Assembly and operating instructions

BA 5050 EN 12.08

Gear Unit Types H.SH, B.SHwith integrated freewheel (overrunning) clutch

on the low­speed shaft (d2)Sizes 3 to 14

in design in accordance with Directive 94/9/EC

A. Friedr. Flender AG • D‐46393 Bocholt • Tel. 02871/92‐0 • Telefax 02871/92‐2596 • www.flender.com

Translation of the original assembly and operating instructions

2 / 42BA 5050 EN 12.08

Notes and symbols in these assembly and operating instructions

WARNING! Imminent explosion!

The information indicated by this symbol must always be observed to avoid explosion damage.

WARNING! Imminent personal injury!

The information indicated by this symbol is given to prevent personal injury.

WARNING! Imminent damage to the product!

The information indicated by this symbol is given to prevent damage to the product.

WARNING! Hot surfaces!

The information indicated by this symbol is given to prevent risk of burns due to hot surfacesand must always be observed.

NOTE!

The information indicated by this symbol must be treated as general operating information.

Breather position: yellow

Oil­filling point: yellow Oil drain position: white

Oil level: red Oil level: red

Lubrication: red Apply grease! :

Lifting eyes: Eye bolt:

Do not unscrew! : "SPM system":

Alignment surfaces:

Horizontal: Vertical:

These symbols indicate the oil­level checking procedure using the oildipstick.

These symbols indicate that the oil dipstick must always be firmlyscrewed in.

Note: The term "Assembly and operating instructions" will in the following also be shortened to"Instructions".

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3 / 42BA 5050 EN 12.08

Contents

1. Technical data 51.1 General technical data 5

1.1.1 Variants 5

1.2 Marking of the gear units in design in accordance with Directive 94/9/EC 6

1.2.1 Ambient temperature 6

1.2.2 Weights 6

1.2.3 Measuring­surface sound­pressure level 7

1.2.3.1 Measuring­surface sound­pressure level for helical­gear units 7

1.2.3.2 Measuring­surface sound­pressure level for bevel­helical gear units 8

2. General notes 92.1 Introduction 9

2.2 Copyright 9

3. Safety instructions 103.1 Proper use 10

3.2 Obligations of the user 10

3.3 Environmental protection 11

3.4 Special dangers and personal protective equipment 11

4. Handling and storage 124.1 Scope of supply 12

4.2 Handling 12

4.3 Storing the gear unit 14

4.4 Standard coating and corrosion protection 14

5. Technical description 155.1 General description 15

5.2 Housing 15

5.3 Toothed components 15

5.4 Lubrication 15

5.5 Shaft bearings 16

5.6 Shaft seals 16

5.6.1 Radial shaft­sealing rings 16

5.6.2 Taconite seals 16

5.7 Freewheel (overrunning) clutch 17

5.8 Cooling 18

5.9 Oil­temperature measurement 18

5.10 Oil­level monitoring system 19

4 / 42BA 5050 EN 12.08

6. Fitting 206.1 General information on fitting 20

6.2 Fitting the gear unit on the installation 21

6.2.1 Foundation 21

6.2.2 Description of installation work 21

6.2.2.1 Alignment surfaces, alignment thread 22

6.2.2.2 Mounting on a foundation frame 23

6.2.2.3 Mounting on a concrete foundation by means of stone bolts or foundation blocks 23

6.2.2.4 Mounting on a concrete foundation by means of anchor bolts 24

6.3 Couplings, clutches 26

6.4 Gear unit with add­on components 27

6.5 Oil­temperature measurement 27

6.6 Oil­level monitoring system 27

6.7 Final work 28

6.8 Screw­connection classes, tightening torques and initial tensioning forces 28

6.8.1 Screw­connection classes 28

6.8.2 Tightening torques and initial tensioning forces 29

7. Start­up 307.1 Procedure before start­up 30

7.1.1 Removal of preservative agent 30

7.1.2 Filling with lubricant 31

7.1.2.1 Oil quantities 32

7.2 Startup and removal from service 32

7.2.1 Oil level 32

7.2.2 Temperature measurement 32

7.2.3 Checking procedure 33

7.3 Removal from service 33

7.3.1 Interior preservation during longer disuse after start­up 33

7.3.1.1 Interior preservation with gear oil 33

7.3.1.2 Interior preservation with preservative agent 33

7.3.2 Exterior preservation of bright machined surfaces 34

8. Operation 35

9. Faults, causes and remedy 359.1 General information on faults and malfunctions 35

9.2 Possible faults 36

10. Maintenance and repair 3710.1 General notes on maintenance 37

10.2 Description of maintenance and repair work 38

10.2.1 Testing water content of oil 38

10.2.2 Changing the oil 38

10.2.3 Cleaning the breather screw 39

10.2.4 Refilling Taconite seals with grease 39

10.2.5 Cleaning of fan (on the freewheel (overrunning) clutch) and gear unit 39

10.2.6 Topping up oil 39

10.2.7 Checking tightness of all base bolts 39

10.3 Final work 39

10.3.1 General inspection of the gear unit 39

10.4 Lubricants 40

11. Spare parts, customer­service addresses 4011.1 Stocking spare parts 40

11.2 Spare parts and customer­service addresses 40

12. Declaration by the manufacturer / Declaration of conformity 41

5 / 42BA 5050 EN 12.08

1. Technical data

1.1 General technical data

The most important technical data are shown on the rating plate. These data and the contractualagreements between FLENDER and the customer for the gear unit determine the limits of its correct use.

(see item 1.2)

①

②

③

⑤

④

⑥

⑦ ⑧

⑨ ⑩ ⑪

⑫

Fig. 1: Rating plate

① Company logo and place of manufacture ⑦ Speed n2 (high speed)

② Special information ⑧ Speed n2 (low speed)

③ Order no. ­ item ­ seq. no. ⑨ Type of oil

④ Year of construction of the gear unit ⑩ Oil viscosity ISO VG

⑤ Type / size *) ⑪ Quantity of oil in litres for main housing

⑥ Power rating P2 in kW or T2 in Nm ⑫ Instructions number(s)

*) Example

B 3 S H 13

Size 3 ... 14. . . . . . . . . . . . . . . . . . . . . . Installation H = horizontal. . . . . . . . . . . . . . . . . Type of output shaft S = solid shaft. . . . . . . . . Number of stages 2, 3 or 4. . . . . . . . . . Gear-unit type H = helical gear unit. . . . . . . . . . . . .

B = bevel-helical gear unit

1.1.1 Variants

Gear units with integrated freewheel (overrrunning) clutch on the shaft d2 are basically distinguished in2 variants:

Variant 1 Variant 2

Helical gear unit Bevel-helical gear unit

Variant 1 Variant 2

Fig. 2: Possible variants

Data on weights and measuring­surface sound­pressure levels of the various gear types are given initems 1.2.2 and 1.2.3.

For further technical data, refer to the drawings in the gear­unit documentation.

6 / 42BA 5050 EN 12.08

1.2 Marking of the gear units in design in accordance with Directive 94/9/EC

Table 1: ATEX marking

Equipmentgroup

Equipmentcategory

"Ex"atmosphere

Explosiongroup

Temperatureclass

Marking

�� 3 Dust (D) II 3 D 120 °C bck Ta.. 1)

1) Tamin ≤ Ta ≤ Tamax = permissible ambient temperature range in °C:Tamin = minimum permissible ambient temperature rangeTamax = maximum permissible ambient temperature rangeTa = symbol for ambient temperature in °C

With gear units without electrical explosion hazard monitoring device (such astemperature, oil level) no ignition protection "b" is available.

The rating plate on the gear unit indicates the marking for the applicable caseof application.

1.2.1 Ambient temperature

The specifications of Directive 94/9/EC apply to the ambient temperature range of from ­ 20 °C to + 40 °C.By adopting various suitable measures the gear unit may be used at ambient temperatures of between­ 40 °C and + 60 °C. However, this must always be approved by FLENDER.In individual cases the permissible ambient temperature range specified on the rating plate always applies.

1.2.2 Weights

Table 2: Weights (approximate values) for variant 1

TypeApproximate weight (kg) Variant 1 for size

4 5 6 7 8 9 10 11 12 13 14

H2SH 220 375 435 625 720 970 1115 1555 1850

on request

H3SH - 395 445 660 755 1015 1175 1620 1910

H4SH - - - 670 775 1015 1165 1680 1960

B2SH 265 435 490 735 830 1140 1310 1860 2145

B3SH 240 400 460 670 765 1030 1175 1675 1965

B4SH - 410 465 675 785 1030 1180 1705 1985

Table 3: Weights (approximate values) for variant 2

TypeApproximate weight (kg) Variant 2 for size

3 4 5 6 7 8 9 10 11 12 13 14

H2SH 180 254 445 500 735 820 1150 1280 1885 2165

on request

H3SH - - 465 510 770 855 1195 1340 1950 2225

H4SH - - - - 780 875 1195 1330 2010 2275

B2SH - 299 505 555 845 930 1320 1475 2190 2460

B3SH - 274 470 525 780 865 1210 1340 2005 2280

B4SH - - 480 530 785 885 1210 1345 2035 2300

All weights are indicated for units without oil filling and without add­on parts. For theexact weights, refer to the drawings in the gear­unit documentation.

7 / 42BA 5050 EN 12.08

1.2.3 Measuring­surface sound­pressure level

The gear unit has a measuring­surface sound­pressure level at a distance of 1 m, which can be found intable 4 and 5.

The measurement is carried out to DIN EN ISO 9614 Part 2, using the sound­intensity method.

The workplace of the operating personnel is defined as the area on the measuring­surface at a distanceof 1 metre in the vicinity of which persons may be present.

The sound­pressure level applies to the warmed up gear unit and with performance data stated on therating plate. If several figures are given, the highest speed and power values apply.

The measuring­surface sound­pressure level does not include add­on lubricating units.

If repeat measurements on site do not produce conclusive results with regard to measuring technology,the measurement obtained on the FLENDER test bench will apply.

The sound­pressure levels stated in the table were obtained by statistical calculation by our Quality ControlDept. The gear unit can be statistically expected to comply with these sound­pressure levels.

1.2.3.1 Measuring­surface sound­pressure level for helical­gear units

Table 4: Measuring­surface sound­pressure level for helical­gear units

Measuring-surface sound-pressure level LpA in dB(A) for helical-gear units

Type iNn1

1/min

Gear-unit size

3 4 5 6 7 8 9 10 11 12 13 14

H2SH

6.3 1500 68 71 74 75 76 77 79 79 80 81 81 82

. 1000 63 66 69 70 71 72 74 74 75 76 76 77

10 750 60 63 66 67 67 69 70 71 72 73 73 74

11.2 1500 66 69 72 73 74 75 77 77 78 79 79 80

. 1000 61 64 67 68 69 70 72 72 73 74 74 75

16 750 58 61 64 65 66 67 69 69 70 71 71 72

18 1500 64 66 69 70 71 72 74 74 75 76 77 78

. 1000 1) 61 64 65 66 68 69 69 70 71 72 73

28 750 1) 1) 61 62 63 64 66 66 67 68 69 70

H3SH

22.4 1500 - - 68 69 73 74 74 75 77 77 78 79

. 1000 - - 63 65 68 69 69 71 72 73 73 74

35.5 750 - - 60 61 65 66 65 67 69 69 70 71

35.5 1500 - - 65 67 70 71 71 73 74 75 76 76

. 1000 - - 1) 62 65 66 66 68 69 70 71 72

63 750 - - 1) 1) 62 63 63 65 66 67 67 68

71 1500 - - 62 64 67 68 68 70 71 72 73 74

. 1000 - - 1) 1) 62 63 63 65 66 67 68 69

112 750 - - 1) 1) 1) 1) 1) 62 63 64 65 66

H4SH

100 1500 - - - - 66 67 68 69 70 71 72 73

. 1000 - - - - 62 63 63 64 65 66 67 68

140 750 - - - - 1) 1) 1) 61 62 63 64 64

160 1500 - - - - 64 65 66 66 68 68 69 70

. 1000 - - - - 1) 60 61 62 63 64 64 65

250 750 - - - - 1) 1) 1) 1) 60 61 61 62

280 1500 - - - - 61 62 63 64 65 66 67 67

. 1000 - - - - 1) 1) 1) 1) 60 61 62 63

450 750 - - - - 1) 1) 1) 1) 1) 1) 1) 1)

1) LpA < 60 dB(A)

8 / 42BA 5050 EN 12.08

1.2.3.2 Measuring­surface sound­pressure level for bevel­helical gear units

Table 5: Measuring­surface sound­pressure level for bevel­helical gear units

Measuring-surface sound-pressure level LpA in dB(A) for bevel-helical gear units

Type iNn1

1/min

Gear-unit size

4 5 6 7 8 9 10 11 12 13 14

B2SH

5 1500 75 78 80 82 83 84 86 87 88 89 90

. 1000 70 72 73 76 77 78 79 81 82 83 84

8 750 63 65 66 69 71 72 73 74 75 77 78

9 1500 71 74 75 77 79 80 81 83 84 85 86

. 1000 65 67 69 72 73 74 76 77 78 80 81

14 750 1) 60 63 65 66 67 69 71 72 73 74

16 1500 66 69 71 72 74 75 77 78 80 81 82

. 1000 61 63 65 67 68 69 71 72 74 75 77

22.4 750 1) 1) 1) 60 62 63 64 66 67 68 70

B3SH

12.5 1500 68 71 74 75 76 77 79 81 83 84 85

. 1000 63 66 68 69 70 72 73 75 77 78 80

31.5 750 1) 1) 61 62 64 65 66 68 71 71 73

35.5 1500 65 67 70 71 71 72 74 77 79 80 81

. 1000 1) 62 65 65 66 66 69 71 73 75 76

56 750 1) 1) 1) 1) 1) 1) 62 65 67 68 69

63 1500 61 64 70 67 68 68 70 73 75 76 78

. 1000 1) 1) 63 62 62 62 65 68 70 71 72

90 750 1) 1) 1) 1) 1) 1) 1) 61 63 64 65

B4SH

80 1500 - 64 65 67 68 70 72 75 76 77 79

. 1000 - 1) 1) 61 63 64 67 69 70 72 73

125 750 - 1) 1) 1) 1) 1) 1) 62 64 65 66

140 1500 - 60 61 63 65 66 68 71 72 73 75

. 1000 - 1) 1) 1) 1) 61 63 65 67 68 69

224 750 - 1) 1) 1) 1) 1) 1) 1) 1) 61 62

250 1500 - 1) 1) 1) 62 63 65 67 69 70 71

. 1000 - 1) 1) 1) 1) 1) 1) 62 63 64 66

400 750 - 1) 1) 1) 1) 1) 1) 1) 1) 1) 1)

1) LpA < 60 dB(A)

9 / 42BA 5050 EN 12.08

2. General notes

2.1 Introduction

These instructions are an integral part of the gear unit supplied and must be kept in its vicinity for referenceat all times.

All persons carrying out work on the gear unit must have read and understoodthese instructions and must adhere to them. FLENDER accepts noresponsibility for damage or disruption caused by disregard of theseinstructions.

The "FLENDER gear unit with integrated freewheel (overrunning) clutch on the low speed shaft(d2)" described in these Instructions (BA) has been developed for stationary use in general engineeringapplications and complies with the requirements in Directive 94/9/EC. The gear unit is used as an auxiliaryor maintenance drive.

The gear unit is designed only for the application specified in section 1, "Technical data". Other operatingconditions must be contractually agreed.

The gear unit described in these operating instructions reflects the state of technical development at thetime these instructions went to print.

In the interest of technical progress we reserve the right to make changes to the individual assemblies andaccessories which we regard as necessary to preserve their essential characteristics and improve theirefficiency and safety.

2.2 Copyright

The copyright to these instructions is held by FLENDER AG.

These instructions must not be wholly or partly reproduced for competitive purposes, used in anyunauthorised way or made available to third parties without our agreement.

Technical enquiries should be addressed to the following works or to one of our customer services.

A. FRIEDR. FLENDER AGGeschäftsbereich Heavy DutyAm Industriepark 2D‐46562 Voerde / Friedrichsfeld

Tel.: +49 (0)2871/92‐0Fax: +49 (0)2871/92‐1544E‐mail: heavy.duty.aud@siemens.com

Internet: www.flender.com

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10 / 42BA 5050 EN 12.08

3. Safety instructions

3.1 Proper use

• The gear unit has been manufactured in accordance with the state of the art and is delivered ina condition for safe and reliable use. It complies with Directive 94/9/EC.

• The gear unit must be used and operated strictly in accordance with the conditions laid down in thecontract governing performance and supply agreed by FLENDER and the customer.

Any changes on the part of the user are not permitted. This applies equally tosafety features designed to prevent accidental contact.

3.2 Obligations of the user

• The operator must ensure that everyone carrying out work on the gear unit has read and understoodthese instructions and is adhering to them in every point:

─ avoid injury or damage,

─ ensure the safety and reliability of the unit,

─ avoid disruptions and environmental damage through incorrect use.

• During transport, assembly, installation, dismantling, operation and maintenance of the unit, the relevantsafety and environmental regulations must be complied with at all times.

• The gear unit must be operated, maintained and/or repaired only by authorised, duly trained andqualified personnel.

• The gear unit must not be cleaned using high­pressure cleaning equipment.

• All work must be carried out with great care and with due regard to safety.

All work on the gear unit must be carried out only when it is not in operation.The drive unit must be secured against being switched on accidentally (e.g. bylocking the key switch or removing the fuses from the power supply). A noticeshould be attached to the start switch stating clearly that work is in progress.

• No welding work must be done on the gear unit.The gear unit must not be used as an earthing point for welding operations. Toothed parts and bearingsmay be irreparably damaged by welding.

If any changes are noticed during operation (e.g. overheating or unusualnoises), the drive assembly must be switched off immediately.

Rotating drive components such as couplings and belt drives must be protectedagainst accidental contact.

Only belts with adequate leakage resistance (< 109 Ω) must be used. Beforefitting a protective cover a risk analysis must be carried out to ensure that itcannot represent a fire or explosion hazard. The risk analysis must be carriedout by the manufacturer of the protective cover.

On belt pulleys the correct belt tension must be adhered to (see order­specificdimensioned drawing).

All add­on parts must satisfy the requirements in Directive 94/9/EC.Monitoring equipment that does not satisfy Directive 94/9/EC must be operatedwith an isolation amplifier.

If the gear unit is intended for installation in plant or machinery, themanufacturer of such plant or machinery must ensure that the contents of theseinstructions are incorporated in his own instructions.

11 / 42BA 5050 EN 12.08

The coating must not carry an impermissibly high electrostatic charge!The operator must ensure that highly effective mechanisms which can set up acharge in the coating are safely avoided.

• When removing the safety equipment the fixation means should be stored for later use. Removed safetyequipment must be re­installed prior to starting up.

• Notices attached to the gear unit, e.g. rating plate, direction arrows etc. must always be observed. Theymust be kept free from dirt and paint at all times. Missing plates must be replaced.

• Screws which have been damaged during assembly or disassembly work must be replaced with newones of the same strength class and type.

• Spare parts should always be obtained from FLENDER (see also section 2).

3.3 Environmental protection

• Dispose of any packaging material in accordance with regulations or separate it for recycling.

• When changing oil, the used oil must be collected in suitable containers. Any pools of oil which may havecollected should be removed at once with an oil binding agent.

• Preservative agent should be stored separately from used oil.

• Used oil, preservative agent, oil­binding agents and oil­soaked cloths must be disposed of inaccordance with environmental legislation.

• Disposal of the gear unit after its useful life:

─ Drain all the operating oil, preservative agent and/or cooling agent from the gear unit and dispose inaccordance with regulations.

─ Depending on national regulations, gear­unit components and/or add­on parts may have to bedisposed of in different manners or be separated for recycling.

3.4 Special dangers and personal protective equipment

The gear unit complies with the requirements in Directive 94/9/EC.

When carrying out assembly and disassembly work, ensure that no explosivegas mixtures and dust concentrations are present.

• Depending on operating conditions, the surface of the gear unit may heat up or cool down to extremevalues.

In the case of hot surfaces (> 55 °C) there is risk of burns!

In the case of cold surfaces (< 0 °C) there is risk of frost injury (pain, numbness,frostbite)!

During oil changes there is a risk of scalding from escaping oil!

Small foreign matter such as sand, dust, etc. can get into the cover plates of therotating parts and be thrown back by these.Risk of eye injury!

In addition to any generally prescribed personal safety equipment (such as safetyshoes, safety clothing, helmet) handling the gear unit requires wearing suitable safetygloves and suitable safety glasses!

12 / 42BA 5050 EN 12.08

4. Handling and storage

Observe the instructions in section 3, "Safety instructions"!

4.1 Scope of supply

The products supplied are listed in the despatch papers. Check immediately on receipt to ensure that allthe products listed have actually been delivered. Parts damaged or missing parts must be reported toFLENDER in writing immediately.

If there is any visible damage, the gear unit must not be put into operation.

4.2 Handling

When handling FLENDER products, use only lifting and handling equipment ofsufficient load­bearing capacity!Observe the notes regarding load distribution on the packaging.

The gear unit is delivered in the fully assembled condition. Additional items are delivered separatelypackaged, of applicable.

Different forms of packaging may be used, depending on the size of the unit and method of transport.Unless otherwise agreed, the packaging complies with the HPE Packaging Guidelines.

The symbols marked on the packaging must be observed at all times. These have the following meanings:

Top Fragile Keep Keep Centre of Use no Attachdry cool gravity hand hook here

Fig. 3: Transport symbols

Transport of the gear unit must be carried out so as to avoid personal damageand damage to the gear unit.If, for example, the free shaft ends are knocked, this may damage the gear unit.

The gear units must be transported with suitable equipment only.During transport the gear unit should be left without oil filling and on the transportpackaging.

Use only the eyes provided to attach lifting equipment to the unit.Handling of the gear unit by attaching it to the piping is not permitted.The pipework must not be damaged.Do not use the front threads at the shaft ends to attach slinging equipment forthe transport.Slinging equipment must be adequate for the weight of the gear unit.

STOP

13 / 42BA 5050 EN 12.08

Fig. 4: Attachment points

For drive units where add­on parts such as motor, add­on coupling etc. are mounted on the gear unit anadditional attachment point may be required because of the shift in the centre of gravity.

Units which are slung by eyebolts must not be tilted.

Fig. 5: Attachment points H.SH gear unit with motor

Fig. 6: Attachment points B.SH gear unit with motor

Fig. 7: Attachment points B.SH gear unit with gear­unit swing base

A detailed view of the gear unit can be obtained from the drawings in the gear­unit documentation.

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14 / 42BA 5050 EN 12.08

4.3 Storing the gear unit

The gear unit must be stored in the position of use in a sheltered place; it must be placed on a vibration­free,dry wooden base and covered over.

When temporarily storing the gear unit and any single components supplied with it, the preservative agentshould be left on them. It must not be damaged, otherwise there is a risk of corrosion.

Do not stack gear units on top of one another.

If the gear unit is being stored out of doors, it must be particularly carefullycovered, and care must be taken that neither moisture nor foreign material cancollect on the unit. Waterlogging should be avoided.

Unless otherwise agreed by contract, the gear units must not be exposed to harmfulenvironmental factors such as chemically aggressive products.

Provision for special environmental conditions during transport (e.g. transport by ship)and storage (climate, termites, etc.) must be contractually agreed.

4.4 Standard coating and corrosion protection

The gear unit is provided with an interior preservative agent; the free shaft ends are painted for protection.

The characteristics of the external coat depend on the ambient conditions stipulated in the order relatingto method of transport and area of application.

The gear unit is normally delivered completely ready, with a priming and finish coat.

The gear unit is normally delivered completely ready, with a priming and finishcoat.

The coating complies with the requirements for the conductivity of the coatingand the limitation of the layer thickness of the applied coating defined DIN EN13 463­1. The permissible maximum coating thickness depends on theindicated explosion group (IIA or IIB or IIC) defined DIN EN 50014. Wherelacquer coatings have a thickness less than 200 μm, no electrostatic charge isto be expected.

Where gear units are delivered with a priming coat only it is necessary to applya finish coat in accordance with directive applying to the specific case ofapplication.The priming coat is not suitable to provide a sufficient long­term corrosionprotection.

The coating must not carry an impermissibly high electrostatic charge!The operator must ensure that highly effective mechanisms which can set up acharge in the coating are safely avoided.

Examples of highly effective mechanisms are:­ the rapid passage of heavily dust­laden air near by­ the sudden escape of particle­laden compressed gases­ other heavy friction action (not manual cleaning/rubbing with cleaning cloths)

Ensure that the coat is not damaged!

Any damage may cause failure of the external protective coating and corrosion.

Unless otherwise contractually agreed, the interior preservation is guaranteed for24 months, and the exterior preservation for 36 months, provided that storage is in dry,frostfree sheds.

The guarantee period starts on the date of delivery.

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15 / 42BA 5050 EN 12.08

For longer periods of storage (> 24 months) we advise regular checking and, if necessary, renewal of theinterior and exterior preservation (see items 7.3.1 and 7.3.2).

The output shaft must be rotated at least one turn to change the position of the rolling element in thebearings. The input shaft must not come to a standstill in the same position as before rotation.

This procedure must be repeated and documented every 24 months until start­up.

The preservation of the free shaft ends must be inspected every 3 years and, if necessary, renewed(see item 7.3.2).

5. Technical description

Observe the instructions in section 3, "Safety instructions"!

5.1 General description

The "FLENDER gear unit with integrated freewheel (overrunning) clutch on the low­speedshaft (d2)" described in these instructions has been developed for use in general engineeringapplications.

The unit is supplied as a two­, three­ or four­stage gear unit. It is designed for installation in the horizontalposition.

The gear unit has been engineered as a drive on the high­speed shaft and transmits the torque only in theprovided direction of rotation. In the case of the low­speed shaft the direction of transmission is inversed.

The gear units are characterised by a low noise level, which is achieved by helical gears with a high contactratio and a special sound­damping housing.

The good temperature characteristics of the gear unit are achieved by its high degree of efficiency, largehousing surface and performance­related cooling system.

5.2 Housing

The housings are of cast iron. If required, they may also be of steel.

Housings up to size 12 are made in one section, larger sizes are in two sections. It is of torsionally rigiddesign and its shape imparts very favourable noise and temperature characterics.

The gear­unit housing comes with the following equipment:

• Lifting eyes (adequately dimensioned for transport)

• Inspection and/or assembly cover (for oil filling and/or inspection)

• Oil dipstick or oil sight glass (to check the oil level)

• Oil drain plug (to change the oil)

• Air filter (for venting)

5.3 Toothed components

The toothed components of the gear unit are case­hardened. The helical gear teeth are ground; dependingon their size and transmission ratio, bevel­helical gear teeth are lapped, ground or HPG­gear­cut. The highquality of the teeth leads to a significant noise reduction and ensures safe and reliable running.

The gear wheels are joined to the shafts by interference fits and parallel keys.

5.4 Lubrication

The teeth, bearings and freewheel (overrunning) clutch are adequately lubricated by splash lubrication.This means that the gear units require very little maintenance.

16 / 42BA 5050 EN 12.08

5.5 Shaft bearings

All shafts are mounted in rolling bearings.

5.6 Shaft seals

Radial shaft seals or Taconite seals at the shaft outlets prevent oil from escaping from, or dirt from enteringinto the gear unit.

5.6.1 Radial shaft­sealing rings

Radial shaft­sealing rings are preferably fitted with an additional dust lip to protect the actual sealing lipfrom external contamination.

For special mounting positions the radial shaft‐sealing ring is used witha grease filling in combination with a ring.Where large quantities of dust occur in accordance with the conditionspermitted under Directive 94/9/EC, use is possible only in combination with theTaconite seal (see item 5.6.2).

Fig. 8: Radial shaft­sealing ring

5.6.2 Taconite seals

In the case of gear units with integrated freewheel (overrunning) clutch on the low speed shaft (d2) Taconiteseals are used as standard seals.

Taconite seals were specially developed for use in a dusty environment. Thepenetration of dust is prevented by a combination of seal elements (radialshaft­sealing ring, lamellar seal and grease­charged labyrinth seal).

Taconite seals are divided into the following types:

1

2

3

4

Taconite "E" Taconite "F"

Fig. 9: Taconite seals

1 Radial shaft­sealing ring 3 Grease­charged labyrinth seal (re­chargeable)2 Lamellar seal 4 Flat grease nipple AM10x1 to DIN 3404

For re­charging the labyrinth seals with grease, the specified frequency must beobserved (see Table 16 in item 10.1)

17 / 42BA 5050 EN 12.08

5.7 Freewheel (overrunning) clutch

The gear unit is used as an auxiliary. Coupling to the main gear unit is realised by way of an integratedfreewheel (overrunning) clutch on the shaft d2. This allows, when driving by the auxiliary drive, a torquetransmission in one direction of rotation, while there is "free­wheeling operation" when driven by themain drive .

The output shaft of the gear unit will rotate in the same direction of rotation, both if the drive is effected viathe main motor and via the auxiliary drive.

The freewheel (overrunning) clutch is integrated in the gear unit and in the oil circuit of the gear unit.Maintenance and oil change take place simultaneously with maintenance and oil change of the drive.

The freewheel (overrunning) clutch is provided with centrifugally operated grippers. If the (d2) low­speedshaft is rotating in the specified direction of rotation in the main gear unit, the inner ring will rotate togetherwith the grippers, while the outer ring remains stationary. From a certain speed of rotation (see alsotable 6), the grippers will lift off and the freewheel (overrunning) clutch will operate without wear. If the driveis effected by the motor of the auxiliary drive via the outer ring, the freewheel (overrunning) clutch will bein "carrier operation", i.e. the main gear unit is turned over slowly in the chosen direction of rotation. Atthe same time, the drive shaft of the main gear unit and, if a flexible coupling is used between main motorand main gear unit, possibly the main motor will rotate slowly along with it.

When driving via the auxiliary drive, the drive shaft of the main gear unit will rotate alongsimultaneously. This rotary motion must not be impeded. A brake arranged on the driveside in the main drive must be released if the drive is effected via the auxiliary drive.

When filling the Variant 2 gear unit with oil, start by supplying the lubricatingpoint 1 at the intermediate flange with the oil type specified on the rating plate.For the oil quantity, refer to table 11 (see item 7.1.2.1).

Variant 1 Variant 2

7

2

6

8

5

4

3

61

7 2

8

4

3

5

Fig. 10: Freewheel (overrunning) clutch

1 Oil filler plug 5 Cage with sprags2 Relubrication nipple 6 Outer ring of the freewheel (overrunning) clutch3 Inner ring of the freewheel 7 Residual­oil drain overrunning clutch

(overrunning) clutch 8 Fan for freewheel (overrunning) clutch4 d2 shaft (low speed)

The transmission direction of the freewheel (overrunning) clutch can be changed byturning the cage around. If a change in transmission direction is required, FLENDERmust always be consulted beforehand.

18 / 42BA 5050 EN 12.08

The minimum lift­off speeds must not be fallen below during operation of themain motor.

Table 5: Lift­off speeds

VariantLift-off speed in 1/min

3 4 5 6 7 8 9 10 11 12 13 14

1 - 320 240 240 220 220 200 200 180 180on request

2 310 310 240 240 220 220 200 200 180 180

Before connecting the motor, determine the direction of rotation of the three­phase current supply usinga phase­sequence indicator, and connect the motor in accordance with the pre­determined direction ofrotation.

To avoid overspeeds in case of malfunctions of the freewheel (overrunning) clutch and for safety reasons,the drive combination is equipped with a speed monitoring device. The speed monitoring device(EOC system) consists of a pulse generator mounted in the intermediate flange, and of an evaluatinginstrument.

The speed at the monitoring point must not exceed that indicated on thedimensioned drawing (normally: operating speed with auxiliary motor + 20 %).Otherwise all motors must be shut down and the holding brake applied. Thecause of the excessive speed must then be found and removed. Only then maythe drive be put back into operation.

This speed monitoring device is an absolute must for safety reasons sinceotherwise in case of a defect in the overrunning system the auxiliary drive canbe destroyed with explosive effect.

5.8 Cooling

The heat released is dissipated over the surface of the gear unit and by the fanof the overrunning clutch (on the shaft d2).

5.9 Oil­temperature measurement

The gear unit is fitted with a Pt 100 resistance thermometer for measuring theoil temperature in the oil sump. In order to measure the temperatures and/ortemperature differences, the Pt 100 resistance thermometer, which shouldcomply with the requirements of Directive 94/9/EC, must be connected to asuitable evaluating instrument provided by the customer. The thermometer hasa connection head (protection type IP54) for the wiring.

1 1 1 1

Fig. 11: Resistance thermometer

1 Resistance thermometer Pt 100

For a detailed illustration of the gear unit and the position of the add­on parts, please refer to the drawingsof the gear­unit documentation.

For operation and maintenance, always observe the operating instructionsindicated in the order­specific appendix.For technical data, refer to the order­specific list of equipment.

19 / 42BA 5050 EN 12.08

5.10 Oil­level monitoring system

Depending on the order specification, the gear unit can be fitted with an oil­levelmonitor in the form of a level limit switch. This monitoring is designed as astandstill monitoring (gear unit stop) and checks the level of the oil before theunit is started up. When the signal "oil level too low" is given, it should be wiredin such a way that the drive motor cannot start and an alarm is given. Duringoperation, any signal should be bridged.

Fig. 12: Oil­level monitoring system

For a detailed illustration of the gear unit and the position of the add­on parts, please refer to the drawingsof the gear­unit documentation.

For operation and maintenance, always observe the operating instructionsindicated in the order­specific appendix.For technical data, refer to the order­specific list of equipment.

If an the oil­level monitoring device is in use, it is very important that gear unit is in a horizontal position.

20 / 42BA 5050 EN 12.08

6. Fitting

Observe the instructions in section 3, "Safety instructions"!

The gear unit must not be installed whilst the environment is explosive.

6.1 General information on fitting

When transporting the gear unit observe the notes in section 4.

Fitting work must be done with great care by trained and qualified personnel. The manufacturer cannot beheld liable for damage caused by incorrect assembly and installation.

During the planning phase sufficient space must be allowed around the gear unit for later care andmaintenance work.

Adequate lifting equipment must be available before beginning the fitting work.

When installing outdoors, direct sunlight is prohibited.Safety equipment such as covers, roofing, etc. must be provided as required!Do avoid a heat concentration.The operator should ensure that no foreign bodies affect the proper function ofthe gear unit (e.g. falling objects or heaping over).

No welding work must be done at all on the drive.The drives must not be used as an earthing point for welding operations.Toothed parts and bearings may be irreparably damaged by welding.

All the fastening points provided by the design of the unit must be used.A means of potential equalisation must be ensured. Points are provided on thegear unit for attaching a suitable connecting cable.Screws which have been damaged during assembly or disassembly work mustbe replaced with new ones of the same strength class and type.

To ensure proper lubrication, the installation position specified in the order and agreed by contract mustalways be observed.

STOP

21 / 42BA 5050 EN 12.08

6.2 Fitting the gear unit on the installation

6.2.1 Foundation

The foundation must be horizontal and level; the gear unit must not beexcessively stressed when tightening the fastening screws.

It must be designed in such a way that no resonance vibrations are set up and that no vibrations aretransmitted from adjacent foundations. Steel structures on which the unit is to be mounted must be rigid.It must be designed according to the mass and torque, taking into account the forces acting on the gearunit.

When fastening the gear unit to concrete foundations by means of stone bolts und/or foundation blocks,suitable recesses should be made in the foundation.

Slide rails should be correctly aligned and embedded in the concrete foundation.

Careful alignment with the machine on the in­ and output side must be ensured. Any elastic deformationthrough operating forces must be taken into consideration.

Fastening bolts or nuts must be tightened to the prescribed torque. For thecorrect torque, refer to item 6.8. Bolts of the minimum strength class 8.8 mustbe used.

If external forces are acting upon the gear unit, it is advisable to prevent the unit from displacement bymeans of lateral stops.

Dimensions and space requirement should be taken from the drawings in the gear unitdocumentation.

6.2.2 Description of installation work

The gear unit must not be cleaned in an explosive environment.

• Remove any corrosion­preventive agent from the shafts using a suitable cleaning agent such asbenzine.

Do not allow the cleaning agent (e.g. benzine) to contact the shaft­sealing rings.

Ensure adequate ventilation. Do not smoke!Danger of explosion!

• If applicable mount input and output drive elements (e.g. coupling components) on the shafts, andsecure them. If these are to be heated before mounting, refer to the dimensioned drawings in thecoupling documentation for the correct joining temperatures.

Unless otherwise specified, the components may be heated inductively, with a burner or in a furnace.

Take precautions to avoid burns from hot components!

Protect shaft­sealing rings from damage and heating to over + 100 °C (useheat­protective screens to protect against radiant heat.)

The elements must be pulled smartly onto the shaft as far as stated in the dimensioned drawing preparedin accordance with the order.

Fit the coupling with the aid of suitable fitting equipment. The parts must not bedriven on by abrupt force, as this may damage the gear unit.The shaft­sealing rings and running surfaces of the shaft must not be damagedwhen pulling in the coupling parts.

STOP

STOP

STOP

22 / 42BA 5050 EN 12.08

When installing the drives, make absolutely certain that the individualcomponents are accurately aligned in relation to each other. Inadmissibly largeerrors in the alignment of the shaft ends to be connected due to angular andaxial misalignments result in premature wear and/or material damage. Ifpossible, the deviation should be zero (exception: ZAPEX couplings). Foramongst others the special requirements for the couplings, refer to the specificoperating instructions. Insufficiently rigid base frames or sub­structures canalso during operation cause a radial or axial misalignment, which cannnot bemeasured when the unit is at a standstill.

Gear units whose weight requires the use of lifting gear must be attached at the pointsshown in section 4, "Handling and storage". If the gear unit is to be transported withadd­on parts, additional attachment points may be required. The position of theseattachment points is shown in the order related dimensioned drawing.

Non­observance can cause shaft rupture, resulting in serious injury or dangerof life.

6.2.2.1 Alignment surfaces, alignment thread

Preliminary alignment of the gear units (sizes 4 to 12) in a horizontal direction is done by the surfaces ofthe inspection and/or assembly cover.

11

Fig. 13: Preliminary alignment up to size 12

Gear units of sizes > 12 have additional alignment surfaces on the top of the housing for preliminaryalignment of the gear units. To facilitate alignment of gear units of these sizes, alignment threads areprovided on the housing base.

1 1

2

1

2

Fig. 14: Preliminary alignment from size 12 upward

1 Alignment surfaces 2 Alignment thread

23 / 42BA 5050 EN 12.08

6.2.2.2 Mounting on a foundation frame

• Clean the undersurface of the gear­unit base.

• Using suitable lifting gear, place the gear unit on the foundation frame.

• Tighten the foundation bolts to the specified torque (see item 6.8). If necessary, use stops to prevent theunit from displacement.

The gear unit must not be excessively stressed when tensioning the fasteningbolts.

The final fine alignment with the assemblies on the in­ and output side must be carried out accurately bythe shaft axes, using:

• Rulers, spirit level, dial gauge, feeler gauge, etc.

Only then should the gear unit be fastened and the alignment checked once again.

6.2.2.3 Mounting on a concrete foundation by means of stone bolts or foundation blocks

• Clean the undersurface of the gear­unit base.

─ Placing stone bolts:

─ Hook stone bolts with washers and hexagon nuts into the foundation fastening points on the gear­unithousing (see fig. 15).

The hexagon nuts must only be tightened when the concrete has set.

4

5

3

2

1

1 Hexagon nut2 Washer3 Gear-unit base4 Stone bolt5 Foundation

Fig. 15: Stone bolt

─ Placing the foundation blocks:

─ Hook the foundation blocks with washers and fastening bolts into the foundation fastening points onthe gear­unit housing (see fig. 16).

The fastening bolts must only be tightened when the concrete has set.

4

5

9

6

321

7

8

1 Fastening bolt2 Washer3 Gear-unit base4 Threaded stud5 Flat steel plate6 Foundation7 Final foundation height8 Prepared foundation height9 Foundation block

Fig. 16: Foundation block

STOP

STOP

STOP

24 / 42BA 5050 EN 12.08

• Using suitable lifting gear, place the gear unit on the concrete foundation.

• Align gear unit horizontally by in­ and output shafts:

─ if using stone bolts, with shims.

─ if using foundation blocks, with the aid of the set screws (if available).

• If considerable forces may apply, use stops to prevent the unit from displacement.

Before pouring the concrete foundation, fill up the openings in the foundation blocks withadequate material such as polystyrene.

• Pour concrete into the recesses of the stone bolts or foundation blocks.

When the concrete has set, tighten the hexagon nuts of the stone bolts orfastening bolts to the specified torque (see item 6.8).

The gear unit must not be excessively stressed when tensioning the hexagonnuts or fastening bolts.

6.2.2.4 Mounting on a concrete foundation by means of anchor bolts

• Clean the undersurface of the gear­unit base.

• Place support on the base plate in the fine grout.

• Insert anchor bolts.

• Place pressure plates in position and screw nuts on.

• Pack the anchor bolts with wood so that they are about 10 mm from the upper edge of the support(see fig. 17).

1 Anchor bolt2 Support3 Base plate4 Pressure plate5 Hexagon nut6 Wood7 Fine-grout concrete8 Raw foundation

4

6

5

2

3

1

7

8

Fig. 17: Anchor bolt

• Place gear unit on foundation.

25 / 42BA 5050 EN 12.08

Use only the eyes provided to attach lifting equipment to the unit.Do not use the front threads at the shaft ends to attach slinging equipment forthe transport.

• Pull anchor bolts up (for this a bolt or threaded rod can be screwed into the thread on the front face).

• Fit washer.

• Unscrew hexagon nut a few turns by hand.

• Align gear unit with supports (see fig. 18).

─ The values punched into the screeds must always be observed.

─ Alignment tolerances in relation to the units on the input and output sides are to be in accordance withthe permissible angular and axial displacements of the couplings (see coupling drawings).

─ The alignment values must be recorded.

4

5

2

3

1

7

8

6 1 Anchor bolt2 Support3 Base plate4 Washer5 Hexagon nut6 Housing base7 Fine-grout concrete8 Raw foundation

Fig. 18: Anchor bolt

Prior to tensioning the anchor bolts, the fine­grout concrete must have set forat least 28 days.

• Keep anchor bolts in their position by tightening the nut with your fingers.

• Place the protective sleeve.

• Place hydraulic tensioning device in position.

• Initially tension the bolts alternately (for initial tensioning forces, see item 6.8).

• Using a suitable tool, screw hexagon nuts on as far as the stop.

To ensure correct handling and adjustment of the pretensioning tool, the manufacturer’soperating instructions must be adhered to.

The tensioning pressures and/or the initial tensioning forces should be recorded (see also item 7.2.3).

The final fine alignment with the assemblies on the in­ and output side must be carried out accurately bythe shaft axes, using:

• rulers

• spirit level

• dial gauge

• feeler gauge, etc.

Only then should the gear unit be fastened and the alignment checked once again.

STOP

26 / 42BA 5050 EN 12.08

6.3 Couplings, clutches

As a rule, flexible couplings or safety slip clutches are provided for the drive of the gear unit.

If rigid couplings or other in‐ and/or output elements, which create additional radial and/or axial forces,(e.g. gear wheels, belt pulleys, disk flywheels, hydraulic couplings) are used, these must be agreed bycontract.

Couplings with peripheral velocities on the outer diameter of up to 30 m/s mustbe statically balanced. Couplings with peripheral velocities over 30 m/s must bedynamically balanced.

For maintenance and operation of the couplings, refer to the specific operatinginstructions for the couplings.

When installing the drives, make absolutely certain that the individualcomponents are accurately aligned in relation to each other. Inadmissibly largeerrors in the alignment of the shaft ends to be connected due to angular andaxial misalignments result in premature wear and/or material damage.Insufficiently rigid base frames or sub­structures can also during operationcause a radial or axial misalignment, which cannnot be measured when the unitis at a standstill.

For permissible alignment errors in the case of couplings supplied by FLENDER, pleaserefer to the operating manuals for the couplings.If you use couplings manufactured by other manufacturers, ask these manufacturerswhich alignment errors are permissible, stating the radial loads occurring.

Increased system service life and reliability and reduced running noise can be achievedthrough the least possible radial and angular misalignment.

The coupling parts may get out of alignment

• by imprecise alignment during assembly or installation.

• during operation of the system by:

─ heat expansion, shaft flexure, too weak machine frames, etc.

Kw

Kr

ΔKa

�

�

Axial misalignment�ΔKa)

Angular misalignment�ΔKw)

Radial misalignment�ΔKr)

Fig. 19: Possible misalignments

Alignment has to be done in two axial planes arranged perpendicularly to each other. This can be done bymeans of a ruler (radial misalignment) and feeler gauge (angular misalignment), as shown in theillustration. The aligning accuracy can be increased by using a dial gauge or a laser alignment system.

27 / 42BA 5050 EN 12.08

3

3

3

31

2

Fig. 20: Example of alignment on a flexible coupling

1 Ruler 2 Feeler gauge 3 Measuring points

The maximum permissible misalignment values are specified in the operatinginstructions for the coupling; they must under no circumstances be exceededduring operation.Angular and radial misalignments may occur at the same time. The sum of bothmisalignments must not exceed the maximum permissible value of the angularor radial misalignment.If you use couplings manufactured by other manufacturers, ask thesemanufacturers which alignment errors are permissible, stating the radial loadsoccurring.

6.4 Gear unit with add­on components

• For technical data to the add­on parts, see the list of equipment for the specific order.

The electrical equipment for regulation and control must be wired in accordancewith the equipment suppliers’ instructions and Directive 94/9/EC.

For operation and maintenance the operating instructions provided specificallyfor the order as well as the descriptions must be observed.

6.5 Oil­temperature measurement

Connect resistance thermometer with evaluating instrument (to be provided bycustomer) electrically.

6.6 Oil­level monitoring system

Connect oil­level monitor electrically.

STOP

28 / 42BA 5050 EN 12.08

6.7 Final work

After installation of the gear unit check all screw connections for tight fit.

Check the alignment after tightening the fastening elements (the alignmentmust not be changed).

Check by means of the order­specific list of equipment as well as the associateddrawings whether all units which may have been removed for transport havebeen refitted.

Oil drain cocks, if any, must be secured against accidental opening.

If an oil sight glass is used for monitoring the oil level, it must be protectedagainst damage.

The gear unit must be protected against falling objects.

Protective devices for rotating parts must be checked for correct seating.Contact with rotating parts is not permitted.

6.8 Screw­connection classes, tightening torques and initial tensioning forces

6.8.1 Screw­connection classes

The specified screw connections are to be fastened applying the tightening torques specified in the tablebelow:

Table 7: Screw­connection classes

Screw-connectionclass

Distributionof emitted torque

on the tool

Tightening procedure(Usually the tightening processes

lie within the stated tool distribution)

C ± 5 % up to ± 10 %

‐ hydraulic tightening with mechanical screwdriver‐ torque-controlled tightening with torque wrench,

signal-emitting torque wrenchup to‐ tightening with precision mechanical screwdriver

with dynamic torque measuring

D ± 10 % up to ± 20 % ‐ torque-controlled tightening with mechanical screwdriver

E ± 20 % up to ± 50 %

‐ tightening with pulse screwdriver or impact wrenchwithout adjustment checking device

‐ tightening by hand, using a spannerwithout torque measuring device

Foundation bolts, hub bolts and bearing cover bolts must always be tightenedin accordance with screw­connection class ”C”!

STOP

29 / 42BA 5050 EN 12.08

6.8.2 Tightening torques and initial tensioning forces

The tightening torques apply to friction coefficients of μtotal = 0.14. The frictioncoefficient μtotal = 0.14 applies here to lightly oiled steel bolts, black­annealed orphospatised and dry, cut mating threads in steel or cast iron. Lubricants which alter thefriction coefficient must not be used and may overload the screw connection.

Table 8: Initial tensioning forces and tightening torques for screw connections of strength classes 8.8;10.9; 12.9 with a common friction coefficient of μtotal = 0.14

Nominalthread

diameter ∅

Strengthclass of the

screw

Initial tensioning force forscrew-connection classes from

table 7

Tightening torque forscrew-connection classes from

table 7

C D E C D E

dmm

FM min.N

MANm

M10

8.8 18000 11500 7200 44.6 38.4 34.3

10.9 26400 16900 10600 65.4 56.4 50.4

12.9 30900 19800 12400 76.5 66.0 58.9

M12

8.8 26300 16800 10500 76.7 66.1 59.0

10.9 38600 24700 15400 113 97.1 86.6

12.9 45100 28900 18100 132 114 101

M16

8.8 49300 31600 19800 186 160 143

10.9 72500 46400 29000 273 235 210

12.9 85000 54400 34000 320 276 246

M20

8.8 77000 49200 30800 364 313 280

10.9 110000 70400 44000 520 450 400

12.9 129000 82400 51500 609 525 468

M24

8.8 109000 69600 43500 614 530 470

10.9 155000 99200 62000 875 755 675

12.9 181000 116000 72500 1020 880 790

M30

8.8 170000 109000 68000 1210 1040 930

10.9 243000 155000 97000 1720 1480 1330

12.9 284000 182000 114000 2010 1740 1550

M36

8.8 246000 157000 98300 2080 1790 1600

10.9 350000 224000 140000 2960 2550 2280

12.9 409000 262000 164000 3460 2980 2670

M42

8.8 331000 212000 132000 3260 2810 2510

10.9 471000 301000 188000 4640 4000 3750

12.9 551000 352000 220000 5430 4680 4180

M48

8.8 421000 269000 168000 4750 4090 3650

10.9 599000 383000 240000 6760 5820 5200

12.9 700000 448000 280000 7900 6810 6080

M56

8.8 568000 363000 227000 7430 6400 5710

10.9 806000 516000 323000 10500 9090 8120

12.9 944000 604000 378000 12300 10600 9500

M64

8.8 744000 476000 298000 11000 9480 8460

10.9 1060000 676000 423000 15600 13500 12000

12.9 1240000 792000 495000 18300 15800 14100

30 / 42BA 5050 EN 12.08

Nominalthread

diameter ∅

Tightening torque forscrew-connection classes from

table 7

Initial tensioning force forscrew-connection classes from

table 7

Strengthclass of the

screw

EDCEDC

dmm

MANm

FM min.N

M72x6

8.8 944000 604000 378000 15500 13400 11900

10.9 1340000 856000 535000 22000 18900 16900

12.9 1570000 1000000 628000 25800 22200 19800

M80x6

8.8 1190000 760000 475000 21500 18500 16500

10.9 1690000 1100000 675000 30500 26400 23400

12.9 1980000 1360000 790000 35700 31400 27400

M90x6

8.8 1510000 968000 605000 30600 26300 23500

10.9 2150000 1380000 860000 43500 37500 33400

12.9 2520000 1600000 1010000 51000 43800 39200

M100x6

8.8 1880000 1200000 750000 42100 36200 32300

10.9 2670000 1710000 1070000 60000 51600 46100

12.9 3130000 2000000 1250000 70000 60400 53900

Damaged bolts must be replaced with new bolts of the same type and strengthclass.

7. Start­up

Observe the instructions in section 3, "Safety instructions"!

The gear unit must not be started up without the required instructions beingavailable.

7.1 Procedure before start­up

7.1.1 Removal of preservative agent

• Unscrew the oil drain plugs or open the oil drain cock, allow the preservative agent or run­in oil to draininto a suitable container and dispose of it in accordance with regulations. Any residual­oil drain plugs(e.g. on the freewheel (overrunning) clutch) should also be opened. The location of the oil draining pointsis marked by an appropriate symbol in the dimensioned drawing in the gear­unit documentation.

Remove any oil spillage immediately with an oil­binding agent.

• Screw in the oil drain plugs.

A detailed view of the gear unit can be obtained from the drawings in the gear­unit documentation.

Before start­up, replace the yellow plastic plug with a breather screw with cap(see also notice on gear unit).

STOP

STOP

31 / 42BA 5050 EN 12.08

7.1.2 Filling with lubricant

Fill the gear unit with fresh oil of the grade specified on the rating plate, usinga filter (max. mesh 25 μm).

• Release the fastening bolts on the inspection and/or assembly cover and remove the cover (includingseal) from the housing or use the marked oil filler plugs. Do not discard the seal.

• When filling the Variant 2 gear unit with oil, start by supplying the lubricating point 1 at the intermediateflange with the oil type specified on the rating plate. For the oil quantity, refer to table 10. After filling theoil filling screw must be replaced.

Pour oil into the gear unit until it reaches the MAX mark on the oil dipstick or oilsight glass.Remember to fill the oil pockets above the bearings and, with bevel­gear units,also at the input shaft on the inside.

After the initial filling wait a suitable period until the oil level is equal in all innerrooms. Then the oil level should be checked again and oil should be topped upas necessary.

The sealing surfaces must not be contaminated nor damaged.

For the type of oil of the approved brands to be used, refer to the BA 7300 EN operatinginstructions supplied separately.Information on the type, quantity and viscosity of the oil is given on the rating plate on thegear unit.The quantity of oil indicated on the rating plate is an approximation only. The marks onthe dipstick or oil sight glass are decisive for the amount of oil to be filled in.

• Check the oil level in the gear unit housing with the oil dipstick or by means of the oil sight glass.

The oil level must be at the upper mark on the oil dipstick or oil sight glass.

Remove any oil spillage immediately with an oil­binding agent.

• Place the inspection und/or assembly cover (including seal) on the housing and replace and tighten thefastening bolts (see item 6.8).

STOP

STOP

STOP

32 / 42BA 5050 EN 12.08

7.1.2.1 Oil quantities

Table 9: Oil quantity for Variant 1

TypeApproximate total oil quantity in litres Variant 1 for size

4 5 6 7 8 9 10 11 12 13 14

H2SH 14 22 23 41 45 65 68 101 107

on request

H3SH - 23 25 42 46 70 72 115 121

H4SH - - - 38 40 69 71 107 115

B2SH 14 23 27 46 49 72 74 111 129

B3SH 12 22 23 40 44 63 67 99 105

B4SH - 23 25 43 46 69 82 107 118

Table 10: Oil quantity for Variant 2

TypeApproximate total oil quantity in litres Variant 2 for size

3 4 5 6 7 8 9 10 11 12 13 14

H2SH 10.5 14.5 23 24 39 43 61 64 96 102

on request

H3SH - - 24 26 40 44 66 68 110 116

H4SH - - - - 36 38 65 67 102 110

B2SH - 14.5 24 28 44 47 68 70 106 124

B3SH - 12.5 23 24 38 42 59 63 94 100

B4SH - - 24 26 41 44 65 78 102 113

Table 11: Oil quantity for freewheel (overrunning) clutch

VariantApproximate quantity of oil in litres for freewheel (overrunning) clutch

3 4 5 6 7 8 9 10 11 12 13 14

1 - 2 5 5 10 10 16 16 19 19on request

2 2.5 2.5 6 6 8 8 12 12 14 14

7.2 Startup and removal from service

Before re­starting the gear unit, replace the screw plug with the air filter, ifapplicable.

7.2.1 Oil level

The oil level must be monitored by means of the oil level monitoring equipment provided. To do so, the gearunit must be shut down. When the oil is cool, the level should be at the upper mark on the oil dipstick oroil sight glass. When the oil is warm it may slightly exceed this mark.

It must in no case be allowed to fall below the mark. If necessary, top up to thecorrect level.

7.2.2 Temperature measurement

During first start­up and after maintenance work, the oil sump temperature mustbe measured during correct use (maximum machine performance) afterappropriate running in.The difference in temperature from the ambient temperature (max. + 40 °C) mustnot exceed 50 K. If temperatures are higher, the gear unit must be shut downimmediately and FLENDER customer service consulted (see also item 1.2.1).

STOP

33 / 42BA 5050 EN 12.08

7.2.3 Checking procedure

The following visual checks must be conducted and recorded when starting up:

Presence of explosion­protection marking

Oil level

Opening condition of the shut­off valves

Effectiveness of the shaft seals

Freedom of the rotating parts from contact

The tension pressures and/or pretensioning forces specified in item 6.2.2.2to 6.2.2.4 must also be recorded in this document.

The document must be kept with the instructions.

7.3 Removal from service

• To take the gear unit out of service, first switch off the drive unit.

Secure the drive unit to prevent it from being started up unintentionally.Attach a warning notice to the start switch!

7.3.1 Interior preservation during longer disuse after start­up

Depending on the type of lubrication or shaft sealing, the following types of interior preservative agent canbe used.

7.3.1.1 Interior preservation with gear oil

The helical­gear units can be filled with the type of oil already used up to just below the breather screw.

7.3.1.2 Interior preservation with preservative agent

Gear units should be filled with preservative agent and run without load before long­term storage.

Interior preservation procedure:

• Switch the gear unit off and drain the oil as described in section 10, "Maintenance and repair".

• Pour in the preservative agent specified in Table 12 or 13 through the venting hole or the opening in theinspection and/or assembly cover until it reaches the top mark on the oil dipstick or oil sight glass.

• Close the venting hole and/or the opening in the inspection or assembly cover.

• Screw in oil filler plug.

• Start the gear unit and allow it to idle briefly.

• Unscrew the oil drain plug and allow the preservative agent to drain into a suitable container and disposeof it according to regulations.

There is a risk of scalding from the preservative agent escaping from thesystem. Wear protective gloves!

• Screw in the oil drain plug.

34 / 42BA 5050 EN 12.08

Table 12: Preservation procedure when using mineral oil or PAO­based synthetic oil

Duration of protection Preservative agent Special measures

up to 6 months

Castrol Alpha SP 220 S

none

up to 24 months

Close gear unit, replace breather screw or airfilter with a yellow plug screw (replace theoriginal parts before start-up).

Storage in enclosed dry rooms.

For storage periods longer than 24 months, renew the preservative agent.For storage periods longer than 36 months, FLENDER should be consulted before.

Table 13: Preservation procedure when using PG­based synthetic oil

Duration of protection Preservative agent Special measures

up to 6 months

Special anti-corrosion oilTRIBOL 1390 1)

none

up to 36 months

Close gear unit, replace breather screw or airfilter with a yellow plug screw (replace theoriginal parts before start-up).

Storage in enclosed dry rooms.

For storage periods longer than 36 months, FLENDER should be consulted before.

1) Resistant to tropical conditions and sea water. Max. ambient temperature 50 °C

7.3.2 Exterior preservation of bright machined surfaces

Exterior preservation procedure:

• Clean the surfaces.

• For separation between the sealing lip of the shaft­sealing ring and the preservative agent, the shaftshould be brushed with grease in way of the sealing lip.

• Apply preservative agent.

Table 14: Exterior preservation of shaft ends and other bright machined surfaces

Durationof protection

Preservativeagent

Layerthickness

Remarks

up to 36 months Tectyl 846 K19 approx. 50 μm

Long-term wax-based preservative agent,resistant to sea water and tropicalconditions (soluble with CH compounds)

Storage in enclosed dry rooms.

35 / 42BA 5050 EN 12.08

8. Operation

Observe the instructions in section 3, "Safety instructions", in section 9, "Faults, causes and remedy", andin section 10, "Maintenance and repair"!

The coating must not carry an impermissibly high electrostatic charge!The operator must ensure that highly effective mechanisms which can set up acharge in the coating are safely avoided.

During operation the unit must be monitored for:

Oil temperature The difference in temperature from the ambienttemperature (max. + 40 °C) must not exceed 50 K.If temperatures are higher, the gear unit must beshut down immediately and FLENDER customerservice consulted (see also item 1.2.1).

Changes in gear noise

Possible oil leakage at the housing and shaft seals

Correct oil level (see section 7, "Start­up")

If any irregularities are noticed during operation, switch the drive unit off atonce. Determine the cause of the fault, using the table in section 9.

The trouble­shooting table contains a list of possible faults, their causes andsuggested remedies.

If the cause cannot be found, a fitter from one of our customer­service centresshould be called in (see section 11).

9. Faults, causes and remedy

Observe the instructions in section 3, "Safety instructions", and in section 10, "Maintenance and repair"!

9.1 General information on faults and malfunctions

Faults and malfunctions occurring during the guarantee period and requiring repair workon the gear unit must be carried out only by FLENDER Customer Service.In the case of faults and malfunctions occurring after the guarantee period and whosecause cannot be precisely identified, we advise our customers to contact our customerservice.

FLENDER will not be bound by the terms of the guarantee or otherwise beresponsible in cases of improper use of the gear unit, modifications carried outwithout FLENDER's agreement or use of spare parts not supplied by FLENDER.

To remedy faults and malfunctions, the gear unit must always be taken out ofservice.Secure the drive unit to prevent it from being started up unintentionally.Attach a warning notice to the start switch!

36 / 42BA 5050 EN 12.08

9.2 Possible faults

Table 15: Faults, causes and remedies

Faults Possible causes Remedy

Loud noises in area ofgear­unit fastening.

Gear­unit fastening has workedloose.

Tighten bolts / nuts to specified torque.Replace damaged bolts / nuts.

Changes in gear noise. Damage to gear teeth.

Excessive bearing play.

Bearing defective.

Contact Customer Service.- Check all toothed components

and replace any damaged parts.

Contact Customer Service.- Adjust bearing play.

Contact Customer Service.- Replace defective bearings.

Increased temperature at thebearing points.

Oil level in gear­unit housing toolow or too high.

Oil too old.

Bearing defective.

Check oil level at room temperature and, ifnecessary, top up oil.

Contact Customer Service.- Check date of last oil change.

Contact Customer Service.- Check and, if necessary,

replace bearings.

Increased operatingtemperature.

Oil level in housing too high.

Oil too old.

Oil badly contaminated.

Check oil level and, if necessary, adjust.

Contact Customer Service.- Change oil.

Contact Customer Service.- Change oil.

Gear unit is oiled up. Inadequate sealing of housingcovers or joints.

Labyrinth seals oiled up.

Seal joints.

Check oil filling.If necessary, clean labyrinth seals.

Oil leakage from gear unit. Inadequate sealing of housingcovers or joints.

Radial shaft­sealing ringsdefective.

Check and, if necessary, replace seals.Seal joints.

Contact Customer Service.- Replace radial shaft­sealing rings.

Oil foams. Water in oil.

Oil too old(defoaming agent used up).

Unsuitable oils mixed up.

Test the oil, change oil if necessary.

Test the oil, change oil if necessary.

Test the oil, change oil if necessary.

Water in oil. Gear unit exposed to cold air frommachine­room ventilator: watercondensing.

Protect gear unit with suitable heatinsulation.If possible, close air outlet or alter itsdirection by structural measures.

Motor will not start. Freewheel (overrunning) clutchblocked.

Contact Customer Service.- Install a new freewheel (overrunning)

clutch.

Installation will not start. Wrong installation or defect ofcage with grippers of freewheel(overrunning) clutch.

Contact Customer Service.- Install cage of freewheel (overrunning)

clutch turned by 180° or renew.

37 / 42BA 5050 EN 12.08

10. Maintenance and repair

Observe the instructions in section 3, "Safety instructions", and in section 9, "Faults, causes and remedy"!

10.1 General notes on maintenance

Maintenance and repair work must be done with care and by duly trained and qualified personnel only.

The following applies to all work in item 10.2:

Switch gear unit and add­on components off.

Secure the drive unit to prevent it from being started up unintentionally.Attach a warning notice to the start switch!

The gear unit must be protected against falling objects.

Protective devices for rotating parts must be checked for correct seating.Contact with rotating parts is not permitted.

The periods indicated in table 16 depend on the conditions under which the gearunit is operated. Only average periods can therefore be stated here. These referto:

a yearly operating time of 36 ha duty factor of 100 %an input­drive speed of 1 500 1/mina maximum oil temperature of 90 °C

For operation and maintenance, always observe the operating instructionsindicated in the order­specific appendix.For technical data, refer to the order­specific list of equipment.

The operator must ensure that the intervals stated in table 16 are adhered to.This also applies if the maintenance work is included in the operator’s internalmaintenance schedules.

Table 16: Maintenance and repair work

Measures Periods Remarks

Check oil temperature continuously duringthe operation

Check for unusual gear-unit noise during operation

Check gear unit for leaks during operation

Check oil level each time before starting upthe gear unit

Test oil for water content once per year at least See item 10.2.1

Oil change every 4 years 1) See item 10.2.2

Clean the breather screw yearly See item 10.2.3

Refill Taconite seals with grease yearly See item 10.2.4

Clean fan, fan cowl and gear-unit housing depending on requirements,at least every 4 years

See item 10.2.5

Check tightness of fastening bolts after first oil change,then every 4 years

See item 6.8

Check the preservation of the free shaft ends every 3 years See item 4.4

Complete inspection of gear unit every 4 years See item 10.3.1

1) When using synthetic oils, the periods can be doubled.

38 / 42BA 5050 EN 12.08

10.2 Description of maintenance and repair work

10.2.1 Testing water content of oil

For detailed information on testing the oil for water content apply to the lubricant manufacturer.

10.2.2 Changing the oil

As an alternative to the oil change intervals indicated in Table 16 (see item 10.1) it is possible to have theoil sample tested at regular intervals by the Technical Service of the relevant oil company and to have itreleased for further use.

If reusability has been confirmed, no oil change will be necessary.

Please observe the separately attached operating instructions BA 7300 EN.

• The instructions in item 7.2 must be observed!

• Drain the oil while it is still warm, i.e. immediately after shutting down the machinery.

When changing the oil, always re­fill the gear unit with the same type of oil. Nevermix different types of oil and/or oils made by different manufacturers. Never mixsynthetic oils with mineral­based oils or with other synthetic oils. Whenchanging to any different oil type, the gear unit must be flushed thoroughlyusing the new oil type.

When changing the oil, the housing must be flushed with oil to remove sludge, metalparticles and oil residue. Use the same type of oil as is used for normal operation.High­viscosity oils must be heated beforehand using suitable means. Ensure that allresidues have been removed before filling with fresh oil.

• Place a suitable container under the oil drain plug of the gear­unit housing.

• Unscrew the air filter including reducing screw at the housing top.

• Unscrew the oil drain plug and allow the oil to drain into the container.

• Drain the oil from the oil­supply system (see operating instructions to the oil­supply system).

There is a danger of scalding from the hot oil emerging from the housing.Wear protective gloves!Remove any oil spillage immediately with an oil­binding agent.

Check the condition of the sealing ring (the sealing ring is vulcanised onto the oil drainplug). If necessary, use a new oil drain plug.

• Screw in the oil drain plug.

• Clean the oil filter in the oil­cooling system (see operating instructions of the oil­supply system).

• Clean the breather screw (see item 10.2.3).

• Screw in breather screw and reducing screw.

• Fill fresh oil into the gear unit (see item 7.1.2).

39 / 42BA 5050 EN 12.08

10.2.3 Cleaning the breather screw

If a layer of dust has built up, the breather screw must be cleaned, whether ornot the minimum period of 3 months has expired. To do this, the breather screwis removed, cleaned with benzine or similar agent and dried, or it can be cleanedby blowing out with compressed air.

Foreign bodies must be prevented from entering the gear unit.

10.2.4 Refilling Taconite seals with grease

• Inject approx. 30 g lithium­based bearing grease into each of the lubrication points of the Taconite seal.The lubrication points are fitted with flat grease nipples type AM10x1 to DIN 3404.

Remove and dispose of any old grease escaping.

10.2.5 Cleaning of fan (on the freewheel (overrunning) clutch) and gear unit

• Remove the fan cowl.

• Using a stiff brush, remove any dirt adhering to the fan wheel, cowl and safety grid.

• Remove any corrosion.

• Screw safety grid back onto the fan cowl.

To prevent the build­up of dust on the gear unit, cleaning must be done inaccordance with operating conditions.

The gear unit must not be cleaned with high­pressure cleaning equipment.

10.2.6 Topping up oil

• The instructions in item 7.1.2 must be observed!

• Always top up with the same type of oil as already used (see also item 10.2.2).

10.2.7 Checking tightness of all base bolts

• The instructions in item 10.1 must be observed!

• Check tightness of all fastening bolts (see item 6.8).

Damaged bolts must be replaced with new bolts of the same type and strength class.

10.3 Final work

The final work is to be done in accordance with the instructions in item 6.7.

10.3.1 General inspection of the gear unit

The general inspection of the gear unit should be carried out by the FLENDER Customer Service, as ourengineers have the experience and training necessary to identify any components requiring replacement.

40 / 42BA 5050 EN 12.08

10.4 Lubricants

The quality of the oil used must meet the requirements of the separately enclosed BA 7300 EN operatinginstructions, otherwise the guarantee given by FLENDER will lapse. We urgently recommend using oneof the oils listed in BA 7300 EN, because they have been tested and meet the requirements.

To avoid misunderstandings, we should like to point out that this recommendation is inno way intended as a guarantee of the quality of the lubricant supplied. Each lubricantmanufacturer is responsible for the quality of his own product.

Information on the type, quantity and viscosity of the oil is given on the rating plate on the gear unit or inthe supplied documentation.

The quantity of oil indicated on the rating plate is an approximation only. The marks on the dipstick or oilsight glass are decisive for the amount of oil to be filled in.

The use instructions for lubricants currently recommended by FLENDER are also available on the Internetat "http://www.flender.com".

The oils listed there are subjected to continuous tests. Under certain circumstances the oils recommendedthere may therefore later be removed from the range or replaced with further developed oils.

We recommend regularly checking whether the selected lubricating oil is still recommended byFLENDER. If it is not, the brand of oil must be changed.

11. Spare parts, customer­service addresses

11.1 Stocking spare parts

By stocking the most important spare and wearing parts on site you can ensure that the gear unit is readyfor use at any time.

To order spare parts, refer to the spare­parts list.

For further information refer to the spare­parts drawing stated in the list.

We guarantee only the original spare parts supplied by us. Non­original spareparts have not been tested or approved by us. They may alter technicalcharacteristics of the gear unit, thereby posing an active or passive risk tosafety. FLENDER will assume no liability or guarantee for damage caused byspare parts and accessories not supplied by FLENDER. The same applies to anyaccessories not supplied by FLENDER.

Please note that certain components often have special production and supply specifications and that wesupply you with spare parts which comply fully with the current state of technical development as well ascurrent legislation.

When ordering spare parts, always state the following:

Order number, item Type, size Part number Quantity

11.2 Spare parts and customer­service addresses

When ordering spare parts or requesting a service specialist, please contact FLENDER first (seesection 2.).

STOP

41 / 42BA 5050 EN 12.08

12. Declaration by the manufacturer / Declaration of conformity

Declaration by the manufacturer

in accordance with EC Engineering Directive 98/37/EC, Appendix II B

We hereby declare that the components described in these assembly and operating instructions:

Gear Unit Types H.SH, B.SHwith integrated freewheel (overrunning) clutch

on the low­speed shaft (d2)Sizes 3 to 14

in design in accordance with Directive 94/9/EC

are intended for incorporation in a machine and that they must not be put into service before verifyingthat the machine into which they are incorporated complies with the EC Directive (original edition98/37/EC including any subsequent amendments thereto).

Voerde, 2008‐12‐01Dr. Nico van de Sandt (Director Engineering HDE)

42 / 42BA 5050 EN 12.08

Declaration of conformity

within the meaning of EC Directive 94/9/EC of 23.03.94 and with the legal requirements laid down for itsimplementation

The manufacturer, A. Friedr. Flender AG, D ­ 46393 Bocholt, declares that the equipment described in theseassembly and operating instructions,

Gear Unit Types H.SH, B.SHwith integrated freewheel (overrunning) clutch

on the low­speed shaft (d2)Sizes 3 to 14

in design in accordance with Directive 94/9/EC

is in conformity with Article 1 and Article 8, Paragraph 1 c) of Directive 94/9/EC and complies with therequirements of Directive 94/9/EC and the following standards:

DIN EN 1127‐1 : 10‐1997DIN EN 13463‐1 : 04‐2002DIN EN 13463‐5 : 03‐2004DIN EN 13463‐6 : 07‐2005DIN EN 13463‐8 : 01‐2004DIN EN 50014 : 02‐2000

Voerde, 2008‐12‐01Dr. Nico van de Sandt (Director Engineering HDE)

Voerde, 2008‐12‐01Dr. Heinz­Peter Ehren (Director Business Subsegment HD)