Siemens FLENDER H3LV User manual

FLENDER gear units
Gear unit
H3LV
Sizes 6 to 18
Assembly and operating instructions
BA 5080 en 06/2014

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Gear unit
H3LV
Sizes 6 to 18
Assembly and operating instructions
Translation of the original assembly and operating instructions
T
echnical data
Spare parts,
customer service
Maintenance
and repair
Faults, causes
and remedy
Operation
Startup
Fitting
T
echnical
description
T
ransport and
storage
Safety instructions
General notes
Declarations
1
12
11
10
9
8
7
6
5
4
3
2

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Legal notes
Warning note concept
This manual comprises notes which must be observed for your personal safety and for preventing material
damage. Notes for your personal safety are marked with a warning triangle, those only for preventing
material damage appear without a warning triangle. Depending on the level of hazard, the warning notes
are shown in reverse order of seriousness, as follows.
DANGER
means, that death or serious injury will result, if the appropriate preventive action is not taken.
WARNING
means that death or serious injury may result, if the appropriate preventive action is not taken.
CAUTION
means that a slight injury may result, if the appropriate preventive action is not taken.
NOTICE
means that material damage may result, if the appropriate preventive action is not taken.
Where there is more than one hazard level, the warning note for whichever hazard is the most serious is
always used. If in a warning note a warning triangle is used to warn of possible personal injury, a warning
of material damage may be added to the same warning note.
Qualified personnel
The product or system to which this documentation relates may be handled only by persons qualified for
the work concerned and in accordance with the documentation relating to the work concerned, particularly
the safety and warning notes contained in those documents.
Qualified personnel must be specially trained and have the experience necessary to recognise risks
associated with these products and to avoid possible hazards.
Proper use of Siemens products
Observe also the following:
WARNING
Siemens products must be used only for the applications provided for in the catalogue and the relevant
technical documentation. If products and components of other makes are used, they must be
recommended or approved by Siemens. The faultfree, safe operation of the products calls for proper
transport, proper storage, erection, assembly, installation, startup, operation and maintenance. The
permissible ambient conditions must be adhered to. Notes in the relevant documentations must be
observed.
Trademarks
All designations to which the registered industrial property mark ® is appended are registered trademarks
of Siemens AG. Other designations used in this document may be trademarks the use of which by third
parties for their own purposes may infringe holders’ rights.
Exclusion of liability
We have checked the content of the document for compliance with the hard and software described.
Nevertheless, variances may occur, and so we can offer no warranty for complete agreement. The
information given in this document is regularly checked, and any necessary corrections are included in
subsequent editions.

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Foreword
The term "Assembly and operating instructions" will in the following also be shortened to "instructions"
or "manual".
Symbols in these assembly and operating instructions
This symbol additionally indicates an imminent risk of explosion in the meaning of Directive 94/9/EC.
This symbol additionally indicates an imminent risk of burns due to hot surfaces in the meaning of
standard "DIN EN ISO 137321".
This symbol warns against risks from lifted and/or suspended loads.
Earthconnection point Airrelief point yellow
Oilfilling point yellow Oildraining point white
Oil level red Oil level red
Oil level red Connection for
vibrationmonitoring device
Lubricating 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.
These symbols indicate that the oil dipstick must always be firmly screwed in.

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Contents
1. Technical data 8.....................................................
1.1 General technical data 8...............................................................
1.1.1 Ambient temperature 9................................................................
1.2 Measuringsurface soundpressure level 9...............................................
1.3 Weights 9...........................................................................
1.4 List of equipment 9....................................................................
2. General notes 10.....................................................
2.1 Introduction 10........................................................................
2.2 Copyright 10..........................................................................
3. Safety instructions 11.................................................
3.1 Obligations of the user 11...............................................................
3.2 Special dangers and personal protective equipment 12......................................
3.3 The five safety rules 13.................................................................
3.3.1 Five safety rules 13....................................................................
3.4 Environmental protection 14.............................................................
4. Transport and storage 15.............................................
4.1 Scope of supply 15....................................................................
4.2 Transport 15..........................................................................
4.3 Storing the gear unit 17.................................................................
4.4 Standard coating and preservation 18....................................................
4.4.1 Interior preservation with preservative agent 18............................................
4.4.1.1 Represerving the interior of the gear unit (main gear unit) in case of longer periods of storage 19..
4.4.2 Exterior preservation 22................................................................
4.4.2.1 Represervation of the metallic bright exterior surfaces of the gear unit 22......................
5. Technical description 23..............................................
5.1 General description 23.................................................................
5.2 Construction and method of operation 25..................................................
5.2.1 Spentgrain removal and spentgrain cutting 25............................................
5.2.2 Vertical adjustment of the spentgrain cutting machine 25....................................
5.2.3 Bevelgear motor (electric motor I) 25.....................................................
5.2.4 Height adjustment 25...................................................................
5.2.4.1 Bevelgear motor (electric motor II) 25....................................................
5.2.4.2 Hydraulic cylinder (optional) 26..........................................................
5.2.5 Helicalgear unit 26....................................................................
5.2.6 Strokemounting flange 26..............................................................
5.2.6.1 Strokemounting flange with bevelgear motor 26...........................................
5.2.6.2 Strokemounting flange with lifting cylinder 26..............................................
5.2.7 Gearunit cam-operated switch (optional) 26...............................................
5.2.8 Oilequalising tank 27..................................................................
5.2.9 Bellows 27............................................................................
5.2.10 Limit switch (optional) 27................................................................
5.2.11 Shaft coupling and limitswitch plate (optional) 27..........................................
5.2.12 Frequency inverter (optional) 27.........................................................
5.3 Housing 28...........................................................................
5.4 Toothed components 30................................................................
5.5 Lubrication 31.........................................................................
5.5.1 Splash lubrication 31...................................................................
5.6 Shaft bearings 31......................................................................
5.7 Shaft seal 31..........................................................................
5.7.1 Radial shaftsealing rings 31............................................................
5.8 Oillevel monitoring (optional) 31.........................................................
5.9 Indication of oil level 31.................................................................

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6. Fitting 32.............................................................
6.1 General information on fitting 32.........................................................
6.2 Unpacking 33.........................................................................
6.3 Fitting the gear unit 33..................................................................
6.3.1 Fitting the gearunit on a housing base 33.................................................
6.3.1.1 Foundation 33.........................................................................
6.3.1.2 Fitting the hydraulic cylinder 34..........................................................
6.3.2 Description of fitting work 35.............................................................
6.3.2.1 Alignment 37..........................................................................
6.3.2.2 Fitting on a foundation frame 38..........................................................
6.4 Shrink disk 39.........................................................................
6.4.1 Fitting the shrink disk 39................................................................
6.4.2 Demounting the shrink disk 42...........................................................
6.4.3 Cleaning and greasing the shrink disk 43..................................................
6.4.4 Refitting the shrink disk 44..............................................................
6.4.5 Inspection of the shrink disk 44..........................................................
6.5 Oillevel monitoring (optional) 44.........................................................
6.6 General notes on addon components 44.................................................
6.7 Fitting the limit switch (optional) 44.......................................................
6.7.1 Tangential alignment of the limit switch relative to the switch plate (optional) 45.................
6.7.2 Axial positioning of the limit switch relative to the switch plate (optional) 45.....................
6.8 Fitting the frequency inverter (optional) 45.................................................
6.9 Final work 45..........................................................................
6.10 Screwconnection classes, tightening torques and initialtensioning forces 46..................
6.10.1 Screwconnection classes 46............................................................
6.10.2 Tightening torques and initialtensioning forces 46..........................................
7. Startup 48...........................................................
7.1 Procedure before startup 48............................................................
7.1.1 Removal of preservative agent from exterior 48............................................
7.1.2 Removal of preservative agent from interior 48.............................................
7.1.3 Filling with lubricant 51.................................................................
7.1.3.1 Helicalgear unit (main gear unit) 51......................................................
7.1.3.2 Bevel-gear unit 52.....................................................................
7.2 Setting of the cam-operated switches (in the gearunit cam operated switch) 53.................
7.3 Setting the rotary angle transducer (in the gearunit cam operated switch) 53...................
7.4 Setting of the EMERGENCYOFF limit switches 53.........................................
7.5 Startup 54...........................................................................
7.5.1 Oil level 54............................................................................
7.5.2 Temperature measurement 54...........................................................
7.5.3 Oillevel monitoring (optional) 55.........................................................
7.5.4 Checking procedure 55.................................................................
7.6 Shutting down 55......................................................................
7.6.1 Interior preservation for longer disuse 56..................................................
7.6.1.1 Interior preservation with gearunit oil 56..................................................
7.6.1.2 Interior preservation (main gear unit) with "Castrol Alpha SP 220 S" preservative agent 57........
7.6.2 Exterior preservation 58................................................................
7.6.2.1 Exteriorpreservation procedure 58.......................................................
8. Operation 59.........................................................
8.1 General 59............................................................................
8.2 Oil level 59............................................................................
8.3 Irregularities 59........................................................................
9. Faults, causes and remedy 60.........................................
9.1 General information on faults and malfunctions 60..........................................
9.2 Possible faults 61......................................................................
9.2.1 Leakage and leaktightness 63...........................................................

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10. Maintenance and repair 64............................................
10.1 General notes on maintenance 64........................................................
10.1.1 General service lives of oils 65...........................................................
10.2 Description of maintenance and repair works 65............................................
10.2.1 Examine water content of oil, conduct oil analyses 65.......................................
10.2.2 Changing the oil (main gear unit) 66......................................................
10.2.3 Replace the wetair filter 67.............................................................
10.2.4 Clean the air filter 68...................................................................
10.2.5 Clean the gear unit 68..................................................................
10.2.6 Top up oil 68..........................................................................
10.2.7 Check tightness of fastening bolts 69.....................................................
10.3 Final work 69..........................................................................
10.4 General inspection of the gear unit 69.....................................................
10.5 Lubricants 69.........................................................................
11. Spare parts, customer service 70......................................
11.1 Stocking spare parts 70.................................................................
11.2 Addresses for ordering spare parts and customer service 70.................................
12. Declarations 71.......................................................
12.1 Declaration of incorporation 71..........................................................

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1. Technical data
1.1 General technical data
The most important technical data are shown on the rating plate. These data and the contractual
agreements between Siemens and the customer for the gear unit determine the limits of its correct use.
①
②
③④
⑤⑥
⑦⑧
⑨
⑩
⑪
⑫
⑬
Fig. 1: Rating plate on gear unit
①Company logo
②Manufacturing number #)
③Total weight in kg
④Special information
⑤Type, size *)
⑥Power rating P2in kW or torque T2in Nm
⑦Speed n1
⑧Speed n2
⑨Oil data (oil type, oil viscosity, oil quantity)
⑩Instructions number(s)
⑪Special information
⑫Manufacturer and place of manufacture
⑬Country of origin
#) Code production plant / order number, item, sequence number / year built
*)Example
H3 LV 6
Size 6 ... 18......................
Mounting position V = Vertical..........
Type of output shaft L = Lauter tun.........
Vertically adjustable output shaft
Number of stages 3..........
Gear-unit type H = Helical-gear unit.............
Data on weights and measuringsurface soundpressure levels of the various gearunit types are given in
items 1.2 and 1.3.
For further technical data, refer to the drawings in the gearunit documentation and the orderspecific data
sheet.

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1.1.1 Ambient temperature
Note
Unless otherwise agreed by contract, the gear unit must not be exposed to harmful environmental factors
such as chemically aggressive products. By adopting various suitable measures the gear unit may be
used at ambient temperatures of between  40 °C and + 60 °C. However, Siemens must always have
approved and confirmed this in the order specification.
1.2 Measuringsurface soundpressure level
The measuringsurface soundpressure level for the gear unit at a distance of 1 m can be found in table 1.
The measurement is carried out to standard "DIN EN ISO 9614" Part 2, using the soundintensity method.
The workplace of the operating personnel is defined as the area on the measuring surface at a distance
of 1 metre in the vicinity of which persons may be present.
The soundpressure level applies to the warmedup gear unit at input speed n1and output power P2stated
on the rating plate, as measurement obtained on the Siemens test bench. If several figures are given, the
highest speed and power values apply.
The measuringsurface soundpressure level includes addon lubrication units, if applicable. With
outgoing and incoming pipes, the flanges are the interfaces.
The soundpressure levels stated in the table were obtained by statistical evaluation by our Quality Control
Dept. The gear unit can be statistically expected to comply with these noise levels.
Table 1: Measuringsurface soundpressure level
Measuring-surface sound-pressure level LpA in dB(A)
Type Gear-unit size
6 8 10 12 13 14 15 16 17 18
H3LV 79 81 82 83 82 83 81 79 82 83
1.3 Weights
Table 2: Weights (approximate values)
Approximate weight (kg)
Type Gear-unit size
6 8 10 12 13 14 15 16 17 18
H3LV 760 1190 1720 2770 3520 4200 5150 6200 6600 7200
Note
All weights are indicated for units without oil filling and without addon parts. For the exact weights, refer
to the drawings in the gearunit documentation.
1.4 List of equipment
Note
All important accessory components are listed in the orderspecific list of equipment as well as the
related technical data.

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2. General notes
2.1 Introduction
These instructions are an integral part of the gear unit supplied and must be kept in its vicinity for reference
at all times.
NOTICE
Material damage
Risk of damage to the gear unit or disruptions to operation.
All persons carrying out work on the gear unit must have read and understood these instructions and
must adhere to them.
Siemens accepts no responsibility for damage or disruptions to operation caused by disregard of these
instructions.
The "FLENDER gear unit" described in these Instructions has been designed for driving lautertun
spentgrain cutting machines.
The gear unit is designed only for the application specified in section 1, "Technical data". Other operating
conditions must be agreed by contract.
The gear unit has been manufactured in accordance with the state of the art and is delivered in a condition
for safe and reliable use.
The gear unit must be used and operated strictly in accordance with the conditions laid down in the contract
governing performance and supply agreed by Siemens and the customer.
The gear unit described in these instructions reflects the state of technical development at the time these
instructions went to print.
In the interest of technical progress we reserve the right to make changes to the individual assemblies and
accessories which we regard as necessary to preserve their essential characteristics and improve their
efficiency and safety.
2.2 Copyright
The copyright to these instructions is held by Siemens AG.
These instructions must not be wholly or partly reproduced for competitive purposes, used in any
unauthorised way or made available to third parties without our agreement.
Technical enquiries should be addressed to the following factory or to one of our customer services:
Siemens AG
Am Industriepark 2
46562 Voerde
Tel.: [phone] / 92‐0
Fax: [phone] / 92‐1544

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3. Safety instructions
WARNING
Risk of falling
Risk of serious injury through falling.
The gear unit and its addon parts must not be entered.
WARNING
Risk of injury through unauthorised modifications
Any changes on the part of the user are not permitted.
This applies equally to safety features designed to prevent accidental contact.
3.1 Obligations of the user
• The operator must ensure that everyone carrying out work on the gear unit has read and understood
these instructions and is adhering to them in every point in order to:
─ avoid injury or damage,
─ ensure the safety and reliability of the gear unit,
─ avoid disruptions to operation and environmental damage through incorrect use.
• During transport, assembly, fitting, demounting, operation and maintenance of the unit, the relevant
safety and environmental regulations must be complied with.
• The gear unit may only be operated, maintained and/or repaired by persons qualified for the work
concerned (see "Qualified personnel" on page 3 of this manual).
• The outside of the gear unit must not be cleaned with highpressure cleaning equipment.
• All work must be carried out with great care and with due regard to safety.
DANGER
Danger to life through switchedon installation
To carry out work on the gear unit, the gear unit must always be stopped.
The drive unit must be secured against being switched on accidentally (e.g. by locking the key switch
or removing the fuses from the power supply).
A notice should be attached to the ON switch stating clearly that work is in progress on the gear unit.
At the same time the complete installation must be without load, so that no danger occurs during
demounting operations.
• No welding work must be done at all on the drive system.
The drive systems must not be used as an earthing point for electricwelding operations. Toothed parts
and bearings may be irreparably damaged by welding.
• A potential equalisation in accordance with the applying regulations and directives must be carried out!
If no threaded holes for earth connection are available on the gear unit, other appropriate measures
must be taken. This work must always be done by specialist electricians.

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NOTICE
Material damage
Risk of damage to the gear unit.
If any inexplicable changes are noticed during operation of the gear unit, such as an important increase
in temperature or unusual noises, the drive unit must be stopped immediately.
DANGER
Danger to life through rotating and/or movable parts
Risk of being caught or drawn in by rotating and/or movable parts.
Rotating and/or movable parts must be fitted with suitable safeguards to prevent contact.
Note
When the gear unit is incorporated in plant or machinery, the manufacturer of such plant or machinery
must ensure that the prescriptions, notes and descriptions contained in these instructions are
incorporated in his own instructions.
• Removed safety equipment must be refitted prior to starting up.
• Notices attached to the gear unit, such as rating plate and direction arrow, must always be observed.
They must be kept free from dirt and paint at all times. Missing plates must be replaced.
• Screws which have been damaged during assembly or disassembly work must be replaced with new
ones of the same strength class and type.
• Spare parts must be obtained from Siemens (see section 11, "Spare parts, customer service").
3.2 Special dangers and personal protective equipment
Depending on operating conditions, the surface of the gear unit may heat up or cool down to extreme
temperatures.
WARNING
Risk of burns
Risk of serious injury through burns on hot surfaces (> 55 °C).
Wear suitable protective gloves and protective clothing.
WARNING
Danger through low temperatures
Risk of serious injury through frost (pain, numbness, frostbite) on cold surfaces (< 0 °C).
Wear suitable protective gloves and protective clothing.
WARNING
Risk of scalding
Risk of serious injury through escaping hot operating media, when they are being changed.
Wear suitable protective gloves, protective glasses and protective clothing.

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WARNING
Risk of eye injury
Small foreign matter such as sand or dust can get into the cover plates of the rotating parts and be thrown
back by these.
Wear suitable protective glasses.
Note
In addition to any generally prescribed personal safety equipment (such as safety shoes, safety clothing,
helmet) handling the gear unit requires wearing suitable safety gloves and suitable safety glasses.
DANGER
Risk of explosion
Danger to life through ignition of any explosible atmosphere resulting from of the gear unit.
The gear unit does not comply with the requirements in Directive 94/9/EC and must therefore, in the
area of applicability of this directive, not be used in potentially explosive areas.
Should the gear unit be used outside the area of applicability of Directive 94/9/EC within potentially
explosive areas, the nationally applying protective prescriptions with regard to explosion protection must
always be observed.
3.3 The five safety rules
For your personal safety and to avoid material damage, comply always with the safetyrelevant instructions
and the safety rules to standard EN 501101 "Working in tensionfree status" indicated below, when
working on electrical components of the plant. Apply the five safety rules in the indicated order, before
starting work on the machine.
3.3.1 Five safety rules
1) Disconnect completely
Disconnect the auxiliary circuits, e.g. standby heating
2) Secure against reconnection
3) Verify that the installation is voltagefree ("dead")
4) Carry out earth and shortcircuiting
5) Provide protection against adjacent live parts
After completion of the work the taken measures should be undone in the reverse order.

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3.4 Environmental protection
• Dispose of any packaging material in accordance with regulations or separate it for recycling.
• When changing oil, the used oil must be collected in suitable containers. Any pools of oil which may
have collected should be removed at once with an oilbinding agent.
• Preservative agents should be stored separately from used oil.
• Used oil, preservative agents, oilbinding agents and oilsoaked cloths must be disposed of in
accordance with environmental legislation.
• Disposal of the gear unit after its useful life:
─ All the operating oil, preservative agent and/or cooling agent must be drained from the gear unit and
disposed of in accordance with regulations.
─ Gearunit components and/or addon parts may have to be disposed of or separated for recycling
in accordance with national regulations.

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4. Transport and storage
Observe the instructions in section 3, "Safety instructions"!
4.1 Scope of supply
The products supplied are listed in the dispatch papers. Check on receipt to ensure that all the products
listed have actually been delivered. Parts damaged and/or missing parts must be reported to Siemens in
writing immediately.
WARNING
Serious injury through defective product
If there is any visible damage, the gear unit must not be put into operation.
4.2 Transport
Note
The weight of the product is specified on the rating plate.
DANGER
Danger of life
Danger to life from loads falling through incorrect slinging
Do not stay under suspended loads.
When attaching, lifting, lowering and shifting loads, observe the following:
– Note the load limits.
– Correct fastening of the slinging equipment.
– Any centre of gravity which is off the load centre.
– Even load distribution when using loadcarrying means with several load hooks.
– Low displacement speed.
– The load must not be swung and/or attached to objects or building parts.
– Lifting hooks must not be loaded by the tip.
– Always place the items on an even, slipfree and stable surface.
WARNING
Danger of squeezing
Risk of being squeezed by a transported component, when the used lifting gear and loadcarrying means
are not suitable and the component gets loose.
The unit may be attached only at the marked slinging points. Use only lifting and loadcarrying equipment
of sufficient loadbearing capacity.
When lifting items, observe the notes regarding load distribution on the packing.
The product must be handled slowly and carefully, when lifted, to avoid personal injury and damage to
the gear unit.
If, for example, the free shaft ends are knocked, this may cause damage in the gear unit.
The gear unit is delivered in the fully assembled condition. Additional items may be delivered separately
packaged, if applicable.

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Different forms of packaging may be used, depending on the size of the unit and method of transport.
Unless agreed otherwise, the packaging complies with the HPE Packaging Guidelines.
The symbols marked on the packing must be observed at all times. They have the following meanings:
Top Fragile Keep dry Keep cool Centre of
gravity
Use no hand
hook
Attach
here
Fig. 2: Transport symbols
Note
The gear unit must be transported only with appropriate transport equipment.
During transport the gear unit (main gear unit) should be left without oil filling and on the transport
packing.
The bevelgear units are delivered ex works with oil filling.
In case of addon bevelgear motors the instructions applying must be observed.
NOTICE
Material damage
Risk of damage to the gear unit when using incorrect attachment points. Use only the eyes provided to
attach lifting equipment to the unit.
Transport of the unit by attaching it to the pipework is not permitted.
The pipework must not be damaged.
Do not use the front threads at the shaft ends to attach slinging and lifting gear for transport.
Slinging and lifting gear must be adequate for the weight of the gear unit.
1) 2)
Fig. 3: Attachment points
1) Lauter tun with hoist gear unit 2) Lauter tun with lifting cylinder
For a detailed illustration of the gear unit and the position of the attachment points, refer to the drawings
in the orderspecific gearunit documentation.

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4.3 Storing the gear unit
The gear unit must be stored in a sheltered place in the position of the original packaging or in the position
of use, placed on a vibrationfree, dry base, and covered over.
NOTICE
Material damage
Any damage to the coating may cause failure of the exterior protective coating and thus corrosion.
When temporarily storing the gear unit and any single components supplied with it, the preservative
agent should be left on them.
Ensure that the coat is not damaged.
DANGER
Danger to life through tilting or falling gear unit
Risk of being squeezed or killed by a tipping or falling gear unit.
Do not stack gear units on top of one another
NOTICE
Material damage
Risk of damage to the gear unit through build up of a layer of foreign bodies or moisture. If the gear unit
is being stored out of doors, it must be particularly carefully covered, and care must be taken that neither
moisture nor foreign material can collect on the unit.
Waterlogging must be avoided.
NOTICE
Material damage
Risk of damage to the gear unit through external sources.
Unless otherwise agreed by contract, the gear unit must not be exposed to harmful environmental factors
such as chemically aggressive products.
Provision for special environmental conditions during transport (e.g. transport by ship) and storage
(climate, termites, etc.) must be agreed by contract.

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4.4 Standard coating and preservation
The gear unit is provided with an interior preservative agent; the free shaft ends are painted for protection.
The characteristics of the exterior coat depend on the ambient conditions stipulated in the order relating
to method of transport and area of application.
NOTICE
Material damage
Risk of damage to the gear unit through corrosion.
The gear unit is normally delivered completely ready, with a priming and a finish coat.
Where gear units are delivered with a priming coat only, it is necessary to apply a finish coat in
accordance with directives applying to the specific application.
The priming coat alone is not suitable to provide a sufficient longterm corrosion protection.
NOTICE
Material damage
Any damage to the coating may cause failure of the exterior protective coating and thus corrosion.
Ensure that the coat is not damaged.
Note
Unless otherwise contractually agreed, the durability periods of the interior gear unit preservation
specified in table 3 will apply, provided the related measures are adhered to. The durability period for the
exterior preservation and the related requirements can be found in table 4.
The guarantee period starts on the date of delivery or that of the notice that the item is ready for shipment.
In case of a storage period other than the durability periods indicated in tables 3 and in table 4, the interior
and the exterior preservation must be checked and, as necessary, be renewed (see items 7.6.1 and 7.6.2).
4.4.1 Interior preservation with preservative agent
Table 3: Durability period and measures for interior preservation when using mineral oil
Durability period Preservative agent Special measures
Up to 6 months
Castrol Alpha SP 220 S
None
Up to 24 months
– Close all holes on the gear unit.
– Replace the air filter or wet-air filter with
the screw plug. (Replace the screw plug
with the air filter or wet-air filter before
start-up.)
For storage periods longer than 24 months, renew the preservative agent (see item 4.4.1.1).
Note
The procedure for interiorpreservation treatment is described in section 7 (see item 7.6.1).

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4.4.1.1 Represerving the interior of the gear unit (main gear unit) in case of longer periods of storage
CAUTION
Risk of injury
Risk of injury to eyes or hands through chemically aggressive operating media.
Wear suitable protective glasses and protective gloves.
Remove any oil spillage immediately with a binding agent.
For storage periods longer than 24 months (see table 3), renew the preservation in the interior of the gear
unit. The following procedure is recommended:
• Unscrew the air filter or wetair filter (1) on the oilequalising tank (see fig. 4 or fig. 5).
• Place a suitable container under the oildrain points (4 and 5) of the gearunit housing.
• Open the oildrain cock (4) and unscrew the residualoil drain plug (5) and drain the used preservative
oil into a suitable container.
• Dispose of the residue of the preservative oil in accordance with regulations.
• Shut the oildrain cock (4) and screw in the residualoil drain plug (5).
• Fill the gear unit with "Castrol Alpha SP 220 S".
Determine the filling quantity according to the gearunit dimensions: length x width x height x 0.05.
NOTICE
Material damage
Corrosion possible through use of an unsuitable preservative agent.
Use special oil "Castrol Alpha SP 220 S" with additional anticorrosive agent (additive "S").
• Screw in the air filter or wetair filter (1).
• Replace the air filter or wetair filter (1) with the screw plug.
NOTICE
Material damage
Corrosion possible through leaving the gear unit open too long.
Close the gear unit airtightly at the latest one hour after opening.
Before restarting the gear unit take the following measure:
– Replace the screw plug with the air filter or wetair filter.
The gear unit has thus been preserved for another period of 24 months.
NOTICE
Material damage
Risk of damage to the gear unit through inadequate lubrication through preservative agent and operating
oil being mixed up.
The use of synthetic oil is not permissible.

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BA 5080 en 06/2014
13
12
4
5
14
11
15
8
7
62,3
1
9
10
16
(I)
(I)
(Ia)
(Ib)
(II)
(II)
(II)
(III)
(III)
(III)
Fig. 4: Oil inlet and oil drain – gear unit with hoist gear unit
1 Air filter or wet-ait filter
Ventilation (I) main gear unit
2 Oil filling (I) main gear unit
3 Dipstick; oil filling (I) main gear unit
4 Oil-drain cock (Ia); oil drain main gear unit
5 Oil-drain plug; residual oil (Ib) main gear unit
6 Ventilation; oil filling (II) primary gear unit
7 Oil level (II) primary gear unit
8 Oil-drain plug (II) primary gear unit
9 Ventilation / oil filling (III) hoist
gear unit
10 Oil level (III) hoist gear unit
11 Oil-drain plug (III) hoist gear unit
12 Bellows
13 Vent hole
14 Leak hole
15 Leak hole
16 Inspection and/or assembly cover