PM-0002-0011 Manual de Chancado_419_501

7/24/2019 PM-0002-0011 Manual de Chancado_419_501

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26 Gilbert St.

Monroe, NY 10950

800-865-7756

Phone: (845) 782-5650 Fax: (845) 783-0271

Web: www.b-loc.com Email: [email protected]

Printed in U.S.A. 2002 B-LOC Corporation. All rights reserved.Information subject to change without prior notification.

B-LOC

O R P

KEYLESS FRICTIONAL LOCKING DEVICES

AUTHORIZED DISTRIBUTOR


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MOTOR HIDRAULICO


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Dim MA 141 MA 200 MB 283 MB 400MB 566MB800

MB 1150MB 1600 MB 2400

MB 3200MB 4000

A mmin

1405,5118

1556,1024

1807,0866

2007,8740

26010,2362

34013,3858

36014,1732

46018,1102

B mmin

843,31

843,31

1064,17

1174,61

1536,02

2158,46

25710,12

30011,81

C mmin

1335,24

1485,83

1746,85

1947,64

25410

33413,15

35413,94

45417,87

MarathonEngineering manual

AM-2.1

Dimensions98-03-01, Replaces 97-10-01

Installation dimensions and material for driven shaft

Design of driven shaft end on heavily-loaded shaft.

Where the driven shaft is heavily loaded and issubject to high stresses, for example on changesin the direction of rotation, it is recommended thatthe driven shaft should have a stress relievinggroove; see Fig. 3.1 and tables 3.1 and 3.3.

Normally-loaded shaft

In drives with only one direction of rotation wherethe stresses in the shaft are moderate, the shaftcan be plain, see Fig. 3.2 and tables 3.1 and 3.3.

0-0,025

0-0,00098

0-0,025

0-0,00098

-0,014-0,054

-0,00055-0,00213

-0,015-0,061

-0,00059-0,00240

-0,017-0,069

-0,00067-0,00272

-0,018-0,075

-0,00068-0,00292

-0,018-0,075

-0,00068-0,00292

Note! The dimensions are valid for +20C (68F)

Thread for mounting tool

Fig. 3.1

Fig. 3.2

Table 3.2 Alternative thread (Fig.3.1 and 3.2)

Table 3.1 Valid for couplings with slitted inner ring.

Table 3.3 Recommended material in the shaft

The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.

1(2)Hgglunds Drives AB, S-890 42 Mellansel, SWEDEN

To make it easier to mount the motor on the driven

shaft end or to remove the motor from the shaft itis recommended that a hole (Table 3.2) should bedrilled and tapped in the centre of the shaft for amounting tool. The tool has both a UNC thread anda metric thread, so that the hole can be drilled andtapped to conform to one of the two alternativesgiven in table 3.2.

MA 141 - MA 200MB 283 - MB 800*

MB1150/1600/2400

3200/4000D M20 UNC 5/8" M30 UNC 1"

E >17 (0,67) >13,5 (0,53) >25 (1) -

F 25 (0,98) 22 (0,87) 40 (1,57) 30 (1,18)

G 50 (1,97) 30 (1,18) 60 (2,36) -

Bidirectional drives

Unidirectional drives

Steel with yield strength Relmin

= 300 N/mm2


= 450 N/mm2

Max

Max

-0,020-0,083

-0,00075-0,00323

*MB 800, please contact your nearest Hggglunds Drivesrepresentative.


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The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.

2(2)Hgglunds Drives AB, S-890 42 Mellansel, SWEDEN

Dimensions, AM-2.1

Motor MA 141 MA 200 MB 283 MB 400MB 566MB 800

MB 800High speed

MB 1150MB 2400

MB 3200MB 4000

Tooth profile andbottom form

DIN 5480 DIN 5480 DIN 5480 DIN 5480 DIN 5480 DIN 5480 DIN 5480 DIN 5480

Tolerance 8f 8f 8f 8f 8f 8f 8f 8f

Guide Back Back Back Back Back Back Back Back

Pressure angle 30 30 30 30 30 30 30 30

Module 5 5 5 5 8 5 8 8

Number of teeth 26 28 34 38 36 50 44 54

Pitch diameter 130 140 170 190 288 250 352 432

Minor diameter 128 138 168 188 280 248 340,8 420,8

Major diameter 139 h11 149 h11 179 h11 199 h11 298,4 h11 259 h11 358,4 h11 438,4 h11

Measure overmeasuring pins

149,908 159,961 190,091 210,158 316,665 270,307 377,099 457,155

Diameter ofmeasuring pins

10 10 10 10 16 10 16 16

Addendummodification X M

+2,25 +2,25 +2,25 +2,25 +1,6 +2,25 -0,4 -0,4

Spline

The splines shall be lubricated, either oiled withhydraulic oil at assembly, or filled with transmissionoil from the connected gearbox. To avoid wear inthe splines, the installation must be within the

specified tolerances in fig. 3.3. For control of splinesee table 3.4.

Table 3.4

Fig. 3.3

0

-1,178

0

-1,178

0

-1,178

0

-1,201

0

-1,201

0

-1,801

0

-1,801

-0,085

-0,150

-0,085

-0,151

-0,087

-0,155

-0,088

-0,157

-0,102

-0,180

-0,103

-0,181-0,107

-0,188




= 450 N/mm2


= 700 N/mm2

98-03-01, 97-10-01

0

-1,825

-0,121

-0,212


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Installation and Maintenance ManualMarathon

EN320-19h 2002


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Preface

Hgglunds Drives is one of the worlds leading manufacturers of large hydrau-lic Drive Systems. A leading position, made possible by unbeatable servicespirit and of continuing development of both products and markets all over theworld. Our drives are to be found in most industrial and marine segments,where there are extremely high demands for efficiency and reliability. Our mainoffice and production plant is in Mellansel, Sweden and we have our ownsales- and representation offices in some 40 different countries.

Our high quality Drive Systems, are based upon our unique hydraulic pistonmotors, developed through a wealth of experience accumulated over 30 yearsin crane and winch business. Today this ongoing development work has resultedin the largest hydraulic motor ever built - the powerful MARATHON industrialmotor. New, as well as proven technical solutions, contribute to the creation ofthis product. The most desirable features and operating reliability have beendesigned in this hydraulic motor, which is the largest in the world!

This manual provides necessary information for installation and maintenanceof the motor. In order to find particular information, just search for the wanted

section as listed in the table of contents. However, changes in the equipmentmay occur. We therefore reserve the right to introduce amendments in themanual as we deem necessary without notice or obligations.

This Installation and Maintenance Manual is valid for motorsmanufactured after 98-01-01. For older motors please contactyour nearest Hgglunds Drives representative.

nalEN320-18a,

2000

Preface Installation and Maintenance Manual, Marathon


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Contents

1. GENERAL........................................................................................................................4

1.1 Safety precautions ...........................................................................................................4

1.2 Motor data ........................................................................................................................5

1.3 Functional description ...................................................................................................... 7

2. TECHNICAL DATA ..........................................................................................................8

2.1 Recommended charge pressure ......................................................................................8

2.2 Noise level from a complete installation ...........................................................................9

2.3 Choice of hydraulic fluid .................................................................................................10Environmentally acceptable fluids .................................................................................. 11

3. INSTALLATION .............................................................................................................12

3.1 Mounting instructions .....................................................................................................12

Thread for mounting tool ................................................................................................ 133.1.1 Lifting methods ...............................................................................................................14

Standing the motor on a flat surface .............................................................................. 15

3.1.2 Mounting the coupling onto the motor shaft ...................................................................15Instruction to follow when mounting the Marathon motor on a driven shaft ................... 15

3.1.3a Fitting the torque arm to the motor .................................................................................18

3.1.3b Fitting the double ended torque arm ..............................................................................19

3.1.4a Mounting the motor onto the driven shaft .......................................................................20

3.1.4b Mounting the motor onto the driven shaft - splines ........................................................23

3.1.5 Removing the motor from the driven shaft .....................................................................23

3.1.6 Mounting the reaction point ............................................................................................25

3.2 Oil connections...............................................................................................................26

3.2.1 Direction of rotation of motor shaft .................................................................................27

3.2.2 Draining and venting the motor ......................................................................................28

3.2.3 Flushing..........................................................................................................................29

4. OPERATING INSTRUCTIONS ......................................................................................29

4.1 Storage...........................................................................................................................29

4.2 Before commissioning ....................................................................................................30

4.3 Commissioning...............................................................................................................30

4.4 Periodic maintenance.....................................................................................................31Maintenance chart .........................................................................................................31Motor .............................................................................................................................. 32Filters ............................................................................................................................. 32Oil ................................................................................................................................... 32

5. FAULT FINDING ............................................................................................................33

DECLARATION OF CONFORMITY .............................................................................. 34

Installation and Maintenance Manual, Marathon Contents


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1. GENERAL

1.1 Safety precautions

It is of high importence that the Safety precautions are always followed, if you areunsure about something, please dont hesitate to contact your nearest HD-office foradvice.

WARNINGis used to indicate the presence of a hazardwhich can cause severe personal injury, death, orsubstantial property damage if the warning is ignored.

DANGER is used to indicate the presence of a hazardwhich will cause severe personal injury, death, or substantialproperty damage if the warning is ignored.

CAUTIONis used to indicate the presence of a hazardwhich will or can cause minor personal injury or propertydamage if the warning is ignored.

In this manual you will find the following signs which indicate a potential hazard, which can or willcause personal enjury or substantial property damage. Depending on the probability of the hazard,and how serious the injury or property damage could be, there are three levels of classification.

Warning signs

Application area

Mounting

Before starting up

All new and rebuild applications, should always be approved and supervised by HgglundsDrives personel.

Before starting up new, rebuild or just worked on applications, all accessories and safety ar-rangements functions, should be controlled/tested.

Carefully follow the instructions and be aware of the high weights and forces during lifting.

Periodic maintenanceNotice the intervals in maintenance chart (section 4.4) and keep a record.

DismountingCarefully follow the instructions and be aware of the high weights and forces during lifting.

General Installation and Maintenance Manual, Marathon


9/83

Metric

Motor type

Sindex

DisplacementSpecifictorque

Ratedspeed*

Max.speed

Max.pressure**

Max. outputpower

intermittent.

MA 141 8890 141 56 80 350 254

MA 200 12575 200 38 55 350 254

MB 283 17768 283 38 50 350 390

MB 800-283(1 20 17768 283 80 130 350 515

MB 400 25145 400 28 35 350 390MB 800-400(3 25145 400 36 50 350 515

MB 800-400(1 20 25145 400 56 95 350 515

MB 1150-400(1 25145 400 90 125 350 1031

MB 566 35561 566 28 35 350 515

MB 1150-566(1 35561 566 70 110 350 1031

MB 800-575(1 20 36121 575 42 65 350 515

MB 800 50265 800 18 25 350 515

MB 800-800(2 20 50265 800 28 45 350 515

MB 1150-683(1 42899 683 62 90 350 1031

MB 1150-800(1 50258 800 55 75 350 1031

MB 1150-975(1 61249 975 40 62 350 1031

MB 1150 72241 1150 38 53 350 1031

MB 1600-1375(1 86392 1375 30 43 350 1031

MB 1600 100529 1600 28 38 350 1031

MB 2400-1725(1 108383 1725 22 33 350 1546

MB 2400-1950(1 122520 1950 22 30 350 1546

MB 2400-2175(1 136657 2175 18 27 350 1546

MB 2400 150794 2400 16 24 350 1546

MB 3200 201059 3200 10 16 350 1580

MB 4000 251323 4000 8 12 350 1580

Installation and Maintenance Manual, Marathon General

1.2 Motor data

Table 1.1

Quantity Symbol Metric USPower P = kW hpDisplacement V

i= cm3/rev in3/rev

Specific torque Ts

= Nm/bar lbfft/1000 psiSpeed n = rpm rpmPressure p = bar psi

* Spec. considerations regarding charge pressure, cooling and choice of hydraulic system for speeds above rated.** The motors are designed according to DNV-rules. Test pressure 420 bar/6000 psi. Peak/transient pressure 420 bar/6000 psi maximum, allowed to occur 10000 times.(1High speed, Magnum port end and standard or lower displacement.(2High speed, Magnum port end.(3Lower displacement.

Vi T

s n n p P


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General Installation and Maintenance Manual, Marathon

US

Motor type

Sindex

DisplacementSpecifictorque

Ratedspeed*

Max.speed

Max.pressure**

Max. outputpower

intermittent.

MA 141 542 7170 56 80 5000 340

MA 200 767 10170 38 55 5000 340

MB 283 1084 14390 38 50 5000 523

MB 800-283(1

20 1084 14380 80 130 5000 690MB 400 1534 20340 28 35 5000 523

MB 800-400(3 1534 20340 36 50 5000 690

MB 800-400(1 20 1534 20340 56 95 5000 690

MB 1150-400(1 1534 20340 90 125 5000 1382

MB 566 2170 28780 28 35 5000 690

MB 1150-566(1 2170 28780 70 110 5000 1382

MB 800-575(1 20 2204 29240 42 65 5000 690

MB 800 3066 40680 18 25 5000 690

MB 800-800(2 20 3066 40680 28 45 5000 690

MB 1150-683(1

2618 34720 62 90 5000 1382MB 1150-800(1 3067 40680 55 75 5000 1382

MB 1150-975(1 3738 49570 40 62 5000 1382

MB 1150 4408 58480 38 53 5000 1382

MB 1600-1375(1 5270 69920 30 43 5000 1382

MB 1600 6132 81360 28 38 5000 1382

MB 2400-1725(1 6611 87700 22 33 5000 2072

MB 2400-1950(1 7473 99150 22 30 5000 2072

MB 2400-2175(1 8336 110600 18 27 5000 2072

MB 2400 9198 122050 16 24 5000 2072

MB 3200 12265 162750 10 16 5000 2117

MB 4000 15330 203440 8 12 5000 2117

Table 1.2

Quantity Symbol Metric USPower P = kW hpDisplacement V

i= cm3/rev in3/rev

Specific torque Ts

= Nm/bar lbfft/1000 psiSpeed n = rpm rpm

Pressure p = bar psi

* Spec. considerations regarding charge pressure, cooling and choice of hydraulic system for speeds above rated.** The motors are designed according to DNV-rules. Test pressure 420 bar/6000 psi. Peak/transient pressure 420 bar/6000 psi maximum, allowed to occur 10000 times.(1High speed, Magnum port end and standard or lower displacement.(2High speed, Magnum port end.(3Lower displacement.

Motor data

Vi T

s n n p P


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1.3 Functional description

5

11

R, L

9

8

10

6

4

3

2

1

D1

D2

Hgglunds Drives hydraulic industrial motorMARATHON is of the radial-piston type with arotating cylinder block/hollow shaft and astationary case. The cylinder block is mounted

in fixed roller bearings in the case. An evennumber of pistons are radially located in boresinside the cylinder block, and the valve platedirects the incoming and outgoing oil to andfrom the working pistons. Each piston isworking against a cam roller.

When the hydraulic pressure is acting on thepistons, the cam rollers are pushed against theslope on the cam ring that is rigidly connectedto the case, thereby producing a torque. Thereaction force is transferred by the guide roller

bearings on the cam rollers shaft ends to thetwo guide plates which are connected to thecylinder block/hollow shaft. Rotation thereforeoccurs, and the torque available is proportio-nal to the pressure in the system.

Oil main lines are connected to ports R and L

in the connection block and drain lines to portsD

1, D

2, D

3or (D

4)* in the port end housing.

The motor is connected to the shaft of the dri-ven machine through the hollow shaft of the

cylinder block.The torque is transmitted byusing a mechanical shaft coupling, or alterna-tively by splines.

Valid patents

US 4522110, SE 456517, EP 0102915,JP 83162704, GB 1385693, EU 0524437.

Quality

To assure that our quality is outstanding wemaintain a Quality Assurance system, certifiedto standard ISO 9001, EN 29001 and BS 5750;Part 1.

Fig. 1 The MARATHON motor

1. Cam ring2. Cam roller

3. Piston

4. Shaft coupling

5. Cylinder block / hollow shaft

6. Guide plates

7. Guide roller bearing

7a. Cylinder block bearing

8. Connection block9. Valve plate

10. Shaft end housing

11. Port end housing

R = inlet or outlet port R

L = inlet or outlet port L

D1, D

2, D

3and D

4= drain ports

7

7a

D

Installation and Maintenance Manual, Marathon General

(D4)*

*D4= MB 1150 - MB 4000


12/83

0

2

4

6

8

10

12

14

16

18

0 10 20 30 40 50 60

0

50

100

150

200

250

MB

400

0

MB

320

0

MB

240

0

MB

800

MB

400

MB

566

MB

160

0

MB

115

0

MB

283

MA

200

MA 141

barpsi

Technical data Installation and Maintenance Manual, Marathon

2. TECHNICAL DATA

2.1 Recommended charge pressure

The hydraulic system must be such that the motor will recieve sufficient charge pressure at thelow-pressure port. This applies to all types of installations.

There are two distinct cases:

Case 1:

The motor works in braking mode. Requiredcharge pressure at the inlet port is accordingto diagram below.

Case 2:

The motor works in driving mode only. Requiredback pressure at the outlet port corresponds to30% of value given in diagram below, but maynot be lower than 2 bar (29 psi).

Table 2.1 Charge pressure

Oil viscosity 40 cSt (187 SSU).Valid for 1 bar (15 psi) case pressure. With increasing case pressure the charge pressure mustbe increased accordingly.

Max. case pressure is 3 bar (43,5 psi) (for 1% of the operation time evenly divided, pressurepeaks of max. 5 seconds up to 8 bar (116 psi) are allowed).

Max. permitted case pressure at stand-still is 8 bar (116 psi).

rpm


13/83

2.2 Noise level from a complete installation

Hydraulic motor

The hydraulic motor is a known noise level.(Tables of sound data - see subsection 4.9 inthe Engineering Manual).

Driven unit

The driven unit is an unknown sound source(for us) but can through certain information

probably be obtained from the supplier. Whensecuring the torque arm of a hydraulic motorto the foundation or casing of a driven machine,it is highly important to study the constructionof the foundation or casing. This may well bethe most important factor to consider, sincemany structures may give rise to resonance,resulting in severe noise problems.

Remarks:

Background noise

The background noise can not normally beinfluenced but is usually known or easy tomeasure.

Pump unit

The pump unit is a known noise level.

Pipe noise

The pipe noise is probably the source of themajority of mistakes in installations: all pipeclamps should be of vibration insulating typesecured to concrete ceiling, wall or floor.Securing to non-rigid metal structures orstructures is likely to give resonance and shouldbe avoided.

Installation and Maintenance Manual, Marathon Technical data

Background noise

Pumpmotor

Pipenoise

Hydraulicmotor

Noise fromdriven unit

Foundation and construction noise


14/83

Technical data Installation and Maintenance Manual, Marathon

The Hgglunds Drives hydraulic motors are primarily designed to operate on conventional petro-leum based hydraulic oils. The hydraulic oil can be chosen in consultation with the oil supplier ofyour local sales office, bearing the following requirements in mind:

GENERAL

The oil shall have FZG (90) fail stage minimum 11 described in IP 334 (DIN 51354). The oil mustalso contain inhibitors to prevent oxidation, corrosion and foaming. The viscosity of mineral oil ishighly dependent of the temperature. The final choice of oil must depend on the operating tempera-ture that can be expected or that has been established in the system and not in the hydraulic tank.

2.3 Choice of hydraulic fluid

Fire resistant fluids

OPERATING WITH FIRE RESISTANT FLUIDSThe following fluids are tested for Hgglunds Drives motors: (ISO/DP 6071)

** Low viscosity gives reduced service life for the motors andreduction of max. allowed power for "MARATHON".

IMPORTANT! Down rating of pressure data and service life must be considered whenusing fire resistant fluid. The Hgglunds Drives company or its authorised representative

RECOMMENDED VISCOSITY ATOPERATING TEMPERATURE

40-150 cSt/187-720 SSU.

Temperature limits

Normal operating temperature should be lessthan +50C (122F)

Nitrile seals (std motor)Viton seals

-35C to +70C-20C to +100C

Nitrile seals (std motor)Viton seals

-31F to +158F -4F to +212F

Fluid Approved Seals Internal paint

HFA: Oil (3-5%) in water emulsion No - -

HFB: Inverted emulsion 40-45% water in oil Yes Nitrile (std motor) Not painted*

HFC: Water-glycol Yes Nitrile (std motor) Not painted*

HFD synthetic fluids

HFD:R - Phosphate esters Yes Viton Not painted*

HFD:S - Chlorinated hydrocarbons Yes Viton Not painted*

HFD:T - Mixture of the above Yes Viton Not painted*

HFD:U - Other compositions Yes Viton Not painted*

Viscosity limits

Viscosity index= 100 recommended= 150* for operationwith large temperaturedifference

Min. permitted in continuous dutyMin. permitted in intermittent dutyMax. permitted

40 cSt/187 SSU20 cSt/98 SSU**10000 cSt/48000 SSU

High temperatures in the system greatly reducethe service life of oil and rubber seals, as wellas resulting in low viscosity, which in turn prov-ides poor lubrication.

Content of water shall be less than 0,1%. InIndustrial applications with high demands for

service life, the content of water shall be lessthan 0,05%.

* Many hydraulic fluids with VI-improvers are subject to temporary and permanent reductions of the viscosity.

*Must be specified in the order.


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Environmentally acceptable fluids

Explanation of "Grade of filtration"

Grade of filtration 10=75 indicates thefollowing:

10means the size of particle 10m that willbe removed by filtration.

=75means the grade of filtration of abovementioned size of particle. The grade of filtrationis defined as number of particles in the oilbefore filtration in relation to number of particlesin the oil after filtration.

Ex. Grade of filtration is 10=75.

Before the filtration the oil contains Nnumberof particles 10m and after passing the filter

once the oil contains number of particles

10m.

This means that number of

particles have been filtered (=98,6%).

*Vegetable fluids give good lubrication and small change of viscosity with different temperature. Vegetablefluids must be controlled every 3 months and temperature shall be less than +45C (113F) to give goodservice life for the fluid.

**Environmental acceptable fluid give the same servicelife for the drive, as mineral oil.

The oil in a hydraulic system must always befiltered and also the oil from your supplier has

to be filtered when adding it to the system. Thegrade of filtration in a hydraulic system is aquestion of service life v.s. money spent on filt-ration.

In order to obtain stated service life it isimportant to follow our recommendationsconcerning contamination level.

When choosing the filter it is important toconsider the amount of dirt particles that thefilter can absorb and still operate satisfactory.

For that reason we recommend a filter with anindicator that gives a signal when it is time tochange the filter cartridge.

Filtering recommendations

Before start-up, check that the system isthoroughly cleaned.

1. In general the contamination level in ourmotors should not exceed ISO 4406 19/15(NAS 10).

2. For heavy-duty industrial applications thecontamination level should not exceed ISO4406 16/13 (NAS 7).

3. When filling the tank and motor case, werecommend the use of a filter with the gradeof filtration 10=75.

Filtration

Installation and Maintenance Manual, Marathon Technical data

Fluid Approved Seals Internal paint

Vegetable */**Fluid HTG

YesNitrile

(std motor)-

Synthetic **Esters HE

Yes Nitrile(std motor)

-


16/83

Installation Installation and Maintenance Manual, Marathon

3. INSTALLATION

3.1 Mounting instructions

If the motor is to work properly it must beinstalled with the greatest possible precision.Every item connected to the motor that does

not meet the requirements of the followinginstructions may result in stresses that ad-versely affect the basic rating life of the motor.

Normally the motor must be completely full ofoil. When the motor is installed with the shaftin the horizontal plane, the drain ports must bepositioned vertically. The higher of the two drainports must be used: see Fig. 3.24 "Oilconnections", page 26.

When the motor is mounted with the shaft in

the vertical plane, drain outlet D1or D2must beconnected to the drain hole on the shaft endhousing or end cover. A preloaded check valvemust be connected in the drain line to ensurethat the motor is filled with oil; see Fig. 3.28 -3.30 "Draining and venting the motor", page28.

The drain line must be dimensioned so thatmax. 3 bar (43,5 psi) motor case pressure isnot exceeded.

The max case pressure is 3 bar (43,5 psi). Briefpeaks during operation up to 8 bar (116 psi)are permissible. The permitted case pressurewhen the motor is stationary is 8 bar (116 psi).

The motor must always be connected in sucha way as to give a sufficient boost make-upflow at the low pressure connection. This isparticularly important at high speeds and withrapid reversing, see 2.1 "Recommendedcharge pressure".

Design of driven shaft end on heavily-loaded shaft

Where the driven shaft is heavily loaded andis subject to high stresses, for example on

changes in the direction of rotation, it isrecommended that the driven shaft should havea stress relieving groove; see Fig. 3.1 and tables3.1 and 3.2.

Table 3.1 Valid for couplings with slitted inner ring

E

CAD

30

R 3,2

G

F

60,5

B0,5

(B0,02)

(0,240,02)R 50(R 1,97)

a

Fig. 3.1

Normally-loaded shaft

In drives with only one direction of rotationwhere the stresses in the shaft are moderate,the shaft can be plain, see Fig. 3.1a and tables3.1 and 3.2

Fig. 3.1a

Dim MA 141 MA 200 MB 283 MB 400MB 566MB800

MB 1150MB 1600 MB 2400

MB 3200MB 4000

A mmin

1405,5118

1556,1024

1807,0866

2007,8740

26010,2362

34013,3858

36014,1732

46018,1102

B mm

in

84

3,31

84

3,31

106

4,17

117

4,61

153

6,02

215

8,46

257

10,12

300

11,81

C mmin

1335,24

1485,83

1746,85

1947,64

25410

33413,15

35413,94

45417,87

0-0,025

0-0,00098

0-0,025

0-0,00098

-0,014-0,054

-0,00055-0,00213

-0,015-0,061

-0,00059-0,00240

-0,017-0,069

-0,00067-0,00272

-0,018-0,075

-0,00068-0,00292

-0,018-0,075

-0,00068-0,00292

Max

Max



Steel with yield strength = 300 N/mmRel

Steel with yield strength = 450 N/mmRel

-0,020-0,083

-0,00075-0,00323

min

min

2

2


17/83

Thread for mounting tool

To make it easier to mount the motor on the driven shaft end or to remove the motor from the shaftit is recommended that a hole (table 3.2) should be drilled and tapped in the centre of the shaft fora mounting tool; see 3.1.4 "Mounting the motor onto the driven shaft", and 3.1.5 "Removing themotor from the driven shaft".

Table 3.2 Alternative thread (Fig. 3.1 and 3.1a)

Installation and Maintenance Manual, Marathon Installation

MA 141 - MA 200MB 283 - MB 800*

MB1150/1600/2400

3200/4000

D M20 UNC 5/8" M30 UNC 1"

E >17 (0,67) >13,5 (0,53) >25 (1) -

F 25 (0,98) 22 (0,87) 40 (1,57) 30 (1,18)

G 50 (1,97) 30 (1,18) 60 (2,36) -

The tool has both a UNC thread and a metricthread, so that the hole can be drilled andtapped to conform to one of the two alter-natives given in table 3.2.

Spline

*MB 800, please contact Hgglunds Drivesrepresentative.

Motor MA 141 MA 200 MB 283 MB 400MB 566MB 800

MB 800High speed

MB 1150MB 2400

MB 3200MB 4000

Tooth profile andbottom form DIN 5480 DIN 5480 DIN 5480 DIN 5480 DIN 5480 DIN 5480 DIN 5480 DIN 5480

Tolerance 8f 8f 8f 8f 8f 8f 8f 8f

Guide Back Back Back Back Back Back Back Back

Pressure angle 30 30 30 30 30 30 30 30

Module 5 5 5 5 8 5 8 8

Number of teeth 26 28 34 38 36 50 44 54

Pitch diameter 130 140 170 190 288 250 352 432

Minor diameter 128 138 168 188 280 248 340,8 420,8

Major diameter 139 h11 149 h11 179 h11 199 h11 298,4 h11 259 h11 358,4 h11 438,4 h11

Measure overmeasuring pins

149,908 159,961 190,091 210,158 316,665 270,307 377,099 457,155

Diameter ofmeasuring pins

10 10 10 10 16 10 16 16

Addendum

Table 3.3

The splines shall be lubricated, either oiled with hydraulic oil at assembly, or filled with transmissionoil from the connected gearbox. Motors that carry radial load, must have the splines filled with oil. Toavoid wear in the splines, the installation must be within the specified tolerances in fig. 3.2. Forcontrol of spline see table 3.3.

0-1,178

0

-1,178

0

-1,1780

-1,201

0

-1,201

0-1,801

-0,085

-0,150

-0,085

-0,151

-0,087

-0,155

-0,088

-0,157

-0,102

-0,180

-0,103-0,181

0,4 A

A

0,15 A

Fig. 3.2

min

min

2

2

0

-1,8010

-1,801

-0,107

-0,188-0,121-0,212

Steel with yield strength Rel = 450 N/mm

Steel with yield strength Rel = 450 N/mm




18/83


Fig. 3.5 MA141 - MB 800

Note:Must be lifted inmin. four lifting eyes.

Fig. 3.6.b MB 2400/3200/4000Fig. 3.6.a MB 1150/1600

Table 3.4

Fig. 3.8

Lifting the torque arm

Table 3.5

Fig. 3.7

Always make sure where thecentre of gravity is before anylifting, never stand below a

MotorWeight Lifting eye dimensions

kg lb A B C

MA 141 990 2183

1" UNC 1" UNC

3/4" UNCMA 200 1130 2490

MB 283 1395 3075

1" UNCMB 400 1625 3594

MB 566 2108 46471 1/4" UNC 1 1/4" UNC

MB 800 2580 5688

MB 1150 4600 10140

-

M24 M24MB 1600 4600 10140

MB 2400 6460 14222

MB 3200 8930 19730M30 M30

MB 4000 10750 23700

Torque armWeight

kg lb

TMA 20 75 165

TMA 40 133 283

TMA 60 207 456

TMA 80 420 930

Max 60

Max 60

Max 60

Fig. 3.3 Fig. 3.4

Before lifting, check that the liftingeyes are screwed fully home. Makesure that the lifting tools can handlethe weight (see table 3.4)

3.1.1 Lifting methods

One of the lifting methods shown here must be used when handling the motor and torque arm;see Figures 3.3-3.8.


19/83

Standing the motor on a flat surface

When the motor is placed on a flat surface such as a floor, it must stand either on its outer diameteror on the suitably protected end face of the hollow shaft (see Fig. 3.9 and 3.10).

NOTE:The motor must not be placed on the end face of the hollow shaft when the coupling is fitted, sincethis may cause damage to the coupling.

When in storage, the motor must always be placed on the end face to the hollow shaft. It is alsoadvisable to provide supports at the mounting surface of the motor; see Fig. 3.10.

3.1.2 Mounting the coupling onto the motor shaft

Fig. 3.10

Fig. 3.9

The motor is delivered with anti-rust treatment on the hollow shaft and coupling.

Instruction to follow when mounting the Marathon motor on a driven shaft

Before the motor is mounted there are somepreconditions which must be fulfilled:

- The shaft material for the driven shaft mustbe of a quality which meets the minimumrequirements specified by HgglundsDrives (see recommendations, page 12).

- The shaft must have the dimensions asrecommended in the section 3.1.

- You should note that the couplings are fromthe factory lubricated with MoS

2(Molycote)

on the conical surfaces and the bolts. Thislubricants shall remain on those surfaces but:

It is therefore important that you clean your

If those conditions are fulfilled you may startthe mounting.

- Clean the driven shaft and the out- andinside of the Marathon motor hollow shaft,see Fig. 3.12. Use acetone or similar.

- Remove the spacers between the twoclamping rings of the coupling.

- Mount the coupling on the hollow shaft of

the motor. The coupling must be pushedright up to the stop of the shaft.

- Mount the motor onto the driven shaft byfollowing the instruction in the section 3.1.4page 20, 21 and 22 (With or without usingthe mounting tool).Molycote must under no

circumstances be trans-ferred to the surfacesbetween the driven shaftand the motor.

Never tighten the couplingscrews until the motor hasbeen mounted onto the dri-ven shaft.


Support


20/83


However for the tightening of the couplingscrews the following must be observed:

Keep tension in your lifting wires to avoidskew setting of the motor on the shaftduring the tightening of the screws.Wobbling caused by skew setting of the

motor gives extra forces on the mainbearings.

In order to avoid the misalignment of the twoclamping rings during the screw tightening, thegap between the rings must be measured inseveral places during the process, see Fig.3.13.a, page 17. The difference between themeasured gaps must never vary more than 1mm (0,04") during any stage of the tighteningprocess. For motors MB 1150 and larger thisdimension may be max. 2 mm (0,08").

Pre-set the coupling screws in opposite pairs(12-6-3-9 oclock) until you reach max. 50% ofthe torque specified for the screws. It is veryimportant that when you reach this stage themisalignment is controlled as described above.

Mark the screw heads at 12 oclock with a penor paint so that you can follow the turningsequence of the screws.

Set the torque wrench for the specified maxi-mum torque. Tightening torque of the coupling

screws; see the sign on the coupling, or table3.6, page 17.

Now start tightening the screws in sequenceshown in Fig. 3.13.b, page 17.

Keep on doing this until you have reached thestated torque. Several passes are requiredbefore the screws are tightened to specifiedtorque. Keep checking the alignment of thecoupling (15-20 passes may be necessary).

When the specified torque is reached it is

important that all screws are tightened withspecified torque and that no further movementcan be observed.

Remember:

The following factors are important forsuccessful mounting:

- Right material and dimension on the drivenshaft.

- The conical surface between the couplingring and the clamping rings + the bolts shallbe coated with MoS

2 (Molycote), see Fig.

3.11.This is done from the factory atdelivery! When a motor has been in foroverhaul or service and shall be reassembled it may be necessary to relubricatethose surfaces with Molycote again butremember only the specified surfaces!

- Absolutely No Molycoteon the surfacesbetween shaft and motor. Clean the driven

shaft and the inside of the motor hollow shaft.

- Alignment of the motor on the shaft(dimensional check).

- Minimum variation in the gap between theclamping rings (dimensional check).

- Right torque on the bolts (use torquewrench).

Before starting the motor,check that the rotatingcoupling can not causedamage.

Fig. 3.11

Clamping rings - - - - - = Coated surface

Washer

Couplingring

Seal

Cleaned surface


21/83

Clean the driven shaftand the inside of themotor hollow shaft.

Fig. 3.12

Table 3.6

Note 1 Uncoated screws greased with MoS2.

Note 2 There is a metallic sign on every coupling with a tightening torque stamped on it.This torque is always to be used.

Note 3 Tightening torque value is critical. Use calibrated torque wrench.

Fig. 3.13.bFig. 3.13.a


Motor typeNo. of

screwsScrew dim

Tightening torque Strengthclass

Type ofhead

Nm lbfftMA 141 12

M16 x 65 250 185

10.9

Hexagon

MA 200 14

MB 283 12 M20 x 80

490 362

MB 400 15 M20 x 90

MB 566 20M20 x 100

MB 800 20

MB 1150 32M20 x 130

MB 1600 32

MB 2400 36 M20 x 160

570 420 12.9MB 3200 48M20 x 180

MB 4000 48


22/83


3.1.3a Fitting the torque arm to the motor

The torque arm is fitted to the motor beforethe motor is mounted on the driven shaft.

- Clean the spigot surface on the torque armand motor with trichlorethylene or similar

solvent.- Oil the screws.

- Make sure that the torque arm will bepointing in the right direction when themotor is mounted in place on the machine.

- Line up the torque arm on the motor byusing the screws.

- Tighten the screws to the torque stated inthe table below.

Note: Use torque wrench and oiled screws!

Table 3.7

Fig. 3.14.a MA 141 - MB 800 Fig. 3.14.b MB 1150/1600

Fig. 3.14.c MB 2400

Do not weld, drill, grind or carry outany similar work on the torque armwithout Hgglunds Drives approval.

Motor Screw dimensionsNumber of

screws

Tighteningtorque

Nm lbfft

MA 141 3/4" UNCStrength class 8.8 24x76mm 340 250MA 200

MB 283

1" UNCStrength class 8.8

24x89mm

810 597MB 400

MB 56636x89mm

MB 800

MB 1150 M24Strength class 8.8 43x80mm 650 480

MB 1600

MB 2400M24

Strength class 10.9900 660MB 3200

86x80mmMB 4000

Fig. 3.14.d MB 3200/4000


23/83

A

B

L R

C


3.1.3b Fitting the double ended torque arm

The torque arm is fitted to the motor before themotor is mounted on to the driven shaft. See3.1.3a "Fitting the torque arm to the motor".

Check and adjust the rod end (pos 1) accordingto the drawing. Mount the rod to the torque arm,use the shaft (pos 2) and lock them with circlips.Tighten the 4 pcs of screw (pos 3) on the rodend, torque according to table 3.7b.

Mount the hydraulic cylinder. The piston rod hasto be mounted upwards, and on the right handviewed from the motors main connection side.

Cylinders oil connection A, B and C must pointin the direction to the motor. Mount the hoses.The hose mounted to connection (R) has tobe mounted to the hydraulic cylinders

connection B, and the hose from connection(L) has to be mounted to the cylindersconnection A.

Remark!Start the system and run it for some minutes.Vent the cylinder from air. Use the vent screwson the cylinder (pos 4).

3

4

2

1


24/83

3.1.4a Mounting the motor onto the driven shaft

The motor can be mounted onto the driven shaft with or without a mounting tool, but the use of amounting tool is recommended since it make the work easier.

If the motor is to be mounted with the shaft pointing upwards, a venting nipple and hose must beconnected to the shaft end housing of the motor; see section 3.2.2 "Draining and venting the

motor", Fig. 3.28. It is recommended that the nipple and hose should be fitted to the motor beforethe coupling and torque arm are fitted. Then fit the torque arm to the motor; see section 3.1.3.

It is important to arrive at the correct clamping length between the driven shaft and the hollow shaftof the motor.

Ensure that the full clamping length is used by, for example, measuring and marking the drivenshaft. This is of particular importance if the duty is so severe that a stress relieving groove has beenmade on the driven shaft. See Fig. 3.20 and the table 3.8 on page 22.

Mounting the motors MA 141 - MB 800 with a mounting tool

- Pull the motor onto the shaft by turning thenut on the mounting tool; see Fig.3.18.b,until the length stated in the table 3.8 onpage 22 is obtained; see Fig. 3.20.

- Remove the mounting tool and also theend cover.

- Refit the plug in the centre shaft by tight-ening to the given torque. Finally fit the endcover and plug. Tighten the screws properlytogether with washers.

- Remove the plug, the end cover together

with screws and washers, and the plug inthe centre shaft; see Fig. 3.18.a.

- Mount the end cover without plug.

- Align the motor with the driven shaft.

- Locate the existing plastic washer insidethe nut on the mounting tool. Pass themounting tool through the end cover andthe centre shaft of the motor, and screw itinto the driven shaft to stated depth byusing the key handle in the end of the tool.

Fig. 3.18.a Mounting the MA 141 - 200 and MB 283 - 800

Fig. 3.18.b

End cover

Plug

Plug 70 Nm(50 lbfft)

Plastic washer

Nut

Mounting tool



25/83


Mounting the motors MB 1150 - MB 4000 with a mounting tool

Fig. 3.19.a Mounting the MB 1150 - 4000 Fig. 3.19.b

- Remove the end cover with screws andwashers; see Fig. 3.19.a.

- Remove the lock ring.

- Align the motor with the driven shaft.

- Pass the mounting tool through the centreshaft of the motor, and screw it into thedriven shaft by using the key handle in theend of the tool. Make sure that the tool isscrewed into the shaft end to specified length.

- Pull the motor onto the shaft by turning thenut on the mounting tool; see Fig. 3.19.b,until the length stated in the table 3.8 onpage 22 is obtained; see Fig. 3.20.

- Remove the mounting tool.

- Refit the lock ring.

- Finally fit the end cover, tighten the screwsproperly together with washers.

End cover

Lock ring

Mounting tool

Nut


26/83


Fig. 3.21

Mounting the motor without amounting tool

The motor can be mounted onto the drivenshaft without using a mounting tool, though thisis more difficult and takes longer time.However,it is easier to mount the motor if during mountingthe compressed air trapped within the hollowshaft is evacuated.

To do this, perform in the following manner:

Remove the end cover together with plug, aswell as the plug in the centre shaft; see Fig.3.18.a. After mounting, refit the removedcomponents.Tighten the end cover screwsproperly, as also the plug in the centre shaft togiven torque.

Remove the end cover during mounting;see Fig. 3.19.a. After mounting, refit the endcover. Tighten the screws properly.

Align the motor with the driven shaft using anoverhead crane or lifting truck and press itcarefully onto the shaft so that the lengthstated in the table beside is obtained, seeFig. 3.20.

To achieve the highest possible oil level in themotor case, the motor must be turned until the

drain outlets are positioned vertically one abovethe other, see fig 3.21.

Table 3.8

Fig. 3.20.a Without stress relieving groove

Fig. 3.20.b With stress relieving groove

Motors MA 141 - MB 800

Motors MB1150 - MB 4000

Motor

Length

B mm B in

MA 14184 3,31

MA 200

MB 283 106 4,17

MB 400 117 4,61

MB 566153 6,02

MB 800

MB 1150215 8,46

MB 1600

MB 2400 257 10,12

MB 3200300 11 81

Vertical line


27/83


3.1.4b Mounting the motor onto the driven shaft - splines

For flange mounted motors, the spline shallnormally not be subject to radial load.With noradial load, the splineshaft can be greased

before mounting the motor. If the motor is sub-ject to radial load, the splines shall be filled upwith oil.

- Mount the motor on to the shaft.

- Bolt the motor to the flange.

- Fill up hydraulic oil to the G1 plug.

- Torque the G1 plug. MV=125 Nm/90 lbf.ft.

Motors that carry radial load, must have thesplines oiled. The motor can be used for hori-zontal mounting and mounting with motor shaftpointing downwards.

- Mount the motor on to the shaft.

- Fill up hydraulic oil to the G1 plug.

- Mount washer and bolt.

- Torque the bolt. MV=200 Nm/144 lbf.ft for MA

141- 800. MV=700 Nm/504 lbf.ft for MB 1150-4000.

Flange mounted motors

Torquearm mounted motors

3.1.5 Removing the motor from the driven shaft

Before dismounting the motor from the driven shaft the oil in the motor case must be drainedthrough the lower draining hole. The motor can be removed from the shaft with or without the

mounting tool. The operation is easier if the tool is used.

Removal of motors MA 141 - MB 800 by using the mounting tool

- Slacken the shaft coupling screws gradually;see Fig. 3.13.a and 3.13.b on page 17.Each screw should be slackened onlyabout a quarter of a turn each time. Thustilting and jamming of the collars or threadstretching will be avoided. The screws mustbe slackened until the coupling ring is fullyreleased.

- Remove the plug, the end cover togetherwith screws and washers, and the plug inthe centre shaft; see Fig. 3.18.a.

- Locate the existing plastic washer outsidethe mounting tool nut.Then pass the toolthrough the centre shaft, and screw it intothe driven shaft to stated depth.

- Screw in the nut of the tool until the endcover can be refitted; see Fig. 3.22.

- Remove the motor from the driven shaft byunscrewing the nut of the mounting tool.

- Remove the end cover and mounting tool.Finally, refit the removed plugs and end coveras before.

If oil here, it canbe used for thespline. Then takeaway the sealingwasher.

O-ring

Mounting kit

Mounting kit478 3631-801=MA200, 478 3629-802=MB283-800, 478 3629-803=1150-2400

Oil to be filledbefore tight-ening G1 plug.

5 (0,2) Clearance,when filling oil.

Oil to be filledbefore tighteningbolt.


28/83

Removal of motors MB 1150 - MB 4000by using the mounting tool- Slacken the shaft coupling screws gradually;

see Fig. 3.13.a and 3.13.b on page 17.Each screw should be slackened onlyabout a quarter of a turn each time. Thus

tilting and jamming of the collars or threadstretching will be avoided. The screws mustbe slackened until the coupling ring is fullyreleased.

- Remove the end cover with screws andwashers; see Fig. 3.19.a. Remove the lockring.

- Pass the mounting tool through the centreshaft, and screw it into the driven shaft tostated depth.

- Screw in the nut of the tool until the lock

ring can be fitted outside the nut; see Fig.3.23.- Remove the motor from the driven shaft by

unscrewing the nut on the mounting tool. *Ifthe motor is hard to remove from the shaft,put a tube over the mounting tool to avoidbending of it. Innerdiameter=35 (1,4),MB1150/1600 L=700 (27,5), MB2400L=1000 (39), MB3200 L=1200 (47), MB4000L=1500 (59).

- Remove the lock ring and mounting tool.Finally, refit the lock ring in place, as alsothe end cover.

Removing the motor without using themounting tool- Slacken the screws of the shaft coupling,

see above "Removal of motors by using themounting tool".

- Remove some components to allow air to

enter the space in the hollow shaft of themotor; see Mounting the motor without amounting tool, page 22. After removal ofthe motor, refit the removed components asbefore.

- Carefully pull the motor off the driven shaftsupported by an overhead crane or a liftingtruck.

Always make sure that thelifting equipment is strong

enough, and never standbelow the motor duringdisassembly.

Each screw should beslackened only about aquarter of a turn each time.

Fig. 3.22 Removal of MA 141 - 200and MB 283 - 800


End cover

Plastic washer

Nut

Mounting tool

Mounting tool

Nut

Lock ring

Fig. 3.23 Removal of MB 1150 - 2400

*


29/83


3.1.6 Mounting the reaction point

Fig. 3.15 Mounting of pivoted attachment

Make sure that the found-ation can withstand theforces from the torque arm.

Fig. 3.16 Mounting of torque arm on pivoted attachment TMA 20, 40, 60, 80, 100.

Fig. 3.17 Torque arm installation

x = 2 mm (0,079) misalignment in installation.x 15 mm (0,59) movement when in use.

Alternativeposition

Steel: EN 10113S355N DIN St E39 BS 4360 Grade 50 C

Attachment

Singel torque arm Twin torque arm

R

=90 =90

2RL

Double torque arm with acylinder on the right hand-side of the motor

Bolted to the foundation

Note:The toggle bearing must bedismounted during welding

Protected against corrosion, after welding.

DANGER ZONEIn case of failure

of torque arm installation


30/83


3.2 Oil connections

Fig. 3.24

See Fig. 4.4.1 for MB 1150 - MB 4000

* SAE coupling J 518 C, code 62, 414 bar (6000 psi).** One "R"-connection and one "L"-connection is blocked at delivery (se Fig. 4.4.1).

Connection Description Remarks

R Main connection

If R is used as the inlet, the motor shaft rotates

clockwise, viewed from the motor shaft side.

L Main connectionIf L is used as the inlet, the motor shaft rotates anti-clockwise, viewed from the motor shaft side.

D1

Drain outlet Normally plugged at delivery.

D2, D

3Alternative drain outlet Normally plugged at delivery.

F Flushing connection For flushing of radial lip seal. Normally plugged.

T Test connectionsUsed to measure pressure and temperature at the mainconnections. Normally plugged.

MB 2400, MB 3200 and MB 4000 are partly filled with oil atdelivery (Shell Tellus Korrhydraul S68). Please check if it couldbe mixed with the systems oil or have to be exchanged. Seetable beside for filled in volume.

Motor Oil volume, litre (US gal.)

MB 2400 60 (15,8)

MB 3200 90 (23,8)

MB 4000 120 (31,7)

Motor R* L* D1, D2 D3 D4 F T

y

mm

y

in

x

mm

x

in

MA 141

1 1/2"1

1/2"

BSP1 1/4"

BSP1"

-

BSP1/4"

BSP 1/4"xM16

159 6,26

60 2,36MA 200

MB 283172 6,77

MB 400

MB 5662" 2" 201 7,91

91 3,58

MB 800

MB 1150***

2" ** 2" **BSP1 1/4"

BSP1 1/4"

238 9,37

MB 1600***

MB 2400***

MB 3200***

MB 4000***


31/83

Fig. 3.26

With high pressureconnected to R port.

When using (heavy wall) piping and in frequentreversal drives, it is recommended to fit flexiblehoses between the motor and piping to avoiddamage due to vibration and to simplify instal-lation of the motor. The length of the hoses hasto be as short as possible.

Table 3.9 Main connection R,L

Test connection T

Drain connection D1, D

2

Main connection R, L

Fig. 3.25

3.2.1 Direction of rotation of motor shaftWith the high pressure supply connected to R port, the motor shaft rotates in the direction shownby the arrow, i.e. clockwise viewed from the motor shaft side. With the high pressure supply connectedto L port, the motor shaft rotates anti-clockwise viewed from the motor shaft side.

Check directionof rotation.


Motora

mm (in)b

cmm (in)

MA 141

38 (1,5) 5/8" UNC 35 (1,38)MA 200

MB 283

MB 400

MB 566

48 (1,89) 3/4" UNC 36 (1,42)

MB 800

MB 1150

MB 1600

MB 2400

MB 3200

MB 4000

A

B

L R

C

If R is used ashigh pressure

Highpressure

Fig. 3.26a Example of a motor with a doubletorque arm, with cylinder mounted on the righthandside of the motor, viewed from theconnection side.

Air breather


32/83

Vertical mounting

When the motor is mounted vertically, one or theother of the vent holes must be connected tothe drain line. Which of the two holes that is tobe used depends on whether the motor shaft ispointing upwards or downwards.

Motor shaft pointing upwards

The venting hole on the shaft end housing shouldbe connected to the low pressure connection.At bidirectional drives, use the connection withlowest average pressure (connection to highpressure will increase the motor drain flow). Thisgives flushing of the radial lip seal. It is advisableto fit the nipple and the hose to the motor beforefitting the torque arm, see Fig 3.28.

Motor shaft pointing downwardsThe drain line has to be connected to the drainconnection as shown on Fig 3 29 and Fig 3 30

Fig. 3.28

Fig. 3.29

Fig. 3.30


Orifice 1,0 (0,04)

Drain line

Low pressure

Drain line

Drain line

Fig. 3.27

General for all mounting positions

The motors drain lines must be connected directto the oil tank with minimum of restrictions toensure that maximum case pressure is notexceeded. To ensure that proper venting takesplace and that the motor is completely full of oil,the drain connection on the motors highest levelmust be used.

Drain line

3.2.2 Draining and venting the motor

Remark!If the oil tank is placed in lower levelthan the motor, a preloaded check valve mustbe connected in the drain line. The check valvemust be preset to 0,3-0,7 bar (4-10 psi).

Horizontal mounting

When the motor is installed with the shaft in thehorizontal plane, the higher of the two drainoutlets D

1or D

2must always be used; see Fig.

3.24 and 3.27. D1D

2must be connected direct

to the oil-tank.

If a check valve is used in thedrain line, make sure that it isconnected in the right direction.


33/83

Installation and Maintenance Manual, Marathon Maintenance

3.2.3 Flushing

Flushing of motor case

To avoid high temperature in the motor casethe heat must be cooled away, because hightemperature gives lower viscosity and that gi-

ves reduction in service life. Low viscosity alsogives reduced permitted output power from themotor.- For continuous duty in applications with an

ambient temperature of +20C (68F), themotor case must be flushed when theoutput power exceeds the values beside:

Max power without flushing

MA 141 - MB 283 120 kW (160 hp)MB 400/566/800 170 kW (227 hp)MB 1150/1600/2400 250 kW (335 hp)

MB 3200/4000 250 kW (335 hp)For calculation of required flushing, pleasecontact your Hgglunds Drives represent-ative.The flushing oil shall be drained in thenormal drainline. See 3.2.2.

Connect the input line for flushing in the lowestdrain port.

4. OPERATING INSTRUCTIONS

4.1 Storage

The motor is delivered with internal protection in the form of an oil film and external protection in theform of an anti-rust film. This provides sufficient protection for indoor storage in normal temperatu-res for about 12 months.

Note: the anti-rust protection must be touched-up after transport and handling.

If the motor is stored for more than 3 months in unheated premises or more than 12 months inheated premises, it must be filled with oil* and positioned as shown in Fig. 3.10, page 15.

Fill the motor with filtered oil in the following order: D1, R, L. See 2.3, "Filtration".

Take extreme care to ensure that no contamination enters the motor with the oil.

Seal connections R and L with the cover plate fitted to the connection surface at delivery. Checkthat the O-rings or rubber seals are in postion in the cover plate.

Fit the plugs to D1, D

2. The table below states the amount of oil needed to fill the various types of

motors.

Table 4.1

Fig. 4.1

MotorOil volume approx.

Litres US gal.

MA 141 55 14,6

MA 200 60 15,9

MB 283 70 18,5

MB 400 80 21,1

MB 566 100 26,4

MB 800 135 35,7

MB 1150 230 60,7

MB 1600 230 60,7

MB 2400 270 71,2

MB 3200 335 88,4

MB 4000 410 108,2

*See page 32 "Motor"


34/83

Maintenance Installation and Maintenance Manual, Marathon

4.3 Commissioning

- During initial starting and the periodimmediately after it, any hydraulic installa-tion must be regularly and carefully checkedat frequent intervals.

- The working pressure and charge pressuremust be checked to ensure that theycorrespond to the contracted values.

- The pressure in the drain line measured atthe motor must be less than 3 bar (43,5psi). This pressure limit is important for thelife of the motor.

- If leakage occurs, correct the fault andcarry out new measurements.

- Check all lines, connections, screws, etc.and correct if necessary.

- Check other possible leakage points and

replace faulty parts.- During the start up period, dirt particles in

the system are removed by the filters. Thefilter cartridges have to be changed afterthe first 100 working hours and after thataccording to the maintenance chart. Note tocheck the "filter clogged" indicators.

- When starting up the motor it isimportant that the motor output power islimited to 75% of max power accordingto technical data, see Fig. 4.3. A not run-in

motor in combination with dirt particles in theoil can badly affect the sliding surfaces in themotor. This is valid during the first 100working hours.

4.2 Before commissioning

Check the following points before commissio-ning the motor, i.e. before starting the first time:

- Check that the motor is connected to givethe correct direction of rotation (see 3.2"Oil connections" and 3.2.1 "Direction ofrotation of motor shaft").

- Select the hydraulic fluid in accordancewith the recommendations (see 2.3 "Choiceof hydraulic fluid").

- Fill the motor case with hydraulic fluidvia a filter into the drain outlets D

1, D

2or the

vent hole (depending on how the motor ismounted).

- Check the drain line to ensure thatexcessive pressure does not build up in themotor housing; see 3.1 "Mounting instruc-tions" and 3.2.2. "Draining and venting themotor".

- Check that the motor is protected fromoverloads (see 1.1 "Motor data").

- Check that the charge pressure conforms

to the charge pressure curve (see 2.1"Recommended charge pressure").

- Check that all hydraulic couplings andplugs are properly tightened to preventleakage.

- Make sure that the torque arm is sufficientlyfastened, see 3.1.3.

Fig.4.3


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4.4 Periodic maintenance

All motor sizes have separate oil for axial thrust bearing. Oil must be changed every 5 years. Fillup to the top of the connection BSP 3/8". Mobil SHC 634, Mobil SHC 639, Shell Paolina 460, ShellPaolina 680 or equivalent must be used.

When a hydraulic system has been in servicefor some time, it must undergo periodicmaintenance and servicing at intervals whichdepend on the equipment and the type of duty.This periodic maintenance must include thefollowing operations:

- Check the hydraulic system for leakage.Tighten the screws, replace faulty sealsand keep the drive clean.

- Inspect and clean all air, oil and magneticfilters; replace all filter cartridges for whicha filter clogged indication has been given;inspect tank, pump, filters etc. and clean ifnecessary.

- Check the pressure and temperature of thehydraulic fluid and carry out routine opera-tions. Adjust valves etc. if necessary.

- Check the hydraulic fluid; see the Section

headed "Oil", page 32.

- Check that no dirt or other contaminationsenter the system during inspection.Checkthat the outside of the hydraulic motor in aninstallation is kept free of dirt; thus leakageand faults will be detected earlier.

- We recommend that a running log is keptand that planned inspections are carriedout at set intervals.

- Maintenance checks and operations are as follows:

Fig. 4.4.1

Repl. = Replacement Insp. = Inspection

Maintenance chart

Installation and Maintenance Manual, Marathon Maintenance

In operation Oil filters OilOil for axial

thrust bearingTorque arm

After the first 100hours

Repl.Insp.

(fill up)Insp.

After 3 months or500 hours

Repl.

Once every 6months Repl. Insp. *) Insp.

Once every 12months

Insp.(fill up)

Motor sizeVolume neededlitre (US. gal.)

MA 141/200 0,9 (0,24)

MB 283/400 1,8 (0,48)

MB 566/800 2,1 (0,56)

MB 1150/1600/2400MB 3200/4000

4,7 (1,24)

Connection BSP 3/8"for bearing oil 35 Nm / 25 lbt.ft.

(D4Shaft end housing)

Axial thrust bearing

* Inspection (fill up) every 6 months, when themotor shaft is pointing downwards


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If the motor is to be stored stationary for alonger period than about 1 month, it must beprotected from internal rust. This can be doneas follows:

1. Mix anti-rust additive with the hydraulicfluid of the system. Use 5% of Rust VetoConcentrate (manufactured by E FHoughton & Co, Philadelphia, USA). Thisadditive gives rust protection for up to about1 year, after which time the motor must beturned a few revolutions.

2. If no additives are used, the motor mustbe regularly turned a few revolutions.

3. If it is not possible to turn the motor, plug

all connections, open drain outlet D1or D2on the port end housing (or if the motor ismounted vertically, vent hole F on the shaftend housing) and fill the motor with hydrau-lic fluid (see Fig. 4.4.2).

FiltersFilters must be changed after the first 100working hours and the second change is to becarried out after 3 months or 500 working hours

whichever is earlier. They must then bechanged at regular intervals of 6 months or4000 working hours.

Oil (See also 2.3)AnalysisIt is recommended that the oil should be analy-sed every 6 months. The analysis should coverviscosity, oxidation, water content, additivesand contamination.

Most oil suppliers are equipped to analyse thestate of the oil and to recommend appropriateaction. The oil must be replaced immediately if

Fig. 4.4.2

Many hydraulic oils become thinner withincreasing use, and this means poorerlubrication. The viscosity of the oil in servicemust never fall below the minimum recom-mended viscosity.

Oxidation

Hydraulic oil oxidizes with time of use andtemperature. This is indicated by changes incolour and smell, increased acidity or the for-mation of sludge in the tank. The rate of oxida-tion increases rapidly at surface temperaturesabove 60C (140F), and the oil should thenbe checked more often.

The oxidation process increases the acidity ofthe fluid; the acidity is stated in terms of the"neutralisation number". Typical oxidation isslow initially and increases rapidly later.

A sharp increase (by a factor of 2 and 3) in theneutralisation number between inspections isa signal that the oil has oxidized too much andshould be replaced immediately.

Water content

Contamination of the oil by water can bedetected by sampling from the bottom of thetank. Most hydraulic oils repel the water, whichthen collects at the bottom of the tank. Thiswater must be drained off at regular intervals.Certain types of transmission oils and engineoils emulsify the water; this can be detected bycoatings on filter cartridges or a change in thecolour of the oil. Obtain the advice of your oilsupplier in such cases.

Degree of contaminationHeavy contamination of the oil causesincreased wear of the hydraulic systemcomponents. The cause of the contaminationmust be immediately investigated andremedied.

ViscosityMotor

Maintenance Installation and Maintenance Manual, Marathon

All hydraulic fluids are affecteddifferently. Obtain the advice ofyour oil supplier or your nearest


37/83

5. FAULT FINDING

Installation and Maintenance Manual, Marathon Fault finding

Hydraulic motor

Fault Probable cause Action

The motor does not run. Mechanical stop in the drive.

The motor does not deliverenough torque because thepressure difference across themotor is not enough for theload.

Insufficient or no oil beingsupplied to motor.

Check system pressure. If the pressure has

risen to the relief valve setting, remove the loadfrom the drive.

Investigate the pressure level in the system andcorrect the setting of the pressure limiting valveif necessary.

Check the hydraulic system.Check the externalleakage of the motor (The D connection).

Motor rotates in wrongdirection.

Oil supply connections tomotor incorrectly connected.

Connect the oil supply correctly.

Motor runs jerkily. Pressure or flow fluctuations inthe hydraulic system.

Find the cause in the system or in themechanical power transmissions.

Noise in the motor. The motor is being operatedwith the charge pressure toolow.

Internal faults in the motor.

Adjust the charge pressure to the correct level.See 2.1 "Recommended charge pressures".

Investigate the drain oil, if necessary. Put amagnetic plug in the drain flow and check thematerial that sticks to the magnet. Steelparticles indicate damage. Note that finematerial from the castings may be depositedand does not mean internal damage in themotor.

External oil leakage onthe motor.

The radial lip seals is worn. Replace the radial lip seal.


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DECLARATION OF CONFORMITY

Example of the Declaration of Conformity given by Hgglunds Drives AB

Installation and Maintenance Manual, Marathon Declaration of conformity

The DECLARATION OF CONFORMITY above, is available on request for deliveries fromHgglunds Drives AB. Translations into other languages are also available.

Manufacturers name: Hgglunds Drives AB

Manufacturers address: S-890 42 MellanselSweden

Contact Name: Bo Hrnsten

Product Description: Hydraulic Motor

Item no. Model Serial no.

178 1526-801 MB 400 N 0200 514 02234

We herewith declare that the products specified above

- is intended be incorporated into machinery or to be assembled with othermachinery to constitute machinery covered by Directive 98/37/EG, as amended

- does therefore not in every respect comply with the provision of this directive

and that

- the harmonized standards SS-EN 982, SS-EN 292-1 and SS-EN 292-2 have beenapplied.

and furthermore declares that it is not allowed to put the machinery into service until themachinery into which it is to be incorporated or of which it is to be a component hasbeen found and declared to be in conformity with the provision of Directive 89/392/EECand with national implementing legislation, i.e. as a whole, including the machineryreferred to in this declaration.

Signed: ......................................

DECLARATION BY THE MANUFACTURER

(Directive 98/37/EG, Art 4.2 and Annex II, sub B)PROHIBITION TO PUT INTO SERVICE


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Manual de instalacin y mantenimientoMarathon

SP320-7h 2005


40/83

Introduccin

Hgglunds Drives, es en el mundo, uno de los principales fabricantes, de

grandes sistemas de accionamiento hidrulico. Esta posicin de lder es

resultado de un espritu de servicio insuperable y del desarrollo continuo de

productos y mercados por todo el mundo. Nuestros equipos se encuentran

en la mayora de los sectores industriales y marinos, donde se exigen muy

elevadas cotas de eficacia y fiabilidad. Nuestra sede y planta de produccin

principal se encuentra en Mellansel, Suecia, y tenemos oficinas de venta y

representacin en unos 40 pases.

Nuestros sistemas completos de accionamiento de alta calidad estn basados

en nuestros singulares motores de pistones, desarrollada a traves de una granexperiencia acumulada durante ms de 30 aos en la fabricacin de gras

y cabrestantes. Hoy, el desarrollo continuo ha dado como resultado el mayor

motor hidrulico jams construido: el potente motor industrial MARATHON.

Soluciones tcnicas nuevas y bien probadas han contribuido a la creacin

de este producto. Este motor hidrulico, que es el mayor del mundo, posee

las caracteristicas ms deseables, tal como resistencia y fiabilidad, en el

trabajo.

Este manual contiene toda la informacin necesaria para la instalacin y el

mantenimiento del motor. Para encontrar una cierta informacin, busque laseccin deseada en el ndice. No obstante, pueden introducirse cambios en

el equipo. Por ello, nos reservamos el derecho a introducir modificaciones

en el manual segn lo encontremos necesario, sin previo aviso ni obligacin

alguna.

Esta Manual de instalacin y mantenimiento es vlido paralos motores fabricados a partir del 1 de enero de 1998. Paralos motores ms antiguos, srvanse contactar con el repre-sentante local de Hgglunds Drives.

nalEN320-119h,

2002

Introduccin Manual de instalacin y mantenimiento Marathon


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Indice1. GENERALIDADES ..........................................................................................................4

1.1 Instrucciones de seguridad ..............................................................................................4

1.2 Datos del motor ................................................................................................................5

1.3 Descripcin del funcionamiento .......................................................................................7

2. DATOS TECNICOS ..........................................................................................................8

2.1 Presin recomendada en la va de baja presin (retorno) ...............................................8

2.2 Sonido de una instalacin completa .................................................................................9

2.3 Eleccin del fluido hidrulico ..........................................................................................10

Fluidos ecolgicamente aceptables ...............................................................................11

3. INSTALACION ...............................................................................................................12

3.1 Instrucciones de montaje ...............................................................................................12

Rosca para la herramienta de montaje ..........................................................................13Eje estriado ...................................................................................................................13

3.1.1 Mtodos de elevacin .....................................................................................................14

Apoyo del motor sobre una superficie plana ..................................................................15

3.1.2 Montaje del acoplamiento en el eje del motor ................................................................15

Instrucciones para cuando se monta el motor Marathon en un eje conducido ..............15

3.1.3a Montaje del brazo de par en el motor ............................................................................18

3.1.3b Montaje del brazo de par doble ......................................................................................19

3.1.4a Montaje del motor en el eje conducido ...........................................................................20

3.1.4b Montaje del motor en el eje accionado - estriado ...........................................................23

3.1.5 Desmontaje del motor del eje conducido .......................................................................23

3.1.6 Montaje del punto de reaccin .......................................................................................25

3.2 Conexiones de aceite .....................................................................................................26

3.2.1 Sentido de giro del eje del motor ....................................................................................27

3.2.2 Drenaje y purga del motor ..............................................................................................27

3.2.3 Recirculacin de aceite ..................................................................................................29

4. INSTRUCCIONES DE FUNCIONAMIENTO ..................................................................294.1 Almacenaje .....................................................................................................................29

4.2 Antes de la puesta en marcha ........................................................................................30

4.3 Puesta en marcha ..........................................................................................................30

4.4 Mantenimiento peridico ................................................................................................31

Esquema de mantenimiento ...........................................................................................31

Motor ..............................................................................................................................32

Filtros ..............................................................................................................................32

Aceite .............................................................................................................................32

5. LOCALIZACION DE AVERIAS ......................................................................................33

DECLARACION DE CONFORMIDAD ...........................................................................34

Manual de instalacin y mantenimiento Marathon Indice


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1.1 Instrucciones de SeguridadEs de la mxima importancia seguir en todo momento las instrucciones de segu-ridad; si tiene alguna duda al respecto, pngase en contacto con la oficina de HDms cercana.

1. INFORMACIN GENERAL

rea de aplicacinEl personal de Hgglunds Drive siempre debe aprobar y supervisar todas las aplicaciones, ya

sean nuevas o reconstruidas.

MontajeSiga atentamente las instrucciones y preste atencin a los grandes pesos y fuerzas implicadosdurante la elevacin.

Antes del arranqueAntes de arrancar aplicaciones nuevas, reconstruidas o reparadas, deben ser revisados, todos

los accesorios y funcionamiento, de los dispositivos de seguridad.

Mantenimiento peridicoObserve los intervalos del grfico de mantenimiento (4.4) y lleve un registro de los mismos.

DesmontajeSiga atentamente las instrucciones y preste atencin a los grandes pesos y fuerzas durante laelevacin.

PELIGROse utiliza para indicar la existencia de un peligrocuyas consecuencias seran graves lesiones personales,fallecimiento, o importantes daos materiales, si se hiciera

caso omiso de la seal.

AVISO se utiliza para indicar la existencia de un peligroque puede dar lugar a graves lesiones personales, falleci-

miento, o importantes daos materiales, si se hiciera caso

omiso de la seal.

PRECAUCIN se utiliza para indicar la existencia de unpeligro que podra o puede ser causa de lesiones persona-

les o daos materiales menores, si se hiciera caso omiso

de la seal.

Seales de avisoEn este manual encontrar las siguientes seales de aviso, que indican un peligro potencial que

puede derivar en lesiones personales o importantes daos materiales. Dependiendo de la proba-

bilidad de peligro y de lo graves que pudieran ser las lesiones personales o los daos materiales,

existen tres niveles de clasificacin:

Generalidades Manual de instalacin y mantenimiento Marathon


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Mtricos

Tipo de motor

Sindex

CilindradaPar espec-

ficoVelocidadnominal*

Velocidadmxima

Presonmxima**

Potencia mximaintermitente de

salida

MA 141 8890 141 56 80 350 254

MA 200 12575 200 38 55 350 254

MB 283 17768 283 38 50 350 390

MB 800-283 1) 21 17768 283 80 130 350 515

MB 400 25145 400 28 35 350 390

MB 800-400 3) 31 25145 400 36 50 350 515

MB 800-400 1) 21 25145 400 56 95 350 515

MB 1150-400 1) 21 25145 400 90 125 350 1031

MB 566 35561 566 28 35 350 515

MB 1150-566 1) 21 35561 566 70 110 350 1031

MB 800-575 1) 21 36121 575 42 65 350 515

MB 800 50265 800 18 25 350 515

MB 800-800 2) 20 50265 800 28 45 350 515

MB 1150-683 1) 21 42899 683 62 90 350 1031

MB 1150-800 1) 21 50258 800 55 75 350 1031

MB 1150-975 1) 21 61249 975 40 62 350 1031

MB 1150 72241 1150 38 53 350 1031

MB 1600-1375 1) 21 86392 1375 30 43 350 1031

MB 1600 100529 1600 28 38 350 1031

MB 2400-1725 1) 21 108383 1725 22 33 350 1546

MB 2400-1950 1) 21 122520 1950 22 30 350 1546

MB 2400-2175 1) 21 136657 2175 18 27 350 1546

MB 2400 150794 2400 16 24 350 1546

MB 3200 201059 3200 10 16 350 1580

MB 4000 251323 4000 8 12 350 1580

1.2 Datos del motor

* Consideraciones especiales respecto a la contrapresin, refrigeracin y seleccin del sistema hidrulico paravelocidades por encima de las sealadas.

** Los motores estn diseados segn las normas DNV. Presin de prueba 420 bar/6000 psi. Se permiten puntasde presin instantaneas de 420 bar/6000 psi maximo 10.000 veces.

(1 Alta velocidad, conexiones Magnum y estandar o cilindrada reducida.2) Alta velocidad, conexiones Magnum.(3 Cilindrada reducida.

Manual de instalacin y mantenimiento Marathon Generalidades

Tabla 1.1

Unidad Simbolo Mtricos EE.UU.Potencia P = kW hpCilindrada V

i = cm3/rev in3/rev

Par especfico Ts = Nm/bar lbfft/1000 psi

Velocidad n = rpm rpm

Preson p = bar psi

Vi T

s n n p P


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EE.UU.

Tipo de motor

Sindex

CilindradaPar espec-

ficoVelocidadnominal*

Velocidadmxima

Presonmxima**

Potencia mximaintermitente de

salida

MA 141 542 7170 56 80 5000 340

MA 200 767 10170 38 55 5000 340

MB 283 1084 14390 38 50 5000 523

MB 800-283 1) 21 1084 14380 80 130 5000 690MB 400 1534 20340 28 35 5000 523

MB 800-400 3) 31 1534 20340 36 50 5000 690

MB 800-400 1) 21 1534 20340 56 95 5000 690

MB 1150-400 1) 21 1534 20340 90 125 5000 1382

MB 566 2170 28780 28 35 5000 690

MB 1150-566 1) 21 2170 28780 70 110 5000 1382

MB 800-575 1) 21 2204 29240 42 65 5000 690

MB 800 3066 40680 18 25 5000 690

MB 800-800 2) 20 3066 40680 28 45 5000 690

MB 1150-683 1) 21 2618 34720 62 90 5000 1382MB 1150-800 1) 21 3067 40680 55 75 5000 1382

MB 1150-975 1) 21 3738 49570 40 62 5000 1382

MB 1150 4408 58480 38 53 5000 1382

MB 1600-1375 1) 21 5270 69920 30 43 5000 1382

MB 1600 6132 81360 28 38 5000 1382

MB 2400-1725 1) 21 6611 87700 22 33 5000 2072

MB 2400-1950 1) 21 7473 99150 22 30 5000 2072

MB 2400-2175 1) 21 8336 110600 18 27 5000 2072

MB 2400 9198 122050 16 24 5000 2072

MB 3200 12265 162750 10 16 5000 2117MB 4000 15330 203440 8 12 5000 2117

Datos del motor

* Consideraciones especiales respecto a la contrapresin, refrigeracin y seleccin del sistema hidrulico paravelocidades por encima de las sealadas.

** Los motores estn diseados segn las normas DNV. Presin de prueba 420 bar/6000 psi. Se permiten puntasde presin instantaneas de 420 bar/6000 psi maximo 10.000 veces.

(1 Alta velocidad, conexiones Magnum y estandar o cilindrada reducida.(2 Alta velocidad, conexiones Magnum.(3 Cilindrada reducida.

Tabla 1.2

Vi T

s n n p P

Generalidades Manual de instalacin y mantenimiento Marathon

Unidad Simbolo Mtricos EE.UU.Potencia P = kW hpCilindrada V

i = cm3/rev in3/rev

Par especfico Ts = Nm/bar lbfft/1000 psi

Velocidad n = rpm rpmPreson p = bar psi


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1.3 Descripcin del funcionamiento

5

7

11

R, L

9

8

10

6

4

3

2

1

D1

D2

El motor hidrulico industrial MARATHON

de Hgglunds Drives es del tipo de pistones

radiales con bloque de cilindros/eje hueco

giratorio y crter fijo. El bloque de cilindros va

montado en el crter sobre cojinetes de rodil-los. Un nmero par de pistones est situado

radialmente en dicho bloque de cilindros, y la

placa de distribucin dirige el aceite dentro y

fuera de los pistones. Cada pistn acta contra

un rodillo de leva.

Cuando la presin hidrulica acta sobre los

pistones, los rodillos de leva son empujados

contra la inclinacin del aro volumtrico que

est conectado rgidamente al cr

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