FLENDER K.SH - Page 110

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Crane gear unit

Assembly and operating instructions A5850-02en

Edition 06/2022

Flender GmbH

Alfred-Flender-Straße 77

46395 Bocholt

Germany

Main Page

Table of Contents3
Introduction11
Legal Information11
General Information12
Lubricants14
Safety Instructions15
Security Notes15
The Five Safety Rules15
General Information15
General Warnings and Symbols17
Special Types of Danger and Personal Protective Equipment17
Table 2-1 Symbols and Markings17
Table 2-2 General Warnings17
Intended Use20
Description23
General Description23
Output Shaft Versions24
Housing24
Table 3-1 Designs and Associated Directions of Rotation24
Figure 3-1 Output Shaft Versions24
Figure 3-2 Gear Unit Equipment on Gear Units of Type K25
Oil Supply to the Gear Unit26
Splash Lubrication26
Shaft Bearings26
Figure 3-3 Gear Unit Equipment on Gear Units of Type K26
Shaft Seal27
Rotary Shaft Sealing Rings27
Labyrinth Seals27
Figure 3-4 Rotary Shaft Sealing Ring27
Taconite Seal28
Figure 3-5 Labyrinth Seal28
Figure 3-6 Taconite Seal28
Figure 3-7 Design Variants of Taconite Seals29
Tacolab Seal30
Table 3-2 Taconite Seal Versions30
Cooling31
Figure 3-8 Tacolab Seal31
Fan32
Figure 3-9 Fan32
Cooling Coil33
Mounted Oil Supply System34
Figure 3-10: Cooling Coil on Type K..H and K..M Gear Units34
Pump35
Oil Filter35
Pressure Monitor35
Separate Oil Supply System36
Couplings36
Shrink Disk36
Heating37
Table 3-3 Information about the Specific Heat Output37
Figure 3-11 Heating37
Oil Level Indicator38
Oil Temperature Monitoring38
Bearing Monitoring39
Bearing Monitoring by Shock-Pulse Transducer39
Figure 3-12 Oil Temperature Monitor Mounted on the Gear Unit39
Bearing Monitoring by Acceleration Sensor40
Figure 3-13: Bearing Monitoring System with Shock-Pulse Transducer on Type K..H and K..M Gear Units40
Figure 3-14 Fully Assembled Acceleration Sensor (A), and Threaded Connector (B) for Variants 1 to 441
Figure 3-15 Fully Assembled Acceleration Sensor (C), and the Threaded Connector (D) for Variants 5A and 5B41
Gear Changing42
Application Planning43
Scope of Delivery43
Transport43
Figure 4-1 Transport Symbols44
Attachment Points45
Figure 4-2 Shear and Lateral Pulling When Using Eye Bolts45
Figure 4-3 Position of Attachment Points on Gear Unit46
Figure 4-4 Position of Attachment Points on Gear Unit with Motor46
Special Aspects of Gear Unit Lubrication and Preservation47
Oil Filling Point and Oil Drain47
Figure 4-5 Oil Filling Point and Oil Drain47
Assembly49
General Assembly Instructions49
Unpacking the Gear Unit50
Gear Unit Assembly51
Foundation51
Description of Assembly Work52
Alignment53
Figure 5-1 Gap Dimension at the Grease Labyrinth53
Figure 5-2 Alignment Surface54
Figure 5-3 Alignment Surfaces and Alignment Threads on Gear Units of Type K54
Mounting the Gear Unit on the Housing Mounting Foot55
Installation on a Foundation Frame55
Shaft-Mounted Gear Unit with Solid Shaft56
Figure 5-4 Installation Procedure for Gear Unit with Three-Point Housing Bearings and Solid Shaft56
Shaft-Mounted Gear Unit with Hollow Shaft and Parallel Keyway57
Preparations57
Figure 5-5 Gear Unit with a Hollow Shaft and Parallel Keyway57
Mounting58
Axial Locking59
Figure 5-6 Mounting with a Screw Spindle59
Dismantling60
Shaft-Mounted Gear Unit with Hollow Shaft and Shrink Disk61
Figure 5-7 Dismantling Using an End Plate61
Preparations62
Mounting62
Figure 5-8 Preparation for Gear Units with Hollow Shaft and Shrink Disk62
Pulling on with Integrated du Bushing63
Figure 5-9 Mounting with a Screw Spindle64
Mounting with du Bushing as a Separate Component65
Axial Locking65
Dismantling66
Figure 5-10 Dismantling Using an End Plate67
Figure 5-11 Dismantling Using Hydraulic Pulling Equipment67
Mounting the Torque Arm for the Gear Unit Housing68
Mounting the Torque Arm68
Figure 5-12 Mounting the Torque Arm68
Couplings69
Assembling the Coupling70
Aligning the Coupling71
Figure 5-13 Possible Displacements71
Figure 5-14 Alignment Process Based on the Example of a Flexible Coupling72
Connecting Components73
Gear Units with Mounted Components73
Connecting the Cooling Coil73
Installing a Separate Oil Supply System73
Connecting the Heating Element74
Connecting the Pt 100 Resistance Thermometer74
Electrical Connections75
Tightening Procedure75
Introduction75
Bolt Connection Classes76
Tightening Torques and Preload Forces76
Table 5-1 Information on Tightening Fastening Bolts76
Final Work78
Table 5-2 Preload Forces and Tightening Torques78
Commissioning81
Measures Prior to Commissioning81
Gear Unit with Cooling Coil81
Gear Unit with Oil Supply System82
Measures During Commissioning82
Initial Test Run83
Gear Units with Heating83
Operation85
Operating Data85
Irregularities in Operation85
Table 7-1 Operating Data85
Taking the Unit out of Service86
Servicing87
General Maintenance Information87
Maintenance Schedule87
Maintenance and Servicing Work88
Table 8-1 Maintenance and Servicing Activities88
Checking the Oil Temperature89
Measure the Vibration Levels of the Rolling-Contact Bearings89
Clean the Fan and Gear Unit89
Checking the Cooling Coil90
Inspecting the Shrink Disk91
General Inspection of the Gear Unit91
Check that All of the Fastening Bolts Are Tight91
Final Work91
Possible Faults91
Table 8-2 Possible Faults and How to Rectify Them94
Service & Support95
Contact95
Disposal97
Spare Parts99
Declaration of Incorporation101
Technical Data103
General Technical Data103
Figure B-1 Rating Plate103
Ambient Temperature104
Types104
Weights105
Oil Quantities105
Enveloping Surface Sound Pressure Level105
Index107

FLENDER K.SH - Page 110

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