Page 1
FLENDER Gear Units
Gear unit
Operating Instructions 5118en
Edition 10/2017
H..., B..., M..., SOND
Page 2
18.09.2017 15:44
V7.02
Page 3
FLENDER Gear Units
Gear unit
5118en
H..., B..., M..., SOND
Introduction
1
Operating Instructions
Safety instructions
Description
Application planning
Assembly
Commissioning
Operation
Servicing
2
3
4
5
6
7
8
Service & Support
Disposal
Spare parts
Quality documents
Technical data
9
10
11
A
B
Edition 10/2017
Page 4
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property
damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified
personnel are those who, based on their training and experience, are capable of identifying risks and avoiding
potential hazards when working with these products/systems.
Proper use of Flender products
Note the following:
WARNING
Flender products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended or
approved by Flender. Proper transport, storage, installation, assembly, commissioning, operation and maintenance
are required to ensure that the products operate safely and without any problems. The permissible ambient
conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Flender GmbH. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described.
Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in
this publication is reviewed regularly and any necessary corrections are included in subsequent editions.
Flender GmbH
Alfred-Flender-Straße 77
46395 BOCHOLT
GERMANY
Document order number: 5118en
Ⓟ 09/2017 Subject to change
Copyright © Flender GmbH 2017.
All rights reserved
Page 5
Table of contents
1 Introduction.................................................................................................................................................11
1.1 General information................................................................................................................11
1.2 Lubricants...............................................................................................................................12
2 Safety instructions......................................................................................................................................13
2.1 Security notes........................................................................................................................13
2.2 The five safety rules...............................................................................................................13
2.3 General information................................................................................................................14
2.4 General warnings and symbols..............................................................................................15
2.5 Special types of danger and personal protective equipment.................................................16
2.6 Intended use..........................................................................................................................18
3 Description..................................................................................................................................................21
3.1 General description................................................................................................................21
3.2 Output shaft versions.............................................................................................................21
3.3 Housing..................................................................................................................................21
3.4 Oil supply to the gear unit......................................................................................................24
3.4.1 Splash lubrication...................................................................................................................25
3.4.2 Pressure lubrication...............................................................................................................25
3.5 Bearing arrangement of the shafts.........................................................................................25
3.6 Shaft seal...............................................................................................................................26
3.6.1 Rotary shaft sealing rings.......................................................................................................26
3.6.2 Labyrinth seals.......................................................................................................................26
3.6.3 Taconite seal..........................................................................................................................27
3.6.4 Tacolab seal...........................................................................................................................28
3.7 Cooling...................................................................................................................................30
3.7.1 Fan.........................................................................................................................................30
3.7.2 Cooling coil.............................................................................................................................31
3.7.3 Mounted oil supply system.....................................................................................................33
3.7.3.1 Pump......................................................................................................................................33
3.7.3.2 Oil filter...................................................................................................................................34
3.7.3.3 Pressure monitor....................................................................................................................34
3.7.4 Separate oil supply system....................................................................................................34
3.8 Couplings...............................................................................................................................34
3.9 Heating...................................................................................................................................35
3.10 Oil level indicator....................................................................................................................36
3.11 Oil-level monitoring system....................................................................................................37
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Table of contents
3.12 Oil temperature monitoring.....................................................................................................38
3.13 Bearing monitoring.................................................................................................................38
3.13.1 Bearing monitoring using a Pt 100 resistance thermometer..................................................38
3.13.2 Bearing monitoring by shock-pulse transducer......................................................................39
3.13.3 Bearing monitoring by acceleration sensor............................................................................40
3.14 Speed encoder.......................................................................................................................42
3.15 Torque monitoring system......................................................................................................42
3.16 Gear unit monitoring "Condition Monitoring"..........................................................................43
4 Application planning...................................................................................................................................45
4.1 Scope of delivery....................................................................................................................45
4.2 Transport................................................................................................................................45
4.3 Attachment points..................................................................................................................47
4.4 Special aspects of gear unit lubrication and preservation......................................................51
4.4.1 Oil filling and oil drain.............................................................................................................51
4.4.2 Preservation of gear units with Tacolab seals........................................................................53
5 Assembly....................................................................................................................................................55
5.1 General assembly instructions...............................................................................................55
5.2 Unpacking the gear unit.........................................................................................................56
5.3 Gear unit assembly................................................................................................................57
5.3.1 Foundation.............................................................................................................................57
5.3.2 Description of assembly work................................................................................................58
5.3.2.1 Alignment...............................................................................................................................60
5.3.3 Mounting the gear unit on the housing mounting foot............................................................62
5.3.3.1 Installation on a foundation frame..........................................................................................62
5.3.3.2 Mounting on a concrete foundation using foundation blocks.................................................63
5.3.3.3 Mounting on a concrete foundation using anchor bolts..........................................................64
5.4 Couplings...............................................................................................................................67
5.5 Connecting components........................................................................................................68
5.5.1 Gear units with mounted components....................................................................................68
5.5.2 Connecting the cooling coil....................................................................................................69
5.5.3 Installing a separate oil supply system...................................................................................69
5.5.4 Connecting the pressure monitor...........................................................................................70
5.5.5 Connecting the heating element............................................................................................70
5.5.6 Connecting the oil-level monitoring system............................................................................70
5.5.7 Connecting the Pt 100 resistance thermometer.....................................................................71
5.5.8 Connecting the bearing monitoring system............................................................................71
5.5.9 Connecting a speed encoder.................................................................................................71
5.5.10 Connecting the torque monitoring system..............................................................................72
5.5.11 Connecting the gear unit condition monitoring system..........................................................72
5.5.12 Electrical connections............................................................................................................72
5.6 Tightening procedure.............................................................................................................73
5.6.1 Introduction............................................................................................................................73
5.6.2 Bolt connection classes..........................................................................................................74
5.6.3 Tightening torques and preload forces...................................................................................74
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Table of contents
5.7 Final work...............................................................................................................................76
6 Commissioning...........................................................................................................................................79
6.1 Measures prior to commissioning..........................................................................................79
6.1.1 Gear units with cooling coil....................................................................................................79
6.1.2 Gear units with oil supply system...........................................................................................80
6.2 Measures during commissioning............................................................................................80
6.2.1 Heating...................................................................................................................................81
7 Operation....................................................................................................................................................83
7.1 Operating data.......................................................................................................................83
7.2 Irregularities in operation........................................................................................................83
7.3 Taking the unit out of service.................................................................................................84
8 Servicing.....................................................................................................................................................85
8.1 General maintenance information..........................................................................................85
8.2 Maintenance schedule...........................................................................................................86
8.3 Maintenance and servicing work............................................................................................87
8.3.1 Cleaning the venting screw....................................................................................................87
8.3.2 Checking the oil temperature.................................................................................................88
8.3.3 Measuring the vibration levels of the rolling-contact bearings...............................................88
8.3.4 Cleaning the fan and gear unit...............................................................................................89
8.3.5 Checking the cooling coil.......................................................................................................89
8.3.6 Check that all of the fastening bolts are tight.........................................................................90
8.3.7 General inspection of the gear unit........................................................................................90
8.3.8 Final work...............................................................................................................................90
8.4 Possible faults........................................................................................................................90
9 Service & Support.......................................................................................................................................97
10 Disposal......................................................................................................................................................99
11 Spare parts...............................................................................................................................................101
A Quality documents....................................................................................................................................103
A.1 Declaration of Incorporation.................................................................................................103
B Technical data..........................................................................................................................................105
B.1 General technical data.........................................................................................................105
B.2 Ambient temperature............................................................................................................106
B.3 Types...................................................................................................................................106
B.4 Weights................................................................................................................................106
B.5 Enveloping surface sound pressure level............................................................................106
Index.........................................................................................................................................................107
Tables
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Table of contents
Table 2-1 Symbols and markings................................................................................................................14
Table 2-2 General warnings........................................................................................................................15
Table 3-1 Taconite seal versions.................................................................................................................28
Table 3-2 Information about the specific heat output..................................................................................35
Table 5-1 Information on tightening fastening bolts.....................................................................................74
Table 5-2 Preload forces and tightening torques.........................................................................................75
Table 7-1 Operating data.............................................................................................................................83
Table 8-1 Maintenance and servicing work.................................................................................................86
Table 8-2 Possible faults and their rectification...........................................................................................91
Figures
Figure 3-1 Gear unit equipment for type H2SH 24 (SOND 622) gear units..................................................22
Figure 3-2 Gear unit equipment for type M1S X 315 gear units...................................................................23
Figure 3-3 Gear unit equipment for type H3SX gear units............................................................................24
Figure 3-4 Rotary shaft sealing ring..............................................................................................................26
Figure 3-5 Labyrinth seal..............................................................................................................................27
Figure 3-6 Taconite seal...............................................................................................................................27
Figure 3-7 Design variants of taconite seals.................................................................................................28
Figure 3-8 Tacolab seal................................................................................................................................29
Figure 3-9 Fan mounted on a gear unit........................................................................................................31
Figure 3-10 Cooling coil connections..............................................................................................................32
Figure 3-11 Heating for gear units, type H... and B........................................................................................36
Figure 3-12 Oil-level monitoring system for gear units, types H... and B........................................................37
Figure 3-13 Oil temperature monitoring system for gear units, types H... and B............................................38
Figure 3-14 Bearing monitoring using a Pt 100 resistance thermometer.......................................................39
Figure 3-15 Bearing monitoring using a shock-pulse transducer...................................................................40
Figure 3-16 Fully assembled acceleration sensor (A), and threaded connector (B) for variants 1 to 4..........41
Figure 3-17 Fully assembled acceleration sensor (C), and the threaded connector (D) for variants 5A
and 5B.........................................................................................................................................41
Figure 3-18 Speed encoder............................................................................................................................42
Figure 3-19 Telemetric measuring system to monitor the torque...................................................................43
Figure 4-1 Transport symbols.......................................................................................................................47
Figure 4-2 Shear and lateral pulling when using eye bolts...........................................................................48
Figure 4-3 Position of the attachment points for gear units of type H2SH 24 (SOND 622)..........................49
Figure 4-4 Position of the attachment points for gear units of type M1S X 315...........................................49
Figure 4-5 Position of the attachment points for gear units of type H3SX....................................................50
Figure 4-6 Oil filling points and oil draining points on type H2SH 24 (SOND 622) gear units......................51
Figure 4-7 Oil filling points and oil draining points on type M1S X 315 gear units........................................52
Figure 4-8 Oil filling points and the oil draining points on type H3SX gear units..........................................53
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Table of contents
Figure 4-9 Preservation of gear units with Tacolab seals.............................................................................54
Figure 5-1 Gap dimension at grease labyrinth..............................................................................................59
Figure 5-2 Alignment surface........................................................................................................................60
Figure 5-3 Alignment surfaces and alignment thread at the gear unit..........................................................61
Figure 5-4 Foundation block.........................................................................................................................63
Figure 5-5 Inserted anchor bolt.....................................................................................................................64
Figure 5-6 Tightened anchor bolt..................................................................................................................65
Figure 5-7 Possible displacements...............................................................................................................67
Figure 5-8 Alignment process based on the example of a flexible coupling.................................................68
Figure B-1 Rating plate...............................................................................................................................105
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Table of contents
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10 Operating Instructions 10/2017
Page 11
Introduction
1.1 General information
Purpose of the operating instructions
These operating instructions describe the gear unit and provide information about handling it
- from assembly to maintenance.
Please keep these operating instructions for later use. Please read these operating instructions
prior to handling the gear unit and follow the information in them.
Note
Disclaimer
Please make sure that every person who is commissioned to work on the gear unit has read
and understood these operating instructions prior to handling the gear unit and adheres to all
of the points. Failure to observe these operating instructions can cause product or property
damage or personal injury.
Flender does not accept any liability for damage or operating failures which are due to nonadherence to these operating instructions.
1
The gear unit described in these instructions reflects the state of technical development at the
time these operating instructions went to print.
In the interest of technical advancements, Flender reserves the right to make changes to the
individual components and accessories which are considered necessary for improving their
performance and safety, while maintaining their essential features.
Basic knowledge required
In order to understand these operating instructions, you will need the following general
knowledge about gear units. You will also need a basic understanding of the following topics:
● Application planning
● Assembly
● Commissioning
● Maintenance
Documentation landscape
These operating instructions form part of the delivery of your gear unit.
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Introduction
1.2 Lubricants
Copyright
These operating instructions form part of the complete documentation supplied with the gear
unit. The complete documentation encompasses other documents, including:
● Data sheet
● List of equipment
● Dimension drawing
● Operating instructions for gear unit lubrication and preservation BA 7300
● Operating instructions for mounted components
● Operating instructions for third-party vendor devices
The copyright for these operating instructions is held by Flender.
Without the authorisation of Flender, these operating instructions may not be used wholly or
in parts for competitors’ purposes or be given to third parties.
If you have any technical queries, please contact one of our Customer Services addresses
(Page 97).
1.2 Lubricants
The quality of the oil used must meet the requirements of the operating instructions BA 7300,
which is provided as a separate item, otherwise the warranty provided by Flender will be void.
Flender urgently recommends using one of the oils listed in BA 7300, all of which have been
appropriately tested and meet the requirements.
To avoid misunderstandings, Flender points out that, by making this recommendation, Flender
is not approving the product in the sense of expressing a warranty for the quality of the
lubricants supplied by your supplier. Every lubricant manufacturer is required to guarantee the
quality of his/her products.
Information such as oil type, oil viscosity and required oil quantity can be found on the rating
plate of the gear unit and in the documentation supplied with the gear unit.
The oil quantity specified on the rating plate is an approximate value. The actual quantity of
oil required is determined by the marking on the oil dipstick or oil sight glass.
The operating instructions for the current lubricant recommendations of Flender can also be
viewed in the Internet (http://support.automation.siemens.com/WW/view/de/44231658).
The oils listed there undergo continuous testing. As a result, the recommended oil types might
in future be removed from the list or replaced by more advanced oils.
Flender recommends regular inspection to ascertain whether the selected lubricating oil is still
approved by Flender. If it is not, another brand of oil should be selected instead.
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12 Operating Instructions 10/2017
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Safety instructions
2.1 Security notes
Security notes
Flender offers products and solutions with industrial security functions, which support the safe
and secure operation of plants, systems, machines and networks.
In order to safeguard plants, systems, machines and networks against cyber threats it is
necessary to implement (and continually maintain) a holistic industrial security concept that
corresponds to the current state of the art. Flender products and solutions undergo continuous
development in this respect.
Customers are responsible for preventing unauthorised access to their plants, systems,
machines and networks. Systems, machines and components shall only be connected to the
company network or the Internet when and as far as this is absolutely necessary and
appropriate protective measures (e.g. use of firewalls and network segmentation) shall be
taken.
In addition the recommendations of Siemens regarding appropriate protective measures shall
be observed. You can find further information about industrial security at:
http://www.siemens.com/industrialsecurity.
2
Flender products and solutions undergo continuous development in order to make them even
safer. Flender strongly recommends that you regularly carry out any updates as soon as they
are available and that you only use the current product versions. Use of older or no longer
supported versions can increase the risk of cyber threats.
To keep yourselves informed of any updates to our products you can register for the Siemens
Industrial Security RSS Feed at:
http://www.siemens.com/industrialsecurity
2.2 The five safety rules
In order to protect yourself and prevent any damage to property, always observe the safety
relevant information and the following five safety rules (as per EN 50110-1 "Working on isolated
equipment") when working on electrical components of the plant.
Prior to starting work on the machine, follow the safety rules listed below:
1. Disconnect
Also disconnect auxiliary circuits such as the anti-condensation heater
2. Safeguard against restart
3. Ensure that the system is de-energised
4. Earth and short circuit
5. Cover or cordon off adjacent live parts
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Safety instructions
2.3 General information
When all the work is complete, cancel the safety measures in the reverse sequence.
2.3 General information
Introduction
All work on the gear unit should be performed with care and only by qualified personnel.
Symbols on the gear unit
The following symbols apply to the gear unit; some of which are found as coloured markings
on the gear unit:
Table 2-1 Symbols and markings
Points labelled on the gear unit Symbol Coloured markings
Earth connection point
Air relief point yellow
Oil filling point yellow
Oil draining point white
Oil level indicator red
Oil level measurement red
Oil overflow
Connection point for vibration monitoring
Lubrication point red
Apply grease
Lifting eye
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Safety instructions
2.4 General warnings and symbols
Points labelled on the gear unit Symbol Coloured markings
Eye bolt
Do not unscrew
Alignment surface, horizontal
Alignment surface, vertical
These symbols indicate the oil level check‐
ing procedure using the oil dipstick.
These symbols indicate that the oil dip‐
stick must be firmly screwed in.
2.4 General warnings and symbols
The following table contains general warnings and their associated symbols.
Table 2-2 General warnings
ISO ANSI Warning
Warning - hazardous electrical voltage
Warning - explosive substances
--- Warning - entanglement hazard
--- Warning - hot surfaces
--- Warning - substances that can irritate or which are hazardous to health
--- Warning - caustic substances
--- Warning - suspended load
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Safety instructions
2.5 Special types of danger and personal protective equipment
ISO ANSI Warning
--- Warning - hand injuries
ATEX certification
2.5 Special types of danger and personal protective equipment
Requirements
Fulfil the following requirements before commencing work on the gear unit:
● Ensure that the oil pressure lines are depressurised.
● Only perform work on the gear unit when it is not in operation.
● Disconnect electrical systems from the power supply.
Electric shock
Live parts can cause electric shock.
Ensure that the entire plant is de-energised before starting electrical installation work.
Protective equipment
Wear the following personal protective equipment when handling the gear unit:
● Safety shoes
● Overalls
● Helmet
● Safety gloves
● Safety goggles
Risk of eye injury
Small foreign particles such as sand or dust can enter the cover plates of the rotating parts
and be hurled back by them.
DANGER
WARNING
Wear safety goggles.
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Dangers during operation
Damage to the gear unit is possible.
Switch the gear unit to standstill immediately if inexplicable changes are noticed during
operation. Such changes may include unusual gear unit noise or a significant increase in
operating temperature.
WARNING
Risk of falling
There is an increased risk of falling when standing or walking on the gear unit during operation.
Only walk or stand on the gear unit and its mounted components for maintenance and repair
work when it is at a standstill. Do not walk or stand on shaft ends, protection covers, mounted
components or pipes.
WARNING
Danger to life through rotating or moving parts
There is danger that rotating or moving parts may catch hold of you or pull you in.
Safety instructions
2.5 Special types of danger and personal protective equipment
Secure rotating and/or moving parts against contact using safeguards.
Surface temperature
The surface temperatures of the gear unit can become very extreme depending on the
operating conditions.
Risk of burns
Possible risk of serious burn injury from hot surfaces (> 55 °C).
Wear suitable protective gloves and protective clothing.
Risk of scalding
Risk of serious injury possible through escaping hot operating media when these are being
changed.
Wear suitable protective gloves, safety goggles and protective clothing.
WARNING
WARNING
WARNING
Danger due to low temperatures
Possible risk of serious injuries due to frost (pain, numbness, frostbite) on cold surfaces
(< 0 °C).
Wear suitable protective gloves and protective clothing.
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Safety instructions
2.6 Intended use
Chemical substances
Injuries can be sustained when using chemical substances.
Risk of chemical burns due to chemical substances
There is a risk of chemical burns when handling aggressive cleaning agents.
Please observe the manufacturer's guidelines on how to handle cleaning agents and solvents.
Wear suitable protective equipment (gloves, safety goggles). Please use binding agents to
immediately clear up any spilt solvent.
Risk of injury due to chemically aggressive operating materials
There is a risk of injury to eyes and hands when handling chemically aggressive operating
materials.
Please observe the safety instructions in the data sheets of the oil used. Wear suitable
protective equipment (gloves, safety goggles). Use an oil-binding agent to immediately clean
up spilt oil.
WARNING
CAUTION
Danger of explosion
An explosion may occur in a potentially explosive atmosphere.
DANGER
Danger of explosion through ignition of a potentially explosive atmosphere
Danger to life through ignition of a potentially explosive atmosphere possible when operating
the gear unit
Do not use the gear unit in potentially explosive atmospheres.
2.6 Intended use
Only use the gear unit according to the conditions specified in the service and delivery contract
and the technical data in the annex (Page 105). Deviating operating conditions are considered
improper use. The user or owner of the machine or plant is solely liable for any resulting
damage.
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Safety instructions
2.6 Intended use
When using the gear unit please specifically observe the following:
● Do not make any modifications to the gear unit which go beyond the permissible handling
described in these operating instructions. This also applies to safety features designed to
prevent accidental contact.
● Only ever use original spare parts.
Other spare parts are not tested and approved by Flender. Non-approved spare parts may
possibly change the design characteristics of the gear unit and thus impair its active or
passive safety.
Flender will accept no liability or warranty whatsoever for damage occurring as a result of
the use of non-approved spare parts. The same applies to any accessories which were not
supplied by Flender.
If you have any queries, please contact Customer Services (Page 97).
WARNING
Risk of falling
Risk of possible serious injury through falling.
Only walk or stand on the gear unit for maintenance and repair work when it is at a standstill.
Do not walk or stand on shaft ends, protection covers, mounted components or pipes.
Gear unit use
When using the gear unit, please observe the following basic rules:
● Ensure that the gear unit is operationally safe.
● The gear unit should only be operated, maintained or repaired by authorised, trained and
suitably qualified personnel.
● The relevant work safety and environmental protection regulations must be complied with
at all times during transport, assembly, dismantling, operation, maintenance and servicing.
● The outside of the gear unit must not be cleaned using high-pressure cleaning equipment.
● No welding work must be performed on the gear unit or on parts connected to it. The gear
unit and any parts connected to it must not be used as an earthing point for electric-welding
operations. Gearing and rolling-contact bearings might be irreparably damaged by welding.
● Perform potential equalisation in accordance with the applicable regulations and guidelines.
If no threaded holes are available on the gear unit for an earth connection, please take
suitable measures. This work must always be done by specialist electricians.
● In the case of gear units that are operated in combination with electrical machines that
generate current or through which current flows (e.g. motors and generators), take
measures to ensure that no current can flow through the gear unit.
Current flowing through the gear unit can result in irreparable damage to rolling-contact
bearings and gearing. Short circuits, voltage flashovers and deposits of conductive dust,
for example, can all allow current to flow.
Use insulators and earth the gear unit properly.
● When removing any protective devices, retain their fixings safely.
● Removed protective devices must be re-fitted prior to starting up.
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Safety instructions
2.6 Intended use
● Pay attention to the notices attached to the gear unit such as the rating plate, direction
arrow symbol etc. Notices must not be concealed by paint or dirt. Replace missing plates.
● Bolts which have been damaged during assembly or disassembly work must be replaced
with new ones of the same strength class and type.
DANGER
Danger to life due to live system
Death or serious injury will occur.
Always shut down the gear unit and any oil supply system (whether separate or mounted on
the gear unit) before you carry out any work. Secure the drive unit against being operated
accidentally as follows:
● Turn off the key-operated switch.
● Remove the fuses in the power supply.
● Attach a notice to the start switch, clearly stating that work is being carried out on the gear
unit.
Ensure that the entire unit is load-free so that no danger is posed when you start to dismantle
components.
Reactivating the gear unit
When installing the gear unit in machines or systems, the machine or system manufacturers
must ensure that the regulations, notes and descriptions contained in these operating
instructions are incorporated in their own operating instructions.
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20 Operating Instructions 10/2017
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Description
3.1 General description
The FLENDER® gear unit (referred to below simply as "gear unit") described in these operating
instructions has been developed to drive a mixing system in general machinery construction.
This series of gear units is suitable for applications in the chemical, rubber and plastics
industries, for example.
The helical gear unit and the bevel helical gear unit are available as a two, three or multi-stage
unit. These are designed for horizontal mounting. The gear units can also be implemented
with two output shafts and several input shafts.
It can essentially be operated in both directions of rotation.
Designs
Various shaft arrangements (designs and directions of rotation) are possible for the gear unit.
The direction of rotation arrows indicate the dependency of the direction of rotation of the input
and output shafts. The versions and directions of rotation are specified in the dimension
drawing in the complete documentation for the gear unit.
3
3.2 Output shaft versions
Information regarding the output version is provided in a separate data sheet and in the
dimension drawing in the complete gear unit documentation.
3.3 Housing
Introduction
The housing is made of steel. When specified, the housing can also be manufactured out of
cast iron.
The housing is a two-part component.
The gear unit housing has the following features:
● Attachment points for transporting the gear unit
● Inspection and assembly cover for oil filling and inspection
● Oil filling point for refilling with oil
● Oil sight glass, oil level indicator or dipstick for checking the oil level
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Description
3.3 Housing
● Oil drain screw or oil drain valve for changing the oil
● Air filter or wet-air filter for ventilation and bleeding
Further information
Additional information and a detailed illustrated description of the gear unit can be found in the
dimension drawing provided in the complete gear unit documentation.
Gear unit equipment
The diagram below shows the gear unit equipment on type H2SH 24 (SOND 622) units:
① Cover ⑥ Alignment surfaces
② Inspection and assembly cover ⑦ Lifting eyes
③ Housing ⑧ Gear unit fastening
④ Rating plate ⑨ Shaft seal
⑤ Cover ⑩ Alignment thread
Figure 3-1 Gear unit equipment for type H2SH 24 (SOND 622) gear units
The diagram below shows the gear unit equipment for type M1S x 315 gear units:
22 Operating Instructions 10/2017
Gear unit 5118en
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Description
3.3 Housing
① Rating plate ⑥ Gear unit fastening
② Lifting eyes ⑦ Shaft seal
③ Cover ⑧ Alignment surfaces
④ Cover ⑨ Inspection and assembly cover
⑤ Housing
Figure 3-2 Gear unit equipment for type M1S X 315 gear units
The diagram below shows the gear unit equipment for type H3SX gear units:
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Description
3.4 Oil supply to the gear unit
① Rating plate ⑥ Sling swivels
② Inspection and assembly cover ⑦ Alignment surfaces
③ Cover ⑧ Shaft seal
④ Housing ⑨ Alignment thread
⑤ Cover ⑩ Gear unit fastening
Figure 3-3 Gear unit equipment for type H3SX gear units
Further information
Additional information and a detailed illustrated description of the gear unit can be found in the
dimension drawing provided in the complete gear unit documentation.
3.4 Oil supply to the gear unit
Introduction
The oil supply to the various gear unit components can be implemented using the following oil
supply variants:
● Splash lubrication
● Pressure lubrication
● Combination of both oil supply variants
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3.4.1 Splash lubrication
Unless otherwise agreed by contract, the gearing and rolling-contact bearings are supplied
with an adequate quantity of oil by splash lubrication.
3.4.2 Pressure lubrication
At high input speeds or high gear circumferential velocities, depending on the particular
contract, splash lubrication can be supplemented or replaced by pressure lubrication.
With pressure lubrication, the rolling-contact bearings and gears located above the oil level
are adequately supplied with oil through pipes.
Designs
The following designs are possible:
● Mounted oil supply system
● Separate oil supply system???
Description
3.5 Bearing arrangement of the shafts
Further information
Additional information and a detailed illustrated description of the gear unit and the oil supply
system can be found in the dimension drawing in the complete gear unit documentation.
Additional information about the oil supply system can be found in the separate data sheet, in
the list of equipment and in the oil supply system operating instructions provided in the
complete gear unit documentation.
Mounted oil supply system with motor pump
The oil supply system is mounted on the gear unit and comprises the following components:
● Motor pump
● Double change-over filter
● Pressure monitor
● Piping
Further information
Additional information and a detailed illustrated description of the gear unit and the oil supply
system can be found in the dimension drawing in the complete gear unit documentation.
3.5 Bearing arrangement of the shafts
All shafts are mounted on rolling-contact bearings.
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Description
3.6 Shaft seal
3.6 Shaft seal
Introduction
Depending on requirements, shaft seals prevent oil from escaping from the gear unit or dirt
from entering the gear unit.
3.6.1 Rotary shaft sealing rings
Rotary shaft sealing rings are the standard seal used. Wherever possible, rotary shaft sealing
rings are equipped with an additional dust lip which protects the actual sealing lip against
external contaminants.
NOTICE
Irreparable damage to the rotary shaft sealing ring caused by high concentration of dust
A damaged rotary shaft sealing ring might not be able to effectively seal the gear unit.
In very dusty atmospheres, do not use rotary shaft sealing rings unless they have additional
protection.
The diagram below shows a rotary shaft sealing ring
Figure 3-4 Rotary shaft sealing ring
3.6.2 Labyrinth seals
Labyrinth seals as non-contact seals prevent shaft wear. They do not require any maintenance
and improve the temperature behaviour of the gear unit. Labyrinth seals can only be used with
pressure lubrication and with a reduced oil level.
The spare parts drawing and spare parts list specify whether or not the gear unit is equipped
with labyrinth seals.
A labyrinth seal is illustrated in the diagram below:
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Figure 3-5 Labyrinth seal
To work reliably, labyrinth seals must be installed in stationary, horizontal positions without
dirty water or any substantial amount of dust. Overfilling the gear unit can result in leaks, the
same applies to oil with a high foam content.
3.6.3 Taconite seal
The taconite seal is a combination of two sealing elements:
Description
3.6 Shaft seal
● Rotary shaft sealing ring to prevent the escape of lubricating oil
● Grease-filled dust seal (comprising a labyrinth and a lamellar seal) to allow operation of the
gear unit in extremely dusty environments
The taconite seal is ideal for use in dusty environments.
NOTICE
Gear unit leaks caused by poor sealing
Regrease the labyrinth seals at the specified regreasing intervals. The regreasing intervals
are specified in the Maintenance schedule (Page 86).
A taconite seal is illustrated in the diagram below:
① Labyrinth, filled with grease, can be regreased ③ Lamellar seal
② Grease nipple ④ Rotary shaft sealing ring
Figure 3-6 Taconite seal
The following design variants of taconite seal are available:
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7DFRQLWH(7DFRQLWH)
Description
3.6 Shaft seal
Figure 3-7 Design variants of taconite seals
The various taconite seals are described in the following table:
Table 3-1 Taconite seal versions
Taconite seal versions Application Remarks
"E" All input shafts with or without fan
"F" Output shaft
● Regreasable labyrinth
NOTICE
Sparking, inadmissible temperature rise and shaft seal wear due to insufficient gap dimension
Sparking, inadmissible temperature rise and shaft seal wear possible due to insufficient gap
dimension
In the case of a shaft seal with taconite seals, ensure that the set gap dimension of 1
on the grease labyrinth is not changed when the input and output elements (e.g. coupling
parts) are mounted. Rotating and stationary parts must not touch.
3.6.4 Tacolab seal
Application
Only use Tacolab seals with pressure lubrication and with a reduced oil level.
+0.5
mm
Features
Tacolab seals are non-contact, low-maintenance seals that do not wear. It is not therefore
necessary to interrupt operation in order to service or replace them.
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Description
3.6 Shaft seal
The Tacolab seal is a combination of two sealing elements:
● Labyrinth seal comprising two labyrinth sealing rings to prevent the escape of lubricating
oil
● Grease-filled dust seal (comprising a labyrinth and a lamellar seal) to allow operation of the
gear unit in extremely dusty environments
A Tacolab seal is illustrated in the diagram below:
① Outer labyrinth seal ④ Labyrinth, filled with grease, can be regreased
② Inner labyrinth seal ⑤ Grease nipple
③ Lamellar seal
Figure 3-8 Tacolab seal
NOTICE
Sparking, inadmissible temperature rise and shaft seal wear due to insufficient gap dimension
Sparking, inadmissible temperature rise and shaft seal wear possible due to insufficient gap
dimension
If the shaft is sealed by Tacolab seals, make sure that the set gap dimension of 1
+0.5
mm at
the grease labyrinth is not altered when the input and output elements (e.g. coupling
elements) are installed. Rotating and stationary parts must not touch.
For reliable operation, Tacolab seals require a stationary, horizontal installation position
without any contact with dirty water ‐ or high dust levels. Overfilling the gear unit can result in
leaks, the same applies to oil with a high foam content.
NOTICE
Gear unit leaks caused by poor sealing
Gear unit leaks caused by poor sealing are possible.
Regrease the labyrinth seals at the specified regreasing intervals. The regreasing intervals
are specified in the Maintenance schedule (Page 85).
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Description
3.7 Cooling
Further information
Check in the spare parts drawing and the spare parts list as to whether the gear unit is equipped
with Tacolab seals.
3.7 Cooling
Introduction
The gear unit can be equipped with the following cooling equipment depending on
requirements:
● Fan
● Cooling coil
● Oil supply system mounted on gear unit
● Separate oil supply system
When installing the gear unit, make sure that unhindered convection across the housing
surface is possible in order to protect the gear unit against overheating.
3.7.1 Fan
Principle of operation
Generally, the fan is mounted on the high-speed shaft of the gear unit and is protected from
accidental contact using an air guide cover. The fan draws in air through the protective grille
of the air guide cover and blows it along the lateral air ducts on the gear unit housing. The fan
dissipates a certain amount of heat from the housing.
Improper use can damage the gear unit. Follow the instructions given below in order to protect
the gear unit against overheating:
● When you install the protective device for the coupling or similar on gear units that are
equipped with a fan, make sure that you leave sufficient clearance for cooling air to be
drawn into the fan.
The required clearance is specified in the dimension drawing in the complete
documentation for the gear unit.
● Make sure that the air guide cover is correctly fastened.
● Protect the air guide cover against damage by external components.
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1 2
%
+
1 2
Description
3.7 Cooling
● Make sure that there is no contact between the fan and the air guide cover.
● Note that the cooling effect can be significantly impaired if the fan is dirty or if the surface
of the housing is covered with dust or contaminants that act as an insulating layer.
Clean the fan and the gear unit. Observe the cleaning information in chapter Maintenance
and servicing work (Page 87).
A fan mounted on a gear unit is illustrated in the diagram below:
① Fan ② Air guide cover
Figure 3-9 Fan mounted on a gear unit
Further information
Further information and a detailed illustration of the gear unit and the position of the mounted
components can be found in the dimension drawings in the complete documentation for the
gear unit.
3.7.2 Cooling coil
Introduction
The gear unit can be equipped with a cooling coil in the oil sump. The cooling coil is connected
to a cooling water supply. The cooling water connection must be provided by the operator. The
cooling water can be fresh water, sea water or brackish water.
Principle of operation
Heat from the gear unit oil is transferred to the cooling water as it flows through the cooling
coil.
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Description
3.7 Cooling
Note
To prevent the formation of condensation, make sure that the cooling coil is fully immersed in
the oil.
Improper use can damage the cooling coil. Be sure to take the following precautions:
● Make sure that the cooling water pressure does not exceed 8 bar.
The direction of water flow through the gear unit is optional.
● Make sure that the ends of the cooling coil are not twisted and that the reducer screws are
not removed.
● If there is a risk of freezing temperatures, drain the cooling water out of the coil and blow
the coil out with compressed air to remove any water residue.
● Use a suitable cooling water flow regulator (e.g. a pressure reducing valve or an appropriate
isolation valve) in order to prevent excessive water pressure at the cooling water inlet.
WARNING
Further information
Risk of eye injury from compressed air
Water residue and dirt particles can cause damage to eyes.
Wear suitable safety goggles.
The diagram below shows the cooling coil connections:
① Output shaft ③ Reducer screw
② Cooling water connection
Figure 3-10 Cooling coil connections
For further information and a detailed illustration of the gear unit and the connection
dimensions, please refer to the dimension drawings in the complete gear unit documentation.
The required cooling water flow rate and the maximum permissible inlet temperature can be
found in the separate data sheet, the list of equipment or the dimension drawing in the complete
documentation for the gear unit.
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3.7.3 Mounted oil supply system
Introduction
Depending on the particular contract, the gear unit can be equipped with a mounted oil supply
system.
Components of the oil supply system
The mounted oil supply system comprises the following components:
● Motor pump
● Piping
● Oil filter
● Monitoring devices
Note
Observe the flow direction of the motor pump
Description
3.7 Cooling
When connecting the valves, observe the actual flow direction of the motor pump.
Refer to the motor pump operating instructions in the complete gear unit documentation to
ascertain whether the flow direction of the motor pump used depends on the direction of
rotation.
Further information
Additional information about the oil supply system can be found in the separate data sheet, in
the list of equipment and in the oil supply system operating instructions provided in the
complete gear unit documentation.
Additional information and a detailed illustrated description of the gear unit and the oil supply
system can be found in the dimension drawing in the complete gear unit documentation.
3.7.3.1 Pump
Requirements placed on the medium being pumped
The pump being used is suitable for pumping lubricating oil. It is not permissible that the oil
contains abrasive components and must not chemically attack the materials used in the pump.
Clean oil with good lubricating properties is a precondition for ensuring the correct function,
high operational reliability and long service life of the pump.
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Description
3.8 Couplings
3.7.3.2 Oil filter
Introduction
The oil filter protects downstream units, measuring and control devices against dirt and
pollution.
Principle of operation
The oil filter comprises a housing with connections and a filter cartridge. The medium flows
through the filter housing, where, depending on the filter gauge, most of the dirt particles larger
than a defined size in the oil are filtered out. Dirty filter cartridges must be cleaned or replaced.
3.7.3.3 Pressure monitor
The pressure of the mounted oil supply system is monitored using a pressure monitor.
Further information
You can find additional information on the pressure monitor in the pressure monitor operating
instructions provided in the complete gear unit documentation.
You can find additional technical data in the separate data sheet and in the list of equipment
provided in the complete gear unit documentation.
3.7.4 Separate oil supply system
A separate oil supply system can be used for cooling the oil.
Further information
Further information about separate oil supply systems can be found in the oil supply system
operating instructions in the complete documentation for the gear unit.
You can find additional information about the components of the oil supply system in the
operating instructions for the components in the complete gear unit documentation.
You can find additional technical data in the separate data sheet and in the equipment list in
the complete gear unit documentation.
3.8 Couplings
Flexible couplings or safety couplings are generally used at the input end of the gear unit.
Use of rigid couplings or other input or output elements that generate additional radial or axial
forces (e.g. gear wheels, belt pulleys, flywheels or hydraulic couplings) must be agreed
contractually.
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Further information
You can find additional information about the couplings in the coupling operating instructions
provided in the complete gear unit documentation.
3.9 Heating
Introduction
At low ambient temperatures it may be necessary to preheat the gear unit oil before switching
on the drive or while it is in operation.
Heating elements
Heating elements can be used for these applications, for example. Heating elements convert
electricity into heat and transfer this to the oil in which they are immersed. The heating elements
are installed in protective tubes in the housing so that they can be replaced without draining
off the oil first.
Description
3.9 Heating
Complete immersion of the heating elements in the oil bath must be ensured by adhering to
the installation position in accordance with the dimension drawings in the complete
documentation and the oil level.
WARNING
Explosion and fire hazard
Exposed heating elements pose a fire hazard.
Do not switch on the heating elements unless you have checked that they are completely
immersed in the oil bath.
If heating elements are retrofitted, the heat output at the outer surface of the heating element
must not exceed the maximum values stated in the table below.
The following table contains information about the specific heat output PHO as a function of
ambient temperature:
Table 3-2 Information about the specific heat output
PHO in W/cm
0.9 10 to 0
0.8 0 to -25
0.7 -25 to -50
2
Ambient temperature in °C
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Description
3.10 Oil level indicator
The diagram below shows gear unit heating:
① Temperature monitor ② Heating element
Figure 3-11 Heating for gear units, type H... and B...
Heating element control
Heating elements can be controlled by a temperature monitor. The temperature monitor
provides a signal to be amplified when the minimum and maximum temperatures are reached.
Further information
Further information about the position of the mounted components and a detailed illustration
of the gear unit can be found in the dimension drawing in the complete documentation for the
gear unit.
Further information about heating elements can be found in the separate data sheet, in the list
of equipment and in the heating element operating instructions in the complete documentation
for the gear unit.
Further information about the temperature monitor (such as control instructions) can be found
in the temperature monitor operating instructions in the complete documentation for the gear
unit.
3.10 Oil level indicator
The following components for visual monitoring of the oil level can be mounted on the gear
unit:
● Oil sight glass
● Oil level indicator
● Oil dipstick
Check the oil level when the gear unit is stationary and with the oil in a cool state.
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Further information
Further information about the oil level indicator and checking the oil can be found in the
operating instructions BA 7300 in the complete documentation for the gear unit.
Further information and a detailed illustration of the gear unit and the position of the mounted
components can be found in the dimension drawing in the complete documentation for the
gear unit.
3.11 Oil-level monitoring system
Introduction
Depending on the order specification, the gear unit can be equipped with an oil-level monitoring
system using a filling-level limit switch.
The oil-level monitoring system has been designed to check the oil level when the gear unit is
at a standstill before it starts.
Description
3.11 Oil-level monitoring system
Mounting position
Further information
When using an oil-level monitoring system it is especially important to ensure that the gear
unit is in a horizontal mounting position.
The diagram below shows the oil-level monitoring system for the gear unit:
Figure 3-12 Oil-level monitoring system for gear units, types H... and B...
Further information and a detailed illustration of the gear unit and the position of the mounted
components can be found in the dimension drawing in the complete documentation for the
gear unit.
Further information about oil level monitoring, control instructions and the technical data can
be found in the operating instructions for the oil level monitor, in the list of equipment and in
the separate data sheet in the complete documentation for the gear unit.
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Description
3.12 Oil temperature monitoring
3.12 Oil temperature monitoring
Depending on the order specification, the gear unit can be fitted with a Pt 100 resistance
thermometer for measuring the oil temperature in the oil sump.
To measure temperatures or temperature differences, connect the Pt 100 resistance
thermometer to an evaluation unit (to be supplied by the customer). The resistance
thermometer is fitted with a connector head for the wiring. A two-wire circuit is provided from
the factory, but the customer can also install a three- or four-wire circuit.
The following diagram shows an oil temperature monitor mounted on the gear unit:
① Pt 100 resistance thermometer
Figure 3-13 Oil temperature monitoring system for gear units, types H... and B...
Further information
Further information and a detailed illustration of the gear unit and the position of the mounted
components can be found in the dimension drawing in the complete documentation for the
gear unit.
Further information about oil temperature monitoring (such as control instructions) and the
technical data can be found in the operating instructions for the oil temperature monitor and
in the list of equipment in the complete documentation for the gear unit.
3.13 Bearing monitoring
3.13.1 Bearing monitoring using a Pt 100 resistance thermometer
Depending on the order specification, the gear unit can be equipped with Pt 100 resistance
thermometers to monitor the bearings.
You must connect the Pt 100 resistance thermometer to an evaluation unit provided by the
customer to be able to measure temperatures or temperature differences. The resistance
thermometer has a connection head for the wiring. A two-wire circuit is provided in the factory.
However, customers can also configure a three or four-wire circuit.
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Further information
Description
3.13 Bearing monitoring
The following diagram shows bearing monitoring using a Pt 100 resistance thermometer:
① Pt 100 resistance thermometer
Figure 3-14 Bearing monitoring using a Pt 100 resistance thermometer
Further information and a detailed illustration of the gear unit and the position of the mounted
components can be found in the dimension drawing in the complete documentation for the
gear unit.
Further information about bearing monitoring using a Pt 100 resistance thermometer (such as
control instructions) and the technical data can be found in the operating instructions for the
Pt 100 resistance thermometer and in the list of equipment in the complete documentation for
the gear unit.
3.13.2 Bearing monitoring by shock-pulse transducer
Depending on the order specification, the gear unit can be equipped with measuring nipples
for monitoring the bearings.
These measuring nipples are used to attach shock-pulse transducers through a fast-release
coupling; they are located on the housing close to the bearings to be monitored.
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Description
3.13 Bearing monitoring
The following diagram shows a bearing monitoring system that uses a shock-pulse transducer:
① Shock-pulse transducer
Figure 3-15 Bearing monitoring using a shock-pulse transducer
Further information
Further information and a detailed illustration of the gear unit and the position of the mounted
components can be found in the dimension drawing in the complete documentation for the
gear unit.
3.13.3 Bearing monitoring by acceleration sensor
Depending on the order specification, the gear unit can be supplied with threaded holes in
which acceleration sensors can be inserted. These threaded holes have an M6 or M8 thread
depending on the variant.
The following diagram shows the fully assembled acceleration sensor (A), and the threaded
connector (B) for variants 1 to 4:
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Description
3.13 Bearing monitoring
① Shielded cable (oil-proof) ④ Sensitivity specification
② MIL-spec connector ⑤ Set screw
③ Acceleration sensor
Figure 3-16 Fully assembled acceleration sensor (A), and threaded connector (B) for variants 1 to 4
The following diagram shows the fully assembled acceleration sensor (C), and the threaded
connector (D) for variants 5A and 5B:
Figure 3-17 Fully assembled acceleration sensor (C), and the threaded connector (D) for variants 5A
and 5B
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Description
3.14 Speed encoder
Further information
Further information and a detailed illustration of the gear unit with attached sensors can be
found in the dimension drawing in the complete documentation for the gear unit.
Further information about the sensors can be found in the operating instructions for the sensors.
3.14 Speed encoder
Depending on the order specification, an incremental speed encoder can be fitted.
Customers must establish the wiring and provide the evaluation unit required.
The following diagram shows a speed encoder:
① Incremental speed encoder ③ Output
② 12-pole brass connector
Figure 3-18 Speed encoder
Further information
You will find further information, a detailed illustration of the gear unit and the position of the
mounted components in the dimension drawing in the complete documentation for the gear
unit.
You can find further information about the speed encoder (such as control instructions) and
technical data, in the speed encoder operating instructions and in the equipment list provided
in the complete gear unit documentation.
3.15 Torque monitoring system
Depending on the order specification, the gear unit can be equipped with a telemetric
measuring system to monitor the torque.
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Description
3.16 Gear unit monitoring "Condition Monitoring"
Using the telemetric measuring system you can transfer the measured values from a rotating
gearbox shafts contactlessly.
The following diagram shows a telemetric measuring system to monitor the torque:
① Strain gauges (glued to the shaft) ④ Slot with transmit antenna
② Measuring amplifier IS ⑤ Antennae inductive IS (energy supply head)
③ Rotor ring ⑥ Receiver IS
Figure 3-19 Telemetric measuring system to monitor the torque
Further information
You will find further information, a detailed illustration of the gear unit and the position of the
mounted components in the dimension drawing in the complete documentation for the gear
unit.
You will find further information on the torque monitoring system, such as control notes and
technical data, in the operating instructions for the torque monitoring system and in the list of
equipment, which are part of the complete documentation of the gear unit.
3.16 Gear unit monitoring "Condition Monitoring"
Depending on the order specification, the gear unit can be equipped with a complete remote
diagnostic system. This monitoring system "Condition Monitoring" includes a complete
diagnostic system and is coordinated with the customer depending on the specific order.
The gear unit monitoring "Condition Monitoring" can be prepared for the following
measurements and monitoring functions:
● Bearing temperature measurement in the area of the rolling-contact bearings
● Oil sump temperature measurement
● Speed monitoring at the output
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Description
3.16 Gear unit monitoring "Condition Monitoring"
● Vibration measurement using acceleration sensors
Depending on the specific order, you can measure vibration levels at the following locations:
– Outside in the area of the input and the two output shafts
– In the gear unit in the area of the two output shafts
● Torque measurement at the input and output shafts
● Oil level monitoring using separate valves
● Bearing monitoring using shock pulse measurement
Further information
You will find further information, a detailed illustration of the gear unit and the position of the
mounted components in the dimension drawing in the complete documentation for the gear
unit.
You will find further information on the gear unit monitoring "Condition Monitoring", such as
control information and technical data, in the operating instructions for the gear unit monitoring
"Condition Monitoring" and in the list of equipment, which are part of the complete
documentation of the gear unit.
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Application planning
4.1 Scope of delivery
The scope of delivery is listed in the shipping documents. Immediately upon receiving the
gearbox, check that everything has been delivered. Report any damaged and/or missing parts
to Customer Services (Page 97) immediately.
WARNING
Serious injury through defective product
Serious injury may occur.
If the gearbox exhibits any visible damage, you should not put it into operation.
4.2 Transport
General information
4
The gear unit is delivered fully assembled. Additional items such as shrink disks, couplings,
oil coolers, pipework and valves may be delivered separately packaged, as necessary.
When transporting the gear unit, observe the following instructions to avoid damaging the gear
unit:
● Always use suitable equipment to transport the gear unit.
● Transport the gear unit without oil filling and leave it in the transport packaging.
● Do not use incorrect attachment points.
The threads in the end faces of the shaft ends may not be used for attaching lifting
equipment.
● Do not use the pipework to move the gear unit.
● Ensure that the lifting equipment is adequately designed to accommodate the weight of the
gear unit.
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Application planning
4.2 Transport
Risk of crushing
There is a risk of being crushed by a component that becomes detached because the hoisting
gear and load suspension device are not suitable for handling it.
When lifting, please observe the load distribution information on the packaging.
When the product is in a raised position, transport it slowly and carefully to avoid injury to
persons or damage to the gear unit.
Attaching the gear unit
To transport the gear unit, only attach slings to the marked attachment points that are provided
for this purpose.
Please observe the following when attaching slings to the load or raising, lowering or moving
it:
● Do not exceed the specified load limits
WARNING
● If you are using a load suspension device with several load hooks, make sure that the load
is evenly distributed between them
● Note the eccentric centre of gravity
● Make sure that the lifting equipment is securely attached
● Keep your speed down when moving the load
● Do not allow the load to sway and do not attach the load to objects or structures inside the
building
● Loads must not be suspended from the tip of a load hook
● Always place the products down on a level, non-slip and stable base
DANGER
Falling load
There is a risk of fatal injury from falling loads if these have not been securely attached to the
lifting equipment.
Never stand or sit under suspended loads. Do not exceed the load limits of the lifting
equipment.
Packaging
The gear unit is delivered fully assembled. Additional equipment is also delivered separately
packaged, as necessary.
The gear unit may be packed in various forms, depending on the size of the unit and method
of transport.
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Please adhere to the symbols applied on the packaging.
7KLVZD\XS)UDJLOH
.HHS
GU\
.HHS
FRRO
&HQWUHRI
JUDYLW\
'RQRW
XVHKDQGKRRNV
$WWDFKKHUH
Figure 4-1 Transport symbols
4.3 Attachment points
Lifting eyes
Lifting eyes are fitted to the gear unit to assist with its transportation during manufacture and
installation.
Application planning
4.3 Attachment points
Sling swivels
Eye bolts
Carefully ensure that the angle of the vertical load at the gear units lifting eyes does not exceed
45°.
Threads for screwing in transport lugs are provided on the gear unit to assist with its
transportation during manufacture and installation.
The shear pulling must not exceed 45° when the lifting equipment is attached to sling swivels.
Note
Damage to the gear unit during transport
Using the wrong attachment points can cause damage when transporting large gear units.
Always use sling swivels for gear units larger than size 23.
The use of sling swivels instead of eye bolts is generally recommended.
When using eye bolts, please note that their load-bearing capacity may be reduced if they are
alternately attached to different components that require moving.
It is not permitted to load eye bolts through lateral pulling contrary to the direction of the eye
plane.
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The following figure shows the permissible shear and lateral pulling when using eye bolts:
Page 48
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Application planning
4.3 Attachment points
A Permitted shear pulling in direction of eye plane (maximum angle of 45°)
B Non-permitted lateral pulling contrary to direction of eye plane
Figure 4-2 Shear and lateral pulling when using eye bolts
Position of attachment points
DANGER
Falling load
There is a risk of fatal injury from falling loads if these have not been securely attached to the
lifting equipment.
Do not use the lifting eyes at the upper part of the gear unit to lift the complete gear unit.
The diagram below shows the position of the attachment points for gear units of type
H2SH 24 (SOND 622):
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Application planning
4.3 Attachment points
Figure 4-3 Position of the attachment points for gear units of type H2SH 24 (SOND 622)
The diagram below shows the position of the attachment points for gear units of type
M1S X 315:
Figure 4-4 Position of the attachment points for gear units of type M1S X 315
The diagram below shows the position of the attachment points for gear units of type H3SX:
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Application planning
4.3 Attachment points
Figure 4-5 Position of the attachment points for gear units of type H3SX
Drive units with additional components mounted on the gear unit (such as drive motor,
coupling, etc.) may require an extra attachment point owing to the displacement in the centre
of gravity caused by the mounted components.
Further information
Further information, a detailed illustration of the gear unit and the position of the attachment
points can be found in the dimension drawings in the complete documentation for the gear unit.
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Application planning
4.4 Special aspects of gear unit lubrication and preservation
4.4 Special aspects of gear unit lubrication and preservation
4.4.1 Oil filling and oil drain
The diagram below shows the oil filling points and the oil draining points on type
H2SH 24 (SOND 622) gear units:
① Oil filling point ④ Oil draining point
② Inspection and assembly cover ⑤ Oil level indicator
③ Venting point
Figure 4-6 Oil filling points and oil draining points on type H2SH 24 (SOND 622) gear units
The diagram below shows the oil filling points and the oil draining points on type M1S X 315
gear units:
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Application planning
4.4 Special aspects of gear unit lubrication and preservation
① Oil filling point ④ Oil level indicator
② Venting point ⑤ Inspection and assembly cover
③ Oil draining point
Figure 4-7 Oil filling points and oil draining points on type M1S X 315 gear units
The diagram below shows the oil filling points and the oil draining points on type H3SX gear
units:
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Application planning
4.4 Special aspects of gear unit lubrication and preservation
① Venting point ④ Oil filling point
② Oil level indicator ⑤ Oil draining point
③ Inspection and assembly cover
Figure 4-8 Oil filling points and the oil draining points on type H3SX gear units
Further information
Further information and a detailed illustrated description of the gear unit can be found in the
dimension drawing in the complete documentation for the gear unit.
4.4.2 Preservation of gear units with Tacolab seals
After gear units with Tacolab seals have been preserved according to the standard procedure,
the air gap is hermetically sealed with adhesive tape.
The diagram below shows the procedure for preserving gear units with Tacolab seals:
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Application planning
4.4 Special aspects of gear unit lubrication and preservation
① Adhesive tape ③ Labyrinth, filled with grease, can be regreased
② Air gap ④ Labyrinth seal
Figure 4-9 Preservation of gear units with Tacolab seals
Do not remove the adhesive tape until you are ready to commission the unit.
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Assembly
5.1 General assembly instructions
The assembly work must be performed very carefully by authorised, trained and suitably
instructed personnel. Liability will be disclaimed for damage caused by the incorrect
performance of this work.
Requirements
Improper use can damage the gear unit. Be sure to take the following precautions:
● Protect the gear unit against falling objects and from becoming covered over.
● Do not perform any welding work anywhere on the drive.
● Do not use the gear unit as an earthing point for electric-welding operations.
● Use all of the fastening points fitted to the particular unit design.
● Replace any bolts that are no longer fit for use by new bolts of the same strength class and
type.
● Make sure that sufficient hoisting gear is available.
5
Mounting position and attachment points
During the actual planning phase, be sure to allow for sufficient space around the gear unit to
enable subsequent upkeep and maintenance work. Take suitable measures to ensure that
unhindered convection across the housing surface is possible so that the gear unit does not
overheat. Leave sufficient space to allow a free flow of air into gear units that are equipped
with a fan.
The positions of the attachment points are shown in the dimension drawing. To ensure that
the unit is properly lubricated during operation, please observe the mounting position specified
in the dimension drawings.
NOTICE
Heating of the gear unit by external heat sources
The gear unit must not be heated by external heat sources (exposure to direct sunlight, for
example) while it is in operation and measures must be taken where necessary to protect it.
You can take the following measures to protect the gear unit against this hazard:
● A sun shield
● An additional cooling device
● A temperature monitoring device with trip function in the oil sump
If you use a sun shield, this may cause a build-up of heat.
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Assembly
5.2 Unpacking the gear unit
If you use a temperature monitoring device, it must be capable of issuing an alarm when the
maximum permissible oil sump temperature is reached. It must also be capable of tripping the
drive when the maximum permissible oil sump temperature is exceeded. The operator's
process might be interrupted when the drive is shut down.
WARNING
Ignition of vapours emitted from solvents.
There is a risk of injury due to ignition of vapours emitted from solvents when carrying out
cleaning work.
Please note the following:
● Ensure adequate ventilation.
● Do not smoke.
5.2 Unpacking the gear unit
Introduction
Requirement
The scope of delivery is listed in the shipping documents.
WARNING
Risk of serious injury due to defective product
A defective gear unit can result in serious injury.
Do not put the gear unit into operation if any damage is visible.
Contact Customer Services.
Check that everything has been delivered immediately upon receipt.
NOTICE
Damage to the gear unit due to corrosion
Exposing the gear unit to moisture can result in damage from corrosion.
Do not damage or open the packaging prematurely if the packaging is designed to preserve
the unit.
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Procedure
To unpack and use the gear unit, proceed as follows:
1. Remove packaging and transport devices in accordance with regulations.
2. Perform a visual inspection for damage and accumulations of dirt.
3. Immediately report any damaged and/or missing parts to Customer Services.
4. Dispose of packaging material and transport devices in accordance with regulations.
5.3 Gear unit assembly
5.3.1 Foundation
Properties of the foundation
Assembly
5.3 Gear unit assembly
The foundation must have the following properties:
● Horizontal and level
● Stability
● Designed for torsional rigidity
● Reaction forces from the gear unit must be braced
Requirements of the foundation
The foundation must meet the following requirements:
● Construct the foundation in such a way that it does not generate any resonance vibrations
and that it is isolated against the transmission of vibrations from adjacent foundations.
● Design the foundation according to the relevant weight and torque, taking into account the
forces acting on the gear unit.
● Align the foundation carefully with the equipment installed on the input and output sides of
the gear unit.
In order to guarantee absolute distortion-free operation for a multi-motor drive, ensure that
the motors are absolutely precisely aligned to the gear unit. For distortion-free operation,
it is crucial that the motors run in absolute synchronism.
● Take into account any elastic deformation that may be caused by operating forces.
● Install lateral stops to prevent displacement if external forces are acting on the gear unit.
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Assembly
5.3 Gear unit assembly
NOTICE
Lack of stable foundation for the gear unit
Damage to the gear unit is possible if it is not mounted on a stable foundation.
Use bolts of at least strength class 8.8. Information and guidance on the tightening torque
can be found in chapter Tightening procedure (Page 73). Tighten the fastening bolts and nuts
to the specified tightening torque. When tightening the fastening bolts, make sure that the
gear unit is free of mechanical stress.
Further information
Further information about dimensions, space requirements and arrangement of supply
connections can be found in the complete documentation for the gear unit.
5.3.2 Description of assembly work
Measures to be taken prior to assembly
CAUTION
Risk of chemical burns due to chemical substances
There is a risk of chemical burns when handling aggressive cleaning agents.
Please observe the manufacturer's guidelines on how to handle cleaning agents and solvents.
Wear suitable protective equipment (gloves, safety goggles). Please use binding agents to
immediately clear up any spilt solvent.
WARNING
Risk of burns
There is a risk of serious burn injury from hot surfaces (> 55 °C).
Wear suitable protective gloves and protective clothing.
Improper use can damage the gear unit. Be sure to take the following precautions:
● Use a suitable cleaning agent to remove the corrosion protection from the shafts and
mounting surfaces.
● Do not allow the cleaning agent to come into contact with the shaft-sealing rings.
● Use an assembly fixture to mount the input and output elements (e.g. coupling components)
onto the shafts and lock them securely.
● Do not use force (hammer blows, etc.) to fit the coupling components as this can cause
internal damage to the gear unit.
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Assembly
5.3 Gear unit assembly
● Take care not to damage the shaft sealing rings or shaft running surfaces when fitting the
coupling components.
● If you must heat up the input and output elements before assembly, the joining temperatures
required are listed in the dimension drawings in the coupling operating instructions.
● Unless otherwise specified, heat the coupling parts by an induction heater, with a torch or
in an oven.
● Use heat shields designed to protect against radiant heat in order to safeguard the shaft
sealing rings against damage or heating to above 100 °C.
● The elements must be quickly pulled onto the shaft as far as stated in the dimension drawing
prepared in accordance with order specifications.
● Use suitable hoisting gear to place the gear unit in position.
NOTICE
Poor alignment
The gear unit or individual components can be damaged as a result of poor alignment.
When installing and mounting the drive ensure that the individual components are precisely
aligned with one another.
Inadmissibly high alignment errors of the shaft ends to be connected as a result of angular
or axial offset result in premature wear and material damage. Base frames or substructures
that are too soft can cause the coupling parts to become radially or axially displaced during
operation. This displacement is not measurable when the drive is at a standstill.
The following figure shows the gap dimension at the grease labyrinth:
Figure 5-1 Gap dimension at grease labyrinth
NOTICE
Sparking, inadmissible temperature rise and shaft seal wear due to insufficient gap dimension
An insufficient gap dimension can cause sparking, inadmissible temperature rise and shaft
seal wear.
If the shaft is sealed by taconite or Tacolab seals, make sure that the set gap dimension of
+0.5
1
mm at the grease labyrinth is not altered when the input and output elements (e.g.
coupling parts) are installed. Rotating and stationary parts must not touch.
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Assembly
5.3 Gear unit assembly
Further information
Further information about removing the corrosion protection can be found in the operating
instructions BA 7300 in the complete documentation for the gear unit.
Additional information on how gear units should be attached which, as a result of their weight,
require a crane or lifting gear, is provided in chapter Application planning (Page 45).
If the gear unit is to be transported with mounted parts and components, then it may be
necessary to use additional attachment points. The position of these attachment points can
be found in the dimension drawing in the complete documentation for the gear unit.
5.3.2.1 Alignment
Introduction
Depending on the order specification, the top of the housing has machined surfaces (alignment
surfaces) to assist with provisional alignment of the gear unit in the horizontal direction.
DANGER
Procedure
Risk of fatal injury from flying fragments
Failure to align the unit with the required degree of accuracy can cause the shaft to rupture.
A ruptured shaft can result in serious or even fatal injuries.
Align the gear unit exactly so that it conforms to the specified alignment values.
Damage to the gear unit or its components or mounted parts is possible.
The accuracy of the alignment between the shaft axes largely determines the service life of
the shafts, bearings and couplings. Please therefore always endeavour to achieve zero
deviation in the alignment of the shaft axes (does not apply to ZAPEX couplings). In this
context, please also refer to the relevant operating instructions for further information about,
for example, the requirements of couplings.
The gear unit can be equipped with alignment threads in the housing feet to make it simpler
to align.
Figure 5-2 Alignment surface
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Assembly
5.3 Gear unit assembly
To align the gear unit by its alignment surface, proceed as follows:
1. For the precise position of the alignment surfaces, refer to the dimension drawings in the
complete documentation.
2. Note the values inscribed in the alignment surfaces.
3. Use these surfaces as a guide for aligning the gear unit horizontally to ensure that it will
run smoothly.
The following diagram shows the alignment surfaces and alignment thread at the gear units:
Further information
Tools
① Alignment surfaces ② Alignment thread
Figure 5-3 Alignment surfaces and alignment thread at the gear unit
Further information and the precise position of the alignment thread are provided in the
dimension drawing in the overall gear unit documentation.
The following tools are needed to perform the final fine alignment (Page 67) work on the shaft
axes of the gear unit and the equipment installed on the input and output sides.
● Rulers
● Spirit level
● Dial gauge
● Feeler gauge etc.
Once the gear unit is finely aligned, tighten the foundation bolts and check the settings again.
Record the alignment dimensions and keep the report in a safe place together with these
operating instructions.
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Assembly
5.3 Gear unit assembly
5.3.3 Mounting the gear unit on the housing mounting foot
5.3.3.1 Installation on a foundation frame
Use of incorrect attachment points
Use of incorrect attachment points may result in damage to the gear unit. To transport the gear
unit, only attach slings to the attachment points provided for this purpose.
The threads in the end faces of the shaft ends may not be used for attaching lifting equipment.
Lifting equipment must be adequately designed to accommodate the weight of the gear unit.
Requirements
The following requirements must be fulfilled before the assembly work commences:
● The foundation must be horizontal and level.
● When tightening the fastening bolts, make sure that the gear unit is free of mechanical
stress.
Procedure
NOTICE
Poor stability
Damage to the gear unit is possible if it is not mounted on a stable foundation.
The foundation frame must be horizontal and level.
It is particularly important that the surface on which the gear unit is mounted is level because
this determines the contact pattern of the teeth and the load on the bearings, and so has an
influence on the service life of the gear unit.
All points on the gear unit mounting surface must lie between two imaginary parallel planes
that are 0.1 mm per 1 m apart.
To install the gear unit on a foundation frame, proceed as follows:
1. Clean the underside of the gear unit feet.
2. Use suitable hoisting gear to set the gear unit down on the foundation frame.
3. Tighten the foundation bolts to the specified tightening torque (Page 73). If necessary, install
stops to prevent displacement.
4. Align the gear unit precisely with the input and output equipment (Page 60).
5. Record the alignment dimensions.
6. Keep the report in a safe place together with these operating instructions.
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NOTICE
Damage caused by unevenly tightening the fastening bolts
The gear unit can be damaged by unevenly tightening the fastening bolts.
Evenly tighten the fastening bolts. When tightening the fastening bolts, make sure that the
gear unit is free of mechanical stress.
5.3.3.2 Mounting on a concrete foundation using foundation blocks
Requirement
The lower side of the gear unit mounting feet must be clean.
Gear unit with foundation blocks
Assembly
5.3 Gear unit assembly
Procedure
The following diagram shows a foundation block:
① Fastening bolt ⑥ Foundation
② Washer ⑦ Foundation block
③ Gear unit foot ⑧ Flat steel plate
④ Height of the completed foundation ⑨ Set screw
⑤ Height of the prepared foundation
Figure 5-4 Foundation block
Proceed as follows to mount the gear unit using foundation blocks:
1. Attach the foundation blocks with washers and fastening bolts in the foundation mounting
points in the gear unit housing.
2. Using a suitable crane or lifting gear, place the gear unit down on the concrete foundation.
3. Align the gear unit so that the input and output shafts are horizontal using the set screws
(if available) (Page 60).
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Assembly
5.3 Gear unit assembly
4. For higher external forces, if necessary, use lateral stops to prevent the gear unit shifting.
5. Before casting the foundation, close the openings in the foundation blocks using a suitable
material (e.g. using polystyrene).
6. Pour concrete into the recesses in the concrete foundation for the stone bolts or foundation
blocks.
7. After the concrete has set, tighten the hexagon nuts of the stone bolts or fastening bolts of
the foundation blocks with the specified tightening torque (Page 73).
NOTICE
Damage caused by unevenly tightening the fastening bolts
The gear unit can be damaged by unevenly tightening the hexagon nuts or fastening bolts.
Evenly tighten the hexagon nuts or fastening bolts. Ensure that the gear unit is not deformed
or distorted when tightening the fastening bolts.
5.3.3.3 Mounting on a concrete foundation using anchor bolts
Requirement
The lower side of the gear unit mounting feet must be clean.
Inserting the anchor bolt
The following diagram shows the inserted anchor bolt:
① Baseplate ⑤ Anchor bolt
② Support ⑥ Pressure plate
③ Fine-grout concrete ⑦ Wood
④ Raw foundation ⑧ Hexagon nut
Figure 5-5 Inserted anchor bolt
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Assembly
5.3 Gear unit assembly
Proceed as follows to insert the anchor bolt:
1. Place the support on the baseplate embedded in the fine-grout concrete.
2. Insert the anchor bolt.
3. Attach the pressure plate and tighten the nuts.
4. Place a piece of wood under the anchor bolt so that it is approximately 10 mm from the
upper edge of the support.
5. Place the gear unit down.
NOTICE
Use of incorrect attachment points
Use of incorrect attachment points may result in damage to the gear unit. When transporting
the gear unit, only attach it at the lifting eyes provided for the purpose.
The threads in the end faces of the shaft ends may not be used for attaching lifting equipment.
Lifting equipment must be adequately designed to accommodate the weight of the gear unit.
Mounting the gear unit using anchor bolts
The following diagram shows a tightened anchor bolt:
① Hexagon nut ⑤ Raw foundation
② Washer ⑥ Anchor bolt
③ Housing foot ⑦ Baseplate
④ Fine-grout concrete ⑧ Support
Figure 5-6 Tightened anchor bolt
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Assembly
5.3 Gear unit assembly
Proceed as follows to mount the gear unit using anchor bolts:
1. Pull the anchor bolts upwards. To do this you can use a screw or threaded bar that you
screw into the thread on the end face.
2. Attach the washer.
3. Screw on the hexagon nut by hand a few turns.
4. Align the gear unit with the supports (Page 60).
– Observe the values on the alignment strips.
– Maintain the alignment tolerances to the units connected at the input and output
5. Document the alignment dimensions in the form of a report, and archive this together with
these instructions.
6. Keep the anchor bolts in their position by tightening the nuts by hand.
7. Locate the protective sleeve.
8. Attach the hydraulic clamping device.
9. Tighten the screws alternating, taking into account the preload forces (Page 73).
according to the permissible angular and axial displacements of the couplings.
10.Tighten the hexagon nuts to their end stops using a suitable tool.
11.Document the tensioning pressures and preload forces, and archive this report together
with these operating instructions.
CAUTION
Incorrect use of the preload tool
Incorrectly using the preload tool can result in injury.
To ensure correct handling and adjustment of the preload tool, you must carefully comply
with the instructions provided in the manufacturers operating instructions for the preload tool.
NOTICE
Inadequate concrete hardness and strength
Damage caused by inadequate stability of the gear unit as a result of inadequate concrete
hardness and strength is possible.
The fine-grout concrete must be allowed to harden for at least 28 days before tensioning the
anchor bolts.
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5.4 Couplings
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Introduction
The coupling parts might become misaligned as a result of:
● Failure to accurately align the parts during assembly
● During operation of the system:
– Due to thermal expansion
– Due to shaft deflection
– Due to machine frames that are too soft
NOTICE
Damage or destruction of the coupling through incorrect alignment
Refer to the coupling operating instructions for the maximum permissible displacements.
Under no circumstances may these values be exceeded in operation.
Assembly
5.4 Couplings
Alignment
Angular and radial displacement might occur simultaneously. Make sure that the total value
of both displacements does not exceed the maximum permissible angular or radial
displacement value.
If couplings from other manufacturers are to be used, then, specifying the radial loads that
occur, ask the manufacturer which alignment errors are permissible.
The following diagram shows the possible displacements:
Figure 5-7 Possible displacements
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Alignment must be carried out in two axis planes that are vertical with respect to one another.
This is possible using rulers (radial offset) and feeler gauges (angular offset) as shown in the
diagram. You will achieve a greater degree of alignment accuracy by using a dial gauge or
laser alignment system.
The diagram below shows the alignment process based on the example of a flexible coupling:
Page 68
Assembly
5.5 Connecting components
① Ruler ③ Measuring points
② Feeler gauge
Figure 5-8 Alignment process based on the example of a flexible coupling
Note
It is advisable to insert shims or metal sheets under the mounting feet in order to align the drive
components in the vertical direction. It is helpful to use support paws with adjusting screws on
the foundation to adjust the drive components laterally.
Note
Gear unit with motor bell housing
Couplings do not have to be aligned if the gear unit and motor are connected through a motor
bell housing.
Further information
You can find additional information about the permissible alignment errors for Flender
couplings in the complete documentation for the gear unit.
If couplings from other manufacturers are to be used, then, specifying the radial loads that
occur, ask the manufacturer which alignment errors are permissible.
5.5 Connecting components
5.5.1 Gear units with mounted components
Depending on the order specification, the gear unit can be equipped with various components.
Connect the closed-loop control and open-loop control electrical devices corresponding to the
specifications of the device supplier.
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Further information
You can find additional information on operation and maintenance in the associated operating
instructions, provided in the complete gear unit documentation.
You can find the technical data of the mounted components in the contract-list of equipment
provided in the complete gear unit documentation.
5.5.2 Connecting the cooling coil
Procedure
To connect the cooling coil to the gear unit, proceed as follows:
1. Before connecting the cooling coil, remove the sealing plugs from the connection sleeves.
2. Flush through the cooling coil to remove any dirt or dust.
3. Connect up the cooling water inlet and drain lines. Refer to the dimension drawing for the
position of the connections.
Assembly
5.5 Connecting components
Further information
Further information about the cooling coil can be found in the complete documentation for the
gear unit.
Note
Observe the information provided in chapter Cooling coils (Page 31).
5.5.3 Installing a separate oil supply system
Procedure
To connect the oil supply system to the gear unit, proceed as follows:
1. Remove the dummy flange from the suction and delivery line before connecting the system.
2. Mount the system on the gear unit in accordance with the dimension drawings in the
complete documentation, or install it as a separate system.
3. Avoid distorting the piping when installing.
Further information
Further information about the oil supply system can be found in the oil supply system operating
instructions in the complete documentation for the gear unit.
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Assembly
5.5 Connecting components
5.5.4 Connecting the pressure monitor
For gear units with mounted oil supply system or separate oil supply system, you must connect
the pressure monitor so that it functions correctly.
Further information
You can find additional information on pressure monitoring in the pressure monitor operating
instructions, provided in the complete gear unit documentation.
5.5.5 Connecting the heating element
Procedure
To connect heating elements to the gear unit, proceed as follows:
1. Check that the heating element connection is not damaged.
2. Install the electrical wiring for the heating elements.
Further information
Further information about the heating can be found in the heating operating instructions in the
complete documentation for the gear unit.
5.5.6 Connecting the oil-level monitoring system
Procedure
To connect the oil-level monitoring system to the gear unit, proceed as follows:
1. Ensure that the filling level limit switch connection is not damaged.
2. Electrically connect the filling level limit switch.
3. Connect the signal so that for the "oil level too low" signal, the drive motor cannot start and
an alarm is output.
Bypass this signal in operation.
Further information
Additional information about the oil-level monitoring system can be found in the operating
instructions for the oil-level monitoring system components provided in the complete gear unit
documentation.
You can find technical data in the separate data sheet and in the equipment list in the complete
gear unit documentation.
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5.5.7 Connecting the Pt 100 resistance thermometer
Procedure
To connect the Pt 100 resistance thermometer, proceed as follows:
1. Check that the Pt 100 resistance thermometer connection is not damaged.
2. Install the electrical wiring between the Pt 100 resistance thermometer and the evaluation
unit. The customer is responsible for providing the evaluation unit.
Further information
Further information about the Pt 100 resistance thermometer can be found in the Pt 100
resistance thermometer operating instructions in the complete documentation for the gear unit.
5.5.8 Connecting the bearing monitoring system
Assembly
5.5 Connecting components
Procedure
To connect the bearing monitoring system to the gear unit, proceed as follows:
1. Make sure that the connections provided for holding the bearing monitoring equipment are
undamaged.
2. Install the bearing monitoring equipment at the customer's site.
Further information
Further information about the bearing monitoring system can be found in the operating
instructions for the bearing monitoring system components provided in the complete gear unit
documentation.
5.5.9 Connecting a speed encoder
Procedure
To connect the air-oil cooler to the gear unit, proceed as follows:
1. Ensure that the speed encoder connection is not damaged.
2. Electrically connect the speed encoder.
Further information
You can find additional information on the speed encoder in the speed encoder operating
instructions, provided in the complete gear unit documentation.
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Assembly
5.5 Connecting components
5.5.10 Connecting the torque monitoring system
Procedure
To connect the torque monitoring system to the gear unit, proceed as follows:
1. Ensure that the connections of the torque monitoring sensors are not damaged.
2. Electrically connect the torque monitoring sensor connections.
Further information
Additional information about the torque monitoring system can be found in the torque
monitoring system operating instructions in the complete documentation for the gear unit.
5.5.11 Connecting the gear unit condition monitoring system
Procedure
To connect the gear unit "Condition Monitoring" system to the gear unit, proceed as follows:
1. Ensure that the connections of the measuring equipment for the gear unit condition
monitoring system are not damaged.
2. Electrically connect the connections of the measuring equipment for the gear unit condition
monitoring system.
Further information
Additional information about the gear unit condition monitoring system can be found in the
gear unit condition monitoring system operating instructions in the complete documentation
for the gear unit.
5.5.12 Electrical connections
Procedure
DANGER
Electric shock
Live parts can cause electric shock.
Ensure that the entire plant is de-energised before starting electrical installation work.
Carefully observe the five safety rules (Page 13).
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To connect the motors and monitoring devices, proceed as follows:
1. Ensure that the connections of the motors and monitoring devices are not damaged.
2. Connect the motors and monitoring devices according to the terminal diagram.
Further information
You can find additional information about the electrical connections in the terminal diagrams
and equipment lists provided in the complete gear unit documentation.
5.6 Tightening procedure
5.6.1 Introduction
Bolts
Assembly
5.6 Tightening procedure
Mating threads
The bolts must have the following properties:
● Made of steel
● Black-annealed or phosphatised
● Lightly oiled (do not add additional oil)
Note
Replacing bolts
Replace any bolts that are no longer fit for use by bolts of the same type and strength class.
The mating threads must have the following properties:
● Made of steel or cast iron
● Dry, cut threads
Note
Using a lubricant
As a rule, lubricants may not be used, because this can result in the bolt connection becoming
overloaded.
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Assembly
5.6 Tightening procedure
5.6.2 Bolt connection classes
In order to affix fastening bolts, note the information in the following table:
Table 5-1 Information on tightening fastening bolts
Further information
Mounting Bolt connection
class
Gear unit
Motor
Brake
Torque arm
D ± 10 % to ± 20 %
Protection cover
Sun shield
C ± 5 % to ± 10 %
E ± 20 % to ± 50 %
Scatter of the tor‐
que emitted on the
tool
Tightening procedure
● Hydraulic tightening with
mechanical screwdriver
● Torque-controlled tightening with
a torque wrench or a signalemitting torque wrench
● Tightening with a precision
mechanical screwdriver with
dynamic torque measurement
● Torque-controlled tightening with
mechanical screwdriver
● Tightening with pulse
screwdriver or impact wrench,
without adjustment checking
device
● Tightening by hand, using a
wrench without torque
measuring device
You can find additional information about tightening torques when mounting motor and brake
in the operating instructions from the particular manufacturer.
5.6.3 Tightening torques and preload forces
The specified bolted connections must be tightened to the torques stated in the table below:
The tightening torques apply to friction values of μ
74 Operating Instructions 10/2017
= 0.14.
total
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Assembly
5.6 Tightening procedure
The following table lists the preload forces and tightening torques for bolt connections, strength
classes 8.8; 10.9; 12.9:
Table 5-2 Preload forces and tightening torques
Nominal
thread di‐
ameter
d
mm
Bolt
strength
class
Preload force for bolt connection
classes from the table in chapter
Bolt connection classes (Page 74).
Tightening torque for bolt connection
classes from the table in chapter Bolt
connection classes (Page 74)
C D E C D E
F
M min.
N
M
Nm
A
M10 8.8 18 000 11 500 7 200 44.6 38.4 34.3
10.9 26 400 16 900 10 600 65.4 56.4 50.4
12.9 30 900 19 800 12 400 76.5 66.0 58.9
M12 8.8 26 300 16 800 10 500 76.7 66.1 59.0
10.9 38 600 24 700 15 400 113 97.1 86.6
12.9 45 100 28 900 18 100 132 114 101
M16 8.8 49 300 31 600 19 800 186 160 143
10.9 72 500 46 400 29 000 273 235 210
12.9 85 000 54 400 34 000 320 276 246
M20 8.8 77 000 49 200 30 800 364 313 280
10.9 110 000 70 400 44 000 520 450 400
12.9 129 000 82 400 51 500 609 525 468
M24 8.8 109 000 69 600 43 500 614 530 470
10.9 155 000 99 200 62 000 875 755 675
12.9 181 000 116 000 72 500 1 020 880 790
M30 8.8 170 000 109 000 68 000 1 210 1 040 930
10.9 243 000 155 000 97 000 1 720 1 480 1 330
12.9 284 000 182 000 114 000 2 010 1 740 1 550
M36 8.8 246 000 157 000 98 300 2 080 1 790 1 600
10.9 350 000 224 000 140 000 2 960 2 550 2 280
12.9 409 000 262 000 164 000 3 460 2 980 2 670
M42 8.8 331 000 212 000 132 000 3 260 2 810 2 510
10.9 471 000 301 000 188 000 4 640 4 000 3 750
12.9 551 000 352 000 220 000 5 430 4 680 4 180
M48 8.8 421 000 269 000 168 000 4 750 4 090 3 650
10.9 599 000 383 000 240 000 6 760 5 820 5 200
12.9 700 000 448 000 280 000 7 900 6 810 6 080
M56 8.8 568 000 363 000 227 000 7 430 6 400 5 710
10.9 806 000 516 000 323 000 10 500 9 090 8 120
12.9 944 000 604 000 378 000 12 300 10 600 9 500
M64 8.8 744 000 476 000 298 000 11 000 9 480 8 460
10.9 1 060 000 676 000 423 000 15 600 13 500 12 000
12.9 1 240 000 792 000 495 000 18 300 15 800 14 100
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Assembly
5.7 Final work
Nominal
thread di‐
ameter
d
mm
M72x6 8.8 944 000 604 000 378 000 15 500 13 400 11 900
M80x6 8.8 1 190 000 760 000 475 000 21 500 18 500 16 500
M90x6 8.8 1 510 000 968 000 605 000 30 600 26 300 23 500
M100x6 8.8 1 880 000 1 200 000 750 000 42 100 36 200 32 300
5.7 Final work
Bolt
strength
class
C D E C D E
10.9 1 340 000 856 000 535 000 22 000 18 900 16 900
12.9 1 570 000 1 000 000 628 000 25 800 22 200 19 800
10.9 1 690 000 1 100 000 675 000 30 500 26 400 23 400
12.9 1 980 000 1 360 000 790 000 35 700 31 400 27 400
10.9 2 150 000 1 380 000 860 000 43 500 37 500 33 400
12.9 2 520 000 1 600 000 1 010 000 51 000 43 800 39 200
10.9 2 670 000 1 710 000 1 070 000 60 000 51 600 46 100
12.9 3 130 000 2 000 000 1 250 000 70 000 60 400 53 900
Preload force for bolt connection
classes from the table in chapter
Bolt connection classes (Page 74).
F
M min.
N
Tightening torque for bolt connection
classes from the table in chapter Bolt
connection classes (Page 74)
M
A
Nm
Measures
Further information
Once all the components have been assembled or connected, perform the following final work:
● Check whether all devices dismantled for transportation have been reassembled.
● Check all bolt connections for tightness after installation of the gear unit has been
completed.
● Check the alignment after tightening the fastening elements. The alignment must not have
changed in any way.
● Lock the oil drain valves against accidental opening.
● Protect the gear unit against falling objects.
● Check that the guards over rotating parts are securely fastened.
Contact (accidental or deliberate) with rotating parts is not permitted.
● Perform potential equalisation in accordance with the applicable regulations and guidelines.
If no threaded holes are available on the gear unit for an earth connection, please take
suitable alternative measures. This work must always be done by specialist electricians.
● Protect the cable entries against penetrating moisture.
Further information about the gear unit and all assembled elements can be found in the
operating instructions for assembled elements in the complete documentation for the gear unit.
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Assembly
5.7 Final work
You can find additional technical specifications in the separate data sheet in the complete gear
unit documentation.
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Assembly
5.7 Final work
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Commissioning
6.1 Measures prior to commissioning
Take the following measures before commissioning the gear unit:
● Read and observe the operating instructions.
● Replace the screw plug with the air filter or the wet-air filter. Read operating instructions
BA 7300 for further information.
● Fill the gear unit with oil.
● Gear unit with oil supply system: Check that the oil supply system is working properly.
● Check the oil level.
● Check the gear unit for leaks.
● Gear unit with oil supply system: Observe the appropriate measures prior to commissioning
gear units equipped with oil supply system.
● Ensure that all pipes and components are filled with oil.
Further information
6
Further information about oil and replacement of air filters can be found in the operating
instructions BA 7300 in the complete documentation for the gear unit.
Further information about individual components can be found in the operating instructions for
the components in the complete documentation for the gear unit.
6.1.1 Gear units with cooling coil
Implement the following measures before commissioning the gear unit with cooling coil:
● Make sure that the pressure in the cooling coil does not exceed the maximum permissible
pressure.
● Make sure that the temperature of the cooling coil does not exceed the maximum
permissible temperature.
Further information
Further information about the cooling coil can be found in the separate data sheet and the list
of equipment in the complete documentation for the gear unit.
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Commissioning
6.2 Measures during commissioning
6.1.2 Gear units with oil supply system
Implement the following measures before commissioning the gear unit with oil supply system:
● Ensure that the maximum permissible pressure in the oil supply system components is not
exceeded.
● Ensure that the maximum permissible temperature of the oil supply system components is
not exceeded.
● Using the oil supply system, lubricate the gear unit for 2 minutes using a pre-lubrication
phase. During this time, the rolling-contact bearings and gearing are supplied with sufficient
oil for starting.
Carefully ensure that the pre-lubrication phase is not longer than 5 minutes as the oil can
foam up at low temperatures. For oil temperatures below 10 °C, heat up the oil using suitable
measures and contact Flender in this regard.
Further information
You can find additional information on the oil cooling system in the separate data sheet, and
in the equipment list in the complete gear unit documentation.
6.2 Measures during commissioning
Please observe the following measures to commission the gear unit and document these:
● For gear units with oil supply system: Check that the oil supply system is working properly.
● Check the oil level.
● Measure the oil sump temperature (Page 88) after the gear unit has run in.
● Check that the shaft seal on the gear unit does not leak.
● Check that no contact with rotating parts is possible.
● Check whether the shutoff valves are open.
– Check that all of the oil drain valves are closed.
– Ensure that all of the other shutoff valves are open.
● Check all the connection lines are securely tightened and leak-free.
● For gear units with bearing monitoring by measuring the vibration: Measure the vibration
levels of the rolling-contact bearings (Page 88) to create initial and comparison values.
● When commissioning, the pressure monitor signal should be bypassed for approximately
20 seconds. This is necessary as the pressure in the gear unit must first stabilise.
Further information
You can find additional information on the topic of oil in the operating instructions BA 7300,
provided in the complete gear unit documentation.
Further information about the oil supply system can be found in the oil supply system operating
instructions in the complete documentation for the gear unit.
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6.2.1 Heating
Please observe the following measures to commission the gear unit with heating:
● Ensure that the heating elements are not exposed.
● Check the switching points of the temperature monitor.
The oil sump can catch fire
The oil sump can catch fire if exposed heating elements are switched on.
Never switch on the heating elements until you have checked that they are completely
immersed in the oil bath.
Further information
Further information about heating elements can be found in the heating element operating
instructions in the complete documentation for the gear unit.
Commissioning
6.2 Measures during commissioning
WARNING
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Commissioning
6.2 Measures during commissioning
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Operation
7.1 Operating data
Introduction
To ensure correct, trouble-free operation of the system, observe the operating data of the gear
unit. The valid operating data can be found in the annex Technical data.
The following operating data apply to the oil:
Table 7-1 Operating data
7
Maximum operating tempera‐
ture
Maximum operating tempera‐
ture
Oil pressure of the oil supply
system
Water pressure in the cooling
coil
Further information
You can find additional technical data of the gear unit in the separate data sheet and in the
equipment list in the complete gear unit documentation.
7.2 Irregularities in operation
Introduction
Switch off the drive assembly immediately if it exhibits irregular behaviour during operation.
A few irregularities are listed below as examples:
90 °C is applicable for mineral oil, API groups I or II and saturated
synthetic ester
100 °C is applicable for semi-synthetic oils, API group III, PAO and
PG oils
> 0.5 bar
< 8.0 bar
● Oil temperature exceeds the maximum permissible value
● Alarm tripped by the pressure monitor in the oil cooling system or oil supply system
● Unusual operating noise
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Operation
7.3 Taking the unit out of service
NOTICE
Faults can cause damage to the gear unit
The gear unit might sustain damage if it is not shut down when a fault occurs.
Switch off the drive assembly immediately if any fault condition develops.
Rectifying irregularities in operation
Proceed as follows to rectify any irregularities in operation:
1. Switch off the drive assembly if it exhibits irregular behaviour during operation.
2. Refer to the Fault information (Page 90) to find the cause of the fault.
3. If you still cannot determine the fault cause, contact Flender Customer Services.
7.3 Taking the unit out of service
If you take the unit out of service for a prolonged period, you must take the following measures
depending on the length of time that the gear unit will remain out of service:
● Switch off the drive assembly.
● For gear units with cooling coil:
– Drain the water from the cooling coil if there is a risk of frost.
– Close the shutoff valves for the cooling water inlet and drain lines.
● For gear units with an oil supply system, perform the following steps before you preserve
the gear unit:
– Detach the connection between the oil supply system and the gear unit.
– Seal the openings in the gear unit and oil supply system so that they are air-tight.
● Take measures to preserve the gear unit if it is to be out of service for a prolonged period.
Follow the procedure described in operating instructions BA 7300.
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Servicing
8.1 General maintenance information
The operator must ensure compliance with the stipulated time limits. This also applies if the
maintenance activities are included in the operator’s internal maintenance schedules.
The gear unit could be damaged if the stipulated time limits for maintenance and servicing are
not observed.
The time limits stipulated in the maintenance schedule are largely dependent on the conditions
of use of the gear unit. For this reason, it is only possible to state average time limits here.
These refer to the following conditions of use:
● Daily operating time 24 h
● Duty cycle "ED" 100%
● Gear unit input speed 1500 rpm
● Permissible average oil temperature (Page 83)
WARNING
Danger to life due to live system
8
Working on a gear unit while it is in operation is hazardous and can result in potentially fatal
injuries.
Always shut down the gear unit and any oil supply system (whether separate or mounted on
the gear unit) before you carry out any work. Take measures to prevent the accidental
restarting of the drive assembly. Display a warning notice that clearly states that work is being
carried out on the gear unit.
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Servicing
8.2 Maintenance schedule
8.2 Maintenance schedule
Maintenance and servicing work
The following table provides an overview of all maintenance and servicing work which you are
required to perform continuously or at regular intervals.
Table 8-1 Maintenance and servicing work
Intervals and time limits Measures
As required Replace the wet-air filter
Plate on the gear unit, gear unit dimension
drawing
Daily Check the oil temperature
Monthly and prior to every start-up Check for leaks
400 operating hours after commissioning Check the water content of the oil
Every 3 months Check the speed monitoring of the auxiliary drive
Every 3 000 operating hours Measure the vibration levels of the rolling-contact bear‐
Every 3 000 operating hours, at least every
6 months
Every 5 000 operating hours, at least every
10 months
Every 12 months Check the friction linings of the torque-limiting backstop
Every 10 000 operating hours, at least every
2 years
Clean the air filter
Clean the fan and gear unit
Replace the backstop
Check the oil pressure (if pressure lubrication is fitted)
Check for changes in the gear unit noise
Check the oil level
Change the oil (or depending on results of the oil sam‐
ple test)
Check that all of the fastening bolts are tight
Check the auxiliary drive
Clean the oil filter
Clean the air filter
ings
Regrease taconite seals
Regrease Tacolab seals
Replenish grease in the oil retaining pipe
Inspect the hose lines
Inspect the shrink disk
Check the water content of the oil
Change the oil if using mineral oil of API Group I or II
or saturated synthetic esters (or depending on the re‐
sult of the oil sample test)
Check the air‐oil cooler (the same time as you change
the oil)
Check the water‐oil cooler (the same time as you
change the oil)
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Further information
Servicing
8.3 Maintenance and servicing work
Intervals and time limits Measures
Every 2 years Carry out a general inspection of the gear unit
Check the cooling coil
Check that all of the fastening bolts are tight
Clean the fan and gear unit
Every 20 000 operating hours, at least every
4 years
6 years after the specified date of manufacture Change the hoses
Change the oil if using semi-synthetic oil of API Group
III, PAO or PG oil (or depending on the result of the oil
sample test)
Further information about additional maintenance and servicing work can be found in the
separate data sheet in the complete documentation for the gear unit.
Further information about installed components can be found in the operating instructions for
the components in the complete documentation for the gear unit.
8.3 Maintenance and servicing work
Introduction
You can find maintenance and servicing measures relating to gear unit lubrication and
preservation, which are not provided in this chapter, in BA 7300 in the complete gear unit
documentation.
8.3.1 Cleaning the venting screw
Cleaning interval
For dust deposits, you must clean the venting screw before the minimum interval of 3 months
expires.
CAUTION
Compressed air can cause injuries
There is a risk of eye injury when using compressed air.
Wear suitable safety goggles.
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Servicing
8.3 Maintenance and servicing work
Procedure
Proceed as follows to clean the venting screw:
1. Remove the venting screw.
2. Do not allow foreign matter to enter the gear unit.
3. Wash the venting screw with cleaning solvent or a similar cleaning agent.
4. Dry the venting screw and blow it out using compressed air.
8.3.2 Checking the oil temperature
Damage to the gear unit due to excessively high oil sump temperatures.
The gear unit can sustain damage due to inadequate lubrication if you allow it to operate at oil
sump temperatures above the maximum permissible temperature.
Do not operate the gear unit above the maximum permissible oil sump temperature.
Procedure
Proceed as follows to check the oil temperature:
1. Allow the gear unit to reach its normal operating temperature.
2. Operate the gear unit with the maximum driven machine power.
3. Measure the temperature of the oil in the oil sump.
4. Compare the measured value with the maximum permissible oil temperature (Page 83).
5. Immediately stop the gear unit if the maximum permissible oil temperature is exceeded.
Contact Flender Customer Services.
8.3.3 Measuring the vibration levels of the rolling-contact bearings
Procedure
Proceed as follows to measure the vibration levels of the rolling-contact bearings:
1. Document the measurement results.
2. Compare the measured values with the comparison values that were documented when
commissioning the gear unit.
3. Replace defective rolling-contact bearings.
4. Archive the report together with these instructions.
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Further information
You can find additional information on measuring the vibration levels at rolling-contact bearings
in the operating instructions of the measurement sensor provided in the complete gear unit
documentation.
8.3.4 Cleaning the fan and gear unit
Introduction
The gear unit can sustain damage due to inadequate cooling if you operate it with a damaged
or soiled fan. Depending on the conditions at the site of installation, it may therefore be
necessary to clean the fan and gear unit more frequently than stipulated in the maintenance
schedule.
Procedure
Proceed as follows to clean the fan and gear unit:
Servicing
8.3 Maintenance and servicing work
1. Remove the air guide cover.
2. Use a hard brush to remove any stubborn dirt from the impeller, air guide cover and
protective grille. Never use a high-pressure cleaning device.
3. Treat any areas of corrosion.
4. Reinstall the air guide cover.
5. Make sure that the air guide cover is correctly fastened.
Make sure that there is no contact between the fan and the air guide cover.
8.3.5 Checking the cooling coil
Introduction
A soiled cooling coil can cause damage to the gear unit. It is therefore important to check the
cooling coil regularly.
Procedure
To check the cooling coil, proceed as follows:
1. Shut off the cooling water supply.
2. Disconnect the cooling water inlet and drain lines from the cooling coil.
3. Inspect the inner surface of the cooling coil for deposits.
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Servicing
8.4 Possible faults
4. If you discover that there are heavy deposits inside the cooling coil, arrange for the cooling
water or the deposits to be analysed.
Analysis services of this kind are offered by specialist chemical cleaning companies. These
companies also sell special cleaning agents for removing deposits. Before you use a
cleaning agent, check whether it is suitable for use on the cooling coil materials. You must
consult Flender Customer Services. Carefully read the instructions for use supplied by the
manufacturer before using different kinds of cleaning agent.
5. If the cooling coil is severely soiled, it must be replaced by a new one.
Please consult Flender Customer Services for further advice.
6. Reconnect the cooling water inlet and drain lines to the cooling coil.
8.3.6 Check that all of the fastening bolts are tight
Procedure
Proceed as follows to check that the fastening bolts are tight:
1. Observe the data regarding connection classes (Page 74), preload forces and tightening
torques (Page 74).
2. Replace any bolts that are no longer fit for use by bolts of the same strength class and type.
8.3.7 General inspection of the gear unit
General inspection of the gear unit by Customer Services
Arrange for Flender Customer Services to perform a general inspection on the gear unit.
Thanks to their experience, these engineers are best placed to assess which gear unit
components need to be replaced.
8.3.8 Final work
After you have finished all the work listed in the maintenance schedule, replace any bolts that
are no longer fit for use by bolts of the same strength class and type.
8.4 Possible faults
The faults listed below are only intended as a troubleshooting guide.
If any faults occur while the unit is still under warranty, do not allow anyone except Flender
Customer Services to attempt a repair.
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Even after the warranty period has expired, you should still arrange for faults to be rectified by
Flender Customer Services.
Note
Loss of warranty
You will invalidate the warranty for the gear unit if you modify it in any way without seeking the
approval of Flender beforehand, or if you do not use original spare parts.
Only use original spare parts from Flender. Always arrange for Flender Customer Services to
repair any faults that develop while the unit is still under warranty.
Possible faults and their rectification
The following table provides you with an overview of possible faults and indicates how they
can be rectified.
Table 8-2 Possible faults and their rectification
Possible faults Causes Possible remedies
Pressure monitor trig‐
gers an alarm
(For gear units with
pressure lubrication or
air‐oil cooler).
Grease escaping at
the output shaft
Noise
Outer surface of gear
unit soiled with oil
Oil pressure < 0.5 bar
Defective rotary shaft sealing rings
Damage to gearing
The bearing play is excessive.
Defective rolling-contact bearings
Gear unit fastening has worked
loose
Inadequate sealing of the housing
cover or joints
Labyrinth seals soiled with oil, incor‐
rect transport position
● Check the oil level at room temperature
● Top up with oil if necessary
● Check the oil pump
● If required, replace the oil pump
● Check the oil filter and coarse filter
● If required, replace the oil filter or clean the coarse filter
● Inspect the rotary shaft seals and replace if necessary
● Contact Customer Services
● Inspect toothed components
● Replace damaged components if necessary
● Contact Customer Services
● Adjust bearing play
● Contact Customer Services
● Replace defective rolling-contact bearings
● Tighten bolts and nuts to the specified tightening torque
● Replace damaged bolts and nuts
● Seal housing cover or joints
● Check oil filling
● Clean the labyrinths
Servicing
8.4 Possible faults
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Servicing
8.4 Possible faults
Possible faults Causes Possible remedies
Main drive motor does
not start
Main drive motor can
start while the auxiliary
drive is operational
Auxiliary drive motor
does not start
The auxiliary drive mo‐
tor starts, the main
gear unit output shaft
does not turn
Leaks
Motor direction of rotation incorrect
Backstop cage with sprags incor‐
rectly installed or defective
Overrunning clutch blocked
Overrunning clutch cage with
sprags incorrectly installed and/or
defective
Defective electrical interlocking be‐
tween the main and auxiliary motor
Defective speed monitoring
Overload at the output
Defective auxiliary drive motor
Motor brake not released
Motor direction of rotation incorrect
Overrunning clutch cage with
sprags incorrectly installed
Defective overrunning clutch
Inadequate sealing of the housing
cover or joints
Labyrinth seals oiled up or transport
position incorrect
Inadequate sealing of the housing
cover or joints
Defective rotary shaft sealing rings
● Change polarity of motor
● Contact Customer Services
● Install the backstop cage, rotated through 180° - or replace
● Contact Customer Services
● Replace the overrunning clutch
● Contact Customer Services
● Install the overrunning clutch cage, rotated through 180°
- or replace
● Check the connections
● If necessary, replace defective devices
● Check the connections
● If necessary, replace defective devices
● Reduce the load at the output
● Repair the motor or replace
● Correct the electrical connection of the motor brake
● If required, replace the motor brake
● Change polarity of motor
● Contact Customer Services
● Install the overrunning clutch cage, rotated through 180°
- or replace
● Contact Customer Services
● Replace the overrunning clutch
● Seal housing cover or joints
● Check oil filling
● Clean the labyrinths
● Check the seals
● Replace, if necessary
● Seal housing cover or joints
● Check the rotary shaft sealing rings
● Replace, if necessary
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Possible faults Causes Possible remedies
Oil is foaming in the
gear unit
Oil escaping from the
gear unit
Oil supply system mal‐
function
Preservation agent not completely
drained off
Oil supply system left in operation
for too long at low temperatures
Gear unit too cold in operation
Water in the oil
Oil defoamer has run out
Unsuitable mixture of oils
Inadequate sealing of the housing
cover or joints
Leaking pipes
-
● Change the oil
● Switch off the oil supply system
● Degas the oil
● Switch off the gear unit
● Degas the oil
● Start up without cooling water during cold restart
● Take test tube sample to examine oil condition for water
penetration
● Have the oil examined by a chemical lab
● Change the oil if necessary
● Examine the oil
● Change the oil if necessary
● Examine the oil
● Change the oil if necessary
● Check the seals and replace if necessary
● Seal housing cover or joints
● Check the compression seals and retighten screws if
necessary
● Check the pipes, and replace or seal if necessary
● Read the operating instructions for the oil supply system
Servicing
8.4 Possible faults
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Servicing
8.4 Possible faults
Possible faults Causes Possible remedies
Elevated temperature
during operation
Elevated temperature
at bearing points
Increased backstop
temperature with fail‐
ure of the blocking
function
Elevated vibration am‐
plitude at bearing
points
Oil level in the gear unit housing too
high
Oil is too old
Oil is severely contaminated
Oil supply system or cooling coil de‐
fective
Gear unit with oil cooling system:
Cooling liquid flow rate too low or
too high
Gear unit with oil cooling system:
The oil flow through the water-oil
cooler is too low.
Gear units with cooling coil: Depos‐
its in the cooling coil
For gear units with fan: Air intake
opening in air guide cover or gear
unit housing is soiled
Coolant temperature too high
Defective oil pump
Oil level in the gear unit housing too
low or too high
Oil is too old
Oil supply system defective
Defective rolling-contact bearings
Damaged backstop
Defective rolling-contact bearings
Gear wheels defective
● Check the oil level
● If required, correct the oil level
● Check when the last oil change was done
● Change the oil if necessary
● Change the oil
● Check the oil supply system or cooling coil
● Replace defective components if necessary
● Read the operating instructions for the oil supply system
● Fully open the valves in the intake and outlet pipes
● Check that water and oil can freely flow through the wateroil cooler
● Check the oil filter and coarse filter
● If required, replace the oil filter or clean the coarse filter
● Clean, or if necessary, replace the cooling coil
● Clean the air guide cover and gear unit housing
● Check the temperature
● Correct the temperature if necessary
● Check the oil pump function
● If required, repair or replace the oil pump
● Check the oil level at room temperature
● Correct the oil level if necessary
● Check when the last oil change was done
● Change the oil if necessary
● Inspect the oil supply system
● Replace defective components if necessary
● Read the operating instructions for the oil supply system
● Contact Customer Services
● Inspect the rolling-contact bearings and replace if
necessary
● Contact Customer Services
● Check the backstop
● Replace, if necessary
● Contact Customer Services
● Inspect the rolling-contact bearings and replace if
necessary
● Contact Customer Services
● Inspect the gear wheels and replace if necessary
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Possible faults Causes Possible remedies
Contamination indica‐
tor of the double
change-over filter trig‐
gers an alarm
Water in the oil Oil supply system or cooling coil de‐
Double change-over filter clogged
fective
Engine room fan is blowing cold air
onto gear unit: Water condenses
Climatic conditions
Oil foams in the oil sump
● Changeover the double change-over filter corresponding
to the separate operating instructions
● Clean the filter element
● Check the oil supply system or cooling coil
● Replace defective components if necessary
● Read the operating instructions for the oil supply system
● Install suitable thermal insulation to protect gear unit
housing
● Close the air outlet or change the direction of the air outlet
using structural measures.
● Contact Customer Services
● Use wet-air filter if necessary
● Take test tube sample to examine oil condition for water
penetration
● Have the oil examined by a chemical lab
Servicing
8.4 Possible faults
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Servicing
8.4 Possible faults
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Service & Support
Contact
When ordering spare parts, requesting a customer service technician or in the case of technical
queries, please contact our factory or one of our customer service addresses:
Flender GmbH
Am Industriepark 2
46562 Voerde
Germany
Tel.: +49 (0)2871 / 92‐0
Fax: +49 (0)2871 / 92‐1544
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Service & Support
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Disposal
Disposal of the gear unit
When disposing of the gear unit after its useful life, please observe the following measures:
● Remove operating oil, preservative agents and coolant from the gear unit and dispose of
it according to regulations.
● Dispose of the gear unit parts according to applicable national regulations or recycle them.
Environmental protection
Observe the following environmental protection measures for disposal:
● Dispose of or recycle packaging material according to applicable national regulations.
● When changing the oil, collect the used oil in suitable containers. Use oil-binding agents to
clean up any oil spillages immediately.
● Store preservative agents separately from used oil.
● Dispose of used oil, preservative agents, oil binding agents and oil-soaked cloths according
to the applicable environmental protection regulations.
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Disposal
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