Flender Gear Units: Vertical-Mill Gear Unit

FLENDER GEAR UNITS
Vertical-mill gear unit
Assembly and operating instructions 9137en

Edition 06/2020
KMS
225...1100
08.12.2020 17:01
V9.00
Introduction 1
Safety instructions 2
Description 3
FLENDER GEAR UNITS
Application planning 4
9137en 5
Assembly
Commissioning 6
Assembly and operating instructions
Operation 7
Servicing 8
Service & Support 9
Disposal 10
Spare parts 11
KMS Declaration of incorporation A

225...1100
Declaration of Conformity B
Technical data C
Original assembly and operating instructions

Edition 06/2020
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage
to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices
referring only to property damage have no safety alert symbol. These notices shown below are graded according to
the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property
damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Flender products
Note the following:
WARNING
Flender products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended or
approved by Flender. Proper transport, storage, installation, assembly, commissioning, operation and maintenance
are required to ensure that the products operate safely and without any problems. The permissible ambient
conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Flender GmbH. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described.
Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this
publication is reviewed regularly and any necessary corrections are included in subsequent editions.
Flender GmbH Document order number: 9137en Copyright © Flender GmbH 2020.
Alfred-Flender-Straße 77 Ⓟ 12/2020 Subject to change All rights reserved
46395 BOCHOLT
GERMANY
Table of contents
1 Introduction ........................................................................................................................................... 9
1.1 General information............................................................................................................. 9
1.2 Lubricants.......................................................................................................................... 10
2 Safety instructions ............................................................................................................................... 11
2.1 Security notes .................................................................................................................... 11
2.2 The five safety rules ........................................................................................................... 11
2.3 General information........................................................................................................... 12
2.4 General warnings and symbols........................................................................................... 13
2.5 Special types of danger and personal protective equipment ................................................ 14
2.6 Correct use in hazardous zones (explosive atmospheres) .................................................... 16
3 Description........................................................................................................................................... 21
3.1 General description............................................................................................................ 21
3.2 Housing............................................................................................................................. 21
3.3 Delivered state of the gear unit .......................................................................................... 23
3.4 Oil supply to the gear unit .................................................................................................. 23
3.4.1 Hydrodynamic lubrication of tilting pad thrust bearings ...................................................... 24
3.4.2 Hydrodynamic lubrication of tilting pad thrust bearings on gear units with hydrostatic
starting aid ........................................................................................................................ 24
3.4.3 Hydrostatic lubrication of tilting pad thrust bearings with radial piston pump...................... 24
3.5 Shaft seals ......................................................................................................................... 25
3.5.1 Labyrinth seals................................................................................................................... 25
3.6 Couplings .......................................................................................................................... 26
3.7 Heating ............................................................................................................................. 26
3.8 Oil level indicator ............................................................................................................... 27
3.9 Oil level monitoring system ................................................................................................ 28
3.10 Oil temperature monitoring ............................................................................................... 29
4 Application planning ........................................................................................................................... 31
4.1 Scope of delivery ............................................................................................................... 31
4.2 Transport ........................................................................................................................... 31
4.3 Attachment points ............................................................................................................. 33
4.4 Special aspects of gear unit lubrication and preservation .................................................... 34
4.4.1 Oil filling and oil drain ........................................................................................................ 34
4.4.2 Filling with oil .................................................................................................................... 35
4.4.3 Draining oil........................................................................................................................ 36

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Table of contents
4.4.4 Checking the oil level ......................................................................................................... 36

4.4.5 Taking oil samples.............................................................................................................. 36
4.4.6 Preservation ...................................................................................................................... 37
4.4.6.1 Special aspects of extending the durability of the interior preservation ............................... 37
4.4.6.2 Sealing cap ........................................................................................................................ 39
4.4.6.3 Extending the durability of the interior preservation by operating the oil supply system ...... 39
5 Assembly.............................................................................................................................................. 41
5.1 General assembly instructions............................................................................................ 41
5.2 Unpacking the gear unit..................................................................................................... 43
5.3 Gear unit assembly ............................................................................................................ 44
5.3.1 Foundation ........................................................................................................................ 44
5.3.2 Description of assembly work............................................................................................. 45
5.4 Couplings .......................................................................................................................... 47
5.4.1 Assembling the coupling.................................................................................................... 47
5.4.2 Aligning the coupling......................................................................................................... 49
5.5 Mounting the pipes............................................................................................................ 50
5.5.1 Procedure .......................................................................................................................... 50
5.5.2 Pickling after adaptation .................................................................................................... 51
5.6 Installing the motor ........................................................................................................... 52
5.7 Welding work on the mill ................................................................................................... 53
5.8 Connecting components .................................................................................................... 53
5.8.1 Installing further mounted components supplied as separate items .................................... 53
5.8.2 Making terminal box connections for pre-wired gear units .................................................. 54
5.8.3 Gear units with mounted components ............................................................................... 54
5.8.4 Installing a separate oil supply system ................................................................................ 55
5.8.5 Electrical connections ........................................................................................................ 55
5.9 Tightening procedure......................................................................................................... 56
5.9.1 Introduction....................................................................................................................... 56
5.9.2 Bolt connection classes ...................................................................................................... 57
5.9.3 Tightening torques and preload forces................................................................................ 57
5.10 Final work.......................................................................................................................... 59
6 Commissioning .................................................................................................................................... 61
6.1 Measures prior to commissioning ....................................................................................... 61
6.1.1 Rinsing before first commissioning ..................................................................................... 62
6.1.2 Gear unit with oil supply system......................................................................................... 62
6.1.3 Checking procedure ........................................................................................................... 63
6.2 Measures during commissioning ........................................................................................ 64
6.2.1 Initial test run .................................................................................................................... 65
6.2.2 Oil level monitoring system ................................................................................................ 65
6.2.3 Gear unit with heating ....................................................................................................... 66
7 Operation............................................................................................................................................. 67
7.1 Operating data .................................................................................................................. 67
7.2 Irregularities in operation................................................................................................... 67

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Table of contents
7.3 Taking the unit out of service ............................................................................................. 69

8 Servicing .............................................................................................................................................. 71
8.1 General maintenance information...................................................................................... 71
8.2 Maintenance schedule ....................................................................................................... 71
8.3 Maintenance and servicing work ........................................................................................ 73
8.3.1 Contamination limits ......................................................................................................... 73
8.3.2 Servicing ........................................................................................................................... 74
8.3.3 Checking the oil temperature ............................................................................................. 74
8.3.4 Checking the ignition protection system ............................................................................. 74
8.3.5 Measuring the vibration levels............................................................................................ 75
8.3.6 Cleaning the gear unit........................................................................................................ 77
8.3.7 Cleaning the air filter and replacing the air filter element .................................................... 77
8.3.7.1 Cleaning the air filter.......................................................................................................... 77
8.3.7.2 Replacing the air filter element ........................................................................................... 77
8.3.8 Cleaning the double change-over filter ............................................................................... 78
8.3.9 Welding work on the mill ................................................................................................... 79
8.3.10 General inspection of the gear unit .................................................................................... 79
8.3.11 Check that all of the fastening bolts are tight...................................................................... 79
8.3.12 Final work.......................................................................................................................... 80
8.4 Possible faults .................................................................................................................... 80
9 Service & Support ................................................................................................................................ 85
10 Disposal ............................................................................................................................................... 87
11 Spare parts........................................................................................................................................... 89
A Declaration of incorporation ............................................................................................................... 91
B Declaration of Conformity ................................................................................................................... 93
C Technical data...................................................................................................................................... 95
C.1 General technical data ....................................................................................................... 95
C.2 Ambient temperature......................................................................................................... 97
C.3 Weights ............................................................................................................................. 97
C.4 Enveloping surface sound pressure level............................................................................. 97
Index .................................................................................................................................................... 99
Tables
Table 2-1 Symbols and markings ............................................................................................................ 12

Table 2-2 General warnings ................................................................................................................... 13
Table 3-1 Information about the specific heat output.............................................................................. 27
Table 5-1 Information on tightening fastening bolts ............................................................................... 57
Table 5-2 Preload forces and tightening torques ..................................................................................... 58
Table 8-1 Maintenance and servicing activities ....................................................................................... 71
Table 8-2 Possible faults and their rectification........................................................................................ 81

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Table C-1 ATEX marking ......................................................................................................................... 96
Figures
Figure 3-1 Gear unit preservation equipment........................................................................................... 22

Figure 3-2 Arrangement of round cord hollow profile and rotary shaft sealing ring ................................... 23
Figure 3-3 Labyrinth seal ......................................................................................................................... 25
Figure 4-1 Transport symbols................................................................................................................... 33
Figure 4-2 Position of attachment points on type KMS gear units ............................................................. 33
Figure 4-3 Oil filling locations and oil drain locations ............................................................................... 34
Figure 5-1 Possible displacements ........................................................................................................... 49
Figure 5-2 Alignment process based on the example of a flexible coupling ............................................... 50
Figure 8-1 Measuring points for vibration measurements......................................................................... 75
Figure C-1 Rating plate ............................................................................................................................ 95

8 Edition 06/2020
Introduction 1
1.1 General information
Purpose of the operating instructions

These operating instructions describe the gear unit and provide information about handling it
- from assembly to maintenance.
Please keep these operating instructions for later use. Please read these operating instructions
prior to handling the gear unit and follow the information in them.
Note
Disclaimer
Please make sure that every person who is commissioned to work on the gear unit has read and
understood these operating instructions prior to handling the gear unit and adheres to all of the
points. Failure to observe these operating instructions can cause product or property damage or
personal injury.
Flender does not accept any liability for damage or operating failures that are due to non-
adherence to these operating instructions.
The gear unit described in these instructions reflects the state of technical development at the
time these operating instructions went to print.
In the interest of technical advancements, Flender reserves the right to make changes to the
individual components and accessories which are considered necessary for improving their
performance and safety, while maintaining their essential features.
ATEX Directive
The term "ATEX Directive" used in these instructions stands for the harmonisation legislation of
the European Union in compliance with the declaration of conformance for equipment and
protective systems for correct use in hazardous zones.
Basic knowledge required

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

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Introduction
1.2 Lubricants
Documentation landscape
These operating instructions form part of the delivery of your gear unit.
These operating instructions form part of the complete documentation supplied with the gear
unit. The complete documentation encompasses other documents, including:
• Data sheet
• List of equipment
• Dimension drawing
• Operating instructions for gear unit lubrication and preservation BA 7300
• Operating instructions for mounted components
• Operating instructions for third-party vendor devices
Copyright
The copyright for these operating instructions is held by Flender.
Without the authorisation of Flender, these operating instructions may not be used wholly or in
parts for competitors’ purposes or be given to third parties.
If you have any technical queries, please contact one of our Customer Services addresses
(Page 85).
1.2 Lubricants
The quality of the oil used must meet the requirements of the operating instructions BA 7300
that is provided as a separate item, otherwise the warranty provided by Flender will be void.
Flender urgently recommends that one of the oil types listed in BA 7300, which have been
appropriately tested and comply with the requirements, is used.
To avoid misunderstandings, Flender points out that, by making this recommendation, it is not
approving the product in the sense of expressing a warranty for the quality of the lubricants
supplied by your supplier. Each lubricant manufacturer must provide a warranty for the quality
of its own product.
You will find the oil grade, oil viscosity and the required oil quantity on the rating plate of the gear
unit and in the documentation provided with it.
The oil quantity specified on the rating plate is an approximate quantity. The decisive factors for
the oil quantity to be filled are the marking of the oil dipstick or oil sight glass.
The operating instructions for the current lubricant recommendations of Flender can also be
viewed in the Internet (https://www.flender.com/lubricants).
The oils listed there undergo continuous testing. For this reason, oils recommended there may
be removed later or replaced with further developed oils.
Flender recommends regular inspection to ascertain whether the selected lubricating oil is still
approved by Flender. If it is not, a different make should be used instead.

10 Edition 06/2020
Safety instructions 2
2.1 Security notes
Flender offers products and solutions with industrial security functions, which support the safe
and secure operation of plants, systems, machines and networks.
In order to safeguard plants, systems, machines and networks against cyber threats it is
necessary to implement (and continually maintain) a holistic industrial security concept that
corresponds to the current state of the art. Flender products and solutions undergo continuous
development in this respect.
Customers are responsible for preventing unauthorised access to their plants, systems,
machines and networks. These systems, machines and components shall be connected to the
company network or the Internet only when and to the extent that this is absolutely necessary
and appropriate protective measures (e.g. firewalls and/or network segmentation) shall be
taken.
You can find further information about possible protection measures as part of Industrial
Security in the following international series of standards, for example: IEC 62443 "Network and
system security".
Flender products and solutions undergo continuous development in order to make them even
safer. Flender strongly recommends that you regularly implement product updates as soon as
they become available and that you only use the current product versions. Use of older or no
longer supported versions can increase the risk of cyber threats.
2.2 The five safety rules

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

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

The following symbols apply to the gear unit; some of which are found as coloured markings on
the gear unit:
Table 2-1 Symbols and markings
Points labelled on the gear unit Symbol Coloured markings

Earth connection point
Air relief point yellow
Oil filling point yellow
Oil draining point white
Oil level indicator red
Oil level measurement red
Oil overflow
Connection point for vibration monitoring
Lubrication point red
Apply grease
Lifting eye
Eye bolt

12 Edition 06/2020
Safety instructions
2.4 General warnings and symbols
Points labelled on the gear unit Symbol Coloured markings

Do not unscrew
Alignment surface, horizontal
Alignment surface, vertical
These symbols indicate the oil level check‐

ing procedure using the oil dipstick.
These symbols indicate that the oil dipstick

must be firmly screwed in.
2.4 General warnings and symbols

The following table contains general warnings and their associated symbols.
Table 2-2 General warnings
ISO ANSI Warning

Warning - hazardous electrical voltage
Warning - explosive substances
--- Warning - entanglement hazard
--- Warning - hot surfaces
--- Warning - substances that can irritate or which are hazardous to health
--- Warning - caustic substances
--- Warning - suspended load
--- Warning - hand injuries
ATEX certification

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Safety instructions
2.5 Special types of danger and personal protective equipment
Requirements
Fulfil the following requirements before commencing work on the gear unit:
• Ensure that the oil pressure lines are depressurised.
• Only perform work on the gear unit when it is not in operation.
• Disconnect electrical systems from the power supply.
DANGER
Electric shock
Live parts can cause electric shock.
Ensure that the entire plant is de-energised before starting electrical installation work.
Protective equipment
Wear the following personal protective equipment when handling the gear unit:
• Safety shoes
• Overalls
• Helmet
• Safety gloves
• Safety goggles
WARNING
Risk of eye injury
Small foreign particles such as sand or dust can enter the cover plates of the rotating parts and
be hurled back by them.
Wear safety goggles.
Dangers during operation

Damage to the gear unit is possible.

14 Edition 06/2020
Safety instructions
Switch the gear unit to standstill immediately if inexplicable changes are noticed during
operation. Such changes may include unusual gear unit noise or a significant increase in
operating temperature.
WARNING
Risk of falling
There is an increased risk of falling when standing or walking on the gear unit during operation.
Only walk or stand on the gear unit and its mounted components for maintenance and repair
work when it is at a standstill. Do not walk or stand on shaft ends, protection covers, mounted
components or pipes.
WARNING
Danger to life through rotating or moving parts
There is danger that rotating or moving parts may catch hold of you or pull you in.
Secure rotating and/or moving parts against contact using safeguards.
Surface temperature
The surface temperatures of the gear unit can become very extreme depending on the
operating conditions.
WARNING
Risk of burns
Possible risk of serious burn injury from hot surfaces (> 55 °C).
Wear suitable protective gloves and protective clothing.
WARNING
Risk of scalding
Risk of serious injury possible through escaping hot operating media when these are being
changed.
Wear suitable protective gloves, safety goggles and protective clothing.
WARNING
Danger due to low temperatures
Possible risk of serious injuries due to frost (pain, numbness, frostbite) on cold surfaces (< 0 °C).

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Safety instructions
2.6 Correct use in hazardous zones (explosive atmospheres)
Chemical substances
Injuries can be sustained when using chemical substances.
WARNING
Risk of chemical burns due to chemical substances
There is a risk of chemical burns when handling aggressive cleaning agents.
Please observe the manufacturer's guidelines on how to handle cleaning agents and solvents.
Wear suitable protective equipment (gloves, safety goggles). Please use binding agents to
immediately clear up any spilt solvent.
CAUTION
Risk of injury due to chemically aggressive operating materials
There is a risk of injury to eyes and hands when handling chemically aggressive operating
materials.
Please observe the safety instructions in the data sheets of the oil used. Wear suitable
protective equipment (gloves, safety goggles). Use an oil-binding agent to immediately clean
up spilt oil.

Only use the gear unit according to the conditions specified in the service and delivery contract
and the technical data in the annex (Page 95). Deviating operating conditions are considered
improper use. The user or owner of the machine or plant is solely liable for any resulting damage.
When using the gear unit please specifically observe the following:
• Do not make any modifications to the gear unit which go beyond the permissible handling
described in these operating instructions. This also applies to safety features designed to
prevent accidental contact.
• Only ever use original spare parts.
Other spare parts are not tested and approved by Flender. Non-approved spare parts may
possibly change the design characteristics of the gear unit and thus impair its active or
passive safety.
Flender will accept no liability or warranty whatsoever for damage occurring as a result of the
use of non-approved spare parts. The same applies to any accessories which were not
supplied by Flender.
• All mounted components must strictly comply with the requirements laid down in the ATEX
directive.

16 Edition 06/2020
Safety instructions
If you have any queries, please contact Customer Services (Page 85).
WARNING
An explosive atmosphere can be ignited
An explosive atmosphere can be ignited if mounted components are used that do not comply
with the ATEX directive.
All mounted components must strictly comply with the requirements laid down in the ATEX
directive.
Connect basic electrical equipment (e.g. monitoring devices, switches, Pt 100 measuring
resistors) that have no marking according to the ATEX directive using suitable isolating
amplifiers so that intrinsic safety is guaranteed.
WARNING
Risk of falling
Risk of possible serious injury through falling.
Only walk or stand on the gear unit for maintenance and repair work when it is at a standstill.
Do not walk or stand on shaft ends, protection covers, mounted components or pipes.
Gear unit use

When using the gear unit, please observe the following basic rules:
• Ensure that the gear unit is operationally safe.
• The gear unit should only be operated, maintained or repaired by authorised, trained and
suitably qualified personnel.
• The relevant work safety and environmental protection regulations must be complied with
at all times during transport, assembly, dismantling, operation, maintenance and servicing.
• The outside of the gear unit must not be cleaned using high-pressure cleaning equipment or
water.
• No welding work must be performed on the gear unit or on parts connected to it. The gear
unit and any parts connected to it must not be used as an earthing point for electric-welding
operations. Gearing and rolling-contact bearings might be irreparably damaged by welding.
• Establish the appropriate potential equalisation connections.
WARNING
An explosive atmosphere can be ignited if sparking occurs as a result of a gear unit that has
not been earthed.
Perform potential equalisation in accordance with the applicable regulations and
guidelines.
Threaded holes are provided on the gear unit to establish an earth connection. This work
must always be done by specialist electricians.

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Safety instructions
• In the case of gear units that are operated in combination with electrical machines that
generate current or through which current flows (e.g. motors and generators), take
measures to ensure that no current can flow through the gear unit.
Current flowing through the gear unit can result in irreparable damage to rolling-contact
bearings and gearing. Short circuits, voltage flashovers and deposits of conductive dust, for
example, can all allow current to flow.
Use insulators and earth the gear unit properly.
When operating the main motor with frequency converter, please pay attention to the special
measures specified in the operating instructions of the frequency converter.
• When removing any protective devices, retain their fixings safely.
• Removed protective devices must be re-fitted prior to starting up.
• Pay attention to the notices attached to the gear unit such as the rating plate, direction arrow
symbol etc. Notices must not be concealed by paint or dirt. Replace any missing, illegible or
damaged plates.
• Bolts which have been damaged during assembly or disassembly work must be replaced with
new ones of the same strength class and type.
DANGER
Danger to life due to live system
Death or serious injury will occur.
Always shut down the gear unit and any oil supply system (whether separate or mounted on
the gear unit) before you carry out any work. Secure the drive unit against being operated
accidentally as follows:
• Turn off the key-operated switch.
• Remove the fuses in the power supply.
• Attach a notice to the start switch, clearly stating that work is being carried out on the gear
unit.
Ensure that the entire unit is load-free so that no danger is posed when you start to dismantle
components.
WARNING
An explosive atmosphere can be ignited if electrostatic discharge occurs due to the coating
becoming charged.
Carefully ensure that highly efficient charge generating mechanisms, which can cause layers
and coatings to be electrostatically charged, are reliably avoided.
Highly efficient charge generating mechanisms include the following:

• Fast flows of highly dust-laden air
• Sudden discharge of compressed gases that contain particles
• Other operations that involve high frictional forces (does not include manual cleaning or
rubbing with cleaning cloths)

18 Edition 06/2020
Safety instructions
The coating must be electrostatically conductive if explosion protection is required in

accordance with the ATEX Directive for zones of explosion group IIC or with a minimum ignition
energy of ≤ 3 mJ.
Reactivating the gear unit

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

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Safety instructions

20 Edition 06/2020
Description 3
3.1 General description
The FLENDER® bevel helical gear unit (referred to below simply as "gear unit") of type KMS
described in these operating instructions has been developed to drive a vertical mill.
The axial and radial forces generated by the crushing process are transferred to the foundation
via the gear unit housing.
NOTICE
Destruction of the gear unit or parts of the gear unit due to incorrect direction of rotation
The gear unit has been approved for only one direction of rotation.
Pay attention to the direction of rotation arrows on the gear unit.
Further information
Further information and a detailed illustrated description of the gear unit can be found in the
drawings in the complete documentation of the gear unit.
3.2 Housing
Introduction
The housing is made of cast iron or steel.
The gear unit housing has the following features:
• Attachment points for moving the gear unit
• Inspection and assembly cover for inspection
• Oil filling point for refilling with oil
• Oil level indicator for checking the oil level
• Oil drain screw or oil drain valve for changing the oil
• Air filter or wet-air filter for ventilation and bleeding

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Description
3.2 Housing
Further information
Gear unit equipment

The following diagram shows possible equipment for preservation of the gear unit:

① Sealing cap (depending on the order) ④ Pressure pipe (gear unit)

② Round cord hollow profile ⑤ Pressure pipe (pad bearing compartment)
③ Suction pipe (gear unit)
Figure 3-1 Gear unit preservation equipment
The pipes can be of different design depending on the order. The precise design is specified in
the drawings in the complete documentation of the gear unit.
Further information

22 Edition 06/2020
Description
3.4 Oil supply to the gear unit
3.3 Delivered state of the gear unit
The following diagram shows sketches of the arrangement of the round cord hollow profile and
the rotary shaft sealing ring.
① Rotary shaft sealing ring ② Round cord hollow profile

Figure 3-2 Arrangement of round cord hollow profile and rotary shaft sealing ring
The input shaft of the gear unit is fitted with a concealed rotary shaft sealing ring that
effectively seals the interior of the delivered gear unit air-tight for the specified preservation
period. It is not necessary to remove the rotary shaft sealing ring when the gear unit is
commissioned. The reliability of the shaft seal will not be affected if the rotary shaft seal is no
longer capable of fulfilling its sealing function after the unit has been commissioned.
A round cord hollow profile is used to provide a seal between the gear unit housing and the
output flange. The round cord hollow profile also acts to seal the interior of the gear unit air-tight
for the specified preservation period.
Opening the gear unit

If you open the gear unit, you must commission it within one week or take measures to restore
its preservation.
After renewing the preservation, within one hour close and seal the gear unit so that it is airtight.
The gear unit is deemed to have been opened if one of the following actions is taken:
• Removal of the adhesive tape at the labyrinth seal of the input shaft or the output flange
• Removal of the round cord hollow profile
• Opening of a cover
• Opening of a screw plug
Lubrication and cooling are performed by constant oil circulation by a separate oil supply
system. Expansion joints are fitted in the piping system to suppress vibration and compensate
for thermal expansion.

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Description
The lubrication method is specified in the list of equipment drawn up specifically for the order,
in the lubrication diagram and in the separate data sheet.
Toothed components and rolling-contact bearings are forced-lubricated and cooled via the low-
pressure lubrication circuit.
Further information
Additional information and a detailed illustrated description of the gear unit and the oil supply
system can be found in the drawings in the complete gear unit documentation.
Additional information about the oil supply system can be found in the separate data sheet, in
the list of equipment and in the oil supply system operating instructions provided in the
complete gear unit documentation.
3.4.1 Hydrodynamic lubrication of tilting pad thrust bearings

The oil needs to be preheated when ambient temperatures are low. If contractually agreed,
immersion heaters are integrated in the gear unit housing or in the oil tank, or a separate heating
circuit is provided.
The oil is sucked in by the oil pump, cleansed in the double change-over filter (equipped with
visual and electrical contamination indicator), cooled in the cooler and then transferred to the
lubrication points. The oil flow is distributed through valves or orifices to lubricate the gear
wheels and the pad bearing.
The volumetric flow, pressure and temperature are continuously monitored.
3.4.2 Hydrodynamic lubrication of tilting pad thrust bearings on gear units with
hydrostatic starting aid
In addition to hydrodynamic lubrication, part of the oil is fed to the high-pressure pump via a
pipe that branches off directly downstream of the cooler.
The high-pressure pump is a radial piston pump and delivers a constant volume of oil at every
oil connection port. The oil is transferred to four pads distributed around the circumference of
the thrust bearing. Before the mill is started, the oil is pumped between the pads and the race
where it immediately forms a supporting oil film. After a 2-minute period at operating speed, the
high-pressure pump can be shut down.
This operating phase is monitored by pressure switches or pressure transmitters.
3.4.3 Hydrostatic lubrication of tilting pad thrust bearings with radial piston pump
In addition to hydrodynamic lubrication, part of the oil is fed to the high-pressure pumps via a
pipe that branches off directly downstream of the cooler.
To ensure that the high-pressure pumps are running and no pipe is defective, the oil flows are
monitored for minimum and maximum pressure. The pressure depends on the pressing force
actually exerted by the grinding rolls.

24 Edition 06/2020
Description
3.5 Shaft seals
If the pressure or flow rate in a component subject to pressure or flow monitoring falls below the
minimum value, the main drive is shut down. If the pressure exceeds the maximum limit, an
alarm is issued or the main drive is shut down.
3.5 Shaft seals
Depending on requirements, shaft seals prevent oil from escaping from the gear unit or dirt from
entering the gear unit.
The input shaft and the output flange are sealed by labyrinth seals. Air filters are provided on the
housing to provide pressure equalization.
3.5.1 Labyrinth seals

Labyrinth seals as non-contact seals prevent shaft wear. They do not require any maintenance
and improve the temperature behaviour of the gear unit.
A labyrinth seal is illustrated in the diagram below:
① Labyrinth seal at output flange ② Labyrinth seal at input shaft

Figure 3-3 Labyrinth seal
To work reliably, labyrinth seals must be installed in stationary, horizontal positions without dirty
water or any substantial amount of dust. Overfilling the gear unit can result in leaks, the same
applies to oil with a high foam content.
DANGER
Sparking or inadmissible temperature rise due to insufficient gap dimension might result in the
ignition of an explosive atmosphere.
Ensure that the set gap dimension at the labyrinth seal is not changed when the input and
output elements (e.g. coupling parts) are mounted. Rotating and stationary parts must not
touch.

Edition 06/2020 25
Description
3.7 Heating
3.6 Couplings
Flexible couplings are used at the input end of the gear unit.
Further information
You will find further information on the coupling in the operating instructions for the coupling.
3.7 Heating
Introduction
At low ambient temperatures it may be necessary to preheat the gear unit oil before switching
on the drive or while it is in operation.
Heating is only permissible in conjunction with an oil level monitoring system (Page 28).
Heating elements
Heating elements can be used for these applications, for example. Heating elements convert
electricity into heat and transfer this to the oil in which they are immersed. In some
circumstances it is not possible to replace the heating inserts without first draining off the oil.
Please read the relevant information contained in the operating instructions for the heating
elements or ask Customer Services (Page 85).
Complete immersion of the heating elements in the oil bath must be ensured by adhering to the
installation position in accordance with the drawings, which are part of the complete
documentation, and the oil level.
WARNING
Explosion and fire hazard
Exposed heating elements pose a fire hazard.
Do not switch on the heating elements unless you have checked that they are completely
immersed in the oil bath.
If heating elements are retrofitted, the heat output at the outer surface of the heating element
must not exceed the maximum values stated in the table below.

26 Edition 06/2020
Description
3.8 Oil level indicator
The following table contains information about the specific heat output PHO as a function of
ambient temperature:
Table 3-1 Information about the specific heat output
PHO in W/cm2 Ambient temperature in °C

0.9 10 to 0
0.8 0 to -25
0.7 -25 to -50
Heating element control

The heating elements can be controlled by a temperature monitor or an Oil temperature
monitoring (Page 29). The temperature monitor provides a signal to be amplified when the
minimum and maximum temperatures are reached.
Further information
Further information about the position of the mounted components and a detailed illustration
of the gear unit can be found in the drawing in the complete documentation of the gear unit.
Further information about heating elements can be found in the separate data sheet, in the list
of equipment and in the heating element operating instructions in the complete documentation
for the gear unit.
Further information about the temperature monitor as well as control instructions can be found
in the list of equipment and the temperature monitor operating instructions in the complete
documentation for the gear unit.
3.8 Oil level indicator

For visual monitoring of the oil level, oil level indicators are mounted on the gear unit.
Check the oil level when the gear unit is stationary and the oil pump of the low-pressure
lubrication circuit of the oil supply system is running.
Further information
You will find further information about the oil level indicator in the operating instructions
BA 7300, which are part of the complete documentation of the gear unit.
Further information and a detailed illustration of the gear unit and the position of the mounted
components can be found in the drawings in the complete documentation of the gear unit.

Edition 06/2020 27
Description
3.9 Oil level monitoring system
3.9 Oil level monitoring system
Introduction
Depending on the order specification, the gear unit can be equipped with an oil level monitoring
system using a filling-level limit switch.
The oil level monitoring system has been designed to check the oil level when the gear unit is at
a standstill before it starts.
Mounting position
If you are using an oil level monitoring system, take particular care to ensure that the gear unit
is in a horizontal mounting position.
Further information
Further information about oil level monitoring and the technical data can be found in the
operating instructions for the oil level monitoring system, in the list of equipment and in the
separate data sheet in the complete documentation for the gear unit.
Oil level monitoring system for the heating elements

The gear unit must be equipped with an oil level monitoring system.
This monitoring checks the minimum oil level of the gear unit for immersing the heating
elements.
Principle of operation
Connect up the "Oil level too low" signal in such a way that it causes the heating elements to be
switched off.
This guarantees that the heating elements are only operated if they are completely immersed in
the oil.
DANGER
Exposed heating elements pose an explosion or fire hazard as they can ignite an explosive
atmosphere.
Do not switch on the heating elements unless you have checked that they are completely
If heating elements are retrofitted, the heat output at the outer surface of the heating element
must not exceed the maximum heat output values (Page 26).

28 Edition 06/2020
Description
3.10 Oil temperature monitoring
Further information
Further information about oil level monitoring, control instructions and the technical data can
be found in the operating instructions for the oil level monitor, in the list of equipment and in the
separate data sheet in the complete documentation for the gear unit.
Depending on the order specification, the gear unit can be fitted with a Pt 100 resistance
thermometer or a temperature monitor for measuring the oil temperature in the oil sump.
To measure temperatures or temperature differences, connect the Pt 100 resistance
thermometer or the temperature monitor to an evaluation unit (to be supplied by the customer).
Further information
Further information about oil temperature monitoring (such as control instructions) and the
technical data can be found in the operating instructions for the oil temperature monitor and in
the list of equipment in the complete documentation for the gear unit.

Edition 06/2020 29
Description

30 Edition 06/2020
Application planning 4
4.1 Scope of delivery
The scope of delivery is specified in the packing list. Immediately upon receiving the gear unit,
check the completeness of the delivery. The packaging is not allowed to be opened for checking.
Report any damage to the packaging and any missing packages to Customer Services
(Page 85) immediately.
Opening the packaging is considered as changing the packaging and has an effect on the
durability period of the preservation. Follow the instructions in BA 7300 in this regard.
WARNING
Serious injury through defective product
Serious injury may occur.
If the gearbox exhibits any visible damage, you should not put it into operation.
4.2 Transport
General information
The gear unit is delivered fully assembled. Additional items such as shrink disks, couplings, oil
coolers, pipework and valves may be delivered separately packaged, as necessary.
When transporting the gear unit, observe the following instructions to avoid damaging the gear
unit:
• Always use suitable equipment to transport the gear unit.
• Transport the gear unit without oil filling and leave it in the transport packaging.
• Do not use impermissible attachment points. The person responsible for transporting the
unit is also responsible for ensuring that appropriate lifting equipment is selected and
properly used.
The threads in the end faces of the shaft ends may not be used for attaching lifting
equipment.
The output flange of the gear unit must not be lifted.
• Do not use the pipes for moving the gear unit.
• Ensure that the lifting equipment is adequately designed to accommodate the weight of the
gear unit.
• If there are no rope deflectors, use suitable protective devices and equipment to prevent the
gear unit damage.
• It is only permissible to store the product on the substructure supplied and in the transport
position.

Edition 06/2020 31
Application planning
4.2 Transport
WARNING
Risk of crushing
There is a risk of being crushed by a component that becomes detached because the hoisting
gear and load suspension device are not suitable for handling it.
When lifting, please observe the load distribution information on the packaging.
When the product is in a raised position, transport it slowly and carefully to avoid injury to
persons or damage to the gear unit.
Attaching the gear unit

To transport the gear unit, only attach slings to the marked attachment points that are provided
for this purpose.
Please observe the following when attaching slings to the load or raising, lowering or moving it:
• Do not exceed the specified load limits
• If you are using a load suspension device with several load hooks, make sure that the load is
evenly distributed between them
• Note the eccentric centre of gravity
• Make sure that the lifting equipment is securely attached
• Keep your speed down when moving the load
• Do not allow the load to sway and do not attach the load to objects or structures inside the
building
• Loads must not be suspended from the tip of a load hook
• Always place the products down on a level, non-slip and stable base
DANGER
Falling load
There is a risk of fatal injury from falling loads if these have not been securely attached to the
lifting equipment.
Never stand or sit under suspended loads. Do not exceed the load limits of the lifting
equipment.
Packaging
The gear unit is delivered fully assembled. Additional equipment is also delivered separately
packaged, as necessary.
The gear unit may be packed in various forms, depending on the size of the unit and method of
transport.
Please adhere to the symbols applied on the packaging.

32 Edition 06/2020
4.3 Attachment points
7KLVZD\XS )UDJLOH .HHS .HHS &HQWUHRI 'RQRW $WWDFKKHUH

GU\ FRRO JUDYLW\ XVHKDQGKRRNV
Figure 4-1 Transport symbols
4.3 Attachment points
Lifting eyes
Lifting eyes are fitted to the gear unit to assist with its transportation during manufacture and
installation.
Carefully ensure that the angle of the vertical load at the gear units lifting eyes does not exceed
45°.
Transport shackles
Transport shackles are a type of lifting equipment used to lift and connect loads. The transport
shackles are designed to be connected to lifting eyes.
Position of attachment points

The diagram below shows the position of the attachment points on type KMS gear units as an
example:
① Wooden block

Edition 06/2020 33
4.4 Special aspects of gear unit lubrication and preservation
Figure 4-2 Position of attachment points on type KMS gear units
Drive units with additional components mounted on the gear unit (such as drive motor,
coupling, etc.) may require an extra attachment point owing to the displacement in the centre
of gravity caused by the mounted components.
Further information
Further information, a detailed illustration of the gear unit and the position of the attachment
points can be found in the dimension and transport drawings in the complete documentation
of the gear unit.
4.4.1 Oil filling and oil drain
The diagram below shows the oil filling points and the oil draining points for the gear unit:

① Venting point (sealing cap) ⑤ Oil level indicator (gear unit)

② Oil level indicator (pad bearing compartment) ⑥ Oil drain (gear unit)
③ Oil drain (pad bearing compartment) ⑦ Oil drain (sealing cap)
④ Venting point (gear unit)
Figure 4-3 Oil filling locations and oil drain locations

34 Edition 06/2020
Further information
4.4.2 Filling with oil

Follow the instructions in BA 7300.
Shut down the gear unit and the oil supply system.
Filter the oil to be filled before or during filling with a 25 µm filter.
Fill the oil pumps and all oil filling holes identified with special labels with oil before you start up
the gear unit. Fill the oil in through an oil filling hole provided on the oil pump or pressure pipe or
identified by a label. Close the oil filling holes tight so that the oil pump does not suck in air and
no oil escapes.
Fill the oil circuit of the oil cooling systems with oil. Follow the operating instructions of the oil
supply system.
Fill the gear unit with oil as instructed below depending on how the oil supply system is
equipped:
• If the oil supply system is equipped with three-way valves, use these valves to fill the gear unit
with oil. Alternatively, you can fill the gear unit with oil via the oil drain valve of the pad
bearing compartment.
• If the oil supply system is not equipped with three-way valves, use the oil drain valve of the
pad bearing compartment to fill the gear unit with oil.
• If the oil supply system is equipped with a tank, you can also use this tank to fill the gear unit
with oil. To do this, start the low-pressure pump of the oil supply system temporarily to
ensure that the pad bearing compartment is also filled with oil.
• Fill as much oil into the gear unit as is needed to reach the specified oil level (Page 36).
The approximate oil quantity is indicated in the following places:
– If the oil supply system and the pipes are not included in the scope of delivery, then the
quantity of operating oil required for the gear unit is specified on the rating plate and in
the technical data. For determining the overall quantity of operating oil, please consider
additionally the quantity of oil required for the oil supply system and the pipes.
– If the oil supply system and the pipes are included in the scope of delivery, then the overall
quantity of operating oil required for the gear unit is specified in the layout diagram and
in the technical data in the complete documentation of the gear unit.
When the oil supply system is switched off, its oil level is often higher than when it is switched
on because oil can flow back out of the pipes and hoses. Switch the oil supply system on and
off repeatedly until the oil level is correct.
Further information

Edition 06/2020 35
4.4.3 Draining oil

In addition to the oil draining points given in chapter Oil filling and oil drain (Page 34), use the
existing residual oil draining plugs. You can find them in the drawings, which are part of the
complete documentation of the gear unit.
If the oil supply system is equipped with three-way valves, you can use these valves as an
alternative method of draining oil out of the gear unit. Drain off the remaining oil through the
oil drainage valves. If necessary, use new screw plugs.
Further information
4.4.4 Checking the oil level

Check the oil level when the gear unit is stationary and the oil pump of the low-pressure
lubrication circuit of the oil supply system is running.
The correct oil level is indicated by minimum and maximum markings on the oil level indicator
of the main gear unit, the pad bearing compartment and on the oil supply system (on systems
with tank). Hot oil can easily exceed the MAX mark on the oil level indicator.
Further information
Further information can be found in the oil supply system operating instructions in the complete
Further information about checking the oil level can be found in the operating instructions
BA 7300 in the complete documentation for the gear unit.
4.4.5 Taking oil samples

As an alternative to changing the oil (Page 71) at fixed intervals, you can arrange for the
technical services of the oil manufacturer to examine an oil sample regularly every 3 months,
and approve the oil for further use. In this case, the oil manufacturer guarantees that the
properties of the oil will comply with Flender specifications.

36 Edition 06/2020
4.4.6 Preservation
Introduction
The operating instructions BA 7300 describe the standard procedures for preserving gear units
and oil supply systems. Follow these instructions whenever you take measures to preserve the
gear unit.
As an alternative, you can also extend the durability of the interior preservation of the gear unit
by operating the oil supply system (Page 39).
Special aspects of and deviations from the standard preservation procedures are described in
this chapter.
4.4.6.1 Special aspects of extending the durability of the interior preservation
Introduction
Please observe the special aspects and deviations from the instructions in BA 7300 with respect
to extending the durability of the interior preservation.
Improper use can damage the gear unit. Be sure to take the following precautions:
• Remove the coupling if necessary.
• Use a sealing cap (Page 39) to seal the input shaft.
• Use dummy flanges to seal the pressure, suction and return pipes.
• Use a screw plug to seal the oil drain valve at the pad bearing compartment.
• Seal the gear unit by means of a round cord hollow profile between the gear unit housing and
the output flange and tape over the labyrinth seal to seal it air-tight.
The round cord hollow profile can be purchased from Flender.
Procedure for extending the durability of the interior preservation through oil filling
To extend the durability of the interior preservation through oil filling, proceed as follows:
1. Use a screw plug to seal the lower oil drain of the sealing cap.
2. If necessary, replace the air filters at the venting points of the gear unit by screw plugs. The air
filters will be required when the unit is restarted.
3. If a screw plug is fitted at the top of the pad bearing compartment, remove it now.
Alternatively, open the round cord hollow profile so that air can be exchanged with the
ambient air while oil filling is in progress.
4. Fill the sealing cap with oil via the venting point at the cap.
Filter the oil before or during filling with a 25 µm filter.

Edition 06/2020 37
5. When closing the venting point at the sealing cap, note the following:
– If oil escapes from the venting point as the gear unit is being filled, close the venting point.
– If no oil escapes from the venting point as the gear unit is being filled, do not close the
venting point until the gear unit has been filled with oil.
6. Remove the screw plug from the lower oil drain valve of the gear unit if necessary.
7. Using a pump, fill the gear unit with oil via the lower oil drain valve on the unit until the oil
level indicator at the pad bearing compartment is full of oil.
Filter the oil before or during filling with a 25 µm filter.
8. Seal the opening (if provided) at the top of the pad bearing compartment with a screw plug.
Alternatively, completely seal the gear unit again between the gear unit housing and the
output flange by means of the round cord hollow profile and tape over the labyrinth seal to
make it air-tight.
9. Use a screw plug to seal the lower oil drain valve of the gear unit.
Procedure for extending the durability of the interior preservation using Castrol Corrosion Inhibitor
N 213
To extend the durability of the interior preservation using Castrol Corrosion Inhibitor N 213,
proceed as follows:
1. Use screw plugs to seal the oil drain and the venting point of the sealing cap.
2. Seal the lower oil drain valve of the gear unit.
3. Remove the screw plugs or air filters from the venting points of the gear unit.
4. Fill the gear unit with Castrol Corrosion Inhibitor N 213 via the venting points on the gear
unit. The required quantity of Castrol Corrosion Inhibitor N 213 is specified in operating
instructions BA 7300.
5. Use screw plugs to seal the venting points on the gear unit. The air filters will be required
when the unit is restarted.
NOTICE
Damage to the gear unit
Damage to the gear unit is possible due to impaired corrosion protection as a result of turning
the input shaft.
Do not turn the input shaft of the gear unit
Result
The durability period of the interior preservation of the gear unit is extended.
The precise durability period is stated in operating instructions BA 7300.

38 Edition 06/2020
4.4.6.2 Sealing cap

The sealing cap is designed to seal the input shaft while preservative is filled into the interior of
the gear unit and is mounted on the gear unit. The sealing cap is not included in the scope of
delivery as standard but can be purchased from Flender depending on the order.
The sealing cap has the following ports:
• Venting point
• Oil drain
4.4.6.3 Extending the durability of the interior preservation by operating the oil supply
system
Requirements
The following requirements must be fulfilled in order to extend the durability of the interior
preservation by operating the oil supply system:
• The gear unit is installed in the mill.
• The gear unit is connected to the oil supply system.
Preservative oil
You can use the following preservative oils in order to extend the interior preservation by
operating the oil supply system:
• Castrol Alpha SP 220 S
• Castrol Optigear Synthetic 1390/220 (formerly Castrol Tribol 1390/220)
Procedure
To extend the durability of the interior preservation by operating the oil supply system, proceed
as follows:
1. If necessary, drain off old preservative or operating oil.
2. Fill the gear unit with the preservative oil.
3. Ensure that the oil reaches the specified level (Page 36).
4. Switch on the oil supply system and turn the gear unit under no load (at least one rotation
at the output).
5. Drain off the preservative oil.
6. Seal the gear unit and the oil supply system so that they are air-tight.
7. Replace the air filters with screw plugs and seal the plugs. The air filters will be required when
the unit is restarted.

Edition 06/2020 39
8. Seal the gear unit by means of a round cord hollow profile between the gear unit housing and
the output flange.
The round cord hollow profile can be purchased from Flender.
9. Tape over the labyrinth seals at the input shaft and the output flange to make them air-tight
within one hour.
Result
The durability period of the interior preservation of the gear unit is extended.
The precise durability period is stated in operating instructions BA 7300.
Further information
Additional information about the oil supply system can be found in the separate data sheet, in
the list of equipment and in the oil supply system operating instructions provided in the
complete gear unit documentation.
Further information about preservation can be found in the operating instructions BA 7300 in
the complete documentation for the gear unit.

40 Edition 06/2020
Assembly 5
5.1 General assembly instructions
The assembly work must be performed very carefully by authorised, trained and suitably
instructed personnel. Liability will be disclaimed for damage caused by the incorrect
performance of this work.
Requirements
• Protect the gear unit against falling objects and from becoming covered over.
• Do not perform any welding work anywhere on the drive.
• Do not use the gear unit as an earthing point for electric-welding operations.
• Use all of the fastening points fitted to the particular unit design.
• Replace any bolts that are no longer fit for use by new bolts of the same strength class and
type.
• Make sure that sufficient hoisting gear is available.
• When installing the gear unit in the vertical mill, follow the special instructions of the mill
manufacturer.
• Do not remove the adhesive tapes from the labyrinth seals and the round cord hollow profile
between the gear unit housing and the output flange until shortly before commissioning.
Mounting position and attachment points

During the actual planning phase, be sure to allow for sufficient space around the gear unit to
enable subsequent upkeep and maintenance work. It must be possible to inspect the internal
components through the inspection cover openings. Take suitable measures to ensure that
unhindered convection across the housing surface is possible so that the gear unit does not
overheat.
Do not use impermissible attachment points (Page 33). The position of the attachment points
can be found in the dimension and transport drawings in the complete documentation of the
gear unit. To ensure that the unit is properly lubricated during operation, please observe the
mounting position specified in the dimension drawing.
DANGER
Danger of explosion
Danger to life through ignition of a potentially explosive atmosphere possible during assembly
and disassembly work on the gear unit.
The gear unit must not be assembled or disassembled in an explosive environment.

Edition 06/2020 41
Assembly
5.1 General assembly instructions
DANGER
Danger of explosion due to gear unit heating caused by environmental effects.
Danger to life through ignition of a potentially explosive atmosphere possible if gear unit
becomes overheated due to environmental effects.
The gear unit must not be heated by external heat sources (exposure to direct sunlight, for
example) while it is in operation and measures must be taken where necessary to protect it.
You can take the following measures to protect the gear unit against this hazard:
• A sun shield
• An additional cooling device
• A temperature monitoring device with trip function in the oil sump
The ambient temperature range stamped on the rating plate must be complied with.
If you use a sun shield, this may cause a build-up of heat.

If you use a temperature monitoring device, it must be capable of issuing an alarm when the
maximum permissible oil sump temperature is reached. It must also be capable of tripping the
drive when the maximum permissible oil sump temperature is exceeded. The operator's process
might be interrupted when the drive is shut down.
DANGER
Risk of explosion due to ignition of vapours emitted from solvents
There is danger to life due to ignition of vapours emitted from solvents or another explosive
atmosphere when carrying out cleaning work.
It is not permissible that there is any explosive atmosphere in the area when carrying out
cleaning work at the gear unit.
Please note the following:
• Ensure adequate ventilation.
• Do not smoke.
• Keep the solvents away from ignition sources.

42 Edition 06/2020
Assembly
5.2 Unpacking the gear unit
5.2 Unpacking the gear unit
Introduction
The scope of delivery is listed in the shipping documents.
WARNING
Risk of serious injury due to defective product
A defective gear unit can result in serious injury.
Do not put the gear unit into operation if any damage is visible.
Contact Customer Services (Page 85).
Requirements
Check that everything has been delivered immediately upon receipt.
NOTICE
Damage to the gear unit due to corrosion
Exposing the gear unit to moisture can result in damage from corrosion.
Do not damage or open the packaging prematurely if the packaging is designed to preserve the
unit.
WARNING
Risk of crushing
There is a risk of being crushed when the load slides.
Open the packaging slowly and carefully to avoid injury to persons or damage to the gear unit.
Procedure
To unpack and use the gear unit, proceed as follows:
1. Remove packaging and transport devices in accordance with regulations.
2. Perform a visual inspection for damage and accumulations of dirt.
3. Immediately report any damaged and/or missing parts to Customer Services (Page 85).
4. Dispose of packaging material and transport devices in accordance with regulations.

Edition 06/2020 43
Assembly
5.3 Gear unit assembly
5.3.1 Foundation
Properties of the foundation

The foundation must have the following properties:
• Flat
• Secure
• Free of vibration
• Rigid
Requirements of the foundation

The foundation must meet the following requirements:
• Construct the foundation in such a way that it does not generate any resonance vibrations
and that it is isolated against the transmission of vibrations from adjacent foundations.
• Design the foundation according to the relevant weight and torque, taking into account the
forces acting on the gear unit.
• Align the foundation carefully with the equipment installed on the input and output sides of
the gear unit.
• Take into account any elastic deformation that may be caused by operating forces.
• Install lateral stops to prevent displacement if external forces are acting on the gear unit.
NOTICE
Poor stability
Damage to the gear unit is possible if it is not mounted on a stable foundation.
Make sure that the foundation on which the gear unit is mounted is flat, stable, vibration-free
and rigid.
It is particularly important that the surface on which the gear unit is mounted is level because
this determines the contact pattern of the teeth as well as the contact pattern of the tilting pad
thrust bearings, and so has an influence on the service life of the gear unit. Clean the mounting
surfaces of the gear unit and foundation.
All points on the gear unit mounting surface must lie between two imaginary parallel planes
that are 0.1 mm per 500 mm apart. The permissible deviation of the gear unit mounting
surface from the horizontal plane is 0.2 mm per 1000 mm.
Document the levelness of the installed baseplate (gear unit mounting surface) before installing
the gear unit.
Keep the report in a safe place together with these operating instructions.

44 Edition 06/2020
Assembly
The mill manufacturer is responsible for the foundation structure and the bolted connections
between the gear unit and foundation.
Further information
Further information about dimensions, space requirements and arrangement of supply
connections can be found in the drawings in the complete documentation of the gear unit.
5.3.2 Description of assembly work
Measures to be taken prior to assembly
CAUTION
There is a risk of chemical burns when handling aggressive cleaning agents.
Please observe the manufacturer's guidelines on how to handle cleaning agents and solvents.
Wear suitable protective equipment (gloves, safety goggles). Please use binding agents to
immediately clear up any spilt solvent.
• Use a suitable cleaning agent to remove the corrosion protection from the shafts and
mounting surfaces.
• Do not allow the cleaning agent to come into contact with the shaft-sealing rings.
• Use an assembly fixture (retractor) if required to mount the input elements (e.g. coupling
components) onto the shafts and lock them securely. See chapter Couplings (Page 47).
• Use suitable hoisting gear to place the gear unit in position.
Further information
Further information about removing the corrosion protection can be found in the operating
instructions BA 7300 in the complete documentation for the gear unit.
Additional information on how gear units should be attached which, as a result of their weight,
require a crane or lifting gear, is provided in chapter Application planning (Page 31).
If the gear unit is to be transported with mounted parts and components, then it may be
necessary to use additional attachment points. The position of these attachment points can be
found in the dimensional and transport drawings in the complete documentation of the gear
unit.

Edition 06/2020 45
Assembly
Requirement
Follow the special instructions issued by the mill manufacturer when installing the gear unit in
the vertical mill.
Procedure
Proceed as follows to install the gear unit in the machine:
1. Fit the foot fastening bolts in accordance with the mill manufacturer's instructions.
Note the separate operating instructions if you are using clamping nuts.
2. Tighten the foot fastening bolts with the specified tightening torque (Page 56).
If necessary, install stops to prevent displacement.
3. Align the gear unit precisely with the input and output equipment.
4. Mount the specified pins (if provided).
5. Tighten the fixing screws and hexagon nuts evenly. When tightening, ensure that the gear
unit is not deformed due to excess stress.
6. Record the alignment dimensions.
7. Keep the report in a safe place together with these operating instructions.
NOTICE
Destruction of the gear unit or parts of the gear unit due to incorrect direction of rotation
The gear unit or parts of the gear unit can sustain irreparable damage if the gear unit is rotated
in the wrong direction.
The gear unit has been approved for only one direction of rotation.
Ensure that the direction of rotation of the motor matches the direction of rotation arrow
marked on the input shaft of the gear unit.
NOTICE
Damage to the plain bearings
The plain bearings can sustain damage.
The input shaft of the gear unit may be turned by a maximum of 1 rotation at the output for
positioning purposes during assembly of the gear unit if the pad bearing compartment is filled
with oil up to the level required for normal operation.

46 Edition 06/2020
Assembly
5.4 Couplings
5.4 Couplings
Introduction
• If necessary, carry out the following preparatory work in accordance with the operating
instructions for the coupling:
– Machine the finished bore
– Mill the parallel keyway
– Fit the axial locking element
– Balance
• Align the individual components precisely with one another.
• Refer to the operating instructions for the coupling for instructions on how to install,
maintain and operate the coupling.
WARNING
Danger of injury due to coupling rupture
Flying fragments can cause fatal injury.
Observe the operating instructions for the couplings.
NOTICE
Serious or irreparable damage to the gear unit and coupling caused by inaccurate or
incorrect alignment
Failure to accurately or correctly align the gear unit and coupling may result in serious or
irreparable damage to both components.
Align the individual components precisely with one another when installing the drives.
Make sure that the maximum permissible displacement values are not exceeded during
operation.
Further information
Further information about the coupling can be found in the operating instructions for the
coupling in the complete documentation for the gear unit.
5.4.1 Assembling the coupling
Introduction
The method used to assemble the coupling varies according to type. The procedure described in
these operating instructions is general rather than specific to one type of coupling.

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5.4 Couplings
Assemble the coupling as described in the operating instructions for the specific coupling.
• Do not use force (hammer blows, etc.) to fit the coupling parts as this can cause internal
damage to the gear unit.
• Take care not to damage the shaft sealing rings or shaft running surfaces when fitting the
coupling parts.
Procedure
To fit the coupling, proceed as follows:
1. Carefully clean the shaft ends and the coupling parts.
2. Use a suitable fixture to mount the coupling parts on the shaft ends.
3. Lock the coupling parts to prevent axial displacement.
4. Move the machines to be coupled close to one another and thenalign them (Page 49).
5. Join the coupling parts together.
Heating coupling parts prior to mounting

Depending on the order specification, it may be necessary to heat the coupling parts before
mounting them.
WARNING
Risk of burns
Possible risk of serious burn injury from hot surfaces (> 55 °C).
• The required joining temperatures can be found in the dimension drawings in the operating
instructions for the coupling
• Unless otherwise instructed, heat the coupling parts by an induction heater, with a torch or
in an oven.
• Use heat shields designed to protect against radiant heat in order to safeguard the shaft
sealing rings against damage or heating to above 100 °C.
• Quickly fit the coupling parts on the shafts. The mounting dimensions can be found in the
dimension drawings in the operating instructions for the coupling.
Further information
Further information about the coupling can be found in the operating instructions for the
coupling in the complete documentation for the gear unit.

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5.4 Couplings
5.4.2 Aligning the coupling
Introduction
The coupling parts might become misaligned as a result of:
• Failure to accurately align the parts during assembly
• During operation:
– Due to thermal expansion
– Due to shaft deflection
– Due to machine frames that are too soft
Improper use can damage the gear unit or the coupling. Be sure to take the following
precautions:
• Make sure that the maximum permissible displacement values are not exceeded during
operation.
– If you are using couplings supplied by Flender, you will find the maximum permissible
misalignment values in the operating instructions for the coupling.
– If you are using couplings supplied by other manufacturers, contact them and ask them
for the maximum permissible displacement values, making sure that you specify the
potential radial loads for your application. Keep the operating instructions for the
coupling together with these operating instructions.
• Angular and radial displacement might occur simultaneously.
Make sure that the total value of both displacements does not exceed the maximum
permissible angular or radial displacement value.
The diagram below illustrates the potential displacements:
˂.D
˂.Z
˂.U
$[LDOGLVSODFHPHQW $QJXODUGLVSODFHPHQW 5DGLDOGLVSODFHPHQW

˂.D ˂.Z ˂.U
Figure 5-1 Possible displacements
Alignment
Align the individual components in two mutually perpendicular axial planes. The following can
be used as alignment tools:
• Ruler (radial displacement)
• Feeler gauge (angular displacement)
• Spirit level

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Assembly
5.5 Mounting the pipes
• Dial gauge
• Laser alignment system
You will achieve a greater degree of alignment accuracy by using a dial gauge or laser alignment
system.
The diagram below shows the alignment process based on the example of a flexible coupling:

① Ruler ③ Measuring points

② Feeler gauge
Figure 5-2 Alignment process based on the example of a flexible coupling
Further information
Further information about the permissible alignment errors can be found in the coupling
operating instructions in the complete documentation for the gear unit, or contact the
manufacturer in question.
5.5.1 Procedure
To mount the pipes, proceed as follows:
1. Inspect the pipes for damage and soiling.
2. Carefully clean the piping and purge the piping using low viscosity oil.
3. Remove the dummy flange and plugs.
4. Screw on the pipes according to the layout diagram.
The pipe glands seal metallically. Use the appropriate seals for the flanges.

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NOTICE
Tensioning the pipes
The gear unit can be damaged if the pipes are installed so that they are under tension.
Make sure that the pipes are installed free of mechanical stress. Support the pipes on supports
as shown in the layout diagram included in the complete documentation of the gear unit.
5.5.2 Pickling after adaptation
Introduction
If the pipes are adapted on site, you must pickle the pipes carefully after welding.
Procedure
CAUTION
There is a risk of chemical burns when handling acids.
Carefully observe the manufacturer's information when handling acids. Wear suitable
protective clothing. Clean up any spilt acid immediately with a binding agent.
Proceed as follows to pickle the pipes after adaptation:

1. Close and seal off the lower end of the pipes using a suitable plug.
2. To prepare the picking solution, dilute HCl (33 % HCl) with the same quantity of water (H2O).
3. Fill the pipes with the pickling solution.
Allow the pickling solution to work for 1 hour. Make sure that no air bubbles form inside the
pipes.
4. Drain all of the pickling solution out of the pipes and dispose of it in accordance with
regulations.
5. Then flush out the pipes using an adequate amount of water.
6. After you have emptied the pipes, you must fill them with a neutralisation solution (3 % to 5 %
NaOH).
The neutralisation solution should act for 15 minutes.
7. Then flush out the pipes again using water.
8. Then thoroughly flush out the pipes using flushing oil through a 25 μm (0.001 inch) filter.

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5.6 Installing the motor
Note
Preserving the pipes
If the pipes are not mounted immediately, preserve them thoroughly.
5.6 Installing the motor
DANGER
Risk of fatal injury from flying fragments
Failure to align the unit with the required degree of accuracy can cause the shaft to rupture. A
ruptured shaft can result in serious or even fatal injuries.
Align the gear unit exactly so that it conforms to the specified alignment values.
Damage to the gear unit or its components or mounted parts is possible.
The accuracy of the alignment between the shaft axes largely determines the service life of the
shafts, rolling-contact bearings and couplings. As a consequence, always try to achieve a zero
deviation. In this context, please also refer to the relevant operating instructions for further
information about, for example, the requirements of couplings.
Procedure
To install the motor, proceed as follows:
1. Follow the motor manufacturer's operating instructions.
2. Align the drive motor together with the coupling along the centre axis of the gear unit input
shaft and secure the motor in position.
3. Record the alignment dimensions.
4. Keep the report in a safe place together with these operating instructions.

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5.8 Connecting components
5.7 Welding work on the mill

Flender provides no warranty for damage to the gear unit originally caused by welding work on
the mill.
DANGER
Risk of injury due to electric shock or electrostatic discharge
Injuries as a result of electric shock or due to ignition of an existing potentially explosive
atmosphere by electrostatic discharge can occur when welding equipment is used.
Perform potential equalisation in accordance with the applicable regulations and guidelines
before any welding work is carried out on the mill.
The gear unit and any parts connected to it must not be used as an earthing point for electric-
welding operations.
The pad bearing compartment can be optionally fitted with an earth cable that must be
connected to the output flange. Connect the earth cable to the tapped holes on the side of the
output flange. When the welding work is complete, detach the earth cable from the output
flange.
Tapped holes to establish an earth connection are provided on the gear unit or the output
flange. This work must always be done by specialist electricians.
When electric welding is carried out anywhere on the mill, the welding current must not be
conducted through the gear unit. For this reason, the welding current return cable must always
be directly connected to the component to be welded.
5.8.1 Installing further mounted components supplied as separate items
Procedure
To install further mounted components that are supplied as separate items, proceed as follows:
1. Seal all loose parts having a threaded connection with liquid sealant.
2. Install any pipe fittings supplied as separate items whose tapped holes are sealed with sealing
plugs as shown in the drawings supplied.
3. Connect electrical monitoring devices as shown in the terminal diagrams, lists of equipment
and special operating instructions.

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NOTICE
Potential damage to the gear unit due to incompatibility of operating oil and sealant.
Ensure that no sealant can get into the gear unit.
Further information
You will find further information on the electrical monitoring devices in the operating
instructions for the electrical monitoring devices, which are part of the complete documentation
of the gear unit.
You will find further information and technical data for the mounted components in the list of
equipment drawn up specifically for the order, which is part of the complete documentation of
the gear unit.
You will find further information, terminal diagrams and lists of equipment, which are part of the
5.8.2 Making terminal box connections for pre-wired gear units

Connect up all pre-wired gear units as shown on the circuit diagram in the terminal box.
WARNING
Do not put heating elements into service until you have checked that they are completely
Further information
You can find further information about pre-wired gear units in the order-specific list of
equipment in the complete gear unit documentation.
5.8.3 Gear units with mounted components

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

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Further information
You can find additional information on operation and maintenance in the associated operating
instructions, provided in the complete gear unit documentation.
You can find the technical data of the mounted components in the contract-list of equipment
provided in the complete gear unit documentation.
5.8.4 Installing a separate oil supply system
Procedure
To connect the oil supply system to the gear unit, proceed as follows:
1. Remove the dummy flange from the suction and delivery line before connecting the system.
2. Connect the system to the gear unit as shown in the layout diagram in the complete
documentation and install the system separately.
3. When installing the system, make sure that the pipework is not subjected to mechanical
stresses.
Further information
Further information about the oil supply system can be found in the oil supply system operating
instructions in the complete documentation for the gear unit.
5.8.5 Electrical connections
Requirements
Do not use any motor that exceeds the specified speeds of the gear unit as otherwise the gear
unit may become damaged. The speeds are displayed on the rating plate.
• Before connecting the motor, determine the phase sequence of the three-phase power
system using a phase-sequence indicator.
• Connect the motor corresponding to the predefined direction of rotation.

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5.9 Tightening procedure
Procedure
DANGER
Electric shock
Live parts can cause electric shock.
Ensure that the entire plant is de-energised before starting electrical installation work.
Carefully observe the five safety rules (Page 11).
To connect the motors and monitoring devices, proceed as follows:

1. Ensure that the connections of the motors and monitoring devices are not damaged.
2. Connect up the motors and monitoring devices according to the terminal diagram and the
relevant operating instructions.
3. Insulate all cable entry points (glands) at electrical equipment as required for the
environment in which the equipment will operate.
Further information
You can find additional information about the electrical connections in the terminal diagrams
and equipment lists provided in the complete gear unit documentation.
5.9.1 Introduction
Bolts
The bolts must have the following properties:
• Made of steel (as per the specified strength class)
• Black-annealed or phosphatised
• Lightly oiled (do not add additional oil)
Note
Replacing bolts
Replace any bolts that are no longer fit for use by bolts of the same type and strength class.

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Assembly
Mating threads
The mating threads must have the following properties:
• Made of steel or cast iron
• Dry, cut threads
Note
Using a lubricant
As a rule, lubricants may not be used, because this can result in the bolt connection becoming
overloaded.
5.9.2 Bolt connection classes

In order to affix fastening bolts, note the information in the following table:
Table 5-1 Information on tightening fastening bolts
Mounting Bolt connection Scatter of the tor‐ Tightening procedure

class que emitted on
the tool
D ± 10 % to ± 20 % • Torque-controlled tightening
with mechanical screwdriver
Inspection cover E ± 20 % to ± 50 % • Tightening with pulse screwdriv‐
Protection cover er or impact wrench, without ad‐
justment checking device
• Tightening by hand, using a
wrench without torque measur‐
ing device
Further information
You can find additional information about tightening torques when mounting motor and brake
in the operating instructions from the particular manufacturer.
5.9.3 Tightening torques and preload forces

If the drawings do not specify any tightening torques or preload forces, refer to the following
table for the tightening torques. Comply with the tightening torques specifically mentioned in
the production and assembly drawing.
The tightening torques apply to friction values of μtotal = 0.14.

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Assembly
The following table lists the preload forces and tightening torques for bolt connections, strength
classes 8.8; 10.9; 12.9:
Table 5-2 Preload forces and tightening torques
Nominal Bolt Preload force for bolt connection Tightening torque for bolt connec‐
thread di‐ strength classes from the table in tion classes from the table in chap‐
ameter class chapter Bolt connection classes ter Bolt connection classes
(Page 57) (Page 57)
d C D E C D E
mm FM min. MA
N Nm
M10 8.8 18 000 11 500 7 200 44.6 38.4 34.3
10.9 26 400 16 900 10 600 65.4 56.4 50.4
12.9 30 900 19 800 12 400 76.5 66.0 58.9
M12 8.8 26 300 16 800 10 500 76.7 66.1 59.0
10.9 38 600 24 700 15 400 113 97.1 86.6
12.9 45 100 28 900 18 100 132 114 101
M16 8.8 49 300 31 600 19 800 186 160 143
10.9 72 500 46 400 29 000 273 235 210
12.9 85 000 54 400 34 000 320 276 246
M20 8.8 77 000 49 200 30 800 364 313 280
10.9 110 000 70 400 44 000 520 450 400
12.9 129 000 82 400 51 500 609 525 468
M24 8.8 109 000 69 600 43 500 614 530 470
10.9 155 000 99 200 62 000 875 755 675
12.9 181 000 116 000 72 500 1 020 880 790
M30 8.8 170 000 109 000 68 000 1 210 1 040 930
10.9 243 000 155 000 97 000 1 720 1 480 1 330
12.9 284 000 182 000 114 000 2 010 1 740 1 550
M36 8.8 246 000 157 000 98 300 2 080 1 790 1 600
10.9 350 000 224 000 140 000 2 960 2 550 2 280
12.9 409 000 262 000 164 000 3 460 2 980 2 670
M42 8.8 331 000 212 000 132 000 3 260 2 810 2 510
10.9 471 000 301 000 188 000 4 640 4 000 3 750
12.9 551 000 352 000 220 000 5 430 4 680 4 180
M48 8.8 421 000 269 000 168 000 4 750 4 090 3 650
10.9 599 000 383 000 240 000 6 760 5 820 5 200
12.9 700 000 448 000 280 000 7 900 6 810 6 080
M56 8.8 568 000 363 000 227 000 7 430 6 400 5 710
10.9 806 000 516 000 323 000 10 500 9 090 8 120
12.9 944 000 604 000 378 000 12 300 10 600 9 500
M64 8.8 744 000 476 000 298 000 11 000 9 480 8 460
10.9 1 060 000 676 000 423 000 15 600 13 500 12 000
12.9 1 240 000 792 000 495 000 18 300 15 800 14 100

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5.10 Final work
Nominal Bolt Preload force for bolt connection Tightening torque for bolt connec‐
thread di‐ strength classes from the table in tion classes from the table in chap‐
ameter class chapter Bolt connection classes ter Bolt connection classes
(Page 57) (Page 57)
d C D E C D E
mm FM min. MA
N Nm
M72x6 8.8 944 000 604 000 378 000 15 500 13 400 11 900
10.9 1 340 000 856 000 535 000 22 000 18 900 16 900
12.9 1 570 000 1 000 000 628 000 25 800 22 200 19 800
M80x6 8.8 1 190 000 760 000 475 000 21 500 18 500 16 500
10.9 1 690 000 1 100 000 675 000 30 500 26 400 23 400
12.9 1 980 000 1 360 000 790 000 35 700 31 400 27 400
M90x6 8.8 1 510 000 968 000 605 000 30 600 26 300 23 500
10.9 2 150 000 1 380 000 860 000 43 500 37 500 33 400
12.9 2 520 000 1 600 000 1 010 000 51 000 43 800 39 200
M100x6 8.8 1 880 000 1 200 000 750 000 42 100 36 200 32 300
10.9 2 670 000 1 710 000 1 070 000 60 000 51 600 46 100
12.9 3 130 000 2 000 000 1 250 000 70 000 60 400 53 900
5.10 Final work
Measures
DANGER
An explosive atmosphere can be ignited if the gear unit overheats when the oil level is too low.
Lock the oil drain valves against accidental opening. If an oil sight glass or an oil level indicator
is used to check the oil level, protect them against damage.
DANGER
An explosive atmosphere can be ignited by electrostatic discharge.
Perform potential equalisation in accordance with the applicable regulations and guidelines.
Threaded holes are provided on the gear unit to establish an earth connection. This work must
always be done by specialist electricians.

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5.10 Final work
Once all the elements have been assembled or connected, perform the following final work:
• Check whether all devices dismantled for transportation have been reassembled.
• Check all bolt connections for tightness after installation of the gear unit has been completed.
• Check the alignment after tightening the fastening elements. The alignment must not have
changed in any way.
• Protect the gear unit against falling objects.
• Check that the guards over rotating parts are securely fastened.
Contact (accidental or deliberate) with rotating parts is not permitted.
• Protect the cable entries against penetrating moisture.
Further information
You will find further information about the gear unit and all mounted or separately supplied
components in the operating instructions of the relevant components included in the complete
You can find additional technical specifications in the separate data sheet in the complete gear
unit documentation.

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Commissioning 6
Introduction
The precondition for the warranty is first commissioning by specialists from Flender or by skilled
persons who have been appropriately trained and are authorised by Flender.
Flender urgently recommends that the vertical mill is first driven by the gear unit under the
supervision of these specialists or skilled persons.
Follow the operating instructions, particularly with regard to maintenance work on the vertical
mill, during which the mill rotates and the gear unit rotates with it.
DANGER
Danger of explosion
Every time the drive is set in motion represents a commissioning process. Do not commission
the gear unit without having the operating instructions at hand.
During commissioning, start up the gear unit in the load-free condition and without milled
material or roller pressure. The atmosphere around the gear unit must not be explosive.
Adjust the sealing air seal if one is fitted.
6.1 Measures prior to commissioning
Take the following measures before commissioning the gear unit:

• Read and observe the operating instructions.
• Follow the checking procedure (Page 63).
• Replace the screw plugs with the air filters. Follow the instructions in BA 7300.
• Fill the gear unit with oil.
• Gear unit with oil supply system: Check that the oil supply system is working properly.
• Check the oil level.
• Check the gear unit for leaks.
• Gear unit with oil supply system: Follow the instructions in Measures prior to commissioning
with oil supply system (Page 62).
• Ensure that all pipes and components are filled with oil.
• Restart: Make sure that the drive cannot be restarted after safety equipment has responded
unless the restarting lockout is cancelled.

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DANGER
Check the oil level and top up with oil if necessary.
Check the gear unit for the ATEX marking.
Further information
Further information about oil can be found in the operating instructions BA 7300 in the
Further information about individual components can be found in the operating instructions for
the components in the complete documentation for the gear unit.
6.1.1 Rinsing before first commissioning

Filter the flushing oil before or during the flushing operation in the bypass flow with a 25 µm
filter.
The flushing oil can be reused for a maximum of 6 flushing operations.
Start up the oil pump of the low-pressure lubrication circuit and allow it to run for at least 6 hours
for flushing. If the system has a high-pressure lubrication circuit, switch this on 2 minutes later.
6.1.2 Gear unit with oil supply system

Take the following measures before commissioning a gear unit with an oil supply system:
• Make sure that the pressure in the oil supply system components does not exceed the
maximum permissible pressure.
• Make sure that the temperature of the oil supply system components does not exceed the
maximum permissible temperature.
• Using the oil supply system, lubricate the gear unit for 30 minutes in a pre-lubrication phase.
During this time, the rolling-contact bearings, tilting pad thrust bearings and gearing are
supplied with sufficient oil for starting.
On the oil supply system, make sure that the low-pressure lubrication is switched on first and
the high-pressure lubrication only after 2 minutes. This time is necessary to achieve pressure
equalisation in the oil circuit.
Switch on the high-pressure pumps no later than 5 minutes before starting the auxiliary or
main motor.

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Further information
You will find information on the oil supply system in the data sheet, in the list of equipment and
in the operating instructions for the oil supply system, which are part of the complete
documentation of the gear unit.
6.1.3 Checking procedure

Check all drive components after completion of assembly and before the first cold trial run.
Remove all material residue, tools and assembly equipment.
If the oil supply system was supplied by Flender, it has already been function-tested. Before the
trial run of the mill, test the electrical interlocking between the oil supply system and the drive
motors.
To perform the checking procedure, inspect the following items:
• Correct implementation of the foundation
• Foundation bolts tightened as specified
• The gear unit is properly fixed to the foundation
• The grinding table is properly installed
• The directions of rotation of the motor and gear unit match (see rotation direction arrow)
• The adhesive tapes have been removed from the labyrinth seals
• The round cord hollow profile between the housing and the output flange has been removed
• All air filters are installed
• Mounting and cleaning of all pipes as prescribed in the assembly instructions
• The coupling and motor are correctly aligned
• The correct configuration of the pipes and hoses
• Tightness of the pipe and hose connections
• Signs of oil foaming in the oil reservoir (tank for oil supply system and gear unit) during
operation
If signs of oil foaming are visible, check all of the suction pipe connections. Contact the oil
manufacturer if necessary.
• The tank for the oil supply system, the gear unit and the pad bearing compartment of the
gear unit are full of oil
Carry out the inspection when the oil system is running and the gear unit is stationary.
• The oil level is between the minimum and maximum markings
• Connection of all the monitoring devices as shown in the terminal diagram
• The oil supply system has been function-tested
• The electrical interlocking between the gear unit, the oil supply system and the drive motor

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6.2 Measures during commissioning
Document the results of the inspections for the following:

• The interlocking system is functioning as per the interlocking instructions
• Adjustment and correct operation of flow monitors or flow transmitters, pressure switches
or pressure transmitters, temperature sensors and level monitors
• Cooling water inlet open (for oil supply systems with water-oil cooler)
• Adequate air supply to fans (for air-cooled oil supply system)
• Has the alignment between the gear unit and adjacent components been checked, recorded
and documented?
• Levelness of the foundation
You will find further checking procedures in the operating instructions of the following
components:
• Coupling
• Motor
• Oil supply system
• Vertical mill
Please observe the following measures to commission the gear unit and document these:
• For gear units with oil supply system: Check that the oil supply system is working properly.
• Check the oil level.
• Measure the oil sump temperature (Page 74) after the gear unit has run in.
• Check the tightness of the shaft seal on the gear unit (Page 25).
• Check that no contact with rotating parts is possible.
• Check whether the shutoff valves are open.
– Check that all of the oil drain valves are closed.
– Ensure that all of the other shutoff valves are open.
• Check all the connection lines are securely tightened and leak-free.
• Measure the vibration levels at the gear unit (Page 75) following commissioning and
continuous operation in order to create initial and comparison values.
Further information
You can find additional information on the topic of oil in the operating instructions BA 7300,

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Commissioning
Further information about the oil supply system can be found in the oil supply system operating
6.2.1 Initial test run
Requirements
Meet the following requirements before the initial test run:
• Follow the operating instructions.
• Start up the gear unit.
Procedure
To perform the initial test run, proceed as follows:
1. Run the gear unit for several hours at partial load (50 % to 70 %), if possible. If a test run under
partial load is not possible, you can operate the gear unit under no-load with the rollers lifted.
2. If no faults occur, gradually increase the load at suitable time intervals up to full load while
constantly monitoring the gear unit.
3. During this time, pay attention to the following items:
– Noise
During this time, listen for anomalous noises at various points on the gear unit using a
suitable device.
– Foaming
Check whether the oil in the oil reservoir (tank for oil supply system and gear unit) is
exhibiting low levels of surface foam. Surface foam up to approximately 10 mm is
acceptable. If foaming is found, contact the oil manufacturer if necessary. Foaming will
decrease as the temperature rises.
– Vibration measurement
For more information, refer to chapter Measuring the vibration levels (Page 75).
– Oil leaks
Check the screw connections for oil leaks. If necessary, provide extra sealing.
After the first run, the oil level sinks. As the gear unit warms up, the oil level rises to the height
of the marking for the operating oil level.
4. Communicate the date of first commissioning in writing to Flender within 4 weeks.
6.2.2 Oil level monitoring system

The gear unit can be equipped with an oil level monitoring system that uses a filling-level limit
switch.

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Commissioning
The oil level monitoring system has been designed to check the oil level when the gear unit is at
a standstill before it starts.
Note
Connect the signal so that the drive motor cannot start when the "oil level too low" signal is
active and so that an alarm is output. Bypass this signal in operation.
6.2.3 Gear unit with heating

Please observe the following measures to commission the gear unit with heating:
• Ensure that the heating elements are not exposed.
• Check the switching points of the temperature monitor.
WARNING
Do not put heating elements into service until you have checked that they are completely
Further information
Further information about heating elements can be found in the heating element operating

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Operation 7
7.1 Operating data
Introduction
To ensure correct, trouble-free operation of the system, observe the operating data of the gear
unit and, depending on the order specification, the data in the operating instructions for the oil
supply system.
The valid operating data can be found in the annex Technical data (Page 95).
You can find the critical values for the inlet oil temperature in the lubrication diagram and in the
list of equipment in the complete gear unit documentation.
You will find information about the oil pressure in the data sheet, in the list of equipment or in
the drawings in the complete documentation of the gear unit.
DANGER
An explosive atmosphere can be ignited by electrostatic discharge.
Do not electrostatically charge the coating. Carefully ensure that highly efficient charge
generating mechanisms, which can cause layers and coatings to be electrostatically charged,
are reliably avoided.
Highly efficient charge generating mechanisms include the following:

• Fast flows of highly dust-laden air
• Sudden discharge of compressed gases that contain particles
• Other operations that involve high frictional forces (does not include manual cleaning or
rubbing with cleaning cloths)
Further information
Further information about the technical data of the gear unit can be found in the data sheet and
the list of equipment in the complete documentation for the gear unit.
7.2 Irregularities in operation
Introduction
Switch off the drive assembly immediately if it exhibits irregular behaviour during operation.

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7.2 Irregularities in operation
A few irregularities are listed below as examples:

• Oil temperature exceeds the maximum permissible value
• Alarm tripped by the pressure monitor in the oil cooling system or oil supply system
• Unusual operating noise
• Changes in the flow volumes
Document continuous changes in the operating performance of the gear unit by recording
trends.
NOTICE
Faults can cause damage to the gear unit
The gear unit might sustain damage if it is not shut down when a fault occurs.
Switch off the drive assembly immediately if any fault condition develops.
NOTICE
Parts can be damaged as a result of an inadmissible temperature rise
After the gear unit has been shut down as a result of an excessive oil intake temperature, the
gear unit must be operated for at least one hour with cool oil via the lubricating system.
During this hour, while being cooled by the lubricating system, it is not permissible to switch
on the main motor.
Rectifying irregularities in operation

Proceed as follows to rectify any irregularities in operation:
1. Switch off the drive assembly if it exhibits irregular behaviour during operation.
2. Refer to the Fault information (Page 80) to find the cause of the fault.
3. If you still cannot determine the fault cause, contact Flender Customer Services (Page 85).
DANGER
Note the following measures:
• Regularly check the gear unit for leaks.
• Secure oil drain valves against accidental opening.
• Protect any oil sight glasses against damage.
• Ensure that, after safety devices respond and before recommissioning, a restart lockout
must first be withdrawn.

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Operation
7.3 Taking the unit out of service
Introduction
After the gear unit has been shut down, it is protected against internal corrosion by the
operating oil for 7 days.
You have to take various measures depending on the time for which the gear unit will remain out
of service.
Taking the unit out of service

• Switch off the drive assembly.
• During short interruptions: Continue to run the complete oil supply system.
• During long interruptions:
– Continue to run the oil supply system for approx. 60 minutes to avoid heat accumulation.
However, damage can be ruled out due to a sudden stoppage, e.g. due to power failure.
When shutting down an oil supply system with high-pressure lubrication circuit, ensure
that the high-pressure pumps are shut down before the low-pressure pumps.
– If gear units are operated in saline environments or in close proximity to salt water, the oil
supply system should always operate continuously in order to prevent corrosion damage.
In addition, the gear unit must be turned every two weeks via the auxiliary drive or the
main motor (at least one rotation at the output flange).
If this is not possible, take measures to preserve the gear unit.
– When the gear unit is taken out of service for a period in excess of 7 days, start up the oil
supply system once a week and allow it to run for one hour. At the same time, make sure
that the gear unit is turned every 2 weeks (at least one rotation at the output flange).
If it is not possible to start up the lubrication system once a week and to turn the gear unit
every 2 weeks, take measures to preserve the gear unit.
– Close the shutoff valves for the cooling water inlet and drain lines in case of gear units with
water/oil cooler. Drain the water from the water/oil cooler if there is a risk of frost and
remove residual water with compressed air.
– Follow the preservation procedure described in operating instructions BA 7300.
WARNING
Risk of eye injury from compressed air
Water residue and dirt particles can cause damage to eyes.
Wear suitable safety goggles.

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Operation

70 Edition 06/2020
Servicing 8
8.1 General maintenance information
The operator must ensure compliance with the stipulated time limits. This also applies if the
maintenance activities are included in the operator’s internal maintenance schedules.
The gear unit could be damaged if the stipulated time limits for maintenance and servicing are
not observed.
The time limits stipulated in the maintenance schedule are largely dependent on the conditions
of use of the gear unit. For this reason, it is only possible to state average time limits here.
WARNING
Danger to life due to live system
Working on a gear unit while it is in operation is hazardous and can result in potentially fatal
injuries.
Always shut down the gear unit and any oil supply system (whether separate or mounted on
the gear unit) before you carry out any work. Take measures to prevent the accidental
restarting of the drive assembly. Display a warning notice that clearly states that work is being
carried out on the gear unit.
8.2 Maintenance schedule
Maintenance and servicing activities

The following table provides an overview of all maintenance and servicing activities which you
are required to perform continuously or at regular intervals.
Table 8-1 Maintenance and servicing activities
Intervals and time limits Measures

As required Clean the air filter
Replace the air filter element
Clean the gear unit
Replace the oil filter
According to manufacturer’s specifications Check the ignition protection system

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Servicing
8.2 Maintenance schedule
Intervals and time limits Measures

Weekly Check for leaks
Check the oil level
Check the oil temperature
Check for changes in the gear unit noise
Inspect the protection devices
Every 4 weeks Visually inspect the gear unit for cracks, leaks and dam‐
age
Inspect the oil supply system for dirt
Inspect instruments installed in situ (temperatures, oil
pressures)
1 000 operating hours after commissioning Analyse the oil
Change the oil (or depending on results of the oil sample
test (Page 36))
Every 3 months Clean the oil filter
Clean the air filter
Check that the foot fastening bolts are tight
Every 6 months Inspect mounted components (couplings, auxiliary
drive)
Every 12 months Visually inspect the tooth flanks for damage
Inspect the hose lines
Replace the air filter element
Analyse the oil
Every 10 000 operating hours, at least every Change the oil (or depending on results of the oil sample
18 months test (Page 36))
Check the air‐oil cooler (the same time as you change
the oil)
Check the water‐oil cooler (the same time as you change
the oil)
Every 2 years Carry out a general inspection of the gear unit
Clean the gear unit
6 years after the specified date of manufacture Change the hoses
Further information
Further information about additional maintenance and servicing activities can be found in the
separate data sheet in the overall documentation for the gear unit.
Further information about installed components can be found in the operating instructions for
the components in the complete documentation for the gear unit.

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

The following table contains the material-specific contamination values of the oil:
Material Limit proportion Possible source

[mg/kg]
Iron (Fe) 40 Wheel rim with internal teeth, gear teeth, rolling-
contact bearing cages
Chromium (Cr) +4 Plain and rolling-contact bearings, gear teeth
Aluminium (Al) +4 Oil pump bearings
Copper (Cu) +4 Rolling-contact bearing cages
Lead (Pb) +6 Thrust bearings, pump bearings
Tin (Sn) +2 Thrust bearings, pump bearings
Nickel (Ni) +2 Gear teeth
Zinc (Zn) + 10 Zinc-based primer (sometimes used as an addi‐
tive). In this case, contact Flender.
Silicon (Si) +5 Cement dust or other environmental influences,
some oils may contain silicon
Water (H2O) 0.03 % Condensation, water/oil cooler defective (mineral
oil)
The values preceded by "+" refer to the reference sample of the fresh oil.
Note that the deviation in the viscosity of the oil sample from the viscosity of the oil specified in
the technical data should not exceed 10 %.
NOTICE
The gear unit may be damaged by dirty operating oil and mixing different oil grades.
Replace the oil if the contamination limits stated in the table or the purity class -/19/16
according to ISO 4406 is exceeded.
When changing the oil, fill the gear unit with the oil grade that was previously used. Do not mix
oils of different grades or manufacturers.

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Servicing
8.3.2 Servicing
Preparatory measures
Maintenance encompasses all of the measures required to keep and restore the reference state
as well as to identify and assess the actual state of technical equipment of a system.
Attach and secure the individual components and large assemblies to the lifting equipment
carefully during replacement.
8.3.3 Checking the oil temperature
Damage to the gear unit due to excessively high oil sump temperatures.
The gear unit can sustain damage due to inadequate lubrication if you allow it to operate at oil
sump temperatures above the maximum permissible temperature.
Do not operate the gear unit above the maximum permissible oil sump temperature.
Procedure
Proceed as follows to check the oil temperature:
1. Allow the gear unit to reach its normal operating temperature.
2. Operate the gear unit with the maximum driven machine power.
3. Measure the temperature of the oil in the oil sump.
4. Compare the measured value with the maximum permissible oil temperature.
Depending on the order, you can find the maximum permissible oil temperature in the
lubrication diagram and in the list of equipment in the complete gear unit documentation.
5. Immediately stop the gear unit if the maximum permissible oil temperature is exceeded.
Contact Flender Customer Services.
8.3.4 Checking the ignition protection system
Procedure
Proceed as follows to check the ignition protection system:
1. Check the ignition protection system for temperature monitoring to ensure that it is
functioning correctly.
2. Check the ignition protection system for temperature monitoring for measurement accuracy.

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Servicing
Further information
You can find additional information on checking the ignition protection system in the operating
instructions for the ignition protection system, provided in the complete gear unit
documentation.
8.3.5 Measuring the vibration levels
For the KMS type, the diagram below shows the measuring points for portable vibration
measurements as an example:
+ + +
9
9 + + 9
V Vertical measuring point H Horizontal measuring point

Figure 8-1 Measuring points for vibration measurements
(Measuring points 1 and 2 are positioned at the motor bearing points.)

You can contact Customer Services (Page 85) for the precise layout drawing for portable
vibration measurement for the KMS type depending on the order.

Edition 06/2020 75
Servicing
WARNING
Risk of becoming entangled in rotating parts
There is danger that rotating parts may catch hold of you or pull you in.
If you are taking a vibration measurement at a gear unit while it is in operation, make sure that
you do not take the measurement in immediate proximity to rotating parts to avoid accidental
contact with them.
The points shown in the diagram are standard measuring points. All gear units of this type in the
field can be measured at these points. This enables you to make a direct comparison with other
gear units of the same type or size.
Arrange for the vibration measurements to be carried out and evaluated by or in close
cooperation with Flender personnel. It will then be possible to apply experience from previous
measurements on comparable gear units to the measurement process and to the evaluation of
the measurement results.
When taking vibration measurements, please note the following general points:
• Take measurements only at those points shown in the diagram.
• Do not take measurements at resonating bodies such as ribs, inspection covers, pipes, etc.
• Document the motor power at the time the measurement was taken. Power fluctuations can
cause variations in the measurement result.
In order to record the vibration profile of the gear unit, take a base measurement after the whole
system has been commissioned and been in continuous operation. This will form the basis for
a trend analysis if further measurements are taken at monthly intervals.
The gear unit is a Class III driven machine when assessed according to ISO 10816. As regards this
assessment, it must be noted that the axial forces generated by the crushing process are
transferred to the foundation via the gear unit housing. The possibility that vibrations are
attributable to the grinding process rather than the operation of the gear unit cannot therefore
be precluded. For this reason, the extent to which the standard ISO 10816 can be applied to this
type of gear unit is limited.
Further information
More information about diagnosing vibration can be found on the Internet (https://
www.flender.com/service).

76 Edition 06/2020
Servicing
8.3.6 Cleaning the gear unit
Introduction
Layers of dust may affect the dissipation of heat through the surface of the gear unit, resulting
in overheating. Depending on the operating conditions, it may therefore be necessary to clean
the gear unit more frequently than stated in the maintenance schedule.
Procedure
To clean the gear unit, proceed as follows:
1. Use a hard brush to remove any stubborn dirt from the gear unit. Never use a high-pressure
cleaning device or water.
2. Remove any spots of corrosion.
DANGER
An explosive atmosphere can be ignited if the gear unit overheats as a result of inadequate
cooling.
Avoid dust from depositing on the gear unit. Adapt the cleaning intervals to the operational
situation.
8.3.7 Cleaning the air filter and replacing the air filter element
8.3.7.1 Cleaning the air filter

NOTICE
Damage to the gear unit due to penetration of foreign bodies
Damage to the gear unit due to penetration of foreign bodies is possible due to the ambient
conditions of the mill.
Do not allow foreign bodies to enter the gear unit.
8.3.7.2 Replacing the air filter element
Introduction
The paper filter cannot be cleaned.

Edition 06/2020 77
Servicing
Procedure
Proceed as follows to replace the air filter element:
1. Remove the air filter cap
2. Replace the filter element.
3. Mount the air filter cap.
8.3.8 Cleaning the double change-over filter
Procedure
To clean the double change-over filter, proceed as follows:
1. Inspect the double change-over filter.
2. Follow the operating instructions for the double change-over filter.
Further information
You can find additional information about the double change-over filter in the double change-
over filter operating instructions provided in the complete gear unit documentation.
You can find additional technical data in the separate data sheet and in the list of equipment

78 Edition 06/2020
Servicing
8.3.9 Welding work on the mill

Flender provides no warranty for damage to the gear unit originally caused by welding work on
the mill.
DANGER
Risk of injury due to electric shock or electrostatic discharge
Injuries as a result of electric shock or due to ignition of an existing potentially explosive
atmosphere by electrostatic discharge can occur when welding equipment is used.
Perform potential equalisation in accordance with the applicable regulations and guidelines
before any welding work is carried out on the mill.
The gear unit and any parts connected to it must not be used as an earthing point for electric-
welding operations.
The pad bearing compartment can be optionally fitted with an earth cable that must be
connected to the output flange. Connect the earth cable to the tapped holes on the side of the
output flange. When the welding work is complete, detach the earth cable from the output
flange.
Tapped holes to establish an earth connection are provided on the gear unit or the output
flange. This work must always be done by specialist electricians.
When electric welding is carried out anywhere on the mill, the welding current must not be
conducted through the gear unit. For this reason, the welding current return cable must always
be directly connected to the component to be welded.
8.3.10 General inspection of the gear unit

Arrange for Flender Customer Services to inspect the gear unit. Thanks to their experience, these
engineers are best placed to assess which gear unit components need to be replaced.
8.3.11 Check that all of the fastening bolts are tight

Note the following points when checking that the fastening bolts are tight:
• Observe the data regarding connection classes (Page 57), preload forces and tightening
torques (Page 57).
• Tighten the foot fastening bolts with the prescribed preload force or to the required torque.
The relevant information can be found in the dimension drawing in the complete
• Note the separate operating instructions if you are using clamping nuts.
• Replace any bolts that are no longer fit for use by bolts of the same strength class and type.

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Servicing
8.4 Possible faults
8.3.12 Final work

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

The faults listed below are only intended as a troubleshooting guide.
If any faults occur while the unit is still under warranty, do not allow anyone except Flender
Customer Services to attempt a repair.
Even after the warranty period has expired, you should still arrange for faults to be rectified by
Flender Customer Services.
Note
Loss of warranty
You will invalidate the warranty for the gear unit if you modify it in any way without seeking the
approval of Flender beforehand, or if you do not use original spare parts.
Only use original spare parts from Flender. Always arrange for Flender Customer Services to
repair any faults that develop while the unit is still under warranty.

80 Edition 06/2020
Servicing
8.4 Possible faults
Possible faults and their rectification

The following table provides you with an overview of possible faults and indicates how they can
be rectified.
Table 8-2 Possible faults and their rectification
Possible faults Causes Possible remedies

Pressure switch trig‐ Oil pressure has dropped below min‐ • Check the oil level at room temperature
gers alarm imum value • Top up with oil if necessary
• Check the operating temperature
• Check the oil pump
• If required, replace the oil pump
• Check the oil filter
• Clean or replace the oil filter if necessary
• Inspect the pressure switch and replace if necessary
• Check the pipes, and replace or seal if necessary
• Check the flow
Noise Damage to the gear teeth • Contact Customer Services
• Inspect the toothed components
• If necessary, replace damaged components
The bearing play is excessive or re‐ • Contact Customer Services
duced • Adjust bearing play
Defective plain or rolling-contact • Contact Customer Services
bearings • Replace the defective plain or rolling-contact bearings
Gear unit fastening has worked • Tighten bolts and nuts to the specified tightening torque
loose • Replace damaged bolts and nuts
Leakage Labyrinth seals soiled with oil, incor‐ • Check oil filling
rect transport position
• Clean the labyrinths
Inadequate sealing of the housing • Check the seals and replace if necessary
cover or joints • Seal housing cover or joints
Oil level in the gear unit housing too • Check the oil level
high • Correct the oil level if necessary
Leaks in the input shaft • Check the oil level
• Correct the oil level if necessary
Wet-air filter is severely Wet-air filter is spent • Replace the wet-air filter
discoloured
Wet-air filter is becom‐ Water in the oil • Take test tube sample to examine oil condition for water
ing discoloured from penetration
the top downwards
• Have the oil examined by a chemical lab
• Change the oil if necessary

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Servicing
8.4 Possible faults

Oil is foaming in the Preservation agent not completely • Change the oil
gear unit drained off
Oil supply system left in operation • Switch off the oil supply system
for too long at low temperatures • Degas the oil
Gear unit too cold in operation • Switch off the gear unit
• Degas the oil
• Start up without cooling water during cold restart
Water in the oil • Take test tube sample to examine oil condition for water
penetration
Oil defoamer has run out • Examine the oil
Unsuitable mixture of oils • Examine the oil
The fast-running bevel gear swirls • Check the oil level
up the oil • Correct the oil level if necessary
Oil escaping from the Inadequate sealing of the housing • Check the seals and replace if necessary
gear unit cover or joints • Seal housing cover or joints
• Check the compression seals and retighten screws if nec‐
essary
Leaking pipes • Check the pipes, and replace or seal if necessary
Oil supply system mal‐ - • Follow the operating instructions for the oil supply system
function

82 Edition 06/2020
Servicing
8.4 Possible faults

Elevated temperature Oil level in the gear unit housing too • Check the oil level
during operation low or too high • Correct the oil level if necessary
Oil is too old • Find out when the last oil change was done
Oil is severely contaminated • Change the oil
Oil supply system defective • Inspect the oil supply system
• Replace defective components if necessary
• Follow the operating instructions for the oil supply system
Gear unit with water-oil cooler: Cool‐ • Adjust the valves at the supply and return lines
ant flow too low or too high • Check the water-oil cooler for free flow
Gear unit with air-oil cooler: Inade‐ • Clean the air-oil cooler
quate air flow
Gear unit with air-oil cooler: Cooler • Clean the cooler block
block soiled
Gear unit with oil cooling system: • Check the oil filter
Inadequate oil flow through the oil • Clean or replace the oil filter if necessary
cooler
Coolant temperature is too high • Check the temperature; correct if necessary
Defective oil pump • Check the oil pump function
• If required, repair or replace the oil pump
Electrical equipment defective • Check the electrical equipment and replace if necessary
Elevated temperature Oil filter contaminated • Check the oil filter
at temperature sensor • Clean or replace the oil filter if necessary
in pad bearing
Quantity of oil supplied to the pad • Check the setting of the control valves
bearing too small
Monitoring devices defective • Check the monitoring devices and replace if necessary
Changed grinding parameters at mill • Examine and check the grinding parameters
Elevated temperature Oil level in the gear unit housing too • Check the oil level at room temperature
at bearing points low or too high • Correct the oil level if necessary
Oil is too old • Find out when the last oil change was done
Oil supply system defective • Inspect the oil supply system
Defective plain or rolling-contact • Contact Customer Services
bearings • Check the plain or rolling-contact bearings and replace if
necessary
Defective oil pump • Check the oil pump function
• If required, repair or replace the oil pump

Edition 06/2020 83
Servicing
8.4 Possible faults

Increased vibration am‐ Defective plain or rolling-contact • Contact Customer Services
plitude at the bearing bearings • Check the plain or rolling-contact bearings and replace if
points
necessary
Gear wheels defective • Contact Customer Services
• Inspect the gear wheels and replace if necessary
Contamination indica‐ Double change-over filter clogged • Change over the double change-over filter corresponding
tor of the double to the separate operating instructions
change-over filter trig‐
• Clean the filter element
gers an alarm
Volume flowmeter trig‐ Oil too cold • Warm the oil
gers alarm Oil filter contaminated • Check the oil filter
• Clean or replace the oil filter if necessary
Leaking pipes • Check the pipes, and replace or seal if necessary
Volume flowmeter defective • Inspect the volume flowmeter and replace if necessary
Water in the oil Oil supply system defective • Inspect the oil supply system
Cooler leaking • Inspect the cooler and replace if necessary
Engine room fan is blowing cold air • Install suitable thermal insulation to protect gear unit
onto gear unit: Water condenses housing
• Close the air outlet or change the direction of the air outlet
using structural measures.
Climatic conditions • Contact Customer Services
• Use wet-air filter if necessary
Oil foams in the oil sump • Take test tube sample to examine oil condition for water
penetration

84 Edition 06/2020
Service & Support 9
Contact
When ordering spare parts, requesting a customer service technician or in the case of technical
queries, please contact our factory or one of our customer service addresses:
Flender GmbH
Am Industriepark 2
46562 Voerde
Deutschland - Germany
Tel.: +49 (0)2871 / 92‐0
Fax: +49 (0)2871 / 92‐1544
Further information
Further information about service and support can be found on the Internet.
Service & Support (https://www.flender.com/service)

Edition 06/2020 85
Service & Support

86 Edition 06/2020
Disposal 10
Disposal of the gear unit
When disposing of the gear unit after its useful life, please observe the following measures:
• Remove operating oil, preservative agents and coolant from the gear unit and dispose of it
according to regulations.
• Dispose of the gear unit parts according to applicable national regulations or recycle them.
Environmental protection
Observe the following environmental protection measures for disposal:
• Dispose of or recycle packaging material according to applicable national regulations.
• When changing the oil, collect the used oil in suitable containers. Use oil-binding agents to
clean up any oil spillages immediately.
• Store preservative agents separately from used oil.
• Dispose of used oil, preservative agents, oil binding agents and oil-soaked cloths according
to the applicable environmental protection regulations.

Edition 06/2020 87
Disposal

88 Edition 06/2020
Spare parts 11
By stocking the most important spare parts at the installation site you can ensure that the gear
unit is ready for use at any time.
Note
Damage to the gear unit due to use of unsuitable spare parts
Only use original spare parts from Flender. Flender shall not accept any warranty claims for spare
parts that are not supplied by Flender.
Other spare parts are not tested and approved by Flender. Non-approved spare parts may
possibly change the design characteristics of the gear unit and thus impair its active or passive
safety.
Flender will accept no liability or warranty whatsoever for damage occurring as a result of the
use of non-approved spare parts. The same applies to any accessories that are not supplied from
Flender.
The contact address of Flender Customer Services can be found under Service & Support
(Page 85).
Information required when ordering spare parts

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

Edition 06/2020 89
Spare parts

90 Edition 06/2020
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Declaration of incorporation

92 Edition 06/2020
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Edition 06/2020 93
Declaration of Conformity

94 Edition 06/2020
Technical data C
C.1 General technical data
Rating plate
The gear unit rating plate contains the most important technical data.

D
E

① Company logo ⑨ Optional DMC (Data Matrix Code)

② Serial no.: production plant code/order no. ⑩ Oil data: Oil type, oil viscosity, oil quantity
item ser. no./year of manufacture
③ Total weight in kg ⑪ Numbers of operating instructions
④ For special information ⑫a ATEX marking for explosion protection – gas
marking
⑤ Type, size ⑫b ATEX marking for explosion protection –
dust marking
⑥ Power rating P2 in kW or torque T2 in Nm ⑬ Manufacturer documentation / Country of
origin
⑦ Speed n1 ⑭ Hotline
⑧ Speed n2
Figure C-1 Rating plate
The limits of the intended use of the gear unit are defined on the basis of these data and the
contractual agreements concerning the gear unit concluded between Flender and the customer.

Edition 06/2020 95
Technical data
C.1 General technical data
More information
More information about these technical data can be found in the separate data sheet and the
dimension drawings in the complete documentation for the gear unit.
More information about all major accessories including their technical data and control
instructions can be found in the order-specific list of equipment in the complete documentation
for the gear unit.
Example code
The following is an example of the code printed in line 5 of the rating plate and explains the
meaning of the individual letters and numbers.
. 0 6
6L]H
WR
'HVLJQ
6 +HOLFDOJHDUVWDJH
$SSOLFDWLRQ
0 9HUWLFDOPLOOJHDUXQLW
*HDUXQLWW\SH
. %HYHOJHDUXQLW
More information
More information on the weights and the enveloping surface sound pressure levels can be found
in chapters Weights (Page 97) and Enveloping surface sound pressure level (Page 97).
More information about these technical data can be found in the separate data sheet and the
dimension drawings in the complete documentation for the gear unit.
ATEX marking
The ATEX marking for open-cast mining applications is shown in the following table:
Table C-1 ATEX marking
Equip‐ Equip‐ Explosive Dust Maximum Marking example

ment ment atmos‐ group surface tem‐
group catego‐ phere perature
ry
II 3 Dust (D) IIIA, IIIB, 120 °C II 3D Ex h IIIA T120 °C Dc -20 °C ≤ Ta ≤ 40 °C
IIIC

96 Edition 06/2020
Technical data
C.4 Enveloping surface sound pressure level
Please note the following points:

• Only one dust group can be specified for the dust Ex atmosphere.
• Ta min. ≤ Ta ≤ Ta max. = permissible ambient temperature in °C:
Ta min. = minimum permissible ambient temperature
Ta max. = maximum permissible ambient temperature
Ta = ambient temperature code
• The dust group is stated as an example.
• The gear unit is not designed for use in hydride mixtures.
NOTICE
The gear unit can be damaged as a result of incorrect use
The gear unit may be damaged if used for a purpose other than the specified application.
For your particular application, observe the marking on the gear unit rating plate.
C.2 Ambient temperature
The specifications in the ATEX directive are applicable for an ambient temperature range
extending from -20 °C up to 40 °C. By applying various suitable measures, the gear unit can be
used in the ambient temperature range extending from -40 °C up to 60 °C. However, this must
always be authorised by Flender.
In each individual case, the ambient temperature range stamped on the rating plate always
applies.
C.3 Weights
The precise weights are specified in the drawings in the complete documentation or on the
rating plate.
All weight specifications refer to units without oil filling or mounted components.
It is not possible to specify an enveloping surface sound pressure level for a gear unit in operation
because the unit is operated under no load on the Flender test stand during the trial run.

Edition 06/2020 97
Technical data

98 Edition 06/2020
Index
Filling with oil, 35
Final work, 59
A
Air filter, 77
Air filter element, 77
G
ATEX Directive, 9 Gear unit equipment, 22
ATEX marking, 96 Gear unit housing, 21
Attachment points, 41 Gear unit markings, 12
General inspection of the gear unit, 79
C
Checking procedure, 63
H
Coloured markings, 12 Heating
Contact, 85 Commissioning, 66
Contamination limits, 73 Function, 26
Cooling, 23 Heating elements, 26
Copyright, 10 Temperature monitor, 27
Coupling, 26, 47
Customer Services, 85
I
Initial test run, 65
D Interval, 71
Delivered state, 23 Irregularities in operation, 67
Direction of rotation, 21
Disclaimer, 9
Disposal, 87 L
Documentation landscape, 10
Labyrinth seal, 25
Double change-over filter
Lubricant, 10
Cleaning, 78
E M
Maintenance activities, 71
Environmental protection, 87
Maintenance information, 71
Equipment features, 21
Maintenance schedule, 71
Measures
Checking procedure, 63
F during commissioning, 64
Fastening bolts Prior to commissioning, 61
Bolt connection class, 57 Mounted components
Bolts, 56 Mounting, 53
Checking for tightness, 79 Mounting position, 41
Mating threads, 57
Preload force, 57
Tightening procedure, 57 N
Tightening torque, 57
Note about assembly, 41
Fault, 80
Fault rectification, 81

Edition 06/2020 99
Index
Transport symbols, 32
Troubleshooting, 80
O Types of danger, 14
Oil, 10
Contamination limits, 73
Oil drain, 36
U
Oil level indicator, 27 Unpacking, 43
Oil supply, 23 Used oil, 87
Oil supply system Using the gear unit, 17
Commissioning, 62
Oil temperature
Checking, 74 W
Oil temperature monitoring, 29
Warning symbols, 13
Operating data
Compliance with, 67
Oil, 67
Ordering spare parts, 85, 89
P
Packing list, 31
Preservation, 37
Protective equipment, 14
R
Rating plate, 95
ATEX marking, 96
Example of type and size, 96
Reactivating, 19
Resistance thermometer, 29
Rinsing, 62
Rotary shaft sealing ring, 23
Round cord hollow profile, 23
S
Safety rules, 11
Scope of delivery, 31
Sealing cap, 39
Servicing, 74
Servicing activities, 71
Shaft seal, 25
T
Taking oil samples, 36
Taking the unit out of service, 69
Technical data, 95
Transport information, 31

100 Edition 06/2020
FLENDER GEAR UNITS
Edition 06/2020
Flender GmbH
Alfred-Flender-Straße 77
46395 Bocholt
GERMANY

Flender Gear Units: Vertical-Mill Gear Unit

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FLENDER GEAR UNITS

Vertical-mill gear unit

Assembly and operating instructions 9137en

Service & Support 9

KMS Declaration of incorporation A

Original assembly and operating instructions

Assembly and operating instructions 9137en

4.4.4 Checking the oil level ......................................................................................................... 36

Assembly and operating instructions 9137en

7.3 Taking the unit out of service ............................................................................................. 69

Table 2-1 Symbols and markings ............................................................................................................ 12

Assembly and operating instructions 9137en

Table C-1 ATEX marking ......................................................................................................................... 96

Figure 3-1 Gear unit preservation equipment........................................................................................... 22

Assembly and operating instructions 9137en

Purpose of the operating instructions

Basic knowledge required

Assembly and operating instructions 9137en

Assembly and operating instructions 9137en

2.2 The five safety rules

Assembly and operating instructions 9137en

2.3 General information

Symbols on the gear unit

Table 2-1 Symbols and markings

Points labelled on the gear unit Symbol Coloured markings

Air relief point yellow

Oil filling point yellow

Oil draining point white

Oil level indicator red

Oil level measurement red

Connection point for vibration monitoring

Lubrication point red

Assembly and operating instructions 9137en

Points labelled on the gear unit Symbol Coloured markings

Alignment surface, horizontal

Alignment surface, vertical

These symbols indicate the oil level check‐

These symbols indicate that the oil dipstick

2.4 General warnings and symbols

Table 2-2 General warnings

ISO ANSI Warning

Warning - explosive substances

--- Warning - entanglement hazard

--- Warning - hot surfaces

--- Warning - caustic substances

--- Warning - suspended load

--- Warning - hand injuries

Assembly and operating instructions 9137en

2.5 Special types of danger and personal protective equipment

Dangers during operation

Assembly and operating instructions 9137en

Assembly and operating instructions 9137en

2.6 Correct use in hazardous zones (explosive atmospheres)

Assembly and operating instructions 9137en

Gear unit use

Assembly and operating instructions 9137en

Highly efficient charge generating mechanisms include the following:

Assembly and operating instructions 9137en

The coating must be electrostatically conductive if explosion protection is required in