Nabtesco GM Series, Operation Manual

Page 1: ...n Gears Operation Manual Please be sure to read and understand this manual before using the product The administrator and operator of the product should have access to this manual Store this manual at a specified safe place so that it can be referred to when necessary ...

Page 2: ...allation Environments 10 3 2 Preparation of Necessary Materials 10 3 3 Transportation and Unpacking 11 Chapter 4INSTALLATION IN THE MACHINE 14 4 1 Precautions on Hoisting 14 4 2 Hoisting and Installing GM 15 4 3 Hydraulic Piping Connection 17 4 4 Trial Run after Installation 17 Chapter 5HYDRAULIC OILAND LUBRICANT 19 5 1 Precautions when Handling Hydraulic Oil and Lubricant 19 5 2 Type of Hydraulic...

Page 3: ...ibed Ch 3 PREPARATION Installation environments of GM preparation of necessary materials unpacking and hoisting are described along with safety precautions Ch 4 INSTALLATION Installation procedure of GM and precautions to avoid human injuries during installation as well as damage of GM Ch 5 HYDRAULIC OILAND LUBRICANT The following information on hydraulic oil and lubricant is described Precautions...

Page 4: ...ition should be maintained Refer to p 19 in Chapter 5 z The product should be installed in the environmental condition specified by Nabtesco Refer to p 10 on 3 1 in Chapter 3 z Make sure GMs of the same type and model are used when applying them facing each other or synchronizing To prevent damages of GM and the machinery do not use GM of other model or other manufacturer s product z The following...

Page 5: ... manual shall not be copied photocopied or reproduced to any electronic medium or machine readable form without prior consent of Nabtesco z The photographs and drawings described in this manual may not represent actual products strictly z If this manual is lost or damaged immediately contact our customer support Operating or servicing the product without this manual may result in accident z If you...

Page 6: ...uct For handling of the hydraulic oil and the lubricant refer to the indications and recommendations in this manual z Prohibition The work coordinator and or administrator should not let personnel who have no ample knowledge of the product It may result in an injury to the operator or damage to the product Do not put fingers or any foreign object at the opening end of the product It may result in ...

Page 7: ...n measures will result in death or serious injury WARNING Indicates a potential hazardous situation which if not avoided or prepared protection measures could result in death or serious injury CAUTION Indicates a potential hazardous situation which if not avoided or prepared protection measures may result in minor or moderate injury NOTICE Indicates a potential hazardous situation which if not avo...

Page 8: ...n of the name of each part NOTE The following illustration may not strictly represent the actual appearance of the product ordered Fig 2 1 Hydraulic Motor Pilot Port Main Port Control Valve Drain Port Reduction Gears Oil Level Check Port Oil Drain Port Oil Fill Port Mounting Bolt Hole for Equipment Mounting Bolt Hole for Driving Part ...

Page 9: ...te or freeze Outdoors with wind and rain directly Places near chemical substances such as an organic solvent acid and alkali Places exposed to corrosive gas and or dust Places with unstable flooring Places where the floor strength is insufficient Places under vibration NOTE When the product is used or re operated after a long term check the following That there is no rust or corrosion Although GM ...

Page 10: ...llation of GM requires the following parts and materials Please prepare them after confirming the confirmation notice which includes installation drawing z Mounting bolt The specifications and quantity of bolts required to mount GM are described in the confirmation notice If there is anything uncertain please contact our customer support z Hydraulic oil Asmall amount of hydraulic oil remains in GM...

Page 11: ...operator or damage to GM For the personnel who carry out transportation at least observe the following condition and wear the protective gear Aforklift must be operated by a qualified person Be sure to wear a helmet leather gloves and protective footwear Be sure to check that GM is in the correct vertical orientation before unpacking the package If it is turned upside down the packaging material m...

Page 12: ...bricant specified by Nabtesco at the factory When hoisting GM refer to the Hoisting GM section Sections 4 1 and 4 2 on p 14 and p 15 Fig 3 1 z Confirmation of contents Confirm the following before using the product Please contact our customer support if there is any delivery error or damage The confirmation notice number matches the MSP number on the nameplate and the model code shown on the confi...

Page 13: ... the body of GM It indicates the product model and others The model information includes the following product information Indication example of standard product model ＧＭ ＶA Ｋ Design No Product class number Hydraulic motor displacement class number cm3 rev Reduction ratio class symbol Model symbol Size No Representative model Indication example of application product model ＧＭY ＶA B B Design No Pro...

Page 14: ...ar a helmet leather gloves and protective footwear during hoisting work The mass of GM is heavy Use a hoisting tool robust enough to endure the mass of GM If the strength of the hoisting tool is insufficient the tool may be damaged and or drop GM Never get under GM while it is being hoisted WARNING Hoist GM body horizontally in a balanced manner If it loses its balance and falls operators may be i...

Page 15: ...st oil on 1 mounting surface for equipment of GM and 2 bearing surface of the machinery NOTE GM has antirust oil applied to the non painted surfaces before shipping To keep the transmitting torque by bolts high wipe off the antirust oil on the mounting surface sufficiently GM 3 Mounting bolt hole for equipment Machine Driving part 4 Mounting surface for driving part 6 Mounting bolt hole for drivin...

Page 16: ...ng torque Bolt size M12 P1 75 M14 P2 0 M16 P2 0 M20 P2 5 M24 P3 0 Tightening torque N m Recommendation 102 15 7 163 24 5 252 39 2 493 78 5 709 88 3 Step 7 Check that there are no burrs or dirt on 4 mounting surface for driving part of GM and GM mounting surface of the driving part and wipe off the antirust oil on 4 mounting surface for driving part of GM and 5 bearing surface of the driving part N...

Page 17: ... to the confirmation notice for the amount of hydraulic oil NOTICE Fill the motor casing with hydraulic oil before use If GM is operated without supplying hydraulic oil the product may be damaged Step 3 Connect each hydraulic pipe NOTICE Confirm GM piping port rotation direction and piping size in the confirmation notice Select the piping size so that the drain port back pressure is below 0 20MPa ...

Page 18: ...peration do not touch GM until it has cooled down Immediately stop operation when any abnormality occurs Continuous operation may cause injuries to the operator Observe GM specifications and the limitation of specifications specified by us Specifications and the limitation should be in compliance with the confirmation notice for GM or the specifications and operating agreement for the machine for ...

Page 19: ...lic oil at the time of shipment Be sure to fill the motor casing with hydraulic oil before operation If the amount of the lubricant has decreased due to some reason identify and remove the cause and then add the lubricant When draining the lubricant do not drain it on the ground Be sure to drain it into a container Disposal of the waste oil should be in accordance with the applicable laws and regu...

Page 20: ...being mixed in seal container of hydraulic oil and the lubricant after use Avoid direct sun light keep away from fire or heat sources and store in a cool and dark place 5 2 Type of Hydraulic Oil NOTICE Use the hydraulic oil recommended by us Use of any other hydraulic oil may degrade the performance and durability of GM z Hydraulic oil specified by Nabtesco Use a wear resistant hydraulic oil with ...

Page 21: ...n addition if the viscosity is less than 10 mm2 s the performance will decrease significantly and if it is used for a long time the motor sliding part may get damaged resulting in a permanent deterioration in performance 5 3 Replacing Hydraulic Oil z Replacement interval Replace with new oil every 1000 engine hours or 1 year If the deterioration of the hydraulic oil is severe even within the above...

Page 22: ...ay degrade the performance and durability of GM z Lubricant specified by Nabtesco Use a lubricant with extreme pressure additive equipment to SAE 90 API class GL 4 or higher The following brands are recommended Manufacturer name Product name JXTG Nippon Oil Energy Gear Oil GL 4 90 Idemitsu Kosan Apolloil Gear HE90 Exxon Mobil Mobilube HD80W 90 Shell Shell Spirax EP90 Cosmo Oil Cosmo Gear GL 4 90 z...

Page 23: ...ion Metal analysis Al ppm Within 150 Cr ppm Within 20 Cu ppm Within 20 Fe ppm Within 600 Si ppm Within 350 z Replacement procedure CAUTION Confirm that the power of the customer machine is turned off before beginning the replacement work Immediately after operation GM and lubricant may be hot and may cause burns if touched Work after the temperature has dropped sufficiently Lubricant may eject whe...

Page 24: ...in port and oil level check port and drain the lubricant When replenishing the lubricant do not remove the plug of the oil drain port NOTICE Receive the drained lubricant with a container Step 2 After the completion of drainage plug the oil drain port and tighten the plug with the specified tightening torque p 25 Table 5 3 Refer to the confirmation notice for plug size Step 3 Fill up the lubricant...

Page 25: ...the plug into the oil fill port and oil level check port and tighten with the specified tightening torque Refer to the confirmation notice for the plug size NOTICE When tightening the plug with O ring to each port make sure that the O ring is not damaged Step 6 If the lubricant has adhered to the periphery wipe it off sufficiently Table 5 3 Plug size and tightening torque Size G PF 3 8 G PF 1 2 G ...

Page 26: ...t during operation After stopping the operation do not touch GM until it has cooled down Wear appropriate clothing and appropriate protective equipment protective goggles protective gloves and protective footwear Abnormal noise should be checked during operation Never touch the machine during the check 6 2 Periodical Inspection z Periodical inspection list Inspect the following items at least once...

Page 27: ...heck looseness of the mounting bolts for equipment and the mounting bolts for driving part If any are loose retighten with the specified tightening torque Refer to Table 4 1 for the tightening torque 6 2 3 Checking for abnormal noise CAUTION Abnormal noise should be checked during operation Never touch the machine during the check Step 1 Be careful not to touch GM and check abnormal noise or sudde...

Page 28: ...n gears in continuous operation Maximum 80 6 3 Removal from the Machine If it is necessary to remove GM from the machine for maintenance inspection or replacement pay the following precautions and remove it in the reverse procedure described in Section 4 2 Hoisting and Installing GM refer p 15 CAUTION To remove GM hoisting by crane operation is needed Before starting the removal refer to 4 1 Preca...

Page 29: ...nmatingsurfaces Polish the surface using a grindstone polishing paper andsoon Loosenessofbolts Retightenthebolts Fromthecase Loosenessofplugs Retightentheplugs Crackswithstones ReplaceGM Fromthefloatingseal Intrusionofearthandsand Washawaytheearthandsandfromthefloatingseal Wearofslidingsurfaces ReplaceGM O ringcreep ReplaceGM Fromthehydraulicmotor Loosenessofbolts Retightenthebolts O ringdamage Re...

Page 30: ...ebrakevalve Relief pressure drop on either side of thecontrolvalve Correctsetpressure Replacethereliefvalve Speedisinsufficient Lowpumpdischarge Pumpdoesnotworkproperly Replaceorrepairthepump Excessivepumpleakage Replaceorrepairthepump Large amount of leakage from the hydraulicmotor ReplaceGM Abnormalnoiseisproduced FromGM Damage to the hydraulic motor or reductiongears ReplaceGM Fromthepipe Vibra...

Page 31: ...r inquiries be ready to provide the product information described on the nameplate attached on the product Nabtesco Corporation Head office Power Control Company Sales 7 9 2 chome Hirakawa cho Chiyoda ku Tokyo 102 0093 Japan Telephone 81 3 5213 1152 Facsimile 81 3 5213 1172 HOMEPAGE www nabtesco com Name and address here Sales Representatives When contacted by a sales representative ...