FACHINI GEARS
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RIDUTTORI - GIUNTI - INGRANAGGI
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
REFERENCE REDUCER type 2CP650
B2920 D6454A
1
-TECHNICAL DESCRIPTION
1.0
2
-INTRODUCTION Warning How to retrive information
2.0 2.1 2.2
-SAFETY RULES Fire and explosion Wxternal revolving parts Noise
3.0 3.1 3.2 3.3
3
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
8
-LUBRICATION Causes of internal temperature t emperature increases Some remarks on lubrication choise Approved types of lubricant Splash Lubrication Forced Lubrication Filling with Lubricant
REFERENCE 8.0 8.1 8.2 8.3 8.4 8.5 8.6
9
-START UP General conditions
9.0 9.1
10
-MAINTENANCE Warning Lubrication Internal cleaning
10.0 10.1 10.2 10.3
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
-SPEED REDUCER-
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
1 1.0 1
REFERENCE
1.0
-TECHNICAL DESCRIPTION The main reduction gear can transmit the 225 kW , processing rated power at the input speed equalling 1200 rpm and output speed equalling 44.5 rpm (ratio 26.9457) with service factor >4. The casing has an electro-welded structure that underwent welding stress-relief treatment and following sandblasting operation The gears are manufactured with case-hardening alloy steel with ground teeth profile, and properly relief-ground to reduce load concentrations. The bearings are roller type and their processing expected life L10 equals >80,000 hours. Reduction gear lubrication is splash system
D6450A B2929
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
2 2.0-2.1 1
REFERENCE
2.0
-INTRODUCTION Fachini's reducing and multiplying gears are highly specialised products, the outcome of close to 100 years' experience and the most advanced design techniques to guarantee top quality. They are made throughout with materials meeting the CE 2006/42 directivend in full compliance with the strictest precision and safety limits as per UNIEN292. The expression "reducer" herein shall mean both reducing and multiplying gear, hydraulic unit ,ecc. When properly installed and serviced, reducers will perform without problems uninterruptedly for a long time before replacement or major overhauling are needed. This manual contains all the information for proper storage, use and maintenance. Compliance with the instructions herein is necessary to ensure proper operation. It is recommended that such instructions be carefully read
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
2 2.2 2
REFERENCE
2.2
-How
to Retrieve Information on Reducers Hereafter a list of the information that mighttbe useful to the custome and its location.
INFORMATION
Factory number Reducer type Technical data Lubrication data (recommended type of lubrificant , quantity , plant component location , etc.)
Location:
Nameplate Nameplate All drawings Nameplate Layout dwg Nameplate Layout dwg
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
3 3.0 / 3.3 3
REFERENCE 3.0
-SAFETY RULES Familiarity with the following data is necessary for safety. Therefore, such data shall be brought to the attention of those involved in selecting Fachini reducers, of the engineer in charge of designing the machines to which the reducers shall be attached and of those in charge of installation, operation and maintenance. Fachini's reducers run safely and reliably when properly selected, installed, checked and operated. As for any other mechanical facility, specific precautions shall be taken as a protection against those hazards that cannot be eliminated at design stage (UNIEN292, 2006/42/CE). The following list does not rank the hazards according to their importance, since the hazard level depends on external conditions; it is therefore important that the entire list be examined.
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
3 3.4 / 3.7 4
REFERENCE 3.4
-Lifting To lift reducer, only use the attachment points shown in the layout. Use of improper attachment points may endanger personnel and damage the reducer or other goods.
3.5
-Lubrication (UNI-EN 292, CEN TC114 /W412) - Protracted contact with the lubricant may be harmful to the skin: comply with supplier's instructions for use. - Check reducer's type of lubrication before filling. Carefully read and follow all instructions herein and nameplate indications. An error may cause mechanical damage and harm personnel in extreme cases. - Prevent lubricant contamination; shield seals against weather and solar radiation with water-repellent grease.
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
3 3.8 / 3.10 5
REFERENCE Before performing any maintenance intervention, see the manual. Make sure that all works are carried out in extremely "safe" conditions. The works in the hydraulic system must be performed when it is at rest. It is prohibited to work, loosen the flanges and the pipings when the system is pressurised. Stop the pumps and discharge the residual pressure. Pay attention to prevent and protect the environment from ecological contaminations caused by leakages or oil failures. Warning: during oil change and topping-up operations, act in compliance with the precautions that concern the protection of the ecological environment; do not leave areas with scattered oil, as it may be dangerous: use absorbing materials and cleaning solvents
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
4 4.0 6
REFERENCE 4.0
-STATE OF SUPPLY The scope of supply is specified in the shipment documents and the relevant completeness must be checked at the time of receipt. In case of transport damages or lacking products, they must be immediately signalled. Fachini reducers are thoroughly stand-tested using suitable instruments and as requested by the customer. Unless otherwise stated in the contract, reducers are coated with red anti-oil paint inside and with a synthetic primer and synthetic enamel outside. This coating provides adequate protection for normal industrial environments and can be covered with further coats of synthetic paint. When aggressive environmental conditions
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
5/6 5.0/6.0 7
REFERENCE 5.0
-HANDLING & LIFTING D6454A Lift and move reducer using the appropriate lugs and holes and rope slings; for large reducers, also sling the bottom part below the casing joint. Before lifting make sure that the selected eyebolts and brackets will carry the weight of the entire reducer and not just that of the upper half-casing. If not, specific lifting points shall be provided for the bottom half-casing. Reducer weight and lifting point location are shown in the layout drawing D6454A. To move reducers with the lubrication system on board, it is recommended that any easily damaged part be removed, all openings be sealed against foreign matter and the inside protected against attack by external agents.
6.0
-STORAGE
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
6 6.1/6.3 8
REFERENCE 6.1
6.2
- Protection of the Forced-Lubrication System Fill pumps and motor pumps with highviscosity oil; loosen fittings, seal delivery and intake ports with wooden or Neoprene plugs, fill piping with oil and seal. Before start up, flush with fuel oil and fill pumps with lubricating oil. Spray antioxidant on filter cartridges and body; eliminate with mineral oil before start up. Accurately plug all inlet and outlet ports of heat-exchanger. Remove plugs before start up. Wrap electric instruments with polyethylene sheeting and make sure that the contacts are protected with silicone-based or similar antioxidant . - Protection under Special Environmental Conditions If reducer is exposed to moisture and large temperature changes, place hygroscopic material in the casing and replace regularly at intervals depending on the conditions; remove before start up.
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL 7 PARAGRAPH 7.0 / 7.1 SHEET 9 REFERENCE CHAPTER
7.0
-INSTALLATION For optimum operation, carefully follow these installation instructions, with special attention to two points: 1. Right internal alignment: gear meshing should not be compromised by warping of the casing due to unstable, settling or uneven foundations (7.1). Such mistakes may cause uneven gear load, raise noise level in operation and damage tooth surface. 2. Right external position and alignment: the driving and driven shafts shall be propely positioned and lined up to the reducer shafts to prevent casing warping and shaft and bearing overload. Such mistakes may cause damage to shafts and bearings and local overheating, which produce abnormal noise, mistakenly attributed to gear defects.
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
7 7.2 / 7.3 10
REFERENCE Cases B and C should be reported to Fachini when placing the order. Whichever the type of foundation, reducer and primary motor should preferably be mounted on a common bedframe, made fast with suitable bolts and leave sufficient space for the tightening tools so as to facilitate adjusting and dismantling. As far as the supporting base is concerned, the allowed flatness tolerance equals 0.05 mm x metre As far as the power unit is concerned, the aforesaid tolerance can equal 2 mm x metre 7.2
Couplings Elastic, toothed and rigid couplings are those more currently used. With rigid couplings, do not attempt to line up the reducer, motor and driven machinery by tightening the coupling bolts, as shaft stiffness is never adequate. As a result, alignment would be poor and stresses occur in shafts, bearings and coupling.
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
7 2 7.3 11
REFERENCE ECCENTRICITY. Shaft axes are parallel but not coaxial (Fig. 2). Prior to reading eccentricity correct the angle error, especially in the vertical plane. Eccentricity is measured in a similar way as the angle error. In this case, the readings are taken with a dial gauge fastened to one face and bearing on the flange or hub of the other (Fig. 4). In any case, unless laser-instruments are used, straightforward directions cannot be given to determine correction, as correction depends on the specific case; it is mainly a matter of experience. Should such experience not be available, we shall be glad to help and determine the acceptable tolerance for any application.
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
7 7.4 12
REFERENCE
Fig.3- Angularity measure
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REDUCER type 2CP560 GENERAL MANUAL 7 PARAGRAPH 7.5/7.6 SHEET 13 REFERENCE Temperature changes also affect the distance between foundation and shaft; when the temperature difference between casing and motor or driven machine is high, the resulting change in height may be appreciable. As an example, let us consider the height change in a iron casing having H = 700 mm initial height over the foundation and 30°C temperature difference. Iron's linear expansion coefficient being 0.000012, runout, if corrected cold, will attain 0.000012x700x30 = 0.252 mm. Especially for large reducers, these conditions may cause significant increase of bearing load and abnormal vibration. In some cases it is recommended to select a tolerance that will yield the proper alignment under standard operating conditions. CHAPTER
7.5
-Correcting Alignment Errors Any misalignment shall be corrected without causing structural deformation.
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL 7 PARAGRAPH 7.7 SHEET 14 REFERENCE CHAPTER
consegnati completamente assemblati ed allineati al supporto, It is advisable to apply lateral stops or dowel pins on the bedframe as a datum point and to prevent shifting under an external load. If dowel pins are preferred, two of them, placed as far as possible from each other, should be sufficient to preserve alignment. Prevention and safety devices should be available if accidental oil leakages might cause major damage; check all parts to be inspected for accessibility. 7.7
-Clamping torque Recommended clamping torques to tighten screws and tie-rods for Fachini products. Passo grosso M8x1.25 M10x1.5
M (mN) mat. 4.8 7
M (mN) mat. 8.8 15
Passo fine M12x1.25 M14x1.5
M (mN) mat. 4.8 27
M (mN) mat. 8.8 54
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
8 8.0 / 8.3 15
REFERENCE 8.0
-LUBRICATION Lubrication fulfils two essential functions in a reducer: it protects gears and bearings against premature wear and transfers the heat that builds up in the casing to a coolant or any other refrigerating f acility.
8.1
-Causes of Internal Temperature Increases Temperature increases are due to two factors: - Friction between two parts (gearteeth, bearings); it depends on power output and oil's friction-reducing capability. - Oil churning in the reducer and oil resistance in bearings and gears, depending on oil viscosity and severity of churning. Gear lubricants operate under harsh conditions, since tooth pressure can attain several tonnes per cm2. Oil's protective efficiency generally increases with its viscosity, while churning-induced heating also increases with viscosity.
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
8 8.4 / 8.6 16
REFERENCE 8.4
-Splash Lubrication The simplest lubrication method utilizes the churning of the oil induced by the revolving gears; the results are fair as long as the peripheral speed is below 12.5 m/s. The oil stand should be accurately maintained to have the gearwheels immersed by some 20-40 mm; should the level increase above this value, churning-induced heating might significantly increase, with consequent waste of power and excessive operating temperature. Oil level shows in the layout drawing. When the reducer is started up, oil level changes because some of it is thrown by centrifugal force onto the casing walls and gearwheel motion causes the oil to accumulate unevenly. Oil level can also increase or decrease depending on where the level gauge is located with respect to the wheels' sense of rotation. If stick-type level gauges are dismantled and mounted again, check that they are put back where they belong by placing a reference mark
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
9 9.0 17
REFERENCE 9.0
-START UP Prior to start up carry out the following checks: •
•
•
•
•
Check that the necessary lubricant was introduced into the reduction gear; check the oil level by means of the oil dipstick or from the peephole with stopped pump. Check that the shafts can rotate freely in their normal sense of rotation. Check that the motor turns in the right sense, especially for reducers equipped with an anti-reversal device. The gears' sense of rotation show in the assembly drawing. Check that the system is clean from any trace of dirt in order to prevent the oil from being contaminated. All pumps and filters must be de-aerated before the start-up.
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
9 / 10 9.1/10.2 18
REFERENCE 9.1
-General Conditions In reducers running on rolling bearings oil temperature shall not exceed 80°C nor bearing temperature 90°C; minimum oil pressure is 0.5-0.7 bar. For friction bearings, oil temperature shall not exceed 65°C nor bearing temperature 75°C; minimum oil pressure is 0.5-0.7 bar. Max. oil pressure is 3.5 bar, automatically controlled by a valve at circuit end, inside the reducer. For reducers with forced lubrication, first start the pump to check for operativeness; after start up, record pressure and temperature data.
10.0
-MAINTENANCE The concept of maintenance complies with the EN 133006 standard an includes the fields that concern preventive maintenance, inspection and restoration.
10.1
-Warning
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
10 10.3/10.6 19
REFERENCE Always drain the old oil from the drain hole under the casing (see layout dwg). It is suggested that the oil be chemically analyzed by the supplier. In forced-lubrication reducers, clean the piping, nozzles and filter quarterly, check that the oil flows freely and systematically check the efficiency of the control device. 10.3
-Internal Cleaning Yearly clean the inside if possible; wash casing and gears with bland, non-aggressive solvent and flush with the same oil to be used in operation. Avoid skin contact with solvents.
10.4
-Rotating Parts Periodically check bearings and gears for wear with suitable commercially available instruments.
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
10 10.7 20
REFERENCE 10.7
-Inspections It is necessary to schedule a set of inspections according to system complexity and operation continuity by deciding the frequency of the inspections and specifying the checks into particular lists. Inspection entries are listed below; the customer can add inspection steps, which are considered necessary according to its own experience for the type of work being carried out: • • •
• • •
Check of liquid levels: low levels may be caused by leakages Check about exchanger efficiency, water must be clean Check of external sealing, visual inspection of the system to identify possible leakages Check of temperatures Check of pressures Visual inspection of fluid contamination and, if necessary, by
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
11 11.0 21
REFERENCE 11.0
-PROBLEMS, CAUSES AND REMEDIES The problems listed below are considered as a simple support to search for the causes. They represent a first suggestion and often it is necessary to consider other components, too, to search for the origin of a malfunction. In case of doubt, it is advisable to ask for the support of Fachini’s engineers. Problems High oil temperature
Possible cause Air trapped in the exchanger
Remedies Deaerate the exchanger
Dirty exchanger
Clean the exchanger
Damaged bearings
Check bearing
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
11 11.0 22
REFERENCE
Problems High oil pressure
Residue in the filters
Possible cause Remedies Clogged oil piping Identify the clogging towards the reduction and restore gear Check the oil and, if High oil viscosity necessary, change it Dirty pipings Clean and vent the pipings Material being removed due to the scraping off of the reduction gear
Check teeth and bearings, if any; remove the defects
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
12 3 12.0 23
REFERENCE 12.0
-DISMANTLING In general, this operation does not pose huge problems. Detach all external piping and the coupling, remove screws, tierods and covers and dismantle all components. To reassemble proceed in the reverse order; smear casing and cover joint faces with silicone sealant to prevent leaks .
All the above information is based on the current level of knowledge and on our evalutation of potential hazards. For further information , suggestions and advise , write or call:
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
LAY-OUT DRAWING
D6454A
13 24
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
CHAPTER PARAGRAPH SHEET
ASSEMBLY DRAWING
B2929A
7 14 25
FACHINI GEARS
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REDUCER type 2CP560 GENERAL MANUAL
SPARE PARTS
DESCRIPTION
DRAWING
POS. 1
PINION SHAFT Ist REDUCTION
B2920 B2920
2
GEAR Ist REDUCTION
B2920
3
PINION SHAFT IInd REDUCTION
B2920
4
GEAR IInd REDUCTION
B2920
5
SLOW SHAFT
B2920
6
BEARING 22222
B2920
7
BEARING 22236
B2920
8
BEARING 23040
B2920
9
GEARS CASING