Related Manuals for FLENDER H V Series
Summary of Contents for FLENDER H V Series
- Page 1 FLENDER GEAR UNITS Gear unit Assembly and operating instructions 5091en Edition 06/2020 H..V, B..V 23...28...
- Page 2 09.12.2020 16:10 V24.01...
- Page 3 Introduction Safety instructions Description FLENDER GEAR UNITS Application planning Gear unit 5091en Assembly Commissioning Assembly and operating instructions Operation Servicing Service & Support Disposal Spare parts H..V, B..V Declaration of incorporation 23...28 Declaration of conformity Technical data Original assembly and operating instructions...
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Page 4: Legal Information
Note the following: WARNING Flender products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Flender. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. -
Page 5: Table Of Contents
Table of contents Introduction ............................11 General information......................11 Lubricants.......................... 12 Safety instructions ..........................15 Security notes ........................15 The five safety rules ......................15 General information......................16 General warnings and symbols................... 17 Special types of danger and personal protective equipment ..........18 Correct use in hazardous zones (explosive atmospheres) ............ - Page 6 Table of contents 3.10 Heating ..........................51 3.10.1 Oil-level monitoring system for the heating elements ............53 3.11 Oil level indicator ....................... 53 3.12 Oil level monitoring system ....................54 3.13 Oil temperature monitoring ....................54 3.14 Bearing monitoring ......................55 3.14.1 Bearing monitoring using a Pt 100 resistance thermometer ..........
- Page 7 Table of contents 5.6.1 Assembly ......................... 104 5.6.1.1 Pulling on with integrated DU bushing ................105 5.6.1.2 Mounting with DU bushing as a separate component ............107 5.6.1.3 Axial locking ........................107 5.6.2 Dismantling the shaft-mounted gear unit ................. 107 Shaft-mounted gear unit with flange coupling..............
- Page 8 Table of contents 8.3.7 Checking the cooling coil ....................133 8.3.8 Inspecting the shrink disk....................134 8.3.9 Check that all of the fastening bolts are tight..............134 8.3.10 General inspection of the gear unit .................. 135 8.3.11 Final work........................135 Possible faults ........................
- Page 9 Table of contents Figures Figure 3-1 Output shaft versions......................24 Figure 3-2 Output shaft versions for agitator gear units................25 Figure 3-3 Sign: Lubrication point......................26 Figure 3-4 Gear unit equipment on gear units of type H..V with oil expansion unit ........26 Figure 3-5 Gear unit equipment on gear units of type B..V with oil expansion unit........
- Page 10 Table of contents Figure 3-37 Speed encoder........................61 Figure 4-1 Transport symbols........................65 Figure 4-2 Shear and lateral pulling when using eye bolts ................ 66 Figure 4-3 Position of the attachment points for gear units, type H..V and B..V ......... 67 Figure 4-4 Position of the attachment points for gear units, type H..V with motor........
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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: Basic Knowledge Required
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 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. Assembly and operating instructions 5091en...
- Page 14 Introduction 1.2 Lubricants Assembly and operating instructions 5091en Edition 06/2020...
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Page 15: Safety Instructions
In order to safeguard plants, systems, machines and networks against cyber threats it is necessary to implement (and continually maintain) a holistic industrial security concept that corresponds to the current state of the art. Flender products and solutions undergo continuous development in this respect. -
Page 16: General Information
Safety instructions 2.3 General information General information Introduction All work on the gear unit should be performed with care and only by qualified personnel. Symbols on the gear unit The following symbols apply to the gear unit; some of which are found as coloured markings on the gear unit: Table 2-1 Symbols and markings... -
Page 17: General Warnings And Symbols
Safety instructions 2.4 General warnings and symbols Points labelled on the gear unit Symbol Coloured markings Do not unscrew Alignment surface, horizontal Alignment surface, vertical These symbols indicate the oil level check‐ ing procedure using the oil dipstick. These symbols indicate that the oil dipstick must be firmly screwed in. -
Page 18: Special Types Of Danger And Personal Protective Equipment
Safety instructions 2.5 Special types of danger and personal protective equipment Special types of danger and personal protective equipment Requirements Fulfil the following requirements before commencing work on the gear unit: • Ensure that the oil pressure lines are depressurised. •... -
Page 19: Surface Temperature
Safety instructions 2.5 Special types of danger and personal protective equipment Switch the gear unit to standstill immediately if inexplicable changes are noticed during operation. Such changes may include unusual gear unit noise or a significant increase in operating temperature. WARNING Risk of falling There is an increased risk of falling when standing or walking on the gear unit during operation. -
Page 20: Chemical Substances
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 21 Safety instructions 2.6 Correct use in hazardous zones (explosive atmospheres) If you have any queries, please contact Customer Services (Page 141). WARNING An explosive atmosphere can be ignited An explosive atmosphere can be ignited if mounted components are used that do not comply with the ATEX directive.
- Page 22 Safety instructions 2.6 Correct use in hazardous zones (explosive atmospheres) • In the case of gear units that are operated in combination with electrical machines that generate current or through which current flows (e.g. motors and generators), take measures to ensure that no current can flow through the gear unit. Current flowing through the gear unit can result in irreparable damage to rolling-contact bearings and gearing.
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Page 23: 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 24: Output Shaft Versions
Description 3.2 Output shaft versions Design Type H2.V H3.V H4.V B3.V B4.V When an auxiliary drive is mounted (as maintenance or load drive), the assignment of the direction of rotation to the specific version is defined in the dimension drawing. NOTICE Destruction of the gear unit or parts of the gear unit due to incorrect direction of rotation is possible. -
Page 25: Figure 3-2 Output Shaft Versions For Agitator Gear Units
Description 3.3 Housing ① Gear unit with mounting flange Solid shaft ② Gear unit with block flange Hollow shaft with parallel keyway Figure 3-2 Output shaft versions for agitator gear units Further information Further information, a detailed illustration of the gear unit and the position of the mounted components can be found in the dimension drawing in the complete documentation for the gear unit. -
Page 26: Figure 3-3 Sign: Lubrication Point
Description 3.3 Housing The lubrication points are designated using the following sign: Figure 3-3 Sign: Lubrication point Gear unit equipment The diagram below shows the available gear unit equipment on gear units of type H..V with oil expansion unit ① ⑦... -
Page 27: Figure 3-5 Gear Unit Equipment On Gear Units Of Type B
Description 3.3 Housing ① ⑦ Shaft seal Shaft seal ② ⑧ Bearing neck Gear unit fastening ③ ⑨ Lifting eye Cover ④ ⑩ Inspection and/or assembly cover Cover ⑤ ⑪ Rating plate Air guide cover ⑥ ⑫ Oil expansion unit Figure 3-5 Gear unit equipment on gear units of type B..V with oil expansion unit Further information... -
Page 28: Figure 3-6 Gear Unit Equipment On Gear Units Of Type H
Description 3.3 Housing The diagram below shows the available gear unit equipment on gear units of type H..V with mounted oil supply system: ① ⑦ Lifting eye Cover ② ⑧ Shaft seal Shaft seal ③ ⑨ Inspection and/or assembly cover Gear unit fastening ④... -
Page 29: Figure 3-8 Aerator Gear Unit, Type H.bv
Description 3.3 Housing Further information Further information, a detailed illustration of the gear unit and the position of the mounted components can be found in the dimension drawing in the complete documentation for the gear unit. Aerator gear unit The output shaft rotates in an oil retaining pipe (Page 40). This prevents the gear unit oil from escaping at the end of the shaft. -
Page 30: Figure 3-9 Aerator Gear Unit, Type B.bv
Description 3.3 Housing ① ⑧ Shaft seal Gear unit fastening ② ⑨ Bearing neck Bearing neck ③ ⑩ Lifting eye Shaft seal ④ ⑪ Inspection and/or assembly cover Coupling flange ⑤ ⑫ Motor pump (optional) Cover ⑥ ⑬ Rating plate Flange pump (optional) ⑦... -
Page 31: Figure 3-10 Gear Unit With Mounting Flange (E.g. H3Sv With Oil Expansion Unit)
Description 3.3 Housing Gear unit with mounting flange The following diagram shows a gear unit with mounting flange (e.g. H3SV with oil expansion unit): ① ⑦ Lifting eye Shaft seal ② ⑧ Shaft seal Gear unit fastening ③ ⑨ Inspection and/or assembly cover Mounting flange ④... -
Page 32: Figure 3-11 Gear Unit With Coupling Flange At The Output
Description 3.3 Housing Gear unit with coupling flange at the output The diagram below shows a gear unit with coupling flange at the output: ① ⑦ Housing Cover ② ⑧ Lifting eye Coupling flange ③ ⑨ Motor bell housing Shaft seal ④... -
Page 33: Oil Supply To The Gear Unit
Description 3.4 Oil supply to the gear unit Oil supply to the gear unit Introduction The oil supply to the various gear unit components can be implemented using the following oil supply variants: • Dip lubrication • Pressure lubrication • Combination of both oil supply variants 3.4.1 Dip lubrication Unless otherwise agreed by contract, the gearing and rolling-contact bearings are supplied with... -
Page 34: Figure 3-12 Mounted Oil Supply System With Flange Pump For Types H
Description 3.4 Oil supply to the gear unit Oil supply system with flange pump The oil supply system is mounted on the gear unit and comprises the following components: • Flange pump • Double change-over filter • Pressure monitor • Piping The diagram below shows the gear unit equipment on gear units of type H..V with mounted oil supply system: ①... -
Page 35: Figure 3-14 Mounted Oil Supply System With Motor Pump For Types H
Description 3.4 Oil supply to the gear unit Oil supply system with motor pump The oil supply system is mounted on the gear unit and comprises the following components: • Motor pump • Double change-over filter • Pressure monitor • Piping The diagram below shows a mounted oil supply system with motor pump for types H..V: ①... -
Page 36: Bearing Arrangement Of The Shafts
Description 3.6 Shaft seal Bearing arrangement of the shafts All shafts are mounted on rolling-contact bearings. Shaft seal Introduction Depending on requirements, shaft seals prevent oil from escaping from the gear unit or dirt from entering the gear unit. 3.6.1 Rotary shaft sealing rings Rotary shaft sealing rings are the standard seal used. -
Page 37: Dry Running Protection
Description 3.6 Shaft seal 3.6.2 Dry running protection A grease filling and a ring are provided above the shaft sealing ring in order to reliably prevent the rotary shaft sealing ring, located at the top, from running dry. In a case such as this, a shaft sealing ring without additional dust lip is used. The ring is fitted on the input shaft using a set screw, and prevents grease from escaping upwards. -
Page 38: Figure 3-18 Taconite Seal
Description 3.6 Shaft seal A taconite seal is illustrated in the diagram below: ① ③ Rotary shaft sealing ring Labyrinth, filled with grease, can be regreased ② ④ Lamellar seal Grease nipple Figure 3-18 Taconite seal The following design variants of taconite seal are available: Assembly and operating instructions 5091en Edition 06/2020... -
Page 39: Table 3-2 Taconite Seal Versions
Description 3.6 Shaft seal ① ③ Taconite F-F Taconite F-K ② ④ Taconite F-H Output Figure 3-19 Design variants of taconite seals The various taconite seals are described in the following table: Table 3-2 Taconite seal versions Taconite seal versions Application Remarks "E"... -
Page 40: Centrifugal Disk
Description 3.6 Shaft seal Taconite seal versions Application Remarks "F-H" Output shaft • Regreasable labyrinth on the output side, dust-proof protection cover on the oppo‐ Design H: (hollow shaft with parallel keyway) site side Design K: (hollow shaft with spline according to DIN 5480) "F-K"... -
Page 41: Cooling
Description 3.7 Cooling ① ② Oil retaining pipe Lubrication point Figure 3-21 Oil retaining pipe The lower rolling-contact bearing of the output shaft is separated from the inside of the gear unit by the oil retaining pipe and is grease lubricated. A rotary shaft sealing ring is used to prevent grease from escaping. -
Page 42: Fan
Description 3.7 Cooling 3.7.1 Principle of operation Generally, the fan is mounted on the high-speed shaft of the gear unit and is protected from accidental contact using an air guide cover. The fan draws in air through the protective grille of the air guide cover and blows it along the lateral air ducts on the gear unit housing. -
Page 43: Cooling Coil
Description 3.7 Cooling 3.7.2 Cooling coil Introduction The gear unit can be equipped with a cooling coil in the oil sump. The cooling coil is connected to a cooling water supply. The cooling water connection must be provided by the operator. The cooling water can be fresh water, sea water or brackish water. -
Page 44: Mounted Oil Supply System
Description 3.7 Cooling The diagram below shows the cooling coil connections: ① ③ Cooling water connection Output shaft ② Reducer screw Figure 3-23 Cooling coil connections Further information For further information and a detailed illustration of the gear unit and the connection dimensions, please refer to the dimension drawings in the complete gear unit documentation. -
Page 45: Figure 3-24 Oil Supply System With Air-Oil Cooler Mounted On Gear Unit, Type B
Description 3.7 Cooling • Oil filter (double change-over filter or coarse filter) • Pressure monitor • Temperature control valve • Piping Note Observe the flow direction of the pump When connecting the valves, observe the flow direction of the pump. Refer to the pump operating instructions in the complete gear unit documentation to ascertain whether the flow direction of the pump used depends on the direction of rotation. -
Page 46: Temperature Control Valve
Description 3.7 Cooling The diagram below shows an oil supply system mounted on gear unit, types H..V: ① ④ Air-oil cooler Flange pump ② ⑤ Temperature control valve Pressure monitor ③ Double change-over filter Figure 3-25 Oil supply system mounted on gear unit, types H..V: Further information Additional information such as connection dimensions and a detailed illustrated description of the gear unit and the oil supply system with air-oil cooler can be found in the dimension drawing... -
Page 47: Mounted Oil Supply System With Water-Oil Cooler
Description 3.7 Cooling 3.7.3.2 Mounted oil supply system with water-oil cooler Introduction Depending on the order specification, an oil supply system with water-oil cooler can be used. This oil cooling system is mounted on the gear unit. Principle of operation The water-oil cooler is used to cool the gear unit oil;... -
Page 48: Figure 3-26 Oil Supply System With Water-Oil Cooler Mounted On Gear Units, Types H
Description 3.7 Cooling The diagram below shows an oil supply system with water-oil cooler mounted on gear units, types H..V: ① ④ Cooling water intake and outlet Flange pump ② ⑤ Double change-over filter Pressure monitor ③ Water-oil cooler Figure 3-26 Oil supply system with water-oil cooler mounted on gear units, types H..V The diagram below shows an oil supply system with water-oil cooler mounted on gear units, types B..V:... -
Page 49: Pump
Description 3.7 Cooling 3.7.3.3 Pump Requirements placed on the medium being pumped The pump being used is suitable for pumping lubricating oil. It is not permissible that the oil contains abrasive components and must not chemically attack the materials used in the pump. Clean oil with good lubricating properties is a precondition for ensuring the correct function, high operational reliability and long service life of the pump. -
Page 50: Couplings
Description 3.9 Shrink disk Further information Further information about separate oil supply systems can be found in the oil supply system operating instructions in the complete documentation for the gear unit. You can find additional information about the components of the oil supply system in the operating instructions for the components in the complete gear unit documentation. -
Page 51: Heating
Description 3.10 Heating 3.10 Heating Introduction At low ambient temperatures it may be necessary to preheat the gear unit oil before switching on the drive or while it is in operation. Heating is only permissible in conjunction with oil-level monitoring system. Heating elements Heating elements can be used for these applications, for example. -
Page 52: Figure 3-28 Heating For Gear Units With Oil Expansion Unit, Types H
Description 3.10 Heating The diagram below shows heating for gear units with oil expansion unit: ① ② Heating element Temperature monitor Figure 3-28 Heating for gear units with oil expansion unit, types H..V and B..V The diagram below shows heating for gear units with oil expansion unit: ①... -
Page 53: Oil-Level Monitoring System For The Heating Elements
Description 3.11 Oil level indicator Further information about the temperature monitor (such as control instructions) can be found in the temperature monitor operating instructions in the complete documentation for the gear unit. 3.10.1 Oil-level monitoring system for the heating elements Introduction Depending on the order specification, the gear unit can be equipped with an oil-level monitoring system (Page 54). -
Page 54: Oil Level Monitoring System
Description 3.13 Oil temperature monitoring Further information Further information about the oil level indicator and checking the oil can be found in the operating instructions BA 7300 in the complete documentation for the gear unit. Further information, a detailed illustration of the gear unit and the position of the mounted components can be found in the dimension drawing in the complete documentation for the gear unit. -
Page 55: Bearing Monitoring
Description 3.14 Bearing monitoring For gear units belonging to equipment Category 3, an oil temperature monitoring system can be mounted on the gear unit. The following diagram shows an oil temperature monitor mounted on the gear unit: ① Pt 100 resistance thermometer Figure 3-30 Oil temperature monitoring Further information... -
Page 56: Figure 3-31 Bearing Monitoring Using A Pt 100 Resistance Thermometer At Gear Units, Type H2.V
Description 3.14 Bearing monitoring The following diagram shows bearing monitoring using a Pt 100 resistance thermometer at gear units, type H2.V: ① Pt 100 resistance thermometer Figure 3-31 Bearing monitoring using a Pt 100 resistance thermometer at gear units, type H2.V: The following diagram shows bearing monitoring using a Pt 100 resistance thermometer at gear units, type B3.V: Assembly and operating instructions 5091en... -
Page 57: Bearing Monitoring By Shock-Pulse Transducer
Description 3.14 Bearing monitoring ① Pt 100 resistance thermometer Figure 3-32 Bearing monitoring using a Pt 100 resistance thermometer at gear units, type B3.V: Further information Further information, a detailed illustration of the gear unit and the position of the mounted components can be found in the dimension drawing in the complete documentation for the gear unit. -
Page 58: Figure 3-33 Bearing Monitoring Using Shock-Pulse Transducers At Gear Units, Type H2.V
Description 3.14 Bearing monitoring The following diagram shows a bearing monitoring system that uses shock-pulse transducers at gear units, type H2.V: ① Shock-pulse transducer Figure 3-33 Bearing monitoring using shock-pulse transducers at gear units, type H2.V: The following diagram shows a bearing monitoring system using shock-pulse transducers at gear units, type B3.V: Assembly and operating instructions 5091en Edition 06/2020... -
Page 59: Bearing Monitoring By Acceleration Sensor
Description 3.14 Bearing monitoring ① Shock-pulse transducer Figure 3-34 Bearing monitoring using shock-pulse transducers at gear units, type B3.V: Further information Further information, a detailed illustration of the gear unit and the position of the mounted components can be found in the dimension drawing in the complete documentation for the gear unit. -
Page 60: Figure 3-35 Fully Assembled Acceleration Sensor (A), And Threaded Connector (B) For Variants 1 To 4
Description 3.14 Bearing monitoring ① ④ Shielded cable (oil-proof) Sensitivity specification ② ⑤ MIL-spec connector Set screw ③ Acceleration sensor Figure 3-35 Fully assembled acceleration sensor (A), and threaded connector (B) for variants 1 to 4 The following diagram shows the fully assembled acceleration sensor (C), and the threaded connector (D) for variants 5A and 5B: Figure 3-36 Fully assembled acceleration sensor (C), and the threaded connector (D) for variants 5A and... -
Page 61: Speed Encoder
Description 3.15 Speed encoder Further information Further information and a detailed illustration of the gear unit with attached sensors can be found in the dimension drawing in the complete documentation for the gear unit. Further information about the sensors can be found in the operating instructions for the sensors. 3.15 Speed encoder Depending on the order specification, an incremental speed encoder can be fitted. - Page 62 Description 3.15 Speed encoder Assembly and operating instructions 5091en Edition 06/2020...
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Page 63: Application Planning
Application planning Scope of delivery The scope of delivery is listed in the shipping documents. Immediately upon receiving the gearbox, check that everything has been delivered. Report any damaged and/or missing parts to Customer Services (Page 141) immediately. WARNING Serious injury through defective product Serious injury may occur. - Page 64 Application planning 4.2 Transport WARNING Risk of crushing There is a risk of being crushed by a component that becomes detached because the hoisting gear and load suspension device are not suitable for handling it. When lifting, please observe the load distribution information on the packaging. When the product is in a raised position, transport it slowly and carefully to avoid injury to persons or damage to the gear unit.
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Page 65: Attachment Points
Application planning 4.3 Attachment points • Loads must not be suspended from the tip of a load hook • Always place the products down on a level, non-slip and stable base DANGER Falling load There is a risk of fatal injury from falling loads if these have not been securely attached to the lifting equipment. - Page 66 Application planning 4.3 Attachment points The shear pulling must not exceed 45° when the lifting equipment is attached to sling swivels. Note Damage to the gear unit during transport Using the wrong attachment points can cause damage when transporting large gear units. Always use sling swivels for gear units larger than size 23.
- Page 67 Application planning 4.3 Attachment points Position of attachment points The following diagram shows the position of the attachment points for gear units, type H..V and B..V: Figure 4-3 Position of the attachment points for gear units, type H..V and B..V The following diagram shows the position of the attachment points for gear units, type H..V with motor: Figure 4-4...
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Page 68: Special Aspects Of Gear Unit Lubrication And Preservation
Application planning 4.4 Special aspects of gear unit lubrication and preservation Figure 4-5 Position of the attachment points for gear units, type B..V with motor: Drive units with additional components mounted on the gear unit (such as drive motor, coupling, etc.) may require an extra attachment point owing to the displacement in the centre of gravity caused by the mounted components. - Page 69 The grease type is listed in Table "T 7300" (https://www.flender.com/lubricants). The lubrication points are designated using the following sign:...
- Page 70 Application planning 4.4 Special aspects of gear unit lubrication and preservation Assembly and operating instructions 5091en Edition 06/2020...
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Page 71: Assembly
Assembly General assembly instructions The assembly work must be performed very carefully by authorised, trained and suitably instructed personnel. Liability will be disclaimed for damage caused by the incorrect performance of this work. Requirements Improper use can damage the gear unit. Be sure to take the following precautions: •... - Page 72 Assembly 5.1 General assembly instructions DANGER Danger of explosion due to gear unit heating caused by environmental effects. Danger to life through ignition of a potentially explosive atmosphere possible if gear unit becomes overheated due to environmental effects. The gear unit must not be heated by external heat sources (exposure to direct sunlight, for example) while it is in operation and measures must be taken where necessary to protect it.
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Page 73: Unpacking The Gear Unit
Assembly 5.2 Unpacking the gear unit Unpacking the gear unit Introduction The scope of delivery is listed in the shipping documents. WARNING Severe injury caused by the content of the packing sliding When opening the packing in which the part is transported, there is a risk of being crushed. While being transported, the content of the packing can slide. -
Page 74: Gear Unit Assembly
Assembly 5.3 Gear unit assembly Gear unit assembly 5.3.1 Foundation Properties of the foundation The foundation must have the following properties: • Stability • Designed for torsional rigidity • Reaction forces from the gear unit must be braced Requirements of the foundation The foundation must meet the following requirements: •... -
Page 75: Mounting On A Concrete Foundation
Assembly 5.3 Gear unit assembly 5.3.1.1 Mounting on a concrete foundation Mounting on a concrete foundation using foundation blocks Requirement The lower side of the gear unit mounting feet must be clean. Gear unit with foundation blocks The following diagram shows a foundation block: ①... - Page 76 Assembly 5.3 Gear unit assembly 6. Pour concrete into the recesses in the concrete foundation for the stone bolts or foundation blocks. 7. After the concrete has set, tighten the hexagon nuts of the stone bolts or fastening bolts of the foundation blocks with the specified tightening torque (Page 117).
- Page 77 Assembly 5.3 Gear unit assembly 3. Attach the pressure plate and tighten the nuts. 4. Place a piece of wood under the anchor bolt so that it is approximately 10 mm from the upper edge of the support. 5. Place the gear unit down. NOTICE Use of incorrect attachment points Use of incorrect attachment points may result in damage to the gear unit.
- Page 78 Assembly 5.3 Gear unit assembly 4. Align the gear unit with the supports (Page 79). – Observe the values on the alignment strips. – Maintain the alignment tolerances to the units connected at the input and output according to the permissible angular and axial displacements of the couplings. 5.
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Page 79: Mounting
Assembly 5.3 Gear unit assembly 5.3.2 Mounting 5.3.2.1 Mounting on a housing foot Description of assembly work Measures to be taken prior to assembly CAUTION Risk of chemical burns due to chemical substances There is a risk of chemical burns when handling aggressive cleaning agents. Please observe the manufacturer's guidelines on how to handle cleaning agents and solvents. - Page 80 Assembly 5.3 Gear unit assembly NOTICE Damage as a result of blows or impact Damage in the gear unit as a result of blows or impact as possible. Pull on the coupling using the appropriate pulling equipment. Avoid damaging the shaft sealing rings and the shaft running surfaces when fitting coupling parts.
- Page 81 Assembly 5.3 Gear unit assembly Alignment Depending on the order specification, the top of the housing has machined surfaces (alignment surfaces) to assist with provisional alignment of the gear unit in the horizontal direction. DANGER Risk of fatal injury from flying fragments Failure to align the unit with the required degree of accuracy can cause the shaft to rupture.
- Page 82 Assembly 5.3 Gear unit assembly The following diagram shows the alignment surfaces at the gear unit: ① Alignment surfaces Figure 5-5 Alignment surfaces at the gear unit Further information Further information and the precise position of the alignment thread are provided in the dimension drawing in the overall gear unit documentation.
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Page 83: Mounting On A Mounting Flange Or Block Flange
Assembly 5.3 Gear unit assembly 5.3.2.2 Mounting on a mounting flange or block flange Mating flange on the machine side Measures to be taken prior to assembly Be sure to take the following precautions before mounting the mating flange on the machine side: •... - Page 84 Assembly 5.3 Gear unit assembly Use the appropriate heat shields to protect against radiant heat. NOTICE Risk of damage to shaft sealing rings from aggressive chemical cleaning agents Aggressive chemical cleaning agents may cause damage to shaft sealing rings. Do not allow the cleaning agent to come into contact with the shaft-sealing rings. Measures to be taken prior to assembly Improper use can damage the gear unit.
- Page 85 Assembly 5.3 Gear unit assembly • 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. • The area around the face of the mounting and mating flange must be absolutely free of any grease.
- Page 86 Assembly 5.3 Gear unit assembly ① ② Mounting flange Block flange Figure 5-6 Gear unit with mounting flange or block flange NOTICE The gear unit can be damaged by unevenly tightening the flange bolts. The gear unit can be damaged by unevenly tightening the flange bolts. Tighten the flange bolts crosswise and evenly with the full torque.
- Page 87 Assembly 5.3 Gear unit assembly Procedure DANGER Risk of fatal injury from flying fragments Non-adherence to the alignment accuracy can result in a broken shaft and as a consequence risk to life and injury. Align the gear unit exactly so that it conforms to the specified alignment values. Damage to the gear unit or its components or mounted parts is possible.
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Page 88: Mounting The Torque Arm For The Gear Unit Housing
Damage to the gear unit due to incorrect mounting of the motor and torque arm is possible The motor and torque arm may only be mounted after prior consultation with Flender. Mount the torque arm to the machine side without causing any distortion or deformation. -
Page 89: Mounting The Coupling Flange On The Output Side
Assembly 5.3 Gear unit assembly The following diagram shows the torque arm for the gear unit housing: ① ② Machine side Elastic pedestal Figure 5-8 Torque arm for the gear unit housing Further information Further information about constructing the foundation for gear units with a torque arm can be found in chapter Foundation (Page 74). -
Page 90: Shaft-Mounted Gear Unit With Hollow Shaft And Parallel Keyway
Assembly 5.4 Shaft-mounted gear unit with hollow shaft and parallel keyway NOTICE The gear unit can be damaged by unevenly tightening the tensioning screws. The gear unit can be damaged by unevenly tightening the tensioning screws. Tighten the tensioning screws crosswise and evenly with the full torque. Ensure that the gear unit is not deformed or distorted when tightening the flange bolts. -
Page 91: Assembly
Assembly 5.4 Shaft-mounted gear unit with hollow shaft and parallel keyway ① ③ Hollow shaft Parallel key ② ④ Pressure oil connector Machine shaft Figure 5-9 Preparations for gear units with a hollow shaft and parallel keyway 5.4.2 Assembly 5.4.2.1 Introduction Measures to be taken prior to assembly CAUTION... -
Page 92: Mounting
Assembly 5.4 Shaft-mounted gear unit with hollow shaft and parallel keyway NOTICE Risk of damage to shaft sealing rings from cleaning agent Aggressive chemical cleaning agents may cause damage to shaft sealing rings. Do not allow the cleaning agent to come into contact with the shaft-sealing rings. 5.4.2.2 Mounting Procedure... -
Page 93: Axial Locking
Assembly 5.4 Shaft-mounted gear unit with hollow shaft and parallel keyway The diagram below shows the mounting process with screw spindle for gear units with a hollow shaft and parallel keyway: ① ⑤ Hollow shaft ② ⑥ Screw spindle Parallel key ③... -
Page 94: Dismantling
Assembly 5.4 Shaft-mounted gear unit with hollow shaft and parallel keyway 5.4.3 Dismantling Measures prior to dismantling NOTICE Damage to the gear unit The gear unit can become damaged if it skews during dismantling. Do not allow the gear unit to skew as you remove it from the machine shaft. When removing the gear unit using hydraulic pulling equipment, excessive force can be placed on the housing, bearings and other gear unit components. - Page 95 Assembly 5.4 Shaft-mounted gear unit with hollow shaft and parallel keyway The following diagram shows the dismantling procedure using an end plate for gear units with a hollow shaft and parallel keyway: ① ④ End plate for pressing out Parallel key ②...
- Page 96 Assembly 5.4 Shaft-mounted gear unit with hollow shaft and parallel keyway The following diagram shows the dismantling procedure using hydraulic pulling equipment for gear units with hollow shaft and parallel keyway: ① ⑤ Auxiliary plate for pressing out Parallel key ②...
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Page 97: 5.5 Shaft-Mounted Gear Unit With Hollow Shaft And Spline According To Din 5480
Assembly 5.5 Shaft-mounted gear unit with hollow shaft and spline according to DIN 5480 Improper use can damage the gear unit. Be sure to take the following precautions: • When removing a gear unit that is not only supported at the hollow shaft, but also at the housing, ensure that the specified forcing pressures are not exceeded. -
Page 98: Assembly
Assembly 5.5 Shaft-mounted gear unit with hollow shaft and spline according to DIN 5480 ① ③ Hollow shaft DU bushing ② ④ Pressure oil connector Machine shaft Figure 5-13 Preparation for gear units with hollow shaft and spline 5.5.2 Assembly Measures to be taken prior to assembly CAUTION Risk of injury due to chemical substances... -
Page 99: Pulling On With Integrated Du Bushing
Assembly 5.5 Shaft-mounted gear unit with hollow shaft and spline according to DIN 5480 NOTICE Risk of damage to shaft sealing rings Aggressive chemical cleaning agents may cause damage to shaft sealing rings. Do not allow the cleaning agent to come into contact with the shaft-sealing rings. 5.5.2.1 Pulling on with integrated DU bushing Procedure... -
Page 100: Axial Locking
Assembly 5.5 Shaft-mounted gear unit with hollow shaft and spline according to DIN 5480 The following diagram shows the mounting process with integrated DU bushing for gear units with a hollow shaft and spline: ① ⑤ Hollow shaft DU bushing ②... -
Page 101: Dismantling
Assembly 5.5 Shaft-mounted gear unit with hollow shaft and spline according to DIN 5480 5.5.3 Dismantling Measures prior to dismantling NOTICE Damage to the gear unit The gear unit can become damaged if it skews during dismantling. Do not allow the gear unit to skew as you remove it from the machine shaft. When removing the gear unit using hydraulic pulling equipment, excessive force can be placed on the housing, bearings and other gear unit components. - Page 102 Assembly 5.5 Shaft-mounted gear unit with hollow shaft and spline according to DIN 5480 The following diagram shows the dismantling procedure using an end plate for gear units with a hollow shaft and spline: ① ④ End plate DU bushing ②...
- Page 103 Assembly 5.5 Shaft-mounted gear unit with hollow shaft and spline according to DIN 5480 The following diagram shows the dismantling procedure using hydraulic pulling equipment for gear units with hollow shaft and spline: ① ⑤ Auxiliary plate for pressing out Parallel key ②...
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Page 104: Shaft-Mounted Gear Unit With Hollow Shaft And Shrink Disk
Assembly 5.6 Shaft-mounted gear unit with hollow shaft and shrink disk Shaft-mounted gear unit with hollow shaft and shrink disk Introduction The shaft end of the driven machine shaft (material C60+N or higher strength) should have a hole centred in its end face as defined by DIN 332, form DS (with thread). 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. -
Page 105: Pulling On With Integrated Du Bushing
Assembly 5.6 Shaft-mounted gear unit with hollow shaft and shrink disk Note The bore of the hollow shaft and the machine shaft must be free of any grease Make sure that the hollow shaft bore and the machine shaft are completely free of grease in the area around the shrink disk seat. - Page 106 Assembly 5.6 Shaft-mounted gear unit with hollow shaft and shrink disk Proceed as follows to mount the gear unit with hollow shaft and shrink disk onto the driven machine shaft with integrated DU bushing: 1. Use suitable hoisting gear to lift the gear unit. 2.
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Page 107: Mounting With Du Bushing As A Separate Component
Assembly 5.6 Shaft-mounted gear unit with hollow shaft and shrink disk Parts 2, 3 and 4 are not included in the scope of delivery. 5.6.1.2 Mounting with DU bushing as a separate component Notes about mounting with DU bushing as a separate component Canting must be avoided as the gear unit can be damaged when mounting. -
Page 108: Shaft-Mounted Gear Unit With Flange Coupling
Assembly 5.7 Shaft-mounted gear unit with flange coupling NOTICE Use of incorrect attachment points Use of incorrect attachment points may result in damage to the gear unit. • Only attach the gear unit at the lifting eyes provided for this purpose. •... -
Page 109: Couplings
Assembly 5.8 Couplings Couplings Introduction The coupling parts might become misaligned as a result of: • Failure to accurately align the parts during assembly • During operation of the system: – Due to thermal expansion – Due to shaft deflection –... -
Page 110: Connecting Components
Further information You can find additional information about the permissible alignment errors for Flender couplings in the complete documentation for the gear unit. If couplings from other manufacturers are to be used, then, specifying the radial loads that occur, ask the manufacturer which alignment errors are permissible. -
Page 111: Connecting The Cooling Coil
Assembly 5.9 Connecting components Further information You can find additional information on operation and maintenance in the associated operating instructions, provided in the complete gear unit documentation. You can find the technical data of the mounted components in the contract-list of equipment provided in the complete gear unit documentation. -
Page 112: Connecting The Water-Oil Cooler
Assembly 5.9 Connecting components Further information You can find additional information on the air-oil cooler in the air-oil cooler operating instructions, provided in the complete gear unit documentation. Note Observe the information provided in chapter of the Mounted oil supply system with air-oil cooler (Page 44). -
Page 113: Installing A Separate Oil Supply System
Assembly 5.9 Connecting components 5.9.5 Installing a separate oil supply system Procedure To connect the oil supply system to the gear unit, proceed as follows: 1. Remove the dummy flange from the suction and delivery line before connecting the system. 2. -
Page 114: Connecting The Oil-Level Monitoring System
Assembly 5.9 Connecting components 5.9.8 Connecting the oil-level monitoring system Procedure To connect the oil-level monitoring system to the gear unit, proceed as follows: 1. Ensure that the filling level limit switch connection is not damaged. 2. Electrically connect the filling level limit switch. 3. -
Page 115: Electrical Connections
Assembly 5.10 Tightening procedure Further information You can find additional information on the speed encoder in the speed encoder operating instructions, provided in the complete gear unit documentation. 5.9.11 Electrical connections Procedure DANGER Electric shock Live parts can cause electric shock. Ensure that the entire plant is de-energised before starting electrical installation work. -
Page 116: Bolt Connection Classes
Assembly 5.10 Tightening procedure Note 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 117: Tightening Torques And Preload Forces
Assembly 5.10 Tightening procedure Further information You can find additional information about tightening torques when mounting motor and brake in the operating instructions from the particular manufacturer. 5.10.3 Tightening torques and preload forces The specified bolted connections must be tightened to the torques stated in the table below: The tightening torques apply to friction values of μ... -
Page 118: Final Work
Assembly 5.11 Final work Nominal Bolt Preload force for bolt connection Tightening torque for bolt connec‐ thread di‐ strength classes from the table in tion classes from the table in chap‐ ameter class chapter Bolt connection classes ter Bolt connection classes (Page 116). - Page 119 Assembly 5.11 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 120 Assembly 5.11 Final work Assembly and operating instructions 5091en Edition 06/2020...
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Page 121: Commissioning
Commissioning Measures prior to commissioning Take the following measures before commissioning the gear unit: • Read and observe the operating instructions. • Replace the screw plug with the air filter or the wet-air filter. Read operating instructions BA 7300 for further information. •... -
Page 122: Gear Units With Oil Supply System
Carefully ensure that the pre-lubrication phase is not longer than 5 minutes as the oil can foam up at low temperatures. For oil temperatures below 10 °C, heat up the oil using suitable measures and contact Flender in this regard. Further information You can find additional information on the oil cooling system in the separate data sheet, and in the equipment list in the complete gear unit documentation. -
Page 123: Heating
Commissioning 6.2 Measures during commissioning • Check all the connection lines are securely tightened and leak-free. • For gear units with bearing monitoring by measuring the vibration: Measure the vibration levels of the rolling-contact bearings (Page 130) to create initial and comparison values. •... - Page 124 Commissioning 6.2 Measures during commissioning Assembly and operating instructions 5091en Edition 06/2020...
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Page 125: Operation
Operation Operating data Introduction To ensure correct, trouble-free operation of the system, observe the operating data of the gear unit. The valid operating data can be found in the annex Technical data. The following operating data apply to the oil: Table 7-1 Operating data Maximum operating tempera‐... -
Page 126: 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 135) to find the cause of the fault. 3. If you still cannot determine the fault cause, contact Flender Customer Services. DANGER An explosive atmosphere can be ignited An explosive atmosphere can be ignited if the gear unit overheats as the oil level is too low. -
Page 127: Servicing
Servicing General maintenance information The operator must ensure compliance with the stipulated time limits. This also applies if the maintenance activities are included in the operator’s internal maintenance schedules. The gear unit could be damaged if the stipulated time limits for maintenance and servicing are not observed. -
Page 128: Maintenance Schedule
Servicing 8.2 Maintenance schedule Maintenance schedule Maintenance and servicing activities The following table provides an overview of all maintenance and servicing activities which you are required to perform continuously or at regular intervals. Table 8-1 Maintenance and servicing activities Intervals and time limits Measures As required Replace the wet-air filter... -
Page 129: Maintenance And Servicing Work
Servicing 8.3 Maintenance and servicing work Intervals and time limits Measures Every 2 years Carry out a general inspection of the gear unit Check the cooling coil Check that all of the fastening bolts are tight Clean the fan and gear unit Every 20 000 operating hours, at least every Change the oil if using semi-synthetic oil of API Group III, 4 years... -
Page 130: Checking The Oil Temperature
4. Compare the measured value with the maximum permissible oil temperature (Page 125). 5. Immediately stop the gear unit if the maximum permissible oil temperature is exceeded. Contact Flender Customer Services. 8.3.3 Measuring the vibration levels of the rolling-contact bearings... -
Page 131: Replenish Grease In The Oil Retaining Pipe
Replenish grease in the oil retaining pipe Introduction Only use grease that has been approved by Flender as specified in BA 7300. The precise designation of the grease nipple is provided in the complete documentation. The following diagram shows the lubrication points: ①... -
Page 132: Checking The Ignition Protection System
Servicing 8.3 Maintenance and servicing work CAUTION Risk of slipping as a result of grease that has escaped There is a danger of slipping if the grease escapes from the oil retaining pipe. Immediately remove any grease that has escaped from the oil retaining pipe and dispose of it correctly. -
Page 133: Checking The Cooling Coil
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 134: Inspecting The Shrink Disk
8.3 Maintenance and servicing work 5. If the cooling coil is severely soiled, it must be replaced by a new one. Please consult Flender Customer Services for further advice. 6. Reconnect the cooling water inlet and drain lines to the cooling coil. -
Page 135: 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 136: Table 8-2 Possible Faults And Their Rectification
Servicing 8.4 Possible faults Possible faults and their rectification The following table provides you with an overview of possible faults and indicates how they can be rectified. Table 8-2 Possible faults and their rectification Possible faults Causes Possible remedies Pressure monitor trig‐ Oil pressure <... - Page 137 Servicing 8.4 Possible faults Possible faults Causes Possible remedies Auxiliary drive motor Overload at the output • Reduce the load at the output does not start Defective auxiliary drive motor • Repair or replace motor Motor brake not released • Correct the electrical connection of the motor brake •...
- Page 138 Servicing 8.4 Possible faults Possible faults Causes Possible remedies Oil cooling system fault - • Carefully observe the information in the oil cooling system instructions Elevated temperature Oil level in the gear unit housing too • Check the oil level during operation high •...
- Page 139 Servicing 8.4 Possible faults Possible faults Causes Possible remedies Elevated vibration am‐ Defective rolling-contact bearings • Contact Customer Services plitude at bearing • Inspect the rolling-contact bearings and replace if neces‐ points sary Gear wheels defective • Contact Customer Services •...
- Page 140 Servicing 8.4 Possible faults Assembly and operating instructions 5091en Edition 06/2020...
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Page 141: Service & Support
Am Industriepark 2 46562 Voerde 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) Assembly and operating instructions 5091en Edition 06/2020... - Page 142 Service & Support Assembly and operating instructions 5091en Edition 06/2020...
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Page 143: 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 144 Disposal Assembly and operating instructions 5091en Edition 06/2020...
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Page 145: Spare Parts
Note 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 146 Spare parts Assembly and operating instructions 5091en Edition 06/2020...
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Page 147: Declaration Of Incorporation
Declaration of incorporation Assembly and operating instructions 5091en Edition 06/2020... - Page 148 Declaration of incorporation Assembly and operating instructions 5091en Edition 06/2020...
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Page 149: Declaration Of Conformity
Declaration of conformity Assembly and operating instructions 5091en Edition 06/2020... - Page 150 Declaration of conformity Assembly and operating instructions 5091en Edition 06/2020...
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Page 151: Technical Data
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. Assembly and operating instructions 5091en Edition 06/2020... - Page 152 Technical data C.1 General technical data 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. Further information about all major accessories including their technical data can be found in the order-specific list of equipment in the complete documentation for the gear unit.
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Page 153: Table C-1 Atex Marking
Technical data C.1 General technical data ATEX marking The ATEX marking for open-cast mining applications is shown in the following table: Table C-1 ATEX marking Equi Equip Explosive Explo‐ Tem‐ Maximum Marking example ment atmos‐ sion pera‐ surface tem‐ cate‐ phere group/ ture... -
Page 154: Ambient Temperature
-20 °C up to 40 °C. 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. In each individual case, the ambient temperature range stamped on the rating plate always applies. -
Page 155: Weights
The sound pressure level applies to a gear unit in the warm condition at an input speed n output power P according to the rating plate, for measurements carried out on a Flender test bench. If several values are given, then the highest speed and power values apply. -
Page 156: Table
Technical data C.5 Enveloping surface sound pressure level Refer to the following table for the enveloping surface sound pressure level L in dB(A) for bevel helical gear units without fan. Table C-3 Enveloping surface sound pressure level Type in rpm Gear unit size 20 - 31.5 1000... -
Page 157: Enveloping Surface Sound Pressure Level
Technical data C.5 Enveloping surface sound pressure level Refer to the following table for the enveloping surface sound pressure level L in dB(A) for helical gear units without fan. Table C-5 Enveloping surface sound pressure level Type in rpm Gear unit size 6.3 - 10 11.2 - 16 1000... - Page 158 Technical data C.5 Enveloping surface sound pressure level Assembly and operating instructions 5091en Edition 06/2020...
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Page 159: Index
Index Aerator gear unit, 29 Environmental protection, 143 Agitator gear unit, 24 Equipment features, 25 Air-oil cooler, 45, 46 Eye bolts, 66 Principle of operation, 44 Alignment Alignment surface, 81 Prealignment, 81 ATEX Directive, 11 Air guide cover, 42 Attachment points, 71 Principle of operation, 42 Fastening bolts Bolt connection class, 116... - Page 160 Index Operating data, 125 Oil, 125 Ordering spare parts, 141, 145 Output shaft versions, 24 Interval, 128 Irregularities in operation, 125 Pressure lubrication, 33 Pressure monitor, 49 Lateral pulling, 66 Pressure monitoring, 49 Lubricant, 12 Protective equipment, 18 Lubrication point, 26 Pump, 49 Maintenance activities, 128 Rating plate, 151...
- Page 161 Index Technical data, 151 Temperature control valve, 46 Transport information, 63 Transport symbols, 65 Troubleshooting, 135 Types of danger, 18 Unpacking, 73 Used oil, 143 Using the gear unit, 21 Venting screw Cleaning, 129 Warning symbols, 17 Water-oil cooler, 47, 48 Assembly and operating instructions 5091en Edition 06/2020...
- Page 162 Index Assembly and operating instructions 5091en Edition 06/2020...
- Page 164 FLENDER GEAR UNITS Gear unit Assembly and operating instructions 5091en Edition 06/2020 Flender GmbH Alfred-Flender-Straße 77 46395 Bocholt GERMANY...
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