Motox N Operating Manual

Operating Instructions

BA G298 EN 08.98

MOTOX -NHelical Gear Units

and

Gear Motors

191080

FLENDER TÜBINGEN GmbH, Bahnhofstr., D-72072 TübingenTel. 07071/707-0 Telefax 07071/707-400

A company of A. Friedr. Flender AG

BA G298 EN 08.98Page 2 of 39

Contents

1. General notes 41.1 General 41.2 Proper usage 4

2. Safety notes 55. . . . . . .

2.1 Notes and symbols in the Operating Instructions 52.2 Safety notes 5

3. Technical data 63.1 General technical data 63.2 Mounting positions 73.2.1 Two- and three-stage gear units and gear motors, foot mounted, types Z/D 73.2.2 Two- and three-stage gear units and gear motors, flange mounted, types ZF/DF and ZZ/DZ 83.2.3 Two- and three-stage gear units and gear motors, foot/flange mounted, types ZB/DB 83.3 Oil quantities 93.3.1 Two- and three-stage gear units and gear motors 93.4 Weights 103.5 Sound power level 10

4. Handling, Incoming goods and Storage 114.1 Handling 114.2 Incoming goods 114.3 Storage 12

5. Technical description 135.1 General description 135.2 Housings 135.3 Toothed components 135.4 Lubrication 135.5 Bearings 135.6 Shaft seals 135.7 Cooling 135.8 Couplings 135.9 Backstop 145.10 Rating plates 145.11 Coats of paint 15

6. Installation 176.1 General information on installation 176.2 Drives with foot mounting 176.2.1 Foundation 176.2.2 Installation of gear units with foot mounting 176.3 Drives with housing flange mounting 186.4 Drives with foot-/flange mounting

(Mounting positions B3/B5, V1/V5, V3/V6) 186.5 Installation of input drive and output drive elements on gear unit shafts 196.6 Attachment of standard motors 206.6.1 Attachment to coupling lantern with rotation elastic coupling 206.6.2 Attachment to coupling lantern with clamping ring 216.7 Motor base plate 226.7.1 IEC-Motor frame sizes up to 112 226.7.2 IEC-Motor frame sizes 132 to 200 236.7.3 IEC-Motor frame sizes from 225 23

BA G298 EN 08.98 Page 3 of 39

7. Startup 247.1 Measures before startup 247.1.1 Oil level check 247.1.1.1 Checking the oil level in the gear unit housing 247.1.1.2 Oil sight glass (Special feature) 247.1.1.3 Dipstick (Special feature) 247.1.2 Startup without long term preservation 247.1.3 Startup in case of long term preservation 257.1.3.1 Long term preservation up to 18 months 257.1.3.2 Long term preservation up to 36 months 257.1.4 Filling with lubricant 257.1.5 Drive with backstop 257.2 Shutdown 257.3 Preservation with gear oil 267.4 External preservation procedure 26

8. Operation 26

9. Disturbances, reasons and remedy 279.1 General information on malfunctions 27

10. Maintenance and repair 2910.1 General information on maintenance 2910.2 Description of maintenance and repairs 3010.2.1 Carrying out oil changes 3010.2.2 Relubricating the anti-friction bearings in drive units 3010.2.3 Cleaning the vent plug 3110.2.4 Cleaning the drive 3110.2.5 Checking all fixing screws for tightness 3110.2.6 Inspection of the drive 3110.3 Lubricants 32

11. Spare parts stock, service addresses 3411.1 Stocking spare parts 3411.2 Spare parts and Customer Service addresses 34

FLENDER TÜBINGEN Germany 35FLENDER TÜBINGEN Europe 36

FLENDER TÜBINGEN International 37

12. Declaration by the manufacturer 39

BA G298 EN 08.98Page 4 of 39

1. General notes

1.1 General

These Operating Instructions constitute part of the gear unit shipment and should be kept in theimmediate vicinity of the gear unit at all times.

Only a precise knowledge of the Operating Instructions will ensure trouble-free operation ofthe drive by avoiding operating errors and incorrect usage. It is therefore in the interest of theoperator that the Operating Instructions are read, understood and observed in all respects bythe persons responsible for handling, installation and operation.

Note: We accept no liability for any damage or malfunction resulting from non-observanceof the Operating Instructions.

The drives described here are manufactured in accordance with the latest technology at the time ofthese Operating Instructions going into print.

In the interest of further development, we reserve the right to introduce modifications to the individualsubassemblies and accessories which, while retaining the essential features, can be regarded asdesirable to increase their efficiency and safety.

The copyright of these Operating Instructions remains the property of FLENDER TÜBINGEN GmbH .

These Operating Instructions may not be duplicated in part or whole, utilized for the purpose of publicityor communicated to third parties without our express consent.

Alterations or additions of these Operating Instructions may only be carried out by us, otherwisecomplete liability will be cancelled.

Note: For couplings, motors, brake motors and additional features of motors (external fan,back stop, encoder system, etc.) please observe further Operating Instructionssupplied with shipment (e.g. BA 3400, BA M295, BA B295, N-R 430, etc.).For special designs of drives and their optional features the particular contractualagreements and technical documentation, e.g. special dimension sheets, etc. areeffective in addition to these Operating Instructions.

Please contact our works listed below in respect of all technical queries:

FLENDER TÜBINGEN GmbH

Postfach 1709 , D-72007 Tübingen

Bahnhofstr. , D-72072 Tübingen

Tel. (+49) 07071/707-0

Fax (+49) 07071/707-400

or one of our service branches which are listed in Section 11. “Spare parts stock, service addresses”.

1.2 Proper usage

The MOTOX -N drives dealt with in these Operating Instructions have been developed for stationaryuse in general engineering. If not otherwise agreed the drives are suitable for use in machines andplants in industrial areas.

The drives are only designed for the field of application as specified in Section 3. “Technical data”. Thedrives may not be operated outside the given performance limits. Operating conditions which differ fromthose stated will require new contractual agreements.

BA G298 EN 08.98 Page 5 of 39

2. Safety notes

2.1 Notes and symbols in the Operating Instructions

Instructions in the Operating Instructions which concern operating safety are emphasized as follows:

This symbol draws attention to safety measures to prevent personal injury .

This symbol draws attention to the safety measures which must be observed toprevent damage to the gear unit .

Note: This note draws attention to general operating notes which should be especiallyobserved.

2.2 Safety notes

� The gear unit is constructed and tested in accordance with the latest technology and is reliable in thecondition as shipped. Unauthorized modifications which impair its reliability are not permissible. Thisalso applies to guards which are fitted as protection against accidental contact.

� The gear unit may only be used and operated within the scope of the conditions specified in thecontract of performance and supply.

� The operator should ensure that the persons entrusted with installation, operation, care andmaintenance have read and understood the Operating Instructions and observe them in all respectsin order to:

– Prevent hazard to the life and limb of the user and third parties.

– Ensure the reliability of the gear unit.

– Prevent failure and environmental pollution due to incorrect handling.

� The drive unit may only be operated, serviced and repaired by authorized, trained and properlyinstructed personnel. Definition for trained personnel see e.g. IEC 364.

� All work should be carried out carefully with the safety aspect in mind.

� Notes affixed to drive units, such as rating plate, direction of rotation arrows, etc., must be observed.They must be kept free from paint and dirt. Missing plates must be replaced.

� All work on the gear unit may only be carried out when it is stationary.The drive unit must be secured to prevent accidental startup (e.g. by locking the key switch or byremoving the fuses in the power supply). A notice should be displayed at the switch-on point statingthat work is in progress on the gear unit.

� The relevant regulations concerning industrial safety and pollution control should be observed duringhandling, installation, operation, care and maintenance.

� Rotating parts, such as couplings, gear wheels or belt drives must be protected by means of suitableguards to prevent accidental contact.

� The drive unit should be shut off at once if changes in the gear unit are detected during operation,such as increased operating temperature or a change in gear unit noises.

� During installation of the gear unit in devices or systems, the manufacturer of the device or systemis obliged to incorporate the requirements, notes and descriptions contained in these OperatingInstructions in his own Operating Instructions.

� On the occasion of oil changes, the old oil should be collected in a suitable receptacle. Any pools ofoil which have occured should be removed at once with an oil binding agent.Very dirty and oil-soaked cleaning rags should be kept in suitable containers.The oil, the oil binding agent and the cleaning rags should be disposed of in accordance with therelevant pollution control requirements.

Attention!

BA G298 EN 08.98Page 6 of 39

3. Technical data

3.1 General technical data

The rating plate of the gear units or gear motors contains the most essential technical data. This dataand the contractual agreements for the drives define the limits of its proper use.On gear motors normally one rating plate, attached to the motor, is used for the complete drive.In some cases separate rating plates are used on the gear unit and the motor.

Examples: Rating plate of gear motor Rating plate of gear unit

1 2

3

4

5 6

7 8

9 10 11

1213

2511

26

1

20

17

418

314

2224102

12

9

161519

2123682713

1 Date of manufacture (coded, e.g. S01) 14 Phase number and type of current of the motor

2 Weight m [kg] (only if>30kg) (e.g.: 3� Mot. or 1� Mot.)

3 Order No. / consecutive No. 15 Connecting symbol to DIN 40900 T6/IEC 617-6

4 Type - Size 16 Rated voltage U [V]

5 Power rating: T2 [Nm] 17 Rated current Ι [A]

6 Mounting position 18 Rated frequency f [Hz]

7 Total ratio i 19 Rated speed n [1/min] (1/min=1/60s)

8 Speed n2 [1/min] (1/min=1/60s) 20 Rated power P [kW]

9 Oil grade, e.g.: 21 Duty type (if � S1)

CLP-oil DIN 51517/3 (mineral oil) 22 Power factor cos ϕor PGLP-oil (synthetic oil) 23 Type of protection to IEC 34-5 or IEC 529

10 Oil viscosity: ISO VG-class to 24 Thermal class Th. Cl.

DIN 51519 / ISO 3448 25 Regulation taken as basis (Standard)

11 Oil quantity [l] (1l=1dm3≈1kg) e.g.: IEC 34 or EN 60034 or VDE 0530

12 Free field for additional data 26 EC symbol (CE) or other marking (CSA,e.g. commission number (customer’s request) NRTL/C, UL, etc.) if applicable

13 max. ambient temperature TUmax. [°C] 27 Brake data(only if > 40°C)

Symbols (IEC 617-2):

= brake

= coupling, clutch

Data on the weight and sound pressure of the various drives will be found under 3.4 and 3.5.

Further technical data will be found in the drawings and the gear unit documentation.

BA G298 EN 08.98 Page 7 of 39

3.2 Mounting positions

� The drives may only be operated in the mounting position specified on the rating plate. This will ensurethe correct quantity of lubricant.

� The designations of the mounting positons correspond to IEC 34-7 (Code Ι).

Marking: Oil level

Housing ventilation

Oil drain plug

3.2.1 Two- and three-stage gear units and gear motors, foot mounted, types Z/D

B 3 V 5

V 6 B 8

B 7 B 6

A

A

A

A

A A

*

*

*

*

* on opposite side

2-stage gear units

3-stage gear units

A Types Z/D38 are equipped as standard with one plug screw at point A.

BA G298 EN 08.98Page 8 of 39

3.2.2 Two- and three-stage gear units and gear motors, flange mounted, types ZF/DF and ZZ/DZ

B 5 V 1 B 14 V 18

A

A

A

V 3 V 19

*

*

*

3.2.3 Two- and three-stage gear units and gear motors, foot/flange mounted, types ZB/DB

A

A

A

B 3 / B 5 V 1 / V 5

V 3 / V 6

*

*

*

* on opposite side

2-stage gear units

3-stage gear units

A Types ZF/DF38, ZZ/DZ38 and ZB/DB38 are equipped as standard with one plug screw at point A.

BA G298 EN 08.98 Page 9 of 39

3.3 Oil quantities

The exact oil quantities are specified on the rating plates of the drives.

The gear units should always be filled up to the oil level(see Section 7. “Startup”).

Note: The quantities in litres listed in the following are reference values.Due to the different ratios for one a gear type the specified data are carefullydetermined average values. For example thay are meant for lubricant stock up,purchasing or similar purposes.

3.3.1 Two- and three-stage gear units and gear motors

Mounting position

Type B3 B5 B6 B7 B8 V1 V3 V5 V6yp

B3/B5 B14 V18 V19 V1/V5 V3/V6

Z. 38 0.5 0.5 0.6 0.6 0.6 0.7 1.2 0.7 1.1

Z. 48 1.1 1 1.6 1.3 1.5 1.8 2.4 1.9 2.3

Z. 68 1.8 1.7 2.7 2.3 2.5 3 4.1 3.2 4.1

Z. 88 4.2 3.7 6.1 5.3 5.7 6.8 8.8 7.5 8.8

Z. 108 6.7 5.3 10.5 9.3 8.6 12.8 14 13.2 13.6

Z. 128 9 6.4 16 14.1 13.2 17.4 20.7 19.9 20.9

Z. 148 12.2 9.9 20.8 18.3 23.9 23.9 27.7 25.7 27.4

Z. 168 18.8 15.3 34.8 30.1 32.1 43.8 31.1 45.7 41.7

D. 38 0.5 0.5 0.6 0.6 0.6 0.9 1.1 0.9 1.1

D. 48 1.1 1 1.5 1.4 1.5 2.3 2.4 2.4 2.4

D. 68 1.7 1.6 2.6 2.4 2.6 3.9 4 4 4

D. 88 4.2 3.6 5.9 5.4 5.9 8.7 8.9 9.3 8.9

D. 108 6.5 5.1 10.3 9.5 9 15.3 14.2 15.6 13.7

D. 128 8.7 6.1 15.8 14.8 14.1 22.2 21.3 24.4 21.5

D. 148 11.7 9.4 20.4 19.1 23.4 30.6 28.2 32.2 27.9

D. 168 18.1 14.6 34.1 31.2 33.8 53 43.7 54.4 42.2

Attention!

BA G298 EN 08.98Page 10 of 39

3.4 Weights

The weight of the drive is shown on the rating plate of the gear unit or the gear motor, if higher than 30 kg;it can always be found in the shipment documents.

When there are several rating plates on one drive, the value on the main gear unit is decisive.

The weight given refers to the delivery condition of the product ex FLENDER TÜBINGEN .

3.5 Sound power level

The A-qualified sound power levels LWA of a selection of gear units in Figure 3.5 were determinedaccording to DIN EN 21680 measured with testing apparatus to DIN IEC 651.

The sound is dependent upon speed, power rating and ratio.

The MOTOX -N-drives mostly lie within the dark range. Gear units with very small ratios, high powerrating and high input speed may lie in the hatched range.

If no proper measuring system can be established when measuring again at the place of use, themeasurement on the FLENDER TÜBINGEN test rigs are valid.

0.2 0.5 1 2 5 10 20 50 100 160

60

70

80

90

100

110

Sou

nd p

ower

leve

l LW

A [

dB]

Mechanical power rating P [kW]

50

Figure 3.5

� External noises

Noises which are not generated by the gear unit but are emitted by the gear unit are not taken intoconsideration.

Noises which are emitted by input and output machines as well as by the foundation are not taken intoconsideration either, even if they were transmitted to that point by the gear unit.

General guidelines concerning the influence of noise on people should betaken into consideration.

BA G298 EN 08.98 Page 11 of 39

4. Handling, Incoming goods and Storage

4.1 Handling

The drive is shipped in assembled state. Ancillary equippment (such as for example pipes and valves)are shipped packed separately.

The packing of the gear unit will differ, dependent on the method of shipment and size. The packing,unless otherwise agreed contractually, complies with HPE Packing Guidelines .

The symbols shown on the packing should be noted. Their significance is as follows:

Protect

from heat

Keep dry Centre of gravity Use no Sling here

hooksGoods

This side up Fragile

When handling and loading and unloading of the drive, excercise special careto avoid damage due to the use of force.

The drive should be lifted by the largest eye bolt present, this is usually the eyebolt on the gear. Check fixture of the eye bolt, tighten if necessary. Eye bolts on the motor may only be used for - handling of the motor alone or - as an additional support for reaching a horizontal mounting position of the

drive.

The permissible attaching weight is to be observed:

d3 [mm] 36 45 54 63 72 90 108

M M 8 M 10 M 12 M 16 M 20 M 24 M 30

m [kg] 140 230 340 700 1200 1800 3600

Highest load exercised by the drive to be attached in kg with tension ↑ in the directionof the screw axis.

Use additional suitable lifting devices (ropes or similar) for transport orinstallation in order not to exceed the max. load in the direction of the eye boltaxis.When attaching with several chains and ropes, two ropes must already besufficient to support the complete load. Lifting devices such as ropes andsimilar should be secured against slipping.

The threads in the shaft ends must not be used for attaching eye bolts forhandling.

Transport fixtures, if present, should be removed and stored or be madenoneffective according to additional notes. For further transport reuse or make effective again.

4.2 Incoming goods

The contents of the shipment are listed in the shipping documents. The shipment should be checkedfor completeness and shipping damage immediately on receipt. If necessary, a loss advice should bewritten out in the presence of the forewarder, otherwise repairing the damage without costs will not bepossible.

Damaged drives must not be put into operation.

Attention!

d3

M

F

Attention!

Attention!

Attention!

BA G298 EN 08.98Page 12 of 39

4.3 Storage

The drives should be stored in dry rooms with minimum temperature fluctuations in their positions ofuse on a horizontal wooden support and covered.

The storage area must be free of vibrations (shocks) as otherwise theanti-friction bearings may be damaged.

It is not permissible to stack drives on top of one another.

The gear units are provided with internal preservation, the free shaft ends and the flange surfaces areprovided with a protective coating.

Note: Unless agreed to the contrary by contract, a warranty period of 6 months is given forthe standard preservation. The warranty period starts to run on the date of deliveryof the gear unit.

In the case of prolonged interim storage (> 6 months) check preservation and renew it, if necessary(see Section 7. “Startup”).

The contractually agreed external coating (type, structure, colour) was carefully applied by spraypainting. See 5.11 for the resistances of the coating.

Note: Do not damage the coating!Mechanical (scratches), chemical (acids, alkaline solutions) or thermal (sparks,welding beam, heat) damage leads to corrosion and to the failure of the externalprotection.

If stored in the open, the drive should be covered with special care and itshould be ensured that neither moisture nor foreign matter are allowed tocollect on the gear unit.

Attention!

Attention!

BA G298 EN 08.98 Page 13 of 39

5. Technical description

5.1 General description

The gear units are supplied as two- or three-stage helical gear units. The gear units are suitable for thedifferent mounting positions taking into consideration the oil level.

5.2 Housings

The gear unit grey cast iron housings are stable, vibration dampening and are designed for continuousoperation.

The housings are manufactured using totally novel processes on most modern machines. This resultsin a high centre distance precision, which avoids a punctual overload of the tooth flanks. Furthermore,the high precision guarantees a favourable bearing load as well as good noise characterisitcs.

5.3 Toothed components

The toothed gear unit components are hardened and ground. The high quality of the tooth system aswell as the flank- and profile-corrected involute gearing minimizes the noise level of the gear unit andat the same time optimizes the carrying capacity of the flanks.

5.4 Lubrication

The components of the tooth system are adequately supplied with lubricant by splash lubrication. Thisensures that the gear units are especially maintenance-free.

See Section 10. “Maintenance and repair” for trouble-free operation.

5.5 Bearings

All shafts are mounted in anti-friction bearings. Lubrication of the anti-friction bearings is effected bysplash lubrication assisted by the gear wheels. Bearings which are not supplied with lubricant herebyare enclosed and grease lubricated (lifetime lubrication).

5.6 Shaft seals

Radial shaft seal rings at the shaft outlet prevent lubricant from escaping from the housing and dirtentering the housing. In case of higher ambient temperatures (60°C-100°C), shaft seal rings fromtemperature resistant material are used.

5.7 Cooling

The gear units do not require any additional cooling. The generously dimensioned housing surface issufficient for dissipating the heat loss in case of free convection.

The surface of the gear unit or the gear motor should be kept free of dirt(see Section 10. “Maintenance and repair“).

5.8 Couplings

As a rule, flexible couplings should be provided for the input drive and output drive sides of the gearunit.

If rigid couplings or other input drive and output drive elements are used which give rise to additionalradial and/or axial forces (for example gear wheels, belt pulleys, etc.), this must be agreed on bycontract.

Couplings with peripheral speeds at the outside diameter up to 30 m/s mustbe statically balanced. Couplings with peripheral speeds above 30 m/s requiredynamic balancing.

The special Operating Instructions should be noted for operation of the couplings.

Attention!

Attention!

Attention!

BA G298 EN 08.98Page 14 of 39

5.9 Backstop

The gearboxes can be provided with a mechanical backstop for certain requirements. During operation,this permits rotation in the specified direction only. This direction is marked by a corresponding directionof rotation arrow.

The backstop incorporates centrifugally operated grippers. When the gear unit is rotating in thespecified direction, the inner ring and the cage with the grippers rotate, the outer ring remainingstationary. From a certain speed of rotation, the grippers lift off and the back stop now operates withoutwear. The backstops are lubricated ready for duty, they don’t need to be serviced.

To prevent damage to or destruction of the backstop, it is essential to ensurethat the motor is not run against the locked backstop.Please observe the notes on the gear.

5.10 Rating plates

The rating plates of the gear units or gear motors are generally made from laminated aluminium foil.They are covered with a special transparent label, which guarantees an excellent long term resistanceagainst sunlight and media of all kinds (oil, grease, sea-water, cleaning solvents, etc.).

The adhesives and materials are chosen in such a manner, that an extremely tight fixation and a durablegood readability is given, even at the limits of the operating temperature range (–40°C ... +155°C). The edges of the rating plates are included under the respective painting, see 5.11 “Coats of paint”.

In special cases, i.e. with special specifications, riveted or screwed metal rating plates are used.

Attention!

BA G298 EN 08.98 Page 15 of 39

5.11 Coats of paint

All coats of paint are applied carefully by spray painting in the most modern painting plants.

Paintsystem

Typical areaof use

Overpaint-ability

Chem. phys.resistance

Temperatureresistance

Remark

Plastic

Standard:RAL 7011

Standard 1-layercoat of lacquerfor the internal

area, in the openwith roof, i.e.

suitableprotection against

sun andcontinuous

atmosphericinfluence

With plastic lacqueror synthetic resin

lacquer

Good resistance tocleaning agents, oil

and benzine, resistantto short-time attack by

diluted acid andalkaline solution (≤3%),not resistant to solvent

–40°C to 100°C

up to 140°C for ashort time

Standard coat oflacquer with

excellent adhesivecharacteristics

2K-PUR

Standard:RAL 7031

Standard 2-layercoat of lacquerespecially for

installation in theopen or in case of

increaseddemands on

corrosionprotection

After preceedinggrinding with:

2K-PUR lacquer2K-Epoxy lacquer

Excellent resistance to:oil, grease, benzine,water, sea water andcleaning agent; good

resistance toatmospheric influences

and diluted acid andalkaline solution (≤3%);

good mechanicalresistance to abrasion

–40°C to 150°C

Standard coat oflacquer for coolingtower and agitator

drive or if seawater resistancebelow deck or

similar is required

2K-Epoxy

Standard:RAL 7035

High-quality coatof lacquer for theexternal area or

in case of attacksby diluted acidand alkaline

solution (�5%)

After preceedinggrinding with:

2K-PUR lacquer2K-Epoxy lacquer

2K-AC lacquer

Excellent resistance toweak acid and alkaline

solution (≤5%), oil,grease, benzine,

cooling emulsion, salt,solvent; tough andscratch-resistant

coating film

–40°C to 150°C

2K-Epoxy lacquer“chalks” in case ofinstallation in theopen (does not

effect the quality),high gloss with

good mechanicalresistance

Primed

RAL 7032

For overpainting:adhesive agentfor all commonpaint systems,

temporarycorrosionprotection

Excellent with:plastic lacquer,synthetic resin

lacquer, 2K-PUR lacquer,2K-Epoxy lacquer,

SH lacquer,2K-AC lacquer

Good resistance tocleaning agent, to saltspraying and resistant

to oil and benzine–40°C to 150°C

Adhesive agentwith excellent

adhesivecharacteristics and

good corrosionprotection

Un-painted

For overpainting:(adhesive agent)

temporarycorrosionprotection

Excellent with:plastic lacquer,synthetic resin

lacquer, oil paint,bitumenous paint,

2K-PUR paint2K-Epoxy paint

(–40°C to 150°C)

Components fromgrey cast irondip-primed,

components fromsteel primed or

galvanised,components from

Al and plasticuntreated

Note: As a precaution against misunderstandings, we would like to point out that therecommendation does not imply any release in the sense of a warranty for the qualityof the paint provided by your supplier. Each paint manufacturer must warrant thequality of his product himself.

BA G298 EN 08.98Page 16 of 39

*) In case of primed or unpainted delivery of the drives, rating plate and cover foil, see 5.11 “Ratingplates”, are supplied with a painting mask foil. This enables further painting without additionalpreparation, e.g. shelter labeling or similar.

After drying of paint coat (minimum “touchable”) pull off painting mask foil:

Cover foilRating platePainting mask foil

Pull off strap

� Lift strap.� Pull off carefully in direction of the arrow, diagonal (not parallel to rating plate) beginning from one

corner.� If need be clean off paint splinters using a clean cloth or blowing away.

BA G298 EN 08.98 Page 17 of 39

6. Installation

6.1 General information on installation

During installation, the safety notes in Section 2. “Safety notes” should be observed.

Installation should be carried out by specialist personnel with extreme care. Damage caused byimproper execution results in the exclusion of our liability.

Right at the planning stage, it should be ensured that there is adequate space around the gear unit forinstallation and subsequent care and maintenance.

Adequate space for air intake should be left for drives with fan.

The drives may overheat if positioned in strong direct sunlight. Provideappropriate protective devices such as cover, roof or similar!

Before commencing installation, adequate hoist equipment must be provided for lifting the drives.

No welding work must be carried out on the drive. The drives must not be usedas ground points for welding work. Components of the tooth system andbearings may be destroyed by welding.

Note: Use shoulder studs of property class 8.8 or higher for mounting the drives.

All mounting possibilities assigned to the respective mounting positionshould be used.

6.2 Drives with foot mounting

6.2.1 Foundation

The foundation must be flat.

Note: The flatness of the gear unit support must not exceed the following values:for gear units up to size 88 ≤ 0.1 mmfor gear units above to size 108 ≤ 0.2 mm

It should be executed in such a way that no resonance vibrations occur and no vibration can betransmitted from adjacent foundations. Steel structures on which the gear unit is installed must betorsionally rigid. They are to be designed corresponding to weight and torque, taking into account theforces acting on the gear unit.

When mounting the gear unit on a concrete foundation, using foundation blocks, suitable recessesshould be provided in the foundation.

When alignment has been completed, slide rails should be grouted to the concrete foundation.

6.2.2 Installation of gear units with foot mounting

When making use of the highest possible output torque or shearing forces besides the foot mountingsby studs or bolts of property class 8.8. suitable additional positive connections such as e.g. cylindricalgrooved pins, dowel pins, spring type straight pins or fitting pipes should be provided. These measuresare also necessary for dynamically loaded screw connections. In some cases headed screws can’t be used, due to lack of space for insertion. If in doubt, pleasecontact us giving the type of gear.

Do not use spring rings, serrated lock washers, spring washers or tooth lockwashers, plate springs or idler pulleys as substitute for the above mentionedpositive connections.

The gear unit housings must not be distorted when tightening the fasteningscrews.

Note: See 10.2.5 for tightening torques.

Note: Gear units which require the use of a hoist due to their weight should be attachedaccording to 4.1.

Attention!

Attention!

Attention!

Attention!

Attention!

BA G298 EN 08.98Page 18 of 39

6.3 Drives with housing flange mounting

With housing flange (C-Type) at size DZ/ZZ108-168, the customer side can be pinned.The output flanges are designed in a manner, that the permissible torques and radial loads can betransmitted safely by the screw connection.

When there is need for additional safety , e.g. reversing or operation with heavyshock load, the existing pin holes can be used.The gearbox can also be bored and pinned together with the maschine. In thiscase the given dimensions should be observed.

DZ/ZZ108 DZ/ZZ128

DZ/ZZ148 DZ/ZZ168

With heavy straight pins to DIN 1481: Use existing pinholes in the housing flange.

With dowel pins to DIN EN 28740 / ISO 8740: Bore the mating part together with the housing.

Do not exceed max. bore depth given (A-A).

6.4 Drives with foot-/flange mounting(Mounting positions B3/B5, V1/V5, V3/V6)

Fastening of the drive unit for transmission of forces and torque only must be effected by flangemounting or foot mounting according 6.2 to avoid distortion of the gear unit housings.Second fastening facility (foot or flange) normally is provided for attached elements, e.g. guard coversor similar, while its weight should not exceed max. 30% of the drive unit weight.

The gear housings must not be distorted through the attached elements.Likewise, no forces, torque and vibrations should be transmitted to the driveunits, e.g. when small auxiliary units are attached.

Attention!

Attention!

Attention!

BA G298 EN 08.98 Page 19 of 39

6.5 Installation of input drive and output drive elements on gear unit shafts

Elements such as running wheels, chain sprockets and gear wheels, couplings and belt pulleys, etc.should be installed on the gear unit shafts using a fitting device.

Note: Deburr elements to be fitted in the bore and keyway area. Recommendation: 0.2 x 45°

Centre bores according to DIN 332 are provided in the shaft faces which are used in this case.

Description of the assembly work

� Remove corrosion protective coating from the shaft ends and flanges with benzine or solvent, orremove protection skin if existing.

Ensure adequate ventilation. Do not inhale vapours. Do not smoke.Explosion hazard.

Under any circumstances, ensure that benzine or solvent does not contact theshaft seals.

� Fit input drive and output drive elements on the shaft ends and secure them, if necessary.

If couplings are used which are to be fitted after heating, the Operating Instructions of the coupling inquestion should be observed.

Under no circumstances must the part to be installed be driven onto the shaftby hammer blows as this may cause damage to bearings, housing, shaft andcirclips.

Example of a fitting device for installing couplings orhubs on gear unit or motor shaft ends. If possible, the thrust bearing on the fitting device canbe obmitted.

Correct assembly arrangement of running or gearwheel chain sprocket, pulley, or similar, in order tokeep the load of the shaft or bearing by shearing forces as low as possible.

Attention!

Attention!

wrong right

Hub Hub

BA G298 EN 08.98Page 20 of 39

6.6 Attachment of standard motors

6.6.1 Attachment to coupling lantern with rotation elastic coupling


� Put coupling half Pos.556 on motor shaft extension under consideration of 6.5.Secure coupling half with grub screw Pos.564 against axial displace.For motors with half key balancing (marking “H”): Remove any protruding and visible part of the key.

Distance dimension z12 according to Table 6.6.1 should be kept.

Note: Dimension z12 applies to the standard assignment of the coupling. In case of aspecial assignment, the dimension should be taken from the corresponding specialdimension drawing.

� Insert elastic element Pos.557 into coupling half Pos.557.

� Flange motor to coupling lantern and fasten it by means of screws Pos.505 according to theprescribed tightening torque, Table 10.2.5.

Note: In case of installation of the drive outdoors or with a higher degree of protection(� IP 55): Seal the flange, screws (Pos.505) and plugs (Pos.502) if present orinserted elements, e.g. proximity switches with sealing compound.

555 557 564 z12

505

556

502

502 Plug 556 Coupling half505 Hexagon head screw 557 Elastic element555 Coupling half 564 Grub screw

Motor size(IEC B5-Motor)

63 71 80 90 100 112 132 160 180 200 225 250

z12 [mm] 1 5 15 26 30 30 45 66 59 60 90 75

Motor size(Nema-TC-motor)

56C143TC

-145TC

182TC-

184TC

213TC-

215TC

254TC-

256TC

284TC-

286TC

324TC-

326TC

364TC-

365TC

z12 [mm] 27.5 28 36.5 45.5 50 61 71 78

Table 6.6.1

Attention!

BA G298 EN 08.98 Page 21 of 39

6.6.2 Attachment to coupling lantern with clamping ring


� Remove mounting plugs Pos.502 and Pos.503.

� To fasten the clamping ring align input shaft and clamping ring of the gear unit to the mounting bores(Pos.502 and 503) by rotating.

� Flange motor to coupling lantern and fasten it by means of screws Pos.505 according to theprescribed torque, Table 10.2.5.

Note: In case of installation of the drive outdoors or with a higher degree of protection(� IP 55): Seal the flange, screws (Pos.505) and mounting plugs (Pos.502 andPos.503) with sealing compound.

� Screw the grub screw Pos.564 onto the key Pos.563 until a light resistance is felt, then unscrew halfa turn (Wrench size SW1, see table 6.6.2).

� To stop the shafts from turning, use a wrench in the grub screw Pos.564 through bore Pos.503.

� Tighten hexagon socket screw Pos.561 according to the prescribed torque, Table 6.6.2 (wrench sizeSW2 see Table 6.6.2).

� Tighten grub screw Pos.564.

� Cover mounting bores with plugs Pos.502 and Pos.503.

561

503

502 505

564563

502 Mounting plug503 Mounting plug505 Hexagon head screw561 Hexagon socket screw563 Parallel key564 Grub screw

Motor size(IEC B5-Motor)

63 71 80 90 100 112 132 160 180 200

Torque [Nm] 10 10 10 25 25 25 25 25 25 50

SW1 [mm] 2 2 2 3 3 3 3 3 3 4

SW2 [mm] 5 5 5 6 6 6 6 6 6 8

Motor size(NEMA TC-Motor)

56C143TC

-145TC

182TC-

184TC

213TC-

215TC

Torque [Nm] 10 10 25 25

SW1 [mm] 2 2 3 3

SW2 [mm] 5 5 6 6

Table 6.6.2

BA G298 EN 08.98Page 22 of 39

6.7 Motor base plate

The motor base plate serves for supporting a foot mounted IEC standard motor which is mainly usedfor driving a V-belt drive. The motor should be mounted according to the Operating Instructions of themanufacturer.

The appropriate Operating Instructions for V-belt drives, e.g. V51 should beobserved. Assemble pulleys on output shaft Pos.515 under consideration of6.5.

Note: Incorrect belt tension results in belt breakages and damage to the bearing.

In case of other devices, e.g. chain drive or similar, the appropriate instructions of the manufacturershould be observed.

Always install suitable guards for covering belt drives, chain drives or otherunprotected types of drives.

After assembly and adjustment is finished, protect columns Pos.581 and, ifpresent, other shiny areas against corrosion: See 7.4 or using a differentsuitable, long term corrosion protective.

6.7.1 IEC-Motor frame sizes up to 112


� Loosen grub screws (4x) Pos.585.

� Re-adjust height of motor base plate Pos.590 by turning screws Pos.588 equally, e.g. for adjustmentof belt tension.

� After adjustment of proper height, tighten screws Pos.585 using tightening torques given inTable 10.2.5.

585

515

590588588

515 Input shaft 588 Screw585 Screw 590 Motor base plate

Attention!

Attention!

BA G298 EN 08.98 Page 23 of 39

6.7.2 IEC-Motor frame sizes 132 to 200


Do not re-adjust the motor base plate in downward mounting position as it mayslip out of the holder.

� Loosen screws (4x) Pos.585.

� Re-adjust height of motor base plate Pos.590 by turning hexagon nut Pos.589, e.g. for adjustmentof belt tension.

� After adjustment to the correct height, tighten grub screws Pos.585.

590

589

585

515

585

581

581

585

585

515 Input shaft581 Column585 Grub screw589 Hexagon nut590 Motor base plate

6.7.3 IEC-Motor frame sizes from 225


Do not re-adjust the motor base plate in downward mounting position as it mayslip out of the holder.

� Loosen screws (4x) Pos.585.

� Loosen hexagon nuts Pos.592.1 and Pos.592.2 of the support.

� Re-adjust height of motor base plate Pos.590 by turning hexagon nuts (2x) Pos.589 equally, e.g. foradjustment of belt tension.

� After adjustment to the correct height, tighten grub screws Pos.585.

� Tighten hexagon nuts Pos.592.1 and Pos.592.2.

When tightening the hexagon nuts Pos.529.1 and Pos.592.2 the motor baseplate Pos.590 must not be forced into a different position or be distorted.

589

585

585

581

515

590592.1592.2

515 Input shaft581 Column585 Grub screw589 Hexagonal nut590 Motor base plate592.1 Hexagonal nut592.2 Hexagonal nut

Attention!

BA G298 EN 08.98Page 24 of 39

7. Startup

7.1 Measures before startup

7.1.1 Oil level check

� Check oil level before connection of drive unit with mains supply or

� Shut down the gear unit by shutting off the drive unit.

Secure drive unit to prevent accidental startup. Affix notice at the switch-on point.

Note: In case of tandem gear units, each single gear unit should be inspected separately.Check oil level with the oil cooled down. Even after a short run, oil needs a longer ‘rest’ in order to release possible air bubbles.

7.1.1.1 Checking the oil level in the gear unit housing

Screw out the plug screw at the point marked with this symbol .

Note: If the oil level is correct, a small amount of oil may flow out, the oil must at least comeup to the lower edge of the bore.

Oil level

Any oil escaping should be removed immediately with oil binding agent in anenvironmentally compatible way.

For drives with only one plug screw, checking the oil level is not possible.

7.1.1.2 Oil sight glass (Special feature)

� If equipped with an oil sight glass, the oil level must be visible within the area of the sight glass.

Oil level

7.1.1.3 Dipstick (Special feature)

� Check oil level with dipstick:

The oil level must be between the lower and upper mark of the dipstick.

7.1.2 Startup without long term preservation

� MOTOX -N drives are delivered with the appropriate lubricants ready for operation depending onthe specified conditions of use.

In case of gear units which require housing ventilation (sizes 48...168), thenecessary venting screw is supplied separately. Before starting up the gearunit, the venting screw should replace the corresponding plug screw.

It should be inserted at the point marked with this symbol (see 3.2).

Attention!

BA G298 EN 08.98 Page 25 of 39

7.1.3 Startup in case of long term preservation

7.1.3.1 Long term preservation up to 18 months

Before starting up the gear unit, it should be filled with lubricant (see 7.1.4).

7.1.3.2 Long term preservation up to 36 months

The gear unit is completely filled with oil. Before the startup, the oil levelshould be corrected according to the type of construction.

The oil level should be reduced to the level marked with this symbol

(see 7.1.1).


7.1.4 Filling with lubricant

� Screw out venting screw or venting filter or plug screw at the highest point (see 3.2 for point ofventilation).

Fill gear unit up with fresh oil using a filling filter (max. filter coarseness 60 µm).The quantity of oil depends on the mounting position!

Note: Recommendations on the oil to be used should be taken fromSection 10. “Maintenance and repair”.Data, such as oil grade, oil viscosity and oil quantity required will be found on the ratingplate (see Section 3. “Technical data”).

Finally, check the oil level (see 7.1.1).

7.1.5 Drive with backstop


Check the direction of rotation before putting into service!

E.g. by manually turning the input shaft or the motor. Check the motor direction of rotation accordingto the phase sequence, swap two supply leads if necessary.

7.2 Shutdown



Note: If shut down for a considerable period of time, the gear unit should be run briefly atintervals of three weeks. If shut down for a period exceeding six months, the gear unitshould be preserved (see 7.3 and 7.4).

Attention!

Attention!

Attention!

Attention!

Attention!

BA G298 EN 08.98Page 26 of 39

7.3 Preservation with gear oil

� Long term preservation up to 36 months.

Completely top up the gear unit with the filled oil grade.


7.4 External preservation procedure

� Clean surfaces.

Cleaning the drive with a high-pressure cleaning device is not permissible. Do not use sharp-edged tools.

� Smear shaft seal rings with grease for protection against preservatives.

� Coating: check, in case of damage have it repaired by an expert.

� Apply preservatives, e.g.:

Protection time Preservativename

Layer thickness Remarks

up to 12 months Tectyl 846 K19 approx. 50 µmWax base long preservation, sea water resistant,tropic-proof, benzine-soluble

Table 7.4: External preservation of shaft ends and other bright metal surfaces

8. Operation

During operation, the gear units should be checked for

� excessive operating temperature (In continuous operation using mineral oil, the gear unit is suitable for a temperature of 90°C; at higher temperatures, it may be necessary to use synthetic oil.Short-term temperatures of 100°C are permissible, see also Section 10. “Maintenance and repair”)

� any changes in gear unit noises

� possible oil leakage at the housing and the shaft seals

If irregularities are detected during operation, the drive assembly should beshut off immediately . The cause of the malfunction should be determined withthe aid of the Troubleshooting Table (Section 9. “Disturbances, reasons andremedy”). The Troubleshooting Table lists possible malfunctions, their causes andsuggestions for their remedy.If the cause cannot be determined or there is no facility for repair with suitableequipment, we recommend calling in one of our service fitters(see Section 11. “Spare parts stock, service addresses”).

Attention!

Attention!

BA G298 EN 08.98 Page 27 of 39

9. Disturbances, reasons and remedy

9.1 General information on malfunctions

Note: Malfunctions occuring during the warranty period which necessitate repair of the gearunit may only be repaired by FLENDER-HIMMEL service personnel. Even after thewarranty period has elapsed, we recommend our customers to consult our ServiceDivision concerning malfunctions whose cause cannot be clearly ascertained.

Malfunctions Causes Remedy

Temperature rise at bearingpoints

Oil level in gear unit housingtoo low

Oil is overaged

Bearing(s) defective

Check the oil level at roomtemperature; top up if necessary.

Check when last oil changewas carried out; change oil if necessary. See Section 10.

Call in FLENDER TÜBINGENService. Check bearing(s); replace ifnecessary.

Excessive operatingtemperature

Oil level in gear unit housingtoo high

Oil is overaged

Oil is very dirty

Fan cowl of the motor and/ordrive is very dirty

Backstop does not run freely

Check the oil level at roomtemperature; correct oil level if necessary.

Check when last oil changewas carried out; change oil if necessary. See Section 10.

Change oil. See Section 10.

Clean fan cowl and surface ofthe drive.

Call in FLENDER TÜBINGENService. Repair backstop, replace ifnecessary.

Change in gear unit runningnoises

Damage to tooth systems

Excessive bearing play

Bearing defective

External loading on input andoutput too high

Call in FLENDER TÜBINGENService. Check toothed components; ifnecessary replace damagedcomponents.

Call in FLENDER TÜBINGENService. Adjust bearing play.

Call in FLENDER TÜBINGENService. Replace defective bearings.

Correct loading to nominaldata e.g. correct belt tension.

BA G298 EN 08.98Page 28 of 39

Malfunctions RemedyCauses

Loud noises in the region ofthe gear unit mounting

Gear unit mounting hasloosened

Tighten bolts/nuts atrecommended tighteningtorque.Replace damaged bolts/nuts.

Noticeable lubricant leakage Wrong mounting position/oillevel

Inadequate sealing of housingcover or joints

Radial shaft seal defective

Correct mounting positionaccording to rating plate, check oil level.

Call in FLENDER TÜBINGENService. Seal again.

Call in FLENDER TÜBINGENService. Replace radial shaft seal.

Drive does not start or startsunder great effort

Lubricant viscosity incorrect

Oil level in the gear unithousing too high

External loading on output toohigh

Brake of motor is not released

Drive works against the back-stop

Fill in correct lubricant.

Check oil level at roomtemperature, drain oil if necessary.

Correct loading to nominaldata.

Check switching/connection ofbrake, correct if necessary.

Call the customer service! Change the direction of rota-tion of the motor or the back-stop. Check the backstop.

Drop in speed or torque Belt tension too low(with belt drive)

Correct belt tension. Replace belt if necessary.

Play on input and output toohigh

Elastic element worn (with couplings)

Positive connection worn outby overload

Replace elastic element; call in FLENDER TÜBINGENService if necessary.

Call in FLENDER TÜBINGENService.

BA G298 EN 08.98 Page 29 of 39

10. Maintenance and repair

10.1 General information on maintenance

Note: All maintenance and repair work should be carried out with due care and only bythoroughly trained personnel. The notes in Section 2. “Safety notes” should be observed.

The periods listed in T able 10.1 are largely dependent on the conditions of useof the gear unit. For this reason, it is only possible to give average periodswhich refer to a

daily operating time of 24 hduty factor of ED 100 %input drive speed of 1500 1/minmax. oil temperature of 90 °C (with mineral oils, CLP)

100°C (with synth. oils, PGLP)

Note: Under different operating conditions, the periods should be adjusted accordingly.

Measures Causes Remedy

Observe/check gear unitnoise for changes

Observe/check oiltemperature

Check oil level

Check gear unit for leakage

Initial oil change after startup

Subsequent oil changes

Relubrication of anti-frictionbearings (in drive-units“A, K., P” only)

Clean vent plug

Clean drive

Check all fixing screws fortightness

Carry out complete inspectionof gear unit

from time to time, more oftenduring operation if possible

from time to time, more oftenduring operation if possible

monthly

monthly

after approx. 10000 operatinghours, at the latest after 3 years

every 3 years or 10000operating hours 1)

annualy or every 5000 operatinghours 2)

every 3 months

according to the degree ofcontamination

at least once a year

at least once a year

see 7.1.1

see 10.2.1

see 10.2.1

see 10.2.2

see 10.2.3

see 10.2.4

see 10.2.5

see 10.2.6

Table 10.1: Maintenance and repairs

1) With synthetic oils, the times can be doubled.

2) Grease lifetimes indicated are valid for an ambient temperature of max. 40°C. For every 10°C temperature rise reduce the lubrication period by the factor 0,7 (max. 20°C = Factor 0,5).At an ambient temperature of 25 °C twice the grease lifetime can be expected.

Attention!

BA G298 EN 08.98Page 30 of 39

10.2 Description of maintenance and repairs

10.2.1 Carrying out oil changes

When changing the oil the gear unit should always be filled with the oil gradepreviously in use. Mixing oils of different grades is not permissible. Inparticular, synthetic oils may not be mixed with mineral oils or differentsynthetic oils. When changing over from mineral oil to synthetic oil or fromsynthetic oil with a particular base to synthetic oil with another base, the gearunit must be flushed through thoroughly with the new oil grade.

When changing the oil, the housing must also be cleaned thoroughly by flushing with oil to remove oilsludge, abraded particles and residues of old oil. For this purpose, the same oil grade should be usedas is in use for operation of the gear unit. Viscous oils should be warmed beforehand. Only when allresidues have been removed, the fresh oil may be poured in.

Note: The oil should be drained off after shutdown, while the gear unit is still warm.



� Place a suitable collection receptacle under the oil drain plug of the gear unit housing.

� Unscrew the vent plug on top of the housing.

� Unscrew oil drain plug and drain oil off into the receptacle.

There is a risk of scalding from the hot oil emerging. Wear protective gloves.

� Screw in oil drain plug.

Note: Check condition of seal ring, use new seal ring if necessary.

Fill gear unit up with fresh oil using a filling filter (max. filter coarseness 60 µm)

Note: Recommendations on the oil to be used should be taken fromSection 10. “Maintenance and repair”.Data, such as oil grade, oil viscosity and oil quantity required will be found on the ratingplate (see Section 3. “Technical data”).

� Check oil level (see 7.1.1).


� Screw in vent plug on top of the housing.

10.2.2 Relubricating the anti-friction bearings in drive units

Relubricating the drive units is necessary from motor size 225 on.

Do not mix greases of different soap bases when relubricating.

The grease is injected into the bearing point by means of a grease gun via the grease nipples providedfor this purpose. See 10.3 for lubricating greases to be used.

Note: Inject 50 g of grease per lubricating point.

Attention!

Attention!

Attention!

BA G298 EN 08.98 Page 31 of 39

10.2.3 Cleaning the vent plug

The vent plug should be cleaned when a coating of dust has collected - at least every 3 months. Forthis purpose, the vent plug should be unscrewed, rinsed in benzine or a similar cleaning agent and driedor blown through with compressed air.

Ensure adequate ventilation. Do not inhale vapours. Do not smoke.Explosion hazard.

10.2.4 Cleaning the drive



Keep drives free of dirt and dust, etc. in order to ensure a sufficient heat dissipation.

Cleaning the drive with a high-pressure cleaning device is not permissible. Do not use sharp-edged tools.

10.2.5 Checking all fixing screws for tightness



� Check all fixing screws for tightness with a torque wrench

Thread size Property class min. Tightening torque(general tolerance +10%)

M 6 8.8 10 Nm

M 8 8.8 25 Nm

M 10 8.8 50 Nm

M 12 8.8 90 Nm

M 16 8.8 210 Nm

M 20 8.8 450 Nm

M 24 8.8 750 Nm

M 30 8.8 1500 Nm

M 36 8.8 2500 Nm

Table 10.2.5: Tightening torques

Note: Unserviceable screws should be replaced by new ones of the same property classand type.

10.2.6 Inspection of the drive

The drive should be checked annually and with the aid of an inspection plan according to the possiblecriteria listed in Section 9. “Disturbances, reasons and remedies”.

In addition, the drive should be checked according to the criteria described in Section 2. “Safety notes”,e.g. check tight fit of the protective devices.

Any damage of the coating should be repaired by an expert.

Attention!

BA G298 EN 08.98Page 32 of 39

10.3 Lubricants

Oil selection should always be determined by the oil viscosity (ISO VG class) specified on the ratingplate of the gear unit. The viscosity class is valid for the operating conditions agreed on by contract.

Under different operating conditions, it will be necessary to consult us at FLENDER TÜBINGEN .

We have compiled a Lubricant Table of the lubricants suitable for the gear unit (see Table 10.3).

We are acquainted with the composition of these lubricants and know that, in accordance with the latesttechnology, they possess values in respect of loadability, corrosion protection, load carrying capacitywith micro-pitting, as well as compatibility with seals and internal coating on which the design of the gearunit has been based.

Thus, we recommend that our customers should select a lubricant from this Table, taking in accountthe viscosity class stated on the rating plate.

The lubricants listed have no approval according to USDA -H1/-H2 (UnitedStates Department of Agriculture) and are as such not, or only limitedapproved, for use in the food or pharmaceutical industry. The lubricants are not, or only limited biologically decomposeable. They areusually according to the Classes 2 or 1 of hazard for water. If lubricants are necessary according to these classifications, please contactthe factory. If the gearboxes are filled with special lubricants from the factory for the casesgiven above, this can be seen on the name plate e.g.: CLP-H1 VG220 or

CLP E VG220.

Note: As a precaution against misunderstandings, we would like to point out that therecommendation does not imply any release in the sense of a warranty for the qualityof the lubricant provided by your supplier. Each lubricant manufacturer must warrantthe quality of his product himself.

If for any reason you deem important, you do not follow our recommendation, you yourself will assumethe responsibility for the technical suitability of the lubricant.

In order to assist you to minimize the technical risk in such cases, we recommend that you consult usat FLENDER TÜBINGEN.

� In the case of synthetic oils not listed in Table 10.3, the corrosiveness of the oil to our internal coatingshould also be checked. A check of this nature is carried out by us at cost (cost on request).

BA G298 EN 08.98 Page 33 of 39

DesignationExamples of lubricants

Lubricant

Designationaccording

toDIN 51502

MineralOils

OilCLP

ISOVG220

DegolBG220

EnergolGR-XP220

FalconCLP220

SPAR-TAN

EP220

RenolinCLP220

KlüberoilGEM 1

220

Mobil-gear630

OptigearBM220

OMALAOIL220

Ersolan220

TRIBOL1100

ISO220Oils1) Oil

CLPISOVG100

DegolBG100

EnergolGR-XP100

FalconCLP100

SPAR-TAN

EP100

RenolinCLP100

KlüberoilGEM 1

100

Mobil-gear627

OptigearBM100

OMALAOIL100

Ersolan100

TRIBOL1100

ISO100

SyntheticOils

OILPGLP

ISOVG460

DegolGS460

EnersynSG-XP

460

PolydeaPGLP460

GLYCO-LUBE460

RenodiolPGP460

SynthesoD460EP

GlygoyleHE460

OptiflexA460

TIVELAOILSD

TRIBOL800/460

yOils2) OIL

PGLPISOVG220

DegolGS220

EnersynSG-XP

220

PolydeaPGLP220

GLYCO-LUBE220

RenodiolPGP220

SynthesoD220EP

Glygoyle30

OptiflexA220

TIVELAOILWB

TRIBOL800/220

Lithium saponifiedanti-friction bearinggreases NLGI 3/2

AralubHL3,HL2

EnergreaseLS3,LS2

Glissando30,20

BE-ACON

3

RenolitFWA220,FWA160

CENTRO-PLEX

GLP402

Mobilux3,2

LongtimePD2

ALVANIAR3,R2

WiolubLFK2

TRIBOL4020/220-2

Table 10.3: Lubricant selection

Further suitable lubricants of the brandsADDINOL, CASTROL, FUCHS Lubritech, OMV, STATOIL, TEXACO, TUNAP and VALVOLINEwe are pleased to nominate on request at one of our Service Addresses.

1) Mineral base gear oils in accordance with designation CLP as per DIN 51 502.These oils comply with the minimum requirements as specified in DIN 51 517 Part 3. They are suitable for the following operating temperatures:CLP ISO VG 220: –5°C ... +90°CCLP ISO VG 100: –15°C ... +80°CThe maximum temperatures can be exceeded by 10K for a short time.

2) Synthetic lubricants (polyglycols) in accordance with designation PGLP as per DIN 51 502.These oils are distinguished by their high ageing resistance and favourable effect on the efficiencyof the gear unit. They are suitable for the following operating temperatures: PGLP ISO VG 220: –30°C ... +100°C PGLP ISO VG 460: –15°C ... +100°C The maximum temperatures can be exceeded by 10K for a short time.

Note: If the operating temperature of the drive exceeds or undershoots the given limitvalues, the oil selected should be checked for suitability by consultingFLENDER TÜBINGEN .

BA G298 EN 08.98Page 34 of 39

11. Spare parts stock, service addresses

11.1 Stocking spare parts

Maintaining a stock of the most essential replacement and wearing parts on site will ensure that thedrive is serviceable at all times.

We assume warranty only for original spare parts supplied by us.

We would like to explicitly draw attention to the fact that spare parts andaccessories not supplied by us have not been tested and approved by useither. Fitting and/or use of such products can therefore under certaincircumstances adversely effect structurally specified properties of the driveand will thus impair active and/or passive safety. No form of reliability orwarranty will be assumed by FLENDER TÜBINGEN GmbH for damage causedby the use of non-original spare parts and accessories.

Please note that special production and supply specifications frequently exist for components and wewill always offer spare parts in accordance with the latest technology and the latest legal requirements.

When ordering spare parts, the following data should be stated:

Order No. (see rating plate 3 )

Type designation (see rating plate 4 )

Part No. (three-digit pos. No. from the spare parts list, or six-digit ident. No. or seven-digit part No.)

Quantity

11.2 Spare parts and Customer Service addresses FLENDER TÜBINGEN Germany FLENDER TÜBINGEN Europe FLENDER TÜBINGEN International

See following pages.

Attention!

BA G298 EN 08.98 Page 35 of 39

FLENDER Germany

Sales Office BerlinEgellsstraße 21, D-13507 Berlin

Postfach, 13500 BerlinTel.: (030) 4301-0

Fax: (030) 4301-2712

Your contact in Tübingen: Tel.: 07071 / 707-326 Fax: 07071 / 707-475

Sales Office HannoverMarktplatz 3, D-30853 Langenhagen

Postfach 1869, D-30839 LangenhagenTel.: (0511) 77189-0

Fax: (0511) 77189-89


Sales Office HerneWestring 303, D-44629 Herne

Postfach 101240, D-44602 HerneTel.: (02323) 497-0

Fax: (02323) 497-250


Babcock Centre Officec/o Deutsche Babcock AG H2 / 529

Duisburger Straße 375, D-46049 OberhausenTel.: (0208) 833-1430Fax: (0208) 833-2187


Sales Office StuttgartBreitwiesenstraße 27, D-70565 Stuttgart

Postfach 800423, D-70504 StuttgartTel.: (0711) 78054-51Fax: (0711) 78054-50

Your contact in Tübingen : Tel.: 07071 / 707-469 Fax: 07071 / 707-211

Sales Office MünchenLiebigstraße 15, D-85757 KarlsfeldPostfach 1264, D-85750 Karlsfeld

Tel.: (08131) 9003-0Fax: (08131) 9003-33

Your contact in Tübingen : Tel.: 07071 / 707-389 Fax: 07071 / 707-211

FLENDER TÜBINGEN GMBH D-72007 Tübingen - Bahnhofstraße, D-72072 Tübingen Tel.: (07071) 707-0 - Fax: (07071) 707-400

Further partners in the Flender Group:

FLENDER ENGINEERING & SERVICE D-44607 Herne - Südstraße 111, D-44625 Herne ANTRIEBSTECHNIK GMBH Tel.: (02323) 940-0 - Tx.: 8229868 - Fax: (02323) 940-200

A. FRIEDR. FLENDER AG D-46393 Bocholt - Alfred-Flender-Straße 77, D-46395 Bocholt Tel.: (02871) 92-0 - Tx.: 813841 - Fax: (02871) 922596

LOHER AG D-94095 Ruhstorf - Hans-Loher-Straße 32, D-94099 Ruhstorf Tel.: (08531) 390 - Tx.: 8531806 - Fax: (08531) 39437

A. FRIEDR. FLENDER AG Thierbacher Straße 24, D-09320 Penig GETRIEBEWERK PENIG Tel.: (037381) 60 - Tx.: 322661 - Fax: (037381) 80286

FLENDER GUSS GMBH Obere Hauptstraße 228-230, D-09228 Wittgensdorf Tel.: (03722) 64-0 - Tx.: 322352 - Fax: (03722) 64-3112

BA G298 EN 08.98Page 36 of 39

FLENDER EuropeAUSTRIAFlender Ges.m.b.H. � �Industriezentrum Nö-SüdStrasse 4, Objekt 14, Postfach 132A-2355 Wiener NeudorfTel. 02236-64570Tx. 79141Fax 02236-64570-10

BELGIUM & LUXEMBOURGN.V. Flender Belge S.A. � �Cyriel Buyssestraat 130B-1800 VilvoordeTel. 02-2531030Tx. 22449Fax 02-2530966

CZECH REPUBLICA. Friedr. Flender AG �Branch Office Czech RepublicHotel DUO, Teplicka 17CZ-19000 Praha 9Tel. 00420-2-83882300Fax 00420-2-83882205

DENMARKFLENDER AS � �Sydmarken 46DK-2860 SoborgTel. 0045-7025-3000Fax 0045-7025-3001

EAST EUROPEAN COUNTRIESVertriebszentrum Berlin �Egellsstrasse 21D-13507 BerlinTel. 0049-304301-0Fax 0049-304301-2712

FINLANDFlender Oy �Korppaanmäentie 17 CL 6FIN-00300 HelsinkiTel. 09-4361366Fax 09-4361410

FRANCEFlender France S.A.R.L. � �3, Rue Jean MonnetZone des CôtesF-78990 ElancourtB.P. 5F-78312 Maurepas CedexTel. 1-30663900Tx. 699715Fax 1-30663513

BRANCH OFFICES:Flender S.A.R.L.25, Boulevard JoffreF-54000 NancyTel. 038-3308590Fax 038-3308599

Flender S.A.R.L.36, Rue Jean BroquinF-69006 LyonTel. 0472-839520 Fax 0472-839539

GREECEFlender Greece �14, Grevenon Str.GR-11855 AthensTel. 00301-3423827Fax 00301-3423827E-mail: [email protected]

Mangrinox S.A. �14, Grevenon Str.GR-11855 AthensTel. 00301-3423201-3 / 3412427Fax 00301-3459928 / 3459767E-mail: [email protected]

HUNGARYA. Friedr. Flender AG �Branch OfficeBécsi Út 3-5H-1023 BudapestTel. 01-3450720Fax 01-3450729

ITALYFlender Cigala S.p.A. � �Via Privata da Strada Provinciale, 215I-20040 Caponago (Mi)Tel. 0039-02-95742371Fax 0039-02-95743887

THE NETHERLANDSFLENDER NEDERLAND BV � �Lage Brink 5-7NL-7317 BD ApeldoornTel. 055-5275000Fax 055-5218011

NORWAYATB Norge � �G. Bauknecht A.S.Frysjavn 40N-0884 OsloTel. 02-2021036Tx. 71062Fax 02-2021050

POLANDA. Friedr. Flender AG �Branch OfficeOddzial w Mikolowieul. Wyzwolenia 27PL-43-190 MikolowTel. 032-2264561Fax 032-2264562

PORTUGALROVEX �Rol. e Vedantes, Lda.Rua Nelson de Barros, 11 r/c esq.P-1900 LisboaPortugalTel. 00351-1-8160240Fax 00351-1-8145022

SPAINFlender Ibérica S.A. �Poligono Industrial San MarcosCalle Morse, 31 (Parcela D-15)E-28906 Getafe/MadridTel. 00349-1-6836186Fax 00349-1-6834650

SWEDENFlender Svenska AB �Ellipsvägen 11S-141 75 HuddingeTel. 46-8-4495670Fax 46-8-4495690

SWITZERLANDFlender ATB-Loher � �Zeughausstr. 48CH-5600 LenzburgTel. 062-8857600Fax 062-8857676

TURKEYFlender Güc Aktarma Sistemler San.��ve Tic. Ltd. STIImes Sanayi SitesiE Blok 502. sokak No.22TR-81360 Dudullu-IstanbulTel. 0216-3643413Fax 0216-3645913

UNITED KINGDOM & EIREFlender-Himmelwerk Ltd. � �Thornbury Works, Leeds RoadGB-Bradford BD3 7EB West YorkshireTel. 01274-657700Tx. 517543Fax 01274-669836

BOSNIA-HERZEGOVINA /BULGARIA / CROATIA / REPUBLICOF MACEDONIA / REPUBLIC OFYUGOSLAVIA / ROMANIA /SLOVAKIA / SLOVENIA / ALBANIAA. Friedr. Flender AG �Branch OfficeIndustriezentrum Nö-Süd,Strasse 4, Objekt 14A-2355 Wiener NeudorfTel. 02236-6457020Fax 02236-6457023

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BA G298 EN 08.98 Page 37 of 39

FLENDER InternationalA F R I C A A M E R I C AALGERIA & TUNESIASimetra Flender S.A.R.L. �3, Rue Jean MonnetZone des CôtesF-78990 ElancourtB.P. 5, 78312 Maurepas CedexTel. 1-30663900Tx. 699715Fax 1-30663513

EGYPTFarid Hassanen & Co. �81, Matbaa Ahleia StreetBoulac-Cairo, A.R.E.Tel. 5751489Tx. 22936, 22125Fax 5751383

Workshop and Service:13, Selim Oma StreetBoulac-Cairo, A.R.E.Tel. 764656, 774897Tx. 22936, 22125Fax 769741

MOROCCOS.M.E.M. �15, Boulevard du FouaratCasablancaTel. 2-240253, 2-240271Tx. 26923M

SAUDI ARABIA/U.A.E./KUW AITTicos-International �General Trading Co.P.O. Box 2191AjmanTel. 428716Fax 428730

SOUTH AFRICAFlender Power Transmission (Pty.)Ltd.��No.8 Greenfield ParkCnr. Furnace Street & Quality RoadIsando, Kempton Park Tv1.P.O. Box 8358, Elandsfontein 1406Tel. 011-3922850/1/2/3/4/5Tx. 4-28445Fax 011-3922434

BRANCH OFFICE:P.O. Box 28283 � �Bothasig, Cape Town 7406Unit No.3 Marconi ParkNo.9 Marconi CresentMontague GardenTel. 021-5515003Fax 021-523824

BRAZILFlender Brasil Ltda. � �Rua Quartoze Nr. 60, Caixa Postal 29632211-970 Contagem-MGTel. 031-3692000Fax 031-3311893

BRANCH OFFICES:Rua Aratans, 1.455Planalto Paulista04081-005-São Paulo-SPTel. 011-5365211Fax 011-5301252

CANADAFlender Power Transmission Inc. � �215 Shields Court, Units 4-6Markham, Ontario L3R8V2Tel. 905-3051021Fax 905-3051023

BRANCH OFFICES:Flender Power Transmission Inc.Bay # 3, 6565 40th Street S.E.Calgary, Alberta T2C - 2J9Tel. 403-543-7744Fax 403-543-7745

COLOMBIAFlender de ColombiaA.G.P. Representaciones Ltda.Carrera 68 Nr. 16-80 Piso 4.CIPRES TRADE CENTERBogota - ColombiaTel. 91-3460561Fax 91-3460415

CHILESargent S.A. � �Av. Pdte. Bulnes 205, Casilla 166 DSantiagoTel. 02-6991525Fax 02-6983989

MEXICOFlender de Mexico, S.A. de C.V. �Vista Hermosa No.23 Col. Romero VargasAdpo. Postal 2-85Puebla, Pue.C.P. 72131Tel. 22310951, 22310844Fax 22310913

BRANCH OFFICE:Flender de Mexico, S.A. de C.V.Oficina MonterreyDiamante 112, Col. Pedregal del ValleSan Pedro de Garza Garcia, C.P. 66280Monterrey, Nuevo LeonTel. (08)3034806Fax (08)3034806

USAFlender Corporation � �950 Tollgate Road, P.O. Box 1449Elgin, Illinois 60120Tel. 847-9311990Tx. 285394Fax 847-9310711

VENEZUELAF. H. Transmissiones S.A. � �Urb. Buena VistaCalle Johan Schafer o Segunda CalleEdif. F.H.T. (frente a Lab. Boehringer)Municipio Sucre, Petare Edo. MirandaCaracas - VenezuelaTel. 0058-2-215261Fax 0058-2-211838



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BA G298 EN 08.98Page 38 of 39

FLENDER InternationalA U S T R A L I A A S I A

AUSTRALIA Flender (Australia) Pty. Ltd. �� 9 Nello PlaceWetherill ParkN.S.W. 2164SydneyTel. 02-97562322Tx. AA27742Fax 02-97564892

BRANCH OFFICES:20 Eskay Road, South OakleighMelbourneVictoria 3167Tel. 03-95790633Tx. 38437Fax 03-95790417

20 Brookes Street, Bowen HillsBrisbaneQld. 4006Tel. 07-32522711Tx. 41203Fax 07-32523150

1 Dampier RoadWelshpool, PerthW.A. 6106Tel. 09-4518355Tx. 93712Fax 09-4583582

NEW ZEALANDR.R. Fisher & Co.Ltd. �13, Spring StreetPapatoetoeNew ZealandTel. 09-2784059Tx. 2458

ASEANFlender Singapore Pte. Ltd. � �13A, Tech Park CrescentSingapore 637843Tel. 0065-8979466Fax 0065-8979411

PEOPLE’S REPUBLIC OF CHINABeijing Flender � �No. C-411, Office Building,Beijing Lufthansa CenterNo. 50, Liangmaqiao RoadBeijing 100016 P.R.C.Tel. 0086-10-64622151-54Fax 0086-10-64622143

Shanghai Representative Office14C, Zhao Feng Universe Building1800 Zhongshan West RoadShanghai 200233, ChinaTel. 021-64400240/241Fax 021-64400242

INDIAFlender Macneill Gears Limited. �2, St. Georges Gate Road, 5 th Floor Calcutta-700022 West Bengal - IndiaTel 33-223-0164/-0545/-0846 Fax 33-223-0830

Flender Macneill Gears Ltd. Southern Region Office 41, Nelson Manickam Road Aminjikarai Chennai - 600029 Tel. 44-4810476/4810478/4810479 Fax 44-4810473

New DehliTel. 11-6250104Fax 11-6250221

BombayTel. 22-7657227Fax 22-7657228

INDONESIA PT Flenindo Aditransimisi �� Jl. Ketintang Wiyata VI No. 22Surabaya 60231IndonesiaTel. 6231-8291082Fax 6231-8286363

JAPANFlender Ishibashi MFG. Co. Ltd. �(Nogata Industrial Park)4636-15Oaza KamitonnoNogata-Shi, Fukuoka-ken822 JapanTel. 09492-6-3711 Fax 09492-6-3902

KOREA Flender LTD., KOREA � �1128-4 Kuro-Dong, Kuro-Ku,Seoul, Korea. 152-050Tel. 02-859-1750-3Fax 02-859-1754

Sung Ji Trading Co. � �No.211, Ma YeolGochuk Ind. Market 103-4Gochuk DongKuro-Ku, Seoul/KoreaTel. 02-688-8367, 8368Fax 02-688-8368

MALAYSIAGerman Transmission � �Machinery SDN. BHD.Prime Subang Industrial ParkNo.3 Block C, Lot 757Jl Subang 6, off Persiaran Subang47500 Petaling JayaSelangor, MalaysiaTel. 03-7336023Fax 03-7336259

PAKISTANO.T.C. �114 Alama Iqbal RoadLahore-5Tel. 42-869398Tx. 44914Fax 42-305291

PHILLIPPINEOTEC Material Handing Inc. � �P.O. Box 2199Equitable Bank Bldg. Room 401Corner Paseo de Roscas Sen Gil. 406Puyut Ave.Makati 3117, Metro ManilaPhillippinesTel. 2-878551Fax 2-8187158

TAIWANA. Fried. Flender AG Taiwan Branch �� No. 5, Alley 17, Lane 194, HuanHo St.,Hsichih, Taipei Hsien, Taiwan, R. O. C. Tel. 02-26932441-3Fax 02-26943611

THAILANDSmith Technology Co. Ltd. � �128/75 Phyathai Plaza Building7th. Fl., Phyathai RoadRajtheveeBangkok 10400Tel. 02-2165831/3Fax 02-2165799



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BA G298 EN 08.98 Page 39 of 39

12. Declaration by the manufacturer

Declaration by the manufacturer

as defined by EC machinery directive 98/37/EC Annex II B

We hereby declare that the

Gear Units and Gear Motors of types

D./Z. 38 ... D./Z. 168

described in these Operating Instructions are meant for being installed in a machine andthat their putting into operation is prohibited until it has been ascertained that themachine, in which these components will be installed, corresponds to the regulations ofthe EC directive 98/37/EC.

All the harmonised standards published by the EC-Commission in the Official Journal ofthe European Community applicable for our products are either totally or partly observedwith this manufacturers declaration.

These are especially:

EN 292-1 EN 294 EN 60204-1EN 292-2 EN 349

Tübingen, the 31.07.1998(Manager of Standards Department)

Motox N Operating Manual

Documents

long term

painting mask

downward mounting

excellent

pur lacquer

spare parts

excessive

prevent accidental