE-50, AC

DN600, ISO
BASTIDOR HP-50G, RH, D1PSF60HPE-50,
AC DN600, ISO
Rele ROTOR HP-50, CCW, V100%, PS90, T
ROTOR HP-50, CCW, V100%, PS90, T
Rele SCREEN PLATE HP-50, D/T=15/19
PLACA DE CRIBA HP-50, D/T=15/19
Rele GEAR D1PSF60HPE-50, POS1, ROT:+ ,
I=5,611
ENGRANAJE D1PSF60HPE-50, POS1,
ROT:+ , I=5,611
Rele CONTROL UNIT VM/VC/VH/HP, S/CP
UNIDAD DE CONTROL VM/VC/VH/HP,
S/CP
Rele SHAFT SEAL HP-42/50, CP
(FLENDER/MOV-08 GEAR)
ESTANQUEIDAD DEL EJE HP-42/50, CP
Rele SHIELD HP-50G
PROTECCIN HP-50G
ISO 4017
10684
M12x25-8.8-tZn-ISO 10684
PLAIN WASHER 12-200HV-A4-ISO 3506-1 ISO 7089
3506-1
11
STOM000113
12
VAL0007401
printed: 16.11.2015
01
STOM000113
Description
Rele COVER FLANGE HP-42/50

BRIDA DE LA CUBIERTA HP-42/50
HEXAGON SOCKET HEAD CAP SCREW
M20x50-A4-80-ISO 3506
TORNILLO DE CABEZA CILINDRICA CON
HUECO EXAGONAL M20x50-A4-80-ISO
3506
Std.
ISO 4762
Mater.
Size
Weight
Released date
Product
Stock preparation
Length
Width
Pcs
Qty.
Unit Info
pc
pc
590,0
pc
B1
16,0
pc
C6
1080,0
pc
5,0
pc
40,0
pc
2,5
pc
8.8-tZn
M12x25
0,038
pc
200HV-A4
13x24x2,5
0,006
pc
7,0
pc
0,091
pc
A4-80
M20x50
STON008327A.00.xls
B1
page 1/4
2015-11-16
PM Mill Global
Item
STON008327A
company.

Bill of Material
INTERNAL
Rev Drawing
00 STON008327
Lev. No. Item
Description
Main project title
Maule BM19 ValZone
Drawing
17
VAL0079588
18
STOM000122
01
STOM000122
19
GDI0003874
00
GDI0003874
20
VAL0026372
21
VAL0186555
22
STOM000124
23
VAL0007408
24
VAL0041489
25
VAL0017971
26
STOD100019A
00
STOD100019
27
STOD100019B
00
STOD100019
28
STOD100019C
00
STOD100019
29
STOD100019D
00
STOD100019
30
STOD100019E
00
STOD100019
31
VAL0210960
printed: 16.11.2015
Status
Released by
Project search key

M450VALZ
Subtitle
AEE014
Description
Std.
HEXAGON HEAD PIPE PLUG OT 2350

Outokumpu
DN25, 11-0235-06
R1 male thread, 1.4404
TAPON CONICO ROSCADO CON CABEZA
EXAGONAL OT 2350 DN25, 11-0235-06
R1 rosca exterior, 1.4404
Rele DIRECTION ARROW
FLECHA DE DIRECCIN
Rele MACHINE LABEL Valmet OptiSlush, Laser
engraved label template
Holes: 4 pce D2.5mm
Rounded edges
ETIQUETA DE MQUINA Valmet OptiSlush,
Laser engraved label template
DRIVE SCREW KDS Nr6x6-A4
REMACHE A PRESIN KDS Nr6x6-A4
O-RING OVE5X1380-N7665
1380mm (+/-1,0mm) x 25mm (+/-0,7mm)
ANILLO TRICO OVE5X1380-N7665
1380mm (+/-1,0mm) x 25mm (+/-0,7mm)
01
STOM000124
Rele COVER PLATE HP-42/50

PLACA DE LA CUBIERTA HP-42/50
M24x50-A4-80-ISO 3506
3506
M16x25-A4-80-ISO 3506
3506
M12x25-A4-80-ISO 3506
3506
Rele SHIM HP-42/50, S=3
CUA HP-42/50, S=3
Rele SHIM HP-42/50, S=1,5
CUA HP-42/50, S=1,5
CUA HP-42/50, S=1,0
CUA HP-42/50, S=0,5
CUA HP-42/50, S=0,2
O-RING 144,0x4,0 NBR70, 80642212000
ANILLO TRICO 144,0x4,0 NBR70,
80642212000
SMS 1549
Mater.
Size
Weight
1.4404
R1
Released date
Product
Stock preparation
Length
Width
Pcs
Qty.
Unit Info
0,19
pc
0,01
pc
pc
316
100x60x1
A4
3,5x6
0,001
pc
1380x25
2,66
pc
1,2
pc
Trelleborg
NBR70
Sealing Solution
ISO 4762
A4-80
M24x50
0,255
pc
ISO 4762
A4-80
M16x25
0,074
30
pc
ISO 4762
A4-80
M12x25
0,036
pc
pc
pc
pc
pc
pc
pc
Tiivistekeskus
NBR70
144x4
STON008327A.00.xls
0,007
C1
B30
page 2/4
2015-11-16
PM Mill Global
Item
STON008327A
company.

Bill of Material
INTERNAL
Rev Drawing
00 STON008327
Lev. No. Item
Description
Main project title
Maule BM19 ValZone
Drawing
32
STOM000126
01
STOM000126
33
STOD100020A
00
STOD100020
34
STOD100020B
00
STOD100020
35
STOD100020C
00
STOD100020
36
STOD100149A
00
STOD100149
37
VAL0109030
38
VAL0137815
39
VAL0049272
40
VAL0001232
41
VAL0137810
42
VAL0001201
43
VAL0210959
45
VAL0160660
46
STOD100020B
00
STOD100020
47
STOD100020F
00
STOD100020
48
STOD100020G
00
STOD100020
49
VAL0071806
printed: 16.11.2015
Status
Released by
Project search key

M450VALZ
Subtitle
AEE014
Description
Rele LUG M30/M20
OREJETA M30/M20
Rele SHIM S=0,5
CUA S=0,5
Rele SHIM S=1,0
CUA S=1,0
Rele SHIM S=2,0
CUA S=2,0
10684
M24x120-8.8-tZn-ISO 10684
3506-1
Std.
Mater.
Weight
12,0
Product
Stock preparation
Length
Width
Pcs
Qty.
Unit Info
pc
pc
pc
pc
0,35
pc
ISO 4017
8.8-tZn
M24x120
0,491
pc
ISO 7089
200HV-A4
25x44x4
0,032
pc
A4
12x120
pc
A4-80
M12
0,017
pc
200HV-A4
13x24x2,5
0,006
pc
A4-80
M8x16
0,012
pc
Tiivistekeskus
NBR70
96x4
0,005
pc
ISO 4029
A4-21H
M20x25
pc
pc
pc
pc
pc
TAPER PIN WITH EXTERNAL THREAD

ISO 8737
12x120-A4
CLAVIJA CONICA CON ROSCA EXTERIOR
12x120-A4
HEXAGON NUT M12-A4-80-ISO 3506
ISO 4032
TUERCA HEXAGONAL M12-A4-80-ISO
3506
3506-1
ISO 4762
M8x16-A4-80-ISO 3506
HUECO EXAGONAL M8x16-A4-80-ISO 3506
O-RING 96,0x4,0 NBR70, 80641353000
80641353000
HEXAGON SOCKET SET SCREW WITH
CUP POINT M20x25-A4-21H-ISO 3506-3
TORNILLO SIN CABEZA CON HUECO
EXAG.Y EXTREMO BISELADO HUECO
M20x25-A4-21H-ISO 3506-3
Rele SHIM S=1,0
CUA S=1,0
Rele SHIM S=0,1
CUA S=0,1
Rele SHIM S=0,2
CUA S=0,2
10684
M30x120-8.8-tZn-ISO 10684
Size
Released date
ISO 4014
8.8-tZn
M30x120
STON008327A.00.xls
0,5
page 3/4
2015-11-16
PM Mill Global
Item
STON008327A
company.

Bill of Material
INTERNAL
Rev Drawing
00 STON008327
Lev. No. Item
Description
Main project title
Maule BM19 ValZone
Drawing
50
VAL0137819
52
STOD115895
00
STOD115895
53
STOM000121A
02
STOM000121
54
STOM000121D
00
STOM000121
55
VAL0012732
printed: 16.11.2015
Status
Released by
Project search key

M450VALZ
Subtitle
AEE014
Description
Std.
Mater.
Size

3506-1
ISO 7089
200HV-A4
31x56x4
Rele COUPLING GUARD HP-42/50G

PROTECCIN DEL ACOPLAMIENTO HP42/50G
Rele BUSHING D=30, L=5
CASQUILLO D=30, L=5
CASQUILLO D=30, L=20
HEXAGON SCREW M10x50-A4-80-ISO
3506
M10x50-A4-80-ISO 3506
Weight
27,0
ISO 4017
A4-80
M10x50
STON008327A.00.xls
Released date
Product
Stock preparation
Length
Width
Pcs
Qty.
Unit Info
pc
pc
pc
0,1
pc
0,04
pc
page 4/4
2015-11-16
PM Mill Global
Item
STON008327B
company.

Bill of Material
INTERNAL
Rev Drawing
00 STON008327
Lev. No. Item
Description
Main project title
Maule BM19 ValZone
Status
Released by
Project search key

M450VALZ
Subtitle
AEE014
Drawing
STON008327B
00
STON008327

* MODEL: HP-50G
* SERIAL NUMBER: STON008327B
* POS.NO:
* WEIGHT: 3650 kg
2008
MQUINA:
* MODELO: HP-50G
* EL NMERO DE SERIE: STON008327B
* POS.NO:
* PESO: 3650 kg
3650,0
STOD115883E
00
STOD115883.00
1700,0
STOD100076G
03
STOD100076
STOM000170
03
STOM000170
STOD115876ED
01
STOD115876.01
STOD017339A
01
STOD017339
STOM000112B
01
STOM000112
STOD107986
00
STOD107986
VAL0001287
10
VAL0137810
Rele FRAME HP-50G, LH, D1PSF60-HPE-50, AC

DN600, ISO
BASTIDOR HP-50G, LH, D1PSF60-HPE-50,
AC DN600, ISO
Rele ROTOR HP-50, CW, V100%, PS90, T
ROTOR HP-50, CW, V100%, PS90, T
Rele SCREEN PLATE HP-50, D/T=15/19
PLACA DE CRIBA HP-50, D/T=15/19
Rele GEAR D1PSF60HPE-50, POS2, ROT:- ,
I=5,611
ENGRANAJE D1PSF60HPE-50, POS2,
ROT:- , I=5,611
Rele CONTROL UNIT VM/VC/VH/HP, S/CP
UNIDAD DE CONTROL VM/VC/VH/HP,
S/CP
Rele SHIELD HP-50G
PROTECCIN HP-50G
ISO 4017
10684
M12x25-8.8-tZn-ISO 10684
3506-1
11
STOM000113
12
VAL0007401
printed: 16.11.2015
01
STOM000113
Description
Rele COVER FLANGE HP-42/50

BRIDA DE LA CUBIERTA HP-42/50
M20x50-A4-80-ISO 3506
3506
Std.
ISO 4762
Mater.
Size
Weight
Released date
Product
Stock preparation
Length
Width
Pcs
Qty.
Unit Info
pc
pc
590,0
pc
B1
16,0
pc
C6
1080,0
pc
5,0
pc
40,0
pc
2,5
pc
8.8-tZn
M12x25
0,038
pc
200HV-A4
13x24x2,5
0,006
pc
7,0
pc
0,091
pc
A4-80
M20x50
STON008327B.00.xls
B1
page 1/4
2015-11-16
PM Mill Global
Item
STON008327B
company.

Bill of Material
INTERNAL
Rev Drawing
00 STON008327
Lev. No. Item
Description
Main project title
Maule BM19 ValZone
Drawing
17
VAL0079588
18
STOM000122
01
STOM000122
19
GDI0003874
00
GDI0003874
20
VAL0026372
21
VAL0186555
22
STOM000124
23
VAL0007408
24
VAL0041489
25
VAL0017971
26
STOD100019A
00
STOD100019
27
STOD100019B
00
STOD100019
28
STOD100019C
00
STOD100019
29
STOD100019D
00
STOD100019
30
STOD100019E
00
STOD100019
31
VAL0210960
printed: 16.11.2015
Status
Released by
Project search key

M450VALZ
Subtitle
AEE014
Description
Std.
HEXAGON HEAD PIPE PLUG OT 2350

Outokumpu
DN25, 11-0235-06
R1 male thread, 1.4404
TAPON CONICO ROSCADO CON CABEZA
EXAGONAL OT 2350 DN25, 11-0235-06
R1 rosca exterior, 1.4404
Rele DIRECTION ARROW
FLECHA DE DIRECCIN
Rele MACHINE LABEL Valmet OptiSlush, Laser
engraved label template
Holes: 4 pce D2.5mm
Rounded edges
ETIQUETA DE MQUINA Valmet OptiSlush,
Laser engraved label template
DRIVE SCREW KDS Nr6x6-A4
REMACHE A PRESIN KDS Nr6x6-A4
O-RING OVE5X1380-N7665
1380mm (+/-1,0mm) x 25mm (+/-0,7mm)
ANILLO TRICO OVE5X1380-N7665
1380mm (+/-1,0mm) x 25mm (+/-0,7mm)
01
STOM000124
Rele COVER PLATE HP-42/50

PLACA DE LA CUBIERTA HP-42/50
M24x50-A4-80-ISO 3506
3506
M16x25-A4-80-ISO 3506
3506
M12x25-A4-80-ISO 3506
3506
Rele SHIM HP-42/50, S=3
CUA HP-42/50, S=3
CUA HP-42/50, S=1,5
CUA HP-42/50, S=1,0
CUA HP-42/50, S=0,5
CUA HP-42/50, S=0,2
O-RING 144,0x4,0 NBR70, 80642212000
80642212000
SMS 1549
Mater.
Size
Weight
1.4404
R1
Released date
Product
Stock preparation
Length
Width
Pcs
Qty.
Unit Info
0,19
pc
0,01
pc
pc
316
100x60x1
A4
3,5x6
0,001
pc
1380x25
2,66
pc
1,2
pc
Trelleborg
NBR70
Sealing Solution
ISO 4762
A4-80
M24x50
0,255
pc
ISO 4762
A4-80
M16x25
0,074
30
pc
ISO 4762
A4-80
M12x25
0,036
pc
pc
pc
pc
pc
pc
pc
Tiivistekeskus
NBR70
144x4
STON008327B.00.xls
0,007
C1
B30
page 2/4
2015-11-16
PM Mill Global
Item
STON008327B
company.

Bill of Material
INTERNAL
Rev Drawing
00 STON008327
Lev. No. Item
Description
Main project title
Maule BM19 ValZone
Drawing
32
STOM000126
01
STOM000126
33
STOD100020A
00
STOD100020
34
STOD100020B
00
STOD100020
35
STOD100020C
00
STOD100020
36
STOD100149A
00
STOD100149
37
VAL0109030
38
VAL0137815
39
VAL0049272
40
VAL0001232
41
VAL0137810
42
VAL0001201
43
VAL0210959
45
VAL0160660
46
STOD100020B
00
STOD100020
47
STOD100020F
00
STOD100020
48
STOD100020G
00
STOD100020
49
VAL0071806
printed: 16.11.2015
Status
Released by
Project search key

M450VALZ
Subtitle
AEE014
Description
Rele LUG M30/M20
OREJETA M30/M20
Rele SHIM S=0,5
CUA S=0,5
Rele SHIM S=1,0
CUA S=1,0
Rele SHIM S=2,0
CUA S=2,0
10684
M24x120-8.8-tZn-ISO 10684
3506-1
Std.
Mater.
Weight
12,0
Product
Stock preparation
Length
Width
Pcs
Qty.
Unit Info
pc
pc
pc
pc
0,35
pc
ISO 4017
8.8-tZn
M24x120
0,491
pc
ISO 7089
200HV-A4
25x44x4
0,032
pc
A4
12x120
pc
A4-80
M12
0,017
pc
200HV-A4
13x24x2,5
0,006
pc
A4-80
M8x16
0,012
pc
Tiivistekeskus
NBR70
96x4
0,005
pc
ISO 4029
A4-21H
M20x25
pc
pc
pc
pc
pc
TAPER PIN WITH EXTERNAL THREAD

ISO 8737
12x120-A4
CLAVIJA CONICA CON ROSCA EXTERIOR
12x120-A4
HEXAGON NUT M12-A4-80-ISO 3506
ISO 4032
TUERCA HEXAGONAL M12-A4-80-ISO
3506
3506-1
ISO 4762
M8x16-A4-80-ISO 3506
HUECO EXAGONAL M8x16-A4-80-ISO 3506
O-RING 96,0x4,0 NBR70, 80641353000
80641353000
M20x25-A4-21H-ISO 3506-3
Rele SHIM S=1,0
CUA S=1,0
Rele SHIM S=0,1
CUA S=0,1
Rele SHIM S=0,2
CUA S=0,2
10684
M30x120-8.8-tZn-ISO 10684
Size
Released date
ISO 4014
8.8-tZn
M30x120
STON008327B.00.xls
0,5
page 3/4
2015-11-16
PM Mill Global
Item
STON008327B
company.

Bill of Material
INTERNAL
Rev Drawing
00 STON008327
Lev. No. Item
Description
Main project title
Maule BM19 ValZone
Drawing
50
VAL0137819
52
STOD115895
00
STOD115895
53
STOM000121A
02
STOM000121
54
STOM000121D
00
STOM000121
55
VAL0012732
printed: 16.11.2015
Status
Released by
Project search key

M450VALZ
Subtitle
AEE014
Description
Std.
Mater.
Size

3506-1
ISO 7089
200HV-A4
31x56x4
Rele COUPLING GUARD HP-42/50G

PROTECCIN DEL ACOPLAMIENTO HP42/50G
CASQUILLO D=30, L=5
CASQUILLO D=30, L=20
HEXAGON SCREW M10x50-A4-80-ISO
3506
M10x50-A4-80-ISO 3506
Weight
27,0
ISO 4017
A4-80
M10x50
STON008327B.00.xls
Released date
Product
Stock preparation
Length
Width
Pcs
Qty.
Unit Info
pc
pc
pc
0,1
pc
0,04
pc
page 4/4
Bill of Material
2015-11-16
PM Mill Global
Item
STOM000112B
company.

INTERNAL
Rev Drawing
01 STOM000112
Lev. No. Item
Status
Description
SHAFT SEAL HP-42/50, CP (FLENDER/MOV-08 GEAR)
ESTANQUEIDAD DEL EJE HP-42/50, CP (FLENDER/MOV-08 GEAR)
Main project title
Project search key
Maule BM19 ValZone
M450VALZ
Drawing
STOM000112B
01
STOM000112
STOM000114
01
STOM000114
STOM000115
01
STOM000115
STOM000116
01
STOM000116
VAL0045503
STOM000117
VAL0039218
VAL0045506
VAL0109597
10
STOM000118
11
VAL0010317
12
VAL0001419
13
STOD100015G
printed: 16.11.2015
01
01
00
STOM000117
STOM000118
STOD100015
Description
Rele SEALING HOUSING HP-33/42/50
CARCASA DE JUNTA HP-33/42/50
Rele RING HP-33/42/50
ANILLO HP-33/42/50
Rele WATER RING HP-33/42/50
ANILLO DE AGUA HP-33/42/50
BRAIDED PACKING RING 140x172x16mm
GRAFTEF-1
EMPAQUETADURA TRENZADA EN ARO
140x172x16mm GRAFTEF-1
Rele GASKET HP-33/42/50
JUNTA DE ESTANQUEIDAD HP-33/42/50
STUD M12x65-A4
ESPARRAGO M12x65-A4
PREVAILING TORQUE TYPE HEXAGON
NUT M12-A4-80
TUERCA DELGADA M12-A4-80
O-RING 219,3x5,7 NBR701 SS162630
ANILLO TRICO 219,3x5,7 NBR701
SS162630
Rele SLEEVE HP-42/50, METCO 16C
COLLAR HP-42/50, METCO 16C
O-RING 139,3x5,7 NBR701 SS162630
ANILLO TRICO 139,3x5,7 NBR701
SS162630
M8x8-A4-21H-ISO 3506-3
Rele FLINGER RING HP-42/50G, D/d=220/130
ANILLO DIFUSOR HP-42/50G, D/d=220/130
Std.
Released by
Released date
Subtitle
AEE014
Mater.
Size
Weight
Product
Stock preparation
Length
Width
Pcs
Qty.
40,0
B&B TOOLS
Finland
PTFE/GRA
140x172x16
Unit Info
pc
25,0
pc
0,1
pc
1,5
pc
B1
0,21
pc
C5
5,0
pc
0,1
pc
DIN 939
A4
M12x65
DIN 985
A4-80
M12
pc
SMS 1586
NBR70
219,3x5,7
pc
7,0
pc
B1
SMS 1586
NBR70
139,3x5,7
0,015
pc
C1
ISO 4029
A4-21H
M8x8
0,001
pc
pc
STOM000112B.01.xls
C1
page 1/1
John Crane Safematic Oy

P.O. Box 10
FI-40951 MUURAME
FINLAND
INSTALLATION AND
OPERATION INSTRUCTIONS
1 (5)
Tel. +358 14 600 611

Fax +358 14 600 600
No.
Date
Revision No.
Date
20000226EN
01.06.1998
03
11.12.2006
SAFEUNITTM MONITORING AND

CONTROL SYSTEM FOR SEAL WATER
TYPE SFP COMPLETE FOR PACKINGS AND

FLUSH SEALS
BILL OF MATERIAL
1.
2.
3.
4.
5.
6.
7.
8.
Flowmeter
Back valve
Hose coupling
Hose coupling
Hose clamp
Hose (inside diameter 3/8", 10 mm)
Stand
Alarm device (Flush-seals)
1 pc
1 pc
1 pc
1 pc
4 pcs
2 pcs
1 pc (option)
1 pc (option)*
Alarm device type: AC-1, DC-1 or EX-1 (see separate instructions: 20000224, 20000225 or
20000246).
20000226en.doc
No. 20000226EN
2 (5)
Operational limits
SafeunitTM can be used only in applications that use water as seal liquid.
Water temperature must be within +2 - +60 oC (36 - 140 oF). The maximum water
pressure in the control unit is 25 bar (360 psi). The maximum pressure limit must not
be exceeded under any circumstances.
Operation circumstances
SafeunitTM must be istalled so that it does not get exposed to mechanical wear and
tear.
Hot surfaces may not be near SafeunitTM, since they may be able to raise the
temperature in SafeunitTM over 50 oC (122 oF). Due to danger of freezing, SafeunitTM
must not be used in temperatures below +2 oC (36 oF).
SafeunitTM materials have been selected so that its corrosion resistance is sufficient in
normal factory circumstances. Materials are not resistant to strong acids, alcohols and
carbon hydrates. Weak acids and alkalis do not create any problems.
OPERATION INSTRUCTIONS OF SAFEUNITTM FLOWMETER
E
D
22602_a.cdr
Type SFP
Lead water to the flowmeter.

Disconnect the waterline of the packings from the water connection of the stuffing box.
Use the regulating valve (A) to adjust a flow rate allowed to worn packings.
Reconnect the water connection to the packings.
Adjust the tightness of the packings. The pressure gauge shows the pressure in the packing.
Adjust the red indicator (D) of the flowmeter and the red arrow (E) of the pressure gauge to show
the desired values. This allows you to control changes in flow and pressure. These changes
indicate the condition of the seal.
Water connections
1. Water in
20000226en.doc
2. To seal
No. 20000226EN
3 (5)
Cleaning
1. Press the button (C) on the right side of the unit. This does not affect the pressure or the flow of
the sealing water.
2. The display surface is now cleaned by the float.
3. Repeat until full readability is reached.
4. When the alarm is connected, pushing the cleaning button won't cause an extra alarm.
Flow
3=0-3
8=0-8
15 = 0 - 15
l/min
l/min
l/min
(0 - 0,75 GPM)
(0 - 2 GPM)
(0 - 4 GPM)
Pressure
10 = max 10 bar, 145 psi
25 = max 25 bar, 360 psi
INSTALLATION OF SAFEUNITTM
Install the SafeunitTM to a place where it is accessable for reading and testing
according to drawings 1 or 2.
20000226en.doc
Drawing 1
Drawing 2
Safeunit installation to stand 404317.
Safeunit installation to any other stand.
No. 20000226EN
4 (5)
SAFEUNITTM SEALWATER MONITORING AND CONTROL SYSTEM SPARE PARTS
Type SFP
22604.BMP
Type SFQ
22605.BMP
ITEM
1. BASE PLATE
R-thread
NPT-thread
2. ACRYL PART
3 l/min
8 l/min
15 l/min
3. PRESSURE GAUGE COUPLING
4. REGULATING VALVE
5. HOSE COUPLING
6. PRESSURE GAUGE
0-10 bar
0-10 bar (AISI 316)
0-25 bar
0-25 bar (AISI 316)
7. PLUG FOR REGULATING VALVE
8. PLUG FOR PRESSURE GAUGE
9. ALARM
AC-1
DC-1
20000226en.doc
Type SFD
22606.BMP
Type SFP
Type SFQ
Type SFD
22771370
22771350
22771370
22771350
22771370
22771350
22400050
22400100
22400150
22640850
22400200 (1 pc)
22640400 (2 pc)
22400050
22400100
22400150
22400050
22400100
22400150
22640850
22400200 (2 pc)
22640400 (4 pc)
22600050
22600100
22600150
22600200
22770030 (1 pc)
22770511
22770515
22400200 (1 pc)
22640400 (2 pc)
22600050
22600100
22600150
22600200
22770030 (1 pc)
22661350
22770511
22770515
22770511
22770515
No. 20000226EN
DIMENSIONS
Flowmeter, model 3, 8 and 15 l/min
22607.BMP
20000226en.doc
22608.BMP
5 (5)
Bill of materials
Date 30.04.2003
Designed KaL
Code
2211306762
Revision 0
Description SAFEUNIT 306762
SFP-C-08-10-R1/4"/B
Equipment METSO
Part
0
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
Code
Pcs Draw no.
2211306762
1 306762
228442000000 1 228442000000
22640405
1 402556
22641560
1 402792
22600850
1 402039
22640590
1 403437
22640260
1 22640260
22640750
4 22640750
22641710
1 22641710
12641060
1 12641060
12641210
1 12641210
22641584
1 22641584
22640370
1 403474
22661720
1 401949
12661620
2 12661620
12661200
2 12661200
Description
SAFEUNIT 306762
SAFEUNIT
HOSE COUPLING
ADAPTER
CHECK VALVE
HOSE COUPLING
HOSE
HOSE CLAMP
PORT CONNECTOR
FERRULE
NUT
UNION
HOSE COUPLING
BRACKET
ALLEN SCREW
NUT
Material
SFP-C-08-10-R1/4"/B
SFP-08-10 WOHC
AISI316
AISI316
AISI316
AISI316
TEXTILE REINFORCED
AISI316
AISI316
AISI316
AISI316
AISI316
AISI316
AISI304
AISI316
AISI316
Dimensions
L=8000 3/8"
XPEL 12L ISO7/1-R1/4" H

R1/4"u-3/8"
M8x50
M8
1 (4)
INSTALLATION INSTRUCTIONS FOR PACKINGS
ROTATING SHAFTS
1. TO CLEAN AND INSPECT THE HOUSING AND SHAFT

- Used packings can be removed from the housing with a suitable
tool for extraction.
- Inspect the surface of the shaft/shaft sleeve to see that it is not
worn, scratched or damaged.
2. TO INSPECT SEALING LIQUIDS
- The sealing housing must be inspected to insure that the sealing
liquid enters without obstruction.
3. CHOOSING PACKING
- Appropriate packings should be chosen for the intended purpose
with the help of Safematics recommendations.
- The diameter of the packing is the empty space between the
shaft/shaft sleeve and the seal housing.
This can be obtained with the formula:
S = D d (Pict.1)
2
Proper-sized packing should always be used.
4. CUTTING A PACKING
- Packing should be cut when wrapped around a mold that
corresponds to the axel (Diag. 2).
- The right length of these packings can be gotten as follows:
- PTFE-GXL,GRAFON-2, CARBON-60, ARAM-G2, KEVLAR-2
2 (4)
The packing should be wrapped, but not tightened around the mold
and the length marked. Then the packing must be loosened along the
top of the mold by a distance equal to the diameter of the packing
(diag. 3).
- Nominal length of the packing can be obtained with the following
formula:
L=D+dx
2
+S
5. TO INSTALL A PACKING
- The packing must be kept clean. Dirty packings lead to the early
wear of both the packing and the shaft sleeve. We recommend that
the packing is kept inside delivery package until reaching the place
of installation.
- The packing should be pressed into the seal housing with the cut
ends just overlapping.
- Press the rings toward the base, one after another. Special tools
made of wood or plastic may be of help.
- The rings must be placed straight. Adjacent rings must not press
against each other.
- Install rings so that the cut ends of adjacent rings are a distance of
at least 90o apart.
- Before each ring is installed, the shaft should be lubricated with a
substance suitable for the equipment and rotated.
- When there is a question of high pressure and wearing, the lifetime
of the packing can be improved by installing a static packing ring
between adjacent rings. The static seal is cut open straight at one
point and pushed into the shaft.
- During installation, it is important to check that the water ring is
placed correctly in the housing.
- The gland flange is installed by twisting the nuts tight by hand, and
then assuring that the gland is straight.
3 (4)
6. START-UP AND TEST RUN
- Open the sealing liquid valve. The discharge must be consistent
and fairly abundant, dripping is not sufficient.
- Start up the the pump.
- Monitor the temperature of the box from the body of the pump and
the gland flange. If the temperature rises too much or discharge
begins to let up, loosen the nuts of the gland flange.
- When temperature remains appropriate for 15 minutes, tighten the
nuts of the gland flange carefully, 1 keyhole at a time, until the
discharge diminishes to the proper amount, and temperature is
correct and remains constant.
7. MONITORING
- Take care that the discharge does not cease of fall below
regulation. If these symptoms arise, loosen the gland immediately.
If this does not help, stop the pump and investigate the cause.
- When discharge increases too much, tighten the gland as
necessary.
- If the discharge cannot be controlled by tightening, or when the
allowance for tightening has been used up, the packings are worn
out and must be replaced.
VALVES
1. TO CLEAN AND INSPECT A HOUSING AND SHAFT
- Inspect the shaft, seal housing and the adjusting ring to see that it is
not scratched or damaged.
- For those valves with a double-sectioned shaft seal housing, it is
important that there are no noticeable steps between the sections.
2. CHOOSING A PACKING
- See Rotating Shafts, point. 3.
3. CUTTING A PACKING
- Plaited packing should be wrapped around a plastic rod as shown,
and the cutting point marked with two straight lines. The distance
between the lines should be egual to the width of the packing.
- Cut the marked packing one ring at a time on a 45o diagonal with a
sharp knife.
- The diameter of the plastic rod should be larger than diameter of
the shaft to be sealed.
4. INSTALLATION
- Cut plaited packings or pre-pressed rings should be positioned one
by one in the seal housing and pushed tightly into place. The cut
ends of packings placed on top of each other should be positioned
at a 90 angle to each other, and at a 45 angle to the flow opening.
There should be no split between the packings cut ends.
4 (4)
ADJUSTMENT INSTRUCTIONS FOR ONE-ACTIONED PACKING BOX
1. Loosen the hose pipe between the rotameter and the packing.
2. Adjust the flow amount to 3-5 l per minute with a hexagon socket screw in
the controller of the rotameter (= max. flow of the weared packing).
3. Fasten the hose pipe between the rotameter and the packing back to its
place.
4. Adjust the pressure needed for the packing box (2-4 bar) by tightening the
tightening nuts gradually and evenly from all directions.
5. The operative packing should leak outwards (for example 60-100 drops
per minute).
Note! It is recommended to control the operation and temperature of the

packing at first and tighten the packing gradually.
Note! See also the directions of the packing box supplier and the rotameter in
this book.
TECHNICAL DOCUMENTS
Handler/Designer:
Katri Rantanen / Lasse Karisalmi
Walpella Oy
PL 10
37601 Valkeakoski
Finland
Customer Ref.: H11218573

Salesperson ref.: ISD10107030 / Ville Vehkakoski
Project: M450VALZ CHILE
Gear unit type: D1PSF60HPE-50
Manufact. no.: FI-107539 - FI-107539
Delivering following documents: 1 x EN
Document data format: pdf
1 STOD115876EA.01
PART LIST
DRAWINGS
Dimension drawings
D016604
Assembly drawings
Y0031024, D009666, Y0030655
OTHERS
Manufacturer's warranty and buyer's responsibility
MDI-110-AEN
General product safety guide
MDI-120-CEN
Use and maintenance of gearing
MDI-180-BEN
Foundation of industrial gear assemblies standing installation
MDI-140-AEN
Installation of industrial gear assemblies standing installation
MDI-150-AEN
Corrosion protection and storage
MDI-130-AEN
Assembly report
U306EN
Lubricants in industrial gears
MDI-170-DEN
SANTASALO GEARS OY
Vesangantie 1
P.O.Box 1001
40101 Jyvskyl
FINLAND
Tel +358 293 401000

Fax +358 20 184 7101
LY 2646194-8
www.santasalo.com
1 (1)
Technical specification
SpecificationNo.
ISD10107030
Revision
1. General data
1
2
Delivery date EXW
5.1.2016
Customer
Walpella Oy
Issued by
Ville Vehkakoski
Country
Finland
Date
17.9.2015
Revision row no.

Customer order no.
H11218573
Date
17.9.2015
Customer ref.
M450VALZ CHILE
Designed by
Driven Machine / item no.
Pulper HP-50G
Date
Date
Lasse Karisalmi
8
9
2. Product description
10
Gear unit type
D1PSF60HPE-50
Ratio i
5,611
Running data
min.
Rotation speed
Shaft position
norm.
HSS [1/min]
1486
LSS [1/min]
265
Running Power Pk1
[kW]
Running torque Mk2
[kNm]
23
Weight appr.[kg] 1050

max.
Manufacturing nos.
FI-107539 - FI-107539
11
Quantity
12
Service factor Fs
2,46
13
according to
Running power PK1 max
14
Mounting position
Standard
15
315
16
Anch. rod length HA
17
Rot.direction of LSS
Counter clockwise
Hollow shaft nom. dia.
Painting system
ISO 12944-5/S4.13(EPPUR240/3-FeSa 2)
Colour code
Type
AC-motor/inverter
Code
Duration of service[h/day]
24
21
Pm [kW]
315
/n
Max load occ./hour
22
18
RAL7011
19
3. Operating conditions
20
Driving machine
Connection diameters
External loads
1486
[mm] Driving machine shaft

[kN] Fa norm
Fa max
Driven machine shaft

Direction
Fr norm
Fr max
23
Acting point fr. shaft end[mm]
LSS
25
HSS
26
Electrical supply
Main[V]
Ambient temperature
[C] min.
[Hz]
10
50
Instr.supply[V]
[C] norm.
[Hz]
[C] max.
35
Lubricant
27
28
4. Lubrication
Lubrication method
24
29
Splash lubrication
Oil Mineral ISO VG320EP
Ambient temperature range
[C] +10...+35
Oil level indication
Joint level down
Grease type
Lubr. unit location
30
Synt. ISO VG320EPPAO
31
[C]
[C]
[mm]
220
Oil qty appr.

Grease qty [g]
5. Documentation
32
65
33
34
35
Dimension drawing no.
D016604
36
Assembly drawing no.
D009666, Y0030655, Y0031024
37
Other documents
38
39
40
6. Additional equipment/other information
41
Qty
42
GEAR UNIT WITH ACCESSORIES D-SERIES HORIZONTAL PSF, PHF, PHT SMALL (<100)
43
STOD115876EA
44
i=5,611:1
45
Pos. 1, Rot. +
46
47
GEAR UNIT D1PSF60HPE-50
48
DRAIN VALVE G11/2
49
MEASUREMENT NIPPLE SPM 32010
50
LONG CORROSION PROTECTION
51
WATER COOLING COIL AISI316/D1P60
52
53
1 (2)
Part List
Work no.
Customer
Train
Information
Pos. no. Item
ISD10107030
Walpella Oy
ENGS103517
825
Draw. nr.
D016604
ITM2002351
ENGS103575
D009666
* HDRS100406
Y003007813
Manuf. no.
Qty pc
FI-107539
Qty
EXW
Designer
Date/ver.
Item name / Dimensions
1 pcs
GEAR UNIT WITH ACCESSORIES
4 pcs
EYE BOLT DIN580 M20 -
1 pcs
GEAR UNIT -
1 pcs
ASSEMBLY -
1 pcs
GEAR HOUSING
001
** Y003007813
800
*** 601480
8 pcs
HEXAGON SCREW DIN931 M24 90
802
*** 601524
6 pcs
820
*** 614000
4 pcs
PARALLEL PIN DIN7979A 40 16
010
** Y0030930
1 pcs
COVER
011
** 601860
6 pcs
015
** Y0031224
016
Y0030930
Y0031224
1 pcs
COVER
** 601860
6 pcs
017
** 631117
1 pcs
PLUG R1/8 -
018
** 531536
020
** Y0029603
021
** 601860
025
** Y0029597
026
Y0029603
Y0029597
4 pcs
PLUG - DBI NO.11
1 pcs
COVER
6 pcs
1 pcs
COVER
** 601860
6 pcs
027
** 631117
1 pcs
PLUG R1/8 -
028
** 531536
4 pcs
PLUG - DBI NO.11
075
** Y0030795
076
** 601740
077
** G118508
G118508
1 pcs
SEAL - - - 200 KLINGERSIL C-4430 - -
100
** E016334
D016605
1 pcs
LSS SHAFT -
110
** ITM0040952
1 pcs
SPHERICAL ROLLER BEARING 22230 CC/W33
111
** ITM0040965
1 pcs
1232
** 540800
1 pcs
SCREWED PIPE FITTING - R1/2 DA5140
130
** 121400170
1 pcs
KEY DIN6885 B 32 18 170
152
** 4746895
153
** 601780
163
** Y0030549
199
** Y0030266
201
Y0030795
4746895
1 pcs
INSPECTION COVER
6 pcs
1 pcs
END PLATE
3 pcs
Y0030549
1 pcs
BUSHING -
Y0030266
1 pcs
GEAR WHEEL 101
** E016330
D016600
1 pcs
PINION -18
220
*** 4747561
4747561
2 pcs
BEARING BUSHING -
210
** ITM0040982
2 pcs
SPHERICAL ROLLER BEARING 22322 E/C3
230
** 121000159
1 pcs
KEY DIN6885 B 22 14 159
288
** 520085
3310
** E016335
3312
3314
1 pcs
V-RING - - - - - FKM VA-85
1 pcs
FLINGER RING - 214 142 - - S355JO -
** 631950
3 pcs
SET SCREW DIN916 M6 20
** 640053
1 pcs
GREASE NIPPLE DIN71412 R1/8 A
3316
** 640062
1 pcs
EXTENSION - KR1/8 KR1/8 52 MM
3318
** Y0030884
2 pcs
830
** LU5RFSA127
1 pcs
OIL LEVEL GLASS - FSA 127-2.0/-/12/-SO14
831
** 631815
2 pcs
840
** ITM0040871
1 pcs
BREATHER G1 L= 70
843
** 546720
1 pcs
SEAL - 42,9 33,9 3,4 - - USITR-16
860
** 570015
4 pcs
PLUG - SPM CAP-02
861
** AV32010
4 pcs
MEASUREMENT NIPPLE - SPM 32010
904
** Y0031024
Y0031024
1 pcs
ASSEMBLY D1PSF60
*** Y0031038
Y0031038
1 pcs
BAR -
*** Y0031051
*** K052618200
4
5
6
*** Y0003894
D016606
Y0031051
2 pcs
SHEET
2K052-6182
2 pcs
BUSHING -
*** Y0031054
Y0031054
1 pcs
PLATE
*** Y0031055
Y0031055
1 pcs
PLATE
8 pcs
SOCKET HEAD CAP SCREW DIN912 M8 20
1
5.1.2016
Lasse Karisalmi
2 (2)
Part List
Work no.
Customer
Train
Information
Pos. no. Item
ISD10107030
Walpella Oy
Draw. nr.
Manuf. no.
Qty pc
FI-107539
Qty
EXW
Designer
Date/ver.
*** Y0016075
4 pcs
WASHER DIN125 A - 8,4 -
906
** 605500
2 pcs
907
** Y0031059
Y0031059
2 pcs
BUSHING -
* ENGS103580
Y0030655
1 pcs
WATER COOLING COIL D1PSF60HPE-50
1210
** Y0030660
Y0030660
1 pcs
WATER COOLING COIL D1P..60 AISI 316 - -
1212
** Y0000580
1 pcs
THERMOSTATIC VALVE - AVTA 15 003N0107
1214
** 531529
1 pcs
BULB POCKET G1/2 180 017-436766
1216
** 542850
1 pcs
TAPERED FITTING - R1/2 DA9671
1218
** LU816182B
1 pcs
THERMOMETER - R1/2 C/F 90-ANG.
1220
** 640400
1224
** 476501703
1226
** 4763798
001
*** 545700
1230
2 pcs
O-RING DIN3771 - 19,2 3 - FKM -
476501703
2 pcs
*FITTING - - -
4763798
2 pcs
LEADING-IN TUBE - - -
1 pcs
THREAD REDUCER HIFLEX R1-R1/2 RSI-16-08
** 547100
2 pcs
LOCK NUT - R1/2 DA5300
* HDRS100405
1 pcs
ASSEMBLY -
870
** Y0021622
1 pcs
MALE NIPPLE HIFLEX R1 1/2 04500-24
871
** 542760
1 pcs
CONNECTOR HIFLEX R1 1/2 04040-24
872
** 544630
1 pcs
MALE NIPPLE - R1 1/2 L=300 DA5885
873
** 546740
1 pcs
SEAL - 58,7 48,4 3,4 R1 1/2 - USITR-24
874
** 547425
1 pcs
BALL VALVE G11/2 -
877
** ITM0009817
1 pcs
PLUG - VSTI R1 1/2-ED
* ENGS103578
1 pcs
OIL CATCHER D1PSF60HPE-50
900
** Y002948404
1 pcs
OIL CATCHER - D1PSF60 i=5-7.1
901
** 602300
Y0029484
8 pcs
HEXAGON NUT DIN934 M8
902
** 636800
4 pcs
HEX NUT NYLOC DIN985 M8
903
** Y0007611
4 pcs
THREADED BAR DIN976B M8 90
1
5.1.2016
Lasse Karisalmi
565
260
200
290
R1"
M20x35
4 pcs
8.5
LSS
825
HSS
45
250
555
63 214
140
125h7
60
28
124.5
12
124h7
OIL SIGHT GLASS ON

HSS SIDE OF HOUSING
120h6
R11/2
450+0
-1
895
375
PAINTED
45
400
377.5
480
1071
170
400
22 h9
90 90
285
(296)
127
55
120h6
NIMITYS/
MITAT,MUOTO,MALLI/
RAAKA-AINE/
DESCRIPTION
DIMESIONS,FORM,PATTERN
MATERIAL
TYTAPAKOHTAISET TOLERANSSIT/PERMISSIBLE VARIATIONS IN
DIMENSIONS WITHOUT TOLERANCE INDICATION:
LASTUAVA TYST/MACHINING:
ISO 2768-mK
HITSATUT RAKENTEET/WELDINGS: IS0 13920-B
VALUT/CASTINGS:
SFS-ISO 8062 CT-11
POLTTOLEIKKAUS/FLAME CUTTING:EN 10029,
SFS-EN 9013LUOKKA/CLASS II B KENTTA/FIELD 2
WATER IN
R1/2 FEMALE
NIMITYS
TITLE
VALMISTE
PRODUCT
COPYRIGHT MOVENTAS Oy (IG)
PIIRUSTUS/
DRAWING
MASSA KG
MASS
KPL/
PCs
1080
PAIVAYS
DATE
PIIRT.
DRAWN
TARK.
CHKD
HYV.
APPD
2012-03-14
MITTAK.
SCALE
HYVAKSYJA
APPROVED BY
MUUTOS
REVISION
MERKKI
KEY
E016333
VERTEX
A3
1 : 11
NIMI
NAME
LKa
VERT.PIIR.
REF.DWG
0
-0.022
HUOM/
NOTES
DIMENSION DRAWING
D1PSF60HPE-50
D016604
i=5.6...7.1
sp23
OPEN
MUUTTAJA
NAME
LSS 1:5
+0.030
+0.011
HSS 1:4
CLOSED
190
486
285
296
80 m6
OSA/
PART
0
-0.062
M24x50
85
WATER OUT
R1/2 MALE
PVM
DATE
32h9
0
-0.052
M20x42
890
R4
(594)
445
370
270
200
1396
305
230
5
135
48
0.2
0.2+.02
0
+0.2
0
M8;2pcs
10/8.30.1
2 kpl/pcs
7
6
5
4
3
2
1
Washer
Hex. screw
Sheet
Sheet
Bushing
Sheet
Bar
OSA/
PART
NIMITYS/NAME
c)
Y0016075
Y0003894
Drawing
Drawing
Drawing
Drawing
Drawing
KPL/
PC
AINE/
MATERIAL
EUROPEAN PROJ
A8.4
M8x20
Y0031055
Y0031054
2K052-6182
Y0031051
Y0031038
MITAT,MUOTO,MALLI/
HUOM/REMARKS
DIMENSIONS,FORM,PATTERN
SUHDE/SCALE
LASTUAMISTOLERANSSIT
MACHINING TOLERANCES
ISO2768-m
1:1.5
NIMITYS/NAME
MUUTOS/REVISION
4
8
1
1
2
2
1
b)
a)
ASSEMBLY OIL WIPER

D1P60 i=2.8...7.1
P./D.
030401
HMY
T./C.
030401
HMY
H./A.
PIIRUSTUS/DRAWING
Y0031024 A
i=1.25..3.25
i=1.25..3.15
i=1.25..2.5
i=1.25..2.25
i=1.25..2.25
i=1.25..2.25
i=1.25..2.5
(907)
(906)
(904)
D1PSF42HPE
D1PSF50HPE
D1PSF60HPE
D1PSF70HPE
D1PSF80HPE
D1PSF90HPE
D1PSF100HPE
i=3.55..7.1
i=3.55..7.1
i=2.8...7.1
i=2.5...7.1
i=2.5...7.1
i=2.5...7.1
i=2.8...7.1
ISO 6743-9 NLGI2

grease amount according MDI9094
130
rasvausvli 4 kk
regreasing interval 4 months
Fett-Nachschmierungsintervall 4 monaten
smrjningsinterval 4 mnader
rasvaus akselin pyriess
greasing when the shaft is rotating
bei Nachschmierung welle umdrehen
Vid smrjning rotera axeln
(907)
(906)
(904)
100
010
011
018
025
026
(220)
POS.017
YLPUOLELLA OLEVA
REIK TULPATAAN (R1/8)
THE HOLE ON TOP SIDE
IS PLUGGED (R1/8)
110
210
3310
3312
3318
3314
3316
1..3
D1PSF42HPE
D1PSF50HPE
D1PSF60HPE
D1PSF70HPE
D1PSF80HPE
D1PSF90HPE
D1PSF100HPE
820
870
(900)
(901)
(902)
(903)
2.5-3.5
871
872
199
873
874
(860)
(861)
840
843
075
076
077
800
020
021
028
877
(241)
(254)
210
288
825
(220)
015
016
201
230
001
802
(803)
111
153
152
163
Loctite 243 tai
vastaava or similar
POS.027
YLPUOLELLA OLEVA
IS PLUGGED (R1/8)
C=0.4...0.8
ljylasi ensin puolelle
Oil glass on HSS side
002
Kiristysmomentti
Fastening torque
1218
[Nm]
1216 1232
831
1212
830
1220
1224
1226
1230
OSA/
PART
NIMITYS/NAME
KPL/
PC
c)
b)
a) Greasing instruction added

2014-10-28 AHS
M10
M12
M16
M20
19,5
38,1
66,6
161
315
M24
M30
M36
M42
541
1092
1900
3045
AINE/
MATERIAL
EUROPEAN PROJ
NIMITYS/NAME
MUUTOS/REVISION
M8
MITAT,MUOTO,MALLI/
HUOM/REMARKS
SUHDE/SCALE
SFS4011-KESKI
ISO2768-MEDIUM
P./D.
2010-03-05
JMe
PIIRUSTUS/DRAWING
ASSEMBLY D1PSF42HPE...80HPE
T./C.
2010-03-05
JMe
D009666 A
23
H./A.
E009471
1218
1210
1214
1216
R1/2 (MALE/UK.)
1220
*)
(1224)
1212
R1/2 (FEMALE/SK.)
1230
1226
*) Loctite 601 or similar / tms.
OSA/
PART
NIMITYS/NAME
KPL/
PC
AINE/
MATERIAL
EUROPEAN PROJ
MITAT,MUOTO,MALLI/
HUOM/REMARKS
SUHDE/SCALE
ISO2768-m
1:5
NIMITYS/NAME
MUUTOS/REVISION
c)
b)
a)
WATER COOLING COIL D1PSF
P./D.
030211
HMy
T./C.
030211
HMy
H./A.
PIIRUSTUS/DRAWING
Y0030655
TECHNICAL DOCUMENTS
Handler/Designer:
Katri Rantanen / Lasse Karisalmi
Walpella Oy
PL 10
37601 Valkeakoski
Finland
Customer Ref.: H11218573

Salesperson ref.: ISD10107010 / Ville Vehkakoski
Project: M450VALZ CHILE
Gear unit type: D1PSF60HPE-50
Manufact. no.: FI-107538 - FI-107538
Delivering following documents: 1 x EN
Document data format: pdf
1 STOD115876ED.01
PART LIST
DRAWINGS
Dimension drawings
D016612
Assembly drawings
Y0031024, D006909, Y0030655
OTHERS
Manufacturer's warranty and buyer's responsibility
MDI-110-AEN
MDI-120-CEN
Use and maintenance of gearing
MDI-180-BEN
Foundation of industrial gear assemblies standing installation
MDI-140-AEN
Installation of industrial gear assemblies standing installation
MDI-150-AEN
MDI-130-AEN
Assembly report
U306EN
MDI-170-DEN
SANTASALO GEARS OY
Vesangantie 1
P.O.Box 1001
40101 Jyvskyl
FINLAND
Tel +358 293 401000

Fax +358 20 184 7101
LY 2646194-8
www.santasalo.com
1 (1)
Technical specification
SpecificationNo.
ISD10107010
Revision
1. General data
1
2
Delivery date EXW
5.1.2016
Customer
Walpella Oy
Issued by
Ville Vehkakoski
Country
Finland
Date
17.9.2015
Revision row no.

Customer order no.
H11218573
Date
17.9.2015
Customer ref.
M450VALZ CHILE
Designed by
Driven Machine / item no.
Pulper HP-50G
Date
Date
Lasse Karisalmi
8
9
2. Product description
10
Gear unit type
D1PSF60HPE-50
Ratio i
5,611
Running data
min.
Rotation speed
Shaft position
norm.
HSS [1/min]
1486
LSS [1/min]
265
Running Power Pk1
[kW]
Running torque Mk2
[kNm]
14
Weight appr.[kg] 1050

max.
Manufacturing nos.
FI-107538 - FI-107538
11
Quantity
12
Service factor Fs
2,46
13
according to
Running power PK1 max
14
Mounting position
Standard
15
315
16
Anch. rod length HA
17
Rot.direction of LSS
Clockwise
Hollow shaft nom. dia.
Painting system
ISO 12944-5/S4.13(EPPUR240/3-FeSa 2)
Colour code
Type
AC-motor/inverter
Code
Duration of service[h/day]
24
21
Pm [kW]
355
/n
Max load occ./hour
22
18
RAL7011
19
3. Operating conditions
20
Driving machine
Connection diameters
External loads
1486
[mm] Driving machine shaft

[kN] Fa norm
Fa max
Driven machine shaft

Direction
Fr norm
Fr max
23
Acting point fr. shaft end[mm]
LSS
25
HSS
26
Electrical supply
Main[V]
Ambient temperature
[C] min.
[Hz]
10
50
Instr.supply[V]
[C] norm.
[Hz]
[C] max.
35
Lubricant
27
28
4. Lubrication
Lubrication method
24
29
Splash lubrication
Oil Mineral ISO VG320EP
Ambient temperature range
[C] +10...+35
Oil level indication
Joint level down
Grease type
Lubr. unit location
30
Synt. ISO VG320EPPAO
31
[C]
[C]
[mm]
220
Oil qty appr.

Grease qty [g]
5. Documentation
32
60
33
34
35
Dimension drawing no.
D016612
36
Assembly drawing no.
Y0030655, Y0031024, D006909
37
Other documents
38
39
40
6. Additional equipment/other information
41
Qty
42
GEAR UNIT WITH ACCESSORIES D-SERIES HORIZONTAL PSF, PHF, PHT SMALL (<100)
43
STOD115876ED
44
i=5,611:1
45
Pos. 2, Rot. -
46
47
GEAR UNIT D1PSF60HPE-50
48
DRAIN VALVE G11/2
49
MEASUREMENT NIPPLE SPM 32010
50
LONG CORROSION PROTECTION
51
WATER COOLING COIL AISI316/D1P60
52
53
1 (2)
Part List
Work no.
Customer
Train
Information
Pos. no. Item
ISD10107010
Walpella Oy
ENGS103518
825
Draw. nr.
D016612
ITM2002351
ENGS103596
D006909
Manuf. no.
Qty pc
FI-107538
Qty
EXW
Designer
Date/ver.
1 pcs
GEAR UNIT WITH ACCESSORIES
4 pcs
EYE BOLT DIN580 M20 -
1 pcs
GEAR UNIT -
* HDRS100405
1 pcs
ASSEMBLY -
870
** Y0021622
1 pcs
MALE NIPPLE HIFLEX R1 1/2 04500-24
871
** 542760
1 pcs
CONNECTOR HIFLEX R1 1/2 04040-24
872
** 544630
1 pcs
MALE NIPPLE - R1 1/2 L=300 DA5885
873
** 546740
1 pcs
SEAL - 58,7 48,4 3,4 R1 1/2 - USITR-24
874
** 547425
1 pcs
BALL VALVE G11/2 -
877
** ITM0009817
1 pcs
PLUG - VSTI R1 1/2-ED
* ENGS103580
Y0030655
1 pcs
WATER COOLING COIL D1PSF60HPE-50
1210
** Y0030660
Y0030660
1 pcs
WATER COOLING COIL D1P..60 AISI 316 - -
1212
** Y0000580
1 pcs
THERMOSTATIC VALVE - AVTA 15 003N0107
1214
** 531529
1 pcs
BULB POCKET G1/2 180 017-436766
1216
** 542850
1 pcs
TAPERED FITTING - R1/2 DA9671
1218
** LU816182B
1 pcs
THERMOMETER - R1/2 C/F 90-ANG.
1220
** 640400
1224
** 476501703
1226
** 4763798
001
*** 545700
1230
2 pcs
O-RING DIN3771 - 19,2 3 - FKM -
476501703
2 pcs
*FITTING - - -
4763798
2 pcs
LEADING-IN TUBE - - -
1 pcs
THREAD REDUCER HIFLEX R1-R1/2 RSI-16-08
** 547100
2 pcs
LOCK NUT - R1/2 DA5300
* HDRS100406
1 pcs
ASSEMBLY -
1 pcs
GEAR HOUSING
001
** Y003007813
Y003007813
800
*** 601480
8 pcs
802
*** 601524
6 pcs
820
*** 614000
4 pcs
PARALLEL PIN DIN7979A 40 16
010
** Y0030930
1 pcs
COVER
011
** 601860
6 pcs
015
** Y0031224
016
Y0030930
Y0031224
1 pcs
COVER
** 601860
6 pcs
017
** 631117
1 pcs
PLUG R1/8 -
018
** 531536
020
** Y0029603
021
** 601860
025
** Y0029597
026
Y0029603
Y0029597
4 pcs
PLUG - DBI NO.11
1 pcs
COVER
6 pcs
1 pcs
COVER
** 601860
6 pcs
027
** 631117
1 pcs
PLUG R1/8 -
028
** 531536
4 pcs
PLUG - DBI NO.11
075
** Y0030795
076
** 601740
077
** G118508
G118508
1 pcs
SEAL - - - 200 KLINGERSIL C-4430 - -
100
** E016334
D016605
1 pcs
LSS SHAFT -
110
** ITM0040952
1 pcs
111
** ITM0040965
1 pcs
1232
** 540800
1 pcs
SCREWED PIPE FITTING - R1/2 DA5140
130
** 121400170
1 pcs
KEY DIN6885 B 32 18 170
152
** 4746895
153
** 601780
163
** Y0030549
199
** Y0030266
201
** E016330
Y0030795
4746895
1 pcs
INSPECTION COVER
6 pcs
1 pcs
END PLATE
3 pcs
Y0030549
1 pcs
BUSHING -
Y0030266
1 pcs
GEAR WHEEL 101
D016600
1 pcs
PINION -18
1
5.1.2016
Lasse Karisalmi
2 (2)
Part List
Work no.
Customer
Train
Information
Pos. no. Item
ISD10107010
Walpella Oy
Manuf. no.
Draw. nr.
Qty pc
4747561
2 pcs
FI-107538
Qty
EXW
Designer
Date/ver.
220
*** 4747561
BEARING BUSHING -
210
** ITM0040982
2 pcs
SPHERICAL ROLLER BEARING 22322 E/C3
230
** 121000159
1 pcs
KEY DIN6885 B 22 14 159
288
** 520085
3310
** E016335
3312
3314
1 pcs
V-RING - - - - - FKM VA-85
1 pcs
FLINGER RING - 214 142 - - S355JO -
** 631950
3 pcs
** 640053
1 pcs
GREASE NIPPLE DIN71412 R1/8 A
3316
** 640062
1 pcs
EXTENSION - KR1/8 KR1/8 52 MM
3318
** Y0030884
2 pcs
830
** LU5RFSA127
1 pcs
OIL LEVEL GLASS - FSA 127-2.0/-/12/-SO14
831
** 631815
2 pcs
840
** ITM0040871
1 pcs
BREATHER G1 L= 70
843
** 546720
1 pcs
SEAL - 42,9 33,9 3,4 - - USITR-16
860
** 570015
4 pcs
PLUG - SPM CAP-02
861
** AV32010
4 pcs
MEASUREMENT NIPPLE - SPM 32010
904
** Y0031024
Y0031024
1 pcs
ASSEMBLY D1PSF60
*** Y0031038
Y0031038
1 pcs
BAR -
*** Y0031051
*** K052618200
D016606
Y0031051
2 pcs
SHEET
2K052-6182
2 pcs
BUSHING -
*** Y0031054
Y0031054
1 pcs
PLATE
*** Y0031055
Y0031055
1 pcs
PLATE
*** Y0003894
8 pcs
*** Y0016075
4 pcs
WASHER DIN125 A - 8,4 -
906
** 605500
907
** Y0031059
Y0031059
* ENGS103578
900
** Y002948404
901
Y0029484
2 pcs
2 pcs
BUSHING -
1 pcs
OIL CATCHER D1PSF60HPE-50
1 pcs
OIL CATCHER - D1PSF60 i=5-7.1
** 602300
8 pcs
HEXAGON NUT DIN934 M8
902
** 636800
4 pcs
HEX NUT NYLOC DIN985 M8
903
** Y0007611
4 pcs
THREADED BAR DIN976B M8 90
1
5.1.2016
Lasse Karisalmi
565
260
200
290
R1"
M20x35
4 pcs
8.5
375
PAINTED
LSS
825
45
250
555
60
45
120h6
124h7
28
124.5
12
125h7
63 214
OIL SIGHT GLASS ON

HSS SIDE OF HOUSING
140
R11/2
450+0
-1
895
HSS
400
377.5
480
1071
170
400
1396
OPEN
22 h9
285
296
80 m6
890
(594)
445
370
270
200
R4
HYVAKSYJA
APPROVED BY
55
120h6
NIMITYS/
MITAT,MUOTO,MALLI/
RAAKA-AINE/
DESCRIPTION
DIMESIONS,FORM,PATTERN
MATERIAL
TYTAPAKOHTAISET TOLERANSSIT/PERMISSIBLE VARIATIONS IN
DIMENSIONS WITHOUT TOLERANCE INDICATION:
LASTUAVA TYST/MACHINING:
ISO 2768-mK
HITSATUT RAKENTEET/WELDINGS: IS0 13920-B
VALUT/CASTINGS:
SFS-ISO 8062 CT-11
POLTTOLEIKKAUS/FLAME CUTTING:EN 10029,
SFS-EN 9013LUOKKA/CLASS II B KENTTA/FIELD 2
NIMITYS
TITLE
VALMISTE
PRODUCT
COPYRIGHT MOVENTAS Oy (IG)
PIIRUSTUS/
DRAWING
MASSA KG
MASS
KPL/
PCs
1080
PAIVAYS
DATE
PIIRT.
DRAWN
TARK.
CHKD
HYV.
APPD
2012-03-14
MITTAK.
SCALE
MUUTOS
REVISION
MERKKI
KEY
E016339
VERTEX
A3
1 : 11
NIMI
NAME
LKa
VERT.PIIR.
REF.DWG
0
-0.022
HUOM/
NOTES
DIMENSION DRAWING
D1PSF60HPE-50
D016612
i=5.6...7.1
sp14
305
MUUTTAJA
NAME
LSS 1:5
+0.030
+0.011
HSS 1:4
OSA/
PART
0
-0.062
M24x50
85
90 90
M20x42
WATER OUT
R1/2 MALE
PVM
DATE
32h9
0
-0.052
127
(296)
CLOSED
285
486
190
WATER IN
R1/2 FEMALE
230
5
135
48
0.2
0.2+.02
0
+0.2
0
M8;2pcs
10/8.30.1
2 kpl/pcs
7
6
5
4
3
2
1
Washer
Hex. screw
Sheet
Sheet
Bushing
Sheet
Bar
OSA/
PART
NIMITYS/NAME
c)
Y0016075
Y0003894
Drawing
Drawing
Drawing
Drawing
Drawing
KPL/
PC
AINE/
MATERIAL
EUROPEAN PROJ
A8.4
M8x20
Y0031055
Y0031054
2K052-6182
Y0031051
Y0031038
MITAT,MUOTO,MALLI/
HUOM/REMARKS
SUHDE/SCALE
ISO2768-m
1:1.5
NIMITYS/NAME
MUUTOS/REVISION
4
8
1
1
2
2
1
b)
a)
ASSEMBLY OIL WIPER

D1P60 i=2.8...7.1
P./D.
030401
HMY
T./C.
030401
HMY
H./A.
PIIRUSTUS/DRAWING
Y0031024 A
D1PSF42HPE
D1PSF50HP
D1PSF60HP
D1PSF70HP
D1PSF80HP
D1PSF90HP
D1PSF100HP
i=3.55..7.1
i=3.55..7.1
i=2.8...7.1
i=2.5...7.1
i=2.5...7.1
i=2.5...7.1
i=2.8...7.1
D1PSF42HPE
D1PSF50HP
D1PSF60HP
D1PSF70HP
D1PSF80HP
D1PSF90HP
D1PSF100HP
i=1.25..3.25 A
i=1.25..3.15
i=1.25..2.5
i=1.25..2.25
i=1.25..2.25
i=1.25..2.25
i=1.25..2.5
POS.027
YLPUOLELLA OLEVA
IS PLUGGED (R1/8)
(220)
877
020
021
028
(907)
(906)
(904)
(907)
(906)
(904)
230
288
201
(254)
(241)
210
Loctite 243 tai

vastaava or similar
015
016
163
153
152
802
(803)
800
111
873
874
820
872
199
1..3
871
870
(900)
(901)
(902)
(903)
2.5-3.5
ISO 6743-9 NLGI2

grease amount according MDI9094
rasvausvli 4 kk
regreasing interval 4 months
Fett-Nachschmierungsintervall 4 monaten
smrjningsinterval 4 mnader
rasvaus akselin pyriess
greasing when the shaft is rotating
bei Nachschmierung welle umdrehen
Vid smrjning rotera axeln
(860)
(861)
840
843
075
076
077
025
026
210
(220)
3314
3316
110
010
011
018
POS.017
YLPUOLELLA OLEVA
IS PLUGGED (R1/8)
3310
3312
3318
100
825
001
130
C=0.4...0.8
ljylasi ensin puolelle
Oil glass on HSS side
002
Kiristysmomentti
Fastening torque
1218
[Nm]
1216 1232
831
1220
1224
1226
1230
1212
830
OSA/
PART
NIMITYS/NAME
KPL/
PC
c)
b)
Greasing instruction added

2014-10-28 AHS
a)
Text added 110616/MTY
ASSEMBLY D1PSF42HPE...80HPE
14
M10
M12
M16
M20
19,5
38,1
66,6
161
315
M24
M30
M36
M42
541
1092
1900
3045
AINE/
MATERIAL
EUROPEAN PROJ
NIMITYS/NAME
MUUTOS/REVISION
M8
E006781
MITAT,MUOTO,MALLI/
HUOM/REMARKS
SUHDE/SCALE
SFS4011-KESKI
ISO2768-MEDIUM
P./D.
22.10.2008
MNi
T./C.
22.10.2008
MNi
H./A.
PIIRUSTUS/DRAWING
D006909 B
1218
1210
1214
1216
R1/2 (MALE/UK.)
1220
*)
(1224)
1212
R1/2 (FEMALE/SK.)
1230
1226
*) Loctite 601 or similar / tms.
OSA/
PART
NIMITYS/NAME
KPL/
PC
AINE/
MATERIAL
EUROPEAN PROJ
MITAT,MUOTO,MALLI/
HUOM/REMARKS
SUHDE/SCALE
ISO2768-m
1:5
NIMITYS/NAME
MUUTOS/REVISION
c)
b)
a)
WATER COOLING COIL D1PSF
P./D.
030211
HMy
T./C.
030211
HMy
H./A.
PIIRUSTUS/DRAWING
Y0030655
Manufacturers warranty and buyers

responsibility
MDI-110-A-EN
orig. 20.02.2007
ver. 10.10.2012
MANUFACTURERS WARRANTY AND BUYERS RESPONSIBILITY
1.
MANUFACTURERS WARRANTY AND BUYERS RESPONSIBILITY ............................................................... 2
2.
USERS RESPONSIBILITY IN CASE OF DAMAGE .............................................................................................. 2
Santasalo Gears Oy
1(2)
Manufacturers warranty and buyers

responsibility
MDI-110-A-EN
orig. 20.02.2007
ver. 10.10.2012
1. MANUFACTURERS WARRANTY AND BUYERS RESPONSIBILITY

Santasalo Gears warrants that all products
manufactured by it comply with terms to be agreed
upon separately. For the warranty to be applicable,
the customer shall have followed Santasalo Gears
guidelines, national and international standards and
norms, careful procedures and generally accepted
mechanical engineering methods. This set of
instructions is not exhaustive and may not always be
applicable in all respects to all products and
components with which it has been supplied. In
special cases, instructions pertaining to specific uses
shall be taken into consideration. Santasalo Gears
reserves the right to modify the content of this set of
instructions without separate notification.
Santasalo Gears is not liable for damage caused by
transportation, storage, installation, use or other
actions to the product. Santasalo Gears is not liable
for damage to the product resulting from factors
external to the delivery content, such as the corrosive
effects of weather, leakage or welding currents or
magnetism, which may damage the product, increase
the risk of damage or shorten the life cycle of the

product or its components.
Transport, installation, lubrication, use, maintenance
and inspections shall be performed by qualified
personnel to prevent accidents and damage to the
machinery.
All parts of the drive system must be compatible. The
overall system should never run at the critical
rotational speed or exhibit torsional or other
vibrations that could damage the gears. The
responsibility for this lies with the main supplier of the
equipment, as it is most often the only party that has
comprehensive information of all factors affecting the
matter.
Santasalo Gears must be informed without delay if a
significant risk relating to the environment or the
operating staff is about to occur due to a defect in the
machine.
The warranty shall be valid only if the instructions
provided by Santasalo Gears are complied with.
2. USERS RESPONSIBILITY IN CASE OF DAMAGE

In the event of damage during the validity of the
warranty, the users responsibility is to retain the gear
unit as intact as possible until such a time as
Santasalo Gears has issued instructions on further
measures.
The following may void the warranty:
failure to provide maintenance
failure to report any circumstance that essentially

contributed to the occurrence of the damage
refusal to provide reliable maintenance data
failure to comply with instructions from Santasalo

Gears in connection with damage
continued use after detection of damage

gear unit load and use in violation of the
technical specifications
failure to comply with instructions from Santasalo

Gears
Santasalo Gears Oy
2(2)

MDI-120-C-EN
orig. 20.02.2007
ver 16.10.2012
GENERAL PRODUCT SAFETY GUIDE
1 GENERAL PRODUCT SAFETY INSTRUCTIONS

1.1 Gear units
.........................................
.............................................................................
1.2 Safeguarding rotating parts

1.3 Maintenance
............................................................
..........................................................................
1.4 Environmental protection

2 LIFTING WORK
..............................................................
...........................................................................
2.1 General instructions

2.2 Collar eyebolts
...................................................................
........................................................................
2.3 Other hoist brackets

2.4 Other notes on lifting
...................................................................
..................................................................
Santasalo Gears Oy
1(6)

MDI-120-C-EN
orig. 20.02.2007
ver 16.10.2012
1 GENERAL PRODUCT SAFETY INSTRUCTIONS

The purpose of these instructions is to minimize risks
and prevent accidents and injuries. Even though
safety factors have been taken into account in the
design of each Santasalo Gears product, the
equipment may be dangerous if used carelessly or
without sufficient experience. Installation, assembly
and maintenance of mechanical drive units may only
be carried out by qualified personnel. It is prohibited
to make changes to drive units.
All parts of the drive system must be compatible. The
overall system should never run at the critical
rotational speed or exhibit torsional or other
vibrations that could damage the gears. The
responsibility for this lies with the main supplier of the
equipment, as it is most often the only party that has
comprehensive information of all factors affecting the
matter. Santasalo Gears must be informed without
delay if a significant risk relating to the environment
or the operating staff is about to occur due to a defect
in the machine.
Below is a list of the most typical risk factors that
need to be considered when handling mechanical
drive units.
Untidy working conditions

Poor lighting
Noise and vibration
Working on scaffolds or in confined places
Lifting and moving heavy loads
Inappropriate work methods
Automatic functions or unexpected start-ups
Rotating devices and other moving devices
High-pressure hydraulic components
High oil temperature
Any oil leaks
Flammable and corrosive substances as well as

other chemicals that are dangerous to health and
the environment
Separate instructions on mechanical use must
always be followed in addition to these instructions.
___________________________________________________________________________________
1.1 Gear units
1.1.2 Other notes on using the gear unit
1.1.1 Rustproofing
The gear units are equipped with either lifting holes

or eyes to enable the lifting or moving of the gears.
They may only be used for lifting the gear unit.
Always use reliable, inspected and properly
dimensioned lifting eyes, chains or ropes when lifting
gear units or couplings. Disengage all pipes, tubes
and cables as well as drive shafts and couplings
connected to the gear unit before lifting. Lifting must
be carried out in accordance with the plants general
lifting instructions.
Gear units may be equipped with VCI anti-corrosive

agent for rustfree storage and transport. If so, there
will be a red sticker on the side of the housing
displaying the text "DINITROL VCI-UNI 0-40 Internal
Corrosion Protection". Inside the gear unit, there is
air tightly sealed oil that releases VCI inhibitors inside
the gear unit. There are 3-4 liters of VCI oil per free
cubic meter of air inside the gear unit. The VCI oil
can be mixed with gear oil, so there is no need to
remove it. VCI oil is irritating so avoid getting oil on
your skin or in your eyes. Wear protective eyewear.
Open flame near the gear unit is strictly

forbidden.
Always ensure that the machine cannot be started

before connecting the gear unit to the drive system or
disengaging them. Make sure that external energy
sources (electricity, hydraulics, pneumatics, spring
force, masses, etc.) have been disconnected or
reliably secured and locked. You should also ensure
that the warning signs are in place. Do not touch any
moving parts before they have come to a complete
stop. You must not use any aids to stop the moving
parts.
Santasalo Gears Oy
2(6)

MDI-120-C-EN
To avoid slipping accidents, block the oil filling and
draining holes of the gear immediately after
disengagement of joints and remove any leaked oil or
grease from the work area without delay.
The oil temperature and the gear unit surface
temperature are approximately 60 C (140 F) during
operation. The maximum temperature may be as
high as 100 C (212 F) particularly in splash- and
bath-lubricated gears.
The noise level of gear assemblies varies depending
on the mechanical power and gear type. The noise
level may exceed 85 dB, in which case you must use
hearing protectors.
1.2 Safeguarding rotating parts
Installation and maintenance must be performed

using skilled maintenance personnel.
All maintenance procedures shall be performed when
the gears are not in operation.
During maintenance, the gear temperature must be
the same as the ambient temperature.
When lifting, you must adhere to all international

and national rules and work place instructions
Before lifting, a person familiar with lifting

equipment must examine the equipment.
Lifting must be planned carefully: the weight,

shape, lifting position, and center of gravity of the
load must be determined before lifting. Load
division between lifting straps must be
determined before lifting. Lifting straps of
different length and the need for lifting straps
must be considered.
You must not walk under the load, and the

load must be lifted and moved in such a way that
people do not get under the load. You must take
the possible tipping or falling of the load into
account.
You must note that a slanted lifting strap lessens

the permitted load. A - angle of over 45
degrees is never allowed. The maximum angle allowed on large, heavy gears is 20
degrees. (gear units that weigh more than 5
tonnes). Lifting straps should be long enough not
to exceed allowed lifting angles. (See picture 2)
A separate lifting beam must be used where
applicable.
The sliding of flat webbing sling, textile sling, or

other lifting loop on flat surfaces must be
prevented by lifting with an almost vertical
straps, angle max 10 degrees. (See pictures 6
and 9)
If the strap attached to a load is a textile sling,

etc., you must protect sharp edges with rounded
edge protectors. The minimum allowed radius for
an edge against a strap that could possibly get
damaged is 13 mm.
A starting lift where the load detaches from its

platform must always be performed first. After
this, the stability of the load, strap attachment,
and possible deflections/openings must be
checked before the lifting can continue. The
lifting must be performed evenly, avoiding any
jerking motions. Lateral pulling or lifting and
dragging the load is forbidden.
You cannot lift anything heavy besides the gear

unit itself from the gear unit lifting points. When
using only the collar eyebolts of the gear unit,
there must be no large motors, parts of the
customer device, etc., attached to the gear unit
during lifting. When using the gear unit collar
eyebolts, the maximum allowed additional load is
10% of the gear unit weight and the center of
gravity may not shift substantially. (See pictures
5, 6, 7, 8, and 9)
1.4 Environmental protection

When the oil is changed, waste oil and oil filters must
be collected in suitable containers and disposed of in
accordance with national legislation and regulations.
Any leaked oil shall be removed immediately using
oil-absorbent material, which shall be disposed of as
solid oil-containing waste in accordance with national
legislation and regulations.
Any gears delivered to Santasalo Gears for
maintenance must be drained of oil prior to transport.
The gears shall be transported in such a position that
any oil remaining inside the gears will not leak into
the environment.
Any break pads included in a Santasalo Gears
delivery do not contain asbestos, so worn-out pads
may be disposed of with other industrial waste.
ver 16.10.2012
Appropriate safeguards must be used in accordance

with safety legislation so that rotating parts cannot be
touched. The safeguards must be sufficiently strong
to meet the standards.
Mechanical safeguards must not be removed during
the operation of the gears.
1.3 Maintenance
orig. 20.02.2007
2. LIFTING WORK
2.1 General instructions
Santasalo Gears Oy
3(6)

MDI-120-C-EN
orig. 20.02.2007
ver 16.10.2012
2.2 Collar eyebolts

The gear unit collar eyebolts/nuts are DIN580 (201009) / DIN582 (2010/09) lifting eyebolts/nuts.
The maximum allowed - angle is 45 degrees.

(See picture 1)
The lifting eyebolts must be tightened against

their platform before lifting; a slanted lifting force
must not open the eyebolt's thread.
You must consider unevenly distributed loads

and the angle of the lifting strap. The maximum
allowed lifting weight must not be exceeded on
any of the gear unit collar eyebolts.
All the gear unit lifting points/eyebolts must be

used during lifting to ensure distributing the load
as evenly as possible.
You cannot lift anything heavy besides the gear

unit from the gear lifting points. There must be
no large motors, parts of the customer device,
etc., attached to the gear unit during lifting.
Table 1. Maximum load per one collar eyebolt/nut.

DIN580 (2010-09) / DIN582 (2010/09)
Maximum load on one DIN 580 / DIN582 collar eyebolt/nut
Picture 1: A
Lifting
eyebolt/nut
size
M10
M12
M16
M20
M24
M30
M36
M42
M48
M56
Lifting force directly

upwards. Per lifting
eyebolt/nut
[ lbs ]
[ kg ]
230
340
700
1200
1800
3200
4600
6300
8600
11500
505
750
1545
2645
3965
7055
10140
13890
18960
25350
Picture 1: B
Lifting force at an angle
(max. 45 degree - angle).
Per lifting eyebolt/nut
[ lbs ]
[ kg ]
170
240
500
860
1290
2300
3300
4500
6100
8200
Direction not allowed: - angle

over 45
Picture 1. Maximum allowed pulling direction for the
lifting loop is = 45 or less.
2.3 Other hoist brackets
The gear unit may also be equipped with lift holes or
hoist brackets. The lifting strap must usually be
upright so that the hook or other attachment will not
slide off the lifting bracket. The hook may not twist
the lift hole or its surrounding area. ( See picture 2)
375
530
1100
1895
2845
5070
7275
9920
13450
18070
Picture 1: C
Lifting
eyebolt/nut
size
M10
M12
M16
M20
M24
M30
M36
M42
M48
M56
Lifting force directly

upwards and lifting
force at an angle
(max. 45 degree angle). Per lifting
eyebolt/nut
[ kg ]
[ lbs ]
115
170
350
600
900
1600
2300
3150
4300
5750
250
375
770
1320
1980
3525
5070
6940
9480
12670
Santasalo Gears Oy
4(6)

MDI-120-C-EN
orig. 20.02.2007
ver 16.10.2012
Picture 2. The largest strap angle () allowed on

large gear unit (more than 5 tonnes) is 20 degrees.
The strap must be upright if there is a danger of the
hook moving in the lift hole or the hoist bracket. Only
hooks with safety catches or self locking hooks may
be used.
Picture 5. Small accessories that do not alter the

location of the center of gravity significantly and
whose combined weight is no more than 10% of the
weight of the gear unit, can be lifted with the gear unit
by using the gear unit lifting eyebolts.
Picture 3. The gear unit may also be equipped with

small hoist brackets (A) for lifting components, e.g.
housing halves. These may not be used for lifting the
gear unit, instead you must choose the sturdiest
lifting points (B).
If the lift could twist the lifting point surroundings as in
the picture, you must only lift by using upright straps
and a lifting beam.
2.4 Other notes on lifting
The gear unit may never be lifted from the end of

the shaft because the bearings could be
damaged.
Heavy accessories (more than 10% of the gear

units weight) or accessories that are in the way
of the lifting straps and cause steep bends in the
lifting strap must be lifted in some other way than
by using the gear unit lifting points.
Picture 6. A small motor can be lifted with the gear

unit. The maximum angle for the textile sling is 10
degrees so that the flat webbing sling does not start
to slide. Use edge protectors to protect the textile
sling. The lifting eyebolt of the motor or any other
component must never be used to lift the gear unit.
Instead, the components lifting eyebolt may be used
to stabilize the load to prevent tipping it, when
needed.
Santasalo Gears Oy
5(6)

MDI-120-C-EN
Picture 7. Components that are too big (that weigh

more than 10% of the weight of the gear unit or
impair attaching the straps) cannot be lifted with the
gear unit from the gear units lifting points. The lifting
eyebolt of the motor or any other component must
never be used to lift the gear unit.
orig. 20.02.2007
ver 16.10.2012
Picture 9. Components that are too big (that weight

more than 10% of the weight of the gear unit or
impair attaching the straps) cannot be lifted with the
gear unit from the gear units lifting points.
Heavy components can be lifted with the gear unit if
the lifting strap is attached somewhere else than the
gear units lifting points and the weight of the
components is distributed evenly to the lifting straps
in question. Use a sturdy enough lifting strap. Check
the combined mass and the location of the center of
gravity. Check the gear unit weight put on the lifting
eyebolts and compare it with table nr. 1.
The maximum angle for the lifting textile sling is 10
degrees so that the flat webbing sling does not start
to slide. Use edge protectors on sharp edges where
needed.
The lifting eyebolt of the motor or any other
component must never be used to lift the gear unit.
Instead, the components lifting eyebolt may be used
to stabilize the load to prevent tipping it, when
needed.
Picture 8.A: If the lifting eyebolts are missing, the

existing holes can be used for the customers lifting
eyebolts, BUT the customer must check the capacity
of their lifting eyebolts in relation to the weight of the
gear unit and location of the center of gravity. You
must always use at least four lifting points.
Picture 8.B: The motor is too big; you may not lift it
with the gear unit.
Santasalo Gears Oy
6(6)
Use and maintenance of gear units

MDI-180-B-EN 20.02.2007 15.04.2013
USE AND MAINTENANCE OF GEAR UNITS
1.
DEPLOYMENT OF INDUSTRIAL GEAR UNITS ................................................................. 2

1.1
1.2
1.3
2.
PRE-DEPLOYMENT MEASURES.............................................................................................. 2
GEAR LUBRICATION ............................................................................................................. 2
RUNNING IN THE GEAR UNIT ................................................................................................. 2
MAINTENANCE OF INDUSTRIAL GEARS ......................................................................... 2

2.1 INSPECTION DURING OPERATION .......................................................................................... 3
2.2 INSPECTIONS AND MAINTENANCE CARRIED OUT DURING DOWNTIME ........................................ 3
2.2.1 External gear assembly cleaning .................................................................................. 3
2.2.2 Changing the lubrication oil ........................................................................................... 3
2.2.3 Secondary lubrication of grease-lubricated bearings.................................................... 4
2.2.4 Oil heater maintenance ................................................................................................. 4
2.2.5 Lubrication system maintenance................................................................................... 4
Santasalo Gears Oy
1(4)

MDI-180-B-EN 20.02.2007 15.04.2013
1. DEPLOYMENT OF INDUSTRIAL GEAR UNITS

1.1 Pre-deployment measures
Before deployment, check the following
according to their separate instructions:
items
Gear assembly cleaning: MDI-130

Correctness of operating unit installation: MDI150/MDI-160/MDI-165
Safety: MDI-120
In addition to these, also check the following:
Correct direction of rotation and electrical locking

of the electric engine
Safeguarding rotating parts

Connection of any monitoring devices used
Breather installation
Industrial gears are delivered with the breather

detached. The breather is delivered with the gearbox,
packed in a separate protective bag.
1.2 Gear lubrication
The operating principles for gear lubrication are
presented in more detail in the guide MDI-170.
If a splash-lubricated industrial gear has been
warehoused for more than year prior to
deployment, all rolling bearings should be lubricated
through the inspection hole and all mouth gaskets
should be lubricated with a suitable manual
lubrication device. After this, rotate the shafts
manually to spread the lubrication oil throughout the
bearings.
For pressure-feed lubricated industrial gear
assemblies, you need to check before starting the
unit that the pressure-feed lubrication works properly
using a test run. Also ensure that the electric engine
of the pump has the correct direction of rotation, is
properly safeguarded, that the operating engine of
the gear assembly is electrically locked and any
monitoring devices are connected. As the start-up is
the most critical phase with respect to lubrication, you
need to monitor the operation of the pressure-feed
lubrication devices and ensure that the pump sucks
oil and causes pressure on the pressurised side.
We recommend that you connect the electric engine
of the pump in such a way that it must be started first
before the operating engine of the gear assembly can
be started. We also recommend that you protect the
electric engine of the pump with an overcurrent relay.
1.3 Running in the gear unit

Before the actual deployment of the gear unit, it must
be run in. In the run-in, the load and, if possible, the
rotation speed of the gear unit is increased to the full
capacity in 23 steps. This process takes
approximately 810 hours. During run-in, monitor the
smoothness of the gear units operation, any
vibration, sounds of operation, temperature, possible
leaks and lubrication. If something suspicious is
detected, the cause of the anomaly must be
determined and eliminated.
In demanding installations and particularly with large
gear assemblies, tooth contact must be checked after
the run-in executed at the rated capacity using a
permanent colour and the inspection covers of the
gear assembly. For the inspection, the gear assembly
must be stopped and locked properly. The
requirement is almost 100% lateral contact. If the
contact is less than 100%, the gear unit may have
been skewed while tightening with the foundation
bolts or the alignment has been incorrectly carried
out.
If the tooth shape of the stage being inspected has
been corrected and if the run-in is carried out at
partial capacity, the tooth contact must be compared
to the contact diagram in the assembly drawing.
2. MAINTENANCE OF INDUSTRIAL
GEARS
The primary task of the maintenance is to proactively
prevent damage. All major events related to the gear
unit must be marked in the preventive maintenance
job card. The gear unit maintenance job card must
start to be filled in already in the installation stage.
Central issues to be entered in the maintenance job
card include:
Date of completion of the installation and

measured installation accuracies
First oil fill date, oil quality and oil quantity
Time of start of production use as well as power

measurement results
First oil change and any checks and

observations made during it, such as tooth
contact surface condition check
Oil changes actualised and the next planned

time of oil change
All repair and maintenance tasks carried out as

well as spare parts replaced
Run-in start and end time and any observations

made during run-in
Santasalo Gears Oy
2(4)

MDI-180-B-EN 20.02.2007 15.04.2013
It is important for both the user and manufacturer of

the industrial gear that an inspection carried out at
the end of the warranty period is done carefully.
Maintenance and inspection measures can be
divided into two groups:
inspection during operation

inspections and maintenance carried out during
downtime
2.1 Inspection during operation

During operation, observe the following:
heating
oil pressure and flow
whether the oil type used is one of the

recommended types
oil level when the gear unit is stopped
whether the cooler is clogged
sound of operation and vibration (vibration

measurements)
operating power and load peaks
any oil leaks

The operating temperature of the gear unit should be
+40+80 C measured in the oil sump. With
synthetic oils, temperatures up to +90 C can be
allowed, however, also in these cases there may be
isolated areas on the surface of the casing where the
temperature is higher.
If the gear temperature exceeds the allowable limit,
check:
whether the valves in the coolers waterline are

open
the setting of the thermostatic water valve

The normal range for the oil pressure is 0.53 bar.
Any changes in the oil pressure may indicate clogged
pipelines, nozzles, filters or heat exchangers or
damage to the pump.
Observing the power values helps assess the useful
life of the gear unit in the operating environment.
2.2 Inspections and maintenance carried out
during downtime
It is very important that also the condition of the gear
wheels and, if possible, bearings is checked during
the inspection and the results are marked in the
preventive maintenance job card. if there is clearly
increasing wear or flank damage (dents) in the teeth,
you need to determine the cause immediately.
Excessively short useful life may indicate a failed
foundation, overload, wrong lubricant, water in the
lubricant, clogged oil pipeline or wrong load
assessment during the gear specification stage.
2.2.1 External gear assembly cleaning

The external surface and the fan, if any, as well as
the electric engines of the gear unit must be kept
clean because stain accumulation increases the
operating temperature. When using an air-operated
oil cooler, the cells of the cooler must also be kept
clean. During pressure wash, do not aim the jet to the
shaft gaskets or breather. The functionality of the
breather must always be ensured during oil change.
2.2.2 Changing the lubrication oil
We recommend that a pump unit (not included in the
gear assembly delivery) that also filters the refill oil be
used in oil changes. When the oil refill cover is
opened, make sure that impurities do not enter the oil
tank.
Oil change interval
The first oil change must be carried out after 500800
hours of operation. The used oil must be removed
while it is still warm. During oil change, the oil tank
must be washed with rinsing oil if necessary.
For mineral oils, the following oil changes are needed
every one (1) year. The operating temperature
measured at the bearing housing should not exceed
+80 C. For large gear assemblies with large
quantities of oil, the useful life of the mineral oil may
be extended based on the results of the annual oil
analysis results. A permission for extended use of the
oil is usually granted by the oil company.
For synthetic (PAO) oils, the following oil changes are
needed every three (3) years. If the operating
temperature measured at the bearing housing is +90
C or higher, the oil change interval is 12,000 hours
of operation (ca. 1.5 years). Also with synthetic oils, it
is recommended that the oil quality be monitored with
regular oil analyses during the oil use period.
In particular, monitor the water concentration of oil in
gear units used outdoors or in damp places. The
water concentration should not exceed 0.03% (300
ppm).
If a roll-back brake has a separate oil compartment,
its oil must also be replaced every one (1) year.
Minimum purity level for lubrication oil
The purity of industrial gear oil is defined according to
the ISO 4406 standard. The impurity level of a gear
unit that has been in operation must be 20/17/14
(2/5/15 m) or better. The oil sample is taken from
the oil compartment immediately after stopping the
gear unit, however not from the sump.
In pressure-feed lubricated units, the oil sample can
be taken from the pressurised side before the filter
through a sampling valve while the gear unit is in
operation or immediately after stopping.
Significance of correct oil quantity
Santasalo Gears Oy
3(4)

MDI-180-B-EN 20.02.2007 15.04.2013
In spatter-lubricated industrial gear assemblies where

the operating power is close to the thermal power,
the correct amount of oil is of great importance. In
certain cases, the operating temperature may rise
+15+20 C higher than normal because there is
approximately 15% too much oil.
This will result in decreased lubrication capacity of
the oil and, in the worst case, damage to the
industrial gear assembly. If the oil surface is lower
than the arrow that indicates the oil level, there is the
risk that the gear wheel does not reach the oil and
does not therefore splatter oil where lubrication is
needed. In case of any leaks, the oil quantity and
level must be carefully reviewed. Any leaks must be
repaired.
Oil refill
The oil quality must be as recommended by us or
identical, and the oil quantity must be correct. Each
spatter-lubricated industrial gear assembly and those
with a separate lubrication system are equipped with
a plate that lists the oil types recommended for the
assembly. These gear units also have an oil level
indicator, an oil glass or a dipstick with a mark for the
required oil level. The oil surface must reach to the
marked level when the gear assembly is stopped and
the pump, if any, and pipelines are full of oil. The oil
fill must be done according to the oil level mark
because the quantity marked on the plate is only a
recommendation. It should be noted that it is often
impossible to determine the correct level of oil while
the gear assembly is in operation.
2.2.3 Secondary lubrication of grease-lubricated
bearings
For grease-lubricated bearings, the free access of
grease to the oil compartment has been prevented,
and therefore there is little need for secondary
lubrication. The first grease fill of the bearings has
been carried out at our factory. The grease type we
use is indicated on the grease recommendation plate
in the gear unit, as are the alternative greases
recommended by us.
In secondary lubrication objects, such as the bearing

housing or cover, there is a grease nipple, which is
marked with a plate. In most cases, it is sufficient to
add grease during oil change. Beware of excessive
greasing, as it will increase the operating temperature
of the bearing. The secondary lubrication instructions
are provided individually for each gear unit.
2.2.4 Oil heater maintenance
When the oil heater gets stained, it must be detached
and cleaned during oil change. Always make sure
that the heater is powered off before removing the oil.
A heated resistor element may cause the gasified oil
to explode. You can effectively prevent the staining of
the resistor element as well as the aging and staining
of the oil if the resistor element is powered off,
according to instructions, at a temperature
approximately +8+10 C higher than the power-on
temperature.
The resistor element may never be powered on when
the oil temperature exceeds +40 C. The qualities of
the additives in the oil will deteriorate at temperatures
higher than this because of the surface temperature
of the resistor element, accelerating the formation of
an explosive gaseous mix.
2.2.5 Lubrication system maintenance
Parts that require maintenance and monitoring are
the electrical lubrication pump, oil water cooler, filter
and breather.
The most common maintenance task for electric
pumps is external cleaning of the engine to attain
thermal balance. If necessary, the fan must also be
cleaned. In connection with the above, check the
gear units breather and replace or clean it, if
necessary.
During oil change, it is recommended that the oil
water cooler be opened, checked and cleaned, if
necessary. A used filter element must always be
replaced during oil change.
Santasalo Gears Oy
4(4)
Foundation of industrial gear

assemblies standing installation
MDI-140-A-EN
20.02.2007
ver. 15.11.2012
FOUNDATION OF INDUSTRIAL GEAR ASSEMBLIES,

STANDING INSTALLATION
1. FOUNDATION OF INDUSTRIAL GEAR ASSEMBLIES, STANDING INSTALLATION ........ 2

1.1 GENERAL ............................................................................................................................ 2
1.2 BASIC TYPES ....................................................................................................................... 2
1.2.1 Foundation with foundation bars ................................................................................... 2
1.2.2 Foundation on foundation plate..................................................................................... 4
1.2.3 Materials ........................................................................................................................ 5
Santasalo Gears Oy
1(5)
Foundation of industrial gear

MDI-140-A-EN
20.02.2007
ver. 15.11.2012
1. Foundation of industrial gear assemblies, standing installation

1.1 General
The faultless operation of a gear assembly requires a
sturdy and vibration-free foundation. Changes in the
foundation may result in deteriorated tooth contact,
which causes local increase of surface pressure in
the tooth. This may cause heavy wear of the tooth
and result in damage to the gear assembly.
1.2 Basic types

A prerequisite for rapid and reliable installation is the
selection of a suitable foundation type and sufficient
preliminary planning of installation, manifested as
appropriate foundation drawings and the required
structural and dimensional data.
Santasalo Gears recommends foundation on
foundation bars or a foundation plate, which are
presented in this guide. Installation on foundation
bars is suitable for all sizes of standing gear
assemblies. However, for installations in excess of
5,000 kg, we recommend a plate foundation.
The customers own solution, if any, must be of
similar technical and quality level as the basic
solutions in this guide. When installing a gear
assembly on a steel structure, special attention must
be paid to the rigidity of the structure to prevent
harmful vibration and structural swaying. The top
surface of the gear assembly mounting surface must
be mechanised and, in its final structure, meet the
level and other quality requirements set for
mechanised platforms.
For the subsequent installation of a spare gear
assembly, if any, it is recommended that adaptor
plates and centring collars be used in the primary
installation. If necessary, apply latitudinal and
longitudinal support with adjustment screws.
1.2.1 Foundation with foundation bars

The foundation dimensioning is done according to the
load data (static and dynamic) provided by the
hardware supplier. The dimensioning of the
foundation and its reinforcement must take into
account the load caused by the foundation bars (G),
while the reinforcement (usually 300 kg steel / m3)
must correspond at least to the strength of the
mounting screws (H) of the gear assembly. The
grade of concrete of the foundation concreting (A)
must be at least K30-2 (FIN), K30 (SWE), C30 (BS),
B35 (DIN) or 4000PSI (ACI). The concrete surface of
the foundation concreting must be roughened and
cleaned (remove the so-called cement paste from the
surface). Remove any oil stains.
The operating unit (K) is installed on the foundation
bars (G) on top of the foundation concreting (A)
(Figure 1). The reinforcement (C) of the foundation
concreting must be made in such a way as to serve
as good dowel-bar reinforcement for secondary
concreting (B). The foundation concreting is cast high
enough to position the operating unit and the
attached foundation bar close to the required
operating units shaft height. More detailed
adjustment of the shaft height of the operating unit is
to be done with the adjustment screws (E) in the
foundation bar. Figure 1.
After fitting the operating unit in place, the secondary
concreting is done. The compressive strength of the
secondary concreting must be at least 30 N/mm2.
Non-shrinking concrete must be used in the
secondary concreting.
Figure 1: Foundation of the operating unit on foundation bars.
Santasalo Gears Oy
2(5)
Foun
ndation of
o industtrial gearr
assem
mblies sta
anding in
nstallatio
on
MDI-140
0-A-EN
The founda
ation concretting is part of
o the constrruction
work, and therefore the
t
construcctor specifie
es the
material to be
b used and is responsib
ble for
concreting m
carrying outt the work an
nd for its qua
ality.
When usin
ng foundatio
on with foun
ndation barss, the
elected acco
ording to the
e hole
foundation bars are se
size of the ffixing level off the device to
t be founde
ered. If
the founda
ation bars are
a
ordered
d from San
ntasalo
Gears, our delivery will include the
e foundation bars,
stud bolts (T bolts), T groove
g
nuts, installation plates
and adjustm
ment screws (Figure 2). Figure
F
3 and Table
1 present th
he dimension
ning of the fo
oundation barrs.
Figures 4 and 5 and Table 2 pre

esent two diifferent
with
d
dimension
installation
methods
data.
mend an installation metthod conform
mant to
We recomm
Figure 5
Figure 4. There
T
is a hole
in the found
dation
concreting, which is fille
ed
with second
dary
concreting after installin
ng
the foundattion bar.
Figure 2 Fo
oundation ba
ar
and supplie
es Groove forr
T bolts DIN 787, ISO 29
99
DIN 508
and T nuts D
ve
er. 15.11.2012
20.02.2007
Figure 5. Recomme
ended
installattion method. A
seconda
ary concretin
ng is
done on
n top of the
foundattion concretin
ng
after insstalling the
foundattion
b
Figure 3 Foundation
n bar
dimensio
oning
Table 1: Fo
oundation barr dimensionss
SIZE
T- SLOT
DIM
MENSIONS
d2
P-M10
1
12
19
12
25
13
51
405
70
140
49
15
25
M10
P-M12
1
14
23
14
28
14
51
405
70
140
49
15
25
M10
P-M16
1
18
30
18
36
18
60
655
84
200
75
20
30
M12
P-M20
2
22
37
23
45
22
60
656
84
200
75
20
30
M16
P-M24
2
28
46
28
56
28
90
855
124
280
108
24
42
M16
P-M30
3
35
55
35
71
36
90
855
124
280
108
24
42
M20
P-M36
4
42
68
43
85
42
126
1
100
160
360
143
30
60
M20
P-M42
4
48
80
47
95
48
126
1
100
160
360
143
15
60
M20
Santtasalo Gea
ars Oy
3(5)
Foun
ndation of
o industtrial gearr
assem
mblies sta
anding in
nstallatio
on
MDI-140
0-A-EN
20.02.2007
ve
er. 15.11.2012
Table 2. Insstallation dim

mensions of the
th foundatio
on bar.
SIZE
MASS
INSTAL
LLATION
kg
u min
v min
y min
m
P-M10
1,7
150
27
6
60
240
85
P-M12
1,7
150
27
6
60
240
85
P-M16
3,7
210
35
8
80
260
120
P-M20
3,7
210
45
8
80
260
120
P-M24
10,5
280
55
100
330
150
P-M30
10,5
280
68
100
330
150
P-M36
20,3
340
82
120
410
220
P-M42
19,5
340
92
120
410
220
1.2.2 Foun
ndation on fo
oundation plate
p
The foundattion dimensio
oning is done
e according to the
load data (static and dynamic) provided byy the
hardware supplier. The
T
dimen
nsioning of the
foundation and its re
einforcement must take
e into
account the
e load cause
ed by the fo
oundation sccrews
(D), while tthe reinforce
ement (usually 300 kg steel
s
/
m3) must ccorrespond at
a least to th
he strength of
o the
mounting sscrews (H) of the gear assembly.. The
grade of co
oncrete of the foundatio
on concretin
ng (A)
must be at least K30-2 (FIN), K30 (SWE),
(
C30 (BS),
B35 (DIN) o
or 4000PSI (ACI).
(
The co
oncrete surfa
ace of
the foundattion concreting must be
e roughened
d and
cleaned (remove the so
o-called ceme
ent paste from the
surface). Re
emove any oil
o stains. Fig
gure 6.
The founda
ation screw
w holes are created with
w
a
corrugated steel founda
ation tube (C). See also Figure
F
8. The foun
ndation conccreting is casst high enou
ugh to
position the
e foundation plate (G) on
o the adjustment
screws and
d the attache
ed operating unit close to
t the
required op
perating units shaft heig
ght. More de
etailed
adjustment of the shaft height of the
e operating unit
u is
to be done
e with the adjustment
a
s
screws
(E) in the
foundation plate. Th
he distance
e between the
foundation concreting and
a
the botto
om surface of
o the
foundation plate is ap
pproximately 60 mm (2
2570
mm). To ensure that the
t
foundation plate rem
mains
immobile th
hroughout th
he secondary concretin
ng, all
adjustment screws must support the
e foundation plate.
The adjustm
ment may initially be don
ne by using three
adjustment screws.
ne in two ph
hases.
Secondary concreting is to be don
The founda
ation screw holes
h
are ca
ast (B1) up to
t the
top surface of the found
dation concrreting (A) an
nd are
allowed to dry. The foundation screws are pretightened against the adjustment sccrews by 15 % of
the screwss tightening torque
t
after which secondary
concreting ((B2) of the space
s
between the found
dation
concreting and the foundation pla
ate is done
e with
ecial mass.
running spe
To allow fo
or secondarry tightening
g, the secondary
concreting ((B2) must no
ot, however, ccover the nu
uts of
ation screws. If the surfacce of the seco

ondary
the founda
concreting is to be raised above the
e foundation screw
level, a tightening hole
e must be made for the nuts
n
in
the concre
eting. The se
econdary con
ncreting masss (B2)
must properly fill the space bene
eath the platte and
must not shrink.
s
The mass
m
(B1, B2
2) must not contain
c
additives that
t
corrode the pre-ten
nsioned foun
ndation
screws. Th
he secondarry foundation
n is not reinfforced.
The com
mpressive strength
s
of the seco
ondary
concreting must be at least 30 N/m
mm2. Non-shrinking
m
be used in the secon
ndary concre
eting.
concrete must
The founda
ation concre
eting is part of
o the construction
work, and therefore the constructor specifie
es the
d is responsiible for
concreting material to be used and
carrying ou
ut the work and
a for its qua
ality.
Figure 6. Foundation
F
o foundation
on
n plate.
The founda
ation screw (D)
( can be an
n SFS 4632 type A
screw. Fig
gures 6 and 7 and Tab
ble 3 illustra
ate the
installation method with a foundatiion socket (C
C) and
ns. Figure 8 presents a more
present the dimension
e foundation socket.
detailed strructure of the
Santtasalo Gea
ars Oy
4(5)
Foun
ndation of
o industtrial gearr
assem
mblies sta
anding in
nstallatio
on
MDI-140
0-A-EN
20.02.2007
ve
er. 15.11.2012
Figure 7. Short found

dation screw
w with flange
e: SFS
4632 type
e A foundatiion screw dimensioning
d
g. The
foundation concreting (A),
(
seconda
ary concreting
g (B1),
C), fixing iro
on (N) and
d antifoundation socket (C
a
(M) are
e marked in tthe figure.
adhesion agent
Table 3. Dim
mensions, allowed
a
load capacity and
d allowed prre-tensioning
g of a founda
ation screw conformant
c
t SFS
to
4632 and th
he foundation
n socket dimensions.
ALTERNATIVE AXIAL LOA
AD
PRET
TENSIONING
max
max
BOLT
L
L1
m
L2 min
Fdyn
Fstaa
TORQ
QUE
Me
Nm
m
FOR
RCE
Fe
kN
FOUNDATION
SOCK
KET
D
D
mm
mm
mm
m
mm
m
mm
kN
kN
M24
400 500 600
80
260
0
100
20
0
51,1
33,2
301,9
70
0,6
20
00
M30
500 600 700
120
310
0
120
25
5
81,3
52,8
559,2
112
2,2
21
10
M36
SHALL BE
DEFINED IN
DRAWING
120
400
0
140
30
0
118
76,7
104
48
163
3,4
25
50
M42
140
450
0
170
35
5
152
98,8
169
95
226
6,8
29
90
M48
160
550
0
200
35
5
199,1
129,4
248
86
290
0,4
34
40
M56
180
640
0
220
40
0
274,3
178,3
394
49
406
6,4
38
80
mm
m
1.2.3 Mate
erials
Bolt
Grip plate
Nut
Base plate
S355J0 SFS-EN 10
0025, for ou
utdoor
55J2G3
use S35
S235JR
RG2 SFS-E
EN 10025, for
outdoorr use S235J2
2G3
SFS-ISO
O 4032 EN 24032. Gra
ade of
concrete
e 8 SFS-ISO
O 898-2
SFS-ISO
O 887
If the boltss structural material is not S355J0

0, the
correspondiing max. Fs
staat, Fdyn, Fe ja Me ca
an be
obtained byy multiplying the table values with the
e ratio
of the yield limit of the steel
s
used an
nd that of the
e steel
S355J0.
Figure 8. SFS 4632 Corrugated

d steel foun
ndation
socket. The foundation
n socket (C) and base pla
ate (P)
are marked
d in the figurre.
Santtasalo Gea
ars Oy
5(5)
Installation of industrial gear

MDI-150-A-EN 20.02.2007 ver. 28.1.2013
INSTALLATION OF INDUSTRIAL GEAR ASSEMBLIES,

STANDING INSTALLATION
1.
INSTALLATION .................................................................................................................... 2
1.1
FACTORS THAT AFFECT INSTALLATION ................................................................................. 2
2.
INSTALLATION ON FOUNDATION BARS .......................................................................... 2
3.
INSTALLATION ON FOUNDATION PLATE ........................................................................ 2
4.
INSTALLATION ACCURACY .............................................................................................. 3

4.1
4.2
GEAR UNIT INSTALLATION ACCURACY .................................................................................. 3

CHECKING THE TOOTH CONTACT WITH DRUM GEARS............................................................. 3
Santasalo Gears Oy
1(3)

MDI-150-A-EN 20.02.2007 ver. 28.1.2013
1. INSTALLATION
1.1 Factors that affect installation
Before equipment installation, the dimensions of the
foundation must be verified to the appropriate
drawings. Differences between the operating and
installation temperatures of the machines to be
connected may cause thermal expansion and shaft
offset. You need to predict these issues in the
installation. Installation must be carried out so that
the couplings between the machines will work
faultlessly at the normal operating temperature. On
the other hand, it must also be ensured that the
coupling play is sufficient even under the worst
possible operating circumstances
2. INSTALLATION ON FOUNDATION BARS

Couplings are installed on the gear shafts according
to the installation instructions of the coupling.
A gear installed on a concrete foundation is lowered
with its foundation bars (G) and installation supplies
(M, E, D, H) on installation plates (N) on the
foundation concreting (A) (Figure 1). The gear unit
(K) is placed in such a way that it is at the required
operating unit shaft level. Proper gear placement is
required for successful subsequent operating unit
alignment. There are adjustment screws (E) in the
foundation bars for the vertical placement of the gear
unit. The foundation bars are supported with the
reinforced concrete (C) with welds, for example.
After gear unit placement, the grouting of the
foundation is done according to the foundation
instructions. When the concreting is dry, loosen the
tensioning screws (H) so as to straighten the gear
unit that may have been bent during concrete drying.
After this, fine-tune the gear unit placement using
adaptor plates (D). The tensioning screws (H) are
tensioned to the instructed torque. When installing a
new gear unit, adaptor plates (D) must be used
between the gear base and foundation bar (G) to
enable the installation of a spare gear assembly.
The foundation concreting is part of the construction
work, and therefore the constructor specifies the
concreting material to be used and is responsible for
carrying out the work and for its quality.
Figure 1. Installation of an operating unit with

foundation bars. Foundation concreting (A), grouting
(B), foundation concreting reinforcement (C), adaptor
plate (D), adjustment screw (E), foundation bar (G),
fixing screw (H), gear unit (K), installation block (M),
installation plate (N).
3. INSTALLATION ON FOUNDATION PLATE
Figure 2. Installation on foundation plate. Foundation

concreting (A), grouting (B), foundation socket (C),
foundation screw with supplies (D), adjustment screw
(E), foundation plate (G), screw fixing (nut, centring
collar, adaptor plates, screw) (H), gear unit (K).
The operating unit is put in place according to the
basic instructions, which also describe the stages of
the foundation and grouting. The actual installation of
the operating unit can be done after the grouting has
dried. Before the final installation, remove any
centring collars used in the gear unit fixing holes.
When installing a new gear unit, adaptor plates (D)
must be used between the gear base and foundation
plate (G) to enable the installation of a spare gear
assembly.
Santasalo Gears Oy
2(3)

MDI-150-A-EN 20.02.2007 ver. 28.1.2013
The foundation screws are pre-tensioned against
adjustment screws after the concreting has dried.
The adjustment screws are loosened before the
foundation screws are tensioned. The required
tensioning torque is specified in Table 1. Approximate
or estimated tensioning is not allowed. The

foundation screws must be re-tensioned 1 month and
6 months after the installation of the gear unit.
Table 1. Dimensions, allowed load capacity and allowed pre-tensioning of a foundation screw conformant to SFS
4632 and the foundation socket dimensions.
ALTERNATIVE AXIAL LOAD
PRETENSIONING
max
max
FOUNDATION
SOCKET
BOLT
L
L1
L2 min
Fstaa
Fdyn
mm
400 500 600
500 600 700
SHALL BE
DEFINED IN
DRAWING
mm
80
120
mm
260
310
mm
100
120
mm
20
25
kN
51,1
81,3
kN
33,2
52,8
120
400
140
30
118
M42
140
450
170
35
M48
160
550
200
M56
180
640
220
M24
M30
M36
TORQUE
Me
Nm
FORCE
Fe
kN
301,9
559,2
70,6
112,2
mm
200
210
76,7
1048
163,4
250
152
98,8
1695
226,8
290
35
199,1
129,4
2486
290,4
340
40
274,3
178,3
3949
406,4
380
4. INSTALLATION ACCURACY
The gear unit installation accuracy is determined
primarily based on the coupling and connected
machine accuracy as well as on the rotation speeds.
Use Santasalo Gears instructions for coupling
installation accuracy.
4.1 Gear unit installation accuracy
During installation, make sure that the foundation
installation accuracy deviations do not exceed the
ymax values in Table 1. Use keys to help you
straighten the foundation.
ymax
JE
[mm]
[mm]
<400
0,035
400...799
0,060
800...1200
0,090
1200...1600
0,125
1600...2000
0,150
4.2 Checking the tooth contact with drum gears

After installation,
particularly in demanding
installations and with large gear units, check the tooth
contact. You can check the tooth contact through the
inspection door using inspection colour. The
requirement is 80% lateral contact. If the contact is
less than 80%, the gear unit may have been skewed
while tightening with the foundation bolts. To correct
the contact, the fine-tuning of gear placement must
be redone (Figure 3).
Figure 3. Gear unit installation accuracies with

dimensions.
Santasalo Gears Oy
3(3)

MDI-130-B-EN
20.02.2007
ver. 1.4.2015
THE CORROSION PROTECTION AND STORAGE

OF THE INDUSTRIAL GEAR AND ITS SPARE PARTS
1. The corrosion protection and storage of the industrial gear and its spare parts..2
1.1 Internal protection..2
1.2 External protection of the spare parts2
1.3 The external protection of gears and similar larger products 2
1.4 The VCI method.3
1.5 Commissioning.................3
1.6 Application..3
Santasalo Gears Oy
1(3)

MDI-130-B-EN
20.02.2007
ver. 1.4.2015
1. The corrosion protection and storage

of the industrial gear and its spare
parts
Corrosion usually refers to the unintended destruction
of a metal object due to chemical or electro-chemical
reactions caused by the operating environment, e.g.
the rusting of steel. Air humidity, acidity, impurities
and temperature have a significant effect on
corrosion. Storage time and place must be known in
order to design the method of protection.
In their orders, Santasalo Gears factories abide by
the corrosion protection methods of industrial gears
and the related accessories mentioned below.
Protection carried out in the Santasalo Gears factory
must not be damaged in storage. You must be
especially careful not to damage the airtight
packages protected with inhibitors. The supplier
responsibility for the protection becomes void if the
protection is broken.
These methods may also be used by the customer in
storage later. If a Santasalo Gears product is
protected against corrosion by the customer, the
customer has full liability for the protection.
Table 1.
Storage times
Storage time guaranteed by the
protection
Outside in a covered
space
Indoors in a heated space
12 months
The breather is covered with an air tight plastic bag

or it must be removed and replaced with a plug. The
breather is attached to the gear, and it must be
installed according with the instructions before
commissioning the gear.
Alternatively, inner protection for storage can be
carried out by the customer by filling the gear with oil,
if all of the device seals are lip seals. The gear is
filled with as much of normal gear oil as possible,
without exceeding the breather or oil filling
connection. All moving parts, bearings included,
should be covered with oil.
1.2. External protection of spare parts
When carrying out external protection, all unpainted
surfaces should be treated with an easily removable
protective agent (Zerust Perigol VCI230-spray) and
protected with a corrosion inhibiting film (Zerust
Valeno). For marine or overseas transport, the pallets
or boxes containing the pieces should also be
covered in plastic.
Small loose parts, such as spare parts, screws and
nuts, are supplied packed in corrosion inhibiting
Zerust bags.
It should be checked every six months, that the
protection is intact and that the protected piece is free
of corrosion.
36 months
If the product is stored outside in a covered space, it

must be kept in an appropriate package (e.g. original
packaging). The package must also be protected with
a tarpaulin or plastic sheet for added protection
against mechanical dents, splashing water and dirt,
for example.
The shafts must be rotated during storage approx.
every 3 months to lubricate the lip seals.
1.1. Inner protection
Inner protection is established when the gear unit are
road tested at the factory using protective oil (Neste
protective oil 20W/30 ISO VG 100). The protective
agents left behind by the oil protect the inside of the
gear unit against corrosion. Gears are usually
supplied without oil! Alternatively, inner protection
can be carried out using the VCI method, see chapter
1.4. In this case, the gear is sprayed with approx. 1 dl
per m3 of Dinitrol VCI UNI 0-40 VCI oil after the road
test,after which the gear is sealed air tight.
1.3. External protection of larger gear parts

The products external, unpainted surfaces and parts
are treated by spraying the surfaces with a protective
agent (Zerust Axxanol Spray G) and the shaft seal
and seal surfaces are protected from outside with a
special bearing grease. The product is protected with
a corrosion inhibiting film (Zerust Valeno) and the
packaging box lid or the product packaged onto a
pallet is covered with plastic.
Any holes, such as air valve and pressure lubrication
piping openings, fastening drilling and cooling circuit
connections, are protected with plugs and/or VCI
plastic. Drillings that may accumulate water must be
protected with plugs.
Santasalo Gears Oy
2(3)

MDI-130-B-EN
20.02.2007
ver. 1.4.2015
1.4. The VCI method

In the VCI method (Volatile Corrosion Inhibitor),
anticorrosive oil releases VCI inhibitors inside the
gear, where it forms an invisible anticorrosive layer
on the inside surfaces of the gear. Users must be
protected from the effects of the agent. You must
also ensure that there are no open flames or sparks
nearby during the spraying and when the solution
evaporates. In the cold, the release of VCI slows
down, which means that the treated gear must not be
taken out into the cold before the protective layer has
formed (12-24h).
The effectiveness of the VCI additive diminishes due
to the exchange of the inside air of the gear. All holes
must therefore be blocked so that any fumes are
trapped inside the gear. After spraying, the breather
must be blocked or covered with an airtight plastic
bag. During inspection, the gear may only remain
open for a maximum of two hours.
The package protected with a corrosion inhibiting film
or bag may not be damaged during storage. Any
tears must be taped shut immediately.
The gears and packages must be marked with
separate VCI warning stickers. The VCI warning
sticker must be placed as a seal on the edge of the
VCI film. VCI protection must be renewed every three
years.
1.5. Commissioning
Any corrosion inhibiting agents and oil used for
storage must be removed from the gear prior to
commissioning. Please see the instructions on
commissioning in the use and maintenance manual
for the gear.
You must be careful not to damage the lip seals or
surfaces mechanically when cleaning the ends of the
shaft.
1.6. Application
The inner and external protection applies to all
Santasalo products.
The level of protection may be altered if it has been
specifically agreed with the customer.
Santasalo Gears Oy
3(3)
Assembly report
U306EN 25.05.2000 22.05.2013
ASSEMBLY REPORT
GEAR UNIT:
MANUF. NUMBER:
DRIVE:
Offset misalignment
Angular misalignment
0-position
o
o
o
o
o
LSS
HSS
motor
machine
shaft
shaft
HSS
LSS
motor
machine
shaft
shaft
Checked distance of coupling flanges _________ mm

Measured assembly temperature ________C
Height correction of shaft centres observed
Grease filling completed / grease quality ___________________________
Gear unit fastened to foundation with pins
o Gear unit connected to central lubrication
Lubrication of gear unit

Oil type:
o mineral
o synthetic
o VG class _______________
Date _______________________
flow _______ l/min
o Check of oil level height

o Operation of pressure lubrication
_________C
_______bar
Approved: _______________________________________________
Moventas Gears Oy
1(1)

MDI-170-D-EN
17.1.2008
ver. 07.02.2013
LUBRICANTS IN INDUSTRIAL GEARS
1.
SIGNIFICANCE OF LUBRICATION ..................................................................................... 2
2.
LUBRICATION METHODS ................................................................................................... 2

2.1
2.2
2.3
2.4
3.
BATH LUBRICATION .............................................................................................................. 2

SPLASH LUBRICATION .......................................................................................................... 2
GREASE LUBRICATION ......................................................................................................... 2
PRESSURE-FEED LUBRICATION............................................................................................. 2
LUBRICATION IN EXTREME SITUATIONS ........................................................................ 2

3.1 OIL HEATING ....................................................................................................................... 2
3.2 OIL COOLING ....................................................................................................................... 3
3.2.1 Bath and splash lubrication ........................................................................................... 3
3.2.2 Pressure-feed lubrication .............................................................................................. 3
3.3 COLD START ....................................................................................................................... 4
4.
HANDLING AND DISPOSING OF LUBRICANTS ............................................................... 4
5.
APPROVED LUBRICANTS .................................................................................................. 5
Santasalo Gears Oy
1(9)

MDI-170-D-EN
17.1.2008
ver. 07.02.2013
1. SIGNIFICANCE OF LUBRICATION
To secure the appropriate lubrication of a gear
assembly, it is of primary importance that its
lubrication and the related observation and
maintenance tasks have been properly arranged.
The main task of lubrication is to form an oil film
between the working flanks of the gear teeth of a
gear wheel to prevent metal contact and to lubricate
the bearings and seals.
Other lubrication functions include:
reducing friction and the resultant power loss
minimise wear and tear
move impurities and wear-down particles away
transfer heat away from the tooth contact and

bearings
prevent the entry of impurities into the lubricated

parts
reduce vibration
protect the parts from corrosion

The thickness of the oil film depends for example on
the surface pressure of the gear tooth, the viscosity
of the oil and the pitch line velocity. If the oil film fails
repeatedly during operation, the working flank of the
tooth becomes damaged.
Information pertaining to the viscosity and amount of
the gear lubrication oil is presented per application
either in the plate attached to the gear and/or in the
dimensional drawing of the gear. Oil types approved
for use in industrial gears are presented in section 5.
When using oil types not presented in the above
appendix, consult with the gear manufacturer first.
2. LUBRICATION METHODS
2.1 Bath lubrication
In bath lubrication, the oil surface is raised high
enough to submerge the tooth contact and the rolling
elements of the bearings in oil. Bath lubrication is
suitable only for very slow-rotating gear wheels with a
low pitch line velocity.
2.2 Splash lubrication
In splash lubrication, the gear wheels are partially
submersed in oil. Tooth contact is lubricated with the
oil splashing from the gear wheels or conveyed with
the teeth. The bearings are lubricated with oil
splashing from the gear wheels. Splash lubrication is
suitable for relatively slow-rotating gear wheels.
2.3 Grease lubrication
The use of grease lubrication is limited almost solely
to the lubrication of bearings and seals if the bearing
structure of a gear assembly requires that.
2.4 Pressure-feed lubrication

The structure, size, use and cooling requirement of
the gear may require pressure-feed lubrication. In
pressure-feed lubrication, the oil pipeline of the gear
is connected to a central lubrication system, or a
dedicated lubrication pump is located close to the
gear. The lubrication pump may be shaft-operated,
which means that it gets its operating power directly
from the gear shaft, or it may have a dedicated
electric engine.
The equipment level in pressure-feed lubrication is
determined by the demand level, supervision and
gear cooling requirements of the machine being
operated. It is also possible to connect a standard
lubrication unit to the gear and equip it with a water
or air cooling unit.
3. LUBRICATION IN EXTREME
SITUATIONS
3.1 Oil heating
If a gear is located outdoors or in a non-heated
location, the gear manufacturer must be notified of
this and of the temperature variations. The usual
problem at low temperatures is the supply of oil to the
item requiring lubrication because of the high
viscosity of the oil.
An oil heater is a resistor element located in the oil
compartment of the gear and thread-mounted in the
wall of the gear housing. If required, the resistor
element can be detached for cleaning. In this case,
the gear oil must be removed first.
There is a thermostat for controlling the oil heater.
The thermostat must be programmed in such a way
as to power on the oil heater if the temperature in the
gears falls below the pour point in bath or splash
lubricated gears or below the temperature listed in
Table 1 for pressure-feed-ubricated gears.
Table 1. Minimum temperatures (C) with different oil
qualities in pressure-feed-lubricated gears at or
above which the oil viscosity value <2000 cSt occurs.
ISO VG class
680 460
Mineral oil
+25 +20 +15 +10
+5
+15 +10
Synthetic oil
320
220 150
+5
100
-5
In pressure-lubricated gears, the viscosity of the

lubrication oil must be <2000 cSt at the start-up
temperature.
The high end of the thermostat is set to power the
unit off at a temperature of +8..+10 C above the
abovementioned power-on temperature.
Santasalo Gears Oy
2(9)

MDI-170-D-EN
17.1.2008
ver. 07.02.2013
Table 2. Oil viscosity as a function of temperature.
Synthetic PAO oils
Mineral oils
-25 -20-1 5-10 -7
Po ur poi nt [ C]
-40 -40 - 35 -30 Pour p oin t [C ]

30 00
300 0
15 0 32 0
2 20
1 000
22 0 460
200 0
20 00
68 0
1 50
Vi scosity in dex
VI=90...1 00
460
3 20
Viscosi ty i nde x
VI=14 0...1 80
1 000
ISO VG
ISO VG
500
500
20 0
150
2 00
15 0
1 00
100
40
40
Viscosity
2
[mm /s]
Visc osity
2
[mm /s]
10
10
-2 0 -10
10
20
30
40
50
60
70
80
9 0 1 00
-20
Gear units lubricating temperat ure of oil TL [C]
-10
10
20
30
40
50
60
70
80
90
10 0
Gear units lubricating temperature of oil TL [C]
3.2 Oil cooling

The gear manufacturer must be notified of abovenormal operating temperatures and temperature
variations. If the operating temperature of the oil is
higher than the designed temperature, the oil
viscosity falls too low. This may result in decreased
lubrication film thickness, potential metal contact,
surface wear and damage.
greatest allowed operating pressure of the water is 1

MPa (10 bar). The direction of flow of the water is
insignificant in the water cooling coil unit.
The flow amount of the water cooling coil unit must
be adjusted so that the temperature of the oil
compartment in the gear does not exceed +80 C.
There must be a thermometer in the oil compartment
of the gear for monitoring the temperature.
3.2.1 Bath and splash lubrication
3.2.2 Pressure-feed lubrication
The highest allowed operating temperature of bath

and splash-lubricated gears is normally +90 C
measured at the gears bearing housing. In special
cases the highest allowable operating temperature
may be +100 C. If the gears operating power
exceeds the thermal power, the above normal
operating temperature will be exceeded unless the
gear cooling is enhanced.
Gear cooling may be enhanced as follows:
The operating temperature of a gear with pressurefeed lubrication is normally at most +80 C measured
at the gears bearing housing.
Gear cooling may be enhanced as follows:
place a water cooling coil unit in the gears oil

compartment
place one or two fans on the input shaft of the

gear
Fans are not recommended in dusty or humid
environments.
The input side of the water cooling coil unit must
have a thermostat-controlled water valve. The
use a water-cooled oil cooler
use an air-cooled oil cooler

An air-cooled oil cooler must be located in a dust-free
environment.
The input side of a water-cooled oil cooler must have
a thermostat-controlled water valve. The greatest
allowed operating pressure of the water is 1 MPa (10
bar). The direction of water flow marked in the oil
cooler must be adhered to.
In water-cooled oil coolers, the water volume must be
adjusted with a thermostat so that the temperature of
the oil entering the gear is +45..+55 C.
Santasalo Gears Oy
3(9)

MDI-170-D-EN
17.1.2008
ver. 07.02.2013
If the gear has an air-cooled oil cooler, it must be

thermostat-controlled and control the operation of the
fan engine so that the temperature of the oil entering
the gear is +45...+55 .
use different oil for winter and summer

environments
use an oil heater
3.3 Cold start

In a cold start situation, the viscosity of the lubrication
oil must be <2000 cSt at the start-up temperature for
the pressure-feed-lubricated gears. For bath and
splash-lubricated gears, the start-up temperature
must be higher than the pour point of the lubrication
oil. If this is not the case, the seals, bearings and
gear wheels will not be lubricated at all.
If the viscosity of the selected oil exceeds the allowed
viscosity at the start-up temperature, the following
measures can be performed with the gear
manufacturers permission:
use a synthetic polyalphaolephin-based (PAO)

oil
In case of a temporary start-up temperature decrease
(e.g., downtime), start-up problems in pressure-feedlubricated gear wheels can be reduced by allowing
the electric engine pump to run through the
downtime.
use the closest matching oil of a thinner oil group
4. HANDLING AND DISPOSING OF

LUBRICANTS
Lubrication oils are hazardous waste and dangerous
to the environment. National laws and regulations
must be adhered to in their handling and disposal.
Santasalo Gears Oy
4(9)

MDI-170-D-EN
17.1.2008
ver. 07.02.2013
5. APPROVED LUBRICANTS
The lubricant table below lists the lubricants approved for Santasalo Gears industrial gear wheels.
Mineral oils
ISO VG
class
150
220
320
AGMA
number
4EP
5EP
6EP
Company
Oil types
Aral
BP
Castrol
Castrol
Castrol
Castrol
Chevron
Fuchs
Fuchs
Fuchs Lubritech
Klber
Lubrication
Engineers
Lukoil
Mobil
Neste
Petro Canada
Shell
Statoil
Total
Total
Aral
BP
Castrol
Castrol
Castrol
Castrol
Chevron
Fuchs
Fuchs
Fuchs Lubritech
Klber
Lubrication
Engineers
Lukoil
Mobil
Neste
Petro Canada
Shell
Statoil
Total
Total
Aral
BP
Castrol
Castrol
Castrol
Castrol
Chevron
Degol BG 150 plus

Energol GR-XP 150
Alpha SP 150
Alpha MAX 150
Optigear BM 150
Tribol 1100/150
Meropa WM 150
Renolin CLP 150
Renolin CLP 150 PLUS
Gearmaster CLP 150
Klberoil GEM 1-150 N
604 ALMASOL VariPurpose Gear Lubricant
Steelo 150
Mobilgear 600 XP 150
Vaihteisto 150 EP
Ultima EP 150
------Loadway EP 150
------Carter XEP 150
Degol BG 220 plus
Energol GR-XP 220
Alpha SP 220
Alpha MAX 220
Optigear BM 220
Tribol 1100/220
Meropa WM 220
Renolin CLP 220
Gearmaster CLP 220
Steelo 220
Vaihteisto 220 EP
Ultima EP 220
Omala F 220
Loadway EP 220
Degol BG 320 plus
Energol GR-XP 320
Alpha SP 320
Alpha MAX 320
Optigear BM 320
Tribol 1100/320
Meropa WM 320
Santasalo Gears Oy
Viscosity
cSt / 40 C
150
149
150
150
150
146
150
150
150
150
150
150
Pour point
C
-12
-12
-21
-23
-18
-27
-27
-24
-24
-24
< -10
-24
150
150
150
150
-140
-150
220
210
220
220
220
214
220
220
220
220
220
220
-15
-24
-21
-33
--27
--27
-15
-9
-21
-23
-15
-24
-21
-24
-24
-21
< -10
-24
220
220
220
220
220
225
-220
320
311
320
320
320
331
320
-15
-24
-24
-27
-18
-21
--24
-9
-9
-21
-23
-15
-21
-18
5(9)

MDI-170-D-EN
320
460
680
6EP
7EP
8EP
Fuchs
Fuchs
Fuchs Lubritech
Klber
Lubrication
Engineers
Lukoil
Mobil
Neste
Petro Canada
Shell
Statoil
Total
Total
Aral
BP
Castrol
Castrol
Castrol
Castrol
Chevron
Fuchs
Fuchs
Fuchs Lubritech
Klber
Lubrication
Engineers
Lukoil
Mobil
Neste
Petro Canada
Shell
Statoil
Total
Total
Aral
BP
Castrol
Castrol
Castrol
Castrol
Chevron
Fuchs
Fuchs
Fuchs Lubritech
Klber
Lubrication
Engineers
Lukoil
Mobil
Neste
Petro Canada
Shell
Statoil
Total
Total
Renolin CLP 320

Gearmaster CLP 320
Steelo 320
Vaihteisto 320 EP
Ultima EP 320
Omala F 320
Loadway EP 320
Degol BG 460 plus
Energol GR-XP 460
Alpha SP 460
Alpha MAX 460
Optigear BM 460
Tribol 1100/460
Meropa WM 460
Renolin CLP 460
Gearmaster CLP 460
Steelo 460
Vaihteisto 460 EP
Ultima EP 460
Omala F 460
Loadway EP 460
Degol BG 680 plus
Energol GR-XP 680
Alpha SP 680
------Optigear BM 680
Tribol 1100/680
------Renolin CLP 680
Gearmaster CLP 680
Steelo 680
Vaihteisto 680 EP
Ultima EP 680
----Loadway EP 680
Santasalo Gears Oy
17.1.2008
ver. 07.02.2013
320
320
320
320
320
-14
-18
-15
< -10
-18
320
320
320
320
320
337
-320
460
432
460
460
460
460
460
460
460
460
460
460
-15
-24
-12
-21
-15
-18
--18
-18
--6
-9
-12
-21
-15
-12
-14
-12
-10
-15
460
460
460
460
460
440
-460
680
710
680
-680
690
-680
680
680
680
680
-15
-15
-15
-15
-9
-12
--12
-12
--6
--9
-18
--10
-17
-12
-5
-15
680
680
680
680
-645
-680
-15
-9
-12
-15
--9
--9
6(9)

MDI-170-D-EN
17.1.2008
ver. 07.02.2013
Mineral oils for paper machine use

ISO VG
class
220
AGMA
number
5EP
Company
Esso
BP
Mobil
Neste-Exxon
Petro Canada
Petro Canada
Texaco
Texaco
Oil types
Teresstic N 220
Energol PM 220
DTE PM
Paperikone 220D
SEPRO XL 220
ULTIMA EP 220
PMO Premium 220
PMO Ashless 220
Viscosity
cSt / 40 C
220
220
220
220
218
220
220
220
Pour point
C
-12
-18
-6
-12
-21
-27
-18
-18
Synthetic polyalphaolephin-based oils

ISO VG
class
AGMA
number
150
4EP
220
5EP
320
6EP
Company
Aral
BP
Castrol
Castrol
Castrol
Castrol
Fuchs
Klber
Mobil
Mobil
Neste
Petro Canada
Shell
Shell
Statoil
Total
Aral
BP
Castrol
Castrol
Castrol
Castrol
Fuchs
Klber
Mobil
Mobil
Neste
Petro Canada
Shell
Shell
Statoil
Total
Aral
BP
Castrol
Castrol
Castrol
Castrol
Oil types
Degol PAS 150
Enersyn EP-XF 150
Alphasyn EP 150
------Optigear Synthetic X 150
Tribol 1510/150
Renolin Unisyn CLP 150
Klbersynth GEM 4 150 N
Mobil SHC Gear 150
Mobil SHC 629
Vaihteisto S 150 EP
Enduratex Synthetic EP 150
Omala HD 150
Omala S4 GX 150
Mereta 150
Carter SH 150
Degol PAS 220
Enersyn EP-XF 220
Alphasyn EP 220
Optigear Synthetic A 220
Optigear Synthetic X 220
Tribol 1510/220
Mobil SHC Gear 220
Mobil SHC 630
Vaihteisto S 220 EP
Omala HD 220
Omala S4 GX 220
Mereta 220
Carter SH 220
Degol PAS 320
Enersyn EP-XF 320
Alphasyn EP 320
Tribol 1510/320
Santasalo Gears Oy
Viscosity
cSt / 40 C
150
150
150
-146
155
150
150
150
150
150
150
150
150
150
148
220
220
220
210
218
220
220
220
220
220
220
223
220
220
220
220
320
320
320
330
325
330
Pour point
C
-39
-48
-48
--39
-45
-45
-40
-54
-42
-42
-54
-54
-45
-57
-45
-39
-42
-42
-36
-33
-42
-42
-40
-45
-42
-48
-48
-48
-45
-48
-45
-39
-30
-36
-36
-33
-39
7(9)

MDI-170-D-EN
320
6EP
460
7EP
680
8EP
Fuchs
Klber
Mobil
Mobil
Neste
Petro Canada
Shell
Shell
Statoil
Total
Aral
BP
Castrol
Castrol
Castrol
Castrol
Fuchs
Klber
Mobil
Mobil
Neste
Petro Canada
Shell
Shell
Statoil
Total
ARAL
BP
Castrol
Castrol
Castrol
Castrol
Fuchs
Klber
Mobil
Mobil
Neste
Petro Canada
Shell
Shell
Statoil
Total

Mobil SHC Gear 320
Mobil SHC 632
Vaihteisto S 320 EP
Omala HD 320
Omala S4 GX 320
Mereta 320
Carter SH 320
Degol PAS 460
Enersyn EP-XF 460
Alphasyn EP 460
Tribol 1510/460
Mobil SHC Gear 460
Mobil SHC 634
Vaihteisto S 460 EP
Omala HD 460
Omala S4 GX 460
Mereta 460
Carter SH 460
--------------------Tribol 1510/680
Mobil SHC Gear 680
Mobil SHC 636
Vaihteisto S 680 EP
----Omala HD 680
Omala S4 GX 680
Mereta 680
Carter SH 680
17.1.2008
320
320
320
320
320
323
320
320
320
314
460
460
460
463
459
460
460
460
460
460
460
501
460
460
460
455
-----680
680
680
680
680
680
-680
680
680
676
ver. 07.02.2013
-42
-35
-48
-42
-48
-42
-45
-42
-42
-42
-39
-36
-36
-30
-27
-33
-39
-30
-48
-39
-45
-42
-42
-36
-39
-30
------30
-33
-30
-42
-39
-35
--39
-33
-39
-21
Synthetic polyalphaolephin-based oils for paper machine use

ISO VG
class
220
AGMA
number
5EP
Company
Castrol
Mobil
Neste
Texaco
Oil types
Optisynth HT 220
SHC PM 220
Lamda 220 ZF
Paper Machine Oil Premium
Santasalo Gears Oy
Viscosity
cSt / 40 C
220
225
220
Pour point
C
-39
-36
-45
8(9)

MDI-170-D-EN
17.1.2008
ver. 07.02.2013
Roller bearing greases
Operating temperature -30..+100 C

Company
Aral
BP
Castrol
Castrol
Castrol
Chevron
Elf
Exxon
Gulf
Klber
Mobil
Neste
Shell
Statoil
Teboil
Texaco
Total
Grease type
Aralub HLP2
Energrease LS-EP
Tribol 3785/220-1,5
Longtime PD 2
Tribol 4020/220-2
Dura-Lith EP2
Epexa EP2
Beacon EP2
Gulfcrown EP 2
CENTOPLEX 2EP
Mobilux EP2
Allrex EP 2
Alvania Grease EP2
Uniway EP2N
Multi-purpose EP
Multifak EP2
Multis EP2
Penetration
265/295
265/295
265/295
265/295
265/295
265/295
265/295
265/295
265/295
265/295
265/295
265/295
265/295
270/280
265/295
265/295
265/295
NLGI 2 (EP)
Fluency point
C
180
195
>180
260
260
185
207
190
180
190
190
198
180
185
185
186
190
Lubrication of hot-running cone bearings (>80 C)

Company
Castrol
Castrol
Castrol
Klber
Shell
Teboil
Grease type
Tribol 3785/220-1,5
Tribol 4020/220-2
Tribol 4747/220-2
Klberplex BE 31-102
Albida Grease EP2
Multi-purpose HT
NLGI 2 (EP)
Fluency point
Penetration
C
265/295
>180
265/295
260
265/295
>250
265/295
190
265/295
260
265/295
260
Lubrication of slow-rotating, axial, spherical pressure bearings NLGI 0..1 (EP)

Fluency point
Company
Grease type
Penetration
C
Castrol
Molub-Alloy 9141-1
310/340
>230
Castrol
Olista Longtime 1
310/340
>180
Castrol
Optipit
245/275
300
Castrol
Tribol 3020/1000-1
265/295
260
Klber
STABURAGS NBU 30
245/275
220
Klber
Klberplex BEM 41-141
310/345
250
Santasalo Gears Oy
9(9)
FLENDER N-EUPEX and

FLENDER N-EUPEX-DS
couplings
Types A, B
and ADS, BDS
Operating instructions
BA 3100 en 12/2014
FLENDER couplings
FLENDER N-EUPEX and

FLENDER N-EUPEX-DS
couplings
Types A, B
and ADS, BDS
Operating instructions
Technical data
Notes
Fitting
Start-up
and operation
Faults, causes
and remedy
Maintenance
and repair
Stocking spare parts
Declarations
Translation of the original operating instructions
BA 3100 en 12/2014
2 / 24
Notes and symbols in these operating instructions

Note: The term "Operating instructions" will in the following also be shortened to "instructions" or "manual".
Legal notes
Warning-note concept
This manual comprises notes which must be observed for your personal safety and for preventing material damage.
Notes for your personal safety are marked with a warning triangle or an "Ex" symbol (when applying
Directive 94/9/EC), those only for preventing material damage with a "STOP" sign.
WARNING! Imminent explosion!
The notes indicated by this symbol are given to prevent explosion damage.
Disregarding these notes may result in serious injury or death.
WARNING! Imminent personal injury!
The notes indicated by this symbol are given to prevent personal injury.
Disregarding these notes may result in serious injury or death.
WARNING! Imminent damage to the product!
The notes indicated by this symbol are given to prevent damage to the product.
Disregarding these notes may result in material damage.
NOTE!
The notes indicated by this symbol must be treated as general operating information.
Disregarding these notes may result in undesirable results or conditions.
WARNING! Hot surfaces!
The notes indicated by this symbol are made to prevent risk of burns due to hot surfaces
and must always be observed.
Disregarding these notes may result in light or serious injury.
Where there is more than one hazard, the warning note for whichever hazard is the most serious is always used.
If in a warning note a warning triangle is used to warn of possible personal injury, a warning of material damage may
be added to the same warning note.
Qualified personnel
The product or system to which these instructions relate may be handled only by persons qualified for the work
concerned and in accordance with the instructions relating to the work concerned, particularly the safety and
warning notes contained in those instructions. Qualified personnel must be specially trained and have the
experience necessary to recognise risks associated with these products or systems and to avoid possible hazards.
BA 3100 en 12/2014
3 / 24
Intended use of Siemens products

Observe also the following:
Siemens products must be used only for the applications provided for in the catalogue and the relevant
technical documentation. If products and components of other makes are used, they must be
recommended or approved by Siemens. The faultfree, safe operation of the products calls for proper
transport, proper storage, erection, assembly, installation, startup, operation and maintenance. The
permissible ambient conditions must be adhered to. Notes in the relevant documentations must be
observed.
Trademarks
All designations indicated with the registered industrial property mark are registered trademarks of Siemens AG.
Other designations used in these instructions may be trademarks the use of which by third parties for their own
purposes may infringe holders rights.
Exclusion of liability
We have checked the content of the instructions for compliance with the hard and software described.
Nevertheless, variances may occur, and so we can offer no warranty for complete agreement. The information
given in these instructions is regularly checked, and any necessary corrections are included in subsequent editions.
Note on the EC Machinery Directive 2006/42/EC

Siemens couplings in the "FLENDER couplings" product range must be treated as "components" in the sense
of the EC Machinery Directive 2006/42/EC.
Therefore, Siemens needs not issue a declaration of incorporation.
Information on safe fitting, safe startup and safe operation can be found in this instruction manual; in addition the
"warning-note concept" therein must be observed.
BA 3100 en 12/2014
4 / 24
Contents
1.
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
1.2
Speeds, geometric data and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flexible elements (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
10
2.
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
2.1
2.2
2.3
Safety instructions and general notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Marking of the coupling parts for use in potentially explosive zones . . . . . . . . . . . . . . . . . . . . . . . . .
Service conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
12
12
3.
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
3.1
3.2
3.3
3.4
3.5
3.6
3.6.1
3.6.2
3.6.3
3.7
3.8
3.9
Machining the finished bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machining the parallel keyway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axial fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Balancing after machining the finished bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation of the coupling parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible misalignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axial misalignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Angular misalignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radial misalignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaftdisplacement values during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assignment of the tightening torques and wrench widths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
14
14
15
15
16
16
16
16
17
17
18
4.
Startup and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
5.
Faults, causes and remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
5.1
5.2
5.2.1
5.2.2
5.2.3
Possible cause of fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Incorrect use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frequent faults when selecting the coupling and/or coupling size . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frequent faults when fitting the coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frequent faults in maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
19
19
19
20
6.
Maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
6.1
6.2
6.3
Maintenance interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Demounting the coupling parts in case of shaftto-hub connection with parallel key . . . . . . . . . . .
20
21
21
7.
Stocking spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
7.1
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
8.
Declarations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
8.1
EC-Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
BA 3100 en 12/2014
5 / 24
1.
Technical data
The instructions describe the coupling in horizontal mounting position with shaftto-hub connection by
cylindrical or conical bore with parallel key. If a vertical or inclined arrangement or other shafttohub
connections, such as shrink fit or splines to DIN 5480, are to be used, Siemens must be consulted.
The coupling described below may be be used in potentially explosible areas. The couplings must have
a CE marking (for marking, see item 2.2).
Couplings which do not have a CE marking, must not be used in potentially explosive
areas.
If a dimensioned drawing has been made out for the coupling, the data in this drawing must be given
priority. The dimensioned drawing including any other documents should be made available to the user
of the system.
For part numbers and part designations, see the corresponding spareparts drawing in section 7 or the
dimensioned drawing.
Speeds, geometric data and weights
U2
Fig. 1:
Table 1:
Size
D2
NL1
NL2
ND2
U1
D1
ND1
DA
1.1
Type B
Speeds, geometric data and weights of type B
Speed
nmax.
1/min
Maximum bore
1)
D1
D2
mm
mm
DA
mm
ND1
mm
ND2
mm
NL1 / NL2
mm
S
mm
U1
mm
U2
mm
Weight
2)
m
kg
58
7500
19
24
58
58
40
20
2.... 4
20
0.4
68
7000
24
28
68
68
50
20
2.... 4
20
0.54
80
6000
30
38
80
80
68
30
2.... 4
30
10
1.3
95
5500
42
42
95
76
76
35
2.... 4
30
12
2.2
110
5300
48
48
110
86
86
40
2.... 4
34
14
3.3
125
5100
55
55
125
100
100
50
2.... 4
36
18
5.2
140
4900
60
60
140
100
100
55
2.... 4
34
20
5.6
160
4250
65
65
160
108
108
60
2.... 6
39
20
7.8
180
3800
75
75
180
125
125
70
2.... 6
42
20
11.5
200
3400
85
85
200
140
140
80
2.... 6
47
24
16
225
3000
90
90
225
150
150
90
2.... 6
52
18
20
250
2750
100
100
250
165
165
100
3.... 8
60
18
29
280
2450
110
110
280
180
180
110
3.... 8
65
20
38
1) Maximum bore with keyway to DIN 6885/1.

2) Weights apply to maximum bores.
BA 3100 en 12/2014
6 / 24
Table 2:
Size
U2
2
P
D2
D1
ND1
DA
U1
Fig. 2:
NL1
NL2
ND2
Type A
Speeds, geometric data and weights of type A
Speed
nmax
1/min
Maximum bore 1)
D1
D2
mm
mm
DA
mm
ND1
mm
ND2
mm
NL1 / NL2
mm
S
mm
U1
mm
U2
mm
P
mm
Weight 2)
m
kg
110
5300
48
38
110
86
62
40
2.... 4
34
20
33
125
5100
55
45
125
100
75
50
2.... 4
36
23
38
4.8
140
4900
60
50
140
100
82
55
2.... 4
34
28
43
160
4250
65
58
160
108
95
60
2.... 6
39
28
47
8.4
180
3800
75
65
180
125
108
70
2.... 6
42
30
50
12
200
3400
85
75
200
140
122
80
2.... 6
47
32
53
17
225
3000
90
85
225
150
138
90
2.... 6
52
38
61
23
250
2750
100
95
250
165
155
100
3.... 8
60
42
69
31
280
2450
110
105
280
180
172
110
3.... 8
65
42
73
41
315
2150
100
120
100
120
315
165
200
165
200
125
3.... 8
70
47
78
57
61
350
2000
110
140
110
140
350
180
230
180
230
140
3.... 8
74
51
83
78
82
400
1700
120
150
120
150
400
200
250
200
250
160
3.... 8
78
56
88
112
117
440
1550
130
160
130
160
440
215
265
215
265
180
5...10
86
64
99
147
155
480
1400
145
180
145
180
480
240
300
240
300
190
5...10
90
65
104
184
200
520
1300
150
190
150
190
520
250
315
250
315
210
5...10
102
68
115
234
254
560
1200
200
200
560
320
320
220
6...12
115
80
125
329
610
1100
220
220
610
352
352
240
6...12
121
88
135
416
660
1000
240
240
660
384
384
260
6...12
132
96
145
546
710
1000
260
260
710
416
416
290
6...12
138
102
155
680

BA 3100 en 12/2014
7 / 24
U2
Table 3:
Size
D2
D1
ND1
DA
Fig. 3:
NL1
NL2
ND2
U1
Type BDS
Speeds, geometric data and weights of type BDS
Speed
Maximum bore
1)
Weight
2)
nmax.
D1
D2
DA
ND1
ND2
NL1 / NL2
U1
U2
1/min
mm
mm
mm
mm
mm
mm
mm
mm
mm
kg
66
7500
19
24
66
66
40
20
2.... 4
20
0.5
76
7000
24
28
76
76
50
20
2.... 4
20
0.65
88
6000
30
38
88
88
68
30
2.... 4
30
10
1.8
103
5500
42
42
103
76
76
35
2.... 4
30
12
118
5300
48
48
118
86
86
40
2.... 4
34
14
3.7
135
5100
55
55
135
100
100
50
2.... 4
36
18
6.1
152
4900
60
60
152
108
100
55
2.... 4
36
20
172
4250
65
65
172
118
108
60
2.... 6
41
20
11
194
3800
75
75
194
135
125
70
2.... 6
44
20
17
218
3400
85
85
218
150
140
80
2.... 6
47
24
23
245
3000
90
90
245
150
150
90
2.... 6
52
18
27
272
2750
100
100
272
165
165
100
3.... 8
60
18
36
305
2450
110
110
305
180
180
110
3.... 8
65
20
47

BA 3100 en 12/2014
8 / 24
Fig. 4:
Table 4:
Size
U2
D2
D1
ND1
DA
U1
ND2
NL1
NL2
Type ADS
Speeds, geometric data and weights of type ADS
Speed
Maximum bore
1)
Weight
2)
nmax.
D1
D2
DA
ND1
ND2
NL1 / NL2
U1
U2
1/min
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
kg
118
5300
48
38
118
86
62
40
2.... 4
34
20
33
3.5
135
5100
55
45
135
100
75
50
2.... 4
36
23
38
5.5
152
4900
60
50
152
108
82
55
2.... 4
36
28
43
7.7
172
4250
65
58
172
118
95
60
2.... 6
41
28
47
10.5
194
3800
75
65
194
135
108
70
2.... 6
44
30
50
15
218
3400
85
75
218
150
122
80
2.... 6
47
32
53
21
245
3000
90
85
245
150
138
90
2.... 6
52
38
61
28
272
2750
100
95
272
165
155
100
3.... 8
60
42
69
40
305
2450
110
105
305
180
172
110
3.... 8
65
42
73
50
340
200
165
200
125
3.... 8
70
47
78
72
73
340
2150
120
100
120
380
2000
140
110
140
380
230
180
230
140
3.... 8
74
51
83
100
104
430
1700
150
120
150
430
250
200
250
160
3.... 8
78
56
88
135
140
472
1550
160
130
160
472
265
215
265
180
5...10
86
64
99
174
180
514
1400
180
145
180
514
300
240
300
190
5...10
90
65
104
220
237
556
1300
190
150
190
556
315
250
315
210
5...10
102
68
115
281
290

BA 3100 en 12/2014
9 / 24
1.2
Flexible elements (12)
Flexible elements may be stored for up to 5 years.
Flexible elements must be protected against direct sunlight, artificial light with a high ultraviolet content
and extreme temperatures.
Flexible elements must not come into contact with aggressive media.
Flexible elements must not be heated up to impermissible temperatures during fitting work
(see table 5).
Flexible elements mus be replaced in sets; only identical flexible elements may be used in one
coupling.
Table 5:
NEUPEX flexible elements
Material
Hardness
Remark
Mark
Temperature range
NBR
80 Shore A
Standard
black flexible elements

with blue stripes
- 30 C to + 80 C
NBR
65 Shore A
Special, soft,
shift of rotary resonance speed, nominal
torque reduced

with green stripe
- 30 C to + 80 C
NBR
90 Shore A
Special, hard,
shift of rotary resonance speed

with magenta stripe
- 30 C to + 80 C
NBR
80 Shore A
Special, increased (low-backlash)

with yellow stripe
- 30 C to + 80 C
NBR
65 Shore A
Special, increased (low-backlash), shift

of rotary resonance speed, nominal
torque reduced

with white stripe
- 30 C to + 80 C
NR
80 Shore A
Special,
use at low temperature

with orange stripe
- 50 C to + 50 C
HNBR
80 Shore A
Special,
use at high temperature

with red stripe
- 10 C to + 100 C
NBR
80 Shore A
Special,
electrically insulating
green flexible elements
- 30 C to + 80 C
Electrically insulation flexible elements (green) are approved for explosion groups IIA
and IIB.
Hightemperature flexible elements (red marking) are not approved for use in
potentially explosive areas.
Table 6:
Material
NEUPEXDS flexible elements

Hardness
Remark
Mark
Temperature range
NBR
80/90 Shore A
Standard, 2-components,
sizes 66 to 272
- 30 C to + 80 C
NBR
90 Shore A
Standard,
Sizes 305 to 556
- 30 C to + 80 C
PU
95 Shore A
Special,
Electrically insulating
blue / green
flexible elements
- 30 C to + 50 C
Electrically insulation flexible elements (blue / green) are approved for explosion
groups IIA and IIB.
BA 3100 en 12/2014
10 / 24
2.
Notes
2.1
Safety instructions and general notes

All persons involved in the installation, operation, maintenance and repair of the
coupling or clutch must have read and understood these instructions and must
comply with them at all times. Disregarding these instructions may cause damage to
the product and material and/or injury to persons. Damage caused by disregard of
these instructions will result in exclusion of liability.
During transport, installation, dismantling, operation and maintenance of the unit, the relevant safety and
environmental regulations must be complied with at all times.
Lifting gears and load equipment for handling the components must be suitable for the
weight of the coupling.
Depending on national regulations, coupling and clutch components may have to be disposed of
separately or separated for recycling.
The coupling must be stored in a dry environment. Adequate preservation must be carried out.
Operators and users must not make any changes to the coupling themselves over and above the treatment
specified in these instructions.
If there is any visible damage the coupling or clutch must not be fitted or put into
operation!
The coupling must not be operated unless housed in a suitable enclosure in accordance with the standards
applying. This also applies to test runs and when checking the direction of rotation.
All work on the coupling must be carried out only when it is at a standstill. Secure the drive unit to prevent
unintentional switchon. A notice should be attached to the ON switch stating clearly that work is in
progress.
In addition to any generally prescribed personal safety equipment (such as safety shoes, safety clothing,
helmet) suitable safety gloves and suitable safety glasses must be worn when handling the coupling
or clutch!
Only spare parts made by the manufacturer Siemens must be used.
Any enquiries should be addressed to:
Siemens AG
Schlavenhorst 100
46395 Bocholt
Tel.:
Fax:
+49 (0)2871 / 92-0

+49 (0)2871 / 92-2596
BA 3100 en 12/2014
11 / 24
2.2
Marking of the coupling parts for use in potentially explosive zones

Couplings which are ordered in Atex configuration, have the following marking on the outer circumference
of coupling part 1:
Siemens AG
II 2G T4 / T5 / T6 D120 C
(- 50 C) - 30 C Ta + 80 C / + 50 C / + 40 C
46393 Bocholt - Germany

FLENDER couplings N-EUPEX <year built>
I M2
Coupling part 2 or coupling part 4 bear the marking
The marking is in one or two lines.

If, in addition to the CE mark, the letter "U" together with the Siemens order number has been stamped
on, the coupling part has been delivered by Siemens un or prebored.
Siemens supplies unbored and prebored couplings with CE marking only under the
condition that the customer assumes the responsibility and liability for correct
refinishing in a declaration of exemption.
When using electrically insulating flexible elements, the marking of the explosion
group IIA, IIB is added.
2.3
Service conditions
The coupling is suited for service conditions in accordance with Directive 94/9/EC:
Equipment group II (use above ground) of categories 2 and 3 for areas where there are explosible gas,
vapour, mist, air mixtures as well as for areas where dust can form explosible atmospheres.
The permissible temperature classes and/or maximum surface temperatures are assigned as
a function of the maximum ambient temperature occurring in the immediate vicinity of the coupling
(see Table 7).
Table 7:
Temperature classes
Ambient temperature
Temperature class
max. surface temperature
max. 80 C
T4
< 108 C
max. 50 C
T5
< 80 C
max. 40 C
T6
< 68 C
Equipment group I (underground applications) of the category M2.
Explosion group IIA or IIB in case of electrically insulating flexible elements.

If they are to be used below ground in potentially explosive areas the couplings must
only be used with drive motors, which can be switched off on occurring of an
explosible atmosphere.
The machines connected by the coupling must be earthed by an earth leakage
resistance < 106 .
If lacquered couplings are used in potentially explosive areas, the requirements made
of the conductivity of the lacquer and the limitation on the thickness of the lacquer
applied must be observed in accordance with EN 134631. Where lacquer coatings
have a thickness less than 200 m, no electrostatic charge is to be expected.
BA 3100 en 12/2014
12 / 24
3.
Fitting
3.1
Machining the finished bore

Remove the flexible elements (12).
Depreserve and clean coupling parts (1: 2; 2/3; 4).
Clamp on surfaces marked with
, and align.
In case of coupling part 2/3 and coupling part 4 great caution is necessary owing to
the rotating cams.
Machine the finished bore, observe maximum bore described in section 1.
Check finished bore as described in section 5.
IT8 A
IT8 B
IT8 D
IT8 C
3.2
IT6
IT6
IT6
IT6
3.2
3.2
3.2
IT8 C
1)
Fig. 5:
2)
3)
4)
Machining the finished bore
1) Coupling part 1
2) Coupling part 4
3) Coupling part 2
4) Coupling part 2/3
Table 8:
Fit recommendation for bores with parallelkey connection

Push fit
Description
Press fit
Interference fit
suitable for reversing
operation
not suitable for reversing operation
Shaft tolerance
j6
h6
h6
k6
m6
n6
h6
Bore tolerance
H7
J7
K7
H7
H7
H7
M7
The fit assignment m6 / H7 is particularly suitable for many applications.

Failure to observe these instructions may result in breakage of the coupling.
Danger from flying fragments!
The coupling may then become an explosion hazard.
BA 3100 en 12/2014
13 / 24
3.2
Machining the parallel keyway
Parallel keyway to DIN 6885/1 ISO JS9 with usual operating conditions.
Width of parallel keyway ISO P9 with reversing operation.
Arrangement of parallel keyway:
3.3
with coupling part 1:
centrally between the lands of the flexible elements
with coupling part 1 DS:
centrally between the pockets of the flexible elements
with coupling part 2:
centrally between the threaded holes
with coupling part 2 DS:
centrally between the treaded holes and offset to the recesses for the
exchange of flexible elements
with coupling part 4 / 4 DS:
underneath a cam
Axial fastening
Arrange set screw on the parallel keyway. An exception are the following coupling parts:
Part 1:
Size 58 / 66 :
Size 68 / 76 :
Size 80 / 88 :
Size 95 /103 :
Bore D1 15 mm set screw displaced by 180 relative to the keyway.

Part 2:
Size 110 /118 : Bore D1 30 mm set screw displaced by 180 relative to the keyway.
Part 4:
Size 58 / 66 :
Size 68 / 76 :

Position of the set screw to table 9.

Use threaded studs to DIN 916 with cup points as set screws (setscrew size to table 9).
The set screw is intended to fill out the screw thread as much as possible and must not project beyond the
hub.
Alternatively use end plate; as regards recess contact Siemens.
e1
e2
d1
1)
Fig. 6:
e3
d1
2)
d1
d1
3)
Position of the set screw
1) Coupling part 1; position of the set screw up to size 125 / 135

2) Coupling part 1; position of the set screw from size 140 / 152 upwards
3) Coupling part 2
4) Coupling part 4
BA 3100 en 12/2014
14 / 24
e4
4)
Table 9:
Setscrew assignment, setscrew position and tightening torques
58
68
80
95
66
76
88
103 118 135 152 172 194 218 245 272 305 340 380 430 472 514 556
d1
M5
M6
M6
M6
M6
M8
e1
10
10
11
15
18
20
e2
13
13
16
20
22
24
28
35
40
50
60
70
80
75
85
100 100 110 130 140
Size
110 125 140 160 180 200 225 250 280 315 350 400 440 480 520 560 610 660 710
-
M8 M10 M12 M12 M12 M16 M16 M16 M20 M20 M24 M24 M24 M24 M24 M24 M24
e3
12
15
20
30
30
35
40
45
50
60
70
80
90
e4
12
15
18
20
22
25
32
40
40
45
45
1)
15
25
25
25
70
70
70
100 115
130 130 230 230 230 230 230 230 230
1) Tightening torques of the set screws in Nm

Tightening torques apply to bolts with untreated surfaces which are not or only lightly oiled (coefficient of
friction = 0.14). The use of lubricant paint or lubricant, which affects the coefficient of friction "", is not
permitted.
The specified tightening torques TA must be complied with, applying DIN 25202 ScrewConnection
Class C, with an outputtorque scatter of 5 %.
3.4
Balancing after machining the finished bore

The balancing quality is to be specified in accordance with the specific application (however min. G16
to DIN ISO 1940).
Balancing prescription to DIN ISO 8821 of the shaft must be observed.
Balancing bores must not affect the loadbearing capacity of the coupling parts .
The balancing bores must be applied on a large radius with sufficient distance to the lands / pockets of the
flexible elements, cams and the outer circumference.
In case of coupling part 1 the bottom of the pockets of the flexible elements must not
be completely drilled through.
3.5
Installation of the coupling parts

Unscrew the set screw.
Clean holes and shaft ends.
Coat the bores of the coupling parts (1: 2; 4) and the shafts with MoS2 mounting paste
(e.g. Microgleit LP 405).
If demounted, position the coupling part 3 on the shaft before pulling coupling part 2 on.
Coupling parts (1; 2; 4) with tapered bore and parallelkey connection must be fitted
in cold condition and secured with suitable end plates, without drawing the coupling
parts (1; 2; 4) further onto the taper (fitting dimension = 0).
Place coupling parts (1; 2; 4), with cylindrical bore heat up to max. + 150 C, if necessary. When heating
up observe the temperature range of the flexible elements (12) (see table 5 or 6), if necessary demount
the flexible elements (12).
Heated coupling parts form an explosion hazard, therefore a nonexplosive
environment must be ensured.
BA 3100 en 12/2014
15 / 24
Axial securing is effected by means of the set screw or end plate. When securing by set screw the shaft
must not project or be set back from the inner sides of the hub.
Fit the set screw or end plate (tightening torques of the set screw to table 9).
The coupling may then become an explosion hazard.
If necessary, refit flexible elements (12). Observe the temperature range (see table 5 or 6).
Align the coupling as described in item 3.7.
3.6
Possible misalignments
Smax.
Smax.
Smin.
Smin.
1)
Fig. 7:
Kr
Kw
Ka
2)
3)
Possible misalignments
1) Axial misalignment (Ka)

2) Angular misalignment (Kw)
3) Radial misalignment (Kr)
3.6.1
Axial misalignment
The gap dimension Ka should be set within the deviation permitted for the dimension "S" (see section 1).
3.6.2
Angular misalignment
The angular misalignment Kw can be measured as difference of the gap dimension (S = Smax. Smin.).
Sperm., see table 10.
If required, the permissible angular misalignment Kw can be calculated as follows:
3.6.3
Kwperm. in RAD = Sperm. / DA
Sperm., see table 10.
Kwperm. in GRAD = (Sperm. / DA) x (180 / )
"DA" in mm see section 1.
Radial misalignment
The permissible radial misalignment Krperm. can be found in table 10 (depending on the operating
speed).
BA 3100 en 12/2014
16 / 24
3.7
Alignment
When aligning the angular and radial misalignment should be kept as low as possible.
Misalignment values specified in table 10 are maximum permissible overall values in operation, resulting
from mispositioning through imprecision during alignment and misalignment through operation
(e.g. deformation through load, heat expansion).
Reduced misalignment in the coupling minimises expected wear on the flexible elements. Misalignment
in the coupling gives rise to restorative forces which may impose inadmissible stress on adjacent machine
parts (e.g. bearings).
3.8
Shaftdisplacement values during operation

The following maximum permissible misalignments must by no means be exceeded during
operation.
When aligning the angular and radial misalignment should be kept appreciably smaller
(tending towards zero).
Table 10: Shaftdisplacement values Sperm. and Kperm., maximum permissible during operation,
stated in mm (rounded)
Type, size
A, B
ADS, BDS
Coupling speed in 1/min

250
500
750
1000
1500
2000
3000
4000
5000
58
66
0.4
0.3
0.25
0.2
0.2
0.15
0.15
0.1
0.1
68
76
0.4
0.3
0.25
0.2
0.2
0.15
0.15
0.1
0.1
80
88
0.4
0.3
0.25
0.2
0.2
0.15
0.15
0.1
0.1
95
103
0.5
0.35
0.25
0.25
0.2
0.2
0.15
0.1
0.1
110
118
0.5
0.35
0.3
0.25
0.2
0.2
0.15
0.1
0.1
125
135
0.5
0.4
0.3
0.25
0.25
0.2
0.15
0.15
0.1
140
152
0.6
0.4
0.35
0.3
0.25
0.2
0.2
0.15
160
172
0.6
0.5
0.4
0.35
0.3
0.25
0.2
0.15
180
194
0.6
0.5
0.4
0.35
0.3
0.25
0.2
200
218
0.8
0.55
0.45
0.4
0.3
0.3
0.2
225
245
0.8
0.55
0.5
0.4
0.35
0.3
0.25
250
272
0.8
0.6
0.5
0.4
0.35
0.3
280
305
0.7
0.6
0.5
0.4
0.35
315
340
0.7
0.6
0.5
0.4
0.35
350
380
0.8
0.6
0.6
0.5
400
430
1.2
0.9
0.7
0.6
0.5
440
472
1.3
0.7
0.7
0.6
480
514
1.4
0.8
0.7
520
556
1.5
1.1
0.9
0.8
560
1.6
1.2
0.8
610
1.8
1.3
0.9
660
1.9
1.4
1.1
710
1.5
1.2
The numerical values of the table, as well as the intermediate values, can be calculated as follows:
Krperm. = Sperm. = (0.1 + DA / 1000) x 40 / n
Coupling speed "n" in 1/min

"DA" in mm, see section 1.
Radial misalignment Krperm. in mm
For speeds < 250 1/min the values in the colon "250 1/min" in table 10 apply.
BA 3100 en 12/2014
17 / 24
3.9
Assignment of the tightening torques and wrench widths

The use of an impact screwdriver is not permissible!
Tightening torques apply to bolts with untreated surfaces which are not or only lightly oiled (coefficient of
friction = 0.14). The use of lubricant paint or lubricant, which affects the coefficient of friction "", is not
permitted.
The specified tightening torques TA must be complied with, applying DIN 25202 ScrewConnection
Class C, with an outputtorque scatter of 5 %.
The tightening torques and wrench widths of the set screws are specified in table 9.
Table 11: Tightening torques for part 13 of Types A and ADS
4.
N-EUPEX
coupling
N-EUPEX-DS
coupling
Tightening torque TA and wrench width SW for

hexagon socket screws to DIN EN ISO 4762
Size
Size
TA
Nm
SW
mm
110
118
14
125
135
17.5
140
152
29
160
172
35
180
194
44
200
218
67.5
10
225
245
86
10
250
272
145
14
280
305
185
14
315
340
200
14
350
380
260
17
400
430
340
17
440
472
410
17
480
514
550
19
520
556
670
19
560
710
19
610
1450
22
660
1450
22
710
1450
22
Startup and operation

Bolttightening torques for the coupling and tightening torques for the foundation
bolts of the coupled machine must be checked before startup. Enclosures (coupling
protection, contact guard) must be fitted!
Overload conditions during startup cannot be excluded. If the coupling breaks
through overload, metal parts may fly off and cause personal injury and/or material
damage.
If it is to be used below ground in potentially explosive areas, the coupling, which is
made of cast iron or steel, must be provided with a robust casing to preclude the risk
of ignition from e.g. friction, impact or friction sparks.
The depositing of heavy metal oxides (rust) on the coupling must be precluded by the
casing or other suitable precautions.
The coupling must run with little noise and without vibration. Irregular behaviour must be treated as a fault
requiring immediate remedy. In case of fault the drive must be stopped at once. The necessary measures
for repair must be taken in accordance with the safety regulations applying.
BA 3100 en 12/2014
18 / 24
5.
Faults, causes and remedy
5.1
Possible cause of fault

Change in alignment:
Rectify the cause of the change in alignment (e.g. loose foundation bolts).
Align the coupling.
Check the axial fastening and, if necessary, adjust.
Wear check of the flexible elements (12) as described in section 6.
Flexible elements (12) worn:
Wear check of the flexible elements (12) as described in section 6, if necessary replace flexible
elements (12).
5.2
Incorrect use
Through incorrect use the coupling may become an explosion hazard.
5.2.1
5.2.2
Frequent faults when selecting the coupling and/or coupling size
Important information for describing the drive and the environment are not communicated.
System torque too high.
System speed too high.
Application factor not correctly selected.
Chemically aggressive environment not taken into consideration.
The ambient temperature is not permissible.
Finished bore with inadmissible diameter and/or inadmissible assigned fits.
Machining of parallel keyways of which the width across corners is greater than the width across
corners of the parallel keyways to DIN 6885/1 with a maximum permissible bore.
The transmission capacity of the shaftto-hub connection is not appropriate to the operating conditions.
Maximum load or overload conditions are not being taken into consideration.
Dynamic load conditions are not being taken into consideration.
Shaftto-hub connection resulting in impermissible material stress on the coupling.
Operating conditions are being changed without authorisation.
Coupling and machine / drive train form a critical torsional, axial and bending vibration system.
Fatigue torque load too high.
Frequent faults when fitting the coupling
Components with transport or other damage are being fitted.
When fitting coupling parts in a heated condition, already fitted NEUPEX flexible elements (12) are
being excessively heated.
The shaft diameter is beyond the specified tolerance range.
Coupling parts are being interchanged, i.e. their assignment to the specified shaft is incorrect.
BA 3100 en 12/2014
19 / 24
5.2.3
Specified axial fastenings are not fitted.
Specified tightening torques are not being adhered to.
Bolts are inserted dry or greased.
Flange surfaces of screwed connections have not been cleaned.
Alignment and/or shaftmisalignment values do not match the specifications in the instructions manual.
The coupled machines are not correctly fastened to the foundation, and as a result shifting of the
machines, e.g. through loosening of the foundationscrew connection, is causing excessive
displacement of the coupling parts.
The coupled machines are not sufficiently earthed.
NEUPEX flexible elements (12) are not fitted.
The coupling guard used is not suitable.
Frequent faults in maintenance
Maintenance intervals are not being adhered to.
Original NEUPEX spare parts are not being used.
Old or damaged NEUPEX spare parts are being used.
Diffenrent NEUPEX flexible elements (12) are being used.
Leakage in the vicinity of the coupling is not being identified and as a result chemically aggressive
media are damaging the coupling.
Fault indications (noise, vibration, etc.) are not being observed.
Specified tightening torques are not being adhered to.
Alignment and/or shaftmisalignment values do not match the specifications in the instructions manual.
6.
Maintenance and repair
6.1
Maintenance interval
On Types A and B the torsional backlash between the two coupling parts must be
checked after three months, then at least once a year.
On Types ADS and BDS the torsional backlash of the flexible elements (12) need be
checked against Directive 94/9/EC only if a failure of the flexible elements (12) and as
a result a stoppage of the drive result in an explosion hazard. It is recommended that
preventive maintenance, also on coupling types ADS and BDS, include the regular
check of the torsional backlash.
SV
The flexible elements (12) must be replaced, when the torsional backlash exceeds the value stated in
table 12.
Fig. 8:
Wear mark
BA 3100 en 12/2014
20 / 24
Table 12: Wear mark for the torsional backlash, Types A and B
Size
58
Wear mark
SV
(mm)
68
80
95
110 125 140 160 180 200 225 250 280 315 350 400 440 480 520 560 610 660 710
5.5 5.5
5.0
6.0
7.0
8.0
8.0
8.0
8.0
8.5
9.0 10.0 11.5 10.5 11.5 13.0 14.0 15.5 17.5 17.5 19.5 21.0 22.5
Table 13: Wear mark for the torsional backlash, Types ADS and BDS
Size
66
76
88
103
118
135
152
172
194
218
245
272
305
340
380
430
472
514
556
Wear mark
SV
(mm)
6.0
7.0
5.0
7.0
9.0
10.5
11.5
9.0
8.0
7.0
6.5
7.0
8.0
6.5
7.0
10.0
12.0
14.0
16.0
If the above specified maintenance instructions are not adhered to, a correct operation
within the meaning of the explosion prevention requirements and/or Directive 94/9/EC
can no longer be guaranteed on Types A and B (types with form fitting of the metal
parts).
Use in potentially explosive areas is then not permitted.
6.2
Replacement of wearing parts

Replacement of the flexible elements (12) is possible without shifting the coupled machines only on
Types A and ADS.
After releasing the connection of coupling parts 2/3, coupling part 3 is shifted axially. The flexible
elements (12) will then be made freely accessible by rotating coupling part 2. To facilitate the release of
coupling part 3, on sizes 225 to 430 forcingoff threads are provided in coupling part 1. From size 440
onwards the forcingoff thread is located within coupling part 3.
1)
Fig. 9:
2)
Releasing coupling part 3
1) Forcingoff thread in coupling part 1
2) Forcingoff thread in coupling part 3
The flexible elements (12) must be replaced in sets. Only identical flexible elements (12) may be used.
For reassembly, the instructions in sections 3 and 4 must be observed.
6.3
Demounting the coupling parts in case of shaftto-hub connection with parallel key
Move the coupled machines apart.
Remove the axial fastening (set screw, end plate). Mount suitable detaching device. Using a burner, heat
coupling part (1; 2; 4) along its length and above the parallel keyway (max. + 80 C). When heating up
observe the temperature range of the flexible elements (12) (see tables 5 and 6), if necessary demount the
flexible elements (12).
Burner and heated coupling parts form an explosion hazard; therefore a nonexplosive
environment must be ensured.
Pull the coupling part off. Examine the hub bore and the shaft for damage, and protect against rust.
Damaged parts must be replaced.
For reassembly, the instructions in sections 3 and 4 must be observed.
BA 3100 en 12/2014
21 / 24
7.
Stocking spare parts
7.1
Spare parts
For ordering spare parts state the following data, as far as possible:
Siemens order number and position
Drawing number
Coupling type and coupling size
Part numer (see spareparts list)
Bore, bore tolerance, keyway and balancing as well as particular characteristics such as
flangeconnection dimensions, intermediateshaft length, brakedrum dimensions
Any special details such as temperature, electrically insulating

1
12
16
13
12
2)
1)
Fig. 10: Spareparts drawing

1) Types A and ADS
2) Types B and BDS
Table 14: Spareparts list
Type A, ADS
Part number
Type B, BDS
Designation
Coupling part 1
2
3
12
Flexible element
13
Cheese-head bolt
16
Parallel pin
only on Type A Size 560 to 710
Part number
Designation
Coupling part 1
Coupling part 2
Coupling part 4
Coupling part 3
12
Flexible element
BA 3100 en 12/2014
22 / 24
8.
Declarations
8.1
EC-Declaration of conformity
EC-Declaration of conformity
within the meaning of EC Directive 94/9/EC of 23.03.1994 and the legal requirements laid down for its
implementation
The manufacturer, Siemens AG, 46395 Bocholt, Germany, declares that the equipment described in these
operating instructions:
FLENDER N-EUPEX and

FLENDER N-EUPEX-DS
couplings
Types A, B
and ADS, BDS
is in conformity with Article 1 and Article 8, Paragraph 1 b) ii) of Directive 94/9/EC and complies with the
requirements of Directive 94/9/EC and the following standards:
DIN EN 11271 : 102011
DIN EN 13463-1 : 07-2009
The technical documentation has been delivered to the body named below:
DEKRA EXAM GmbH, D 44727 Bochum, code number: 0158.
Bocholt, 20141204
Andre Jansen
(Director Engineering KUE)
Bocholt, 20141204
Nicola Warning
(Director Business Subsegment KU)
BA 3100 en 12/2014
23 / 24
Further Information:
"FLENDER gear units" on the Internet
www.siemens.com/gearunits
"FLENDER couplings" on the Internet
www.siemens.com/couplings
Service & Support:
http://support.automation.siemens.com/WW/view/en/10803928/133300
Lubricants:
http://support.automation.siemens.com/WW/view/en/42961591/133000
Siemens AG
Industry Sector
Mechanical Drives
Alfred-Flender-Strae 77
46395 Bocholt
GERMANY
Subject to modifications
Siemens AG 2014
www.siemens.com/drivetechnologies
Preventive Maintenance Jobs

Customer
Cartulinas CMPC
Maule BM19
(M450VALZ)
1.
Position
2.
Position Name
STOD163527
Valzone Pulper
Machine
BM19
3.
Maintenance Item/Specification
Product
OptiSlush Broke (HP-50G)
4.
Job Specification
Document No.
STOA110077GA
5.
No. of
Maint.
Items
Rev.
02
6.
Maint.
Interval
7.
Unit
(h/wk)
Prepared by
JKo
8.
Lube Method
9.
Qty/Item
Date
15.2.2012
10.
Unit
Revised by
JTe
11.
Lubricant
12.
Operation/
Shutdown
Date
16.11.2015
13.
Supplier's
Reference
14.
Note
Horizontal pulper HP-50G drive /

See manufacturers inst.
Gear
Secondary shaft lip seal
Motor bearings
Control unit for sealing water /
Check operation
Sealing water flow and pressure
Rotor unit / Shaft seal
Check leaks
Horizontal pulper drive / Gear oil

Check operation
level, pressure and temperature
Horizontal pulper drive /
Coupling
Rotor unit / Screen/slot plates
Rotor unit / Rotor clearance
Rotor unit / Attachment
Horizontal pulper / Condition of
bearings
Horizontal pulper
Horizontal pulper
Horizontal pulper
Horizontal pulper / Pipe
connections
Horizontal pulper / Pipe
connections
Horizontal pulper / Sealing water
connections
Horizontal pulper / Sealing water
connections
Check wear
Check wear
Calibration
Check screw torque
Check sound, temperature and
vibration
Check sound, temperature and
vibration
Clean and check, outside
Clean and check, inside
wk
Operation
wk
Operation
wk
Operation
52
wk
Shutdown
1
1
52
52
52
wk
wk
wk
Shutdown
Shutdown
Shutdown
wk
Operation
26
wk
Operation
1
1
52
wk
Shutdown
Shutdown
Check leaks
26
wk
Shutdown
Check screw torque
26
wk
Shutdown
Check leaks
24
Operation
Check screw torque
26
wk
Shutdown
Horizontal pulper /
Check leaks
Instrumentation air connections
24
Operation
Horizontal pulper /
Check screw torque
Instrumentation air connections
26
wk
Shutdown
wk
Operation
Guards
Drive motor
Check screw torque

Cord packing tightening

or replacing. Mechanical
seal change. When
leakage occurs.
During every shutdown.
Book1
1(1)
Basicinformationonlubricantgroups
ForStockPreparationequipment
SeedetailedinformationonlubricationpointsandlubricantsinMachineManual,5.Mechanical
MaintenanceandintheLubricationandPreventiveMaintenanceJobsTablein10.Appendices
Deflakers
OptiFinerDF
p
MG15MI2,MG40MI2
,
PlugScrewsandPreheaters
OptiFinerDPL
OptiFinerHI
MG15MI2
MG25SY1,5
Dispersers
OptiFinerOFD,OFDi
MG40MI2,MG55SY2orMG55MI2,MO15MI100,
MG40MI2
MG55SY2 or MG55MI2 MO15MI100
MO20MI68
Refiners
OptiFinerRF0,1
OptiFinerRF2,3,4
OptiFinerRF4i
OptiFinerRF5
i i
OptiFinerPro1
OptiFinerPro2,Pro3
MG15MI2,MG40MI2,MG55SY2orMG55MI2
MG40MI2,MG55SY2orMG55MI2,MO20MI68
MG40MI2,MO20MI68
MG40MI2,MO15MI100
MG10SY2,MG15SY2
MG40MI2,MO20MI68
Screens
OptiScreenCS,ProCS
OptiScreenFS,ProFS
p
,
OptiScreenTF
OptiScreenMS,ProMS
MG15SY1,5,MG15MI2
MG15SY1,5,MG15MI2
, ,
MG15SY1,5,MG15MI2
MG15SY1,5,MG15MI2
Pulpers
OptiSlushDS
OptiSlushHP
OptiSlush OSD
OptiSlushOSD
OptiSlushSP,SPi
OptiSlushV
MG15MI2
MG15SY1,5
MG15MI 2
MG15MI2
MG15SY1,5
MG15SY1,5
ThickenersandGapWashers
OptiThickGT
OptiThickGW
MG15SY1,5
MG15SY1,5
Other
Ragger,TailCutter
MG15SY1,5,MG15MI2
Greases
RequiredPerformance
ApplicationandOtherQualityandSpecial
Requirements
MG10SY2
NLGIgrade2(DIN51818).
Base oil: synthetic.
Baseoil:synthetic.
Viscosity120...220cSt/40C(ASTMD445).
Operatingtemperaturerange40...+180C.
Multipurposegrease.
Forhighandlowrevolutions.
For
high and low revolutions.
Suitableforlongtermandlifetimelubrication.
Thickenertype:lithiumorlithiumcomplex.
Workedpenetration265...295(DINISO2137).
Waterresistance+90C(DIN51807T.1).
Droppoint>+180C(DINISO2176).
P
Pumpability:ClassE/E/D
bilit Cl E/E/D
Goodcorrosionresistance.
Goodhotandcoldwaterresistance.
MG15SY1,5
NLGIgrade1.5(DIN51818).
Baseoil:synthetic.
y
/
(
)
Multipurposegrease.
Forhighandlowtemperatures.
g
p
PumpabilityC/C/C
Suitableforcentralgreaselubrication.
MG15SY2
NLGIgrade2(DIN51818).
Baseoil:synthetic
Multipurposegrease.
Forhighandlowtemperatures.
PumpabilityF/E/E
MG15MI2
NLGIgrade2(DIN51818)
Baseoil,mineral.
Multipurposegrease.
Viscosity150...220cSt/40C(ASTMD445)
Operatingtemperaturerange20...+150C
Suitableforsinglelubricationwithlongtermeffect.
Workedpenetration265...295(DINISO2137)
Waterresistance+90C(DIN51807T.1)
Droppoint>+180C(DINISO2176)
Pumpability:ClassE/D/D
Thickenertype,lithiumorlithiumcomplex.
MG25SY1,5
NLGIgrade1.5(DIN51818).
Baseoil:synthetic.
PumpabilityC/C/C
Specialtygreaseforhightemperatures.
Thickenertype:e.g.lithiumcomplex.
Goodresistancetoacidprocesswaters.
MG40MI 2
MG40MI2
Specialtygreaseforcouplingsandloadedslidesurfaces.
Baseoil,mineral.
Viscosity200...800cSt/40C(ASTMD445)
Operatingtemperaturerange20...+120C
p
g
p
g
Suitableforsinglelubricationwithlongtermeffect.
Goodadherence.
Thickenertype,lithium/lithiumcomplex.
MG55SY2
Viscosity460...1500cSt/40
/ oC(ASTMD445)
(
)
Bearingssubjecttohighloads,sphericalplainbearings
andbushings,joints,guidewaysandgearcouplings.
Suitableforimpactloadsandlowandchanging
movementspeeds.
Suitablealsoformachineswithverticalshafts.Good
sealingproperties.
Operatingtemperaturerange20...+150oC
Goodadherenceandstaysontheloadingsurface.
Highloadbearingcapacity.Goodvibrationresistance.
Thickenertype:lithium/lithiumcomplex.
Goodcorrosionresistanceagainstalkalineandacidic
processwater.
NLGIclass2(DIN51818)
Baseoil,synthetic.
Fourballtest(ASTMD2596),loadcarrying
capacity620kg
Goodalkalinewaterresistance.
MG55MI2
Bearingssubjecttohighloads,sphericalplainbearings
andbushings,joints,guidewaysandgearcouplings.
Suitableforimpactloadsandlowandchanging
Base oil, mineral
Baseoil,mineral
movement speeds.
movementspeeds.
Viscosity320500cSt/40C(ASTMD445)and Suitablealsoformachineswithverticalshafts.Good
10001800cSt/40C(ASTMD445).
sealingproperties.
Operatingtemperaturerange10...+130oC
Goodadherenceandstaysontheloadingsurface.
Highloadcarryingcapacity.Goodvibrationresistance.
Thi
k
t
lithi /lithi
l i / l i
Thickenertype:lithium/lithiumcalcium/calcium
sulphonate.
Goodcorrosionresistanceagainstalkalineandacidic
processwater.
Goodalkalinewaterresistance.
Oils
RequiredPerformance
MO15MI100
ISOVG100
Viscosity90...110cSt/40
Viscosity
90 110 cSt / 40C
C(ASTMD445)
(ASTM D 445)
Viscosity11.1...12.0cSt/100C(ASTMD445)
Pourpoint21...30C(ASTMD97)
Flashpoint220...235C(ASTMD93)
Thermalresistanceatleast+80C
PassesrustpreventiontestsAandB(ASTMD
665).
665)
FZG(DIN51354),class12astheminimum
requirement
MO20MI68
ISOVG68
Pourpoint18...33C(ASTMD97)
Flashpoint220...235C(ASTMD93)
Thermalresistanceatleast+80
Thermal
resistance at least +80C
C
Permittedstartuptemperature+5C
PassesrustpreventiontestsAandB(ASTMD
665).
FZG(DIN51354)class12astheminimum
requirement(=level11passed)
ApplicationandOtherQualityandSpecial
Requirements
Gearswithintegratedlubricationand/orhydraulic
systems.
Oils contain extreme pressure additives (EP)
Oilscontainextremepressureadditives(EP).
Goodoxidationresistance,waterandairseparation
propertiesandfilterability.
Goodfoamingandwearresistanceproperties.
Actuatorhydraulicsystems.
y
y
Oilscontainasmallamountofadditives.
Goodoxidationresistance,waterandairseparation
propertiesandfilterability.
Goodfoamingandwearresistanceproperties.
Insomespecialcases,oilisrequiredtobezincfree.
Product data for lubricants

Voiteluaineiden
presented in the tables is given
tuotetiedot taulukoissa
ovat valmistajien antamia. by the manufacturers.
Ryhm
Group
Rasvatyyppi, ominaisuus
tai kytttarkoitus
Saennin
Thickener
Grease type, property or

application
MG10
MG10SY
NLGI- ljyluokka yhti

class Oil
company
Tuotenimike
Product name
Perusljyn
visk.
Base
oil
visc.
cSt/
40 C
Kyttlmptilaalue
Temperat.
range
Pumpattavuus
Pumpability
A/B/C/D/E/F
Paineistusaika
Pressurisation
time
min
5
15
30
YLEISRASVAT MULTIPURPOSE
GREASES
Synteettisperusljypohjainen
Synthetic basic oil based
Osasynt./Semi-synthetic
Li
1,5
Castrol
Tribol 3785/220-1,5
220
-40+140
Biohajoava/Biodegradable
Li
Shell
Alvania EPB 2
120
-40+120
Li-kompl.
2
2
2
2
2
Castrol
Mobil
Neste
Shell
Teboil
Tribol 4747/220-2
Mobilith SHC 220
Synlix
Albida PPS 2
Syntec Grease
220
220
160
220
160
-40...+180
-40+180
-40...+150
-40+150
-40+150
1,5
Neste
Semilix
120
-35+150
Ryhm
Group
tai kytttarkoitus
Saennin
Thickener

class Oil
company
Tuotenimike
Product name
Perusljyn
visk.
Base
oil
visc.
cSt/
Kyttlmptilaalue
Temperat.
range
Pumpattavuus
Pumpability
A/B/C/D/E/F
Paineistusaika
Pressurisation
time
min
Li
2
2
Neste
Shell
Allrex EP 2
Alvania EP 2
200
190
-30...+120
-20+120
E
E
E
D
D
D
Li-kompl.
1
1
Castrol
Mobil
Tribol 4020/220-1
Mobilgrease XHP 461
220
460
-30...+150
-15...+150
Li-kompl.
1,5
Shell
Limona LX 1
550
-25+150
Li-kompl.
2
2
Castrol
Castrol
Tribol 4020/220-2
220
Molub-Alloy 860/220-2 220
-30...+150
-30...+150
2
2
2
Mobil
Neste
Shell
Mobilgrease XHP 222

Superlix EP 2
Albida PP2
220
200
220
-25+150
-30...+150
-25+150
G
-
F
E
Ca-sulf.
Castrol
Molub-Alloy 6040-2
150
-25...+180
Bentoniitti
Mobil
Mobiltemp 1
460
0+180
Li
1,5
Castrol
Tribol 3785/220-1,5
220
-40+140
Li-kompl.
1,5
1,5
2
2
2
Mobil
Mobil
Neste
Shell
Shell
Mobilith SHC PM 220

Mobilith SHC PM 460
Synlix
Albida PPS 2
Albida HLS 2
220
460
160
220
460
-40...+200
-40...+200
-40...+150
-40+150
-35+150
C
F
C
E
C
E

application
MG15
MG15MI
MG15SY
PAPERIKONERASVAT PAPER
MACHINE GREASES
Mineraaliperusljy
Mineral basic oil
Synteettinen perusljy
Synthetic basic oil
Ryhm
Group
tai kytttarkoitus
Saennin
Thickener

class Oil
company
Tuotenimike
Product name
Perusljyn
visk.
Base
oil
visc.
cSt/
Kyttlmptilaalue
Temperat.
range
Li
Castrol
Molub-Alloy 777-1
860
-30+120
Li
2
2
2
2
Castrol
Neste
Shell
Teboil
Molub-Alloy 777-2
Allrex M
Retinax HDX 2
Universal M
860
200
160
110
-30+120
-30...+110
-30+120
-30+120
Li-kompl.
Mobil
Mobilgrease XHP 322

Special
320
-20+150

application
MG40MI
MG40MI
MOLYBDEENIRASVAT
MOLYBDENUM GREASES
Mineraaliperusljypohjainen
Mineral basic oil based
Pumpattavuus
Pumpability
A/B/C/D/E/F
Paineistusaika
Pressurisation
time
min
Ryhm
Group
tai kytttarkoitus
Saennin
Thickener

class Oil
company
Tuotenimike
Product name
Perusljyn
visk.
Base
oil
visc.
cSt/
Kyttlmptilaalue
Temperat.
range
Pumpattavuus
Pumpability
A/B/C/D/E/F
Paineistusaika
Pressurisation
time
min
Li
Castrol
Tribol 3020/1000-1
1000
-30+120
Li
Li
2
2
Castrol
Castrol
Tribol 3020/1000-2
Molub-Alloy 870
1000
1776
-30+120
-10+120
Li
2,5
Castrol
Optipit
1500
-10+140
Li-kompl.
Li-kompl.
1
1
Castrol
Mobil
Tribol 4020/460-1
Mobilgrease XHP 461
460
460
-20+150
-15...+150
Li-kompl.
Castrol
Tribol 4020/460-2
460
-20+150
Li/Ca
Shell
Steelrol EPH 2
1000
-20+130
Li/Cakompl.
Neste
Avora
750
-30...+150
Li/Cakompl.
0,5
Teboil
Gear Grease XHP
700
-30+140
Li/Cakompl.
1,5
Teboil
Gear Grease XHP 1,5
500
-20+140
Ca-sulf.
1,5
Castrol
Molub-Alloy 6040-1,5
460
-25+185
Ca
Shell
SRS 4000
800
-20+110

application
MG55
MG55MI
HITAIDEN JA RASKAIDEN
KYTTJEN RASVAT / SLOW
AND HEAVY DRIVE GREASES
Mineraaliperusljypohjainen
Mineral basic oil based
Ryhm
Group
tai kytttarkoitus
Saennin
Thickener

class Oil
company
Tuotenimike
Product name
Perusljyn
visk.
Base
oil
visc.
cSt/
Li-kompl.
2
2
Mobil
Mobil
Mobilith SHC 460

Mobilith SHC 1500
460
1500
Geeli
Castrol
Molub-Alloy BioTop
9488
500

application
MG55SY
Biohajoava/Biodegradeable
Kyttlmptilaalue
Temperat.
range
Synteettisperusljypohjainen
Synthetic basic oil based
-20+120
Pumpattavuus
Pumpability
A/B/C/D/E/F
Paineistusaika
Pressurisation
time
min
Voiteluaineiden tuotetiedot
taulukoissa ovat valmistajien
antamia.
Ryhm
Group
MO15
MO15MI
Product data for lubricants presented

in the tables is given by the
manufacturers.
ljytyyppi,
ISOVG
ominaisuus tai
-luokka
class
kytttarkoitus
Oil type, property or application
ljyTuotenimike
yhti
Product name
Oil
company
Viskositeetti
Viscosity
cSt/
cSt/
Jhmepiste
Pour
point
40 C
100 C
VAIHTEISTOLJYT GEAR OILS

Mineraaliljyt
Mineral oils
46
Neste
Vaihteisto 46 EP
46
6,7
-48,0
68
Castrol
Mobil
Neste
Shell
Teboil
Alpha SP 68
Mobilgear 626
Vaihteisto 68 EP
Omala 68
Pressure Oil 68
68
68
68
68
68
8,5
9,2
8,8
8,7
9,0
-21,0
-27,0
-33,0
-27,0
-27,0
100
Castrol
Mobil
Neste
Shell
Teboil
Alpha SP 100
Mobilgear 627
Vaihteisto 100 EP
Omala 100
Pressure Oil 100
100
100
100
100
100
11,1
12,0
11,4
11,4
11,4
-21,0
-27,0
-30,0
-27,0
-27,0
150
Castrol
Mobil
Neste
Shell
Teboil
Alpha SP 150
Mobilgear 629
Vaihteisto 150 EP
Omala 150
Pressure Oil 150
150
150
150
150
150
14,5
15,8
14,9
15,0
15,0
-21,0
-27,0
-21,0
-27,0
-21,0
220
Castrol
Mobil
Neste
Alpha SP 220
Mobilgear 630
Vaihteisto 220 EP
220
220
220
18,7
19,5
19,0
-21,0
-24,0
-24,0
Ryhm
Group
MO15MI (cont.)
ljytyyppi,
ominaisuus tai
kytttarkoitus
Oil type,
ISOVG
-luokka
class
ljyTuotenimike
yhti
Product name
Oil
company
property or
application
Mineraaliljyt
Mineral oils
Viskositeetti
Viscosity
Jhmepiste
Pour
point
cSt/
40 C
cSt/
100 C
Shell
Teboil
Omala 220
Pressure Oil 220
220
220
19,4
18,0
-21,0
-18,0
Castrol
Mobil
Neste
Shell
Teboil
Castrol
Mobil
Neste
Shell
Teboil
Alpha SP 320
Mobilgear 632
Vaihteisto 320 EP
Omala 320
Pressure Oil 320
Alpha SP 460
Mobilgear 634
Vaihteisto 460 EP
Omala 460
Preesure Oil 460
320
320
320
320
320
460
460
460
460
460
24,0
24,5
24,2
25,0
23,0
30,5
29,9
31,1
30,8
29,0
-21,0
-18,0
-12,0
-15,0
-15,0
-6,0
-12,0
-15,0
-12,0
-12,0
680
Castrol
Neste
Shell
Mobil
Alpha SP 680
Vaihteisto 680 EP
Omala 680
Mobilgear 636
680
680
680
680
37,6
41,7
38,0
39,2
-6,0
-12,0
-9,0
-9,0
1000
Castrol
Molub-Alloy 300S/1000
1000
50,0
-12,0
1500
Castrol
Molub-Alloy 1500
1500
64,0
-9,0
320
460
Ryhm
Group
MO15MI
ljytyyppi,
ominaisuus tai
kytttarkoitus
Oil type,
ISOVG
-luokka
class
ljyTuotenimike
yhti
Product name
Oil
company
property or
application
Mineraaliljyt, mikropittingluokitellut
Mineral oils, micropitting graded
Viskositeetti
Viscosity
Jhmepiste
Pour
point
cSt/
40 C
cSt/
100 C
68
Castrol
Mobil
Tribol 1100/68
Mobilgear XMP 68
68
68
8,9
8,6
-33,0
-27,0
100
Castrol
Mobil
Tribol 1100/100
Mobilgear XMP 100
100
100
11,2
11,1
-30,0
-27,0
150
Castrol
Mobil
Tribol 1100/150
Mobilgear XMP 150
150
150
14,7
14,6
-27,0
-27,0
220
Castrol
Mobil
Neste
Shell
Tribol 1100/220
Mobilgear XMP 220
Vaihteisto 220 EP
Omala F 220
220
220
220
220
18,9
18,8
19,0
19,4
-24,0
-24,0
-24,0
-18,0
320
Castrol
Mobil
Neste
Shell
Tribol 1100/320
Mobilgear XMP 320
Vaihteisto 320 EP
Omala F 320
320
320
320
320
23,6
34,1
24,2
25,0
-21,0
-18,0
-12,0
-15,0
460
Castrol
Mobil
Neste
Tribol 1100/460
Mobilgear XMP 460
Vaihteisto 460 EP
460
460
460
29,9
30,6
31,1
-21,0
-12,0
-15,0
680
Castrol
Mobil
Neste
Tribol 1100/680
Mobilgear XMP 680
Vaihteisto 680 EP
680
680
680
35,9
36,9
41,7
-18,0
-9,0
-12,0
1000
Castrol
Tribol 1100/1000
1000
42,7
-18,0
1500
Castrol
Tribol 1100/1500
1500
54,7
-15,0
Ryhm
Group
MO20
MO20MI
ljytyyppi,
ominaisuus tai
kytttarkoitus
Oil type,
ISOVG
-luokka
class
ljyTuotenimike
yhti
Product name
Oil
company
property or
application
HYDRAULILJYT HYDRAULIC OILS
Mineraaliljyt
Mineral oils
Jhmepiste
Pour
point
cSt/
40 C
cSt/
100 C
46
Castrol
Castrol
Esso
Mobil
Neste
Neste
Shell
Shell
Teboil
Hyspin AWS 46
Hyspin VG 46 SS
Nuto H 46
DTE 25
Paine 46
Paine 46 ZF
Tellus S 46
Tellus DO 46
Larita Oil 46
46
46
46
44
46
46
46
46
46
6,7
7,0
6,7
6,6
7,2
7,2
6,9
6,8
6,9
-21,0
-18,0
-24,0
-27,0
-30,0
-24,0
-30,0
-27,0
-36,0
68
Castrol
Esso
Mobil
Neste
Shell
Shell
Teboil
Hyspin AWS 68
Nuto H 68
DTE 26
Paine 68
Tellus S 68
Tellus DO 68
Larita Oil 68
68
68
71
68
68
68
68
8,6
8,5
8,5
9,4
8,9
8,7
8,8
-21,0
-18,0
-21,0
-30,0
-30,0
-24,0
-33,0
Sinkitn/Zinc free
Sinkitn/Zinc free
Sinkitn/Zinc free
Sinkitn/Zinc free
Puhdist.lisaine/Purifying detergent
Viskositeetti
Viscosity
Ryhm
Group
MO20MI
ljytyyppi,
ominaisuus tai
kytttarkoitus
Oil type,
ISOVG
-luokka
class
ljyTuotenimike
yhti
Product name
Oil
company
property or
application
Mineraaliljyt, korkea VI
Mineral oils, high VI
68
100
150
Viskositeetti
Viscosity
Jhmepiste
Pour
point
cSt/
40 C
cSt/
100 C
Castrol
Esso
Mobil
Neste
Shell
Shell
Teboil
Castrol
Esso
Mobil
Shell
Teboil
Hyspin AWH-M 68
Univis N 68
DTE 16M
Hydrauli 68
Tellus T 68
Tellus TX 68
Hydraulic Oil 68 S
Hyspin AWH-M 100
Univis N 100
DTE 18M
Tellus T 100
Hydraulic Oil 100
68
68
68
68
68
68
68
100
100
100
100
100
10,9
11,0
10,0
11,1
10,9
11,4
11,1
13,2
14,5
12,8
11,3
14,1
-39,0
-42,0
-45,0
-39,0
-36,0
-39,0
-48,0
-30,0
-42,0
-37,0
-24,0
-36,0
Castrol
Mobil
Hyspin AWH-M 150

DTE 19M
150
150
15,0
16,5
-30,0
-36,0
STOA018707_01 EN / ES
Noise level specification / Especificaciones
sobre el nivel de ruido
Erkki Lindberg
03.03.14
OptiSlush HP-series
Sound pressure level, Lp in dB(A) at 1 meter distance, on load.

Sound power level Lw = Lp + Lw.
Measurements and calculations were done according to ISO 3746 standard.
Nivel de presin acstica, Lp en dB(A) a 1 metro de distancia bajo carga.

Nivel de potencia acstica Lw = Lp + Lw.
Las medidas y los clculos se han realizado de acuerdo con el estndar ISO 3746.
The values are typical values and may change according to the machines position and environment of
the equipment.
Los valores indicados son valores tpicos y pueden variar en funcin de la posicin de la mquina y el entorno
del equipo.
Modelo
Lp
Lw
HP-24
92
16
HP-33
92
17
HP-42
92
17
HP-50
92
18
HP-63
92
18
HP-77
92
18
HP_STOA018707_01_EN_ES.doc
Tapio Marjamki
10.09.2015
INSTALLATION INSTRUCTION
1
INSTALLATION INSTRUCTION ............................................................................1

1.1
Safety during Installation ..............................................................................1
1.2
Installation ....................................................................................................2
1.2.1
Installing Vat and Chutes ................................................................2
1.2.2
Installing Rotor Unit ........................................................................4
1.3
Tightening Torques ......................................................................................6
PREVENTIVE MAINTENANCE AND LUBRICATION ............................................8

2.1
Lubrication ...................................................................................................8
2.1.1
Lubrication Points ...........................................................................9
2.1.2
Lubrication Instrucions....................................................................9
2.2
Installation Inspection .................................................................................10
Horizontal Pulper
STOA007905A.05.EN
Tapio Marjamki
10.09.2015
1 INSTALLATION INSTRUCTION
1.1
Safety during Installation

This installation instruction includes warnings. On the basis of the type
of accident or damage that can result from the danger, the warnings are
divided into two groups:
Indicates that the danger in question could result in an accident or
death.
Indicates that the product, process, or environment could suffer
damage from the event in question.
All installation work must be carried out in accordance with general
conditions must be taken into account
The weight of the equipment or its parts is indicated
and/or in the bill of material. Always ensure that the
marked on the lifting equipment is not exceeded.
instructions for other equipment and components that
equipment.
in the drawing
maximum load
Also read the
come with this
When installing a chute section, be careful with the components sharp

edges.
Handling and disposal of substances used during transport and
installation (e.g., sealants, oils, glues, paints, chemicals) must be done
in accordance with the instructions in operational safety bulletins, plantspecific waste disposal instructions, and current local legislation.
Horizontal Pulper
STOA007905A.05.EN
Tapio Marjamki
1.2
10.09.2015
Installation
1.2.1 Installing Vat and Chutes

Delivery of the vat and chutes
The method of delivery depends on both the mode of transportation and
the installation site. A small vat is usually delivered in one piece. In
general, a vat is delivered in two separate pieces, in which case the vat
is horizontally divided into two pieces. The biggest vats can be delivered
in, for example, four pieces if necessary.
Installation of a vat delivered in one piece
Horizontal Pulper
STOA007905A.05.EN
Before delivering the vat to the installation site, check that the
anchor bolts in the foundation are installed according to the
measurements given in the installation drawing.
Transport the vat to the installation site.
Before lifting the vat onto the foundation, attach the foundation bolts
and nuts to the vat feet.
Adjust the vat in the longitudinal and latitudinal direction according
to the drawing.
Attach the nuts for the foundation bolts.
Adjust the vat in the vertical direction, ensuring that the flange of the
vat is exactly vertical.
Install the unattached pipe connections.
Perform grouting.
Tapio Marjamki
10.09.2015
Installation of a vat delivered in segments
Before delivering the pieces to the installation site, check that the
anchor bolts in the foundation are installed according to the
measurements given in the installation drawing.
Transport the pieces to the installation site.
Before lifting the pieces onto the foundation, fasten the foundation
bolts and nuts to the vat feet.
Using a screw joint, join the parts together, adjust vertical seams,
and tack weld them.
Weld the bottom stiffeners together, using extra balk if needed.
Install the bottom cover plate and weld the seams.
Adjust the vat in the longitudinal and latitudinal direction according

to the drawing.
Fasten the nuts to the foundation bolts.
Adjust the vat in the vertical direction, ensuring that the flange of the
vat is exactly vertical.
Install the unattached pipe connections.
Perform grouting.
Installing the pulper chutes
Horizontal Pulper
STOA007905A.05.EN
Different chute constructions are used in different installations, and

therefore installation must be made according to the special chute
installation drawing made for each pulper.
Before starting the installation work, a plan of installation order
should be made. The order can be different depending on the
construction of the chutes or other matters connected to the
installation.
Tapio Marjamki
10.09.2015
In general, the installation order is as follows:

1. Chutes
2. Any inside ventilation channel and shower pipes
3. Support balks for the front and rear chutes + the chutes
4. Outside shower pipes
The chute sections are usually welded together with lap seam, so
the inside part is completely firm. The outside part of the seam
should be tack welded firmly enough in order to avoid breakage.
When installing shower pipes, check that the showers are correctly
directed, for this will ensure the proper direction of the web. See
Customer Assembly Drawing.
Finally, any temporary welds must be ground off and the welded
seams cleaned.
1.2.2 Installing Rotor Unit

Delivery of the rotor unit
The rotor unit is delivered almost fully assembled. The equipment
delivered separately includes:
seal water rotameter
foundation screws with shims
coupling flanges with accessories (gear drives)
pulleys with belts (belt drives)
coupling/belt guard
motor (normally delivered by customer)
fastening equipment for the motor (normally delivered by customer)
Before the rotor is mounted, the pulper vat should be permanently

mounted in its place.
Before starting the mounting, make sure that the foundation is of the
correct height and furnished with an anchor plate.
Horizontal Pulper
STOA007905A.05.EN
Tapio Marjamki
10.09.2015
Installing the rotor unit

1. Mount the O-ring in the groove in the frame flange.
2. To make mounting easier, lubricate the O-ring and mounting
opening with silicon grease, for example.
3. Fasten the rotor unit as straight as possible in the mounting hoist
and move the rotor unit over the foundation.
4. Fasten the mounting plates with a screw attached to the frame.
Mount the adjusting screws.
5. Lower the unit into place. At the same time, place the mounting
beams under the mounting plates.
6. Adjust the height so that the unit meets the opening.
7. Draw the unit in its place with a pulley. Make sure that the O-ring is
not cut.
8. Make the final adjustment so that the shaft is exactly horizontal.
Using a feeler gauge, make sure that the rotor is exactly in the
center of the opening (metal must not touch metal).
9. Weld the mounting beams and mounting plates.
10. Now the unit is ready for grouting.
Installing the motor
1. Wash the protective grease from the rotor unit and motor shaft.
2. Heat the coupling halves to about 200C (392 F) and mount them
in place (gear drives).
3. The belt pulleys are fastened with conical sleeves. Mount the
wheels according to the appropriate instructions (belt drives).
4. Mount the motor with the mounting equipment delivered. In the case
of belt drive, the motor is mounted on tightening rails.
5. Carry out the motor alignment according to the instructions
delivered.
6. The final alignment is made after drying of the grout.
7. Mount the accessories, such as rotameters and the belt/coupling
guard.
Horizontal Pulper
STOA007905A.05.EN
Tapio Marjamki
1.3
10.09.2015
Tightening Torques
Follow the guidelines given in the following table, unless otherwise
specified in the customer-specific drawings.
TIGHTENING TORQUES
steel screws and nuts
EN ISO 4014, EN ISO 4017, EN ISO 3506-1, EN ISO 4762
EN ISO 4032, EN ISO 3506-2
Thread
8,8 Zne
A4 - 80
A4 70
Nm 1)
Nm 2)
Nm 2)
M5
5
5
3,7
M6
9
8
6
M8
24
22
16
M 10
45
42
31
M 12
85
75
55
M 14
125
115
85
M 16
200
175
130
M 20
400
350
265
M 22
525
465
348
M 24
675
600
450
M 27
980
795
M 30
1345
990
M 33
1820
1200
M 36
2350
1385
M 39
3000
1800
1) Dry
2) Primarily: Molykote 1000/Molykote HSC Plus
Substitute: e.g., Chesterton 785, Loctite 8155
Hirange (friction coefficient always < 0.20)
Horizontal Pulper
STOA007905A.05.EN
Tapio Marjamki
Thread
10.09.2015
TIGHTENING TORQUES
steel screws and nuts
ANSI 18, 2, 1, ANSI B 18,3
8,8
Zne 1)
A4 80 2)
Nm
Ft-lbs
Nm Ft - lbs
10
8
10
7
23
17
22
15
42
30
38
28
100
73
89
65
200
145
175
130
350
260
315
230
560
410
500
365
825
610
730
540
1640 1210
2850 2100
-
1 / 4 UNC
5 / 16 UNC
3 / 8 UNC
1 / 2 UNC
5 / 8 UNC
3 / 4 UNC
7 / 8 UNC
1 UNC
1 UNC
1 UNC
1) Dry
2) Primarily: Molykote 1000/Molykote HSC Plus
Substitute: e.g., Chesterton 785, Loctite 8155
Hirange (friction coefficient always < 0.20)
Horizontal Pulper
STOA007905A.05.EN
A4 70 2)
Nm Ft - lbs
7,5 5,2
16 11
28 21
66 48
131 97
236 172
375 273
547 405
1210 895
1680 1240
Tapio Marjamki
10.09.2015
2 PREVENTIVE MAINTENANCE AND LUBRICATION

The inspection and maintenance procedures and lubrication points
related to maintaining the equipment are presented in the Preventive
Maintenance Jobs table, see Appendices. No daily routines performed
by the production and/or mechanical maintenance personnel are
included in this table.
2.1
Lubrication
The industrial lubrication oils and greases needed for lubricating the
equipment are desrcibed in the tables below.
Industrial lubrication Greases

Code
Required Performance
Application and Other Quality

and Special Requirements
MG15SY-1,5
NLGI grade 1,5 (DIN 51818).
Multi-purpose grease.
Base oil: synthetic.
For high and low revolutions.
Viscosity 220...460 cSt / 40C

(ASTM D 445).
For high and low temperatures.
Operating temperature range 40... +200C.
Suitable for long-term and lifetime

lubrication.
Worked penetration 295...310

(DIN ISO 2137).
Suitable for central grease lubrication.
Water resistance +90C (DIN

51807 T.1).
Thickener type: lithium or lithium

complex.
Drop point > +180C (DIN ISO

2176).
Good corrosion resistance.
Pumpability C/C/C.
Good hot and cold water resistance.
Horizontal Pulper
STOA007905A.05.EN
Tapio Marjamki
10.09.2015
2.1.1 Lubrication Points

Belt driven pulper
Figure 1
Lubrication points of a belt driven pulper (STOA017995)
1. Bearing, rotor side

2. Bearing, drive side
3. Motor bearings (motor manufacturers instructions)
2.1.2 Lubrication Instrucions

Belt driven pulper
Grease for Initial Installation
The bearing assembly has been lubricated prior to delivery, but the first
re-lubrication must be performed before commissioning. The grease for
initial installation is Mobilith SHC PM 460, synthetic base oil thickened
by a lithium complex.
Horizontal Pulper
STOA007905A.05.EN
Tapio Marjamki
10.09.2015
10
Grease for Re-lubrication

The grease used in re-lubrication must be compatible with that used at
initial installation. Grade MG15SY-1,5 grease is recommended for the
pulper bearings in all process conditions.
Gear driven pulper

See gear documentation for manufacturers instructions on the points to
be lubricated, lubrication intervals and lubrication oils and greases.
2.2
Installation Inspection
Finally, an installation inspection is to be performed. During installation
inspection should be paid special attention to the operational safety of
the equipment. All guards must be properly attached so that they cannot
be removed without using tools. All electrical work must be checked by
a qualified electrician.
Horizontal Pulper
STOA007905A.05.EN

En Stoa110077 00 HP50G2

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En Stoa110077 00 HP50G2

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Pulper

COPYRIGHT NOTICE AND LIABILITY DISCLAIMER

Valmet Technologies, Inc., 2015. All rights reserved.

Valmet (China) Co., Ltd.

Valmet Paper Technology

Design and Operating Principle

Service and Spare Parts

GENERAL SAFETY INSTRUCTIONS ................................................................................. 1

General Safety Instructions ......................................................................... 1

General Safety Equipment .......................................................................... 2

Working Safety ............................................................................................ 3

Equipment Disassembly and Disposal of the Parts .................................... 5

SAFETY DURING INSTALLATION ....................................................................................... 7

Safety during Installation .............................................................................. 7

SAFETY DURING OPERATION ........................................................................................... 9

Safety during Operation ............................................................................... 9

SAFETY DURING MAINTENANCE .................................................................................... 11

Safety during Maintenance ......................................................................... 11

Indicates that the danger in question could result in an accident or

In the interest of safety, Valmet Technologies, as the manufacturer of

The owner of the equipment makes the safety instructions

The personnel operating, maintaining and monitoring the

The operating, maintenance and monitoring personnel possess

The operating, maintenance and monitoring personnel comply

The owner of the equipment is responsible for supervising that

The guards must not be removed while the equipment is running. If

Automation System Safety

Warnings and Guides

Hazard caused by High-Pressure Fluid or Steam

Slipping, Tripping and Falling

These hazards must be particularly considered in connection with such

Harmful Fluids, Gases and other Discharges

Follow the manufacturers instructions for replacing parts and their

Lifting and transferring parts of the equipment must be performed in

the fastening and tightness of the pipe connections

the overflow connection in order to detect any blockage

the fastening and tightness of the sealing water connections

the fastening and tightness of the instrumentations air

the fastening of the rotor unit to the foundation

tightness of the gear fastenings in order to prevent possible oil

Due to noise generated by the gear, hearing protectors must be used

When working from a sampling or other hatch, be careful not to open

Start the pulpers exhaust pump

Start the ventilation

Open the manhole as soon as the stock level allows this

Lifting and transferring parts of the equipment must be performed in

Detach the motor from the mains in order to prevent accidental

Shut down the stock feed to the pulper

Follow instructions of the motor supplier when replacing the motor.

Use protective gloves and appropriate tools when handling melted or

When performing maintenance and repair work, the pulper must be

The equipments pneumatic system must be locked in case of

maintenance work inside the pulper is not allowed when the

the person responsible for operating the equipment has been

signs warning of the maintenance have been placed in

all of the pulpers feed conveyors have been locked to prevent

cover openings have been blocked so that objects cannot fall

supplied lifting tools must be used when lifting parts

general lifting equipment must be appropriate, inspected and

parts of the equipment are prevented from striking personnel or

If the maintenance requires going inside the pulper, in the interest of

harmful chemicals and bacteria have been rinsed out of the

electric tools used during maintenance have been inspected for