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FLENDER 114 Assembly And Operating Instructions Manual

Crane gear unit
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Crane gear unit
Assembly and operating instructions B5832-01en
Edition 06/2022
H3SH
114...116

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  • Page 1 Crane gear unit Assembly and operating instructions B5832-01en Edition 06/2022 H3SH 114...116...
  • Page 2 Original assembly and operating instructions B5832-01 Edition 06/2022 29/07/2022 Copyright (©2022 Flender GmbH) 13:23:45...

  • Page 3: Table Of Contents

    Table of contents Introduction...............................11 Legal information ........................11 General information .........................12 Lubricants ..........................14 Safety instructions ...........................15 Security notes ..........................15 The five safety rules .........................15 General information .........................15 General warnings and symbols....................17 Special types of danger and personal protective equipment ........... 17 Intended use ..........................20 Description ..............................23 General description ........................23...
  • Page 4 Table of contents Special aspects of gear unit lubrication and preservation............35 4.4.1 Oil filling point and oil drain ......................35 4.4.2 Checking the oil level .......................35 Assembly..............................37 General assembly instructions ....................37 Unpacking the gear unit ......................38 Gear unit assembly ........................39 5.3.1 Foundation ..........................39 5.3.2...
  • Page 5 Table of contents 8.3.1 Clean the venting screw......................58 8.3.2 Checking the oil temperature ....................59 8.3.3 Cleaning the gear unit......................59 8.3.4 General inspection of the gear unit ..................60 8.3.5 Check that all of the fastening bolts are tight ................60 8.3.6 Final work..........................60 Possible faults ..........................60 Service &...
  • Page 6 Table of contents Edition 06/2022 B5832-01en...
  • Page 7 List of tables Table 2-1 Symbols and markings .......................16 Table 2-2 General warnings ........................17 Table 3-1 Taconite seal versions........................27 Table 3-2 Information about the specific heat output .................28 Table 5-1 Information on tightening fastening bolts ...................49 Table 5-2 Preload forces and tightening torques ..................50 Table 7-1 Operating data..........................55 Table 8-1 Maintenance and servicing activities..................57 Table 8-2...
  • Page 8 List of tables Edition 06/2022 B5832-01en...
  • Page 9 List of figures Figure 3-1 Gear unit equipment on type H3SH gear units ................24 Figure 3-2 Rotary shaft sealing ring......................25 Figure 3-3 Taconite seal ..........................26 Figure 3-4 Taconite seal, variants E, F, F‐F, F‐H and F‐K ................26 Figure 3-5 Heating on type H3SH gear units....................29 Figure 4-1 Transport symbols........................32 Figure 4-2...
  • Page 10 List of figures Edition 06/2022 B5832-01en...

  • Page 11: Introduction

    Introduction Legal information 1.1 Legal information Warning system These instructions contain information you must observe for your own personal safety as well as to avoid damage to property and persons. The information regarding your personal safety is highlighted with a warning triangle. Information exclusively regarding property dam- age alone is not marked with a warning triangle.

  • Page 12: General Information

    Please note the following: WARNING Flender products are only suitable for the uses set out in the catalogue and associated technical documentation. If third-party products and components are used, these must be recommended and/or authorised by Flender. Safe and flawless operation of the products requires proper transport, proper storage, setup, assembly, installation, commissioning, operation and maintenance.
  • Page 13 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.

  • Page 14: Lubricants

    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. Edition 06/2022...

  • Page 15: Safety Instructions

    In order to safeguard plants, systems, machines and networks against cyber threats it is ne- cessary to implement (and continually maintain) a holistic industrial security concept that cor- responds to the current state of the art. Flender products and solutions undergo continuous development in this respect.
  • Page 16 Safety instructions 2.3 General information 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: Points labelled on the gear unit Symbol Coloured markings Earth connection point Air relief point yellow Oil filling point...

  • Page 17: General Warnings And Symbols

    Safety instructions 2.4 General warnings and symbols Points labelled on the gear unit Symbol Coloured markings These symbols indicate that the oil dip- stick must be firmly screwed in. Table 2-1: Symbols and markings General warnings and symbols 2.4 General warnings and symbols The following table contains general warnings and their associated symbols.
  • Page 18 Safety instructions 2.5 Special types of danger and personal protective equipment DANGER 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: •...
  • Page 19 Safety instructions 2.5 Special types of danger and personal protective equipment Surface temperature The surface temperatures of the gear unit can become very extreme depending on the oper- ating conditions. WARNING Risk of burns Possible risk of serious burn injury from hot surfaces (> 55 °C). Wear suitable protective gloves and protective clothing.

  • Page 20: Intended Use

    Flender will accept no liability or warranty whatsoever for damage occurring as a result of the use of non-approved replacement parts. The same applies to any accessories which were not supplied by Flender.
  • Page 21 Safety instructions 2.6 Intended use • Cleaning the outside of the gear unit with a high-pressure cleaning device is not permit- ted. • Do not perform any welding work anywhere on the gear unit or connected parts. Do not use the gear unit or connected parts as an earthing point for electric-welding operations. Gear parts and rolling-contact bearings may be irreparably damaged by welding.
  • Page 22 Safety instructions 2.6 Intended use Edition 06/2022 B5832-01en...

  • Page 23: Description

    General description 3.1 General description ® The FLENDER gear unit (referred to below simply as "gear unit") described in these operat- ing instructions has been developed for use as a hoist and luffing gear gear unit. Potential applications for this series of gear units include, for example, conveyors and lifting gear, cranes and elevators.

  • Page 24: Oil Supply To The Gear Unit

    Description 3.3 Oil supply to the gear unit Gear unit equipment The diagram below shows the available gear unit equipment on a type H3SH gear unit: Figure 3-1: Gear unit equipment on type H3SH gear units ① Lifting eye ⑤ Shaft seal ②...

  • Page 25: Shaft Seal

    Description 3.5 Shaft seal Shaft seal 3.5 Shaft seal Introduction Depending on requirements, shaft seals prevent oil from escaping from the gear unit or dirt from entering the gear unit. 3.5.1 Rotary shaft sealing rings 3.5 Shaft seal Rotary shaft sealing rings are the standard seal used. Wherever possible, rotary shaft seal- ing rings are equipped with an additional dust lip which protects the actual sealing lip against external contaminants.

  • Page 26: Figure 3-3 Taconite Seal

    Description 3.5 Shaft seal A Taconite seal is illustrated in the diagram below: Figure 3-3: Taconite seal ① Labyrinth, filled with grease, can be re- ③ Lamellar seal greased ② Grease nipple ④ Rotary shaft sealing ring The following design variants of Taconite seal are available: Figure 3-4: Taconite seal, variants E, F, F‐F, F‐H and F‐K ①...

  • Page 27: Couplings

    Description 3.6 Couplings Taconite seal versions Application Remarks "E" All input shafts with or without fan • Regreasable labyrinth "F" Output shaft Design S: Solid shaft Design V: Solid shaft, reinforced Design F: Flanged shaft "F-F" Output shaft • Labyrinth which can be regreased on both sides, including cover to protect Design H: Hollow shaft with parallel keyway against accidental contact at the gear unit...

  • Page 28: Brake

    Description 3.7 Brake Brake 3.7 Brake The gear unit is prepared for mounting a blocking brake. The brake drum is mounted on the input shaft (brake shaft) of the gear unit. Further information You will find further information on the brake in the operating instructions for the brake, which are part of the complete documentation of the gear unit.

  • Page 29: Oil Level Indicator

    Description 3.9 Oil level indicator The diagram below shows a heating system on type H3SH gear units: Figure 3-5: Heating on type H3SH gear units ① Temperature monitor ② Heating element 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 30: Oil Temperature Monitoring

    Description 3.10 Oil temperature monitoring More information, a detailed illustration of the gear unit and the position of the mounted com- ponents can be found in the dimension drawing in the complete documentation for the gear unit. 3.10 Oil temperature monitoring 3.10 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.

  • Page 31: Application Planning

    Application planning Scope of delivery 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 63) immediately. WARNING Serious injury through defective product Serious injury may occur.

  • Page 32: Attachment Points

    Application planning 4.3 Attachment points Please observe the following when attaching slings to the load or raising, lowering or moving • Do not exceed the specified load limits • If you are using a load suspension device with several load hooks, make sure that the load is evenly distributed between them •...

  • Page 33: Figure 4-2 Shear And Lateral Pulling When Using Eye Bolts

    Application planning 4.3 Attachment points Attach slings to the lifting eyes in accordance with the specifications in the dimension draw- ings. Sling swivels Threads for screwing in transport lugs are provided on the gear unit to assist with its trans- portation during manufacture and installation.

  • Page 34: Figure 4-3 Position Of The Attachment Points On The Type H3Sh Gear Unit

    Application planning 4.3 Attachment points Position of attachment points The diagram below shows the position of the attachment points on the type H3SH gear unit: Figure 4-3: Position of the attachment points on the type H3SH gear unit The diagram below shows the position of the attachment points on type H3SH gear units with motor: Figure 4-4: Position of the attachment points on type H3SH gear units with motor Drive units with additional components mounted on the gear unit (such as drive motor, coup-...

  • Page 35: 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 Special aspects of gear unit lubrication and preservation 4.4.1 Oil filling point and oil drain 4.4 Special aspects of gear unit lubrication and preservation The following diagram shows the oil filling locations and oil drain locations for the gear unit: Figure 4-5: Oil filling and oil drain ①...
  • Page 36 Application planning 4.4 Special aspects of gear unit lubrication and preservation Edition 06/2022 B5832-01en...

  • Page 37: Assembly

    Assembly General assembly instructions 5.1 General assembly instructions The assembly work must be performed very carefully by authorised, trained and suitably in- structed personnel. Liability will be disclaimed for damage caused by the incorrect perform- ance of this work. Requirements Improper use can damage the gear unit.

  • Page 38: 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 39: Gear Unit Assembly

    Assembly 5.3 Gear unit assembly Gear unit assembly 5.3 Gear unit assembly 5.3.1 Foundation 5.3 Gear unit assembly Properties of the foundation The foundation must have the following properties: • Horizontal and flat • Stability • Designed for torsional rigidity •...

  • Page 40: Description Of Assembly Work

    Assembly 5.3 Gear unit assembly 5.3.2 Description of assembly work 5.3 Gear unit assembly CAUTION Risk of chemical burns from chemical substances There is a risk of chemical burns when handling aggressive cleaning agents. Please observe the manufacturer’s instructions on how to handle cleaning agents and solvents.

  • Page 41: Alignment

    Assembly 5.3 Gear unit assembly Gap dimension at the grease labyrinth The diagram below shows the gap dimension at the grease labyrinth: Figure 5-1: Gap dimension at the 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.

  • Page 42: Figure 5-2 Alignment Surface

    Assembly 5.3 Gear unit assembly Procedure The gear unit can be equipped with alignment threads in the housing feet to make it simpler to align. Figure 5-2: Alignment surface Proceed as follows to align the gear unit at the alignment surface: 1. For the precise position of the alignment surfaces, refer to the dimension drawings in the complete documentation.

  • Page 43: Couplings

    Assembly 5.4 Couplings Couplings 5.4 Couplings Introduction Improper use can damage the gear unit. Be sure to take the following precautions: • If necessary, carry out the following preparatory work in accordance with the operating instructions for the coupling: – Machine the finished bore –...
  • Page 44 Assembly 5.4 Couplings • Do not use force (hammer blows, etc.) to fit the coupling parts as this can cause internal damage to the gear unit. • Take care not to damage the shaft sealing rings or shaft running surfaces when fitting the coupling parts.

  • Page 45: Aligning The Coupling

    This displacement is not measurable when the drive is at a standstill. – If you are using couplings supplied by Flender, you will find the maximum permissible misalignment values in the operating instructions for the coupling.

  • Page 46: Connecting Components

    Assembly 5.5 Connecting components • Laser alignment system You will achieve a greater degree of alignment accuracy by using a dial gauge or laser align- ment system. The diagram below shows the alignment process based on the example of a flexible coup- ling: Figure 5-5: Alignment process based on the example of a flexible coupling ①...

  • Page 47: Connecting The Heating Element

    Assembly 5.5 Connecting components Further information You can find additional information on operation and maintenance in the associated operat- ing 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 48: Electrical Connections

    Assembly 5.5 Connecting components 5.5.4 Electrical connections 5.5 Connecting components 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 15). To connect the motors and monitoring devices, proceed as follows: 1.

  • Page 49: Bolt Connection Classes

    Assembly 5.6 Tightening procedure Information Using a lubricant As a rule, lubricants may not be used, because this can result in the bolt connection becom- ing overloaded. 5.6.2 Bolt connection classes 5.6 Tightening procedure In order to affix fastening bolts, note the information in the following table: Mounting Bolt connection Scatter of the...
  • Page 50 12.9 181 000 116 000 72 500 1 020 170 000 109 000 68 000 1 210 1 040 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 1 550 246 000 157 000 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...

  • Page 51: Final Work

    Assembly 5.7 Final work Nominal Bolt Preload force for bolt connection Tightening torque for bolt connec- thread dia- strength classes from the table in chapter tion classes from the table in meter class Bolt connection classes chapter Bolt connection classes (Page 49) (Page 49) M min.
  • Page 52 Assembly 5.7 Final work • 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.

  • Page 53: Commissioning

    Commissioning Measures prior to 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 air release screw. Note the instructions 7300 for this.

  • Page 54: Gear Units With Heating

    Commissioning 6.2 Measures during commissioning 6.2.1 Gear units with heating 6.2 Measures during commissioning 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 Explosion and fire hazard Exposed heating elements pose a fire hazard.

  • Page 55: Operation

    Operation Operating data 7.1 Operating data Introduction To ensure correct, trouble-free operation of the system, observe the operating data of the gear unit and, depending on the order specification, the data in the operating instructions for the oil supply system. The valid operating data can be found in the annex Technical data (Page 71).

  • Page 56: Taking The Unit Out Of Service

    Operation 7.3 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 60) to find the cause of the fault. 3. If you still cannot determine the fault cause, contact FlenderCustomer Services (Page 63).

  • Page 57: Servicing

    Servicing General maintenance information 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 intervals for maintenance and servicing work are not observed.

  • Page 58: Maintenance And Servicing Work

    Servicing 8.3 Maintenance and servicing work Intervals and time limits Measures 400 operating hours after commissioning Check the water content of the oil Change the oil (or depending on the result of the oil sample test) Check that all of the fastening bolts are tight Every 3 months Clean the venting screw Every 3 000 operating hours, at least every...

  • Page 59: Checking The Oil Temperature

    3. Measure the temperature of the oil in the oil sump. 4. Compare the measured value with the maximum permissible oil temperature (Page 55). 5. Immediately stop the gear unit if the maximum permissible oil temperature is exceeded. Contact Flender Customer Services. 8.3.3 Cleaning the gear unit 8.3 Maintenance and servicing work...

  • Page 60: General Inspection Of The Gear Unit

    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. Even after the warranty period has expired, you should still arrange for faults to be rectified by Flender Customer Services.
  • Page 61 Servicing 8.4 Possible faults Possible faults Causes Possible remedies Grease escaping at Defective rotary shaft sealing rings • Inspect the rotary shaft sealing rings and replace if ne- the output shaft cessary Noise Damage to the gear teeth • Contact Customer Service •...

  • Page 62: Table 8-2 Possible Faults And How To Rectify Them

    Servicing 8.4 Possible faults Possible faults Causes Possible remedies Oil escaping from the Inadequate sealing of the housing • Check the seals and replace if necessary gear unit cover or joints • Seal housing cover or joints • Check the compression seals and retighten bolts if ne- cessary Elevated temperature Oil level in the gear unit housing...

  • Page 63: Service & Support

    Flender Industriegetriebe GmbH Thierbacher Strasse 24 09322 Penig Germany Tel.: +49 (0)37381 / 61-0 Fax: +49 (0)37381 / 80286 More information Further information about service and support can be found on the Internet: Service & Support (https://www.flender.com/service) B5832-01en Edition 06/2022...
  • Page 64 Service & Support 9.1 Contact Edition 06/2022 B5832-01en...

  • Page 65: 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 66 Disposal Edition 06/2022 B5832-01en...

  • Page 67: Spare Parts

    Information Damage to the gear unit due to use of unsuitable spare parts Only use original spare parts from Flender. Flender shall not accept any warranty claims for spare parts that are not supplied by Flender. 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.
  • Page 68 Spare parts Edition 06/2022 B5832-01en...

  • Page 69: Declaration Of Incorporation

    Directive 2006/42/EC. Representative for issuing this Declaration of Incorporation on behalf of the manufacturer: Flender Industriegetriebe GmbH Penig, 2022-06-30 Jens Klein, CEO, Flender Industriegetriebe GmbH Translation of the Declaration of Incorporation B5832-01en Edition 06/2022...
  • Page 70 Declaration of Incorporation Declaration of Incorporation Edition 06/2022 B5832-01en...

  • Page 71: Technical Data

    ⑭ Hotline 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 cus- tomer. More 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 72: Ambient Temperature

    By applying various suit- able 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 73: Enveloping Surface Sound Pressure Level

    VDI 2159, which is applied to produce the 80 % characteristic curve of the emis- sion characteristic map. You can assume with statistical certainty that the limit values are complied with under the specified Flender test conditions. B5832-01en Edition 06/2022...
  • Page 74 Technical data Enveloping surface sound pressure level Edition 06/2022 B5832-01en...

  • Page 75: Index

    Index Attachment points, 37 Heating Commissioning, 54 Connecting the heating element, 47 Design, 29 Function, 28 Coloured markings, 16 Heating elements, 28 Copyright, 13 Temperature monitor, 29 Coupling, 27 Integration note, 21 Danger of explosion, 20 Interval, 57 Disclaimer, 12 Irregularities in operation, 55 Disposal, 65 Documentation landscape, 13 Lateral pulling, 33 Lubricant, 14 Environmental protection, 65 Equipment features, 23 Eye bolts, 33 Maintenance activities, 57 Maintenance information, 57 Maintenance schedule, 57...
  • Page 76 Index Oil temperature monitoring Connecting the resistance thermometer, 47 Resistance thermometer, 30 Operating data Compliance with, 55 Oil, 55 Ordering spare parts, 67 Protective equipment, 18 Rating plate, 71 Type and size, 72 Rotary shaft sealing ring, 25 Safety rules, 15 Scope of delivery, 31 Servicing activities, 57 Shaft bearings, 24 Shaft seal, 25 Shear pulling, 33 Shipping documents, 31 Splash lubrication, 24...
  • Page 78 Crane gear unit Assembly and operating instructions B5832-01en Edition 06/2022 Flender GmbH Alfred-Flender-Straße 77 46395 Bocholt Germany...

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