AutomationDirect IronHorse HGR-37-005-A User manual
IronHorse® HelIcal Gearbox User ManUal
IH-HG-USER-M-WO
1st Ed. Rev. B
IronHorse® Helical Gearbox User Manual – 1st Ed. Rev. B
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Page W–1IronHorse® Helical Gearbox User Manual – 1st Ed. Rev. B
Warnings and Trademarks
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Page W–2 IronHorse® Helical Gearbox User Manual – 1st Ed. Rev. B
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Page H–1IronHorse® Helical Gearbox User Manual – 1st Ed. Rev. B
IronHorse®
Helical Gearbox
User Manual
User Manual Revision History
Please include this Manual Number and the Manual Issue, both shown below, when communicating
with AutomationDirect Technical Support regarding this publication.
Publication History
First Edition 06/02/2016 Original Issue
1st Edition Rev. A 06/07/2016 Revised dimensional drawing
1st Edition Rev. B 10/09/2018 Added additional installation information in chapter 3
Page H–2 IronHorse® Helical Gearbox User Manual – 1st Ed. Rev. B
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Page A–1IronHorse® Helical Gearbox User Manual – 1st Ed. Rev. B
IronHorse® HelIcal Gearbox
User ManUal Table of conTenTs
W–1
W–1
W–1
W–2
W–2
1–1
1–2
1–2
1–2
1–2
1–2
1–3
1–3
1–3
1–4
1–4
2–1
2–2
2–2
2–3
2–8
3–1
3–2
3–3
3–4
3–4
3–4
3–5
3–6
3–7
3–7
3–7
3–8
Page A–2 IronHorse® Helical Gearbox User Manual – 1st Ed. Rev. B
Table of Contents
Page 1–1IronHorse® Helical Gearbox User Manual – 1st Ed. Rev. B
GettinG Started 1
1
1
Chapter
Chapter
Chapter
1–2
1–2
1–2
1–2
1–2
1–3
1–3
1–3
1–4
1–4
Page 1–2 IronHorse® Helical Gearbox User Manual – 1st Ed. Rev. B
Chapter 1: Getting Started
Manual Overview
The IronHorse Helical Gearbox User Manual describes the installation, operation, and preventative
maintenance of IronHorse Helical Gearboxes.
This manual contains important information for people who will install, maintain, and/or operate
any of the IronHorse Helical Gearboxes.
Our technical support group is glad to work with you to answer your questions. Please call
the technical support group if you need technical assistance, or visit our web site. Our website
contains technical and non-technical information about our products and our company.
By telephone: (770) 844-4200 (Mon – Fri, 9:00 am – 6:00 pm ET)
On the Web: www.automationdirect.com
When you see the “notepad” icon in the left-hand margin, the paragraph to
its immediate right will be a special note.
When you see the “exclamation mark” icon in the left-hand margin, the paragraph to its
immediate right Will be aWarning. this information could prevent injury, loss of property, or
even death (in extreme cases).
Chapter 1: Getting Started
Page 1–3IronHorse® Helical Gearbox User Manual – 1st Ed. Rev. B
IronHorse® Helical Gearbox Introduction
Gearboxes, also known as enclosed gear drives or speed reducers, are mechanical drive
components that can control a load at a reduced fixed ratio of the motor speed. The output
torque is also increased by the same ratio, while the horsepower remains the same (less
efficiency losses). For example, a 10:1 ratio gearbox outputs approximately the same motor
output horsepower, but motor speed is divided by 10, and motor torque is multiplied by 10.
Helical gearboxes use helical gears to provide quiet startup and smooth operation. IronHorse
helical gearboxes are manufactured in an ISO9001 certified plant by one of the leading and most
internationally acclaimed gearbox manufacturers in the world today. Only the highest quality
materials are tested, certified, and used in the manufacturing process. Strict adherence to and
compliance with the toughest international and U.S. testing standards and manufacturing
procedures assure you the highest quality products. We offer straight-through helical gearboxes
with cast-iron frames. The output shaft is parallel to the input. Our gearboxes utilize C-face and
TC-face mounting interfaces for C-face and TC-face motors.
After receiving the IronHorse Helical Gearbox, please check for the following:
Page 1–4 IronHorse® Helical Gearbox User Manual – 1st Ed. Rev. B
Chapter 1: Getting Started
Part Number Explanation
HGR - 67 - 060 - A
Motor Size Input
A: 56C face frame
B: 145TC face frame
C: 182/4TC face frame
D: 213/5TC face frame
E: 254/6TC face frame
Ratio
Three digit input for output of 1
Example: 060 = 60:1 ratio
Box Size
37: 37 box size
47: 46 box size
67: 67 box size
77: 77 box size
87: 87 box size
Gearbox Type Series Designation
HGR: Helical gear
Nameplate Information
Gearbox Type
Gearbox Actual Ratio
Gearbox Model Number
Gearbox Serial Number
Gearbox Box Size
Page 2–1IronHorse® Helical Gearbox User Manual – 1st Ed. Rev. B
SpecificationS 2
2
2
chapter
chapter
chapter
2–2
2–2
2–3
2–8
Page 2–2 IronHorse® Helical Gearbox User Manual – 1st Ed. Rev. B
Chapter 2: Specifications
Gearbox Selection Factors
Service Factors for Selecting Gearboxes
(when used with electric motors)
Occasional 1/2 hour 1.00 1.00 1.00 1.25
Less than 3 hours 1.00 1.00 1.25 1.50
3-10 hours 1.00 1.25 1.50 1.75
More than 10 hours 1.25 1.50 1.75 2.00
* Shock results from sudden increases in the torque demand of
the load, such as: sudden stopping, restarting, and/or reversing;
significantly heavy loads dropped onto a moving conveyor;
impact loads such as punch press operations.
Depending upon the load characteristics, divide the gearbox HP,
Overhung Load, and Maximum Mechanical Capacity ratings by
the applicable service factor.
Overhung Load K Factors
for Various Drive Types
Chain & Sprocket 1.00
Gear 1.25
V-belt 1.50
Flat Belt 2.50
Variable Pitch Belt 3.50
Divide gearbox OHL ratings by the
applicable OHL K factors.
Chapter 2: Specifications
Page 2–3IronHorse® Helical Gearbox User Manual – 1st Ed. Rev. B
IronHorse® Cast-Iron Helical Gearbox Specifications
IronHorse Cast-Iron Helical Gearbox Specifications – Box Size 37
Part Number
Nominal Ratio
Actual Ratio
Output RPM @ 1750 rpm
Input
Nominal HP @ 1.0 Service
Factor 1
NEMA Motor Frame
Output Shaft Diameter (in)
Input Power (hp)
Output Torque (lb·in)
OHL (lbs)2
Efficiency (%)
Stages
Approx Weight (lb)
HGR-37-005-A 5:1 4.88 359 1.0 56C
1
5.91 970 305 93.4
2
32
HGR-37-005-B 2.0 145TC
HGR-37-010-A 10:1 10.02 175 1.0 56C 4.04 1360 388 93.3
HGR-37-010-B 2.0 145TC
HGR-37-015-A 15:1 15.75 111 1.0 56C 2.99 1580 451 93.2
HGR-37-015-B 2.0 145TC
HGR-37-020-A 20:1 19.95 88 1.0 56C 2.49 1670 489 93.3
HGR-37-020-B 2.0 145TC
HGR-37-030-A 30:1 31.02 56 1.5 56C 1.75 1770 565 90.5
3
HGR-37-030-B 2.0 145TC
HGR-37-040-A 40:1 40.08 44 1.0 56C 1.35 1770 615 90.8
HGR-37-060-A 60:1 60.84 29 1.0 56C 0.89 1770 705 90.8
1) Nominal Motor HP is the highest HP 1800 rpm motor to be used with the gearbox under conditions of 1.0 service factor.
Gearbox input power capacity decreases as motor speed decreases and as service factor increases.
2) OHL= Overhung Load ratings are for forces perpendicular to the output shaft and located at the shaft midpoint, such as
from a gear, pulley, or sprocket with a belt or chain. Divide OHL ratings by the applicable OHL K factors shown separately
in the Selection Factors tables. OHL ratings should also be divided by applicable service factors.
3) Maximum Mechanical Ratings are limits based on strength and durability of gearbox components; applicable when
operating time is short and stopped time is greater than or equal to operating time. These ratings are applicable for 1.0
service factor loads, and may require modification depending upon characteristics of the applicable driven loads. Refer to
the “Service Factors” table for more information.
Page 2–4 IronHorse® Helical Gearbox User Manual – 1st Ed. Rev. B
Chapter 2: Specifications
IronHorse Cast-Iron Helical Gearbox Specifications (continued)
IronHorse Cast-Iron Helical Gearbox Specifications – Box Size 47
5:1 4.85 361 2.0 145TC
1-1/4
9.59 1565 440 93.4
2
45
5.0 182/4TC
51
10:1 11.27 155 3.0 182TC 5.95 2255 590 93.4
15:1 15.18 115 3.0 182TC 4.87 2490 650 93.5
20:1 18.37 95 2.0 145TC 4.29 2650 690 93.4 45
3.0 182TC 51
30:1 31.83 55 2.0 145TC 2.73 2830 835 90.4
3
45
3.0 182/4TC 51
40:1 41.51 42 1.0 56C 2.09 2830 910 90.6
60:1 63.37 28 1.0 56C 1.37 2830 1050 90.5 45
1) Nominal Motor HP is the highest HP 1800 rpm motor to be used with the gearbox under conditions of 1.0 service factor.
Gearbox input power capacity decreases as motor speed decreases and as service factor increases.
2) OHL= Overhung Load ratings are for forces perpendicular to the output shaft and located at the shaft midpoint, such as from
a gear, pulley, or sprocket with a belt or chain. Divide OHL ratings by the applicable OHL K factors shown separately in the
Selection Factors tables. OHL ratings should also be divided by applicable service factors.
3) Maximum Mechanical Ratings are limits based on strength and durability of gearbox components; applicable when operating
time is short and stopped time is greater than or equal to operating time. These ratings are applicable for 1.0 service factor
loads, and may require modification depending upon characteristics of the applicable driven loads. Refer to the “Service
Factors” table for more information.
Chapter 2: Specifications
Page 2–5IronHorse® Helical Gearbox User Manual – 1st Ed. Rev. B
IronHorse Cast-Iron Helical Gearbox Specifications (continued)
IronHorse Cast-Iron Helical Gearbox Specifications – Box Size 67
5:1 5.23 335 2.0 145TC
1-3/8
15.38 2710 710 93.5
2
63
5.0 182/4TC 69
10:1 9.90 177 5.0 182/4TC 12.39 4130 880 93.5
15:1 15.41 114 2.0 145TC 9.23 4785 1020 93.4 63
3.0 182TC 69
20:1 22.90 76 5.0 182/4TC 6.87 4720 1165 83.3
3
30:1 32.02 55 2.0 145TC 4.83 5045 1305 90.6
63
40:1 41.22 42 2.0 145TC 3.75 5045 1420 90.6
60:1 63.07 28 1.0 56C 2.45 5045 1480 90.7
1) Nominal Motor HP is the highest HP 1800 rpm motor to be used with the gearbox under conditions of 1.0 service factor.
Gearbox input power capacity decreases as motor speed decreases and as service factor increases.
2) OHL= Overhung Load ratings are for forces perpendicular to the output shaft and located at the shaft midpoint, such as from
a gear, pulley, or sprocket with a belt or chain. Divide OHL ratings by the applicable OHL K factors shown separately in the
Selection Factors tables. OHL ratings should also be divided by applicable service factors.
3) Maximum Mechanical Ratings are limits based on strength and durability of gearbox components; applicable when operating
time is short and stopped time is greater than or equal to operating time. These ratings are applicable for 1.0 service factor
loads, and may require modification depending upon characteristics of the applicable driven loads. Refer to the “Service
Factors” table for more information.
Page 2–6 IronHorse® Helical Gearbox User Manual – 1st Ed. Rev. B
Chapter 2: Specifications
IronHorse Cast-Iron Helical Gearbox Specifications (continued)
IronHorse Cast-Iron Helical Gearbox Specifications – Box Size 77
5:1 4.78 366 5.0 182/4TC
1-5/8
25.13 4040 785 93.4
2
82
7.5 213/5TC 93
10:1 10.91 160 7.5 213/5TC 16.89 6205 1035 93.5
20:1 23.31 75 5.0 182/4TC 7.84 6150 1330 93.4
82
30:1 31.97 55 5.0 182/4TC 6.36 6640 1480 90.7
3
40:1 39.31 45 3.0 182TC 5.49 6640 1555 85.4
60:1 57.73 30 2.0 145TC 3.52 6640 1800 90.7 76
1) Nominal Motor HP is the highest HP 1800 rpm motor to be used with the gearbox under conditions of 1.0 service factor.
Gearbox input power capacity decreases as motor speed decreases and as service factor increases.
2) OHL= Overhung Load ratings are for forces perpendicular to the output shaft and located at the shaft midpoint, such as from
a gear, pulley, or sprocket with a belt or chain. Divide OHL ratings by the applicable OHL K factors shown separately in the
Selection Factors tables. OHL ratings should also be divided by applicable service factors.
3) Maximum Mechanical Ratings are limits based on strength and durability of gearbox components; applicable when operating
time is short and stopped time is greater than or equal to operating time. These ratings are applicable for 1.0 service factor
loads, and may require modification depending upon characteristics of the applicable driven loads. Refer to the “Service
Factors” table for more information.
Chapter 2: Specifications
Page 2–7IronHorse® Helical Gearbox User Manual – 1st Ed. Rev. B
IronHorse Cast-Iron Helical Gearbox Specifications (continued)
IronHorse Cast-Iron Helical Gearbox Specifications – Box Size 87
5:1 4.73 370 10.0 213/5TC
2-1/8
38.49 6120 1800 93.3
2
163
20.0 254/6TC 169
10:1 10.66 164 10.0 213/5TC 27.28 9790 2375 93.5 163
15:1 15.29 114 10.0 213/5TC 21.45 11040 2680 93.5
20:1 20.06 87 5.0 182/4TC 15.13 9915 2925 90.7
3
156
10.0 213/5TC 163
30:1 31.73 55 5.0 182/4TC 11.15 11550 3010 90.6 156
40:1 38.20 46 5.0 182/4TC 11.36 14170 3010 90.7
60:1 61.54 28 2.0 145TC 7.05 14170 3010 90.7 150
5.0 182/4TC 156
1) Nominal Motor HP is the highest HP 1800 rpm motor to be used with the gearbox under conditions of 1.0 service factor.
Gearbox input power capacity decreases as motor speed decreases and as service factor increases.
2) OHL= Overhung Load ratings are for forces perpendicular to the output shaft and located at the shaft midpoint, such as from
a gear, pulley, or sprocket with a belt or chain. Divide OHL ratings by the applicable OHL K factors shown separately in the
Selection Factors tables. OHL ratings should also be divided by applicable service factors.
3) Maximum Mechanical Ratings are limits based on strength and durability of gearbox components; applicable when operating
time is short and stopped time is greater than or equal to operating time. These ratings are applicable for 1.0 service factor
loads, and may require modification depending upon characteristics of the applicable driven loads. Refer to the “Service
Factors” table for more information.
Page 2–8 IronHorse® Helical Gearbox User Manual – 1st Ed. Rev. B
Chapter 2: Specifications
IronHorse Cast-Iron Helical Gearbox Dimensions
See our website www.AutomationDirect.com for complete Engineering drawings.
Dimensions – inches [mm] – IronHorse Cast-Iron Helical Gearboxes
C JL M
56C
6.40
[162.5]
5.71
[145.0]
3.54
[90.0]
10.55
[268.0]
6.30
[160.0]
3.05
[77.5]
1.00
[25.4]
0.63
[15.9]
0.25
[6.4]
0.19
[4.8]
4.33
[110.0]
5.12
[130.0]
0.35
[8.9]
8.25
[209.5]
6.69
[170.0]
4.53
[115.0]
11.63
[295.4]
7.68
[195.0]
3.98
[101.0]
1.25
[31.8]
5.31
[134.9]
6.50
[165.1] 0.55
[14.0]
8.89
[226.0]
8.27
[210.0]
5.12
[130.0]
13.13
[333.5]
9.25
[235.0]
4.45
[113.0]
1.38
[34.9]
0.31
[7.9]
5.91
[150.1]
7.68
[195.1]
145TC
6.40
[162.5]
5.71
[145.0]
3.54
[90.0]
10.94
[278.0]
6.30
[160.0]
3.05
[77.5]
1.00
[25.4]
0.88
[22.2]
0.25
[6.4]
4.33
[110.0]
5.12
[130.0]
0.35
[8.9]
8.25
[209.5]
6.69
[170.0]
4.53
[115.0]
12.03
[305.5]
7.68
[195.0]
3.98
[101.0]
1.25
[31.8]
5.31
[134.9]
6.50
[165.1] 0.55
[14.0]
8.89
[226.0]
8.27
[210.0]
5.12
[130.0]
13.52
[343.5]
9.25
[235.0]
4.45
[113.0]
1.38
[34.9]
0.31
[7.9]
5.91
[150.1]
7.68
[195.1]
10.04
[255.0]
9.06
[230.0]
5.51
[140.0]
14.23
[361.5]
9.65
[245.0]
6.38
[162.0]
1.63
[41.4]
0.38
[9.7]
6.69
[170.0]
8.07
[205.0] 0.71
[18.0]
12.99
[330.0]
11.42
[290.0]
7.09
[180.0]
17.20
[437.0]
12.20
[310.0]
8.05
[204.5]
2.13
[54.1]
0.50
[12.7]
8.46
[215.0]
10.24
[260.0]
182/4TC*
8.25
[209.5]
6.69
[170.0]
4.53
[115.0]
12.76
[324.0]
7.68
[195.0]
3.98
[101.0]
1.25
[31.8]
1.13
[28.7]
0.25
[6.4]
0.25
[6.4]
5.31
[134.9]
6.50
[165.1] 0.55
[14.0]
8.89
[226.0]
8.27
[210.0]
5.12
[130.0]
14.25
[362.0]
9.25
[235.0]
4.45
[113.0]
1.38
[34.9]
0.31
[7.9]
5.91
[150.1]
7.68
[195.1]
10.04
[255.0]
9.06
[230.0]
5.51
[140.0]
14.96
[380.0]
9.65
[245.0]
6.38
[162.0]
1.63
[41.4]
0.38
[9.7]
6.69
[170.0]
8.07
[205.0] 0.71
[18.0]
12.99
[330.0]
11.42
[290.0]
7.09
[180.0]
17.32
[440.0]
12.20
[310.0]
8.05
[204.5]
2.13
[54.1]
0.50
[12.7]
8.46
[215.0]
10.24
[260.0]
213/5TC
10.04
[255.0]
9.06
[230.0]
5.51
[140.0]
17.22
[437.5]
9.65
[245.0]
6.38
[162.0]
1.63
[41.4] 1.38
[35.0]
0.38
[9.7] 0.31
[7.9]
6.69
[170.0]
8.07
[205.0] 0.71
[18.0]
12.99
[330.0]
11.42
[290.0]
7.09
[180.0]
19.59
[497.5]
12.20
[310.0]
8.05
[204.5]
2.13
[54.1]
0.50
[12.7]
8.46
[215.0]
10.24
[260.0]
254/6TC 12.99
[330.0]
11.42
[290.0]
7.09
[180.0]
20.57
[522.5]
12.20
[310.0]
8.05
[204.5]
2.13
[54.1]
1.63
[41.4]
0.50
[12.7]
0.38
[9.7]
8.46
[215.0]
10.24
[260.0]
0.71
[18.0]
*Note: 184TC motor frame sizes where applicable. See gearbox specifications for more information.
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