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Operating Instructions MOTOX -N

1. 588 588 590 i oa EB DE dh 7 74 515 a Bi V 585 Figure 6 12 1 Mounting motor bedplates IEC motors up to size 112 515 Drive shaft 588 Bolt 590 Motor plate 585 Bolt 1 Loosen the screw part 585 4x 2 Adjust the height of the motor plate part 590 by evenly turning the screw part 588 and adjust e g the belt tension 3 After adjusting to the correct height tighten the bolts part 585 4x to the prescribed torque acc to table 6 12 1 Tightening torque TA fitted motor Thread size Strength class min 88 Tead size Strength class min 88 Nm Nm 4 3 M16 210 M5 6 M 20 450 6 10 M 24 750 M8 25 M30 1500 M10 50 36 2500 M12 90 Table 6 12 1 Tightening torque Ta fitted motor Caution On completing installation and adjusting work protect bright parts against corrosion Use a suitable durable corrosion preventive medium BA 2010 EN 05 04 53 90 FLENDER 6 12 2 Mounting IEC motors sizes 132 to 200 Danger Motor bedplate may slip out out of the fastening Do not adjust when in a suspended mounting position 588 589
2. DR ZR B5 IM B5 DR ZR V1 IM V1 DR ZR V3 IM V3 Be ee LI E LII 2 S5 LY i Figure 3 5 2 7 Mounting positions for DR ZR68 DR ZR88 DR ZR B5 IM 85 DR ZR V1 IM V1 DR ZR V3 IM V3 r rua N _ 8 2 an lt q 8 x ae LL 9 lt I gt L p i Y LI LI a Figure 3 5 2 8 Mounting positions for DR ZR108 DR ZR168 BA 2010 EN 05 04 16 90 FLENDER 3 5 3 Bevel helical gear units Note 1 For key to diagram symbols see section 3 5 Mounting positions The assembly options shown apply also to the foot flange mounted housing size 188 m9 nm o Figure 3 5 3 1 Presentation foot flange housing K 188 K B3 00 IM B3 00 K B8 00 IM B8 00 K B7 00 IM B7 00 KA H 01 KA H 02 KA H 03 111 VEEN LII K B6 00 IM B6 00 K V5 00 IM V5 00 K V6 00 IM V6 00 KA H 04 KA H 05 KA H 06 Figure 3 5 3 2 Mounting positions for K KA KAS KAT Size 38 188 BA 2010 EN 05 04 17 90 FLENDER Note 1 For key to diagram symbols see section 3 5 Mounti
3. eg i gt 2 8 IV 111 NS p c Figure 3 5 6 Operating position for dual gear unit a Main gear unit BA 2010 EN 05 04 21 90 FLENDER 3 6 Oil quantities Caution Incorrect oil quantities cause damage to the drive The exact oil quantities are specified on the rating plates of the drives The oil quantities listed in the tables are approximate values They aerve for the storage and procurement of lubricant 3 61 Helical gear units Mounting position Type 25 88 VIR s V6 E 38 02 02 03 03 04 05 06 05 06 C 48 03 03 06 6 5 07 07 14 07 1 1 68 05 05 10 11 15 1 7 19 18 19 88 os 07 16 16 25 22 38 23 38 E 108 13 10 27 28 46 37 66 38 66 E 128 23 23 53 52 72 64 109 64 109 E 148 40 28 70 70 103 93 145 95 148 2 38 05 05 06 oe 06 08 12 07 11 2 48 1 1 10 16 13 15 18 24 19 24 2 68 18 17 27 23 25 30 41 32 41 2 88 41 37 61 53 57 68 83 75 7 108 7 60 105 9 3 86 13 8 140 132 13 6 7 128 95 70 160 141 132 185 207 199 209 7 148 130
4. 07 77108 07 77128 712 111 gt lt gt gt 07 77148 07 77168 DZ ZZ188 5 1360 07 136 10020 07 716 111 07 77168 07 77188 gt j 10010 07 lt 136 0 07 100 s NS 07 77168 Figure 6 5 1 C type housing flange helical gear units BA 2010 EN 05 04 38 90 FLENDER 7 108 F Z 108B ai RE gt Gr a 10310 07 103 7 148 L 7 1488 18 145 145 0 07 a 161111 3110 07 ES 14540 07 E 145 K Z 128 7 128 14 125 12510 07 612111 S 43 0 07 43 L 43 43 0 07 Lt 12510 07 125 K Z 168 K Z 188 L 7 1688 F Z 188B 18 171 17110 07 _ SAO ON 171 0 07 171 Figure 6 5 2 C type housing flange bevel helical gear units and parallel shaft helical gear units 9 Spring pins heavy duty design to DIN 1481 Use pin holes provided in the housing flange Cylindrical grooved pins with chamfer to DIN EN 28740 ISO 8740 Drill connecting component together with housi ng BA 2010 EN 05 04 39 90 FLENDER 6 6 Installation of input drive and output drive elements on gear uni
5. 502 505 Figure 6 11 1 Coupling housing with torsionally flexible coupling 502 Plug 555 Coupling half 557 flexible element 505 Hexagon head screw 556 Coupling half 564 Set screw 1 Fit the coupling half part 556 onto the end of the motor shaft in accordance with section 6 6 Installation of input drive and output drive elements on gear unit shafts 2 Adhere to the spacing dimension z12 acc to table 6 11 1 3 Distance dimension z12 ein IEC B5 80 90 100 112 132 160 180 200 25225 250 315 212 mm 15 26 30 30 45 66 59 60 90 75 33 56C 143TC 182TC 213TC 254TC 28410 324TC 36410 NEMA TC 145TC 184TC 215TC 256TC 286TC 326TC 36510 z12 mm 27 5 28 36 5 45 5 50 61 71 78 Table 6 11 1 3 Distance dimension 212 e Note t Dimension z12 applies to standard assignment of the coupling In the case of a special assignment refer for the dimension to the relevant special dimension diagram 3 Using the set screw part 564 secure the coupling half part 556 against axial displacement 4 In the case of motors which are balanced with a half parallel key symbol H machine off projecting and visible parts of the parallel key BA 2010 EN 05 04 49 90 FLENDER 5 Insert the flexible element part 557 inti the coupling half part 555 6 Flange
6. 1 C 585 585 515 IC eu e 585 EE 56 586 Figure 6 12 2 Mounting motor bedplate IEC motors sizes 132 to 200 515 Drive shaft 586 Pillar 589 Hexagon nut 585 Set screw 588 Bolt 590 Motor plate 1 Loosen the set screws Pos 585 4x 2 Adjust the height of the motor plate part 590 by evenly turning the screw part 588 and adjust e g the belt tension 3 After setting the correct height tighten the set screws part 585 4x Caution On completing installation and adjusting work protect bright parts against corrosion Use a suitable durable corrosion preventive medium BA 2010 EN 05 04 54 90 FLENDER 6 12 3 Mounting IEC motors from size 225 592 592 590 2 I 585 i T _ 586 Figure 6 12 3 Mounting motor bedplate IEC motors from size 225 515 Drive shaft 588 Bolt 590 Motor plate 585 Set screw 589 Hexagon nut 592 Hexagon nut 586 Pillar 1 Loosen the set screws Pos 585 4x 2 Undo the hexagon nuts part 592 of the support 3 Adjust the height of the motor plate part 590 by evenly turning the screw part 588 and adjust e g the belt tension 4 After setting the cor
7. 70 250 500 1000 2500 5000 10000 25000 50000 h Figure 10 3 Approximate values for oil change intervals T Oil bath steady state temperature C Oil change interval in operating hours h BA 2010 EN 05 04 75 90 FLENDER Mineral oil Synthetic oil PG Polyglycol PG Designation to CLP ISO VG 220 CLP PG ISO VG 220 CLP PG ISO VG 460 DIN 51 502 Gear unit types E 0 7 K F E D Z K 10 40 C 20 50 C 0 60 C temperatures AUDIRIDE CLP 220 S Degol BG 220 Degol GS 220 Degol GS 460 Energol GR XP 220 Enersyn SG XP 220 Enersyn SG XP 460 S Castrol Alpha SP 220 Optigear BM 220 Tribol 1100 220 Optiflex A 220 800 220 Optiflex A 460 Tribol 800 460 Falcon CLP 220 Polydea PGLP 220 Polydea PGLP 460 Spartan EP 220 Glycolube 220 Glycolube 460 Hor 6 Renolin CLP 220 Renolin 220 Renolin PG 460 KLOBER LUBRICATION Kl beroil GEM 1 220 Syntheso D 220 EP Syntheso D 460 EP Mobil Mobilgear XMP 220 Shell Omala 220 Tivela WB Tivela SD Table 10 3 1 Oils BA 2010 EN 05 04 76 90 FLENDER Note The service life of the grease is approx 4 000 operating hours It is based on a max ambient temperature of 40 C The service life of the grease dec
8. DZ ZZ B14 IM B14 DZ ZZ V18 IM V18 x CECI amp im amp t 1 Figure 3 5 2 5 Mounting positions for D Z 108 D Z 168 SO N 8 C ld 2 Z DZ V6 IM V6 H Y ZK DF ZF V3 IM V3 DZ ZZ V19 IM V19 ME H 68 722 222 Z ZK DF ZF V3 IM V3 07 77 V19 IM V19 ul gt 0 2010 05 04 15 90 FLENDER Note 1 For key to diagram symbols see section 3 5 Mounting positions ZK DF ZF 85 IM B5 ZK DF ZF V1 IM V1 ZK DF ZF V3 IM V3 0222 814 IM 814 0222 V18 IM V18 0222 V19 IM V19 HE 5 7 _ S LIII e Figure 3 5 2 6 Mounting positions for D Z 188
9. Figure 6 13 1 Torque arm on bevel helical gear unit Reaction torque on gear unit housing output torque To Fs Bracing force of the torque arm against the suspension Properties of the rubber elements Basic material natural rubber 60 Shore thermal resistance 45 70 C 1 Clean the contact surfaces between housing and torque arm 2 Secure the bolts for fastening the torque arm on the gear unit with Schnorr lock washers Tighten the bolts to the prescribed torque acc to table 6 13 1 Tightening torque TA Fitting torque arm BA 2010 EN 05 04 56 90 FLENDER 6 13 2 Thread size strength class min 68 size Strength class min 88 Nm Nm M8 25 M 20 450 M 10 50 M 24 750 M 12 90 M 30 1500 M 16 210 Table 6 13 1 Tightening torque TA Fitting torque arm Mounting torque arm on parallel shaft helical gear unit e Note 1 We recommend using pretensioned damping rubber elements Suggestion for fastening the rubber elements ordered from and supplied by us 3 y BY u 35 Figure 6 13 2 Torque arm on parallel shaft helical gear unit Fixings such as angle screw nut etc are not included in the delivery Type F38B F 48B F 68B F 88B F 108B F 128B F 148B F 168B F 188B x mm 13 1 18 2 17 27 2 26 35 8 34 8 46 2 45 1
10. E 886 IM 86 E V5 0MV5 E V6 IM V6 H cy ET 1 V pe Ga lt LL IL IL VLL d w 4 L 2 Figure 3 5 1 1 Mounting positions for E38 E148 65 IM B5 EF EK 1 IM V1 EF EK 3 IM V3 EZ B14 IM B14 EZ V18 IM V18 EZ V19 IM V19 8 Figure 3 5 1 2 Mounting positions for 38 148 2010 05 04 13 90 FLENDER Two and three stage helical gear units e Note For key to diagram symbols see section 3 5 Mounting positions D Z B3 B3 V DZ B6 B6 DZ B8 IM B8 S lt 8 LI GSI Z DZ 15 IM V5 2 Figure 3 5 2 1 Mounting positions for 0 238 0 288 DZ B3 1 D Z B6 IM B6 SS D Z B8 IM B8 2 2 LI LI Z d DZ V5 IM V5 f
11. u 08 7 S Figure 3 5 2 2 Mounting positions for D Z108 D Z168 DZ B7 IM B7 V lt 881 DZ V6 IMV6 D Z V6 IM V6 g 2010 05 04 14 90 FLENDER Note 1 For key to diagram symbols see section 3 5 Mounting positions DZ 83 M83 D Z B8 88 D Z B7 IM B7 D Z B6 IM B6 D Z V5 IM V5 gt By B 9 i Figure 3 5 2 3 Mounting positions for 0 2188 ZK DF ZF V1 IM V1 DZ ZZ V18 IM V18 ZK DF ZF B5 IM B5 B14 IM B14 DZ ZZ _ 1 9 Figure 3 5 2 4 Mounting positions for D Z 38 D Z 88 ZK DF ZF B5 IM B5 ZK DF ZF V1 IM V1
12. G D ck T4 120 EC Declarations of Conformity and or EC Type Test Certificates for further equipment added to the gear unit and or for safety systems are enclosed These may be specifically Rotating electrical machines Safety systems for oil level and or temperature monitoring equipment The technical documentation for gear units of category 2 has been subjected to a voluntary inspection and filed with the specified office no 0123 TUV PRODUCT SERVICE GmbH RidlerstraBe 31 D 80339 M nchen Porn T bingen 03 05 2004 p p Head of Gear Unit Development p p Head of Quality Management BA 2010 EN 05 04 90 90
13. 001 020 030 032 035 037 040 045 070 090 091 095 101 130 131 Gear unit housing Bearings Bearings Supporting disk shim Locking ring Locking ring Output flange Bolt Sealing cap Torque arm Rubber bush Bolt Output shaft Bearings Supporting disk shim 133 135 140 143 144 146 160 201 205 210 211 220 225 301 Nilos ring Locking ring Bearings Nilos ring Supporting disk shim Locking ring Shaft seal Adapter plate Bolt Bolt Screw lock Seal Seal Plug in pinion 305 331 335 340 345 346 401 411 412 413 415 418 420 430 Gear wheel Parallel key Locking ring Worm shaft Worm wheel Parallel key Screw plug Bolt Screw lock Washer Locking ring Plug sealing cap Breather filter Eye bolt BA 2010 EN 05 04 84 90 FLENDER 13 13 1 Declaration by the manufacturer Declaration of Conformity Declaration by the manufacturer in accordance with EC Engineering Guideline 98 37 EC Appendix II B We hereby declare that the Single stage helical gear units and gear motors of the types E 38 E 88 E 148 E 48 E 108 E 68 E 128 Two and three stage helical gear units and gear motor of the types D Z 38 D Z 88 D Z 148 0 7 48 D Z 108 D Z 168 D Z 68 D Z 128 D Z 188 Bevel helical gear units and gear motors of the types K 38 K 88 K 148 K 48 K 108 K 168 K 68 K 128 K 188 Parallel shaft helical gear units and gear motors of the types F 38B F 88B F 148B
14. 4 10 Backstop For certain requirements the gear units can be fitted with a mechanical backstop It can be fitted either in the coupling housing or in the bevel helical gear unit It permits only the correct direction of rotation during the operation of the unit This is marked by a corresponding direction arrow Caution Damage or destruction of the backstop through wrong direction of rotation Do not run motor against the backstop Observe information on the gear unit The backstop is fitted with centrifugally operated sprags When the gear unit is running in the specified direction the inner ring and the cage with the sprags also rotate while the outer ring remains stationary Where the backstop is used in the coupling housing lifting of the sprags is ensured at speeds above 1 000 rpm The backstop is wear free Caution In the case of applications at speeds under 1 000 rpm or frequent starting and stopping operations gt 20 starts stops an hour the service life is limited Ensure that the backstop is replaced in good time If used in the bevel helical gear unit the backstop operates below the lift off speed of the sprags in the oil The oil must be changed at the same intervals as those of the gear unit Rating plates The rating plates of the gear units or gear motors are normally of coated aluminium foil They are covered with a special masking film which guarantees permanent resistance to UV radiation and media of
15. Align and grout the slide rails into the foundation Installing gear units with foot mounting Use stud bolts or headless bolts of strength class 8 8 or higher for the foot mounting Drive units in foot or flange version The drive must be fastened for force and torque transmission only to either the flange or the foot mounting in accordance with section 6 3 Drives with foot mounting to prevent overstress on the gear unit housings The second mounting option foot or flange is usually intended for add on elements e g safety covers with an intrinsic weight of up to 30 of the weight of the drive Caution Do not subject gear housings to overstress from add on elements Add on elements must not transmit forces torques and vibration to the drives BA 2010 EN 05 04 37 90 FLENDER 6 5 Drive units with C type housing flange In the case of sizes 108 188 the customer s interface can be pinned on the C type housing flange The drive flanges are designed to enable the permissible torques and radial forces to be reliably transmitted by the bolt connections For additional fastening e g in the case of reversing operation or high shock loads the drilled pin holes can be used The gear unit can also be drilled and pinned together with the machine For this the specified dimensions must be adhered to Caution Observe maximum drilling depth A A
16. 108 038 6 0 10 0 13 5 9 9 9 2 8 8 8 8 0 5 19 6 0 5 24 4 0 8 15 8 1 2 16 9 0 5 16 1 0 5 K 128 238 8 8 20 1 25 2 17 0 17 4 16 6 8 3 1 0 19 6 1 0 24 4 1 8 15 8 2 4 16 9 1 0 16 1 1 0 K 128 248 9 3 20 6 26 2 18 2 17 9 17 1 8 8 0 5 19 6 0 5 24 4 0 9 15 8 1 1 16 9 0 5 16 1 0 5 128 038 8 8 20 1 25 3 16 9 17 4 16 6 14 8 0 5 30 2 0 5 37 0 0 8 22 0 1 2 25 8 0 5 27 0 0 5 148 238 15 3 30 7 37 8 23 2 26 3 27 5 14 8 1 7 30 2 1 7 37 0 3 0 22 0 4 1 25 8 1 7 27 0 1 7 148 268 16 5 31 9 40 0 26 1 27 5 28 7 14 8 0 5 30 2 0 5 37 0 0 9 22 0 1 1 25 8 0 5 27 0 0 5 148 038 15 3 30 7 37 9 23 1 26 3 27 5 21 6 1 0 45 6 1 0 60 5 1 8 34 2 2 4 40 2 1 0 38 5 1 0 168 248 22 6 46 6 62 3 36 6 41 2 39 5 21 6 1 7 45 6 1 7 60 5 3 0 34 2 4 1 40 2 1 7 38 5 1 7 168 268 23 3 47 3 63 5 38 3 41 9 40 2 21 6 1 1 45 6 1 1 60 5 2 3 34 2 2 4 40 2 1 1 38 5 1 1 168 048 227 46 7 62 8 36 6 41 3 39 6 33 8 1 7 82 5 1 7 104 2 3 63 4 4 1 70 7 1 7 69 4 1 7 188 268 35 5 84 2 107 2 67 5 72 4 71 1 33 8 3 7 82 5 3 7 104 2 6 8 63 4 8 8 70 7 3 7 69 4 3 7 188 288 37 5 86 2 111 72 2 74 4 73 1 33 8 1 6 82 5 1 6 104 2 3 9 63 4 4 70 7 1 6 69 4 1 6 188 068 35 4 84 1 108 1 67 4 72 3 71 0 Table 3 6 5 2 1 Oil quantities for K KA KAS KAT Size 38 188 BA 2010 EN 05 04 26 90 FLENDER Mounting position Type B5 01 B5 03
17. 7 4 2 Long term preservation up to 36 months The gear unit is delivered with a complete oil filling Caution Before starting up adjust oil level in accordance with the assembly option see section 3 5 Mounting positions 1 Unscrew the sealing element at the point marked with this symbol see section 3 5 Mounting positions and drain the oil 2 Check the oil level 3 Rectify the oil level if necessary see section 10 2 3 Oil change and check it again 7 5 Drive with backstop special version Qo Caution Before starting up check direction of rotation Turn drive side or motor over manually Check direction of motor rotation with the aid of the phase sequence If necessary exchange two outer conductors BA 2010 EN 05 04 60 90 FLENDER 8 Operation Drives version The difference between the temperature of the housing and the ambient temperature max 40 must not exceed 70 K Using a suitable temperature sensor measure the temperature at the lowest point of the housing oil sump or at the mounting surface in the case of output assemblies Changes are an indication of possible incipient damage Caution In case of changes during operation the drive must be switched off immediately Determine the cause of the fault with the aid of the fault table in section 9 Faults causes and remedy Remedy faults or have faults remedied Check the gear
18. In the case of reversing operation or high shock loads provide additional suitable positive fastenings such as cylindrical taper pins or spring pins Caution Do not use spring washers serrated lock washers spring or toothed lock washers cup washers or conical spring washers as a substitute for the above mentioned positive fastenings Do not subject the gear unit housing to excessive stress when tightening the fastening bolts Cap screws cannot be used in some cases as there is insufficient space available for inserting them In case of doubt please contact the FLENDER TUBINGEN GMBH customer service quoting the type of gear unit BA 2010 EN 05 04 36 90 FLENDER 6 3 6 3 1 6 3 2 6 4 Drives with foot mounting Foundation The foundation must be level and free from dirt Note 1 The levelness of the gear unit support must not exceed the following values for gear units up to size 88 lt 0 1 mm for gear units from size 108 lt 0 2 mm The foundation should be designed in such a way that no resonance vibrations are created and that no vibrations are transmitted from adjacent foundations Steel structures on which the unit is to be mounted must be rigid They must be designed according to the weight and torque taking into account the forces acting on the gear unit When fastening the gear unit to concrete foundations by means of foundation blocks suitable recesses should be made in the foundation
19. 12 2 2 12 2 3 12 2 4 12 2 5 12 3 13 13 1 13 2 Oil quality Oil change Replacing bearings Relubrication of the rolling bearings in drive units Change rolling bearing grease Seal check Clean ventilation filter Clean drive Checking tightness of fastening bolts Inspection of the drive Carry out maintenance on slip coupling Lubricants Disposal Stocking spare parts and customer service addresses Stocking spare parts Spare parts lists One stage helical gear units Two and three stage helical gear units Bevel helical gear units Parallel shaft helical gear units Helical worm gear units Customer service addresses FLENDER TUBINGEN GMBH Germany FLENDER TUBINGEN GMBH Europe FLENDER TUBINGEN GMBH International Declaration by the manufacturer Declaration of Conformity Declaration by the manufacturer EC Declaration of Conformity 65 65 66 66 67 69 69 69 69 70 71 71 72 72 72 72 73 73 73 74 78 79 79 80 80 81 82 83 84 85 85 87 89 89 90 BA 2010 EN 05 04 5 90 FLENDER 1 1 1 1 2 Important instructions Instruction symbols in the operating instructions Instructions relating to operating safety are emphasized as follows AN Danger Possible consequences Death or very severe injuries Caution Possible consequences Damage to the drive and the environment Note Pointers for application and useful information Drives in ATEX version Instruc
20. 2 340 8 2 440 8 2 4 0 8 2 4 0 8 0 48 228 1 4 1 3 1 8 1 7 1 8 3 1 3 2 3 2 3 2 D 68 228 pu En Ps b 4 0 0 8 d i 8 4 8 1 7 0 5 1 6 0 5 2 6 0 5 24 0 5 2 6 0 5 3 9 0 8 4 0 1 2 4 0 0 7 4 0 1 2 0 68 238 2 2 2 1 3 1 2 9 3 1 4 7 5 2 4 7 5 2 1 7 0 5 1 6 0 5 2 6 0 5 2 4 0 5 2 6 0 5 3 9 0 9 4 0 1 1 4 0 0 9 4 0 1 1 0 68 038 2 2 2 1 3 1 2 9 3 1 4 8 5 1 4 9 5 1 4 0 0 3 3 6 0 3 5 940 3 5 4 0 3 5 9 0 3 8 7 0 8 8 9 0 8 9 340 8 8 9 0 8 D 88 228 4 3 3 9 6 2 5 7 6 2 9 5 9 7 10 1 9 7 4 0 0 5 3 6 0 5 5 9 0 5 5 4 0 5 5 940 5 8 7 0 8 8941 2 9 3 0 7 8 9 1 2 D 88 238 4 5 4 1 6 4 5 9 6 4 9 5 10 1 10 0 10 1 D 88 D38 2508 Pw Po ER P E pen E E 7 1 0 3 5 740 8 10 3 0 3 9 5 0 3 10 0 0 3 16 3 0 8 14 2 0 8 15 6 0 8 13 7 0 8 D 108 228 7 4 6 0 10 6 9 8 10 3 17 1 15 0 16 4 14 5 7 1 0 5 5 740 5 10 3 0 5 9 5 0 5 10 0 0 5 16 3 0 8 14 2 1 2 15 6 0 7 13 7 1 2 0 108 238 7 6 6 2 10 8 10 0 10 5 17 1 15 4 16 3 14 9 7 1 0 5 5 7 0 5 10 3 0 5 9 5 0 5 10 0 0 5 16 3 0 9 14 2 1 1 15 6 0 9 13 7 1 1 0 108 038 7 6 6 2 10 8 10 0 10 5 17 2 15 2 16 5 14 8 9 4 0 3 6 8 0 3 15 8 0 3 14 8 0 3 14 1 0 3 24 6 0 8 21 8 0 8 24 4 0 8 21 5 0 8 0 128 228 9 7 7 1 16 1 15 1 14 4 25 4 22 6 25 2 22 3 9 4 0 5 6 8 0 5 15 8 0 5 14 8 0 5 14 1 0 5 24 6 0 8 21 8 1 2 24 4 0 7 21 5 1 2 0 128 238 9 9 7 3 16 3 15
21. 7 Rectify the oil level if necessary see section 10 2 3 Oil change and check it again BA 2010 EN 05 04 69 90 FLENDER 10 2 3 Oil change P P P Danger Secure the drive unit to prevent it from being started up unintentionally Attach a warning notice to the start switch Danger Danger of scalding from the hot oil emerging Before starting any work wait until the oil has cooled down to 30 C Danger Remove any oil spillage immediately with an oil binding agent in compliance with environmental requirements Caution The oil quantity and the position of the sealing elements depend upon the assembly option see section 3 5 Mounting positions Note As a rule mineral oil is used as lubricant Synthetic oils with special properties are available optionally For data such as oil grade oil viscosity and oil quantity required refer to the rating plate see section 3 2 General technical data For oil compatibility refer to see section 10 3 Lubricants Note In case of double gear units every single unit is to be considered separately Note In case of ambient conditions deviating from the normal high ambient temperatures high relative humidity aggressive ambient media the intervals between changes should be shorter In such cases contact the FLENDER TUBINGEN GMBH customer service to determine the individual lubricant change intervals BA 2010 EN 05 04 70 90
22. 99 208 183 269 239 277 257 274 Z 168 210 153 348 301 321 480 311 480 417 7 188 185 185 500 460 750 720 700 720 700 0 38 05 05 06 06 06 6 9 11 09 1 1 D 48 14 10 15 14 15 23 24 24 24 D 68 17 16 26 24 26 39 40 40 40 D 88 40 36 59 54 59 87 89 93 89 D 108 7 1 57 103 9 5 100 163 142 156 137 128 94 68 15 8 14 8 141 246 218 24 4 215 D 148 125 9 4 204 191 234 306 282 322 279 D 168 190 160 31 312 338 580 437 544 42 2 188 184 184 480 460 730 690 680 690 68 0 Table 3 6 1 quantities for E 38 C 148 D Z 38 D Z 188 BA 2010 EN 05 04 22 90 FLENDER 3 6 2 Bevel helical gear units Mounting position Type B3 00 B8 00 B7 00 B6 00 V5 00 V6 00 H 01 H 02 H 03 H 04 H 05 H 06 K 38 0 5 14 1 4 0 8 1 0 0 9 K 48 0 7 1 6 2 0 1 4 1 5 1 8 K 68 1 6 3 2 3 9 2 7 3 0 3 0 K 88 2 6 5 7 7 4 5 0 4 9 5 2 K 108 5 5 9 5 12 6 8 8 8 7 8 3 128 8 3 19 6 24 4 15 8 16 9 16 1 K 148 14 8 30 2 37 0 22 0 25 8 27 0 K 168 21 6 45 6 60 5 34 2 40 2 38 5 K 188 33 8 82 5 104 2 63 4 70 7 69 4 Table 3 6 2 1 Oil quantities for K KA KAS KAT Size 38 188 Mounting position Type B5 01 B5 03 B5 02 B5 00 V1 00 V3 00 1 01 1 02 1 03 H 04 H 05 H 06 K 38 0 5 1 1 1 5 0 8 1 0 0 9 K 48 0 7 17 2 0 1 4 1 6 1 8 K 68 1
23. F 48B F 108B F 168B F 68B F 128B F 188B Helical worm gear units and gear motors of the types C 38 C 68 C 48 C 88 described in these operating instructions are intended for incorporation in a machine and that it is prohibited to put them into service before verifying that the machine into which they are incorporated complies with the EC Guidelines 98 37 EC This Manufacturer s Declaration takes into account all the unified standards applying to our products in part or in whole published by the European Commission in the Official Journal of the European Community These include in particular EN 292 1 EN 292 2 EEN 294 EEN 349 EN 60204 1 ota ire T bingen 03 05 2004 p p Head of Gear Unit Development BA 2010 EN 05 04 89 90 FLENDER 13 2 EC Declaration of Conformity Document GKFSN298 DE 07 03 Equipment designation MOTOX N Gear unit series Type Z K F Sizes 38 188 Add on subassemblies A P The designated equipment conforms to the requirements of the explosion protection guideline 94 9 EC It has been developed and manufactured in conformity to the following European standards e EN 1050 1996 e EN 1127 1 1997 EN 13463 1 2001 6 pr EN 13463 5 2002 6 pr EN 13463 8 2001 e EN 50281 1 2 1999 6 pr EN 13463 6 2002 Kind of explosion protection for equipment group II of category 2 and 3 12 G D ck T4 120 C 12 G D bek T4 120
24. Table 6 13 2 Setting dimension x Properties of the rubber elements Basic material natural rubber 70 Shore A hermal resistance 40 80 C BA 2010 EN 05 04 57 90 FLENDER 6 13 3 Mounting torque arm on helical worm gear unit Danger The torque arm bush must be mounted in bearings on both sides Suggestion for fitting the gear unit with torque arm Figure 6 13 3 Torque arm on helical worm gear unit The torque arm may be fitted in various positions depending on the hole circle pitch Properties of the rubber elements Basic material natural rubber 60 Shore A thermal resistance 45 70 1 Clean the contact surfaces between housing and torque arm 2 Tighten the bolts to the prescribed torque acc to table 6 13 3 Tightening torque TA Fitting torque arm Thread size class min 8B Thread size class min 8 8 Nm Nm M8 25 M 20 450 M 10 50 24 750 12 90 M 30 1500 M 16 210 Table 6 13 3 Tightening torque TA Fitting torque arm BA 2010 EN 05 04 58 90 FLENDER 7 1 7 2 7 3 7 3 1 7 3 2 Start up Danger Secure the drive unit to prevent it from being started up unintentionally Attach a warning notice to the start switch Danger Remove any oil spillage immediately with an oil binding agent in compliance with environmental requirements Oil level check before start up Check the oil level be
25. 0 5 0 3 1 7 0 3 1 8 0 8 1 6 0 8 1 3 0 3 1 3 0 3 C 48 228 0 8 2 0 2 6 2 4 1 6 1 6 1 5 0 3 3 6 0 3 4 2 0 8 3 3 0 8 3 1 0 3 3 2 0 3 C 68 Z28 1 8 3 9 5 0 4 1 3 4 3 5 1 5 0 5 3 6 0 5 4 2 0 8 3 3 1 2 3 1 0 5 3 2 0 5 C 68 Z38 2 0 4 1 5 0 4 5 3 6 3 7 1 54 0 5 3 6 0 5 4 2 0 9 3 3 1 1 3 1 0 5 3 2 0 5 C 68 D38 2 0 4 1 5 1 4 4 3 6 3 7 1 7 0 3 6 6 0 3 7 3 0 8 5 2 0 8 4 8 0 3 4 8 0 3 C 88 228 2 0 6 9 8 1 6 0 5 1 5 1 pum 1 7 0 5 6 6 0 5 7 3 0 8 5 2 1 2 4 8 0 5 4 8 0 5 2 2 71 8 1 6 4 5 3 5 3 1 7 0 5 6 6 0 5 7 3 0 9 5 2 1 1 4 8 0 5 4 8 0 5 C 88 038 2 2 7 1 8 2 6 3 5 3 5 3 Table 3 6 5 4 2 Oil quantities for CZ CF CAD CAF CADS CAFS 0425 Size 38 88 BA 2010 EN 05 04 29 90 FLENDER 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 Technical description General description The gear units are supplied with one two or three transmission stages The gear units are suitable for the different mounting positions taking into consideration the oil level Housing The gear unit housings of grey cast iron are designed for continuous operation Toothed components The toothed components of the gear unit are hardened In the case of helical gear units the worm is hardened and ground and the gear manufactured from bronze Lubrication The toothed components are adequately supplied with lubricant by dip lubrication Shaft bearing All shafts are mounted in rolling bearings
26. 1 3 1 2 1 2 1 2 C 48 0 7 1 6 1 7 1 6 1 3 1 3 C 68 1 5 33 4 1 33 2 8 2 9 C 88 1 7 6 1 6 5 5 1 4 5 4 5 Table 3 6 4 1 Oil quantities for CA CAS CAT Size 38 88 Mounting position Type B5 01 B5 03 B5 02 B5 00 V1 00 V3 00 H 01 H 02 H 03 H 04 H 05 H 06 C 38 0 4 1 2 1 3 1 1 1 0 1 0 C 48 0 5 1 7 1 8 1 6 1 8 1 8 68 1 5 3 6 4 2 3 3 3 1 3 2 C 88 1 7 6 6 7 3 5 2 4 8 4 8 Table 3 6 4 2 Oil quantities for CZ CF CAD CAF CAZ CADS CAFS CAZS CADT CAFT CAZT Size 38 88 BA 2010 EN 05 04 24 90 FLENDER 3 6 5 3 6 5 1 Two and three stage helical gear units Tandem gear unit compound helical gear unit Mounting position Type B5 V1 V3 B3 814 6 87 88 V18 V19 V5 V6 738 728 Ps ru m oe ms P d 1 1 0 8 f B 5 1 9 1 1 0 3 1 0 0 3 1 6 0 3 1 3 0 3 1 5 0 3 1 8 0 8 2 440 8 1 9 0 8 2 440 8 2 48 228 1 4 1 3 1 9 1 6 1 8 2 6 3 2 2 7 3 2 1 8 0 3 1 8 0 3 2 7 0 3 2 3 0 3 2 5 0 3 3 0 0 8 4 1 0 8 3 2 0 8 4 1 0 8 2 68 228 2 1 2 1 3 0 2 6 2 8 3 8 4 9 4 0 4 9 1 8 0 5 1 8 0 5 2 7 0 5 2 3 0 5 2 5 0 5 3 0 0 8 4 1 1 2 3 2 0 7 4 1 1 2 2 68 238 2 3 2 3 8 2 2 8 3 0 3 8 5 3 3 9 5 3 0 5 0 3 0 5 0 3 0 6 0 3 0 6 0 3 0 6 0 3 0 9 0 8 1 1 0 8 0 9 0 8 1 1 0 8 0 38 228 0 8 0 8 0 9 0 9 0 9 1 7 1 9 1 7 1 9 1 1 0 3 1 0 0 3 1 5 0 3 1 4 0 3 1 5 0 3
27. 29 1 277 29 8 14 8 0 5 30 1 0 5 41 0 0 9 25 0 1 1 26 0 0 5 28 1 0 5 148 038 15 3 30 6 41 9 26 1 26 5 28 6 21 7 1 0 46 3 1 0 62 6 1 8 34 8 2 4 41 1 1 0 39 4 1 0 168 248 227 47 3 64 4 37 2 42 1 40 4 21 7 1 7 46 3 1 7 62 6 3 0 34 8 4 1 41 1 1 7 39 4 1 7 168 768 23 4 48 0 65 6 38 9 42 8 41 1 21 7 1 1 46 3 1 1 62 6 2 3 34 8 2 4 41 1 1 1 39 4 1 1 K 168 D48 22 8 47 4 64 9 37 2 42 2 40 5 Kies 33 8 1 7 82 5 1 7 104 2 3 63 4 4 1 70 7 1 7 69 4 1 7 35 5 84 2 107 2 67 5 72 4 71 1 33 8 3 7 82 5 3 7 104 2 6 8 63 4 8 8 70 7 3 7 69 4 3 7 188 288 37 5 86 2 111 72 2 74 4 73 1 33 8 1 6 82 5 1 6 104 2 3 9 63 4 4 70 7 1 6 69 4 1 6 188 068 35 4 84 1 108 1 67 4 72 3 71 0 Table 3 6 5 2 2 Oil quantities for KZ KF KAD KAZ KADS KAFS KAZS KADT KAZT Size 38 188 BA 2010 EN 05 04 27 90 FLENDER 3 6 5 3 Parallel shaft helical gear units Mounting position Type B5 01 B5 03 B5 02 B5 00 1 00 V3 00 H 01 H 02 H 03 H 04 H 05 H 06 0 9 0 3 0 6 0 3 0 7 0 3 0 7 0 3 0 9 0 9 1 1 1 0 FD 38B 228 i a Bh PA ai 2 0 0 3 0 9 0 3 1 3 0 3 1 3 0 3 1 8 0 9 2 0 1 0 FD 48B 228 26 1 1d 18 gt ds 2 0 0 5 0 9 0 5 1 3 0 5 1 3 0 5 1 8 0 8 2 0 1 2 FD 48B 238 dn s 2 2 0 0 5 0 9 0 5 1 3 0 5 1 3 0 5 1 8 0 9 2 0 1 1 FD 48B 038 8 18 3 34 0 3 2 34 0 3 2 4 0 3 2 3 0 3 3 2 0 9 3 8 1 0 FD 68B 228 35 ae
28. 3 14 6 25 4 23 0 25 1 22 7 9 4 1 0 6 8 1 0 15 8 1 0 14 8 1 0 14 1 1 0 24 6 1 8 21 8 2 4 24 4 1 8 21 5 2 4 0 128 248 10 4 7 8 16 8 15 8 15 1 26 4 24 2 26 2 23 9 9 4 0 5 6 8 0 5 15 8 0 5 14 8 0 5 14 1 0 5 24 6 0 9 21 8 1 1 24 4 0 9 21 5 1 1 0 128 038 9 9 7 3 16 3 15 3 14 6 25 5 22 9 25 3 22 6 12 5 0 5 9 4 0 5 20 4 0 5 19 1 0 5 23 4 0 5 30 6 0 8 28 2 1 2 32 2 0 7 27 9 1 2 0 148 238 13 0 9 9 20 9 19 6 23 9 31 4 29 4 32 9 29 1 12 5 1 0 9 4 1 0 20 4 1 0 19 1 1 0 23 4 1 0 30 6 1 8 28 2 2 4 32 2 1 8 27 9 2 4 0 148 248 13 5 10 4 21 4 20 1 24 4 32 4 30 6 34 0 30 3 12 5 0 5 9 4 0 5 20 4 0 5 19 1 0 5 23 4 0 5 30 6 0 9 28 2 1 1 32 2 0 9 27 9 1 1 0 148 038 13 0 9 9 20 9 19 6 23 9 31 5 29 3 33 1 29 0 19 0 1 0 16 0 1 0 34 1 1 0 31 2 1 0 33 8 1 0 53 0 1 8 43 7 2 4 54 4 1 8 42 2 2 4 0 168 248 20 0 17 0 35 1 32 2 34 8 54 8 46 1 56 2 446 19 0 1 7 16 0 1 7 34 1 1 7 31 2 1 7 33 8 1 7 53 0 3 0 43 7 4 1 54 4 3 0 42 2 4 1 0 168 268 20 7 17 7 35 8 32 9 35 5 56 0 47 8 57 4 46 3 19 0 1 0 16 0 1 0 34 1 1 0 31 2 1 0 33 8 1 0 53 0 2 3 43 7 2 4 54 4 2 3 42 2 2 4 0 168 048 20 0 17 0 35 1 32 2 34 8 55 3 46 1 56 7 44 6 18 4 1 0 18 4 1 0 48 0 1 0 46 0 1 0 73 0 1 0 83 0 1 8 68 0 2 4 83 0 1 8 68 0 2 4 0 188 248 19 4 19 4 49 0 47 0 74 0 84 8 70 4 84 8 70 4 18 4 1 7 18 4 1 7 48 0 1 7 46 0 1 7 73 0 1 7 83 0 3 0 68 0 4
29. aligned with the machine shaft to avoid misalignment Failure of the bearings from overload in the case of flange mounted drive Do not overstress hollow shaft axially and radially 4 Secure the hollow shaft axially on the machine shaft with e g a locking ring washer or set screw at a tightening torque T4 acc to table 6 9 1 Tightening torque TA set screw Size 38 48 68 88 108 128 148 168 188 Ta Nm 16 28 69 69 138 138 138 237 237 Table 6 9 1 Tightening torque TA set screw Note for shrink disks The hollow shaft is axially secured on the machine shaft by means of a shrink disk connection BA 2010 EN 05 04 43 90 FLENDER Figure 6 9 1 1 Mounting hollow shaft and parallel key Part 3 Part 4 are not included in scope of delivery 1 2 6 5 3 4 Figure 6 9 1 2 Mounting hollow shaft and splines Part 3 Part 4 are not included in scope of delivery 1 8 2 5 4 0 0 Figure 6 9 1 3 Mounting hollow shaft and shrink disk a greased b absolutely free of grease Part 3 Part 5 are not included in scope of delivery 1 Machine shaft 4 Threaded spindle 7 Parallel key 2 Hollow shaft 5 Washer 8 Bronze bush 3 Hexagon nut 6 Locking ring e Note 1 Coat with a suitable lubricant e g Calypsol type H 443 HD88 grease to prevent frictional corrosion of the contact surfaces of the customer s machine shaft in the vicinity of the bron
30. lock Seal Seal 201 210 220 301 305 320 325 327 328 331 335 340 345 346 351 401 411 413 415 418 420 Plug in pinion Gear wheel Bevel gear pair Bevel pinion shaft Parallel key Locking ring Parallel key Locking ring Pinion shaft Gear wheel Parallel key Parallel key Screw plug Bolt Washer Locking ring Plug sealing cap Breather filter BA 2010 EN 05 04 82 90 FLENDER 12 2 4 Parallel shaft helical gear units 331 306 40 0 3 J 034 SS 001 Gear unit housing 109 Locking ring 210 Bolt 020 Bearings 110 Locking ring 211 Screw lock 021 Supporting disk shim 120 Shrink disc 220 Seal 022 Supporting disk shim 128 Supporting disk shim 225 Seal 025 Locking ring 129 Supporting disk shim 301 Pinion 030 Bearings 130 Bearings 305 Gear wheel 034 Nilos ring 131 Supporting disk shim 306 Parallel key 040 Output flange 132 Spacer bush 307 Spacer bush 045 Bolt 133 Nilos ring 310 Locking ring 050 Housing cover 135 Locking ring 311 Supporting disk shim 051 Bolt 140 Bearings 325 Pinion shaft 055 Seal 141 Spacer bush 330 Gear wheel 065 Sealing cap 143 Nilos ring 331 Parallel key 070 Sealing cap 144 Supporting disk shim 340 Pinion shaft 091 Rubber bush 146 Locking ring 345 Gear wheel 101 Drive shaft 160 Shaft seal 346 Parallel key 107 Bearings 201 Adapter plate 401 Screw plug 108 Bearings 205 Bolt 420 Breather filter BA 2010 EN 05 04 83 90 FLENDER 12 2 5 Helical worm gear units
31. s slight pressure Figure 6 11 2 4 Pressure on motor shaft 8 Mount the fan cowl 9 Screw the set screw part 564 onto parallel key part 563 until slight resistance is felt then unscrew the set screw half a turn 10 Insert the Allen key into set screw part 564 through the hole for part 503 This prevents the shaft turning Caution Set screw part 564 must not be in contact of hexagon socket screw part 561 has been tightened BA 2010 EN 05 04 51 90 FLENDER 11 Tighten the hexagon socket screw part 561 to tightening torque TA swo acc to table 6 11 2 2 TA and SW 12 Tighten the set screw to tightening torque TA sw acc to table 6 11 2 2 Ta and SW an IEC B5 63 71 80 90 100 112 132 160 180 200 225 250 280 Taswi Nm 13 1 3 1 3 2 9 2 9 29 5 8 9 9 9 9 99 99 99 48 SW1 mm 2 2 2 3 3 3 4 5 5 5 5 5 8 512 Nm 15 15 15 35 35 35 70 120 120 295 295 295 580 SW2 mm 5 5 5 6 6 6 8 10 10 14 14 14 17 56 143 145 182 184 213 215 SW1 Nm 1 3 2 9 2 9 5 8 SW1 mm 2 3 3 4 Ta swe Nm 15 15 35 70 SW2 mm 5 5 6 8 Table 6 11 2 2 TA and SW Caution If drives are inadequately sealed moisture may find a way in If installing the drive outside or in the case of a higher type of protection
32. the hole but not screwed in The oil level must be between the lower and upper min max marks on the oil dipstick If the electric oil level monitoring system is used the oil must be level with the upper max mark on the oil dipstick Rectify the oil level if necessary see section 10 2 3 Oil change and check it again 10 2 1 4 Checking the oil level sensor special version Drives in ATEX version The oil level sensor indicates the oil level only when the gear unit is shut off Lower the oil level and fill it up again until the oil level sensor gives a switching signal Observe the separate operating instructions for the oil level sensor 10 2 2 Oil quality 1 Switch off the power supply to the drive 2 Unscrew the sealing element at the point marked with this symbol see section 3 5 Mounting positions and take a small sample of oil 3 Check the condition of the sealing ring on the sealing element if necessary replace the sealing ring 4 Seal the gear unit with the sealing element 5 Signs of changes in the oil can be seen with the naked eye Fresh oil is clear to the eye and has a typical smell and a specific product colour Clouding or a flocculent appearance indicate water and or contamination A dark or black colour indicates residue severe thermal decomposition or contamination If you detect such abnormalities the oil must be changed immediately 6 Check the oil level
33. use at any time Caution Please note that spare parts and accessories not supplied by us have not been tested or approved by us The installation and or use of such products may therefore impair essential characteristics of the drive thereby posing an active or passive risk to safety FLENDER T BINGEN GMBH will assume no liability or guarantee for damage caused by spare parts and accessories not supplied by FLENDER TUBINGEN GMBH We guarantee only the original spare parts supplied by us Please note that certain components often have special production and supply specifications and that we always supply you with spare parts which comply fully with the current state of technical development as well as current legislation When ordering spare parts always state the following Order see rating plate 4 Type designation see rating plate 5 Part no 3 digit part no from spare parts list 6 digit code no or 7 digit article no Quantity BA 2010 EN 05 04 79 90 FLENDER 12 2 Spare parts lists 12 2 1 One stage helical gear units 001 Gear unit housing 145 Locking ring 225 Seal 101 Output shaft 160 Shaft seal 301 Plug in pinion 103 Spacer bush 201 Adapter plate 305 Gear wheel 105 Parallel key 205 Bolt 335 Parallel key 130 Bearings 210 Bolt 401 Screw plug 135 Locking ring 211 Screw lock 420 Breather filter 136 Locking ring 220 Seal 430
34. 1 83 0 3 0 68 0 4 1 0 188 268 20 1 20 1 49 7 477 74 7 86 0 721 86 0 721 18 4 1 0 18 4 1 0 48 0 1 0 46 0 1 0 73 0 1 0 83 0 2 3 68 0 2 4 83 0 2 3 68 0 2 4 0 188 048 19 4 19 4 49 0 47 0 74 0 85 3 70 4 85 3 70 4 Table 3 6 5 1 Oil quantities for 7 38 7 68 D 38 D 188 BA 2010 EN 05 04 25 90 FLENDER 3 6 5 2 Bevel helical gear units Mounting position Type B3 00 B8 00 B7 00 B6 00 V5 00 V6 00 H 01 H 02 H 03 H 04 H 05 H 06 0 50 3 1 1 0 3 1 4 0 8 0 8 0 8 1 0 0 3 0 9 0 3 K 38 228 0 8 1 4 2 2 1 6 1 3 1 2 0 7 0 3 1 6 0 3 2 0 0 8 1 2 0 8 1 5 0 3 1 8 0 3 48 228 1 0 1 9 2 8 2 0 1 8 2 1 1 6 0 3 3 2 0 3 3 9 0 8 2 7 0 8 3 0 0 3 3 0 0 3 68 228 1 9 3 5 4 7 3 5 3 3 3 3 1 6 0 5 3 2 0 5 3 9 0 8 2 7 1 2 3 0 0 5 3 0 0 5 68 738 2 1 3 7 4 7 3 9 3 5 3 5 1 6 0 5 3 2 0 5 3 9 0 9 2 7 1 1 3 0 0 5 3 0 0 5 K 68 038 2 1 3 7 4 8 3 8 3 5 3 5 2 6 0 3 5 7 0 3 7 4 0 8 5 0 0 8 4 9 0 3 5 2 0 3 K 88 228 2 9 6 0 8 2 5 8 5 2 5 5 2 6 0 5 5 7 0 5 7 4 0 8 5 0 1 2 4 9 0 5 5 2 0 5 88 238 3 1 6 2 8 2 6 2 5 4 5 7 2 6 0 5 5 7 0 5 7 4 0 9 5 0 1 1 4 9 0 5 5 2 0 5 88 038 3 1 6 2 8 3 6 1 5 4 5 7 5 54 0 5 9 54 0 5 12 6 0 8 8 8 1 2 8 7 0 5 8 3 0 5 M 108 238 6 0 10 0 13 4 10 0 9 2 8 8 5 5 1 0 9 5 1 0 12 6 1 8 8 8 2 4 8 7 1 0 8 3 1 0 M 108 248 6 5 10 5 14 4 11 2 9 7 9 3 5 5 0 5 9 5 0 5 12 6 0 9 8 8 1 1 8 7 0 5 8 3 0 5
35. 1354 force level gt 12 resistance to grey staining and compatibility with seals and interior paint coats which are necessary for the type of gear unit concerned We therefore advise our customers to select one of the lubricants listed in this table taking into account the VG class specified on the nameplate If by agreement gear units are filled at the factory with special lubricants for the above mentioned special applications this is shown on the rating plate e g CLP H1 VG220 or CLP E VG220 The guarantee specifications are valid only for the lubricants shown in these operating instructions Service life of the lubricants Note If oil sump temperatures exceed 80 C the service life may also be lower than shown in figure 10 3 Approximate values for oil change intervals The general rule is that an increase in temperature by 10 K will halve the service life e Note 1 In the case of rolling bearings with grease filling we recommend changing the grease filling as well when changing the oil With an oil sump temperature of 80 C the following service life with adherence to the characteristics required by FLENDER TUBINGEN GMBH s expected 1 Mineral oil Biologically degradable oil Physiologically safe oil USDA H1 H2 10 000 operating hours or 2 years 2 Synthetic oil PG 20 000 operating hours or 4 years 5 160 I 150 140 lt 130 120 ae 110 100 90 80
36. 2r 26 R 3 3 0 5 2 3 0 5 2 4 0 5 2 3 0 5 3 2 0 8 3 8 1 2 FD 68B 238 2 3 a Be 3 34 0 5 2 34 0 5 2 4 0 5 2 3 0 5 3 2 0 9 3 8 1 1 FD 68B 038 35 20 3 6 3 0 3 5 0 0 3 4 7 0 3 4 7 0 3 6 8 0 9 6 7 1 0 FD 88B 228 i3 i ih ie A 6 3 0 5 5 0 0 5 4 7 0 5 4 7 0 5 6 8 0 8 6 7 1 2 FD 88B 238 dh ds 8 a 6 3 0 5 5 0 0 5 4 7 0 5 4 7 0 5 6 8 0 9 6 7 1 1 FD 88B D38 d 25 _ ds 10 6 0 5 9 1 0 5 8 2 0 5 8 2 0 5 11 1 0 8 13 0 1 2 FD 108B 238 as 10 6 0 5 9 1 0 5 8 2 0 5 8 2 0 5 11 1 0 9 13 0 1 1 FD 108B 038 ab PA 16 8 0 5 13 5 0 5 15 2 0 5 14 8 0 5 21 6 0 8 22 5 1 2 FD 128B 238 i a o Bah 16 8 1 0 13 5 1 0 15 2 1 0 14 8 1 0 21 6 1 8 22 5 2 4 FD 128B 248 a jus an a 16 8 0 5 13 5 0 5 15 2 0 5 14 8 0 5 21 6 0 9 22 5 1 1 FD 128B D38 i 0 ja Sis MA 24 740 5 20 340 5 21 8 0 5 22 3 0 5 33 6 0 8 32 6 1 2 FD 148B 238 PA es A s ni 24 7 1 0 20 3 1 0 21 8 1 0 22 3 1 0 33 6 1 8 32 6 2 4 FD 148B 248 pe His gt x 24 7 0 5 20 3 0 5 21 8 0 5 22 3 0 5 33 6 0 9 32 6 1 1 FD 148B 038 25 m a 44 0 1 0 28 8 1 0 36 0 1 0 35 8 1 0 52 4 1 8 51 9 2 4 FD 168B 248 205 n ds MA 44 0 1 7 28 8 1 7 36 0 1 7 35 8 1 7 52 4 3 0 51 9 4 1 FD 168B 268 43 s bo as 44 0 1 0 28 8 1 0 36 0 1 0 35 8 1 0 52 4 2 3 51 9 2 4 FD 168B 048 10 a a 52 0 1 0 38 4 1 0 44 5 1 0 45 1 1 0 66 0 1 8 65 2 2 4 FD 188
37. 6 3 2 3 9 2 6 2 8 3 0 88 2 6 5 8 5 0 5 1 5 0 108 6 2 9 9 13 7 8 9 10 0 8 9 128 8 7 19 6 25 0 14 8 17 5 16 6 K 148 14 8 30 1 41 0 25 0 26 0 28 1 K 168 21 7 46 3 62 6 34 8 41 1 39 4 K 188 33 8 82 5 104 5 63 4 70 7 69 4 Table 3 6 2 2 Oil quantities for KZ KF KAD KAZ KADS KAFS KAZS KADT KAFT KAZT Size 38 188 BA 2010 EN 05 04 23 90 FLENDER 3 6 3 3 6 4 Parallel shaft helical gear units Mounting position Type B5 01 B5 03 B5 02 B5 00 V1 00 V3 00 H 01 H 02 H 03 H 04 H 05 H 06 FZ 38B 0 7 0 6 0 7 0 7 1 0 1 1 FZ 48B 1 6 1 0 1 3 1 3 1 8 2 1 FZ 68B 2 5 2 3 2 4 2 3 3 3 3 8 2 88 45 5 0 4 8 46 7 0 6 6 FZ 108B 7 4 9 2 8 4 8 1 11 1 13 1 FZ 128B 13 8 13 7 15 5 14 8 22 1 22 7 FZ 148B 19 5 20 8 22 7 22 3 34 5 33 5 FZ 168B 32 8 30 0 37 0 35 8 53 8 53 0 FZ 188B 41 4 40 7 44 2 46 5 68 0 66 4 FD 38B 0 9 0 6 0 7 0 7 0 9 1 1 FD 48B 2 0 0 9 1 3 1 3 1 8 2 0 FD 68B 3 3 2 3 2 4 2 3 3 2 3 8 FD 88B 6 3 5 0 4 7 4 7 6 8 6 7 FD 108B 10 6 9 1 8 2 8 2 11 1 13 0 FD 128B 16 8 13 5 15 2 14 8 21 6 22 5 FD 148B 24 7 20 3 21 8 22 3 33 6 32 6 FD 168B 44 0 28 8 36 0 35 8 52 4 51 9 FD 188B 52 0 38 4 44 5 45 1 66 0 65 2 Table 3 6 3 Oil quantities for F 38B F 188B Helical worm gear units Mounting position Type B3 00 88 00 87 00 86 00 V5 00 V6 00 01 02 03 1 04 1 05 1 06 C 38 0 5 1 2
38. B 248 38 pe 52 0 1 7 38 4 1 7 44 5 1 7 45 1 1 7 66 0 3 0 65 2 4 1 FD 188B 268 n put is ioni da FD 188B D48 52 0 1 0 38 4 1 0 44 5 1 0 45 1 1 0 66 0 2 3 65 2 2 4 53 0 39 4 45 5 46 1 68 3 67 6 Table 3 6 5 3 Oil quantities for F 38B L 1888 BA 2010 EN 05 04 28 90 FLENDER 3 6 5 4 Helical worm gear units Type Mounting position B3 00 88 00 87 00 86 00 V5 00 V6 00 H 01 H 02 H 03 H 04 H 05 H 06 0 5 0 3 1 2 0 3 1 3 0 8 1 2 0 8 1 2 0 3 1 2 0 3 C 38 Z28 0 8 1 5 2 1 2 0 1 5 1 5 0 7 0 3 1 6 0 3 1 7 0 8 1 6 0 8 1 3 0 3 1 3 0 3 C 48 728 1 0 1 9 2 5 2 4 1 6 1 6 1 5 0 3 3 3 0 3 4 1 0 8 3 3 0 8 2 8 0 3 2 9 0 3 C 68 728 1 8 3 6 4 9 4 1 3 1 3 2 1 5 0 5 3 3 0 5 4 1 0 8 3 3 1 2 2 8 0 5 2 9 0 5 C 68 738 2 0 3 8 4 9 4 5 3 4 1 5 0 5 3 3 0 5 4 1 0 9 3 3 1 1 2 8 0 5 2 9 0 5 2 0 3 8 5 0 4 4 3 3 3 4 1 7 0 3 6 1 0 3 6 5 0 8 5 1 0 8 4 5 0 3 4 5 0 3 C 88 728 2 0 6 4 7 3 5 9 4 8 4 8 daa ote 1 7 0 5 6 1 0 5 6 5 0 8 5 1 1 2 4 5 0 5 4 5 0 5 2 2 6 6 7 3 6 3 5 0 5 0 1 7 0 5 6 1 0 5 6 5 0 9 5 1 1 1 4 5 0 5 4 5 0 5 C 88 038 2 2 6 6 7 4 6 2 5 0 5 0 Table 3 6 5 4 1 Oil quantities for CA CAS CAT Size 38 88 Mounting position Type B5 01 B5 03 B5 02 B5 00 V1 00 V3 00 H 01 H 02 H 03 H 04 H 05 H 06 0 4 0 3 1 2 0 3 1 3 0 8 1 1 0 8 1 0 0 3 1 0 0 3 C 38 Z28 0 7 1 5 2 1 1 9 1 3 1 3
39. B5 02 B5 00 V1 00 V3 00 H 01 H 02 H 03 H 04 H 05 H 06 mp 0 5 0 3 1 1 0 3 1 5 0 8 0 8 0 8 1 0 0 3 0 9 0 3 0 8 1 4 2 3 1 6 1 3 1 2 0 7 0 3 1 7 0 3 2 3 0 8 1 2 0 8 1 6 0 3 1 8 0 3 48 728 1 0 2 0 3 1 2 0 1 9 2 1 1 6 0 3 3 2 0 3 3 9 0 8 2 6 0 8 2 8 0 3 3 0 0 3 K 68 Z28 1 9 3 5 4 7 3 4 3 1 3 3 1 6 0 5 3 2 0 5 3 9 0 7 2 6 1 2 2 8 0 5 3 0 0 5 2 1 3 7 4 6 3 8 3 3 3 5 1 6 0 5 3 2 0 5 3 9 0 9 2 6 1 1 2 8 0 5 3 0 0 5 K 68 038 2 1 3 7 4 8 3 7 3 3 3 5 2 6 0 3 5 8 0 3 7 7 0 8 5 0 0 8 5 1 0 3 5 0 0 3 K 88 728 2 9 6 1 8 5 5 8 5 4 5 3 2 6 0 5 5 8 0 5 7 7 0 7 5 0 1 2 5 1 0 5 5 0 0 5 K 88 738 3 1 6 3 8 4 6 2 5 6 5 5 2 6 0 5 5 8 0 5 7 7 0 9 5 0 1 1 5 1 0 5 5 0 0 5 3 1 6 3 8 6 6 1 5 6 5 5 6 2 0 5 9 9 0 5 13 7 0 7 8 9 1 2 10 0 0 5 8 9 0 5 108 738 6 7 10 4 14 4 10 1 10 5 9 4 6 2 1 0 9 9 1 0 13 7 1 8 8 9 2 4 10 0 1 0 8 9 1 0 108 748 7 2 10 9 15 5 11 3 11 0 9 9 Wm 6 240 5 9 9 0 5 13 7 0 9 8 9 1 1 10 0 0 5 8 9 0 5 6 7 10 4 14 6 10 0 10 5 9 4 8 7 0 5 19 6 0 5 25 0 0 7 14 8 1 2 17 5 0 5 16 6 0 5 128 238 9 2 20 1 25 7 16 0 18 0 17 1 8 7 1 0 19 6 1 0 25 0 1 8 14 8 2 4 17 5 1 0 16 6 1 0 128 748 9 7 20 6 26 8 17 2 18 5 17 6 pas 8 7 0 5 19 6 0 5 25 0 0 9 14 8 1 1 17 5 0 5 16 6 0 5 MERE 9 2 20 1 25 9 15 9 18 0 174 14 8 0 5 30 1 0 5 41 0 0 7 25 0 1 2 26 0 0 5 28 1 0 5 148 238 15 3 30 6 417 26 2 26 5 28 6 14 8 1 7 30 1 1 7 41 0 3 0 25 0 4 1 26 0 1 7 28 1 1 7 148 268 16 5 31 8 44 0
40. Eye bolt 140 Bearings BA 2010 EN 05 04 80 90 FLENDER 12 2 2 Two and three stage helical gear units 420 401 430 001 001 Gear unit housing 141 Supporting disk shim 306 Parallel key 020 Bearings 144 Supporting disk shim 315 Bearings 025 Locking ring 145 Locking ring 320 Bearings 030 Bearings 160 Shaft seal 325 Pinion shaft 050 Housing cover 201 Adapter plate 330 Gear wheel 051 Bolt 205 Bolt 331 Parallel key 055 Seal 210 Bolt 335 Locking ring 101 Output shaft 211 Screw lock 340 Pinion shaft 103 Spacer bush 215 Parallel pin 345 Gear wheel 105 Parallel key 220 Seal 346 Parallel key 130 Bearings 225 Seal 401 Screw plug 135 Locking ring 301 Plug in pinion 420 Breather filter 140 Bearings 305 Gear wheel 430 Eye bolt BA 2010 EN 05 04 81 90 FLENDER 12 2 3 Bevel helical gear units 001 020 022 027 030 031 040 045 050 051 055 060 061 063 065 070 090 091 Gear unit housing Bearings Supporting disk shim Locking ring Bearings Supporting disk shim Output flange Bolt Housing cover Bolt Seal Bearings Supporting disk shim Nilos ring Locking ring Sealing cap Torque arm Rubber bush 095 096 101 130 131 133 135 140 143 144 146 160 201 205 210 211 220 225 205 0 225 Bolt Screw lock Output shaft Bearings Supporting disk shim Nilos ring Locking ring Bearings Nilos ring Supporting disk shim Locking ring Shaft seal Adapter plate Bolt Bolt Screw
41. FLENDER Draining the oil Note 1 The oil must be warm as too cold oil will flow too sluggishly to drain properly If necessary allow gear unit to run for 15 30 minutes to warm up 1 Switch off the power supply to the drive 2 Unscrew the sealing element at the point marked with this symbol see section 3 5 Mounting positions 3 Unscrew the sealing element at the point marked with this symbol see section 3 5 Mounting positions A 2 4 Place a sufficiently large suitable receptacle under the oil drainage plug 5 Unscrew the sealing element at the point marked with this symbol see section 3 5 Mounting positions and completely drain off the oil into the receptable 6 Check the condition of the sealing ring on the sealing element if necessary replace the sealing ring 7 Seal the gear unit with the sealing element Fill in oil 1 Unscrew the sealing element at the point marked with this symbol see section 3 5 SSS Mounting positions 2 Fill the gear unit with fresh oil using a filter max mesh 25 um When refilling use the same type of oil with the same viscosity 3 Check the oil level 4 Rectify the oil level if necessary see section 10 2 3 Oil change and check it again 5 Check the condition of the sealing ring on the sealing element if necessary replace the seal
42. H test bench will apply External noises Noises not generated by the gear unit but emitted from it are not taken into consideration here Likewise noises emitted from the prime mover and output machines and from the foundation are not taken into consideration here even if transmitted to these by the gear unit Mounting positions The assembly option designations are in accordance with IEC 60034 7 Code I The drives must be operated only in the assembly option specified on the rating plate This ensures that the correct quantity of lubricant is provided Identification marking J c Oil level Housing ventilation T NS Oil drain plug T Oil dipstick A B Position of stub shaft and or solid shaft V Gear units of size 38 are standard fitted with a screw plug at point V Ventilation is not required opposite side two stage gear unit three stage gear unit 9 Tandem gear unit alternative BA 2010 EN 05 04 12 90 FLENDER 3 5 1 helical gear units e Note For key to diagram symbols see section 3 5 Mounting positions E B3 IM B3 E B8 IM B8 E B7 IM B7 D lt gt 1 q
43. IP 55 Seal flange bolts part 505 and mounting plugs part 502 and part 503 with a suitable sealing compound Flange mounted motors must generate a sealing surface running all the way round 13 Seal the mounting holes with the plugs part 502 and part 503 6 12 Motor base plate Drives in ATEX version The motor bedplate version is delivered without belt belt pulley and safety cover Sparks may be caused by friction or impact A safety system must be used to ensure that the belt does not slip and so become a source of combustion no foreign bodies can get into the belt drive zone Danger Rotating drive parts Always fit suitable safety equipment to cover the belt chain or other open drives Caution Belt breakage and bearing damage through incorrect belt tension Observe operating instructions for V belt drives Fit belt pulleys onto the drive shaft part 515 in accordance with section 6 6 Installation of input drive and output drive elements on gear unit shafts The motor bedplate serves to mount an IEC B3 foot mounted motor used mainly to drive a V belt drive Fit the motor in accordance with the manufacturer s operating instructions For other types of drive e g chain drive please observed the relevant operating instructions or manufacturer s information BA 2010 EN 05 04 52 90 FLENDER 6 12 1 Mounting IEC motors up to size 112
44. In the case of the bearings of the output shaft or intermediate shafts the grease quantity must fill 2 3 and in the case of bearings on the input side 1 3 of the space between the bearing bodies Seal check Oil or grease escaping in small quantities a few drops from the shaft sealing ring must be regarded as normal during the running in phase 24 hours running time If the quanties escaping are great or leakage continues after the running in phase the shaft sealing ring must be replaced to prevent consequential damage Because of its structure and function a shaft sealing ring is subject to natural wear The service life depends on the operating conditions II is recommended that the shaft sealing rings be included in the periodic maintenance and servicing work on the system Clean ventilation filter Clean the ventilation filter depending on the degree of soiling at least every 6 months 1 Unscrew the ventilation filter 2 Flush out the ventilation filter with petroleum ether or a similar cleaning agent 3 Blow the ventilation filter out with compressed air 4 Seal the gear unit with the ventilation filter Clean drive Drives in ATEX version Dust deposits prevent heat radiation and cause high housing temperatures Keep the drive free from dirt and dust Caution Do not use a high pressure cleaning appliance to clean the drive Do not use tools with sharp edges Switch off the power supply to the drive before clea
45. N This way Fragile Keep dry Keep cool Centre of gravity Use no Attach here up hand hook Figure 5 2 1 Symbols on packaging Fasten drive for suspended transport Danger Adhere to the maximum load in direction F of the transport eyes and eye bolt axis see figure and table 5 2 2 bzw 5 2 3 Max load in kg from drive to be attached Use eye bolt on motor only for transporting the unmounted or demounted motor or as auxiliary support for the drive e g to achieve a horizontal mounting position If necessary use additional suitable carrying means for transport or on installation When attaching by a number of chains and ropes just two strands must be sufficient to bear the entire load Secure carrying means against slipping 002 K 38 K 48 68 88 K 108 K 128 K 148 K 168 K 188 02 mm 22 22 26 30 35 40 44 55 55 m kg 200 250 350 600 750 800 1300 1800 2300 Figure and Table 5 2 2 Max load in kg from drive to be attached with pull T in direction F BA 2010 EN 05 04 34 90 FLENDER 5 3 fd mm 36 45 54 63 72 90 108 M8 M 10 12 M 16 20 24 M 30 m kg 140 230 340 700 1200 1800 3600 Figure and Table 5 2 3 Max load in kg from drive to be attached with pull T in direction F of the bolt axis Caution Do not use the front threads at the shaft ends to attach eye
46. Operating Instructions BA 2010 EN 05 04 MOTOX N 8 Gear Units FLENDER FLENDER T BINGEN GMBH Bahnhotstr 40 44 D 72072 T bingen Telefon 49 0 70 71 707 0 Fax 49 0 70 71 707 400 http www flender com E mail sales motox flender motox com A company of the Flender group FLENDER Contents 1 Important instructions 1 1 Instruction symbols in the operating instructions 1 2 General instructions 1 3 Amendments 2 Safety instructions 2 1 Intended use 2 2 General safety instructions 3 Technical data 3 1 designations 3 2 General technical data 3 3 Weights 3 4 Sound pressure level 3 5 Mounting positions 3 5 1 One stage helical gear units 352 Two and three stage helical gear units 3 5 3 Bevel helical gear units 3 5 4 Parallel shaft helical gear units 3 5 5 Helical worm gear units 3 5 6 Tandem gear unit compound helical gear unit 3 6 Oil quantities 3 6 1 Helical gear units 3 6 2 Bevelt helical gear units 3 6 3 Parallel shaft helical gear units 3 6 4 Helical worm gear units 3 6 5 Tandem gear unit compound helical gear unit 3 6 5 1 Two and three stage helical gear units 3 6 5 2 Bevel helical gear units 3 6 5 3 Parallel shaft helical gear units 3 6 5 4 Helical worm gear units 4 Technical description 4 1 General description 4 2 Housing 4 3 Toothed components 4 4 Lubri
47. Rating plate gear motor To 07 B 20 2 22 23 24 25 26 O ao d D 23 43 2 Figure 3 2 1 Rating plate 1 Company logo 2 Manufacturing date encoded 3 Weight m kg 4 Order no seq no 5 Model Type Size 6 Performance rating 2 Nm 7 Mounting position 8 Total transmission ratio i 9 Speed n 10 Type of oil 11 Oil viscosity ISO VG class to DIN 51519 ISO 3448 12 Oil quantity I Main gear unit ancillary transmission extruder flange 13 Free space for additional data 14 max ambient temperature TUma C Symbols IEC 617 2 Brake _ 210 Coupling Rating plate gear unit 5 6 D 2 15 16 18 19 20 22 23 24 26 27 28 Phase number and type of current of the motor Switch symbols to DIN EN 60617 T6 IEC 617 6 Rating voltage U V Rating current I A Rating frequency f Hz Rating speed n min Rating performance P kW Operating mode if S1 Performance factor cos Type of protection to IEC 60034 5 or IEC 529 Heat class Th Cl applied standard CE marking or other marking if any Brake data BA 2010 EN 05 04 10 90 FLENDER Drives in ATEX version Example Rating plate FLENDER 3 Figure 3 2 2 Rating plate ATEX version 1 Type designation 4 Explosion hazard symbol and 2 Mounting position order number explosion hazard marking CE mar
48. The rolling bearings are lubricated by dip lubrication or oil spray lubrication Bearings that are not supplied with lubricant are closed and grease lubricated Shaft seals Radial shaft sealing rings at the shaft outlets prevent lubricant from escaping from the housing and dirt from entering Where by contractual agreement housings are subjected to high temperatures shaft sealing rings of temperature resistant material are used Cooling Caution Dirt deposits impair cooling The gear units normally require no additional cooling The generously dimensioned housing surface is sufficient for conducting away dissipated heat where there is free convection If the difference between the temperature of the housing and the ambient temperature max 40 C exceeds 70 K please contact the FLENDER TUBINGEN GMBH customer service Couplings As a rule flexible couplings are provided for the input and output drive sides of the gear unit If rigid couplings or other input or output elements which generate additional radial and or axial forces e g gear wheels belt pulleys are to be used this must be agreed by contract Caution Couplings with peripheral velocities on the outer diameter of up to 30 m s must be statically balanced Couplings with peripheral velocities over 30 m s must be dynamically balanced The special operating instructions should be observed for operation of the couplings BA 2010 EN 05 04 30 90 FLENDER 4 9
49. all kinds oils greases salt water cleaning agents etc The adhesives and materials are selected to ensure extremely firm adhesion and permanent high legibility even at the limits of the range of operating temperatures 40 155 C The edges of the rating plates are coated with a matching special paint see section 4 11 Paint coats In special cases i e special specifications riveted or bolted metal plates are used BA 2010 EN 05 04 31 90 FLENDER 4 11 Paint coats 4 11 1 General All paint finishes are sprayed on Drives in ATEX version Plastic surfaces exposed to friction in normal operation can become electrostatically charged With use in zone 21 and 22 dusts the thickness of the paint finish must not exceed 200 um Note 1 Information repaintability is not guarantee of the quality of the paint material supplied by your supplier Only the paint manufacturer is liable for the quality and compatibility 4 11 2 Painted version Paint system Plastic 2K PUR 2K epoxide Colours RAL 1007 1012 1023 2000 2004 3000 5007 5009 5010 5012 5015 6011 7001 7011 7030 7032 7035 9005 9006 black mat RAL 1003 1018 2004 5002 5015 6011 7000 7031 9010 9011 9016 RAL 5015 6018 7031 7035 Typical area of application Standard 1 layer paint finish for interior areas Standard 2 layer paint finish especially for outside installation o
50. been designed for use in plant and equipment in industral environments The drives have been manufactured in accordance with the state of the art and are delivered ina condition for safe and reliable use Any changes on the part of the user which may affect safety and reliability are prohibited The drives are designed only for the application described in section 3 Technical data They must not be operated outside the specified power limits Other operating conditions must be contractually agreed Drives in ATEX version The ATEX drive satisfies the requirements of explosion safety guideline 94 9 EG The performance data apply at an ambient temperature of 20 C to 40 C In the case of drives in ATEX version please observe the instructions marked with this symbol General safety instructions The drives must be installed started up operated maintained and if necessary repaired only by authorised properly trained and qualified personnel For definition of expert staff refer to i a IEC 364 The operator must ensure that all persons involved in installation operation maintenance and repair have read and understood these operating instructions and comply with them at all times in order to avoid injury or damage ensure the safety and reliability of the drive avoid disruptions and environmental damage through incorrect use Carry out work on the drives only when they are at a standstill Secure the drive units a
51. bolts for transport Caution The use of force causes damage to the drive unit Transport drive carefully Avoid knocks Remove any transport fixtures fitted before putting into operation and keep them safe or render them ineffective Use them again for further transport or render them ineffective again Mount the drive on the transport device by the heaviest permissible weight to be attached This will normally be on the main gear unit 2 3 5 Storage Check that the eye bolt is firmly seated Drive is slung for transport The gear unit must be stored in its position of use on a horizontal wooden support in a dry place not subject to high temperature fluctuations and covered over The storage place must be free from vibration and shaking AN Danger Do not stack drive units one on top of another Caution Mechanical damage scratches chemical damage acids alkalis and thermal damage sparks welding beads heat cause corrosion which may cause failure of the external protective coating Ensure that the paint is not damaged The drive units are provided with an interior preservative agent the free shaft ends and flanges are painted for protection 1 Note The guarantee period for the standard preservative lasts 6 months and unless otherwise agreed begins at the date of delivery of the gear unit In the case of longer periods of storage gt 6 months special arrangements must be made for preservat
52. cation 4 5 Shaft bearing 4 6 Shaft seals 4 7 Cooling 4 8 Couplings 4 9 Backstop 4 10 Rating plates 4 11 Paint coats 4 11 1 General 4 11 2 Painted version 4 11 3 Primed version 5 Incoming goods Handling and Storage 5 1 Incoming goods 5 2 Handling 5 3 Storage 2010 05 04 3 90 FLENDER 6 1 6 2 6 3 6 3 1 6 3 2 6 4 6 5 6 6 6 7 6 9 6 9 1 6 9 2 6 9 3 6 10 6 10 1 6 10 2 6 10 3 6 11 6 11 1 6 11 2 6 12 6 12 1 6 12 2 6 12 3 6 13 6 13 1 6 13 2 6 13 3 7 1 7 2 7 3 7 3 1 7 3 2 7 4 7 4 1 7 4 2 7 5 Installation General information on installation Fastening in the case of reversing operation or high shock loads Drives with foot mounting Foundation Installing gear units with foot mounting Drive units in foot or flange version Drive units with C type housing flange Installation of input drive and output drive elements on gear unit shafts Steel safety cover for hollow shaft and shrink disc Cast iron end cover for hollow shaft Shaft mounting gear unit with hollow shaft and parallel key hollow shaft and splines hollow shaft and shrink disk Mounting the hollow shaft Remove hollow shaft and parallel key Suggested design for threaded piece and disc Shrink disc Mounting the shrink disc Pulling off the shrink disc Cleaning and greasing the shrink disc Attachment of standard motors Fit stan
53. ce sealing defective e g on cover flange reseal transport damage e g microcracks check drive for transport damage Oil leakage on gear unit ventilation incorrect oil level for the assembly option used and or incorrect ventilation position check position of ventilation and assembly option see section 3 5 Mounting positions Check oil level see section 10 2 1 Oil level frequent cold starts during which the oil foams up contact customer service Gear unit overheating motor fan cover and or drive badly soiled clean fan cover and surface of drive see section 10 2 9 Clean drive incorrect oil level for assembly option used check assembly option see section 3 5 Mounting positions Check oil level see section 10 2 1 Oil level incorrect oil being used e g incorrect viscosity check oil used see section 10 2 2 Oil quality oil too old check date of last oil change Change oil see section 10 2 3 Oil change excessive bearing play and or bearing defective check and if necessary replace bearings backstop not running freely replace backstop Output shaft does not turn when motor is running force flow interrupted by breakage in the gear unit contact customer service BA 2010 EN 05 04 63 90 FLENDER Malfunctions Causes Remedy Drive does not run or starts with diffic
54. dard motor on coupling housing with torsionally flexible coupling Using a clamp ring attach standard motor to coupling housing Motor base plate Mounting IEC motors up to size 112 Mounting IEC motors sizes 132 to 200 Mounting IEC motors from size 225 Torque arm with shaft mounted gear units Fit torque arm to bevel helical gear unit Mounting torque arm on parallel shaft helical gear unit Mounting torque arm on helical worm gear unit Start up Oil level check before start up Fill in oil Ventilation of the gear unit Filter for ventilation or pressure relief valve without securing clip Pressure relief valve with securing clip special version Start up after long term preservation Long term preservation up to 18 months Long term preservation up to 36 months Drive with backstop special version Operation Faults causes and remedy 36 36 36 37 37 37 37 38 40 41 42 BA 2010 EN 05 04 4 90 FLENDER 10 10 1 10 2 10 2 1 Maintenance and repair General information for maintenance Description of maintenance and repair work Oil level 10 2 1 1 Check the oil level in the gear housing 10 2 1 2 Checking the oil level by the oil sight glass special version 10 2 1 3 Checking the oil level by the oil dipstick special version 10 2 1 4 Checking the oil level sensor special version 10 2 2 10 2 3 10 2 4 10 2 5 10 2 6 10 2 7 10 2 8 10 2 9 10 2 10 10 2 11 10 2 12 10 3 11 12 12 1 12 2 12 2 1
55. design for threaded piece and disc 012 0010 01 010 Figure 6 9 3 Suggested design for threaded piece and disc Size b10 b11 b12 d10 d11 s11 mm mm mm mm mm mm mm 38 6 15 10 29 9 20 M10x1 5 33 8 34 9 24 10 48 6 15 5 M12X1 5 43 39 9 28 12 39 9 28 12 68 7 20 7 M16X1 5 48 5 44 9 14 49 9 36 14 88 7 20 10 M16x1 5 64 59 9 45 18 59 9 45 18 108 10 24 10 M20x1 5 74 5 69 9 54 20 69 9 54 20 128 10 24 5 M20x1 5 85 79 9 62 22 79 9 62 22 148 10 24 7 M20x1 5 95 89 9 72 25 99 9 80 106 168 10 30 8 M24x1 5 28 109 9 90 116 188 10 30 11 119 9 95 M24x1 5 127 32 Table 6 9 3 Suggested design for threaded piece and disc BA 2010 EN 05 04 46 90 FLENDER 6 10 Shrink disc 6 10 1 Mounting the shrink disc The shrink disc is delivered ready for installation Caution Do not dismantle shrink disc before initial fitting Caution Lubricants in the area of the shrink disk seat impair torque transmission Keep bore in hollow shaft and machine shaft completely grease free Do not use impure solvents and cleaning cloths Caution Plastic deformation of the hollow shaft when tightening the tensioning bolts before fitting the machine shaft First fit machine shaft Then tighten tensioning bolts Figure 6 10 1 1 Shrink disc a greas
56. ed b absolutely free of grease 1 Machine shaft 3 Inner ring 5 Tensioning bolt 2 Hollow shaft 4 Outer ring Caution The end face of the hollow shaft part 2 must be flush with the inner ring part 3 of the shrink disc Caution Avoid overloading the individual bolts Do not exceed the maximum torque acc to table 6 10 1 Tightening torque TA clamping screw at 0 1 Of prior importance is the alignment of the end faces If this alignment is not achieved when tensioning the tolerance of the stub shaft must be checked BA 2010 EN 05 04 47 90 FLENDER 6 10 2 6 10 3 Clamping screw 1 Tightening torque TA Tightening torque TA thread strength class 10 9 strength class 12 9 mm Nm Nm M6 12 30 12 8 36 68 29 35 M 10 75 100 58 70 M12 105 125 100 121 M 14 135 155 160 193 M 16 160 200 240 295 M 20 220 280 470 570 Table 6 10 1 Tightening torque TA clamping screw 1 The clamping screws part 5 must be tightened one after the other working round several times until the front faces of the outer and inner ring are flush Forcing thread Forcing thread Figure 6 10 1 2 Sequence for tightening the clamping screws 2 In this way you can check for the optimum tightening condition 3 If necessary grease the outside surfaces of the hollow shaft in the area of the shrink disk seat 4 Fit the safety cover delivered with the unit see sectio
57. fore starting up rectify the oil level if necessary Note 1 Description of the work see section 10 2 1 Oil level Fill in oil If the gear unit has been delivered without oil put in lubricant before starting up e Note 1 Description of the work see section 10 2 3 change Ventilation of the gear unit Filter for ventilation or pressure relief valve without securing clip In the case of gear units with required housing ventilation the necessary ventilation filter or pressure relief valve without a securing clip is delivered separately They must be replaced with the appropriate screw plug before starting up the gear unit SO 1 Unscrew the sealing element at the point marked with this symbol see section 3 5 SSS Mounting positions 2 Seal the gear unit with the ventilation filter or the pressure relief valve without securing clip Pressure relief valve with securing clip special version In the case of gear units with the required housing ventilation the pressure relief valve is fitted Remove the transport fixture by pulling the securing clip in the direction of the arrow Securing clip BA 2010 EN 05 04 59 90 FLENDER 7 4 Start up after long term preservation 7 4 4 Long term preservation up to 18 months The gear unit is preserved internally but delivered without oil Caution Before starting up fill the gear unit with lubricant see section 10 2 3 Oil change
58. gainst unintentional starting e g lock key switches or remove fuses in the power supply A notice should be attached to the start switch stating clearly that work on the drives is in progress Carry out all work with great care and with due regard to safety Always observe the instructions on the plates on the drives The plates must be kept free from paint and dirt at all times Replace any missing plates Ensure compliance with the relevant safety and environmental regulations during transport assembly and dismantling operation and care and maintenance of the unit Secure rotating drive parts e g couplings gears or belt drives against contact by means of suitable safety devices Ensure adequate ventilation when working with solvents Do not inhale vapours Do not smoke Collect and dispose of used oil in accordance with regulations Remove any oil spillage immediately with an oil binding agent in compliance with environmental requirements When installing the drives in plant or equipment the manufacturer of such plant or equipment must ensure that the contents of the present operating instructions are incorporated in his own instructions information and descriptions BA 2010 EN 05 04 8 90 FLENDER 8 Technical data 3 1 Type designations Main gear unit Example F D F Gear unit type Transmission steps Type Size helical gear unit 88 B 2 38 K4 Revision marks Trans
59. gard as necessary to preserve their essential characteristics and improve the efficiency and safety of the drive The copyright to these operating instructions is held by FLENDER TUBINGEN GMBH These operating instructions must not be wholly or partly reproduced used in any unauthorised way for competitive purposes or made available to third parties without our agreement Amendments or additions to these operating instructions may be made only by us otherwise any guarantee claim against us will lapse Technical enquiries should be addressed to the following works FLENDER TUBINGEN GMBH Postfach 1709 D 72007 T bingen Bahnhofstr 40 44 D 72072 T bingen Telefon 49 0 70 71 707 0 Fax 49 0 70 71 707 400 E mail sales motox flender motox com http www flender com 24 h Service Hotline 49 0 172 7 32 29 55 or to one of our customer services The addresses of the customer services are given in section 12 Stocking spare parts and customer service addresses Amendments These amended overall operating instructions replace the individual operating instructions BA G298 BA K298 BA F298 BA F298B and BA 5298 including their annexes BA 2010 EN 05 04 7 90 FLENDER 2 1 2 2 Safety instructions Intended use The drives described in these operating instructions have been developed for stationary use in general engineering applications Unless otherwise agreed the drives have
60. gram symbols see section 3 5 Mounting positions 6 83 00 IM 83 00 6 88 00 IM 88 00 C 87 00 IM 87 00 CA H 01 CA H 02 CA H 03 171 E os 11 6 00 86 00 V5 00 IM V5 00 6 V6 00 IM V6 00 CA H 04 CA H 05 CA H 06 RUN IX Figure 3 5 5 1 Mounting positions for C CA CAS CAT Size 38 88 7 85 01 IM 85 01 CZ 5 03 IM 5 03 CZ CF 65 02 IM 85 02 CA H 01 CA H 02 CA H 03 Es Q CZ CF 85 00 IM 85 00 CZ V1 00 IM Vi 00 2 CF V3 00 IM V3 00 H 04 CA H 05 CA H 06 1111 1 I B UT Z A A 4 0 amp 2 V 22 dal N gt Figure 3 5 5 2 Mounting positions for CZ CF CAD CAF CAZ CADS CAFS CAZS CAFT CAZT Size 38 88 BA 2010 EN 05 04 20 90 FLENDER 3 5 6 Tandem gear unit compound helical gear unit 1 In a horizontal operating position the bulging of the housing of the 2 gear unit generally faces downwards Types Z 28 are standard fitted with three screw plugs horizontal operating position vertical operating position
61. ing ring 6 Seal the gear unit with the sealing element 10 2 4 Replacing bearings Drives in ATEX version The bearing life depends very much on the operating conditions It is therefore very difficult to calculate it reliably If the operating conditions are specified by the operator the bearing life can be calculated and indicated on the rating plate If no information is given changes in the vibration and noise pattern can serve as an indication that an immediate bearing replacement is necessary 10 2 5 Relubrication of the rolling bearings in drive units Caution When relubricating do not mix greases with different soap bases BA 2010 EN 05 04 71 90 FLENDER 10 2 6 10 2 7 10 2 8 10 2 9 Relubicating the drive units is required from motor size 160 upwards The bearings have already been initially greased The standard lubricating grease used is a mineral oil based lithium saponified grease of NLGI class 3 see table 10 3 2 Rolling bearing greases Using a grease gun inject the grease into the bearing point via the lubricating nipples l provided Inject 50 g grease per lubricating point unless otherwise specified in the vicinity of the lubricating point Figure 10 2 5 Grease nipple Change rolling bearing grease The rolling bearings have been filled with a lithium saponified rolling bearing grease at the factory Clean the bearing before filling it with fresh lubricant
62. ion Contact the FLENDER TUBINGEN GMBH customer service BA 2010 EN 05 04 35 90 FLENDER 6 6 1 6 2 Installation General information on installation Danger When working with solvents ensure adequate ventilation Do not inhale vapours Do not smoke Caution Overheating of the drives through exposure to direct sunlight Provide suitable safety equipment such as covers and roofs Caution Irreparable damage to toothed components and bearings from fusing Do not carry out any welding work on the drive The drives must not be used as an earthing point for welding operations Note Use headless bolts of strength class 8 8 or higher to fasten the drives Drives version Affect bearings stray electric currents from electrical equipment When mounting or connecting the gear unit to the machine care must be taken that potential is equalised Exercise particular care when assembling and installing The manufacturer cannot be held liable for damage caused by incorrect assembly and installation Ensure that there is sufficient 50808 around the drive for assembly maintenance and repair On drives with a fan leave sufficient free space for the entry of air Provide sufficient lifting gear at the start of assembly and fitting work Use all the fastening means which have been assigned to the relevant assembly option Fastening in the case of reversing operation or high shock loads
63. king 3 Output speed min 1 5 Oil quantity I Output torque 12 Nm Type of oil Transmission ratio i Weight m kg Duty factor 6 Space for additional information Input speed ni Input torque T4 Nm Weights The weight of the overall drive including motor is indicated on the rating plate of the gear unit or gear motor if it exceeds 30 kg in each case it is shown in the delivery documents Where there are several rating plates on one drive the specification on the main gear unit is decisive The weight specification refers only to the condition on delivery of the products Sound pressure level The A assessed sound pressure levels Lwa of a selection of gear units in figure 3 4 Sound pressure level have been measured to DIN EN 21680 using measuring instruments to DIN IEC 651 The noise depends mainly on speed output and transmission ratio 110 3 100 80 4 70 60 01 02 05 1 2 5 10 20 50 100 160 P kW Figure 3 4 Sound pressure level BA 2010 EN 05 04 11 90 FLENDER 3 5 The sound pressure levels of MOTOX N gear motors fall mainly in the dark coloured part of the range Gear units with very small transmission ratios high output and high input speed may fall in the cross hatched part I repeat measurements on site do not produce conclusive results with regard to measuring technology the measurement obtained on the FLENDER TUBINGEN GMB
64. lding from the hot oil emerging Before starting any work wait until the oil has cooled down to 30 C Danger Remove any oil spillage immediately with an oil binding agent in compliance with environmental requirements Caution The oil quantity and the position of the sealing elements depend upon the assembly option see section 3 5 Mounting positions Note As a rule mineral oil is used as lubricant Synthetic oils with special properties are available optionally For data such as oil grade oil viscosity and oil quantity required refer to the rating plate see section 3 2 General technical data For oil compatibility refer to see section 10 3 Lubricants Note In case of double gear units every single unit is to be considered separately BA 2010 EN 05 04 66 90 FLENDER 10 2 1 1 Check the oil level in the gear housing Figure 10 2 1 1 1 Oil level a Oil level 1 Switch off the power supply to the drive pH 2 Unscrew the sealing element at the point marked with this symbol see section 3 5 Mounting positions L4 3 Check the oil level Check the condition of the sealing ring on the sealing element if necessary replace the sealing ring Rectify the oil level II necessary see section 10 2 3 Oil change and check again Seal the gear
65. mission steps Size Drive group for motor size Drive group 100 Gear unit type Helical gear unit K Bevel helical gear unit F Parallel shaft helical gear unit Helical worm gear unit Transmission steps E single stage Z two stage D three stage Type Shaft Solid shaft A Hollow shaft Fixing Foot mounted design Flanged version A type Housing flange C type Torque arm Flange A type opposite output shaft Agitatot flange Agitator mixer flange Extruder flange 1 Connection Parallel key S Shrink disc T Holow shaft with splines Backstop X Backstop in intermediate stage Compound helical gear unit Transmission steps Z two stage D three stage Drive group K4 Bell housing with stub shaft connection for IEC flanged motors K2 Bell housing with flexible coupling for IEC flanged motors A Drive flange with free drive flange P Motor bedplate version BA 2010 EN 05 04 9 90 FLENDER 3 2 General technical data The most important technical data are shown on the rating plate of the gear units of gear motors These data together with the contractual agreements on the drive units determine the limits of its proper use In the case of gear motors a rating plate attached to the motor serves for the entire drive In certain cases separate rating plates are attached to the gear unit and the motor Examples
66. mount the motor on the coupling housing and fasten it with the bolts part 505 to the prescribed torque acc to table 6 11 1 4 Tightening torque TA fitted motor Thread size strength class min 88 Thread size Strength class min 88 Nm Nm M4 3 M 16 210 M5 6 M 20 450 M6 10 M 24 750 M8 25 M 30 1500 M 10 50 36 2500 M12 90 Table 6 11 1 4 Tightening torque TA fitted motor Caution If drives are inadequately sealed moisture may find a way in If installing the drive outside or in the case of a higher type of protection IP 55 Seal flange bolts part 505 and any sealing plugs part 502 provided or elements fitted e g proximity switches with a suitable sealing compound Flange mounted motors must generate a sealing surface running all the way round 6 11 2 Using a clamp ring attach standard motor to coupling housing 502 503 564 560 Sy 515 563 561 505 505 Figure 6 11 2 3 Coupling lantern with clamping ring 502 Mounting plug 515 Drive shaft 563 Parallel key 503 Mounting plug 560 Clamp ring 564 Set screw 505 Hexagon head screw 561 Hexagon socket head screw 1 Remove the mounting plugs part 502 and part 503 2 Align drive shaft part 515 and clamp ring part 560 of the gear unit by turning to the mounting holes for mo
67. n 6 7 Steel safety cover for hollow shaft and shrink disc Pulling off the shrink disc If the outer ring does not release from the inner ring several clamping screws can be removed and then screwed into adjacent forcing threads The rings can then be released without difficulty 1 Loosen the clamping screw one after the other working round several times 2 Pull the shrink disc from the hollow shaft Cleaning and greasing the shrink disc Loosened shrink discs need not be dismantled and re greased before being re tensioned Dismantle and clean the shrink disc Before reassembly grease only the inner sliding surfaces of the shrink disc Use for this a solid lubricant with a friction coefficient of 0 04 in accordance with table 6 10 3 Lubricants for shrink disc cleaning BA 2010 EN 05 04 48 90 FLENDER Lubricant Commercial form Manufacturer Molykote 321 R lubricating paint Spray Molykote Spray Powder spray DOW Corning Molykote G Rapid Spray or Paste Sp Kl ber Lubrication Unimily P 5 Powder Aemasol MO 19 P Spray or Paste A C Matthes Table 6 10 3 Lubricants for shrink disc cleaning Attachment of standard motors Fit standard motor on coupling housing with torsionally flexible coupling 555 557 556 564 212 7
68. ng positions KZ KF B5 01 IM B5 01 KZ KF B5 03 IM B5 03 KZ KF B5 02 IM B5 02 KA H 01 KA H 02 KA H 03 KZ KF B5 00 IM B5 00 KZ KF V1 00 IM V1 00 KZ KF V3 00 IM V3 00 KA H 04 KA H 05 KA H 06 Figure 3 5 3 3 Mounting positions for KZ KF KAD KAF KAZ KADS KAFS KAZS KAZT Size 38 188 BA 2010 EN 05 04 18 90 FLENDER 3 5 4 Parallel shaft helical gear units e Note 1 For key to diagram symbols see section 3 5 Mounting positions FZ 85 01 IM 85 01 FZ F F 85 03 IM 85 03 FZ 85 02 IM 85 02 1 01 02 1 03 888 1888 V B 488 1088 EA L 1288 1888 F Z 85 00 IM 85 00 EZ E F V1 00 IM V1 00 FZ V3 00 IM V3 00 1 04 05 1 06 8 888 1888 e Fe i o U k d M A Figure 3 5 4 Mounting positions for F 38B F 188B BA 2010 EN 05 04 19 90 FLENDER 3 5 5 Helical worm gear units Note For key to dia
69. ning it BA 2010 EN 05 04 72 90 FLENDER 10 2 10 Checking tightness of fastening bolts 10 2 11 10 2 12 Drives in ATEX version Loose parts can cause sparks through impact Entry of foreign bodies may cause sparks e Note 1 Damaged headless screws must be replaced with new screws of the same type and strength class 1 Switch off the power supply to the drive 2 Using a torque wrench check that all fastening bolts are correctly tightened for torque acc to table 10 2 10 Tightening torques Ta fastening bolts Tightening torque TA Thread size Strength class Strength class 8 8 10 9 Nm Nm M4 3 4 M5 6 9 10 14 M8 25 35 M 10 50 20 M12 90 120 M 16 210 295 M 20 450 80 M 24 750 1000 M30 1500 2000 M 36 2500 3600 Table 10 2 10 Tightening torques fastening bolts Inspection of the drive Routinely inspect the drive once a year in accordance with the possible criteria listed in section 9 Faults causes and remedy Check the drive in accordance with the criteria set out in section 2 Safety instructions Touch up damaged paintwork carefully Carry out maintenance on slip coupling 1 Check the condition of the slip clutch initially after 500 operating hours and then at least once yearly and after every blockage of the machine If necessary readjust the slip torque or replace the wearing parts friction lining and b
70. ort damage damage through blocking contact customer service during start up bearing of drive unit not relubricate bearing see section lubricated from motor size 10 2 5 Relubrication of the rolling 160 upwards bearings in drive units Unusual noises on the excessive bearing play and or check and if necessary replace drive unit bearing defective bearings tighten bolts nuts see section fastening bolts loose 10 2 10 Checking tightness of fastening bolts excessive bearing play and or check and if necessary replace bearing defective bearings Unusual noises on the TT motor motor brake rubbing check and if adjust lifting inverter parametrisation correct parametrisation BA 2010 EN 05 04 62 90 FLENDER Malfunctions Causes Remedy Oil leak incorrect oil level for assembly option used check assembly option see section 3 5 Mounting positions Check oil level see section 10 2 1 Oil level overpressure due to lack of ventilation mount ventilation acc to mounting position see section 3 5 Mounting positions overpressure due to soiled ventilation clean ventilation system see section 10 2 8 Clean ventilation filter shaft sealing rings defective replace shaft sealing rings cover flange bolts loose tighten bolts nuts see section 10 2 10 Checking tightness of fastening bolts Continue observation of drive unit surfa
71. plications are outside the temperature ranges specified in the table 10 3 1 Oils likewise contact the FLENDER T BINGEN GMBH customer service with regard to the choice of oil If due to its mounting position or load the temperature of the gear unit rises above 80 contact the FLENDER T BINGEN GMBH customer service with regard to the choice of a suitable synthetic lubricant Note The lubricants are not or are only conditionally biodegradable If lubricants are required in accordance with these classifications please contact the FLENDER TUBINGEN GMBH customer service Note These recommendations are not a guarantee of the quality of the lubricant supplied by your supplier Each lubricant manufacturer is responsible for the quality of his own product The oil selected for use in the gear unit must be of the viscosity ISO VG class stated on the rating plate The viscosity class indicated applies for the contractually agreed operating conditions In the case of different operating conditions contact with FLENDER T BINGEN GMBH is required The lubricants suitable for use in the gear unit are listed in table 10 3 1 Oils and table 10 3 2 Rolling bearing greases BA 2010 EN 05 04 74190 FLENDER We are familiar with the composition of these lubricants and as far as we are currently aware they possess the properties acc to state of the art with regard to load bearing capacity corrosion resistance FZG Test DIN 5
72. r higher corrosion protection requirements high quality paint finish in the outside area or where exposed to dilute acid and alkaline solution lt 5 Repaintability after prior rubbing down with Plastic or synthetic resin paint after prior rubbing down with 2K PUR paint 2K epoxide paint after prior rubbing down with 2K PUR paint 2K epoxide paint 2K AC paint Chem phys resistance good resistance to cleaning agent oil and petrol resistant to exposure to dilute acid and alkaline solution for a short time lt 3 not solvent resistant not steam resistant very good resistance to oil grease petrol water seawater and cleaning agent good resistance to weather action and dilute acid and alkaline solution lt 3 good mechanical resistance to abrasion excellent resistance to weak acid and alkaline solution lt 5 oil grease petrol cooling emulsion salt solvent tough and scratchproof paint film Temperature resistance 40 C 100 C temporarily up to 140 C 40 150 40 150 C Remark Standard paint finish with very good adhesive property not suitable for storage or installation outside Standard paint finish for cooling tower and agitator drives or if requested resistance to sea water below deck etc 2K epoxide paint becomes chalky when installed outside without effect on qualit
73. reases by a factor of 0 7 for every 10 K rise in temperature Lithium saponified greases MLCI 3 2 Aralub HL3 HL2 Energrease LS3 LS2 Castrol Longtime PD2 TRIBOL 4020 220 2 Glissando 30 20 Beacon 3 6 Renolit FWA160 FWA220 13 Centroplex GLP402 LUBRICATION Mobil Mobilux 3 2 Alvania RL3 RL2 Shell sles Wiolub LFK2 Table 10 3 2 Rolling bearing greases BA 2010 EN 05 04 77 90 FLENDER 11 Disposal Dispose of the housing parts gears shafts and rolling bearings as steel scrap This also applies to grey cast iron parts if no separate collection is made The worm wheels are made partly from non ferrous metal Dispose of them accordingly Danger Incorrect disposal of used oil is a threat to the environment and health After use the oil must be taken to a used oil collection point Any addition of foreign material such as solvents and brake and cooling fluid is prohibited Avoid prolonged contact with the skin Collect and dispose of used oil in accordance with regulations Remove any oil spillage immediately with an oil binding agent in compliance with environmental requirements BA 2010 EN 05 04 78 90 FLENDER 12 12 1 Stocking spare parts and customer service addresses Stocking spare parts By stocking the most important spare and wearing parts on site you can ensure that the drive is ready for
74. rect height tighten the set screws part 585 4x Caution When tightening the hexagon nuts part 592 do not force or twist the motor plate part 590 into a different position 5 Tighten the hexagon nuts part 592 of the support BA 2010 EN 05 04 55 90 FLENDER 6 13 6 13 1 Torque arm with shaft mounted gear units The torque arm serves to absorb the reaction torque and if necessary the weight of the drive Drives in ATEX version Worn or irreparably damaged rubber elements will not function properly Sparks may be caused by impact The rubber elements must be replaced immediately Caution Dangerously high impact moments due to too high backlash Ensure that the torque support does not give rise to excessive constraining forces e g through the driven shaft running out of true Caution Keep solvents oils greases and fuels away from the rubber elements Fit torque arm to bevel helical gear unit Danger The torque arm bush must be mounted in bearings on both sides gt Suggestion for fitting the gear unit with torque arm ZX SS Il
75. rised personnel Only parts supplied by FLENDER TUBINGEN GMBH must be used for servicing Measure Interval Description of work Observe and check drive unit for unusual noises vibrations or changes daily if possible more frequently during operation Check housing temperature after 3 1 day then monthly 589 section 8 Operation Checking oil level after the 1st day then monthly see section 10 2 1 1 Check the oil level in the gear housing Checking the function of the oil sensor regularly and after oil change 966 section 10 2 1 4 Checking the oil level sensor Checking the oil quality every 6 months See section 10 2 2 Oil quality First oil change after start up after approx 10 000 operating hours at the latest after 2 years Subsequent oil changes every 2 months or 10 000 operating hours see section 10 2 3 Oil change Checking gear unit for leaks after the 1st day then monthly see section 10 2 7 Seal check Clean ventilation and if necessary replace Clean drive depending on degree of soiling at least every 6 months see section 10 2 8 Clean ventilation filter see section 10 2 9 Clean drive Check and if necessary adjust slip coupling every 12 months at least 589 section 10 2 12 Carry out maintenance on slip coupling Check coupling for first time after 3 months Observe the
76. rong right Where couplings are to be fitted in a heated condition please observe the specific operating instructions for the coupling BA 2010 EN 05 04 40 90 FLENDER 6 7 Steel safety cover for hollow shaft and shrink disc Drives in ATEX version Sparks may be caused by a damaged safety cover Replace damaged safety cover immediately The steel safety cover is delivered ready fitted to the gear unit flange The safety cover must be demounted to fit the output shaft Mounting the protective cover 1 Undo screws part 1 and remove protective cover part 2 2 Using a suitable cleaning agent clean the support surface of the safety cover part 2 on the gear unit 3 Ensure that the O ring part 3 is correctly seated 4 Coat the supporting surface of the safety cover part 2 with a suitable sealing agent 5 Fasten protective cover part 2 by screws 3 2 3 1 4 Figure 6 7 Steel safety cover 1 Bolt 3 O ring 5 Gear unit housing 2 Protective cover 4 Adaptor ring The adaptor ring part 4 is provided only on foot mounted versions of bevel helical gear units sizes 68 108 128 148 and 168 BA 2010 EN 05 04 41 90 FLENDER 6 8 Cast iron end cover for hollow shaft The cast iron end cover is delivered ready fitted on the gear unit flange The end cover must be demounted to fit the output shaft Assembly of end cover 1 Undo screws part 1 and remove end cover part 2 2 Using a s
77. s peeled off be at least touch proof gt Masking film L Rating plate Paint protective film Peeling tab Figure 4 11 3 Peel off paint protective film EE Company Logo 1 Pull peeling tab up 2 Carefully peel the paint protective film off diagonally from one corner not parallel to the plate 3 If necessary blow paint fragments away or wipe them off with a clean cloth BA 2010 EN 05 04 33 90 FLENDER 5 5 1 5 2 Incoming goods Handling and Storage Incoming goods Note 1 Inspect the delivery immediately after arrival for completeness and any transport damage Notify the freight company of any damage caused during transport immediately as otherwise it is not possible to have damage rectified free of charge Caution Ensure that damaged drives are not put into operation The drive unit is delivered in the fully assembled condition Additional items are delivered separately packaged The products supplied are listed in the despatch papers Handling Different forms of packaging may be used depending on the size of the drive and method of transport Unless otherwise agreed the packaging complies with the HPE Packaging Guidelines Bundesverband Holzpackmittel Paletten Exportverpackungen e V Note the symbols applied to the packing These have the following meanings 4 4 4 44 Du Z
78. separate operating instructions Carrying out complete inspection of drive unit every 12 months see section 10 2 11 Inspection of the drive Check that fastening bolts of gear unit and mounted elements are securely tightened Check that covers and sealing plugs are securely fastened after 3 h then at regular intervals 966 section 10 2 10 Checking tightness of fastening bolts BA 2010 EN 05 04 65 90 FLENDER 10 2 10 2 1 Measure Interval Description of work Relubricating the rolling at least every 12 months or 2 bearings in drive units every 4 000 operating hours bearings in drive units Change rolling bearing grease along with oil change see section 10 2 6 Change rolling bearing grease Replace bearing see section 10 2 4 Replacing bearings Checking rubber buffers of torque arm see section 6 13 Torque arm every 6 months with shaft mounted gear units Table 10 1 Maintenance measures Description of maintenance and repair work Oil level 6 gt Drives ATEX version After the screw plug has been removed the oil level may not be more than 3 mm in the case of 3 8 hole or 5 mm in the case of 3 4 hole below the minimum filling level Danger Secure the drive unit to prevent it from being started up unintentionally Attach a warning notice to the start switch Danger Danger of sca
79. stance x max distance x between oil level and marking on oil dipstick Type mm B3 B6 B7 B8 V5 V6 E 38 43 37 37 31 23 19 Z 38 93 83 83 83 75 32 D 38 89 82 82 82 52 5 V1 V3 814 V18 V19 EF 38 44 24 18 ZF 38 87 56 33 DF 38 81 31 26 B3 00 B8 00 B7 00 B6 00 V5 00 V6 00 H 01 H 02 H 03 H 04 H 05 H 06 K 38 64 35 21 52 40 46 B5 01 B5 03 B5 02 B5 00 V1 00 V3 00 H 01 H 02 H 03 H 04 H 05 H 06 KF 38 66 40 20 54 45 50 B5 01 B5 03 B5 02 B5 00 V1 00 V3 00 H 01 H 02 H 03 H 04 H 05 H 06 FZ 38B 137 152 137 137 87 73 FD 38B 110 147 132 132 110 65 Table 10 2 1 1 Values for distance x 9 Rectify the oil level if necessary see section 10 2 3 Oil change and check it again 10 Check the condition of the sealing ring on the sealing element if necessary replace the sealing ring 11 Seal the gear unit with the sealing element part 1 12 Mount the drive BA 2010 EN 05 04 68 90 FLENDER 10 2 1 2 Checking the oil level by the oil sight glass special version In the case of the oil sight glass the oil level must be in the middle of the sight glass Oil level Figure 10 2 1 2 Oil level in the oil sight glass Rectify the oil level if necessary see section 10 2 3 Oil change and check it again 10 2 1 3 Checking the oil level by the oil dipstick special version Measure the oil level with the dipstick resting on
80. t shafts Use a fitting device to fit the drive or output elements Located in the shaft end faces are centring holes to DIN 332 which can be used for this lt Example of a fitting device for fitting couplings or hubs on the ends of gear unit or motor shafts If necessary the axial thrust bearing on the fitting device can be dispensed with Figure 6 6 1 Fitting device e Note 1 Deburr the parts of elements to be fitted in the area of the hole or keyways Recommendation 0 2 x 45 Mount in or output elements Caution Damage to shaft sealing ring through solvent or benzine Protect against contact at all time 1 Using petrol ether or solvent remove the corrosion preventive paint coat on the shaft ends and flanges or remove any protective skin provided Caution Damage to bearings housing shaft and locking rings Do not use a hammer to force the drive and output elements to be mounted onto the shaft 2 Fit the drive and output elements onto the shafts and if necessary secure them Correct mounting arrangement of running wheel i gear or chain wheel belt pulley etc to keep the shaft and bearing load exerted by transverse forces as low as possible A gt V Fs so Figure 6 6 2 Mounting arrangement a Hub 2X w
81. tions and measures applying in particular to drives in ATEX version General instructions These operating instructions are an integral part of the gear unit delivery These operating instructions apply to the standard version of the MOTOX N gear unit Helical gear units E Z and D Size 38 188 Bevel helical gear units K Size 38 188 Parallel shaft helical gear units F Size 38B 188B Helical worm gear units C Size 38 88 Note Special types of drive and their additional equipment are governed by the special contractual agreements and technical documents Note also the other operating instructions for couplings motors brake motors additional equipment for motors etc delivered with the equipment Note We accept no responsibility for damage or disruption resulting from disregard of these operating instructions BA 2010 EN 05 04 6 90 FLENDER 1 3 Keep these operating instructions in the vicinity of the gear unit Read these operating instructions before working with the drive Only a precise knowledge of these operating instructions will guarantee reliable faultfree operation of the drive by avoiding operating errors and improper use The drives described in these Instructions reflect the state of technical development at the time these instructions went to print In the interest of technical progress we reserve the right to make changes to the individual assemblies and accessories which we re
82. uitable cleaning agent clean the support surface of the end cover part 2 on the gear unit 3 Coat the supporting surface of the end cover part 2 with a suitable sealing agent 4 Fasten end cover part 2 by screws 3 Figure 6 8 End cover made from cast iron 1 Bolt 2 End cover 3 Gear unit housing BA 2010 EN 05 04 42 90 FLENDER 6 9 Shaft mounting gear unit with hollow shaft and parallel key hollow shaft and splines hollow shaft and shrink disk 6 9 1 Mounting the hollow shaft lt Caution Damage to shaft sealing ring through solvent or benzine Protect against contact at all time 1 Using petrol or a solvent remove the corrosion preventive paint coat from the shaft ends and flanges 2 Check the seats or edges of the hollow and machine shaft for damage In case of damage contact the FLENDER TUBINGEN GMBH customer service Note Coat with the mounting paste which comes with the delivery or any suitable lubricant e g Calypsol type H 443 HD88 grease to prevent frictional corrosion of the contact surfaces Caution in the case of shrink disks Lubricants in the area of the shrink disk seat impair torque transmission Keep bore in hollow shaft and machine shaft completely grease free Do not use impure solvents and cleaning cloths 3 Fit the drive with the aid of nut and threaded spindle The counterforce is provided by the hollow shaft Caution The hollow shaft must be precisely
83. ulty incorrect oil level for assembly option used check assembly option see section 3 5 Mounting positions Check oil level see section 10 2 1 Oil level incorrect oil being used e g incorrect viscosity check oil used see section 10 2 2 Oil quality excessive load on drive and output check load on rating data E g adjust belt tension motor brake is not lifted check switching connection of brake Check brake for wear If necessary readjust brake drive runs against backstop change direction of motor or backstop rotation Excessive play on drive and output flexible elements worn e g with couplings replace flexible elements positive connection disrupted contact customer service by overload belt tension too low in case of check belt tension replace belt if Drop of speed torque belt drive necessary Table 9 Faults causes and remedy BA 2010 EN 05 04 64 90 FLENDER 10 10 1 Maintenance and repair General information for maintenance All inspection maintenance and repair work must be done with care by trained and qualified personnel only Observe the instructions given in section 2 Safety instructions Drives in ATEX version All measures and checks and their results must be documented by the operator and kept in a safe place Maintenance and servicing must be carried out only by properly trained autho
84. unit during operation for excessive operating temperature changes in gear noise possible oil leakage at the housing and shaft seals BA 2010 EN 05 04 61 90 FLENDER 9 Faults causes and remedy Note 1 Faults and malfunctions occurring during the guarantee period and requiring repair work on the drive must be carried out only by FLENDER T BINGEN GMBH Customer Service In the case of faults and malfunctions occurring after the guarantee period and whose cause cannot be precisely identified we advise our customers to contact our customer service If you need the help of our customer service please state the following data on the rating plate kind and extent of the fault suspected cause Malfunctions Causes Remedy il level too check oil level see section 10 2 1 oil level too low level foreign bodies in oil irregular stop drive Check oil quality Clean 9 noise g drive Change oil see section 10 2 2 Oil quality excessive bearing play and or check and if necessary replace bearing defective bearings check teeth and if necessary Unusual noises on the teeth defective replace gear unit tighten 00119 nuts see section fastening bolts loose 10 2 10 Checking tightness of fastening bolts excessive load on drive and check load on rating data E g output adjust belt tension transport damages check drive for transp
85. unit with sealing element Check the oil level in the gear housing size 38 Size 38 gear units have no screw plug for checking the oil level E 38 EF 38 D DF 38 Z ZF 38 K 38 KF 38 FD 38B FZ 38 2 2 2 2 Figure 10 2 1 1 2 Oil level check on size 38 gear unit 1 Switch off the power supply to the drive 2 Demount the drive and set it up in accordance with figure 10 2 1 1 2 Oil level check on size 38 gear unit The screw plug part 1 must be on the upward side 3 Unscrew the plug part 1 BA 2010 EN 05 04 67 90 FLENDER 4 Puta mark a on a suitable dipstick part 2 5 Insert the dipstick part 2 vertically through the hole until the mark a is level with the surface of the gear unit 6 Pull the dipstick part 2 out vertically 7 Measure the distance x on the dipstick see figure 10 2 1 1 3 Distance x I 3 x 2 mm Figure 10 2 1 1 3 Distance x 8 Compare value x with the value acc to table 10 2 1 1 Values for di
86. unting plugs part 502 and part 503 3 Coat the set screw part 564 with adhesive medium strength e g Loctite 243 see figure 6 11 2 3 Coupling lantern with clamping ring 4 Fix clamp ring part 560 BA 2010 EN 05 04 50 90 FLENDER Caution Do not overstress the motor shaft axially when flange mounting the motor Keep the motor shaft completely grease free in the area of the clamp ring In the case of brake motors release the brake while flange mounting 5 Flange mount the motor to the coupling housing and fasten it with the bolts part 505 to the prescribed torque acc to table 6 11 2 1 Tightening torque TA fitted motor Thread size gtrength class min 9a 55 class min 8 8 Nm Nm M4 3 M 16 210 M5 6 M 20 450 M6 10 M 24 750 M8 25 M 30 1500 M 10 50 M 36 2500 M 12 90 Table 6 11 2 1 Tightening torque TA fitted motor Caution When pushing the motor onto the coupling the motor bearing on the ventilation side may become overstressed When fitting the motor in a vertical position from size 100 upwards the weight of the rotor shaft prevents the bearing from being overstressed When fitting the motor in a horizontal position and for motors up to size 90 see work steps 6 8 6 Remove the fan cover 7 Ease the overstress on the bearing by lightly pressing the shaft end by hand see figure 6 11 2 4 Pressure on motor shaft ee
87. ushes Friction linings must always be replaced in pairs We recommend replacing worn bushes in sets For this please observe the relevant operating instructions for the clutch BA 2010 EN 05 04 73 90 FLENDER 10 3 Lubricants 1 Danger The listed lubricants are not approved under USDA H1 H2 United States Department of Agriculture They are not or only conditionally approved for use in the foodstuffs or pharmaceutical industry If lubricants with USDA H1 H2 approval are required please contact the FLENDER T BINGEN GMBH customer service Caution When changing oil of the same type the quantity of oil remaining in the gear unit should be kept as low as possible Generally speaking a small remaining quantity will cause no particular problems Gear oils of different types and manufacturers must not be mixed necessary the manufacturer should confirm that the new oil is compatible with residues of the used oil If changing very different types of oil or oils with very different additives always flush out the gear unit with the new oil This applies particularly when changing from polyglycols PG to another gear oil or vice versa Residues of used oil must be completely removed from the gear unit Caution Gear oils must never be mixed with other substances Flushing with paraffin or other solvents is not permitted as traces of these substances always remain inside the unit Caution If ap
88. y high gloss with good mechanical resistance Table 4 11 2 Painted version BA 2010 EN 05 04 32 90 FLENDER 4 11 3 Primed version Paint system primed unpainted Standard colour RAL 7032 Typical area of application for repainting adhesion promoter for all common paint systems temporary corrosion prevention for repainting temporary corrosion prevention Repaintability very good with plastic paint synthetic resin paint 2K PUR paint 2K epoxide paint SH paint 2K AC paint very good with Plastic paint synthetic resin paint oil paint bitumen paint 2K PUR paint 2K epoxide paint Chem phys resistance good resistance to cleaning agent good salt spray resistance resistant to oil and petrol Temperature resistance 40 150 C 40 150 C Remark Adhesion promoter with very good adhesive property and good corrosion prevention GCI parts dip primed steel parts primed or galvanised aluminium and plastic parts untreated Table 4 11 3 Primed version drive versions which are primed or unpainted the rating plate and the masking film are covered with a paint protective film see section 4 10 Rating plates It enables repainting without further preparation e g masking with adhesive tape Peel off paint protective film The paint coat must have fully hardened before the paint protective film i
89. ze bush Instead of the nut and threaded spindle shown in the diagram other types of equipment such as hydraulic lifting equipment may be used BA 2010 EN 05 04 44 90 FLENDER 6 9 2 Remove hollow shaft and parallel key Caution Before driving out the machine shaft fasten a suitably dimensioned means of absorbing load to the drive Slightly pretension the drive element so that the drive does not drop into the drive element when the insert shaft is released If frictional corrosion has occurred on the seat surfaces use rust solvent to enable the gear unit to be pulled off Allow the rust solvent to work in sufficiently 1 Remove the axial fastening of the hollow shaft Caution It is essential to prevent misalignment when removing the gear unit 13 12 11 10 9 8 Figure 6 9 2 Remove hollow shaft and parallel key 8 Threaded spindle 10 Hexagon nut 12 Threaded block 9 Hexagon nut 11 Parallel key 13 Washer Part 8 Part 13 are not included in scope of delivery Suggested design for threaded piece and disc see figure 6 9 3 and table 6 9 3 2 Drive out the machine shaft with the aid of the disk part 13 threaded block part 12 parallel key part 11 and threaded spindle parts 8 10 3 When the rust solvent has sufficiently worked in pull off the gear unit using the device see figure 6 9 2 Remove hollow shaft and parallel key BA 2010 EN 05 04 45 90 FLENDER 6 9 3 Suggested

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