Kalmar HG90V hoist gear manual

operating instructions
 M-SERIES Gear units and modular
accessories mounting, operating and maintenance

CONTENTS

1. BASIC MODULE (GEAR UNIT) DOCUMENTS PAGE

U307M Safety instructions 1.1.1

E102 Gear unit operation and maintenance 1.2.1
J103 Corrosion protection and storing 1.4
B201 Lubricating oils and greases 1.5.1
C202 Bath and splash lubrication 1.5.2
U215 Greasing, M-series 1.5.3
U306 Assembly report (for mounting and comissioning) 1.6

2. MODULAR ACCESSORIES DOCUMENTS PAGE

15004 Torque arm, M-series 2.3
62004 Oil heater, sensor, thermostat 2.5.4
 Safety Instructions
U307MENk

SAFETY INSTRUCTIONS
1. Manufacturer’s warrantee and buyer’s
responsibility
In order to ensure the validity of the warrantee the
buyer must ensure that storage, mounting, lubrication,
operation and maintenance of the gear unit is carried
out according to manufacturer´s instructions and
operating conditions are as specified in the contract.
2.2 Protection of rotating parts
Appropriate guards must be provided in order to ensure
that rotating parts cannot be touched, as required by
safety laws.
Mechanical guards must not be removed
when the gear unit is running.

Transport, installation, plumbing, operation, 2.3 Maintenance

maintenance, and inspections should be handled by
properly trained technicians; otherwise, injury or
damage to the machine may result.
The main contractor is responsible for the stability of
the drive system because he has control over the
affecting factors. The system of connected rotating
parts must be compatible, free from critical speed as
well as torsional and other type vibrations within the
specified speed range.
All maintenance procedures are to be carried out when
the gear unit is at rest.
When opening the inspection cover be careful that no
contamination gets in to the gear unit.
NOTE! The gear units are delivered without oil!
ATTENTION! Gear unit temperature must be at
ambient when completing any service work.

Manufacturer must be informed if a significant risk to 3. Markings in instructions

the environment or operating personnel may arise by
failure of the machine.
Electrical shock danger
Warrantee applies only when manufacturer´s
instructions are met.

2. Safety Mechanical danger

2.1 Temperature Important instruction

The outer surface of the gear unit when running
exceeds 60°C. The maximum temperature may rise as
high as 100°C, especially in splash and bath lubricated
gear units.

1.1.1 1(1)
 Corrosion protection and storing
J103ENk
CORROSION PROTECTION AND STORING

Table 1: Selection of corrosion protection and packing (chapter number)

transportation storage conditions transport conditions
and outdoors under indoors in heated Land/normal Sea transportation
storage time roof conditions transportation
6 months chapter 1 chapter 4 chapter 5
12 months chapter 1 chapter 4 chapter 5
24 months chapter 3 chapter 4 chapter 5
36 months chapter 3 chapter 4 chapter 5
separately
- chapter 2 chapter 4 -
agreeded

1. Standard protection
- interior protection: all gear units are test driven
without load using a protective oil (Neste Protective
oil 20W/30 ISO VG 100), which protects the gear
unit interior against corrosion. The gear unit is
delivered normally without oil!
- oil seals and seal surfaces are protected externally
by suitable grease
- unpainted surfaces including spare parts, are coated
with protective-coating Tectyl 506EH at works.
Solvent cleaning is required when mounting
- small spare parts and small loose parts e.g. bolts,
nuts, etc. are delivered wrapped in plastic anti-
corrosion VCI bags
- threaded holes and blind holes are sealed with
plastic plugs.
2. Short term protection
- interior protection as in chapter 1
- unpainted surfaces including spare parts, are
sprayed with CRC400 or RostOff –anti corrosion
spray at works
- threaded holes and blind holes are sealed with
plastic plugs
- customers is fully responsible for the corrosion
protection of the gear unit.
3. Long term protection
- interior protection: vapour phase inhibitor solvent
(VPI range) is sprayed through the inspection hole
by means of, for instance, a dye sprayer. The gear
units are delivered normally without oil!
- gear case is made as air tight as possible and free
from moisture. The breather is replaced by a plug.
The breather is tied to the gear unit with instructions
to put it back before start-up
- unpainted surfaces including spare parts, are coated
with protective-coating Tectyl 506EH at works.
Solvent cleaning is required when mounting
- threaded holes and blind holes are sealed with
plastic plugs.
- additionally, if VPI cannot be used or extra long term
protection is required manufacturer recommends the
customer to fill the gear unit with oil (see technical
specification for oil type) as high as possible but not
higher than breather or filling connection so that all
rotating parts including bearings are in oil.
• filling the gear unit with oil, applies only when all
seals are lip type seals
• during filling rotate the shafts (if possible) and
check for any oil leaks
Shell vapour phase inhibitors (VPI range) are volatile
solids, which when placed in enclosed spaces saturate
the surrounding air with their vapour. Gear unit internal
parts, when placed in this atmosphere are coated by an
invisible film of VPI, which protects them from corrosion.
The Shell VPI 260 is used as powder. The powders are
dissolved as 10% solution in methanol or ethanol.
The solvent is allowed to evaporate before the protected
gear unit is closed. In addition it must be emphasized
that methanol and ethanol are inflammable and
furthermore methanol is toxic. Care must therefore be
taken to protect operators from the vapours and also to
ensure that no open flames or sparks are presented
either during application or while the volatile solvent is
evaporating.
As a guidance one can use 0.5 l of a 10% solution per
one interior m³ of the gear unit.
The treatment must be repeated after 36 or 24 months
(acc. to table 1).

1.4 1(2)
 Corrosion protection and storing
J103ENk

4. Standard packing 7. Prior to commissioning

- all oils used for storage purposes must be drained
away
- breather is checked and fitted
- gear unit must be thoroughly cleaned out with
flushing oil
WHEN CLEANING TECTYL FROM SHAFT
ENDS DO NOT USE SOLVENTS WHICH
INCLUDE AROMATIC INGREDIENTS, AS
AROMATICS ARE HARMFUL FOR THE OIL
SEALS. ONLY AROMATIC-FREE ALIPHATIC
SOLVENTS ARE RECOMMENDED FOR
THIS PURPOSE.
WHEN CLEANING SHAFT ENDS, DO NOT
5. Seaworthy packing MECHANICALLY SCRAPE LIP SEALS AND
Seaworthy packing is recommended as mechanical SEAL SURFACES!
protection and protection against moisture during - Solvents for cleaning TECTYL 506EH are for
transport and storage. Closed plywood or plastic cover example:
with wooden framework. Neste LIAV 230
Esso Exxsol D 60
Exxon Exxsol D 60
Shell Shellsol D 70
- visual inspection of gear unit interior must be done
whilst rotating the output shaft (LSS) one full
revolution to verify if any corrosion exists.
- fill the gear unit to specified level with correct oil type
for operating conditions when gear unit is standing
still. See Instruction B201
- check that the pressure lubrication system (if
included) functions correctly.

6. Electrical equipment
Electrical equipment are protected by packing them
wrapped in anti-corrosion plastic film or bag, including a
silicasel bag.

1.4 2(2)
 Lubricating oils and greases for gear
units

LUBRICATING OILS AND GREASES FOR GEAR UNITS

1. Lubricating oils 3. Synthetic oils (PAO)
In addition to the required viscosity, the oil must have a
3.1 Lubricating oils standards
high viscosity index, and it must contain anti-wear, anti-
rust, anti-oxidant and anti-foam additives. Lubricating oils are grouped in ISO VG viscosity classes
Because of the high tooth contact pressures normally according to standards ISO 3448 and DIN 51519.
occurring in gear units, the oil must also contain ISO ISO 6743-6
pressure-resistant additives (EP additivies). If synthetic class designation
oils are selected due to operating temperatures or oil 100 ISO-L-CKT 100 to DIN or AGMA standards,
change intervals, manufacturer recommends 150 ISO-L-CKT 150 which are given as
polyalfaolefin based (PAO) oil. 220 ISO-L-CKT 220 minimum requirements for
320 ISO-L-CKT 320 mineral oils
460 ISO-L-CKT 460
2. Mineral oils Containing EP additives
3.2 Selection of viscosity
2.1 Lubricating oils standards
Nomograph (Fig. 2.) makes it possible to decide the
Lubricating oils are grouped in ISO VG viscosity classes required viscosity of the oil at operating temperature. The
according to standards ISO 3448 and DIN 51519. situation at cold starting should be checked before
selecting the oil group. Manufacturer decides the
ISO ISO 6743-6 DIN 51517-3 AGMA 9005-D94 required viscosity.
class designation designation designation
68 ISO-L-CKC DIN 51517- AGMA 2 EP 3.3 Selection of lubricating oil
68 CLP 68 Synthetic PAO oils (table 2.)
100 ISO-L-CKC DIN 51517- AGMA 3 EP For synthetic PAO oil there is a separate plate with oil
100 CLP 100 recommendations. Normally the same oils is used
150 ISO-L-CKC DIN 51517- AGMA 4 EP throughout the year.
150 CLP 150
220 ISO-L-CKC DIN 51517- AGMA 5 EP 4. Lubricating greases
220 CLP 220
320 ISO-L-CKC DIN 51517- AGMA 6 EP 4.1 Lubricating greases standards
320 CLP 320 Containing EP additives. Only to be used for greasing of
460 ISO-L-CKC DIN 51517- AGMA 7 EP bearings. Hardness class NLGI 2.
460 CLP 460 ISO 6743-9 designation DIN 51502 designation
680 ISO-L-CKC DIN 51517- AGMA 8 EP
680 CLP 680 ISO-L-XCCFB 2 DIN 51502 K2K-30
Containing EP additives Lithium soap based greases are recommended.
4.2 Selection of lubricating grease
2.2 Selection of viscosity For roller bearings the greases shown in table 3 are
Maximum operating temperature of mineral oil is 80°C. used. A plate with grease recommendations is attached
Nomograph (Fig 1.), makes it possible to decide the if the gear unit requires grease lubrication.
required viscosity of the oil at operating temperature. The
situation at cold starting should be checked before 5. Low speed gear units
selecting the oil group. Manufacturer decides the
When the pitch line velocity of the last stage is under
required viscosity.
1 m/s (n2 < 15 1/min), gear units operate in boundary
lubrication area.
2.3 Selection of lubricating oil
It is recommended to use:
Mineral oils (table 1.) - mineral oils with EP- and antiwear additives
If the gear unit is located out of doors, it is equipped with - running viscosity should be ≥ 200 cSt
two plates for recommended mineral oils, one for normal - the cleanliness of the oil and the oil sump must be
conditions (+5...+35°C) and one for cold conditions (- ensured.
30...+5°C). If the gear unit is provided with an oil heater,
it will in most cases function with the same oil in all
conditions.

1.4 1(8)
 Lubricating oils and greases for gear
units

Fig. 1 Mineral oils

-30 -28 -25 -20 -15 -10 -7 Pour point [°C]

3000

2000 Last centre distance [mm]:

68 150 320 680 Viscosity index
100 220 460 VI=90...100 ≤ 250
1000 1000
ISO VG
400
500

Operating viscosity 560

required by gear unit
800
200
150

100 100

Example:
40 Last centre distance = 400 mm
n2 =50 1/min
To=50°C
Viscosity Viscosity
Oil required
[cSt] ISO VG 320
[cSt]

10 10

-20 -10 0 10 20 30 40 50 60 70 80 90 100 1000 500 200 100 50 20 10 5 2 1

Gear unit’s operating temperature of oil To [°C] Low speed shaft (LSS) rotation speed n2 (1/min)

M-Series
Operating temperature of lubrication oil is determined as: Size / last centre distance:
- splash and bath lubricated gear units: temperature at oil surface 10 154
20 169
- in pressure lubricated gear units: temperature of oil going into the gear unit
30 205
40 235
Fig. 2 Synthetic PAO oils 50 269
60 311
70 354
-45 -40 -40 -35 -30 Pour point [°C] 80 388
3000
100 220 460
2000
150 320 Viscosity index
Synthetic oils are not
VI=140...180
allowed to use in
1000 ISO VG 1000
slowspeed gear units

Last centre distance [mm]

500
≤ 400
Operating viscosity
560
required by gear unit
200
150
800
100 100

Example:
Last centre distance = 400 mm
40 n2 =50 1/min
Viscosity
To=50°C
Viscosity [cSt]
Oil required
[cSt] ISO VG 320

10 10

-20 -10 0 10 20 30 40 50 60 70 80 90 100 1000 500 200 100 50 20 10 5 2 1

Gear unit’s operating temperature of oil To [°C] Low speed shaft (LSS) rotation speed n2 (1/min)

Operating temperature of lubrication oil is determined as:

- splash and bath lubricated gear units: temperature at oil surface
- in pressure lubricated gear units: temperature of oil going into the gear unit

1.4 2(8)
 Lubricating oils and greases for gear
units
Mineral oils (Table 1, part 1) *) Oils used for lubrication of separate back stops ISO VG 10/15
ISO VG AGMA Company Oil Viscosity Pour point
class Number cSt/40°C °C
BP Energol HPL 10 9.5 -45
Castrol Hyspin AWS 10 10 -39
Exxon NUTO H 15 14.5 -45
Esso NUTO H 15 14.5 -45
10/15 *) Gulf Gulf Harmony 10 AW 9.7 -48
Klüber Crucolan 10 10.5 -50
Kuwait Q8 Haydn 10 10 -30
Mobil Arctic Oil Light 13 -45
Neste Paine 10 9.5 -51
Nynäs Nynäs TD 10 EX 9.8 -54
Optimol Optimol Ultra 10 10 -40
Shell Tellus Oil R 10 10 -54
Statoil Hydraway HM 15 14.5 -45
Teboil Larita Oil 15 15 -48
Texaco Rando Oil HDZ 15 16 -60
Total Equivis ZS 15 15 -42
Aral Aral Degol BG 68 68 -30
Castrol Alpha SP 68 68 -21
BP Energol GR-XP 68 65 -30
Chevron EP Industrial Oil 68 68 -24
Esso Spartan EP 68 65 -33
Exxon Spartan EP 68 65 -33
Fuchs Renolin CLP 68 Plus 68 -27
Gulf Gulf EP Lubricant HD 68 65 -30
Klüber Klüberoil GEM 1-68 68 -25
Kuwait Q8 Goya 68 68 -30
68 2EP Mobil Mobilgear 626 64 -33
Mobil Mobilgear XMP 68 68 -27
Molub-Alloy MA-804 64 -32
Neste Vaihteisto 68 EP 65 -30
Nynäs Nynäs GL 68 68 -27
Optimol Optigear BM 68 68 -24
Petro Canada Ultima EP68 68 -36
Shell Omala Oil 68 68 -32
Statoil Loadway EP 68 65 -33
Teboil Pressure Oil 68 68 -27
Texaco Meropa 68 68 -30
Total Carter EP 68 68 -21
Tribol Tribol 1100-68 70 -34
Aral Aral Degol BG 100 100 -24
Castrol Alpha SP 100 100 -21
BP Energol GR-XP 100 96 -30
Chevron EP Industrial Oil 100 100 -15
Esso Spartan EP 100 95 -30
Exxon Spartan EP 100 95 -30
Fuchs Renolin CLP 100 Plus 99 -21
Gulf Gulf EP Lubricant HD 100 95 -30
Klüber Klüberoil GEM 1-100 100 -15
Kuwait Q8 Goya 100 -30
100 3EP Lubrication Eng. LE-606 100 -26
Mobil Mobilgear 627 100 -29
Mobil Mobilgear XMP 100 100 -27
Molub-Alloy MA-80 95 -29
Neste Vaihteisto 100 96 -30
Nynäs Nynäs GL 100 100 -24
Optimol Optigear BM 100 101 -24
Petro Canada Ultima EP100 101.4 -33
Shell Omala Oil 100 100 -32
Teboil Pressure Oil 100 100 -27
Texaco Meropa 100 91 -30
Total Carter EP 100 100 -21
Tribol Tribol 1100-100 100 -31

1.4 3(8)
 Lubricating oils and greases for gear
units

Mineral oils (Table 1, part 2)

ISO VG AGMA Company Oil Viscosity Pour point
class number cSt/40°C °C
Aral Aral Degol BG 150 150 -24
Castrol Alpha SP 150 150 -21
BP Energol GR-XP 150 140 -27
Chevron EP Industrial Oil 150 150 -15
Exxon Spartan EP 150 140 -27
Esso Spartan EP 150 140 -27
Fuchs Renolin CLP 150 Plus 148 -21
150 4EP Gulf Gulf EP Lubricant HD 150 146 -27
Klüber Klüberoil GEM 1-150 150 -15
Kendall NSMP 80W-90 148 -29
Kuwait Q8 Goya 150 150 -27
Mobil Mobilgear 629 142 -24
Mobil Mobilgear XMP 150 150 -27
Molub-Alloy MA-814 140 -26
Neste Vaihteisto 150 EP 145 -27
Nynäs Nynäs GL 150 150 -24
Optimol Optigear BM 150 157 -18
Petro Canada Ultima EP150 152 -27
Shell Omala Oil 150 150 -25
Statoil Loadway EP 150 140 -27
Teboil Pressure Oil 150 150 -21
Texaco Meropa 150 148 -24
Total Carter EP 150 150 -18
Tribol Tribol 1100-150 151 -28
Aral Aral Degol BG 220 220 -21
Castrol Alpha SP 220 220 -21
BP Energol GR-XP 220 210 -27
Chevron EP Industrial Oil 220 220 -12
Esso Spartan EP 220 225 -21
Exxon Spartan EP 220 225 -21
Fuchs Renolin CLP 220 Plus 223 -21
Gulf Gulf EP Lubricant HD 220 219 -15
Kendall Super Three Star 80W-140 262 -29
Klüber Klüberoil GEM 1-220 220 -15
Kuwait Q8 Goya 220 220 -21
220 5EP Lubrication Eng. LE-607 220 -23
Mobil Mobilgear 630 209 -23
Mobil Mobilgear XMP 220 220 -24
Molub-Alloy MA-90 217 -23
Neste Vaihteisto 220 EP 210 -27
Nynäs Nynäs GL 220 220 -18
Optimol Optigear BM 220 218 -16
Petro Canada Ultima EP220 223 -30
Shell Omala Oil 220 220 -18
Statoil Loadway EP 220 225 -21
Teboil Pressure Oil 220 220 -18
Texaco Meropa 220 217 -21
Total Carter EP 220 220 -12
Tribol Tribol 1100-220 222 -25

1.4 4(8)
 Lubricating oils and greases for gear
units

Mineral oils (Table 1, part 3)

ISO VG AGMA Company Oil Viscosity Pour point
class Number cSt/40°C °C
Aral Aral Degol BG 320 320 -18
BP Energol GR-XP 320 305 -24
Castrol Alpha SP 320 320 -21
Chevron EP Industrial Oil 320 320 -9
Esso Spartan EP 320 337 -18
Exxon Spartan EP 320 337 -18
Fuchs Renolin CLP 320 Plus 323 -21
Gulf Gulf EP Lubricant HD 320 300 -12
Klüber Klüberoil GEM 1-320 320 -15
Kuwait Q8 Goya 320 320 -18
Lubrication Eng. LE-605 300 -18
320 6EP Mobil Mobilgear 632 304 -18
Mobil Mobilgear XMP 320 320 -18
Molub-Alloy MA-690 320 -21
Neste Vaihteisto 320 EP 305 -24
Nynäs Nynäs GL 320 320 -12
Optimol Optigear BM 320 320 -15
Petro Canada Ultima EP320 320 -21
Shell Omala Oil 320 320 -15
Statoil Loadway EP 320 337 -18
Teboil Pressure Oil 320 320 -12
Texaco Meropa 320 320 -15
Total Carter EP 320 320 -12
Tribol Tribol 1100-320 317 -23
Aral Aral Degol BG 460 460 -18
Castrol Alpha SP 460 460 -6
BP Energol GR-XP 460 450 -15
Chevron EP Industrial Oil 460 460 -9
Esso Spartan EP 460 440 -12
Exxon Spartan EP 460 440 -12
Fuchs Renolin CLP 460 Plus 458 -12
Gulf Gulf EP Lubricant HD 460 480 -15
Klüber Klüberoil GEM 1-460 460 -15
Kuwait Q8 Goya 460 460 -15
Lubrication Eng. LE-608 460 -15
460 7EP Mobil Mobilgear 634 437 -18
Mobil Mobilgear XMP 460 460 -12
Molub-Alloy MA-140 447 -18
Neste Vaihteisto 460 EP 450 -15
Optimol Optigear BM 460 459 -12
Petro Canada Ultima EP460 452 -15
Shell Omala Oil 460 460 -9
Statoil Loadway EP 460 440 -12
Teboil Pressure Oil 460 460 -9
Texaco Meropa 460 447 -15
Total Carter EP 460 460 -12
Tribol Tribol 1100-460 464 -21

1.4 5(8)
 Lubricating oils and greases for gear
units

Mineral oils (Table 1, part 4)

ISO VG AGMA Company Oil Viscosity Pour point
class Number cSt/40°C °C
Aral Aral Degol BG 680 680 -12
Castrol Alpha SP 680 680 -6
BP Energol GR-XP 680 630 -9
Esso Spartan EP 680 645 -9
Exxon Spartan EP 680 645 -9
Fuchs Renolin CLP 680 Plus 671 -15
Gulf Gulf EP Lubricant HD 680 680 -12
Klüber Klüberoil GEM 1-680 680 -10
Kuwait Q8 Goya 680 680 -9
Lubrication Eng. LE-609 680 -12
680 8EP Mobil Mobilgear 636 646 -9
Mobil Mobilgear XMP 680 680 -9
Molub-Alloy MA-190 670 -15
Neste Vaihteisto 680 EP 630 -9
Optimol Optigear BM 680 670 -9
Petro Canada Ultima EP680 680 -9
Shell Omala Oil 680 680 -9
Statoil Loadway EP 680 645 -9
Texaco Meropa 680 690 -12
Total Carter EP 680 680 -9
Tribol Tribol 1100-680 673 -21

Synthetic polyalfaolefin-based (PAO) oil (Table 2, Part1 )

ISO VG AGMA Company Oil Viscos Pour
40 °C 100 °C °C
Esso Spartan Synthetic EP 100 100 14.8 -48
Exxon Spartan Synthetic EP 100 100 14.8 -48
Fuchs Renolin Unisyn CLP 100 104 14.9 -45
Kendall SHP Gear Lube 75W-90 136 17.5 -46
Klüber Klübersynth GEM 4-100 100 14 -45
100 3EP Neste Vaihteisto S 100 EP 98 16.5 -54
Nynäs Mereta 100 100 15 -45
Teboil Pressure Oil 100 S 105 14 -45
Tribol Tribol 1510-100 105 14.2 -49
Texaco Pinnacle EP 100 100 13.7 -54
Optimol Optigear Synthetic A 100 98 13.8 -45
Castrol Alphasyn EP 150 150 19.3 -48
Esso Spartan Synthetic EP 150 160 20.1 -42
Exxon Spartan Synthetic EP 150 160 20.1 -42
Fuchs Renolin Unisyn CLP 150 151 19.4 -39
Klüber Klübersynth GEM 4-150 150 19 -45
Lubrication Eng. LE-9920 150 25 -45
Mobil Mobilgear SHC XMP 150 150 21 -48
Neste Vaihteisto S 150 EP 155 21.5 -48
150 4EP Nynäs Mereta 150 150 20 -42
Teboil Teboil Sypres 150 20 -48
Total Carter EP/HT 150 150 19 -42
Tribol Tribol 1510-100 105 14.2 -49
Texaco Pinnacle EP 150 150 19.8 -50

1.4 6(8)
 Lubricating oils and greases for gear
units

Synthetic polyalfaolefin-based (PAO) oil (Table 2, Part2 )

ISO VG AGMA Company Oil Viscosity cSt Pour
class number point
Castrol Alphasyn EP 220 220 25.3 -42
Esso Spartan Synthetic EP 220 232 26.5 -39
Exxon Spartan Synthetic EP 220 232 26.5 -39
Fuchs Renolin Unisyn CLP 220 221 25.8 -36
Klüber Klübersynth GEM 4-220 220 26 -40
Mobil Mobilgear SHC XMP 220 220 28 -45
220 5EP Neste Vaihteisto S 220 EP 205 27 -45
Nynäs Mereta 220 220 26 -39
Optimol Optigear Synthetic A 220 210 23.5 -36
Shell Omala HD 220 220 26 -48
Teboil Teboil Sypres 220 25 -39
Total Carter EP/HT 220 220 25 -39
Tribol Tribol 1510-220 220 24.7 -41
Texaco Pinnacle EP 220 220 25.8 -48
Castrol Alphasyn EP 320 320 32.8 -36
Esso Spartan Synthetic EP 320 328 34.3 -36
Exxon Spartan Synthetic EP 320 328 34.3 -36
Fuchs Renolin Unisyn CLP 320 321 33.1 -33
Klüber Klübersynth GEM 4-320 320 38 -40
Mobil Mobilgear SHC XMP 320 320 37 -39
320 6EP Neste Vaihteisto S 320 EP 312 39 -39
Nynäs Mereta 320 320 34 -39
Optimol Optigear Synthetic A 320 290 30 -36
Shell Omala HD 320 320 34 -45
Teboil Teboil Sypres 320 33 -36
Total Carter EP/HT 320 320 33 -36
Tribol Tribol 1510-320 320 32.1 -38
Texaco Pinnacle EP 320 320 35.2 -39
Castrol Alphasyn EP 460 460 41.6 -36
Esso Spartan Synthetic EP 460 460 44.9 -33
Exxon Spartan Synthetic EP 460 460 44.9 -33
Fuchs Renolin Unisyn CLP 460 470 45.0 -33
Klüber Klübersynth GEM 4-460 460 48 -35
Mobil Mobilgear SHC XMP 460 460 48 -36
460 7EP Neste Vaihteisto S 460 EP 420 50 -36
Optimol Optigear Synthetic A 460 460 44 -35
Shell Omala HD 460 460 46 -43
Teboil Teboil Sypres 460 43 -30
Total Carter EP/HT 460 460 44 -33
Tribol Tribol 1510-460 445 40.1 -33
Texaco Pinnacle EP 460 460 47.2 -39

1.4 7(8)
 Lubricating oils and greases for gear
units

Roller bearing greases (Table 3)

Operating temperature -30°C...+100°C NLGI 2 (EP)
Company Grease Penetration Drop point
°C
Aral Aralub HLP2 265/295 180
BP Energrease LS-EPS 265/295 190
Castrol Spheerol EPL 2 265/295 175
Chevron Dura-Lith EP2 265/295 185
Elf Epexa EP2 265/295 180
Esso Beacon EP2 270/280 185
Exxon Beacon EP2 270/280 185
Gulf Gulf crown Grease 2 279/290 193
Kendall L-426 265/295 182
Klüber Centoplex EP2 265/295 190
Kuwait Q8 Rembrandt EP2 265/295 180
Lubrication Eng. LE-1275 280 232
Mobil Mobilux EP2 265/295 177
Molub-Alloy BRB-572 240/270 188
Neste Yleisrasva EP 2 265/295 198
Nynäs L42 265/295 190
Optimol Olista Longtime 2 265/295 180
Shell Alvania EP2 265/295 180
Statoil Uniway EP2 270/280 185
Teboil Universal EP 280/300 180
Texaco Multifak EP2 265/295 186
Total Multis EP2 265/295 190
Tribol Tribol 3030-2 265/295 182

Lubrication of hot (>80°C) running tapered roller bearings NLGI 2 (EP)

Company Grease Penetration Drop point
°C
Castrol LMX 265/295 260
Klüber Klüberplex BE 31-102
Molub-alloy MA-860-220-2
Optimol Longtime PD 2
Shell Albida Grease EP2 265/295 260
Teboil Universal EPS
Tribol Tribol 4020/220-2

Lubrication of slow running thrust bearings NLGI 0...1 (EP)

Company Grease Penetration Drop point
°C
Klüber Unimoly GL 402
Shell Albida Grease HD2 (NLGI 2) 265/295 260
Tribol Tribol 3020/1000-1
Voiteluopti Optimol Lontime PD1 310/340 180

1.4 8(8)

BATH AND SPLASH LUBRICATION OF GEAR UNIT
1. General
Lubrication, inspection and planned maintenance are of
prime importance to ensure trouble free running of gear
units.
2. Lubrication principles
The main purpose of lubrication is to provide a film of oil
which prevents direct metal to metal contact between the
working flanks and at the same time to lubricate the
bearings and seals. Other functions of lubrications are:
- to reduce friction
- to dissipate heat from tooth contact surfaces and
bearings
- to minimize wear
- to remove wear particles
- to inhibit corrosion
The thickness of the oil film depends on the surface
stress of the tooth, the oil viscosity and pitch line
velocity. If the oil film repeatedly breaks during operation,
the working flanks of the teeth will be damaged.
3. Lubrication methods
3.1 Choice of lubrication method
The lubrication method depends in the first place on the
pitch line velocity. Design, type and size of the gear unit
must also be considered.
The lubrication method depends on the pitch line velocity
(v) of the gear unit as follows:
- bath lubrication is normally used when v < 6 m/s
- with helical gearing splash lubrication is normally
used when v < 15 m/s
- with bevel gearing splash lubrication is normally
used when v < 12 m/s
3.2 Bath lubrication
When using bath lubrication, the oil level is raised so
that contact surfaces of teeth and roller elements of the
bearings are submerged in oil.
3.3 Splash lubrication
Splash lubrication is the most commonly used method.
The contact surfaces of teeth are lubricated by oil
splashing from the gears or oil carried by the teeth. The
bearings are also lubricated by oil splashing from the
gears. Normally a pitch line velocity of v = 15 m/s sets
the upper limit for splashing lubrication, but with special
arrangements, higher pitch line velocities are possible.
1.5.2
Bath and splash lubrication
C202ENk
3.4 Grease lubrication
Grease lubrication is used exclusively for bearings and
seals where the structure of the gear unit bearings
requires it.
4. Oil heating
If the gear unit is to be used out doors or in unheated
premises, manufacturer should be informed of this and of
the variation in temperature to be expected.
The oil heater consist of a resistor element which is
placed in the oil sump of the gear unit and screwed in to
the wall of the gear case. It can be removed for cleaning.
The oil must always first be drained from the gear unit.
The oil heater is controlled by thermostat. The
thermostat must be set so that it switches the oil heater
on when the oil temperature in the gear unit falls below
the pour point of oil.
The upper limit of the thermostat is set so that the oil
heater switches off at a temperature of 8-10°C higher
than the above-mentioned switch on temperature.
5. Oil cooling
The highest permitted operating temperature for a gear
unit, measured at the bearing housing, is normally
+90°C. In special cases a maximum temperature of
+100°C is allowed. If the mechanical running load of the
gear unit is higher than the thermal rating, the above
mentioned normal temperatures will be exceeded if oil
cooling is not provided.
The gear unit can be cooled by:
- by mounting one or two fans at the input shaft of the
gear unit
- incorporating a cooling water coil in the oil sump of
the gear unit
Santasalo does not recommend using a fan in dusty or
humid conditions.
A thermostat controlled water valve must be fitted on the
inlet side of the cooling water coil. The maximum
permitted water pressure is 1MPa (10 bar). The direction
of flow in the cooling water coil is not important.
The amount of water flow in the cooling water coil should
be regulated so that the temperature of the oil sump
does not rise above +80°C. There is a thermometer in
the oil sump for this purpose.
6. Cold start
In cold start situation the starting temperature has to be
higher than the pour point of the lubricating oil. Otherwise
the alternatives are:
- using different oils for summer and winter conditions
- using an oil heater
1(1)
 Greasing, M-series
U215ENk

GREASING, M-SERIES
1. Grease plates
The right grease type is marked in the grease plates. The amount of grease nipples is marked in the technical
specification.

2. Greasing of seals, horizontal gear units (M.P)

Douple lip seal with regreasable dust protection cover; dusty environment with abrasive particles
- grease between the seals (when assembling the seals)
- grease between outer seal and cover (greasing through the grease nipple, when the shaft is rotating)
- service greasing after every 3-4 months (through the grease nipple, when the shaft is rotating)

1.5.3 1(1)
 Assembly report
U306ENk

ASSEMBLY REPORT
GEAR UNIT: MANUF. NUMBER:
DRIVE:

Offset misalignment HSS LSS

motor machine

shaft shaft

Angular misalignment HSS LSS

0-position

motor machine

shaft shaft

o Checked distance of coupling flanges _________ mm

o Measured assembly temperature ________°C
o Height correction of shaft centres observed

o Grease filling completed / grease quality ___________________________

o Gear unit fastened to foundation with pins

Lubrication of gear unit o Gear unit connected to central lubrication

flow _______ l/min
Oil type: o mineral o Check of oil level height
o synthetic o Operation of pressure lubrication
o VG class _______________ _________°C _______bar

Date _______________________ Approved: _______________________________________________

1.6 1(1)
 Torque arm, M-series
15004ENk

TORQUE ARM, M-SERIES

1. Design of the torque arm Elastic washers (nylon) (pos. 705) are assembled under
Torque arm can be placed in either tension or the anchoring foot (pos. 702).
compression.
If the torque arm is of our supply it will be manufactured 2. Foundation for torque arm
according to figure 1. The torque arm will be delivered The foundation is made according to figure 1. The
with foundation screws, washers and nuts. The supporting girders are mounted horizontally in their fixed
supporting girders are not included in our delivery, but locations and embodied in the base concrete. The
recommendation for dimensioning the foundation is given mounting tolerance should be 10 mm in all directions.
in figure 1. The concrete base must be adequately reinforced and
When ordering the torque arm, dimension HA must be interlocked by the use of steel rods. The base concrete
advised. It can be freely chosen between HA min and must withstand at least the same load as the weld joints
HA max. If HA is to be longer than HA max the torque arm will of the foundation screws.
be of special design. Crouting, which is laid in connection with the mounting of
If customer manufactures the torque arm himself, the torque arm, must be bonded to the base concrete
following items must be considered: with steel rods.
Tightening of nuts (pos. 704) are to be done after
◊ Torque arm and its foundation must be capable to
crouting has dried.
withstand the anchoring force
◊ In the torque arm there must be two hinges and the
construction must allow axial movement of the gear
unit because of heat expansion, run out errors of
driven shaft and other erection errors.
Gear unit sizes
500-800 pos. description
700 joint pin
701 rod
702 foot
701 703 foundation screw
704 nut
705 washer (nylon)
706 bush (nylon)
707 locking ring
707
706 Tensile strength of the
702 700 supporting girders and
705 foundation screws (pos.
704 703) must be at least
703 2
350 N/mm .

Positions refer only to

this instruction

Picture 1: Torque arm parts and dimensions

Table 1 Dimensions [mm]
Gear unit A B C ØD E N HA max HA min K L ØM O P R pcs supporting
size H8 girder, bxc
50 172 125 15 32 75 32 950 125 50 50 24 7 100 M20 4 100x260
60-90 240 180 20 45 90 45 1070 175 70 70 28 9 125 M24 4 100x320
Dimensions are not binding.

2.2.5 1(2)
 Torque arm, M-series
15004ENk

Clearance to allow lateral movement

Material GRP, welding not allowed

Picture 2: allowed mounting tolerances

2.2.5 2(2)
 Oil Heater
62004ENk

OIL HEATER

Picture 1: Heating element and thermostat

1. Design of the heater A B

Material of the resistance elements is stainless

steel.
The oil heater is controlled by a thermostat.The
thermostate is an 1-hubbed change-over-contact,
position of which is depending on the temperature
of the sensor.
Surface power of the oil heater is 1 W/cm2.
Standard voltage is 230/400V.

2. Mounting
- the heater and the gasket are mounted on the C
gear unit
- the tubular heating elements must be totally
immersed in liquid at all times
- the base of the terminal box is fixed to the
immersion heater by means of a mounting ring
- check that the gasket sits properly between the
box and the element head
- the sensor of the thermostat is introduced into
the oil sump of the gear unit and the desired Picture 2 Wiring diagrams
temperature is set on the thermostat, see
chapter 2.3.
2.2 Check-list for the electrical connection
2.1 Electrical installation - verify that the mains voltage corresponds to the
voltage stamped on the rating plate.
The supply cable has to be chosen according to the
- Close the lid of the terminal box and make sure
total power of the heater, and attention must be the seal sits properly between the lid and the
paid to its temperature rating.
base of the box.
Connection: WARNING !
- single phase supply (picture 2, A, C); terminate
Faulty connected or on the top of oil
the supply cable to terminals L1 and N in
surface working heater may cause a
accordance with diagram A (or C in case of danger of explosion. Check that there is oil in the
single heating element). Terminate the earth
gear unit before the heating element is connected
lead to the earth terminal on the base of the
to the net. The assembly is allowed to be done only
terminal box. by a skilled worker.
- three-phase supply (picture 2, B); remove the
brown branch wire. Terminate the phase leads
of the supply cable to terminals L1, L2 and L3.
If neutral lead is available, terminate it to
terminal N. Terminate the earth lead to the
earth terminal on the base of the terminal box.

2.5.4 1(2)
 Oil Heater
62004ENk

2.3 Setting up the thermostat of the oil heater 3. MAINTENANCE

- The thermostat must be set so that it switches
the oil heater on when the oil temperature in the
gear unit falls below temperature shown in table
1 (bath or splash lubrication) or table 2
(pressure lubrication).
- The upper limit of the thermostat is set so the
oil heater switches off at a temperature
8…10°C higher than the above mentioned
switching on temperature.
2.3.1 Gear units without pump (bath or splash
lubrication)
The minimum starting temperature in splash- and
bath lubricated gear units is the same as pour point
of the oil. If the temperature of the gear unit and the
oil is lower than pour point, an oil heater is needed.
Table 1. Pour points [°C]
ISO VG 680 460 320 220 150 100
The resistance element can be removed for
cleaning in connection to the oil change, if
necessary. The cleaning of the resistance element
can be performed with dissolvents, but never with
the chisel and such like of thing which damages the
resistance element.
- verify at regular intervals, e.g. once a year, that
the leads are tightly fastened to the terminals
and that they are not oxidized.
- if the immersion heater does not function,
check that the thermal cut-out device has not
tripped (if the system has one) and that the
heating elements and the thermostat are
undamaged.
- a damaged immersion heater has to be
replaced.
- check the elements. Encrusted elements must
be cleaned or replaced. The oil must always
first be drained from the gear unit.

Mineral oil -7 -10 -15 -20 -25 -28

Synthetic -30 -35 -40 -40 -45

2.3.2 Gear units with pump (pressure

lubrication)
If the temperature of the gear unit and the oil is
lower than minimum starting temperature, an oil
heater is needed. In pressure lubricated gear units
the oil viscosity in minimum starting temperature
must be lower than 2000 cSt:

Table 2. Minimum temperatures [°C]

ISO VG 680 460 320 220 150 100

Mineral oil +25 +20 +15 +10 +5

Synthetic +15 +10 +5 0 -5

2.5.4 2(2)