Related Manuals for FLENDER REDUREX
Summary of Contents for FLENDER REDUREX
- Page 1 FLENDER GEAR UNITS REDUREX Gear unit Operating Instructions 5200en Edition 03/2019 S.N, S.O, S.A, K.N, K.O, K.A, S.NS, S.LS, S.AS, S.OS, S.DS, K.NS, K.LS, K.AS, K.OS, K.DS, K.OV, K.OH, K.AU, SOND 80...800...
- Page 2 07.03.2019 13:01 V4.00...
- Page 3 Introduction Safety instructions Description FLENDER GEAR UNITS Application planning REDUREX Gear unit 5200en Mounting Commissioning Operating Instructions Operation Maintenance Service & Support Disposal Spare parts S.N, S.O, S.A, K.N, K.O, K.A, S.NS, S.LS, S.AS, S.OS, Quality documents S.DS, K.NS, K.LS, K.AS, K.OS, K.DS, K.OV, K.OH, K.AU, SOND...
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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
Mounted oil supply system with air-oil cooler.................30 3.7.3.2 Mounted oil supply system with water-oil cooler ..............32 3.7.3.3 Pump............................33 3.7.3.4 Oil filter ...........................33 3.7.4 Separate oil supply system ....................33 Backstop ..........................34 Couplings ..........................35 3.10 Shrink disks..........................36 3.11 Heating...........................36 REDUREX Gear unit 5200en Operating Instructions 03/2019... - Page 6 Connecting the cooling coil ....................73 5.7.3 Connecting the air‐oil cooler ....................74 5.7.4 Connecting the water-oil cooler....................74 5.7.5 Installing a separate oil supply system...................75 5.7.6 Electrical connections ......................75 5.7.7 Connecting the oil temperature monitor .................76 REDUREX Gear unit 5200en Operating Instructions 03/2019...
- Page 7 Checking the cooling coil .......................97 8.3.11 Inspecting the shrink disk.......................98 8.3.12 Check that all of the fastening bolts are tight .................98 8.3.13 General inspection of the gear unit ..................99 8.3.14 Final work..........................99 Possible faults ........................99 REDUREX Gear unit 5200en Operating Instructions 03/2019...
- Page 8 Gear unit equipment for type K.N gear units ................23 Figure 3-5 Rotary shaft sealing ring......................25 Figure 3-6 Fey labyrinth seal ........................26 Figure 3-7 Labyrinth seals ..........................26 Figure 3-8 Taconite‐seal..........................27 Figure 3-9 Tacolab seal ..........................28 REDUREX Gear unit 5200en Operating Instructions 03/2019...
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Page 9: Redurex Gear Unit 5200En
Figure 5-9 Preparation for gear units with hollow shaft and shrink disk ............70 Figure 5-10 Possible displacements.......................72 Figure 5-11 Alignment process based on the example of a flexible coupling..........72 Figure B-1 Rating plate ..........................113 REDUREX Gear unit 5200en Operating Instructions 03/2019... - Page 10 Table of contents REDUREX Gear unit 5200en Operating Instructions 03/2019...
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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
Oil filling point yellow Oil draining point white Oil level indicator Oil level measurement Oil overflow Connection point for vibration monitoring Lubrication point Apply grease Lifting eye Eye bolt Do not unscrew REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 15: General Warnings And Symbols
Warning - entanglement hazard Warning - hot surfaces Warning - substances that can irritate or which are hazardous to health Warning - caustic substances Warning - suspended load Warning - hand injuries ATEX certification REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 16: Special Types Of Danger And Personal Protective Equipment
Small foreign particles such as sand or dust can enter the cover plates of the rotating parts and be hurled back by them. Wear safety goggles. Dangers during operation Damage to the gear unit is possible. REDUREX Gear unit 5200en Operating Instructions 03/2019... - Page 17 Wear suitable protective gloves, safety goggles and protective clothing. 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. REDUREX Gear unit 5200en Operating Instructions 03/2019...
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Page 18: 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 113). Deviating operating conditions are considered improper use. The user or owner of the machine or plant is solely liable for any resulting damage. REDUREX Gear unit 5200en Operating Instructions 03/2019... - 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 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. REDUREX Gear unit 5200en Operating Instructions 03/2019...
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Page 21: Description
It can essentially be operated in both directions of rotation. Gear units equipped with backstop or overrunning clutch are the exceptions in this case. Flender must be consulted if, for these versions, the direction of rotation is to be reversed. -
Page 22: Housing
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. The lubrication points are designated using the following sign: Figure 3-2 Sign: Lubrication point REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 23: Figure 3-3 Gear Unit Equipment For Type S.n Gear Units
Gear unit equipment for type K.N 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. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 24: Gear Unit Oil Supply
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. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 25: Bearing Arrangement Of The Shafts
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: REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 26: Taconite Seal
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 92). REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 27: Tacolab Seal
● 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 REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 28: Cooling
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. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 29: Cooling Coil
● 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. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 30: Mounted Oil Supply System
A mounted oil supply system with air-oil cooler can include the following components: ● Air-oil cooler ● Flange pump ● Oil filter (double change-over filter or coarse filter) ● Pressure monitor ● Temperature control valve ● Piping REDUREX Gear unit 5200en Operating Instructions 03/2019... - Page 31 You can find additional technical data in the separate data sheet and in the list of equipment provided in the complete gear unit documentation. REDUREX Gear unit 5200en Operating Instructions 03/2019...
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Page 32: Mounted Oil Supply System With Water-Oil Cooler
● 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. WARNING Risk of eye injury from compressed air Water residue and dirt particles can cause damage to eyes. Wear suitable safety goggles. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 33: Pump
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. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 34: Backstop
Data indicating the replacement intervals is provided in the dimension drawing and on a plate attached to the gear unit. This plate is attached to the gear unit housing close to the backstop. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 35: Couplings
The blocking direction of the backstop can be changed by turning over the cage. You must always contact Flender in advance if you wish to change the blocking direction. NOTICE Damage to the backstop and gear unit due incorrect direction of rotation Damage to the backstop and gear unit due incorrect direction of rotation possible. -
Page 36: Shrink Disks
The heating elements are installed in protective tubes in the housing so that they can be replaced without draining off the oil first. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 37: Table 3-1 Information About The Specific Heat Output
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. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 38: Oil Level Indicator
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. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 39: Oil Temperature Monitoring System
However, customers can also configure a three or four-wire circuit. The following diagram shows bearing monitoring using a Pt 100 resistance thermometer: ① Pt 100 resistance thermometer Figure 3-11 Bearing monitoring using a Pt 100 resistance thermometer: REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 40: Bearing Monitoring By Acceleration Sensor
These threaded holes have an M6 or M8 thread depending on the variant. ① Shock-pulse transducer Figure 3-12 Bearing monitoring using a shock-pulse transducer The following diagram shows the complete acceleration sensor (A) and the threaded connector (B): REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 41: Auxiliary Drive
Either Flender or the customer provides the auxiliary drive. The auxiliary drive is connected to the main gear unit through an overrunning clutch. The auxiliary drive is mounted onto a connection flange, which in turn is attached to the main gear unit. -
Page 42: Overrunning Clutch
When the auxiliary unit drive motor is used as drive via the outer ring, then the overrunning clutch is also driven; this means that the main gear unit is slowly rotated in the selected direction REDUREX Gear unit 5200en Operating Instructions 03/2019... - Page 43 The overrunning clutch is located in an intermediate flange and has a separate oil space. When the main gear unit is serviced and its oil changed, then the overrunning clutch is also serviced and its oil changed at the same time. REDUREX Gear unit 5200en Operating Instructions 03/2019...
- Page 44 Description 3.16 Auxiliary drive REDUREX Gear unit 5200en Operating Instructions 03/2019...
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Page 45: Application Planning
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. REDUREX Gear unit 5200en Operating Instructions 03/2019... - Page 46 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. REDUREX Gear unit 5200en Operating Instructions 03/2019...
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Page 47: Attachment Points
It is not permitted to load eye bolts through lateral pulling contrary to the direction of the eye plane. The following figure shows the permissible shear and lateral pulling when using eye bolts: REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 48: Figure 4-3 Position Of The Attachment Points, At Type S.n ≤ 280 And K.n ≤ 280 Gear Units
Figure 4-4 Position of the attachment points, at type S.N ≥ 280 and K.N ≥ 280 gear units The diagram below shows the position of the attachment points on a type SZNS gear unit: REDUREX Gear unit 5200en Operating Instructions 03/2019... - Page 49 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. REDUREX Gear unit 5200en Operating Instructions 03/2019...
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Page 50: Special Features Relating To Gear Unit Lubrication
Oil filling locations and oil drain locations for type K.N 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. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 51: Mounting
● 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. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 52: Unpacking The Gear Unit
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. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 53: Gear Unit Mounting
● 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. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 54: Fastening
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. ● Do not allow the cleaning agent to come into contact with the shaft-sealing rings. REDUREX Gear unit 5200en Operating Instructions 03/2019... - Page 55 If the gear unit is 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 order-specific dimension drawing in the complete documentation for the gear unit. REDUREX Gear unit 5200en Operating Instructions 03/2019...
- Page 56 3. Use these surfaces as a guide for aligning the gear unit horizontally to ensure that it will run smoothly. Further information Further information and the precise position of the alignment thread are provided in the dimension drawing in the overall gear unit documentation. REDUREX Gear unit 5200en Operating Instructions 03/2019...
- Page 57 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. REDUREX Gear unit 5200en Operating Instructions 03/2019...
- Page 58 3. Align the gear unit so that the input and output shafts are horizontal using shims (Page 56). 4. For higher external forces, if necessary, use lateral stops to prevent the gear unit shifting. 5. Pour concrete into the recesses in the concrete foundation for the stone bolts. REDUREX Gear unit 5200en Operating Instructions 03/2019...
- Page 59 5. For higher external forces, if necessary, use lateral stops to prevent the gear unit shifting. 6. Before casting the foundation, close the openings in the foundation blocks using a suitable material (e.g. using polystyrene). REDUREX Gear unit 5200en Operating Instructions 03/2019...
- Page 60 Raw foundation Hexagon nut Figure 5-4 Inserted anchor bolt 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. REDUREX Gear unit 5200en Operating Instructions 03/2019...
- Page 61 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 79). REDUREX Gear unit 5200en Operating Instructions 03/2019...
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Page 62: Mounting The Gear Unit Swing Base
Damage to the gear unit due to incorrect attachment of the torque arm Incorrect attachment of the torque arm could cause damage to the gear unit. Mount the torque arm in such a way that it is free of mechanical stress. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 63: Shaft-Mounted Gear Unit With Hollow Shaft And Parallel Keyway
The following diagram shows a gear unit with hollow shaft and parallel keyway: ① ④ End plate Machine shaft ② ⑤ Hollow shaft Bolts ③ Parallel key Figure 5-6 Gear unit with a hollow shaft and parallel keyway REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 64: Mounting
The gear unit can become damaged if it skews during assembly. The hollow shaft must be flush with the machine shaft during assembly of the gear unit on the machine shaft. The gear unit must be prevented from skewing. REDUREX Gear unit 5200en Operating Instructions 03/2019... - Page 65 Screw spindle for gear units with hollow shaft and parallel keyway Special aspects of shaft-mounted gear units with hollow shaft and parallel keyway Hydraulic pulling equipment can be used instead of the nut and screw spindle shown in the diagram. REDUREX Gear unit 5200en Operating Instructions 03/2019...
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Page 66: Axial Locking
4. Depending on the conditions on site, you can use one of the following methods to remove the gear unit from the machine shaft: – With a central screw spindle – Using hydraulic pulling equipment REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 67: Shaft-Mounted Gear Unit With Hollow Shaft And Shrink Disk
The shrink disks are not supplied with the gear unit. They can be supplied when requested. Further information Further information about the connection dimensions of the driven machine shaft can be found in the dimension drawing in the complete documentation for the gear unit. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 68: Mounting
The reliability with which torque is transmitted depends to a large extent on this. Do not use any contaminated solvents or soiled cleaning cloths, nor any cleaning agents that contain oil (such as petroleum or turpentine) to degrease the surfaces. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 69: Pulling On With Integrated Du Bushing
2. Mount the gear unit using the nut and screw spindle. The gear unit is supported by the hollow shaft. 3. Quickly pull the shaft into the hollow shaft up to the end plate. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 70: Axial Locking
2. Lift the gear unit off the machine shaft using jacking screws until the seats under the shrink disk and the DU bushing are exposed. 3. Use suitable hoisting gear to lift the gear unit off the machine shaft. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 71: Couplings
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: REDUREX Gear unit 5200en Operating Instructions 03/2019... - Page 72 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. REDUREX Gear unit 5200en...
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Page 73: 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 29). REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 74: Connecting The Air-Oil Cooler
3. Connect up the cooling water inlet and drain lines. Refer to the dimension drawing for the direction of flow and the position of the connections. 4. Electrically connect the pressure monitor (only for appropriately equipped gear units). REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 75: Installing A Separate Oil Supply System
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. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 76: Connecting The Oil Temperature Monitor
You can find technical data in the separate data sheet and in the equipment list in the complete gear unit documentation. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 77: Connecting The Heating Element
Tightening procedure 5.8.1 Introduction Bolts The bolts must have the following properties: ● Made of steel ● Black-annealed or phosphatised ● Lightly oiled (do not add additional oil) REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 78: Bolt Connection Classes
Protection cover ± 20 % to ± 50 % ● Tightening with pulse screwdriver or impact wrench, Sun shield without adjustment checking device ● Tightening by hand, using a wrench without torque measuring device REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 79: Tightening Torques And Preload Forces
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 REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 80: Final Work
● 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. REDUREX Gear unit 5200en Operating Instructions 03/2019... - Page 81 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. You can find additional technical specifications in the separate data sheet in the complete gear unit documentation. REDUREX Gear unit 5200en Operating Instructions 03/2019...
- Page 82 Mounting 5.9 Final work REDUREX Gear unit 5200en Operating Instructions 03/2019...
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Page 83: Commissioning
● 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. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 84: Gear Unit With Backstop
● For a maintenance drive: Check the shutdown function of the speed monitoring. Further information You can find additional information on the auxiliary drive in the description (Page 41) and in the auxiliary drive operating instructions, provided in the complete gear unit documentation. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 85: Gear Units With Oil Supply System
Ensure that the pre-lubrication phase does not last longer than 3 minutes, as the oil foams up heavily at low temperatures. For oil temperatures below 10 °C, heat up the oil using suitable measures and contact Flender in this regard. NOTICE... -
Page 86: Oil Temperature Monitoring System
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. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 87: Heating
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. REDUREX Gear unit 5200en Operating Instructions 03/2019... - Page 88 Commissioning 6.2 Measures to be taken during commissioning REDUREX Gear unit 5200en Operating Instructions 03/2019...
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Page 89: Operation
A few irregularities are listed below as examples: ● 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 REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 90: 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 99) to find the cause of the fault. 3. If you still cannot determine the fault cause, contact Flender Customer Services (Page 105). Taking the unit out of service... -
Page 91: Maintenance
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. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 92: Maintenance Schedule
(or depending on the result 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) REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 93: Maintenance And Service 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. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 94: Cleaning The Venting Screw
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. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 95: Replacing The Backstop
1. Clean the oil filling point of the backstop. 2. Open the oil filling screw of the backstop. 3. Fill the amount of oil that is specified on the backstop plate. 4. Screw in the oil filling screw. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 96: Measuring The Vibration Levels Of The Rolling-Contact Bearings
5. Have Customer Services replace defective rolling-contact bearings. Further information Further information about measuring the temperature at the rolling-contact bearings can be found in the Pt 100 resistance thermometer operating instructions in the complete documentation for the gear unit. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 97: Checking The Auxiliary Drive
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. REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 98: Inspecting The Shrink Disk
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. -
Page 99: General Inspection Of The Gear Unit
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. Even after the warranty period has expired, you should still arrange for faults to be rectified by Flender Customer Services. -
Page 100: Table 8-2 Possible Faults And Their Rectification
● Check the connections start while the auxiliary tween the main and auxiliary motor ● If necessary, replace defective devices drive is operational Defective speed monitoring ● Check the connections ● If necessary, replace defective devices REDUREX Gear unit 5200en Operating Instructions 03/2019... - Page 101 ● Check the compression seals and retighten screws if necessary Leaking pipes ● Check the pipes, and replace or seal if necessary Oil supply system mal‐ ● Read the operating instructions for the oil supply system function REDUREX Gear unit 5200en Operating Instructions 03/2019...
- Page 102 ● Contact Customer Services plitude at bearing ● Inspect the rolling-contact bearings and replace if points necessary Gear wheels defective ● Contact Customer Services ● Inspect the gear wheels and replace if necessary REDUREX Gear unit 5200en Operating Instructions 03/2019...
- Page 103 ● Use wet-air filter if necessary Oil foams in the oil sump ● Take test tube sample to examine oil condition for water penetration ● Have the oil examined by a chemical lab REDUREX Gear unit 5200en Operating Instructions 03/2019...
- Page 104 Maintenance 8.4 Possible faults REDUREX Gear unit 5200en Operating Instructions 03/2019...
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Page 105: Service & Support
46562 Voerde Deutschland - Germany Tel.: +49 (0)2871 / 92‐0 Fax: +49 (0)2871 / 92‐1544 Further information Further information about service and support can be found on the Internet. Service & Support (https://www.flender.com/service) REDUREX Gear unit 5200en Operating Instructions 03/2019... - Page 106 Service & Support REDUREX Gear unit 5200en Operating Instructions 03/2019...
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Page 107: Disposal
● 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. REDUREX Gear unit 5200en Operating Instructions 03/2019... - Page 108 Disposal REDUREX Gear unit 5200en Operating Instructions 03/2019...
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Page 109: 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 110 Spare parts REDUREX Gear unit 5200en Operating Instructions 03/2019...
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Page 111: Quality Documents
Quality documents Declaration of incorporation REDUREX Gear unit 5200en Operating Instructions 03/2019... - Page 112 Quality documents A.1 Declaration of incorporation REDUREX Gear unit 5200en Operating Instructions 03/2019...
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Page 113: 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 114 Example code The following is an example of the code printed in line 5 of the rating plate and explains the meaning of the individual letters and numbers. REDUREX Gear unit 5200en Operating Instructions 03/2019...
- Page 115 Weights (Page 118) and Enveloping surface sound pressure level (Page 121). 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. REDUREX Gear unit 5200en Operating Instructions 03/2019...
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Page 116: 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 117 Technical data B.3 Types REDUREX Gear unit 5200en Operating Instructions 03/2019...
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Page 118: Weights
All weight specifications refer to units without oil filling or mounted components. Refer to the following tables for the weights (approximate values, in kg) of the gear units: Table B-1 Weights Type Gear unit size REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 119: Table B-2 Weights
2700 3800 5100 7100 1180 1550 2050 2750 3900 5200 7200 1180 1680 2300 3250 1180 1680 2300 3250 1050 1450 2050 2800 3800 1250 1750 2400 3200 1050 1450 2050 2800 3800 REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 120: Table B-3 Weights
2400 3170 4520 6200 8500 11600 KZOS 1170 1560 2220 2985 4300 5805 7905 10905 KZDS 1170 1560 2220 2985 4300 5805 7905 10905 KDNS 1300 1720 2450 3220 4620 6300 8600 11600 REDUREX Gear unit 5200en Operating Instructions 03/2019... -
Page 121: Enveloping Surface Sound Pressure Level
The gear unit complies with a sound power level, which places it in a gear unit type class defined in VDI 2159, which is applied to produce the 80 % characteristic curve of the emission characteristic map. Adherence to limit values can, under specified Flender test conditions, be assumed with statistical certainty. REDUREX Gear unit 5200en... - Page 122 Technical data B.5 Enveloping surface sound pressure level REDUREX Gear unit 5200en Operating Instructions 03/2019...
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Page 123: Index
Connecting the heating element, 77 Coupling, 35 Function, 36 Customer Services, 105 Heating elements, 36 Temperature monitor, 37 Danger of explosion, 18 Directions of rotation, 21 Interval, 92 Disclaimer, 11 Irregularities in operation, 89 Disposal, 107 REDUREX Gear unit 5200en Operating Instructions 03/2019... - Page 124 Types of danger, 16 Operating data, 89 Oil, 89 Ordering spare parts, 105, 109 Output shaft versions, 21 Unpacking, 52 Used oil, 107 Using the gear unit, 19 Pressure lubrication, 24 Protective equipment, 16 Pump, 33 REDUREX Gear unit 5200en Operating Instructions 03/2019...
- Page 125 Index Venting screw Cleaning, 94 Warning symbols, 15 Water-oil cooler, 32 REDUREX Gear unit 5200en Operating Instructions 03/2019...
- Page 126 Index REDUREX Gear unit 5200en Operating Instructions 03/2019...
- Page 128 FLENDER GEAR UNITS REDUREX Gear unit Operating Instructions 5200en Edition 03/2019 Flender GmbH Alfred-Flender-Straße 77 46395 Bocholt GERMANY...