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FLENDER H1SHN Assembly And Operating Instructions Manual

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FLENDER ONE
Assembly and operating instructions B7400-01en
Version 10/2024
H1SHN
26 ... 541

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Summary of Contents for FLENDER H1SHN

  • Page 1 FLENDER ONE Assembly and operating instructions B7400-01en Version 10/2024 H1SHN 26 ... 541...
  • Page 2 Original assembly and operating instructions B7400-01 144115192947304203 Version 10/2024 29/01/2025 Copyright (©2025 Flender GmbH) 16:25:00...

  • Page 3: Table Of Contents

    Table of contents Introduction .............................. 15 About these instructions......................15 1.1.1 General ............................ 15 1.1.2 Safety-relevant information ...................... 16 Technical documentation ......................17 Liability disclaimer........................17 Copyright..........................17 Trademarks..........................17 Lubricants ..........................18 Safety ................................ 19 General ............................ 19 Qualified personnel ........................19 Intended use ..........................
  • Page 4 Table of contents Gear unit components......................32 Housing............................ 33 Oil supply of the gear unit ......................33 3.6.1 Splash lubrication........................33 3.6.2 Pressure lubrication ......................... 34 3.6.2.1 Introduction ..........................34 3.6.2.2 Attached oil supply system ...................... 34 3.6.2.2.1 Pump............................36 3.6.2.2.2 Oil filter.............................
  • Page 5 Table of contents 3.15.5 Bearing monitoring by acceleration sensor................61 3.16 Terminal box und wiring......................62 Application planning..........................63 Scope of delivery ........................63 Transport..........................63 Attachment points ........................64 4.3.1 Lifting eyes..........................64 4.3.2 Position of the attachment points..................... 65 Special aspects of gear unit lubrication and preservation ............
  • Page 6 Table of contents 5.6.3 Gear units with mounted components ..................81 5.6.4 Making terminal box connections for pre-wired gear units............81 5.6.5 Guards at the shaft end ......................81 5.6.6 Connecting the cooling coil ...................... 81 5.6.7 Connecting the air‐oil cooler ....................82 5.6.8 Connecting the water-oil cooler ....................
  • Page 7 Table of contents 8.3.5 Cleaning the coarse filter ....................... 105 8.3.6 Cleaning the double change-over filter .................. 105 8.3.7 Cleaning the single filter......................105 8.3.8 Measuring the vibration levels of the rolling-contact bearings ..........106 8.3.9 Measuring the temperature at the rolling-contact bearings............ 106 8.3.10 Check that the fastening bolts are tight..................
  • Page 8 Table of contents Version 10/2024 B7400-01en...
  • Page 9 Figures Figure 3-1 Version of the low-speed shaft (LSS)..................30 Figure 3-2 High-speed shaft (HSS) version....................31 Figure 3-3 Gear unit components up to gear unit size 312 .................32 Figure 3-4 Gear unit components of the gear unit size 408 ................32 Figure 3-5 Attached oil supply system for gear unit sizes up to 179 ............34 Figure 3-6 Attached oil supply system for gear unit sizes 234 to 312 ............35 Figure 3-7...
  • Page 10 Figures Figure 3-27 Position of the heating elements up to gear unit size 312............51 Figure 3-28 Position of the heating elements for gear unit sizes 408 and 541..........51 Figure 3-29 Oil-level monitoring system up to gear unit size 312..............53 Figure 3-30 Oil-level monitoring system for gear unit sizes 408 and 541............54 Figure 3-31 Position of the oil-temperature monitoring system up to gear unit size 312.......55 Figure 3-32...
  • Page 11 Figures Figure B-2 Plate: Lubrication point......................123 B7400-01en Version 10/2024...
  • Page 12 Figures Version 10/2024 B7400-01en...
  • Page 13 Tables Table 2-1 Overview: Qualified personnel ....................19 Table 2-2 Personal protective equipment....................21 Table 2-3 General warnings ........................22 Table 2-4 Symbols and markings .......................23 Table 3-1 Versions and associated directions of rotation................29 Table 3-2 Taconite seal versions........................39 Table 4-1 Number of shackles for transport ....................64 Table 5-1 Information on screwing fastening screws/bolts.................86 Table 5-2 Preload forces and tightening torques ..................87 Table 7-1...
  • Page 14 Tables Version 10/2024 B7400-01en...

  • Page 15: Introduction

    Introduction About these instructions 1.1 About these instructions 1.1.1 General 1.1 About these instructions Please take note of this information to achieve the best results when working with the in- structions. This product, which can be used as a reduction gear unit and/or multiplier gear unit, is re- ferred to below as “gear unit”.

  • Page 16: Safety-Relevant Information

    Introduction 1.1 About these instructions Information Information Information Information provides additional assistance and tips for handling the product. 1.1.2 Safety-relevant information 1.1 About these instructions These instructions contain information you must observe for your own personal safety as well as to avoid property damage. Safety information Specifications for handling the product safely and the associated safety information are de- scribed in the “Safety information”...

  • Page 17: Technical Documentation

    Copyright 1.4 Copyright The copyright of these instructions is held by Flender GmbH. Without the express authorisa- tion of Flender, this document may not be used wholly or in parts for competitors’ purposes or be given to third parties. Trademarks 1.5 Trademarks...

  • Page 18: 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. Version 10/2024...

  • Page 19: Safety

    Safety General 2.1 General The following general safety information is intended to prevent injury and property damage and applies primarily to the use of the described gear unit. Read the additional user informa- tion in the complete documentation carefully. Qualified personnel 2.2 Qualified personnel The gear unit may only be used by qualified personnel trained to perform the relevant task.

  • Page 20: Intended Use

    • Observe the servicing and maintenance intervals. • Shut down the gear unit if there are any deviations to normal operation. • Only use original Flender spare parts. • Protect the gear unit from direct sunlight. • Protect the gear unit from other sources of heat.

  • Page 21: Responsibility Of The Operator

    Safety 2.5 Responsibility of the operator • Take surface temperature into account in the machine’s safety plan. • Perform potential equalisation in accordance with the applicable regulations and direct- ives. • Ensure that no current from electrical mounted component (motor, generator, etc.) can flow through the gear unit.

  • Page 22: Product Labelling

    Safety 2.7 Product labelling Symbol Personal protective equipment Protective gloves are gloves that protect the hands from injury from external mechan- ical, thermal or chemical hazards. Hearing protection minimises the effects of noise on hearing, so that noise-induced hearing impairment does not occur or worsen. Table 2-2 : Personal protective equipment Product labelling 2.7 Product labelling...
  • Page 23 Safety 2.7 Product labelling Symbol Colour Meaning marking Earth connection point yellow Air release point yellow Oil filling point white Oil draining point Oil level indicator Oil level measurement Oil overflow Connection point for vibration monitoring Lubrication point Apply grease Lifting eye Eye bolt Do not unscrew...

  • Page 24: Signs

    Safety 2.7 Product labelling Symbol Colour Meaning marking green Transport attachment point white Stipulated direction of rotation Oil filling point Fill required minimum amount of oil prior to commis- sioning green Covered foot fastening bolt green Covered attachment point Table 2-4 : Symbols and markings 2.7.3 Signs 2.7 Product labelling...

  • Page 25: Information On Operation

    Safety 2.8 Safety information Attachments and components Crushing or injury through heavy lifting can result if attachments or components are not lifted properly. • Lift heavy attachment and components with suitable hoisting gear. 2.8.2 Information on operation 2.8 Safety information Emission sound pressure level During operation, emission sound pressure level may exceed 80 dB (A).

  • Page 26: Handling Hydraulic Systems

    Safety 2.8 Safety information Hot oil During an oil change, hot oil can lead to serious injuries. • Allow the machine to cool down sufficiently before working on it. • Wear protective gloves, eye protection and protective clothing. Live parts There is a danger of life-threatening injuries as a result of electric shock when working on live parts.

  • Page 27: Handling Chemical Substances

    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 corresponds to the current state of the art. Flender Products and solutions undergo continu- ous development in this respect.
  • Page 28 Safety 2.9 Industrial Security Version 10/2024 B7400-01en...

  • Page 29: Description

    (HSS) and low-speed shaft (LSS). Version Model H1SHN Table 3-1 : Versions and associated directions of rotation Execution of the low-speed shaft (LSS) 3.2 Execution of the low-speed shaft (LSS) The low-speed shaft (LSS) is designed with a connection for the coupling connection.

  • Page 30: Figure 3-1 Version Of The Low-Speed Shaft (Lss)

    Description 3.3 High-speed shaft (HSS) version The following diagram shows the version of the low-speed shaft (LSS): Figure 3-1: Version of the low-speed shaft (LSS) Low-speed shaft (LSS) Further information Additional information and a detailed illustration of the gear unit can be found in the dimen- sion drawing provided in the complete gear unit documentation.

  • Page 31: Figure 3-2 High-Speed Shaft (Hss) Version

    Description 3.3 High-speed shaft (HSS) version The following diagram shows the high-speed shaft (HSS) version: Figure 3-2: High-speed shaft (HSS) version High-speed shaft (HSS) Further information Additional information and a detailed illustration of the gear unit can be found in the dimen- sion drawing provided in the complete gear unit documentation.

  • Page 32: Gear Unit Components

    3.4 Gear unit components Gear unit components 3.4 Gear unit components The diagram below shows the available gear unit components of the H1SHN type gear unit up to gear unit size 312: Figure 3-3: Gear unit components up to gear unit size 312...

  • Page 33: Housing

    Description 3.5 Housing Further information You can find additional information about the position of the mounted components and a de- tailed illustration of the gear unit in the dimension drawing in the complete documentation for the gear unit. Housing 3.5 Housing Gear units up to and including size 312 have a one-part housing.

  • Page 34: Pressure Lubrication

    • Oil filter • Pressure monitoring • Pipes The diagram below shows an H1SHN gear unit for gear unit sizes up to 179 with an attached oil supply system: Figure 3-5: Attached oil supply system for gear unit sizes up to 179...

  • Page 35: Figure 3-6 Attached Oil Supply System For Gear Unit Sizes 234 To 312

    Description 3.6 Oil supply of the gear unit The diagram below shows an H1SHN gear unit for gear unit sizes 234 to 312 with an at- tached oil supply system: Figure 3-6: Attached oil supply system for gear unit sizes 234 to 312...

  • Page 36: Pump

    Description 3.6 Oil supply of the gear unit 3.6.2.2.1 Pump 3.6 Oil supply of the gear unit Depending on the order, the pump can be designed as a flange pump or motor pump. Requirements placed on the medium being pumped The pump being used is suitable for pumping lubricating oil.

  • Page 37: Labyrinth Seals

    Description 3.8 Shaft seal 3.8.2 Labyrinth seals 3.8 Shaft seal Labyrinth seals as non-contact seals prevent shaft wear. They do not require any mainten- ance and improve the temperature behaviour of the gear unit. The spare parts drawing and list specify whether or not the gear unit is equipped with labyrinth seals.

  • Page 38: Figure 3-10 Taconite Seal

    Description 3.8 Shaft seal A Taconite seal is illustrated in the figure below: Figure 3-10: Taconite seal Grease nipple Ring carrier with lamellar seal Rotary shaft sealing ring Labyrinth, filled with grease, can be re- greased The following figure shows the gap dimension at the grease labyrinth: Figure 3-11: Gap dimension at grease labyrinth Version 10/2024 B7400-01en...

  • Page 39: Tacolab Seal

    Description 3.8 Shaft seal A distinction is made between the following design variants of Taconite seals: Figure 3-12: Taconite‐seal, versions E, F The various Taconite seals are described in the following table: Taconite seal ver- Application Remarks sions “E” All high-speed shafts (HSS) with or •...

  • Page 40: Figure 3-13 Tacolab Seal

    Description 3.8 Shaft seal A Tacolab seal is illustrated in the diagram below: Figure 3-13: Tacolab seal Outer labyrinth seal Inner labyrinth seal Grease nipple Ring carrier with lamellar seal Labyrinth, filled with grease, can be re- greased The following figure shows the gap dimension at the grease labyrinth: Figure 3-14: Gap dimension at grease labyrinth To ensure reliable operation of Tacolab seals, the gear unit must be permanently installed in a horizontal position and not exposed to spray or wastewater.

  • Page 41: Cooling

    The fan dissipates a certain amount of heat from the housing. The following diagram shows a fan on an H1SHN gear unit for gear unit sizes up to 312: Figure 3-15: Fan up to gear unit size 312...

  • Page 42: Motor Fan

    Description 3.9 Cooling The following diagram shows a fan on an H1SHN gear unit for gear unit sizes 408 and 541: Figure 3-16: Fans for gear unit sizes 408 and 541 Air guide cover Further information You can find further information and a detailed illustration of the gear unit and the position of the mounted components in the dimension drawings provided in the complete documenta- tion for the gear unit.

  • Page 43: Cooling Coil

    Description 3.9 Cooling The following diagram shows a motor fan on an H1SHN gear unit for gear unit sizes 408 and 541: Figure 3-18: Motor fan for gear unit sizes 408 and 541 Motor fan Air guide cover Further information You can find additional information about the position of the mounted components and a de- tailed illustration of the gear unit in the dimension drawing in the complete documentation for the gear unit.

  • Page 44: Figure 3-19 Cooling Coil Connections Up To Gear Unit Size 312

    Description 3.9 Cooling The diagram below shows the cooling coil connections on an H1SHN gear unit for gear unit sizes up to 312: Figure 3-19: Cooling coil connections up to gear unit size 312 Low-speed shaft (LSS) Reducer screw Locknut Cooling water connection...

  • Page 45: Mounted Oil Supply System With Air-Oil Cooler

    Description 3.9 Cooling The diagram below shows the cooling coil connections on an H1SHN gear unit for gear unit sizes 408 and 541: Figure 3-20: Cooling coil connections for gear unit sizes 408 and 541 Low-speed shaft (LSS) Reducer screw Locknut Cooling water connection...

  • Page 46: Figure 3-21 Attached Oil Supply System With Air-Oil Cooler For Gear Unit Sizes Up To 234

    • Pipes • Temperature control valve The diagram below shows an attached oil supply system with air-oil cooler on an H1SHN gear unit for gear unit sizes up to 234: Figure 3-21: Attached oil supply system with air-oil cooler for gear unit sizes up to 234...

  • Page 47: Pump

    Description 3.9 Cooling The diagram below shows an attached oil supply system with air-oil cooler on an H1SHN gear unit for gear unit sizes 408 and 541: Figure 3-23: Attached oil supply system with air-oil cooler for gear unit sizes 408 and 541...

  • Page 48: Mounted Oil Supply System With Water-Oil Cooler

    • Pressure monitoring • Pipes The diagram below shows an attached oil supply system with water-oil cooler on an H1SHN gear unit for gear unit sizes up to 179: Figure 3-24: Attached oil supply system with water-oil cooler connections for gear unit sizes up to 179...

  • Page 49: Figure 3-25 Attached Oil Supply System With Water-Oil Cooler Connections For Gear Unit Sizes 234 To

    Description 3.9 Cooling The diagram below shows an attached oil supply system with water-oil cooler on an H1SHN gear unit for gear unit sizes 234 to 312: Figure 3-25: Attached oil supply system with water-oil cooler connections for gear unit sizes 234 to...

  • Page 50: Pump

    Description 3.9 Cooling You can find additional information about the oil supply system, control instructions, the re- quired cooling water flow rate and the maximum permissible water intake temperature in the separate data sheet, in the list of equipment and in the instructions for the components in the complete gear unit documentation.

  • Page 51: Figure 3-27 Position Of The Heating Elements Up To Gear Unit Size 312

    Heating elements convert electricity into heat and transfer this to the oil in which they are im- mersed. The diagram below shows the position of the heating elements on an H1SHN gear unit for gear unit sizes up to 312: Figure 3-27: Position of the heating elements up to gear unit size 312...

  • Page 52: Couplings

    Description 3.11 Couplings Heating element control The heating elements can be controlled by a temperature monitor or an oil-temperature mon- itoring system (Page 54). The temperature monitor provides a signal which must be ampli- fied when the minimum and maximum temperatures are reached. Further information You can find further information about the position of the mounted components and a de- tailed illustration of the gear unit in the dimension drawing in the complete documentation for...

  • Page 53: Oil Level Monitoring System

    1. When using an oil level indication system, observe the mounting position specified in the dimension drawing. The diagram below shows the oil-level monitoring system on an H1SHN gear unit for gear unit sizes up to 312: Figure 3-29: Oil-level monitoring system up to gear unit size 312...

  • Page 54: Oil Temperature Monitoring

    Description 3.14 Oil temperature monitoring The diagram below shows the oil-level monitoring system on an H1SHN gear unit for gear unit sizes 408 and 541: Figure 3-30: Oil-level monitoring system for gear unit sizes 408 and 541 Low-speed shaft (LSS) Filling level limit switch...

  • Page 55: Figure 3-31 Position Of The Oil-Temperature Monitoring System Up To Gear Unit Size 312

    Low-speed shaft (LSS) Resistance thermometer The diagram below shows the position of the oil level monitoring system on an H1SHN gear unit for gear unit sizes 408 and 541: Figure 3-32: Position of the oil-temperature monitoring system for gear unit sizes 408 and 541...

  • Page 56: Bearing Monitoring

    Description 3.15 Bearing monitoring 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. Further information about the oil-temperature monitoring system, such as control instructions and the technical specifications, is provided in the instructions of the oil-temperature monitor- ing system and in the list of equipment in the complete documentation for the gear unit.

  • Page 57: Figure 3-33 Bearing Monitoring Using A Pt 100 Resistance Thermometer Up To Gear Unit Size 312

    The diagram below shows the position of the bearing monitoring system using the Pt 100 resistance thermometer on an H1SHN gear unit for gear unit sizes up to 312: Figure 3-33: Bearing monitoring using a Pt 100 resistance thermometer up to gear unit size 312...

  • Page 58: Figure 3-35 Bearing Monitoring Using The Compact Pt 100 Resistance Thermometer For Gear Unit Sizes

    The diagram below shows the position of the bearing monitoring system using the compact Pt 100 resistance thermometer on a model H1SHN gear unit for gear unit sizes 408 and 541: Figure 3-36: Bearing monitoring using a compact Pt 100 resistance thermometer for gear unit sizes...

  • Page 59: Bearing Monitoring Using Vibration Sensors

    These measuring nipples are used to attach vibration sensors through a quick-release coup- ling. The diagram below shows the bearing monitoring system using vibration sensors on an H1SHN gear unit for gear unit sizes up to 312: Figure 3-37: Bearing monitoring using vibration sensors up to gear unit size 312 Low-speed shaft (LSS)

  • Page 60: Bearing Monitoring Using A Shock-Pulse Transducer

    These measuring nipples are used to attach shock-pulse transducers with a quick-release coupling. The diagram below shows the bearing monitoring system using shock-pulse transducers on an H1SHN gear unit for gear unit sizes up to 312: Figure 3-39: Bearing monitoring using shock-pulse transducers up to gear unit size 312 Low-speed shaft (LSS)

  • Page 61: Bearing Monitoring By Acceleration Sensor

    3.15 Bearing monitoring The diagram below shows the bearing monitoring system using shock-pulse transducers on an H1SHN gear unit for gear unit sizes 408 and 541: Figure 3-40: Bearing monitoring system using shock-pulse transducers for gear unit sizes 408 and 541 Low-speed shaft (LSS)

  • Page 62: Terminal Box Und Wiring

    Description 3.16 Terminal box und wiring 3.16 Terminal box und wiring 3.16 Terminal box und wiring Depending on the order specification, the gear unit can be equipped with one or more ter- minal boxes and corresponding wiring. More information You will find additional information on the terminal boxes and the corresponding wiring in the complete documentation for the gear unit.

  • Page 63: 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 gear unit, check that everything has been delivered. Report any damaged and/or missing parts to Customer Service (Page 113) immediately. Transport 4.2 Transport WARNING...

  • Page 64: Attaching The Load

    Application planning 4.3 Attachment points • Gear units with labyrinth seals are not suitable for transport filled with oil. • Do not use incorrect attachment points. Do not use the threads in the face sides of the shaft ends to attach any lifting equipment. •...

  • Page 65: Position Of The Attachment Points

    Position of the attachment points 4.3 Attachment points The diagram below shows the position of the attachment points on a model H1SHN gear unit for gear unit sizes up to 312: Figure 4-2: Position of the attachment points up to gear unit size 312...

  • Page 66: Special Aspects Of Gear Unit Lubrication And Preservation

    Application planning 4.4 Special aspects of gear unit lubrication and preservation Special aspects of gear unit lubrication and preservation 4.4 Special aspects of gear unit lubrication and preservation 4.4.1 Regreasing rolling-contact bearings 4.4 Special aspects of gear unit lubrication and preservation 4.4.1.1 Grease-lubricated rolling-contact bearing 4.4 Special aspects of gear unit lubrication and preservation...

  • Page 67: Assembly

    Assembly General assembly instructions 5.1 General assembly instructions Assembly work must be performed very carefully by authorised, trained and suitably instruc- ted 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 68: Unpacking The Gear Unit

    Assembly 5.3 Unpacking the gear unit Use a sunshield in such a way that sufficient air circulation is possible. 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 switching the drive off when the maximum permissible oil sump temperature is exceeded.

  • Page 69: Description Of Assembly Work

    Assembly 5.4 Gear unit assembly The foundation must meet the following requirements: • Construct the foundation in such a way that it does not produce any resonance vibra- tions and that it is isolated against the transmission of vibrations from adjacent founda- tions.

  • Page 70: Gap Dimension At Grease Labyrinth

    Assembly 5.4 Gear unit assembly • The elements must be quickly pulled as far onto the shaft as specified in the order-spe- cific dimension drawing. • Use suitable hoisting gear to place the gear unit in position. Further information Further information about removing the corrosion protection can be found in the Instructions 7300 in the complete documentation for the gear unit.

  • Page 71: Gear Unit Alignment

    To make it even simpler to align, gear units of these sizes have alignment threads in the housing feet. The diagram below shows the alignment surfaces on an H1SHN gear unit for gear unit sizes 408 and 541: Figure 5-3: Alignment surfaces for gear unit sizes 408 and 541...

  • Page 72: Gear Unit Assembly On Housing Foot

    Assembly 5.4 Gear unit assembly Tools Final fine alignment relative to equipment connected at the input and output is performed along the shaft axes using the following tools: • Rulers • Spirit level • Dial gauge • Laser alignment system •...

  • Page 73: Assembly On A Concrete Foundation Using Stone Bolts Or Foundation Blocks

    Assembly 5.4 Gear unit assembly Procedure WARNING Risk of crushing due to falling load Falling load can cause serious physical injury or death. • Transport may only be carried out by qualified personnel. • Make sure that there are no persons under suspended loads. •...

  • Page 74: Mounting Gear Units Using Foundation Blocks

    Assembly 5.4 Gear unit assembly 1. Clean the contact surfaces between the gear unit and the installation location. 2. Attach the stone bolts with washers and hexagon nuts in the foundation mounting points in the gear unit housing. 3. Using suitable hoisting gear, set the gear unit down on the concrete foundation. 4.

  • Page 75: Mounting On A Concrete Foundation Using Anchor Bolts

    Assembly 5.4 Gear unit assembly 6. For higher external forces, if necessary, use stops to prevent displacement. 7. Before casting the foundation, close the openings in the foundation blocks using a suit- able material (e.g. using polystyrene). 8. Pour concrete into the recesses in the concrete foundation for the foundation blocks. 9.

  • Page 76: Mounting The Gear Unit Using Anchor Bolts

    Assembly 5.4 Gear unit assembly 5.4.3.4.2 Mounting the gear unit using anchor bolts 5.4 Gear unit assembly The following diagram shows a tightened anchor bolt: Figure 5-7: Tightened anchor bolt Hexagon nut Washer Housing foot Fine-grout concrete Raw foundation Anchor bolt Baseplate Support CAUTION Risk of injury caused by incorrect use of pre-tensioning device...

  • Page 77: Coupling And Other Input And Output Elements

    Assembly 5.5 Coupling and other input and output elements 8. Record the alignment dimensions. Archive the report together with these instructions. 9. Keep the anchor bolts in their position by tightening the nuts by hand. 10.Fit the protective sleeve. 11.Attach the hydraulic clamping device. 12.Tighten the screws alternating, taking into account the preload forces.

  • Page 78: Aligning The Coupling And Other Input And Output Elements

    Assembly 5.5 Coupling and other input and output elements Further information Further information on joining temperatures, the connection dimensions and the position of the coupling or other input and output elements can be found on the dimension drawing in the complete documentation for the gear unit. 5.5.2 Aligning the coupling and other input and output elements 5.5 Coupling and other input and output elements...

  • Page 79: Connecting Components

    Feeler gauge Measuring points Further information Further information about misalignment tolerances for couplings supplied by Flender can be found in the relevant instructions for the couplings in the complete documentation for the gear unit. If couplings from other manufacturers are to be used, then ask the manufacturer which align- ment errors are permissible, making sure that you specify the radial loads that occur.

  • Page 80: Connecting The Monitoring Devices

    Assembly 5.6 Connecting components Procedure WARNING Electric shock due to live parts Death or serious injury • Carefully observe the five safety rules in the safety information chapter. • Ensure that the entire system is disconnected from the power supply before starting electrical installation work.

  • Page 81: Gear Units With Mounted Components

    Assembly 5.6 Connecting components 5.6.3 Gear units with mounted components 5.6 Connecting components Depending on the order specification, the gear unit can be equipped with various compon- ents. 1. Connect the electrical components for closed-loop control and open-loop control accord- ing to the specifications of the component supplier.

  • Page 82: Connecting The Air-Oil Cooler

    Assembly 5.6 Connecting components 1. Before connecting the cooling coil, remove the sealing plugs from the connection sleeves. 2. Flush through the cooling coil to remove any dirt or contaminants. 3. Connect the cooling water inlet and drain lines. Refer to the dimension drawing for the position of the connections.

  • Page 83: Connecting The Water-Oil Cooler

    Assembly 5.6 Connecting components Further information You can find further information about the air-oil cooler in the instructions for the air-oil cooler, which are part of the complete documentation for the gear unit. 5.6.8 Connecting the water-oil cooler 5.6 Connecting components Requirements •...

  • Page 84: Connecting The Separate Oil Supply System

    Assembly 5.6 Connecting components 1. Check that the heating element connection is not damaged. 2. Connect the oil-temperature monitoring system in the oil sump. 3. Connect the electric wiring of the heating elements. Further information You can find additional information about the heating in the heating instructions in the com- plete documentation for the gear unit.

  • Page 85: Tightening Procedure

    Assembly 5.7 Tightening procedure Tightening procedure 5.7 Tightening procedure 5.7.1 Properties of the bolts and mating threads 5.7 Tightening procedure Bolts Information Replacing bolts Replace any bolts that are no longer fit for use by bolts of the same type and strength class. The bolts must have the following properties: •...

  • Page 86: Bolt Connection Classes

    Assembly 5.7 Tightening procedure 5.7.2 Bolt connection classes 5.7 Tightening procedure For screwing fastening screws/bolts, note the information in the following table: Fastening of Screw/bolt con- Range of the Tightening procedure nection class torque exerted by the tool Gear unit ± 5% to ± 10% •...
  • Page 87 Assembly 5.7 Tightening procedure The following table lists the preload forces and tightening torques for bolt connections, strength classes 8.8; 10.9; 12.9: Nominal Strength Preload force for screw/bolt con- Tightening torque for screw/bolt thread dia- class of nection classes from table in the connection classes from table in meter the screw/...

  • Page 88: Final Work

    Assembly 5.8 Final work Nominal Strength Preload force for screw/bolt con- Tightening torque for screw/bolt thread dia- class of nection classes from table in the connection classes from table in meter the screw/ Chapter Bolt connection classes the Chapter Bolt connection bolt (Page 86) classes (Page 86)
  • Page 89 Assembly 5.8 Final work 8. Establish the appropriate potential equalisation connections. If no threaded holes are available on the gear unit for an earth connection, please take suitable alternative meas- ures. This work must be carried out by specialists in electrical engineering. 9.
  • Page 90 Assembly 5.8 Final work Version 10/2024 B7400-01en...

  • Page 91: Commissioning

    Commissioning Measures prior to commissioning 6.1 Measures prior to commissioning 6.1.1 List of the measures prior to commissioning 6.1 Measures prior to commissioning CAUTION Risk of injury due to chemically aggressive operating materials There is a risk of injury to eyes and hands when handling chemically corrosive consum- ables.

  • Page 92: Measures For Gear Units With Cooling Coil

    Commissioning 6.1 Measures prior to commissioning 1. Connect the signal so that the drive motor cannot start when the “oil level too low” signal is given. 2. Connect the signal so that an alarm is output when the “oil level too low” signal is active. 3.

  • Page 93: Measures For Gear Units With Oil Supply System

    Commissioning 6.1 Measures prior to commissioning Further information You can find further information about heating elements in the heating element instructions provided in the complete documentation for the gear unit. 6.1.5 Measures for gear units with oil supply system 6.1 Measures prior to commissioning CAUTION Hearing loss due to high emission sound pressure level During operation, the emission sound pressure level may exceed 80 dB (A).

  • Page 94: Measures During Commissioning

    Commissioning 6.2 Measures during commissioning Measures during commissioning 6.2 Measures during commissioning 6.2.1 List of measures during commissioning 6.2 Measures during commissioning CAUTION Hearing loss due to high emission sound pressure level During operation, the emission sound pressure level may exceed 80 dB (A). This could lead to tinnitus or hearing loss.
  • Page 95 Commissioning 6.2 Measures during commissioning Further information You can find further information on the topic of oil in the Instructions 7300, which are part of the complete documentation of the gear unit. Further information about the oil supply system can be found in the oil supply system instruc- tions contained in the complete documentation for the gear unit.
  • Page 96 Commissioning 6.2 Measures during commissioning Version 10/2024 B7400-01en...

  • Page 97: Operation

    Operation Operating data 7.1 Operating data To ensure correct, trouble-free operation of the system, observe the operating values of the gear unit and, depending on the order specification, the data in the instructions for the oil supply system. The operating values specified on the rating plate apply. The rating plate is explained in more detail in the Annex Technical specifications (Page 121).

  • Page 98: Information On The Water-Oil Cooler

    Operation 7.2 Information on cooling water • The recommended pH value of the cooling water is 7 to 9.5 to prevent corrosion. • Cooling coils made of stainless steel may be exposed to a pH value of up to 12, depend- ing on the alloy.

  • Page 99: Taking The Unit Out Of Service

    1. Switch off the drive aggregate. 2. Refer to the “Possible faults” (Page 107) table to find the cause of the fault. 3. If you still cannot determine the cause of the fault, contact Flender Customer Service (Page 113). 4. After safety devices have been activated and before restarting: First release a restarting lockout.
  • Page 100 Operation 7.4 Taking the unit out of service Version 10/2024 B7400-01en...

  • Page 101: Maintenance

    Maintenance General maintenance information 8.1 General maintenance information The operator must ensure compliance with the stipulated time limits. This also applies if the maintenance activities are included in the operator’s internal maintenance schedules. The gear unit could be damaged if the stipulated intervals for maintenance and servicing work are not observed.

  • Page 102: Table 8-1 Maintenance And Servicing Activities

    Maintenance 8.2 Maintenance schedule Intervals and time limits Measures Every 3 months Clean the oil filter Clean the air filter Clean the air release screw Every 3,000 operating hours Measure the vibration levels of the rolling-contact bearings Every 3,000 operating hours, at least every Regrease Taconite seals 6 months Regrease Tacolab seals...

  • Page 103: Service And Maintenance Work

    4. Compare the measured value with the maximum permissible oil temperature (Page 113). 5. Immediately stop the gear unit if the maximum permissible oil temperature is exceeded. Contact Flender Customer Service (Page 113). 8.3.3 Cleaning the fan and gear unit 8.3 Service and maintenance work The gear unit can sustain damage due to inadequate cooling if you operate it with a dam- aged or soiled fan.

  • Page 104: Checking The Cooling Coil

    Contact Flender Customer Service (Page 113). 7. Carefully observe the instructions of the manufacturer before using different kinds of cleaning agent. 8. Replace heavily soiled cooling coils with new ones. Contact Flender Customer Service (Page 113). 9. Reconnect the cooling water inlet and return lines.

  • Page 105: Cleaning The Coarse Filter

    Maintenance 8.3 Service and maintenance work Information Special aspects during cleaning of the cooling coil Specialised chemical cleaning companies offer an analysis of the deposits in the cooling coil and sell special cleaning agents to remove the analysed deposits. 8.3.5 Cleaning the coarse filter 8.3 Service and maintenance work To clean the coarse filter, proceed as follows:...

  • Page 106: Measuring The Vibration Levels Of The Rolling-Contact Bearings

    Maintenance 8.3 Service and maintenance work You can find further information about the technical data in the separate data sheet and in the list of equipment provided in the complete documentation for the gear unit. 8.3.8 Measuring the vibration levels of the rolling-contact bearings 8.3 Service and maintenance work Proceed as follows to measure the vibration levels of the rolling-contact bearings: 1.

  • Page 107: General Inspection Of The Gear Unit

    Service to repair any faults that develop while the unit is still under warranty. 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 Service to attempt a repair.
  • Page 108 Maintenance 8.4 Possible faults Possible faults Causes Possible remedies Noise Damage to the gears • Contact Customer Service • Inspect the gear components • If necessary, replace damaged components The bearing play is excessive • Contact Customer Service • Adjust bearing play Defective rolling-contact bearings •...
  • Page 109 Maintenance 8.4 Possible faults Possible faults Causes Possible remedies The auxiliary drive motor starts, Overrunning clutch cage with • Contact Customer Service but the low-speed shaft (LSS) sprags incorrectly installed • Rotate the overrunning clutch cage 180° – or re- of the main gear unit does not place turn...
  • Page 110 Maintenance 8.4 Possible faults Possible faults Causes Possible remedies Oil supply system malfunction • Observe the instructions for the oil supply system Elevated temperature during Gear unit housing very dirty • Clean the gear unit housing including the cooling operation fins Oil level in the gear unit housing •...

  • Page 111: Final Work After Maintenance And Faults

    Maintenance 8.5 Final work after maintenance and faults Possible faults Causes Possible remedies Elevated temperature at bear- Defective oil pump • Check the oil pump function ing points • Repair or replace oil pump if required Elevated temperature at back- Damaged backstop •...
  • Page 112 Maintenance 8.5 Final work after maintenance and faults 3. Restore the conditions for intended operation. When doing this, observe the information in the “Commissioning” chapter. 4. Gear unit with Taconite or Tacolab seals: Check the gap after completing the work. When doing this, observe the information in Chapter Gap dimension at grease labyrinth (Page 70).

  • Page 113: Service & Support

    Flender Industriegetriebe GmbH Thierbacher Strasse 24 09322 Penig Germany Tel.: +49 (0)37381 / 61-0 Fax: +49 (0)37381 / 80286 More information Further information about service and support can be found on the Internet: Service & Support (https://www.flender.com/service) B7400-01en Version 10/2024...
  • Page 114 Service & Support 9.1 Contact Version 10/2024 B7400-01en...

  • Page 115: Disposal

    Disposal 10.1 Disposal of the gear unit 10.1 Disposal of the gear unit When disposing of the gear unit after its useful life, please observe the following measures: 1. Remove gear unit oil, preservation agents and coolant from the gear unit and dispose of them according to regulations.
  • Page 116 Disposal 10.2 Environmental protection Version 10/2024 B7400-01en...

  • Page 117: Spare Parts

    Flender Will accept no liability or warranty whatsoever for damage occurring as a result of the use of non-approved spare parts. The same applies to any accessories which were not supplied by Flender.
  • Page 118 Spare parts 11.1 General information on replacement parts Version 10/2024 B7400-01en...

  • Page 119: Declaration Of Incorporation

    Directive 2006/42/EC. Representative for issuing this Declaration of Incorporation on behalf of the manufacturer: Flender Industriegetriebe GmbH Penig, 2024-10-18 Armin Bittner, CEO, Flender Industriegetriebe GmbH Translation of the Declaration of Incorporation B7400-01en Version 10/2024...
  • Page 120 Declaration of Incorporation Declaration of Incorporation Version 10/2024 B7400-01en...

  • Page 121: Technical Specifications

    Hotline origin 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. Further information Further information about these technical data can be found in the separate data sheet and the dimension drawings in the complete documentation for the gear unit.
  • Page 122 Technical specifications General technical specifications Structure of gear unit markings Field 5 of the rating plate contains the gear unit markings. The following table explains the meaning of each letter and number. Gear unit size Version Mounting Version of the low-speed shaft (LSS) No.

  • Page 123: Lubrication Point As A Plate On Housing

    By applying various suitable measures, the gear unit can be used in the ambient temperat- ure range extending from -40 °C up to 60 °C. However, this must always be authorised by Flender and specified in the order text. Observe the heating information specified in the dimension drawing and list of equipment! At temperatures below -30°C, the gear unit must be preheated for at least 6 hours before...

  • Page 124: Enveloping Surface Sound Pressure Level

    The sound pressure level applies to a warm-running gear unit with speed of the high-speed shaft (HSS) n1 and power of the driven machine P2 according to the rating plate when measured on a Flender test bench. If more than one value is stated, the highest speed and power values apply.

  • Page 125: Table B-3 Enveloping Surface Sound Pressure Level Without Fan

    Technical specifications Enveloping surface sound pressure level Model Gear unit size H1SHN > 2.0 … 3.55 1,000 > 3.55 … 7.1 1,800 1,500 1,000 < 60 < 60 Table B-3 : Enveloping surface sound pressure level without fan Model Gear unit size H1SHN 1.0 … 2.0...

  • Page 126: Table B-5 Enveloping Surface Sound Pressure Level With Fan

    Technical specifications Enveloping surface sound pressure level Model in rpm Gear unit size H1SHN > 3.55 … 7.1 1,500 1,000 Table B-5 : Enveloping surface sound pressure level with fan Version 10/2024 B7400-01en...

  • Page 127: Index

    Index Fastening bolts Bolts, 85 check for tight fit, 106 Air guide cover, 104 Mating threads, 85 Air-oil cooler, 45 Preload force, 86 connecting, 79, 82 Tightening torque, 86 Attachment points, 65, 67 Fastening screws/bolts Screw/bolt connection class, 86 Tightening procedure, 86 Fault, 107 Bearing monitoring Fault rectification, 107 Accelerometer, 61 Fault-finding, 107 connecting, 80 Final work, 88 Resistance thermometer, 56 Shock-pulse transducer, 60 Vibration sensors, 59...
  • Page 128 Index Measures Rolling-contact bearings During commissioning, 94 Measure temperature, 106 Prior to commissioning, 91 Measuring vibrations, 106 Motor fan, 42 connecting, 79 Motor pump connecting, 79, 84 Scope of delivery, 63 Mounting position, 67 Separate oil supply system connecting, 79, 84 Servicing activities, 101 Shaft bearings, 36 Notes regarding assembly, 67 Shaft seal, 36 Shipping documents, 63 Shock-pulse transducer connecting, 80...
  • Page 130 FLENDER ONE Assembly and operating instructions B7400-01en Version 10/2024 Flender GmbH Alfred-Flender-Strasse 77 46395 Bocholt Germany...

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