FLENDER GEAR UNITS

DURUNORM Gear unit

Assembly and operating instructions 5240en

Edition 06/2020

..S.N, ..S.H, ..S.A, ..S.V, ..S.O, ..S.U, ..K.N, ..K.H, ..K.A, ..K.V, ..K.O, ..K.U

80...800
04.12.2020 21:48
V10.00
 Introduction 1

Safety instructions 2

Description 3
FLENDER GEAR UNITS
Application planning 4
DURUNORM Gear unit
5240en 5
Mounting

Commissioning 6
Assembly and operating instructions

Operation 7

Maintenance 8

Service & Support 9

Disposal 10

Spare parts 11

..S.N, ..S.H, ..S.A, ..S.V, ..S.O, ..S.U, ..K.N, ..K.H, ..K.A, .. Declaration of incorporation A
K.V, ..K.O, ..K.U
80...800
Technical data B

Original assembly and operating instructions

Edition 06/2020
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage
to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices
referring only to property damage have no safety alert symbol. These notices shown below are graded according to
the degree of danger.

DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION
indicates that minor personal injury can result if proper precautions are not taken.

NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property
damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Flender products
Note the following:

WARNING
Flender products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended or
approved by Flender. Proper transport, storage, installation, assembly, commissioning, operation and maintenance
are required to ensure that the products operate safely and without any problems. The permissible ambient
conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks
All names identified by ® are registered trademarks of Flender GmbH. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described.
Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this
publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Flender GmbH Document order number: 5240en Copyright © Flender GmbH 2020.
Alfred-Flender-Straße 77 Ⓟ 12/2020 Subject to change All rights reserved
46395 BOCHOLT
GERMANY
Table of contents

1 Introduction ......................................................................................................................................... 11
1.1 General information........................................................................................................... 11
1.2 Lubricants.......................................................................................................................... 12
2 Safety instructions ............................................................................................................................... 13
2.1 Security notes .................................................................................................................... 13
2.2 The five safety rules ........................................................................................................... 13
2.3 General information........................................................................................................... 14
2.4 General warnings and symbols........................................................................................... 15
2.5 Special types of danger and personal protective equipment ................................................ 16
2.6 Intended use...................................................................................................................... 18
3 Description........................................................................................................................................... 21
3.1 General description............................................................................................................ 21
3.2 Output shaft versions......................................................................................................... 21
3.3 Housing............................................................................................................................. 22
3.4 Oil supply to the gear unit .................................................................................................. 24
3.4.1 Splash lubrication .............................................................................................................. 24
3.4.2 Pressure lubrication............................................................................................................ 24
3.5 Bearing arrangement of the shafts ..................................................................................... 25
3.6 Shaft seal .......................................................................................................................... 25
3.6.1 Rotary shaft sealing rings ................................................................................................... 25
3.6.2 Labyrinth seal with radial shaft seal.................................................................................... 26
3.7 Cooling.............................................................................................................................. 26
3.7.1 Fan .................................................................................................................................... 27
3.7.2 Cooling coil........................................................................................................................ 27
3.7.3 Mounted oil supply system................................................................................................. 28
3.7.3.1 Mounted oil supply system with air-oil cooler ..................................................................... 28
3.7.3.2 Mounted oil supply system with water-oil cooler ................................................................ 30
3.7.3.3 Pump................................................................................................................................. 31
3.7.3.4 Oil filter ............................................................................................................................. 31
3.7.4 Separate oil supply system ................................................................................................. 32
3.8 Backstop............................................................................................................................ 32
3.9 Couplings .......................................................................................................................... 34
3.10 Shrink disk ......................................................................................................................... 34
3.11 Heating ............................................................................................................................. 35
3.12 Oil level indicator ............................................................................................................... 36

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3.13 Oil level monitoring system ................................................................................................ 36

3.14 Oil temperature monitoring ............................................................................................... 37
3.15 Bearing monitoring ............................................................................................................ 37
3.15.1 Bearing monitoring using a Pt 100 resistance thermometer ................................................ 37
3.15.2 Bearing monitoring by acceleration sensor ......................................................................... 38
3.16 Auxiliary drive.................................................................................................................... 39
3.16.1 Overrunning clutch ............................................................................................................ 40
4 Application planning ........................................................................................................................... 43
4.1 Scope of delivery ............................................................................................................... 43
4.2 Transport ........................................................................................................................... 43
4.3 Attachment points ............................................................................................................. 45
4.4 Special aspects of gear unit lubrication and preservation .................................................... 47
4.4.1 Oil filling and oil drain ........................................................................................................ 47
5 Mounting ............................................................................................................................................. 49
5.1 General assembly instructions............................................................................................ 49
5.2 Unpacking the gear unit..................................................................................................... 50
5.3 Gear unit mounting ........................................................................................................... 51
5.3.1 Foundation ........................................................................................................................ 51
5.3.2 Description of assembly work............................................................................................. 52
5.3.2.1 Alignment ......................................................................................................................... 54
5.3.3 Mounting the gear unit on the housing foot ....................................................................... 55
5.3.3.1 Installation on a foundation frame ..................................................................................... 55
5.3.3.2 Mounting on a concrete foundation using stone bolts or foundation blocks ........................ 56
5.3.3.3 Mounting on a concrete foundation using anchor bolts ...................................................... 58
5.3.4 Mounting the gear unit swing base .................................................................................... 61
5.3.5 Mounting the torque arm for the gear unit housing ............................................................ 61
5.4 Shaft-mounted gear unit with hollow shaft and parallel keyway.......................................... 62
5.4.1 Mounting .......................................................................................................................... 63
5.4.1.1 Introduction....................................................................................................................... 63
5.4.1.2 Mounting .......................................................................................................................... 63
5.4.1.3 Axial locking ...................................................................................................................... 65
5.4.2 Dismantling ....................................................................................................................... 65
5.5 Shaft-mounted gear unit with hollow shaft and shrink disk................................................. 66
5.5.1 Mounting .......................................................................................................................... 67
5.5.1.1 Pulling on with integrated DU bushing ............................................................................... 68
5.5.1.2 Axial locking ...................................................................................................................... 69
5.5.2 Dismantling the shaft-mounted gear unit ........................................................................... 69
5.6 Couplings .......................................................................................................................... 70
5.7 Connecting components .................................................................................................... 72
5.7.1 Gear units with mounted components ............................................................................... 72
5.7.2 Connecting the cooling coil................................................................................................ 72
5.7.3 Connecting the air‐oil cooler .............................................................................................. 73
5.7.4 Connecting the water-oil cooler ......................................................................................... 73
5.7.5 Connecting the heating element ........................................................................................ 74

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5.7.6 Installing a separate oil supply system ................................................................................ 75

5.7.7 Connecting the oil temperature monitor............................................................................. 75
5.7.8 Connecting the oil-level monitoring system ........................................................................ 75
5.7.9 Connecting the Pt 100 resistance thermometer .................................................................. 76
5.7.10 Connecting the temperature monitor ................................................................................. 76
5.7.11 Connecting the bearing monitoring system ........................................................................ 77
5.7.12 Electrical connections ........................................................................................................ 77
5.8 Tightening procedure......................................................................................................... 78
5.8.1 Introduction....................................................................................................................... 78
5.8.2 Bolt connection classes ...................................................................................................... 79
5.8.3 Tightening torques and preload forces................................................................................ 79
5.9 Final work.......................................................................................................................... 81
6 Commissioning .................................................................................................................................... 83
6.1 Measures prior to commissioning ....................................................................................... 83
6.1.1 Gear units with cooling coil................................................................................................ 83
6.1.2 Gear unit with heating ....................................................................................................... 84
6.1.3 Gear unit with backstop ..................................................................................................... 84
6.1.4 Gear unit with auxiliary drive ............................................................................................. 85
6.1.5 Gear unit with oil supply unit ............................................................................................. 85
6.1.6 Oil level monitoring system ................................................................................................ 86
6.1.7 Oil temperature monitoring system .................................................................................... 86
6.2 Measures during commissioning ........................................................................................ 86
6.2.1 Gear units with heating...................................................................................................... 87
7 Operation............................................................................................................................................. 89
7.1 Operating data .................................................................................................................. 89
7.2 Irregularities in operation................................................................................................... 89
7.3 Taking the unit out of service ............................................................................................. 90
8 Maintenance........................................................................................................................................ 91
8.1 General maintenance information...................................................................................... 91
8.2 Maintenance schedule ....................................................................................................... 92
8.3 Maintenance and servicing work ........................................................................................ 93
8.3.1 Checking the oil temperature ............................................................................................. 93
8.3.2 Replacing the backstop ...................................................................................................... 94
8.3.3 Filling the backstop with oil................................................................................................ 94
8.3.4 Checking the auxiliary drive ............................................................................................... 95
8.3.5 Filling the overrunning clutch of the auxiliary drive with oil ................................................ 95
8.3.6 Cleaning the fan and gear unit ........................................................................................... 95
8.3.7 Checking the cooling coil ................................................................................................... 96
8.3.8 Cleaning the coarse filter.................................................................................................... 97
8.3.9 Cleaning the double change-over filter ............................................................................... 97
8.3.10 Checking the speed monitoring of the auxiliary drive.......................................................... 97
8.3.11 Measuring the vibration levels of the rolling-contact bearings............................................. 98
8.3.12 Inspecting the shrink disk................................................................................................... 98
8.3.13 Check that all of the fastening bolts are tight...................................................................... 99
8.3.14 General inspection of the gear unit .................................................................................... 99
8.3.15 Final work.......................................................................................................................... 99

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8.4 Possible faults .................................................................................................................... 99

9 Service & Support .............................................................................................................................. 105
10 Disposal ............................................................................................................................................. 107
11 Spare parts......................................................................................................................................... 109
A Declaration of incorporation ............................................................................................................. 111
B Technical data.................................................................................................................................... 113
B.1 General technical data ..................................................................................................... 113
B.2 Ambient temperature....................................................................................................... 115
B.3 Types............................................................................................................................... 115
B.4 Weights ........................................................................................................................... 115
B.5 Enveloping surface sound pressure level........................................................................... 115
Index .................................................................................................................................................. 117

Tables

Table 2-1 Symbols and markings ............................................................................................................ 14

Table 2-2 General warnings ................................................................................................................... 15
Table 3-1 Information about the specific heat output.............................................................................. 35
Table 5-1 Information on tightening fastening bolts ............................................................................... 79
Table 5-2 Preload forces and tightening torques ..................................................................................... 80
Table 7-1 Operating data ....................................................................................................................... 89
Table 8-1 Maintenance and servicing activities ....................................................................................... 92
Table 8-2 Possible faults and how to rectify them ................................................................................. 100

Figures

Figure 3-1 Sign: Lubrication point............................................................................................................ 22

Figure 3-2 Gear unit equipment for type S.N gear units ............................................................................ 23
Figure 3-3 Gear unit equipment for type K.N gear units............................................................................ 23
Figure 3-4 Rotary shaft sealing ring ......................................................................................................... 25
Figure 3-5 Labyrinth seal with radial shaft seal......................................................................................... 26
Figure 3-6 Backstop................................................................................................................................. 33
Figure 3-7 Bearing monitoring using a Pt 100 resistance thermometer ..................................................... 38
Figure 3-8 Bearing monitoring using a shock-pulse transducer ................................................................. 38
Figure 3-9 Complete acceleration sensor ("A") and threaded connector ("B")............................................. 39
Figure 3-10 Gear unit with main and auxiliary drive ................................................................................... 40
Figure 4-1 Transport symbols................................................................................................................... 45
Figure 4-2 Shear and lateral pulling when using eye bolts ........................................................................ 46

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Figure 4-3 Position of the attachment points, at type S.N ≤ 280 and K.N ≤ 280 gear units......................... 46
Figure 4-4 Position of the attachment points, at type S.N ≥ 280 and K.N ≥ 280 gear units......................... 46
Figure 4-5 Oil filling and oil drain for gear units, type S.N ......................................................................... 47
Figure 4-6 Oil filling and oil drain for gear units, type K.N ......................................................................... 48
Figure 5-1 Alignment surface .................................................................................................................. 54
Figure 5-2 Stone bolt............................................................................................................................... 56
Figure 5-3 Foundation block .................................................................................................................... 57
Figure 5-4 Inserted anchor bolt................................................................................................................ 59
Figure 5-5 Tightened anchor bolt............................................................................................................. 60
Figure 5-6 Gear unit with a hollow shaft and parallel keyway ................................................................... 62
Figure 5-7 Screw spindle for gear units with hollow shaft and parallel keyway .......................................... 64
Figure 5-8 Dismantling using hydraulic pulling equipment ....................................................................... 66
Figure 5-9 Preparation for gear units with hollow shaft and shrink disk .................................................... 69
Figure 5-10 Possible displacements ........................................................................................................... 71
Figure 5-11 Alignment process based on the example of a flexible coupling ............................................... 71
Figure B-1 Rating plate .......................................................................................................................... 113

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Assembly and operating instructions 5240en

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Introduction 1
1.1 General information

Purpose of the operating instructions

These operating instructions describe the gear unit and provide information about handling it
- from assembly to maintenance.
Please keep these operating instructions for later use. Please read these operating instructions
prior to handling the gear unit and follow the information in them.

Note
Disclaimer
Please make sure that every person who is commissioned to work on the gear unit has read and
understood these operating instructions prior to handling the gear unit and adheres to all of the
points. Failure to observe these operating instructions can cause product or property damage or
personal injury.
Flender does not accept any liability for damage or operating failures that are due to non-
adherence to these operating instructions.

The gear unit described in these instructions reflects the state of technical development at the
time these operating instructions went to print.
In the interest of technical advancements, Flender reserves the right to make changes to the
individual components and accessories which are considered necessary for improving their
performance and safety, while maintaining their essential features.

Basic knowledge required

In order to understand these operating instructions, you will need the following general
knowledge about gear units. You will also need a basic understanding of the following topics:
• Application planning
• Assembly
• Commissioning
• Maintenance

Documentation landscape
These operating instructions form part of the delivery of your gear unit.

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Introduction
1.2 Lubricants

These operating instructions form part of the complete documentation supplied with the gear
unit. The complete documentation encompasses other documents, including:
• Data sheet
• List of equipment
• Dimension drawing
• Operating instructions for gear unit lubrication and preservation BA 7300
• Operating instructions for mounted components
• Operating instructions for third-party vendor devices

Copyright
The copyright for these operating instructions is held by Flender.
Without the authorisation of Flender, these operating instructions may not be used wholly or in
parts for competitors’ purposes or be given to third parties.
If you have any technical queries, please contact one of our Customer Services addresses
(Page 105).

1.2 Lubricants
The quality of the oil used must meet the requirements of the operating instructions BA 7300,
which is provided as a separate item, otherwise the warranty provided by Flender will be void.
Flender strongly recommends using one of the oils listed in BA 7300, all of which have been
appropriately tested and meet the requirements.
To avoid misunderstandings, Flender points out that, by making this recommendation, it is not
approving the product in the sense of expressing a warranty for the quality of the lubricants
supplied by your supplier. Every lubricant manufacturer is required to guarantee the quality of
his/her products.
Information such as oil type, oil viscosity and required oil quantity can be found on the rating
plate of the gear unit and in the documentation supplied with the gear unit.
The oil quantity specified on the rating plate is an approximate value. The actual quantity of oil
required is determined by the marking on the oil dipstick or oil sight glass.
The operating instructions for the current lubricant recommendations of Flender can also be
viewed in the Internet (https://www.flender.com/lubricants).
The oils listed there undergo continuous testing. As a result, the recommended oil types might
in future be removed from the list or replaced by more advanced oils.
Flender recommends regular inspection to ascertain whether the selected lubricating oil is still
approved by Flender. If it is not, another brand of oil should be selected instead.

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Safety instructions 2
2.1 Security notes
Flender offers products and solutions with industrial security functions, which support the safe
and secure operation of plants, systems, machines and networks.
In order to safeguard plants, systems, machines and networks against cyber threats it is
necessary to implement (and continually maintain) a holistic industrial security concept that
corresponds to the current state of the art. Flender products and solutions undergo continuous
development in this respect.
Customers are responsible for preventing unauthorised access to their plants, systems,
machines and networks. These systems, machines and components shall be connected to the
company network or the Internet only when and to the extent that this is absolutely necessary
and appropriate protective measures (e.g. firewalls and/or network segmentation) shall be
taken.
You can find further information about possible protection measures as part of Industrial
Security in the following international series of standards, for example: IEC 62443 "Network and
system security".
Flender products and solutions undergo continuous development in order to make them even
safer. Flender strongly recommends that you regularly implement product updates as soon as
they become available and that you only use the current product versions. Use of older or no
longer supported versions can increase the risk of cyber threats.

2.2 The five safety rules

In order to protect yourself and prevent any damage to property, always observe the safety
relevant information and the following five safety rules (as per EN 50110-1 "Working on isolated
equipment") when working on electrical components of the plant.
Prior to starting work on the machine, follow the safety rules listed below:
1. Disconnect
Also disconnect auxiliary circuits such as the anti-condensation heater
2. Safeguard against restart
3. Ensure that the system is de-energised
4. Earth and short circuit
5. Cover or cordon off adjacent live parts
When all the work is complete, cancel the safety measures in the reverse sequence.

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Safety instructions
2.3 General information

2.3 General information

Introduction
All work on the gear unit should be performed with care and only by qualified personnel.

Symbols on the gear unit

The following symbols apply to the gear unit; some of which are found as coloured markings on
the gear unit:

Table 2-1 Symbols and markings

Points labelled on the gear unit Symbol Coloured markings

Earth connection point

Air relief point yellow

Oil filling point yellow

Oil draining point white

Oil level indicator red

Oil level measurement red

Oil overflow

Connection point for vibration monitoring

Lubrication point red

Apply grease

Lifting eye

Eye bolt

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 Safety instructions
2.4 General warnings and symbols

Points labelled on the gear unit Symbol Coloured markings

Do not unscrew

Alignment surface, horizontal

Alignment surface, vertical

These symbols indicate the oil level check‐

ing procedure using the oil dipstick.

These symbols indicate that the oil dipstick

must be firmly screwed in.

2.4 General warnings and symbols

The following table contains general warnings and their associated symbols.

Table 2-2 General warnings

ISO ANSI Warning

Warning - hazardous electrical voltage

Warning - explosive substances

--- Warning - entanglement hazard

--- Warning - hot surfaces

--- Warning - substances that can irritate or which are hazardous to health

--- Warning - caustic substances

--- Warning - suspended load

--- Warning - hand injuries

ATEX certification

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Safety instructions
2.5 Special types of danger and personal protective equipment

2.5 Special types of danger and personal protective equipment

Requirements
Fulfil the following requirements before commencing work on the gear unit:
• Ensure that the oil pressure lines are depressurised.
• Only perform work on the gear unit when it is not in operation.
• Disconnect electrical systems from the power supply.

DANGER
Electric shock
Live parts can cause electric shock.
Ensure that the entire plant is de-energised before starting electrical installation work.

Protective equipment
Wear the following personal protective equipment when handling the gear unit:
• Safety shoes
• Overalls
• Helmet
• Safety gloves
• Safety goggles

WARNING
Risk of eye injury
Small foreign particles such as sand or dust can enter the cover plates of the rotating parts and
be hurled back by them.
Wear safety goggles.

Dangers during operation

Damage to the gear unit is possible.

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 Safety instructions
2.5 Special types of danger and personal protective equipment

Switch the gear unit to standstill immediately if inexplicable changes are noticed during
operation. Such changes may include unusual gear unit noise or a significant increase in
operating temperature.

WARNING
Risk of falling
There is an increased risk of falling when standing or walking on the gear unit during operation.
Only walk or stand on the gear unit and its mounted components for maintenance and repair
work when it is at a standstill. Do not walk or stand on shaft ends, protection covers, mounted
components or pipes.

WARNING
Danger to life through rotating or moving parts
There is danger that rotating or moving parts may catch hold of you or pull you in.
Secure rotating and/or moving parts against contact using safeguards.

Surface temperature
The surface temperatures of the gear unit can become very extreme depending on the
operating conditions.

WARNING
Risk of burns
Possible risk of serious burn injury from hot surfaces (> 55 °C).
Wear suitable protective gloves and protective clothing.

WARNING
Risk of scalding
Risk of serious injury possible through escaping hot operating media when these are being
changed.
Wear suitable protective gloves, safety goggles and protective clothing.

WARNING
Danger due to low temperatures
Possible risk of serious injuries due to frost (pain, numbness, frostbite) on cold surfaces (< 0 °C).
Wear suitable protective gloves and protective clothing.

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Safety instructions
2.6 Intended use

Chemical substances
Injuries can be sustained when using chemical substances.

WARNING
Risk of chemical burns due to chemical substances
There is a risk of chemical burns when handling aggressive cleaning agents.
Please observe the manufacturer's guidelines on how to handle cleaning agents and solvents.
Wear suitable protective equipment (gloves, safety goggles). Please use binding agents to
immediately clear up any spilt solvent.

CAUTION
Risk of injury due to chemically aggressive operating materials
There is a risk of injury to eyes and hands when handling chemically aggressive operating
materials.
Please observe the safety instructions in the data sheets of the oil used. Wear suitable
protective equipment (gloves, safety goggles). Use an oil-binding agent to immediately clean
up spilt oil.

Danger of explosion
An explosion may occur in a potentially explosive atmosphere.

DANGER
Danger of explosion through ignition of a potentially explosive atmosphere
Danger to life through ignition of a potentially explosive atmosphere possible when operating
the gear unit
Do not use the gear unit in potentially explosive atmospheres.

2.6 Intended use

Only use the gear unit according to the conditions specified in the service and delivery contract
and the technical data in the annex (Page 113). Deviating operating conditions are considered
improper use. The user or owner of the machine or plant is solely liable for any resulting damage.

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 Safety instructions
2.6 Intended use

When using the gear unit please specifically observe the following:
• Do not make any modifications to the gear unit which go beyond the permissible handling
described in these operating instructions. This also applies to safety features designed to
prevent accidental contact.
• Only ever use original spare parts.
Other spare parts are not tested and approved by Flender. Non-approved spare parts may
possibly change the design characteristics of the gear unit and thus impair its active or
passive safety.
Flender will accept no liability or warranty whatsoever for damage occurring as a result of the
use of non-approved spare parts. The same applies to any accessories which were not
supplied by Flender.
If you have any queries, please contact Customer Services (Page 105).

WARNING
Risk of falling
Risk of possible serious injury through falling.
Only walk or stand on the gear unit for maintenance and repair work when it is at a standstill.
Do not walk or stand on shaft ends, protection covers, mounted components or pipes.

Gear unit use

When using the gear unit, please observe the following basic rules:
• Ensure that the gear unit is operationally safe.
• The gear unit should only be operated, maintained or repaired by authorised, trained and
suitably qualified personnel.
• The relevant work safety and environmental protection regulations must be complied with
at all times during transport, assembly, dismantling, operation, maintenance and servicing.
• The outside of the gear unit must not be cleaned using high-pressure cleaning equipment.
• No welding work must be performed on the gear unit or on parts connected to it. The gear
unit and any parts connected to it must not be used as an earthing point for electric-welding
operations. Gearing and rolling-contact bearings might be irreparably damaged by welding.
• Perform potential equalisation in accordance with the applicable regulations and guidelines.
If no threaded holes are available on the gear unit for an earth connection, please take
suitable measures. This work must always be done by specialist electricians.
• In the case of gear units that are operated in combination with electrical machines that
generate current or through which current flows (e.g. motors and generators), take
measures to ensure that no current can flow through the gear unit.
Current flowing through the gear unit can result in irreparable damage to rolling-contact
bearings and gearing. Short circuits, voltage flashovers and deposits of conductive dust, for
example, can all allow current to flow.
Use insulators and earth the gear unit properly.
• When removing any protective devices, retain their fixings safely.
• Removed protective devices must be re-fitted prior to starting up.

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Safety instructions
2.6 Intended use

• Pay attention to the notices attached to the gear unit such as the rating plate, direction arrow
symbol etc. Notices must not be concealed by paint or dirt. Replace missing plates.
• Bolts which have been damaged during assembly or disassembly work must be replaced with
new ones of the same strength class and type.

DANGER
Danger to life due to live system
Death or serious injury will occur.
Always shut down the gear unit and any oil supply system (whether separate or mounted on
the gear unit) before you carry out any work. Secure the drive unit against being operated
accidentally as follows:
• Turn off the key-operated switch.
• Remove the fuses in the power supply.
• Attach a notice to the start switch, clearly stating that work is being carried out on the gear
unit.
Ensure that the entire unit is load-free so that no danger is posed when you start to dismantle
components.

Reactivating the gear unit

When installing the gear unit in machines or systems, the machine or system manufacturers
must ensure that the regulations, notes and descriptions contained in these operating
instructions are incorporated in their own operating instructions.

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Description 3
3.1 General description

The FLENDER® DURUNORM gear unit (referred to below simply as "gear unit") described in these
operating instructions has been developed to drive a wide range of machines in general
machinery construction.
The gear unit is available as a one, two, three or four-stage helical or bevel helical gear unit.
These are designed for horizontal mounting. The gear unit is also available for other mounting
positions on request.
When required, standard gear units can be equipped with a motor bell housing, motor swing
base, torque arm, oil cooler and backstop.
It can essentially be operated in both directions of rotation. Gear units equipped with backstop
or overrunning clutch are the exceptions in this case. Flender must be consulted if, for these
versions, the direction of rotation is to be reversed.

Designs
Various shaft arrangements (designs and directions of rotation) are possible. Additional
information and a detailed illustrated description can be found in the dimension drawing in the
complete gear unit documentation.

NOTICE
Destruction of the gear unit or parts of the gear unit due to incorrect direction of rotation
is possible.
Depending on the specific contract, the gear unit can have one direction of rotation if it is
equipped with a backstop or overrunning clutch.

3.2 Output shaft versions

The following versions of output shaft are available:

• A = Hollow shaft, gear unit without foot
• H = Hollow shaft, gear unit with foot
• O = Shafts one above the other, output shaft at top
• U = Shafts one above the other, output shaft at bottom
• V = Vertical gear unit design
• N = Solid shaft, gear unit with foot

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Description
3.3 Housing

Further information
Additional information and a detailed illustrated description can be found in the dimension
drawing in the complete gear unit documentation.

3.3 Housing

Introduction
The housing is made of cast iron. When specified, the housing can also be manufactured out of
steel.
The housing is a two-part component.
The gear unit housing has the following features:
• Attachment points for transporting the gear unit
• Inspection and assembly cover for oil filling and inspection
• Oil filling point for refilling with oil
• Oil sight glass, oil level indicator or dipstick for checking the oil level
• Oil drain screw or oil drain valve for changing the oil
• Venting screw, air filter or wet-air filter for ventilation and bleeding

Further information
Additional information and a detailed illustrated description of the gear unit can be found in the
dimension drawing provided in the complete gear unit documentation.
The lubrication points are designated using the following sign:

/XEULFDWLRQSRLQW
J OLWKLXPVRDSEDVHGJUHDVH

DIWHU RSHUDWLQJKRXUV

Figure 3-1 Sign: Lubrication point

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3.3 Housing

Gear unit equipment

The diagram below shows the gear unit equipment on type S.N gear units:

  

 

    

① Upper housing section ⑤ Lower housing section

② Inspection and/or assembly cover ⑥ Shaft seals
③ Rating plate ⑦ Gear unit fastening
④ Cover
Figure 3-2 Gear unit equipment for type S.N gear units

The diagram below shows the gear unit equipment on type K.N gear units:

  

    

① Upper housing section ⑤ Lower housing section

② Inspection and/or assembly cover ⑥ Shaft seals
③ Rating plate ⑦ Gear unit fastening
④ Cover
Figure 3-3 Gear unit equipment for type K.N gear units

Further information
Further information about the position of the mounted components and a detailed illustration
of the gear unit can be found in the dimension drawing in the complete documentation for the
gear unit.

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Description
3.4 Oil supply to the gear unit

3.4 Oil supply to the gear unit

The oil supply to the various gear unit components can be implemented using the following oil
supply variants:
• Splash lubrication
• Pressure lubrication
• Combination of both oil supply variants

3.4.1 Splash lubrication

Unless otherwise agreed by contract, the gearing and rolling-contact bearings are supplied with
an adequate quantity of oil by splash lubrication.

3.4.2 Pressure lubrication

For special application conditions, depending on the order specification, splash lubrication can
be supplemented or replaced by oil pressure lubrication.
For specific individual applications, a motor pump can be used instead of a flange pump.

Designs
The following designs are possible:
• Mounted oil supply system
• Separate oil supply system

Note
All of the monitoring devices must be connected up and be functioning before commissioning.

Further information
Additional information and a detailed illustrated description of the gear unit and the oil supply
system can be found in the dimension drawing in the complete gear unit documentation.
Additional information about the oil supply system and control instructions can be found in the
separate data sheet, in the list of equipment and in the oil supply system operating instructions
provided in the complete gear unit documentation.

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3.6 Shaft seal

3.5 Bearing arrangement of the shafts

All shafts are mounted on rolling-contact bearings.

3.6 Shaft seal

Introduction
Depending on requirements, shaft seals prevent oil from escaping from the gear unit or dirt from
entering the gear unit.

3.6.1 Rotary shaft sealing rings

Rotary shaft sealing rings are the standard seal used. Wherever possible, rotary shaft sealing
rings are equipped with an additional dust lip which protects the actual sealing lip against
external contaminants.

NOTICE
Irreparable damage to the rotary shaft sealing ring caused by high concentration of dust
A damaged rotary shaft sealing ring might not be able to effectively seal the gear unit.
In very dusty atmospheres, do not use rotary shaft sealing rings unless they have additional
protection.

The diagram below shows a rotary shaft sealing ring

Figure 3-4 Rotary shaft sealing ring

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3.7 Cooling

3.6.2 Labyrinth seal with radial shaft seal

The radial shaft seal comprises the following sealing elements:
• Rotary shaft sealing ring to prevent the escape of lubricating oil
• Grease-packed dust seal, which allows use in very dusty environments
The labyrinth seal is ideal for use in dusty environments.

NOTICE
Gear unit leaks caused by poor sealing
Regrease the labyrinth seals at the specified regreasing intervals. The regreasing intervals are
specified in the Maintenance schedule (Page 92).

A labyrinth seal with radial shaft seal is illustrated in the diagram below:




① Grease nipple ③ Rotary shaft sealing ring

② Labyrinth, filled with grease, can be regreased
Figure 3-5 Labyrinth seal with radial shaft seal

3.7 Cooling

Introduction
The gear unit can be equipped with the following cooling equipment depending on
requirements:
• Fan
• Cooling coil
• Mounted oil supply system with air-oil cooler

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3.7 Cooling

• Mounted oil supply system with water-oil cooler

• Separate oil supply system
When installing the gear unit, make sure that unhindered convection across the housing surface
is possible in order to protect the gear unit against overheating.

3.7.1 Fan

Principle of operation
Generally, the fan is mounted on the high-speed shaft of the gear unit and is protected from
accidental contact using an air guide cover. The fan draws in air through the protective grille of
the air guide cover and blows it along the lateral air ducts on the gear unit housing. The fan
dissipates a certain amount of heat from the housing.
Improper use can damage the gear unit. Follow the instructions given below in order to protect
the gear unit against overheating:
• When you install the protective device for the coupling or similar on gear units that are
equipped with a fan, make sure that you leave sufficient clearance for cooling air to be drawn
into the fan.
The required clearance is specified in the dimension drawing in the complete documentation
for the gear unit.
• Make sure that the air guide cover is correctly fastened.
• Protect the air guide cover against damage by external components.
• Make sure that there is no contact between the fan and the air guide cover.
• Note that the cooling effect can be significantly impaired if the fan is dirty or if the surface of
the housing is covered with dust or contaminants that act as an insulating layer.
Clean the fan and the gear unit. Observe the cleaning information in chapter Cleaning the fan
and gear unit (Page 95).

3.7.2 Cooling coil

Introduction
The gear unit can be equipped with a cooling coil in the oil sump. The cooling coil is connected
to a cooling water supply. The cooling water connection must be provided by the operator. The
cooling water can be fresh water, sea water or brackish water.

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Description
3.7 Cooling

Principle of operation
Heat from the gear unit oil is transferred to the cooling water as it flows through the cooling coil.

Note
To prevent the formation of condensation, make sure that the cooling coil is fully immersed in
the oil.

Improper use can damage the cooling coil. Be sure to take the following precautions:
• Make sure that the cooling water pressure does not exceed 8 bar.
The direction of water flow through the gear unit is optional.
• Make sure that the ends of the cooling coil are not twisted and that the reducer screws are
not removed.
• If there is a risk of freezing temperatures, drain the cooling water out of the coil and blow the
coil out with compressed air to remove any water residue.
• Use a suitable cooling water flow regulator (e.g. a pressure reducing valve or an appropriate
isolation valve) in order to prevent excessive water pressure at the cooling water inlet.

WARNING
Risk of eye injury from compressed air
Water residue and dirt particles can cause damage to eyes.
Wear suitable safety goggles.

Further information
For further information and a detailed illustration of the gear unit and the connection
dimensions, please refer to the dimension drawings in the complete gear unit documentation.
The required cooling water flow rate and the maximum permissible inlet temperature can be
found in the separate data sheet, the list of equipment or the dimension drawing in the complete
documentation for the gear unit.

3.7.3 Mounted oil supply system

3.7.3.1 Mounted oil supply system with air-oil cooler

Introduction
Depending on the order specification, an oil supply system with air-oil cooler can be used. This
oil cooling system is mounted on the gear unit.

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3.7 Cooling

Principle of operation
The air-oil cooler is used to cool the gear unit oil; the ambient air is used as coolant. The oil is fed
through the cooler in one or several channels, depending on the volume flow, while passing by
the ambient air blown through the cooler by the fan. For cold starts, a bypass pipe with a
temperature-controlled valve is provided.
A mounted oil supply system with air-oil cooler can include the following components:
• Air-oil cooler
• Flange pump
• Oil filter (double change-over filter or coarse filter)
• Pressure monitor
• Temperature control valve
• Piping

Note
Observe the flow direction of the pump
When connecting the valves, observe the flow direction of the pump.
Refer to the pump operating instructions in the complete gear unit documentation to ascertain
whether the flow direction of the pump used depends on the direction of rotation.

Improper use can damage the gear unit. Follow the instructions given below in order to protect
the gear unit against overheating:
• When installing a gear unit with mounted air-oil cooler, carefully ensure that air can freely
circulate.
The necessary minimum clearance to adjacent components such as walls and panels is
specified in the dimension drawing in the complete gear unit documentation.
• Please note that the cooling effect is considerably reduced as a result of a dirty air-oil cooler
or the insulating effect of dirt or pollution on the housing surface.
Clean the air-oil cooler and the gear unit. Cleaning information is provided in
chapter Cleaning the fan and gear unit (Page 95).

Further information
Additional information such as connection dimensions and a detailed illustrated description of
the gear unit and the oil supply system with air-oil cooler can be found in the dimension drawing
in the complete gear unit documentation.
Additional information about the oil supply system and control notes can be found in the
separate data sheet, in the list of equipment and in the oil supply system operating instructions
provided in the complete gear unit documentation.

Temperature control valve

A temperature control valve is installed in the air-oil cooler bypass.

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3.7 Cooling

Principle of operation
At a preset temperature, the temperature control valve starts to open and some oil flows through
the oil cooler; when a second preset temperature is reached, then all of the oil flows through the
oil cooler.

Further information
You can find additional information on the temperature control valve in the temperature control
valve operating instructions provided in the complete gear unit documentation.
You can find additional technical data in the separate data sheet and in the list of equipment
provided in the complete gear unit documentation.

3.7.3.2 Mounted oil supply system with water-oil cooler

Introduction
Depending on the order specification, an oil supply system with water-oil cooler can be used.
This oil cooling system is mounted on the gear unit.

Principle of operation
The water-oil cooler is used to cool the gear unit oil; water is used as coolant.
For certain applications, a motor pump can be used instead of a flange pump.
A mounted oil supply system with water-oil cooler can include the following components:
• Water-oil cooler
• Flange pump
• Oil filter (double change-over filter)
• Pressure monitor
• Piping
The operating company must establish the cooling water connection required.

Note
Observe the flow direction of the pump
When connecting the valves, observe the flow direction of the pump.
Refer to the pump operating instructions in the complete gear unit documentation to ascertain
whether the flow direction of the pump used depends on the direction of rotation.

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3.7 Cooling

Improper use can damage the gear unit. Be sure to take the following precautions:
• Ensure that the cooling water pressure is a maximum of 8 bar.
• Maintain the specified flow direction of the water-oil cooler so that an optimum cooling
power is achieved. Do not interchange the cooling water intake and outlet.
• If there is a risk of freezing temperatures, drain the cooling water out of the coil and blow the
coil out with compressed air to remove any water residue.

WARNING
Risk of eye injury from compressed air
Water residue and dirt particles can cause damage to eyes.
Wear suitable safety goggles.

Further information
Additional information such as connection dimensions and a detailed illustrated description of
the gear unit and the oil supply system with water-oil cooler can be found in the dimension
drawing in the complete gear unit documentation.
Additional information about the oil supply system, control notes, the required cooling water
quantity and the maximum permissible water intake temperature can be found in the separate
data sheet, in the list of equipment and in the oil supply system operating instructions provided
in the complete gear unit documentation.

3.7.3.3 Pump

Requirements placed on the medium being pumped

The pump being used is suitable for pumping lubricating oil. It is not permissible that the oil
contains abrasive components and must not chemically attack the materials used in the pump.
Clean oil with good lubricating properties is a precondition for ensuring the correct function,
high operational reliability and long service life of the pump.

3.7.3.4 Oil filter

Introduction
The oil filter protects downstream units, measuring and control devices against dirt and
pollution.

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Description
3.8 Backstop

Principle of operation
The oil filter comprises a housing with connections and a filter cartridge. The medium flows
through the filter housing, where, depending on the filter gauge, most of the dirt particles larger
than a defined size in the oil are filtered out. Dirty filter cartridges must be cleaned or replaced.

3.7.4 Separate oil supply system

A separate oil supply system can be used for cooling the oil.

Further information
Further information about separate oil supply systems can be found in the oil supply system
operating instructions in the complete documentation for the gear unit.
You can find additional information about the components of the oil supply system in the
operating instructions for the components in the complete gear unit documentation.
You can find additional technical data in the separate data sheet and in the equipment list in the
complete gear unit documentation.

3.8 Backstop

Introduction
For some requirements, the gear unit can be equipped with a mechanical backstop. In
operation, the backstop only permits the specified direction of rotation. The direction of rotation
is specified at the gear unit input ‐ and ‐ output using an arrow.
The backstop is mounted to the gear unit through an intermediate flange creating an oil tight
seal; the backstop is integrated in the gear unit oil circuit.

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3.8 Backstop

Principle of operation
The backstop is fitted with centrifugally-operated sprags. If the gear unit rotates in the specified
direction, the inner ring rotates together with the sprag cage in the direction of rotation of the
shaft, while the outer ring remains stationary. Above a certain speed (disengagement speed)
the sprags disengage from the outer ring. In this operating state, the backstop operates without
any wear.

NOTICE
Damage to the backstop as a result of increased wear for operation below
disengagement speeds
Damage to the backstop as a result of increased wear for operation below disengagement
speeds is possible.
Regularly replace the backstop when operating the gear unit with speeds below the
disengagement speed of the backstop. Data indicating the replacement intervals is provided in
the dimension drawing and on a plate attached to the gear unit. This plate is attached to the
gear unit housing close to the backstop.

The diagram below shows a backstop:

   

 

① Cover ④ Shaft
② Outer ring ⑤ Cage with sprags
③ Inner ring ⑥ Residual oil drain
Figure 3-6 Backstop

Before connecting the motor, identify the phase sequence of the three-phase mains using a
phase sequence instrument. Connect the motor corresponding to the defined direction of
rotation.

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3.10 Shrink disk

The blocking direction of the backstop can be changed by turning over the cage. You must
always contact Flender in advance if you wish to change the blocking direction.

NOTICE
Damage to the backstop and gear unit due incorrect direction of rotation
Damage to the backstop and gear unit due incorrect direction of rotation possible.
Do not operate the motor adversely to the blocking direction of the gear unit. Observe the note
attached to the gear unit.

3.9 Couplings

Flexible couplings or safety couplings are generally used at the input end of the gear unit.
Use of rigid couplings or other input or output elements that generate additional radial or axial
forces (e.g. gear wheels, belt pulleys, flywheels or hydraulic couplings) must be agreed
contractually.

Further information
You can find additional information about the couplings in the coupling operating instructions
provided in the complete gear unit documentation.

3.10 Shrink disk

A shrink disk is provided as a frictional clamping connection between the gear unit hollow shaft
and the driven machine on shaft-mounted gear units.
The shrink disk allows an interference fit to be created between a hollow shaft and a stub shaft
(machine shaft), referred to hereafter as "stub shaft". The interference fit is capable of
transferring torques, bending moments and forces. Crucial to the successful transmission of
torques and/or power is the joint pressure between the hollow and stub shafts generated by the
shrink disk.

Further information
Further information about the shrink disk can be found in the shrink disk operating instructions.
These are included in the complete documentation for the gear unit.

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3.11 Heating

3.11 Heating

Introduction
At low ambient temperatures it may be necessary to preheat the gear unit oil before switching
on the drive or while it is in operation.

Heating elements
Heating elements can be used for these applications, for example. Heating elements convert
electricity into heat and transfer this to the oil in which they are immersed. The heating elements
are installed in protective tubes in the housing so that they can be replaced without draining off
the oil first.
Complete immersion of the heating elements in the oil bath must be ensured by adhering to the
installation position in accordance with the dimension drawings in the complete
documentation and the oil level.

WARNING
Fire hazard
Exposed heating elements pose a fire hazard.
Do not switch on the heating elements unless you have checked that they are completely
immersed in the oil bath.
If heating elements are retrofitted, the heat output at the outer surface of the heating element
must not exceed the maximum values stated in the table below.

The following table contains information about the specific heat output PHO as a function of
ambient temperature:

Table 3-1 Information about the specific heat output

PHO in W/cm2 Ambient temperature in °C

0.9 10 to 0
0.8 0 to -25
0.7 -25 to -50

Control of the heating elements

Heating elements can be controlled by a temperature monitor. The temperature monitor
provides a signal to be amplified when the minimum and maximum temperatures are reached.

Further information
You will find further information on the position of the mounted components and a detailed
illustrated description of the gear unit in the dimension drawing.

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Description
3.13 Oil level monitoring system

You will find further information on the heating in the separate data sheet, in the list of
equipment or in the heating operating instructions, which are part of the complete
documentation of the gear unit.
You will find information on the temperature monitor (such as control information) in the
temperature monitor operating instructions, which are part of the complete documentation of
the gear unit.

3.12 Oil level indicator

The following components for visual monitoring of the oil level can be mounted on the gear unit:
• Oil sight glass
• Oil level indicator
• Oil dipstick
If several components for checking the oil level are mounted on the gear unit, the dipstick should
be regarded as the most reliable.
Check the oil level when the gear unit is stationary and with the oil in a cool state.

Further information
Further information about the oil level indicator and checking the oil can be found in the
operating instructions BA 7300 in the complete documentation for the gear unit.
Further information and a detailed illustration of the gear unit and the position of the mounted
components can be found in the dimension drawing in the complete documentation for the
gear unit.

3.13 Oil level monitoring system

Introduction
Depending on the order specification, the gear unit can be equipped with an oil-level monitoring
system using a filling-level limit switch.
The oil-level monitoring system has been designed to check the oil level when the gear unit is
at a standstill before it starts.

Mounting position
When using an oil-level monitoring system it is especially important to ensure that the gear unit
is in a horizontal mounting position.

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3.15 Bearing monitoring

Further information
Further information and a detailed illustration of the gear unit and the position of the mounted
components can be found in the dimension drawing in the complete documentation for the
gear unit.
Further information about oil level monitoring, control instructions and the technical data can
be found in the operating instructions for the oil level monitor, in the list of equipment and in the
separate data sheet in the complete documentation for the gear unit.

3.14 Oil temperature monitoring

Depending on the order specification, the gear unit can be fitted with a Pt 100 resistance
thermometer for measuring the oil temperature in the oil sump.
To measure temperatures or temperature differences, connect the Pt 100 resistance
thermometer to an evaluation unit (to be supplied by the customer). The resistance
thermometer is fitted with a connector head for the wiring. A two-wire circuit is provided from
the factory, but the customer can also install a three- or four-wire circuit.

Further information
Further information and a detailed illustration of the gear unit and the position of the mounted
components can be found in the dimension drawing in the complete documentation for the
gear unit.
Further information about oil temperature monitoring (such as control instructions) and the
technical data can be found in the operating instructions for the oil temperature monitor and in
the list of equipment in the complete documentation for the gear unit.

3.15 Bearing monitoring

3.15.1 Bearing monitoring using a Pt 100 resistance thermometer

Depending on the order specification, the gear unit can be equipped with Pt 100 resistance
thermometers to monitor the bearings.
You must connect the Pt 100 resistance thermometer to an evaluation unit provided by the
customer to be able to measure temperatures or temperature differences. The resistance
thermometer has a connection head for the wiring. A two-wire circuit is provided in the factory.
However, customers can also configure a three or four-wire circuit.

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Description
3.15 Bearing monitoring

The following diagram shows bearing monitoring using a Pt 100 resistance thermometer:

  

① Pt 100 resistance thermometer

Figure 3-7 Bearing monitoring using a Pt 100 resistance thermometer

Further information
Additional information and a detailed illustrated description of the gear unit can be found in the
dimension drawing provided in the complete gear unit documentation.
Further information about bearing monitoring using a Pt 100 resistance thermometer (such as
control instructions) and the technical data can be found in the operating instructions for the Pt
100 resistance thermometer and in the list of equipment in the complete documentation for the
gear unit.

3.15.2 Bearing monitoring by acceleration sensor

Depending on the order specification, the gear unit can be supplied with threaded holes in which
acceleration sensors can be inserted. These threaded holes have an M6 or M8 thread depending
on the variant.

  

① Shock-pulse transducer
Figure 3-8 Bearing monitoring using a shock-pulse transducer

The following diagram shows the complete acceleration sensor (A) and the threaded connector
(B):

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3.16 Auxiliary drive

š

 
0





r




%

0

① Shielded cable (oil-proof) ④ Sensitivity specification

② MIL-spec connector ⑤ Set screw
③ Acceleration sensor
Figure 3-9 Complete acceleration sensor ("A") and threaded connector ("B")

Further information
Further information and a detailed illustration of the gear unit with attached sensors can be
found in the dimension drawing in the complete documentation for the gear unit.
Further information about the sensors can be found in the operating instructions for the sensors.

3.16 Auxiliary drive

For specific applications, the gear unit can be equipped with an auxiliary drive. The auxiliary
drive enables the main gear unit to be operated at a lower output speed in the same direction
of rotation. Either Flender or the customer provides the auxiliary drive. The auxiliary drive is
connected to the main gear unit through an overrunning clutch. The auxiliary drive is mounted
onto a connection flange, which in turn is attached to the main gear unit. The overrunning
clutch is located in a separate oil space. The auxiliary drive has its own oil circuit, which is
separate from that of the main gear unit.
Before connecting the motor, identify the phase sequence of the three-phase mains using a
phase sequence instrument. Then connect the motor so that it rotates in the defined direction.
Observe the note attached to the gear unit.

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Description
3.16 Auxiliary drive

The basic configuration of the gear unit with main and auxiliary drive is shown in the following
diagram.










① Main gear unit ⑤ Main motor

② Output shaft of the main gear unit ⑥ Auxiliary motor
③ Backstop ⑦ Auxiliary gear unit
④Coupling ⑧ Overrunning clutch
Figure 3-10 Gear unit with main and auxiliary drive

Depending on the particular application, two auxiliary drives with two different ratings are
available for each gear unit size.

Further information
You can find further information, a detailed illustration of the gear unit and the position of the
auxiliary drive in the dimension drawing in the complete gear unit documentation.

3.16.1 Overrunning clutch

If, in addition to the main drive, you couple an auxiliary drive to the gear unit, then this coupling
is realised using an overrunning clutch.
When the auxiliary drive is used to drive the gear unit, the overrunning clutch allows torque to
be transferred in one direction of rotation, while "free-wheeling operation" applies when driven
by the main drive.
The output shaft of the main drive rotates in the same direction of rotation, irrespective of
whether the main drive is used or the auxiliary drive.

Principle of operation
The overrunning clutch as centrifugally-operated sprags. When the main gear unit rotates with
the specified direction of rotation, the inner ring with the sprags rotates, while the outer ring
remains stationary. Above a certain speed the sprags disengage, and the overrunning clutch
operates without any wear.
When the auxiliary unit drive motor is used as drive via the outer ring, then the overrunning
clutch is also driven; this means that the main gear unit is slowly rotated in the selected direction

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3.16 Auxiliary drive

of rotation. In this case, the input shaft of the main gear unit and the main motor simultaneously
also slowly rotate when a flexible coupling is used between the main motor and gear unit.

Note
Electrically interlock the main motor and the auxiliary drive motor so that only one of the two
motors can be switched on.

Note
When driven by the auxiliary drive, then the input shaft of the main gear unit also slowly rotates.
It is not permissible that this rotary motion is prevented. A brake located on the drive side in the
main drive must be opened when driven by the auxiliary drive.

Oil supply for the overrunning clutch

The overrunning clutch is located in an intermediate flange and has a separate oil space. When
the main gear unit is serviced and its oil changed, then the overrunning clutch is also serviced
and its oil changed at the same time.

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3.16 Auxiliary drive

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Application planning 4
4.1 Scope of delivery
The scope of delivery is listed in the shipping documents. Immediately upon receiving the
gearbox, check that everything has been delivered. Report any damaged and/or missing parts
to Customer Services (Page 105) immediately.

WARNING
Serious injury through defective product
Serious injury may occur.
If the gearbox exhibits any visible damage, you should not put it into operation.

4.2 Transport

General information
The gear unit is delivered fully assembled. Additional items such as shrink disks, couplings, oil
coolers, pipework and valves may be delivered separately packaged, as necessary.
When transporting the gear unit, observe the following instructions to avoid damaging the gear
unit:
• Transport the gear unit only by suitable means of transport.
• Transport the gear unit without an oil filling and leave the gear unit on the transport
packaging.
• Do not use incorrect attachment points.
The threads in the front shaft ends must not be used for attaching lifting equipment.
• Do not use the pipes for moving the gear unit.
• Ensure that the lifting equipment is able to bear the weight of the gear unit plus a safety
margin.

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Application planning
4.2 Transport

WARNING
Risk of crushing
There is a risk of being crushed by the transported component if the lifting equipment and load
suspension devices used are not suitable and the component becomes detached.
When attaching the load, observe the load distribution information on the packaging.
Transport the product slowly and carefully in the lifted condition to avoid personal injury and
damage to the gear unit.

Attaching the load

For transport, only attach the the gear unit at the identified attachment points intended for this
purpose.
Ensure the following measures are taken when attaching, lifting, lowering and moving the load:
• Keep within the load limits
• If you are using a load suspension device with several load hooks, make sure that the load is
evenly distributed between them
• Be aware that the centre of gravity is not in the centre
• Ensure that load suspension devices are correctly secured
• Move the equipment slowly
• Load sway and attachment of the load to objects or parts of buildings is not permissible
• Load hooks must not be loaded at their tip
• Only set down products on a flat, non-slip and strong base

DANGER
Falling load
A danger to life is posed by a falling load due to incorrect attachment.
Do not stand under suspended loads. Keep within the load limits.

Packaging
The gear unit is delivered fully assembled. Additional equipment is also delivered separately
packaged, as necessary.
The gear unit may be packed in various forms, depending on the size of the unit and method of
transport.
Please pay attention to the symbols applied on the packaging.

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4.3 Attachment points

7KLVZD\XS )UDJLOH .HHS .HHS &HQWUHRI 'RQRW $WWDFKKHUH

 GU\ FRRO JUDYLW\ XVHKDQGKRRNV
Figure 4-1 Transport symbols

4.3 Attachment points

Lifting eyes
Lifting eyes are fitted to the gear unit to assist with its transportation during manufacture and
installation.
Carefully ensure that the angle of the vertical load at the gear units lifting eyes does not exceed
45°.

Sling swivels
Gear units have threaded holes to specifically attach lifting eyes so that they can be transported
during assembly.
When the load is attached at sling swivels, the diagonal pull must not be at a greater angle than
45°.

Note
Damage to the gear unit during transport
If incorrect attachment points are used, gear units can be damaged when they are transported.

Eye bolts
The use of sling swivels instead of eye bolts is generally recommended.
When using eye bolts, please note that their load-bearing capacity may be reduced if they are
alternately attached to different components that require moving.
It is not permitted to load eye bolts through lateral pulling contrary to the direction of the eye
plane.
The following figure shows the permissible shear and lateral pulling when using eye bolts:

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r r

$ %

A Permitted shear pulling in direction of eye plane (maximum angle of 45°)

B Non-permitted lateral pulling contrary to direction of eye plane
Figure 4-2 Shear and lateral pulling when using eye bolts

Position of attachment points

The diagram below shows the position of the attachment points on type S.N ≤ 280 and K.N ≤ 280
gear units:

 

① S.N ≤ 280 ② K.N ≤ 280

Figure 4-3 Position of the attachment points, at type S.N ≤ 280 and K.N ≤ 280 gear units

The diagram below shows the position of the attachment points on type S.N ≥ 280 and K.N ≥ 280
gear units:

 

① S.N ≥ 280 ② K.N ≥ 280

Figure 4-4 Position of the attachment points, at type S.N ≥ 280 and K.N ≥ 280 gear units

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4.4 Special aspects of gear unit lubrication and preservation

Drive units with additional components mounted on the gear unit (such as drive motor,
coupling, etc.) may require an extra attachment point owing to the displacement in the centre
of gravity caused by the mounted components.

Further information
You will find further information and a detailed illustration of the gear unit, the position of the
attachment points and the centre of gravity in the drawings, which are part of the complete
documentation of the gear unit.

4.4 Special aspects of gear unit lubrication and preservation

4.4.1 Oil filling and oil drain

The diagram below shows the oil filling points and the oil draining points on type S.N gear units:

  

① Housing ventilation and bleeding ④ Oil drain screw

② Inspection and/or assembly cover ⑤ Oil filling point
③ Oil dipstick
Figure 4-5 Oil filling and oil drain for gear units, type S.N

The diagram below shows the oil filling points and the oil draining points on type K.N gear units:

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4.4 Special aspects of gear unit lubrication and preservation

  

① Inspection and/or assembly cover ④ Oil drain screw

② Housing ventilation and bleeding ⑤ Oil filling point
③ Oil dipstick
Figure 4-6 Oil filling and oil drain for gear units, type K.N

Further information
Additional information and a detailed illustrated description of the gear unit can be found in the
dimension drawing provided in the complete gear unit documentation.

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5.1 General assembly instructions
The assembly work must be performed very carefully by authorised, trained and suitably
instructed personnel. Liability will be disclaimed for damage caused by the incorrect
performance of this work.

Requirements
Improper use can damage the gear unit. Be sure to take the following precautions:
• Protect the gear unit against falling objects and from becoming covered over.
• Do not perform any welding work anywhere on the drive.
• Do not use the gear unit as an earthing point for electric-welding operations.
• Use all of the fastening points fitted to the particular unit design.
• Replace any bolts that are no longer fit for use by new bolts of the same strength class and
type.
• Make sure that sufficient hoisting gear is available.

Mounting position and attachment points

During the actual planning phase, be sure to allow for sufficient space around the gear unit to
enable subsequent upkeep and maintenance work. Take suitable measures to ensure that
unhindered convection across the housing surface is possible so that the gear unit does not
overheat. Leave sufficient space to allow a free flow of air into gear units that are equipped with
a fan.
Do not use incorrect attachment points (Page 43). The position of the attachment points are
shown in the dimension drawing in the complete documentation for the gear unit. To ensure
that the unit is properly lubricated during operation, please observe the mounting position
specified in the dimension drawings.

NOTICE
Heating of the gear unit by external heat sources
The gear unit must not be heated by external heat sources (exposure to direct sunlight, for
example) while it is in operation and measures must be taken where necessary to protect it.
You can take the following measures to protect the gear unit against this hazard:
• A sun shield
• An additional cooling device
• A temperature monitoring device with trip function in the oil sump

If you use a sun shield, this may cause a build-up of heat.

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If you use a temperature monitoring device, it must be capable of issuing an alarm when the
maximum permissible oil sump temperature is reached. It must also be capable of tripping the
drive when the maximum permissible oil sump temperature is exceeded. The operator's process
might be interrupted when the drive is shut down.

WARNING
Ignition of vapours emitted from solvents.
There is a risk of injury due to ignition of vapours emitted from solvents when carrying out
cleaning work.
Please note the following:
• Ensure adequate ventilation.
• Do not smoke.

5.2 Unpacking the gear unit

Introduction
The scope of delivery is listed in the shipping documents.

WARNING
Risk of serious injury due to defective product
A defective gear unit can result in serious injury.
Do not put the gear unit into operation if any damage is visible.
Contact Customer Services (Page 105).

Requirements
Check that everything has been delivered immediately upon receipt.

NOTICE
Damage to the gear unit due to corrosion
Exposing the gear unit to moisture can result in damage from corrosion.
Do not damage or open the packaging prematurely if the packaging is designed to preserve the
unit.

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Procedure
To unpack and use the gear unit, proceed as follows:
1. Remove packaging and transport devices in accordance with regulations.
2. Perform a visual inspection for damage and accumulations of dirt.
3. Immediately report any damaged and/or missing parts to Customer Services (Page 105).
4. Dispose of packaging material and transport devices in accordance with regulations.

5.3 Gear unit mounting

5.3.1 Foundation

Properties of the foundation

The foundation must have the following properties:
• Horizontal and level
• Stability
• Designed for torsional rigidity
• Reaction forces from the gear unit must be braced

Requirements of the foundation

The foundation must meet the following requirements:
• Construct the foundation in such a way that it does not generate any resonance vibrations
and that it is isolated against the transmission of vibrations from adjacent foundations.
• Design the foundation according to the relevant weight and torque, taking into account the
forces acting on the gear unit.
• Align the foundation carefully with the equipment installed on the input and output sides of
the gear unit.
• Take into account any elastic deformation that may be caused by operating forces.
• Install lateral stops to prevent displacement if external forces are acting on the gear unit.

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NOTICE
Lack of stable foundation for the gear unit
Damage to the gear unit is possible if it is not mounted on a stable foundation.
Use bolts of at least strength class 8.8. Information and guidance on the tightening torque can
be found in chapter Tightening procedure (Page 78). Tighten the fastening bolts and nuts to
the specified tightening torque. When tightening the fastening bolts, make sure that the gear
unit is free of mechanical stress.

Further information
Further information about dimensions, space requirements and arrangement of supply
connections can be found in the complete documentation for the gear unit.

5.3.2 Description of assembly work

Measures to be taken prior to assembly

CAUTION
Risk of chemical burns due to chemical substances
There is a risk of chemical burns when handling aggressive cleaning agents.
Please observe the manufacturer's guidelines on how to handle cleaning agents and solvents.
Wear suitable protective equipment (gloves, safety goggles). Please use binding agents to
immediately clear up any spilt solvent.

WARNING
Risk of burns
There is a risk of serious burn injury from hot surfaces (> 55 °C).
Wear suitable protective gloves and protective clothing.

Improper use can damage the gear unit. Be sure to take the following precautions:
• Use a suitable cleaning agent to remove the corrosion protection from the shafts.
• Do not allow the cleaning agent to come into contact with the shaft-sealing rings.
• Mount the input elements (e.g. coupling parts) on the shafts and lock them securely.
• If these input elements must be fitted hot, the joining temperatures required are listed in the
dimension drawings in the coupling operating instructions.

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• Unless otherwise specified, heat the coupling parts by an induction heater, with a torch or in
an oven.
• The elements must be quickly pulled onto the shaft as far as stated in the dimension drawing
prepared in accordance with order specifications.

NOTICE
Risk of damage to shaft sealing rings due to heat
Shaft sealing rings can be damaged if they are heated up to over 100 °C.
Use the appropriate heat shields to protect against radiant heat.

NOTICE
Damage as a result of blows or impact
Damage in the gear unit as a result of blows or impact as possible.
Pull on the coupling using the appropriate pulling equipment.
Avoid damaging the shaft sealing rings and the shaft running surfaces when fitting coupling
parts.

NOTICE
Poor alignment
The gear unit or individual components can be damaged as a result of poor alignment.
When installing and mounting the drive ensure that the individual components are precisely
aligned with one another.
Inadmissibly high alignment errors of the shaft ends to be connected as a result of angular or
axial offset result in premature wear and material damage.
Base frames or substructures that are too soft can cause the coupling parts to become radially
and/or axially displaced during operation. This displacement is not measurable when the drive
is at a standstill.

Further information
Further information about removing the corrosion protection can be found in the operating
instructions BA 7300 in the complete documentation for the gear unit.
Additional information on how gear units should be attached which, as a result of their weight,
require a crane or lifting gear, is provided in chapter Application planning (Page 43).
If the gear unit is transported with mounted parts and components, then it may be necessary to
use additional attachment points. The position of these attachment points can be found in the
order-specific dimension drawing in the complete documentation for the gear unit.

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5.3.2.1 Alignment

Introduction
Depending on the order specification, the top of the housing has machined surfaces (alignment
surfaces) to assist with provisional alignment of the gear unit in the horizontal direction.

DANGER
Risk of fatal injury from flying fragments
Failure to align the unit with the required degree of accuracy can cause the shaft to rupture. A
ruptured shaft can result in serious or even fatal injuries.
Align the gear unit exactly so that it conforms to the specified alignment values.
Damage to the gear unit or its components or mounted parts is possible.
The accuracy of the alignment between the shaft axes largely determines the service life of the
shafts, bearings and couplings. Please therefore always endeavour to achieve zero deviation in
the alignment of the shaft axes (does not apply to ZAPEX couplings). In this context, please also
refer to the relevant operating instructions for further information about, for example, the
requirements of couplings.

Procedure
The gear unit can be equipped with alignment threads in the housing feet to make it simpler to
align.

Figure 5-1 Alignment surface

To align the gear unit by its alignment surface, proceed as follows:

1. For the precise position of the alignment surfaces, refer to the dimension drawings in the
complete documentation.
2. Note the values inscribed in the alignment surfaces.
3. Use these surfaces as a guide for aligning the gear unit horizontally to ensure that it will run
smoothly.

Further information
Further information and the precise position of the alignment thread are provided in the
dimension drawing in the overall gear unit documentation.

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Tools
The following tools are needed to perform the final fine alignment (Page 70) work on the shaft
axes of the gear unit and the equipment installed on the input and output sides.
• Rulers
• Spirit level
• Dial gauge
• Laser alignment system
• Feeler gauge etc.
Once the gear unit is finely aligned, tighten the foundation bolts and check the settings again.
Record the alignment dimensions and keep the report in a safe place together with these
operating instructions.

5.3.3 Mounting the gear unit on the housing foot

5.3.3.1 Installation on a foundation frame

Requirements
The following requirements must be fulfilled before the assembly work commences:
• The foundation must be horizontal and level.
• When tightening the fastening bolts, make sure that the gear unit is free of mechanical
stress.

NOTICE
Poor stability
Damage to the gear unit is possible if it is not mounted on a stable foundation.
Make sure that the foundation frame is horizontal and level. It is particularly important that the
surface on which the gear unit is mounted is level because this determines the contact pattern
of the teeth and the load on the bearings, and so has an influence on the service life of the gear
unit. All points on the gear unit mounting surface must lie between two imaginary parallel
planes that are 0.1 mm per 1 m apart.
Design the foundation frame according to the relevant weight and torque, taking into account
the forces acting on the gear unit. The feet of the gear unit must be properly supported. Base
frames or substructures that are too soft can result in radial or axial displacement during
operation. This displacement is not measurable when the drive is at a standstill.

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Procedure
To install the gear unit on a foundation frame, proceed as follows:
1. Clean the underside of the gear unit feet.
2. Use suitable hoisting gear to set the gear unit down on the foundation frame.
3. Tighten the foundation bolts to the specified tightening torque (Page 78). If necessary,
install stops to prevent displacement.
4. Align the gear unit precisely with the input and output equipment (Page 54).
5. Record the alignment dimensions.
6. Keep the report in a safe place together with these operating instructions.

NOTICE
Damage caused by unevenly tightening the fastening bolts
The gear unit can be damaged by unevenly tightening the fastening bolts.
Evenly tighten the fastening bolts. When tightening the fastening bolts, make sure that the
gear unit is free of mechanical stress.

5.3.3.2 Mounting on a concrete foundation using stone bolts or foundation blocks

Requirements
The lower side of the gear unit mounting feet must be clean.

Mounting a gear unit using stone bolts

The following diagram shows a stone bolt:

 





① Washer ④ Foundation
② Hexagon nut ⑤ Stone bolt
③ Gear unit foot
Figure 5-2 Stone bolt

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Proceed as follows to mount the gear unit using stone bolts:

1. Attach the stone bolts with washers and hexagon nuts in the foundation mounting points in
the gear unit housing.
2. Using a suitable crane or lifting gear, place the gear unit down on the concrete foundation.
3. Align the gear unit so that the input and output shafts are horizontal using shims (Page 54).
4. For higher external forces, if necessary, use lateral stops to prevent the gear unit shifting.
5. Pour concrete into the recesses in the concrete foundation for the stone bolts.
6. After the concrete has set, tighten the hexagon nuts of the stone bolts with the
specified tightening torque (Page 78).
7. Record the alignment dimensions and keep the report in a safe place together with these
operating instructions.

NOTICE
Damage caused by unevenly tightening the hexagon nuts
The gear unit can be damaged by unevenly tightening the hexagon nuts.
Evenly tighten the hexagon nuts. Ensure that the gear unit is not deformed or distorted when
tightening the fastening bolts.

Mounting gear units using foundation blocks

The following diagram shows a foundation block:

 







① Fastening bolt ⑥ Foundation

② Washer ⑦ Foundation block
③ Gear unit foot ⑧ Flat steel plate
④ Height of the completed foundation ⑨ Set screw
⑤ Height of the prepared foundation
Figure 5-3 Foundation block

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Proceed as follows to mount the gear unit using foundation blocks:

1. Attach the foundation blocks with washers and fastening bolts in the foundation mounting
points in the gear unit housing.
2. Tighten the fastening bolts until the housing feet are lying flat on the foundation blocks.
3. Using a suitable crane or lifting gear, place the gear unit down on the concrete foundation.
4. Align the gear unit so that the input and output shafts are horizontal using the set screws (if
available) (Page 54).
5. For higher external forces, if necessary, use lateral stops to prevent the gear unit shifting.
6. Before casting the foundation, close the openings in the foundation blocks using a suitable
material (e.g. using polystyrene).
7. Pour concrete into the recesses in the concrete foundation for the foundation blocks.
8. After the concrete has set, tighten the fastening bolts of the foundation blocks with the
specified tightening torque (Page 78).
9. Record the alignment dimensions and keep the report in a safe place together with these
operating instructions.

NOTICE
Damage caused by unevenly tightening the fastening bolts
The gear unit can be damaged by unevenly tightening the fastening bolts.
Evenly tighten the fastening bolts. Ensure that the gear unit is not deformed or distorted when
tightening the fastening bolts.

5.3.3.3 Mounting on a concrete foundation using anchor bolts

Requirements
The lower side of the gear unit mounting feet must be clean.

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Inserting the anchor bolt

The following diagram shows the inserted anchor bolt:

  

 

① Baseplate ⑤ Anchor bolt

② Support ⑥ Pressure plate
③ Fine-grout concrete ⑦ Wood
④ Raw foundation ⑧ Hexagon nut
Figure 5-4 Inserted anchor bolt

Proceed as follows to insert the anchor bolt:

1. Place the support on the baseplate embedded in the fine-grout concrete.
2. Insert the anchor bolt.
3. Attach the pressure plate and tighten the nuts.
4. Place a piece of wood under the anchor bolt so that it is approximately 10 mm from the upper
edge of the support.
5. Using suitable lifting gear, set the gear unit down in position.

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Mounting the gear unit using anchor bolts

The following diagram shows a tightened anchor bolt:

 

 




① Hexagon nut ⑤ Raw foundation

② Washer ⑥ Anchor bolt
③ Housing foot ⑦ Baseplate
④ Fine-grout concrete ⑧ Support
Figure 5-5 Tightened anchor bolt

Proceed as follows to mount the gear unit using anchor bolts:

1. Pull the anchor bolts upwards. To do this you can use a screw or threaded bar that you screw
into the thread on the end face.
2. Attach the washer.
3. Screw on the hexagon nut by hand a few turns.
4. Align the gear unit with the supports (Page 54).
– Observe the values on the alignment strips.
– Maintain the alignment tolerances to the units connected at the input and output
according to the permissible angular and axial displacements of the couplings.
5. Document the alignment dimensions in the form of a report, and archive this together with
these instructions.
6. Keep the anchor bolts in their position by tightening the nuts by hand.
7. Locate the protective sleeve.
8. Attach the hydraulic clamping device.
9. Tighten the screws alternating, taking into account the preload forces (Page 78).
10.Tighten the hexagon nuts to their end stops using a suitable tool.
11.Document the tensioning pressures and preload forces, and archive this report together with
these instructions.

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CAUTION
Incorrect use of the preload tool
Incorrectly using the preload tool can result in injury.
To ensure correct handling and adjustment of the preload tool, you must carefully comply with
the instructions provided in the manufacturers operating instructions for the preload tool.

NOTICE
Inadequate concrete hardness and strength
Damage caused by inadequate stability of the gear unit as a result of inadequate concrete
hardness and strength is possible.
The fine-grout concrete must be allowed to harden for at least 28 days before tensioning the
anchor bolts.

5.3.4 Mounting the gear unit swing base

NOTICE
Damage to the gear unit due to incorrect attachment of the gear unit swing base
The gear unit can be damaged by incorrectly mounting the gear unit swing base.
Mount the gear unit swing base in such a way that it is free of mechanical stress to avoid any
distortion.

Further information
You will find further information on the position of the gear unit swing base in the dimension
drawing, which is part of the overall documentation of the gear unit.

5.3.5 Mounting the torque arm for the gear unit housing

NOTICE
Damage to the gear unit due to incorrect attachment of the torque arm
Incorrect attachment of the torque arm could cause damage to the gear unit.
Mount the torque arm in such a way that it is free of mechanical stress.

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5.4 Shaft-mounted gear unit with hollow shaft and parallel keyway

Further information
Additional information about designing and building a foundation to attach a torque arm can be
found in Chapter AUTOHOTSPOT.

5.4 Shaft-mounted gear unit with hollow shaft and parallel keyway

The shaft end of the driven machine shaft (material C60+N or higher strength) must have a
parallel key as defined by DIN 6885, Part 1, form A. Furthermore, it should have a hole centred
in its end face as defined by DIN 332, form DS (with thread). The connection dimensions for the
driven machine shaft can be found in the dimension drawing in the complete documentation.

View
The following diagram shows a gear unit with hollow shaft and parallel keyway:







① End plate ④ Machine shaft

② Hollow shaft ⑤ Bolts
③ Parallel key
Figure 5-6 Gear unit with a hollow shaft and parallel keyway

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5.4.1 Mounting

5.4.1.1 Introduction

Measures to be taken prior to assembly

CAUTION
Risk of injury due to chemical substances
Observe the manufacturer’s guidelines on how to handle lubricants and solvents.
Wear suitable protective clothing.

Improper use can damage the gear unit. Be sure to take the following precautions:
• Use a suitable cleaning agent to remove the corrosion protection from the hollow shaft and
the machine shaft.
• Inspect the hollow and machine shafts for damaged seats and edges.
• If necessary, rework the components with an appropriate tool and then clean them again.
• Apply an appropriate lubricant to the contact surfaces to protect them against fretting
corrosion.

NOTICE
Risk of damage to shaft sealing rings from cleaning agent
Aggressive chemical cleaning agents may cause damage to shaft sealing rings.
Do not allow the cleaning agent to come into contact with the shaft-sealing rings.

5.4.1.2 Mounting

Procedure

NOTICE
Damage to the gear unit
The gear unit can become damaged if it skews during assembly.
The hollow shaft must be flush with the machine shaft during assembly of the gear unit on the
machine shaft. The gear unit must be prevented from skewing.

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5.4 Shaft-mounted gear unit with hollow shaft and parallel keyway

NOTICE
Damage to the rolling-contact bearings
The rolling-contact bearings can become damaged if the gear unit skews during mounting.
The hollow shaft may be mounted on a machine shaft shoulder only if the gear unit features
one of the following:
• Torque arm
• Supported by gear unit swing base

Proceed as follows to install the gear unit:

1. Use suitable hoisting gear to lift the gear unit.
2. Mount the gear unit using the nut and screw spindle.
The gear unit is supported by the hollow shaft.
The diagram below shows the mounting process with screw spindle for gear units with a hollow
shaft and parallel keyway:










① Bolts ⑤ Nut
② Hollow shaft ⑥ Screw spindle
③ Parallel keyway ⑦ Nut
④ Machine shaft ⑧ Fixture
Figure 5-7 Screw spindle for gear units with hollow shaft and parallel keyway

Special aspects of shaft-mounted gear units with hollow shaft and parallel keyway
Hydraulic pulling equipment can be used instead of the nut and screw spindle shown in the
diagram.

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5.4.1.3 Axial locking

Depending on the version, the hollow shaft must be locked axially on the machine shaft (e.g. by
a locking ring, end plate, adjusting screw).

5.4.2 Dismantling

Measures prior to dismantling

NOTICE
Damage to the gear unit
The gear unit can become damaged if it skews during dismantling.
Do not allow the gear unit to skew as you remove it from the machine shaft. When removing
the gear unit using hydraulic pulling equipment, excessive force can be placed on the housing,
bearings and other gear unit components. Always check the hollow shaft bearings for damage
before reattaching the gear unit to the machine shaft.

Note
Reducing the risk of corrosion
When using jacking screws or screw spindles, to avoid the risk of corrosion, round off and grease
the end of the thread (head) that presses against the driven machine.

Procedure
In order to dismantle a shaft-mounted gear unit from the machine shaft, proceed as follows:
1. Remove the axial locking element from the hollow shaft.
2. If fretting corrosion has formed on the seat surfaces, rust remover must be applied so that the
gear unit can be more easily detached. The rust remover can be pumped in through the
pressure oil connector.
3. Wait for the rust remover to work and then use a fixture to dismantle the gear unit.
4. Depending on the conditions on site, you can use one of the following methods to remove
the gear unit from the machine shaft:
– With a central screw spindle
– Using hydraulic pulling equipment

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5.5 Shaft-mounted gear unit with hollow shaft and shrink disk

The following diagram shows the dismantling procedure using hydraulic pulling equipment for
gear units with hollow shaft and parallel keyway:







① Screw spindle ④ Machine shaft

② Hollow shaft ⑤ hydraulic pulling equipment
③ Parallel keyway
Figure 5-8 Dismantling using hydraulic pulling equipment

5.5 Shaft-mounted gear unit with hollow shaft and shrink disk

Introduction
The shaft end of the driven machine shaft (material C60+N or higher strength) should have a
hole centred in its end face as defined by DIN 332, form DS (with thread). Depending on the
version, hollow shafts can be equipped with DU bushings to guide the shaft.
The shrink disks are not supplied with the gear unit. They can be supplied when requested.

Further information
Further information about the connection dimensions of the driven machine shaft can be found
in the dimension drawing in the complete documentation for the gear unit.

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5.5.1 Mounting

Measures to be taken prior to assembly

CAUTION
Risk of injury due to chemical substances
Observe the manufacturer’s guidelines on how to handle lubricants and solvents.
Wear suitable protective clothing.

Improper use can damage the gear unit. Be sure to take the following precautions:
• Use a suitable cleaning agent to remove the corrosion protection from the hollow shaft and
the machine shaft.
• Inspect the hollow shaft and machine shaft for damaged seats and edges.
• If necessary, rework the components with an appropriate tool and then clean them again.

NOTICE
Risk of damage to shaft sealing rings
Aggressive chemical cleaning agents may cause damage to shaft sealing rings.
Do not allow the cleaning agent to come into contact with the shaft-sealing rings.

Note
The bore of the hollow shaft and the machine shaft must be free of any grease
Make sure that the hollow shaft bore and the machine shaft are completely free of grease in the
area around the shrink disk seat. The reliability with which torque is transmitted depends to a
large extent on this.
Do not use any contaminated solvents or soiled cleaning cloths, nor any cleaning agents that
contain oil (such as petroleum or turpentine) to degrease the surfaces.

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5.5.1.1 Pulling on with integrated DU bushing

Procedure

NOTICE
Damage to the gear unit
The gear unit can become damaged if it skews during assembly.
The hollow shaft must be flush with the machine shaft during assembly of the gear unit on the
machine shaft. The gear unit must be prevented from skewing.

NOTICE
Damage to the rolling-contact bearings
The rolling-contact bearings can become damaged if the gear unit skews during mounting.
The hollow shaft may be mounted on a machine shaft shoulder only if the gear unit features
one of the following:
• Torque arm
• Supported by gear unit swing base

Proceed as follows to mount the gear unit with hollow shaft and shrink disk onto the driven
machine shaft with integrated DU bushing:
1. Use suitable hoisting gear to lift the gear unit.
2. Mount the gear unit using the nut and screw spindle.
The gear unit is supported by the hollow shaft.
3. Quickly pull the shaft into the hollow shaft up to the end plate.

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The following diagram shows the preparation for gear units with hollow shaft and shrink disk:







① End plate ⑤ Nut

② Jacking screw ⑥ Screw spindle
③ DU bushing ⑦ Nut
④ Machine shaft
Figure 5-9 Preparation for gear units with hollow shaft and shrink disk

5.5.1.2 Axial locking

Tightening the shrink disk as per specification ensures that the gear unit is properly axially
locked. It is not necessary to install any further axial locking elements.

5.5.2 Dismantling the shaft-mounted gear unit

Procedure
1. Dismantle the shrink disk.
2. Lift the gear unit off the machine shaft using jacking screws until the seats under the shrink
disk and the DU bushing are exposed.
3. Use suitable hoisting gear to lift the gear unit off the machine shaft.

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5.6 Couplings

NOTICE
Use of incorrect attachment points
Use of incorrect attachment points may result in damage to the gear unit.
• Only attach the gear unit at the lifting eyes provided for this purpose.
• Do not use the pipework to move the gear unit. The pipework must not be damaged.
• Do not use the threads in the end faces of the shaft ends for attaching lifting equipment to
transport the gear unit.
• Lifting equipment must be adequately designed to accommodate the weight of the gear
unit.

5.6 Couplings

Introduction
Couplings must be balanced as specified in the relevant operating instructions. Balance the
couplings if required.
The coupling parts might become misaligned as a result of:
• Failure to accurately align the parts during assembly
• During operation of the system, e.g.:
– Due to thermal expansion
– Due to shaft deflection
– Due to machine frames or substructures that are too soft

NOTICE
Premature wear and material damage to gear units due to misalignment
Gear units might suffer premature wear and material damage if they are misaligned.
Make sure that the maximum permissible displacement values are never exceeded during
operation. These values can be found in the operating instructions for the coupling.
Angular and radial displacement might occur simultaneously. Make sure that the total value of
both displacements does not exceed the maximum permissible angular or radial displacement
value.
If you are using couplings supplied by other manufacturers, contact them and ask them for the
maximum permissible misalignment tolerances, making sure that you specify the potential
radial loads for your application.

The following diagram shows the possible displacements:

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˂.D

˂.Z

˂.U
/DWHUDOPLVDOLJQPHQW $QJXODUPLVDOLJQPHQW 5DGLDOPLVDOLJQPHQW
˂.D ˂.Z ˂.U
Figure 5-10 Possible displacements

Alignment
Alignment must be carried out in two axis planes that are vertical with respect to one another.
This is possible using rulers (radial offset) and feeler gauges (angular offset) as shown in the
diagram. You will achieve a greater degree of alignment accuracy by using a dial gauge or laser
alignment system.
The diagram below shows the alignment process based on the example of a flexible coupling:




 




① Ruler ③ Measuring points

② Feeler gauge
Figure 5-11 Alignment process based on the example of a flexible coupling

Note
It is advisable to insert shims or metal sheets under the mounting feet in order to align the drive
components in the vertical direction. It is helpful to use support paws with adjusting screws on
the foundation to adjust the drive components laterally.

Note
Gear unit with motor bell housing
Couplings do not have to be aligned if the gear unit and motor are connected by a motor bell
housing.

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Further information
Further information about misalignment tolerances for couplings supplied by Flender can be
found in the relevant operating instructions for the couplings in the complete documentation
for the gear unit.
If couplings from other manufacturers are to be used, then, specifying the radial loads that
occur, ask the manufacturer which alignment errors are permissible.
You can find additional information about couplings in the associated operating instructions.

5.7 Connecting components

5.7.1 Gear units with mounted components

Depending on the order specification, the gear unit can be equipped with various components.
Connect the closed-loop control and open-loop control electrical devices corresponding to the
specifications of the device supplier.

Further information
You can find additional information on operation and maintenance in the associated operating
instructions, provided in the complete gear unit documentation.
You can find the technical data of the mounted components in the contract-list of equipment
provided in the complete gear unit documentation.

5.7.2 Connecting the cooling coil

Procedure
To connect the cooling coil to the gear unit, proceed as follows:
1. Before connecting the cooling coil, remove the sealing plugs from the connection sleeves.
2. Flush through the cooling coil to remove any dirt or dust.
3. Connect up the cooling water inlet and drain lines. Refer to the dimension drawing for the
position of the connections.

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Further information
Further information about the cooling coil can be found in the complete documentation for the
gear unit.

Note
Observe the information provided in chapter Cooling coils (Page 27).

5.7.3 Connecting the air‐oil cooler

Procedure
To connect the air-oil cooler to the gear unit, proceed as follows:
1. Make sure that air can circulate freely before you connect up the air-oil cooler.
2. Blast the air-oil cooler with compressed air.
3. Electrically connect the contamination indicator of the double changeover filter and the
pressure monitor.
4. Electrically connect the fan motor.

Further information
You can find additional information on the air-oil cooler in the air-oil cooler operating
instructions, provided in the complete gear unit documentation.

Note
Observe the information provided in chapter of the Mounted oil supply system with air-oil cooler
(Page 28).

5.7.4 Connecting the water-oil cooler

NOTICE
Damage to the water-oil cooler
When installing the piping, it is not permissible that the connections of the water-oil cooler are
subject to force, torque or vibration.

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Procedure
To connect the water-oil cooler to the gear unit, proceed as follows:
1. Remove the connecting bushes from the cooling water connection before connecting the
water-oil cooler.
2. Flush the water-oil cooler to remove any dirt and pollution.
3. Connect up the cooling water inlet and drain lines. Refer to the dimension drawing for the
direction of flow and the position of the connections.
4. Electrically connect the pressure monitor (only for appropriately equipped gear units).

Further information
You can find additional information on the water-oil cooler in the water-oil cooler unit operating
instructions, provided in the complete gear unit documentation.

Note
Observe the information provided in chapter of the Mounted oil supply system with water-oil
cooler (Page 30).

5.7.5 Connecting the heating element

Procedure
To connect heating elements to the gear unit, proceed as follows:
1. Check that the heating element connection is not damaged.
2. Install the electrical wiring for the heating elements.

Further information
You will find further information on the heating in the operating instructions for the heating,
which are part of the complete documentation of the gear unit.

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5.7.6 Installing a separate oil supply system

Procedure
To connect the oil supply system to the gear unit, proceed as follows:
1. Remove the dummy flange from the suction and delivery line before connecting the system.
2. Connect the system to the gear unit in accordance with the dimension drawings in the
complete documentation and install it as a separate system.
3. When installing the system, make sure that the pipework is not subjected to mechanical
stresses.

Further information
Further information about the oil supply system can be found in the oil supply system operating
instructions in the complete documentation for the gear unit.

5.7.7 Connecting the oil temperature monitor

Procedure
To connect the Pt 100 resistance thermometer, proceed as follows:
1. Check that the Pt 100 resistance thermometer connection is not damaged.
2. Install the electrical wiring between the Pt 100 resistance thermometer and the evaluation
unit. The customer is responsible for providing the evaluation unit.

Further information
Further information about the Pt 100 resistance thermometer can be found in the Pt 100
resistance thermometer operating instructions in the complete documentation for the gear unit.

5.7.8 Connecting the oil-level monitoring system

Procedure
To connect the oil-level monitoring system to the gear unit, proceed as follows:
1. Ensure that the filling level limit switch connection is not damaged.
2. Electrically connect the filling level limit switch.
3. Connect the signal so that for the "oil level too low" signal, the drive motor cannot start and
an alarm is output.
Bypass this signal in operation.

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Further information
Additional information about the oil-level monitoring system can be found in the operating
instructions for the oil-level monitoring system components provided in the complete gear unit
documentation.
You can find technical data in the separate data sheet and in the equipment list in the complete
gear unit documentation.

5.7.9 Connecting the Pt 100 resistance thermometer

Procedure
To connect the Pt 100 resistance thermometer, proceed as follows:
1. Check that the Pt 100 resistance thermometer connection is not damaged.
2. Install the electrical wiring between the Pt 100 resistance thermometer and the evaluation
unit. The customer is responsible for providing the evaluation unit.

Further information
Further information about the Pt 100 resistance thermometer can be found in the Pt 100
resistance thermometer operating instructions in the complete documentation for the gear unit.

5.7.10 Connecting the temperature monitor

Procedure
To connect the temperature monitor to the gear unit, proceed as follows:
1. Make sure that the temperature monitor connection is undamaged.
2. Install the electrical wiring for the temperature monitor.

Further information
Further information about the temperature monitor can be found in the temperature monitor
operating instructions in the complete documentation for the gear unit.

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5.7.11 Connecting the bearing monitoring system

Procedure
To connect the bearing monitoring system to the gear unit, proceed as follows:
1. Make sure that the connections provided for holding the bearing monitoring equipment are
undamaged.
2. Install the bearing monitoring equipment at the customer's site.

Further information
Further information about the bearing monitoring system can be found in the operating
instructions for the bearing monitoring system components provided in the complete gear unit
documentation.

5.7.12 Electrical connections

Procedure

DANGER
Electric shock
Live parts can cause electric shock.
Ensure that the entire plant is de-energised before starting electrical installation work.
Carefully observe the five safety rules (Page 13).

To connect the motors and monitoring devices, proceed as follows:

1. Ensure that the connections of the motors and monitoring devices are not damaged.
2. Connect up the motors and monitoring devices according to the terminal diagram and the
relevant operating instructions.
3. Insulate all cable entry points (glands) at electrical equipment as required for the
environment in which the equipment will operate.

Further information
You can find additional information about the electrical connections in the terminal diagrams
and equipment lists provided in the complete gear unit documentation.

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5.8 Tightening procedure

5.8.1 Introduction

Bolts
The bolts must have the following properties:
• Made of steel
• Black-annealed or phosphatised
• Lightly oiled (do not add additional oil)

Note
Replacing bolts
Replace any bolts that are no longer fit for use by bolts of the same type and strength class.

Mating threads
The mating threads must have the following properties:
• Made of steel or cast iron
• Dry, cut threads

Note
Using a lubricant
As a rule, lubricants may not be used, because this can result in the bolt connection becoming
overloaded.

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5.8.2 Bolt connection classes

In order to affix fastening bolts, note the information in the following table:

Table 5-1 Information on tightening fastening bolts

Mounting Bolt connection Scatter of the tor‐ Tightening procedure

class que generated by
the tool
Gear unit C ± 5 % to ± 10 % • Hydraulic tightening with me‐
Motor chanical screwdriver
Brake • Torque-controlled tightening
Torque arm with a torque wrench or a signal-
emitting torque wrench
• Tightening with a precision me‐
chanical screwdriver with dynam‐
ic torque measurement
D ± 10 % to ± 20 % • Torque-controlled tightening
with mechanical screwdriver
Protection cover E ± 20 % to ± 50 % • Tightening with pulse screwdriv‐
Sun shield er or impact wrench, without ad‐
Inspection cover justment checking device
• Tightening by hand, using a
wrench without torque measur‐
ing device

Further information
You can find additional information about tightening torques when mounting motor and brake
in the operating instructions from the particular manufacturer.

5.8.3 Tightening torques and preload forces

The specified bolted connections must be tightened to the torques stated in the table below:
The tightening torques apply to friction values of μtotal = 0.14.

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The following table lists the preload forces and tightening torques for bolt connections, strength
classes 8.8; 10.9; 12.9:

Table 5-2 Preload forces and tightening torques

Nominal Bolt Preload force for bolt connection Tightening torque for bolt connec‐
thread di‐ strength classes from the table in tion classes from the table in chap‐
ameter class chapter Bolt connection classes ter Bolt connection classes
(Page 79) (Page 79)
d C D E C D E
mm FM min. MA
N Nm
M10 8.8 18 000 11 500 7 200 44.6 38.4 34.3
10.9 26 400 16 900 10 600 65.4 56.4 50.4
12.9 30 900 19 800 12 400 76.5 66.0 58.9
M12 8.8 26 300 16 800 10 500 76.7 66.1 59.0
10.9 38 600 24 700 15 400 113 97.1 86.6
12.9 45 100 28 900 18 100 132 114 101
M16 8.8 49 300 31 600 19 800 186 160 143
10.9 72 500 46 400 29 000 273 235 210
12.9 85 000 54 400 34 000 320 276 246
M20 8.8 77 000 49 200 30 800 364 313 280
10.9 110 000 70 400 44 000 520 450 400
12.9 129 000 82 400 51 500 609 525 468
M24 8.8 109 000 69 600 43 500 614 530 470
10.9 155 000 99 200 62 000 875 755 675
12.9 181 000 116 000 72 500 1 020 880 790
M30 8.8 170 000 109 000 68 000 1 210 1 040 930
10.9 243 000 155 000 97 000 1 720 1 480 1 330
12.9 284 000 182 000 114 000 2 010 1 740 1 550
M36 8.8 246 000 157 000 98 300 2 080 1 790 1 600
10.9 350 000 224 000 140 000 2 960 2 550 2 280
12.9 409 000 262 000 164 000 3 460 2 980 2 670
M42 8.8 331 000 212 000 132 000 3 260 2 810 2 510
10.9 471 000 301 000 188 000 4 640 4 000 3 750
12.9 551 000 352 000 220 000 5 430 4 680 4 180
M48 8.8 421 000 269 000 168 000 4 750 4 090 3 650
10.9 599 000 383 000 240 000 6 760 5 820 5 200
12.9 700 000 448 000 280 000 7 900 6 810 6 080
M56 8.8 568 000 363 000 227 000 7 430 6 400 5 710
10.9 806 000 516 000 323 000 10 500 9 090 8 120
12.9 944 000 604 000 378 000 12 300 10 600 9 500
M64 8.8 744 000 476 000 298 000 11 000 9 480 8 460
10.9 1 060 000 676 000 423 000 15 600 13 500 12 000
12.9 1 240 000 792 000 495 000 18 300 15 800 14 100

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Nominal Bolt Preload force for bolt connection Tightening torque for bolt connec‐
thread di‐ strength classes from the table in tion classes from the table in chap‐
ameter class chapter Bolt connection classes ter Bolt connection classes
(Page 79) (Page 79)
d C D E C D E
mm FM min. MA
N Nm
M72x6 8.8 944 000 604 000 378 000 15 500 13 400 11 900
10.9 1 340 000 856 000 535 000 22 000 18 900 16 900
12.9 1 570 000 1 000 000 628 000 25 800 22 200 19 800
M80x6 8.8 1 190 000 760 000 475 000 21 500 18 500 16 500
10.9 1 690 000 1 100 000 675 000 30 500 26 400 23 400
12.9 1 980 000 1 360 000 790 000 35 700 31 400 27 400
M90x6 8.8 1 510 000 968 000 605 000 30 600 26 300 23 500
10.9 2 150 000 1 380 000 860 000 43 500 37 500 33 400
12.9 2 520 000 1 600 000 1 010 000 51 000 43 800 39 200
M100x6 8.8 1 880 000 1 200 000 750 000 42 100 36 200 32 300
10.9 2 670 000 1 710 000 1 070 000 60 000 51 600 46 100
12.9 3 130 000 2 000 000 1 250 000 70 000 60 400 53 900

5.9 Final work

Measures
Once all the elements have been assembled or connected, perform the following final work:
• Check whether all devices dismantled for transportation have been reassembled.
• Check all bolt connections for tightness after installation of the gear unit has been completed.
• Check the alignment after tightening the fastening elements. The alignment must not have
changed in any way.
• Lock the oil drain valves against accidental opening.
• Protect the gear unit against falling objects.
• Check that the guards over rotating parts are securely fastened.
Contact (accidental or deliberate) with rotating parts is not permitted.
• Perform potential equalisation in accordance with the applicable regulations and guidelines.
If no threaded holes are available on the gear unit for an earth connection, please take
suitable alternative measures. This work must always be done by specialist electricians.
• Protect the cable entries against penetrating moisture.

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Further information
You will find further information about the gear unit and all mounted or separately supplied
components in the operating instructions of the relevant components included in the complete
documentation for the gear unit.
You can find additional technical specifications in the separate data sheet in the complete gear
unit documentation.

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6.1 Measures prior to commissioning

Take the following measures before commissioning the gear unit:

• Read and observe the operating instructions.
• Replace the screw plug with the air filter or the wet-air filter. Read operating instructions BA
7300 for further information.
• Gear units with backstop: Observe the appropriate measures prior to commissioning gear
units equipped with backstop.
• Fill the gear unit with oil.
• Gear unit with oil supply system: Check that the oil supply system is working properly.
• Check the oil level.
• Check the gear unit for leaks.
• Gear unit with oil supply system: Observe the appropriate measures prior to commissioning
gear units equipped with oil supply system.
• Ensure that all pipes and components are filled with oil.

Further information
Further information about oil and replacement of air filters can be found in the operating
instructions BA 7300 in the complete documentation for the gear unit.
Further information about individual components can be found in the operating instructions for
the components in the complete documentation for the gear unit.

6.1.1 Gear units with cooling coil

Implement the following measures before commissioning the gear unit with cooling coil:
• Make sure that the pressure in the cooling coil does not exceed the maximum permissible
pressure.
• Make sure that the temperature of the cooling coil does not exceed the maximum
permissible temperature.

Further information
Further information about the cooling coil can be found in the separate data sheet and the list
of equipment in the complete documentation for the gear unit.

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6.1.2 Gear unit with heating

Please observe the following measures to commission the gear unit with heating:
• Ensure that the heating elements are not exposed.
• Check the switching points of the temperature monitor.

WARNING
Fire hazard
Exposed heating elements pose a fire hazard.
Do not put heating elements into service until you have checked that they are completely
immersed in the oil bath.

Further information
Further information about heating elements can be found in the heating element operating
instructions in the complete documentation for the gear unit.

6.1.3 Gear unit with backstop

Take the following measures before commissioning the gear unit with backstop:
• Fill the backstop with oil (Page 94).
• Check that the backstop can be easily rotated in the free-wheeling direction without having
to exert excessive force. When doing his, observe the direction of rotation arrows at the gear
unit.
• Before connecting the motor, identify the phase sequence of the three-phase mains.
Connect the motor corresponding to the defined direction of rotation.

NOTICE
The backstop and the gear unit can be damaged
If you operate the gear unit adversely to the blocking direction of the backstop, the backstop
and the gear unit can be damaged.
Do not operate the gear unit adversely to the blocking direction of the backstop. Observe the
information on the plate attached to the gear unit.

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6.1.4 Gear unit with auxiliary drive

Implement the following measures before commissioning the gear unit with auxiliary drive:
• Please observe the information provided in the operating instructions for the auxiliary drive.
• Fill the overrunning clutch with oil via the intermediate flange. Use the same oil type and
viscosity as for the gear unit itself.
• If required, release the brake on the auxiliary motor.
• Check that the overrunning clutch can be easily rotated in the free-wheeling direction
without having to exert excessive force.
To do this, rotate the motor shaft of the auxiliary drive in the opposite direction to the
direction of rotation arrow to the gear unit.
• Before connecting the auxiliary motor, identify the phase sequence of the three-phase mains.
Connect the auxiliary motor corresponding to the defined direction of rotation.
• Electrically interlock the main motor and the auxiliary motor so that only one of the two
motors can be switched on.
• For a maintenance drive: Check the shutdown function of the speed monitoring (Page 97).

Further information
You can find additional information on the auxiliary drive in the description (Page 39) and in the
auxiliary drive operating instructions, provided in the complete gear unit documentation.

6.1.5 Gear unit with oil supply unit

Implement the following measures before commissioning the gear unit with oil supply system:
• Ensure that the maximum permissible pressure in the oil supply system components is not
exceeded.
• Ensure that the maximum permissible temperature of the oil supply system components is
not exceeded.
• Using the oil supply system, lubricate the gear unit for 2 minutes using a pre-lubrication
phase. During this time, the rolling-contact bearings and gearing are supplied with
sufficient oil for starting.
Carefully ensure that the pre-lubrication phase is not longer than 5 minutes as the oil can
foam up at low temperatures. For oil temperatures below 10 °C, heat up the oil using suitable
measures and contact Flender in this regard.

Further information
You can find additional information on the oil cooling system in the separate data sheet, and in
the equipment list in the complete gear unit documentation.

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6.1.6 Oil level monitoring system

The gear unit can be equipped with an oil level monitoring system that uses a filling-level limit
switch.
The oil level monitoring system has been designed to check the oil level when the gear unit is at
a standstill before it starts.

Note
Connect the signal so that the drive motor cannot start when the "oil level too low" signal is
active and so that an alarm is output. Bypass this signal in operation.

6.1.7 Oil temperature monitoring system

The gear unit can be equipped with an oil temperature monitoring system that uses a
temperature sensor.
The oil temperature monitoring has been designed to check the oil temperature while the gear
unit is operation.

6.2 Measures during commissioning

Please observe the following measures to commission the gear unit and document these:
• For gear units with oil supply system: Check that the oil supply system is working properly.
• Check the oil level.
• Measure the oil sump temperature (Page 93) after the gear unit has run in.
• Check that the shaft seal on the gear unit does not leak.
• Check that no contact with rotating parts is possible.
• Check whether the shutoff valves are open.
– Check that all of the oil drain valves are closed.
– Ensure that all of the other shutoff valves are open.
• Check all the connection lines are securely tightened and leak-free.
• For gear units with bearing monitoring by measuring the vibration: Measure the vibration
levels of the rolling-contact bearings (Page 98) to create initial and comparison values.
• When commissioning, the pressure monitor signal should be bypassed for approximately 20
seconds. This is necessary as the pressure in the gear unit must first stabilise.

Further information
You can find additional information on the topic of oil in the operating instructions BA 7300,
provided in the complete gear unit documentation.

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Further information about the oil supply system can be found in the oil supply system operating
instructions in the complete documentation for the gear unit.

6.2.1 Gear units with heating

Please observe the following measures to commission the gear unit with heating:
• Ensure that the heating elements are not exposed.
• Check the switching points of the temperature monitor.

WARNING
The oil sump can catch fire
The oil sump can catch fire if exposed heating elements are switched on.
Never switch on the heating elements until you have checked that they are completely
immersed in the oil bath.

Further information
You will find further information about the heating elements in the operating instructions for the
heating elements, which are part of the complete documentation of the gear unit.

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7.1 Operating data

Introduction
To ensure correct, trouble-free operation of the system, observe the operating data of the gear
unit and, depending on the order specification, the data in the operating instructions for the oil
supply system.
The valid operating data can be found in the annex Technical data (Page 113).
The following operating data apply to the oil:

Table 7-1 Operating data

Maximum operating tempera‐ 90 °C is applicable for mineral oil, API groups I or II and saturated
ture synthetic ester
Maximum operating tempera‐ 100 °C is applicable for mineral oil, API groups I or II and saturated
ture synthetic ester
(for brief periods)
Oil pressure of the oil supply > 0.5 bar
system
Water pressure of the water-oil < 8.0 bar
cooler

Further information
Further information about the technical data of the gear unit can be found in the data sheet and
the list of equipment in the complete documentation for the gear unit.

7.2 Irregularities in operation

Introduction
Switch off the drive assembly immediately if it exhibits irregular behaviour during operation.
A few irregularities are listed below as examples:
• Oil temperature exceeds the maximum permissible value
• Alarm tripped by the pressure monitor in the oil cooling system or oil supply system
• Unusual operating noise

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7.3 Taking the unit out of service

NOTICE
Faults can cause damage to the gear unit
The gear unit might sustain damage if it is not shut down when a fault occurs.
Switch off the drive assembly immediately if any fault condition develops.

Rectifying irregularities in operation

Proceed as follows to rectify any irregularities in operation:
1. Switch off the drive assembly if it exhibits irregular behaviour during operation.
2. Refer to the Fault information (Page 99) to find the cause of the fault.
3. If you still cannot determine the fault cause, contact Flender Customer Services (Page 105).

7.3 Taking the unit out of service

If you take the unit out of service for a prolonged period, you must take the following measures
depending on the length of time that the gear unit will remain out of service:
• Switch off the drive assembly.
• For gear units with a cooling coil or a water-oil cooler:
– Drain the water out of the cooling coil or the water-oil cooler if there is a risk of frost.
– Close the shutoff valves for the cooling water inlet and drain lines.
• For gear units with an oil supply system, perform the following steps before you preserve the
gear unit:
– Detach the connection between the oil supply system and the gear unit.
– Seal the openings in the gear unit and oil supply system so that they are air-tight.
• Start up the gear unit briefly (5 to 10 minutes) at intervals of approximately 3 weeks (if it is
taken out of service for up to 6 months).
• Take measures to preserve the gear unit if it is to be out of service for a prolonged period.
Follow the procedure described in operating instructions BA 7300.

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8.1 General maintenance information
The operator must ensure compliance with the stipulated time limits. This also applies if the
maintenance activities are included in the operator’s internal maintenance schedules.
The gear unit could be damaged if the stipulated time limits for maintenance and servicing are
not observed.
The time limits stipulated in the maintenance schedule are largely dependent on the conditions
of use of the gear unit. For this reason, it is only possible to state average time limits here. These
refer to the following conditions of use:
• Daily operating time 24 h
• Duty cycle "ED" 100%
• Gear unit input speed 1500 rpm
• Average oil temperature in the oil sump (see operating instructions BA 7300)

WARNING
Danger to life due to live system
Working on a gear unit while it is in operation is hazardous and can result in potentially fatal
injuries.
Always shut down the gear unit and any oil supply system (whether separate or mounted on
the gear unit) before you carry out any work. Take measures to prevent the accidental
restarting of the drive assembly. Display a warning notice that clearly states that work is being
carried out on the gear unit.

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8.2 Maintenance schedule

8.2 Maintenance schedule

Maintenance and servicing activities

The following table provides an overview of all maintenance and servicing activities which you
are required to perform continuously or at regular intervals.

Table 8-1 Maintenance and servicing activities

Intervals and time limits Measures

As required Replace the wet-air filter
Clean the air filter
Clean the venting screw
Clean the fan and gear unit
Daily Check the oil temperature
Check the oil pressure (if pressure lubrication is fitted)
Check for changes in the gear unit noise
Check the water pressure
Monthly and prior to every start-up Check for leaks
Check the oil level
400 operating hours after commissioning Check the water content of the oil
Change the oil (or depending on the result of the oil
sample test)
Check that the fastening bolts are tight
Every 3 months Check the speed monitoring of the auxiliary drive
Check the auxiliary drive
Clean the oil filter
Clean the air filter
Clean the venting screw
Every 3 000 operating hours Measure the vibration levels of the rolling-contact bear‐
ings
Every 3 000 operating hours, at least every Regrease taconite seals
6 months Regrease Tacolab seals
At least every 6 months (see specification on Replenish grease in grease-lubricated rolling-contact
plate at lubrication point) bearings
Every 5 000 operating hours, at least every Replenish grease in the oil retaining pipe
10 months
Every 12 months Check the friction linings of the torque-limiting backstop
Inspect the hose lines
Inspect the shrink disk
Check the water content of the oil

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Intervals and time limits Measures

Every 10 000 operating hours, at least every Change the oil if using API Groups I or II mineral oils, or
2 years saturated synthetic ester (or depending on the result of
oil sample test)
Check the condition of the air‐oil cooler (the same time
as you change the oil)
Check the condition of the water‐oil cooler (the same
time as you change the oil)
Every 2 years Carry out a general inspection of the gear unit
Check the cooling coil
Check that the fastening bolts are tight
Clean the fan and gear unit
Every 20 000 operating hours, at least every 4 Change the oil if using semi-synthetic oil of API Group III,
years PAO or PG oil (or depending on the result of the oil sam‐
pling)
6 years after the specified date of manufacture Change the hoses

Further information
Further information about additional maintenance and servicing activities can be found in the
separate data sheet in the complete documentation for the gear unit.
Further information about installed components can be found in the operating instructions for
the components in the complete documentation for the gear unit.

8.3 Maintenance and servicing work

Introduction
You can find maintenance and servicing measures relating to gear unit lubrication and
preservation, which are not provided in this chapter, in BA 7300 in the complete gear unit
documentation.

8.3.1 Checking the oil temperature

Damage to the gear unit due to excessively high oil sump temperatures.
The gear unit can sustain damage due to inadequate lubrication if you allow it to operate at oil
sump temperatures above the maximum permissible temperature.
Do not operate the gear unit above the maximum permissible oil sump temperature.

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Procedure
Proceed as follows to check the oil temperature:
1. Allow the gear unit to reach its normal operating temperature.
2. Operate the gear unit with the maximum driven machine power.
3. Measure the temperature of the oil in the oil sump.
4. Compare the measured value with the maximum permissible oil temperature (Page 89).
5. Immediately stop the gear unit if the maximum permissible oil temperature is exceeded.
Contact Flender Customer Services.

8.3.2 Replacing the backstop

Introduction
If you operate the gear unit at speeds below the disengagement speed of the backstop, then you
must regularly replace the backstop.
The replacement intervals are provided in the dimension drawing and on a plate attached to the
gear unit. This plate is attached to the gear unit housing close to the backstop.

Procedure
Proceed as follows to replace the backstop:
1. Replace the backstop.
2. Fill the new backstop with oil (Page 94).

8.3.3 Filling the backstop with oil

Oil type and filling filter

When filling the backstop with oil, observe the following points:
• Use the same oil type and oil viscosity as for the gear unit itself.
• Use a filling filter with the same filter mesh size as for the gear unit itself.

Procedure
Proceed as follows to fill the backstop with oil:
1. Clean the oil filling point of the backstop.
2. Open the oil filling screw of the backstop.

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3. Fill the amount of oil that is specified on the backstop plate.

4. Screw in the oil filling screw.

8.3.4 Checking the auxiliary drive

Further information
You can find information on checking the auxiliary drive in the auxiliary drive operating
instructions, provided in the complete gear unit documentation.

8.3.5 Filling the overrunning clutch of the auxiliary drive with oil

Oil type and filling filter

When filling the overrunning clutch with oil, observe the following points:
• Use the same oil type and oil viscosity as for the gear unit itself.
• Use a filling filter with the same filter mesh size as for the gear unit itself.

Procedure
Proceed as follows to fill the overrunning clutch with oil:
1. Open the oil filling screw of the overrunning clutch.
2. Fill the amount of oil that is specified on the overrunning clutch rating plate.
3. Screw in the oil filling screw.

8.3.6 Cleaning the fan and gear unit

Introduction
The gear unit can sustain damage due to inadequate cooling if you operate it with a damaged
or soiled fan. Depending on the conditions at the site of installation, it may therefore be
necessary to clean the fan and gear unit more frequently than stipulated in the maintenance
schedule.

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8.3 Maintenance and servicing work

Procedure
Proceed as follows to clean the fan and gear unit:
1. Remove the air guide cover.
2. Use a hard brush to remove any stubborn dirt from the impeller, air guide cover and
protective grille. Never use a high-pressure cleaning device.
3. Treat any areas of corrosion.
4. Reinstall the air guide cover.
5. Make sure that the air guide cover is correctly fastened.
Make sure that there is no contact between the fan and the air guide cover.

8.3.7 Checking the cooling coil

Introduction
A soiled cooling coil can cause damage to the gear unit. It is therefore important to check the
cooling coil regularly.

Procedure
To check the cooling coil, proceed as follows:
1. Shut off the cooling water supply.
2. Disconnect the cooling water inlet and drain lines from the cooling coil.
3. Inspect the inner surface of the cooling coil for deposits.
4. If you discover that there are heavy deposits inside the cooling coil, arrange for the cooling
water or the deposits to be analysed.
Analysis services of this kind are offered by specialist chemical cleaning companies. These
companies also sell special cleaning agents for removing deposits. Before you use a cleaning
agent, check whether it is suitable for use on the cooling coil materials. You must consult
Flender Customer Services. Carefully read the instructions for use supplied by the
manufacturer before using different kinds of cleaning agent.
5. If the cooling coil is severely soiled, it must be replaced by a new one.
Please consult Flender Customer Services for further advice.
6. Reconnect the cooling water inlet and drain lines to the cooling coil.

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8.3.8 Cleaning the coarse filter

Procedure
To clean the coarse filter, proceed as follows:
1. Inspect the coarse filter.
2. Remove the drain plug.
3. Pull out the strainer and remove particles of dirt.
4. Replace any strainers or sealing rings that are defective.

Further information
You can find additional information about the coarse filter in the coarse filter operating
instructions provided in the complete gear unit documentation.
You can find additional technical data in the separate data sheet and in the list of equipment
provided in the complete gear unit documentation.

8.3.9 Cleaning the double change-over filter

Procedure
To clean the double change-over filter, proceed as follows:
1. Inspect the double change-over filter.
2. Follow the operating instructions for the double change-over filter.

Further information
You can find additional information about the double change-over filter in the double change-
over filter operating instructions provided in the complete gear unit documentation.
You can find additional technical data in the separate data sheet and in the list of equipment
provided in the complete gear unit documentation.

8.3.10 Checking the speed monitoring of the auxiliary drive

Procedure
Proceed as follows to check the speed monitoring of the auxiliary drive:
1. Switch on the auxiliary drive.
2. Check whether the speed monitor switches.

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Result
If the speed monitor does not switch, repair it or if necessary replace it.

Further information
You can find additional information on the auxiliary drive in the auxiliary drive operating
instructions, provided in the complete gear unit documentation.

8.3.11 Measuring the vibration levels of the rolling-contact bearings

Procedure
Proceed as follows to measure the vibration levels of the rolling-contact bearings:
1. Measure the vibrations at the rolling-contact bearings.
2. Document the measurement results.
3. Compare the measured values with the comparison values that were documented when
commissioning the gear unit.
4. Archive the report together with these instructions.
5. Have Customer Services replace defective rolling-contact bearings.

Further information
You can find additional information on measuring the vibration levels at rolling-contact bearings
in the operating instructions of the measurement sensor provided in the complete gear unit
documentation.

8.3.12 Inspecting the shrink disk

Introduction
The shrink disk inspection is limited to a visual assessment of its condition.

Aspects of the inspection

Observe the following points when inspecting the shrink disk:
• Loose bolts
• Damage due to use of force
• Inner ring resting flush against the outer ring

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Further information
Further information about the shrink disk can be found in the shrink disk operating instructions
in the complete documentation for the gear unit.

8.3.13 Check that all of the fastening bolts are tight

Note the following points when checking that the fastening bolts are tight:
• Observe the data regarding connection classes (Page 79), preload forces and tightening
torques (Page 79).
• Replace any bolts that are no longer fit for use by bolts of the same strength class and type.

8.3.14 General inspection of the gear unit

Arrange for Flender Customer Services to inspect the gear unit. Thanks to their experience, these
engineers are best placed to assess which gear unit components need to be replaced.

8.3.15 Final work

After you have finished all the work listed in the maintenance schedule, replace any bolts that
are no longer fit for use by bolts of the same strength class and type.

8.4 Possible faults

The faults listed below are only intended as a troubleshooting guide.

If any faults occur while the unit is still under warranty, do not allow anyone except Flender
Customer Services to attempt a repair.
Even after the warranty period has expired, you should still arrange for faults to be rectified by
Flender Customer Services.

Note
Loss of warranty
You will invalidate the warranty for the gear unit if you modify it in any way without seeking the
approval of Flender beforehand, or if you do not use original spare parts.
Only use original spare parts from Flender. Always arrange for Flender Customer Services to
repair any faults that develop while the unit is still under warranty.

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8.4 Possible faults

Possible faults and how to rectify them

The following table provides an overview of the possible faults and how to rectify them.

Table 8-2 Possible faults and how to rectify them

Possible faults Causes Possible remedies

Pressure monitor trig‐ Oil pressure < 0.5 bar • Check the oil level at room temperature
gers an alarm • Top up with oil if necessary
(For gear units with
• Check the oil pump
pressure lubrication,
air-oil cooler or water- • If required, replace the oil pump
oil cooler). • Check the oil filter, and replace if necessary
Grease escaping at the Defective rotary shaft sealing rings • Inspect the rotary shaft sealing rings and replace if neces‐
output shaft sary
Noise Damage to the gear teeth • Contact Customer Service
• Inspect the toothed components
• If necessary, replace damaged components
The bearing play is excessive. • Contact Customer Service
• Adjust bearing play
Defective rolling-contact bearings • Contact Customer Service
• Replace defective rolling-contact bearings
Gear unit fastening has worked • Tighten bolts and nuts to the specified tightening torque
loose • Replace damaged bolts and nuts
Outer surface of gear Inadequate sealing of the housing • Seal housing cover or joints
unit soiled with oil cover or joints
Labyrinth seals soiled with oil, incor‐ • Check oil filling
rect transport position • Clean labyrinth seals
Static seal defective • Check the seals
Main drive motor does Motor direction of rotation incorrect • Interchange the motor phases
not start Brake blocked • Release the brake
• Check the connections
Backstop cage with sprags incorrect‐ • Contact Customer Service
ly installed or defective • Install the backstop cage, rotated through 180° - or replace
Overrunning clutch blocked • Contact Customer Service
• Replace the overrunning clutch
Overrunning clutch cage with • Contact Customer Service
sprags incorrectly installed and/or • Install the overrunning clutch cage, rotated through 180°
defective
- or replace
Main drive motor can Defective electrical interlocking be‐ • Check the connections
start while the auxiliary tween the main and auxiliary motor • If necessary, replace defective devices
drive is operational
Defective speed monitoring • Check the connections
• If necessary, replace defective devices

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Possible faults Causes Possible remedies

Auxiliary drive motor Overload at the output • Reduce the load at the output
does not start Defective auxiliary drive motor • Repair the motor or replace
Motor brake not released • Correct the electrical connection of the motor brake
• If required, replace the motor brake
The auxiliary drive mo‐ Motor direction of rotation incorrect • Interchange the motor phases
tor starts, the main Overrunning clutch cage with • Contact Customer Service
gear unit output shaft sprags incorrectly installed
does not turn • Install the overrunning clutch cage, rotated through 180°
- or replace
Defective overrunning clutch • Contact Customer Service
• Replace the overrunning clutch
Leaks Inadequate sealing of the housing • Seal housing cover or joints
cover or joints • Check the seals and if required, replace
Labyrinth seals oiled up or transport • Check oil filling
position incorrect • Clean labyrinth seals
Defective rotary shaft sealing rings • Inspect the rotary shaft sealing rings and replace if neces‐
sary
Oil is foaming in the Preservation agent not completely • Change the oil
gear unit drained off
Oil supply system left in operation • Switch off the oil supply system
for too long at low temperatures • Degas the oil
Gear unit too cold in operation • Switch off the gear unit
• Degas the oil
• Start up without cooling water during cold restart
Water in the oil • Take test tube sample to examine oil condition for water
penetration
• Have the oil examined by a chemical lab
• Change the oil if necessary
Oil defoamer has run out • Examine the oil
• Change the oil if necessary
Unsuitable mixture of oils • Examine the oil
• Change the oil if necessary
Oil escaping from the Inadequate sealing of the housing • Check the seals and if required, replace
gear unit cover or joints • Seal housing cover or joints
• Check the compression seals and retighten screws if nec‐
essary
Leaking pipes • Check the pipes, and replace or seal if necessary
Oil supply system mal‐ - • Read the operating instructions for the oil supply system
function

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Possible faults Causes Possible remedies

Elevated temperature Oil level in the gear unit housing too • Check the oil level
during operation high • If required, correct the oil level
Oil is too old • Check when the last oil change was performed
• Change the oil if necessary
Oil is severely contaminated • Change the oil
Oil supply system defective • Check the oil supply system
• If necessary, replace defective components
• Read the operating instructions for the oil supply system
Gear unit with oil cooling system: • Adjust the valves of the supply and return lines completely
Cooling liquid flow rate too low or • Check that water and oil can freely flow through the water-
too high
oil cooler
Gear unit with oil cooling system: • Check the oil filter, and replace or clean if necessary
The oil flow through the water-oil
cooler is too low.
On gear units with a fan: Air intake • Clean the air guide cover and gear unit housing
opening in air guide cover or gear
unit housing is soiled
Coolant temperature too high • Check the temperature
• Correct the temperature if necessary
Defective oil pump • Check the oil pump function
• If required, repair or replace the oil pump
Elevated temperature Oil level in the gear unit housing too • Check the oil level at room temperature
at bearing points low or too high • Top up with oil if necessary
Oil is too old • Check when the last oil change was performed
• Change the oil if necessary
Oil supply system defective • Check the oil supply system
• If necessary, replace defective components
• Read the operating instructions for the oil supply system
Defective rolling-contact bearings • Contact Customer Service
• Inspect the rolling-contact bearings and replace if neces‐
sary
Increased backstop Damaged backstop • Contact Customer Service
temperature with fail‐ • Inspect the backstop and replace if necessary
ure of the blocking
function
Increased vibration am‐ Defective rolling-contact bearings • Contact Customer Service
plitude at the bearing • Inspect the rolling-contact bearings and replace if neces‐
points
sary
Gear wheels defective • Contact Customer Service
• Inspect the gear wheels and replace if necessary
Contamination indica‐ Double change-over filter clogged • Changeover the double change-over filter corresponding
tor of the double to the separate operating instructions
change-over filter trig‐
• Clean the filter element
gers an alarm

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Possible faults Causes Possible remedies

Water in the oil Oil supply system defective • Check the oil supply system
• If necessary, replace defective components
• Read the operating instructions for the oil supply system
Machinery compartment fan is • Install suitable thermal insulation to protect gear unit
blowing cold air onto gear unit: Wa‐ housing
ter condenses
• Close the air outlet or change the direction of the air outlet
using structural measures.
Climatic conditions • Contact Customer Service
• Use wet-air filter if necessary
Oil foams in the oil sump • Take test tube sample to examine oil condition for water
penetration
• Have the oil examined by a chemical lab

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Service & Support 9
Contact
When ordering spare parts, requesting a customer service technician or in the case of technical
queries, please contact our factory or one of our customer service addresses:
Flender GmbH
Am Industriepark 2
46562 Voerde
Germany
Tel.: +49 (0)2871 / 92‐0
Fax: +49 (0)2871 / 92‐1544

Further information
Further information about service and support can be found on the Internet.
Service & Support (https://www.flender.com/service)

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Disposal 10
Disposal of the gear unit
When disposing of the gear unit after its useful life, please observe the following measures:
• Remove operating oil, preservative agents and coolant from the gear unit and dispose of it
according to regulations.
• Dispose of the gear unit parts according to applicable national regulations or recycle them.

Environmental protection
Observe the following environmental protection measures for disposal:
• Dispose of or recycle packaging material according to applicable national regulations.
• When changing the oil, collect the used oil in suitable containers. Use oil-binding agents to
clean up any oil spillages immediately.
• Store preservative agents separately from used oil.
• Dispose of used oil, preservative agents, oil binding agents and oil-soaked cloths according
to the applicable environmental protection regulations.

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Spare parts 11
By stocking the most important spare parts at the installation site you can ensure that the gear
unit is ready for use at any time.

Note
Damage to the gear unit due to use of unsuitable spare parts
Only use original spare parts from Flender. Flender shall not accept any warranty claims for spare
parts that are not supplied by Flender.
Other spare parts are not tested and approved by Flender. Non-approved spare parts may
possibly change the design characteristics of the gear unit and thus impair its active or passive
safety.
Flender will accept no liability or warranty whatsoever for damage occurring as a result of the
use of non-approved spare parts. The same applies to any accessories which were not supplied
by Flender.

The contact address of Flender Customer Services can be found under Service & Support
(Page 105).

Information required when ordering spare parts

To order spare parts, refer to the spare-parts list. Only ever use Flender spare parts.
When ordering spare parts, please provide the following information:
• Order number with item
• Type and size
• Part number
• Quantity

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Declaration of incorporation A
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Declaration of incorporation

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Technical data B
B.1 General technical data

Rating plate
The gear unit rating plate contains the most important technical data.

       










① Company logo ⑧ Speed n2

② Serial no.: production plant code/order no. ⑨ Optional DMC (Data Matrix Code)
item ser. no./year of manufacture
③ Total weight in kg ⑩ Oil data: Oil type, oil viscosity, oil quantity
④ For special information ⑪ Numbers of operating instructions
⑤ Type, size ⑫ For special information
⑥ Power rating P2 in kW or torque T2 in Nm ⑬ Manufacturer documentation / Country of ori‐
gin
⑦ Speed n1 ⑭ Hotline
Figure B-1 Rating plate

The limits of the intended use of the gear unit are defined on the basis of these data and the
contractual agreements concerning the gear unit concluded between Flender and the customer.

Further information
Further information about these technical data can be found in the separate data sheet and the
dimension drawings in the complete documentation for the gear unit.

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Technical data
B.1 General technical data

Further information about all major accessories including their technical data and control
instructions can be found in the order-specific list of equipment in the complete documentation
for the gear unit.

Example code
The following code is an example of a complete gear unit designation from the DURUNORM
program. The inscription on the rating plate can be found in field 5. For longer character strings
in the designation, the inscription on the rating plate can be found in field 4.

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 Technical data
B.5 Enveloping surface sound pressure level

Further information
You can find additional information on the weights and the enveloping surface sound pressure
levels in chapters Weights (Page 115) and Enveloping surface sound pressure level (Page 115).
Further information about these technical data can be found in the separate data sheet and the
dimension drawings in the complete documentation for the gear unit.

B.2 Ambient temperature

The gear unit may be operated in an ambient temperature range from -20 °C to 40 °C. By
applying various suitable measures, the gear unit can be used in the ambient temperature range
extending from -40 °C up to 60 °C. However, this must always be authorised by Flender and
specified in the order text.

Storing the gear unit

Do not expose the gear unit to harmful effects such as aggressive chemical products,
environments with high levels of air pollution or humidity, or ambient temperatures below 0 °C
or above 40 °C range.

B.3 Types

Information regarding the actual type is provided in a separate data sheet and in the dimension
drawing in the complete gear unit documentation.

B.4 Weights

The precise weights are specified in the dimension drawings in the complete documentation or
on the rating plate.
All weight specifications refer to units without oil filling or mounted components.

B.5 Enveloping surface sound pressure level

The gear unit complies with a sound power level, which places it in a gear unit type class
defined in VDI 2159, which is applied to produce the 80 % characteristic curve of the emission
characteristic map.
Adherence to limit values can, under specified Flender test conditions, be assumed with
statistical certainty.

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B.5 Enveloping surface sound pressure level

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Index
Disclaimer, 11
Disposal, 107
A Documentation landscape, 11
Double change-over filter
Air-oil cooler
Cleaning, 97
Principle of operation, 28
Alignment
Alignment surface, 54
Prealignment, 54
E
Attachment points, 49 Environmental protection, 107
Auxiliary drive Equipment features, 22
Checking, 95 Eye bolts, 45
Checking the speed monitoring, 97
Commissioning, 85
Filling the overrunning clutch with oil, 95 F
Fan
Air guide cover, 27
B Principle of operation, 27
Backstop Fastening bolts
Commissioning, 84 Bolt connection class, 79
Design, 33 Bolts, 78
filling with oil, 94 Checking for tightness, 99
Principle of operation, 32 Mating threads, 78
replacing, 94 Preload force, 79
Bearing monitoring Tightening procedure, 79
Acceleration sensor, 38 Tightening torque, 79
Connecting, 77 Fault, 99
Resistance thermometer, 37 Fault rectification, 100
Filter, 31
Final work, 81
C
Coarse filter
Cleaning, 97
G
Coloured markings, 14 Gear unit designs, 21
Contact, 105 Gear unit equipment, 23
Cooling, 26 Gear unit housing, 22
Cooling coil Gear unit markings, 14
Commissioning, 83 General inspection of the gear unit, 99
Connecting, 72
Principle of operation, 27
Copyright, 12 H
Coupling, 34
Heating
Customer Services, 105
Commissioning, 84, 87
Connecting the heating element, 74
Function, 35
D Heating elements, 35
Danger of explosion, 18 Temperature monitor, 35
Directions of rotation, 21

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Index

I P
Interval, 92 Pressure lubrication, 24
Irregularities in operation, 89 Protective equipment, 16
Pump, 31

L
Labyrinth seal, 26
R
Lateral pulling, 45 Rating plate, 113
Lubricant, 12 Example of type and size, 114
Lubrication point, 22 Reactivating, 20
Resistance thermometer
Connecting, 76
M Rolling-contact bearings
Measuring the vibration levels, 98
Maintenance activities, 92
Rotary shaft sealing ring, 25
Maintenance information, 91
Maintenance schedule, 92
Measures
during commissioning, 86
S
Prior to commissioning, 83 Safety rules, 13
Mounting position, 49 Scope of delivery, 43
Servicing activities, 92
Shaft bearings, 25
N Shaft seal, 25
Shaft-mounted gear unit
Note about assembly, 49
Assembly, 62
Axial locking, 65
Dismantling, 65
O Hydraulic pulling equipment, 66
Oil, 12 Shear pulling, 45
Oil level indicator, 36 Shipping documents, 43
Oil supply, 24 Shrink disk
Oil supply system, 24, 30, 32 Checking, 98
Air-oil cooler, 28 Splash lubrication, 24
Commissioning, 85
Oil supply variants, 24
Oil temperature T
Checking, 94
Taking the unit out of service, 90
Oil temperature monitoring
Technical data, 113
Connecting the resistance thermometer, 75
Temperature control valve, 29
Resistance thermometer, 37
Temperature monitor
Oil-level monitoring system
Connecting, 76
Connecting the filling level limit switch, 75
Transport information, 43
Filling level limit switch, 36
Transport symbol, 44
Operating data
Troubleshooting, 99
Compliance with, 89
Types of danger, 16
Oil, 89
Ordering spare parts, 105, 109
Output shaft versions, 21

Assembly and operating instructions 5240en

118 Edition 06/2020
 Index

U
Unpacking, 50
Used oil, 107
Using the gear unit, 19

W
Warning symbols, 15
Water-oil cooler, 30

Assembly and operating instructions 5240en

Edition 06/2020 119
Index

Assembly and operating instructions 5240en

120 Edition 06/2020
FLENDER GEAR UNITS
DURUNORM Gear unit
Assembly and operating instructions 5240en
Edition 06/2020

Flender GmbH
Alfred-Flender-Straße 77
46395 Bocholt
GERMANY