9138en

FLENDER gear units

Vertical­mill gear unit

KMPSizes 180 to 450

Assembly and operating instructionsBA 9138 EN 12/2010

2 / 44BA 9138 EN 12/2010

Vertical­mill gear unit

KMPSizes 180 to 450

Assembly and operating instructions

Translation of the original assembly and operating instructions

Technical data

Spare parts,customer service

Maintenanceand repair

Faults, causesand remedy

Operation

Start­up

Fitting

Technicaldescription

Transport andstorage

Safety instructions

General notes

Declarations

1

12

11

10

9

8

7

6

5

4

3

2

3 / 44BA 9138 EN 12/2010

Notes and symbols in these assembly and operating instructions

Note: The term "Assembly and operating instructions" will in the following also be shortened to "instructions"or "manual".

Legal notes

Warning note concept

This manual comprises notes which must be observed for your personal safety and for preventing material damage.Notes for your personal safety are marked with a warning triangle or an "Ex" symbol (when applyingDirective 94/9/EC), those only for preventing material damage with a "STOP" sign.

WARNING! Imminent explosion!

The notes indicated by this symbol are given to prevent explosion damage.Disregarding these notes may result in serious injury or death.

WARNING! Imminent personal injury!

The notes indicated by this symbol are given to prevent personal injury.Disregarding these notes may result in serious injury or death.

WARNING! Imminent damage to the product!

The notes indicated by this symbol are given to prevent damage to the product.Disregarding these notes may result in material damage.

NOTE!

The notes indicated by this symbol must be treated as general operating information.Disregarding these notes may result in undesirable results or conditions.

WARNING! Hot surfaces!

The notes indicated by this symbol are made to prevent risk of burns due to hot surfacesand must always be observed.Disregarding these notes may result in light or serious injury.

Where there is more than one hazard, the warning note for whichever hazard is the most serious is always used.If in a warning note a warning triangle is used to warn of possible personal injury, a warning of material damage maybe added to the same warning note.

Qualified personnel

The product or system to which these instructions relate may be handled only by persons qualified for the workconcerned and in accordance with the instructions relating to the work concerned, particularly the safety andwarning notes contained in those instructions. Qualified personnel must be specially trained and have theexperience necessary to recognise risks associated with these products or systems and to avoid possible hazards.

4 / 44BA 9138 EN 12/2010

Intended use of Siemens products

Observe also the following:

Siemens products must be used only for the applications provided for in the catalogue and the relevanttechnical documentation. If products and components of other makes are used, they must berecommended or approved by Siemens. The faultfree, safe operation of the products calls for propertransport, proper storage, erection, assembly, installation, start­up, operation and maintenance. Thepermissible ambient conditions must be adhered to. Notes in the relevant documentations must beobserved.

Trademarks

All designations indicated with the registered industrial property mark ® are registered trademarks of Siemens AG.Other designations used in these instructions may be trademarks the use of which by third parties for their ownpurposes may infringe holders’ rights.

Exclusion of liability

We have checked the content of the instructions for compliance with the hard­ and software described.Nevertheless, variances may occur, and so we can offer no warranty for complete agreement. The informationgiven in these instructions is regularly checked, and any necessary corrections are included in subsequent editions.

Symbols

Earth connection point Air relief point yellow

Oil­filling point yellow Oil­draining point white

Oil level red Oil level red

Oil level redConnection forvibration­monitoring device

Lubrication point red Apply grease

Lifting eye Eye bolt

Do not unscrew

Alignment surface, horizontal Alignment surface, vertical

These symbols indicate the oil­level checking procedure using the oil dipstick.

These symbols indicate that the oil dipstick must always be firmly screwed in.

5 / 44BA 9138 EN 12/2010

Contents

1. Technical data, rating plate 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 General technical data 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Measuring­surface sound­pressure level 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. General notes 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Introduction 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Copyright 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Safety instructions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Obligations of the user 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Environmental protection 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Special dangers and personal protective equipment 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Transport and storage 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Scope of supply 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Transport 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Storing the gear unit 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.1 Preservation (preservation time < 24 months) 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.2 Long­term preservation (preservation time > 24 months) 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.2.1 Preparatory work 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.2.2 Filling with oil 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.2.3 Durability of the internal gear unit preservation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Technical description 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 General description 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Lubrication 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.1 Hydrodynamic lubrication 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.2 Hydrodynamic lubrication and hydrostatic starting aid 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.2.1 Hydrostatic lubrication system with radial piston pump 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Sealing 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Drive coupling 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Fitting 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 General information on fitting 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Installation conditions 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.1 Dimensions and weights 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.2 Lifting device 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Preparatory measures for gear unit installation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3.1 Maintaining preservation if the gear unit has been opened in the meanwhile 19. . . . . . . . . . . . . . . . .

6.3.2 Foundation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 Gear­unit installation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 Installing the pipework 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6 Pickling of adapted pipes 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7 Installing the couplings 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8 Installing the motor 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9 Fitting add­on parts delivered loosely with the unit 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.10 Welding work on the mill 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11 Final work 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 / 44BA 9138 EN 12/2010

7. Start­up 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Procedure before start­up 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.1 Depreservation of the gear unit 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.2 Flushing before initial start­up 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.3 Oil filling 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.4 Oil quantity 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.4.1 Oil quantity for flushing 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.4.2 Oil quantity for initial start-up 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.5 Oil­supply system 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.6 Checks before start­up 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 Start­up 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2.1 Pre­lubrication phase 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2.2 Initial start­up 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2.3 Checking procedure 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 Removal from service 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3.1 Preservation during longer periods of non­use 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3.1.1 Interior preservation with preservative agent 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3.1.2 Interior­preservation procedure 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3.1.3 Interior preservation by oil filling 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3.2 Exterior preservation 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3.2.1 Exterior­preservation procedure 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Operation 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 General 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Irregularities 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. Faults, causes and remedy 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 General information on faults and malfunctions 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 Possible faults 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. Maintenance and repair 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 General notes on maintenance 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2 Cleaning the gear­unit surface 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.3 Clean the air filter 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.3.1 Replacing the air­filter cartridge 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.4 Flushing 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.5 Oil filling 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.6 Inspection 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.7 Maintenance 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.7.1 Examine water content of oil / conducting oil analyses 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.7.2 Change oil 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.7.3 Checking tightness of the foundation bolts 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.8 General inspection of the gear unit 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.9 Welding work on the mill 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.10 Vibration measurements 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.11 Repair 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.12 Lubricants 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11. Spare parts, customer­service 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Stocking spare parts 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2 Spare parts and customer­service addresses 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12. Declarations 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1 Declaration of incorporation 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 / 44BA 9138 EN 12/2010

1. Technical data, rating plate

1.1 General technical data

The most important technical data are shown on the rating plate. These data and the contractualagreements between Siemens and the customer for the gear unit determine the limits of its correct use.

①

②

③ ④

⑤ ⑥

⑦ ⑧

⑨

⑩

⑪

⑫⑬

Fig. 1: Rating plate gear unit

① Company logo ⑧ Speed n2

② Order number, item, sequence number, year built ⑨ Oil data

③ Total weight in kg (oil type, oil viscosity, oil quantity)

④ Special information ⑩ Instructions number(s)

⑤ Type, size *) ⑪ Special information

⑥ Power rating P2 in kW or torque T2 in Nm ⑫ Manufacturer and place of manufacture

⑦ Speed n1 ⑬ Country of origin

*) Example

K M P 180

Size 180 ... 425. . . . . . . . . . . . . . . . . . . . . .

Types P = Planetary stage. . . . . . . . . . . . . . . . . . . . .

Application Vertical mill. . . . . . . . . . . . . . . .

Type Bevel­gear unit. . . . . . . . . . . . . . . . . . . . . .

For details regarding weight and further technical data, please refer to the drawings in the gear­unitdocumentation and the order­specific data sheet.

1.2 Measuring­surface sound­pressure level

A measuring­surface sound­pressure level cannot be specified, as during the test run the gear unit isoperated on the Siemens test rig without load.

8 / 44BA 9138 EN 12/2010

2. General notes

2.1 Introduction

These instructions are an integral part of the gear unit supplied and must be kept in its vicinity for referenceat all times.

All persons carrying out work on the gear unit must have read and understood theseinstructions and must adhere to them. Siemens accepts no responsibility for damageor disruption caused by disregard of these instructions.

The "FLENDER vertical­mill gear unit" described in these Instructions has been designed for drivinga mud pump.

The gear unit is designed only for the application specified in section 1, "Technical data". Other operatingconditions must be contractually agreed.

The gear unit has been manufactured in accordance with the state of the art and is delivered in a conditionfor safe and reliable use.

The gear unit must be used and operated strictly in accordance with the conditions laid down in the contractgoverning performance and supply agreed by Siemens and the customer.

The gear unit described in these instructions reflects the state of technical development at the time theseinstructions went to print.

In the interest of technical progress we reserve the right to make changes to the individual assemblies andaccessories which we regard as necessary to preserve their essential characteristics and improve theirefficiency and safety.

2.2 Copyright

The copyright to these instructions is held by Siemens AG.

These instructions must not be wholly or partly reproduced for competitive purposes, used in anyunauthorised way or made available to third parties without our agreement.

Technical enquiries should be addressed to the following works or to one of our customer services:

Siemens AGAm Industriepark 246562 Voerde

Tel.: +49 (0)2871 / 92‐0Fax: +49 (0)2871 / 92‐1544E‐mail: [email protected]

9 / 44BA 9138 EN 12/2010

3. Safety instructions

Entry to the gear unit and its added components is not permitted during operation!Entry for maintenance and repair work is only permitted when the gear unit is ata standstill!Caution! Risk of falling!

Any changes on the part of the user are not permitted. This applies equally to safetyfeatures designed to prevent accidental contact.

3.1 Obligations of the user

• The operator must ensure that everyone carrying out work on the gear unit has read and understoodthese instructions and is adhering to them in every point in order to:

─ avoid injury or damage.

─ ensure the safety and reliability of the unit.

─ avoid disruptions and environmental damage through incorrect use.

• During transport, assembly, installation, dismantling, operation and maintenance of the unit, therelevant safety and environmental regulations must be complied with at all times.

• The gear unit may only be operated, maintained and/or repaired by persons qualified for the workconcerned (see "Qualified personnel" on page 3 of this manual).

• The outside of the gear unit must not be cleaned with high­pressure cleaning equipment.

• All work must be carried out with great care and with due regard to safety.

All work on the gear unit must be carried out only when it is not in operation.The drive unit must be secured against being switched on accidentally (e.g. by lockingthe key switch or removing the fuses from the power supply). A notice should beattached to the start switch stating clearly that work is in progress.

• No electrical welding work must be done at all on the drive.The drives must not be used as an earthing point for welding operations. Toothed parts and bearingsmay be irreparably damaged by welding.

• A potential equalisation in accordance with the applying regulations and directives must be carried out!If no threaded holes for earth connection are available on the gear unit, other appropriate measuresmust be taken. This work must always be done by specialist electricians.

If any inexplicable changes are noticed during operation of the gear unit, such as animportant increase in temperature or unusual noises, the drive assembly must beswitched off immediately.

Rotating and/or movable drive components must be fitted with suitable safeguards toprevent contact.

When the gear unit is incorporated in plant or machinery, the manufacturer of suchplant or machinery must ensure that the contents of these instructions areincorporated in his own instructions.

10 / 44BA 9138 EN 12/2010

• Removed safety equipment must be re­installed prior to starting up.

• Notices attached to the gear unit, e.g. rating plate, direction arrows etc., must always be observed.They must be kept free from dirt and paint at all times. Missing plates must be replaced.

• Screws which have been damaged during assembly or disassembly work must be replaced with newones of the same strength class and type.

• Spare parts should always be obtained from Siemens (refer also to section 11).

3.2 Environmental protection

• Dispose of any packing material in accordance with regulations or separate it for recycling.

• When changing oil, the used oil must be collected in suitable containers. Any pools of oil which mayhave collected should be removed at once with an oil­binding agent.

• Preservative agents should be stored separately from used oil.

• Used oil, preservative agents, oil­binding agents and oil­soaked cloths must be disposed of inaccordance with environmental legislation.

• Disposal of the gear unit after its useful life:

─ Drain all the operating oil, preservative agent and/or cooling agent from the gear unit and disposeof in accordance with regulations.

─ Depending on national regulations, gear­unit components and/or add­on parts may have to bedisposed of or sent for recycling separately.

3.3 Special dangers and personal protective equipment

• Depending on operating conditions, the surface of the gear unit may heat up or cool down to extremetemperatures.

In case of hot surfaces (> 55 °C) there is a risk of burns!

In case of cold surfaces (< 0 °C) there is a risk of frost injury (pain, numbness,frostbite)!

During oil changes there is a risk of scalding from escaping oil!

Small foreign matter such as sand, dust, etc. can get into the cover plates of therotating parts and be thrown back by these.Risk of eye injury!

In addition to any generally prescribed personal safety equipment (such as safety shoes,safety clothing, helmet) handling the gear unit requires wearing suitable safety gloves andsuitable safety glasses!

The gear unit is not suitable for operation in explosion hazard locations. It must underno circumstances be used in such locations because of the risk to life and limb.

When handling oils and/or preservative agents, protective gloves and safety glassesmust always be worn! The oil must not come into contact with the skin (e.g. theoperator’s hands).The safety notes on the data sheets for the oil used must be observed here!

11 / 44BA 9138 EN 12/2010

4. Transport and storage

Observe the instructions in section 3, "Safety instructions"!

4.1 Scope of supply

The products supplied are listed in the despatch papers. Check immediately on receipt to ensure that allthe products listed have actually been delivered. Parts damaged and/or missing parts must be reportedto Siemens in writing immediately.

If there is any visible damage, the gear unit must not be put into operation.

4.2 Transport

When transporting our products, use only lifting and handling equipment of sufficientload­bearing capacity!Observe the notes regarding load distribution on the packing.

The gear unit is delivered in the fully assembled condition and without oil filling. Additional items (e.g. pipesand fittings) can be delivered separately packaged.

Different forms of packaging may be used, depending on the size of the unit and method of transport.Unless otherwise agreed, the packaging complies with the HPE Packaging Guidelines.

The symbols marked on the packing must be observed at all times. These have the following meanings:

Top Fragile Keep dry Keep cool Centre ofgravity

Use no handhook

Attachhere

Fig. 2: Transport symbols

Transport of the gear unit must be carried out so as to avoid personal damage anddamage to the gear unit.If, for example, the free shaft ends are knocked, this may damage the gear unit.

Gear units provided with pipework must be transported with especial care.

The gear unit must be transported using suitable equipment only. During transport the gear unitshould be left without oil filling and on the transport packing.

Use only the eyes provided to attach lifting equipment to the unit. Attach slings withshackles to the eyebolts.Slinging and lifting gear must be adequate for the weight of the gear unit.To prevent the housing, output flange and pipework from being damaged by thedeflection of the transport rope, wooden blocks must be placed under the rope.The output flange of the gear unit must never be lifted.

12 / 44BA 9138 EN 12/2010

1 1

Fig. 3: Attachment points

1 Wooden block

For a detailed illustration of the gear unit and the position of the attachment points, please referto the drawings of the order­specific gear­unit documentation.

4.3 Storing the gear unit

The gear unit must be stored in a sheltered place in the position of the original packaging or in the positionof use, placed on a vibration­free, dry base, and covered over.

When temporarily storing the gear unit and any single components supplied with it,the preservative agent should be left on them. It must not be damaged, otherwise thereis a risk of corrosion.

Do not stack gear units on top of one another.

If the gear unit is being stored out of doors, it must be particularly carefully covered,and care must be taken that neither moisture nor foreign material can collect on theunit.

Unless otherwise agreed by contract, the gear unit must not be exposed to harmfulenvironmental factors such as chemical products.

Provision for special environmental conditions during transport (e.g. transport by ship) andstorage (climate, termites, etc.) must be contractually agreed.

13 / 44BA 9138 EN 12/2010

4.3.1 Preservation (preservation time < 24 months)

The gear unit is provided with an interior preservative agent; the free shaft end is painted for protection.

The properties of the outer paint coat are as follows: Resistant to acids, weak alkalis, solvents,atmospheric action, temperatures up to 120 °C / 248 °F (briefly up to 140 °C / 284 °F), and to tropicalconditions.

Corrosion prevention times depend on the kind of packing and the place of installation and/orstorage (see item 4.3.2.3).

If the corrosion prevention time is exceeded, the internal and external preservation must be renewed(see section 7, "Start­up").

The labyrinth seals on the input shaft and output flange are additionally sealed with adhesive tape.

The adhesive tape on the labyrinth seals must not be removed until just before themachine is started up.

4.3.2 Long­term preservation (preservation time > 24 months)

One possible long­time preservation method to be recommended is to completely fill the gear unit withpreservative oil (here Siemens must be consulted).

4.3.2.1 Preparatory work

To seal the labyrinth seal on the input shaft, a sealing cap must be fitted to the gear unit and sealed.

The oil drain of the sealing cap must be sealed with a screw plug.

The breather in the sealing cap must remain open during the oil filling (see item 4.3.2.2) until the oil runsover. Then this too must be sealed.

The lower drain cock on the gear unit must be fitted and sealed with a screw plug.

The pressure and suction lines mst be sealed with blank flanges.

1 3

5

8

9

2 7 4

6 10

1 3

5

8

9

2 7 4

6 10

Fig. 4: Gear­unit features for preservation measures

1 Breather of sealing cap 6 Oil drain (tilting pad thrust bearing chamber)2 Oil drain of sealing cap 7 Oil drain (gear unit)3 Sealing cap 8 Pressure line (gear unit)4 Indication of oil level (gear unit) 9 Pressure line (tilting pad thrust bearing chamber)5 Suction line (gear unit) 10 Indication of oil level

(tilting pad thrust bearing chamber)

The air filter for the gear unit must be replaced and sealed with a screw plug.

The air filter on the tilting­pad thrust bearing chamber serves for ventilation during the oil filling. If the airfilter has been replaced with a screw plug, the screw plug must be removed in any case. When the fillingoperation has finished, the air filter must be replaced with a screw plug or the tapped hole sealed witha screw plug.

14 / 44BA 9138 EN 12/2010

4.3.2.2 Filling with oil

The oil to be put in must be filtered beforehand with a 25 μm (0.0010 inch) filter gauge.

The service oil of the gear unit with the corresponding high viscosity (see rating plate) can alsobe used as a preservative oil.For easier filling, it is recommended to use an oil of lower viscosity, although this is not suitablefor later operation of the gear unit and so must be completely drained off.In both cases of oil grade and/or viscosity selection (high or low viscosity) reuse andpreparation after a correspondingly long preservation or storage period (> 24 months) must beclarified with the oil manufacturer.

The gear unit must be filled with oil via the oil­drain cock of the tilting­pad thrust bearing.

During filling care must be taken that the breather of the sealing cap on the input shaft is not sealed untiloil emerges from it. After sealing the oil filling can be continued.

If oil emerges from the labyrinth seal of the tilting­pad thrust bearing chamber, the oil flow quantity mustbe reduced.

The gear unit is not completely filled until during filling oil alone (without air) escapes from the upper air ventof the tilting pad thrust bearing chamber.

After complete filling the upper oil­drain cock (tilting­pad thrust bearing chamber) must be closed andsealed with a screw plug.

Remove any oil spillage immediately with an oil­binding agent!Oil leaks occurring during filling must be stopped immediately!The local environmental protection requirements of the country concerned must beobserved.

The long­time preservation with oil filling is suitable for a period of 10 years. After 10 years the oil filling mustbe completely renewed.

The gear unit must be inspected for leaks at regular intervals.

Before starting up the gear unit the oil must be drained off at the oil drain on the tilting­pad thrust bearingchamber and the oil drain on the gear unit base. Then installation and start­up must be carried out inaccordance with these operating instructions.

15 / 44BA 9138 EN 12/2010

4.3.2.3 Durability of the internal gear-unit preservation

The following table shows the durability of the internal gear-unit preservation, depending on the packingand the place of installation or storage.

If the unit is stored out of doors without packing, item 4.3 in particular must be observed.

For internal gear-unit preservative agent, see technical data.

Table 1: Durability of the internal gear-unit preservation

Internalgear­unit

preservativeagent

Duration ofprotection

Climatic zoneat the place ofinstallation or

storage

Kind of transport

Minimum measures

on thegear unit

for thepacking

at the placeof

installationor storage

Tribol1390/220

up to6 months

A not including sea transport

A1 B2 C2

or

A1 B3 C1

A including sea transport A1 B2 C2

Bnot including sea transport

A1 B2 C2including sea transport

up to12 months

Anot including sea transport A1 B2 C2

including sea transport A2 B3 C2

Bnot including sea transport

A2 B3 C2including sea transport

up to24 months

Anot including sea transport A2 B2 C3

including sea transport A2 B3 C3

Bnot including sea transport

A2 B3 C3including sea transport

A

A

B

North pole 90° N

South pole 90° S

Arctic Circle 66.5° N

Antarctic Circle 66.5° S

Northern Tropic 23.5° N

Southern Tropic 23.5° S

Equator 0°

Table 2: Packaging and Place of installation or storage

Measureson the gear unit

PackingPlace of installation/

storageSpecial

measures

A1no special measures(gear unit in normalassembled condition).

B1nopackaging.

C1unprotectedout of doors.

D1

Specification byagreement(statement aboutprotection timesin agreement withthe customerunder preciselystipulatedconditions.Description in theSiemens orderconfirmation)

A2Close gear unit (as A1, but close breathers,seal labyrinths).

B2plaintransport packing..

C2covered overorcovered.

B3seaworthypacking.. 1) C3 in enclosed space.

1) On reception of the goods the seaworthy packing must be inspected for damage.If damaged, the packing must be restored to its seaworthy condition.

The higher the numbers affixed to the letters of the subitems are, the better the corrosion prevention.

16 / 44BA 9138 EN 12/2010

5. Technical description

Observe the instructions in section 3, "Safety instructions"!

5.1 General description

The KMP type vertical­mill gear unit is a bevel­gear planetary gear unit for driving a vertical mill.

The axial forces resulting from the grinding process are conducted via the gear­unit housing to thefoundation.

A detailed view of the gear unit can be obtained from the drawings in the gear­unit documentation.

For operation and maintenance, always observe the operating instructions indicatedin the order­specific appendix.For technical data, refer to the order­specific documents.

5.2 Lubrication

Lubrication and cooling is provided by continuous oil circulation from a separate oil­supply system.

The technical data on the oil­supply system are specified in the list of equipment of theoil­supply system.When operating and servicing the components of the oil­supply system, observe theoperating instructions of the oil­supply system.

The type of lubrication is specified in the order­specific list of equipment.

Toothed parts and rolling bearings are force­lubricated and cooled via the low­forced lubrication circuit.

5.2.1 Hydrodynamic lubrication

If ambient temperatures are low, the oil must be prewarmed. If contractually agreed, immersion heaterswill be fitted in the gear­unit housing or the oil tank, or a separate heating circuit will be provided.

The oil is drawn in by the oil pump, cleaned in the double­changeover filter, which is fitted with an opticaland electrical contamination indicator, then cooled in the cooler and conducted to the lubricating points.The oil flow is divided by valves or orifice plates for the lubrication of the gears and tilting­pad thrust bearing.

Volumetric flow, pressure and temperature are constantly monitored by monitoring equipment. To preventvibration and compensate for heat expansion, compensators are provided for in the pipe system.

17 / 44BA 9138 EN 12/2010

5.2.2 Hydrodynamic lubrication and hydrostatic starting aid

In addition to the hydrodynamic lubrication, part of the oil is fed immediately downstream of the cooler tothe high­pressure pumps via a branch circuit.

The pumps are radial­piston pumps and deliver a constant oil quantity at each connection. The oil isconducted to four axial thrust bearing segments distributed around the circumference. Before the mill isstarted, the oil is pumped between the pads and the race. A bearing oil film will form immediately. After2 minutes' operation at operating speed the high­pressure pump can be turned off.

Pressure switches monitor this operating phase and the non­return valves built into the pads prevent theoil from backing up during normal operation.

5.2.2.1 Hydrostatic lubrication system with radial piston pump

In addition to the hydrodynamic lubrication, part of the oil is fed immediately downstream of the cooler tothe high­pressure pumps via a branch circuit.

The pumps are radial­piston pumps and deliver a constant oil quantity at each connection. The same oilquantity is supplied to each bearing pad independently of the counterpressure. The oil connections aredistributed so that no two adjacent pads are supplied by one pump. In this way the drive can be bypassedwhile the failed pump is being replaced.

To ensure that the pumps are operating and no oil line is defective, the oil flows are monitored for minimumpressure. The pressure at the pressure gauge is adjusted by the pressure actually exerted by the grindingrollers.

If the minimum setting of a pressure­ or flow­monitored component is fallen below, the main drive isswitched off. The non­return valves built into the pads prevent the oil from backing up during normaloperation.

5.3 Sealing

The input shaft and output flange are sealed with labyrinth seals. Air filters are provided on the housing toregulate the pressure.

5.4 Drive coupling

A flexible coupling is to be provided for the gear unit drive. For maintenance and operation of the coupling,refer to the operating instructions for the coupling.

18 / 44BA 9138 EN 12/2010

6. Fitting

Observe the instructions in section 3, "Safety instructions"!

6.1 General information on fitting

When transporting the gear unit observe the notes in section 4.

Adequate lifting equipment must be available before beginning the fitting work.

Fitting to the mill must be undertaken under the supervision of Siemens specialists orby suitably trained specialists authorised by Siemens.

No liability can be accepted for damage resulting from incorrect installation by non­FLENDER staff.

The operator should ensure that no foreign bodies affect the proper function of thegear unit (e.g. falling objects or heaping over).

When fitting in the vertical mill, the mill manufacturer's special instructions must beobserved.

6.2 Installation conditions

As early as during the planning phase, sufficient space must be allowed around the gear unit for latermounting, care and maintenance work.

Care must be taken that the oil can be drained and an adequate air supply is provided. It must be possibleto check the internal parts through the holes in the inspection hole covers.

Machines located up­ and downstream are to be arranged accordingly.

If the pipes connecting the gear unit and oil­supply system are included in the Siemens delivery, theinstallation plan is enclosed with the documentation.

All the fastening points provided by the design of the unit must be used.Screws which have been damaged during assembly or disassembly work must bereplaced with new ones of the same strength class and type.

6.2.1 Dimensions and weights

For details regarding weight and further technical data, please refer to the drawings in the gear­unitdocumentation and the order­specific data sheet.

6.2.2 Lifting device

Adequate lifting equipment must be available before beginning the fitting work.

The load­bearing capacity of the lifting gear to be installed and used must correspond at least to the weightof the gear unit (for details see section 1, "Technical data").

Refer to section 4 for notes regarding transport.

19 / 44BA 9138 EN 12/2010

6.3 Preparatory measures for gear unit installation

The packing must be removed before the gear unit is installed in the vertical mill. The adhesive tape on thelabyrinths must not be removed until the gear unit is started up.

Opening the gear unit (e.g. removing the adhesive tape on the input shaft or on theoutput flange, or opening a cover) reduces the guaranteed life of the preservative(see item 6.3.1).

If the gear unit is opened (e.g. the adhesive tape on the labyrinth seal of the input shaft and/or the outputflange or a cover or a screw plug is opened), the gear unit must be started up within a week.

The input shaft of the gear unit must be rotated for positioning during installation onlywhen the tilting­pad thrust bearing chamber is filled with oil up to the specified level.

The gear unit must be cleaned on the outside and all preserved surfaces washed down with a solvent,e.g. benzine.

To ensure function (coefficient of friction), the contact surfaces of the gear unit andfoundation must be cleaned.

Ensure adequate ventilation. Do not smoke!Danger of explosion!

If start­up is delayed, special measures are necessary to maintain preservation (see item 6.3.1).

6.3.1 Maintaining preservation if the gear unit has been opened in the meanwhile

If a gear unit which has been opened in the meanwhile is left standing without transport packing in anunprotected, but covered environment for longer than a week and the gear unit cannot be flushed out forone hour and turned for 15 minutes every 2 days, the preservation can partly be maintained by proceedingas follows:

• If the gear unit has not not been flushed out, it must be closed airtight (covering the labyrinth seal of theinput shaft and the output flange with adhesive tape; replacing air filters with screw plugs; if applicable,closing pipe holes airtight).

The following preservation times can then be guaranteed:

• Zone A (see item 4.3.2.3) six months corrosion prevention (starting from the date at which the gear unitwas first opened).

• Zone B (see item 4.3.2.3) four months corrosion prevention (starting from the date at which the gearunit was first opened).

The maximum durability of the gear-unit preservation (see item 4.3.2.3) must not beexceeded, even if the gear unit has been resealed.

6.3.2 Foundation

The gear unit must be installed on a level, secure, vibration­free and rigid foundation.

The levelness of the gear unit standing surface is especially important, as the contactpattern of the teeth and the carrying portion of the axial thrust bearing depend on it andthe service life of the gear unit is affected by it.

All points on the gear unit standing surface must lie between two imaginary parallelplanes 0.1 mm per 1 m (0.012 inch per 1 ft) apart.

The permissible deviation of the gear unit standing surface from the horizontal planeis 0.2 mm per 1 m (0.024 inch per 1 ft).

20 / 44BA 9138 EN 12/2010

6.4 Gear­unit installation

The gear unit must be installed under the vertical mill in accordance with the mill manufacturer'sinstructions.

The input shaft of the gear unit must be rotated for positioning during installation onlywhen the tilting­pad thrust bearing chamber is filled with oil up to the specified level.

The gear unit must be fastened down with the foundation bolts provided for in the parts list. Forpretensioning and tightening torque values for foundation bolts of strength class 8.8 to DIN 267, please seetable 3.

Table 3: Initial tension, tightening torque, initial­tensioning tool

Thread size Initial­tensioning force Tightening torqueInitial­

tensioning toolphydraulic

[ N ] [ lft x104 ] [ Nm ] [ ft lbs ] [ bar ]

M 20 114000 25.7 410 303

Operatinginstructions of the

manufacturer of thehydraulic

initial­tensioningtool

M 24 164000 36.9 710 524

M 30 262000 58.9 1450 1070

M 36 382000 85.9 2530 1867

M 42 526000 118.4 4070 3004

M 48 693000 155.9 6140 4531

M 56 959000 215.8 9840 7262

M 64 1268000 285.3 14300 10553

M 72 x 6 1600000 360.0 20800 15350

M 80 x 6 1950000 438.8 28900 21328

M 90 x 6 2550000 573.8 41650 30738

M 100 x 6 3200000 720.0 57800 42730

For Superbolt nuts the separate instructions of the manufacturer apply(see item "Other operating instructions" in the gear­unit documentation).

After the gear unit has been aligned, the pins specified in the dimensioned drawing must be fitted. Lateralstops can also be fitted to prevent the gear unit from shifting.

The gear unit is approved for one direction of rotation only. The direction of rotationof the motor must correspond to the direction indicated by the arrow on the gear­unitinput shaft.

Gear units which are used out of doors or under other very unfavourable environmental conditions ­e.g. dirt, dust, heat or water spray ­ must be protected against these by suitable means. However, the freemovement of air over the surface of the housing must not be obstructed.

Screws which have been damaged during assembly or disassembly work must bereplaced with new ones of the same strength class and type.

21 / 44BA 9138 EN 12/2010

6.5 Installing the pipework

The pipework must be carefully cleaned and flushed through with a low­viscosity oil.

The pipework must be screwed on in accordance with the specifications on the drawings. Blank flangesand plugs must be removed beforehand. The screw connections seal metallically, while the associatedseals must be used for the flanges.

The pipework must not be overstressed.

The pipework must be supported with struts as indicated in the drawings in the gear­unit documentation.

If the pipework is adapted on site, the pipes must be carefully pickled after welding.

6.6 Pickling of adapted pipes

Personal protective equipment (gloves, safety glasses) must be worn during thisprocess. Risk of corrosion burns.

• The lower end of each pipe must be sealed with a plug.

• Pickling solution: 33 % hydrochloric acid (HCl) diluted with the same quantity of water (H2O).

• Air bubbles must not under any circumstances be allowed to form on the inside of the pipes.

• The pipes must be filled with the pickling solution. Acting time: 1 hour.

• Flush pipes out well with water (H2O).

• When the pipes are empty, they must be filled with a neutralising solution (sodium lye 3 % to 5 % NaOH).Neutralisation time: 15 minutes. Then flush the pipes out once more with water (H2O).

• The pipes must then be flushed out thoroughly with flushing oil via a 10 μm (0.0004 inch) filter.

If the pipes are not fitted straightaway, they must be carefully preserved.

6.7 Installing the couplings

When installing the couplings, the related operating instructions for the couplingsmust be observed.

Before beginning installation, the shaft ends and the coupling parts must be carefully cleaned.

Couplings must be hoisted with the aid of the thread centring hole at the shaft ends. The couplings mustbe secured to prevent them from being shifted axially.

The parts must not be driven on by abrupt force, as this may damage the gear unit.

6.8 Installing the motor

The drive motor must be aligned precisely with the central axis of the input shaft of the gear unit and fixedin position.

• Record alignment dimensions.

When installing the motor, the specific operating instructions for the motor must beobserved.

The precise alignment of the shafts one with the other is of fundamental importance for theservice life of the shafts, bearings and couplings.

22 / 44BA 9138 EN 12/2010

6.9 Fitting add­on parts delivered loosely with the unit

All loose parts with a thread connection must be sealed with fluid seals. No sealing agent must get into thegear unit.

Any loose fittings the tapped holes of which are sealed with plugs must be fitted in accordance with thedrawings supplied with them.

Electrical monitoring instruments must be connected in accordance with terminaldiagrams, lists of equipment and specific operating instructions.

6.10 Welding work on the mill

Siemens will assume no liability for damage caused to the gear unit by welding work carriedout on the mill.

The gear unit must not be used as an earthing point for welding operations. Beforewelding work is carried out on the mill, the gear unit must be properly earthed!

When carrying out electric welding anywhere on the mill the welding current must notbe conducted through the gear unit. The welding current return wire must thereforealways be connected direct to the component to be welded.

6.11 Final work

• After installation of the gear unit check all screw connections for tight fit.

• Check the alignment after tightening the fastening elements (the alignment must not have beenchanged).

• Check that all the devices which have been demounted for transport reasons have been refitted.

─ For this refer to the details in the data sheet, the list of equipment and the associated drawings.

• Oil­drain cocks, if any, must be secured against accidental opening.

• If an oil­sight glass is used for monitoring the oil level, it must be protected against damage.

• The gear unit must be protected against falling objects.

• Protective devices for rotating parts must be checked for correct seating. Contact with rotating partsis not permitted.

• A potential equalisation in accordance with the applying regulations and directives must be carried out!If no threaded holes for earth connection are available on the gear unit, other appropriate measuresmust be taken. This work must always be done by specialist electricians.

• Cable entries should be protected against moisture.

• Check that protective measures have been taken!

23 / 44BA 9138 EN 12/2010

7. Start­up

Observe the instructions in section 3, "Safety instructions"!

The gear unit must not be started up, if the required instructions are not available.

During start­up the initial run of the gear unit is loadfree, that is, without grindingmaterial and roller pressure.

7.1 Procedure before start­up

A precondition of the warranty is initial start­up by Siemens specialists or suitably trained specialistsauthorised by Siemens.

Any setting of the drive in motion represents a start­up!

For this reason the operating instructions must be adhered to, particularly if maintenance work is carriedout on the mill during which this is rotated and the gear unit along with it.

7.1.1 Depreservation of the gear unit

When depreserving the gear unit, all the preservative paint coats must be removed with a suitable cleanser(e.g. benzine). Preserving and/or running­in oil residues must be drained off via the oil­drain cocks on thegear unit and then the gear unit flushed out.

Remove any oil spillage immediately with an oil­binding agent.

The following additional work is necessary:

• Insert air filter in accordance with the dimensioned drawing in the gear unit documentation.

• Remove the adhesive tape on the labyrinth seal of the input shaft and the output flange.

7.1.2 Flushing before initial start­up

In all cases a distinction must be made between "flushing" during the initial start­up and "flushing" beforeand after repairs and overhauls (see item 10.4, "Flushing").

Flushing before initial start­up serves to minimise residues from previous lubricating oils or preservativeagents.

Flushing should be carried out with the selected service lubricating oil. Other viscosities of oil of the samegrade and make as that used as service lubricating oil may also be used as flushing oil.

• Put in flushing oil. For flushing, the gear unit and/or the tank of the oil­supply system must be filled withsufficient oil for the oil pump of the oil­supply system to be able to be operated for flushing.

• Flushing times:For flushing, operate the oil pump of the low­pressure lubricating circuit for at least 6 hours.

After flushing the oil must be carefully drained off via the oil­drain cocks on the gearunit and the oil­supply system. It may be re­used only as flushing oil. The flushing oilmust be cleaned before re­use. The flushing oil can be reused for a maximum ofsix flushing operations.

24 / 44BA 9138 EN 12/2010

7.1.3 Oil filling

The gear unit must be filled with oil after flushing and before initial start-up of the gearunit, once parts such as pressure gauges, thermometers, pipework, etc. which havebeen delivered separately or removed for transport have been fitted.

The quality of the oil used must meet the requirements of the separately supplied BA 7300 ENoperating instructions, otherwise the guarantee given by Siemens will lapse. We urgentlyrecommend using one of the oils listed in BA 7300 EN, because they have been tested andmeet the requirements.Information on the type, quantity and viscosity of the oil is given on the rating plate on the gearunit.

In case of gear units with oil cooling system the oil circuit must additionally be topped up. For this, theoperating instructions of the oil­supply system must be observed.

Only the oil level marks of the oil­level indicators on the gear unit and/or the oil­supplysystem (in the case of the version with tank) are decisive for the oil quantity to be putin.

Quantities indicated on the rating plate of the gear unit are only guide values.

Oil pumps and all parts the oil filling holes of which are identified by a special information sign must be filledwith oil before starting up the gear unit.

This is done by way of:

─ an oil­filling hole on the oil pump of the lubricating system or

─ an oil-filling hole on the pressure line or

─ an oil-filling hole marked with an instruction plate

These oil­filling holes must be tightly closed to prevent the pump from drawing in air and/or oil fromescaping.

1

2

3

4

5

6

Fig. 5: Oil level, oil drain and breather

1 Oil drain Gear unit 4 Oil level Tilting pad thrust bearing2 Oil drain Tilting pad thrust bearing 5 Air filter Gear unit3 Oil level Gear unit 6 Air filter Tilting pad thrust bearing

A detailed view of the gear unit can be obtained from the drawings in the gear­unit documentation.

25 / 44BA 9138 EN 12/2010

The gear unit can be filled with oil in different ways, depending on the equipment of the oil­supply system.

• The oil to be put in must be filtered beforehand with a 25 μm (0.0010 inch) filter gauge.

• If the oil­supply system is fitted with three­way cocks, the gear unit can be filled either via the three­waycocks of the oil­supply system or via the oil­drain cock of the tilting­pad thrust bearing of the gear unit.

• If the oil­supply system is not fitted with three­way cocks, the gear unit is filled via the oil­drain cock ofthe tilting­pad thrust bearing.

• If the oil­supply system is fitted with a tank, the gear unit can be also filled with oil via the oil tank of theoil­supply system. For this, it is necessary in the meantime to start the low­pressure pump of theoil­supply system in order to also fill the tilting­pad thrust bearing chamber of the gear unit with oil.

7.1.4 Oil quantity

7.1.4.1 Oil quantity for flushing

For flushing, the gear unit and/or the tank of the oil­supply system must be filled with sufficient oil for theoil pump of the oil­supply system to be able to be operated for flushing. The flushing­oil quantity may bebetween 50 % and 100 % of the total oil filling (see technical data), depending on the design of the gearunit.

7.1.4.2 Oil quantity for initial start-up

Sufficient oil must be put in to reach the specified oil level on the oil­level indicators of the gear unit(see dimensioned drawing of gear unit) and/or on the oil­supply system (in the case of version with tank)while the gear unit is stationary and the oil pumps (low­ and high­pressure circuit) are operating.

7.1.5 Oil­supply system

The main gear unit is supplied with lubricating and cooling oil by the oil­supply system (see operatinginstructions for the oil­supply system).

7.1.6 Checks before start­up

When the installation has been completed and before the first cold test run, all the drive parts must beinspected and all material residues, tools and installation aids removed.

If no shut­off equipment for the cooling water supply has been installed by Siemens, it must be providedby the customer.

The entire drive must also be checked against the following check list:

□ Has the foundation been correctly constructed?

□ Are all the foundation bolts tightened to specification?

□ Has the gear unit been correctly fastened in place?

□ Has the grinding bowl been correctly installed?

□ Are the direction of rotation of the motor and that of the gear unit identical (see direction of rotationarrow)?

□ Has the adhesive tape on the labyrinth seals been removed?

□ Has all the pipework been fitted and cleaned in accordance with the installation instructions?

Especial care must be taken to ensure that the oil­conducting pipework is clean, sinceany dirt in it would be conducted through the gear unit before it could be filtered outat the filter of the oil­supply system!

26 / 44BA 9138 EN 12/2010

□ Are the coupling and the motor correctly aligned?

□ Have the pipework and the hoses been correctly fitted?

□ Have the pipe and hose connections been checked for leaks? Especial attention must be given to theflange connections on the suction line. If air gets into it, the oil tends to foam.

□ Is the oil in the oil reservoir (tank of oil­supply system and/or gear unit) low­foaming on the surfaceduring operation? If there is foam, check all the suction line connections. If necessary, also contact theoil manufacturer.

□ Have the tank of the oil­supply system and/or the gear unit and the tilting pad thrust bearing chamberbeen fllled with oil up to the mark? The oil level must be checked while the oil­supply system is runningand the gear unit is stationary.

□ Has all the monitoring equipment been connected up in accordance with the terminal diagram?

□ Has the electric interlock between the gear unit, oil supply and mill drive motor been checked?

Have the following checks been recorded?

□ Function of the interlock according to interlock specifications.

□ Adjustment and function of flow monitor, pressure switch and temperature sensor.

□ Cooling­water supply opened, on oil­supply systems with water oil­cooler.

For further checks, see the operating instructions for the couplings, motors, oil­supply system and verticalmill.

7.2 Start­up

7.2.1 Pre­lubrication phase

Prior to each start­up, the gear unit must always be prelubricated for approx. 30 minutes by means of theoil­supply system.

During this time rolling bearings, axial tilting­pad thrust bearings and teeth for the initial start are suppliedwith lubricating oil.

Care must be taken in the case of gear units with high­forced lubrication that the low­forced lubricationsystem is started first and then after 2 minutes the high­forced lubrication system. This time is necessaryto ensure the pressure balance in the oil circuit.

The high­pressure pumps which may have been installed must be started no later than 5 minutes beforethe auxiliary or main motor is started.

27 / 44BA 9138 EN 12/2010

7.2.2 Initial start­up

After due observance of the relevant operating instructions, the gear unit can be put into operation.

If possible, the gear unit should run for several hours on part load (50 % to 70 %). If part load is not possible,the gear unit can also be run without load and with the rolls and/or rollers lifted. If no faults are indicated,the load can be gradually increased to full load at suitable intervals under continuous observation.

During this time, in particular the following points have to be observed:

a) Noise.If possible, during this time the gear unit must be listened to for unusual noises at various points witha suitable instrument (e.g.a stethoscope).

b) Foam formationIs the oil in the oil reservoir (tank of oil­supply system and/or gear unit) low­foaming on the surface?If there is foam, check all the suction line connections. If necessary, also contact the oil manufacturer.

c) Vibration measurement(for this see section 10, "Maintenance and repair", item 10.10)

d) Oil leakagesAll the screw connections in the oil lines must be monitored for oil leaks and, if necessary, resealed!

The date of initial start­up must be notified to Siemens within 4 weeks.

7.2.3 Checking procedure

The following visual checks must be conducted and recorded when starting up:

□ Oil level

□ Leaktightness of the oil­cooling or oil­supply lines

□ Opening condition of the shut­off valves

□ Effectiveness of the shaft seals

□ Freedom of the rotating parts from contact.

The document must be kept with the operating instructions.

28 / 44BA 9138 EN 12/2010

7.3 Removal from service

Switch motors off.

Secure the drive unit to prevent it from being started up unintentionally.

Attach a warning notice to the start switch!

• Our recommendation is that during short interruptions the complete oil­supply system be keptoperating. If the unit is stationary for longer periods, we recommend that the oil­supply system be keptrunning for approx. 60 minutes to prevent heat from building up. If there is a sudden stoppage, like thatcaused by a power failure, however, no damage will result.

• It should be noted that, when oil­supply systems with a high­pressure lubricating circuit are shut off, thehigh­pressure pumps must be shut down at first.

• During longer stoppages the shut­off valves in the coolant inlet and outlet lines must be closed.If a water oil­cooler is used, the water must be drained off to prevent damage from freezingat possible sub­zero temperatures.

• If gear units are operated in a saline environment or in the vicinity of bodies of saline water, the oil­supplysystem must be run through its cycle to prevent damage from corrosion. Additionally, the gear unit mustbe turned over with the auxiliary drive or main motor for 15 minutes every week (see item 7.2).

If taken out of service for longer periods, the gear unit must be flushed through for one hour androtated for 15 minutes every 7 days. The prerun time for the oil­supply system of 30 minutesbefore the vertical mill is set in motion must be adhered to. If the gear unit cannot be regularlyset in motion, it must be preserved (see item 7.3.1).

7.3.1 Preservation during longer periods of non­use

7.3.1.1 Interior preservation with preservative agent

Before a longer period of storage the gear unit must be run without load with the preservative agent listedin table 4.

Table 4: Preservative agent

Duration of protection Preservative agentSpecial measures after running

with preservative

Depending on the correct use ofthe preservation agent.Up to 36 months

Tribol 1390 / 220

Close gear unit.Put an airtight seal on the labyrinth onthe input shaft and on the output flange.Replace breather screw and/or air filterwith a (yellow) plug screw (replace theoriginal parts before start­up).

After internal reservation the gear unit must be closed airtight (see item 7.3.1.2) (see also "Special measures" intable 4).

29 / 44BA 9138 EN 12/2010

7.3.1.2 Interior­preservation procedure

• Switch the gear unit off and drain the oil as described in section 10, "Maintenance and repair".

• Pour preservative agent in through the ventilation hole and/or the hole in the inspection cover up to theupper mark on the oil­level indicators.

• Close the venting hole and/or the opening in the inspection cover.

• Start oil­supply system (low­ and high­pressure circuit). Running time of the oil­supply system forpreservation: at least 1 hour.

• Start the gear unit and allow it to idle briefly. The gear unit must start once. If this is not possible, the gearunit must be rotated for at least one revolution on the output flange. This can be done by rotating theinput shaft by hand.

Observe direction of rotation of the gear unit!

• Unscrew the oil­drain plug and allow the preservative to drain into a suitable container and dispose ofit according to regulation.

There is a risk of scalding from the hot preservative agent draining from the gear unit.Wear protective gloves.

• Screw in the oil­drain plug.

• Seal labyrinth seals on the input shaft and output flange with adhesive tape.

7.3.1.3 Interior preservation by oil filling

Alternatively the gear unit can also be filled with operating oil. Observe details at item 4.3.2. ContactSiemens.

7.3.2 Exterior preservation

Table 5: Exterior preservation of shaft ends and other bright machined surfaces

Duration ofprotection

Preservativeagent Layer thickness Remarks

min. 12 months Tectyl 846 K19 approx. 50 μm

Long­term wax­based preservativeagent, resistant to sea water andtropical conditions(soluble with CH compounds).The Duration of protecton dependson the conditions of storage.

7.3.2.1 Exterior­preservation procedure

• Clean the surfaces.

• Apply preservative agent.

30 / 44BA 9138 EN 12/2010

8. Operation

Observe the instructions in section 3, "Safety instructions", in section 9, "Faults, causes and remedy", andin section 10, "Maintenance and repair"!

8.1 General

During operation the gear unit must be monitored for:

Oil temperature The gear unit is designed for a oil-feed temperatureof 50 °C (122 °F) in continuous operation.If the oil-feed temperature reaches critical values(see lubrication plan and equipment list), the gear unitmust be shut down immediately and Siemensconsulted.

Changes in gear noise.

Possible oil leakage at the housing and shaft seals.

Bearing vibrations with present measuring instrument

Correct oil level (see section 7, "Start­up").

To check the oil level, the gear unit must be taken out of operation and the oil level checkedwhile the oil pump of the low­forced lubrication circuit of the oil­supply system is running.The oil level should be between the two marks of the oil­level indicator. If the oil falls below thelower mark of the oil­level indicator, the oil must be topped up.If the oil level in the gear unit rises above the upper mark, the oil may foam more, because thehigh­speed bevel gear churns up the oil. If the oil level is too high, leaks may also develop onthe input shaft. If necessary, the oil level must be adjusted.

8.2 Irregularities

The drive unit must be switched off at once,

– if irregularities are found during the operation

or

– if the pressure monitoring device in the oil­cooling system triggers alarm(only with correspondingly equipped gear units).

Determine the cause of the fault, using table 6, "Faults, causes and remedy"(see item 9.2).

Table 6, "Faults, causes and remedy", contains a list of possible faults, their causesand suggested remedies.

If the cause cannot be found, a specialist from one of our customer­service centresshould be called in (see section 2).

Continuous changes in the operating behaviour of the gear unit must be recorded with the aid of trendrecords.

31 / 44BA 9138 EN 12/2010

9. Faults, causes and remedy

Observe the instructions in section 3, "Safety instructions", and in section 10, "Maintenance and repair"!

9.1 General information on faults and malfunctions

Faults and malfunctions occurring during the guarantee period and requiring repair work on thegear unit must be carried out only by Siemens customer service.In the case of faults and malfunctions occurring after the guarantee period and whose causecannot be precisely identified, we advise our customers to contact our customer service.

Siemens will not be bound by the terms of the guarantee or otherwise be responsiblein cases of improper use of the gear unit, modifications carried out without Siemens’agreement or use of spare parts not supplied by Siemens.

To remedy faults and malfunctions, the gear unit must always be taken out of service.Secure the drive unit to prevent it from being started up unintentionally.Attach a warning notice to the start switch!

9.2 Possible faults

Table 6: Faults, causes and remedy

Faults Possible causes Remedy

Changes in gear­unit noise. Damage to gear teeth.

Bearing backlash too high or toolow.

Bearing defective.

Contact Customer Service.Check all toothed componentsand replace any damaged parts.

Contact Customer Service.Adjust bearing backlash.

Contact Customer Service.Replace defective bearings.

Increased temperature at thebearing points.

Oil level in gear­unit housing too lowor too high.

Oil too old.

Mechanical oil pump defective.

Bearing defective.

Check the oil level at roomtemperature and, if necessary,adjust oil level.

Contact Customer Service.Check date of last oil change.

Contact Customer Service.Check that oil pump is workingcorrectly.Repair or replace oil pump.

Contact Customer Service.Check and, if necessary,replace bearings.

Oil leakage from the gear unit. Inadequate sealing of housingcovers and/or joints.

Oil level in housing too high.

Check and, if necessary,replace sealings. Seal joints.

Check oil level and,if necessary, adjust.

32 / 44BA 9138 EN 12/2010

Faults RemedyPossible causes

Volumetric­flow meter triggersalarm.

Oil too cold.

Oil filter dirty.

Pipes leaky.

Heat oil.

Clean oil filter.Consult operating instructions foroil­supply system.

Check and, if necessary replace pipes.

Pressure monitor triggersalarm.

Oil level too low.

Oil pump defective.

Operating temperature too high.

Oil filter dirty.

Pipes leaky.

Check oil level and, if necessary,top up oil.

Check and, if necessary,replace oil pump.

See Faults "Operating temperaturetoo high".

Clean the oil filter.Consult operating instructions foroil­supply system.

Check and, if necessary replace pipes.

Increased operatingtemperature.

Oil level in housing too high.

Oil too old.

Oil badly contaminated.

Oil pump defective.

Oil filter dirty.

Cooler defective (dirty).

Cooling­water feed and/orcooling­air feed defective.

Check oil level and, if necessary,adjust.

Contact Customer Service.Check date of last oil change.

Contact Customer Service.Change oil.

Check and, if necessary, replace oilpump. Consult operating instructionsfor oil­supply system.

Clean the oil filter.Consult operating instructionsfor oil­supply system.

Check and, if necessary, replacecooler. Observe operating instructionsfor cooler.

Check cooling­water feed and/orcooling­air feed. Observe operatinginstructions for cooler.

Excessive temperature ontemperature sensor in tiltingpad thrust bearing.

Oil filter dirty.

Oil quantity to tilting pad thrustbearing too small.

Monitoring devices defective.

may also be connected with alteredgrinding parameters, e.g. raising ofthe temperature of the gas in thevertical mill.

Check oil filter for dirt.Consult operating instructionsfor oil­supply system.

Check setting of the control valves.

Check all monitoring devices.Observe operating instructions tomonitoring devices.

Analyse and check milling parameters.

33 / 44BA 9138 EN 12/2010

Faults RemedyPossible causes

The oil foams. Water in oil.

Oil too old(defoaming agent used up).

Unsuitable oils mixed up.

Test the oil, change oil if necessary.

Test the oil, change oil if necessary.

Test the oil, change oil if necessary.

Water in oil. Cooler leaky.

Water condensing.

Replace cooler.

Change oil.

Reduce water content by heatingthe oil.

Fault in oil­supply system. Consult operating instructionsfor oil­supply system.

34 / 44BA 9138 EN 12/2010

10. Maintenance and repair

Observe the instructions in section 3, "Safety instructions", and in section 9, "Faults, causes and remedy"!

Once the maintenance and repair work is completed, the information in section 7, "Start­up" should benoted.

10.1 General notes on maintenance

Maintenance comprises all measures for preserving and restoring the required condition and forascertaining and assessing the actual condition of the technical means of a system.

In this context maintenance is a comprehensive generic concept which can be subdivided into three areas:

• Inspection.

• Maintenance (including lubrication).

• Repair.

All maintenance and repair work must be done with care and by duly trained and qualifiedpersonnel only.

Before carrying out maintenance work, repairs or other work on the gear unit, theoperator of the system must ensure that the drive motor is secured againstunintentional starting. We also refer to the relevant accident prevention regulations atthe place of installation.

The gear unit must be protected against falling objects.

Protective devices for rotating parts must be checked for correct seating. Contact withrotating parts is not permitted.

For operation and maintenance the information given in the order­specific gear­unitdocumentation must be observed.

10.2 Cleaning the gear­unit surface

To prevent the build­up of dust on the gear unit, cleaning must be done in accordancewith operating conditions.

The gear unit must not be cleaned with high­pressure cleaning equipment.

10.3 Clean the air filter

• Every 12 weeks or when the air filter (breathing filter) is very contaminated.

• Unscrew the filter and clean it with benzine or similar cleaning agents.

Be especially careful when cleaning with compressed air.Wear protective glasses!

• Screw in again dry air filter.

10.3.1 Replacing the air­filter cartridge

• Every 12 weeks or when the air filter is very contaminated.

• Remove the air­filter cover and replace the filter element (the paper filter cannot be cleaned).

35 / 44BA 9138 EN 12/2010

10.4 Flushing

In all cases a distinction must be made between "flushing" during the initial start­up and "flushing" beforeand after repairs and overhauls.

Flushing before and after repairs and overhauls serves to remove impurities (e.g. carbon deposits, oilfoam, abraded material).

The flushing action can be improved by using e.g OPTIMOL Detergen System Cleaner, to dissolveresidues or reduce coagulated substances.

Flushing should be carried out with the selected service lubricating oil. Other viscosities of oil of the samegrade and make as that used as service lubricating oil may also be used as flushing oil.

• For flushing­oil quantity see item 7.1.4.1.

• Flushing times:For flushing, operate the oil pump of the low­pressure lubricating circuit for at least 6 hours.

After flushing the oil must be carefully drained off via the oil­drain cocks on the gearunit and the oil­supply system. It may be re­used only as flushing oil. The flushing oilmust be cleaned before re­use. The flushing oil must be filtered beforehand or duringfilling using a nominal filter gauge of 25 μm (0.0010 inch). The flushing oil can bereused for a maximum of six flushing operations.

10.5 Oil filling

After flushing and before the initial run of the gear unit the gear unit must be filled withoil.

Information on the type, quantity and viscosity of the oil is given in the order­specific gear­unitdocumentation.For oil grades which can be used, see the recommended lubricants in the operatinginstructions BA 7300 EN (see item 10.12, "Lubricants").

36 / 44BA 9138 EN 12/2010

10.6 Inspection

The inspection comprises all measures for ascertaining and assessing the actual condition.

The measures must be recorded.

Table 7: Inspection measures

Measures Periods Remarks

General visual check for cracks, leaksand damage

Every 4 weeks

Visual check of the tooth­flank conditionfor damage

Every 4 weeks

Check oil filters of the oil­supply systemfor contamination

Every 4 weeks Visual indication, see also operatinginstructions oil­supply system.

Check of the instruments installed onsite (temperatures, oil pressures)

Every 4 weeks

Inspection of the oil­conducting lines forleaks

Weekly

Oil level check at the oil­level indicatorson the gear unit and, if necessary, onthe oil­supply system (version with tank)

Weekly See also operating instructionsoil­supply system.

Check­ unusual noises,­ temperature,­ safety equipment.

Every 4 weeks

Check of the add­on parts such ascouplings, possibly auxiliary drive

Yearly See operating instructions individualcomponents.

37 / 44BA 9138 EN 12/2010

10.7 Maintenance

Maintenance comprises all measures for preserving the required condition.

Table 8: Maintenance measures

Measures Periods Remarks

Cleaning the filter elements Every 4 weeks or when the filtersare dirty

See operating instructions for theindividual components

Test oil for water content After approx. 400 operatinghours, thereafter at least once peryear

See item 10.7.1

First oil change after start­up After approx. 1000 operatinghours or depending on the resultsof the oil analysis carried out

See item 10.7.2

Oil analyses Every 1000 operating hours See item 10.7.1

Subsequent oil changes Depending on the oil­analysisresults; (without oil analysis:every 18 monthsand/or 5000 operating hours)

See item 10.7.2

Cleaning the air filter(breathing filter)

Every 12 weeks see item 10.3

Replacing the air­filter cartridge Every 12 weeks see item 10.3.1

Checking tightness of the foundationbolts

Every 12 weeks See item 10.7.3

Carrying out complete inspectionof gear unit

Every 2 years see item 10.8

Maintenance work on the oil­supplysystem

See also operating instructionsoil­supply system.

See also operating instructionsoil­supply system.

Check couplings Every 26 weeks See operating instructionsindividual components

38 / 44BA 9138 EN 12/2010

10.7.1 Examine water content of oil / conducting oil analyses

More information about examining the oil for water content or conducting oil analyses is obtainable fromyour lubricant manufacturer or our customer service.

• For reference purposes, a fresh sample of the operating lubricating oil used must be sent with the usedoil sample to the analysing institute for analysis.

• The oil sample must be taken downstream of the filter of the oil­supply system while the gear unit isrunning. A suitable connection point is normally located upstream of the gear unit input (e.g. oil­draincock in the pressure line).

• A special sample container should be filled with the specified quantity of oil.If there is no such sample container available, at least one litre of oil must be put in a clean,transportworthy, sealable vessel.

• The viscosity of the oil sample may not deviate by more than 10% from that specified in the technicaldata.

• The oil purity should be between 15/13/10 (high availability) and 17/15/12 (normal availability) toISO 4406.

• Limit values for oil contamination.

Table 9: Material­related contamination limit values of the oil

MaterialLimit content

[ mg/kg ]Possible source

Iron (Fe) 40 Gear rim with internal teeth, teeth, bearing cage

Chromium (Cr) 4 Rolling bearing, teeth

Aluminium (Al) 4 Oil­pump bearing

Copper (Cu) 4 Cage of bearing

Lead (Pb) 6 Plain thrust bearings, pump bearings

Tin (Sn) 2 Plain thrust bearings, pump bearings

Nickel (Ni) 2 Teeth

Zinc (Zn) 10Zinc­based primer (is sometimes used as additive). In this caseplease contact Siemens.

Silicon (Si) 20 Cement dust or other environmental factors

Water (H2O) 0.10 % Water condensation; water­oil cooler defective

10.7.2 Change oil

When changing the oil, always re­fill the gear unit with the same type of oil. Never mixdifferent types of oil and/or oils made by different manufacturers. Polyglycol­basedsynthetic oils in particular must not be mixed with PAO­based synthetic oils or mineraloils. If changing to a different grade or make of oil, the gear unit must, if necessary, beflushed out with the new oil grade. Flushing is not necessary, if the new service oil isfully compatible with the old service oil in all respects. Compatibility must beconfirmed by the oil supplier. If there is a change to another oil grade or make, Siemensrecommends flushing out the gear unit with the new grade of service oil.

When changing the oil, the housing and, where present, the oil cooling system must also be cleanedthoroughly by flushing with oil to remove oil sludge, abraded particles and residues of old oil. Use the sametype of oil as is used for normal operation. High­viscosity oils must be heated beforehand. Ensure that allresidues have been removed before filling with fresh oil.

39 / 44BA 9138 EN 12/2010

The oil change should be carried out immediately after the shut down of the gear unit while theoil is still warm.

• Stop the gear unit by switching off the drive unit.

Secure the drive assembly to prevent it from being started up accidentally.Attach a warning notice to the start switch.

• A suitable container should be placed under the oil­drain cock of the gear­unit housing and the tiltingpad thrust bearing chamber.

• Unscrew the screw plugs of the oil­drain cocks and allow the oil to drain into the container.

There is a danger of scalding from the hot oil emerging from the housing.Wear protective gloves.Remove any oil spillage immediately with an oil­binding agent.Dispose of the old oil according to the environmental protection regulations.

• If the oil­supply system is fitted with three­way cocks, the gear unit can be emptied via these. Theremaining residual oil must then be drained off via the oil­drain cocks.

1

2

3

4

5

6

Fig. 6: Oil level, oil drain and breather

1 Oil drain Gear unit 4 Oil level Tilting pad thrust bearing2 Oil drain Tilting pad thrust bearing 5 Air filter Gear unit3 Oil level Gear unit 6 Air filter Tilting pad thrust bearing

• Screw in screw plugs into the oil­drain cocks again.

Check the condition of the sealing ring (the sealing ring is vulcanised onto the screw plug);if necessary, use a new screw plug.

For data such as oil grade, oil viscosity and oil quantity required, refer to the technical data.For oil grades which can be used, see the recommended lubricants in the operatinginstructions (see information in item 10.12, "Lubricants").

For filling oil into the gear unit the information given in items 7.1.3 and 7.1.4 must be observed.

40 / 44BA 9138 EN 12/2010

10.7.3 Checking tightness of the foundation bolts

Foundation bolts of strength class 8.8 to DIN 267 must be tightened in accordance with the values(pretension, tightening torque) given in table 3 (see item 6.4).

Damaged bolts must be replaced with new bolts of the same type and strength class.

10.8 General inspection of the gear unit

The general inspection of the gear unit should be carried out by the Siemens Customer Service, as ourengineers have the experience and training necessary to identify any components requiring replacement.

10.9 Welding work on the mill

Siemens will assume no liability for damage caused to the gear unit by welding work carriedout on the mill.

The gear unit must not be used as an earthing point for welding operations. Beforewelding work is carried out on the mill, the gear unit must be properly earthed!

When carrying out electric welding anywhere on the mill the welding current must notbe conducted through the gear unit. The welding current return wire must thereforealways be connected direct to the component to be welded.

10.10 Vibration measurements

If vibration is measured on a gear unit while it is in operation, care must be taken notto carry out the measurement in the immediate vicinity of rotating parts to avoidaccidentally touching the rotating parts.

3V 4V 6H4V3V8H6H7H5H

3H 4H 4H 5H

Fig. 7: Measuring points

V Vertical measuring point H Horizontal measuring point

(The measuring points 1 and 2 are located at the bearing points on the motor.).

The measuring points specified in figure 7 are standard measuring points. All the gear units of this type inthe field are measured at these measuring points. This enables direct comparison with other gear units ofthe same type and size. A detailed view of the gear unit can be obtained from the drawings in the gear­unitdocumentation.

Vibration measurements and their evaluation should be conducted by Siemens personnel and/or in closecollaboration with Siemens personnel. In this way experience gained from measurements conducted oncomparable bevel­gear planetary gear units can be incorporated into the measurement and the evaluationof its results.

41 / 44BA 9138 EN 12/2010

Generally, when measuring vibration, the following should be observed:

a) Measure only at the measuring points indicated in the diagram shown above.

b) Do not measure on resonance cavities (e.g. fins, inspection covers, pipes, etc.).

c) The motor output should also be recorded at the time of measurement, as output fluctuations may resultin different measurements.

After start­up and continuous operation of the entire system a initial measurement should be carried outto obtain the vibration profile of the gear unit. Subsequent measurements at monthly intervals will thenenable a trend analysis to be carried out.

For assessing the gear unit to DIN ISO 10816 the classification III applies to this machine. Withthis assessment, however, it must be noted that the axial forces arising from the grindingprocess are conducted to the foundation via the gear­unit housing so that it cannot be ruled outthat vibrations are due to the grinding process and are not generated by the gear unit. For thisreason DIN ISO 10816 has only limited application for this type of gear unit.

Further information about vibration diagnosis is obtainable from:

http://www.automation.siemens.com/mcms/mechanical-drives/en/gear-units/service

10.11 Repair

Repair comprises all measures for restoring the required condition after faults.

When carrying out repair work, especial care must be taken that, when doing electric weldingwork at any point on the unit, the welding current is not conducted through rolling bearings orother movable connections and measuring equipment. The welding current return wire musttherefore be connected direct to the part to be welded.

When replacing individual components and other subassemblies, these must be carefully fastened tolifting gear and secured to prevent hazards.

Use only suitable, technically faultfree lifting gear and load­bearing equipment withsufficient carrying capacity!Do not stand or work under suspended loads!

10.12 Lubricants

The quality of the oil used must meet the requirements of the separately supplied BA 7300 EN operatinginstructions, otherwise the guarantee given by Siemens will lapse. We urgently recommend using one ofthe oils listed in BA 7300 EN, because they have been tested and meet the requirements.

To avoid misunderstandings, we should like to point out that this recommendation is in no wayintended as a guarantee of the quality of the lubricant supplied. Each lubricant manufactureris responsible for the quality of his own product.

Information on the type, quantity and viscosity of the oil is given on the rating plate on the gear unit and/orin the supplied documentation.

The quantity of oil indicated on the rating plate is an approximation only. The marks on the oil dipstick oroil­sight glass are decisive for the amount of oil to be filled in.

The manual containing the current lubricants recommended by Siemens can also be consulted on theinternet (see back cover).

The oils listed there are subjected to continuous tests. Under certain circumstances the oils recommendedthere may therefore later be removed from the range or replaced with further developed oils.

We recommend regularly checking whether the selected lubricating oil is still recommended by Siemens.If it is not, the brand of oil should be changed.

42 / 44BA 9138 EN 12/2010

11. Spare parts, customer­service

11.1 Stocking spare parts

By stocking the most important spare and wearing parts on site you can ensure that the gear unit is readyfor use at any time.

To order spare parts, refer to the spare­parts list.

For further information refer to the spare­parts drawing stated in the spare parts list.

We guarantee only the original spare parts supplied by us. Non­original spare partshave not been tested or approved by us. They may alter technical characteristics ofthe gear unit, thereby posing an active or passive risk to safety. Siemens will assumeno liability or guarantee for damage caused by spare parts not supplied by Siemens.The same applies to any accessories not supplied by Siemens.

Please note that certain components often have special production and supply specifications and that wesupply you with spare parts which comply fully with the current state of technical development as well ascurrent legislation.

When ordering spare parts, always state the following:

Order number, item Type, size Part number Quantity

11.2 Spare parts and customer­service addresses

When ordering spare parts or requesting a service specialist, please contact Siemens first (see section 2).

43 / 44BA 9138 EN 12/2010

12. Declarations

12.1 Declaration of incorporation

Declaration of incorporation

in accordance with Directive 2006/42/EC, Annex II 1 B

The manufacturer, Siemens AG, D ­ 46393 Bocholt, declares with regard to the partly completed machinery

Vertical­mill gear unitKMP

Sizes 180 to 450

for driving a vertical mill:

‐ The special technical documents described in Annex VII B have been prepared.

‐ The following basic health and safety requirements set out in Directive 2006/42/EC, Annex I, are applied and are satisfied:

1.1, 1.1.2, 1.1.3, 1.1.5; 1.2.4.4, 1.2.5, 1.2.6; 1.3.1 ‐ 1.3.4, 1.3.6 ‐ 1.3.8.1, 1.3.8.2; 1.4.1, 1.4.2.1;1.5.1, 1.5.2, 1.5.4 - 1.5.11, 1.5.13, 1.5.15, 1.5.16; 1.6.1 ‐ 1.6.3; 1.7.1 - 1.7.2, 1.7.3 ‐ 1.7.4.3

‐ The partly completed machinery must not be put into service until it has been establishedthat the machinery into which the partly completed machinery is to be incorporated has beendeclared in conformity with the provisions of Directive 2006/42/EC, as appropriate.

‐ The manufacturer undertakes, in response to a reasoned request by the national authorities,to transmit in electronic form relevant information about the partly completed machinery.

‐ The person authorised to compile the relevant technical documentation is:Dr. Nico van de Sandt (Head of Engineering DAE)

Voerde, 2010‐12‐02Dr. Nico van de Sandt(Head of Engineering DAE)

Voerde, 2010‐12‐02Dr. Bernhard Hoffmann(Vice‐President Business Subsegment DA)

Siemens AGIndustry SectorMechanical DrivesAlfred-Flender-Straße 7746395 BocholtGERMANY

www.siemens.com/drivetechnology

Subject to modifications

© Siemens AG 2010