Gearbx Installatin Manual Rtrk Gears HOB/MPR & HOS/MPR ranges (Electrnic cpy available n www.rtrk.cm)! This manual cntains imprtant safety infrmatin. Please ensure it is thrughly read and understd befre installing the gearbx.! This manual is prduced t enable a cmpetent persn t install, perate, adjust and inspect Rtrk gearbxes. Only persns cmpetent by virtue f their training r experience shuld install, maintain and repair Rtrk gearbxes.! The gearbx weight is recrded n the packaging and n a label attached t the gearbx.! WARNING: Gearbx may present an unbalanced lad.! WARNING: With respect t handwheel peratin f Rtrk gearbxes, under n circumstances shuld any additinal lever device such as a wheel-key r wrench be applied t the handwheel in rder t develp mre frce when clsing r pening the valve as this may cause damage t the valve and/r gearbx r may cause the valve t becme stuck in the seated/backseated psitin.! WARNING: Damage t prtective catings shuld be crrectly rectified and may invalidate warranty. RG-HOBMPR_HOSMPR-INSTALL-002 / PUB027-050-00_0817 Page 1 f 9
Cntents 1. Intrductin... 3 2. Health and safety... 3 3. Strage... 3 4. Unpacking... 3 5. Handling... 3 6. Installatin & Maintenance fr Multi-Turn HOB/MPR & HOS/MPR Cmbinatins... 4 6.1. Output Sleeve Remval, Machining and Re-Fitting... 4 6.2. Munting t the valve... 5 6.2.1. All Gearbxes... 6 6.2.2. Gearbxes HOB/MPR14, HOS/MPR14 and HOS/MPR16... 7 6.3. Maintenance Instructins fr HOB/MPR & HOS/MPR gear peratrs... 7 7. Paint Repair prcedure... 8 8. Reference... 9 9. Handwheel Types... 9 RG-HOBMPR_HOSMPR-INSTALL-002 / PUB027-050-00_0817 Page 2 f 9
1. Intrductin Unless therwise specified the gearbx is supplied assembled. 2. Health and safety Wrk undertaken must be carried ut in accrdance with the instructins in this and any ther relevant manuals. The user and thse persns wrking n this equipment shuld be familiar with their respnsibilities under any statutry prvisins relating t the Health and Safety f their wrkplace. Due cnsideratin f additinal hazards shuld be taken when using the gearbx with ther equipment. Shuld further infrmatin and guidance relating t the safe use f the Rtrk prducts be required, it will be prvided n request. The mechanical installatin shuld be carried ut as utlined in this manual and als in accrdance with relevant standards such as British Standard Cdes f Practice. N inspectin r repair shuld be undertaken unless it cnfrms t the specific hazardus area certificatin requirements. Fr maintenance f the actuatr, refer t the actuatr installatin and maintenance manual.! WARNING: The gearbx enclsure materials may include; Cast Irn, Ductile Irn, Carbn Steel r Stainless Steel. 3. Strage If the gearbx cannt be installed immediately, stre it in a clean and dry place until installatin can take place. The recmmended strage temperature range is 0 C t 40 C (32 F 104 F). 4. Unpacking Gearbxes are packed in a variety f cnfiguratins depending n size, type and quantity f the cnsignment. It is the respnsibility f the individual unpacking and handling the gearbx cmbinatin t carry ut a risk assessment t ensure safe wrking practices are used. Refer t Sectin 5. Packaging material used may include wd, cardbard, plyethylene and steel. recycled accrding t lcal regulatins. 5. Handling! Individual weights fr gearbxes are recrded n their respective nameplates. Packaging shuld be! Only trained and experienced persnnel shuld carry ut handling. At all times, safe handling must be ensured.! Each gearbx cmbinatin must be assessed t identify all risks assciated with handling.! The gearbxes must be fully supprted until full valve stem engagement is achieved and the gearbx is secured t the valve flange.! Once cnnected t the valve, each assembly must be assessed n an individual basis fr safe handling/lifting. Never lift the cmplete gearbx and valve assembly via the gearbx.! If it is necessary t lift the gearbx using lifting equipment, certified sft slings are recmmended. Damage t prtective catings shuld be crrectly rectified and may invalidate warranty.! We recmmend fitting a blt and washer system nt the baseplate f HOB/MPR and HOS/MPR gearbxes befre mving them, as demnstrated in Figure 3 and Figure 4. RG-HOBMPR_HOSMPR-INSTALL-002 / PUB027-050-00_0817 Page 3 f 9
6. Installatin & Maintenance fr Multi-Turn HOB/MPR & HOS/MPR Cmbinatins 6.1. Output Sleeve Remval, Machining and Re-Fitting HOB/MPR and HOS/MPR range f gearbxes have a remvable utput sleeve. Unless specifically requested at the rdering stage, the utput sleeve will be supplied blank and must be machined t suit the valve stem. Befre re-fitting the machined utput sleeve, check that the surfaces marked A in Figure 1 and Figure 2 are nt damaged. Damaged surfaces can break the gearbx seals r bearings and cause water ingress r grease leakage. Fr all HOB/MPR and HOS/MPR gearbxes apart frm HOB3, see Figure 1: Fr the HOB3 gearbx, see Figure 2: Figure 1 - Splined Output Sleeve, Imprtant Surfaces Figure 2 - Dg Drive Output Sleeve, Imprtant Surfaces An anti-frictin cmpund cntaining mlybdenum disulphide, such as MI-Setral-9M shuld be applied t the faces marked with * and highlighted in red in Figure 1 and Figure 2, befre inserting the utput sleeve back int the gearbx. Fr clarificatin n the suitability f an anti-frictin cmpund, please cntact Rtrk Gears. With reference t Figure 3 belw, nte that the utput sleeve arrangement is identical fr HOB/MPR and HOS/MPR gearbxes. The utput sleeve (14) can be easily remved frm the gearbx by first remving the spigt ring (15) frm the baseplate (16). A small frce may have t be applied t the face marked C in Figure 1 and Figure 2 t assist in remving the sleeve.! WARNING: It is imperative that the thrust bearings in the utput are fitted crrectly, alng with the utput sleeve and the spigt ring. That is, the needle thrust bearings MUST have a thrust washer (12) at each side f the needle race (13). A bearing / washer assembly MUST be fitted at each side f the utput sleeve thrust shulder. All thrust elements and bearing cavities must be packed with grease f the crrect specificatin. RG-HOBMPR_HOSMPR-INSTALL-002 / PUB027-050-00_0817 Page 4 f 9
! WARNING: Bearings, Output sleeve and Valve Stem/shaft shuld be thrughly greased with apprpriate grease befre fitting anytime they are fitted int the gearbx/valve. Nte the spigt ring has an internal and external seal that shuld als be greased. All utput sleeves, with the exceptin f the HOB3, are splined and may have t be rtated slightly t engage with the mating spline in the utput gear. The HOB3 has a dg drive which needs t be aligned t the mating sectins in the utput gear. 6.2. Munting t the valve Figure 3 HOB/MPR / HOS/MPR Output Sleeve Assembly! WARNING: Ensure the valve is fully supprted and capable f accepting increased weight and a change f centre f gravity resulting frm the additin f the gearbx cmbinatin. The recmmended maximum unsupprted length fr cver tubes is shwn in Table 1.! WARNING: Bearings, Output sleeve and Valve Stem/shaft shuld be thrughly greased with apprpriate grease befre fitting int the gearbx/valve. Nte the spigt ring has an internal and external seal that shuld als be greased! WARNING We recmmend fitting a nut (19) and washer (18) fixture int the base f the gearbx as demnstrated in Figure 3 and Figure 4. Nte that the washers must verlap the spigt ring (15). This will stp the utput sleeve assembly frm becming detached frm the main bdy. The blts and washers are nt supplied by Rtrk Gears. If the gearbx has been supplied with a handwheel, it is recmmended that this be fitted t the gearbx befre munting nt the valve. This will make it easier t rtate the gearing t pick up the valve stem, key, thread r spline lcatin. Figure 4 - Securing Spigt Example RG-HOBMPR_HOSMPR-INSTALL-002 / PUB027-050-00_0817 Page 5 f 9
! WARNING: Threaded stems shuld be thrughly lubricated with grease befre fitting the utput sleeve. 6.2.1. All Gearbxes Ensure that the gearbx baseplate is parallel t the valve flange when lwering. This will avid jamming. It is recmmended that a silicn sealant is used between the gearbx baseplate and the valve flange. D in Figure 5 highlights where this sealant shuld be applied. Figure 5 - Sealing f Valve Munting Flange It is recmmended that the machined utput sleeve assembly is assembled nt the valve stem first and then the gearbx lwered nt the utput sleeve assembly. See Figure 6 and Figure 7 fr assembly details. Fit the machined utput sleeve (14), thrust bearings (12 & 13) and baseplate spigt ring (15) n the valve shaft as shwn in the Figure 6. Bearings shuld be lubricated with the apprpriate grease. Grease the utput sleeve and valve stem. Nte that the spigt ring has an internal and external seal that shuld als be greased. Figure 6 - Valve Stem Assembly Figure 7 - Valve Stem (Assembled) Fr rising stem valves, a cver tube must be fitted t prtect the valve stem.! WARNING: D nt pack the cver tube with grease as this can lead t a pressure build up in the cver tube. Screw r blt the cver tube int the gearbx and seal with a suitable sealant t prevent water ingress. RG-HOBMPR_HOSMPR-INSTALL-002 / PUB027-050-00_0817 Page 6 f 9
Cver tubes are extensins t the gearcase and thus, damage t the cver tube can cause damage t the gearcase. It is essential that the cver tubes are prtected r supprted t avid side lads as a result f the envirnment r the applicatin. See Table 1: Gearbx HOB3 t HOB/MPR5, HOS/MPR4 t HOS/MPR5 HOB/MPR6 t HOB/MPR7, HOS/MPR6 t HOS/MPR7 HOB/MPR8 t HOB/MPR9, HOS/MPR8 t HOS/MPR9 HOB/MPR10 t HOB/MPR14, HOS/MPR10 t HOS/MPR20 Table 1 - Maximum Unsupprted Tube Lengths Maximum Unsupprted Tube Length 2.0m (6.6ft) 2.8m (9.2ft) 3.0m (9.8ft) 5.0m (16.4ft) 6.2.2. Gearbxes HOB/MPR14, HOS/MPR14 and HOS/MPR16 Instead f bullet pints 3 and 4 in Sectin 6.2.1, it is recmmended that the cylindrical rller bearings and machined utput sleeve are assembled nt the valve stem first and then the gearbx lwered t lcate n the utput sleeve assembly. See Figure 8 fr assembly details: Fit in the fllwing rder: RG-HOBMPR_HOSMPR-INSTALL-002 / PUB027-050-00_0817 Page 7 f 9 Figure 8 - Valve Stem Assembly with Cylindrical Rller Bearings Spigt Ring, Husing Washer (Largest Outside Diameter), Bearing Shaft Washer (Smallest Outside Diameter), Output Sleeve, Shaft Waster (Smallest Outside Diameter), Bearing Husing washer (Largest Outside Diameter) The washer faces that are either chamfered r have markings MUST FACE AWAY frm the bearings t decrease wear n the bearing. Bearings shuld be lubricated with the apprpriate grease. Grease the utput sleeve and valve stem. Nte that the spigt ring has an internal and external seal that shuld als be greased. 6.3. Maintenance Instructins fr HOB/MPR & HOS/MPR gear peratrs Fr standard duties, all gear cavities are lubricated fr life with Fuchs Renlit CL-X2 grease. Under nrmal perating cnditins, n maintenance is required fr the gearbx. Hwever, shuld the valve be taken ut f service fr verhaul, the gearbx baseplate may be remved and the grease changed using the fllwing
recmmended lubricant. The baseplate must be sealed using silicne sealant n re-assembly, unless fitted with an O ring. All O rings shuld be renewed. An anti-frictin cmpund cntaining mlybdenum disulphide, such as MI-Setral-9M shuld be applied t the faces marked with * and highlighted in red in Figure 1 and Figure 2, befre inserting the utput sleeve back int the gearbx. Fr clarificatin n the suitability f an anti-frictin cmpund, please cntact Rtrk Gears. Nte: All thrust elements and bearing cavities must be cleaned, re-greased and re-fitted in the crrect rder. The recmmended lubricant is shwn in Table 2. Gearbx Manufacturer Name Temperature Range HOB/MPR and HOS/MPR Fuchs Renlit CL-X2-60 C t +120 C Table 2 - Recmmended Lubricatin fr Bevel and Spur Gearbxes An equivalent extreme pressure lubricant may be used. cnsult Rtrk. Fr extreme temperature applicatins, please 7. Paint Repair prcedure If paint repair is required, the fllwing prcedure shuld be fllwed: Clean surface using slvent if necessary. Rinse surface with clean fresh water t remve any freign matter and traces f slvent. Abrade area using wet and dry sandpaper, r pwer sander, feather edges f sund intact paint arund damaged area by 2.5 cm Apply paint system as per riginally applied t unit ensuring that dry film thickness (dft) limits are met and time is allwed fr each cat t cure. All as per the paint manufacturer s data sheets. Ambient Cnditins - N cleaning r cating applicatin shall be undertaken if: The relative humidity is mre than 85% The metal temperature is less than 3ºC abve the dew pint. The ambient cnditins are utside thse stated in the paint manufacturer s data sheet fr each cating. Catings shall nly be applied r cured at ambient and steel temperatures abve 10ºC r therwise recmmended by paint supplier. RG-HOBMPR_HOSMPR-INSTALL-002 / PUB027-050-00_0817 Page 8 f 9
8. Reference Table 3 shws recmmended tightening trques fr munting the gearbx t the valve. Gearbx t valve fixing must cnfrm t Material Specificatin ISO Class 8.8, yield strength 628N/mm² t use Table 3 belw: Imperial Trque Metric Size Trque Size (Hex) Nm lbs/ft. (Hex) Nm lbs/ft. 3/8 34 25 M5 5 4 7/16 55 40 M6 9 6 ½ 83 61 M8 21 15 9/16 120 89 M10 41 30 5/8 166 122 M12 71 53 ¾ 291 215 M16 177 131 7/8 469 346 M20 346 255 1 702 518 M24 598 441 1 ¼ 1403 1035 M30 1189 877 1 ½ 2441 1800 M36 2079 1533 Table 3 - Trque Tightening Figures 9. Handwheel Types Size in mm CD (Cast) Handwheel Type - Weight Kgs (lbs) PS (Pressed Steel) SG (Steel - Welded) S (Stainless Steel) 50 0.11 (0.24) - - - - 75 0.21 (0.46) - - - - 100 0.32 (0.71) 0.15 (0.33) - - - 125 0.54 (1.19) 0.2 (0.44) - - - 150 - - 1 (2.20) 0.4 (0.88) - 160-0.35 (0.77) - - - F/FS (Steel - Welded) 200 1 (2.20) 0.75 (1.65) 1.35 (2.98) 1 (2.20) 1 (2.20) 250-1.5 (3.31) 1.4 (3.09) - - 300 - - 1.8 (3.97) - 1.5 (3.31) 315-2 (4.41) - - - 350 - - 2.3 (5.07) 1.5 (3.31) - 400-3.5 (7.72) 2.8 (6.17) - 2.2 (4.85) 450 - - 3 (6.61) - - 500 - - 3.5 (7.72) - 3 (6.61) 600 - - 4.5 (9.92) - 3.2 (7.05) 700 - - 5 (11.02) - 5.5 (12.13) 800 - - 5.5 (12.13) - 6.6 (14.55) 900 - - 6 (13.23) - 7.2 (15.87) 1000 - - - - 8.4 (18.52) 1100 - - - - 9.4 (20.72) 1200 - - - - 10.27 (22.64) Table 4 - Handwheel Weights by Type RG-HOBMPR_HOSMPR-INSTALL-002 / PUB027-050-00_0817 Page 9 f 9