Installation and Maintenance Manual: Gearboxes WD
Contents
1. 44 2 9 REASONABLY EXPECTED INCORRECT WS ES epar dark t tint durante aevo d toni ar kin rane 44 3 TECHNICAL INFORMATION ab Seine tuli su Roa atia Soeur ane 46 3 1 GENERAL DESCRIPTION OF THE MACHINE 46 Ju CONDITIONS AND RESTRICTIONS OF USE x temen tia a Eun nae aund 46 3 3 TECHNICAGDATA Pc m 46 4 TRANSPORT HANDLING AND STORAGE sese 48 Sd HANDEINGITIE THE PAGS i orpipnn be ode cna peu DU 48 Qo p 49 4 3 STORAGE mE 50 5 INSTALLATION AND ASSEMBLY 0cccieiscoisccesssccrensaseccernstonendenedecortecnnneasrnesdintdcincusubtapnantdeeatdensnannane 51 5 1 INSTALLATION OF GEARBOXES IN SERIES WD RW i vcccosscsadscscnntanissssesnincatncengrnanceserasaminceartne 51 5 2 INSTALLATION OF GEARBOXES IN SERIES eskdanedebbebka Fides btau da 52 x9 GCGONNECHONTOIBRAK E metaren rnn i E aE Ea E E A a a a 53 6 START UP AND TESTING pinioane ai leri aa bri Taa 54 T CUBRICATION em 55 FA YPE OF LUBRICATION auna 55 pc Ea tpe m 55 SOIL FILLING AND LEVEL CHECKING irainei 56 rg PEELING PROCEDURE er e a of Gearboxes with rotating housing in series WD RW EH 37 din2. BP Energol GR XP Enersyn EPX Enersyn HTX CASTROL Alpha SP Alphasyn EP Alphasyn PG CHEVRON Ultra Gear Tegra Synthetic HiPerSYN DEA Falcon CLP ELF Reductelf EIf Syntherma EIf Syntherma ESSO Spartan EP Spartan S EP Glycolube FINA Giran IP Mellana Telesia Oil KL BER Kluberoil GEM 1 Klubersynt EG4 Klubersynt GH6 MOBIL Mobilgear XMP Mobilgear SHC Glygoile OPTIMOL Ultra Q8 Goya EI Greco EI Greco SHELL Omala 52 G Omala S4 GX Omala S4 WE TOTAL Carter EP Carter SH Carter SY Lubricants for the food industry Manufacturer Gear oil AGIP Rocol Foodlube Hi Torque ESSO Gear Oil FM KL BER Kl beroil 4 HU1 N MOBIL DTE FM SHELL Cassida Fluid GL 7 3 OIL FILLING AND LEVEL CHECKING Each gearbox has oil level filling and drainage caps Cap configuration may be seen in the dimensional drawing Gearboxes with rotating housing in series WD RW EH 7 Lubrication 56 dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual 7 4 FILLING PROCEDURE When being filled the gearbox must be in the exact position that it will be in when operating Ensure the power supply is disconnected when filling 7 4 1 Filling series WD gearboxes e Horizontal position and level with rod Unscrew the cap with the rod in the top part of the level kit Pour the appropriate amount of oil through the corresponding hole see point 7 5 Use the cap with the rod to check when the l
3. Annex 1 oil weights and quantities dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual ANNEX 2 TIGHTENING TORQUE FOR LARGE THREAD SCREWS AND CAPS Class 8 8 Class 10 9 Class 12 9 Screw thread Torque Nm Torque Nm Torque Nm M10 44 62 74 M12 77 108 130 M14 122 172 207 M16 191 269 323 M18 263 370 444 M20 373 525 630 M22 507 714 857 M24 645 908 1090 M27 944 1330 1590 M30 1280 1800 2160 M33 1740 2460 2940 M36 2240 3150 3780 M39 2900 4080 4890 M42 3580 5040 6050 Cap thread Torque Nm 1 8 5 1 4 7 3 8 7 1 2 14 3 4 14 1 25 OVERHAUL INDEX R 0 Gearboxes with rotating housing in series WD RW EH Annex 2 tightening torque for large thread screws and caps 67
4. standards in force in the country where the disposal takes place For countries in the European Community with the issue of Commission decision 2000 532 EC subsequently amended by decisions 2001 118 EC and 2001 19 EC from the Commission and 2001 573 EC from the Council new community provisions have been introduced regarding waste classification they have undergone checks and tests and or replacements by specialist personnel Do not attempt to reuse parts or components which may seem to be complete after and declared no longer fit for use Gearboxes with rotating housing in series WD RW EH 65 10 Dismantling and disposal dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual ANNEX 1 OIL WEIGHTS AND QUANTITIES Liters n d WD Ip WD 1023 150 3 5 WD 1523 200 4 5 WD 2003 225 5 WD 2523 275 6 WD 3003 350 8 WD 4803 455 10 WD 8003 660 15 WD16004 1100 30 Liters E RW on RW 512 75 2 RW 513 85 2 3 RW 612 90 2 3 RW 613 100 2 5 RW 812 130 3 RW 813 140 3 5 RW 1022 145 4 RW 1023 155 4 2 RW 1532 195 5 RW 2522 275 7 Liters i EH EH 10000 SC 410 6 5 EH 13000 SC 440 7 5 EH 16000 SC 680 11 5 EH 22000 SC 880 15 EH 26000 SC 980 18 EH 33000 SC 1280 21 EH 33000 W 1280 25 EH 45000 SC 1560 24 EH 60000 SC 3120 50 EH 70000 SC 3120 50 Gearboxes with rotating housing in series WD RW EH 66
5. the motor switched on the slow shaft of the gearbox does not turn Motor not fitted correctly Check the coupling between the motor and the gearbox Jammed brake Check the hydraulic circuit Internal problem Contact the DINAMIC OIL S p A technical assistance service Parking brake will not release Lack of pressure Check the hydraulic circuit Internal problem Contact the DINAMIC OIL S p A technical assistance service Parking brake will not apply Residual pressure in brake Check the hydraulic circuit Worn plate Gearboxes with rotating housing in series WD RW EH 9 Breakdowns and solutions Contact the DINAMIC OIL S p A technical assistance service 64 dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual 10 DISMANTLING AND DISPOSAL Before scrapping the gearbox it needs to be rendered unusable and emptied of lubricant remembering that used oil has a serious impact on the environment The gearbox must be dismantled by expert operators adhering to the applicable laws on occupational health and safety and environmental protection Non biodegradable products must not be disposed of into the environment under any circumstances Disassembled and disused gearboxes produce the following waste iron aluminium cast iron lubricant plastic copper and bronze The gearbox parts must be disposed of according to the selective sorting
6. use they must be operated as described in this manual and in accordance with the other technical documents data sheets catalogues etc The manufacturer has designed these units for industrial uses Any use application and or installation beyond those described in this manual and other technical documents data sheets catalogues etc must be agreed approved by the DINAMIC OIL S p A technical assistance service For the purposes of Directive 2006 42 EC on machinery the gearbox is considered partly completed machinery which will be fitted onto other machines and or installations The gearbox must not be incorporated into them and used until all safety issues have been resolved and itis not permitted to start up the final product for its intended use until it has been verified as compliant with Directive 2006 42 EC on machinery The customer must accept responsibility for compliance with the Directive 2006 42 EC on machinery and any other community directive relating to safety of machinery Planetary gearboxes can pose hazards to persons animals and material goods For this reason all handling transport fitting installation start up and support operations must only be carried out by personnel who are trained qualified and authorised to carry out the task and who are aware of the potential hazards Personnel must have the required qualifications for the task to be carried out and have attested experience in handling transporting f
7. 4 10 DISMANTLING AND DISPOSAL seen nne nnne n nnne nen nennen 65 ANNEX 1 OIL WEIGHTS AND QUANTITIES dti item Eit aee npa a tuy pa udbE Dod uc Et oko eana SER anche n qe teta bes 66 ANNEX 2 TIGHTENING TORQUE FOR LARGE THREAD SCREWS AND 5 67 Gearboxes with rotating housing in series WD RW EH 38 dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual 1 GENERAL INFORMATION The instructions contained in this manual are an integral part of the planetary gearboxes range for winches required information for purchasers and engineers is included on the dimensional drawings and data sheets provided in the proposal In the absence of such information the data provided in the catalogue should be considered correct In addition to adhering to rules of best practice in construction this information should be carefully read and stringently applied If in any doubt contact the DINAMIC OIL S p A technical assistance service These installation instructions have been designed for the safety of all persons carrying out assembly transport handling installation start up and support on planetary gearboxes however any other technical or specific documentation from the order must also be followed There may be attachments to this manual The manual is relevant to the following units e Gearboxes with rotating housing To comply with their intended
8. E 7 4 3 Filling series EH wheel gearboxes e Horizontal position Position the gearbox as shown in the figure below Unscrew caps A and Fill with the appropriate amount of oil through the hole in cap B see point 7 5 adding oil until it comes out of the hole in cap A Tighten the caps again to the recommended torque see Annex 2 In the case of a cooling system oil enters and exits through caps C and D while cap E is used to open the brake Gearboxes with rotating housing in series WD RW EH 58 7 Lubrication dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual For information on filling in other assembly positions contact the Dinamic Oil Sales Technical Assistance Service 7 5 AMOUNT OF OIL Indicative oil amounts are given in Annex 1 of this manual These amounts are indicative only Refer to the level control instruments on the gearbox in order to fill with the correct amount of oil 7 6 BRAKE LUBRICATION Negative hydraulic brakes with multiple discs and a lubrication chamber are already lubricated 7 6 1 FW FY brakes without a free wheel for series WD gearboxes These are dry brakes requiring no lubrication 7 6 2 FW FY brakes with free wheel for series WD gearboxes Brakes of this type have a lubrication chamber filled with ISO VG 32 hydraulic oil FX about 0 4 liters FY
9. Italy Headquarters Installation use mania dinamicoil eee ee Manuale Installazione Uso e Manutenzione riduttori carcassa rotante serie WD RW EH A Installation use and maintenance manual Gearboxes with rotating housing in series WD RW EH p EE Installations Gebrauchs und Wartungshandbuch Getriebe mit drehbarem Geh use in den Serien WD RW EH dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual INDEX T GENERAL INFORMATION ME PT SUD QUEMA 39 1 1 JERMSANESTMBULS pute ten e E MEE M MN EH 40 1 sc w 40 VES Bd ze ipe T 42 2 1 GENERAL SAFETY 42 2 2 SAFETY WARNINGS FOR HANDLING WHEN UNPACKING AND TRANSPORTING 42 2 3 SAFETY WARNINGS FOR USE AND OPERATION 5 53 a Rte tak RE Ek k p pERIMEMR FEM ENRUE ERE DUO data ku 42 2 4 SAFETY WARNINGS FOR INSTALLATION AND ASSEMBLY eene 43 2 5 SAFETY WARNINGS REGARDING ENVIRONMENTAL IMPACT eee 43 2 6 SAFETY AND INFORMATION NOTES texsxunsuekXzin ptu rsa ie Ph pana nnb ERR sb ap ca M detr 43 2 7 MANUFACTURER S LIABIDII Y oap petto ad Em EEEE 43 End RR UM IIl
10. WD RW EH 40 1 General information dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual A Take the utmost care when unpacking The gearboxes are supplied as follows e Arranged for installation in the assembly position stated when the order was placed e Without lubrication oil unless otherwise provided for by contractual arrangement e Painted externally with a red water based anti oxidising undercoat unless otherwise provided for by contract This protective coating is suitable for normal industrial environments even outdoors and allows further finishing coats of synthetic paint to be applied e The external machined parts of the gearbox such as the outside of the shafts the resting surfaces and centring units as well as the internal kinematic mechanisms require protection with anti oxidising oil Gearboxes with rotating housing in series WD RW EH 41 1 General information dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual 2 SAFETY INFORMATION Follow the simple instructions given in the relevant parts of the manual to reduce or eliminate risk situations 2 1 GENERAL SAFETY WARNINGS e These safety warnings apply to all types of gearbox wheels and other products made by DINAMIC OIL S p A e Safety warnings contained in the other chapters of this manual must also be observed e The safety warnings must be observed at every stage of the p
11. about O 8 liters 7 6 3 F9 brake with or without free wheel for series RW gearboxes This type of brake uses lubricant oil from the gearbox 7 6 4 F5 brake for series RW gearboxes This type of brake has a lubrication chamber filled with ISO VG 32 mineral oil about 0 1 liters 7 6 5 Brake for series EH gearbox This type of brake is integrated into the gearbox and uses the gearbox s own lubricant oil Gearboxes with rotating housing in series WD RW EH 59 7 Lubrication dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual 8 SUPPORT AND SERVICING e Servicing must be performed by expert authorised personnel adhering to the work and environmental safety standards in force Servicing on the gearbox must be performed with the power supply disconnected and the gearbox taken out of service to prevent it from being switched on accidentally The oil temperature must be at a safe level so as not to burn the operators The instructions given in this paragraph must be followed ensuring the gearbox is operational and that required levels of safety are met Only use original spare parts refer to the Spare Parts List for the gearbox in question e Use lubricants that are recommended by the manufacturer e After any servicing work always replace the seal washers and any lubricating oil e Carry out the routine servicing work as set out by the manufacturer e Use additional lighting if carr
12. admissible torque will be exceeded Gearboxes with rotating housing in series WD RW EH 52 5 Installation and assembly dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual Further important operational information is given in the dimensional drawings data sheets or in any specific documentation for the order 5 3 CONNECTION TO BRAKE In the case of gearboxes prepared for hydraulic motors and complete with brakes at the time of installation use an appropriate tube to connect the hydraulic circuit with the command opening on the body of the brake identifiable by its red cap Gearboxes with rotating housing in series WD RW EH 53 5 Installation and assembly dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual 6 START UP AND TESTING A Improper start up can damage the gearbox At the factory the gearbox s seals are checked for leaks and a vacuum test is performed Check the following before start up e That the machinery incorporating the gearbox is compliant with Directive 2006 42 EC on machinery and any other applicable safety standards in force e That all rotating parts are sufficiently protected in compliance with Directive 2006 42 EC on machinery e That any risks to the safety of persons animals or objects are resolved e That the assembly position is the same as the one shown and required on the identification plate e That the oil leve
13. amic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual ON 57 re iccini eccuse ict area 58 1 4 3 Filling series EH wheel gearboxes Tw 58 TOAMOUNT OF s em ERE 59 BRAKE CUBRICAMION eee 59 7 6 1 FW FY brakes without a free wheel for series WD 65 59 7 6 2 FW FY brakes with free wheel for series WD 65 59 7 6 3 F9 brake with or without free wheel for series RW 6 59 7 6 4 F5 brake for series RW gearboxes 59 7 6 5 Brake tor senes EH gearDOXuucas iacet i et Has x echan bt a a da ar ru EISE IN MR Us aud idaki 59 8 SUPPORT AND SERVICING ssssssssssssseeneeeeereeenn nm rennen nennen nen hnnnnes nnne n nnns nnne 60 NIS NU co M 60 8 2 SUPPLEMENTARY SERVICING s atten dn EROR udis qn a EE 61 fecti 62 8 3 1 Oil replacement procedure for RW WD sssssssssssseeeeeeeeeeeenenenn nennen nnne nnns 62 5 908 On CHV VIII POG OC TOF EM cec date e 63 9 BREAKDOWNS AND SOLUTIONS 2 PR Rx RR nna pr peer icd 6
14. be washed with a suitable liquid before filling with new oil Oils with different viscosity or different brands of oil should not be mixed In particular synthetic and mineral oils must never be mixed together Once the machine is in operation periodically check lubricant level and top up if necessary HL Do not release used oil into the environment Collect it and send it to authorised bodies for disposal in accordance with legislative provisions in force Empty the oil when the gearbox is warm but at a temperature not exceeding 40 45 C to prevent the risk of burns 8 3 1 Oil replacement procedure for RW WD e Place a container of appropriate size under the oil drainage cap e Unscrew the gearbox oil filling and drainage caps and let all the oil flow out s m e d n i Er Gearboxes with rotating housing in series WD RW EH 62 8 Support and servicing dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual e Wash the inside of the gearbox with a suitable liquid e Refill the gearbox with oil see point 7 4 8 3 2 Oil changing proce
15. d This operation requires special care and must be repeated after a few minutes of operation to make sure that the level is correct 7 2 SELECTING AN OIL Any mechanical transmission oil with EP additives in viscosity classes ISO VG220 to ISO VG320 under ISO 3448 can be used In special cases oils with different viscosities may be used In this case contact the DINAMIC OIL S p A technical assistance service The oil viscosity must be chosen to suit the room temperature and the gearbox s real operating temperature If the gearboxes must operate at very high ambient temperatures or with very large temperature excursions synthetic oil is recommended Lubricants are potentially harmful toxic substances to health always refer to the manufacturer s safety data sheets Do not release used oil into the environment Collect it and send it to authorised bodies for disposal in accordance with legislative provisions in force i Recommended viscosity ISO VG 3448 o 10 20 30 40 50 60 70 80 90 100 220 320 Gearboxes with rotating housing in series WD RW EH 55 7 Lubrication dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual Lubricants for general use Manufacturer Mineral oil Synthetic oil Polyalphaolefins Polyglycols PG PAO AGIP Blasia Blasia SX Blasia S ARAL Degol BG Degol GS
16. dure for EH e Position the gearbox as shown below e Place a container of appropriate size under oil drainage cap B e Unscrew drainage cap B and level cap A and let all the oil flow out e Wash the inside of the gearbox with a suitable liquid e Refill the gearbox with oil see point 7 4 Gearboxes with rotating housing in series WD RW EH 8 Support and servicing 63 dinamic oil Hoisting Solutions Power Transmission 9 BREAKDOWNS AND SOLUTIONS PROBLEM POSSIBLE CAUSE SOLUTION Installation Operation and Service Manual Excessive and or abnormal noise Internal problem Contact the DINAMIC OIL S p A technical assistance service Excessive vibration Gearbox not installed correctly Check the fastening Weak coupling structure Strengthen the structure Internal problem Contact the DINAMIC OIL S p A technical assistance service Seeping of lubricant from seals Seals worn or damaged Contact the DINAMIC OIL S p A technical assistance service Seals stiffened after prolonged time in storage Clean the area and check for seeping after a few hours of operation Damaged seats Restore the seats Excessive heat Lack of lubricating oil Apply lubricating oil High thermal power Contact the DINAMIC OIL S p A technical assistance service Insufficient lubrication Contact the DINAMIC OIL S p A technical assistance service With
17. elated problems of final regulations in accordance with Directive 2006 42 EC on machinery and other community directives e g ATEX For certain applications and to satisfy specific requirements the gearbox may be supplied in various structural forms and configurations including a range of accessories and optional modifications For all the technical and information and descriptions about these see the relevant sales catalogue It is the user s responsibility to use the gearbox in a correct manner complying with the warnings given in this manual 3 2 CONDITIONS AND RESTRICTIONS OF USE plate Any change to its installation position must be authorised by DINAMIC OIL The gearbox may only be installed in the position indicated on the identification S p A The recommended ambient temperature for use of standard gearboxes is min 15 C max 40 C Using the gearbox in aggressive environments in water or other liquids is not permitted unless agreed during the planning stage Unless duly marked ATEX plate the gearbox may not be used in potentially explosive atmospheres or where explosion proof equipment is required 3 3 TECHNICAL DATA The gearboxes are equipped with identification plates containing the unit s main technical and manufacturing information To interpret the product description A refer to the sales catalogue dinamicoil A Product description customer code A re
18. em from tipping over during handling Gearboxes with rotating housing in series WD RW EH 48 4 Transport handling and storage dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual Use accessories that comply with the directive on machinery and which are suitable for the weight to be lifted shown on the pack nm The weight gripping points and centre of gravity of the package to be handled are 4 2 HANDLING OF EQUIPMENT Before taking the gearbox out of its packaging prepare the relevant lifting accessories e g chains bands grills eyebolts etc or handle it using a pallet as a resting platform Take the utmost care when unpacking Use accessories that comply with the directive on machinery and which are suitable for the weight to be lifted Lift the gearbox taking care not to unbalance the load while moving Refrain from making abrupt movements and perform an initial slow manoeuvre to ensure that the load is balanced Move and lay down the gearbox in the area prepared for unloading HL The weight of the equipment to be lifted can be found in Annex 1 Gearboxes with rotating housing in series WD RW EH 49 4 Transport handling and storage dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual 4 3 STORAGE For correct storage of the units the following steps must be taken e For storage for over 2 months protect the co
19. es and the oil level kit of the gearbox if present to ensure that it can be accessed and used After completing installation check that the bending angle AH does not exceed 0 3 mm Gearboxes with rotating housing in series WD RW EH 51 5 Installation and assembly dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual AH On the side opposite to the gearbox on the winch structure there must be an axially free bearing to prevent the winch and the gearbox from being abnormally overloaded Anchor the gearbox to the structure with class 12 9 screws applying the tightening torque shown in Annex 2 Further important operational information is given in the dimensional drawings data sheets or in any specific documentation for the order 5 2 INSTALLATION OF GEARBOXES IN SERIES EH Make sure that the gearbox and the rigid structure to which it will be anchored are aligned and at right angles and that the surfaces to be joined are clean and not dented Anchor the gearbox to the structure of the machine with class 8 8 screws applying the tightening torque shown in Annex 2 Use class 10 9 or 12 9 screws when the applications will involve strong shocks frequent stopping and start up and or inversion of the direction of motion and when 70 of maximum
20. evel reaches the mid point Replace the cap with the rod tightening it to the recommended torque see Annex 2 e Horizontal position with visual level Unscrew the cap in the upper part of the level kit Pour the appropriate amount of oil through the corresponding hole see point 7 5 Use the clear tube mounted on this kit to check when the level reaches the mid point Replace the cap tightening it to the recommended torque see Annex 2 m a ell P D rom D q Gearboxes with rotating housing in series WD RW EH 57 7 Lubrication dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual 7 4 2 Filling series RW gearboxes e Horizontal position Unscrew the cap in the upper part of the flange Pour the appropriate amount of oil through the corresponding hole see point 7 5 Use the visual cap to check when the level reaches the mid point Replace the cap tightening it to the recommended torque see Annex 2 LT
21. h the information appearing in the data sheet 2 5 SAFETY WARNINGS REGARDING ENVIRONMENTAL IMPACT Units must be disposed of according to the environmental standards in force 2 6 SAFETY AND INFORMATION NOTICES Manufacturers applying the CE mark are responsible for applying safety and information notices 2 7 MANUFACTURER S LIABILITY The manufacturer will not be held liable in the event of e Gearbox use contrary to national laws on safety and safe working practices e Incorrect installation inadequate or incorrect observance of the instructions given in this manual e Electrical or hydraulic power supply failure for motor gears e Alteration or tampering e Operations performed by untrained unqualified or unauthorised personnel e Use applications or installations which do not comply with the instructions given the data sheets or this manual and have not been approved by DINAMIC OIL S p A The safety of the gearbox also relies upon strict observance of the instructions given in this manual and in particular e The gearbox must only be operated within its limitations of use see data sheets catalogues etc e Diligent routine servicing must always be carried out e Operators assigned to inspection and servicing must be sufficiently trained e Only original spare parts must be used e The configurations shown on the dimensional drawings and their instructions in the catalogue are the only ones permitted e Donotattemptto u
22. here required It is worth checking for the vibration noise and temperature of the gearbox while it is in operation When repairing top up the oil to the correct quantity 8 2 SUPPLEMENTARY SERVICING If agreed with the customer DINAMIC OIL S p A can supply suitable servicing procedures on a case by case basis DINAMIC OIL S p A prohibits the gearbox from being opened for any operations which are not defined as routine servicing DINAMIC OIL S p A will accept no liability for harm to objects or persons caused by operations carried out which do not fall within routine servicing and have not been agreed with the customer nm If in need of assistance contact the DINAMIC OIL S p A technical sales office Gearboxes with rotating housing in series WD RW EH 61 8 Support and servicing dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual 8 3 OIL REPLACEMENT Replace the lubricating oil according to the schedule set out in the following table or at least every 2 years Average operating duration according to oil type Oil type Operating temperture Synthetic oil Mineral oil Polyalphaolefins PAO Polyglycols PG 70 C 7000 hours 15000 hours 16000 hours 80 C 5000 hours 10000 hours 12000 hours 90 C 3000 hours 7500 hours 9000 hours To make it easier to empty the gearbox it is recommended that oil be changed when the gearbox is warm Internal parts must
23. is the responsibility of the customer 29 1 4 3 Special requirements for protective The choice of special requirements devices for protective devices is the responsibility of the customer 2 9 REASONABLY EXPECTED INCORRECT USES Incorrect use of the partly completed machinery is defined as a use different from that described in the instructions of this manual and the data sheets but which is reasonably expected human behaviour e Negligence of the operator in following the instructions contained in this manual e Instinctive reactions of the operator e Lack of concentration or carelessness during installation or servicing Gearboxes with rotating housing in series WD RW EH 44 2 Safety information dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual e Behaviour resulting from the pressure to keep the machine running under any circumstances Gearboxes with rotating housing in series WD RW EH 45 2 Safety information dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual 3 TECHNICAL INFORMATION 3 1 GENERAL DESCRIPTION OF THE MACHINE DINAMIC OIL S p A gearboxes have been designed and built to be incorporated into and powered by an electric or hydraulic motor in finished devices or systems for use in industrial sectors such as construction chemical mechanical agri foodstuff transport naval etc once the manufacturer has resolved all safety r
24. itting installing starting up and supporting planetary gearboxes see chapter 2 Safety information Gearboxes with rotating housing in series WD RW EH 39 1 General information dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual 1 1 TERMS AND SYMBOLS Warning Precautionary measures to be followed to ensure the safety of the operator and persons present in the working area animals and objects Operations which must only be performed by specialist authorised personnel Information Important information or procedures e T Specialist authorised personnel Customer Manufacturer of final machinery Manufacturer of final machinery Person fitting the partly completed machinery gearbox onto the final machinery Manufacturer Constructor DINAMIC OIL S p A A Oil fill Oil level Oil drain 1 2 SUPPLY Upon receipt of the gearbox check that it has not been damaged and that the item supplied matches the one ordered If any of these conditions is not fulfilled contact the DINAMIC OIL S p A sales technical assistance service immediately DINAMIC OIL S p A gearboxes are delivered in cases pallets carton pallets or simple cardboard boxes which are carefully organised to prevent movement The packaging material should be disposed of according to the national and international environmental standards in force Gearboxes with rotating housing in series
25. l is correct see point 7 4 e That there is no leakage of lubricant from the caps or washers e That when the gearbox is installed the anchorage screws are correctly housed and preloaded according to the table Annex 2 e That appropriate supply systems are used and that they are in good working order e That accessories are correctly fitted e That the direction of drum rotation is correct in the presence of a brake with a free wheel Further important operational information is given in the dimensional drawings data sheets or in any specific documentation for the order Before start up the machinery must undergo a functional documented test checking the following Temperature noise any abnormal events braking torque working order of accessories DINAMIC OIL S p A will not be held liable for damage caused to persons animals or objects if these tests are not carried out Gearboxes with rotating housing in series WD RW EH 54 6 Start up and testing dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual 7 LUBRICATION All DINAMIC OIL S p A gearboxes are supplied without lubricating oil The user is required to ensure the units are filled with the correct lubricants before putting the machine to use 7 1 TYPE OF LUBRICATION The gearboxes are oil bath lubricated They must be filled with oil before the gearbox is started visually checking that the right oil level has been reache
26. rbox operates correctly and safely All the installation operations must be performed to ensure maximum safety levels are guaranteed for both workers and third parties and that the gearbox operates correctly and safely Before installing the gearbox check that it is in the correct assembly position e Tampering with the gearbox and any of the accessories fitted during production is strictly prohibited e When any lifting and handling manoeuvres are carried out care must be taken to ensure the end of the shaft does not hit anything The relative hoisting straps and or eyebolts must be used suitably arranged and with hoisting means whose capacity is sufficient for the job e Welding operations on gearboxes are strictly prohibited without suitable protection e Any installation work or servicing must be carried out with the gearbox stationary therefore it is recommended that you ensure the gearbox cannot be switched on accidentally e In the event of connections involving the use of rotary parts such as shafts joint or pulleys with belts suitable accident prevention gear must be provided nm General information unless otherwise indicated on the relevant data sheets 5 1 INSTALLATION OF GEARBOXES IN SERIES WD RW Make sure that the gearbox and the rigid structure to which it will be anchored are aligned and at right angles and that the surfaces to be joined are clean and not dented Create slits in the structure aligned with the oil hol
27. re B Serial number week year identifying number C Product code Gearboxes with rotating housing in series WD RW EH 46 3 Technical information dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual The product description may be replaced by a code supplied by the customer information on it is no longer legible request a copy from the manufacturer and Ensure the identification plate is kept clean and clearly visible If even one item of replace it Gearboxes with rotating housing in series WD RW EH 47 3 Technical information dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual 4 TRANSPORT HANDLING AND STORAGE A e themselves and for persons in the vicinity Handling personnel must ensure that the required safety conditions are enforced for are for coverage only The cases have a load bearing structure on the bottom only while the other sides Those structures must therefore not be loaded 4 1 HANDLING OF THE PACK Before handling the pack prepare an appropriate area marked out and with a flat paved floor for unloading and placing the packs on the ground Move the pack using equipment e g forklift trucks cranes or transpallets appropriate for the type of pack in perfect working order taking into consideration the pack s size weight and centre of gravity Keep packs level to prevent th
28. roduct life cycles described in this manual transport handling packaging storage installation fitting start up operation servicing dismantling disposal e Failure to observe safety warnings can result in serious health risks and harm to objects and animals e f uncertain about safety warnings contact the DINAMIC OIL S p A sales technical assistance service e The personnel that this manual is addressed to must have attested experience and be authorised to carry out the operations e While performing the various operations personnel must also comply with national and international standards on safety and safe working practices e Installing and operating damaged units can pose serious safety risks e Serious harm can be caused to persons animals or objects as a result of improper use incorrect installation or use unauthorised removal of protection systems e The following risks arise during and after gearbox operation overheated parts moving parts parts under pressure 2 2 SAFETY WARNINGS FOR HANDLING WHEN UNPACKING AND TRANSPORTING See point 4 Transport handling and storage 2 3 SAFETY WARNINGS FOR USE AND OPERATION Gearboxes with rotating housing in series WD RW EH 42 2 Safety information dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual Comply with the information appearing in the data sheet 2 4 SAFETY WARNINGS FOR INSTALLATION AND ASSEMBLY Comply wit
29. se the gearbox in any other way than indicated by the provided instructions e The instructions given in this manual are supplementary to and do not replace the obligations of current safety legislation Gearboxes with rotating housing in series WD RW EH 43 2 Safety information dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual 2 8 RESIDUAL RISKS Residual risks are potential hazards which cannot be eliminated or can only be partially eliminated and which can harm the operator if incorrect methods or working practices are used Directive Note Description Remarks Annex I 19 1 3 4 Risks posed by surfaces edges or Correct and non hazardous angles positioning is the responsibility of the customer 22 1 3 7 Risks related to moving parts Protection of the operator from potential risks related to moving parts is the responsibility of the customer 23 1 3 8 Choice of protection against risks Protection of the operator from arising from moving parts potential risks related to moving parts is the responsibility of the customer 25 1 4 1 General requirements for guards The choice of requirements for and protective devices guards and protective devices is the responsibility of the customer 26 1 4 2 1 Fixed guards Fitting any fixed guards is the responsibility of the customer 28 1 4 2 3 Adjustable guards restricting Fitting any adjustable guards access restricting access
30. upling surfaces such as the flanges shafts and joints with a very thin layer of grease and or protective anti corrosion fluids e Store in a dry place with temperatures of between 5 C and 30 C e Always place wooden planks or a platform made of other materials between the unit and the floor to prevent direct contact e Do not stack the packages e Check the internal gears regularly by rotating the input shaft manually If the unit is fitted with negative lamellar brakes release the brake with a hydraulic pump or suchlike e Before starting up the unit we recommend you replace the washers of the static and rotary seals e For storage for over 6 months fill the gearbox with the same type of oil as the oil that is planned to be used when operational placing the vent cap in the upper part of the gearbox Before starting up fill the gearbox with the right amount of oil The static and rotary seals will begin to deteriorate after 6 months Gearboxes with rotating housing in series WD RW EH 50 4 Transport handling and storage dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual 5 INSTALLATION AND ASSEMBLY e T Gearboxes must be installed carefully and professionally by suitably suitably trained and technically skilled authorised personnel All the installation operations must be performed to ensure maximum safety levels are guaranteed for both workers and third parties and that the gea
31. ying out servicing work in dimly lit areas to ensure that it is performed safely e Take relevant precautions if carrying out servicing work in enclosed spaces to ensure that it is performed safely DINAMIC OIL S p A will not be held liable for damage caused to persons animals or objects if non original spare parts are used 8 1 ROUTINE SERVICING Scheduled routine servicing work is carried out on DINAMIC OIL S p A gearboxes by the operator nm Proper servicing improves performance longevity and safety After the first 150 hours of operation e Check there are no metal residues of abnormal size in the magnetic caps on the gearboxes e Clean the surfaces of the gearbox body and the air ventilation pathways to ensure correct heat dispersal e Replace lubricating oil see point 8 3 Gearboxes with rotating housing in series WD RW EH 60 8 Support and servicing dinamic oil Hoisting Solutions Power Transmission Installation Operation and Service Manual e Check the screws are all tight and tighten them where required After every 500 hours of operation e Check the oil levels with the relevant caps e Check for any leaks in the seals e Check the screws are all tight and tighten them where required After every 2000 hours of operation or at least every 12 months e Clean the surfaces of the gearbox body and the air ventilation pathways to ensure correct heat dispersal e Check the screws are all tight and tighten them w
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