TG

ASSURANCE OF QUALITY
FLENDER-GRAFFENSTADEN
OPERATING AND MAINTENANCE INSTRUCTIONS
Page : 1
P.O. BOX N 84 - 67402 ILLKIRCH GRAFFENSTADEN CEDEX TELEPHONE : +33 (0) 3 88.67.60.84. FAX : +33 (0) 3 88.67.60.85. E - MAIL : Flensav@flender-graff.com

GEARBOX WITH PARALLEL SHAFTS
TRL65/1C
CUSTOMER REFERENCES. NAME : ORDER N : JOB NAME : F.G. REFERENCES. OL N : FILE N : MACHINE N :
BHEL B708P027 West Coast
30193.01 34530 10282
E D C B A
Rvision
06/09
Date Revisions
FOURNAISE
MARTIN P.
KRATZ
Written by
Checked by
Quality assurance
Non compliance with the OPERATING AND MAINTENANCE INSTRUCTIONS, will lead to cancellation of our guarantee.
OPERATING AND MAINTENANCE INSTRUCTIONS CONTENTS
Page : 2
1. TECHNICAL DESCRIPTION OF THE GEARBOX ........................................................................3 1.1. CASING ...........................................................................................................................................3 1.1.1. Lower casing .............................................................................................................................3 1.1.2. Upper casing..............................................................................................................................3 1.2. GEAR SET .......................................................................................................................................3 1.2.1. Toothing.....................................................................................................................................3 1.2.2. Material .....................................................................................................................................3 1.2.3. Oil seals......................................................................................................................................3 1.3. RADIAL BEARINGS......................................................................................................................3 1.4. THRUST BEARINGS .....................................................................................................................3 1.5. LUBRICATION...............................................................................................................................4 1.6. INSTRUMENTATION ...................................................................................................................4 2. PROTECTION - SHIPMENT.............................................................................................................4 2.1. STORAGE........................................................................................................................................4 3. INSTALLATION ON SITE...................................................................................................................4 3.1. FOUNDATIONS..............................................................................................................................4 3.2. ALIGNMENT ..................................................................................................................................5 3.3. HANDLING .....................................................................................................................................5 3.4. LEVELLING ...................................................................................................................................5 3.5. TOOTH CONTACT PATTERN....................................................................................................5 4. ASSEMBLY & DISMANTLING OF THE GEARBOX .....................................................................5 4.1. DISMANTLING ..............................................................................................................................5 4.2. ASSEMBLY .....................................................................................................................................6 5. OPERATION ..........................................................................................................................................6 5.1. OIL SYSTEM PREPARATION AND FLUSHING .....................................................................6 5.2. STARTUP ........................................................................................................................................6 5.3. CONTROL .......................................................................................................................................6 5.3.1. Oil pressure ...............................................................................................................................6 5.3.2. Temperatures ............................................................................................................................6 5.3.2.1. Oil outlet temperature .......................................................................................................6 5.3.2.2. Bearing temperatures ........................................................................................................6 5.3.3. Vibration amplitude .................................................................................................................6 5.4. SPECIFIC RECOMMANDATIONS.............................................................................................6 5.5. SHUTDOWN ...................................................................................................................................6 5.6. RESTART OF THE GEARBOX ...................................................................................................7 5.7. OPERATING INSTRUCTIONS IN CASE OF ANOMALIES...................................................7 5.7.1. Oil pressure fault ......................................................................................................................7 5.7.2. Temperature faults ...................................................................................................................7 5.7.3. Increase in vibration or noise level..........................................................................................7 6. MAINTENANCE AND SERVICING ON GEARBOX ......................................................................7 6.1. GENERAL .......................................................................................................................................7 6.2. EXTERNAL PARAMETERS TO BE MONITORED.................................................................8 6.2.1. Oil...............................................................................................................................................8 6.2.2. Stability of foundations/attachments.......................................................................................8 6.2.3. Vibrations ..................................................................................................................................8 6.2.4. Bearing temperatures ...............................................................................................................8 7. SPARE PARTS .......................................................................................................................................8 8. CORRESPONDENCE ...........................................................................................................................8 9. APPENDICES.........................................................................................................................................8
Page : 3
1.
TECHNICAL DESCRIPTION OF THE GEARBOX
1.2.2.
Material
The gearbox is reducer.

See data sheet in Appendix 01
The pinion and the wheel are of case-hardened alloy steel. The gear teeth are surface hardened by casehardening followed by tempering to obtain the necessary hardness to transmit the load. Pinion shaft and wheel shaft are forged. The wheel can be hollow to allow the passing of a quill shaft.
1.1.
CASING
The casing is made of welded sheet steel. It is designed to keep rotating parts as well as journal and thrust bearings in their correct positions under each and every possible load situation. A stabilisation heat treatment is done to reduce residual stress. A horizontal joint is separating the two parts of the casing.
1.2.3.
Oil seals
Oil tightness of shafts is obtained with two-parts labyrinth seals in aluminium or bronze. Their radial clearance is determined according to bearing clearance.
1.1.1.
Lower casing
1.3.
RADIAL BEARINGS
The lower casing is fixed on an underframe or mounting base plate. It includes oil inlet and outlet flange and the oil collector. Unit slinging and handling will be done with attachment hooks fitted to the lower casing.
Each shaft is fitted with two bearings. The radial bearings are of the hydrodynamic type, and are designed to guarantee satisfactory running. The bearings are in two parts and made of steel with antifriction coating. They can be dismounted easily. Profile choice is done according to running conditions. Possible types are OFFSET, 4 LOBES, LEMON, CYLINDRICAL or TILTING PADS. . The bearings are positioned in the casing with an antirotation pin. The majority of our gearboxes are equipped with an adjustable bearing to optimize the tooth contact. This operation has to be carried out by FLENDER GRAFFENSTADEN personnel.
1.1.2.
Upper casing
The upper casing acts as bearing cap by maintaining the high speed and the low speed shaft line bearings. It has a visiting door wich can eventually have a filter breather. The following auxilliaries can be fixed to the casing : turning gear, driven pump, LS and HS coupling cover, measurement and control instrumentation.
1.4.
THRUST BEARINGS
When thrust bearings are needed, they are dimensioned to support the axial thrust from the toothing as well as external thrusts from the couplings. Two types are being used : TAPERED LANDS or TILTING PADS.
1.2. 1.2.1.
GEAR SET Toothing
The tooth profile is of the single or double helical type, with tip and root relieve to optimize mesh conditions and a supplementary tooth correction for optimzed tooth contact pattern under load.

2.1.
Page : 4
1.5.
LUBRICATION
STORAGE
The unit is lubricated by forced oil circulation. The bearings are lubricated by internal bores between the bearing and the main collector. The teeth are lubricated with calibrated nozzles. When orifices are used, these must be correctly marked before being removed. The oil flow to the tank must be as direct as possible with a slope greater than 5. The diameter of the drain pipe must be at least equal to the hole designed for it in the unit.
Short term storage : for 1 to 2 Medium term storage : months at the most. 6 months The unit is delivered on a The unit is protected in a simple wood frame without sealed watertight case packaging. fitted with air drier bags and is delivered inside a wood box packing.
! ! !
For a long term storage (after 6 months), you have to contact FLENDERGRAFFENSTADEN for more informations. The machine should be stored in a dry room without any large temperature variation. FLENDER-GRAFFENSTADEN manufacturer declines any liability for the consequences of inadequate storage if storage rules given here-above are not respected.
!
1.6.
The oil in use has to be conforme to the OIL TABLE in Appendix 04. INSTRUMENTATION
For this chapter, please refer to the outline drawing and wiring diagram in Appendix 08.
2.
PROTECTION - SHIPMENT 3. INSTALLATION ON SITE
During reassembly after works testing, all internal machined parts are given a coat of Castrol SAFECOAT DW 33 or similar. Orifices are plugged or covered. External machined parts are given a coat of MOLYDAL MULTI TP or similar and shaft ends are protected against physical damages. For shipment, sprags or shipping clamps may by provided for moving parts. See diagram n 01 in Appendix 02. On reaching the final destination, the unit shall be carefully inspected to detect any damage caused by transportation. The internal protection oil applied in the factory before dispatch must be kept until start up, and will be eliminated by lube oil flow.
!
3.1.
These operations are not included in the services provided by the manufacturer.
FOUNDATIONS
The foundations should be built and calculated with appropriate stiffness and damping to prevent resonance phenomena. Take into consideration gearbox data as given on the outline drawing. See outline drawing on Appendix 08. The base plate of the unit is machined flat and parallel to the shafts. Any deformation in the casing due to tightening will affect the teeth contact pattern. It is useful to introduce shims 10 to 20 mm thick between the foundations and the base plate of the unit to facilitate any misalignment correction that may prove necessary.
Page : 5
3.2.
ALIGNMENT
Control surfaces must be clean and without rust. If the surfaces are not clean or are damaged, please contact FLENDER-GRAFFENSTADEN.
Remove transport protections, sprags and shipping clamps before startup. If LS shaft is equipped with a quillshaft, leave centering wedges in place during alignment. Remove these parts before startup. Insert centering wedges again before handling LS shaft. If the installation is to operate satisfactorily in service, the different machines must be strictly aligned according to the values given by FG. Faulty alignment will lead to increased vibration and noise levels on the gearbox and on the whole shaft line. The best possible allowance must be made for thermal expansion of the casing and movement of the shafts in the bearings. The design shaft positions for operation under full load are indicated on the outline drawing Appendix 08.
!
3.5.
After each tooth contact control necessary to check the levelling. TOOTH CONTACT PATTERN
it
is
After levelling and alignment but before coupling, make a first tooth contact pattern check. Open inspection door, and apply prussian blue to a few teeth of the gearwheel. Turn a few times and slow down pinion at the same time. The obtained tooth contact pattern must be conform with Appendix 08. A control of tooth contact pattern after 1-2 hours of running, under full load must be performed. Apply DYKEN RED varnish to a few teeth of the pinion ( DYKEN RED can be obtained from FLENDERFRAFFENSTADEN customer support department). Clean tooth flanks with a solvent before applying DYKEN RED varnish. This method must reveal a contact pattern along the whole length of the tooth.
These positions are given as an illustration, and serve to define the alignment criteria of the different machines. To optimize performance, it is recommended that alignment should be verified with the machines "hot". During alignment take into consideration 3.4. LEVELLING.
4.
ASSEMBLY & THE GEARBOX
DISMANTLING
OF
3.3.
HANDLING
!
4.1.
Use slinging hooks provided on the lower casing, never attach to any other location such as pipework, components, etc...
During the warranty period, dismantling of the gearbox requires FLENDERGRAFFENSTADEN approval. DISMANTLING
3.4.
1. Remove all accessories. LEVELLING The following operations have to be executed by qualified personnel. 2. Remove upper casing. 3. Remove probes and pipework. 4. Remove upper half-bearings. 5. Sling the shaft and lift it while maintaining it horizontal, the lower half-bearings must remain in the casing. 6. Protect probe tracks using adhesive paper or equivalente. 7. Remove the lower half-bearings.
Levelling of the gearbox is done to obtain a correct tooth contact pattern. The gearbox has to be levelled within an admitted tolerance of 0.02 mm /m. Use a precision bubble level on both sides of the gearbox. See diagram n 02 in Appendix 02. It is not necessary to remove upper casing during levelling.

5.3. 5.3.1.
Page : 6
4.2.
ASSEMBLY
CONTROL Oil pressure
1. The bearings have to be lubricated with clean oil. 2. Two half bearings and their place in the casing must have the same reference. 3. For thrust bearings, load faces of half bearings must point in the same section. 4. When lowering a shaft into a thrust bearing, keep shaft horizontal to avoid damage to thrust surface. 5. Install instrumentation and piping. 6. Internal screws and bots have to be locked. 7. Tighten nuts on the gearbox with the tightening torque indicated on the Assembly drawing in Appendix 08. 8. If one or more bearings were replaced you have to recheck the tooth contact pattern.
Pressure switch adjustment must be conform to the values given in Appendix 03.
5.3.2. 5.3.2.1.
Temperatures Oil outlet temperature
If thermostats are installed on oil return, they must be adjusted as follows : alarm at 10C above normal full load temperature, shutdown at 5C above alarm temperature.
5.3.2.2.
Bearing temperatures
!
5. 5.1.
After assembly and dismantling refer to 3 INSTALATION ON SITE.
Defined temperature limits must not be exceeded to protect white metal in the bearing. You have to respect the temperature threshold given in Appendix 03.
OPERATION
OIL SYSTEM FLUSHING PREPARATION AND
5.3.3.
Vibration amplitude Shaft vibration - allowable limits See tables in Appendix 03.
Before startup, start the auxiliary oil pump. As soon as the oil circulation is established the oil filter must be cleaned frequently until it is completely clean. Since the bearings and the teeth are connected to the same circuit, it is recommend to provisionally place a metal screen with 0.05 mm mesh at the input to the collector on our unit. This precaution will avoid serious incidents in the bearings due to foreign particles coming from the pipes and carried by the oil.
5.4.
SPECIFIC RECOMMANDATIONS In case of incident on site, repeat all controls mentioned in this manual.
Degradation of lubrication oil : oil in service deteriorates depending on many factors. Laboratory analyses must be carried out approximately every 2500 to 3000 hours. Check if oil is conform with 6.2. EXTERNAL PARAMETERS TO BE MONITORED. Extended shutdown : If a unit is stopped for a longer period, we recommend that the lubrication circuit be operated approximately once a week for one hour. During this operation we recommend that the shafts be turned from time to time.
!
5.2.
The metal screen must be removed as soon as oil circuit flushing is finished.
STARTUP
Before starting rotations, lube oil pressure and temperature must have reached minimum levels.
5.5.
SHUTDOWN
There are no special instructions for shutdown. The lubrication system must be operational until the unit is completely stopped.
Page : 7
5.6.
RESTART OF THE GEARBOX
Generally speaking the gearbox can be started up immediatly after shut down. Respect startup informations descreibed 5.2. STARTUP.
individual rise : monitor the temperature rise closely. If it stabilizes or returns to normal, the unit can continue operating. general rise : check the oil inlet pressure. Check that the heat exchanger is operating properly. If no fault is found and if one or more temperatures are near the shutdown value, the installation must be stopped in time to avoid serious damage to the unit.
5.7.
OPERATING INSTRUCTIONS IN CASE OF ANOMALIES The pressure, temperature and vibration should be recorded at all measurment points. If these records are not available, no warranty demands can be brought against F-G.
5.7.3.
Increase in vibration or noise level
The main causes of variations in the vibration or noise level are the following : misalignment, wear (bearing or thrust bearing), meshing fault, loose attached element (protective cover, etc...). In all cases the origin of the change in noise or vibration level must be found and eliminated as soon as possible. In case of warm startup a thermal imbalance can lead to increased shaft vibrations. They will disappear once the gearbox has reached nominal speed.
Instructions to be followed on appearance of alarm :
5.7.1.
Oil pressure fault
If the pressure does not rise again and falls below the shutdown pressure for more than 3 seconds the installation must be stopped automatically. However, the unit may operate temporarily provided that temperature limits are very closely monitored. See Appendix 3. Possible causes : oil level, filter or cooler dirty, incorrect pressure setting, leak, bearing wear, oil quality. If the nominal pressure cannot be reached, stop the installation and search for the cause of the incident.
6. 6.1.
MAINTENANCE AND SERVICING ON GEARBOX

GNRAL
The purpose is to describe the frequency and operations necessary for correct maintenance of our machines. See maintenance table in Appendix 07. There is also a table that describes the means to be used to carry out these operations. Finally, the causes of the most frequent incidents due to auxiliary equipment are described. Obviously, these are minimum recommendations. Verifications should be made between programmed maintenance work and after any incident that could create abnormal operating conditions and/or any drift in vibration and temperature measurements.
5.7.2.
Temperature faults
If oil inlet temperature increases above the values given in 5.3.2.1. OIL OUTLET TEMPERATURE, the unit may operate during a short time under constant surveillance of bearing temperatures. If there is a high temperature alarm it is necessary to find out whether this is due to an individual fault (bearing or thrust bearing) or to a general rise at all the monitored points.
Page : 8
6.2.
EXTERNAL MONITORED
PARAMETERS
TO
BE
7.
SPARE PARTS
In order to optimize machine lifetime it is necessary to monitor the following parameters :
When ordering spare parts, please indicate the following : 1. unit type and number, 2. the number of parts, their quantity, reference number and designation, 3. the drawing number, if necessary. See spare parts list in APPENDIX 05. Level 1 priority: * * Level 2 priority: *
6.2.1.
1. flow,
Oil
2. temperature (inlet and outlet), 3. pressure, 4. filtration, 5. FZG level (must be greater than 7, unless mentioned otherwise), 6. water content maxi. 50 ppm, 7. acidity, 8. metal particles content.
8.
CORRESPONDENCE FLENDER-GRAFFENSTADEN BP 84 67402 ILLKIRCH GRAFFENSTADEN : +33 (0) 3 88 67 60 00

Spare parts Technical support
: +33 (0) 3 88 67 60 31 FAX : +33 (0) 3 88 67 60 85
6.2.2.
Stability of foundations/attachments
In particular, check that the casing is not twisted (joint plane geometry).
6.2.3.
Vibrations
: +33 (0) 3 88 67 60 19 FAX : +33 (0) 3 88 67 61 40
In accordance with the limiting values specified in instructions. See Appendix 03.
E-mail : Flensav@flender-graff.com
6.2.4.
Bearing temperatures
In accordance with values specified in the instructions. See Appendix 03.
9.
APPENDICES
A01 A02 A03 A04 A05 A06 A07 A08
Machine characteristics data sheet Position of blocking parts & planeness of the joint plane Set values Oils table Spare parts list Technical instructions for accessories Maintenance table List of drawings
ASSURANCE DE LA QUALITE
GUIDE DEXPLOITATION ET DENTRETIEN OPERATING AND MAINTENANCE INSTRUCTIONS BETRIEBS UND WARTUNGSVORSCHRIFTEN
A 01
FICHE CARACTERISTIQUE DE LA MACHINE MACHINE KENNZEICHEN GEAR DATA
CARACTERISTIQUES
Puissance de calcul Facteur de service Vitesse PV Vitesse GV Rapport de vitesse PV/GV CONSTRUCTION Entraxe Masse totale Masse carter suprieur Masse carter infrieur Masse mobile GV Masse mobile PV LUBRIFICATION Huile, nature et viscosit Filtration Pression dentre Temprature dentre nominale Temprature dentre maximale Dbit Quantit de chaleur vacuer
BETRIEBSDATEN
Auslegeleistung Betriebs faktor Nenndrehzahl LW Nenndrehzahl SW Uebersetzungsverhaeltnis LW/SW KONSTRUKTIONSDATEN Achsabstand Gesamtgewicht Gehuseoberteilgewicht Gehuseunterteilgewicht Gewicht Schnelldrehende Welle Gewicht Langsamdrehende Welle SCHMIERUNG Oelviskositaet Filtrierung Eintrittsdruck Normale Eintrittstemperatur Maximale Eintrittstemperatur Oelbedarf Abzufuehrende Waermemenge
GEAR DATA
Gear rated power Service factor Rated speed LS Rated speed HS Speed ratio LS/HS : 43500 kW : AGMA 421/06 >1.3 : 3000 RPM : 5022 RPM : 1.67
CONSTRUCTION FEATURES Centerlines distance Total weight Upper casing weight Lower casing weight High speed shaft weight Low speed shaft weight LUBRIFICATION Lube oil designation Filtering Inlet pressure Normal oil inlet temp. Maximal oil inlet temp. Oil flow Calories to evacuate : 46 ISO VG : 25 m : 1.5 bar act. : 45 C : 55 C : 860 l/mm : 463860 kCal/h : 650 : 11700 : 1050 : 10650 : 1152.3 : 2533.6 mm kg kg kg kg kg
A 02
SKETCH N 01 : BOLT STEEL PLATE SHAFT END SECONDARY WITH PLATE MODEL
POSITION OF BLOCKING PARTS
SKETCH N 02 : PRECISION BUBBLE LEVEL ON STRAIGHT - EDGE

+ 0.02 mm per meter
CHECK PLANENESS OF THE JOINT PLANE
A 03
VALUES OF MONITORING AND PROTECTION SETPOINTS IN OPERATION SHAFT VIBRATION PTP [m] Shaft line LS HS Alarm 92 73 Shut down 137 108
During start-up, gears can exhibit a transient spike reading of vibration levels that will exceed shut down settings. Therefore a Trip Multiplier is recommended in the control system. SHAFTS DISPLACEMENT (AXIAL) [mm] Shaft line LS HS Alarm 0,40 Shut down 0,45
HOUSING VIBRATION (sensor in radial position) Alarm Overall value in mm/s RMS in the frequency range 10 to 2500 Hz 7 Shut down 11
Alarm Overall value in g peak in the frequency range 2500 to 10000 Hz 18
Shut down
Acceleration not used for protection shut down. (API670/4th5.4.5.1)
OIL PRESSURE at gearbox inlet flange [bar] Normal 1,5 Alarm 1,2 Shut down 0,8
JOURNAL BEARING AND THRUST BEARING TEMPERATURE Measurement using rigid removable sensors Alarm: Shut down: Alarm: Shut down: OIL INLET TEMPERATURES [C] Minimum inlet temperature before start-up: Nominal inlet temperature range: Alarm: Shut down: 20 45 55 60 Measurement using flexible sensors
Stabilization temperature +10C Maximum 125C Stabilization temperature +20C Maximum 130C
A 04
LUBRICATING OIL RECOMMENDATIONS Mineral oil : classification TSE and TGE (of ISO 6743-5)
Method Test ISO VG Viscosity Index, mini Viscosity cST 100 C, mini Flash point, C, mini Pour point, C, maxi Air release at 50 C, minute, maxi Demulsibility at 54 C, 40/40/0, minute, maxi Foam, Seq, ml/ml, maxi ISO 3448 ISO 2909 ISO 3104 ISO 2592 ISO 3016 DIN 51381 ISO 6614 ISO 6247
Caractristics
32 100 5,1 210 -10 3 5 I : 10 / 0 II : 20 / 0 III : 10 / 0 min. 7 450 4000 0.2
46 6,5 220 4 10
FZG damage load stage RBOT, minute, mini Tost, hour to IA=2, mini Acidity, TAN, mgKOH/g, maxi
DIN 51354 / 2 ASTM D2272 ISO7624 ISO 6618
OPERATING CARACTERISTICS
Water content, ppm, maxi Start-up temperature, C, mini Filtration BETA for 25 m, mini Normal supply temperature for continuous operation C
in tank oil inlet oil inlet ISO 4572 oil inlet
100 20 150 45 to 55 50 to 60
OPERATING AND MAINTENANCE INSTRUCTIONS A 05 SPARE PARTS LIST
Assembly drawing : Outline drawing : ITEM Number GEARING DESIGNATION
02S287 02N357 Spare parts Type

Drawing or Norm
1**
2*
A100
GEAR WHEEL
PV
04AE578
A201
PINION SHAFT
GV
04AE579
SPARE PARTS LIST
A 05
R-GRAFFENSTADEN
Spare parts ITEM Number BEARINGS & THRUSTS BEARINGS DESIGNATION Type
Drawing or Norm
1**
2*
B110
BEARING
EP280 OF 280 RR
05F984
**
B120
BEARING
BD1T280OF290
05N804
**
B210
ADJUSTABLE BEARING ASSEMBLY
DN250
02D550
**
B220
BEARING
RR250 OF 250
05L590
**
SPARE PARTS LIST
A 05
R-GRAFFENSTADEN
Spare parts ITEM Number OIL SEAL DESIGNATION Type

Drawing or Norm
1**
2*
K110
OIL SEAL
220-280
03AH638
**
K210
OIL SEAL
220-240
03AH632
**
SPARE PARTS LIST
A 05
R-GRAFFENSTADEN
Spare parts ITEM Number INSTRUMENTATION DESIGNATION Type

Drawing or Norm
1**
2*
L111 L121 L151 L161 L213 L223
2 2 2 2 2 2
TEMPERATURE RTD'S TEMPERATURE RTD'S TEMPERATURE RTD'S TEMPERATURE RTD'S TEMPERATURE RTD'S TEMPERATURE RTD'S
PT100 2X3FILS PT100 2X3FILS PT100 2X3FILS PT100 2X3FILS PT100 2X3FILS PT100 2X3FILS
08T165/05 08T165/05 08T165/05 08T165/05 08T165/05 08T165/05
* * * * * *
L110 L210 L210 L220
1 1 1 1
THERMOMETER THERMOMETER THERMOMETER THERMOMETER
WIKA D 100 WIKA D 100 WIKA D 100 WIKA D 100
* * * *
SPARE PARTS LIST
A 05
R-GRAFFENSTADEN
Spare parts ITEM Number PUMP DESIGNATION Type

Drawing or Norm
1**
2*
M100 M160 M180
1 1 1
PUMP DRIVING WHEEL DRIVER WHEEL
PFPZ126#3CHOR 23C792 23C793
* * *
GUIDE DEXPLOITATION ET DENTRETIEN OPERATING AND MAINTENANCE INSTRUCTIONS BETRIEBS UND WARTUNGSVORSCHRITEN MANUAL DE USO Y DE MANTENIMIENTO LIBRETTO DUSO E MANUTENZIONE
A 06
DESCRIPTION TECHNIQUE DES ACCESSOIRES TECHNICAL INSTRUCTIONS FOR ACCESSORIES BESCHREIBUNG / KENNDATEN / ZUBEHR NOTA TECNICA DE LOS ACCESORIOS AVVERTENZA TECNICA DEGLI ACCESSORI
VIREUR / TURNING GEAR / DREHVORRICHTUNG / VIRADOR / VIRATOR

REDUCTEUR / SPEED REDUCER /UNTERSETZUNGSGETRIEBE / REDUCTORDE VELOCIDAD / RIDUTTORE DI VELOCITA : KAF148 JOINT TOURNANT / ROTATING SEAL / GLEITRINGDICHTUNG / JUANTA ROTATIVA / GUARNIZIONE MOBILE MOTEUR / MOTOR / MOTOREN / MOTORES / MOTORI : LS225ST Dmarreur statorique / Electrical starter/ Anlasswieder stand / Darranque estatorico / Avviamento statorico EMBRAYAGE / CLUTCH / BERHOLKUPPLUNG / EMBRAGUES / INNESTI : 36T SM : 17007 POMPE / PUMP / LPUMPE / BOMBA / POMPA : SEIM ACCOUPLEMENT / COUPLING / KUPPLUNG / ACOPLAMIENTO / GUINTI :
A 06bis
1.
TECHNICAL DESCRIPTION OF THE TURNING GEAR

A turning gear device is composed of : Electrical motor. Electrical contact preventing starting of the electrical motor when handwheel is in position. Handwheel for manual turning operations. Speed reducer. SSS Gears automatic clutch.
2.
CARACTERISTICS 2.1.
GNRAL FEATURES : : : 150 5714 Rpm on HS shaft. mN
Turning speed Breakaway torque
2.2.
LECTRICAL MOTOR : : : : : : : : : LS225ST 415 37 50 1470 IP55 V1/FF400 Classe F V kW Hz RPM.
Type Voltage Power Frequency Speed Protection Shape Insulation
2.3.
SPEED REDUCER FG : : : KAF148 9.77
Type Reduction ratio
2.4.
SSS GEARS COUPLING : : : 36T SM 17007
Type Assembly drawing
2.5. 2.6.
LECTRICAL CONTACTOR : : XCKL1
Type STARTING DEVICE : Type Drawing/sketch
: : N -27D652
A 06bis
STARTING PHASE OF THE SHAFT LINE :
Speed of rotation
Operating unit
Stopping pulse of the turning gear driver Disengagement of the clutch Turning
time Start of turning gear motor Width of backlash elimination Stopping of turning gear motor
STOPPING AND TURNING PHASE OF THE SHAFT-LINE :
Speed of rotation Stopping of the main driver
Operating unit
Starting pulse of the turning gear driver
Turning
Engagement of the clutch
time Start of turning gear motor
Operating Instructions
BA 2010 EN 01.06
Part no. 0322040
MOTOX N
Gear Units
FLENDER TBINGEN GMBH Bahnhofstr. 40 44 D 72072 Tbingen Telefon +49 (0) 70 71 707 0 Fax +49 (0) 70 71 707 400 http://www.flender.com E mail: sales motox@flender motox.com A company of the Flender group
Contents
1.
1.1 1.2 1.3
Important instructions
Instruction symbols in the operating instructions General instructions Amendments
6
6 6 7
2.
2.1 2.2
Safety instructions
Intended use General safety instructions
8
8 8
3.
3.1 3.2 3.3 3.4 3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.5.6 3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 3.6.5.1 3.6.5.2 3.6.5.3 3.6.5.4
Technical data
Type designations General technical data Weights Sound pressure level Mounting positions One stage helical gear units Two and three stage helical gear units Bevel helical gear units Parallel shaft helical gear units Helical worm gear units Tandem gear unit compound helical gear unit Oil quantities Helical gear units Bevel helical gear units Parallel shaft helical gear units Helical worm gear units Tandem gear unit compound helical gear unit Two and three stage helical gear units Bevel helical gear units Parallel shaft helical gear units Helical worm gear units
9
9 10 12 12 13 14 15 17 19 20 21 22 22 23 24 25 25 25 26 28 29
4.
4.1 4.2 4.3 4.4 4.5 4.6 4.6.1 4.6.2 4.7 4.8 4.9 4.10 4.10.1 4.10.2 4.10.3
Technical description
General description Housing Toothed components Lubrication Shaft bearing Shaft seals Radial shaft sealing rings Combination shaft sealing rings (optional) Cooling Backstop Rating plates Paint coats General Painted version Primed version BA 2010 EN 01.06 3 / 90
30
30 30 30 30 30 30 30 31 31 31 32 32 32 33 34
5.
5.1 5.2 5.3
Incoming goods, Handling and Storage

Incoming goods Handling Storage
35
35 36 37
6.
6.1 6.2 6.3 6.3.1 6.3.2 6.4 6.5 6.6 6.7 6.8 6.9 6.9.1 6.9.2 6.9.3 6.10 6.10.1 6.10.2 6.10.3 6.11 6.11.1 6.11.2
Installation
General information on installation Fastening in the case of high shock loads Drives with foot mounting Foundation Installing gear units with foot mounting Drive units in foot or flange version Drive units with C type housing flange Installation of input drive and output drive elements on gear unit shafts Steel safety cover for hollow shaft and shrink disc Cast iron end cover for hollow shaft Shaft mounting gear unit with hollow shaft and parallel key, hollow shaft and splines, hollow shaft and shrink disk Mounting the hollow shaft Remove hollow shaft and parallel key Suggested design for threaded piece and disc Shrink disc Mounting the shrink disc Pulling off the shrink disc Cleaning and greasing the shrink disc Torque arm with shaft mounted gear units Fit torque arm on bevel helical gear unit and helical gear unit Mounting torque arm on parallel shaft helical gear unit
38
38 39 39 39 39 39 40 41 43 44 45 45 47 48 49 49 50 51 51 52 53
7.
7.1 7.2 7.3 7.3.1 7.3.2 7.4 7.4.1 7.4.2 7.5
Start up
Oil level check before start up Fill in oil Ventilation of the gear unit Filter for ventilation or pressure relief valve without securing clip Pressure relief valve with securing clip (special version) Start up after long term preservation Long term preservation up to 18 months Long term preservation up to 36 months Drive with backstop (special version)
54
54 54 54 54 55 55 55 55 55
8. 9.
Operation Faults, causes and remedy
56 56
BA 2010 EN 01.06 4 / 90
10.
10.1 10.2 10.2.1 10.2.1.1 10.2.1.2 10.2.1.3 10.2.1.4 10.2.2 10.2.3 10.2.4 10.2.5 10.2.6 10.2.7 10.2.8 10.2.9 10.2.10 10.2.11 10.2.12 10.2.13 10.3
Maintenance and repair

General information for maintenance Description of maintenance and repair work Oil level Check the oil level in the gear housing Checking the oil level by the oil sight glass (special version) Checking the oil level by the oil dipstick (special version) Checking the oil level sensor (special version) Oil quality Oil change Replacing bearings Relubrication of the rolling bearings in drive units Change rolling bearing grease Oil changing with backstop in bevel helical gear unit Seal check Clean ventilation filter Clean drive Checking tightness of fastening bolts Inspection of the drive Carry out maintenance on slip coupling Lubricants
59
59 61 61 62 64 65 65 65 66 68 68 68 69 69 69 70 70 71 71 71
11. 12.
12.1 12.2 12.2.1 12.2.2 12.2.3 12.2.4 12.2.5 12.2.6 12.3
Disposal Stocking spare parts and customer service addresses

Stocking spare parts Spare parts lists One stage helical gear units Size 38 148 Two and three stage helical gear units Size 38 188 Bevel helical gear units Size B38 Bevel helical gear units Size 38 188 Parallel shaft helical gear units Size 38B 188B Helical worm gear units Size 38 88 Customer service addresses
76 76
76 77 77 78 79 80 82 83 85
13.
13.1 13.2
Declaration by the manufacturer, Declaration of Conformity

Declaration by the manufacturer EC Declaration of Conformity
89
89 90
BA 2010 EN 01.06 5 / 90
1.
1.1
Important instructions
Instruction symbols in the operating instructions
Instructions relating to operating safety are emphasized as follows:
Danger.
Possible consequences: Death or very severe injuries.
Caution.
Possible consequences: Damage to the drive and the environment.
Note.
Pointers for application and useful information.
Drives in ATEX version.
Instructions and measures applying in particular to drives in ATEX version.
1.2
General instructions
These operating instructions are an integral part of the gear unit delivery. These operating instructions apply to the standard version of the MOTOX N gear unit: Helical gear units E, Z and D size 18 188. Bevel helical gear units B, K size 28 188. Parallel shaft helical gear units F size 28, 38B 188B. Helical worm gear units C size 28 88.
Note.
Special types of drive and their additional equipment are governed by the special contractual agreements and technical documents. Note also the other operating instructions for drive assemblies BA 2019, optional add on units BA 2510, couplings, motors, brake motors, additional equipment for motors, etc., delivered with the equipment.
Note.
We accept no responsibility for damage or disruption resulting from disregard of these operating instructions.
BA 2010 EN 01.06 6 / 90
Keep these operating instructions in the vicinity of the gear unit. Read these operating instructions before working with the drive. Only a precise knowledge of these operating instructions will guarantee reliable, faultfree operation of the drive by avoiding operating errors and improper use. The drives described in these Instructions reflect the state of technical development at the time these instructions went to print. In the interest of technical progress we reserve the right to make changes to the individual assemblies and accessories which we regard as necessary to preserve their essential characteristics and improve the efficiency and safety of the drive. The copyright to these operating instructions is held by FLENDER TBINGEN GMBH. These operating instructions must not be wholly or partly reproduced, used in any unauthorised way for competitive purposes or made available to third parties without our agreement. Amendments or additions to these operating instructions may be made only by us; otherwise any guarantee claim against us will lapse. Technical enquiries should be addressed to the following works FLENDER TBINGEN GMBH Postfach 1709 D 72007 Tbingen Bahnhofstr. 40 44 D 72072 Tbingen Telefon +49 (0) 70 71 707 0 Fax +49 (0) 70 71 707 400 E mail: sales motox@flender motox.com http://www.flender.com 24 h Service Hotline +49 (0) 172 7 32 29 55 or to one of our customer services. The addresses of the customer services are given in section 12. Stocking spare parts and customer service addresses.
1.3
Amendments
These revised operating instructions replace the operating instructions BA 2010 07.05. Oil quantity for FD.28 with V3 00/H 06 modified. Oil quantity for CAZ88 with B5 03/H 02 modified. In item 10.2.1 figure and oil quantity for B38 added. Item 10.2.5 revised. Table 10.3-1 Oils" revised.
BA 2010 EN 01.06 7 / 90
2.
2.1
Safety instructions
Intended use
The MOTOX N drives described in these operating instructions have been developed for stationary use in general engineering applications. Unless otherwise agreed, the drives have been designed for use in plant and equipment in industral environments. The drives have been manufactured in accordance with the state of the art and are delivered in a condition for safe and reliable use. Any changes on the part of the user which may affect safety and reliability are prohibited. The drives are designed only for the application described in section 3. Technical data. They must not be operated outside the specified power limits. Other operating conditions must be contractually agreed.
The ATEX drive satisfies the requirements of explosion safety guideline 94/9/EG. In the case of drives in ATEX version please observe the instructions marked with this symbol.
The performance data apply at an ambient temperature of -20 C to +40 C and for an installation up to 5000 m altitude above sea level. In case of other ambient temperatures and installation altitudes, please contact the FLENDER TBINGEN GMBH customer service.
Note.
2.2
General safety instructions

The drives must be installed, started up, operated, maintained and, if necessary, repaired only by authorised, properly trained and qualified personnel. For definition of expert staff, refer to i.a. IEC 364. The operator must ensure that all persons involved in installation, operation, maintenance and repair have read and understood these operating instructions and comply with them at all times in order to: avoid injury or damage ensure the safety and reliability of the drive avoid disruptions and environmental damage through incorrect use. Carry out work on the drives only when they are at a standstill. Secure the drive units against unintentional starting (e.g. lock key switches or remove fuses in the power supply). A notice should be attached to the start switch stating clearly that work on the drives is in progress. Carry out all work with great care and with due regard to safety. Always observe the instructions on the plates on the drives. The plates must be kept free from paint and dirt at all times. Replace any missing plates. Ensure compliance with the relevant safety and environmental regulations during transport, assembly and dismantling, operation, and care and maintenance of the unit. Secure rotating drive parts, e.g. couplings, gears or belt drives, against contact by means of suitable safety devices.
BA 2010 EN 01.06 8 / 90
Ensure adequate ventilation when working with solvents. Do not inhale vapours. Do not smoke. Collect and dispose of used oil in accordance with regulations. Remove any oil spillage immediately with an oil binding agent in compliance with environmental requirements. When installing the drives in plant or equipment, the manufacturer of such plant or equipment must ensure that the contents of the present operating instructions are incorporated in his own instructions, information and descriptions.
3.
3.1
Technical data
Type designations
Main gear unit Example: Gear unit type Transmission steps Type Size Revision marks Transmission steps Size Drive group (for motor size) Gear unit type () Helical gear unit B Bevel helical gear unit, two stage K Bevel helical gear unit, three stage F Parallel shaft helical gear unit C Helical worm gear unit Transmission steps () E single stage Z two stage D three stage Type Shaft () Solid shaft A Hollow shaft Fixing () Foot mounted design BA 2010 EN 01.06 9 / 90 F D F 108 B Compound helical gear unit Z 38 Drive group K4 (100)
F Z D G R M E K U
Flanged version (A type) Housing flange (C type) Torque arm Flange (A type) opposite output shaft Agitator flange Agitator / mixer flange Extruder flange Cooling tower flange Submersible version (rotating mechanical seal)
Connection () Parallel key S Shrink disc T Hollow shaft with splines Backstop X Backstop in intermediate stage Compound helical gear unit Transmission steps Z two stage D three stage Drive group A/A5 Drive flange with free drive flange K2 Bell housing with flexible coupling for IEC flanged motors K2TC Bell housing with flexible coupling for NEMA motors K4 Bell housing with stub shaft connection for IEC flanged motors K5TC Bell housing with stub shaft connection for NEMA motors KQ(S) Bell housing with backlashfree, flexible coupling for SERVO motors P Motor bedplate version for IEC motor P5 Motor bedplate version for NEMA Motor
3.2
General technical data

The most important technical data are shown on the rating plate of the gear units or gear motors. These data together with the contractual agreements on the drive units determine the limits of its proper use. In the case of gear motors a rating plate attached to the motor serves for the entire drive. In certain cases separate rating plates are attached to the gear unit and the motor. Examples: Rating plate gear motor
1 16 20 22 24 7 9 28 14 17 15 5 18 21 23 25 11 3 13 19 6 26 12 27 2 8 10 14 11 4
Rating plate gear unit

1 2 5 3
7 9 12 13
10
Figure 3.2-1: Rating plate 1 2 3 4 Company logo Manufacturing date encoded Weight m [kg] Order no. / seq. no. BA 2010 EN 01.06 10 / 90
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Model Type Size Performance rating T2 [Nm] Mounting position Total transmission ratio i Speed n2 [min-1] Type of oil Oil viscosity ISO VG class to DIN 51519 / ISO 3448 Oil quantity [l] Main gear unit / ancillary transmission + extruder flange Free space for additional data max. ambient temperature TUmax [C] Phase number and type of current of the motor Switch symbols to DIN EN 60617 T6 / IEC 617 6 Rating voltage U [V] Rating current [A] Rating frequency f [Hz] Rating speed n [min-1] Rating performance P [kW] Operating mode (if 0 S1) Performance factor cos Type of protection to IEC 60034 5 or IEC 529 Heat class Th. Cl. applied standard CE marking or other marking, if any Brake data
Symbols (IEC 617 2):
= Brake = Coupling

Example: Rating plate
1 2 3 4 5 6
Figure 3.2-2: Rating plate ATEX version 1 2 3 Type designation Mounting position, order number Output speed n2 [min-1] Output torque T2 [Nm] Transmission ratio i Duty factor Input speed n1 [min-1] Input torque T1 [Nm] Explosion hazard symbol and explosion hazard marking, CE marking Oil quantity [l] Type of oil Weight m [kg] Space for additional information BA 2010 EN 01.06 11 / 90
4 5 6
3.3
Weights
The weight of the overall drive including motor is indicated on the rating plate of the gear unit or gear motor, if it exceeds 30 kg; in each case it is shown in the delivery documents. Where there are several rating plates on one drive, the specification on the main gear unit is decisive. The weight specification refers only to the condition on delivery of the products.
3.4
Sound pressure level

The A assessed sound pressure levels LWA of a selection of gear units in figure 3.4 Sound pressure level" have been measured to DIN EN 21680, using measuring instruments to DIN IEC 651. The noise depends mainly on speed, output and transmission ratio. LWA [dB] 110 100 90 80 70 60 0.1 0.2 0.5 1 2 5 10 20 50 100 160 P [kW]
Figure 3.4: Sound pressure level The sound pressure levels of MOTOX N gear motors fall mainly in the dark coloured part of the range. Gear units with very small transmission ratios, high output and high input speed may fall in the cross hatched part. If repeat measurements on site do not produce conclusive results with regard to measuring technology, the measurement obtained on the FLENDER TBINGEN GMBH test bench will apply.
External noises
Noises not generated by the gear unit but emitted from it are not taken into consideration here. Likewise noises emitted from the prime mover and output machines and from the foundation are not taken into consideration here, even if transmitted to these by the gear unit.
BA 2010 EN 01.06 12 / 90
3.5
Mounting positions
The assembly option designations are in accordance with IEC 60034 7 (Code ). The drives must be operated only in the assembly option specified on the rating plate. This ensures that the correct quantity of lubricant is provided
Note.
Size 18 and 28 gear units are lubricated for life. Screw plugs are not provided. Identification marking:
Oil level
Housing ventilation
Oil drain plug
Oil dipstick
Oil filling A,B Position of stub shaft and / or solid shaft V * Gear units of size 38 are standard fitted with a screw plug at point "V". Ventilation is not required. on opposite side two stage gear unit three stage gear unit Tandem gear unit - - - alternative
BA 2010 EN 01.06 13 / 90
3.5.1
One stage helical gear units Note.

For key to diagram symbols, see section 3.5 Mounting positions.
B3 (IM B3)
B8 (IM B8) *
B7 (IM B7)
V V V
B6 (IM B6)
V5 (IM V5)
V6 (IM V6)
Figure 3.5.1-1: Mounting positions for E Size 38 148 EF, EK EZ B5 (IM B5) B14 (IM B14) EF, EK EZ V1 (IM V1) V18 (IM V18) EF, EK EZ V3 (IM V3) V19 (IM V19)
V V
EF, EK EZ
B5 02 (IM B5 02) B14 02 (IM B14 02)
EF, EK EZ
B5 03 (IM B5 03) B14 03 (IM B14 03) *
EF, EK EZ
B5 00 (IM B5 00) B14 00 (IM B14 00)
V V * V
Figure 3.5.1-2: Mounting positions for E. Size 38 148 BA 2010 EN 01.06 14 / 90
3.5.2
Two and three stage helical gear units Note.

D/Z
B3 (IM B3)
D/Z
B8 (IM B8)
D/Z
B7 (IM B7)
V * V * V
D/Z
B6 (IM B6)
D/Z
V5 (IM V5)
D/Z
V6 (IM V6)
* Figure 3.5.2-1: Mounting positions for D/Z Size 18 88 D/Z B3 (IM B3) D/Z B8 (IM B8) D/Z B7 (IM B7)
* D/Z B6 (IM B6) D/Z V5 (IM V5) D/Z V6 (IM V6)
* *
Figure 3.5.2-2: Mounting positions for D/Z Size 108 168 BA 2010 EN 01.06 15 / 90
Note.
D/Z
B3 (IM B3)
D/Z
B8 (IM B8) *
D/Z
B7 (IM B7)
* D/Z B6 (IM B6) D/Z V5 (IM V5) D/Z V6 (IM V6)
* *
Figure 3.5.2-3: Mounting positions for D/Z188 ZK, DF/ZF, DR/ZR B5 (IM B5) ZK, DF/ZF, DR/ZR V1 (IM V1) DZ/ZZ B14 (IM B14) DZ/ZZ V18 (IM V18) ZK, DF/ZF, DR/ZR V3 (IM V3) DZ/ZZ V19 (IM V19)
V * V * Figure 3.5.2-4: Mounting positions for DF/ZZ, DZ/ZZ Size 18 88, DR/ZR Size 68 88 ZK, DF/ZF, DR/ZR B5 (IM B5) ZK, DF/ZF, DR/ZR V1 (IM V1) DZ/ZZ B14 (IM B14) DZ/ZZ V18 (IM V18) ZK, DF/ZF, DR/ZR V3 (IM V3) DZ/ZZ V19 (IM V19) V *
* * * Figure 3.5.2-5: Mounting positions for D./Z. Size 108 168 BA 2010 EN 01.06 16 / 90
Note.
ZK, DF/ZF DZ/ZZ
B5 (IM B5) B14 (IM B14)
ZK, DF/ZF DZ/ZZ
V1 (IM V1) V18 (IM V18)
ZK, DF/ZF DZ/ZZ
V3 (IM V3) V19 (IM V19)
* *
Figure 3.5.2-6: Mounting positions for D./Z.188
3.5.3
Bevel helical gear units

B BZ, BF BA. B3 00 (IM B3 00) B5 01 (IM B5 01) H 01 B B8 00 (IM B8 00) BZ, BF B5 03 (IM B5 03) BA. H 02 B BZ, BF BA. B7 00 (IM B7 00) B5 02 (IM B5 02) H 03
B BZ, BF BA.
B6 00 (IM B6 00) B5 00 (IM B5 00) H 04
B V5 00 (IM V5 00) BZ, BF V1 00 (IM V1 00) BA. H 05
B BZ, BF BA.
V6 00 (IM V6 00) V3 00 (IM V3 00) H 06
Figure 3.5.3-1: Mounting positions for B. Size 28 38 BA 2010 EN 01.06 17 / 90
Note.
The assembly options shown apply also to the foot/flange mounted housing, size 188.
Figure 3.5.3-2: Presentation foot/flange housing K.188
Note.
In the case of assembly options B3 00/H 01 the hole with the marking "K" should be used for checking the oil level.
K KA.
B3 00 (IM B3 00) H 01
K KA.
B8 00 (IM B8 00) H 02
K KA.
B7 00 (IM B7 00) H 03
V K V V
K KA.
B6 00 (IM B6 00) H 04
K KA.
V5 00 (IM V5 00) H 05
K KA.
V6 00 (IM V6 00) H 06
B V V V A
Figure 3.5.3-3: Mounting positions for K, KA, KAS, KAT Size 38 188
BA 2010 EN 01.06 18 / 90
Note.
KZ, KF KA.
B5 01 (IM B5 01) H 01
KZ, KF KA.
B5 03 (IM B5 03) H 02
KZ, KF KA.
B5 02 (IM B5 02) H 03
KZ, KF KA.
B5 00 (IM B5 00) H 04
KZ, KF KA. B
V1 00 (IM V1 00) H 05
KZ, KF KA.
V3 00 (IM V3 00) H 06 V A
V A V B
Figure 3.5.3-4: Mounting positions for KZ, KF, KAD, KAF, KAZ, KADS, KAFS, KAZS, KADT, KAFT, KAZT Size 38 188
3.5.4
Parallel shaft helical gear units

F.Z, F.F F.A. B5 01 (IM B5 01) H 01 F.Z, F.F F.A. B5 03 (IM B5 03) H 02 V B A V A V B * F.Z, F.F F.A. B5 02 (IM B5 02) H 03
BA 2010 EN 01.06 19 / 90
Note.
In the case of assembly options V3 00/H 06 the hole with the marking "F" should be used for checking the oil level.
Note.
F.Z, F.F F.A.
B5 00 (IM B5 00) H 04 *
F.Z, F.F F.A.
V1 00 (IM V1 00) H 05
F.Z, F.F F.A.
V3 00 (IM V3 00) H 06 A
B V V
F V
A Figure 3.5.4: Mounting positions for F.28, F. Size 38B 188B
3.5.5
Helical worm gear units

C CA. B3 00 (IM B3 00) H 01 C CA. B8 00 (IM B8 00) H 02 C CA. B7 00 (IM B7 00) H 03
* C CA. B6 00 (IM B6 00) H 04 * C CA. B V5 00 (IM V5 00) H 05 C CA. V6 00 (IM V6 00) H 06
Figure 3.5.5-1: Mounting positions for C, CA, CAS, CAT Size 28 88 BA 2010 EN 01.06 20 / 90
Note.
CZ, CF CA.
B5 01 (IM B5 01) H 01
CZ, CF CA.
B5 03 (IM B5 03) H 02
CZ, CF CA.
B5 02 (IM B5 02) H 03
CZ, CF CA.
B5 00 (IM B5 00) H 04
CZ, CF CA.
V1 00 (IM V1 00) H 05 B
CZ, CF CA.
V3 00 (IM V3 00) H 06 A
Figure 3.5.5-2: Mounting positions for CZ, CF, CAD, CAF, CAZ, CADS, CAFS, CAZS, CADT, CAFT, CAZT Size 28 88
3.5.6
Tandem gear unit compound helical gear unit Note.
In a horizontal operating position the bulging part of the housing of the 2nd gear unit generally faces downwards.
Note.
In case of double gear units every single unit is to be considered separately. Size 28 and 38 gear units of the second gear unit are lubricated for life. Screw plugs are not provided.
BA 2010 EN 01.06 21 / 90
Note.
horizontal operating position
vertical operating position
a * a b b * * a b
Figure 3.5.6: Operating position for dual gear unit a b Main gear unit 2. Gear unit
3.6
Oil quantities Caution.
Incorrect oil quantities cause damage to the drive. The exact oil quantities are specified on the rating plates of the drives. The oil quantities listed in the tables are approximate values. They aerve for the storage and procurement of lubricant.
3.6.1
Helical gear units

Mounting position Type E.38 E.48 E.68 E.88 E.108 E.128 E.148 B3 0.2 0.3 0.5 0.8 1.3 2.3 4.0 B5 B14 0.2 0.3 0.5 0.7 1.0 2.3 2.8 B5 00 B5 02 B5 03 B14 00 B14 02 B14 03 0.23 0.23 0.4 0.5 1.0 1.6 2.7 5.2 6.7 0.5 1.0 1.6 2.7 5.1 6.7 0.7 1.4 2.5 4.5 7.2 10.3 B6 0.3 0.6 1.0 1.6 2.7 5.3 7.0 B7 0.3 0.5 1.1 1.6 2.8 5.2 7.0 B8 0.4 0.7 1.5 2.5 4.6 7.2 10.3 V1 V18 0.5 0.7 1.7 2.2 3.7 6.4 9.3 V3 V19 0.6 1.1 1.9 3.8 6.6 10.9 14.5 V5 0.5 0.7 1.8 2.3 3.8 6.4 9.5 V6 0.6 1.1 1.9 3.8 6.6 10.9 14.8
Table 3.6.1-1: Oil quantities for E. Size 38 148
BA 2010 EN 01.06 22 / 90
Mounting position Type Z.18 Z.28 Z.38 Z.48 Z.68 Z.88 Z.108 Z.128 Z.148 Z.168 Z.188 D.18 D.28 D.38 D.48 D.68 D.88 D.108 D.128 D.148 D.168 D.188 B3 0.2 0.25 0.5 1.1 1.8 4.1 7.3 9.5 13.0 21.0 18.5 0.2 0.25 0.5 1.1 1.7 4.0 7.1 9.4 12.5 19.0 18.4 B5 B14 0.2 0.25 0.5 1.0 1.7 3.7 6.0 7.0 9.9 15.3 18.5 0.2 0.25 0.5 1.0 1.6 3.6 5.7 6.8 9.4 16.0 18.4 B6 0.35 0.45 0.6 1.6 2.7 6.1 10.5 16.0 20.8 34.8 50.0 0.35 0.45 0.6 1.5 2.6 5.9 10.3 15.8 20.4 34.1 48.0 B7 0.3 0.4 0.6 1.3 2.3 5.3 9.3 14.1 18.3 30.1 46.0 0.3 0.4 0.6 1.4 2.4 5.4 9.5 14.8 19.1 31.2 46.0 B8 0.4 0.6 0.6 1.5 2.5 5.7 8.6 13.2 26.9 32.1 75.0 0.4 0.6 0.6 1.5 2.6 5.9 10.0 14.1 23.4 33.8 73.0 V1 V18 0.5 0.6 0.8 1.8 3.0 6.8 13.8 18.5 23.9 48.0 72.0 0.5 0.6 0.9 2.3 3.9 8.7 16.3 24.6 30.6 53.0 69.0 V3 V19 0.5 0.7 1.0 2.4 4.1 8.3 14.0 20.7 27.7 31.1 70.0 0.5 0.7 1.1 2.4 4.0 8.9 14.2 21.8 28.2 43.7 68.0 V5 0.5 0.6 0.7 1.9 3.2 7.5 13.2 19.9 25.7 48.0 72.0 0.5 0.6 0.9 2.4 4.0 9.3 15.6 24.4 32.2 54.4 69.0 V6 0.5 0.7 1.1 2.4 4.1 8.8 13.6 20.9 27.4 41.7 70.0 0.5 0.7 1.1 2.4 4.0 8.9 13.7 21.5 27.9 42.2 68.0
Table 3.6.1-2: Oil quantities for D./Z. Size 18 188
3.6.2
Bevel helical gear units

Mounting position Type B.28 B.38 K.38 K.48 K.68 K.88 K.108 K.128 K.148 K.168 K.188 B3 00 H 01 0.25 0.7 0.5 0.7 1.6 2.6 5.5 8.3 14.8 21.6 33.8 B8 00 H 02 0.6 1.1 1.1 1.6 3.2 5.7 9.5 19.6 30.2 45.6 82.5 B7 00 H 03 0.9 1.6 1.4 2.0 3.9 7.4 12.6 24.4 37.0 60.5 104.2 B6 00 H 04 0.55 1.0 0.8 1.4 2.7 5.0 8.8 15.8 22.0 34.2 63.4 V5 00 H 05 0.5 0.95 1.0 1.5 3.0 4.9 8.7 16.9 25.8 40.2 70.7 V6 00 H 06 0.5 0.8 0.9 1.8 3.0 5.2 8.3 16.1 27.0 38.5 69.4
Table 3.6.2-1: Oil quantities for B, BA, BAS, BAT Size 28 38; K, KA, KAS, KAT Size 38 188
BA 2010 EN 01.06 23 / 90
Mounting position Type B.28 B.38 K.38 K.48 K.68 K.88 K.108 K.128 K.148 K.168 K.188 B5-01 H-01 0.25 0.7 0.5 0.7 1.6 2.6 6.2 8.7 14.8 21.7 33.8 B5-03 H-02 0.6 1.1 1.1 1.7 3.2 5.8 9.9 19.6 30.1 46.3 82.5 B5-02 H-03 0.9 1.6 1.5 2.0 3.9 7.7 13.7 25.0 41.0 62.6 104.5 B5-00 H-04 0.55 1.0 0.8 1.4 2.6 5.0 8.9 14.8 25.0 34.8 63.4 V1-00 H-05 0.5 0.95 1.0 1.6 2.8 5.1 10.0 17.5 26.0 41.1 70.7 V3-00 H-06 0.5 0.8 0.9 1.8 3.0 5.0 8.9 16.6 28.1 39.4 69.4
Table 3.6.2-2: Oil quantities for BZ, BF, BAD, BAF, BAZ, BADS, BAFS, BAZS, BADT, BAFT, BAZT Size 28 38; KZ, KF, KAD, KAF, KAZ, KADS, KAFS, KAZS, KADT, KAFT, KAZT Size 38 188
3.6.3
Parallel shaft helical gear units

Mounting position Type FZ.28 FZ.38B FZ.48B FZ.68B FZ.88B FZ.108B FZ.128B FZ.148B FZ.168B FZ.188B FD.28 FD.38B FD.48B FD.68B FD.88B FD.108B FD.128B FD.148B FD.168B FD.188B B5-01 H-01 0.6 0.7 1.6 2.5 4.5 7.4 13.8 19.5 32.8 41.4 0.6 0.9 2.0 3.3 6.3 10.6 16.8 24.7 44.0 52.0 B5-03 H-02 0.45 0.6 1.0 2.3 5.0 9.2 13.7 20.8 30.0 40.7 0.45 0.6 0.9 2.3 5.0 9.1 13.5 20.3 28.8 38.4 B5-02 H-03 0.5 0.7 1.3 2.4 4.8 8.4 15.5 22.7 37.0 44.2 0.5 0.7 1.3 2.4 4.7 8.2 15.2 21.8 36.0 44.5 B5-00 H-04 0.5 0.7 1.3 2.3 4.6 8.1 14.8 22.3 35.8 46.5 0.5 0.7 1.3 2.3 4.7 8.2 14.8 22.3 35.8 54.1 V1-00 H-05 0.65 1.0 1.8 3.3 7.0 11.1 22.1 34.5 53.8 68.0 0.65 0.9 1.8 3.2 6.8 11.1 21.6 33.6 52.4 66.0 V3-00 H-06 0.85 1.1 2.1 3.8 6.6 13.1 22.7 33.5 53.0 66.4 0.75 1.1 2.0 3.8 6.7 13.0 22.5 32.6 51.9 65.2
Table 3.6.3: Oil quantities for F.28, F. Size 38B 188B
BA 2010 EN 01.06 24 / 90
3.6.4
Helical worm gear units

Mounting position Type C.28 C.38 C.48 C.68 C.88 B3 00 H 01 0.2 0.5 0.7 1.5 1.7 B8 00 H 02 0.4 1.2 1.6 3.3 6.1 B7 00 H 03 0.6 1.3 1.7 4.1 6.5 B6 00 H 04 0.2 1.2 1.6 3.3 5.1 V5 00 H 05 0.6 1.2 1.3 2.8 4.5 V6 00 H 06 0.35 1.2 1.3 2.9 4.5
Table 3.6.4-1: Oil quantities for C, CA, CAS, CAT Size 28 88 Mounting position Type C.28 C.38 C.48 C.68 C.88 B5-01 H-01 0.2 0.4 0.5 1.5 1.7 B5-03 H-02 0.4 1.2 1.7 3.6 5.9 B5-02 H-03 0.6 1.3 1.8 4.2 7.3 B5-00 H-04 0.2 1.1 1.6 3.3 5.2 V1-00 H-05 0.6 1.0 1.3 3.1 4.8 V3-00 H-06 0.35 1.0 1.3 3.2 4.8
Table 3.6.4-2: Oil quantities for CZ, CF, CAD, CAF, CAZ, CADS, CAFS, CAZS, CADT, CAFT, CAZT Size 28 88
3.6.5
Tandem gear unit compound helical gear unit
3.6.5.1 Two and three stage helical gear units

Mounting position Type Z.38 Z 38 D/Z28 D.48 D 48 D/Z28 D.68 D 68 D/Z28 D.88 D 88 D/Z28 D.108 D 108 Z38 D.108 D 108 D38 D.128 D 128 Z38 D.128 D 128 Z48 D.128 D 128 D38 D.148 D 148 Z38 B3
0.5+0.25 0.75 1.1+0.25 1.35 1.7+0.25 1.95 4.0+0.25 4.25 7.1+0.5 7.6 7.1+0.5 7.6 9.4+0.5 9.9 9.4+1.0 10.4 9.4+0.5 9.9 12.5+0.5 13.0
B5 B14
0.5+0.25 0.75 1.0+0.25 1.25 1.6+0.25 1.85 3.6+0.25 3.85 5.7+0.5 6.2 5.7+0.5 6.2 6.8+0.5 7.3 6.8+1.0 7.8 6.8+0.5 7.3 9.4+0.5 9.9
B6
0.6+0.25 0.85 1.5+0.25 1.75 2.6+0.25 2.85 5.9+0.25 6.15 10.3+0.5 10.8 10.3+0.5 10.8 15.8+0.5 16.3 15.8+1.0 16.8 15.8+0.5 16.3 20.4+0.5 20.9
B7
0.6+0.25 0.85 1.4+0.25 1.65 2.4+0.25 2.65 5.4+0.25 5.65 9.5+0.5 10.0 9.5+0.5 10.0 14.8+0.5 15.3 14.8+1.0 15.8 14.8+0.5 15.3 19.1+0.5 19.6
B8
0.6+0.25 0.85 1.5+0.25 1.75 2.6+0.25 2.85 5.9+0.25 6.15 10.0+0.5 10.5 10.0+0.5 10.5 14.1+0.5 14.6 14.1+1.0 15.1 14.1+0.5 14.6 23.4+0.5 23.9
V1 V18
0.8+0.6 1.4 2.3+0.6 2.9 3.9+0.6 4.5 8.7+0.6 9.3 16.3+0.8 17.1 16.3+0.9 17.2 24.6+0.8 25.4 24.6+1.8 26.4 24.6+0.9 25.5 30.6+0.8 31.4
V3 V19
1.0+0.7 1.7 2.4+0.7 3.1 4.0+0.7 4.7 8.9+0.7 9.6 14.2+1.0 15.2 14.2+1.1 15.3 21.8+1.0 22.8 21.8+2.4 24.2 21.8+1.1 22.9 28.2+1.0 29.2
V5
0.7+0.6 1.3 2.4+0.6 3.0 4.0+0.6 4.6 9.3+0.6 9.9 15.6+0.7 16.3 15.6+0.9 16.5 24.4+0.7 25.1 24.4+1.8 26.2 24.4+0.9 25.3 32.2+0.7 32.9
V6
1.1+0.7 1.8 2.4+0.7 3.1 4.0+0.7 4.7 8.9+0.7 9.6 13.7+1.2 14.9 13.7+1.1 14.8 21.5+1.2 22.7 21.5+2.4 23.9 21.5+1.1 22.6 27.9+1.2 29.1
BA 2010 EN 01.06 25 / 90
Type D.148 D 148 Z48 D.148 D 148 D38 D.168 D 168 Z48 D.168 D 168 Z68 D.168 D 168 D48 D.188 D 188 Z48 D.188 D 188 Z68 D.188 D 188 D48
Mounting position B3
12.5+1.0 13.5 12.5+0.5 13.0 19.0+1.0 20.0 19.0+1.7 20.7 19.0+1.0 20.0 18.4+1.0 19.4 18.4+1.7 20.1 18.4+1.0 19.4
B5 B14
9.4+1.0 10.4 9.4+0.5 9.9 16.0+1.0 17.0 16.0+1.7 17.7 16.0+1.0 17.0 18.4+1.0 19.4 18.4+1.7 20.1 18.4+1.0 19.4
B6
20.4+1.0 21.4 20.4+0.5 20.9 34.1+1.0 35.1 34.1+1.7 35.8 34.1+1.0 35.1 48.0+1.0 49.0 48.0+1.7 49.7 48.0+1.0 49.0
B7
19.1+1.0 20.1 19.1+0.5 19.6 31.2+1.0 32.2 31.2+1.7 32.9 31.2+1.0 32.2 46.0+1.0 47.0 46.0+1.7 47.7 46.0+1.0 47.0
B8
23.4+1.0 24.4 23.4+0.5 23.9 33.8+1.0 34.8 33.8+1.7 35.5 33.8+1.0 34.8 73.0+1.0 74.0 73.0+1.7 74.7 73.0+1.0 74.0
V1 V18
30.6+1.8 32.4 30.6+0.9 31.5 53.0+1.8 54.8 53.0+3.0 56.0 53.0+2.3 55.3 83.0+1.8 84.8 83.0+3.0 86.0 83.0+2.3 85.3
V3 V19
28.2+2.4 30.6 28.2+1.1 29.3 43.7+2.4 46.1 43.7+4.1 47.8 43.7+2.4 46.1 68.0+2.4 70.4 68.0+4.1 72.1 68.0+2.4 70.4
V5
32.2+1.8 34.0 32.2+0.9 33.1 54.4+1.8 56.2 54.4+3.0 57.4 54.4+2.3 56.7 83.0+1.8 84.8 83.0+3.0 86.0 83.0+2.3 85.3
V6
27.9+2.4 30.3 27.9+1.1 29.0 42.2+2.4 44.6 42.2+4.1 46.3 42.2+2.4 44.6 68.0+2.4 70.4 68.0+4.1 72.1 68.0+2.4 70.4
Table 3.6.5.1: Oil quantities for Z.38, D. Size 48 188
3.6.5.2 Bevel helical gear units

Mounting position Type K.38 K 38 D/Z28 K.48 K 48 D/Z28 K.68 K 68 D/Z28 K.88 K 88 D/Z28 K.108 K 108 Z38 K.108 K 108 Z48 K.108 K 108 D38 K.128 K 128 Z38 K.128 K 128 Z48 K.128 K 128 D38 K.148 K 148 Z38 K.148 K 148 Z68 K.148 K 148 D38 K.168 K 168 Z48 B3 00 H 01
0.5+0.25 0.75 0.7+0.25 0.95 1.6+0.25 1.85 2.6+0.25 2.85 5.5+0.5 6.0 5.5+1.0 6.5 5.5+0.5 6.0 8.3+0.5 8.8 8.3+1.0 9.3 8.3+0.5 8.8 14.8+0.5 15.3 14.8+1.7 16.5 14.8+0.5 15.3 21.6+1.0 22.6
B8 00 H 02
1.1+0.25 1.35 1.6+0.25 1.85 3.2+0.25 3.45 5.7+0.25 5.95 9.5+0.5 10.0 9.5+1.0 10.5 9.5+0.5 10.0 19.6+0.5 20.1 19.6+1.0 20.6 19.6+0.5 20.1 30.2+0.5 30.7 30.2+1.7 31.9 30.2+0.5 30.7 45.6+1.0 46.6
B7 00 H 03
1.4+0.6 2.0 2.0+0.6 2.6 3.9+0.6 4.5 7.4+0.6 8.0 12.6+0.8 13.4 12.6+1.8 14.4 12.6+0.9 13.5 24.4+0.8 25.2 24.4+1.8 26.2 24.4+0.9 25.3 37.0+0.8 37.8 37.0+3.0 40.0 37.0+0.9 37.9 60.5+1.8 62.3
B6 00 H 04
0.8+0.7 1.5 1.2+0.7 1.9 2.7+0.7 3.4 5.0+0.7 5.7 8.8+1.0 9.8 8.8+2.4 11.2 8.8+1.1 9.9 15.8+1.0 16.8 15.8+2.4 18.2 15.8+1.1 16.9 22.0+1.0 23.0 22.0+4.1 26.1 22.0+1.1 23.1 34.2+2.4 36.6
V5 00 H 05
1.0+0.25 1.25 1.5+0.25 1.75 3.0+0.25 3.25 4.9+0.25 5.15 8.7+0.5 9.2 8.7+1.0 9.7 8.7+0.5 9.2 16.9+0.5 17.4 16.9+1.0 17.9 16.9+0.5 17.4 25.8+0.5 26.3 25.8+1.7 27.5 25.8+0.5 26.3 40.2+1.0 41.2
V6 00 H 06
0.9+0.25 1.15 1.8+0.25 2.05 3.0+0.25 3.25 5.2+0.25 5.45 8.3+0.5 8.8 8.3+1.0 9.3 8.3+0.5 8.8 16.1+0.5 16.6 16.1+1.0 17.1 16.1+0.5 16.6 27.0+0.5 27.5 27.0+1.7 28.7 27.0+0.5 27.5 38.5+1.0 39.5
BA 2010 EN 01.06 26 / 90
Type K.168 K 168 Z68 K.168 K 168 D48 K.188 K 188 Z68 K.188 K 188 Z88 K.188 K 188 D68
Mounting position B3 00 H 01
21.6+1.7 23.3 21.6+1.1 22.7 33.8+1.7 35.5 33.8+3.7 37.5 33.8+1.6 35.4
B8 00 H 02
45.6+1.7 47.3 45.6+1.1 46.7 82.5+1.7 84.2 82.5+3.7 86.2 82.5+1.6 84.1
B7 00 H 03
60.5+3.0 63.5 60.5+2.3 62.8 104.2+3 107.2 104.2+6.8 111 104.2+3.9 108.1
B6 00 H 04
34.2+4.1 38.3 34.2+2.4 36.6 63.4+4.1 67.5 63.4+8.8 72.2 63.4+4.0 67.4
V5 00 H 05
40.2+1.7 41.9 40.2+1.1 41.3 70.7+1.7 72.4 70.7+3.7 74.4 70.7+1.6 72.3
V6 00 H 06
38.5+1.7 40.2 38.5+1.1 39.6 69.4+1.7 71.1 69.4+3.7 73.1 69.4+1.6 71.0
Table 3.6.5.2-1: Oil quantities for K, KA, KAS, KAT Size 38 188
Mounting position Type K.38 K 38 D/Z28 K.48 K 48 D/Z28 K.68 K 68 D/Z28 K.88 K 88 D/Z28 K.108 K 108 Z38 K.108 K 108 Z48 K.108 K 108 D38 K.128 K 128 Z38 K.128 K 128 Z48 K.128 K 128 D38 K.148 K 148 Z38 K.148 K 148 Z68 K.148 K 148 D38 K.168 K 168 Z48 K.168 K 168 Z68 K.168 K 168 D48 K.188 K 188 Z68 B5-01 H-01
0.5+0.25 0.75 0.7+0.25 0.95 1.6+0.25 1.85 2.6+0.25 2.85 6.2+0.5 6.7 6.2+1.0 7.2 6.2+0.5 6.7 8.7+0.5 9.2 8.7+1.0 9.7 8.7+0.5 9.2 14.8+0.5 15.3 14.8+1.7 16.5 14.8+0.5 15.3 21.7+1.0 22.7 21.7+1.7 23.4 21.7+1.1 22.8 33.8+1.7 35.5
B5-03 H-02
1.1+0.25 1.35 1.7+0.25 1.95 3.2+0.25 3.45 5.8+0.25 6.05 9.9+0.5 10.4 9.9+1.0 10.9 9.9+0.5 10.4 19.6+0.5 20.1 19.6+1.0 20.6 19.6+0.5 20.1 30.1+0.5 30.6 30.1+1.7 31.8 30.1+0.5 30.6 46.3+1.0 47.3 46.3+1.7 48.0 46.3+1.1 47.4 82.5+1.7 84.2
B5-02 H-03
1.5+0.6 2.1 2.3+0.6 2.9 3.9+0.6 4.5 7.7+0.6 8.3 13.7+0.7 14.4 13.7+1.8 15.5 13.7+0.9 14.6 25.0+0.7 25.7 25.0+1.8 26.8 25.0+0.9 25.9 41.0+0.7 41.7 41.0+3.0 44.0 41.0+0.9 41.9 62.6+1.8 64.4 62.6+3.0 65.6 62.6+2.3 64.9 104.2+3 107.2
B5-00 H-04
0.8+0.7 1.5 1.2+0.7 1.9 2.6+0.7 3.3 5.0+0.7 5.7 8.9+1.0 9.9 8.9+2.4 11.3 8.9+1.1 10.0 14.8+1.0 15.8 14.8+2.4 17.2 14.8+1.1 15.9 25.0+1.0 26.0 25.0+4.1 29.1 25.0+1.1 26.1 34.8+2.4 37.2 34.8+4.1 38.9 34.8+2.4 37.2 63.4+4.1 67.5
V1-00 H-05
1.0+0.25 1.25 1.6+0.25 1.85 2.8+0.25 3.05 5.1+0.25 5.35 10.0+0.5 10.5 10.0+1.0 11.0 10.0+0.5 10.5 17.5+0.5 18.0 17.5+1.0 18.5 17.5+0.5 18.0 26.0+0.5 26.5 26.0+1.7 27.7 26.0+0.5 26.5 41.1+1.0 42.1 41.1+1.7 42.8 41.1+1.1 42.2 70.7+1.7 72.4
V3-00 H-06
0.9+0.25 1.15 1.8+0.25 2.05 3.0+0.25 3.25 5.0+0.25 5.25 8.9+0.5 9.4 8.9+1.0 9.9 8.9+0.5 9.4 16.6+0.5 17.1 16.6+1.0 17.6 16.6+0.5 17.1 28.1+0.5 28.6 28.1+1.7 29.8 28.1+0.5 28.6 39.4+1.0 40.4 39.4+1.7 41.1 39.4+1.1 40.5 69.4+1.7 71.1
BA 2010 EN 01.06 27 / 90
Mounting position Type K.188 K 188 Z88 K.188 K 188 D68 B5-01 H-01
33.8+3.7 37.5 33.8+1.6 35.4
B5-03 H-02
82.5+3.7 86.2 82.5+1.6 84.1
B5-02 H-03
104.2+6.8 111 104.2+3.9 108.1
B5-00 H-04
63.4+8.8 72.2 63.4+4.0 67.4
V1-00 H-05
70.7+3.7 74.4 70.7+1.6 72.3
V3-00 H-06
69.4+3.7 73.1 69.4+1.6 71.0
Table 3.6.5.2-2: Oil quantities for KZ, KF, KAD, KAF, KAZ, KADS, KAFS, KAZS, KADT, KAFT, KAZT Size 38 188
3.6.5.3 Parallel shaft helical gear units

Mounting position Type FD.38B FD 38B D/Z28 FD.48B FD 48B D/Z28 FD.68B FD 68B D/Z28 FD.88B FD 88B D/Z28 FD.108B FD 108B Z38 FD.108B FD 108B D38 FD.128B FD 128B Z38 FD.128B FD 128B Z48 FD.128B FD 128B D38 FD.148B FD 148B Z38 FD.148B FD 148B Z48 FD.148B FD 148B D38 FD.168B FD 168B Z48 FD.168B FD 168B Z68 FD.168B FD 168B D48 FD.188B FD 188B Z48 FD.188B FD 188B Z68 FD.188B FD 188B D48 B5-01 H-01
0.9+0.25 1.15 2.0+0.25 2.25 3.3+0.25 3.55 6.3+0.25 6.6 10.6+0.5 11.1 10.6+0.5 11.1 16.8+0.5 17.3 16.8+1.0 17.8 16.8+0.5 17.3 24.7+0.5 25.2 24.7+1.0 25.7 24.7+0.5 25.2 44.0+1.0 45.0 44.0+1.7 45.7 44.0+1.0 45.0 52.0+1.0 53.0 52.0+1.7 53.7 52.0+1.0 53.0
B5-03 H-02
0.6+0.25 0.85 0.9+0.25 1.15 2.3+0.25 2.55 5.0+0.25 5.3 9.1+0.5 9.6 9.1+0.5 9.6 13.5+0.5 14.0 13.5+1.0 14.5 13.5+0.5 14.0 20.3+0.5 20.8 20.3+1.0 21.3 20.3+0.5 20.8 28.8+1.0 29.8 28.8+1.7 30.5 28.8+1.0 29.8 38.4+1.0 39.4 38.4+1.7 40.1 38.4+1.0 39.4
B5-02 H-03
0.7+0.25 0.95 1.3+0.25 1.55 2.4+0.25 2.65 4.7+0.25 5.0 8.2+0.5 8.7 8.2+0.5 8.7 15.2+0.5 15.7 15.2+1.0 16.2 15.2+0.5 15.7 21.8+0.5 22.3 21.8+1.0 22.8 21.8+0.5 22.3 36.0+1.0 37.0 36.0+1.7 37.7 36.0+1.0 37.0 44.5+1.0 45.5 44.5+1.7 46.2 44.5+1.0 45.5
B5-00 H-04
0.7+0.25 0.95 1.3+0.25 1.55 2.3+0.25 2.55 4.7+0.25 5.0 8.2+0.5 8.7 8.2+0.5 8.7 14.8+0.5 15.3 14.8+1.0 15.8 14.8+0.5 15.3 22.3+0.5 22.8 22.3+1.0 23.3 22.3+0.5 22.8 35.8+1.0 36.8 35.8+1.7 37.5 35.8+1.0 36.8 54.1+1.0 55.1 54.1+1.7 55.8 54.1+1.0 55.1
V1-00 H-05
0.9+0.6 1.5 1.8+0.6 2.4 3.2+0.6 3.8 6.8+0.6 7.7 11.1+0.8 11.9 11.1+0.9 12.0 21.6+0.8 22.4 21.6+1.8 23.4 21.6+0.9 22.5 33.6+0.8 34.4 33.6+1.8 35.4 33.6+0.9 34.5 52.4+1.8 54.2 52.4+3.0 55.4 52.4+2.3 54.7 66.0+1.8 67.8 66.0+3.0 69.0 66.0+2.3 68.3
V3-00 H-06
1.1+0.7 1.8 2.0+0.7 2.7 3.8+0.7 4.5 6.7+0.7 7.7 13.0+1.0 14.0 13.0+1.1 14.1 22.5+1.0 23.5 22.5+2.4 24.9 22.5+1.1 23.6 32.6+1.0 33.6 32.6+2.4 35.0 32.6+1.1 33.7 51.9+2.4 54.3 51.9+4.1 56.0 51.9+2.4 54.3 65.2+2.4 67.6 65.2+4.1 69.3 65.2+2.4 67.6
Table 3.6.5.3: Oil quantities for FD. Size 38B 188B BA 2010 EN 01.06 28 / 90
3.6.5.4 Helical worm gear units

Type yp B3 00 H 01 C.38 C 38 D/Z28 C.48 C 48 D/Z28 C.68 C 68 D/Z28 C.88 C 88 D/Z28
0.5+0.25 0.75 0.7+0.25 0.95 1.5+0.25 1.75 1.7+0.25 0.95
Mounting position B8 00 H 02
1.2+0.25 1.45 1.6+0.25 1.85 3.3+0.25 3.55 6.1+0.25 6.35
B7 00 H 03
1.3+0.6 1.9 1.7+0.6 2.3 4.1+0.6 4.7 6.5+0.6 7.1
B6 00 H 04
1.2+0.7 1.9 1.6+0.7 2.3 3.3+0.7 4.0 5.1+0.7 5.8
V5 00 H 05
1.2+0.25 1.45 1.3+0.25 1.55 2.8+0.25 3.05 4.5+0.25 4.75
V6 00 H 06
1.2+0.25 1.45 1.3+0.25 1.55 2.9+0.25 3.15 4.5+0.25 4.75
Table 3.6.5.4-1: Oil quantities for C, CA, CAS, CAT Size 38 88 Mounting position Type C.38 C 38 D/Z28 C.48 C 48 D/Z28 C.68 C 68 D/Z28 C.88 C 88 D/Z28 B5-01 H-01
0.4+0.25 0.65 0.5+0.25 0.75 1.5+0.25 1.75 1.7+0.25 0.95
B5-03 H-02
1.2+0.25 1.45 1.7+0.25 1.95 3.6+0.25 3.85 5.9+0.25 6.15
B5-02 H-03
1.3+0.6 1.9 1.8+0.6 2.4 4.2+0.6 4.8 7.3+0.6 7.9
B5-00 H-04
1.1+0.7 1.8 1.6+0.7 2.3 3.3+0.7 4.0 5.2+0.7 5.9
V1-00 H-05
1.0+0.25 1.25 1.3+0.25 1.55 3.1+0.25 3.35 4.8+0.25 5.05
V3-00 H-06
1.0+0.25 1.25 1.3+0.25 1.55 3.2+0.25 3.45 4.8+0.25 5.05
Table 3.6.5.4-2: Oil quantities for CZ, CF, CAD, CAF, CAZ, CADS, CAFS, CAZS, CADT, CAFT, CAZT Size 38 88
BA 2010 EN 01.06 29 / 90
4.
4.1
Technical description
General description
The gear units are supplied with one, two or three transmission stages. The gear units are suitable for the different mounting positions, taking into consideration the oil level.
4.2
Housing
The gear unit housings are of grey cast iron or of aluminium in the case of size 18 and 28.
4.3
Toothed components
The toothed components of the gear unit are hardened. In the case of helical gear units the worm is hardened and ground and the gear manufactured from bronze.
4.4
Lubrication
The toothed components are adequately supplied with lubricant by dip lubrication.
4.5
Shaft bearing
All shafts are mounted in rolling bearings. The rolling bearings are lubricated by dip lubrication or oil spray lubrication. Bearings that are not supplied with lubricant are closed and grease lubricated.
4.6
Shaft seals
Radial shaft sealing rings, combination shaft sealing rings, Taconite seals and rotating mechanical seals at the shaft outlets prevent lubricant from escaping from the housing and impurities from entering, see BA 2510.
4.6.1
Radial shaft sealing rings

Radial shaft sealing rings are used throughout as a standard seal. They are provided with an additional dust lip to protect the actual seal lip against contaminants from outside. At higher ambient temperatures (> +40 C ... +100 C) shaft sealing rings of temperature resistant material are used (by contractual agreement).
BA 2010 EN 01.06 30 / 90
4.6.2
Combination shaft sealing rings (optional)

Combination shaft sealing rings offer an improved oil seal. Protected running surface for radial shaft sealing ring, no damage during fitting. Additional sealing lips for protection against dirt, decoupled sealing system prevents shaft shrinkage through corrosion or dirt. Rubberised inside and outside diameter. Grease packing prevents the seal lips from running dry.
Figure 4.6.2: Combination shaft sealing ring During repair, e.g. if the shaft has shrunk, the standard seal can be replaced with a combination shaft sealing ring.
4.7
Cooling Caution.
Dirt deposits impair cooling.
The gear units normally require no additional cooling. The generously dimensioned housing surface is sufficient for conducting away dissipated heat where there is free convection. If the difference between the temperature of the housing and the ambient temperature (max. +40 C) exceeds 70 K, please contact the FLENDER TBINGEN GMBH customer service.
4.8
Backstop
For certain requirements, the gear units can be fitted with a mechanical backstop. It can be fitted either in the coupling housing or in the bevel helical gear unit. It permits only the correct direction of rotation during the operation of the unit. This is marked by a corresponding direction arrow.
Caution.
Damage or destruction of the backstop through wrong direction of rotation. Do not run motor against the backstop. Observe information on the gear unit. The backstop is fitted with centrifugally operated sprags. When the gear unit is running in the specified direction, the inner ring and the cage with the sprags also rotate while the outer ring remains stationary. Where the backstop is used in the coupling housing, lifting of the sprags is ensured at speeds above 1000 rpm. The backstop is wear free. These need no maintenance.
BA 2010 EN 01.06 31 / 90
The drive speed must not fall below 1000 rpm in continuous operation. Starting and stopping operations ( 20 starts/stops per hour) are permitted.
Caution.
In the case of applications at speeds under 1000 rpm or frequent starting and stopping operations ( 20 starts / stops an hour) the service life is limited. Ensure that the backstop is replaced in good time. If used in the bevel helical gear unit (gear unit intermediate shaft), the backstop operates at below the lift off speed of the sprags in a separate oil chamber. The oil must be changed at the same intervals as the gear unit.
4.9
Rating plates
The rating plates of the gear units or gear motors are normally of coated aluminium foil. They are covered with a special masking film which guarantees permanent resistance to UV radiation and media of all kinds (oils, greases, salt water, cleaning agents, etc.). The adhesives and materials are selected to ensure extremely firm adhesion and permanent high legibility, even at the limits of the range of operating temperatures (-40 C ... +155 C). The edges of the rating plates are coated with a matching special paint, see section 4.10 Paint coats. In special cases, i.e. special specifications, riveted or bolted metal plates are used.
4.10
Paint coats
4.10.1 General
All paint finishes are sprayed on.
Plastic surfaces exposed to friction in normal operation can become electrostatically charged. With use in zone 21 and 22 (dusts) the thickness of the paint finish must not exceed 200 mm.
Note.
Information on repaintability is not a guarantee of the quality of the paint material supplied by your supplier. Only the paint manufacturer is liable for the quality and compatibility.
BA 2010 EN 01.06 32 / 90
4.10.2 Painted version

Paint system Plastic RAL 1007, 1012, 1023, 2000, 2004, 3000, 5007, 5009, 5010, 5012, 5015, 6011, 7001, 7011, 7030, 7032, 7035, 9005, 9006, black mat 2K PUR 2K epoxide
Colours
RAL 1003, 1018, 2004, RAL 5015, 6018, 7031, 5002, 5015, 6011, 7000, 7035 7031, 9010, 9011, 9016 Standard 2 layer paint finish, especially for outside installation or higher corrosion protection requirements after prior rubbing down with: 2K PUR paint, 2K epoxide paint high quality paint finish in the outside area or where exposed to dilute acid and alkaline solution (v 5%) after prior rubbing down with: 2K PUR paint, 2K epoxide paint, 2K AC paint
Typical area of application
Standard 1 layer paint finish for interior areas after prior rubbing down with: Plastic or synthetic resin paint; overpaintable after a setting time of 3 days good resistance to: cleaning agent, oil and petrol; resistant to: exposure to dilute acid and alkaline solution for a short time (v 3%); not solvent resistant; not steam resistant -40 C ... +100 C temporarily up to +140 C Standard paint finish with very good adhesive property, not suitable for: storage or installation outside
Repaintability
Chem. phys. resistance
very good resistance to: excellent resistance oil, grease, petrol, water, to: weak acid and seawater and cleaning alkaline solution agent; good resistance (v 5%), oil, grease, to: weather action and petrol, cooling dilute acid and alkaline emulsion, salt, solvent; solution (v 3%); good tough and mechanical resistance scratchproof paint film to: abrasion -40 C ... +150 C -40 C ... +150 C
Temperature resistance
Remark
2K epoxide paint Standard paint finish for becomes chalky when cooling tower and installed outside agitator drives or, if (without effect on requested, resistance to quality), high gloss sea water below deck, with good mechanical etc. resistance
Table 4.10.2: Painted version
BA 2010 EN 01.06 33 / 90
4.10.3 Primed version

Paint system Standard colour Typical area of application primed RAL 7032 for repainting*): adhesion promoter for all common paint systems, temporary corrosion prevention very good with: plastic paint, synthetic resin paint, 2K PUR paint, 2K epoxide paint, SH paint, 2K AC paint good resistance to: cleaning agent, good salt spray resistance; resistant to: oil and petrol -40 C ... +150 C Adhesion promoter with very good adhesive property and good corrosion prevention (-40 C ... +150 C) GCI parts, dip primed, steel parts primed or galvanised, aluminium and plastic parts untreated for repainting*): temporary corrosion prevention very good with: Plastic paint, synthetic resin paint, oil paint, bitumen paint, 2K PUR paint, 2K epoxide paint unpainted
Repaintability
Chem. phys. resistance Temperature resistance Remark Table 4.10.3: Primed version
*)On drive versions which are primed or unpainted the rating plate and the masking film are covered with a paint protective film, see section 4.9 Rating plates". It enables repainting without further preparation, e.g. masking with adhesive tape.
BA 2010 EN 01.06 34 / 90
Peel off paint protective film

The paint coat must have fully hardened before the paint protective film is peeled off (be at least "touch proof").
Masking film Rating plate Paint protective film Peeling tab
Figure 4.10.3: Peel off paint protective film Company Logo 1) Pull peeling tab up. 2) Carefully peel the paint protective film off diagonally from one corner (not parallel to the plate). 3) If necessary, blow paint fragments away or wipe them off with a clean cloth.
5.
5.1
Incoming goods, Handling and Storage

Incoming goods Caution.
Ensure that damaged drives are not put into operation.
Note.
Inspect the delivery immediately after arrival for completeness and any transport damage. Notify the freight company of any damage caused during transport immediately, as otherwise it is not possible to have damage rectified free of charge. The drive unit is delivered in the fully assembled condition. Additional items are delivered separately packaged. The products supplied are listed in the despatch papers.
BA 2010 EN 01.06 35 / 90
5.2
Handling
Different forms of packaging may be used, depending on the size of the drive and method of transport. Unless otherwise agreed, the packaging complies with the HPE Packaging Guidelines (German Federal Association for wooden packaging means, pallets and export packaging). Note the symbols applied to the packing. These have the following meanings:
This way up
Fragile
Keep dry
Keep cool
Centre of gravity
Use no hand hook
Attach here
Figure 5.2-1: Symbols on packaging
Fasten drive for suspended transport Danger.
Adhere to the maximum load in direction F of the transport eyes and eye bolt axis, see figure and table 5.2-2 bzw. 5.2-3 Max. load in kg from drive to be attached. Use eye bolt on motor only for transporting the unmounted or demounted motor or as auxiliary support for the drive, e.g. to achieve a horizontal mounting position. If necessary, use additional, suitable carrying means for transport or on installation. When attaching by a number of chains and ropes just two strands must be sufficient to bear the entire load. Secure carrying means against slipping.
K.38 d2 [mm] m [kg] 22 200
K.48 22 250
K.68 26 350
K.88 K.108 K.128 K.148 K.168 K.188 30 600 35 750 40 800 44 1300 55 1800 55 2300
Figure and Table 5.2-2: Max. load in kg from drive to be attached, with pull in direction F.
d3 [mm] M m [kg]
36 M8 140
45 M 10 230
54 M 12 340
63 M 16 700
72 M 20 1200
90 M 24 1800
108 M 30 3600
Figure and Table 5.2-3: Max. load in kg from drive to be attached, with pull in direction F of the bolt axis.
BA 2010 EN 01.06 36 / 90
Caution.
Do not use the front threads at the shaft ends to attach eye bolts for transport.
The use of force causes damage to the drive unit. Transport drive carefully. Avoid knocks. Remove any transport fixtures fitted before putting into operation and keep them safe or render them ineffective. Use them again for further transport or render them ineffective again. 1) Mount the drive on the transport device by the heaviest permissible weight to be attached. This will normally be on the main gear unit. 2) Check that the eye bolt is firmly seated. 3) Drive is slung for transport.
Caution.
5.3
Storage
The gear unit must be stored in its position of use on a horizontal wooden support in a dry place not subject to high temperature fluctuations and covered over. The storage place must be free from vibration and shaking.
Danger.
Do not stack drive units one on top of another.
Caution.
Mechanical damage (scratches), chemical damage (acids, alkalis) and thermal damage (sparks, welding beads, heat) cause corrosion which may cause failure of the external protective coating. Ensure that the paint is not damaged. The drive units are provided with an interior preservative agent; the free shaft ends and flanges are painted for protection.
The guarantee period for the standard preservative lasts 6 months and, unless otherwise agreed, begins at the date of delivery of the gear unit. In the case of longer periods of storage (> 6 months) special arrangements must be made for preservation. Contact the FLENDER TBINGEN GMBH customer service.
Note.
BA 2010 EN 01.06 37 / 90
6.
6.1
Installation
General information on installation Drives in ATEX version.
Affect on bearings of stray electric currents from electrical equipment. When mounting or connecting the gear unit to the machine care must be taken that potential is equalised.
When working with solvents, ensure adequate ventilation. Do not inhale vapours. Do not smoke!
Danger.
Overheating of the drives through exposure to direct sunlight. Provide suitable safety equipment, such as covers and roofs.
Caution.
Irreparable damage to toothed components and bearings from fusing. Do not carry out any welding work on the drive. The drives must not be used as an earthing point for welding operations.
Caution.
Note.
Use headless bolts of strength class 8.8 or higher to fasten the drives.
Exercise particular care when assembling and installing. The manufacturer cannot be held liable for damage caused by incorrect assembly and installation. Ensure that there is sufficient space around the drive for assembly, maintenance and repair. On drives with a fan leave sufficient free space for the entry of air. Provide sufficient lifting gear at the start of assembly and fitting work. Use all the fastening means which have been assigned to the relevant assembly option. Cap screws cannot be used in some cases, as there is insufficient space available for inserting them. In case of doubt please contact the FLENDER TBINGEN GMBH customer service, quoting the type of gear unit.
BA 2010 EN 01.06 38 / 90
6.2
Fastening in the case of high shock loads

In the case of high shock loads provide additional suitable positive fastenings such as cylindrical taper pins or spring pins.
Do not use spring washers, serrated lock washers, spring or toothed lock washers, cup washers or conical spring washers as a substitute for the above mentioned positive fastenings. Do not subject the gear unit housing to excessive stress when tightening the fastening bolts.
Caution.
6.3 6.3.1
Drives with foot mounting Foundation

The foundation must be level and free from dirt.
The levelness of the gear unit support must not exceed the following values: for gear units up to size 88 v 0.1 mm for gear units from size 108 v 0.2 mm. The foundation should be designed in such a way that no resonance vibrations are created and that no vibrations are transmitted from adjacent foundations. Steel structures on which the unit is to be mounted must be rigid. They must be designed according to the weight and torque, taking into account the forces acting on the gear unit. When fastening the gear unit to concrete foundations by means of foundation blocks, suitable recesses should be made in the foundation. Align and grout the slide rails into the foundation.
Note.
6.3.2
Installing gear units with foot mounting

Use stud bolts or headless bolts of strength class 8.8 or higher for the foot mounting.
6.4
Drive units in foot or flange version

The drive must be fastened for force and torque transmission only to either the flange or the foot mounting in accordance with section 6.3 Drives with foot mounting" to prevent overstress on the gear unit housings. The second mounting option (foot or flange) is usually intended for add on elements, e.g. safety covers with an intrinsic weight of up to 30% of the weight of the drive.
BA 2010 EN 01.06 39 / 90
Do not subject gear housings to overstress from add on elements. Add on elements must not transmit forces, torques and vibration to the drives.
Caution.
6.5
Drive units with C type housing flange

In the case of sizes 108 to 188 the customer's interface can be pinned on the C type housing flange. The output flanges are designed to enable the permissible torques and radial forces to be reliably transmitted by the bolt connections. For additional fastening, e.g. in the case of high shock loads, the drilled pin holes can be used. The gear unit can also be drilled and pinned together with the machine. For this the specified dimensions must be adhered to.
Caution.
Observe maximum drilling depth (A A).
EZ128, DZ/ZZ108
EZ148, DZ/ZZ128
DZ/ZZ148
DZ/ZZ168, DZ/ZZ188
Figure 6.5-1: C type housing flange helical gear units BA 2010 EN 01.06 40 / 90
K.Z.108, F.Z.108B
K.Z.128, F.Z.128B
K.Z.148, F.Z.148B
K.Z.168, K.Z.188, F.Z.168B, F.Z.188B
Figure 6.5-2: C type housing flange bevel helical gear units and parallel shaft helical gear units Spring pins, heavy duty design, to DIN 1481: Use pin holes provided in the housing flange. Cylindrical grooved pins with chamfer to DIN EN 28740/ISO 8740: Drill connecting component together with housing.
6.6
Installation of input drive and output drive elements on gear unit shafts
Use a fitting device to fit the drive or output elements. Located in the shaft end faces are centring holes to DIN 332 which can be used for this.
Note.
Deburr the parts of elements to be fitted in the area of the hole or keyways. Recommendation: 0.2 x 45
BA 2010 EN 01.06 41 / 90
Example of a fitting device for fitting couplings or hubs on the ends of gear unit or motor shafts. If necessary, the axial thrust bearing on the fitting device can be dispensed with.
Figure 6.6-1: Fitting device
Mount in or output elements Caution.
Damage to shaft sealing ring through solvent or benzine. Protect against contact at all time. 1) Using petrol ether or solvent, remove the corrosion preventive paint coat on the shaft ends and flanges or remove any protective skin provided.
Caution.
Damage to bearings, housing, shaft and locking rings. Do not use a hammer to force the drive and output elements to be mounted onto the shaft. 2) Fit the drive and output elements onto the shafts and, if necessary, secure them. F a F a Correct mounting arrangement of running wheel, gear or chain wheel, belt pulley, etc., to keep the shaft and bearing load exerted by transverse forces as low as possible.
Figure 6.6-2: Mounting arrangement a Hub wrong right Where couplings are to be fitted in a heated condition, please observe the specific operating instructions for the coupling.
BA 2010 EN 01.06 42 / 90
6.7
Steel safety cover for hollow shaft and shrink disc Drives in ATEX version.
Sparks may be caused by a damaged safety cover. Replace damaged safety cover immediately. The steel safety cover is delivered ready fitted to the gear unit flange. The safety cover must be demounted to fit the output shaft.
Mounting the protective cover

1) Undo screws part 1 and remove protective cover part 2. 2) Using a suitable cleaning agent, clean the support surface of the safety cover, part 2, on the gear unit. 3) Ensure that the O ring, part 3, is correctly seated. 4) Coat the supporting surface of the safety cover, part 2, with a suitable sealing agent. 5) Fasten protective cover part 2 by screws.
1 3
1 4 Figure 6.7: Steel safety cover 1 2 3 4 5 Bolt Protective cover O ring Adaptor ring Gear unit housing
The adaptor ring, part 4, is provided only on foot mounted versions of bevel helical gear units sizes 68, 108, 128, 148 and 168.
BA 2010 EN 01.06 43 / 90
6.8
Cast iron end cover for hollow shaft

The cast iron end cover is delivered ready fitted on the gear unit flange. The end cover must be demounted to fit the output shaft.
Assembly of end cover

1) Undo screws part 1 and remove end cover part 2. 2) Using a suitable cleaning agent, clean the support surface of the end cover, part 2, on the gear unit. 3) Coat the supporting surface of the end cover, part 2, with a suitable sealing agent. 4) Fasten end cover part 2 by screws.
3 1
Figure 6.8: End cover made from cast iron 1 2 3 Bolt End cover Gear unit housing
BA 2010 EN 01.06 44 / 90
6.9
Shaft mounting gear unit with hollow shaft and parallel key, hollow shaft and splines, hollow shaft and shrink disk Mounting the hollow shaft Caution.
6.9.1
Damage to shaft sealing ring through solvent or benzine. Protect against contact at all time. 1) Using petrol or a solvent, remove the corrosion preventive paint coat from the shaft ends and flanges. 2) Check the seats or edges of the hollow and machine shaft for damage. In case of damage contact the FLENDER TBINGEN GMBH customer service.
Note.
Coat with the mounting paste which comes with the delivery or any suitable lubricant, e.g. Calypsol type H 443 HD88 grease, to prevent frictional corrosion of the contact surfaces.
Caution in the case of shrink disks.
Lubricants in the area of the shrink disk seat impair torque transmission. Keep bore in hollow shaft and machine shaft completely grease free. Do not use impure solvents and cleaning cloths. 3) Fit the drive with the aid of nut and threaded spindle. The counterforce is provided by the hollow shaft.
The hollow shaft must be precisely aligned with the machine shaft to avoid misalignment. Do not overstress hollow shaft axially and radially. Failure to adhere to these may result in a failure of the bearings through excessive load. 4) Secure the hollow shaft axially on the machine shaft with e.g. a locking ring, washer or set screw at a tightening torque TA acc. to table 6.9.1 Tightening torque TA set screw". Set screw TA [Nm] M5 5 M6 8 M8 8 M 10 14 M 12 24 M 16 60 M 20 120 M 24 200
Caution.
Table 6.9.1: Tightening torque TA set screw
Note for shrink disks.
The hollow shaft is axially secured on the machine shaft by means of a shrink disk connection.
BA 2010 EN 01.06 45 / 90
Figure 6.9.1-1: Mounting hollow shaft and parallel key Part. 3 Part 4 are not included in scope of delivery. 1 2 6 5 3 4
Figure 6.9.1-2: Mounting hollow shaft and splines Part. 3 Part 4 are not included in scope of delivery. 1 8 2 5 3 4
Figure 6.9.1-3: Mounting hollow shaft and shrink disk Part 3 Part 5 are not included in scope of delivery. a b 1 2 3 4 5 6 7 8 greased absolutely free of grease Machine shaft Hollow shaft Hexagon nut Threaded spindle Washer Locking ring Parallel key Bronze bush
BA 2010 EN 01.06 46 / 90
Coat with a suitable lubricant, e.g. Calypsol type H 443 HD88 grease, to prevent frictional corrosion of the contact surfaces of the customer's machine shaft in the vicinity of the bronze bush. Instead of the nut and threaded spindle shown in the diagram, other types of equipment such as hydraulic lifting equipment may be used.
Note.
6.9.2
Remove hollow shaft and parallel key Caution.
Before driving out the machine shaft fasten a suitably dimensioned means of absorbing load to the drive. Slightly pretension the drive element so that the drive does not drop into the drive element when the insert shaft is released.
If frictional corrosion has occurred on the seat surfaces, use rust solvent to enable the gear unit to be pulled off. Allow the rust solvent to work in sufficiently. 1) Remove the axial fastening of the hollow shaft.
Caution.
It is essential to prevent misalignment when removing the gear unit. 13 12 11 10 9 8
Figure 6.9.2: Remove hollow shaft and parallel key 8 9 10 11 12 13 Threaded spindle Hexagon nut Hexagon nut Parallel key Threaded block Washer
Part 8 Part 13 are not included in scope of delivery.
BA 2010 EN 01.06 47 / 90
Suggested design for threaded piece and disc see figure 6.9.3 and table 6.9.3. 2) Drive out the machine shaft with the aid of the disk, part 13, threaded block, part 12, parallel key, part 11, and threaded spindle, parts 8 10. 3) When the rust solvent has sufficiently worked in, pull off the gear unit, using the device, see figure 6.9.2 Remove hollow shaft and parallel key" .
6.9.3
Suggested design for threaded piece and disc
Figure 6.9.3: Suggested design for threaded piece and disc Size 28 b10 [mm] 3 b11 [mm] 15 b12 [mm] 10 d10 [mm] 19.9 24.9 d11 [mm] 10 14 14 38 6 6 7 7 10 10 10 10 10 15 10 29.9 29 9 34.9 39.9 39.9 44.9 49.9 59.9 59.9 69.9 69.9 79.9 79.9 89.9 99.9 109.9 119.9 18 24 28 28 33 36 45 45 54 54 62 62 72 80 90 95 s11 M6 M8 M8 M10 M12 M16 M16 M20 M20 M20 M24 M24 tmax [mm] 22,5 28 28 33 38 43 48.5 48 5 64 74.5 74 5 85 95 106 116 127 u [mm] 6 8 8 10 10 12 12 14 14 18 18 20 20 22 22 25 28 32
48 68 88 108 128 148 168 188
15 20 20 24 24 24 30 30
5 7 10 10 5 7 8 11
Table 6.9.3: Suggested design for threaded piece and disc
BA 2010 EN 01.06 48 / 90
6.10
Shrink disc
6.10.1 Mounting the shrink disc

The shrink disc is delivered ready for installation.
Caution.
Do not dismantle shrink disc before initial fitting.
Caution.
Lubricants in the area of the shrink disk seat impair torque transmission. Keep bore in hollow shaft and machine shaft completely grease free. Do not use impure solvents and cleaning cloths.
Plastic deformation of the hollow shaft when tightening the tensioning bolts before fitting the machine shaft. First fit machine shaft. Then tighten tensioning bolts.
Caution.
Note.
Lightly grease the shrink disk seat on the hollow shaft.
Size 28 4 a b 3 5 a 2
Size 38 188 4 a b 3 5 a 2
1 Figure 6.10.1-1: Shrink disc a b 1 2 3 4 5 greased absolutely free of grease Machine shaft Hollow shaft Inner ring Outer ring Tensioning bolt
BA 2010 EN 01.06 49 / 90
1) Tighten the tension bolts, item 5, handtight initially. 2) Working round several times, evenly tighten the tension bolts, item 5, 1/4 turn each time.
Avoid overloading the individual bolts. Do not exceed the maximum torque acc. to table 6.10.1 Tightening torque TA clamping screw" at m+0,1. Size 28: Tighten tension bolts, item 5, to the tightening torque specified in table 6.10.1 Tightening torque TA clamping screw". Size 38 188: The most important thing is that the end faces of items 3 and 4 are square. If this squareness is not achieved during tensioning, check the tolerance of the insert shaft. Size 28 38, 48, 68 88, 108, 128 148 168, 188 Tensioning bolt M5 M8 M 10 M 12 M 14 strength class 8.8 12.9 12.9 12.9 12.9 max. tightening torque TA [Nm] 5 35 70 121 193 90 max. *)
Caution.
Table 6.10.1: Tightening torque TA clamping screw *) max. tightening angle per bolt per pass 3) Fit the safety cover delivered with the unit, see section 6.7 Steel safety cover for hollow shaft and shrink disc.
6.10.2 Pulling off the shrink disc

1) Working round several times, loosen the tensioning bolts one after the other a 1/4 turn each time. 2) Pull the shrink disc from the hollow shaft. Size 38 188: If the outer ring does not release from the inner ring, several clamping screws can be removed and then screwed into adjacent forcing threads. The rings can then be released without difficulty.
BA 2010 EN 01.06 50 / 90
6.10.3 Cleaning and greasing the shrink disc

Loosened shrink discs need not be dismantled and re greased before being re tensioned. If the shrink disk is dirty, clean and relubricate it. Before reassembly grease only the inner sliding surfaces of the shrink disc. Use for this a solid lubricant with a friction coefficient of m = 0,04 in accordance with table 6.10.3 Lubricants for shrink disc cleaning". Grease the bolts on the thread and the part below the head with a paste containing MoS2, e.g. Molykote BR2. Lubricant Molykote 321 R (lubricating paint) Molykote Spray (Powder spray) Molykote G Rapid Molykombin UMFT 1 Unimily P 5 Aemasol MO 19 P Table 6.10.3: Lubricants for shrink disc cleaning Commercial form Spray Spray or Paste Spray Powder Spray or Paste Klber Lubrication A. C. Matthes Manufacturer DOW Corning g
6.11
Torque arm with shaft mounted gear units

The torque arm serves to absorb the reaction torque and, if necessary, the weight of the drive.
Worn or irreparably damaged rubber elements will not function properly. Sparks may be caused by impact. The rubber elements must be replaced immediately.
Caution.
Dangerously high impact moments due to too high backlash. Ensure that the torque support does not give rise to excessive constraining forces (e.g. through the driven shaft running out of true).
Caution.
Keep solvents, oils, greases and fuels away from the rubber elements.
BA 2010 EN 01.06 51 / 90
6.11.1 Fit torque arm on bevel helical gear unit and helical gear unit Danger.
The torque arm bush must be mounted in bearings on both sides.
Suggestion for fitting the gear unit with torque arm:
Figure 6.11.1-1: Torque arm on foot
Figure 6.11.1-2: Torque arm on flange The torque arm may be fitted in various positions, depending on the hole circle pitch. Properties of the rubber elements: Basic material natural rubber 60 Shore A thermal resistance -45 C ... +70 C 1) Clean the contact surfaces between housing and torque arm. 2) Tighten the bolts to the prescribed torque acc. to table 6.11.1 Tightening torque TA Fitting torque arm".
BA 2010 EN 01.06 52 / 90
Thread size
Tightening torque TA strength class min. 8.8 [Nm] 25 50 90 210
Thread size
Tightening torque TA strength class min. 8.8 [Nm] 450 750 1500
M8 M 10 M 12 M 16
M 20 M 24 M 30
Table 6.11.1: Tightening torque TA Fitting torque arm
6.11.2 Mounting torque arm on parallel shaft helical gear unit Note.
We recommend using pretensioned, damping rubber elements. Suggestion for fastening the rubber elements ordered from and supplied by us:
Figure 6.11.2: Torque arm on parallel shaft helical gear unit Fixings such as angle, screw, nut etc. are not included in the delivery. Type x [mm] F.28 14 F.38B 13.1 F.48B 18.2 F.68B 17 F.88B F.108B F.128B F.148B F.168B F.188B 27.2 26 35.8 34.8 46.2 45.1
Table 6.11.2: Setting dimension x Properties of the rubber elements: Basic material natural rubber 70 Shore A hermal resistance -40 C ... +80 C
BA 2010 EN 01.06 53 / 90
7.
Start up
Danger.
Secure the drive unit to prevent it from being started up unintentionally. Attach a warning notice to the start switch.
Danger.
Remove any oil spillage immediately with an oil binding agent in compliance with environmental requirements.
7.1
Oil level check before start up

Check the oil level before starting up, rectify the oil level, if necessary.
Note.
Description of the work see section 10.2.1 Oil level.
7.2
Fill in oil
If the gear unit has been delivered without oil, put in lubricant before starting up.
Note.
Description of the work see section 10.2.3 Oil change.
7.3 7.3.1
Ventilation of the gear unit Filter for ventilation or pressure relief valve without securing clip
In the case of gear units with required housing ventilation the necessary ventilation filter or pressure relief valve without a securing clip is delivered separately. They must be replaced with the appropriate screw plug before starting up the gear unit. 1) Unscrew the sealing element at the point marked with this symbol, see section 3.5 Mounting positions". 2) Seal the gear unit with the ventilation filter or the pressure relief valve without securing clip.
BA 2010 EN 01.06 54 / 90
7.3.2
Pressure relief valve with securing clip (special version)

In the case of gear units with the required housing ventilation the pressure relief valve is fitted. Remove the transport fixture by pulling the securing clip in the direction of the arrow.
Securing clip
7.4 7.4.1
Start up after long term preservation Long term preservation up to 18 months

The gear unit is preserved internally, but delivered without oil.
Caution.
Before starting up fill the gear unit with lubricant, see section 10.2.3 Oil change".
7.4.2
Long term preservation up to 36 months

The gear unit is delivered with a complete oil filling.
Before starting up adjust oil level in accordance with the assembly option, see section 3.5 Mounting positions".
Caution.
1) Unscrew the sealing element at the point marked with this symbol, see section 3.5 Mounting positions" and drain the oil. 2) Check the oil level. 3) Rectify the oil level, if necessary, see section 10.2.1 Oil level, and check it again.
7.5
Drive with backstop (special version) Caution.
Before starting up check direction of rotation. Turn drive side or motor over manually. Check direction of motor rotation with the aid of the phase sequence. If necessary, exchange two outer conductors.
BA 2010 EN 01.06 55 / 90
8.
Operation
The difference between the temperature of the housing and the ambient temperature (max. +40 C) must not exceed 70 K. Using a suitable temperature sensor, measure the temperature at the lowest point of the housing (oil sump) or at the mounting surface in the case of output assemblies. Changes are an indication of possible incipient damage.
In case of changes during operation the drive must be switched off immediately. Determine the cause of the fault with the aid of the fault table in section 9. Faults, causes and remedy". Remedy faults or have faults remedied. Check the gear unit during operation for: excessive operating temperature changes in gear noise possible oil leakage at the housing and shaft seals.
Caution.
9.
Faults, causes and remedy

Note.
Faults and malfunctions occurring during the guarantee period and requiring repair work on the drive must be carried out only by FLENDER TBINGEN GMBH Customer Service. In the case of faults and malfunctions occurring after the guarantee period and whose cause cannot be precisely identified, we advise our customers to contact our customer service. If you need the help of our customer service, please state the following: data on the rating plate kind and extent of the fault suspected cause.
BA 2010 EN 01.06 56 / 90
Malfunctions
Causes oil level too low foreign bodies in oil (irregular noise) excessive bearing play and/or bearing defective
Remedy check oil level, see section 10.2.1 Oil level". stop drive. Check oil quality. Clean drive. Change oil, see section 10.2.2 Oil quality". check and, if necessary, replace bearings. check teeth and, if necessary, replace. tighten bolts / nuts, see section 10.2.11 Checking tightness of fastening bolts". check load on rating data. E.g. adjust belt tension. check drive for transport damage. contact customer service. relubricate bearing, see section 10.2.5 Relubrication of the rolling bearings in drive units". check and, if necessary, replace bearings. tighten bolts / nuts, see section 10.2.11 Checking tightness of fastening bolts". check and, if necessary, replace bearings. check, and if necessary adjust lifting gap. correct parametrisation.
Unusual noises on the gear unit
teeth defective fastening bolts loose excessive load on drive and output transport damages damage through blocking during start up bearing of drive unit not lubricated (from motor size 160 upwards)
Unusual noises on the drive unit
excessive bearing play and/or bearing defective fastening bolts loose excessive bearing play and/or bearing defective motor brake rubbing inverter parametrisation
Unusual noises on the U l i h motor
BA 2010 EN 01.06 57 / 90
Malfunctions
Causes incorrect oil level for assembly option used overpressure due to lack of ventilation overpressure due to soiled ventilation
Remedy check assembly option, see section 3.5 Mounting positions". Check oil level, see section 10.2.1 Oil level. mount ventilation acc. to mounting position, see section 3.5 Mounting positions". clean ventilation system, see section 10.2.9 Clean ventilation filter". replace shaft sealing rings. tighten bolts / nuts, see section 10.2.11 Checking tightness of fastening bolts". Continue observation of drive unit. reseal. check drive for transport damage. check position of ventilation and assembly option, see section 3.5 Mounting positions". Check oil level, see section 10.2.1 Oil level. contact customer service. clean fan cover and surface of drive, see section 10.2.10 Clean drive". check assembly option, see section 3.5 Mounting positions". Check oil level, see section 10.2.1 Oil level. check oil used, see section 10.2.2 Oil quality". check date of last oil change. Change oil, see section 10.2.3 Oil change". check and, if necessary, replace bearings. replace backstop.
Oil leak l k
shaft sealing rings defective cover / flange bolts loose surface sealing defective (e.g. on cover, flange) transport damage (e.g. microcracks) incorrect oil level for the assembly option used and/or incorrect ventilation position frequent cold starts, during which the oil foams up motor fan cover and/or drive badly soiled incorrect oil level for assembly option used
Oil leakage on gear unit ventilation
Gear unit overheating
incorrect oil being used (e.g. incorrect viscosity) oil too old excessive bearing play and/or bearing defective backstop not running freely
BA 2010 EN 01.06 58 / 90
Malfunctions Output shaft does not turn when motor is running
Causes force flow interrupted by breakage in the gear unit incorrect oil level for assembly option used incorrect oil being used (e.g. incorrect viscosity) excessive load on drive and output motor brake is not lifted drive runs against backstop
Remedy contact customer service. check assembly option, see section 3.5 Mounting positions". Check oil level, see section 10.2.1 Oil level. check oil used, see section 10.2.2 Oil quality". check load on rating data. E.g. adjust belt tension. check switching/connection of brake. Check brake for wear. If necessary, readjust brake. change direction of motor or backstop rotation. replace flexible elements. contact customer service. check belt tension, replace belt, if necessary.
Drive does not run or starts with difficulty
Excessive play on drive and output Drop of speed or torque
flexible elements worn (e.g. with couplings) positive connection disrupted by overload belt tension too low (in case of belt drive).
Table 9.: Faults, causes and remedy
10.
10.1
Maintenance and repair

General information for maintenance
All inspection, maintenance and repair work must be done with care by trained and qualified personnel only. Observe the instructions given in section 2. Safety instructions.
All measures and checks and their results must be documented by the operator and kept in a safe place.
Caution.
Maintenance and servicing must be carried out only by properly trained, authorised personnel. Only parts supplied by FLENDER TBINGEN GMBH must be used for servicing.
BA 2010 EN 01.06 59 / 90
Note.
Size 18 and 28 gear units are lubricated for life. No lubricant change is necessary.
Measure Observe and check drive unit for unusual noises, vibrations or changes Check housing temperature Checking oil level Checking the function of the oil sensor Checking the oil quality First oil change after start up Subsequent oil changes Checking gear unit for leaks Clean ventilation and, if necessary, replace Clean drive Check, and if necessary adjust slip coupling Check coupling Carrying out complete inspection of drive unit
Interval daily; if possible, more frequently during operation after 3 h, 1 day, then monthly after the 1st day, then monthly regularly and after oil change every 6 months after approx. 10000 operating hours, at the latest after 2 years. every 2 years or 10000 operating hours 1)
Description of work see section 8. Operation. see section 10.2.1.1 Check the oil level in the gear housing. see section 10.2.1.4 Checking the oil level sensor. see section 10.2.2 Oil quality. see section 10.2.3 Oil change. change see section 10.2.8 Seal check". see section 10.2.9 Clean ventilation filter". see section 10.2.10 Clean drive. see section 10.2.13 Carry out maintenance on slip coupling. Observe the separate operating instructions. see section 10.2.12 Inspection of the drive".
after the 1st day, then monthly depending on degree of soiling, soiling at least every 6 months. every 12 months at least for first time after 3 months every 12 months
BA 2010 EN 01.06 60 / 90
Measure Check that fastening bolts of gear unit and mounted elements are securely tightened. Check that covers and sealing plugs are securely fastened Relubricating the rolling bearings in drive units Change rolling bearing grease Replace bearing Checking rubber buffers of torque arm Table 10.1: Maintenance measures
Interval after 3 h, then at regular intervals.
Description of work see section 10.2.11 Checking tightness of fastening bolts. see section 10.2.5 Relubrication of the rolling bearings in drive units". see section 10.2.6 Change rolling bearing grease". see section 10.2.4 Replacing bearings". see section 6.11 Torque arm with shaft mounted gear units.
at least every 12 months or every 4 000 operating hours along with oil change
every 6 months
1) In the case of synthetic oils the time intervals can be doubled. The specifications apply to an oil temperature of +80 C. For oil change intervals for other temperatures, see figure 10.3 Approximate values for oil change intervals.
10.2
Description of maintenance and repair work
10.2.1 Oil level Drives in ATEX version.
After the screw plug has been removed, the oil level may not be more than 3 mm (in the case of 3/8" hole) or 5 mm (in the case of 3/4" hole) below the minimum filling level.
Danger.
Danger.
Danger of scalding from the hot oil emerging. Before starting any work wait until the oil has cooled down to +30 C.
BA 2010 EN 01.06 61 / 90
Danger.
Caution.
The oil quantity and the position of the sealing elements depend upon the assembly option, see section 3.5 Mounting positions".
The volume of gear oils changes with temperature. If the temperature rises, the volume increases. Where temperature differences and filling quantities are great, the increase may amount to several litres. The oil level must therefore be checked while still slightly warm approx. 30 minutes after switching off the drive.
Caution.
For data such as oil grade, oil viscosity and oil quantity required, refer to the rating plate, see section 3.2 "General technical data". For oil compatibility refer to, see section 10.3 Lubricants.
Note.
Note.
In case of double gear units every single unit is to be considered separately. Size 28 and 38 gear units of the second gear unit are lubricated for life. Screw plugs are not provided.
10.2.1.1Check the oil level in the gear housing
Oil level
Figure 10.2.1.1-1: Oil level 1) Switch off the power supply to the drive. 2) Unscrew the sealing element at the point marked with this symbol, see section 3.5 Mounting positions". 3) Check the oil level. 4) Rectify the oil level, if necessary, see section 10.2.1 Oil level, and check it again. 5) Check the condition of the sealing ring on the sealing element; if necessary, replace the sealing ring. 6) Seal the gear unit with the sealing element. BA 2010 EN 01.06 62 / 90
Check the oil level in the gear housing size 38

Size 38 gear units have no screw plug for checking the oil level. E.38, EF.38 2 a D/DF.38, Z/ZF.38 2 a 1 1 B.38, BF.38 2 a 1 1 K.38, KF.38 2 a FD.38B, FZ.38 2 a 1
Figure 10.2.1.1-2: Oil level check on size 38 gear unit a 1 2 Mark Screw plug Dipstick
1) Switch off the power supply to the drive. 2) Demount the drive and set it up in accordance with figure 10.2.1.1-2 Oil level check on size 38 gear unit. The screw plug, part 1, must be on the upward side. 3) Unscrew the plug, part 1. 4) Put a mark (a) on a suitable dipstick, part 2. 5) Insert the dipstick, part 2, vertically through the hole until the mark (a) is level with the surface of the gear unit. 6) Pull the dipstick, part 2, out vertically. 7) Measure the distance x" on the dipstick, see figure 10.2.1.1-3 Distance x".
x "2 mm Figure 10.2.1.1-3: Distance x"
BA 2010 EN 01.06 63 / 90
8) Compare value x" with the value acc. to table 10.2.1.1 Values for distance x"". max. distance "x" between oil level and marking on oil dipstick [mm] B3 E.38 Z.38 D.38 43 93 89 B5 B14 44 87 81 B3 00 H 01 126 64 B5-01 H-01 KF.38 66 B5-01 H-01 FZ.38B FD.38B 137 110 B6 37 83 82 V1 V18 24 56 31 B8 00 H 02 74 35 B5-03 H-02 40 B5-03 H-02 152 147 B7 37 83 82 V3 V19 18 33 26 B7 00 H 03 22 21 B5-02 H-03 20 B5-02 H-03 137 132 B6 00 H 04 89 52 B5-00 H-04 54 B5-00 H-04 137 132 V5 00 H 05 95 40 V1-00 H-05 45 V1-00 H-05 87 110 V6 00 H 06 112 46 V3-00 H-06 50 V3-00 H-06 73 65 B8 31 83 82 V5 23 75 52 V6 19 32 35
Type
EF.38 ZF.38 DF.38
B.38 K.38
Table 10.2.1.1: Values for distance x" 9) Rectify the oil level, if necessary, see section 10.2.1 Oil level, and check it again. 10) Check the condition of the sealing ring on the sealing element part 1; if necessary, replace the sealing ring. 11) Seal the gear unit with the sealing element, part 1. 12) Mount the drive.
10.2.1.2Checking the oil level by the oil sight glass (special version)
In the case of the oil sight glass the oil level must be in the middle of the sight glass. Oil level
Figure 10.2.1.2: Oil level in the oil sight glass Rectify the oil level, if necessary, see section 10.2.1 Oil level, and check it again.
BA 2010 EN 01.06 64 / 90
10.2.1.3Checking the oil level by the oil dipstick (special version)

Measure the oil level with the dipstick resting on the hole but not screwed in. The oil level must be between the lower and upper (min. max.) marks on the oil dipstick. If the electric oil level monitoring system is used, the oil must be level with the upper (max.) mark on the oil dipstick. Rectify the oil level, if necessary, see section 10.2.1 Oil level, and check it again.
10.2.1.4Checking the oil level sensor (special version) Drives in ATEX version.
The oil level sensor indicates the oil level only when the gear unit is shut off. Lower the oil level and fill it up again until the oil level sensor gives a switching signal. Observe the separate operating instructions for the oil level sensor.
10.2.2 Oil quality

1) Switch off the power supply to the drive. 2) Unscrew the sealing element at the point marked with this symbol, see section 3.5 Mounting positions" and take a small sample of oil. 3) Check the condition of the sealing ring on the sealing element; if necessary, replace the sealing ring. 4) Seal the gear unit with the sealing element. 5) Signs of changes in the oil can be seen with the naked eye. Fresh oil is clear to the eye and has a typical smell and a specific product colour. Clouding or a flocculent appearance indicate water and/or contamination. A dark or black colour indicates residue, severe thermal decomposition or contamination. If you detect such abnormalities, the oil must be changed immediately. 6) Check the oil level. 7) Rectify the oil level, if necessary, see section 10.2.1 Oil level, and check it again.
BA 2010 EN 01.06 65 / 90
10.2.3 Oil change Danger.
Danger.
Danger of scalding from the hot oil emerging. Before starting any work wait until the oil has cooled down to +30 C.
Danger.
Caution.
The oil quantity and the position of the sealing elements depend upon the assembly option, see section 3.5 Mounting positions".
For data such as oil grade, oil viscosity and oil quantity required, refer to the rating plate, see section 3.2 "General technical data". For oil compatibility refer to, see section 10.3 Lubricants.
Note.
Note.
In case of double gear units every single unit is to be considered separately. Size 28 and 38 gear units of the second gear unit are lubricated for life. No lubricant change is necessary.
In case of ambient conditions deviating from the normal (high ambient temperatures, high relative humidity, aggressive ambient media), the intervals between changes should be shorter. In such cases contact the FLENDER TBINGEN GMBH customer service to determine the individual lubricant change intervals.
Note.
BA 2010 EN 01.06 66 / 90
Note.
The oil must be warm, as too cold oil will flow too sluggishly to drain properly. If necessary, allow gear unit to run for 15 30 minutes to warm up.
Draining the oil

1) Switch off the power supply to the drive. 2) Unscrew the sealing element at the point marked with this symbol, see section 3.5 Mounting positions". 3) Unscrew the sealing element at the point marked with this symbol, see section 3.5 Mounting positions". 4) Place a ssuitable, sufficiently large receptacle under the oil drainage plug. 5) Unscrew the sealing element at the point marked with this symbol, see section 3.5 Mounting positions" and completely drain off the oil into the receptable. 6) Check the condition of the sealing ring on the sealing element; if necessary, replace the sealing ring. 7) Seal the gear unit with the sealing elements.
Draining the oil with B38 V5 00/V1 00/H 05 and V6 00/V3 00/H 06
1) Switch off the power supply to the drive. 2) Place a suitable, sufficiently large receptacle under the gear unit. 3) Unscrew the sealing element at the point marked with this symbol, see section 3.5 Mounting positions". Using a length of hose, siphon off all the oil into the receptacle. Or: 4) Unscrew the cover and drain all the oil off into the receptacle. 5) Change the seal in the cover. 6) Seal the gear unit with the cover.
Fill in oil
1) Unscrew the sealing element at the point marked with this symbol, see section 3.5 Mounting positions". 2) Fill the gear unit with fresh oil, using a filter (max. mesh 25 mm). When refilling, use the same type of oil with the same viscosity.
BA 2010 EN 01.06 67 / 90
3) Check the oil level. 4) Rectify the oil level, if necessary, see section 10.2.1 Oil level, and check it again. 5) Check the condition of the sealing ring on the sealing element; if necessary, replace the sealing ring. 6) Seal the gear unit with the sealing element.
10.2.4 Replacing bearings Drives in ATEX version.
The bearing life depends very much on the operating conditions. It is therefore very difficult to calculate it reliably. If the operating conditions are specified by the operator, the bearing life can be calculated and indicated on the rating plate. If no information is given, changes in the vibration and noise pattern can serve as an indication that an immediate bearing replacement is necessary.
10.2.5 Relubrication of the rolling bearings in drive units Caution.
When relubricating, do not mix greases with different soap bases. Relubicating the drive units is required from motor size 160 upwards in the case of K2, A and P and , from motor size 225 upwards in the case of K4. The bearings have already been initially greased. The standard lubricating grease used is a mineral oil based lithium saponified grease of NLGI class 3, see table 10.3-2 Rolling bearing greases.
Using a grease gun, inject the grease into the bearing point via the lubricating nipples provided. Inject 50 g grease per lubricating point, unless otherwise specified in the vicinity of the lubricating point. Figure 10.2.5: Grease nipple
10.2.6 Change rolling bearing grease

The rolling bearings have been filled with a lithium saponified rolling bearing grease at the factory. Clean the bearing before filling it with fresh lubricant. In the case of the bearings of the output shaft or intermediate shafts the grease quantity must fill 2/3 and in the case of bearings on the input side 1/3 of the space between the bearing bodies.
BA 2010 EN 01.06 68 / 90
10.2.7 Oil changing with backstop in bevel helical gear unit

The oil must be changed at the same intervals as the gear unit. K.88 Oil quantities [l] 0.04 Table 10.2.7: Oil quantities for backstop These oil quantities apply to all gear unit mounting options. K.108 0.06 K.128 0.09 K.148 0.104 K.168 0.44
Oil level
Figure 10.2.7: Oil level For the standard temperature range (0 C to +60 C) the backstops are filled with Klber Summit HYSYN FG68. In the case of ambient temperatures above +60 C please consult FLENDER TBINGEN GMBH.
10.2.8 Seal check

Oil or grease escaping in small quantities (a few drops) from the shaft sealing ring must be regarded as normal during the running in phase (24 hours running time). If the quanties escaping are great or leakage continues after the running in phase, the shaft sealing ring must be replaced to prevent consequential damage. Because of its structure and function a shaft sealing ring is subject to natural wear. The service life depends on the operating conditions. It is recommended that the shaft sealing rings be included in the periodic maintenance and servicing work on the system.
10.2.9 Clean ventilation filter

Clean the ventilation filter, depending on the degree of soiling at least every 6 months. 1) Unscrew the ventilation filter. 2) Flush out the ventilation filter with petroleum ether or a similar cleaning agent. 3) Blow the ventilation filter out with compressed air. 4) Seal the gear unit with the ventilation filter.
BA 2010 EN 01.06 69 / 90
10.2.10 Clean drive Drives in ATEX version.
Dust deposits prevent heat radiation and cause high housing temperatures. Keep the drive free from dirt and dust.
Caution.
Do not use a high pressure cleaning appliance to clean the drive. Do not use tools with sharp edges. Switch off the power supply to the drive before cleaning it.
10.2.11 Checking tightness of fastening bolts Drives in ATEX version.
Loose parts can cause sparks through impact. Entry of foreign bodies may cause sparks.
Note.
Damaged headless screws must be replaced with new screws of the same type and strength class. 1) Switch off the power supply to the drive. 2) Using a torque wrench, check that all fastening bolts are correctly tightened for torque, acc. to table 10.2.11 Tightening torques TA fastening bolts. Tightening torque TA strength class 8.8 10.9 [Nm] M4 M5 M6 M8 M 10 M 12 3 6 10 25 50 90 [Nm] 4 9 14 35 70 120 M 16 M 20 M 24 M 30 M 36 Tightening torque TA strength class 8.8 10.9 [Nm] 210 450 750 1500 2500 [Nm] 295 580 1000 2000 3600
Thread size
Thread size
Table 10.2.11: Tightening torques TA fastening bolts
BA 2010 EN 01.06 70 / 90
10.2.12 Inspection of the drive

Routinely inspect the drive once a year in accordance with the possible criteria listed in section 9. Faults, causes and remedy". Check the drive in accordance with the criteria set out in section 2. Safety instructions". Touch up damaged paintwork carefully.
10.2.13 Carry out maintenance on slip coupling Note.
Check the condition of the slip clutch initially after 500 operating hours and then at least once yearly and after every blockage of the machine. If necessary, readjust the slip torque or replace the wearing parts (friction lining and bushes). Friction linings must always be replaced in pairs. We recommend replacing worn bushes in sets. For this, please observe the relevant operating instructions for the clutch.
10.3
Lubricants Danger.
The listed lubricants are not approved under USDA H1 / H2 (United States Department of Agriculture). They are not or only conditionally approved for use in the foodstuffs or pharmaceutical industry. If lubricants with USDA H1 / H2 approval are required, please contact the FLENDER TBINGEN GMBH customer service.
When changing oil of the same type, the quantity of oil remaining in the gear unit should be kept as low as possible. Generally speaking, a small remaining quantity will cause no particular problems. Gear oils of different types and manufacturers must not be mixed. If necessary, the manufacturer should confirm that the new oil is compatible with residues of the used oil. If changing very different types of oil or oils with very different additives, always flush out the gear unit with the new oil. This applies particularly when changing from polyglycols (PG) to another gear oil or vice versa. Residues of used oil must be completely removed from the gear unit.
Caution.
BA 2010 EN 01.06 71 / 90
Gear oils must never be mixed with other substances. Flushing with paraffin or other solvents is not permitted, as traces of these substances always remain inside the unit.
Caution.
If applications are outside the temperature ranges specified in the table 10.3-1 Oils likewise contact the FLENDER TBINGEN GMBH customer service with regard to the choice of oil. If due to its mounting position or load the temperature of the gear unit rises above +80 C, contact the FLENDER TBINGEN GMBH customer service with regard to the choice of a suitable synthetic lubricant.
Caution.
The lubricants are not or are only conditionally biodegradable. If lubricants are required in accordance with these classifications, please contact the FLENDER TBINGEN GMBH customer service.
Note.
These recommendations are not a guarantee of the quality of the lubricant supplied by your supplier. Each lubricant manufacturer is responsible for the quality of his own product. The oil selected for use in the gear unit must be of the viscosity (ISO VG class) stated on the rating plate. The viscosity class indicated applies for the contractually agreed operating conditions. In the case of different operating conditions contact with FLENDER TBINGEN GMBH is required. The lubricants suitable for use in the gear unit are listed in table 10.3-1 Oils" and table 10.3-2 Rolling bearing greases". We are familiar with the composition of these lubricants and, as far as we are currently aware, they possess the properties acc. to state of the art with regard to load bearing capacity, corrosion resistance (FZG Test DIN 51354 = force level > 12), resistance to grey staining and compatibility with seals and interior paint coats which are necessary for the type of gear unit concerned. We therefore advise our customers to select one of the lubricants listed in this table, taking into account the VG class specified on the nameplate. If by agreement gear units are filled at the factory with special lubricants for the above mentioned special applications, this is shown on the rating plate, e.g.: CLP H1 VG220 or CLP E VG220. The guarantee specifications are valid only for the lubricants shown in these operating instructions.
Note.
BA 2010 EN 01.06 72 / 90
Service life of the lubricants Note.
If oil sump temperatures exceed +80 C, the service life may also be lower than shown in figure 10.3 Approximate values for oil change intervals". The general rule is that an increase in temperature by 10 K will halve the service life.
Note.
In the case of rolling bearings with grease filling we recommend changing the grease filling as well when changing the oil.
With an oil sump temperature of +80 C the following service life with adherence to the characteristics required by FLENDER TBINGEN GMBH s expected: 1) Mineral oil Biologically degradable oil Physiologically safe oil (USDA H1 / H2) 2) Synthetic oil (PG)
160 150 140 130 120 110 100 90 80 70
10000 operating hours or 2 years 20000 operating hours or 4 years
T [C]
2)
1)
250 500 1000 2500 5000 10000 25000 50000
I [h]
Figure 10.3: Approximate values for oil change intervals T Oil bath steady state temperature [C] I Oil change interval in operating hours [h]
BA 2010 EN 01.06 73 / 90
Mineral oil Designation to DIN 51 502 Gear unit types Ambient temperatures CLP ISO VG 220 E., D./Z., K., F. -10 C ... +40 C CLP 220 S Degol BG 220 Energol GR XP 220 Alpha SP 220 Alpha MAX 220 Optigear BM 220 Tribol 1100/220 Spartan EP 220 1) Renolin CLP 220 Plus Klberoil GEM 1 220 N Mobilgear XMP 220 Omala 220 Ersolan 220 Table 10.3-1: Oils 1) Europe only
Synthetic oil / Polyglycol (PG) CLP PG ISO VG 220 CLP PG ISO VG 460
E., D./Z., B., K., F., C. -20 C ... +50 C 0 C ... +60 C
Degol GS 220 Enersyn SG XP 220
Degol GS 460 Enersyn SG XP 460
Optiflex A 220 Tribol 800/220
Optiflex A 460 Tribol 800/460
Renolin PG 220 Syntheso D 220 EP
Renolin PG 460 Syntheso D 460 EP
Tivela S 220
Tivela S 460
BA 2010 EN 01.06 74 / 90
The service life of the grease is approx. 4000 operating hours. It is based on a max. ambient temperature of +40 C. The service life of the grease decreases by a factor of 0,7 for every 10 K rise in temperature. Lithium saponified greases NLGI 3/2 Aralub HL3, HL2 Energrease LS3, LS2 Longtime PD2 TRIBOL 4020/220 2 Glissando 30, 20 Beacon 3 Renolit FWA160, FWA220 Centroplex GLP402 Mobilux 3, 2 Alvania RL3, RL2 Wiolub LFK2 Table 10.3-2: Rolling bearing greases
Note.
BA 2010 EN 01.06 75 / 90
11.
Disposal
Dispose of the housing parts, gears, shafts and rolling bearings as steel scrap. This also applies to grey cast iron parts, if no separate collection is made. The worm wheels are made partly from non ferrous metal. Dispose of them accordingly.
Incorrect disposal of used oil is a threat to the environment and health. After use the oil must be taken to a used oil collection point. Any addition of foreign material such as solvents and brake and cooling fluid is prohibited. Avoid prolonged contact with the skin. Collect and dispose of used oil in accordance with regulations. Remove any oil spillage immediately with an oil binding agent in compliance with environmental requirements.
Danger.
12.
12.1
Stocking spare parts and customer service addresses

Stocking spare parts
By stocking the most important spare and wearing parts on site you can ensure that the drive is ready for use at any time.
Please note that spare parts and accessories not supplied by us have not been tested or approved by us. The installation and/or use of such products may therefore impair essential characteristics of the drive, thereby posing an active or passive risk to safety. FLENDER TBINGEN GMBH will assume no liability or guarantee for damage caused by spare parts and accessories not supplied by FLENDER TBINGEN GMBH. We guarantee only the original spare parts supplied by us. Please note that certain components often have special production and supply specifications and that we always supply you with spare parts which comply fully with the current state of technical development as well as current legislation. When ordering spare parts, always state the following: Order no. (see rating plate ) Type designation (see rating plate ) Part no. (3 digit part no. from spare parts list, 6 digit code no. or 7 digit article no.) Quantity
Caution.
BA 2010 EN 01.06 76 / 90
12.2
Spare parts lists
12.2.1 One stage helical gear units Size 38 148
001 101 103 105 130 135 136 140 145 160 201 205 210 211 220 225 301 305 335 401 420 430
Gear unit housing Output shaft Spacer/bush Parallel key Bearings Locking ring Locking ring Bearings Locking ring Shaft seal Adapter plate Bolt Bolt Screw lock Seal Seal Plug in pinion Gear wheel Parallel key Screw plug Breather filter Eye bolt
BA 2010 EN 01.06 77 / 90
12.2.2 Two and three stage helical gear units Size 38 188
001 020 025 030 050 051 055 101 103 105 130 135 140 141 144 145 160 201 205 210 211 215 220 225 301 305 306 315
Gear unit housing Bearings Locking ring Bearings Housing cover Bolt Seal Output shaft Spacer/bush Parallel key Bearings Locking ring Bearings Supporting disk/shim Supporting disk/shim Locking ring Shaft seal Adapter plate Bolt Bolt Screw lock Parallel pin Seal Seal Plug in pinion Gear wheel Parallel key Bearings BA 2010 EN 01.06 78 / 90
320 325 330 331 335 340 345 346 401 420 430
Bearings Pinion shaft Gear wheel Parallel key Locking ring Pinion shaft Gear wheel Parallel key Screw plug Breather filter Eye bolt
12.2.3 Bevel helical gear units Size B38
001 020 022 027 030 031 040 045 050 051 055 090 091 095 101 130 131 135 140 144
Gear unit housing Taper roller bearing Supporting disk/shim Locking ring Taper roller bearing Supporting disk/shim Output flange Bolt Housing cover Bolt Seal Torque arm Rubber bush Bolt Output shaft Deep groove ball bearing Supporting disk/shim Locking ring Deep groove ball bearing Supporting disk/shim BA 2010 EN 01.06 79 / 90
146 160 205 210 220 301 305 320 331 351 401 411 412 413 415 418
Locking ring Shaft seal Bolt Nut Seal Plug in pinion Gear wheel Bevel gear pair Parallel key Parallel key Screw plug Bolt Spring washer Washer Locking ring Plug/sealing cap
12.2.4 Bevel helical gear units Size 38 188
001 020 022 027 030 031 040 045 050 051 055 060 061 063 065
Gear unit housing Bearings Supporting disk/shim Locking ring Bearings Supporting disk/shim Output flange Bolt Housing cover Bolt Seal Bearings Supporting disk/shim Nilos ring Locking ring BA 2010 EN 01.06 80 / 90
070 090 091 095 096 101 130 131 133 135 140 143 144 146 160 201 205 210 211 220 225 301 305 320 325 327 328 331 335 340 345 346 351 401 411 413 415 418 420
Sealing cap Torque arm Rubber bush Bolt Screw lock Output shaft Bearings Supporting disk/shim Nilos ring Locking ring Bearings Nilos ring Supporting disk/shim Locking ring Shaft seal Adapter plate Bolt Bolt Screw lock Seal Seal Plug in pinion Gear wheel Bevel gear pair Bevel pinion shaft Parallel key Locking ring Parallel key Locking ring Pinion shaft Gear wheel Parallel key Parallel key Screw plug Bolt Washer Locking ring Plug/sealing cap Breather filter
BA 2010 EN 01.06 81 / 90
12.2.5 Parallel shaft helical gear units Size 38B 188B
001 020 021 022 025 030 034 040 045 050 051 055 065 070 091 101 107 108 109 110 120 128 129 130 131 132 133 135 140
Gear unit housing Bearings Supporting disk/shim Supporting disk/shim Locking ring Bearings Nilos ring Output flange Bolt Housing cover Bolt Seal Sealing cap Sealing cap Rubber bush Drive shaft Bearings Bearings Locking ring Locking ring Shrink disc Supporting disk/shim Supporting disk/shim Bearings Supporting disk/shim Spacer/bush Nilos ring Locking ring Bearings BA 2010 EN 01.06 82 / 90
141 143 144 146 160 201 205 210 211 220 225 301 305 306 307 310 311 325 330 331 340 345 346 401 420
Spacer/bush Nilos ring Supporting disk/shim Locking ring Shaft seal Adapter plate Bolt Bolt Screw lock Seal Seal Pinion Gear wheel Parallel key Spacer/bush Locking ring Supporting disk/shim Pinion shaft Gear wheel Parallel key Pinion shaft Gear wheel Parallel key Screw plug Breather filter
12.2.6 Helical worm gear units Size 38 88
001 020 030 032
Gear unit housing Bearings Bearings Supporting disk/shim BA 2010 EN 01.06 83 / 90
035 037 040 045 070 090 091 095 101 130 131 133 135 140 143 144 146 160 201 205 210 211 220 225 301 305 331 335 340 345 346 401 411 412 413 415 418 420 430
Locking ring Locking ring Output flange Bolt Sealing cap Torque arm Rubber bush Bolt Output shaft Bearings Supporting disk/shim Nilos ring Locking ring Bearings Nilos ring Supporting disk/shim Locking ring Shaft seal Adapter plate Bolt Bolt Screw lock Seal Seal Plug in pinion Gear wheel Parallel key Locking ring Worm shaft Worm wheel Parallel key Screw plug Bolt Screw lock Washer Locking ring Plug/sealing cap Breather filter Eye bolt
BA 2010 EN 01.06 84 / 90
12.3
Customer service addresses
FLENDER DRIVES & AUTOMATION Deutschland
FLENDER TBINGEN GMBH
Bahnhofstrae 40 - 44 72072 Tbingen 24h Service Hotline
Postfach 1709 72007 Tbingen
Tel.: (0 70 71) 7 07 - 0 Fax: (0 70 71) 7 07 - 4 00 +49 (0) 1 72 - 7 32 29 55
sales-motox@flendermotox.com www.flender.com
A. FRIEDR. FLENDER AG Kundenservice Center Nord
Alfred-Flender-Strae 77 46395 Bocholt
Postfach 1364 46393 Bocholt
Tel.: (0 28 71) 92 - 0 Fax: (0 28 71) 92 - 14 35
ksc.nord@flender.com www.flender.com
A. FRIEDR. FLENDER AG Kundenservice Center Sd
Bahnhofstrae 40 - 44 72072 Tbingen
Postfach 1709 72007 Tbingen
Tel.: (0 70 71) 7 07 - 0 Fax: (0 70 71) 7 07 - 3 40
ksc.sued@flender.com www.flender.com
A. FRIEDR. FLENDER AG Kundenservice Center Sd (Auenstelle Mnchen)
Liebigstrae 14
85757 Karlsfeld
Tel.: (0 81 31) 90 03 - 0 Fax: (0 81 31) 90 03 - 33
ksc.sued@flender.com www.flender.com
A. FRIEDR. FLENDER AG Kundenservice Center Ost / Osteuropa
Schlossallee 8
13156 Berlin
Tel.: (0 30) 91 42 50 58 Fax: (0 30) 47 48 79 30
ksc.ost@flender.com www.flender.com
FLENDER DRIVES & AUTOMATION International

EUROPE
AUSTRIA BELGIUM & LUXEMBOURG BULGARIA
Flender Ges.m.b.H. N.V. Flender Belge S.A. Auto-Profi N GmbH
Industriezentrum N-Sd Strasse 4, Objekt 14 Postfach 132 Cyriel Buyssestraat 130 52, Alabin Str. Mandroviceva 3a Branch Office Fibichova 218 Rugmarken 35 B Suur-Sjame 32 Ruosilantie 2 B
Head Office 3, rue Jean Monnet - B.P. 5
2355 Wiener Neudorf 1800 Vilvoorde 1000 Sofia 10 000 Zagreb 27601 Mlnk Tschechische Republik 3520 Farum 11 415 Tallinn (Esthonia) 00 390 Helsinki 78 996 Elancourt Cedex
Phone: +43 (0) 22 36 - 6 45 70 Fax: +43 (0) 22 36 - 6 45 70 10 Phone: +32 (0) 2 - 2 53 10 30 Fax: +32 (0) 2 - 2 53 09 66 Phone: +359 (0) 2 - 9 80 66 06 Fax: +359 (0) 2 - 9 80 33 01 Phone: +385 (0) 1 - 2 30 60 25 Fax: +385 (0) 1 - 2 30 60 24 Phone: +420 (0) 315 - 62 12 20 Fax: +420 (0) 315 - 62 12 22 Phone: +45 - 70 22 60 03 Fax: +45 - 44 99 16 62 Phone: +372 (0) 6 - 27 99 99 Fax: +372 (0) 6 - 27 99 90 Phone: +358 (0) 9 - 4 77 84 10 Fax: +358 (0) 9 - 4 36 14 10 Phone: +33 (0) 1 - 30 66 39 00 Fax: +33 (0) 1 - 30 66 35 13 Phone: +33 (0) 4 - 72 83 95 20 Fax: +33 (0) 4 - 72 83 95 39 Phone: +30 210 - 2 91 72 80 Fax: +30 210 - 2 91 71 02 Phone: +36 (0) 1 - 3 45 07 90 Fax: +36 (0) 1 - 3 45 07 92 Phone: +39 (0) 02 - 95 96 31 Fax: +39 (0) 02 - 95 74 39 30 Phone: +31 (0) 55 - 5 27 50 00 Fax: +31 (0) 55 - 5 21 80 11 Phone: +45 - 70 22 60 03 Fax: +45 - 44 99 16 62
office@flender.at www.flender.at sales@flender.be flender@auto-profi.com flender@hi.htnet.hr info-cz@flender.com kontakt@ flenderscandinavia.com www.flenderscandinavia.com flender@addinol.ee www.addinol.ee webmaster@flender.fi www.flender.fi sales@flender.fr sales@flender.fr flender@otenet.gr flender@monornet.hu jambor.laszlo@axelero.hu info@flendercigala.it sales@flender.nl www.flender.nl kontakt@ flenderscandinavia.com www.flenderscandinavia.com
CROATIA / SLOVENIA BOSNIA HUM - Naklada d.o.o. HERZEGOVINA CZECH REPUBLIC
A. Friedr. Flender AG Flender Scandinavia A/S Addinol Minerall Marketing O Flender Oy Flender S.a.r.l. Flender S.a.r.l
DENMARK ESTHONIA / LATVIA LITHUANIA FINLAND FRANCE
Sales Office 69 230 Saint Genis Agence de Lyon Laval Parc Inopolis, Route de Vourles 2, Delfon str. Bcsi t 3 - 5 Parco Tecnologico Manzoni Palazzina G Viale delle industrie, 17 Lage Brink 5 - 7 Postbus 1073 Rugmarken 35 B 11 146 Athens 1023 Budapest 20 040 Caponago (MI) 7317 BD Apeldoorn 7301 BH Apeldoorn 3520 Farum
GREECE HUNGARY
Flender Hellas Ltd. Wentech Kft. Flender Cigala S.p.A. Flender Nederland B.V. Flender Scandinavia A/S
ITALY
THE NETHERLANDS
NORWAY
BA 2010 EN 01.06 85 / 90
POLAND
A. Friedr. Flender AG Rodamientos FEYC, S.A CN Industrial Group srl Flender OOO A. Friedr. Flender AG Flender Ibrica S.A.
Branch Office Przedstawicielstwo w Polsce ul. Wyzwolenia 27 R. Jaime Lopes Dias, 1668 CV B-dul Garii Obor nr. 8 D Sector 2 Tjuschina 4 - 6 Branch Office Vajanskho 49, P.O. Box 286 Poligono Industrial San Marcos Calle Morse, 31 (Parcela D - 15) senvgen 2 Zeughausstr. 48 IMES Sanayi, Sitesi E Blok 502, Sokak No. 22 Prospect Pobedy 44 Thornbury Works, Leeds Road
43 - 190 Mikolw 1750 - 124 Lissabon 021 747 Bucuresti 191 119 St. Petersburg 08 001 Presov 28 906 Getafe - Madrid
Phone: +48 (0) 32 - 2 26 45 61 Fax: +48 (0) 32 - 2 26 45 62 Phone: +351 (0) 21 - 7 54 24 10 Fax: +351 (0) 21 - 7 54 24 19 Phone: +40 (0) 21 - 2 52 98 61 Fax: +40 (0) 21 - 2 52 98 60 Phone: +7 (0) 8 12 - 3 20 90 34 Fax: +7 (0) 8 12 - 3 40 27 60 Phone: +421 (0) 51 - 7 70 32 67 Fax: +421 (0) 51 - 7 70 32 67 Phone: +34 (0) 91 - 6 83 61 86 Fax: +34 (0) 91 - 6 83 46 50 Phone: +46 (0) 302 - 1 25 90 Fax: +46 (0) 302 - 1 25 56 Phone: +41 (0) 62 - 8 85 76 00 Fax: +41 (0) 62 - 8 85 76 76
flender@pro.onet.pl www.flender.pl info@rfportugal.com office@flender.ro flendergus@mail.spbnit.ru micenko.flender@nextra.sk f-iberica@flender.es www.flender.es kontakt@ flenderscandinavia.com www.flenderscandinavia.com info@flender.ch www.flender.ch
PORTUGAL ROMANIA RUSSIA SLOVAKIA
SPAIN
SWEDEN
Flender Scandinavia Flender AG Flender Gc Aktarma Sistemleri Sanayi ve Ticaret Ltd. Sti. DIV-Deutsche Industrievertretung Flender Power Transmission Ltd.
44 339 Lerum 5600 Lenzburg 34 776 Dudullu Istanbul 03 057 Kiev Bradford West Yorkshire BD3 7EB 11 070 Novi Beograd
SWITZERLAND
TURKEY
Phone: +90 (0) 2 16 - 4 66 51 41 cuzkan@flendertr.com Fax: +90 (0) 2 16 - 3 64 59 13 www.flendertr.com Phone: +380 (0) 44 - 2 30 29 43 Fax: +380 (0) 44 - 2 30 29 30 Phone: +44 (0) 12 74 - 65 77 00 Fax: +44 (0) 12 74 - 66 98 36 Phone: +381 (0) 11 - 60 44 73 Fax: +381 (0) 11 - 3 11 67 91 flender@div.kiev.ua info@flender-power.co.uk www.flender-power.co.uk
UKRAINE UNITED KINGDOM & EIRE SERBIA MONTENEGRO ALBANIA MACEDONIA
G.P.Inzenjering d.o.o.
III Bulevar 54 / 19
flender@eunet.yu
AFRICA
NORTH AFRICAN COUNTRIES EGYPT
Flender S.a.r.l. Sons of Farid Hassanen Flender Power Transmission (Pty.) Ltd. Flender Power Transmission (Pty.) Ltd. Flender Power Transmission (Pty.) Ltd. Flender Power Transmission (Pty.) Ltd. Flender Power Transmission (Pty.) Ltd.
3, rue Jean Monnet - B.P. 5 81 Matbaa Ahlia Street

Head Office Cnr. Furnace St & Quality Rd. P.O. Box 131
78 996 Elancourt Cedex Boulac 11 221, Cairo Isando-Johannesburg Isando 1600
Phone: +33 (0) 1 - 30 66 39 00 Fax: +33 (0) 1 - 30 66 35 13 Phone: +20 (0) 2 - 5 75 15 44 Fax: +20 (0) 2 - 5 75 17 02 Phone: +27 (0) 11 - 5 71 20 00 Fax: +27 (0) 11 - 3 92 24 34 Phone: +27 (0) 21 - 5 51 50 03 Fax: +27 (0) 21 - 5 52 38 24 Phone: +27 (0) 31 - 7 05 38 92 Fax: +27 (0) 31 - 7 05 38 72 Phone: +27 (0) 13 - 6 92 34 38 Fax: +27 (0) 13 - 6 92 34 52 Phone: +27 (0) 35 - 7 51 15 63 Fax: +27 (0) 35 - 7 51 15 64
sales@flender.fr hussein@sonfarid.com sales@flender.co.za www.flender.co.za
SOUTH AFRICA
Sales Offices Cape Town Unit 3 Marconi Park 9 Marconi Crescent, Montague Chempet 7442 Gardens, P.O. Box 37 291 Unit 3 Goshawk Park Falcon Industrial Estate P.O. Box 1608 9 Industrial Crescent, Ext. 25 P.O. Box 17 609 New Germany - Durban New Germany 3620 Witbank Witbank 1035
sales@flender.co.za
sales@flender.co.za sales@flender.co.za sales@flender.co.za
Unit 14 King Fisher Park, Alton Richards Bay Cnr. Ceramic Curve & Alumina Meerensee 3901 Allee, P.O. Box 101 995
AMERICA
ARGENTINA
Chilicote S.A. Flender Brasil Ltda.
Avda. Julio A. Roca 546

Head Office Rua Quatorze, 60 Cidade Industrial
C 1067 ABN Buenos Aires 32 210 - 660 Contagem - MG 04 576 - 050 So Paulo - SP 14 015 - 110 Ribeiro Preto - SP Markham Ontario L3R 8V2 Providencia, Santiago
Phone: +54 (0) 11 - 43 31 66 10 Fax: +54 (0) 11 - 43 31 42 78 Phone: +55 (0) 31 - 33 69 20 00 Fax: +55 (0) 31 - 33 31 18 93 Phone: +55 (0) 11 - 55 05 99 33 Fax: +55 (0) 11 - 55 05 30 10 Phone: +55 (0) 16 - 6 35 15 90 Fax: +55 (0) 16 - 6 35 11 05 Phone: +1 (0) 9 05 - 3 05 10 21 Fax: +1 (0) 9 05 - 3 05 10 23 Phone: +56 (0) 2 - 2 35 32 49 Fax: +56 (0) 2 - 2 64 20 25 Phone: +57 (0) 1 - 5 70 63 53 Fax: +57 (0) 1 - 5 70 73 35 Phone: +52 (0) 2 22 - 2 37 19 00 Fax: +52 (0) 2 22 - 2 37 11 33 Phone: +52 (0) 55 - 52 54 30 37 Fax: +52 (0) 55 - 55 31 69 39 Phone: +52 (0) 81 - 83 63 82 82 Fax: +52 (0) 81 - 83 63 82 83
chilicote@chilicote.com.ar vendas@flenderbrasil.com
BRASIL
Flender Brasil Ltda. Flender Brasil Ltda.

CANADA CHILE / ARGENTINA BOLIVIA / ECUADOR PARAGUAY URUGUAY COLOMBIA
Sales Offices Rua James Watt, 152 conjunto 142 - Brooklin Novo Rua Campos Sales, 1095 sala 14 - centro 215 Shields Court, Units 4 - 6
flesao@uol.com.br flender.ribpreto@uol.com.br info@flenderpti.com www.flender.ca flender@flender.cl www.flender.cl aguerrero@agp.com.co www.agp.com.co szugasti@flendermexico.com www.flendermexico.com info@flendermexico.com info@flendermexico.com
Flender Power Transmission Inc. Flender Cono Sur Ltda. A.G.P. Representaciones Ltda. Flender de Mexico S.A. de C.V. Flender de Mexico S.A. de C.V. Flender de Mexico S.A. de C.V.
Avda. Galvarino Gallardo 1534

Flender Liaison Office Colombia Av Boyaca No. 23 A 50 Bodega UA 7 - 1 Head Office 17, Pte, 713 Centro
Bogot 72 000 Puebla 11 520 Mexico, D.F. 64 660 Monterrey, N.L.
MEXICO
Sales Offices Lago Nargis No. 38 Col. Granada Ave. San Pedro No. 231 - 5 Col. Miravalle
BA 2010 EN 01.06 86 / 90
PERU USA
Flender Cono Sur Ltda. Flender Corporation Flender Corporation
Avda. Galvarino Gallardo 1534 950 Tollgate Road P.O. Box 1449 Service Centers West 4234 Foster Ave.
Providencia, Santiago Elgin, IL. 60 123 Bakersfield, CA. 93 308
Phone: +56 (0) 2 - 2 35 32 49 Fax: +56 (0) 2 - 2 64 20 25 Phone: +1 (0) 8 47 - 9 31 19 90 Fax: +1 (0) 8 47 - 9 31 07 11 Phone: +1 (0) 6 61 - 3 25 44 78 Fax: +1 (0) 6 61 - 3 25 44 70 Phone: +58 (0) 2 12 - 21 52 61 Fax: +58 (0) 2 12 - 21 18 38
flender@flender.cl www.flender.cl flender@flenderusa.com www.flenderusa.com flender1@lightspeed.net fhtransm@telcel.net.ve www.fhtransmisiones.com
VENEZUELA
F. H. Transmisiones S.A.
Calle Johan Schafer o Segunda Petare, Caracas Calle, Municipio Sucre
ASIA
BANGLADESH SRI LANKA
Flender Limited
No. 2 St. Georges Gate Road 5th Floor, Hastings

Head Office Shuanghu-Shuangchen Rd. West, Beichen Economic Development Area (BEDA)
Kolkata - 700 022
Phone: +91 (0) 33 - 2 23 05 45 Fax: +91 (0) 33 - 2 23 18 57 Phone: +86 (0) 22 - 26 97 20 63 Fax: +86 (0) 22 - 26 97 20 61
flender@flenderindia.com flender@flendertj.com www.flendertj.com
PEOPLE'S REPUBLIC Flender Power TransOF CHINA mission (Tianjin) Co., Ltd.
Tianjin 300 400
Flender Power Transmission (Tianjin) Co., Ltd. Flender Power Transmission (Tianjin) Co., Ltd. Flender Power Transmission (Tianjin) Co., Ltd. Flender Power Transmission (Tianjin) Co., Ltd. Flender Power Transmission (Tianjin) Co., Ltd. Flender Power Transmission (Tianjin) Co., Ltd. Flender Power Transmission (Tianjin) Co., Ltd.
INDIA
Sales Offices C - 414, Lufthansa Center 50 Liangmaqiao Rd. Chaoyang District 1101 - 1102 Harbour Ring Plaza 18 Xizang Zhong Rd. Rm. 1503, Jianyin Building 709 Jianshedadao, Hankou Rm. 2802, Guangzhou International Electronics Tower 403 Huanshi Rd. East G - 6 / F Guoxin Mansion 77 Xiyu Street Rm. 3 - 705, Tower D City Plaza Shenyang 206 Nanjing Street (N) Heping District Rm. 302, Shanzi Zhong Da International Mansion 30 Southern Rd.
Head Office No. 2 St. Georges Gate Road 5th Floor
Beijing 100 016
Phone: +86 (0) 10 - 64 62 21 51 Fax: +86 (0) 10 - 64 62 21 43 Phone: +86 (0) 21 - 53 85 31 48 Fax: +86 (0) 21 - 53 85 31 46 Phone: +86 (0) 27 - 85 48 67 15 Fax: +86 (0) 27 - 85 48 68 36 Phone: +86 (0) 20 - 87 32 60 42 Fax: +86 (0) 20 - 87 32 60 45 Phone: +86 (0) 28 - 86 19 83 72 Fax: +86 (0) 28 - 86 19 88 10 Phone: +86 (0) 24 - 23 34 20 48 Fax: +86 (0) 24 - 23 34 20 46 Phone: +86 (0) 29 - 87 20 32 68 Fax: +86 (0) 29 - 87 20 32 04 Phone: +91 (0) 33 - 22 23 05 45 Fax: +91 (0) 33 - 22 23 18 57 Phone: +91 (0) 3222 - 23 33 07 Fax: +91 (0) 3222 - 23 33 64 Phone: +91 (0) 33 - 22 23 05 45 Fax: +91 (0) 33 - 22 23 08 30 Phone: +91 (0) 22 - 27 65 72 27 Fax: +91 (0) 22 - 27 65 72 28 Phone: +91 (0) 44 - 23 74 39 21 Fax: +91 (0) 44 - 23 74 39 19 Phone: +91 (0) 11 - 51 85 96 56 Fax: +91 (0) 11 - 51 85 96 59 Phone: +62 (0) 21 - 58 90 20 15 Fax: +62 (0) 21 - 58 90 20 19 Phone: +98 (0) 21 - 88 73 02 14 Fax: +98 (0) 21 - 88 73 39 70 Phone: +972 (0) 52 - 4 76 14 26 Fax: +972 (0) 4 - 8 14 60 37 Phone: +81 (0) 43 - 2 13 39 30 Fax: +81 (0) 43 - 2 13 39 55 Phone: +82 (0) 2 - 34 78 63 37 Fax: +82 (0) 2 - 34 78 63 45 Phone: +965 (0) - 4 82 97 15 Fax: +965 (0) - 4 82 97 20 Phone: +60 (0) 3 - 78 80 42 63 Fax: +60 (0) 3 - 78 80 42 73 Phone: +63 (0) 2 - 8 49 39 93 Fax: +63 (0) 2 - 8 49 39 17 Phone: +90 (0) 2 16 - 4 99 66 23 Fax: +90 (0) 2 16 - 3 64 59 13
beijing@flenderprc.com.cn shanghai@ flenderprc.com.cn wuhan@flenderprc.com.cn guangzhou@ flenderprc.com.cn chengdu@flenderprc.com.cn
Shanghai 200 001 Wuhan 430 015 Guangzhou 510 095 Chengdu 610 015
Shenyang 110 001
shenyang@flenderprc.com.cn
Xian 710 002 Hastings Kolkata - 700 022 Nimpura Kharagpur - 721 302 Hastings Kolkata - 700 022 Vashi Navi Mumbai - 400 705
xian@flenderprc.com.cn
Flender Limited Flender Limited Flender Limited Flender Limited Flender Limited Flender Limited
flender@flenderindia.com works@flenderindia.com ero@flenderindia.com wro@flenderindia.com sro@flenderindia.com nro@flenderindia.com
Industrial Growth Centre Rakhajungle Eastern Regional Sales Office No. 2 St. Georges Gate Road 5th Floor Western Regional Sales Office Plot No. 23, Sector 19 - C
Southern Regional Sales Office Aminjikarai 41 Nelson Manickam Road Chennai - 600 029 Northern Regional Sales Office 302 Bhikaji Cama Bhawan 11 Bhikaji Cama Palace New Delhi - 110 066
INDONESIA
Representative Office Flender Singapore Pte. Ltd. 6 - 01 Wisma Presisi Jl. Taman Aries Blok A1 No. 1 Cimaghand Co. Ltd. Greenshpon Flender Japan Co., Ltd. P.O. Box 15 745 - 493 No. 13, 16th East Street Beyhaghi Ave., Argentina Sq. Boaz 3 WBG Marive East 21 F Nakase 2 - 6 Mihama-ku, Chiba-shi 7th Fl. Dorim Bldg. 1823 Bangbae - Dong Seocho - Ku Al-Showaikh Ind. Area P.O. Box 26229
Jakarta Barat 11 620
bobwall@cbn.net.id
IRAN
Tehran 15 156 34487 Haifa Chiba 261 - 7121
info@cimaghand.com ram@greenshpon.de www.greenshpon.co.il contact@flender-japan.com sales@flender-korea.com www.flender-korea.com adelameen@awalnet.net.sa flender@tm.net.my
ISRAEL
JAPAN
KOREA
Flender Ltd. South Gulf Company
Seoul 137 - 060 Safat 13 123 47301 Petaling Jaya Selangor Darul Ehsan
KUWAIT MALAYSIA
Representative Office Flender Singapore Pte. Ltd. 37 A - 2, Jalan PJU 1/39 Dataran Prima Flender Singapore Pte. Ltd. Flender Gc Aktarma Sistemleri Sanayi ve Ticaret Ltd. Sti. Representative Office 28 / F, Unit 2814, The Enterprise Centre, 6766 Ayala Avenue corner, Paeso de Roxas Middle East Sales Office IMES Sanayi Sitesi E Blok 502, Sokak No. 22
PHILIPPINES BAHRAIN / IRAQ LYBIA / JORDAN OMAN / QATAR U.A.E. / YEMEN
Makati City
junt@flender.com.ph
34 776 Dudullu Istanbul
meso@flendertr.com
BA 2010 EN 01.06 87 / 90
SAUDI ARABIA SINGAPORE
South Gulf Sands Est.
Bandaria Area, Dohan Bldg. Flat 3 / 1, P.O. Box 32 150
Al-Khobar 31 952 Singapore 63 7843
Phone: +966 (0) 3 - 8 87 53 32 Fax: +966 (0) 3 - 8 87 53 31 Phone: +65 (0) - 68 97 94 66 Fax: +65 (0) - 68 97 94 11 Phone: +963 (0) 11 - 6 11 67 94 Fax: +963 (0) 11 - 6 11 09 08 Phone: +886 (0) 2 - 26 93 24 41 Fax: +886 (0) 2 - 26 94 36 11 Phone: +66 (0) 38 - 49 51 66 - 8 Fax: +66 (0) 38 - 49 51 69 Phone: +84 (0) 8 - 8 23 62 97 Fax: +84 (0) 8 - 8 23 62 88
adelameen@awalnet.net.sa flender@singnet.com.sg www.flender.com.sg ismael.misrabi@gmx.net
Flender Singapore Pte. Ltd. 13 A, Tech Park Crescent Mezzeh Autostrade Transportation Building 4 / A, 5th Floor P.O. Box 12 450 1 F, No. 5, Lane 240 Nan Yang Street, Hsichih Representative Office Talay-Thong Tower, 53 Moo 9 10th Floor Room 1001 Sukhumvit Rd., T. Tungsukla
SYRIA
Misrabi Co & Trading
Damascus
TAIWAN
Flender Taiwan Limited
Taipei Hsien 221 A. Sriracha Chonburi 20 230
flender_tw@flender.com.tw
THAILAND
Flender Singapore Pte. Ltd.
contact@flender.th.com
VIETNAM
Representative Office Flender Singapore Pte. Ltd. Suite 22, 16 F Saigon Tower 29 Le Duan Street, District 1
Ho Chi Minh City
flender_vn@flender.com.vn
AUSTRALIA
AUSTRALIA
Head Office Flender (Australia) Pty. Ltd. 9 Nello Place, P.O. Box 6047 Wetherill Park Sales Offices Flender (Australia) Pty. Ltd. Suite 3, 261 Centre Rd. Bentleigh Flender (Australia) Pty. Ltd. Flender (Australia) Pty. Ltd. Suite 5, 1407 Logan Rd. Mt. Gravatt Suite 2 403 Great Eastern Highway
N.S.W. 2164, Sydney
Phone: +61 (0) 2 - 97 56 23 22 Fax: +61 (0) 2 - 97 56 48 92 Phone: +61 (0) 3 - 95 57 08 11 Fax: +61 (0) 3 - 95 57 08 22 Phone: +61 (0) 7 - 34 22 23 89 Fax: +61 (0) 7 - 34 22 24 03 Phone: +61 (0) 8 - 94 77 41 66 Fax: +61 (0) 8 - 94 77 65 11 Phone: +61 (0) 2 - 97 56 23 22 Fax: +61 (0) 2 - 97 56 48 92
sales@flender.com.au www.flender.com.au sales@flender.com.au sales@flender.com.au sales@flender.com.au sales@flender.com.au
VIC 3204, Melbourne QLD 4122, Brisbane W.A. 6104 Redcliffe - Perth N.S.W. 2164, Sydney
NEW ZEALAND
9 Nello Place, P.O. Box 6047 Flender (Australia) Pty. Ltd. Wetherill Park
BA 2010 EN 01.06 88 / 90
13.
13.1
Declaration by the manufacturer, Declaration of Conformity

Declaration by the manufacturer
in accordance with EC Engineering Guideline 98/37/EC, Appendix II B We hereby declare that the
Single stage helical gear units and gear motors of the types
E.38 E.48 D./Z.18 D./Z.28 D./Z.38 B.28 B.38 K.38 F.28 F.38B F.48B C.28 C.38
E.68 E.88 D./Z.48 D./Z.68 D./Z.88 K.48 K.68 K.88 F.68B F.88B F.108B C.48 C.68
E.108 E.128 D./Z.108 D./Z.128 D./Z.148 K.108 K.128 K.148 F.128B F.148B F.168B C.88
E.148
Two and three stage helical gear units and gear motor of the types
D./Z.168 D./Z.188
Bevel helical gear units and gear motors of the types
K.168 K.188
Parallel shaft helical gear units and gear motors of the types
F.188B
Helical worm gear units and gear motors of the types
described in these operating instructions are intended for incorporation in a machine, and that it is prohibited to put them into service before verifying that the machine into which they are incorporated complies with the EC Guidelines 98/37/EC. This Manufacturer's Declaration takes into account all the unified standards applying to our products in part or in whole published by the European Commission in the Official Journal of the European Community. These include in particular: EN 292 1 EN 292 2 EEN 294 EEN 349 EN 60204 1
Tbingen, 02.01.2006
(p.p. Head of Gear Unit Development)
BA 2010 EN 01.06 89 / 90
13.2
EC Declaration of Conformity
Document No. KE GKFSN298 DE / 07.03
Equipment designation: Type: Sizes: Add on subassemblies:
MOTOX-N Gear unit series E, Z, D, K, F, C 38 188 A, P K ,
The designated equipment conforms to the requirements of the explosion protection guideline 94/9/EC. It has been developed and manufactured in conformity to the following European standards: EN 1050/1996 pr EN 13463 5/2002 pr EN 13463 6/2002 EN 1127 1/1997 pr EN 13463 8/2001 EN 13463 1/2001 EN 50281 1/ 2/1999
Kind of explosion protection for equipment group II of category 2 and 3: II2 G/D ck T4/120 C II2 G/D bck T4/120 C II3 G/D ck T4/120 C
EC Declarations of Conformity and/or EC Type Test Certificates for further equipment added to the gear unit and/or for safety systems are enclosed. These may be specifically: Rotating electrical machines Safety systems for oil level and/or temperature monitoring equipment.
The technical documentation for gear units of category 2 has been subjected to a voluntary inspection and filed with the specified office no. 0123 TV PRODUCT SERVICE GmbH, Ridlerstrae 31, D 80339 Mnchen.
Tbingen, 02.01.2006
(p.p. Head of Gear Unit Development) (p. p. Head of Quality Management)
BA 2010 EN 01.06 90 / 90
Manual Number IB.545 Issue No. 9 23-7-03
GEARS LTD
Technical Manual for a
Type 36T, 44T, 55T, 65T, 80T Clutch

For a Turning Gear Drive
SSS Gears Ltd. Park Road, Sunbury-on-Thames, Middlesex, TW16 5BL. England. Tel: 01932 780644. Fax: 01932 780018
Contents and index
Preface Section 1 General description

1.1 1.2 1.3 The function of the clutch Lubrication Main clutch components - diagrammatic view
Section 2
Installation of the clutch

2.1 2.2 2.3 2.4 2.5 Clutch identification Direction of rotation Pre-installation actions Clutch installation - method 1 Clutch installation - method 2
Section 3 Section 4
Maintenance of the clutch

3.1 Clutch maintenance requirements
Fault finding
4.1 4.2 4.3 General Clutch fails to engage from rest or at low speed Clutch fails to disengage
Section 5 Section 6
Parts lists
5.1 Clutch parts list
Spare Parts
6.1 6.2 Ordering spare parts Recommended spares
Section7
Drawings
Clutch assembly drawing
Section 8
Principles of operation
Applicable principles Basic SSS clutch principle Dashpot - double acting
SSS Gears Turning Gear Clutch: Manual Number IB.545 Use only Clutch Assembly Drawing Number - SM.17016
GEARS LIMITED
Preface
This manual and its associated assembly drawing relates to a complete family of turning gear clutches of the following sizes. Size - 36T, 44T, 55T, 65T, and 80T. Two types of size 36T clutch are covered. One for standard installation and one for installation where a greater axial expansion is demanded. The instructions contained in this manual are suitable for all clutches in this family. The assembly drawing clearly shows all relevant dimensions, weights, torques, and lubrication requirements for each size of clutch.
Use in potentially explosive atmospheres
II 2G T4
These SSS clutches are intended only for use in slow speed turning gear drives and may only be used in accordance with these instructions and the operating instructions for the complete turning gear system. These clutches comply with the requirements of Directive 94/9/EC Group II Category 2G provided that: Lubricating oil is supplied to the SSS Clutch continuously when any part of the clutch is rotating. The limitations on clutch alignment and installed length are strictly observed.
GEARS LIMITED
Section 1
1.1
1.1.1
General description
The function of the clutch
The SSS (synchro-self-shifting) turning gear clutch is installed between a turning gear motor drive and its associated driven machinery. It is designed to provide a simple, mechanical, means of automatically engaging and disengaging the turning gear motor as and when it is required. If the driven machinery is stationary, the clutch will automatically engage from rest at the moment the turning gear motor starts to rotate. The clutch will automatically disengage as the driven machinery accelerates away under its main drive, allowing the turning gear motor to be shut down independently. The turning gear motor can be independently started while the main drive is still operating so that when the main drive is shut down and the driven machinery decelerates, the clutch will automatically engage to maintain the driven machinery at turning gear speed.
1.1.2
1.1.3
1.1.4
1.1.5
1.2
1.2.1
Lubrication
Lubricating oil is supplied to the clutch input shaft from the main plant lubrication system through the input hub to the input shaft. From there it is distributed through internal drillings to lubricate the rotating and sliding parts and feed the dashpot.
1.2.2
GEARS LIMITED
Section 1
1.3
1.3.1
General description
Main clutch components
The clutch comprises three main sub-assemblies: An input assembly; A helical sliding assembly; An output assembly. These are shown in the top half of the illustration in 1.3.2. The main component parts are shown in the bottom half.
1.3.2
Helical sliding assembly Input assembly Output assembly
Helical splines
Dashpot
Helical sliding component Driving teeth Ratchet pawls Driven teeth
Output clutch ring
A diagrammatic view of the clutch and its component parts
GEARS LIMITED
Section 2
2.1
2.1.1

Clutch identification
Each clutch is marked with an individual four figure serial number preceded by the letter R. The number (illustrated below), is marked on the outside of the clutch and, where possible, each individual sub-assembly.
CLUTCH
2.2
2.2.1
SERIAL No R * * * *
Direction of rotation
The outside diameter of the input flange is marked with an arrow (illustrated below) indicating the direction of rotation.
DIRECTION OF
INPUT
ROTATION
2.3
2.3.1 2.3.2
Pre-installation actions
Read the Preface of this manual. Ensure that the clutch assembly drawing is available and used throughout the assembly operation. Ensure that the main plant driving and driven shafts, have been inspected and meet technical specification and tolerance. Particular attention should be paid to alignment details given in the illustration in 2.3.4 and the distance between flange faces shown on the assembly drawing.
2.3.3
2.3.4
To check concentricity, use the driving shaft flange as a datum and rotate the indicator about the outside diameter of the driven shaft flange.
Maximum dial indicator reading to be as specified by machinery manufacturer.
To check parallelism, use the driving shaft flange as a datum and rotate the indicator about the face of the driven shaft.
GEARS LIMITED
Section 2
2.4
2.4.1

Clutch installation - method 1
Axially shorten the clutch by carefully sliding the output clutch ring (3) towards the input shaft (1). This ensures that the assembly clears the location spigots on the driving and the driven shafts. Position the clutch between the driving and driven shafts and fit the input shaft flange (1) onto the spigot of the turning gear shaft flange. Align the bolt holes and bolt the two flanges together. Axially extend the clutch by carefully sliding the output clutch ring (3) away from the input shaft (1). Fit the output clutch ring flange onto the spigot of the driven machine shaft flange. Align the bolt holes and bolt the two flanges together. Ensure that filtered lubrication oil is supplied to the clutch via the drilled oilway in the input shaft and refer to the assembly drawing to check the specified flow rate and pressure. Check that the input and output halves of the clutch are running true on their respective driving and driven shafts (see 2.4.7). Be aware that it is possible to fit the clutch back-to-front. Always re-check that the clutch input shaft has been fitted to the turning gear drive before starting the drive.
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
2.4.7
Check that the input half of the clutch is is fitted concentric and parallel. Maximum dial indicator reading = 0.03 mm TIR Check that the output half of the clutch is fitted concentric and parallel.
GEARS LIMITED
Section 2
2.5
2.5.1 2.5.2

Clutch installation - method 2
Remove the output clutch ring (3) from the clutch assembly. Fit the output clutch ring flange (3) onto the spigot of the driven machine input shaft flange. Align the bolt holes and bolt together. Fit the clutch input shaft flange (1) and the remaining clutch assembly onto the spigot of the turning gear shaft flange. Align the bolt holes and bolt together. Fit the turning gear drive and clutch assembly into its operating position, carefully feeding the clutch mechanism into the, already fitted, output clutch ring. Accurately position and secure the turning gear drive. Ensure that filtered lubrication oil is supplied to the clutch via the drilled oilway in the input shaft and refer to the assembly drawing to check the specified flow rate and pressure. Check that the input and output halves of the clutch are running true on their respective driving and driven shafts (see 2.4.7). Be aware that it is possible to fit the clutch back-to-front. Always re-check that the clutch input shaft has been fitted to the turning gear drive before starting the drive.
2.5.3
2.5.4
2.5.5 2.5.6
2.5.7
2.5.8
GEARS LIMITED
Section 3
3.1
3.1.1
Maintenance of the clutch

Clutch maintenance requirements
The SSS Clutch requires no routine maintenance and is designed to last the lifetime of the main plant. During overhaul of the main plant, it is recommended that the SSS clutch should be removed for inspection. SSS Gears should be contacted in this regard.
3.1.2
GEARS LIMITED
Section 4
4.1
4.1.1
Fault finding
General
The only faults likely to occur are those caused by operational defects - notably a lack of lubricating oil during operation and/or misalignment. A lack of lubricating oil will result in overheating and damage to the clutch teeth and the pawl and ratchet mechanism. Misalignment could result in damage to the pawl and ratchet mechanism such that the clutch will not engage.
4.1.2
4.1.3
4.2
4.2.1
The clutch fails to engage from rest or at low speed

If the turning gear motor will not rotate the driven machine from standstill or if, when at low speed, the turning gear motor is able to rotate slightly faster than the driven machinery, then there is damage to the pawl and ratchet mechanism. Action: Stop the drive immediately to prevent further damage and contact SSS Gears.
4.2.2
4.3
4.3.1
The clutch fails to disengage

If the speed of the turning gear motor will not reduce below the speed of the driven machine when the turning gear motor is turned off, this indicates that the clutch mechanism is damaged and held in the engaged position. Action: Stop both the driven machine and the turning gear motor immediately to prevent further damage and contact SSS Gears.
4.3.2
GEARS LIMITED
Section 5
5.1
Parts List
Clutch parts list Item
1 2 3 4 5 6 7 8 9 10 11 12 13
Description
Input shaft Helical sliding component Output clutch ring Stop cap Not used Pawl Pawl spring Pawl pin Pawl stop pin Not used Socket head cap screw Socket set screw Socket set screw
Qty
1 1 1 1 2 2 2 2 4 2 2
GEARS LIMITED
Section 6
6.1
6.1.1
Spare parts
Ordering spare parts
Five items of information are required when ordering spare parts from the manufacturers. (1) The quantity required, (2) The item number, (3) The description, (4) The drawing number, (5) The clutch serial number. The clutch serial number (preceded by the letter R) is marked on the outside of the clutch. The remaining information required is found in Section 5 of this manual and on the assembly drawing. Order example: Quantity 2, Item 6, Pawl, Drawing number SL.*****, Serial number (see clutch).
6.1.2
6.1.3
6.2
6.2.1
Recommended spares
It is advised that the following spares are carried as stock.
Item
6 7 8 9 12 13
Description
Pawl Pawl spring Pawl pin Pawl stop pin Socket set screw Socket set screw
Qty
2 2 2 2 2 2
GEARS LIMITED
Section 7
7.1
Assembly Drawing
Clutch assembly drawing - SM.17016
The clutch assembly drawing is provided in this manual as a bound-in insert
GEARS LIMITED
Section 8
Applicable principles
The SSS clutch incorporates a number of features. As an aid to understanding these features, the applicable SSS principles of operation are contained in the pages of this section. These principles are: Basic SSS clutch principle Dashpot - double acting SSS Principle No. 1a. SSS Principle No. 4.
The diagrams used to describe these SSS principles are generic and not descriptive of any individual SSS Clutch. A diagrammatic view of the clutch is contained in Section 1 and assembly drawings can be found at the back of this manual.
GEARS LIMITED
Section 8
Basic SSS clutch principle (SSS Principle No.1a)
The initials SSS denote the 'Synchro-Self-Shifting' action of the clutch, whereby the clutch driving and driven teeth are phased and then automatically shifted axially into engagement when rotating at precisely the same speed. The clutch disengages as soon as the input speed slows down relative to the output speed. The basic operating principle of the SSS clutch can be compared to the action of a nut screwed on to a bolt. If the bolt rotates with the nut free, the nut will rotate with the bolt. If the nut is prevented from rotating while the bolt continues to turn, the nut will move in a straight line along the bolt. In an SSS clutch the input shaft has helical splines which correspond to the thread of the bolt. Mounted on the helical splines is a sliding component which simulates the nut. The sliding component has external clutch teeth at one end, and external ratchet teeth at the other (see Figure 1). When the input shaft rotates, the sliding component rotates with it until a ratchet tooth contacts the tip of a pawl on the output clutch ring to prevent rotation of the sliding component relative to the output clutch ring, and align the driving and driven clutch teeth (see Figure 1 and Figure 4). As the input shaft continues to rotate, the sliding component will move axially along the helical splines of the input shaft moving the clutch driving and driven teeth smoothly into engagement. During this movement, the only load taken by the pawl is that required to shift the lightweight
Input shaft
Pawls
Output clutch ring Clutch teeth
Ratchet
Helical sliding component
Helical splines
Figure 1: Clutch disengaged
Movement into engagement
Figure 2: Engaging travel (pawls unloaded)
GEARS LIMITED
Section 8
SSS Principle No.1a -continued
sliding component along the helical splines. As the sliding component moves along the input shaft, the pawl passes out of contact with the ratchet tooth, allowing the driving teeth to come into flank contact with the driven teeth and continues the engaging travel (see Figure 2). Driving torque from the input shaft will only be transmitted when the sliding component completes its travel by contacting an end stop on the input shaft, with the clutch teeth fully engaged and the pawls unloaded (see Figure 3). When a nut is screwed against the head of a bolt, no external thrust is produced. Similarly when the sliding component of an SSS clutch reaches its end stop and the clutch is transmitting driving torque, no external thrust loads are produced by the helical splines.
Figure 3: Clutch engaged
As the clutch input overtakes the clutch output, the pawls engage with the ratchet....... Clutch output Pawl Ratchet
Clutch input ......and the driving and driven teeth are perfectly aligned for inter-engagement Figure 4: Clutch teeth alignment.
If the speed of the input shaft is reduced relative to the output shaft, the torque on the helical splines will reverse. This causes the sliding component to return to the disengaged position and the clutch will overrun. At high overrunning speeds, pawl ratcheting is prevented by a combination of centrifugal and hydrodynamic effects acting on the pawls. The basic SSS clutch can operate continuously engaged or overrunning at maximum speed without wear occurring.
GEARS LIMITED
Section 8
Dashpot - double acting type (SSS Principle No.4)
The purpose of the double acting dashpot is to cushion clutch engagement at high acceleration and slow down the rate of disengagement.
Figure 1: Clutch Disengaged The dashpot is continuously supplied with low pressure Dashpot filled oil - usually from the main with oil machinery lubrication system.
Input shaft Free movement
Ratchet Pawls
Output clutch ring
Clutch teeth
Helical splines Oil supply Helical sliding component
Figure 2: Clutch Engaging Strong dashpot action starts after the pawls are unloaded, and then continues to the end of the clutch engaging travel.
Cushioned movement Pawls unloaded
Oil supply
Figure 3: Clutch Engaged Final clutch engaging travel is cushioned by the dashpot action. The dashpot also slows down the rate of clutch disengagement.
GEARS LIMITED
GUIDE DEXPLOITATION ET DENTRETIEN OPERATING AND MAINTENANCE INSTRUCTIONS BETRIEBS UND WARTUNGSVORSCHRIFTEN LIBRETTO DUSO E MANUTENZIONE MANUAL DE USO Y DE MANTENIMIENTO
A 06
DISPOSITIF DE DEMARRAGE STARTING DEVICE ANLASSWIEDER STAND DISPOSITIVO DE DARRANQUE DISPOSITIVO DI AVVIAMENTO
Version : ENGLISH
OPERATING AND MAINTENANCE MANUAL PT -PU PUMP TYPE
SEIM PUMP TYPE Distributed by SEIM FRANCE
SEIM France 14 Avenue des Vieux Moulins ZI de Vovray 74000 ANNECY Tel : 04.50.10.10.36 - Fax : 04.50.10.10.45 e-mail : seim@wanadoo.fr
I - PUMP IDENTIFICATION PLATE

Every SEIM T3C and T3A and PU pumps type is identified by a metal plate riveted to the body of the pump bearing the pump model code number and the serial number of the individual pump. The metal plate looks like this:
I.1 - IDENTIFICATION CRITERIA Tables 1 and 2 illustrate the pump identification criteria in full. The dimensionnal and functional charateristics of each model of pump are indicated in specific tables. I.2 - DIRECTION OF ROTATION The direction of rotation of the motor must conform with the direction indicated by the arrow of the identification plate.
II - INSTALLATION
T3C and T3A and PU pumps type have cast iron bodies. Pumps may be installed in any position but the delivery flange should be higher than the suction flange to allow air to exit. The pressure at the suction flange can be positive or negative (see the specific tables) Although SEIM screw pumps have excellent self priming characteristics, it is advisable that the suction line and the pump form a siphon system to keep the pump full when it is not in operation and thus avoid damage at start-up. Do not use a non-return valve to ensure that fluid is retained as this would cause loss of head on the suction line to increase.
II.1 - SUCTION AND DELIVERY FLANGES
The suction flanges are conformed with the UNI 2281-67 PN10 or PN 16 standard. The delivery flanges are designed to take UNI 2284-67 PN40. ANSI flanges can be supplied on request. For the T3C and PUC pump, the suction flange can be fitted at a 90 angles to the delivery fitting: to position the suction flange correctly follow the procedure below (the numbers in brackets refer to the components shown in figure 1): 2.1.1 - Position of the suction flange with hexagonal nuts 1) Loosen the hexagonal nuts (15) and remove the screws (17); 2) Turn the suction flange (21) until the desired position is reached; take care not to damage the o-ring (16) fitted on the housing on the body of the valve (14); 3) Push the suction flange (21) against the body of the valve (14); 4) Replace the screws (17) and tighten the hexagonal nuts (15). When supplied by SEIM, the openings of the suction and delivery attachments of the pump are protected by plastic covers and the motor shaft is also covered with plastic to respect the pump and ensure that impurities do not get inside. The plastic covers must not be removed until just before the pump is fitted to the hydraulic system line. II.2 - CONNECTION TO ELECTRIC MOTOR The pump is connected to B35 type motors (motors with feet and flanges) by a normalised flexible coupling and spider, and to B3 type motors (motors with feet) by means of a flexible coupling (in this case, the pump will be equipped with feet), or to B5 type motors (motors with flanges) for immersed vertical installations. This system reduces the extent of any alignement errors to values easily compensated by the flexible coupling. When a B5 type motor is used the spider can be fitted with feet. II.3 - FILTER ON THE SUCTION LINE It is advisable to install a 125 micrometer filter on the suction line since particulate contaminants in the fluid can cause wear by abrasion and increase slack and internal blowby, thus reducing the head. The dimensions of the filter can be adequately defined according to the head, operating temperature and difference in pressure across the filter itself.
III - PUMP START - UP

III.1 - BEFORE START - UP When installing the pump (new or reconditions), fill the pump with the operating fluid and turn the shaft manually in the direction indicated on the identification plate to lubricate the internal components of the pump. It is then ready for start-up. III.2 - DIRECTION OF ROTATION To check the direction of rotation of the pump, switch the electric motor on and off rapidly and observe the rotation of the motor impeller or, if easier, of the shaft by making a suitable opening on the spider. The direction of rotation must match the one indicated by the arrow on the identification plate. III.3 - START-UP The pump can only be started if the suction and delivery lines are fully open. The pump is primed when it starts to deliver head. Leave the pump operating for a few minutes to remove air from the fluid then regulate the pressure to the system value. If priming does not occur within 30 seconds stop the motor, wait a few seconds and repeat the start-up operation. If the pump cannot be primed check the conformance of the system.
IV - DISMANTLING AND FITTING THE PUMP

These instructions assume that the pump has already been disconnected from the spider, or flexible coupling for the fixing feet version, and from the suction and delivery lines, and that it has been completely drained of fluid and the flexible half-coupling removed. IV.1 - DISMANTLING THE PUMP The following procedure should be followed (the numbers in brackets refer to the components shown in figures 1 and 2):
1) Block the body of the pump (14) horizontally, ensuring that the data on the identification plate is not obscured; 2) Loosen the nuts (15) and remove the 4 screws (17) which connect the suction flange (21) to the body of the pump (14); 3) Remove the suction flange (21) taking care not to damage the o-ring (16); 4) Unscrew the 4 screws (20) which hold the support plate (19) to the body of the pump, by means of the spacing pins (18); 5) Remove the side screws (13) by turning clockwise; 6) Remove the tab (1) from the central screw (12); 7) Unscrew the 4 fixing screws (5); 8) Remove the flexible washer (2) on the central screw; 9) Use an extractor to remove the motor coupling flange (6); the bearing (4), labyrinth (8) and the fixed part of the mechanical seal (9) remain inside the flange (6); 10)Remove the flexible washer (3) and bearing (4) from the flange; 11)Remove the flexible washer (7) and labyrinth (8) from the flange; 12)If necessary remove the fixed part of the mechanical seal (9) from the coupling flange (6) following the instructions given in section 5 ( Replacement of the mechanical seal ); if left in place do not let your hands touch the sliding surface of the seal. 13)If necessary remove the fixed part of the mechanical seal (11) from the central screw (12) following the instructions given in sections 5 ( Replacement of the mechanical seal ); if left in place do not let your hands touch the sliding surface of the seal. IV.2 - INSPECTION If correctly installed and if start up has been performed correctly, SEIM pumps need very limited inspection. However, if the components of the pump are so worn that pressure is not maintained it is normally preferable to replace the whole pump rather than specific components, as when one of the component is worn the others generally are too. To inspect the pump and determine the state of wear, check the following parts which can be replaced easily: Fixed part of the mechanical seal (9), rotating part of the mechanical seal (11), o-ring (10 and 16), bearing (4), labyrinth (8) and support plate (19).
IV.3 - ASSEMBLY
To assemble the pump the procedure described for dismantling must be followed in reverse. It is advisable to take the following precautions: 1) Fit the rotating part of the mechanical seal (11) on the central screw (12) following the instructions given in section 5 ( Replacement of the mechanical seal ); Check that drainage hole on the motor coupling flange (6) is free of any impurities; If previously dismantled, fit the fixed part of the mechanical seal (9) in the motor coupling flange (6) following the instructions given in section 5; Slide the labyrinth (8) inside the coupling flange (6) and block it with the flexible washer (7); Clean the sliding surfaces of the rotation part of the mechanical seal (11), fitted on the central screw (12) with methylated spirit, taking care to leave no residue; Clean the sliding surfaces of the fixed part of the mechanical seal (9), fitted on the motor coupling flange (6) with methylated spirit. Clean the central screw leaving no residue and fit into the body of the pump. Slide the motor coupling flange (6) on the central screw, centering the screw with the internal washer of the labyrinth (8); Taking care not to damage the o-ring (10), fit the motor coupling flange (6) correctly to the body of the pump (14) and tighten the 4 screws (5);
2) 3)
4)
5)
6)
7) 8)
9)
10) From the side of the motor coupling flange (6), use a suitable sized sleeve to push the internal washer of the labyrinth (8) to the edge screw (2) see enlargement in figures 1 and 2; 11) Insert the bearing (4) on the central screw (2) and the motor coupling flange (6), using the flexible rings (2) and (3) block the assembly with the flexible washer ; 12) Clean the two side screws (13) leaving no residue and insert them using an anticlockwise motion into the body of the pump (14) until they reach edge; 13) Clean the support plate (19), lubricate it and then fit to the body (14) using the spacing pins and fixing screws (20), ensuring that the position of the two slide housings correspond with the position of the two side screws (13); 14) Check that the o-ring (16) is intact and fit the suction flange (21) on the body of the pump (14). For the T3C, check that the position of the suction hole in relation to the delivery hole coincides with the requirements of the system; 15) Insert the tab (1) in its housing on the central screw (12) using a plastic hammer;
16) Lubricate the screws and turn the shaft manually in the direction indicated on the identification plate so that the internal components of the pump are lubricated.
V - REPLACEMENT OF THE MECHANICAL SEAL

These instructions suppose that the pump is already disconnected from the spider, suction line and delivery line, and that it has been fully drained and the flexible half-coupling removed. It is advisable to follow the instructions (the numbers in brackets refer to the components listed in figures 1 and 2): 1) Follow the whole procedure described in section 4.1 Dismantling the pump from point 6 to point 10. 2) The internal diameter of the fixed part of the mechanical seal (9) is less than the diameter of the hole (shaft housing) in the motor coupling flange (6). Remove the fixed part of the mechanical seal (9) by pulling it out with your fingers. 3) Remove the rotating part of the mechanical seal (11) from the central screw (12), facilitating the operation by turning the seal clockwise and holding the central screw still. 4) Remove the packaging from the replacement seal without touching its sliding faces with your hands. Do not leave the parts of the seal with the sliding surfaces on the work bench. 5) The fixed part of the mechanical seal (9) must be introduced into the cavity in the motor coupling flange (6) by pressing it with your fingers or using a sleeve with suitable internal and external diameters to press its outer ring without touching the sliding surfaces. Lubricate the o-ring with a thin film of oil. 6) Clean the rotating part of the mechanical seal (11) with methylated spirit, taking care not to touch sliding surface, and slide onto the central screw (12), turning the seal clockwise while holding the central screw still and pressing it against the washer of the central screw (12). 7) Fit the motor coupling flange (6) to the central screw, centring the screw with the internal washer of the labyrinth (8). 8) Follow the Assembly procedure described in section 4-3 from point 9 to point 11.
COMPONENT LIST
1) tab 2) shaft retaining ring 3) internal retaining ring 4) self-lubricating bearing 5) hexagonal-slotted flat head screw 6) motor coupling flange 7) internal retaining ring 8) labyrinth 9) fixed part of the mechanical seal 10) o-ring 11) rotating part of the mechanical seal 12) central screw 13) idler screws 14) pump casing 15) hexagonal nuts 16) o-ring 17) hexagonal head fixing screws 18) spacing pins 19) support plate 20) hexagonal-slotted flat head screw 21) suction flange
Table 1 - Type T3C - T3A pump identification number

1 Digit: version T = pump for external installation with cast iron body external diameter of central screw (mm) screw length number 3 = number of hydraulic seals on central screw screw gauge in mm internal characteristics O = standard version T = anti-clockwise rotation external characteristics A = axial suction flange version C = radial suction flange version special versions O = standard version A = version in accordance with API 676 K = built-in safety valve with internal recirculation L = built-in safety valve with external recirculation type of gaskets and seals O = Viton gaskets and widia/widia mechanical seal safety valve characteristics A = gauge pressure 0-7 bar B = gauge pressure 7-15 bar C = gauge pressure 15-40 bar inlet/outlet flanges characteristics A = ANSI 150 RF norm B = ANSI 300 RF norm D = DIN norm P = body with fixed feet: horizontal position L = body with fixed feet: vertical position
2 - 4 Digit: 5 Digit:
6 - 8 Digit: 9 Digit:
10 Digit:
11 Digit:
12 Digit:
13 Digit:
14 Digit:
15 Digit:
Table 2 - Individual pump serial number

1-2 Digit: 3-4 Digit: 5-8 Digit: year of production code number (example : 10=1995 ; 11=1996) month tested serial number
10
11

A 07 MAINTENANCE BOARD
FLENDER-GRAFFENSTADEN Operations to be done before :
years HOURS
1
200 8000
10
16000 24000 32000 40000 48000 56000 64000 72000 80000
Bearings (See also note A) Visual inspection Wear measurement Dye penetration if necessary Replace if : max clearance is reached or there are any cracks Toothing (See also note B) Visual inspection (throuth the trap door) Check the contact surface by checking the ''Dyken red'' varnish Mesure the backlash and check the contact with methylene blue Dye penetration or magnetic particle inspection Replace if : wear to severe presence of cracks pitting, ect... Seal Visual inspection Mesure clearance between shaft/oil seal Replace if : too much clearance presence of leaks after installation of new bearing shells Coupling / Quill shaft Dismantling, cleaning Visual check : teeth for toothing coupling spline for quill shaft / sleeve coupling Replace if : severe wear marks excessive clearance breakage and / or deterioration of toothing profiles Casing New compound on joint plane Internal cleanliness check Check of internal pipework Levelling Alignment Inspection and any necessary modification Aucillary equipment
Such as pumps, turning gear, clutchs etc... in accordance with the specific instructions included in our manual
See Appendix 06
Note A : Bearing. In case clearance of bearings exceed maxi recommended 30%, it is absolutely necessary to mount a set of spare bearings. Replacement of bearing may also be necessary in case presence of inlet lubrication oil cannot be maintained. LS and HS thrust bearing pads have to be replaces as soon as half of active area is tarnished. Note B : Toothing. Control of tooth contact has be carried regulary through visiting door. Unilateral tooth contact means that foundation gave way. Such a tooth contact is highly detrimental to good quality of toothing especially in case of turbomachines which are therefore it is important to identify the cause and find remedy for it at very short time.
GUIDE DEXPLOITATION ET DENTRETIEN OPERATING AND MAINTENANCE INSTRUCTIONS BETRIEBS UND WARTUNGSVORSCHRIFTEN LIBRETTO DUSO E MANUTENZIONE MANUAL DE USO Y DE MANTENIMIENTO
A 08
RECAPITULATIF DES PLANS / LIST OF DRAWINGS LISTE DER ZEICHNUNGEN / RECAPITULACION DE LOS PLANOS / REPLOGIO DI PLANI
Plan dassemblage Assembly drawing Montagezeichnung Plano de ensamblaje Piano dassemblaggio Plan dencombrement + caractristiques Outline drawing + characteristics Einbauzeichnung + Technische Angaben Plano di dimensiones + caracteristicas Piano dingombrio + caratteristiche Schma de sortie de cble : Temprature Wiring diagram : Temperature Verkabelungsschema : Temperatur Esquema de montaje del cable : Temperatura Schema di uscita di cavo : Temperatura Shma de montage / cblage : Vibration Wiring diagram : Vibration Verkabelungsschema : Schwingung Esquema de montaje / cableado : Vibracion Schema di montaggio / cablaggio : Vibrazione Porte dentures Tooth contact pattern Verzahnungstragbild Asiento de los dentados Portata dentura N N N N N
02S287
02N357
27D601
04AE577

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OPERATING AND MAINTENANCE INSTRUCTIONS

OPERATING AND MAINTENANCE INSTRUCTIONS

BHEL B708P027 West Coast

30193.01 34530 10282

OPERATING AND MAINTENANCE INSTRUCTIONS CONTENTS

OPERATING AND MAINTENANCE INSTRUCTIONS

TECHNICAL DESCRIPTION OF THE GEARBOX

The gearbox is reducer.

GEAR SET Toothing

OPERATING AND MAINTENANCE INSTRUCTIONS

PROTECTION - SHIPMENT 3. INSTALLATION ON SITE

OPERATING AND MAINTENANCE INSTRUCTIONS

ASSEMBLY & THE GEARBOX

OPERATING AND MAINTENANCE INSTRUCTIONS

CONTROL Oil pressure

Temperatures Oil outlet temperature

After assembly and dismantling refer to 3 INSTALATION ON SITE.

OPERATING AND MAINTENANCE INSTRUCTIONS

RESTART OF THE GEARBOX

Increase in vibration or noise level

Instructions to be followed on appearance of alarm :

Oil pressure fault

MAINTENANCE AND SERVICING ON GEARBOX

OPERATING AND MAINTENANCE INSTRUCTIONS

In order to optimize machine lifetime it is necessary to monitor the following parameters :

CORRESPONDENCE FLENDER-GRAFFENSTADEN BP 84 67402 ILLKIRCH GRAFFENSTADEN : +33 (0) 3 88 67 60 00

: +33 (0) 3 88 67 60 19 FAX : +33 (0) 3 88 67 61 40

In accordance with values specified in the instructions. See Appendix 03.

A01 A02 A03 A04 A05 A06 A07 A08

FICHE CARACTERISTIQUE DE LA MACHINE MACHINE KENNZEICHEN GEAR DATA

OPERATING AND MAINTENANCE INSTRUCTIONS

POSITION OF BLOCKING PARTS

SKETCH N 02 : PRECISION BUBBLE LEVEL ON STRAIGHT - EDGE

CHECK PLANENESS OF THE JOINT PLANE

OPERATING AND MAINTENANCE INSTRUCTIONS

Alarm Overall value in g peak in the frequency range 2500 to 10000 Hz 18

OPERATING AND MAINTENANCE INSTRUCTIONS

32 100 5,1 210 -10 3 5 I : 10 / 0 II : 20 / 0 III : 10 / 0 min. 7 450 4000 0.2

DIN 51354 / 2 ASTM D2272 ISO7624 ISO 6618

in tank oil inlet oil inlet ISO 4572 oil inlet

OPERATING AND MAINTENANCE INSTRUCTIONS A 05 SPARE PARTS LIST

Assembly drawing : Outline drawing : ITEM Number GEARING DESIGNATION

02S287 02N357 Spare parts Type

SPARE PARTS LIST

ADJUSTABLE BEARING ASSEMBLY

SPARE PARTS LIST

Spare parts ITEM Number OIL SEAL DESIGNATION Type

SPARE PARTS LIST

Spare parts ITEM Number INSTRUMENTATION DESIGNATION Type

L111 L121 L151 L161 L213 L223

08T165/05 08T165/05 08T165/05 08T165/05 08T165/05 08T165/05

L110 L210 L210 L220

THERMOMETER THERMOMETER THERMOMETER THERMOMETER

WIKA D 100 WIKA D 100 WIKA D 100 WIKA D 100

SPARE PARTS LIST

Spare parts ITEM Number PUMP DESIGNATION Type

M100 M160 M180

PUMP DRIVING WHEEL DRIVER WHEEL

PFPZ126#3CHOR 23C792 23C793

VIREUR / TURNING GEAR / DREHVORRICHTUNG / VIRADOR / VIRATOR

OPERATING AND MAINTENANCE INSTRUCTIONS

TECHNICAL DESCRIPTION OF THE TURNING GEAR

Turning speed Breakaway torque

For key to diagram symbols, see section 3.5 Mounting positions.

For key to diagram symbols, see section 3.5 Mounting positions.

For key to diagram symbols, see section 3.5 Mounting positions.

For key to diagram symbols, see section 3.5 Mounting positions.

For key to diagram symbols, see section 3.5 Mounting positions.

For key to diagram symbols, see section 3.5 Mounting positions.

For key to diagram symbols, see section 3.5 Mounting positions.