FLENDER GEAR UNITS

Crane gear unit

Assembly and operating instructions 5802en

Edition 06/2020

K3FM

625
02.12.2020 21:42
V12.00
 Introduction 1

Safety instructions 2

Description 3
FLENDER GEAR UNITS
Application planning 4
Crane gear unit
5802en 5
Assembly

Commissioning 6
Assembly and operating instructions

Operation 7

Servicing 8

Service & Support 9

Disposal 10

Spare parts 11

K3FM Declaration of Incorporation A

625

Technical data B

Original assembly and operating instructions

Edition 06/2020
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage
to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices
referring only to property damage have no safety alert symbol. These notices shown below are graded according to
the degree of danger.

DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION
indicates that minor personal injury can result if proper precautions are not taken.

NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property
damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Flender products
Note the following:

WARNING
Flender products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended or
approved by Flender. Proper transport, storage, installation, assembly, commissioning, operation and maintenance
are required to ensure that the products operate safely and without any problems. The permissible ambient
conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks
All names identified by ® are registered trademarks of Flender GmbH. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described.
Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this
publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Flender GmbH Document order number: 5802en Copyright © Flender GmbH 2020.
Alfred-Flender-Straße 77 Ⓟ 12/2020 Subject to change All rights reserved
46395 BOCHOLT
GERMANY
Table of contents

1 Introduction ........................................................................................................................................... 9
1.1 General information............................................................................................................. 9
1.2 Lubricants.......................................................................................................................... 10
2 Safety instructions ............................................................................................................................... 11
2.1 Security notes .................................................................................................................... 11
2.2 The five safety rules ........................................................................................................... 11
2.3 General information........................................................................................................... 12
2.4 General warnings and symbols........................................................................................... 13
2.5 Special types of danger and personal protective equipment ................................................ 14
2.6 Intended use...................................................................................................................... 16
3 Description........................................................................................................................................... 19
3.1 General description............................................................................................................ 19
3.2 Housing............................................................................................................................. 19
3.3 Oil supply to the gear unit .................................................................................................. 20
3.3.1 Splash lubrication .............................................................................................................. 20
3.4 Shaft bearings ................................................................................................................... 20
3.5 Shaft seal .......................................................................................................................... 21
3.5.1 Rotary shaft sealing rings ................................................................................................... 21
3.6 Couplings .......................................................................................................................... 21
3.7 Oil temperature monitoring ............................................................................................... 22
4 Application planning ........................................................................................................................... 23
4.1 Scope of delivery ............................................................................................................... 23
4.2 Transport ........................................................................................................................... 23
4.3 Attachment points ............................................................................................................. 25
4.4 Special aspects of gear unit lubrication and preservation .................................................... 27
4.4.1 Oil filling point and oil drain ............................................................................................... 27
4.4.2 Checking the oil level ......................................................................................................... 28
5 Assembly.............................................................................................................................................. 29
5.1 General assembly instructions............................................................................................ 29
5.2 Unpacking the gear unit..................................................................................................... 30
5.3 Gear unit assembly ............................................................................................................ 31
5.3.1 Foundation ........................................................................................................................ 31
5.3.2 Description of assembly work ............................................................................................. 32

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Table of contents

5.3.2.1 Alignment ......................................................................................................................... 33

5.3.3 Shaft-mounted gear unit with flanged shaft ....................................................................... 34
5.3.3.1 Requirements .................................................................................................................... 34
5.3.3.2 Assembly ........................................................................................................................... 34
5.3.4 Mounting the torque arm for the gear unit housing ............................................................ 35
5.3.4.1 Mounting the torque arm................................................................................................... 35
5.4 Couplings .......................................................................................................................... 36
5.4.1 Assembling the coupling.................................................................................................... 36
5.4.2 Aligning the coupling......................................................................................................... 38
5.5 Connecting components .................................................................................................... 40
5.5.1 Gear units with mounted components ............................................................................... 40
5.5.2 Connecting the Pt 100 resistance thermometer .................................................................. 40
5.5.3 Electrical connections ........................................................................................................ 41
5.6 Tightening procedure......................................................................................................... 41
5.6.1 Introduction....................................................................................................................... 41
5.6.2 Bolt connection classes ...................................................................................................... 42
5.6.3 Tightening torques and preload forces................................................................................ 43
5.7 Final work.......................................................................................................................... 44
6 Commissioning .................................................................................................................................... 47
6.1 Measures prior to commissioning ....................................................................................... 47
6.2 Measures during commissioning ........................................................................................ 47
7 Operation............................................................................................................................................. 49
7.1 Operating data .................................................................................................................. 49
7.2 Irregularities in operation................................................................................................... 49
7.3 Taking the unit out of service ............................................................................................. 50
8 Servicing .............................................................................................................................................. 51
8.1 General maintenance information...................................................................................... 51
8.2 Maintenance schedule ....................................................................................................... 52
8.3 Maintenance and servicing work ........................................................................................ 53
8.3.1 Clean the venting screw ..................................................................................................... 53
8.3.2 Checking the oil temperature ............................................................................................. 53
8.3.3 Cleaning the gear unit........................................................................................................ 54
8.3.4 General inspection of the gear unit .................................................................................... 54
8.3.5 Check that all of the fastening bolts are tight...................................................................... 54
8.3.6 Final work.......................................................................................................................... 55
8.4 Possible faults .................................................................................................................... 55

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 Table of contents

9 Service & Support ................................................................................................................................ 59

10 Disposal ............................................................................................................................................... 61
11 Spare parts........................................................................................................................................... 63
A Declaration of Incorporation ............................................................................................................... 65
B Technical data...................................................................................................................................... 67
B.1 General technical data ....................................................................................................... 67
B.2 Ambient temperature......................................................................................................... 68
B.3 Weights ............................................................................................................................. 68
B.4 Oil quantities ..................................................................................................................... 69
B.5 Enveloping surface sound pressure level............................................................................. 69
Index .................................................................................................................................................... 71

Tables

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

Table 2-2 General warnings ................................................................................................................... 13
Table 5-1 Information on tightening fastening bolts ............................................................................... 42
Table 5-2 Preload forces and tightening torques ..................................................................................... 43
Table 7-1 Operating data ....................................................................................................................... 49
Table 8-1 Maintenance and servicing activities ....................................................................................... 52
Table 8-2 Possible faults and how to rectify them ................................................................................... 55
Table B-1 Weights .................................................................................................................................. 69
Table B-2 Oil quantities .......................................................................................................................... 69
Table B-3 Enveloping surface sound pressure level.................................................................................. 70

Figures

Figure 3-1 Gear unit equipment on a type K3FM gear unit ....................................................................... 20
Figure 3-2 Rotary shaft sealing ring ......................................................................................................... 21
Figure 4-1 Transport symbols................................................................................................................... 25
Figure 4-2 Shear and lateral pulling when using eye bolts ........................................................................ 26
Figure 4-3 Position of the attachment points for type K3FM gear units ..................................................... 26
Figure 4-4 Position of the attachment points on type K3FM gear units with mounted components ........... 26
Figure 4-5 Oil filling points and the oil draining points on type K3FM gear units........................................ 27
Figure 5-1 Torque arm for the gear unit housing ...................................................................................... 35
Figure 5-2 Possible displacements ........................................................................................................... 39
Figure 5-3 Alignment process based on the example of a flexible coupling ............................................... 39
Figure B-1 Rating plate ............................................................................................................................ 67

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Table of contents

Assembly and operating instructions 5802en

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Introduction 1
1.1 General information

Purpose of the operating instructions

These operating instructions describe the gear unit and provide information about handling it
- from assembly to maintenance.
Please keep these operating instructions for later use. Please read these operating instructions
prior to handling the gear unit and follow the information in them.

Note
Disclaimer
Please make sure that every person who is commissioned to work on the gear unit has read and
understood these operating instructions prior to handling the gear unit and adheres to all of the
points. Failure to observe these operating instructions can cause product or property damage or
personal injury.
Flender does not accept any liability for damage or operating failures which are due to non-
adherence to these operating instructions.

The gear unit described in these instructions reflects the state of technical development at the
time these operating instructions went to print.
In the interest of technical advancements, Flender reserves the right to make changes to the
individual components and accessories which are considered necessary for improving their
performance and safety, while maintaining their essential features.

Basic knowledge required

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

Documentation landscape
These operating instructions form part of the delivery of your gear unit.

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Introduction
1.2 Lubricants

These operating instructions form part of the complete documentation supplied with the gear
unit. The complete documentation encompasses other documents, including:
• Data sheet
• List of equipment
• Dimension drawing
• Operating instructions for gear unit lubrication and preservation BA 7300
• Operating instructions for mounted components
• Operating instructions for third-party vendor devices

Copyright
The copyright for these operating instructions is held by Flender.
Without the authorisation of Flender, these operating instructions may not be used wholly or in
parts for competitors’ purposes or be given to third parties.
If you have any technical queries, please contact one of our Customer Services addresses
(Page 59).

1.2 Lubricants
The quality of the oil used must meet the requirements of the operating instructions BA 7300,
which is provided as a separate item, otherwise the warranty provided by Flender will be void.
Flender strongly recommends using one of the oils listed in BA 7300, all of which have been
appropriately tested and meet the requirements.
To avoid misunderstandings, Flender points out that, by making this recommendation, it is not
approving the product in the sense of expressing a warranty for the quality of the lubricants
supplied by your supplier. Each lubricant manufacturer must provide a warranty for the quality
of its own product.
You will find the oil grade, oil viscosity and the required oil quantity on the rating plate of the gear
unit and in the documentation provided with it.
The oil quantity specified on the rating plate is an approximate quantity. The decisive factors for
the oil quantity to be filled are the marking of the oil dipstick or oil sight glass.
The operating instructions for the current lubricant recommendations of Flender can also be
viewed in the Internet (https://www.flender.com/lubricants).
The oils listed there undergo continuous testing. For this reason, oils recommended there may
be removed later or replaced with further developed oils.
Flender recommends regular inspection to ascertain whether the selected lubricating oil is still
approved by Flender. If it is not, a different make should be used instead.

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

2.2 The five safety rules

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

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Safety instructions
2.3 General information

2.3 General information

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

Symbols on the gear unit

The following symbols apply to the gear unit; some of which are found as coloured markings on
the gear unit:

Table 2-1 Symbols and markings

Points labelled on the gear unit Symbol Coloured markings

Earth connection point

Air relief point yellow

Oil filling point yellow

Oil draining point white

Oil level indicator red

Oil level measurement red

Oil overflow

Connection point for vibration monitoring

Lubrication point red

Apply grease

Lifting eye

Eye bolt

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 Safety instructions
2.4 General warnings and symbols

Points labelled on the gear unit Symbol Coloured markings

Do not unscrew

Alignment surface, horizontal

Alignment surface, vertical

These symbols indicate the oil level check‐

ing procedure using the oil dipstick.

These symbols indicate that the oil dipstick

must be firmly screwed in.

2.4 General warnings and symbols

The following table contains general warnings and their associated symbols.

Table 2-2 General warnings

ISO ANSI Warning

Warning - hazardous electrical voltage

Warning - explosive substances

--- Warning - entanglement hazard

--- Warning - hot surfaces

--- Warning - substances that can irritate or which are hazardous to health

--- Warning - caustic substances

--- Warning - suspended load

--- Warning - hand injuries

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Safety instructions
2.5 Special types of danger and personal protective equipment

2.5 Special types of danger and personal protective equipment

Requirements
Fulfil the following requirements before commencing work on the gear unit:
• Ensure that the oil pressure lines are depressurised.
• Only perform work on the gear unit when it is not in operation.
• Disconnect electrical systems from the power supply.

DANGER
Electric shock
Live parts can cause electric shock.
Ensure that the entire plant is de-energised before starting electrical installation work.

Protective equipment
Wear the following personal protective equipment when handling the gear unit:
• Safety shoes
• Overalls
• Helmet
• Safety gloves
• Safety goggles

WARNING
Risk of eye injury
Small foreign particles such as sand or dust can enter the cover plates of the rotating parts and
be hurled back by them.
Wear safety goggles.

Dangers during operation

Damage to the gear unit is possible.

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 Safety instructions
2.5 Special types of danger and personal protective equipment

Switch the gear unit to standstill immediately if inexplicable changes are noticed during
operation. Such changes may include unusual gear unit noise or a significant increase in
operating temperature.

WARNING
Risk of falling
There is an increased risk of falling when standing or walking on the gear unit during operation.
Only walk or stand on the gear unit and its mounted components for maintenance and repair
work when it is at a standstill. Do not walk or stand on shaft ends, protection covers, mounted
components or pipes.

WARNING
Danger to life through rotating or moving parts
There is danger that rotating or moving parts may catch hold of you or pull you in.
Secure rotating and/or moving parts against contact using safeguards.

Surface temperature
The surface temperatures of the gear unit can become very extreme depending on the
operating conditions.

WARNING
Risk of burns
Possible risk of serious burn injury from hot surfaces (> 55 °C).
Wear suitable protective gloves and protective clothing.

WARNING
Risk of scalding
Risk of serious injury possible through escaping hot operating media when these are being
changed.
Wear suitable protective gloves, safety goggles and protective clothing.

WARNING
Danger due to low temperatures
Possible risk of serious injuries due to frost (pain, numbness, frostbite) on cold surfaces (< 0 °C).
Wear suitable protective gloves and protective clothing.

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Safety instructions
2.6 Intended use

Chemical substances
Injuries can be sustained when using chemical substances.

WARNING
Risk of chemical burns due to chemical substances
There is a risk of chemical burns when handling aggressive cleaning agents.
Please observe the manufacturer's guidelines on how to handle cleaning agents and solvents.
Wear suitable protective equipment (gloves, safety goggles). Please use binding agents to
immediately clear up any spilt solvent.

CAUTION
Risk of injury due to chemically aggressive operating materials
There is a risk of injury to eyes and hands when handling chemically aggressive operating
materials.
Please observe the safety instructions in the data sheets of the oil used. Wear suitable
protective equipment (gloves, safety goggles). Use an oil-binding agent to immediately clean
up spilt oil.

Danger of explosion
An explosion may occur in a potentially explosive atmosphere.

DANGER
Danger of explosion through ignition of a potentially explosive atmosphere
Danger to life through ignition of a potentially explosive atmosphere possible when operating
the gear unit
Do not use the gear unit in potentially explosive atmospheres.

2.6 Intended use

Only use the gear unit according to the conditions specified in the service and delivery contract
and the technical data in the annex (Page 67). Deviating operating conditions are considered
improper use. The user or owner of the machine or plant is solely liable for any resulting damage.

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 Safety instructions
2.6 Intended use

When using the gear unit please specifically observe the following:
• Do not make any modifications to the gear unit which go beyond the permissible handling
described in these operating instructions. This also applies to safety features designed to
prevent accidental contact.
• Only ever use original spare parts.
Other spare parts are not tested and approved by Flender. Non-approved spare parts may
possibly change the design characteristics of the gear unit and thus impair its active or
passive safety.
Flender will accept no liability or warranty whatsoever for damage occurring as a result of the
use of non-approved spare parts. The same applies to any accessories which were not
supplied by Flender.
If you have any queries, please contact Customer Services (Page 59).

WARNING
Risk of falling
Risk of possible serious injury through falling.
Only walk or stand on the gear unit for maintenance and repair work when it is at a standstill.
Do not walk or stand on shaft ends, protection covers, mounted components or pipes.

Gear unit use

When using the gear unit, please observe the following basic rules:
• Ensure that the gear unit is operationally safe.
• The gear unit should only be operated, maintained or repaired by authorised, trained and
suitably qualified personnel.
• The relevant work safety and environmental protection regulations must be complied with
at all times during transport, assembly, dismantling, operation, maintenance and servicing.
• The outside of the gear unit must not be cleaned using high-pressure cleaning equipment.
• No welding work must be performed on the gear unit or on parts connected to it. The gear
unit and any parts connected to it must not be used as an earthing point for electric-welding
operations. Gearing and rolling-contact bearings might be irreparably damaged by welding.
• Perform potential equalisation in accordance with the applicable regulations and guidelines.
If no threaded holes are available on the gear unit for an earth connection, please take
suitable measures. This work must always be done by specialist electricians.
• In the case of gear units that are operated in combination with electrical machines that
generate current or through which current flows (e.g. motors and generators), take
measures to ensure that no current can flow through the gear unit.
Current flowing through the gear unit can result in irreparable damage to rolling-contact
bearings and gearing. Short circuits, voltage flashovers and deposits of conductive dust, for
example, can all allow current to flow.
Use insulators and earth the gear unit properly.
• When removing any protective devices, retain their fixings safely.
• Removed protective devices must be re-fitted prior to starting up.

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Safety instructions
2.6 Intended use

• Pay attention to the notices attached to the gear unit such as the rating plate, direction arrow
symbol etc. Notices must not be concealed by paint or dirt. Replace missing plates.
• Bolts which have been damaged during assembly or disassembly work must be replaced with
new ones of the same strength class and type.

DANGER
Danger to life due to live system
Death or serious injury will occur.
Always shut down the gear unit and any oil supply system (whether separate or mounted on
the gear unit) before you carry out any work. Secure the drive unit against being operated
accidentally as follows:
• Turn off the key-operated switch.
• Remove the fuses in the power supply.
• Attach a notice to the start switch, clearly stating that work is being carried out on the gear
unit.
Ensure that the entire unit is load-free so that no danger is posed when you start to dismantle
components.

Reactivating the gear unit

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

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Description 3
3.1 General description

The FLENDER® gear unit (referred to below simply as "gear unit") described in these operating
instructions has been developed for use in hoist gear units in lifting gear, cranes and elevators.
Potential applications for this series of gear units include, for example, hoisting gear for
construction cranes.
The gear unit is available as a three-stage helical gear unit. It is designed for horizontal mounting.
The gear unit can be operated in both directions of rotation.

3.2 Housing

Introduction
The housing is made of cast iron. When specified, the housing can also be manufactured out of
steel.
The housing is a two-part component.
The gear unit housing has the following features:
• Attachment points for moving the gear unit
• Inspection and assembly cover for inspection and oil filling
• Oil level screw for checking the oil level
• Oil drain screw for changing the oil
• Venting screws or air filters for air to pass in and out

Further information
Additional information and a detailed illustrated description of the gear unit can be found in the
dimension drawing provided in the complete gear unit documentation.

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Description
3.4 Shaft bearings

Gear unit equipment

The diagram below shows the available gear unit equipment on a type K3FM gear unit:

     

① Lifting eyes ④ Rating plate

② Inspection cover ⑤ Shaft seals
③ Housing ⑥ Fastening for torque arm
Figure 3-1 Gear unit equipment on a type K3FM gear unit

Further information
Additional information and a detailed illustrated description of the gear unit can be found in the
dimension drawing provided in the complete gear unit documentation.

3.3 Oil supply to the gear unit

3.3.1 Splash lubrication

Unless otherwise agreed by contract, the gearing and rolling-contact bearings are supplied with
an adequate quantity of oil by splash lubrication.

3.4 Shaft bearings

All shafts are mounted on rolling-contact bearings.

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 Description
3.6 Couplings

3.5 Shaft seal

Introduction
Depending on requirements, shaft seals prevent oil from escaping from the gear unit or dirt from
entering the gear unit.

3.5.1 Rotary shaft sealing rings

Rotary shaft sealing rings are the standard seal used. Wherever possible, rotary shaft sealing
rings are equipped with an additional dust lip which protects the actual sealing lip against
external contaminants.

NOTICE
Irreparable damage to the rotary shaft sealing ring caused by high concentration of dust
A damaged rotary shaft sealing ring might not be able to effectively seal the gear unit.
In very dusty atmospheres, do not use rotary shaft sealing rings unless they have additional
protection.

The diagram below shows a rotary shaft sealing ring

Figure 3-2 Rotary shaft sealing ring

3.6 Couplings

Flexible couplings or torque limiters are generally used at the input end of the gear unit.
Use of rigid couplings or other input or output elements that generate additional radial or axial
forces (e.g. gear wheels, belt pulleys, flywheels or hydraulic couplings) must be agreed
contractually.

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Description
3.7 Oil temperature monitoring

Further information
You will find further information on the couplings in the operating instructions of the couplings,
which are part of the complete documentation of the gear unit.

3.7 Oil temperature monitoring

Depending on the order specification, the gear unit can be fitted with a Pt 100 resistance
thermometer for measuring the oil temperature in the oil sump.
To measure temperatures or temperature differences, connect the Pt 100 resistance
thermometer to an evaluation unit (to be supplied by the customer). The resistance
thermometer is fitted with a connector head for the wiring.

Further information
Further information and a detailed illustration of the gear unit and the position of the mounted
components can be found in the dimension drawing in the complete documentation for the
gear unit.
Further information about oil temperature monitoring (such as control instructions) and the
technical data can be found in the operating instructions for the oil temperature monitor and in
the list of equipment in the complete documentation for the gear unit.

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Application planning 4
4.1 Scope of delivery
The scope of delivery is listed in the shipping documents. Immediately upon receiving the
gearbox, check that everything has been delivered. Report any damaged and/or missing parts
to Customer Services (Page 59) immediately.

WARNING
Serious injury through defective product
Serious injury may occur.
If the gearbox exhibits any visible damage, you should not put it into operation.

4.2 Transport

General information
The gear unit is delivered fully assembled. Additional items such as shrink disks, couplings, oil
coolers, pipework and valves may be delivered separately packaged, as necessary.
When transporting the gear unit, observe the following instructions to avoid damaging the gear
unit:
• Always use suitable equipment to transport the gear unit.
• Transport the gear unit without oil filling and leave it in the transport packaging.
• Do not use incorrect attachment points.
The threads in the end faces of the shaft ends may not be used for attaching lifting
equipment.
• Do not use the pipework to move the gear unit.
• Ensure that the lifting equipment is adequately designed to accommodate the weight of the
gear unit.
• Always set the gear unit down onto a suitable base.
The base must be designed such that there is no risk of damage to the gear unit or its
mounted components.

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Application planning
4.2 Transport

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

Attaching the gear unit

To transport the gear unit, only attach slings to the marked attachment points that are provided
for this purpose.
Please observe the following when attaching slings to the load or raising, lowering or moving it:
• Do not exceed the specified load limits
• If you are using a load suspension device with several load hooks, make sure that the load is
evenly distributed between them
• Note the eccentric centre of gravity
• Make sure that the lifting equipment is securely attached
• Keep your speed down when moving the load
• Do not allow the load to sway and do not attach the load to objects or structures inside the
building
• Loads must not be suspended from the tip of a load hook
• Always place the products down on a level, non-slip and stable base

DANGER
Falling load
There is a risk of fatal injury from falling loads if these have not been securely attached to the
lifting equipment.
Never stand or sit under suspended loads. Do not exceed the load limits of the lifting
equipment.

Packaging
The gear unit is delivered fully assembled. Additional equipment is also delivered separately
packaged, as necessary.
The gear unit may be packed in various forms, depending on the size of the unit and method of
transport.
Please adhere to the symbols applied on the packaging.

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 Application planning
4.3 Attachment points

7KLVZD\XS )UDJLOH .HHS .HHS &HQWUHRI 'RQRW $WWDFKKHUH

 GU\ FRRO JUDYLW\ XVHKDQGKRRNV
Figure 4-1 Transport symbols

4.3 Attachment points

Lifting eyes
Lifting eyes are fitted to the gear unit to assist with its transportation during manufacture and
installation.
Carefully ensure that the angle of the vertical load at the gear units lifting eyes does not exceed
45°.
Attach slings to the lifting eyes in accordance with the specifications in the dimension drawings.

Sling swivels
Threads for screwing in transport lugs are provided on the gear unit to assist with its
transportation during manufacture and installation.
The shear pulling must not exceed 45° when the lifting equipment is attached to sling swivels.

Eye bolts
The use of sling swivels instead of eye bolts is generally recommended.
When using eye bolts, please note that their load-bearing capacity may be reduced if they are
alternately attached to different components that require moving.
It is not permitted to load eye bolts through lateral pulling contrary to the direction of the eye
plane.
The following figure shows the permissible shear and lateral pulling when using eye bolts:

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4.3 Attachment points

r r

$ %

A Permitted shear pulling in direction of eye plane (maximum angle of 45°)

B Non-permitted lateral pulling contrary to direction of eye plane
Figure 4-2 Shear and lateral pulling when using eye bolts

Position of attachment points

The following diagram shows the position of the attachment points for type K3FM gear units:

Figure 4-3 Position of the attachment points for type K3FM gear units

The diagram below shows the position of the attachment points on type K3FM gear units with
mounted components:

Figure 4-4 Position of the attachment points on type K3FM gear units with mounted components

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4.4 Special aspects of gear unit lubrication and preservation

Drive units with additional components mounted on the gear unit (such as drive motor,
coupling, etc.) may require an extra attachment point owing to the displacement in the centre
of gravity caused by the mounted components.

Further information
You can find additional information and a detailed illustration of the gear unit, the position of the
attachment points, the centre of gravity and data on the weight in the dimension drawings,
which are part of the complete documentation of the gear unit.

4.4 Special aspects of gear unit lubrication and preservation

4.4.1 Oil filling point and oil drain

The following diagram shows the oil filling locations and oil drain locations for the gear unit:

  

① Air relief point ④ Oil level measurement

② Inspection and assembly cover ⑤ Oil draining point
③ Oil filling point
Figure 4-5 Oil filling points and the oil draining points on type K3FM gear units

Further information
Additional information and a detailed illustrated description of the gear unit can be found in the
dimension drawing provided in the complete gear unit documentation.

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4.4 Special aspects of gear unit lubrication and preservation

4.4.2 Checking the oil level

Carefully read and observe BA 7300 for checking the oil level
The gear unit is equipped with an oil level indicator (oil level screw) for visually checking the oil
level when the unit is at a standstill.
The oil level is correct when the cooled down oil is at the lower edge of the oil level screw.

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5.1 General assembly instructions
The assembly work must be performed very carefully by authorised, trained and suitably
instructed personnel. Liability will be disclaimed for damage caused by the incorrect
performance of this work.

Requirements
Improper use can damage the gear unit. Be sure to take the following precautions:
• Protect the gear unit against falling objects and from becoming covered over.
• Do not perform any welding work anywhere on the drive.
• Do not use the gear unit as an earthing point for electric-welding operations.
• Use all of the fastening points fitted to the particular unit design.
• Replace any bolts that are no longer fit for use by new bolts of the same strength class and
type.
• Make sure that sufficient hoisting gear is available.

Mounting position and attachment points

During the actual planning phase, be sure to allow for sufficient space around the gear unit to
enable subsequent upkeep and maintenance work. Take suitable measures to ensure that
unhindered convection across the housing surface is possible so that the gear unit does not
overheat. Leave sufficient space to allow a free flow of air into gear units that are equipped with
a fan.
Do not use incorrect attachment points (Page 25). You will find the positions of the attachment
points in the dimension drawing, which is part of the complete documentation of the gear unit.
To ensure that the unit is properly lubricated during operation, please observe the mounting
position specified in the dimension drawings.

NOTICE
Heating of the gear unit by external heat sources
The gear unit must not be heated by external heat sources (exposure to direct sunlight, for
example) while it is in operation and measures must be taken where necessary to protect it.
You can take the following measures to protect the gear unit against this hazard:
• A sun shield
• An additional cooling device
• A temperature monitoring device with trip function in the oil sump

If you use a sun shield, this may cause a build-up of heat.

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5.2 Unpacking the gear unit

If you use a temperature monitoring device, it must be capable of issuing an alarm when the
maximum permissible oil sump temperature is reached. It must also be capable of tripping the
drive when the maximum permissible oil sump temperature is exceeded. The operator's process
might be interrupted when the drive is shut down.

WARNING
Ignition of vapours emitted from solvents.
There is a risk of injury due to ignition of vapours emitted from solvents when carrying out
cleaning work.
Please note the following:
• Ensure adequate ventilation.
• Do not smoke.

5.2 Unpacking the gear unit

Introduction
The scope of delivery is listed in the shipping documents.

WARNING
Risk of serious injury due to defective product
A defective gear unit can result in serious injury.
Do not put the gear unit into operation if any damage is visible.
Contact Customer Services (Page 59).

Requirement
Check that everything has been delivered immediately upon receipt.

NOTICE
Damage to the gear unit due to corrosion
Exposing the gear unit to moisture can result in damage from corrosion.
Do not damage or open the packaging prematurely if the packaging is designed to preserve the
unit.

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Procedure
To unpack and use the gear unit, proceed as follows:
1. Remove packaging and transport devices in accordance with regulations.
2. Perform a visual inspection for damage and accumulations of dirt.
3. Immediately report any damaged and/or missing parts to Customer Service (Page 59).
4. Dispose of packaging material and transport devices in accordance with regulations.

5.3 Gear unit assembly

5.3.1 Foundation

Properties of the foundation

The foundation must have the following properties:
• Horizontal and flat
• Stability
• Designed for torsional rigidity
• Reaction forces from the gear unit must be braced

Requirements of the foundation

The foundation must meet the following requirements:
• Construct the foundation in such a way that it does not generate any resonance vibrations
and that it is isolated against the transmission of vibrations from adjacent foundations.
• Design the foundation according to the relevant weight and torque, taking into account the
forces acting on the gear unit.
• Align the foundation carefully with the equipment installed on the input and output sides of
the gear unit.
• Take into account any elastic deformation that may be caused by operating forces.
• Install lateral stops to prevent displacement if external forces are acting on the gear unit.

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5.3 Gear unit assembly

NOTICE
Lack of stable foundation for the gear unit
Damage to the gear unit is possible if it is not mounted on a stable foundation.
Use bolts of at least strength class 8.8. Information and guidance on the tightening torque can
be found in chapter Tightening procedure (Page 41). Tighten the fastening bolts and nuts to
the specified tightening torque. When tightening the fastening bolts, make sure that the gear
unit is free of mechanical stress.

Further information
You can find additional information about dimensions, space requirements and arrangement of
supply connections in the complete documentation for the gear unit.

5.3.2 Description of assembly work

CAUTION
Risk of chemical burns due to chemical substances
There is a risk of chemical burns when handling corrosive cleaning agents.
Please observe the manufacturer's guidelines on how to handle cleaning agents and solvents.
Wear suitable protective equipment (gloves, safety goggles). Please use binding agents to
immediately clear up any spilt solvent.

CAUTION
Risk of injury due to chemically aggressive operating materials
There is a risk of injury to eyes and hands when handling chemically aggressive operating
materials.
Please observe the safety instructions in the data sheets of the oil used. Wear suitable
protective equipment (gloves, safety goggles). Remove any spilt oil immediately with an oil-
binding agent.

Improper use can damage the gear unit. Be sure to take the following precautions:
• Use a suitable cleaning agent to remove the corrosion protection from the shafts and
adjoining mounting surfaces.
• Do not allow the cleaning agent to come into contact with the shaft-sealing rings.
• Mount the input and output elements (e.g. coupling components) onto the shafts and lock
them securely. See chapter Couplings (Page 36).
• Use suitable hoisting gear to place the gear unit in position.

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Further information
Further information about removing the corrosion protection can be found in the operating
instructions BA 7300 in the complete documentation for the gear unit.
Further information about attaching gear units to hoisting gear in cases where the gear weight
necessitates the use of hoisting gear can be found in chapter Application planning (Page 23).
If a gear unit with mounted components needs to be transported, it may require additional
attachment points. The position of these attachment points can be found in the order-specific
dimension drawing in the complete documentation for the gear unit.

5.3.2.1 Alignment

DANGER
Danger to life from flying fragments
Failure to align the unit with the required degree of accuracy can cause the shaft to rupture. A
ruptured shaft can result in serious or even fatal injuries.
Align the gear unit exactly so that it conforms to the specified alignment values.
Damage to the gear unit or its components or mounted components is possible.
The accuracy of the alignment between the shaft axes largely determines the service life of the
shafts, rolling-contact bearings and couplings. Please therefore always endeavour to achieve
zero deviation in the alignment of the shaft axes (does not apply to ZAPEX couplings or cardan
shafts). In this context, please also refer to the relevant operating instructions for further
information about, for example, the requirements of couplings.

Tools
The following tools are needed to perform the final fine alignment (Page 38) work on the shaft
axes of the gear unit and the equipment installed on the input and output sides.
• Rulers
• Spirit level
• Dial gauge
• Laser alignment system
• Feeler gauge etc.
Once the gear unit is finely aligned, tighten the foundation bolts and check the settings again.
Record the alignment dimensions and keep the report in a safe place together with these
operating instructions.

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5.3 Gear unit assembly

5.3.3 Shaft-mounted gear unit with flanged shaft

5.3.3.1 Requirements
Take the following precautions before mounting the shaft-mounted gear unit with flanged shaft:
• The area around the face of the flanged shaft must be absolutely free of any grease. The
reliability with which torque is transmitted depends to a large extent on this.
• Do not use any contaminated solvents or soiled cleaning cloths, nor any cleaning agents that
contain oil (such as petroleum or turpentine) to degrease the surfaces.

NOTICE
Damage to the gear unit by uneven tightening of the connecting bolts
The gear unit can be damaged by unevenly tightening the connecting bolts.
Tighten the connecting bolts diagonally and evenly to the specified tightening torque. When
tightening the connecting bolts, make sure that the gear unit is free of mechanical stress.

5.3.3.2 Assembly

Procedure
To remove the shaft-mounted gear unit with flanged shaft and shrink disk from the machine
shaft, proceed as follows:
1. Clean the contact surfaces of the coupling flange and the mating flange.
2. Using suitable hoisting gear, set the gear unit down on the mating flange.
3. Make sure that the flanges are centred.
4. Tighten the connecting bolts diagonally and evenly to the specified tightening torque.

Further information
You can find additional information about the tightening torque of the connecting bolts in the
dimension drawings in the coupling operating instructions. Replace any bolts that are no longer
fit for use by new bolts of the same strength class and type.

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5.3.4 Mounting the torque arm for the gear unit housing

5.3.4.1 Mounting the torque arm

NOTICE
Damage to the gear unit due to incorrect mounting of the motor and torque arm
Damage to the gear unit due to incorrect mounting of the motor and torque arm is possible
The motor and torque arm may only be mounted after prior consultation with Flender. Mount
the torque arm to the machine side without causing any distortion or deformation.

The diagram below shows the torque arm for the gear unit housing:

① Connection for torque arm

Figure 5-1 Torque arm for the gear unit housing

Further information
You can find additional information about constructing the foundation for gear units with a
torque arm in chapter Foundation (Page 31).

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5.4 Couplings

5.4 Couplings

Introduction
Improper use can damage the gear unit. Be sure to take the following precautions:
• If necessary, carry out the following preparatory work in accordance with the operating
instructions for the coupling:
– Machine the finished bore
– Mill the parallel keyway
– Fit the axial locking element
– Balance
• Align the individual components precisely with one another.
• Refer to the operating instructions for the coupling for instructions on how to install,
maintain and operate the coupling.

WARNING
Danger of injury due to coupling rupture
Flying fragments can cause fatal injury.
Observe the operating instructions for the couplings.

NOTICE
Serious or irreparable damage to the gear unit and coupling caused by inaccurate or
incorrect alignment
Failure to accurately or correctly align the gear unit and coupling may result in serious or
irreparable damage to both components.
Align the individual components precisely with one another when installing the drives.
Make sure that the maximum permissible displacement values are not exceeded during
operation.

Further information
Further information about the coupling can be found in the operating instructions for the
coupling in the complete documentation for the gear unit.

5.4.1 Assembling the coupling

Introduction
The method used to assemble the coupling varies according to type. The procedure described in
these operating instructions is general rather than specific to one type of coupling.

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5.4 Couplings

Assemble the coupling as described in the operating instructions for the specific coupling.
Improper use can damage the gear unit. Be sure to take the following precautions:
• Do not use force (hammer blows, etc.) to fit the coupling parts as this can cause internal
damage to the gear unit.
• Take care not to damage the shaft sealing rings or shaft running surfaces when fitting the
coupling parts.

Procedure
To fit the coupling, proceed as follows:
1. Carefully clean the shaft ends and the coupling parts.
2. Use a suitable fixture to mount the coupling parts on the shaft ends.
3. Lock the coupling parts to prevent axial displacement.
4. Move the machines to be coupled close to one another and thenalign them (Page 38).
5. Join the coupling parts together.

Heating coupling parts prior to mounting

Depending on the order specification, it may be necessary to heat the coupling parts before
mounting them.

WARNING
Risk of burns
Possible risk of serious burn injury from hot surfaces (> 55 °C).
Wear suitable protective gloves and protective clothing.

Improper use can damage the gear unit. Be sure to take the following precautions:
• The required joining temperatures can be found in the dimension drawings in the operating
instructions for the coupling
• Unless otherwise instructed, heat the coupling parts by an induction heater, with a torch or
in an oven.
• Use heat shields designed to protect against radiant heat in order to safeguard the shaft
sealing rings against damage or heating to above 100 °C.
• Quickly fit the coupling parts on the shafts. You will find the mounting dimensions in the
dimension drawings in the operating instructions for the coupling.

Gear units with hollow output shaft or flanged output shaft

There is no need to install the output-side coupling for gear units with a hollow output shaft or
flanged output shaft.

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5.4 Couplings

Mount gear units with hollow output shaft onto the shafts of the customer's driven machine.
Use a mating flange to mount gear units with flanged output shaft onto the shaft of the
customer's driven machine.

Further information
Further information about the coupling can be found in the operating instructions for the
coupling in the complete documentation for the gear unit.

5.4.2 Aligning the coupling

Introduction
The coupling parts might become misaligned as a result of:
• Failure to accurately align the parts during assembly
• During operation:
– Due to thermal expansion
– Due to shaft deflection
– Due to machine frames that are too soft
Improper use can damage the gear unit or the coupling. Be sure to take the following
precautions:
• Make sure that the maximum permissible displacement values are not exceeded during
operation.
Base frames or substructures that are too soft can cause the coupling parts to become radially
or axially displaced during operation. This displacement is not measurable when the drive is
at a standstill.
– If you are using couplings supplied by Flender, you will find the maximum permissible
misalignment values in the operating instructions for the coupling.
– If you are using couplings supplied by other manufacturers, contact them and ask them
for the maximum permissible displacement values, making sure that you specify the
potential radial loads for your application. Keep the operating instructions for the
coupling together with these operating instructions.
• Angular and radial displacement might occur simultaneously.
Make sure that the total value of both displacements does not exceed the maximum
permissible angular or radial displacement value.
The diagram below illustrates the potential displacements:

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˂.D

˂.Z

˂.U
$[LDOGLVSODFHPHQW $QJXODUGLVSODFHPHQW 5DGLDOGLVSODFHPHQW
˂.D ˂.Z ˂.U
Figure 5-2 Possible displacements

Alignment
Align the individual components in two mutually perpendicular axial planes. The following can
be used as alignment tools:
• Ruler (radial displacement)
• Feeler gauge (angular displacement)
• Spirit level
• Dial gauge
• Laser alignment system
You will achieve a greater degree of alignment accuracy by using a dial gauge or laser alignment
system.
The diagram below shows the alignment process based on the example of a flexible coupling:




 




① Ruler ③ Measuring points

② Feeler gauge
Figure 5-3 Alignment process based on the example of a flexible coupling

Note
It is advisable to insert shims or metal sheets under the mounting feet in order to align the drive
components in the vertical direction. It is helpful to use support paws with adjusting screws on
the foundation to adjust the drive components laterally.

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5.5 Connecting components

Gear unit with motor bell housing

If the gear unit and the motor are connected through a motor bell housing, no alignment of the
couplings is necessary.

Further information
Further information about the permissible alignment errors can be found in the coupling
operating instructions in the complete documentation for the gear unit, or contact the
manufacturer in question.

5.5 Connecting components

5.5.1 Gear units with mounted components

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

Further information
You can find additional information on operation and maintenance in the associated operating
instructions, provided in the complete gear unit documentation.
You can find the technical data of the mounted components in the contract-list of equipment
provided in the complete gear unit documentation.

5.5.2 Connecting the Pt 100 resistance thermometer

Procedure
To connect the Pt 100 resistance thermometer, proceed as follows:
1. Check that the Pt 100 resistance thermometer connection is not damaged.
2. Install the electrical wiring between the Pt 100 resistance thermometer and the evaluation
unit. The customer is responsible for providing the evaluation unit.

Further information
Further information about the Pt 100 resistance thermometer can be found in the Pt 100
resistance thermometer operating instructions in the complete documentation for the gear unit.

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5.6 Tightening procedure

5.5.3 Electrical connections

Procedure

DANGER
Electric shock
Live parts can cause electric shock.
Ensure that the entire plant is de-energised before starting electrical installation work.
Carefully observe the five safety rules (Page 11).

To connect the motors and monitoring devices, proceed as follows:

1. Ensure that the connections of the motors and monitoring devices are not damaged.
2. Connect the motors and monitoring devices according to the terminal diagram.

Further information
You can find additional information about the electrical connections in the terminal diagrams
and equipment lists provided in the complete gear unit documentation.

5.6 Tightening procedure

5.6.1 Introduction

Bolts
The bolts must have the following properties:
• Made of steel
• Black-annealed or phosphatised
• Lightly oiled (do not add additional oil)

Note
Replacing bolts
Replace any bolts that are no longer fit for use by bolts of the same type and strength class.

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5.6 Tightening procedure

Mating threads
The mating threads must have the following properties:
• Made of steel or cast iron
• Dry, cut threads

Note
Using a lubricant
As a rule, lubricants may not be used, because this can result in the bolt connection becoming
overloaded.

5.6.2 Bolt connection classes

In order to affix fastening bolts, note the information in the following table:

Table 5-1 Information on tightening fastening bolts

Mounting Bolt connection Scatter of the tor‐ Tightening procedure

class que emitted on
the tool
Gear unit C ± 5 % to ± 10 % • Hydraulic tightening with me‐
Motor chanical screwdriver
Brake • Torque-controlled tightening
Torque arm with a torque wrench or a signal-
emitting torque wrench
• Tightening with a precision me‐
chanical screwdriver with dynam‐
ic torque measurement
D ± 10 % to ± 20 % • Torque-controlled tightening
with mechanical screwdriver
Protection cover E ± 20 % to ± 50 % • Tightening with pulse screwdriv‐
Sun shield er or impact wrench, without ad‐
Inspection cover justment checking device
• Tightening by hand, using a
wrench without torque measur‐
ing device

Further information
You can find additional information about tightening torques when mounting motor and brake
in the operating instructions from the particular manufacturer.

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5.6.3 Tightening torques and preload forces

The specified bolted connections must be tightened to the torques stated in the table below:
The tightening torques apply to friction values of μtotal = 0.14.
The following table lists the preload forces and tightening torques for bolt connections, strength
classes 8.8; 10.9; 12.9:

Table 5-2 Preload forces and tightening torques

Nominal Bolt Preload force for bolt connection Tightening torque for bolt connec‐
thread di‐ strength classes from the table in tion classes from the table in chap‐
ameter class chapter Bolt connection classes ter Bolt connection classes
(Page 42) (Page 42)
d C D E C D E
mm FM min. MA
N Nm
M10 8.8 18 000 11 500 7 200 44.6 38.4 34.3
10.9 26 400 16 900 10 600 65.4 56.4 50.4
12.9 30 900 19 800 12 400 76.5 66.0 58.9
M12 8.8 26 300 16 800 10 500 76.7 66.1 59.0
10.9 38 600 24 700 15 400 113 97.1 86.6
12.9 45 100 28 900 18 100 132 114 101
M16 8.8 49 300 31 600 19 800 186 160 143
10.9 72 500 46 400 29 000 273 235 210
12.9 85 000 54 400 34 000 320 276 246
M20 8.8 77 000 49 200 30 800 364 313 280
10.9 110 000 70 400 44 000 520 450 400
12.9 129 000 82 400 51 500 609 525 468
M24 8.8 109 000 69 600 43 500 614 530 470
10.9 155 000 99 200 62 000 875 755 675
12.9 181 000 116 000 72 500 1 020 880 790
M30 8.8 170 000 109 000 68 000 1 210 1 040 930
10.9 243 000 155 000 97 000 1 720 1 480 1 330
12.9 284 000 182 000 114 000 2 010 1 740 1 550
M36 8.8 246 000 157 000 98 300 2 080 1 790 1 600
10.9 350 000 224 000 140 000 2 960 2 550 2 280
12.9 409 000 262 000 164 000 3 460 2 980 2 670
M42 8.8 331 000 212 000 132 000 3 260 2 810 2 510
10.9 471 000 301 000 188 000 4 640 4 000 3 750
12.9 551 000 352 000 220 000 5 430 4 680 4 180
M48 8.8 421 000 269 000 168 000 4 750 4 090 3 650
10.9 599 000 383 000 240 000 6 760 5 820 5 200
12.9 700 000 448 000 280 000 7 900 6 810 6 080

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5.7 Final work

Nominal Bolt Preload force for bolt connection Tightening torque for bolt connec‐
thread di‐ strength classes from the table in tion classes from the table in chap‐
ameter class chapter Bolt connection classes ter Bolt connection classes
(Page 42) (Page 42)
d C D E C D E
mm FM min. MA
N Nm
M56 8.8 568 000 363 000 227 000 7 430 6 400 5 710
10.9 806 000 516 000 323 000 10 500 9 090 8 120
12.9 944 000 604 000 378 000 12 300 10 600 9 500
M64 8.8 744 000 476 000 298 000 11 000 9 480 8 460
10.9 1 060 000 676 000 423 000 15 600 13 500 12 000
12.9 1 240 000 792 000 495 000 18 300 15 800 14 100
M72x6 8.8 944 000 604 000 378 000 15 500 13 400 11 900
10.9 1 340 000 856 000 535 000 22 000 18 900 16 900
12.9 1 570 000 1 000 000 628 000 25 800 22 200 19 800
M80x6 8.8 1 190 000 760 000 475 000 21 500 18 500 16 500
10.9 1 690 000 1 100 000 675 000 30 500 26 400 23 400
12.9 1 980 000 1 360 000 790 000 35 700 31 400 27 400
M90x6 8.8 1 510 000 968 000 605 000 30 600 26 300 23 500
10.9 2 150 000 1 380 000 860 000 43 500 37 500 33 400
12.9 2 520 000 1 600 000 1 010 000 51 000 43 800 39 200
M100x6 8.8 1 880 000 1 200 000 750 000 42 100 36 200 32 300
10.9 2 670 000 1 710 000 1 070 000 60 000 51 600 46 100
12.9 3 130 000 2 000 000 1 250 000 70 000 60 400 53 900

5.7 Final work

Measures
Once all the elements have been assembled or connected, perform the following final work:
• Check whether all devices dismantled for transportation have been reassembled.
• Check all bolt connections for tightness after installation of the gear unit has been completed.
• Check the alignment after tightening the fastening elements. The alignment must not have
changed in any way.
• Safeguard the oil drain valves against accidental opening.
• Protect the gear unit against falling objects.
• Check that the guards over rotating parts are securely fastened.
Contact (accidental or deliberate) with rotating parts is not permitted.

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• Perform potential equalisation in accordance with the applicable regulations and guidelines.
If no threaded holes are available on the gear unit for an earth connection, please take
suitable alternative measures. This work must always be done by specialist electricians.
• Protect the cable entries against penetrating moisture.

Further information
You will find further information on the gear unit and all mounted or separately supplied
components in the operating instructions of the relevant components, which are part of the
complete documentation of the gear unit.
You can find additional technical specifications in the separate data sheet in the complete gear
unit documentation.

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Commissioning 6
6.1 Measures prior to commissioning

Take the following measures before commissioning the gear unit:

• Read and observe the operating instructions.
• Replace the screw plug with the air filter or the venting screw. Read operating instructions BA
7300 for further information.
• Fill the gear unit with oil.
• Check the oil level.
• Check the gear unit for leaks.
• Check whether the monitoring devices are connected and switched on.
• Ensure that all pipes and components are filled with oil.

Further information
Further information about oil and replacement of air filters can be found in the operating
instructions BA 7300 in the complete documentation for the gear unit.
Further information about individual components can be found in the operating instructions for
the components in the complete documentation for the gear unit.

6.2 Measures during commissioning

Take the following measures when commissioning the gear unit and document them:
• Check the oil level.
• Measure the oil sump temperature (Page 53) after the gear unit has reached its normal
operating temperature.
• Check the tightness of the shaft seal on the gear unit (Page 21).
• Check that no contact with rotating parts is possible.
• Check whether the shutoff valves are open.
– Check that all of the oil drain valves are closed.
– Ensure that all of the other shutoff valves are open.
• Check that existing connecting pipes are firmly seated and tight.

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6.2 Measures during commissioning

Further information
You will find further information on the topic of oil in the operating instructions BA 7300, which
are part of the complete documentation of the gear unit.
You will find further information on the oil supply system in the operating instructions of the oil
supply system, which are part of the complete documentation of the gear unit.

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7.1 Operating data

Introduction
To ensure correct, trouble-free operation of the system, observe the operating data of the gear
unit and, depending on the order specification, the data in the operating instructions for the oil
supply system.
The valid operating data can be found in the annex Technical data (Page 67).
The following operating data apply to the oil:

Table 7-1 Operating data

Maximum operating tempera‐ 90 °C is applicable for mineral oil, API groups I or II and saturated
ture synthetic ester
Maximum operating tempera‐ 100 °C is applicable for semi-synthetic oils, API group III, PAO and
ture PG oils

Further information
You will find further information on the technical data of the gear unit in the data sheet and the
list of equipment, which are part of the complete documentation of the gear unit.

7.2 Irregularities in operation

Introduction
Switch off the drive assembly immediately if it exhibits irregular behaviour during operation.
A few irregularities are listed below as examples:
• Oil temperature exceeds the maximum permissible value
• Alarm tripped by the pressure monitor in the oil cooling system or oil supply system
• Unusual operating noise

NOTICE
Faults can cause damage to the gear unit
The gear unit might sustain damage if it is not shut down when a fault occurs.
Switch off the drive assembly immediately if any fault condition develops.

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7.3 Taking the unit out of service

Rectifying irregularities in operation

Proceed as follows to rectify any irregularities in operation:
1. Switch off the drive assembly if it exhibits irregular behaviour during operation.
2. Refer to the Fault information (Page 55) to find the cause of the fault.
3. If you still cannot determine the fault cause, contact Flender Customer Services (Page 59).

7.3 Taking the unit out of service

If you take the unit out of service for a prolonged period, you must take the following measures
depending on the length of time that the gear unit will remain out of service:
• Switch off the drive assembly.
• Take measures to preserve the gear unit if it is to be out of service for a prolonged period.
Follow the preservation procedure described in operating instructions BA 7300.

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Servicing 8
8.1 General maintenance information
The operator must ensure compliance with the stipulated time limits. This also applies if the
maintenance activities are included in the operator’s internal maintenance schedules.
The gear unit could be damaged if the stipulated time limits for maintenance and servicing are
not observed.
The time limits stipulated in the maintenance schedule are largely dependent on the conditions
of use of the gear unit. For this reason, it is only possible to state average time limits here. These
refer to the following conditions of use:
• Daily operating time 24 h
• Duty cycle "ED" 100%
• Gear unit input speed 1500 rpm
• Average oil temperature in the oil sump (see operating instructions BA 7300)

WARNING
Danger to life due to live system
Working on a gear unit while it is in operation is hazardous and can result in potentially fatal
injuries.
Always shut down the gear unit and any oil supply system (whether separate or mounted on
the gear unit) before you carry out any work. Take measures to prevent the accidental
restarting of the drive assembly. Display a warning notice that clearly states that work is being
carried out on the gear unit.

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Servicing
8.2 Maintenance schedule

8.2 Maintenance schedule

Maintenance and servicing activities

The following table provides an overview of all maintenance and servicing activities that you are
required to perform continuously or at regular intervals.

Table 8-1 Maintenance and servicing activities

Intervals and time limits Measures

As required Clean the air filter
Clean the gear unit
Monthly and prior to every start-up Check for leaks
Check the oil level
Check the oil temperature
Check for changes in the gear unit noise
400 operating hours after commissioning Check the water content of the oil
Change the oil (or depending on the result of the oil
sample test)
Check that all of the fastening bolts are tight
Every 3 months Clean the air filter
Clean the venting screw
Every 12 months Check the water content of the oil
Every 5 000 operating hours, at least every 18 Change the oil if using semi-synthetic oil of API Group III,
months PAO or PG oil (or depending on the result of the oil sam‐
pling)
Every 2 years Carry out a general inspection of the gear unit
Check that all of the fastening bolts are tight
Clean the gear unit

Further information
Further information about additional maintenance and servicing activities can be found in the
separate data sheet in the overall documentation for the gear unit.
Further information about installed components can be found in the operating instructions for
the components in the complete documentation for the gear unit.

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 Servicing
8.3 Maintenance and servicing work

8.3 Maintenance and servicing work

Introduction
You will find maintenance and servicing measures relating to gear unit lubrication and
preservation that are not provided in this chapter in BA 7300, which is part of the complete
documentation of the gear unit.

8.3.1 Clean the venting screw

Cleaning interval
For dust deposits, you must clean the venting screw before the minimum interval of 3 months
expires.

CAUTION
Compressed air can cause injuries
There is a risk of eye injury when using compressed air.
Wear suitable safety goggles.

Procedure
Proceed as follows to clean the venting screw:
1. Remove the venting screw.
2. Do not allow foreign matter to enter the gear unit.
3. Wash the venting screw with cleaning solvent or a similar cleaning agent.
4. Dry the venting screw and blow it out using compressed air.

8.3.2 Checking the oil temperature

Damage to the gear unit due to excessively high oil sump temperatures.
The gear unit can sustain damage due to inadequate lubrication if you allow it to operate at oil
sump temperatures above the maximum permissible temperature.
Do not operate the gear unit above the maximum permissible oil sump temperature.

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Servicing
8.3 Maintenance and servicing work

Procedure
Proceed as follows to check the oil temperature:
1. Allow the gear unit to reach its normal operating temperature.
2. Operate the gear unit with the maximum driven machine power.
3. Measure the temperature of the oil in the oil sump.
4. Compare the measured value with the maximum permissible oil temperature (Page 49).
5. Immediately stop the gear unit if the maximum permissible oil temperature is exceeded.
Contact Flender Customer Services.

8.3.3 Cleaning the gear unit

Introduction
Layers of dust may affect the dissipation of heat through the surface of the gear unit, resulting
in overheating. Depending on the operating conditions, it may therefore be necessary to clean
the gear unit more frequently than stated in the maintenance schedule.

Procedure
To clean the gear unit, proceed as follows:
1. Use a hard brush to remove any stubborn dirt from the gear unit. Never use a high-pressure
cleaning device.
2. Treat any areas of corrosion.

8.3.4 General inspection of the gear unit

Arrange for Flender Customer Services to inspect the gear unit. Thanks to their experience, these
engineers are best placed to assess whether and which gear unit components need to be
replaced.

8.3.5 Check that all of the fastening bolts are tight

Note the following points when checking that the fastening bolts are tight:
• Observe the data regarding connection classes (Page 42), preload forces and tightening
torques (Page 43).
• Replace any bolts that are no longer fit for use by bolts of the same strength class and type.

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 Servicing
8.4 Possible faults

8.3.6 Final work

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

8.4 Possible faults

The faults listed below are only intended as a troubleshooting guide.

If any faults occur while the unit is still under warranty, do not allow anyone except Flender
Customer Services to attempt a repair.
Even after the warranty period has expired, you should still arrange for faults to be rectified by
Flender Customer Services.

Note
Loss of warranty
You will invalidate the warranty for the gear unit if you modify it in any way without seeking the
approval of Flender beforehand, or if you do not use original spare parts.
Only use original spare parts from Flender. Always arrange for Flender Customer Services to
repair any faults that develop while the unit is still under warranty.

Possible faults and how to rectify them

The following table provides an overview of the possible faults and how to rectify them.

Table 8-2 Possible faults and how to rectify them

Possible faults Causes Possible remedies

Grease escaping at the Defective rotary shaft sealing rings • Inspect the rotary shaft sealing rings and replace if neces‐
output shaft sary
Noise Damage to the gear teeth • Contact Customer Service
• Inspect the toothed components
• If necessary, replace damaged components
The bearing play is excessive. • Contact Customer Service
• Adjust bearing play
Defective rolling-contact bearing • Contact Customer Service
• Replace defective rolling-contact bearings
Overrunning noises caused by oper‐ • Contact Customer Service
ation on frequency converter • Check the closed-loop motor control system
Gear unit fastening has worked • Tighten bolts and nuts to the specified tightening torque
loose • Replace damaged bolts and nuts

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Servicing
8.4 Possible faults

Possible faults Causes Possible remedies

Outer surface of gear Inadequate sealing of the housing • Seal housing cover or joints
unit soiled with oil cover or joints
Labyrinth seals soiled with oil, incor‐ • Check oil filling
rect transport position • Clean labyrinth seals
Leaks Labyrinth seals soiled with oil, incor‐ • Check oil filling
rect transport position • Clean labyrinth seals
Inadequate sealing of the housing • Check the seals and replace if necessary
cover or joints • Seal housing cover or joints
Defective rotary shaft sealing rings • Check the rotary shaft sealing rings
• Replace, if necessary
Oil is foaming in the Preservation agent not completely • Change the oil
gear unit drained off
Gear unit too cold during operation • Shut down the gear unit
• Degas the oil
• Start up without cooling water during cold restart
Water in the oil • Take test tube sample to examine oil condition for water
penetration
• Have the oil examined by a chemical lab
• Change the oil if necessary
Oil defoamer has run out • Examine the oil
• Change the oil if necessary
Unsuitable mixture of oils • Examine the oil
• Change the oil if necessary
Oil escaping from the Inadequate sealing of the housing • Check the seals and replace if necessary
gear unit cover or joints • Seal housing cover or joints
• Check the compression seals and retighten bolts if neces‐
sary
Elevated temperature Oil level in the gear unit housing too • Check the oil level
during operation high • If required, correct the oil level
Oil is too old • Check when the last oil change was performed
• Change the oil if necessary
Oil is severely contaminated • Change the oil
Elevated temperature Oil level in the gear unit housing too • Check the oil level at room temperature
at bearing points low or too high • If required, correct the oil level
Oil is too old • Check when the last oil change was performed
• Change the oil if necessary
Defective rolling-contact bearing • Contact Customer Service
• Inspect the rolling-contact bearings and replace if neces‐
sary

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 Servicing
8.4 Possible faults

Possible faults Causes Possible remedies

Elevated vibration am‐ Defective rolling-contact bearing • Contact Customer Service
plitude at bearing • Inspect the rolling-contact bearings and replace if neces‐
points
sary
Gear wheels defective • Contact Customer Service
• Inspect the gear wheels and replace if necessary
Water in the oil Engine room fan is blowing cold air • Install suitable thermal insulation to protect gear unit
onto gear unit: Water condenses housing
• Close the air outlet or change the direction of the air outlet
using structural measures.
Climatic conditions • Contact Customer Service
• Use wet-air filter if necessary
Oil foams in the oil sump • Take test tube sample to examine oil condition for water
penetration
• Have the oil examined by a chemical lab

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Servicing
8.4 Possible faults

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58 Edition 06/2020
Service & Support 9
Contact
When ordering spare parts, requesting a customer service technician or in the case of technical
queries, please contact our factory or one of our customer service addresses:
Flender GmbH
Am Industriepark 2
46562 Voerde
Germany
Tel.: +49 (0)2871 / 92‐0
Fax: +49 (0)2871 / 92‐1544

Further information
Further information about service and support can be found on the Internet.
Service & Support (https://www.flender.com/service)

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Service & Support

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60 Edition 06/2020
Disposal 10
Disposal of the gear unit
When disposing of the gear unit after its useful life, please observe the following measures:
• Remove operating oil, preservative agents and coolant from the gear unit and dispose of it
according to regulations.
• Dispose of the gear unit parts according to applicable national regulations or recycle them.

Environmental protection
Observe the following environmental protection measures for disposal:
• Dispose of or recycle packaging material according to applicable national regulations.
• When changing the oil, collect the used oil in suitable containers. Use oil-binding agents to
clean up any oil spillages immediately.
• Store preservative agents separately from used oil.
• Dispose of used oil, preservative agents, oil binding agents and oil-soaked cloths according
to the applicable environmental protection regulations.

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Disposal

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Spare parts 11
By stocking the most important spare parts at the installation site you can ensure that the gear
unit is ready for use at any time.

Note
Damage to the gear unit due to use of unsuitable spare parts
Only use original spare parts from Flender. Flender shall not accept any warranty claims for spare
parts that are not supplied by Flender.
Other spare parts are not tested and approved by Flender. Non-approved spare parts may
possibly change the design characteristics of the gear unit and thus impair its active or passive
safety.
Flender will accept no liability or warranty whatsoever for damage occurring as a result of the
use of non-approved spare parts. The same applies to any accessories which were not supplied
by Flender.

The contact address of Flender Customer Services can be found under Service & Support
(Page 59).

Information required when ordering spare parts

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

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Spare parts

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64 Edition 06/2020
Declaration of Incorporation A
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Assembly and operating instructions 5802en

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Declaration of Incorporation

Assembly and operating instructions 5802en

66 Edition 06/2020
Technical data B
B.1 General technical data

Rating plate
The gear unit rating plate contains the most important technical data.

       










① Company logo ⑧ Speed n2

② Serial no.: production plant code/order no. ⑨ Optional DMC (Data Matrix Code)
item ser. no./year of manufacture
③ Total weight in kg ⑩ Oil data: Oil type, oil viscosity, oil quantity
④ For special information ⑪ Numbers of operating instructions
⑤ Type, size ⑫ For special information
⑥ Power rating P2 in kW or torque T2 in Nm ⑬ Manufacturer documentation / Country of ori‐
gin
⑦ Speed n1 ⑭ Hotline
Figure B-1 Rating plate

The limits of the intended use of the gear unit are defined on the basis of this data and the
contractual agreements concerning the gear unit concluded between Flender and the customer.

Further information
You can find additional information about these technical data in the separate data sheet and the
dimension drawings in the complete documentation for the gear unit.
You can find additional information about all major accessories including their technical data in
the order-specific list of equipment in the complete documentation for the gear unit.

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Technical data
B.3 Weights

Type and size

The following shows the code printed in line 5 of the rating plate and explains the meaning of
the individual letters and numbers.

.  ) 0 

6L]H


0RXQWLQJ
0 +RUL]RQWDOYHUVLRQZLWKRXWIRRW

9HUVLRQ2XWSXWVKDIW
) )ODQJHGVKDIW

1RRIVWDJHV


*HDUXQLWW\SH
. +HOLFDOJHDUXQLW

Further information
You can find additional information on the weights and the enveloping surface sound pressure
levels in chapters Weights (Page 68) and Enveloping surface sound pressure level (Page 69).
You can find additional information about these technical data in the separate data sheet and the
dimension drawings in the complete documentation for the gear unit.

B.2 Ambient temperature

Unless otherwise contractually agreed, the gear unit must not be exposed to any harmful
atmospheres or substances such as aggressive chemical products. By applying various suitable
measures, the gear unit can be used in the ambient temperature range extending from -40 °C
up to 60 °C. However, this must always be authorised by Flender and specified in the order text.

B.3 Weights

The precise weights are specified in the dimension drawings in the complete documentation or
on the rating plate.
All weight specifications refer to units without oil filling or mounted components.

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 Technical data
B.5 Enveloping surface sound pressure level

Refer to the following table for gear unit weights (approximate values, in kg):

Table B-1 Weights

Type iN Gear unit size

625
K3FM 24.70 635
33.25 635
36.45 640
48.75 670

B.4 Oil quantities

The oil quantity required is specified on the rating plate attached to the gear unit.
Refer to the following table for the oil quantity (approximate values, in litres) for a gear unit in
horizontal mounting position.

Table B-2 Oil quantities

Type Gear unit size

625
K3FM 30

B.5 Enveloping surface sound pressure level

The gear unit has an enveloping surface sound pressure level at a distance of 1 m. Refer to the
following table for the enveloping surface sound pressure level:
The measurement is performed using the sound-intensity method according to DIN EN ISO 9614
Part 2.
The workplace of operating personnel is defined as the area on the measuring surface at a
distance of 1 m around the gear unit and in the vicinity where persons may be present.
The sound pressure level applies to a gear unit in the warm condition at an input speed n1 and
output power P2 according to the rating plate, for measurements carried out on a Flender test
bench. If several values are given, then the highest speed and power values apply.
The enveloping surface sound pressure level includes any mounted lubrication units. With
outgoing and incoming pipes, the flange is considered to be the interface.
The sound pressure levels listed in the table were obtained based on statistical evaluations
carried out by our Quality Control department. With statistical certainty, you can assume that
the gear unit does not exceed these sound pressure levels.

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Technical data
B.5 Enveloping surface sound pressure level

Refer to the following table for the enveloping surface sound pressure level LpA in dB(A) for the
gear unit.

Table B-3 Enveloping surface sound pressure level

Type iN n1 in rpm Gear unit size

625
K3FM 24.70 6000 75 +2
33.25
36.45
48.75

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Index

A I
Attachment points, 29 Interval, 52
Irregularities in operation, 49

C
Coloured markings, 12
L
Contact, 59 Lateral pulling, 25
Copyright, 10 Lubricant, 10
Coupling, 21
Customer Services, 59
M
Maintenance activities, 52
D Maintenance information, 51
Danger of explosion, 16 Maintenance schedule, 52
Disclaimer, 9 Measures
Disposal, 61 during commissioning, 47
Documentation landscape, 9 Prior to commissioning, 47
Mounted components, 40
Mounting position, 29
E
Environmental protection, 61
Equipment features, 19
N
Eye bolts, 25 Note about assembly, 29

F O
Fastening bolts, 54 Oil, 10
Bolt connection class, 42 Check the oil level, 28
Bolts, 41 Oil draining point, 27
Mating threads, 42 Oil filling points, 27
Preload force, 43 Oil temperature, 54
Tightening procedure, 42 Oil temperature monitoring
Tightening torque, 43 Connecting the resistance thermometer, 40
Fault, 55 Resistance thermometer, 22
Fault rectification, 55 Operating data
Final work, 44 Compliance with, 49
Oil, 49
Ordering spare parts, 59, 63
G
Gear unit equipment, 20
Gear unit housing, 19
P
Gear unit markings, 12 Protective equipment, 14
General inspection of the gear unit, 54

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Index

R
Rating plate, 67
Type and size, 68
Reactivating, 18
Rotary shaft sealing ring, 21

S
Safety rules, 11
Scope of delivery, 23
Servicing activities, 52
Shaft bearings, 20
Shaft seal, 21
Shear pulling, 25
Shipping documents, 23
Splash lubrication, 20

T
Taking the unit out of service, 50
Technical data, 67
Transport information, 23
Transport symbols, 24
Troubleshooting, 55
Types of danger, 14

U
Unpacking, 30
Used oil, 61
Using the gear unit, 17

V
Venting screw, 53

W
Warning symbols, 13

Assembly and operating instructions 5802en

72 Edition 06/2020
FLENDER GEAR UNITS
Crane gear unit
Assembly and operating instructions 5802en
Edition 06/2020

Flender GmbH
Alfred-Flender-Straße 77
46395 Bocholt
GERMANY