Siemens FLENDER K DH Series Assembly And Operating Instructions Manual Download Page 1

Page: 1 / 109

FLENDER gear units

Crane gear unit

K.SH, K.SM, K.VH, K.HH, K.KH,
K.DH, K.HM, K.KM, K.DM
Sizes 15 to 24
and sizes 115 to 124

Assembly and operating instructions
BA 5846 en 05/2015

Summary of Contents for FLENDER K DH Series

Page 1: ...FLENDER gear units Crane gear unit K SH K SM K VH K HH K KH K DH K HM K KM K DM Sizes 15 to 24 and sizes 115 to 124 Assembly and operating instructions BA 5846 en 05 2015 ...

Page 2: ...ly and operating instructions Translation of the original assembly and 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 Declarations 1 12 11 10 9 8 7 6 5 4 3 2 ...

Page 3: ...ith 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 associated with these products and to avoid possible hazards Proper use of Siemens products Observe also the following WARNING Siemens products must be used only for the applica...

Page 4: ...s in the meaning of standard DIN EN ISO 13732 1 This symbol warns against risks from lifted and or suspended loads Earth connection point Air relief point yellow Oil filling point yellow Oil draining point white Oil level red Oil level red Oil level red Connection for vibration monitoring device Lubricating point red Apply grease Lifting eye Eye bolt Do not unscrew Alignment surface horizontal Ali...

Page 5: ...18 4 3 Storing the gear unit 21 4 4 Standard coating and preservation 22 4 4 1 Interior preservation with preservative agent 23 4 4 1 1 Interior preservation with Castrol Alpha SP 220 S 23 4 4 1 2 Interior preservation with Castrol Tribol 1390 220 24 4 4 1 3 Re preserving the interior of the gear unit in case of longer periods of storage 24 4 4 2 Exterior preservation 25 4 4 2 1 Re preservation of...

Page 6: ... 6 3 1 1 Foundation 47 6 3 1 2 Foundation for torque arm 47 6 3 2 Description of fitting work 48 6 3 2 1 Alignment 49 6 3 2 2 Fitting on a foundation frame 51 6 4 Shaft mounted gear unit with solid shaft 51 6 5 Fitting a shaft mounted gear unit with hollow shaft and parallel keyway 52 6 5 1 Preparatory work 52 6 5 2 Fitting 52 6 5 2 1 Pulling on 53 6 5 2 2 Axial securing 53 6 5 3 Demounting 54 6 6...

Page 7: ...or 73 7 1 3 Filling with lubricant 75 7 1 3 1 Oil quantities 76 7 2 Start up 77 7 2 1 Oil level 78 7 2 2 Gear unit with cooling coil or external oil supply system 78 7 2 3 Gear unit with oil supply system Pre lubrication phase 79 7 2 3 1 Initial operation 79 7 2 4 Gear unit with backstop 79 7 2 5 Temperature measurement 81 7 2 6 Oil level monitoring system 81 7 2 7 Bearing monitoring vibration mea...

Page 8: ...2 6 Clean the fan and gear unit 103 10 2 7 Recharge grease to splines on output shaft spacer 103 10 2 8 Repack grease in the Taconite seals 103 10 2 9 Check cooling coil 104 10 2 10 Check hose lines 104 10 2 11 Top up oil 105 10 2 12 Check tightness of fastening bolts 105 10 3 Final work 105 10 4 General inspection of the gear unit 105 10 5 Lubricants 105 11 Spare parts customer service 106 11 1 S...

Page 9: ...cturer and place of manufacture Country of origin Code production plant order number item sequence number year built Example K 3 S H 21 Size 15 bis 24 115 to 124 Mounting position H Horizontal M Horizontal design without base Type of output shaft S Solid shaft V Solid shaft reinforced H Hollow shaft with parallel keyway D Hollow shaft for shrink disk K Hollow shaft with splines to standard DIN 548...

Page 10: ...ys only one explosion group can be indicated 3 Always only one temperature class can be indicated 4 Ta min Ta Ta max permissible ambient temperature range in C Ta min permissible minimum ambient temperature Ta max permissible maximum ambient temperature Ta symbol for ambient temperature 5 The indications relating to equipment category explosion group and temperature class are to be understood as a...

Page 11: ...11 109 BA 5846 en 05 2015 1 3 Versions 1 3 1 Gear unit types K DH K HH K KH K DM K HM K KM K SH K VH K SM Fig 2 Types ...

Page 12: ...ned in VDI 2159 which is applied to produce the 80 characteristic curve of the emission characteristic map Adherence to limit values can under specified Siemens test conditions be assumed with statistical certainty 1 5 Weights Note All weights are indicated for units without oil filled in without oil supply system and without add on parts For exact weight specifications refer to the drawings in th...

Page 13: ... the state of the art and is delivered in a condition for safe and reliable use The gear unit complies with the requirements in Directive 94 9 EC The gear unit must be used and operated strictly in accordance with the conditions laid down in the contract governing performance and supply agreed by Siemens and the customer The gear unit described in these instructions reflects the state of technical...

Page 14: ...he unit the relevant safety and environmental regulations must be complied with The gear unit may only be operated maintained and or repaired by persons qualified for the work concerned see Qualified personnel on page 3 of this manual The outside of the gear unit must not be cleaned with high pressure cleaning equipment All work must be carried out with great care and with due regard to safety DAN...

Page 15: ...ialist electricians NOTICE Material damage Risk of damage to the gear unit If any inexplicable changes are noticed during operation of the gear unit such as an important increase in temperature or unusual noises the drive assembly must be stopped immediately DANGER Danger to life through rotating and or movable parts Risk of being caught or drawn in by rotating and or movable parts Rotating and or...

Page 16: ...rts must be obtained from Siemens see section 11 Spare parts customer service 3 2 Special dangers and personal protective equipment Depending on operating conditions the surface of the gear unit may heat up or cool down to extreme temperatures WARNING Risk of burns Risk of serious injury through burns on hot surfaces 55 C Wear suitable protective gloves and protective clothing WARNING Danger throu...

Page 17: ...ompletely Disconnect the auxiliary circuits e g stand by heating 2 Secure against re connection 3 Verify that the installation is voltage free dead 4 Connect to earth and short circuit 5 Cover or shield adjacent live parts After completion of the work the taken measures should be undone in the reverse order 3 4 Environmental protection Dispose of any packaging material in accordance with regulatio...

Page 18: ...tion NOTICE Material damage Risk of damage to the gear unit through corrosion If the gear unit was delivered in seaworthy packaging only the outer packaging crate and foil must be opened The preservative agent on the gear unit itself must not be removed 4 2 Transport Note The weight of the product is specified on the rating plate DANGER Danger to life Danger to life from loads falling through inco...

Page 19: ...reed otherwise the packaging complies with the HPE Packaging Guidelines The symbols marked on the packing must be observed at all times They have the following meanings Top Fragile Keep dry Keep cool Centre of gravity Use no hand hook Attach here Fig 3 Transport symbols Note The gear unit must be transported only with appropriate transport equipment During transport the gear unit should be left wi...

Page 20: ...k of damage to the eye bolts When attaching to eye bolts no lateral pull against the direction in the eye plane must be allowed to occur as otherwise the eye bolts may break A B 45 45 Fig 6 Diagonal and lateral pull on eye bolts A permitted diagonal pull in the direction of the eye plane maximum angle 45 B not permitted lateral pull against the direction of the eye plane For a detailed illustratio...

Page 21: ... tilting or falling gear unit Risk of being squeezed or killed by a tipping or falling gear unit Do not stack gear units on top of one another NOTICE Material damage Risk of damage to the gear unit through build up of a layer of foreign bodies or moisture If the gear unit is being stored out of doors it must be particularly carefully covered and care must be taken that neither moisture nor foreign...

Page 22: ...eaning agents from getting into the gear unit and coming into contact with the shaft seal Note The coating complies with the requirements for the conductivity of the coating and the limitation of the layer thickness of the applied coating in accordance with standard DIN EN 13463 1 The permissible maximum coating thickness depends on the indicated explosion group IIA or IIB or IIC Where coatings ha...

Page 23: ...preservation with preservative agent Note Depending on the operating oil oil type and viscosity as indicated on the rating plate the gear units have been preserved with the preservative agent specified in table 2 or table 3 4 4 1 1 Interior preservation with Castrol Alpha SP 220 S Table 2 Durability period and measures for interior preservation when using mineral oil or PAO based synthetic oil Dur...

Page 24: ...edia Wear suitable protective glasses and protective gloves Remove any oil spillage immediately with a binding agent For storage periods longer than 24 months see table 2 or 36 months see table 3 the interior preservation of the gear unit must be renewed The following procedure is recommended Remove any dirt in the area of the inspection and or assembly cover or that of the marked oil filling poin...

Page 25: ...shing oil must not be used for operation of the unit 4 4 2 Exterior preservation Table 4 Durability period for exterior preservation of shaft ends and other bright machined surfaces Durability period Preservative agent Layer thickness Remarks In case of indoor storage Up to 36 months 1 Tectyl 846 K19 Approx 50 μm Long term wax based preservative agent resistant to seawater resistant to tropical co...

Page 26: ...or an overrunning clutch The gear unit is characterised by a low noise level which is achieved by helical gears with a high contact ratio and a sound damping housing The good temperature characteristics of the gear unit are achieved by its high degree of efficiency large housing surface and performance related cooling system A number of shaft configurations types and rotation directions are possib...

Page 27: ...e oil level Dipstick with MIN and MAX marks for checking the oil level Oil drain plug and or oil drain cock to drain the oil Air filter for ventilation and bleeding Wet air filter for ventilation and bleeding Colour codes for bleeding oil inlet oil level and oil drainage Air relief point yellow Oil drain point white Oil filling point yellow Lubricating point red Oil level Oil sight glass Oil level...

Page 28: ...units of type K M 1 Housing 2 Lifting eye 3 Cover 4 Cover 5 Shaft seal 6 Dipstick 7 Housing ventilation 8 Oil drain 9 Rating plate 10 Gear unit fastening 11 Inspection and or assembly cover 12 Alignment surface 13 Alignment thread 14 Oil inlet 15 Fastening for torque arm 16 Oil sight glass For a detailed illustration of the gear unit and the position of the add on parts refer to the drawings in th...

Page 29: ...ote When operating and servicing the components of the oil supply system observe the operating instructions of the components For technical data and control information refer to the data sheet and or the list of equipment For a detailed illustration of the gear unit and the oil supply system refer to the drawings in the gear unit documentation 5 5 Shaft bearings All shafts are fitted in rolling be...

Page 30: ...nd a grease charged re chargeable labyrinth seal 1 2 3 4 Fig 11 Taconite seal 1 Radial shaft sealing ring 2 Lamellar seal 3 Grease charged labyrinth seal re chargeable 4 Flat grease nipple AM10x1 to standard DIN 3404 The following types of Taconite seals are distinguished Taconite E Taconite F 1 2 3 1 4 Taconite F F and F H Taconite F K Fig 12 Taconite seal variants E F F F F H and F K 1 Output 2 ...

Page 31: ...e charging the labyrinth seals with grease the specified frequency must be observed see table 17 in item 10 1 5 7 Backstop For certain requirements the gear unit can be fitted with a mechanical backstop The backstop permits only the specified direction of rotation during the operation of the unit The direction of rotation is marked by a direction arrow on the input and output side of the gear unit...

Page 32: ...ly replaced The frequency of replacement is stated on the dimensioned drawing of the gear unit and on a plate on the gear unit This plate is attached to the gear unit housing close to the backstop 5 7 1 Torque limiting backstop special design For certain requirements the gear unit can be fitted with a mechanical backstop The backstop permits only the specified direction of rotation during the oper...

Page 33: ...Siemens should always be consulted WARNING Risk of injury through moving plant parts After having stopped the motor there is a danger that the load is not safely held in its position and can run in reverse direction at high speed The slipping torque was set at the correct value at the works it must not be changed Note To safeguard the set slipping torque the lead screws of the compression springs ...

Page 34: ...potentially explosive atmosphere through overheating of the backstop or through sparks If a potentially explosive atmosphere develops the release mechanism type FXRT only must not be operated If a unit of this type with release mechanism is used the operating instructions for this backstop must be followed 5 8 Cooling Depending on requirements the gear unit is fitted with a fan a cooling coil or a...

Page 35: ... of overheating of the gear unit through insufficient air feed For gear units fitted with a fan sufficient space must be allowed for air intake when fitting the safety guards for the coupling or other components The required distance is shown on the dimensioned drawing in the gear unit documentation It must be ensured that the air guide cover is correctly fastened The air guide cover must be prote...

Page 36: ...ing water must not exceed 8 bar The ends of the cooling coil must not be twisted nor must the reducing screws be removed If there is a danger of freezing the cooling water must be drained off Remaining water must be blown out using compressed air The water can flow through the gear unit in either direction To avoid excessive water pressure the cooling water inlet must be fitted with a suitable coo...

Page 37: ... driving the gear unit If rigid couplings or other in and or output elements which create additional radial and or axial forces e g gear wheels disk flywheels hydraulic couplings are to be used this must be agreed by contract 5 9 1 Shrink disk The shrink disk makes a press fit connection between a hollow shaft and a stub shaft driven machine shaft in the following called stub shaft The interferenc...

Page 38: ...pes K H K M 1 Heating element 2 Temperature monitor 1 K H K M Sizes 15 to 24 2 K H K M Sizes 115 to 124 For a detailed illustration of the gear unit and the position of the add on parts refer to the drawings in the gear unit documentation DANGER Risk of explosion or fire Fire hazard or risk of ignition of an explosible atmosphere through exposed heating elements Never switch on the heating element...

Page 39: ...on the heating elements unless complete immersion of the heating elements in the oil bath is ensured If heating elements are fitted afterwards the maximum heating capacity see table 7 on the outer surface of the heating elements must not be exceeded For a detailed illustration of the gear unit and the position of the add on parts refer to the drawings in the gear unit documentation Note Be sure to...

Page 40: ...ory 3 in conformity with Directive 94 9 EC this equipment is possible as an option Note In order to measure the temperatures and or the temperature differences in case of a Pt 100 resistance thermometer without evaluating instrument the Pt 100 resistance thermometer should be connected to an evaluation instrument provided by the customer 1 1 1 1 1 2 Fig 18 Oil temperature monitoring on gear units ...

Page 41: ...onitoring system 5 15 1 Bearing monitoring by Pt 100 resistance thermometer The gear unit may have been fitted with Pt 100 resistance thermometers for monitoring the bearings In order to measure the temperatures and or temperature differences the Pt 100 resistance thermometers must be connected to a suitable evaluating instrument provided by the customer The resistance thermometers have a connecti...

Page 42: ...ermometers For this version Siemens must be consulted X X SW17 X X 1 Fig 20 Bearing monitoring by shock pulse transducer 1 Measuring nipple For a detailed illustration of the gear unit and the position of the add on parts refer to the drawings in the gear unit documentation 5 15 3 Bearing monitoring by accelerometer The gear unit can have been provided with threaded bores suitable for receiving ac...

Page 43: ... in the gear unit documentation Note For operation of the sensors the special operating instructions should be observed 5 15 4 Gear unit with torque limiting backstop Note If a torque limiting backstop see item 5 7 1 is used on gear units the slipping torque will already have been set at the correct value during the manufacturing process Resetting or checking during startup is not necessary ...

Page 44: ...e alignment to occur automatically when the shift ring is shifted axially If the teeth meet in such a way that the rotary movement does not occur automatically the shift lever must be returned to the initial position The input shaft must be turned by hand to put the shifting parts into a shiftable position This procedure applies to all speeds It must be ensured that after shifting to another speed...

Page 45: ... work NOTICE Material damage Risk of damage to the gear unit Care must be taken to ensure that no electric current can flow through gear units that are operated together with electrical equipment that generate electric current or in which electric current flows e g motors generators Electric current flow can cause irreparable damage to bearings and teeth Electric current flow can be caused by e g ...

Page 46: ...ed Screws which have been damaged during assembly or disassembly work must be replaced with new screws of the same strength class and type Note To ensure proper lubrication during operation the mounting position specified on the drawings must always be observed 6 2 Unpacking NOTICE Material damage Risk of damage to the gear unit through corrosion The packaging must not be opened or damaged beforeh...

Page 47: ...by means of lateral stops Note For dimensions space requirement and arrangement of supply connections refer to the drawings in the gear unit documentation 6 3 1 2 Foundation for torque arm NOTICE Material damage Risk of damage through insufficiently safe positioning of the gear unit The foundation must be horizontal and level The gear unit must not be excessively stressed when tensioning the faste...

Page 48: ...ing lubricants and solvents Wear suitable protective clothing NOTICE Material damage Risk of damage to the shaft sealing rings through chemically aggressive cleaning agents The cleaning agent must in no way be allowed to come into contact with the shaft sealing rings The screw plugs and or sealing flanges must be removed and the fittings supplied separately must be fitted to the system according t...

Page 49: ...rve the manual to the toothed coupling Insufficiently rigid base frames or sub structures can also during operation cause a radial and or axial misalignment which cannot be measured when the unit is at a standstill Note Gear units with a weight that requires the use of lifting gear must be attached at the points shown in section 4 Transport and storage If the gear unit is to be transported with ad...

Page 50: ...ons Note The record must be kept with these instructions DANGER Danger to life through flying fragments Non observance of the alignment accuracy can cause shaft rupture resulting in serious injury and danger to life Align the gear unit precisely adhere to the specified values Risk of damage to the gear unit or its components or add on parts The accuracy of shaft axis alignment is an important fact...

Page 51: ...nit must not be excessively stressed when tightening the fastening bolts Align the gear unit exactly with the units on the input and output sides see item 6 3 2 1 Record the alignment dimensions Note The record must be kept with these instructions 6 4 Shaft mounted gear unit with solid shaft Note Clean the recesses on the gear unit housing Place the gear unit in the bearing shells which are to be ...

Page 52: ...ust releasing agent 3 1 2 4 Fig 25 Hollow shaft with parallel keyway preparation 1 Machine shaft 2 Hollow shaft 3 Parallel key 4 Pressure oil connection 6 5 2 Fitting DANGER Risk of explosion Danger to life through ignition of solvent agent vapours or any other potentially explosive atmosphere during cleaning work The gear unit must not be cleaned in a potentially explosive atmosphere Avoid igniti...

Page 53: ...ft must be in line with the driven machine shaft Any canting must be avoided 2 3 1 4 7 6 5 Fig 26 Hollow shaft with parallel keyway fitting with threaded spindle 1 Machine shaft 2 Hollow shaft 3 Parallel key 4 Nut 5 Threaded spindle 6 Nut 7 End plate Instead of the nut and threaded spindle shown in the diagram other types of equipment such as a hydraulic cylinder may be used NOTICE Material damage...

Page 54: ...g the device see figures 27 and 28 Removing the gear unit from the driven machine shaft can be done as follows preferably using a hydraulic lifting unit using forcing off screws in an end plate see figure 28 or using a central threaded spindle Note The end plate and or the auxiliary plate for forcing off the gear unit are not included in the Siemens delivery 5 4 6 3 1 2 7 Fig 27 Hollow shaft with ...

Page 55: ...nents If the support is provided not only by the hollow shaft but also by the housing when forcing the gear unit off as shown in figure 27 the forces used must not exceed the values given in table 8 below Before the gear unit is fitted on the machine shaft again the hollow shaft bearings must be checked for damage Table 8 Maximum forcing off pressures Gear unit size Maximum forcing off pressure N ...

Page 56: ...9 Hollow shaft with splines preparation 1 Machine shaft 2 Hollow shaft 3 DU bush 4 Pressure oil connection 6 6 2 Fitting DANGER Risk of explosion Danger to life through ignition of solvent agent vapours or any other potentially explosive atmosphere during cleaning work The gear unit must not be cleaned in a potentially explosive atmosphere Observe also the following Avoid ignition sources Do not s...

Page 57: ... by the hollow shaft NOTICE Material damage Risk of damage to the gear unit through canting during fitting work When fitting the gear unit care must be taken that the hollow shaft and the machine shaft are aligned and that the tooth position of the machine shaft relative to the hollow shaft is correct The correct tooth position can be determined by turning the input shaft or by swivelling the gear...

Page 58: ...amage to the rolling bearings through canting when the gear unit is fitted The hollow shaft may be tightened against a machine shaft collar only if the gear unit configuration is one of the following Torque arm 6 6 2 3 Axial securing Depending on type secure the hollow shaft axially on the machine shaft e g with locking ring end plate set screw 6 6 3 Demounting Remove the axial securing device fro...

Page 59: ... Machine shaft 2 Hollow shaft 3 DU bush 4 Hydraulic lifting unit 5 Threaded spindle 6 Pressure oil connection 7 Auxiliary plate for forcing out 5 6 4 3 1 2 Fig 32 Hollow shaft with splines demounting with end plate 1 Machine shaft 2 Hollow shaft 3 DU bush 4 End plate 5 Pressure oil connection 6 Forcing off screws ...

Page 60: ...orcing the gear unit off as shown in figure 31 the forces used must not exceed the values given in table 9 below Before the gear unit is fitted on the machine shaft again the hollow shaft bearings must be checked for damage Table 9 Maximum forcing off pressures Gear unit size Maximum forcing off pressure N Gear unit size Maximum forcing off pressure N 15 115 193000 20 120 1 16 116 215000 21 121 1 ...

Page 61: ...ink disk preparation 1 Machine shaft 2 Hollow shaft 3 DU bush 4 Pressure oil connection 6 7 2 Fitting DANGER Risk of explosion Danger to life through ignition of solvent agent vapours or any other potentially explosive atmosphere during cleaning work The gear unit must not be cleaned in a potentially explosive atmosphere Observe also the following Avoid ignition sources Do not smoke Ensure adequat...

Page 62: ...ts containing oil such as paraffin or turpentine are not suitable for removing grease 6 7 2 1 Fitting with integrated DU bush Fit the gear unit by means of nut and threaded spindle The support is provided by the hollow shaft NOTICE Material damage Risk of damage to the gear unit through canting during fitting work When fitting the gear unit on the driven machine shaft the hollow shaft must be in l...

Page 63: ...ted according to instructions see item 6 7 3 the gear unit is fixed securely enough in the axial direction Additional axial securing is not required 6 7 3 Shrink disk The shrink disk is delivered ready for fitting Note For the shrink disk used take the instructions in the related operating instructions B 3233 into account These operating instructions are an integral part of the order specific docu...

Page 64: ...ssure oil connection 7 Auxiliary plate for forcing out 5 6 4 3 1 2 Fig 36 Hollow shaft in design with shrink disk demounting with end plate 1 Machine shaft 2 Hollow shaft 3 DU bush 4 End plate 5 Pressure oil connection 6 Forcing off screws NOTICE Material damage Damage to the gear unit possible through canting during demounting work When pulling the gear unit off the driven machine shaft any canti...

Page 65: ...given in table 10 below Before the gear unit is fitted on the machine shaft again the hollow shaft bearings must be checked for damage Table 10 Maximum forcing off pressures Gear unit size Maximum forcing off pressure N Gear unit size Maximum forcing off pressure N 15 115 193000 20 120 1 16 116 215000 21 121 1 17 117 240000 22 122 1 18 118 266000 23 123 1 19 119 1 24 124 1 1 on request Note When u...

Page 66: ... single components through incorrect alignment When positioning the drive units the instructions for the alignment of the individual components given in the manuals belonging to the components must be observed Inadmissibly large errors in the alignment of the shaft ends to be connected through angular and or axial misalignments result in premature wear and material damage When using toothed coupli...

Page 67: ...e coupling 1 Ruler 2 Feeler gauge 3 Measuring points NOTICE Material damage Risk of damage to or destruction of the coupling through incorrect alignment The maximum permissible misalignment values are specified in the operating instructions for the coupling they must under no circumstances be exceeded during operation Angular and radial misalignments may occur at the same time The sum of both misa...

Page 68: ...In case of separately fitted gear units it must be ensured that the gear unit is not subjected to external forces through possible displacement The torque arm should be designed for the resetting moment and the weight forces involved Note The torque arm is not included in our scope of delivery For design of the foundation for fastening the torque arm see item 6 3 1 2 Foundation 6 10 Gear unit with...

Page 69: ...in accordance with the equipment suppliers instructions and Directive 94 9 EC WARNING Risk of injury through electric shock Risk of injury through electric shock when connecting up electrical components Before connecting up equipment ensure that they are voltage free 6 13 Gear unit with heating Wire the heating system electrically Wire the oil level monitors for the heating rods in EX version elec...

Page 70: ...o leakage Any oil drain cocks must be secured against accidental opening If an oil sight glass is used for monitoring the oil level it must be protected against damage The gear unit must be protected against falling objects Protective devices for rotating parts must be checked for correct seating Contact with rotating parts is not permitted DANGER Electrostatic discharge Danger to life through ign...

Page 71: ...ng threads through incorrect tightening Foundation bolts hub bolts and bearing cover bolts must always be tightened in accordance with the specifications for screw connection class C 6 19 2 Tightening torques and initial tensioning forces The tightening torques apply to friction coefficients of μtotal 0 14 The friction coefficient μtotal 0 14 applies here to lightly oiled steel bolts black anneale...

Page 72: ...00 3750 12 9 551000 352000 220000 5430 4680 4180 M48 8 8 421000 269000 168000 4750 4090 3650 10 9 599000 383000 240000 6760 5820 5200 12 9 700000 448000 280000 7900 6810 6080 M56 8 8 568000 363000 227000 7430 6400 5710 10 9 806000 516000 323000 10500 9090 8120 12 9 944000 604000 378000 12300 10600 9500 M64 8 8 744000 476000 298000 11000 9480 8460 10 9 1060000 676000 423000 15600 13500 12000 12 9 1...

Page 73: ...entilation Replace the screw plug with the air filter or wet air filter before start up Remove adhesive tape from the labyrinth seals see item 4 4 1 The position of the oil drain points is marked by a symbol on the dimensioned drawing in the gear unit documentation Oil drain point Place suitable containers under the oil drain points Unscrew the oil drain plug and or open the oil drain cock Remove ...

Page 74: ...r 2 Dipstick 3 Air relief point 4 Oil drain 5 Oil inlet 3 4 5 2 1 Fig 41 Gear unit with backstop 1 Gear unit 2 Sealing cover backstop 3 Backstop 4 Screw plug Residual oil drain 5 Screw plug Oil filling For a detailed illustration of the gear unit and the position of the add on parts refer to the drawings in the gear unit documentation ...

Page 75: ...ck During the filling operation make sure that no dirt can enter into the gear unit Note The quality of the oil used must meet the requirements of the separately supplied BA 7300 operating instructions otherwise the guarantee given by Siemens will lapse We urgently recommend using one of the oils listed in table T 7300 for a link to the Internet see the back cover as they have been tested and meet...

Page 76: ...ly cover with the seal on the housing Screw in the fastening screws of the cover and tighten them to the specified tightening torque see item 6 19 Screw in the air filter with the reducing screw or the wet air filter again NOTICE Material damage Risk of damage to the wet air filter Prior to using the wet air filter 2 of the 8 sealed bores at the underside of the wet air filter must be opened 7 1 3...

Page 77: ...uction of the gear unit or gear unit components through incorrect direction of rotation The gear unit can only be operated in one direction of rotation It is possible that a certain direction of rotation has been specified in the order which is realised by adding on a backstop NOTICE Material damage Risk of damage to the gear unit through missing or insufficient ventilation Replace the screw plug ...

Page 78: ...es must it be allowed to fall below the lower edge on the oil sight glass the MIN mark on the oil level indicator or the MIN mark on the dipstick If necessary top up oil to the correct level 7 2 2 Gear unit with cooling coil or external oil supply system NOTICE Material damage Risk of damage to the gear unit through missing or insufficient cooling and or lubrication Fully open the stop valves in t...

Page 79: ...structions Start operation of the gear unit A no load run of the gear unit should be limited to a minimum time During idling time the following points have to be observed Oil level After the first run the oil level will fall As the gear unit continues to heat up the oil level will rise to the level of the mark showing the operating oil level If the gear unit does not heat up with too low load the ...

Page 80: ...hed to the gear unit housing close to the backstop NOTICE Material damage Damage to or destruction of the backstop possible through overheating Check the dimension xmin regularly every 12 months The dimension xmin must not be smaller than that stated on the rating plate of the backstop The operating instructions of the backstop must be observed WARNING Risk of explosion Danger to life through igni...

Page 81: ... switch The oil level monitoring device has been designed for checking the oil level when the gear unit is at a standstill prior to operating start DANGER Risk of explosion Danger to life through ignition of a potentially explosive atmosphere through overheating of the gear unit due to too low oil level Wire the signal in such a manner that the drive motor cannot start on the occurence of the sign...

Page 82: ...ete immersion of the heating elements in the oil bath is ensured If heating elements are fitted afterwards the maximum heating capacity see table 7 on the outer surface of the heating elements must not be exceeded Note Be sure to observe the operating instructions of the oil level monitoring device for operation and maintenance The correct setting of the switch points must be checked see item 5 10...

Page 83: ... preservation for longer disuse Depending on the type of lubrication and or shaft sealing the following types of interior preservation can be applied 7 3 1 1 Interior preservation with gear unit oil Gear units with splash lubrication systems and contacting shaft seals can be filled with the type of oil already filled in up to a point just below the air filter or wet air filter The duration of this...

Page 84: ...ive agent Before longer shut down periods gear units with force feed lubrication systems oil circulation cooling and or non contacting shaft seals should be filled with preservative agent and run without load Place a suitable container under the oil drain point of the gear unit housing Unscrew the oil drain plug and or open the oil drain cock Drain the operating oil into a suitable container see s...

Page 85: ...on the housing Screw in the fastening screws of the inspection and or assembly cover and tighten them to the specified tightening torque see item 6 19 Screw in the air filter with the reducing screw or the wet air filter again NOTICE Material damage Risk of damage to the wet air filter Prior to using the wet air filter 2 of the 8 sealed bores at the underside of the wet air filter must be opened S...

Page 86: ...n of the sealing ring the sealing ring is vulcanised onto the oil drain plug If necessary use a new oil drain plug Shut the oil drain cock and or screw in the oil drain plug again Unscrew the air filter or wet air filter on the top of the housing Replace the air filter or wet air filter with a screw plug Note Carefully clean the air filter see item 10 2 4 and keep it on a safe place it will be req...

Page 87: ...g Before re starting the gear unit take the following measure Replace the screw plug with the air filter or wet air filter 7 3 2 Exterior preservation 7 3 2 1 Exterior preservation procedure Clean the surfaces NOTICE Material damage Risk of damage to the shaft sealing ring through contact with chemically aggressive preservative agent For separation between the sealing lip of the radial shaft seali...

Page 88: ... any potentially explosive atmosphere through electrostatic discharge The coating must not carry an electrostatic charge The operator must ensure that highly effective mechanisms which can set up a charge in the coating are safely avoided During operation the gear unit must be monitored for the following Operating temperature The maximum permitted temperature is 90 C At higher temperatures the gea...

Page 89: ... the MAX mark on the dipstick NOTICE Material damage Insufficient lubrication possible through too low oil level Check the oil level Under no circumstances must it be allowed to fall below the lower edge on the oil sight glass the MIN mark on the oil level indicator or the MIN mark on the dipstick If necessary top up oil to the correct level Note The oil level in the oil supply system must be chec...

Page 90: ...ossible faults their causes and suggested remedies If the cause cannot be found a specialist from a Siemens customer service centre should be called in see section 2 General notes DANGER Risk of explosion Ignition of a potentially explosive atmosphere possible through overheating of the gear unit in case of too low oil level due to leakage Any oil drain cocks must be secured against accidental ope...

Page 91: ...y separate oil supply unit to carry out maintenance and or repair work or to remove the protective equipment Secure the drive unit against being switched on accidentally Attach a notice to the ON switch stating clearly that work is in progress on the gear unit WARNING Risk of injury from live parts The removal of covers incorrect use of the system incorrect operation or inadequate maintenance may ...

Page 92: ...tion amplitudes at the bearing points Bearing is defective Gears are defective Contact Customer Service Check and if necessary replace bearings Contact Customer Service Check and if necessary replace gears Exterior of gear unit is oiled up Inadequate sealing of housing covers and or joints Labyrinth seals oiled up Incorrect transport position Seal housing covers and or joints Check oil filling Cle...

Page 93: ...alter its direction by structural measures Contact Customer Service If necessary use wet air filter Check the oil supply system or cooling coil replace any defective parts Consult operating instructions for oil supply system Increased operating temperature Oil level in housing too high Oil too old Oil badly contaminated Oil supply system or cooling coil defective Gear unit with cooling coil Deposi...

Page 94: ...Change polarity of motor Contact Customer Service Fit cage of the backstop turned by 180 or replace Changeover of the gear unit Contact Customer Service Check shifting device of the gear unit replace if necessary Fault in the oil supply system Consult operating instructions for oil supply system NOTICE Material damage Risk of damage to the gear unit through use of operating oils of insufficient qu...

Page 95: ...h underneath sealing lip The sealing lip must not be contaminated Observe The radial shaft sealing ring often dries by itself in further operation No reason for complaint Measurable leak Small trickle to be seen on the bottom side of the radial shaft sealing ring dripping Change radial shaft sealing ring if necessary identify possible cause of radial shaft sealing ring failure and rectify May be a...

Page 96: ... removal of covers incorrect use of the system incorrect operation or inadequate maintenance may result in death serious injury or material damage When working on the system always adhere to the Five safety rules see section 3 Safety Instructions Always remove covers strictly in accordance with these operating instructions Operate the system correctly Maintain the system regularly and correctly Th...

Page 97: ...r unit for leaks Monthly Examine the water content of the oil After approx 400 operating hours at least once a year See item 10 2 1 Perform the first oil change Approx 400 operating hours after start up See item 10 2 2 Perform subsequent oil changes Every 24 months or 10 000 operating hours See items 10 2 2 and 10 1 1 Replace the wet air filter As required See item 10 2 3 Clean the air filter Ever...

Page 98: ...al esters such as rape seed oils for synthetic oils poly α olefins and polyglycols 20 000 operating hours or maximally 4 years Note The actual service lives may differ The general rule is that an increase in temperature of 10 K will halve the service life and a temperature decrease of 10 K will approximately double the service life 10 2 Maintenance and repair work 10 2 1 Examine water content of o...

Page 99: ...must be flushed out with the new oil type Flushing is not necessary if the new operating oil is fully compatible with the previously used operating oil in all respects The compatibility must be confirmed by the oil supplier If there is a change to another oil Siemens recommends flushing out the gear unit with the new type of operating oil Note When changing the oil the housing and the oil supply s...

Page 100: ... and or assembly cover with the seal on the housing Screw in the fastening screws of the cover and tighten them to the specified tightening torque see item 6 19 Screw in the air filter with the reducing screw or the wet air filter again NOTICE Material damage Risk of damage to the wet air filter Prior to using the wet air filter 2 of the 8 sealed bores at the underside of the wet air filter must b...

Page 101: ...lasses NOTICE Material damage Risk of damage to the gear unit through entry of foreign bodies Foreign bodies must be prevented from entering the gear unit 10 2 5 Check friction linings of torque limiting backstop WARNING Risk of injury through movable plant parts After having stopped the motor there is a danger that the load is not safely held in its position and can run in reverse direction at hi...

Page 102: ...will expire if the locking wire for the screws is missing or has been damaged WARNING Risk of injury through movable plant parts After having stopped the motor there is a danger that the load is not safely held in its position and can run in reverse direction at high speed The slipping torque was set at the correct value at the works it must not be changed Note To safeguard the set slipping torque...

Page 103: ... on output shaft spacer The lubricating interval of 6 months or 5000 operating hours relates to a temperature of 50 C The temperature on the housing surface close to the bearing point is measured Note In case of temperatures above 50 C the lubricating interval must be reduced to the half of the original value for each 15 K increase in temperature NOTICE Material damage Risk of damage to the output...

Page 104: ...hrough chemical substances Avoid burns when working with corrosive cleaning agents Observe manufacturer s instructions for handling lubricants and solvents Wear suitable personal protective equipment gloves safety glasses Seriously contaminated cooling coils must be replaced Consult the Siemens Customer Service for this Re connect the cooling water in and outflow pipes 10 2 10 Check hose lines Eve...

Page 105: ...ions otherwise the guarantee given by Siemens will lapse We urgently recommend using one of the oils listed in table T 7300 for a link to the Internet see the back cover as they have been tested and meet the requirements Note To avoid misunderstandings we should like to point out that this recommendation is in no way intended as a guarantee of the quality of the lubricant supplied Each lubricant m...

Page 106: ...acteristics of the gear unit thereby posing an active or passive risk to safety Siemens will assume no liability or guarantee for damage caused by spare parts not supplied by Siemens The same applies to any accessories not supplied by Siemens Note that certain components often have special production and supply specifications and that Siemens supplies you with spare parts which comply fully with t...

Page 107: ... 1 4 1 1 4 2 1 1 5 1 1 5 2 1 5 4 1 5 5 1 5 6 1 5 7 1 5 8 1 5 9 1 5 10 1 5 11 1 5 13 1 5 15 1 6 1 1 7 1 1 7 1 1 1 7 4 1 7 4 1 1 7 4 2 1 7 4 3 The partly completed machinery must not be put into service until it has been established that the machinery into which the partly completed machinery is to be incorporated has been declared to be in conformity with the provisions of Directive 2006 42 EC as a...

Page 108: ... K HM K KM K DM Sizes 15 to 24 and sizes 115 to 124 is in conformity with Article 1 and Article 8 Paragraph 1 b ii or 1 c of Directive 94 9 EC and complies with the requirements of Directive 94 9 EC and the following standards DIN EN 1127 1 10 2011 DIN EN 13463 1 07 2009 DIN EN 13463 5 10 2011 DIN EN 13463 6 07 2005 DIN EN 13463 8 01 2004 DIN EN 60079 0 06 2014 The technical documentation has been...

Page 109: ...ject to modifications Siemens AG 2015 Further Information FLENDER gear units on the Internet www siemens com gearunits FLENDER couplings on the Internet www siemens com couplings Service Support http support automation siemens com WW view en 10803928 133300 Lubricants http support automation siemens com WW view en 42961591 133000 ...

Search results

Summary of Contents for FLENDER K DH Series

Reviews:

Related manuals for FLENDER K DH Series

Brands by name

Popular brands

Siemens FLENDER K DH Series, Assembly And Operating Instructions Manual

Search results

Summary of Contents for FLENDER K DH Series

Reviews:

Related manuals for FLENDER K DH Series

Brands by name

Popular brands