No.

TIM12-003

PARAMAX
INSTRUCTION MANUAL

TYPE YVA040P3DG-RL-57.962
YVD060P3DG-RL-57.328
YHD060P3SP-RL-55.391/78.456
YHD070P3SP-RL-77.373
YHD080P3SP-LR-76.353
YHD080P3-LR-55.066

Sumitomo Heavy Industries(Tangshan), Ltd.

ENGINEERING DEPT.

DATE APPR.

2012/8/23 Y.HAIQING M.NAKAOKA

 CONTENTS
1 PREFACE......................................................................................................................................... 2
2 CONSTRUCTION ............................................................................................................................. 2
3 INSTALLATION ................................................................................................................................ 2
4 OPERATION..................................................................................................................................... 2
5 LUBRICATION.................................................................................................................................. 3
5-1 Lubrication method .................................................................................................................... 3
5-2 Selection of lubricant oils ........................................................................................................... 3
5-3 Oil quantity................................................................................................................................. 3
6 MAINTENANCE................................................................................................................................ 3
6-1 Oil check and change ................................................................................................................ 3
6-2 Oil filling and draining ................................................................................................................ 3
6-3 Oil seal inspection and change .................................................................................................. 3
6-4 Extended storage of the unit ...................................................................................................... 3
7 MAINTENANCE OF PARTS............................................................................................................. 4
7-1 Renewal parts............................................................................................................................ 4
7-2 Dismantling and Assembly ........................................................................................................ 4
8 ESSENTIALS OF LONG-TERM STORAGE..................................................................................... 4
9 Warranty ........................................................................................................................................... 5
10 Table 1.Recommended lubricants................................................................................................. 6
12 Table 2. Oil Quantity List ............................................................................................................... 6
13 Table 3. Corrosion Preventive Oil Quantity List............................................................................. 6
14 Table 4. Oil Seal List ..................................................................................................................... 6
15 Table 5. Bearing List ..................................................................................................................... 7
16 SAFETY AND OTHER PRECAUTIONS ....................................................................................... 8

1
1 PREFACE
This Instruction Manual should be thoroughly reviewed before commencement of
installation and operation of the units.

2 CONSTRUCTION
(1) External gears are used for this reduction gear unit.
(2) Gears are made of hardened steel to insure a long life. Helical gears are used to provide
sufficient strength and operation.

(3) Shafts are made of a properly heat treated alloy steel.

(4) Bearings are used for the reduction gear unit.

(5) Extreme care is taken to prevent oil leaks by liquid packings at gear box mating surfaces and
cover mounting surfaces, and oil seals at input and output shafts.

(6) The reduction gear unit is equipped with an oil filler, a drain plug, air breather , oil gauge.

3 INSTALLATION
(1) The reduction gear unit must be securely installed in position on the flat and rigid foundation to
prevent heavy stresses on the unit. Accelerated wear, vibration or noise can be caused by incorrect
installation.

(2) When couplings are used, never use rigid coupling. Use flexible couplings.

(3) When shrunk fitted gears, pulleys or couplings to shafts, use care to prevent damage.
(4) The alignment of the reduction gear unit with a driving motor and other machines must be made
as accurately as possible. Allowable parallel and off-set misalignment is within 50 um.
(5) Never install the reduction gear unit such a manner, as to cause defamation of the housing.
Such installation method will have adverse effect on the bearings.

(6) Bolts used for the installation of the drive unit must be the equivalent of JIS Class 10.9 strength.

4 OPERATION
Accomplish the following procedures for the operation of the unit after installation.
(1) Make sure that proper lubricants are used. Recommended lubricant oils are shown in Table 1.
(2) Lubricant oil is drained from the unit before shipment. Fill the unit with oil, using care to prevent
foreign matter from entering the unit. Check the oil level in unit with an oil level gauge.
(3) A “run-in” operation is carried out for all the reduction gear units before shipment. However, they
should be rechecked before placing them in operation to ensure that they work smoothly. On initial
operation do not apply a full load on the unit. Increase the load gradually.
(4) Extreme care should be exercised especially when extended storage of the unit is expected.
Gears and bearings are splash lubricated. A unit kept idle for a long time may need oiling before
operation. On initial operation accomplish the above procedure, (3) , after inching the unit several
times with no load.
(5) During operation keep a record of temperatures and noise of the major portions. This will be of
some reference to future maintenance and operation.

(6) If any of the followings occur, stop and check the unit.
1) Oil temperature rises above 90℃
2) Excessive noise or vibration occurs suddenly.

2
 (7) Oil should be drained before transportation from the units.

5 LUBRICATION

5-1 Lubrication method

Gear and Bearinng : Oil bath

5-2 Recommended lubricants

Recommended lubricants are listed in Table1.

5-3 Oil quantity

Use an oil gauge or a dip stick to check the unit for the proper amount of oil.
Outline oil quantity is shown in Table 2.

6 MAINTENANCE

6-1 Oil check and change

(1) Oil quantity should be checked periodically by means of an oil sight gauge. For accurate
measurement, stop the unit. When the unit has not been used for a long period, check the unit after
no load operation for about 2 to 3 minutes as mentioned on above 4-(4).

(2) The first oil change should be made after 500hours of operation or 6months, whichever comes
first. The second oil replacement should be conducted after 2,500hours of operation or 6months,
whichever comes first.

(3) The oil should be replaced with new oil every 5,000hours or every 1year, whichever comes first,
if the oil temperature falls below 70℃. If the oil temperature rises above 70℃, the oil should be
changed every 2,500hours or every 6months, whichever comes first.

(4) Where operating conditions are severe, such as rapid rise and fall of temperature, or the
presence of corrosive gases in the atmosphere which will result in the rapid deterioration of the oil,
reference should be made to lubricant manufactures.

(5) Oil flushing helps cleaning. The use of a solvent should be avoided to clean the internal parts of
the unit.

6-2 Oil filling and draining

(1) Drain the oil from a drain plug, by removing the oil drain plug.

(2) While taking all possible care to prevent the entry of rain water and other foreign matter through
the oil filler, the prescribed quantity of oil should be poured into the unit while observing the oil level
gauge. Quantity below the prescribed level will result in inadequate lubrication, while excessive
supply will cause excessive temperature rise and accelerate oil deterioration.

6-3 Oil seal inspection and change

Worn oil seals may result in oil leaks. Inspect and replace oil seals at regular interval.

6-4 Extended storage of the unit

(1) If the unit is not to be operated for over a month, replace the oil upon suspension of operation,
3
 and run the unit with no load on it at least once a week.

(2) If the unit is not operated for over three months or it is difficult to accomplish instructions in
above article (1), drain oil, fill the unit with the proper amount of corrosion preventive oil (JIS NP20
or equivalent) in accordance with Table3, and seal it. When staring the unit again, replace the
anti-corrosion oil with the proper amount of recommended lubricating oils. NOTE, be sure to seal
the air vent plug to keep the unit tightly closed dusting storage.

7 MAINTENANCE OF PARTS

Overhaul the machine 3－5 year after initial operation, depending on the operating
condition. Replace the following parts to extend the service life.

7-1 Renewal parts

・ Bearing, oil seal, collar, shim, packing, visible gauge, air breather

・ Shafts and gears when damage is found.

・ Other parts (incl. special applications) as necessary.

7-2 Dismantling and Assembly

The PARAMAX DRIVE should be returned to our plant for dismantling and assembly, in
principle. Advise us of the machine No. of the speed reducer to overhaul, serial No., type,
number of speed reducers, and period.

8 ESSENTIALS OF LONG-TERM STORAGE

1. Using interior of general factory of warehouse, store the machine under comparatively
favorable conditions.

2. Store in an environment where moisture, dust, violent temperature variations and corrosive
gases like sulfurous acid gas are absent.

3. Make sure of the rusting situation inside the equipment and then spray and also supply Shell
VSI Circulating Oil 32 of the Shell Oil Company and seal it hermetically and repeat the
procedure identified above every half a year.

4. Do not use any mixture with other rust-proof oil.

5. Drain the rust-proof oil when operation is to be commenced; start operation after supplying the
recommended lubricant. Do not operate the equipment with dust-proof oil in.

6. While Daphne Ever Coat No.1 is coated on the shaft thrusting unit and the mounting face, make
sure of the rust situation by sight.

7. The oil quantity of Shell VSI Circulating Oil is in a Table3.

4
9 Warranty
The warranty for PARAMAX DRAIVE is as follows:

The warranty period for the Products shall be 18 months after the shipment of the
Warranty Products from the seller’s works or 12 months from the Products coming into
Period operation, whichever comes first.
In case that any problems, troubles or damages on the Products arise due to the
defects in the Products during the above “Warranty Period”, although the Products
are appropriately and properly installed in, connected or combined to the equipment
or machines, or maintained in accordance with the maintenance manual and are
properly operated under the conditions as described in the catalogue or otherwise as
agreed upon in writing between the Seller and the Buyer or its customers, the Seller
Warranty will provide, at its sole discretion, appropriate repair or replacement on the Products
Condition free of charge, except as stipulated in the “Exception for Warranty” as described
below.
However, in the event that the Products is installed in, connected or combined to or
integrated into the equipment or machines, the Seller shall not reimburse the costs
for removal or re-installation of the Products or other incidental costs related thereto
and any lost opportunity, loss of profit or any other incidental or consequential
losses or damages incurred by the Buyer or its customers.
1. Notwithstanding the above warranty, the warranty as set forth herein shall not
be applied to the problems, troubles or damages on the Products which are
caused by: installations, connections, combinations or integration of the
Products in or to the other equipment or machines, which are rendered by any
person or entity other than the Seller,
2. the insufficient maintenance or improper operation by the Buyer or its
customers, such that the Product is not appropriately maintained in accordance
with the maintenance manual provided or designated by the Seller,
3. the improper uses or operations of the Products by the Buyer or its customers
which are not informed to the Seller, including, without limitation, the Buyer’s
or its customers’ operation of the Products not in conformity with the
Exception specifications, or use of the lubrication oil in the Products which is not
for recommended by the Seller,
Warranty 4. any troubles, problems or damages on any equipment or machines in or to
which the Products are installed, connected or combined or installed, or any
specifications particular to the Buyer or its customers, or
5. any changes, modifications, improvements or alterations on the Products or
those functions which are rendered on the Products by any person or entity
other than the Seller,
6. any parts in the Products which are supplied or designated by the Buyer or its
customers,
7. earthquake, fire, flood, sea-breeze, gas, thunder, acts of God or any other
reasons beyond the control of the Seller,
8. waste, exhaustion, normal tear or ware, or deterioration on the parts of the
Products, such as bearing, oil-seal.
9. any other troubles, problems or damages on the Products which are not
attributable to the Seller.

5
10 Table 1. Recommended lubricants

ENERGOL ALPHA OPTIGERA TRIBOL GEAR

GR-XP-220 SP220 BM220 1100/220 COMPOUNDS
ISO VG220* EP220
AGMA 5EP MEROPA SPARTAN MOBILGEAR OMALA CARTER
WM220 EP220 630 220 EP220

ENERGOL ALPHA OPTIGERA TRIBOL GEAR

GR-XP-460 SP460 BM460 1100/460 COMPOUNDS
ISO VG460* EP460
AGMA 7EP MEROPA SPARTAN MOBILGEAR OMALA CARTER
WM460 EP460 600XP460 460 EP460
*ISO VG number is the value of the kinematic viscosity in mm2/s(cSt)at 40℃.
*Note recommended lubrication oil is VG220 for YHD080 and VG460 for other models.

11 Table 2. Oil Quantity List (per one unit)

TYPE Oil Quantity[L]

YVA040P3DG-RL-57.962 50
YVD060P3DG-RL-57.328 100
YHD060P3SP-RL-55.391/78.456 60
YHD070P3SP-RL-77.373 85
YHD080P3-LR/RL-55.066/76.353 65

12 Table 3. Corrosion Preventive Oil Quantity List(per one unit)

Oil Quantity
TYPE
Filling Spray
YVA040P3DG-RL-57.962 APPROX. 500cc 50cc
YVD060P3DG-RL-57.328 APPROX. 1,000cc 100cc
YHD060P3SP-RL-55.391/78.456 APPROX. 1,000cc 100cc
YHD070P3SP-RL-77.373 APPROX. 1,000cc 100cc
YHD080P3-LR/RL-55.066/76.353 APPROX. 2,000cc 200cc

13 Table 4. Oil Seal List(per one unit)

HIGH SPEED SHAFT D-40×52×8
YVA040P3DG-RL-57.962
LOW SPEED SHAFT D-120×150×14
HIGH SPEED SHAFT D-50×65×9
YVD060P3DG-RL-57.328
LOW SPEED SHAFT D-140×170×14
HIGH SPEED SHAFT D-65×85×13
YHD060P3SP-RL-55.391/78.456
LOW SPEED SHAFT D-170×200×16
HIGH SPEED SHAFT D-65×85×13
YHD070P3SP-RL-77.373
LOW SPEED SHAFT D-190×220×15
HIGH SPEED SHAFT D-80×100×12
YHD080P3-LR/RL-55.066/76.353
LOW SPEED SHAFT D-170×200×16

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14 Table 5. Bearing List(per one unit)
YVA040P3DG-RL-57.962
HIGH SPEED SHAFT #32307×1 #33208×1
INTERMEDIATE SHAFT #32310×2
INTERMEDIATE SHAFT #32312×2
LOW SPEED SHAFT #30221×2
YVD060P3DG-RL-57.328
HIGH SPEED SHAFT #22308×2
INTERMEDIATE SHAFT #22314×2
INTERMEDIATE SHAFT #22316×2
LOW SPEED SHAFT #22226×2
YHD060P3SP-RL-55.391/78.456
HIGH SPEED SHAFT #32309×1 #33211×1
INTERMEDIATE SHAFT #32313×2
INTERMEDIATE SHAFT #23220×2
LOW SPEED SHAFT #23030×2
YHD070P3SP-RL-77.373
HIGH SPEED SHAFT #32311×1 #33213×1
INTERMEDIATE SHAFT #32314×2
INTERMEDIATE SHAFT #23222×2
LOW SPEED SHAFT #23034×2
YHD080P3-LR/RL-55.066/76.353
HIGH SPEED SHAFT #32311×1 #33213×1
INTERMEDIATE SHAFT #22314×2
INTERMEDIATE SHAFT #23222×2
LOW SPEED SHAFT #23034×2

7
15 SAFETY AND OTHER PRECAUTIONS
• The gear unit should be handled,installed and maintained by trained technicians.
• Carefully read manual and all accompanying documents before use(installation, operation,
maintenance, inspection, etc.)
Thoroughly understand the machine, information abut safety, and all precautions for correct
operation. Maintain this manual for future reference.
• Pay particular attention to the “DANGER” and “CAUTION” warnings regarding safety and proper
use.

! DANGER ：Improper handling may result in damage, serious personal injury

and/or
death.
! CAUTION
： Improper handling may result in damage and/or personal injury.

Matters described ! CAUTION in may lead to serious danger depending on the situation.
Be to observe important matters herein.

! DANGER
General
z Transport, installation, plumbing, operation, maintenance, and inspections should be handled by
properly trained technicians; otherwise, injury or the machine may result.
z When the unit is to be used in a system for transport of human beings, a secondary safety device
should be installed to minimize chances of accidents resulting in injury, death, or damage to the
system.
z When the unit is to be used for an elevator, install a safety device on the elevator side to prevent
it from falling, otherwise, serious injury, death, or the elevator may result.
Installation
z Never stand directly under a unit suspended by a crane or other lifting mechanism; otherwise
personal injury or death may result.
Operation
z Never approach or touch any rotating parts(shaft, etc.)during operation, loose clothing caught in
these rotating parts may result in severe injury and/or death.
Daily inspection and maintenance
z Never approach or touch any rotating parts(shaft, etc.)when maintaining or inspecting the
reducer during operation.
Loose clothing cought in these rotating parts may result severe injury and/or death.
z Be sure to stop both the driving and driven machines before checking any tooth surfaces,
otherwise, you may be caught in the gear engaging section. resulting in severe injury and/or
death.
z Do not operate any units without all(safety)covers in place. Failure to do so may cause injury
and/or death.

《Note》
z A copy this manual should be sent to the actual user of the gear unit.
z This manual should be maintained by the user.

8
 ! CAUTION
General
z The unit should be operated only within its design and performance specifications; otherwise, injury or damage to
a system may occur.
z Keep hands and foreign objects from the internal moving parts of the unit ; otherwise, injury or damage to a
system may occur.
z Damaged units should be taken off-line and not put back in operation until properly repaired.
z Any modifications or alterations of any kind, to the unit, will void the warranty and all subsequent claims.
z Do not remove the rating plate.
Inspection upon delivery
z unpack the after verifying that it is positioned right side up ; otherwise, injury may result.
z Verify that the unit received is in fact the one ordered. When a different product is installed, injury or damage to
the system may result.
Transport
z Exercise ample care not to drop the unit during transport. When a hanging bolt or hole is provided, be sure to use
it. after mounting the unit on a system, however, do not hoist the entire system using the hanging bolt or hole.
Before hoisting, check the weight with the rating plate, crate, outline drawing, catalog, etc. Never hoist the unit
that exceeds the rating of the crane or other mechanism being used to lift it ; otherwise, injury or damage to the
unit and/or lifting device may occur.
Installation
z Do not place objects that will hinder ventilation around the unit ; otherwise, cooling effect is reduced, and may lead
to a possible fire hazard due to excessive heat build-up.
z Do not step on or hang from the unit ; otherwise, injury may result.
z Do not touch the key way at the shaft end or on the inside of the unit ; injury may result.
z When the unit is used in food processing applications vulnerable to oil contamination, install an oil pan or other
such device to cope with oil leakage due to failure or limited service life. Otherwise, oil leakage may damage
products.
Coupling with other machines
z When coupling unit with a load, confirm that the alignment error is within the specified limits shown in the
maintenance manual, drawings, catalog, etc.;otherwise, damage to the system may result, due to misalignment.
z Correctly tighten respective bolts to the specified torque shown in the drawing, catalog, etc. ; otherwise ; scattering
fragments may damage the system.
z When a belt is used for coupling the unit with another machine, check that the belt tension and the parallelism of
the pulley are within the specified limits. When the unit is directly coupled with another machine, check that the
direct coupling accuracy is within the specified limits ; otherwise, the system may be damaged, due to
misalignment.
z Install appropriate guard devices around rotating parts ; otherwise, injury may result.
z Remove the key temporarily attached to the output shaft of the unit when the shaft is free-rotating (i.e. not
loaded) ;otherwise, injury may result.
z Confirm the direction of rotation before coupling the unit with its driven machine. Difference in the direction of
rotation may cause injury or damage to the system.
Operation
z The reducer will get very hot during operation. Do not touch or come in contact in any way with the reducer ;
otherwise, you may suffer bums.
z If the reducer is operating in an abnormal way, stop the unit immediately ; otherwise, injury may result.
z Do not operate the reducer in a manner the exceeds its rating criteria ; otherwise, injury or damage to the system
may result.
z Do not remove any covers or open the reducer during operation;otherwise, splashing lubricant may cause burns.
z Do not loosen the oil filler plug during operation ; otherwise, splashing lubricant may cause bums.
z For a system in which a lubricant motor pump is provided separately, switch on the pump motor prior to switching
on the reducer motor. This will enable praper lubrication of the bearings prior to start-up. Failure to do so may
damage the unit.
z When reversing the direction of rotation, first bring the unit to a complete stop, then commence reverse rotation ;
otherwise, the system may be damaged.
z Identify and provide appropriate corective action in a timely fashion for any abnormal operation characteristics
according as the maintenance manual. Do not operate the unit until corrective action has been taken.
Daily inspection and maintenance
z Change lubricant according to the maintenance manual, and use only those recommended lubricants ; otherwise,
the system may be damaged.
z Do not change the oil during operation or soon after operation has ceased ; otherwise, the hot oil may cause burns.
Disassembly and reassembly
z Repair, disassembly, and reassembly should be handled by properly trained technicians ; the system may be
damaged.
Disposal
z Dispose the reducer and lubricant as general industrial waste.