FLENDER H Series Operating Instructions Manual
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FLENDER H Series Operating Instructions Manual

Gear unit
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FLENDER Gear Units
Gear unit
Operating Instructions 5118en
Edition 10/2017
H..., B..., M..., SOND

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Summary of Contents for FLENDER H Series

  • 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 Introduction Safety instructions Description FLENDER Gear Units Application planning Gear unit 5118en Assembly Commissioning Operating Instructions Operation Servicing Service & Support Disposal Spare parts H..., B..., M..., SOND Quality documents Technical data Edition 10/2017...

  • Page 4: Edition

    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.

  • Page 5: Table Of Contents

    Table of contents Introduction..............................11 General information........................11 Lubricants..........................12 Safety instructions............................13 Security notes........................13 The five safety rules.......................13 General information........................14 General warnings and symbols....................15 Special types of danger and personal protective equipment..........16 Intended use..........................18 Description..............................21 General description........................21 Output shaft versions......................21 Housing..........................21 Oil supply to the gear unit......................24 3.4.1 Splash lubrication........................25 3.4.2...
  • Page 6 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 Application planning...........................45 Scope of delivery........................45 Transport..........................45...
  • Page 7 Table of contents Final work..........................76 Commissioning............................79 Measures prior to commissioning..................79 6.1.1 Gear units with cooling coil....................79 6.1.2 Gear units with oil supply system...................80 Measures during commissioning....................80 6.2.1 Heating...........................81 Operation..............................83 Operating data........................83 Irregularities in operation......................83 Taking the unit out of service....................84 Servicing..............................85 General maintenance information..................85 Maintenance schedule......................86...
  • Page 8 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...

  • Page 9: Gear Unit 5118En Operating Instructions 10/2017

    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...

  • Page 10: Operating Instructions

    Table of contents Gear unit 5118en Operating Instructions 10/2017...

  • Page 11: Introduction

    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 non- adherence to these operating instructions. The gear unit described in these instructions reflects the state of technical development at the time these operating instructions went to print.

  • Page 12: 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.

  • Page 13: Safety Instructions

    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.

  • Page 14: General Information

    Safety instructions 2.3 General information When all the work is complete, cancel the safety measures in the reverse sequence. 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;...

  • Page 15: General Warnings And Symbols

    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‐...

  • Page 16: Special Types Of Danger And Personal Protective Equipment

    Safety instructions 2.5 Special types of danger and personal protective equipment ANSI Warning Warning - hand injuries ATEX certification 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. ●...
  • Page 17 Safety instructions 2.5 Special types of danger and personal protective equipment 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.

  • Page 18: Intended Use

    Safety instructions 2.6 Intended use Chemical substances Injuries can be sustained when using chemical substances. WARNING 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).
  • Page 19 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.
  • Page 20 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.

  • Page 21: Description

    Description 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.

  • Page 22: Figure 3-1 Gear Unit Equipment For Type H2Sh 24 (Sond 622) Gear Units

    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.

  • Page 23: Figure 3-2 Gear Unit Equipment For Type M1S X 315 Gear Units

    Description 3.3 Housing ① ⑥ Rating plate Gear unit fastening ② ⑦ Lifting eyes Shaft seal ③ ⑧ Cover Alignment surfaces ④ ⑨ Cover 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: Gear unit 5118en Operating Instructions 10/2017...

  • Page 24: Oil Supply To The Gear Unit

    Description 3.4 Oil supply to the gear unit ① ⑥ Rating plate Sling swivels ② ⑦ Inspection and assembly cover Alignment surfaces ③ ⑧ Cover Shaft seal ④ ⑨ Housing Alignment thread ⑤ ⑩ Cover 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...

  • Page 25: Splash Lubrication

    Description 3.5 Bearing arrangement of the shafts 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.

  • Page 26: Shaft Seal

    Description 3.6 Shaft seal 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.

  • Page 27: Taconite Seal

    Description 3.6 Shaft seal 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:...

  • Page 28: Tacolab Seal

    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 ● Regreasable labyrinth "F"...

  • Page 29: Figure 3-8 Tacolab Seal

    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 ● 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...

  • Page 30: Cooling

    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. Cooling Introduction The gear unit can be equipped with the following cooling equipment depending on requirements: ●...

  • Page 31: Cooling Coil

    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.

  • Page 32: Figure 3-10 Cooling Coil Connections

    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.

  • Page 33: Mounted Oil Supply System

    Description 3.7 Cooling 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: ●...

  • Page 34: Oil Filter

    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.

  • Page 35: Heating

    Description 3.9 Heating Further information You can find additional information about the couplings in the coupling operating instructions provided in the complete gear unit documentation. 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.

  • Page 36: Oil Level Indicator

    Description 3.10 Oil level indicator The diagram below shows gear unit heating: ① ② Temperature monitor 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.

  • Page 37: Oil-Level Monitoring System

    Description 3.11 Oil-level monitoring system 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.

  • Page 38: Oil Temperature Monitoring

    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).

  • Page 39: Bearing Monitoring By Shock-Pulse Transducer

    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 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.

  • Page 40: Bearing Monitoring By Acceleration Sensor

    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.

  • Page 41: Figure 3-16 Fully Assembled Acceleration Sensor (A), And Threaded Connector (B) For Variants 1 To 4

    Description 3.13 Bearing monitoring ① ④ Shielded cable (oil-proof) Sensitivity specification ② ⑤ MIL-spec connector 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...

  • Page 42: Speed Encoder

    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.

  • Page 43: Gear Unit Monitoring "Condition Monitoring

    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 ④ Strain gauges (glued to the shaft) Slot with transmit antenna ②...
  • Page 44 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 –...

  • Page 45: Application Planning

    Application planning 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.
  • Page 46 Application planning 4.2 Transport WARNING 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.

  • Page 47: Attachment Points

    Application planning 4.3 Attachment points Please adhere to the symbols applied on the packaging. Figure 4-1 Transport symbols Attachment points Lifting eyes Lifting eyes are fitted to the gear unit to assist with its transportation during manufacture and installation. Carefully ensure that the angle of the vertical load at the gear units lifting eyes does not exceed 45°.

  • Page 48: Figure 4-2 Shear And Lateral Pulling When Using Eye Bolts

    Application planning 4.3 Attachment points Permitted shear pulling in direction of eye plane (maximum angle of 45°) 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...

  • Page 49: Figure 4-3 Position Of The Attachment Points For Gear Units Of Type H2Sh 24 (Sond 622)

    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: Gear unit 5118en...

  • Page 50: Figure 4-5 Position Of The Attachment Points For Gear Units Of Type H3Sx

    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.

  • Page 51: Special Aspects Of Gear Unit Lubrication And Preservation

    Application planning 4.4 Special aspects of gear unit lubrication and preservation 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...

  • Page 52: Figure 4-7 Oil Filling Points And Oil Draining Points On Type M1S X 315 Gear Units

    Application planning 4.4 Special aspects of gear unit lubrication and preservation ① ④ Oil filling point Oil level indicator ② ⑤ Venting point 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: Gear unit 5118en...

  • Page 53: Preservation Of Gear Units With Tacolab Seals

    Application planning 4.4 Special aspects of gear unit lubrication and preservation ① ④ Venting point Oil filling point ② ⑤ Oil level indicator 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.
  • Page 54 Application planning 4.4 Special aspects of gear unit lubrication and preservation ① ③ Adhesive tape Labyrinth, filled with grease, can be regreased ② ④ Air gap 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. Gear unit 5118en Operating Instructions 10/2017...

  • Page 55: Assembly

    Assembly 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: ●...

  • Page 56: Unpacking The Gear Unit

    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.

  • Page 57: Gear Unit Assembly

    Assembly 5.3 Gear unit assembly 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.

  • Page 58: Description Of Assembly Work

    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).
  • Page 59 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.

  • Page 60: Alignment

    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).
  • Page 61 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.

  • Page 62: Mounting The Gear Unit On The Housing Mounting Foot

    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.

  • Page 63: Mounting On A Concrete Foundation Using Foundation Blocks

    Assembly 5.3 Gear unit assembly 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.

  • Page 64: Mounting On A Concrete Foundation Using Anchor Bolts

    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.
  • Page 65 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.
  • Page 66 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.

  • Page 67: Couplings

    Assembly 5.4 Couplings Couplings 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 –...

  • Page 68: Connecting Components

    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.

  • Page 69: Connecting The Cooling Coil

    Assembly 5.5 Connecting components 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.

  • Page 70: Connecting The Pressure Monitor

    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.

  • Page 71: Connecting The Pt 100 Resistance Thermometer

    Assembly 5.5 Connecting components 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.

  • Page 72: Connecting The Torque Monitoring System

    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.

  • Page 73: Tightening Procedure

    Assembly 5.6 Tightening procedure 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.

  • Page 74: Bolt Connection Classes

    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 Mounting Bolt connection Scatter of the tor‐ Tightening procedure class que emitted on the tool Gear unit ±...
  • Page 75 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 Bolt Preload force for bolt connection Tightening torque for bolt connection thread di‐...

  • Page 76: Final Work

    Assembly 5.7 Final work Nominal Bolt Preload force for bolt connection Tightening torque for bolt connection thread di‐ strength classes from the table in chapter classes from the table in chapter Bolt ameter class Bolt connection classes (Page 74). connection classes (Page 74) M min.
  • Page 77 Assembly 5.7 Final work You can find additional technical specifications in the separate data sheet in the complete gear unit documentation. Gear unit 5118en Operating Instructions 10/2017...
  • Page 78 Assembly 5.7 Final work Gear unit 5118en Operating Instructions 10/2017...

  • Page 79: Commissioning

    Commissioning 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. ●...

  • Page 80: Gear Units With Oil Supply System

    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.

  • Page 81: Heating

    Commissioning 6.2 Measures during commissioning 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. WARNING The oil sump can catch fire The oil sump can catch fire if exposed heating elements are switched on.
  • Page 82 Commissioning 6.2 Measures during commissioning Gear unit 5118en Operating Instructions 10/2017...

  • Page 83: Operation

    Operation 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 Maximum operating tempera‐...

  • Page 84: Taking The Unit Out Of Service

    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. Taking the unit out of service...

  • Page 85: Servicing

    Servicing 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.

  • Page 86: Maintenance Schedule

    Servicing 8.2 Maintenance schedule 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...

  • Page 87: Maintenance And Servicing Work

    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 Change the oil if using semi-synthetic oil of API Group 4 years...

  • Page 88: Checking The Oil Temperature

    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...

  • Page 89: Cleaning The Fan And Gear Unit

    Servicing 8.3 Maintenance and servicing work 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.

  • Page 90: Check That All Of The Fastening Bolts Are Tight

    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. Gear unit 5118en...

  • Page 91: Table 8-2 Possible Faults And Their Rectification

    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.
  • Page 92 Servicing 8.4 Possible faults Possible faults Causes Possible remedies Main drive motor does Motor direction of rotation incorrect ● Change polarity of motor not start Backstop cage with sprags incor‐ ● Contact Customer Services rectly installed or defective ● Install the backstop cage, rotated through 180° - or replace Overrunning clutch blocked ●...
  • Page 93 Servicing 8.4 Possible faults Possible faults Causes Possible remedies Oil is foaming in the Preservation agent not completely ● Change the oil gear unit drained off Oil supply system left in operation ● Switch off the oil supply system for too long at low temperatures ●...
  • Page 94 Servicing 8.4 Possible faults Possible faults Causes Possible remedies Elevated temperature Oil level in the gear unit housing too ● Check the oil level during operation high ● If required, correct the oil level Oil is too old ● Check when the last oil change was done ●...
  • Page 95 Servicing 8.4 Possible faults Possible faults Causes Possible remedies Contamination indica‐ Double change-over filter clogged ● Changeover the double change-over filter corresponding tor of the double to the separate operating instructions change-over filter trig‐ ● Clean the filter element gers an alarm Water in the oil Oil supply system or cooling coil de‐...
  • Page 96 Servicing 8.4 Possible faults Gear unit 5118en Operating Instructions 10/2017...

  • Page 97: Service & Support

    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...
  • Page 98 Service & Support Gear unit 5118en Operating Instructions 10/2017...

  • Page 99: Disposal

    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. ●...
  • Page 100 Disposal Gear unit 5118en Operating Instructions 10/2017...

  • Page 101: Spare Parts

    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.
  • Page 102 Spare parts Gear unit 5118en Operating Instructions 10/2017...

  • Page 103: Quality Documents

    Quality documents Declaration of Incorporation Gear unit 5118en Operating Instructions 10/2017...
  • Page 104 Quality documents A.1 Declaration of Incorporation Declaration of incorporation Company name and full address of the manufacturer: Flender GmbH Am Industriepark 2 46562 Voerde Deutschland – Germany Name and address of the person, authorised to compile the relevant technical documentation:...

  • Page 105: Technical Data

    Figure B-1 Rating plate The limits of the intended use of the gear unit are defined on the basis of these data and the contractual agreements concerning the gear unit concluded between Flender and the customer. Further information Further information about these technical data can be found in the separate data sheet and the dimension drawings in the complete documentation for the gear unit.

  • Page 106: Ambient Temperature

    By applying various suitable measures, the gear unit can be used in the ambient temperature range extending from -40 °C up to 60 °C. However, this must always be authorised by Flender and specified in the order text.

  • Page 107: Index

    Index Alignment Alignment surface, 60 Air guide cover, 30 Prealignment, 60 Principle of operation, 30 Attachment points, 55 Fastening bolts Bolt connection class, 74 Bolts, 73 Mating threads, 73 Preload force, 74 Bearing monitoring Tightening procedure, 74 Acceleration sensor, 40 Tightening torque, 74 Connecting, 71 Fault, 90...
  • Page 108 Index Lateral pulling, 47 Lubricant, 12 Rating plate, 105 Reactivating, 20 Maintenance activities, 86 Rolling-contact bearings Maintenance information, 85 Measuring the vibration levels, 88 Maintenance schedule, 86 Rotary shaft sealing ring, 26 Measures during commissioning, 80 Prior to commissioning, 79 Motor pump, 25 Safety rules, 13 Mounting position, 55...
  • Page 109 AA 5118_EN_EBE...
  • Page 110 FLENDER Gear Units Gear unit Operating Instructions 5118en Edition 10/2017 Flender GmbH Alfred-Flender-Straße 77 46395 Bocholt GERMANY...

This manual is also suitable for:

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