FLENDER 114 User manual

H3SH
114...116
Assembly and operating instructions B5832-01en
Edition 06/2022
Crane gear unit

Original assembly and operating instructions
B5832-01
Edition 06/2022
Copyright (©2022 Flender GmbH)
V3
29/07/2022
13:23:45

B5832-01en Edition 06/2022 3
Table of contents
1 Introduction...............................................................................................................................................11
1.1 Legal information .....................................................................................................................11
1.2 General information .................................................................................................................12
1.3 Lubricants ................................................................................................................................14
2 Safety instructions ...................................................................................................................................15
2.1 Security notes ..........................................................................................................................15
2.2 The five safety rules.................................................................................................................15
2.3 General information .................................................................................................................15
2.4 General warnings and symbols................................................................................................17
2.5 Special types of danger and personal protective equipment ...................................................17
2.6 Intended use ............................................................................................................................20
3 Description................................................................................................................................................23
3.1 General description..................................................................................................................23
3.2 Housing....................................................................................................................................23
3.3 Oil supply to the gear unit ........................................................................................................24
3.3.1 Splash lubrication.....................................................................................................................24
3.4 Shaft bearings..........................................................................................................................24
3.5 Shaft seal .................................................................................................................................25
3.5.1 Rotary shaft sealing rings ........................................................................................................25
3.5.2 Taconite seal............................................................................................................................25
3.6 Couplings .................................................................................................................................27
3.7 Brake........................................................................................................................................28
3.8 Heating.....................................................................................................................................28
3.9 Oil level indicator......................................................................................................................29
3.10 Oil temperature monitoring ......................................................................................................30
4 Application planning ................................................................................................................................31
4.1 Scope of delivery .....................................................................................................................31
4.2 Transport..................................................................................................................................31
4.3 Attachment points ....................................................................................................................32

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4 Edition 06/2022 B5832-01en
4.4 Special aspects of gear unit lubrication and preservation........................................................35
4.4.1 Oil filling point and oil drain ......................................................................................................35
4.4.2 Checking the oil level ...............................................................................................................35
5 Assembly...................................................................................................................................................37
5.1 General assembly instructions.................................................................................................37
5.2 Unpacking the gear unit ...........................................................................................................38
5.3 Gear unit assembly ..................................................................................................................39
5.3.1 Foundation ...............................................................................................................................39
5.3.2 Description of assembly work ..................................................................................................40
5.3.2.1 Alignment .................................................................................................................................41
5.4 Couplings .................................................................................................................................43
5.4.1 Assembling the coupling ..........................................................................................................43
5.4.2 Aligning the coupling................................................................................................................45
5.5 Connecting components ..........................................................................................................46
5.5.1 Gear units with mounted components .....................................................................................46
5.5.2 Connecting the heating element ..............................................................................................47
5.5.3 Connecting the Pt 100 resistance thermometer.......................................................................47
5.5.4 Electrical connections ..............................................................................................................48
5.6 Tightening procedure ...............................................................................................................48
5.6.1 Introduction ..............................................................................................................................48
5.6.2 Bolt connection classes ...........................................................................................................49
5.6.3 Tightening torques and preload forces ....................................................................................49
5.7 Final work.................................................................................................................................51
6 Commissioning.........................................................................................................................................53
6.1 Measures prior to commissioning ............................................................................................53
6.2 Measures during commissioning .............................................................................................53
6.2.1 Gear units with heating ............................................................................................................54
7 Operation...................................................................................................................................................55
7.1 Operating data .........................................................................................................................55
7.2 Irregularities in operation .........................................................................................................55
7.3 Taking the unit out of service ...................................................................................................56
8 Servicing ...................................................................................................................................................57
8.1 General maintenance information............................................................................................57
8.2 Maintenance schedule .............................................................................................................57
8.3 Maintenance and servicing work..............................................................................................58

Table of contents
B5832-01en Edition 06/2022 5
8.3.1 Clean the venting screw...........................................................................................................58
8.3.2 Checking the oil temperature ...................................................................................................59
8.3.3 Cleaning the gear unit..............................................................................................................59
8.3.4 General inspection of the gear unit ..........................................................................................60
8.3.5 Check that all of the fastening bolts are tight ...........................................................................60
8.3.6 Final work.................................................................................................................................60
8.4 Possible faults..........................................................................................................................60
9 Service & Support.....................................................................................................................................63
9.1 Contact.....................................................................................................................................63
10 Disposal.....................................................................................................................................................65
11 Spare parts................................................................................................................................................67
A Declaration of Incorporation....................................................................................................................69
A.1 Declaration of Incorporation.....................................................................................................69
B Technical data...........................................................................................................................................71
B.1 General technical data .............................................................................................................71
B.2 Ambient temperature ...............................................................................................................72
B.3 Weights ....................................................................................................................................72
B.4 Oil quantities ............................................................................................................................72
B.5 Enveloping surface sound pressure level ................................................................................73
Index ..........................................................................................................................................................75

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

List of tables
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B5832-01en Edition 06/2022 9
List of figures
Figure3-1 Gear unit equipment on type H3SH gear units ..........................................................................24
Figure3-2 Rotary shaft sealing ring.............................................................................................................25
Figure3-3 Taconite seal..............................................................................................................................26
Figure3-4 Taconite seal, variants E, F, F‐F, F‐H and F‐K ..........................................................................26
Figure3-5 Heating on type H3SH gear units...............................................................................................29
Figure4-1 Transport symbols......................................................................................................................32
Figure4-2 Shear and lateral pulling when using eye bolts..........................................................................33
Figure4-3 Position of the attachment points on the type H3SH gear unit...................................................34
Figure4-4 Position of the attachment points on type H3SH gear units with motor .....................................34
Figure4-5 Oil filling and oil drain .................................................................................................................35
Figure5-1 Gap dimension at the grease labyrinth ......................................................................................41
Figure5-2 Alignment surface.......................................................................................................................42
Figure5-3 Alignment surfaces.....................................................................................................................42
Figure5-4 Possible displacements..............................................................................................................45
Figure5-5 Alignment process based on the example of a flexible coupling................................................46
FigureB-1 Rating plate ................................................................................................................................71

List of figures
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B5832-01en Edition 06/2022 11
Introduction 1
1.1 Legal information1.1 Legal information
Warning system
These instructions contain information you must observe for your own personal safety as
well as to avoid damage to property and persons. The information regarding your personal
safety is highlighted with a warning triangle. Information exclusively regarding property dam-
age alone is not marked with a warning triangle. Depending on the hazard class, the warn-
ings shall be depicted as follows, in descending order.
DANGER
means that death or severe physical injury will occur if the relevant precautionary meas-
ures are not taken.
WARNING
means that death or severe physical injury may occur if the relevant precautionary meas-
ures are not taken.
CAUTION
means that mild physical injury may occur if the relevant precautionary measures are not
taken.
NOTICE
means that damage to property may occur if the relevant precautionary measures are not
taken.
If multiple hazard classes come into play, the warning for the highest level in question shall
always be used. If a warning containing the warning triangle warns of harm to individuals, the
same warning may also include a warning regarding damage to property.
Information
Information
Information offers additional notes, assistance and tips for handling the product.

Introduction
1.2 General information
12 Edition 06/2022 B5832-01en
Qualified personnel
The product/system associated with this documentation may only be used by qualified per-
sonnel trained to perform the relevant tasks, taking into account the associated documenta-
tion for the relevant tasks, particularly the safety information and warnings included therein.
Due to their qualification and experience, qualified personnel are capable of detecting risks
and avoiding potential hazards when dealing with these products/systems.
Intended use of Flender products
Please note the following:
WARNING
Flender products are only suitable for the uses set out in the catalogue and associated
technical documentation. If third-party products and components are used, these must be
recommended and/or authorised by Flender. Safe and flawless operation of the products
requires proper transport, proper storage, setup, assembly, installation, commissioning,
operation and maintenance. The permissible environmental conditions must be adhered
to. Instructions in the associated documentation must be followed.
Trademarks
All designations marked with the trademark symbol ® are registered trademarks of Flender
GmbH. Other designations in this document may be trademarks whose use by third parties
for their own purposes may violate the rights of the owner.
Liability disclaimer
We have assessed the contents of these instructions for compliance with the hardware and
software described. However, deviations cannot be ruled out, so we are unable to accept li-
ability for full compliance. The details in these instructions are regularly reviewed and neces-
sary corrections are contained in subsequent editions.
1.2 General information1.2 General information
Purpose of the operating instructions
These operating instructions describe the gear unit and provide information about handling it
- from assembly to maintenance.
Please keep these operating instructions for later use. Please read these operating instruc-
tions prior to handling the gear unit and follow the information in them.

Introduction
1.2 General information
B5832-01en Edition 06/2022 13
Information
Disclaimer
Please make sure that every person who is commissioned to work on the gear unit has
read and understood these operating instructions prior to handling the gear unit and ad-
heres to all of the points. Failure to observe these operating instructions can cause product
or property damage or personal injury.
Flender does not accept any liability for damage or operating failures which are due to non-
adherence to these operating instructions.
The gear unit described in these instructions reflects the state of technical development at
the time these operating instructions went to print.
In the interest of technical advancements, Flender reserves the right to make changes to the
individual components and accessories which are considered necessary for improving their
performance and safety, while maintaining their essential features.
Required basic knowledge
In order to understand these operating instructions, you will need to have general knowledge
about gear units. You will also need a basic understanding of the following topics:
• Application planning
• Assembly
• Commissioning
• Maintenance
Documentation landscape
These operating instructions form part of the delivery of your gear unit.
These operating instructions form part of the complete documentation supplied with the gear
unit. The complete documentation encompasses other documents, including:
• Data sheet
• List of equipment
• Dimension drawing
• Operating Instructions 7300 on gear unit lubrication and preservation
• Operating instructions for mounted components
• Instructions for third-party devices
Copyright
The copyright for these operating instructions is held by Flender.
Without the authorisation of Flender, these operating instructions may not be used wholly or
in parts for competitors’ purposes or be given to third parties.
If you have any technical queries, please contact one of our Customer Services addresses
(Page63).

Introduction
1.3 Lubricants
14 Edition 06/2022 B5832-01en
1.3 Lubricants1.3 Lubricants
The quality of the oil used must meet the requirements of the instructions7300, which is
provided as a separate item, otherwise the warranty provided by Flender will be void. Flen-
derurgently recommends that one of the oil types listed in instructions 7300, which have
been appropriately tested and comply with the requirements, is used.
To avoid misunderstandings, Flender points out that, by making this recommendation, it is
not approving the product in the sense of expressing a warranty for the quality of the lubric-
ants supplied by your supplier. Every lubricant manufacturer is required to guarantee the
quality of his/her products.
Information such as oil type, oil viscosity and required oil quantity can be found on the rating
plate of the gear unit and in the documentation supplied with the gear unit.
The oil quantity specified on the rating plate is an approximate value. The actual quantity of
oil required is determined by the marking on the oil dipstick or oil sight glass.
The operating instructions for the current lubricant recommendations of Flender can also be
viewed on the Internet (https://www.flender.com/lubricants).
The oils listed there undergo continuous testing. As a result, the recommended oil types
might in future be removed from the list or replaced by more advanced oils.
Flender recommends regular inspection to ascertain whether the selected lubricating oil is
still approved by Flender. If it is not, another brand of oil should be selected instead.

B5832-01en Edition 06/2022 15
Safety instructions 2
2.1 Security notes2.1 Security notes
Flender offers products and solutions with industrial security functions, which support the
safe and secure operation of plants, systems, machines and networks.
In order to safeguard plants, systems, machines and networks against cyber threats it is ne-
cessary to implement (and continually maintain) a holistic industrial security concept that cor-
responds to the current state of the art. Flender products and solutions undergo continuous
development in this respect.
Customers are responsible for preventing unauthorised access to their plants, systems, ma-
chines and networks. These systems, machines and components shall be connected to the
company network or the Internet only when and to the extent that this is absolutely neces-
sary and appropriate protective measures (e.g. firewalls and/or network segmentation) shall
be taken.
You can find further information about possible protection measures as part of Industrial Se-
curity in the following international series of standards, for example: IEC62443 "Network and
system security".
Flender products and solutions undergo continuous development in order to make them
even safer. Flender strongly recommends that you regularly implement product updates as
soon as they become available and that you only use the current product versions. Use of
older or no longer supported versions can increase the risk of cyber threats.
2.2 The five safety rules2.2 The five safety rules
In order to protect yourself and prevent any damage to property, always observe the safety
relevant information and the following five safety rules (as per EN50110-1 "Working on isol-
ated equipment") when working on electrical components of the plant.
Prior to starting work on the machine, follow the safety rules listed below:
1. Disconnect
Also disconnect auxiliary circuits such as the anti-condensation heater
2. Safeguard against restart
3. Ensure that the system is de-energised
4. Earth and short circuit
5. Cover or cordon off adjacent live parts
When all the work is complete, cancel the safety measures in the reverse sequence.
2.3 General information2.3 General information
Introduction
All work on the gear unit should be performed with care and only by qualified personnel.

Safety instructions
2.3 General information
16 Edition 06/2022 B5832-01en
Symbols on the gear unit
The following symbols apply to the gear unit; some of which are found as coloured markings
on the gear unit:
Points labelled on the gear unit Symbol Coloured markings
Earth connection point
Air relief point yellow
Oil filling point yellow
Oil draining point white
Oil level indicator red
Oil level measurement red
Oil overflow
Connection point for vibration monitoring
Lubrication point red
Apply grease
Lifting eye
Eye bolt
Do not unscrew
Alignment surface, horizontal
Alignment surface, vertical
These symbols indicate the oil level
checking procedure using the oil dipstick.

Safety instructions
2.4 General warnings and symbols
B5832-01en Edition 06/2022 17
Points labelled on the gear unit Symbol Coloured markings
These symbols indicate that the oil dip-
stick must be firmly screwed in.
Table2-1: Symbols and markings
2.4 General warnings and symbols2.4 General warnings and symbols
The following table contains general warnings and their associated symbols.
ISO ANSI Warning
Warning – hazardous electrical voltage
Warning – explosive substances
--- Warning – entanglement hazard
--- Warning – hot surfaces
--- Warning – corrosive substances
--- Warning – suspended load
--- Warning – hand injuries
Table2-2: General warnings
2.5 Special types of danger and personal protective equipment2.5 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.

Safety instructions
2.5 Special types of danger and personal protective equipment
18 Edition 06/2022 B5832-01en
DANGER
Electric shock
Live parts can cause electric shock.
Ensure that the entire plant is de-energised before starting electrical installation work.
Protective equipment
Wear the following personal protective equipment when handling the gear unit:
• Safety shoes
• Overalls
• Helmet
• Safety gloves
• Safety goggles
WARNING
Risk of eye injury
Small foreign particles such as sand or dust can enter the cover plates of the rotating parts
and be hurled back by them.
Wear safety goggles.
Dangers during operation
Damage to the gear unit is possible.
Switch the gear unit to standstill immediately if inexplicable changes are noticed during oper-
ation. Such changes may include unusual gear unit noise or a significant increase in operat-
ing temperature.
WARNING
Risk of falling
There is an increased risk of falling when standing or walking on the gear unit during oper-
ation.
Only walk or stand on the gear unit and its mounted components for maintenance and re-
pair work when it is at a standstill. Do not walk or stand on shaft ends, protection covers,
mounted components or pipes.
WARNING
Danger to life through rotating or moving parts
There is danger that rotating or moving parts may catch hold of you or pull you in.
Secure rotating and/or moving parts against contact using safeguards.

Safety instructions
2.5 Special types of danger and personal protective equipment
B5832-01en Edition 06/2022 19
Surface temperature
The surface temperatures of the gear unit can become very extreme depending on the oper-
ating conditions.
WARNING
Risk of burns
Possible risk of serious burn injury from hot surfaces (>55°C).
Wear suitable protective gloves and protective clothing.
WARNING
Risk of scalding
Risk of serious injury possible through escaping hot operating media when these are being
changed.
Wear suitable protective gloves, safety goggles and protective clothing.
WARNING
Danger due to low temperatures
Possible risk of serious injuries due to frost (pain, numbness, frostbite) on cold surfaces
(<0°C).
Wear suitable protective gloves and protective clothing.
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.

Safety instructions
2.6 Intended use
20 Edition 06/2022 B5832-01en
Danger of explosion
An explosion may occur in a potentially explosive atmosphere.
DANGER
Danger of explosion through ignition of a potentially explosive atmosphere
Danger to life through ignition of a potentially explosive atmosphere possible when operat-
ing the gear unit
Do not use the gear unit in potentially explosive atmospheres.
2.6 Intended use2.6 Intended use
Only use the gear unit according to the conditions specified in the service and delivery con-
tract and the technical data in the Annex (Page71). Deviating operating conditions are con-
sidered improper use. The user or operator of the machine or plant is solely liable for any
resulting damage.
When using the gear unit, please specifically observe the following:
• Do not make any modifications to the gear unit that go beyond the permissible handling
described in these operating instructions. This also applies to the guards designed to
prevent accidental contact.
• Only ever use original replacement parts.
Other replacement parts are not tested and approved by Flender. Non-approved replace-
ment parts may possibly change the design characteristics of the gear unit and thus im-
pair its active or passive safety.
Flender will accept no liability or warranty whatsoever for damage occurring as a result of
the use of non-approved replacement parts. The same applies to any accessories which
were not supplied by Flender.
If you have any questions, please contact Customer Service (Page63).
WARNING
Risk of falling
Risk of serious injury through falling.
Only walk or stand on the gear unit for maintenance and repair work when it is at a stand-
still. Do not walk or stand on shaft ends, protective covers, mounted components or pipe-
work.
Using the gear unit
When using the gear unit, please observe the following basic rules:
• Ensure that the gear unit is operationally safe.
• The gear unit must only be operated, maintained and repaired by authorised, trained, in-
structed and qualified personnel.
• The relevant occupational safety and environmental protection provisions must be taken
into account in transport, assembly and dismantling, operation, servicing and mainten-
ance.