Crane Gear Unit: Assembly and Operating Instructions B5832-01en Edition 06/2022

Crane gear unit
Assembly and operating instructions B5832-01en

Edition 06/2022
H3SH
114...116
Original assembly and operating instructions
B5832-01
Edition 06/2022 V3
29/07/2022
Copyright (©2022 Flender GmbH) 13:23:45
Table of contents
1 Introduction...............................................................................................................................................11
1.1 Legal information .....................................................................................................................11
1.2 General information .................................................................................................................12
1.3 Lubricants ................................................................................................................................14
2 Safety instructions ...................................................................................................................................15
2.1 Security notes ..........................................................................................................................15
2.2 The five safety rules .................................................................................................................15
2.3 General information .................................................................................................................15
2.4 General warnings and symbols................................................................................................17
2.5 Special types of danger and personal protective equipment ................................................... 17
2.6 Intended use ............................................................................................................................20
3 Description ................................................................................................................................................23
3.1 General description ..................................................................................................................23
3.2 Housing ....................................................................................................................................23
3.3 Oil supply to the gear unit ........................................................................................................24

3.3.1 Splash lubrication.....................................................................................................................24
3.4 Shaft bearings..........................................................................................................................24
3.5 Shaft seal .................................................................................................................................25

3.5.1 Rotary shaft sealing rings ........................................................................................................25
3.5.2 Taconite seal............................................................................................................................25
3.6 Couplings .................................................................................................................................27
3.7 Brake........................................................................................................................................28
3.8 Heating.....................................................................................................................................28
3.9 Oil level indicator......................................................................................................................29
3.10 Oil temperature monitoring ......................................................................................................30
4 Application planning ................................................................................................................................31
4.1 Scope of delivery .....................................................................................................................31
4.2 Transport..................................................................................................................................31
4.3 Attachment points ....................................................................................................................32
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Table of contents
4.4 Special aspects of gear unit lubrication and preservation........................................................ 35

4.4.1 Oil filling point and oil drain ......................................................................................................35
4.4.2 Checking the oil level ...............................................................................................................35
5 Assembly...................................................................................................................................................37
5.1 General assembly instructions .................................................................................................37
5.2 Unpacking the gear unit ...........................................................................................................38
5.3 Gear unit assembly ..................................................................................................................39

5.3.1 Foundation ...............................................................................................................................39
5.3.2 Description of assembly work ..................................................................................................40
5.3.2.1 Alignment .................................................................................................................................41
5.4 Couplings .................................................................................................................................43

5.4.1 Assembling the coupling ..........................................................................................................43
5.4.2 Aligning the coupling................................................................................................................45
5.5 Connecting components ..........................................................................................................46

5.5.1 Gear units with mounted components .....................................................................................46
5.5.2 Connecting the heating element ..............................................................................................47
5.5.3 Connecting the Pt 100 resistance thermometer....................................................................... 47
5.5.4 Electrical connections ..............................................................................................................48
5.6 Tightening procedure ...............................................................................................................48

5.6.1 Introduction ..............................................................................................................................48
5.6.2 Bolt connection classes ...........................................................................................................49
5.6.3 Tightening torques and preload forces ....................................................................................49
5.7 Final work.................................................................................................................................51
6 Commissioning.........................................................................................................................................53
6.1 Measures prior to commissioning ............................................................................................53
6.2 Measures during commissioning .............................................................................................53

6.2.1 Gear units with heating ............................................................................................................54
7 Operation...................................................................................................................................................55
7.1 Operating data .........................................................................................................................55
7.2 Irregularities in operation .........................................................................................................55
7.3 Taking the unit out of service ...................................................................................................56
8 Servicing ...................................................................................................................................................57
8.1 General maintenance information............................................................................................57
8.2 Maintenance schedule .............................................................................................................57
8.3 Maintenance and servicing work..............................................................................................58
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Table of contents
8.3.1 Clean the venting screw...........................................................................................................58

8.3.2 Checking the oil temperature ...................................................................................................59
8.3.3 Cleaning the gear unit..............................................................................................................59
8.3.4 General inspection of the gear unit ..........................................................................................60
8.3.5 Check that all of the fastening bolts are tight ........................................................................... 60
8.3.6 Final work.................................................................................................................................60
8.4 Possible faults ..........................................................................................................................60
9 Service & Support.....................................................................................................................................63
9.1 Contact.....................................................................................................................................63
10 Disposal.....................................................................................................................................................65
11 Spare parts ................................................................................................................................................67
A Declaration of Incorporation....................................................................................................................69
A.1 Declaration of Incorporation.....................................................................................................69
B Technical data...........................................................................................................................................71
B.1 General technical data .............................................................................................................71
B.2 Ambient temperature ...............................................................................................................72
B.3 Weights ....................................................................................................................................72
B.4 Oil quantities ............................................................................................................................72
B.5 Enveloping surface sound pressure level ................................................................................ 73
Index ..........................................................................................................................................................75
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Table of contents
6 Edition 06/2022 B5832-01en

List of tables
Table 2-1 Symbols and markings ...............................................................................................................16
Table 2-2 General warnings .......................................................................................................................17
Table 3-1 Taconite seal versions................................................................................................................27
Table 3-2 Information about the specific heat output .................................................................................28
Table 5-1 Information on tightening fastening bolts ...................................................................................49
Table 5-2 Preload forces and tightening torques .......................................................................................50
Table 7-1 Operating data............................................................................................................................55
Table 8-1 Maintenance and servicing activities..........................................................................................57
Table 8-2 Possible faults and how to rectify them ......................................................................................61
Table B-1 Oil quantities...............................................................................................................................73
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List of tables
8 Edition 06/2022 B5832-01en

List of figures
Figure 3-1 Gear unit equipment on type H3SH gear units ..........................................................................24
Figure 3-2 Rotary shaft sealing ring.............................................................................................................25
Figure 3-3 Taconite seal ..............................................................................................................................26
Figure 3-4 Taconite seal, variants E, F, F‐F, F‐H and F‐K ..........................................................................26
Figure 3-5 Heating on type H3SH gear units...............................................................................................29
Figure 4-1 Transport symbols......................................................................................................................32
Figure 4-2 Shear and lateral pulling when using eye bolts ..........................................................................33
Figure 4-3 Position of the attachment points on the type H3SH gear unit...................................................34
Figure 4-4 Position of the attachment points on type H3SH gear units with motor .....................................34
Figure 4-5 Oil filling and oil drain .................................................................................................................35
Figure 5-1 Gap dimension at the grease labyrinth ......................................................................................41
Figure 5-2 Alignment surface.......................................................................................................................42
Figure 5-3 Alignment surfaces.....................................................................................................................42
Figure 5-4 Possible displacements..............................................................................................................45
Figure 5-5 Alignment process based on the example of a flexible coupling................................................46
Figure B-1 Rating plate ................................................................................................................................71
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List of figures
10 Edition 06/2022 B5832-01en

Introduction
1
1.1 Legal information 1.1 Legal information
Warning system
These instructions contain information you must observe for your own personal safety as
well as to avoid damage to property and persons. The information regarding your personal
safety is highlighted with a warning triangle. Information exclusively regarding property dam-
age alone is not marked with a warning triangle. Depending on the hazard class, the warn-
ings shall be depicted as follows, in descending order.
DANGER
means that death or severe physical injury will occur if the relevant precautionary meas-
ures are not taken.
WARNING
means that death or severe physical injury may occur if the relevant precautionary meas-
ures are not taken.
CAUTION
means that mild physical injury may occur if the relevant precautionary measures are not
taken.
NOTICE
means that damage to property may occur if the relevant precautionary measures are not
taken.
If multiple hazard classes come into play, the warning for the highest level in question shall
always be used. If a warning containing the warning triangle warns of harm to individuals, the
same warning may also include a warning regarding damage to property.
Information
Information
Information offers additional notes, assistance and tips for handling the product.
B5832-01en Edition 06/2022 11

Introduction
1.2 General information
Qualified personnel
The product/system associated with this documentation may only be used by qualified per-
sonnel trained to perform the relevant tasks, taking into account the associated documenta-
tion for the relevant tasks, particularly the safety information and warnings included therein.
Due to their qualification and experience, qualified personnel are capable of detecting risks
and avoiding potential hazards when dealing with these products/systems.
Intended use of Flender products

Please note the following:
WARNING
Flender products are only suitable for the uses set out in the catalogue and associated
technical documentation. If third-party products and components are used, these must be
recommended and/or authorised by Flender. Safe and flawless operation of the products
requires proper transport, proper storage, setup, assembly, installation, commissioning,
operation and maintenance. The permissible environmental conditions must be adhered
to. Instructions in the associated documentation must be followed.
Trademarks
All designations marked with the trademark symbol ® are registered trademarks of Flender
GmbH. Other designations in this document may be trademarks whose use by third parties
for their own purposes may violate the rights of the owner.
Liability disclaimer
We have assessed the contents of these instructions for compliance with the hardware and
software described. However, deviations cannot be ruled out, so we are unable to accept li-
ability for full compliance. The details in these instructions are regularly reviewed and neces-
sary corrections are contained in subsequent editions.
1.2 General information 1.2 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 instruc-
tions prior to handling the gear unit and follow the information in them.
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Introduction
Information
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 ad-
heres 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 which 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.
Required basic knowledge

In order to understand these operating instructions, you will need to have general knowledge
about gear units. You will also need a basic understanding of the following topics:
• Application planning
• Assembly
• Commissioning
• Maintenance
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 7300 on gear unit lubrication and preservation
• Operating instructions for mounted components
• Instructions for third-party 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 63).
B5832-01en Edition 06/2022 13

Introduction
1.3 Lubricants
1.3 Lubricants 1.3 Lubricants
The quality of the oil used must meet the requirements of the instructions 7300, which is
provided as a separate item, otherwise the warranty provided by Flender will be void. Flen-
derurgently recommends that one of the oil types listed in instructions 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 lubric-
ants supplied by your supplier. Every lubricant manufacturer is required to guarantee the
quality of his/her products.
Information such as oil type, oil viscosity and required oil quantity can be found on the rating
plate of the gear unit and in the documentation supplied with the gear unit.
The oil quantity specified on the rating plate is an approximate value. The actual quantity of
oil required is determined by the marking on the oil dipstick or oil sight glass.
The operating instructions for the current lubricant recommendations of Flender can also be
viewed on the Internet (https://www.flender.com/lubricants).
The oils listed there undergo continuous testing. As a result, the recommended oil types
might in future be removed from the list or replaced by more advanced oils.
Flender recommends regular inspection to ascertain whether the selected lubricating oil is
still approved by Flender. If it is not, another brand of oil should be selected instead.
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Safety instructions
2
2.1 Security notes 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 ne-
cessary to implement (and continually maintain) a holistic industrial security concept that cor-
responds 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, ma-
chines 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 neces-
sary 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 Se-
curity 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 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 isol-
ated 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.
2.3 General information 2.3 General information
Introduction
All work on the gear unit should be performed with care and only by qualified personnel.
B5832-01en Edition 06/2022 15

Safety instructions
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:
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
Do not unscrew
Alignment surface, horizontal
Alignment surface, vertical
These symbols indicate the oil level

checking procedure using the oil dipstick.
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Safety instructions
2.4 General warnings and symbols
Points labelled on the gear unit Symbol Coloured markings
These symbols indicate that the oil dip-

stick must be firmly screwed in.
Table 2-1: Symbols and markings
2.4 General warnings and symbols 2.4 General warnings and symbols
The following table contains general warnings and their associated symbols.
ISO ANSI Warning
Warning – hazardous electrical voltage
Warning – explosive substances
--- Warning – entanglement hazard
--- Warning – hot surfaces
--- Warning – corrosive substances
--- Warning – suspended load
--- Warning – hand injuries
Table 2-2: General warnings
2.5 Special types of danger and personal protective equipment 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.
B5832-01en Edition 06/2022 17

Safety instructions
2.5 Special types of danger and personal protective equipment
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.
Switch the gear unit to standstill immediately if inexplicable changes are noticed during oper-
ation. Such changes may include unusual gear unit noise or a significant increase in operat-
ing temperature.
WARNING
Risk of falling
There is an increased risk of falling when standing or walking on the gear unit during oper-
ation.
Only walk or stand on the gear unit and its mounted components for maintenance and re-
pair 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.
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Safety instructions
2.5 Special types of danger and personal protective equipment
Surface temperature
The surface temperatures of the gear unit can become very extreme depending on the oper-
ating 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).
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.
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Safety instructions
2.6 Intended use
Danger of explosion
An explosion may occur in a potentially explosive atmosphere.
DANGER
Danger of explosion through ignition of a potentially explosive atmosphere
Danger to life through ignition of a potentially explosive atmosphere possible when operat-
ing the gear unit
Do not use the gear unit in potentially explosive atmospheres.
2.6 Intended use 2.6 Intended use
Only use the gear unit according to the conditions specified in the service and delivery con-
tract and the technical data in the Annex (Page 71). Deviating operating conditions are con-
sidered improper use. The user or operator 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 that go beyond the permissible handling
described in these operating instructions. This also applies to the guards designed to
prevent accidental contact.
• Only ever use original replacement parts.
Other replacement parts are not tested and approved by Flender. Non-approved replace-
ment parts may possibly change the design characteristics of the gear unit and thus im-
pair 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 replacement parts. The same applies to any accessories which
were not supplied by Flender.
If you have any questions, please contact Customer Service (Page 63).
WARNING
Risk of falling
Risk of serious injury through falling.
Only walk or stand on the gear unit for maintenance and repair work when it is at a stand-
still. Do not walk or stand on shaft ends, protective covers, mounted components or pipe-
work.
Using the gear unit

When using the gear unit, please observe the following basic rules:
• Ensure that the gear unit is operationally safe.
• The gear unit must only be operated, maintained and repaired by authorised, trained, in-
structed and qualified personnel.
• The relevant occupational safety and environmental protection provisions must be taken
into account in transport, assembly and dismantling, operation, servicing and mainten-
ance.
20 Edition 06/2022 B5832-01en

Safety instructions
2.6 Intended use
• Cleaning the outside of the gear unit with a high-pressure cleaning device is not permit-
ted.
• Do not perform any welding work anywhere on the gear unit or connected parts. Do not
use the gear unit or connected parts as an earthing point for electric-welding operations.
Gear parts and rolling-contact bearings may be irreparably damaged by welding.
• Perform potential equalisation in accordance with the applicable regulations and direct-
ives.
If there are no threaded holes on the gear unit for an earth connection, other suitable
measures must be taken. This work must be carried out by specialists in electrical engin-
eering.
• 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 gears. 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 removing any guards, store their fixings in a safe place.
• Removed guards must be re-fitted prior to starting.
• Observe the notices mounted on the gear unit, e.g. rating plate, direction of rotation ar-
row symbol, etc. The notices must be kept free from paint or dirt. Replace missing
plates.
• Screws which have become unusable during assembly and dismantling must be re-
placed with new screws of the same strength class and design.
DANGER
Danger to life when the system is switched on
Death or serious injury will occur.
Always shut down the gear unit and any oil supply system (whether separate or attached
to the gear unit) before you perform any work. Secure the drive aggregate against being
operated accidentally as follows:
• Turn off the key-operated switch.
• Remove the fuses in the power supply.
• Attach an information notice to the start switch, clearly stating that work is being car-
ried out on the gear unit.
• Ensure that the entire system is not under a load to avoid danger during dismantling
work.
Further use of the gear unit

When integrating the gear unit in machines or systems, the machine or system manufacturer
is obliged to include the provisions, instructions and descriptions contained in this set of in-
structions in their machine instructions.
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Safety instructions
2.6 Intended use
22 Edition 06/2022 B5832-01en

Description
3
3.1 General description 3.1 General description
®
The FLENDER gear unit (referred to below simply as "gear unit") described in these operat-
ing instructions has been developed for use as a hoist and luffing gear gear unit. Potential
applications for this series of gear units include, for example, conveyors and lifting gear,
cranes and elevators.
The gear unit is available as a three-stage helical gear unit. It is designed for horizontal
mounting. The gear unit is available for other mounting positions on request.
The gear unit can be operated in both directions of rotation.
3.2 Housing 3.2 Housing
Introduction
The housing is made of cast iron.
The housing is a two-part component.
The gear unit housing has the following features:
• Attachment points for moving the gear unit
• Inspection and assembly cover for inspection and oil filling
• Oil sight glass and dipstick for checking the oil level
• Oil drain screw and/or oil drain valve for changing the oil
• Venting screw for air to pass in and out
Further information
Additional information and a detailed illustrated description of the gear unit can be found in
the dimension drawing provided in the complete gear unit documentation.
B5832-01en Edition 06/2022 23

Description
3.3 Oil supply to the gear unit
Gear unit equipment

The diagram below shows the available gear unit equipment on a type H3SH gear unit:

Figure 3-1: Gear unit equipment on type H3SH gear units
① Lifting eye ⑤ Shaft seal

② Cover ⑥ Rating plate
③ Housing ⑦ Housing fastening
④ Cover
Further information
3.3 Oil supply to the gear unit 3.3 Oil supply to the gear unit
3.3.1 Splash lubrication 3.3 Oil supply to the gear unit
Unless otherwise agreed by contract, the gearing and rolling-contact bearings are supplied
with an adequate quantity of oil by splash lubrication.
3.4 Shaft bearings 3.4 Shaft bearings
All shafts are mounted on rolling-contact bearings.
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Description
3.5 Shaft seal
3.5 Shaft seal 3.5 Shaft seal
Introduction
Depending on requirements, shaft seals prevent oil from escaping from the gear unit or dirt
from entering the gear unit.
3.5.1 Rotary shaft sealing rings 3.5 Shaft seal
Rotary shaft sealing rings are the standard seal used. Wherever possible, rotary shaft seal-
ing rings are equipped with an additional dust lip which protects the actual sealing lip against
external contaminants.
NOTICE
Irreparable damage to the rotary shaft sealing ring caused by high concentration of
dust
A damaged rotary shaft sealing ring might not be able to effectively seal the gear unit.
In very dusty atmospheres, do not use rotary shaft sealing rings unless they have addi-
tional protection.
The diagram below shows a rotary shaft sealing ring
Figure 3-2: Rotary shaft sealing ring
3.5.2 Taconite seal 3.5 Shaft seal
The Taconite seal is a combination of two sealing elements:

• Rotary shaft sealing ring to prevent the escape of lubricating oil
• Grease-filled dust seal (comprising a labyrinth and a lamellar seal) to allow operation of
the gear unit in extremely dusty environments
The Taconite seal is ideal for use in dusty environments.
NOTICE
Gear unit leaks caused by poor sealing
Regrease the labyrinth seals at the specified regreasing intervals. The regreasing intervals
are specified in the Maintenance schedule (Page 57).
B5832-01en Edition 06/2022 25

Description
3.5 Shaft seal
A Taconite seal is illustrated in the diagram below:

Figure 3-3: Taconite seal

① Labyrinth, filled with grease, can be re- ③ Lamellar seal
greased
② Grease nipple ④ Rotary shaft sealing ring
The following design variants of Taconite seal are available:
7DFRQLWH( 7DFRQLWH)

7DFRQLWH)) 7DFRQLWH).
7DFRQLWH)+
Figure 3-4: Taconite seal, variants E, F, F‐F, F‐H and F‐K
① Taconite "F-F" ③ Taconite "F-K"
② Taconite "F-H" ④ Output
The various Taconite seals are described in the following table:
26 Edition 06/2022 B5832-01en

Description
3.6 Couplings
Taconite seal versions Application Remarks
"E" All input shafts with or without fan • Regreasable labyrinth
"F" Output shaft

Design S: Solid shaft
Design V: Solid shaft, reinforced
Design F: Flanged shaft
"F-F" Output shaft • Labyrinth which can be regreased on

Design H: Hollow shaft with parallel keyway both sides, including cover to protect
against accidental contact at the gear unit
Design K: Hollow shaft with spline according to end facing away from the output shaft
DIN 5480
"F-H" Output shaft • Regreasable labyrinth on the output side,

Design H: Hollow shaft with parallel keyway dust-proof protection cover on the oppos-
ite side
Design K: Hollow shaft with spline according to
DIN 5480
"F-K" Output shaft

Design D: Hollow shaft for shrink disk
Table 3-1: Taconite seal versions
NOTICE
Sparking, inadmissible temperature rise and shaft seal wear due to insufficient gap
dimension
An insufficient gap dimension can cause sparking, inadmissible temperature rise and shaft
seal wear.
+0.5
If the shaft is sealed by Taconite seals, ensure that the set gap dimension of 1 mm on
the grease labyrinth is not changed when the input and output elements (e.g. coupling
parts) are mounted. Rotating and stationary parts must not touch.
3.6 Couplings 3.6 Couplings
Flexible couplings or torque limiters are generally used at the input end of the gear unit.
Use of rigid couplings or other input or output elements that generate additional radial or
axial forces (e.g. gear wheels, belt pulleys, flywheels or hydraulic couplings) must be agreed
contractually.
Further information
You will find further information on the couplings in the operating instructions of the coup-
lings, which are part of the complete documentation of the gear unit.
B5832-01en Edition 06/2022 27

Description
3.7 Brake
3.7 Brake 3.7 Brake
The gear unit is prepared for mounting a blocking brake. The brake drum is mounted on the
input shaft (brake shaft) of the gear unit.
Further information
You will find further information on the brake in the operating instructions for the brake, which
are part of the complete documentation of the gear unit.
3.8 Heating 3.8 Heating
Introduction
At low ambient temperatures it may be necessary to preheat the gear unit oil before switch-
ing on the drive or while it is in operation.
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. The heating ele-
ments are installed in protective tubes in the housing so that they can be replaced without
draining off the oil first.
Complete immersion of the heating elements in the oil bath must be ensured by adhering to
the installation position in accordance with the dimension drawings in the complete docu-
mentation 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 ele-
ment must not exceed the maximum values stated in the table below.
The following table contains information about the specific heat output PHO as a function of
ambient temperature:
2
PHO in W/cm Ambient temperature in °C
0.9 10 to 0
0.8 0 to -25
0.7 -25 to -50
Table 3-2: Information about the specific heat output
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Description
3.9 Oil level indicator
The diagram below shows a heating system on type H3SH gear units:

Figure 3-5: Heating on type H3SH gear units

① Temperature monitor ② Heating element
Heating element control

Heating elements can be controlled by a temperature monitor. The temperature monitor
provides a signal to be amplified when the minimum and maximum temperatures are
reached.
Further information
You can find additional information about the position of the mounted components and a de-
tailed illustration of the gear unit in the dimension drawing in the complete documentation for
the gear unit.
You can find additional information about heating elements in the separate data sheet, in the
list of equipment and in the heating element operating instructions in the complete docu-
mentation for the gear unit.
You can find additional information about the temperature monitor (such as control instruc-
tions) in the temperature monitor operating instructions in the complete documentation for
the gear unit.
3.9 Oil level indicator 3.9 Oil level indicator
The following components can be mounted to the gear unit to visually check the oil level:
• Oil sight glass
• Oil dipstick
Check the oil level when the gear unit is stationary and with the oil in a cool state.
More information
You can find additional information about the oil level indicator in the instructions 7300 in the
complete documentation for the gear unit.
B5832-01en Edition 06/2022 29

Description
3.10 Oil temperature monitoring
More information, a detailed illustration of the gear unit and the position of the mounted com-
ponents can be found in the dimension drawing in the complete documentation for the gear
unit.
3.10 Oil temperature monitoring 3.10 Oil temperature monitoring
Depending on the order specification, the gear unit can be fitted with a Pt 100 resistance
thermometer for measuring the oil temperature in the oil sump.
To measure temperatures or temperature differences, connect the Pt 100 resistance thermo-
meter to an evaluation unit (to be supplied by the customer). The resistance thermometer is
fitted with a connector head for the wiring.
Further information
Further information and a detailed illustration of the gear unit and the position of the mounted
components can be found in the dimension drawing in the complete documentation for the
gear unit.
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.
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Application planning
4
4.1 Scope of delivery 4.1 Scope of delivery
The scope of delivery is listed in the shipping documents. Immediately upon receiving the
gearbox, check that everything has been delivered. Report any damaged and/or missing
parts to Customer Services (Page 63) immediately.
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 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 incorrect attachment points.
The threads in the end faces of the shaft ends may not be used for attaching lifting equip-
ment.
• Do not use the pipework to move the gear unit.
• Ensure that the lifting equipment is adequately designed to accommodate the weight of
the gear unit.
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.
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4.3 Attachment points
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.
7KLVZD\XS )UDJLOH .HHS .HHS &HQWUHRI 'RQRW $WWDFKKHUH

GU\ FRRO JUDYLW\ XVHKDQGKRRNV
Figure 4-1: Transport symbols
4.3 Attachment points 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 ex-
ceed 45°.
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Attach slings to the lifting eyes in accordance with the specifications in the dimension draw-
ings.
Sling swivels
Threads for screwing in transport lugs are provided on the gear unit to assist with its trans-
portation during manufacture and installation.
The shear pulling must not exceed 45° when the lifting equipment is attached to sling swiv-
els.
Eye bolts
The use of sling swivels instead of eye bolts is generally recommended.
When using eye bolts, please note that their load-bearing capacity may be reduced if they
are alternately attached to different components that require moving.
It is not permitted to load eye bolts through lateral pulling contrary to the direction of the eye
plane.
The following figure shows the permissible shear and lateral pulling when using eye bolts:
r r
$ %
Figure 4-2: Shear and lateral pulling when using eye bolts
A Permitted shear pulling in direction of eye
plane (maximum angle of 45°)
B Non-permitted lateral pulling contrary to dir-
ection of eye plane
B5832-01en Edition 06/2022 33

Position of attachment points

The diagram below shows the position of the attachment points on the type H3SH gear unit:
Figure 4-3: Position of the attachment points on the type H3SH gear unit
The diagram below shows the position of the attachment points on type H3SH gear units
with motor:
Figure 4-4: Position of the attachment points on type H3SH gear units with motor
Drive units with additional components mounted on the gear unit (such as drive motor, coup-
ling, etc.) may require an extra attachment point owing to the displacement in the centre of
gravity caused by the mounted components.
Further information
You can find additional information and a detailed illustration of the gear unit, the position of
the attachment points, the centre of gravity and data on the weight in the dimension draw-
ings, which are part of the complete documentation of the gear unit.
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4.4 Special aspects of gear unit lubrication and preservation
4.4 Special aspects of gear unit lubrication and preservation 4.4 Special aspects of gear unit lubrication and preservation
4.4.1 Oil filling point and oil drain 4.4 Special aspects of gear unit lubrication and preservation
The following diagram shows the oil filling locations and oil drain locations for the gear unit:

Figure 4-5: Oil filling and oil drain
① Inspection and assembly cover ④ Oil level indicator

② Oil filling point ⑤ Oil draining point
③ Air relief point ⑥ Oil level measurement
Further information
4.4.2 Checking the oil level 4.4 Special aspects of gear unit lubrication and preservation
Carefully read and observe instructions 7300 for checking the oil level.
The gear unit is equipped with an oil level indicator (oil level screw) for visually checking the
oil level when the unit is at a standstill.
The oil level is correct when the cooled down oil is at the lower edge of the oil level screw.
B5832-01en Edition 06/2022 35

4.4 Special aspects of gear unit lubrication and preservation
36 Edition 06/2022 B5832-01en

Assembly
5
5.1 General assembly instructions 5.1 General assembly instructions
The assembly work must be performed very carefully by authorised, trained and suitably in-
structed personnel. Liability will be disclaimed for damage caused by the incorrect perform-
ance of this work.
Requirements
Improper use can damage the gear unit. Be sure to take the following precautions:
• 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.
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. Take suitable measures to ensure that
unhindered convection across the housing surface is possible so that the gear unit does not
overheat. Leave sufficient space to allow a free flow of air into gear units that are equipped
with a fan.
Do not use incorrect attachment points (Page 32). You will find the positions of the attach-
ment points in the dimension drawing, which is part of 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 drawings.
NOTICE
Heating of the gear unit by external heat sources
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
If you use a sun shield, this may cause a build-up of heat.
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Assembly
5.2 Unpacking the gear unit
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.
WARNING
Ignition of vapours emitted from solvents.
There is a risk of injury due to ignition of vapours emitted from solvents when carrying out
cleaning work.
Please note the following:
• Ensure adequate ventilation.
• Do not smoke.
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 63).
Requirement
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 pre-
serve the 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 Service (Page 63).
4. Dispose of packaging material and transport devices in accordance with regulations.
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Assembly
5.3 Gear unit assembly
5.3 Gear unit assembly 5.3 Gear unit assembly
5.3.1 Foundation 5.3 Gear unit assembly
Properties of the foundation

The foundation must have the following properties:
• Horizontal and flat
• Stability
• Designed for torsional rigidity
• Reaction forces from the gear unit must be braced
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 vibra-
tions and that it is isolated against the transmission of vibrations from adjacent founda-
tions.
• 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
Lack of stable foundation for the gear unit
Damage to the gear unit is possible if it is not mounted on a stable foundation.
Use bolts of at least strength class 8.8. Information and guidance on the tightening torque
can be found in chapter Tightening procedure (Page 48). Tighten the fastening bolts and
nuts to the specified tightening torque. When tightening the fastening bolts, make sure that
the gear unit is free of mechanical stress.
Further information
You can find additional information about dimensions, space requirements and arrangement
of supply connections in the complete documentation for the gear unit.
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Assembly
5.3.2 Description of assembly work 5.3 Gear unit assembly
CAUTION
Risk of chemical burns from chemical substances
There is a risk of chemical burns when handling aggressive cleaning agents.
Please observe the manufacturer’s instructions on how to handle cleaning agents and
solvents. Wear suitable protective equipment (gloves, safety glasses). Remove any spilled
solvent immediately with binding agents.
CAUTION
Risk of injury due to chemically aggressive operating materials
There is a risk of injury to eyes and hands when handling chemically corrosive consum-
ables.
Please observe the safety information in the data sheets of the oil used. Wear suitable pro-
tective equipment (gloves, safety glasses). Immediately clean up any spilt oil using a bind-
ing agent.
Improper use can damage the gear unit. Take the following precautions:
• Use a suitable cleaning agent to remove the corrosion protection from the shafts and ad-
joining mounting surfaces.
• Do not allow the cleaning agent to come into contact with the shaft sealing rings.
• Mount the input and output elements (e.g. coupling parts) on the shafts and lock them
securely. See chapter Couplings (Page 43).
• Use suitable hoisting gear to place the gear unit in position.
More information
Further information about removing the corrosion protection can be found in the instruc-
tions 7300 in the complete documentation for the gear unit.
You can find more information on attaching gear units to hoisting gear in cases where the
weight of the gear unit necessitates the use of hoisting gear in chapter Application planning
(Page 31).
If the gear unit is to be transported with mounted parts and components, then it may be ne-
cessary to use additional attachment points. You will find the position of these attachment
points in the order-specific dimension drawing, which is part of the complete documentation
of the gear unit.
40 Edition 06/2022 B5832-01en

Assembly
Gap dimension at the grease labyrinth

The diagram below shows the gap dimension at the grease labyrinth:

Figure 5-1: Gap dimension at the grease labyrinth
NOTICE
Sparking, inadmissible temperature rise and shaft seal wear due to insufficient gap
dimension
An insufficient gap dimension can cause sparking, inadmissible temperature rise and shaft
seal wear.
+0.5
If the shaft is sealed by Taconite seals, ensure that the set gap dimension of 1 mm on
the grease labyrinth is not changed when the input and output elements (e.g. coupling
parts) are mounted. Rotating and stationary parts must not touch.
5.3.2.1 Alignment 5.3 Gear unit assembly
Introduction
Depending on the order specification, machined surfaces (alignment surfaces) are provided
on the upper side of the housing for prealignment in the horizontal axis.
DANGER
Danger to life from flying fragments
Failure to align the unit with the required degree of accuracy can cause the shaft to rup-
ture. 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 components is possible.
The accuracy of the alignment between the shaft axes largely determines the service life of
the shafts, rolling-contact bearings and couplings. Please therefore always endeavour to
achieve zero deviation in the alignment of the shaft axes (does not apply to ZAPEX coup-
lings or cardan shafts). In this context, please also refer to the relevant operating instruc-
tions for more information about, for example, the requirements of couplings.
B5832-01en Edition 06/2022 41

Assembly
Procedure
The gear unit can be equipped with alignment threads in the housing feet to make it simpler
to align.
Figure 5-2: Alignment surface
Proceed as follows to align the gear unit at the alignment surface:

1. For the precise position of the alignment surfaces, refer to the dimension drawings in the
complete documentation.
2. Note the values inscribed in the alignment surfaces.
3. Using these alignment surfaces, horizontally align the gear unit so that perfect gear unit
operation is ensured.
The following diagram shows the alignment surfaces at the gear unit:

Figure 5-3: Alignment surfaces
① Alignment surfaces ② Alignment thread
Tools
The following tools are needed to perform the final fine alignment (Page 45) work on the
shaft axes of the gear unit and the equipment installed on the input and output sides.
• Rulers
• Spirit level
• Dial gauge
• Laser alignment system
• Feeler gauge etc.
Once the gear unit is finely aligned, tighten the foundation bolts and check the settings
again. Record the alignment dimensions and keep the report in a safe place together with
these operating instructions.
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Assembly
5.4 Couplings
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 ir-
reparable 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 5.4 Couplings
Introduction
The method used to assemble the coupling varies according to type. The procedure de-
scribed in these operating instructions is general rather than specific to one type of coupling.
Assemble the coupling as described in the operating instructions for the specific coupling.
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Assembly
5.4 Couplings
• 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 45).
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 operat-
ing 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. You will find the mounting dimensions in the
dimension drawings in the operating instructions for the coupling.
Gear units with hollow output shaft or flanged output shaft

There is no need to install the output-side coupling for gear units with a hollow output shaft
or flanged output shaft.
Mount gear units with hollow output shaft onto the shafts of the customer's driven machine.
Use a mating flange to mount gear units with flanged output shaft onto the shaft of the cus-
tomer's driven machine.
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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Assembly
5.4 Couplings
5.4.2 Aligning the coupling 5.4 Couplings
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 pre-
cautions:
• Make sure that the maximum permissible displacement values are not exceeded during
operation.
Base frames or substructures that are too soft can cause the coupling parts to become
radially or axially displaced during operation. This displacement is not measurable when
the drive is at a standstill.
– 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 per-
missible angular or radial displacement value.
The diagram below illustrates the potential displacements:
˂.D
˂.Z
˂.U
$[LDOGLVSODFHPHQW $QJXODUGLVSODFHPHQW 5DGLDOGLVSODFHPHQW

˂.D ˂.Z ˂.U
Figure 5-4: 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
• Dial gauge
B5832-01en Edition 06/2022 45

Assembly
5.5 Connecting components
• Laser alignment system

You will achieve a greater degree of alignment accuracy by using a dial gauge or laser align-
ment system.
The diagram below shows the alignment process based on the example of a flexible coup-
ling:

Figure 5-5: Alignment process based on the example of a flexible coupling
① Ruler ③ Measuring points
② Feeler gauge
Information
It is advisable to insert shims or metal sheets under the mounting feet in order to align the
drive components in the vertical direction. It is helpful to use support paws with adjusting
screws on the foundation to adjust the drive components laterally.
Gear unit with motor bell housing

If the gear unit and the motor are connected through a motor bell housing, no alignment of
the couplings is necessary.
Further information
Further information about the permissible alignment errors can be found in the coupling op-
erating instructions in the complete documentation for the gear unit, or contact the manufac-
turer in question.
5.5 Connecting components 5.5 Connecting components
5.5.1 Gear units with mounted components 5.5 Connecting components
Depending on the order specification, the gear unit can be equipped with various compon-
ents.
Connect the closed-loop control and open-loop control electrical devices corresponding to
the specifications of the device supplier.
46 Edition 06/2022 B5832-01en

Assembly
Further information
You can find additional information on operation and maintenance in the associated operat-
ing 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.
5.5.2 Connecting the heating element 5.5 Connecting components
Procedure
To connect heating elements to the gear unit, proceed as follows:
1. Check that the heating element connection is not damaged.
2. Install the electrical wiring for the heating elements.
Further information
You can find additional information about the heating in the heating operating instructions in
the complete documentation for the gear unit.
5.5.3 Connecting the Pt 100 resistance thermometer 5.5 Connecting components
Procedure
To connect the Pt 100 resistance thermometer, proceed as follows:
1. Check that the Pt 100 resistance thermometer connection is not damaged.
2. Install the electrical wiring between the Pt 100 resistance thermometer and the evalu-
ation unit. The customer is responsible for providing the evaluation unit.
Further information
Further information about the Pt 100 resistance thermometer can be found in the Pt 100 res-
istance thermometer operating instructions in the complete documentation for the gear unit.
B5832-01en Edition 06/2022 47

Assembly
5.5.4 Electrical connections 5.5 Connecting components
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 15).
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 the motors and monitoring devices according to the terminal diagram.
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.
5.6 Tightening procedure 5.6 Tightening procedure
5.6.1 Introduction 5.6 Tightening procedure
Bolts
The bolts must have the following properties:
• Made of steel
• Black-annealed or phosphatised
• Lightly oiled (do not add additional oil)
Information
Replacing bolts
Replace any bolts that are no longer fit for use by bolts of the same type and strength class.
Mating threads
The mating threads must have the following properties:
• Made of steel or cast iron
• Dry, cut threads
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Assembly
5.6 Tightening procedure
Information
Using a lubricant
As a rule, lubricants may not be used, because this can result in the bolt connection becom-
ing overloaded.
5.6.2 Bolt connection classes 5.6 Tightening procedure
In order to affix fastening bolts, note the information in the following table:
Mounting Bolt connection Scatter of the Tightening procedure

class torque emitted on
the tool
Gear unit C ± 5 % to ± 10 % • Hydraulic tightening with mech-

Motor anical screwdriver
Brake • Torque-controlled tightening with

a torque wrench or a signal-emit-
Torque arm
ting torque wrench
• Tightening with a precision

mechanical screwdriver with dy-
namic torque measurement
D ± 10 % to ± 20 % • Torque-controlled tightening with

mechanical screwdriver
Protection cover E ± 20 % to ± 50 % • Tightening with pulse screw-

Sun shield driver or impact wrench, without
adjustment checking device
Inspection cover
• Tightening by hand, using a
wrench without torque measur-
ing device
Table 5-1: Information on tightening fastening bolts
Further information
You can find additional information about tightening torques when mounting motor and brake
in the operating instructions from the particular manufacturer.
5.6.3 Tightening torques and preload forces 5.6 Tightening procedure
The specified bolted connections must be tightened to the torques stated in the table below:
The tightening torques apply to friction values of μtotal = 0.14.
The following table lists the preload forces and tightening torques for bolt connections,
strength classes 8.8; 10.9; 12.9:
B5832-01en Edition 06/2022 49

Assembly
5.6 Tightening procedure
Nominal Bolt Preload force for bolt connection Tightening torque for bolt connec-
thread dia- strength classes from the table in chapter tion classes from the table in
meter class Bolt connection classes chapter Bolt connection classes
(Page 49) (Page 49)
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
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Assembly
5.7 Final work
Nominal Bolt Preload force for bolt connection Tightening torque for bolt connec-
thread dia- strength classes from the table in chapter tion classes from the table in
meter class Bolt connection classes chapter Bolt connection classes
(Page 49) (Page 49)
d C D E C D E
mm FM min. MA
N Nm
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
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
Table 5-2: Preload forces and tightening torques
5.7 Final work 5.7 Final work
Measures
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 com-
pleted.
• Check the alignment after tightening the fastening elements. The alignment must not
have changed in any way.
• Safeguard the oil drain valves against accidental opening.
• 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.
B5832-01en Edition 06/2022 51

Assembly
5.7 Final work
• Perform potential equalisation in accordance with the applicable regulations and

guidelines. If no threaded holes are available on the gear unit for an earth connection,
please take suitable alternative measures. This work must always be done by specialist
electricians.
• Protect the cable entries against penetrating moisture.
Further information
You will find further information on the gear unit and all mounted or separately supplied com-
ponents in the operating instructions of the relevant components, which are part of the com-
plete documentation of the gear unit.
You can find additional technical specifications in the separate data sheet in the complete
gear unit documentation.
52 Edition 06/2022 B5832-01en

Commissioning
6
6.1 Measures prior to commissioning 6.1 Measures prior to commissioning
Take the following measures before commissioning the gear unit:

• Read and observe the operating instructions.
• Replace the screw plug with the air filter or the air release screw. Note the instructions
7300 for this.
• Fill the gear unit with oil.
• Check the oil level.
• Check the gear unit for leaks.
• Check whether the monitoring devices are connected and switched on.
• Ensure that all pipes and components are filled with oil.
More information
You can find additional information on oil and changing the air filter in the instructions 7300,
which are part of the complete documentation of the gear unit.
More information about individual components can be found in the operating instructions for
the components in the complete documentation for the gear unit.
6.2 Measures during commissioning 6.2 Measures during commissioning
Take the following measures when commissioning the gear unit and document them:
• Check the oil level.
• Measure the oil sump temperature (Page 59) after the gear unit has run in.
• Check the tightness of the shaft seal on the gear unit (Page 25).
• Check that all rotating parts are free to move.
• 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 that the connecting pipes are firmly seated and tight.
More information
You can find additional information on the topic of oil in the instructions 7300, which are part
of the complete documentation of the gear unit.
More information about the oil supply system can be found in the oil supply system operating
instructions contained in the complete documentation for the gear unit.
B5832-01en Edition 06/2022 53

Commissioning
6.2 Measures during commissioning
6.2.1 Gear units with heating 6.2 Measures during commissioning
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
Explosion and fire hazard
Exposed heating elements pose a fire hazard.
Do not put heating elements into service until you have checked that they are completely
immersed in the oil bath.
Further information
You can find additional information about heating elements in the heating element operating
instructions in the complete documentation for the gear unit.
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Operation
7
7.1 Operating data 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 71).
The following operating data apply to the oil:
Maximum operating temperat- 90 °C is applicable for mineral oil, API groups I or II and satur-
ure ated synthetic ester
Maximum operating temperat- 100 °C is applicable for semi-synthetic oils, API group III, PAO
ure and PG oils
Table 7-1: Operating data
Further information
You will find further information on the technical data of the gear unit in the data sheet and
the list of equipment, which are part of the complete documentation of the gear unit.
7.2 Irregularities in operation 7.2 Irregularities in operation
Introduction
Switch off the drive assembly immediately if it exhibits irregular behaviour during 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
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.
Rectifying irregularities in operation

Proceed as follows to rectify any irregularities in operation:
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Operation
7.3 Taking the unit out of service
1. Switch off the drive assembly if it exhibits irregular behaviour during operation.
2. Refer to the Fault information (Page 60) to find the cause of the fault.
3. If you still cannot determine the fault cause, contact FlenderCustomer Services
(Page 63).
7.3 Taking the unit out of service 7.3 Taking the unit out of service
If you take the unit out of service for a prolonged period, you must take the following meas-
ures depending on the length of time that the gear unit will remain out of service:
• Switch off the drive aggregate.
• Take measures to preserve the gear unit if it is to be out of service for a prolonged
period. Follow the procedure described in instructions 7300.
56 Edition 06/2022 B5832-01en

Servicing
8
8.1 General maintenance information 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 intervals for maintenance and servicing
work are not observed.
The time limits stipulated in the maintenance schedule are largely dependent on the condi-
tions of use of the gear unit. For this reason, it is only possible to state average time limits
here. These refer to the following conditions of use:
• Daily operating time 24 h
• Duty cycle “ED” 100%
• Gear unit input speed 1500 rpm
• Average oil temperature in the oil sump (see instructions 7300)
WARNING
Danger to life when the system is switched on
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 aggregate. Attach a notice stating clearly that work is being per-
formed on the gear unit.
8.2 Maintenance schedule 8.2 Maintenance schedule
Maintenance and servicing activities

The following table provides an overview of all maintenance and servicing activities that you
are required to perform continuously or at regular intervals.
Intervals and time limits Measures
As required Clean the gear unit

Clean the venting screw
Daily Check the oil temperature

Check for changes in the gear unit noise
Monthly and prior to every start-up Check for leaks

Check the oil level
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Servicing
8.3 Maintenance and servicing work
Intervals and time limits Measures
400 operating hours after commissioning Check the water content of the oil
Change the oil (or depending on the result of the oil
sample test)
Check that all of the fastening bolts are tight
Every 3 months Clean the venting screw
Every 3 000 operating hours, at least every Regrease taconite seals

6 months
Every 12 months Check the water content of the oil
Every 10 000 operating hours, at least every Replace the oil if using API Groups I or II mineral oils,
2 years or saturated synthetic ester (or depending on results
of oil sample test)
Every 2 years Carry out a general inspection of the gear unit

Check that all of the fastening bolts are tight
Clean the gear unit
Every 20 000 operating hours, at least every Change the oil if using semi-synthetic oil of API Group
4 years III, PAO or PG oil (or depending on the result of the oil
sampling)
Table 8-1: Maintenance and servicing activities
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.
8.3 Maintenance and servicing work 8.3 Maintenance and servicing work
Introduction
You can find maintenance and servicing measures relating to gear unit lubrication and pre-
servation, which are not provided in this chapter, in instructions 7300 in the complete docu-
mentation for the gear unit.
8.3.1 Clean the venting screw 8.3 Maintenance and servicing work
Cleaning interval
For dust deposits, you must clean the venting screw before the minimum interval of 3
months expires.
58 Edition 06/2022 B5832-01en

Servicing
CAUTION
Compressed air can cause injuries
There is a risk of eye injury when using compressed air.
Wear suitable safety goggles.
Procedure
Proceed as follows to clean the venting screw:
1. Remove the venting screw.
2. Do not allow foreign matter to enter the gear unit.
3. Wash the venting screw with cleaning solvent or a similar cleaning agent.
4. Dry the venting screw and blow it out using compressed air.
8.3.2 Checking the oil temperature 8.3 Maintenance and servicing work
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 (Page 55).
5. Immediately stop the gear unit if the maximum permissible oil temperature is exceeded.
Contact Flender Customer Services.
8.3.3 Cleaning the gear unit 8.3 Maintenance and servicing work
Introduction
Layers of dust may affect the dissipation of heat through the surface of the gear unit, result-
ing 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:
B5832-01en Edition 06/2022 59

Servicing
1. Use a hard brush to remove any stubborn dirt from the gear unit. Never use a high-pres-
sure cleaning device.
2. Treat any areas of corrosion.
8.3.4 General inspection of the gear unit 8.3 Maintenance and servicing work
Arrange for Flender Customer Services to inspect the gear unit. Thanks to their experience,
these engineers are best placed to assess whether and which gear unit components need to
be replaced.
8.3.5 Check that all of the fastening bolts are tight 8.3 Maintenance and servicing work
Note the following points when checking that the fastening bolts are tight:
• Observe the data regarding connection classes (Page 49), preload forces and tightening
torques (Page 49).
• Replace any bolts that are no longer fit for use by bolts of the same strength class and
type.
8.3.6 Final work 8.3 Maintenance and servicing 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 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.
Information
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.
Possible faults and how to rectify them

The following table provides an overview of the possible faults and how to rectify them.
60 Edition 06/2022 B5832-01en

Servicing
8.4 Possible faults
Possible faults Causes Possible remedies
Grease escaping at Defective rotary shaft sealing rings • Inspect the rotary shaft sealing rings and replace if ne-
the output shaft cessary
Noise Damage to the gear teeth • Contact Customer Service
• Inspect the toothed components
• If necessary, replace damaged components
The bearing play is excessive. • Contact Customer Service
• Adjust bearing play
Defective rolling-contact bearing • Contact Customer Service
• Replace defective rolling-contact bearings
Overrunning noises caused by op- • Contact Customer Service

eration on frequency converter
• Check the closed-loop motor control system
Gear unit fastening has worked • Tighten bolts and nuts to the specified tightening torque
loose
• Replace damaged bolts and nuts
Outer surface of gear Inadequate sealing of the housing • Seal housing cover or joints
unit soiled with oil cover or joints
Labyrinth seals soiled with oil, in- • Check oil filling

correct transport position
• Clean labyrinth seals
Leaks Labyrinth seals soiled with oil, in- • Check oil filling
correct transport position
• Clean labyrinth seals
Inadequate sealing of the housing • Check the seals and replace if necessary
cover or joints
• Seal housing cover or joints
Defective rotary shaft sealing rings • Check the rotary shaft sealing rings
• Replace, if necessary
Oil is foaming in the Preservation agent not completely • Change the oil
gear unit drained off
Gear unit too cold during operation • Shut down 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
• Have the oil examined by a chemical lab
• Change the oil if necessary
Oil defoamer has run out • Examine the oil
Unsuitable mixture of oils • Examine the oil
B5832-01en Edition 06/2022 61

Servicing
8.4 Possible faults
Possible faults Causes Possible remedies
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 bolts if ne-

cessary
Elevated temperature Oil level in the gear unit housing • Check the oil level
during operation too high
• If required, correct the oil level
Oil is too old • Check when the last oil change was performed
Oil is severely contaminated • Change the oil
Coolant temperature too high • Check the temperature; correct if necessary
Elevated temperature Oil level in the gear unit housing • Check the oil level at room temperature
at bearing points too low or too high
• If required, correct the oil level
Oil is too old • Check when the last oil change was performed
Defective rolling-contact bearing • Contact Customer Service
• Inspect the rolling-contact bearings and replace if neces-

sary
Elevated vibration Defective rolling-contact bearing • Contact Customer Service

amplitude at bearing
• Inspect the rolling-contact bearings and replace if neces-
points
sary
Gear wheels defective • Contact Customer Service
• Inspect the gear wheels and replace if necessary
Water in the oil 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 out-
let using structural measures.
Climatic conditions • Contact Customer Service
• Use wet-air filter if necessary
Oil foams in the oil sump • Take test tube sample to examine oil condition for water
penetration
• Have the oil examined by a chemical lab
Table 8-2: Possible faults and how to rectify them
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Service & Support
9
9.1 Contact 9.1 Contact
When ordering replacement parts, requesting a customer service technician or if you have
any technical queries, contact our factory or one of our Customer Service addresses:
Flender Industriegetriebe GmbH
Thierbacher Strasse 24
09322 Penig
Germany
Tel.: +49 (0)37381 / 61-0

Fax: +49 (0)37381 / 80286
More information
Further information about service and support can be found on the Internet:
Service & Support (https://www.flender.com/service)
B5832-01en Edition 06/2022 63

Service & Support
9.1 Contact
64 Edition 06/2022 B5832-01en

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 ac-
cording to the applicable environmental protection regulations.
B5832-01en Edition 06/2022 65

Disposal
66 Edition 06/2022 B5832-01en

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.
Information
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 which were not
supplied by Flender.
The contact address of Flender Customer Services can be found under Service & Support
(Page 63).
Information required when ordering spare parts

To order spare parts, refer to the spare-parts list. Only ever use Flender spare parts.
When ordering spare parts, please provide the following information:
• Order number with item
• Type and size
• Part number
• Quantity
B5832-01en Edition 06/2022 67

Spare parts
68 Edition 06/2022 B5832-01en

Declaration of Incorporation
A
Declaration of Incorporation Declaration of Incorporation
Business name and full address of manufacturer:

Thierbacher Straße 24
09322 Penig
Germany
Name and address of the person authorised to compile the relevant technical documentation:
Jens Klein
Thierbacher Straße 24
09322 Penig
Germany
Description and identification of the partly completed machine:

Crane gear unit
H3SH
Sizes 114 to 116
to drive machines
The following “Essential Health and Safety Requirements” from – Directive 2006/42/EC Official Journal L 157, 9 June 2006, pages 24-86,
Annex I, are applied and are fulfilled:
1.1, 1.1.2, 1.1.3, 1.1.5; 1.2.6; 1.3.1, 1.3.2, 1.3.3, 1.3.4, 1.3.6, 1.3.7, 1.3.8, 1.3.8.1; 1.4.1, 1.4.2.1, 1.5.1, 1.5.2, 1.5.4, 1.5.5, 1.5.6, 1.5.7, 1.5.8,
1.5.9, 1.5.10, 1.5.11, 1.5.13, 1.5.15; 1.6.1, 1.6.2; 1.7.1, 1.7.1.1, 1.7.2, 1.7.4, 1.7.4.1, 1.7.4.2, 1.7.4.3
The relevant technical documentation according to Annex VII Part B has been created.
The manufacturer undertakes to send national authorities electronic copies of the relevant technical documentation for the partly completed
machine following a reasoned request.
The partly completed machine may only be put into operation if it has been determined, where applicable, that the machine in which the
partly completed machine is to be incorporated meets the specifications of the Directive 2006/42/EC.
Representative for issuing this Declaration of Incorporation on behalf of the manufacturer:
Penig, 2022-06-30 Jens Klein, CEO, Flender Industriegetriebe GmbH
Translation of the Declaration of Incorporation
B5832-01en Edition 06/2022 69

70 Edition 06/2022 B5832-01en

Technical data
B
B.1 General technical data General technical data
Rating plate
The rating plate of the gear unit contains the most important technical data.

Figure B-1: Rating plate
① Company logo ⑧ Speed n2
② Serial no.: Production plant code / order ⑨ Optional DMC (Data Matrix Code)
no.-item ser. no. / year of manufacture
③ Total weight in kg ⑩ Oil data: Oil type, oil viscosity, oil quantity
④ For special information ⑪ Number(s) of operating instructions, includ-
ing issue date
⑤ Model, size ⑫ For special information
⑥ Power rating P2 in kW or torque T2 in Nm ⑬ Manufacturer documentation / Country of
origin
⑦ Speed n1 ⑭ Hotline
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 cus-
tomer.
More information
Further 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.
You can find more information on all important accessories, including their technical data in
the list of equipment drawn up specifically for the order, which is part of the complete docu-
mentation of the gear unit.
B5832-01en Edition 06/2022 71

Technical data
Ambient temperature
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.
+ 6 +
6L]H
WR
0RXQWLQJ
+ +RUL]RQWDO
9HUVLRQ2XWSXWVKDIW
6 6ROLGVKDIW
1RRIVWDJHV

*HDUXQLWW\SH
+ +HOLFDOJHDUXQLW
Further information
You can find additional information on the weights and the enveloping surface sound pres-
sure levels in chapters Weights (Page 72) and Enveloping surface sound pressure level
(Page 73).
You can find additional information about these technical data in the separate data sheet and
the dimension drawings in the complete documentation for the gear unit.
B.2 Ambient temperature Ambient temperature
Unless otherwise contractually agreed, the gear unit must not be exposed to any harmful at-
mospheres or substances such as aggressive chemical products. By applying various suit-
able 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 and specified in the
order text.
B.3 Weights Weights
The precise weights are specified in the dimension drawings in the complete documentation
or on the rating plate.
All weight specifications refer to units without oil filling or mounted components.
B.4 Oil quantities Oil quantities
Refer to the following table for the oil quantity (approximate values, in litres) for a gear unit in
horizontal mounting position.
72 Edition 06/2022 B5832-01en

Technical data
Enveloping surface sound pressure level
Type Gear unit size
114 115 116
H3SH 165 205 245
Table B-1: Oil quantities
B.5 Enveloping surface sound pressure level Enveloping surface sound pressure level
The gear unit complies with a sound power level, which places it in a gear unit type class
defined in VDI 2159, which is applied to produce the 80 % characteristic curve of the emis-
sion characteristic map.
You can assume with statistical certainty that the limit values are complied with under the
specified Flender test conditions.
B5832-01en Edition 06/2022 73

Technical data
Enveloping surface sound pressure level
74 Edition 06/2022 B5832-01en

Index
A H
Attachment points, 37 Heating
Commissioning, 54
Connecting the heating element, 47
C Design, 29
Coloured markings, 16 Function, 28
Copyright, 13 Heating elements, 28
Coupling, 27 Temperature monitor, 29
D I
Danger of explosion, 20 Integration note, 21
Disclaimer, 12 Interval, 57
Disposal, 65 Irregularities in operation, 55
Documentation landscape, 13
L
E Lateral pulling, 33
Environmental protection, 65 Lubricant, 14
Equipment features, 23
Eye bolts, 33
M
Maintenance activities, 57
F Maintenance information, 57
Fastening bolts, 60 Maintenance schedule, 57
Bolt connection class, 49 Measures
Bolts, 48 during commissioning, 53
Mating threads, 48 Prior to commissioning, 53
Preload force, 49 Mounted components, 46
Tightening procedure, 49 Mounting position, 37
Tightening torque, 49
Fault, 60
Fault rectification, 60 N
Final work, 51 Note about assembly, 37
G O
Gear unit equipment, 24 Oil, 14
Gear unit housing, 23 Check the oil level, 35
Gear unit markings, 16 Oil draining point, 35
Gear unit use, 20 Oil filling points, 35
General inspection of the gear unit, 60 Oil level indicator, 29
Oil temperature, 59
B5832-01en Edition 06/2022 75

Index
Oil temperature monitoring

Connecting the resistance thermometer, 47
Resistance thermometer, 30
Operating data
Compliance with, 55
Oil, 55
Ordering spare parts, 67
P
Protective equipment, 18
R
Rating plate, 71
Type and size, 72
Rotary shaft sealing ring, 25
S
Safety rules, 15
Scope of delivery, 31
Servicing activities, 57
Shaft bearings, 24
Shaft seal, 25
Shear pulling, 33
Shipping documents, 31
Splash lubrication, 24
T
Taconite seal, 25
Taking out of service, 56
Technical specifications, 71
Transport information, 31
Transport symbols, 32
Troubleshooting, 60
Types of danger, 17
U
Unpacking, 38
Used oil, 65
V
Venting screw, 58
W
Warning symbols, 17
76 Edition 06/2022 B5832-01en

Crane gear unit
Assembly and operating instructions B5832-01en
Edition 06/2022
Flender GmbH
Alfred-Flender-Straße 77
46395 Bocholt
Germany

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Crane gear unit

Assembly and operating instructions B5832-01en

1.1 Legal information .....................................................................................................................11

1.2 General information .................................................................................................................12

1.3 Lubricants ................................................................................................................................14

2 Safety instructions ...................................................................................................................................15

2.1 Security notes ..........................................................................................................................15

2.2 The five safety rules .................................................................................................................15

2.3 General information .................................................................................................................15

2.4 General warnings and symbols................................................................................................17

2.5 Special types of danger and personal protective equipment ................................................... 17

2.6 Intended use ............................................................................................................................20

3.1 General description ..................................................................................................................23

3.2 Housing ....................................................................................................................................23

3.3 Oil supply to the gear unit ........................................................................................................24

3.4 Shaft bearings..........................................................................................................................24

3.5 Shaft seal .................................................................................................................................25

3.6 Couplings .................................................................................................................................27

3.9 Oil level indicator......................................................................................................................29

3.10 Oil temperature monitoring ......................................................................................................30

4 Application planning ................................................................................................................................31

4.1 Scope of delivery .....................................................................................................................31

4.3 Attachment points ....................................................................................................................32

B5832-01en Edition 06/2022 3

4.4 Special aspects of gear unit lubrication and preservation........................................................ 35

5.1 General assembly instructions .................................................................................................37

5.2 Unpacking the gear unit ...........................................................................................................38

5.3 Gear unit assembly ..................................................................................................................39

5.4 Couplings .................................................................................................................................43

5.5 Connecting components ..........................................................................................................46

5.6 Tightening procedure ...............................................................................................................48

5.7 Final work.................................................................................................................................51

6.1 Measures prior to commissioning ............................................................................................53

6.2 Measures during commissioning .............................................................................................53

7.1 Operating data .........................................................................................................................55

7.2 Irregularities in operation .........................................................................................................55

7.3 Taking the unit out of service ...................................................................................................56

8.1 General maintenance information............................................................................................57

8.2 Maintenance schedule .............................................................................................................57

8.3 Maintenance and servicing work..............................................................................................58

4 Edition 06/2022 B5832-01en

8.3.1 Clean the venting screw...........................................................................................................58

8.4 Possible faults ..........................................................................................................................60

9 Service & Support.....................................................................................................................................63

11 Spare parts ................................................................................................................................................67

A.1 Declaration of Incorporation.....................................................................................................69

B.1 General technical data .............................................................................................................71

B.2 Ambient temperature ...............................................................................................................72

B.3 Weights ....................................................................................................................................72

B.4 Oil quantities ............................................................................................................................72

B.5 Enveloping surface sound pressure level ................................................................................ 73

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6 Edition 06/2022 B5832-01en

Table 2-1 Symbols and markings ...............................................................................................................16

Table 2-2 General warnings .......................................................................................................................17

Table 3-1 Taconite seal versions................................................................................................................27

Table 3-2 Information about the specific heat output .................................................................................28

Table 5-1 Information on tightening fastening bolts ...................................................................................49

Table 5-2 Preload forces and tightening torques .......................................................................................50