FLENDER P2DP Assembly And Operating Instructions Manual

Planetary gear unit

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Planetary gear unit

Assembly and operating instructions A9219-02en

Edition 06/2022

P2DP, P3CP, P3DP, P3FP, P3KP, P3LP, P3ZP, P3DH, P3SH, P3ZH

345...775

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Page 1 Planetary gear unit Assembly and operating instructions A9219-02en Edition 06/2022 P2DP, P3CP, P3DP, P3FP, P3KP, P3LP, P3ZP, P3DH, P3SH, P3ZH 345...775...
Page 3: Table Of Contents
Table of contents Introduction...............................13 Legal information ........................13 General information .........................14 Lubricants ..........................16 Safety instructions ...........................17 Security notes ..........................17 The five safety rules .........................17 General information .........................17 General warnings and symbols....................19 Special types of danger and personal protective equipment ........... 19 Intended use ..........................22 Description ..............................25 General description ........................25...
Page 4 Table of contents 3.10 Shrink disk ..........................36 3.11 Heating.............................37 3.12 Oil level indicator........................38 3.13 Oil temperature monitoring system ..................38 3.14 Bearing monitoring ........................39 3.14.1 Bearing monitoring using a Pt 100 resistance thermometer ............ 39 3.14.2 Bearing monitoring by shock-pulse transducer................ 40 3.14.3 Bearing monitoring using acceleration sensor .................
Page 5 Table of contents 5.3.8 Mounting the torque arm and the gear unit foot............... 68 5.3.8.1 One-sided torque arm ......................69 5.3.8.2 Chun torque arms ........................70 5.3.8.2.1 Mounting the torque arm at the gear unit................. 70 5.3.8.2.2 Mounting the gear unit on the machine shaft................72 5.3.8.2.3 Mounting the connecting rods....................72 5.3.8.2.4...
Page 6 Table of contents 6.1.2 Gear unit with oil supply system ....................94 Measures during commissioning .....................94 6.2.1 Gear unit with backstop ......................94 6.2.2 Temperature measurement .....................94 6.2.3 Bearing monitoring (vibration measurement)................95 6.2.4 Gear units with heating ......................95 Operation..............................97 Operating data .........................97 Anomalies ..........................97 Taking the unit out of service ....................98 Servicing ..............................99...
Page 7 Table of contents Types .............................120 Weights ..........................121 Enveloping surface sound pressure level ................122 Index ................................125 A9219-02en Edition 06/2022...
Page 8 Table of contents Edition 06/2022 A9219-02en...
Page 9 Tables Table 2-1 Symbols and markings .......................18 Table 2-2 General warnings ........................19 Table 3-1 Information about the specific heat output .................37 Table 4-1 Information about the connection threads for sling swivels............48 Table 5-1 Information on screwing fastening bolts ..................87 Table 5-2 Preload forces and tightening torques ..................88 Table 5-3 Tightening torques........................90 Table 7-1...
Page 10 Tables Edition 06/2022 A9219-02en...
Page 11 Figures Figure 3-1 Gear unit components ........................25 Figure 3-2 Rotary shaft sealing ring......................28 Figure 3-3 Taconite seal ..........................28 Figure 3-4 Backstop.............................29 Figure 3-5 Torque limiting backstop ......................31 Figure 3-6 Fan mounted on a gear unit .......................32 Figure 3-7 Oil temperature monitoring system ....................39 Figure 3-8 Bearing monitoring using a Pt 100 resistance thermometer ............40 Figure 3-9 Fully assembled acceleration sensor (A), and threaded connector (B) for variants 1 to 4..41 Figure 3-10...
Page 12 Figures Edition 06/2022 A9219-02en...
Page 13: 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 14: 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 15: Required Basic Knowledge
Failure to observe these instructions can cause product or property damage and/ or personal injury. Flender does not accept any liability for damage or operating failures which are due to non- adherence to these instructions. The described gear unit represents the state of the art at the time these instructions were printed.
Page 16: 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 17: 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 18 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 19: 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 20: Protective Equipment
Safety instructions 2.5 Special types of danger and personal protective equipment DANGER Electric shock Energised parts can cause an 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 21: Chemical Substances
Safety instructions 2.5 Special types of danger and personal protective equipment WARNING Risk of burns Possible risk of serious burn injury from hot surfaces (> 55 °C). Wear suitable protective gloves and protective clothing. WARNING Risk of scalding Risk of serious injury possible through escaping hot operating media when these are being changed.
Page 22: 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 23 Safety instructions 2.6 Intended use • 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 24 Safety instructions 2.6 Intended use Edition 06/2022 A9219-02en...
Page 25: Description
General description 3.1 General description ® The FLENDER planetary gear unit, abbreviated to “gear unit” in these operating instruc- tions, has been designed to power industrial machines in the most diverse range of sectors. The range of potential applications for gear units in this series includes drainage systems, excavators, the chemical industry, foundries, conveyors, crane systems, the food industry, paper-processing machines, roller presses, cable cars and the cement industry.
Page 26: Housing
Description 3.2 Housing Horizontal mounting posi- Vertical mounting position tion of the gear unit Coaxial planetary gear unit P2.P P3.P Helical planetary gear unit P3.H Housing 3.2 Housing Introduction The housing is usually made of cast iron but can be made of spheroidal cast iron or steel, if required.
Page 27: Oil Supply To The Gear Unit
Description 3.3 Oil supply to the gear unit Further information You can find additional and a detailed illustration of the gear unit and the position of the mounted components in the dimension drawing, which is part of the complete documentation of the gear unit.
Page 28: Taconite Seal
Description 3.5 Shaft seals The diagram below shows a rotary shaft sealing ring: Figure 3-2: Rotary shaft sealing ring 3.5.2 Taconite seal 3.5 Shaft seals The taconite seal is a combination of two sealing elements: • Rotary shaft sealing ring to prevent the escape of lubricating oil •...
Page 29: Backstop
Description 3.6 Backstop NOTICE Sparking, inadmissible temperature rise and shaft seal wear due to insufficient gap dimension Sparking, inadmissible temperature rise and wear of the shaft seal due to insufficient gap dimension are possible. In the case of a shaft seal with taconite seals, ensure that the set gap dimension of +0.5 mm on the grease labyrinth is not changed when the input and output elements (e.g.
Page 30: Torque Limiting Backstop (Special Version)
3.7 Torque limiting backstop (special version) 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 or destruction of the backstop and gear unit due incorrect direction of rotation Do not run the motor in the opposite direction to the blocking direction of the gear unit.
Page 31: Figure 3-5 Torque Limiting Backstop
Changing the stop direction You can change the blocking direction of the backstop 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 Do not run the motor in the opposite direction to the blocking direction of the gear unit.
Page 32: Cooling
Description 3.8 Cooling WARNING Risk of injury as a result of moving system parts There is a risk that after the motor is switched off the load cannot be securely kept in posi- tion, and that it can accelerate in the reverse direction. The slipping torque has been set to the correct value in the factory and must not be changed.
Page 33: Mounted Oil Supply System
Description 3.8 Cooling NOTICE Overheating of the gear unit due to insufficient air supply For gear units fitted with a fan, ensure sufficient clearance for the air intake when mounting safety guards for the coupling or other similar components. You will find the clearance required in the dimension drawing, which is part of the complete documentation of the gear unit.
Page 34: Mounted Oil Supply System With Water-Oil Cooler
Description 3.8 Cooling NOTICE Overheating of the gear unit due to insufficient air supply When installing a gear unit with mounted air-oil cooler, ensure that air can freely circulate. You will find the necessary minimum clearance to adjacent components, such as walls and panels, in the dimension drawing in the complete documentation of the gear unit.
Page 35: Pump
Description 3.8 Cooling WARNING Risk of eye injury from compressed air Water residue and dirt particles can cause damage to eyes. Wear suitable safety goggles. Further information You can find additional information, such as connection dimensions and a detailed illustrated description of the gear unit and the oil supply system with water-oil cooler, in the dimension drawing, which is part of the complete documentation of the gear unit.
Page 36: Separate Oil Supply System
Description 3.8 Cooling You can find additional technical data in the separate data sheet and in the list of equipment, which are part of the complete documentation of the gear unit. 3.8.3 Separate oil supply system 3.8 Cooling A separate oil supply system can be used to cool the oil. Further information You can find additional information about separate oil supply systems in the operating in- structions for the oil supply system, which are part of the complete documentation of the...
Page 37: Heating
Description 3.11 Heating Further information You can find additional information about the shrink disk in the operating instructions for the shrink disk. These operating instructions are included in the complete documentation of the gear unit. 3.11 Heating 3.11 Heating Introduction At low temperatures, it may be necessary to preheat the gear unit oil before the drive is switched on or also during operation.
Page 38: Oil Level Indicator
Description 3.12 Oil level indicator Further information You can find additional information on the position of the mounted components and a de- tailed illustrated description of the gear unit in the dimension drawing. You can find additional information on the heating in the separate data sheet, in the list of equipment or in the heating operating instructions, which are part of the complete document- ation of the gear unit.
Page 39: Bearing Monitoring
Description 3.14 Bearing monitoring The following diagram shows an oil temperature monitor mounted on the gear unit: Figure 3-7: Oil temperature monitoring system ① Pt 100 resistance thermometer Further information You can find additional and a detailed illustration of the gear unit and the position of the mounted components in the dimension drawing, which is part of the complete documentation of the gear unit.
Page 40: Bearing Monitoring By Shock-Pulse Transducer
Description 3.14 Bearing monitoring The following diagram shows bearing monitoring using a Pt 100 resistance thermometer: Figure 3-8: Bearing monitoring using a Pt 100 resistance thermometer ① Pt 100 resistance thermometer Further information You can find additional and a detailed illustration of the gear unit and the position of the mounted components in the dimension drawing, which is part of the complete documentation of the gear unit.
Page 41: Figure 3-9 Fully Assembled Acceleration Sensor (A), And Threaded Connector (B) For Variants 1 To 4
Description 3.14 Bearing monitoring The following diagram shows the fully assembled acceleration sensor (A), and the threaded connector (B) for variants 1 to 4: Figure 3-9: Fully assembled acceleration sensor (A), and threaded connector (B) for variants 1 to 4 ① Shielded cable (oil-proof) ④...
Page 42: Speed Encoder
Description 3.15 Speed encoder The following diagram shows the threaded connector 1/4"-28UNF-2B: Figure 3-11: Threaded connector 1/4"-28UNF-2B More information You can find more information and a detailed illustration of the gear unit with attached sensors in the dimension drawing, which is part of the complete documentation of the gear unit.
Page 43: Dx500Gl
Description 3.16 Torque monitoring system Further information You can find additional and a detailed illustration of the gear unit and the position of the mounted components in the dimension drawing, which is part of the complete documentation of the gear unit. You can find additional about the telemetry system, such as control instructions and tech- nical specifications, in the operating instructions of the telemetry system and in the equip- ment list provided in the complete gear unit documentation.
Page 44 Description 3.16 Torque monitoring system Edition 06/2022 A9219-02en...
Page 45: 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 111) immediately. WARNING Serious injury through defective product Serious injury may occur.
Page 46: Attaching The Load
Application planning 4.2 Transport NOTICE Damage to gear unit When transporting the gear unit, the gear unit packaging or coating can be damaged. When transporting the product in a lifted position, proceed slowly and carefully in order to avoid damage to the packaging or coating. NOTICE Damage to gear unit due to impacts against free shaft ends Damage to gear unit is possible due to impacts against the free shaft ends.
Page 47: Attachment Points
Application planning 4.3 Attachment points The symbols which appear on the packaging must be observed. Figure 4-1: Transport symbols Attachment points 4.3 Attachment points Sling swivels Gear units have tapped holes to specifically attach sling swivels so that they can be trans- ported during mounting.
Page 48: Table 4-1 Information About The Connection Threads For Sling Swivels
Application planning 4.3 Attachment points The following table contains information about the connection thread for sling swivels appro- priate for the gear unit size: Gear unit size Connection thread for sling swivels M72x6 Table 4-1: Information about the connection threads for sling swivels Further information You will find further information and a detailed illustration of the gear unit, the position of the attachment points, the centre of gravity and data on the weight in the drawings, which are...
Page 49: Special Aspects Relating To Lubrication
Application planning 4.4 Special aspects relating to lubrication Special aspects relating to lubrication 4.4 Special aspects relating to lubrication 4.4.1 Oil filling and oil drain 4.4 Special aspects relating to lubrication The diagram below shows the oil filling locations and oil drain locations of a planetary gear unit using a P3DH gear unit type as example: Figure 4-2: Oil filling locations and oil drain locations ①...
Page 50: Figure 4-3 Gear Unit With Backstop
Application planning 4.4 Special aspects relating to lubrication The following diagram shows the oil filling locations and oil drain locations for a gear unit with a backstop: Figure 4-3: Gear unit with backstop ① Oil filling point ④ Screw plug for residual oil drain ②...
Page 51: Assembly
Assembly General assembly instructions 5.1 General assembly instructions The mounting work must be performed very carefully by authorised, trained and suitably in- structed personnel. Liability is excluded for damage caused by the incorrect performance of this work. Requirements Improper use can damage the gear unit. Take the following precautions: •...
Page 52: Unpacking The Gear Unit
Assembly 5.2 Unpacking the gear unit If you use a temperature monitoring device, it must be capable of outputting an alarm when the maximum permissible oil sump temperature is reached. It must also be capable of trip- ping the drive when the maximum permissible oil sump temperature is exceeded. The oper- ator's process might be interrupted when the drive is shut down.
Page 53: Gear Unit Assembly
Assembly 5.3 Gear unit assembly NOTICE Damage to the gear unit due to corrosion Exposing the gear unit to moisture can result in damage from corrosion. Do not damage or open the packaging too early if the packaging is used to preserve the unit.
Page 54: Measures Prior To Mounting
Assembly 5.3 Gear unit assembly • Design the foundation according to the relevant weight and torque, taking into account the forces acting on the gear unit. • Align the foundation carefully with the equipment installed on the input and output sides of the gear unit.
Page 55: Mounting Shaft-Mounted Gear Units With Shrink Disk
Assembly 5.3 Gear unit assembly More information Further information about removing the corrosion protection can be found in the instruc- tions 7300 in the complete documentation for the gear unit. You can find more information on attaching gear units to lifting equipment in cases where the weight of the gear unit necessitates the use of hoisting gear in chapter Application planning (Page 45).
Page 56 Assembly 5.3 Gear unit assembly WARNING Risk of crushing There is the risk of being crushed between the drive unit and the machine shaft during tightening. • Do not stand between the drive unit and the machine shaft. NOTICE Skewing and cold welding can cause damage to the machine shaft and the hollow shaft.
Page 57: Mounting Shaft-Mounted Gear Units Without Shrink Disk
Assembly 5.3 Gear unit assembly – Dial gauge – Laser alignment system Information Use the adjustable chain hoists when aligning. 9. Move the gear unit slowly towards the machine shaft. 10.Pull on the gear unit up to the marking on the machine shaft. 11.Secure the gear unit against inadvertent movements, such as the torque arm falling down.
Page 58 Assembly 5.3 Gear unit assembly WARNING Risk of crushing There is the risk of being crushed between the drive unit and the machine shaft during tightening. • Do not stand between the drive unit and the machine shaft. NOTICE Skewing and cold welding can cause damage to the machine shaft and the hollow shaft.
Page 59: Mounting Gear Units With Flange Shaft
Assembly 5.3 Gear unit assembly Information Use the adjustable chain hoists when aligning. 6. Move the gear unit slowly towards the machine shaft. 7. Pull on the gear unit up to the marking on the machine shaft. 8. Secure the gear unit against inadvertent movements, such as the torque arm falling down.
Page 60: Mounting Gear Units Using The Mounting Foot
Assembly 5.3 Gear unit assembly NOTICE Damage to the gear unit The gear unit with stub shaft can be damaged if it skews when mounting. Do not allow the gear unit with stub shaft to skew when you mount it onto the machine shaft.
Page 61: Alignment
Assembly 5.3 Gear unit assembly 5.3.6.1 Alignment 5.3 Gear unit assembly Introduction DANGER Danger to life from flying fragments Failure to align the unit with the required degree of accuracy can cause the shaft to rup- ture. A ruptured shaft can result in serious or even fatal injuries. Align the gear unit exactly so that it conforms to the specified alignment values.
Page 62: Mounting On A Concrete Foundation Using Foundation Blocks
Assembly 5.3 Gear unit assembly Requirements The following requirements must be fulfilled before the assembly work commences: • The foundation must be horizontal and level. • When tightening the fastening bolts, make sure that the gear unit is free of mechanical stress.
Page 63: Figure 5-1 Foundation Block
Assembly 5.3 Gear unit assembly Gear unit with foundation blocks The following diagram shows a foundation block: Figure 5-1: Foundation block ① Fastening bolt ⑥ Foundation ② Washer ⑦ Foundation block ③ Gear unit foot ⑧ Flat steel plate ④ Height of the completed foundation ⑨...
Page 64: Mounting On A Concrete Foundation Using Anchor Bolts
Assembly 5.3 Gear unit assembly 5.3.6.2.3 Mounting on a concrete foundation using anchor bolts 5.3 Gear unit assembly Requirement The lower side of the gear unit mounting feet must be clean. Inserting the anchor bolt The following diagram shows the inserted anchor bolt: Figure 5-2: Inserted anchor bolt ①...
Page 65: Figure 5-3 Tightened Anchor Bolt
Assembly 5.3 Gear unit assembly Mounting the gear unit using anchor bolts The following diagram shows a tightened anchor bolt: Figure 5-3: Tightened anchor bolt ① Hexagon nut ⑤ Raw foundation ② Washer ⑥ Anchor bolt ③ Housing foot ⑦ Baseplate ④ Fine-grout concrete ⑧...
Page 66: Mounting On A Mounting Flange Or Block Flange
Assembly 5.3 Gear unit assembly CAUTION Incorrect use of the preload tool Incorrectly using the preload tool can result in injury. To ensure correct handling and adjustment of the preload tool, you must carefully comply with the instructions provided in the manufacturers operating instructions for the preload tool.
Page 67: Assembly
Assembly 5.3 Gear unit assembly 5.3.7.2 Assembly 5.3 Gear unit assembly Ensure that the following requirements are met before mounting: • When aligning the machine shaft relative to the mating flange, keep the radial and angu- lar misalignment as small as possible. •...
Page 68: Special Aspects Of Shaft-Mounted Gear Units
Assembly 5.3 Gear unit assembly 4. Insert the gear unit into the mating flange using suitable lifting equipment. 5. Tighten the flange bolts. NOTICE Damage to the gear unit due to uneven tightening of the flange bolts. The gear unit can be damaged if the flange bolts are tightened unevenly. Tighten the flange bolts crosswise and evenly with the full torque.
Page 69: One-Sided Torque Arm
Damage to the gear unit is possible due to incorrect attachment of the torque arm. Torque arms must only be mounted in consultation with Flender. Mount the torque arm on the side of the machine without causing any distortion. Use the maximum possible number of bolts for mounting.
Page 70: Chun Torque Arms
If it has not already been mounted, attach the various components of the torque arm onto the gear unit as specified in the order. The fastening elements required are part of the FLENDER scope of delivery. Only use these fastening elements or equivalent fastening elements with the same property class.
Page 71 Damage to the gear unit is possible due to incorrect attachment of the torque arm. Torque arms must only be mounted in consultation with Flender. Mount the torque arm on the side of the machine without causing any distortion. Use the maximum possible number of bolts for mounting.
Page 72: Mounting The Gear Unit On The Machine Shaft
Assembly 5.3 Gear unit assembly 5.3.8.2.2 Mounting the gear unit on the machine shaft 5.3 Gear unit assembly Procedure First mount the movable roller gear unit (upper torque arm attached to the output side) on the appropriate machine shaft. Carefully follow the information provided in chapter Mounting shaft-mounted gear units with shrink disk (Page 55).
Page 73: Removing The Gear Unit From The Machine Shaft
2. Release the fitting screws (part no. 603) and hexagon nuts (part no. 604). 3. Drive out the fitting screws using a plastic mandrel. When doing this, components and parts can be scored. FLENDER is responsible for assessing the scoring and deciding on whether the parts can be reused.
Page 74: Gear Unit Dismantling
Assembly 5.4 Gear unit dismantling Gear unit dismantling 5.4 Gear unit dismantling 5.4.1 Removing shaft-mounted gear units with shrink disk 5.4 Gear unit dismantling WARNING The runs can be damaged by overloading the chain tackles. Consequently, pay attention to the crane scale so that overloading the runs is prevented. WARNING The machine shaft can be damaged by the oscillating movement of the drive unit.
Page 75: Removing Shaft-Mounted Gear Units Without Shrink Disk
Assembly 5.4 Gear unit dismantling 5. Move the crane step-by-step away from the machine in order to release the gear unit from the machine shaft. When doing this, ensure that the tensile load does not exceed 1.2 times the gear unit weight. Information To simplify disassembly, heat the hollow shaft to up to 50 °C using a suitable heat source, such as a powerful halogen lamp.
Page 76: Removing Gear Units With Flange Shaft
Assembly 5.4 Gear unit dismantling Procedure Proceed as follows to remove the gear unit: 1. Release the connection between the torque arm and the foundation. When doing this, secure the gear unit against inadvertent movements, such as the torque arm falling down.
Page 77: Removing Gear Units With Mounting Foot
Assembly 5.4 Gear unit dismantling 5.4.4 Removing gear units with mounting foot 5.4 Gear unit dismantling WARNING The machine shaft can be damaged by the oscillating movement of the drive unit. Ensure that the drive unit does not hit against the machine shaft during dismantling. En- sure that the oscillating movement is dampened by the crane.
Page 78: Couplings
Assembly 5.5 Couplings Couplings 5.5 Couplings Introduction Improper use can damage the gear unit. Take the following precautions: • If necessary, perform the following preparatory work in accordance with the operating in- structions for the coupling: – Milling the finished bore –...
Page 79: Mounting The Coupling
Assembly 5.5 Couplings 5.5.1 Mounting the coupling 5.5 Couplings Introduction The method used to mount the coupling varies according to type. The procedure described in these operating instructions is general rather than specific to one type of coupling. Mount the coupling as described in the operating instructions for the specific coupling. Improper use can damage the gear unit.
Page 80: Aligning The Coupling
• Make sure that the maximum permissible misalignment values are not exceeded during operation. – If you are using couplings supplied by Flender, you will find the maximum permissible misalignment values in the operating instructions for the coupling. – If you are using couplings supplied by other manufacturers, contact them and ask them for the maximum permissible misalignment values, making sure that you specify the potential radial loads for your application.
Page 81: Figure 5-8 Alignment Process Based On The Example Of A Flexible Coupling
Assembly 5.5 Couplings Alignment Align the individual components in two mutually perpendicular axial planes. The following can be used as alignment tools: • Ruler (radial misalignment) • Feeler gauge (angular misalignment) • Spirit level • Dial gauge • Laser alignment system You will achieve a greater degree of alignment accuracy by using a dial gauge or laser align- ment system.
Page 82: Connecting Components
Assembly 5.6 Connecting components Connecting components 5.6 Connecting components 5.6.1 Gear units with mounted components 5.6 Connecting components Depending on the order specification, the gear unit can be equipped with various compon- ents. Connect the closed-loop control and open-loop control electrical devices corresponding to the specifications of the device supplier.
Page 83: Connecting The Separate Oil Supply System
Assembly 5.6 Connecting components Procedure To connect the water-oil cooler to the gear unit, proceed as follows: 1. Remove the connecting bushes from the cooling water connection before connecting the water-oil cooler. 2. Flush the water-oil cooler to remove any dirt and pollution. 3.
Page 84: Connecting The Heating Element
Assembly 5.6 Connecting components 5.6.6 Connecting the heating element 5.6 Connecting components Procedure To connect heating elements to the gear unit, proceed as follows: 1. Check that the heating element connection is not damaged. 2. Install the electrical wiring for the heating elements. Further information You can find additional information on the heating in the operating instructions for the heat- ing, which are part of the complete documentation of the gear unit.
Page 85: Connecting The Bearing Monitoring
Assembly 5.6 Connecting components 5.6.9 Connecting the bearing monitoring 5.6 Connecting components Procedure To connect the bearing monitoring system to the gear unit, proceed as follows: 1. Check that the connection of the bearing monitoring system is not damaged. 2. Install the electrical wiring for the bearing monitoring system. Further information You can find additional information on the bearing monitoring system in the operating in- structions for the bearing monitoring system, which are part of the complete documentation...
Page 86: Mounting Connecting Hoses
Assembly 5.6 Connecting components Procedure DANGER Electric shock Energised parts can cause an electric shock. Ensure that the entire plant is de-energised before starting electrical installation work. Carefully observe the five safety rules (Page 17). To connect the motors, monitoring devices and electrical components, proceed as follows: 1.
Page 87: Bolt Connection Classes
Assembly 5.7 Tightening procedure Information Replacing bolts Replace any bolts that are no longer fit for use by bolts of the same type and strength class. Mating threads The mating threads must have the following properties: • Made of steel or cast iron •...
Page 88: Tightening Torques And Preload Forces
Assembly 5.7 Tightening procedure 5.7.3 Tightening torques and preload forces 5.7 Tightening procedure The tightening torques specified in the following table apply only to these operating instruc- tions for the gear unit. Bolt the specified bolted connections with the tightening torques as stated in the following table.
Page 89: Table 5-2 Preload Forces And Tightening Torques
Assembly 5.7 Tightening procedure Nominal Strength Preload force for bolt connection Tightening torque for bolt connec- thread dia- class of classes from table in chapter tion classes from table in chapter meter the bolt Bolt connection classes Bolt connection classes M min.
Page 90: Tightening Torques For Flange Connection And Version With A Foot
Assembly 5.7 Tightening procedure 5.7.4 Tightening torques for flange connection and version with a foot 5.7 Tightening procedure The following diagram shows the flange connection (A) and version with a foot (B): Figure 5-9: Flange connection and version with foot Flange connection (torque arm or gear Version with foot unit foot) ①...
Page 91: Final Work
Assembly 5.8 Final work Gear unit Flange connection Version with foot size (strength class 10.9) (strength class 8.8) Nominal Tightening torque Nominal Tightening torque thread dia- for bolt connection class thread dia- for bolt connection class meter "C" from table in the meter "C"...
Page 92 Assembly 5.8 Final work • Protect the gear unit against falling objects. • Check that the guards over rotating parts are securely fastened. Contact (accidental or deliberate) with rotating parts is not permitted. • Check whether transport locks and protective covers of components have been re- moved.
Page 93: 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 instructions. • Replace the screw plug with the air filter or the wet-air filter. Note the instructions 7300 for this.
Page 94: Gear Unit With Oil Supply System
Commissioning 6.1 Measures prior to commissioning 6.1.2 Gear unit with oil supply system 6.1 Measures prior to commissioning Take the following measures before commissioning a gear unit with an oil supply system: • Make sure that the pressure in the oil supply system components does not exceed the maximum permissible pressure.
Page 95: Bearing Monitoring (Vibration Measurement)
Damage to the gear unit due to insufficient lubrication is possible because of excessive temperatures. If the temperature is higher, the gear unit must be stopped immediately and Flender cus- tomer service must be consulted. The maximum permissible oil sump temperature is: •...
Page 96 Commissioning 6.2 Measures during commissioning Edition 06/2022 A9219-02en...
Page 97: 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. The operating data specified in the Appendix Technical data (Page 119) apply. The following operating data apply to the oil: Maximum operating temperat- 80 °C is applicable for mineral oil, API groups I or II and satur- ated synthetic ester...
Page 98: Taking The Unit Out Of Service
Operation 7.3 Taking the unit out of service NOTICE Faults can cause damage to the gear unit The gear unit might sustain damage if it is not shut down when a fault occurs. Switch off the drive unit immediately if any fault condition develops. Rectifying anomalies Proceed as follows to rectify any anomalies: 1.
Page 99: Servicing
Servicing General maintenance information 8.1 General maintenance information The operator must ensure compliance with the stipulated intervals. 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 100: Table 8-1 Maintenance And Servicing Activities
Servicing 8.2 Maintenance schedule Intervals and time limits Measures Monthly and prior to every start-up Check for leaks Check the oil level 400 operating hours after commissioning Check the water content of the oil Change the oil (or depending on results of the oil sample test) Check that the fastening bolts are tight Every 3 months...
Page 101: Service And Maintenance Work
Servicing 8.3 Service and maintenance work More information about installed components can be found in the instructions for the com- ponents in the complete documentation for the gear unit. Service and maintenance work 8.3 Service and maintenance work 8.3.1 Clean the air filter 8.3 Service and maintenance work Cleaning interval For dust deposits, you must clean the air filter before the minimum interval of 3 months ex-...
Page 102: Replacing The Backstop
Servicing 8.3 Service and maintenance work 5. Immediately stop the gear unit if the maximum permissible oil temperature is exceeded. Contact Flender Customer Services. 8.3.3 Replacing the backstop 8.3 Service and maintenance work Introduction If you run the gear unit at speeds below the disengagement speed of the backstop, you must regularly replace the backstop.
Page 103: Figure 8-1 Torque Limiting Backstop
Servicing 8.3 Service and maintenance work Information Loss of warranty The warranty becomes null and void if you remove or damage the locking wire on the guide screws of the springs. Do not change the slipping torque setting. The slipping torque was set to the correct value in the factory.
Page 104: Measuring The Vibration Levels Of The Rolling-Contact Bearings
Servicing 8.3 Service and maintenance work 8.3.6 Measuring the vibration levels of the rolling-contact bearings 8.3 Service and maintenance work Procedure Proceed as follows to measure the vibration levels of the rolling-contact bearings: 1. Document the measurement results. 2. Compare the measured values with the comparison values that were recorded commis- sioning the gear unit was commissioned.
Page 105: Inspecting The Shrink Disk
8.3 Service and maintenance work General inspection of the gear unit by Customer Services Arrange for Flender Customer Services to perform a general inspection on the gear unit. Based on their experience, Siemens technicians can best identify whether gear unit parts must be replaced.
Page 106: Possible Faults
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 107 Servicing 8.4 Possible faults Possible faults Causes Possible remedies Outer surface of gear Mechanical face or labyrinth seals • Check oil filling unit soiled with oil soiled with oil, incorrect position for • Clean labyrinth seals transport Static seal defective •...
Page 108 Servicing 8.4 Possible faults Possible faults Causes Possible remedies Oil is foaming in the Oil supply system left in operation • Switch off the oil supply system gear unit for too long at low temperatures • Degas the oil Gear unit too cold in operation •...
Page 109 Servicing 8.4 Possible faults Possible faults Causes Possible remedies Elevated temperature Coolant temperature too high • Check the temperature during operation • Correct the temperature if necessary Defective oil pump • Check the oil pump function • Repair or replace oil pump if required Elevated temperature Oil level in the gear unit housing •...
Page 110: Table 8-2 Possible Faults And How To Rectify Them
Servicing 8.4 Possible faults Possible faults Causes Possible remedies Water in the oil 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 Table 8-2: Possible faults and how to rectify them Edition 06/2022 A9219-02en...
Page 111: Service & Support
Customer Service addresses: Flender GmbH Am Industriepark 2 46562 Voerde Germany Tel.: +49 (0)2871 / 92‐0 Fax: +49 (0)2871 / 92‐1544 More information Further information about service and support can be found on the Internet: Service & Support (https://www.flender.com/service) A9219-02en Edition 06/2022...
Page 112 Service & Support 9.1 Contact Edition 06/2022 A9219-02en...
Page 113: 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, preservation agents and coolant from the gear unit and dispose of it according to regulations. •...
Page 114 Disposal Edition 06/2022 A9219-02en...
Page 115: 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 116 Spare parts Edition 06/2022 A9219-02en...
Page 117: Declaration Of Incorporation
Description and identification of the partly completed machine: Planetary gear unit PLANUREX 3 P2DP, P3CP, P3DP, P3FP, P3KP, P3LP, P3ZP, P3DH, P3SH, P3ZH Sizes 345 to 775 to drive machines The following “Essential Health and Safety Requirements” from the – Regulations 2008 No. 1597, are applied and are fulfilled: 1.1, 1.1.2, 1.1.3, 1.1.5;...
Page 118 Declaration of incorporation UK Declaration of Incorporation Edition 06/2022 A9219-02en...
Page 119: 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 You can find more information on the technical data in the separate data sheet, which is part of the complete documentation of the gear unit.
Page 120: Example Code
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 121: Weights
Technical data Weights P2DP P3DH P3CP P3DP P3FP P3KP P3LP P3ZP P3SH P3ZH Weights Weights The precise weights are specified in the dimension drawings in the complete documentation or on the rating plate. All stated weights refer to units without oil filling or mounted components.
Page 122: Enveloping Surface Sound Pressure Level
P according to the rating plate, for measurements carried out on a Flender test bench. If more than one value is stated, the highest speed and power values ap- ply. The enveloping surface sound pressure level includes any mounted lubrication units. With outgoing and incoming pipes, the flange is considered to be the interface.
Page 123: Table B-2 Enveloping Surface Sound Pressure Level
Technical data Enveloping surface sound pressure level Type Gear unit size 345 370 395 420 445 475 500 P2DP 26 - 33 P3DH 40 - Table B-2: Enveloping surface sound pressure level Information on the measuring surface sound pressure levels of gear unit types P3CP, P3DP, P3FP, P3KP, P3LP, P3ZP, P3SH and P3ZH is available on request.
Page 124 Technical data Enveloping surface sound pressure level Edition 06/2022 A9219-02en...
Page 125: Index
Index Air filter Cleaning, 101 Air guide cover, 32 Air-oil cooler Principle of operation, 32 Principle of operation, 33 Fastening bolts Anomalies, 97 Bolt connection class, 87 Attachment points, 51 Bolts, 86 Checking for tightness, 105 Mating threads, 87 Preload force, 88 Tightening procedure, 87 Backstop Tightening torque, 88 Blocking direction, 31 Fault, 106 Checking the friction linings, 102 Fault rectification, 106 Commissioning, 93 Final work, 91...
Page 126 Index Maintenance schedule, 99 Shrink disk Measures Checking, 105 during commissioning, 94 Speed encoder prior to commissioning, 93 Connecting, 85 Mounting position, 51 Taconite seal, 28 Note about mounting, 51 Taking out of service, 98 Transport note, 45 Transport symbols, 46 Troubleshooting, 106 Type of danger, 19 Oil, 16 Oil filter, 35 Oil level indicator, 38 Oil supply system, 34, 36 Air-oil cooler, 33 Unpacking, 52...
Page 128 Planetary gear unit Assembly and operating instructions A9219-02en Edition 06/2022 Flender GmbH Alfred-Flender-Straße 77 46395 Bocholt Germany...

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