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FLENDER Zapex ZWB, Operating Instructions Manual

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38

ZAPEX 3502 en

Operating instructions  10/2017

Bleed the next oil pump, connect it to oil channel II and operate it at the pressure specified on the
dimensioned drawing until the oil emerges at oil channel III.

Bleed the next oil pump, connect it to oil channel IV and operate it at the pressure specified on the
dimensioned drawing until a ring of oil emerges at the end face.

Bleed the next oil pump, connect it to oil channel III and operate it at the pressure specified on the
dimensioned drawing until a ring of oil emerges at the end face.

Carefully note the order!

During the entire operation the pressure must be maintained at a constant level on all
the oil channels to which pressure is applied.

If, when pressure is applied, oil emerges to the extent that pressure cannot be maintained, a thicker oil must
be specified.

Only when an unbroken ring of oil emerges from both end faces and after a subsequent waiting period of
approx. 30 minutes can pressure be applied to the hydraulic cylinder (”Lukas”) to slide the coupling hub
smartly off the shaft.

All the oil must be completely collected and disposed of in accordance with the
regulations applying.

Note the stroke of hydraulic cylinder. If re­adjustment is necessary, the end face of the
hydraulic cylinder (”Lukas”) must stop between two oil channels.

After detaching, the oil pumps and retaining device must be removed from the coupling hub.

The hub bore and the shaft should be examined for damage and protected against rust. Damaged parts
must be replaced.

For re­fitting, the instructions in section 6, "Assembly", and section 7, "Start­up", must be carefully
observed.

10.6

Demounting the coupling parts with stepped bore for removal by oil­hydraulic shrinking off

Demounting is done as described in item 10.5, except that a motor­driven pump is connected to the oil
channel located at the point of transition from the smaller bore to the larger, as a large quantity of oil per
unit of time is needed here.

For re­fitting, the instructions in section 6, "Assembly", and section 7, "Start­up", must be carefully
observed.

Summary of Contents for Zapex ZWB

Page 1: ...FLENDER COUPLINGS ZWBT ZWBG ZWB ZWH ZWHD Operating instructions 3502 en Edition 10 2017 ZAPEX flender com ...

Page 2: ......

Page 3: ...ion 10 2017 Translation of the original operating instructions Technical data Spare parts customer service Maintenance and repair Faults causes and remedy Operation Start up Fitting Technical description Transport and storage Safety instructions General notes 1 11 10 9 8 7 6 5 4 3 2 ...

Page 4: ...warning note Qualified personnel The product system to which this documentation relates may be handled only by persons qualified for the work concerned and in accordance with the documentation relating to the work concerned particularly the safety and warning notes contained in those documents Qualified personnel must be specially trained and have the experience necessary to recognise risks associ...

Page 5: ...ore and fitting the axial retaining means set screws and balancing 18 6 1 1 Finished bore for parallel key connection 18 6 1 1 1 Parallel keyway 19 6 1 2 Axial securing in case of parallel key connection 19 6 1 3 Set screws in case of parallel key connection 20 6 1 4 Balancing 22 6 2 General information on fitting 22 6 3 Fitting coupling parts 1 2 in case of shaft hub connection with parallel key ...

Page 6: ...intenance and repair 35 10 1 General 35 10 2 Oil change and or grease change 35 10 3 Replacement of wearing parts 35 10 4 Demounting the coupling parts 1 2 in case of shaft hub connection with parallel key 36 10 5 Demounting coupling parts 1 2 in case of cylindrical and tapered interference fit set up for hydraulic shrinking off 36 10 6 Demounting the coupling parts with stepped bore for removal b...

Page 7: ...1 1 Types ZWBT and ZWBG D 1 P d 3 d 4 d a P l l D 2 d 6 e 1 12 7 S 14 S 15 1 2 1 2 Design A Design AB d 1 S 14 V A9 d 2 1 2 D 1 P d 3 d 4 d a P l l D 2 d 6 e 3 12 7 S 14 S 15 1 2 1 2 Sizes 112 and 128 Design A Design AB d 1 S 14 V A9 1 2 Sizes 112 and 128 ZWBT ZWBG ...

Page 8: ...6 26 41 0 8 98 35 138 110 100 290 39000 70 130 145 330 210 290 180 140 200 186 26 46 0 8 113 35 153 135 125 315 54000 80 145 160 366 230 315 200 160 220 206 26 46 0 8 133 35 173 165 160 290 39000 1600 70 130 145 330 210 290 180 140 200 189 29 49 0 8 711 565 116 35 154 5 150 140 315 54000 80 145 160 366 230 315 200 160 220 209 29 49 0 8 136 35 174 5 180 170 342 69000 90 160 180 392 255 340 225 180 ...

Page 9: ...9 ZAPEX 3502 en Operating instructions 10 2017 1 2 Type ZWB D 1 P d 3 d 4 d a P l l D 2 d 6 d 1 S 5 S 6 S 7 1 2 1 2 1 2 1 2 b 1 Design A Design AB Design B S 5 V A10 ...

Page 10: ... 175 165 25 40 55 1 5 115 255 27000 1000 0 125 294 185 255 160 125 175 168 28 43 58 1 5 630 236 155 290 39000 1000 70 145 330 210 290 180 140 200 188 28 48 68 1 5 180 290 39000 750 70 145 330 210 290 180 140 200 188 28 48 68 1 5 710 265 210 Table 1 2 Torques TN speeds nmax dimensions and weights 1 The specified torques relate to the teeth and not the shaft hub connection This must be checked separ...

Page 11: ...11 ZAPEX 3502 en Operating instructions 10 2017 1 3 Types ZWH and ZWHD D 1 P d 3 d 4 P l l D 2 d 6 S 1 1 2 1 2 D 1 d 3 d 4 D 2 d 6 P P l l S 1 ZWH ZWHD V A11 V A11 ...

Page 12: ...20 90 16 2 350 505 250000 2000 160 275 400 505 365 260 340 92 16 2 450 545 320000 1800 180 300 440 545 405 280 360 96 16 2 570 585 400000 1700 210 330 480 585 445 310 390 102 20 2 710 Table 1 3 Torques TN speeds nmax dimensions and weights 1 The specified torques relate to the teeth and not the shaft hub connection This must be checked separately 2 Max bore with keyway to DIN 6885 1 3 Space requir...

Page 13: ...The coupling must be used and operated strictly in accordance with the conditions laid down in the contract governing performance and supply agreed by Flender and the customer The coupling described in these instructions reflects 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 individu...

Page 14: ... repaired by persons qualified for the work concerned see Qualified personnel on page 3 of this manual All work must be carried out with great care and with due regard to safety All work on the coupling must be carried out only when it is at a standstill The drive unit must be secured against being switched on accidentally e g by locking the key switch or removing the fuses from the power supply A...

Page 15: ... 4 3 1 Storage of the coupling parts The coupling is delivered in a preserved condition and can be stored in a covered dry place for up to 6 months If the unit is to be stored for a longer period it should be treated with a long term preservative agent Flender must be consulted 4 3 2 Storage of the DUO sealing rings 4 3 2 1 General Correct storage will preserve the service life of the DUO sealing ...

Page 16: ...th engage with the internal teeth of the flanged sleeves 5 and or coupling sleeve 5 For the types ZWBT ZWB ZWBG and ZWH DUO sealing rings 12 are used on the outside for sealing the oil chambers 5 1 1 Types ZWBT ZWBG ZWB 1 12 11 10 5 8 9 6 2 ZWBG 52 13 ZWBT ZWB 7 Torque transmission is effected from the shaft over parallel key shrink fit or a comparable connection to the coupling part 1 then over t...

Page 17: ...hrink fit or a comparable connection to the coupling part 1 then over the tooth system to the coupling sleeve 5 and from here over the tooth system to the coupling part 2 and then again via the parallel key shrink fit or a comparable connection to the shaft Type ZWHD is designed for flow through lubrication and is thus not equipped with DUO sealing rings 12 ...

Page 18: ...s shown in the following figure The clamping chuck must always be opposite the sealing surface The coupling part must be aligned carefully For the permissible radial eccentricity see DIN ISO 286 degree of fundamental tolerance IT 6 see table 6 1 The maximum permissible bore diameters see section 1 are designed for parallel key connections without taper action to DIN 6885 1 and must not under any c...

Page 19: ...ct the hub tension resulting from the oversize to the permissible load Failure to adhere to the assigned tolerance zones may impair the shaft hub connection Failure to observe these instructions may result in breakage of the coupling Danger from flying fragments 6 1 1 1 Parallel keyway With the parallel key connection to DIN 6885 1 and a single keyway the tolerance zone of the hub keyway width ISO...

Page 20: ...ded hole but does not project from the hub Lmin d1 The set screws should generally be arranged on the parallel key Check the length of the parallel key The threaded holes are to be arranged in accordance with the drawing considering the used version A or B for the coupling parts 1 2 In case of size 112 the set screws must generally be arranged in the hub side which has not been ground Sealing surf...

Page 21: ...17 22 22 30 30 38 38 58 58 110 10 17 17 22 22 30 30 38 38 58 58 100 M 5 M 6 M 8 M10 M12 M16 25 38 25 255 10 17 17 22 22 30 30 38 38 50 50 110 110 125 10 17 17 22 22 30 30 38 38 50 50 110 110 115 M 5 M 6 M 8 M10 M12 M16 M20 30 45 30 290 10 17 17 22 22 30 30 38 38 50 50 75 75 145 10 17 17 22 22 30 30 38 38 50 50 75 75 130 M 5 M 6 M 8 M10 M12 M16 M20 30 48 30 315 80 160 80 145 M20 40 55 40 342 90 170...

Page 22: ...uested by the customer 6 2 General information on fitting During fitting the Safety Instructions in section 3 must be observed Fitting work must be done with great care by trained and qualified personnel As early as during the planning phase it must be ensured that sufficient space is available for installation and subsequent care and maintenance work Adequate lifting equipment must be available b...

Page 23: ...a burner If heating is done with a burner it must be done along the length of the hub above the groove Take precautions to avoid burns from hot parts The coupling parts 1 2 should be fitted with the aid of suitable equipment to avoid possible damage to the shaft bearings through axial joining forces Always use suitable lifting equipment Care must be taken that the hole and the sealing surface for ...

Page 24: ... compound on one side Note marks sealing compound here 21 Grease filling Grease filling Mark 21 Rear 12 10 12 Position the cover 10 and or 21 with the fitted DUO sealing ring 12 on the shaft so that the DUO sealing ring 12 cannot be damaged by the coupling parts 1 2 to be fitted Check space requirement for inserting the cheese head screws 11 and if necessary insert the screws 11 in the cover 10 an...

Page 25: ...osition In case of types ZWBT and ZWBG place the axial backlash limiting device 52 into the recess of part 1 and pull the flanged sleeve 5 over the in die axial backlash limiting device 52 In case of types ZWBT ZWBG and ZWB place the brake disk 13 between the two flanged sleeves 5 hold in position Move together the machines to be coupled The dimensions S1 to S15 see section 1 Technical data are to...

Page 26: ...r of up to 0 3 When aligning the radial and angular misalignment of the shaft ends must be kept as small as possible because other conditions being equal this increases the service life of the coupling The angular misalignment must however be no less than 0 05 Alignment must be carried out using suitable measuring instruments The following diagram shows alignment suggestions and points of alignmen...

Page 27: ... a misalignment of 0 1 must be aimed for when aligning Misalignments during alignment must however be no less than 0 05 For alignment values see item 6 8 6 7 Possible misalignments Axial misalignment Fig 6 4 Radial misalignment Fig 6 6 Angular misalignment Fig 6 5 Δ Ka Δ Kw Δ Kr Axial radial and angular misalignment Fig 6 7 Δ Ka Δ S S1 S2 S1 S2 Misalignments of the coupling parts in relation to on...

Page 28: ... from section 1 16 To simplify matters the angular misalignment ΔKw figure 6 5 is calculated as the difference ΔS of dimension S for point of alignment A see item 6 6 The measurement must be taken at several points on the circumference For permissible alignment values see item 6 8 6 7 3 Radial misalignment On types ZWB ZWH and ZWHD the maximum possible radial misalignment ΔKrmax figure 6 6 corresp...

Page 29: ... VA11 tan 0 1 For the teeth distances VA9 VA10 and VA11 refer to section 1 Technical data Angular and radial misalignments may occur at the same time The sum of the two misalignments must not exceed ΔKw or ΔKr On types ZWB ZWH and ZWHD up to 10 times the values are permitted during operation taking into account the table in item 6 7 2 On types ZWBT and ZWBG due to the axial backlash limitation onl...

Page 30: ...0 5 13 5 175 49 25 5 17 6 198 49 25 6 17 6 230 49 25 6 17 6 255 86 25 8 19 6 290 86 49 8 19 8 315 210 49 8 24 8 342 210 49 8 24 8 375 210 49 10 24 8 415 410 86 10 30 10 465 410 86 10 30 10 505 410 86 10 30 10 545 710 86 10 36 10 585 710 86 10 36 10 Table 6 6 Tightening torques and wrench widths Tightening torques apply to bolts with untreated surfaces which are not or only lightly oiled coefficien...

Page 31: ...00 CLS Grease Orona FG EP 0 Fibrax EP 370 FLENDER Hoch leistungsfett NLGI class 0 00 00 0 00 0 1 0 00 Company Oils Structovis BHD MF Mobilgear 634 636 Optigear BM 460 680 Omala 460 680 Tribol 1100 460 680 Renolin CLP 460 680 Plus Liquefied greases Grafloscon C SG 500 Mobilux EP 004 Longtime PD 00 Alvania GL 00 Tribol 3020 1000 00 Renolit SO D 6024 NLGI class 0 00 00 00 00 00 00 Table 7 1 Recommend...

Page 32: ...ecified For the oil flow quantities with type ZWHD refer to the dimensioned drawing For easier filling proceed as follows Rotate coupling until the screw plugs 6 are in the position shown in the diagram opposite Remove the two top screw plugs 6 and put in oil grease Measure the correct oil grease quantity with the measuring beaker Screw in again the screw plugs 6 with fitted vulcanised sealing rin...

Page 33: ...s in running noise leaks escaping oil grease If any irregularities are noticed during operation switch the drive assembly off at once Determine the cause of the fault using the table in section 9 The trouble shooting table contains a list of possible faults their causes and suggested remedies If the cause cannot be identified and or the unit cannot be repaired with the facilities available you are...

Page 34: ...after the guarantee period and whose cause cannot be precisely identified we advise our customers to contact our customer service Flender will not be bound by the terms of the guarantee or otherwise be responsible in cases of improper use of the coupling modifications carried out without the agreement of Flender or use of spare parts not supplied by Flender When remedying faults and malfunctions t...

Page 35: ...every 3000 operating hours or at the latest at yearly intervals 10 3 Replacement of wearing parts Unscrew screw plugs 6 and drain off the oil grease into a suitable vessel as shown in the diagram to simplify matters in the case of grease add light bodied oil to the used grease and mix All the oil and grease must be completely collected and disposed of in accordance with the regulations applying Dr...

Page 36: ...t and output side against damage and heating to over 80 C Take precautions to avoid burns from hot parts Pull off coupling parts 1 2 smartly Always use suitable lifting equipment and detaching devices The shaft bearings must not be overloaded Care must be taken that the hole and the sealing surface for the DUO sealing ring are not damaged by lifting gear etc For re fitting the instructions in sect...

Page 37: ...e of the hydraulic cylinder Lukas for axial force consult Flender and or refer to dimensioned drawing Observe manufacturer s instructions for using forcing off detaching device and pumps Before detaching the coupling hub the detaching device must be fitted as shown in diagrams illustrations etc Lukas I II IV III Retaining plate Threaded spindle Shaft 22 Using suitable tools secure coupling parts 1...

Page 38: ... of approx 30 minutes can pressure be applied to the hydraulic cylinder Lukas to slide the coupling hub smartly off the shaft All the oil must be completely collected and disposed of in accordance with the regulations applying Note the stroke of hydraulic cylinder If re adjustment is necessary the end face of the hydraulic cylinder Lukas must stop between two oil channels After detaching the oil p...

Page 39: ...d by us The installation and or use of such products may therefore impair essential characteristics of the coupling under certain circumstances and so pose an active or passive hazard Flender will assume no liability or guarantee for damage caused by non genuine spare parts and accessories Please note that certain components often have special production and supply specifications and that we suppl...

Page 40: ...FLENDER COUPLINGS ZAPEX Operating instructions 3502 en Edition 10 2017 Flender GmbH Alfred Flender Straße 77 46395 Bocholt GERMANY flender com ...

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