General Installation, Operational and Maintenance Procedures

Shipping and Storage

All Hansen gearboxes are shipped without oil but grease points are factory filled. Upon shipping the gear units have been exposed to several hours of testing under 'no load' conditions, aligned as for intended operation and conditions stipulated on the nameplate. When stored, the units should be returned to original supplied shipping conditions.

Installation

When handling a gearbox unit the lifting eye nuts should always be used. These should never be removed. Under 'NO' circumstances should slings be placed around drive shafts with intention of lifting. When mounting do not apply impact loads since this could damage bearings. Concerning external loads, radial loads should be applied as close as possible to the housing. Avoid exaggerated belt tension on input or output shafts by using as large a pulley as possible. Location of foot-mounts should ensure no movement of the unit while in operation. Always mount the gearbox in the position for which it was ordered. Do not invert unless the unit has been altered or designed specifically for that purpose. Align the driving machinery as accurately as possible with the driven system. The general specification for alignment of the motor relative to the gearbox mounted on the base-plate is, 0.1mm/100mm diameter on the face of the coupling, and 0.1mm on the radial deflection of the shafts, if the dial-gauge is mounted on the one shaft clocking the other.

Lubrication. Oil.

Lubrication serves four main purposes:

• Prevents metal to metal contact.

• Reduces friction.

• Dissipates the generated heat from gears and bearings.

• Prevents corrosion.

Different lubrication systems are applied depending on:

• Gear velocity.

• Gear unit mounting position.

• Operating conditions

Hansen Transmissions use one of the following systems:

• Splash lubrication.

• Forced fed lubrication in the form of:

1. Circulation lubrication

2. Pressure lubrication

These systems can have auxiliary cooling systems installed.

The oil used should be mineral oil with extreme pressure additives to increase the load carrying capacity of the oil. An ISO or VG rated oil would be recommended with the unit and these should be used at all times. Synthetic oils are only to be used with permission from Hansen Engineering department.

The operating temperature of oil is extremely important and should be checked if suspected to be more than 90°C to 95°C (190°F - 200°F). A rule of thumb is that oil life is halved for every 5°C increase in temperature above 90°C. Hansen technical personnel should be contacted if high temperatures are encountered.

When filling gearboxes with oil, do so exclusively through the oil filling opening, to ensure all bearings obtain sufficient oil supply. Regularly check the oil level and ensure that breathers are open and free to alleviate internal pressure to protect seals.

When draining oil, do so while the oil is still warm. This should be done within max 800 hours for first oil change.
Preferable 4000-8000 hours for normal oil change (Depending on operating conditions) Max 8000 hours!

A list of approved types and brands of oils that are recommended for use in Hansen gearboxes is obtainable from Hansen Transmissions. This is similar for grease brands.

Grease.

Use only high quality greases with EP additives and consistency NLGI-Grade 3. All grease points have been filled upon shipping. Grease interval is 800 hours.

Cooling.

If cooling fans or systems are installed, regularly check if the wind paths are unobstructed. Keep the housing surfaces that are used to dissipate heat, free of debris to ensure efficient heat transfer to air. 

Backstops.

The operational direction of backstops should be considered and checked before operation. The direction thereof should only be changed by Hansen technical personnel. If external lubrication points exist on the backstop then normal service intervals apply as with the gearboxes. 

More intensive maintenance can be applied, depending on the capital cost of the unit installed. Oil quality can be determined by taking samples and performing analyses. If the concerned gearbox is critical to the operation, vibration condition monitoring could be added.

The most problems with gearboxes take the form of lubrication complications. Oil contamination, oil breakdown due to extended use, oil starvation when level is low and subsequent heat being generated are the usual causes for failure.

See commissioning link for commissioning of a motor and reducer combination.