Flender Gearbox

Operating Instructions
BA S295 EN 06.97
MOTOX
Worm gear units
and
gear motors
161818
FLENDER-HIMMELWERK GmbH, Bahnhofstr., D-72072 Tübingen

Tel. 07071/707-0 Telefax 07071/707-400
A company of A. Friedr. Flender AG
Contents
1. General notes 4
1.1 General 4
1.2 Proper usage 4
2. Safety notes 5
2.1 Safety notes 5
2.1.1 Notes and symbols in the Operating Instructions 5
3. Technical data 6
3.1 General technical data 6
3.2 Mounting positions 7
3.2.1 Gear units and gear motors S. 01 7
3.2.2 Gear units and gear motors S. 06, S. 11 8
3.2.3 Gear units and gear motors C. 10 9
3.2.4 Gear units and gear motors C 21 - C 122, C. 21 - C. 122 10
3.2.5 Tandem gear unit - compound helical gear unit 11
3.3 Oil quantities 11
3.3.1 Type S. 01 11
3.3.2 Type S. 06, S. 11 11
3.3.3 Type C. 10 12
3.3.4 Type C 21 - C 122, C. 21 - C. 122 12
3.3.5 Worm gear unit with attached helical gear motor 13
3.4 Weights 15
3.5 Sound power level 15
4. Incoming goods, handling and storage 16

4.1 Incoming goods 16
4.2 Handling 16
4.3 Storage 17
5. Technical description 18
5.1 General description 18
5.2 Housing 18
5.3 Toothed components 18
5.4 Lubrication 18
5.5 Bearings 18
5.6 Shaft seals 18
5.7 Cooling 18
5.8 Couplings 18
5.9 Backstop 19
5.10 Coats of paint 19
6. Installation 20
6.1 General information on installation 20
6.2 Drives with foot mounting 20
6.2.1 Foundation 20
6.2.2 Installation of gear units with foot mounting 20
6.3 Installation of input drive and output drive elements on gear unit shafts 21
6.4 Shaft mounting gear units with hollow shaft and parallel key 22
6.4.1 Assembly 22
6.4.1.1 Fitting 22
6.4.1.2 Axial safety device 22
6.4.2 Disassembly 23
Page 2 of 47 BA S295 EN 06.97

6.5 Shaft mounting gear unit with hollow shaft and multi-spline gearing 24
6.5.1 Assembly 24
6.5.1.1 Mounting 24
6.6 Shaft mounting gear unit with hollow shaft and shrink disc 25
6.6.1 Assembly 25
6.6.1.1 Mounting 25
6.6.2 Shrink disc type HSD 26
6.6.2.1 Assembly of the shrink disc 26
6.6.2.2 Disassembly of the shrink disc 27
6.6.2.3 Cleaning and lubricating the shrink disc 27
6.7 Attachment of standard motors 28
6.7.1 Attachment to coupling lantern with BIPEX coupling 28
6.7.2 Attachment to coupling lantern with clamping ring 29
6.8 Motor base plate 30
6.9 Torque arm for shaft mounting gear unit 31
7. Startup 32
7.1 Measures before startup 32
7.1.1 Startup without long term preservation 32
7.1.2 Startup in case of long term preservation 32
7.1.2.1 Long term preservation up to 18 months 32
7.1.2.2 Long term preservation up to 36 months 32
7.1.3 Filling with lubricant 32
7.1.4 Drive with backstop 32
7.2 Oil level check 33
7.2.1 Checking the oil level in the gear unit housing 33
7.2.2 Oil sight glass (Special feature) 33
7.2.3 Dipstick (Special feature) 33
7.3 Shutdown 33
7.4 Preservation with gear oil 33
7.5 External preservation procedure 34
8. Operation 34
8.1 General operating data 34
9. Disturbances, reasons and remedy 35

9.1 General information on malfunctions 35
10. Maintenance and repair 37

10.1 General information on maintenance 37
10.2 Description of maintenance and repairs 38
10.2.1 Carrying out oil changes 38
10.2.2 Cleaning the vent plug 39
10.2.3 Cleaning the drive 39
10.2.4 Checking all fixing screws for tightness 39
10.2.5 Inspection of the drive 39
10.3 Lubricants 40
11. Spare parts stock, service addresses 42

11.1 Stocking spare parts 42
11.2 Spare parts and Customer Service addresses 42
FLENDER-HIMMEL Germany 43
FLENDER-HIMMEL Europe 44
FLENDER-HIMMEL International 45
12. Declaration by the manufacturer 47
BA S295 EN 06.97 Page 3 of 47

1. General notes
1.1 General
These Operating Instructions constitute part of the gear unit shipment and should be kept in the
immediate vicinity of the gear unit at all times.
Only a precise knowledge of the Operating Instructions will ensure trouble-free operation of
the drive by avoiding operating errors and incorrect usage. It is therefore in the interest of the
operator that the Operating Instructions are read, understood and observed in all respects by
the persons responsible for handling, installation and operation.
Note: We accept no liability for any damage or malfunction resulting from non-observance
of the Operating Instructions.
The drives described here are manufactured in accordance with the latest technology at the time of
these Operating Instructions going into print.
In the interest of further development, we reserve the right to introduce modifications to the individual
subassemblies and accessories which, while retaining the essential features, can be regarded as
desirable to increase their efficiency and safety.
The copyright of these Operating Instructions remains the property of FLENDER-HIMMELWERK
GmbH.
These Operating Instructions may not be duplicated in part or whole, utilized for the purpose of publicity
or communicated to third parties without our express consent.
Alterations or additions of these Operating Instructions may be done exceptionally by us only; otherwise
complete liability will be cancelled.
Note: For motors, brake motors and additional features of motors (external fan, back stop,
encoder system, etc.) please observe further Operating Instructions supplied with
shipment (e.g.: BA M295, BA B295, N-R 430, etc.).
Please contact our works listed below in respect of all technical queries:
FLENDER-HIMMELWERK GmbH
Postfach 1709 , D-72007 Tübingen
Bahnhofstr. , D-72072 Tübingen
Tel. 07071/707-0
Fax 07071/707-400
or one of our service branches which are listed in Section LEERER MERKER “Spare parts stock,
service addresses”.
1.2 Proper usage
The MOTOX drives dealt with in these Operating Instructions have been developed for as conveyor
drive, e.g. monorails, in material handling or use in general engineering. If not otherwise agreed the
drives are suitable for use in machines and plants in industrial areas.
The drives are only designed for the field of application as specified in Section 3. “Technical data”. The
drives may not be operated outside the given performance limits. Operating conditions which differ from
those stated will require new contractual agreements.
Page 4 of 47 BA S295 EN 06.97

2. Safety notes
2.1 Safety notes

S The gear unit is constructed in accordance with the latest technology and is reliable in the condition
as shipped. Unauthorized modifications which impair its reliability are not permissible. This also
applies to guards which are fitted as protection against accidental contact.
S The gear unit may only be used and operated within the scope of the conditions specified in the
contract of performance and supply.
S The operator should ensure that the persons entrusted with installation, operation, care and
maintenance have read and understood the Operating Instructions and observe them in all respects
in order to:
– Prevent hazard to the life and limb of the user and third parties.
– Ensure the reliability of the gear unit.
– Prevent failure and environmental pollution due to incorrect handling.
S The drive unit may only be operated, serviced and repaired by authorized, trained and properly
instructed personnel. Definition for trained personnel see e.g. IEC 364.
S All work should be carried out carefully with the safety aspect in mind.
S Notes affixed to drive units, such as rating plate, direction of rotation arrows, etc., must be observed.
They must be kept free from paint and dirt. Missing plates must be replaced.
S All work on the gear unit may only be carried out when it is stationary.
The drive unit must be secured to prevent accidental startup (e.g. by locking the key switch or by
removing the fuses in the power supply). A notice should be displayed at the switch-on point stating
that work is in progress on the gear unit.
S The relevant regulations concerning industrial safety and pollution control should be observed during
handling, installation, operation, care and maintenance.
S Rotating parts, such as couplings, gear wheels or belt drives must be protected by means of suitable
guards to prevent accidental contact.
S The drive unit should be shut off at once if changes in the gear unit are detected during operation,
such as increased operating temperature or a change in gear unit noises.
S During installation of the gear unit in devices or systems, the manufacturer of the device or system
is obliged to incorporate the requirements, notes and descriptions contained in these Operating
Instructions in his own Operating Instructions.
S On the occasion of oil changes, the old oil should be collected in a suitable receptacle. Any pools of
oil which have occured should be removed at once with an oil binding agent.
Very dirty and oil-soaked cleaning rags should be kept in suitable containers.
The oil, the oil binding agent and the cleaning rags should be disposed of in accordance with the
relevant pollution control requirements.
2.1.1 Notes and symbols in the Operating Instructions

Instructions in the Operating Instructions which concern operating safety are emphasized as follows:
This symbol draws attention to safety measures to prevent personal injury.
This symbol draws attention to the safety measures which must be observed to
Attention! prevent damage to the gear unit.
Note: This note draws attention to general operating notes which should be especially
observed.
BA S295 EN 06.97 Page 5 of 47

3. Technical data
3.1 General technical data
The rating plate of the gear units or gear motors contains the most essential technical data. These data
and the contractual agreements for the drives define the limits of its proper use.
On gear motors normally one rating plate, attached to the motor, is used for the complete drive.
In some cases separate rating plates are used on the gear unit and the motor.
Examples: Rating plate of gear motor Rating plate of gear unit
14 3 1 2
4
3
15 16 17 18
19 20 4
21 22 5 6
23 24 25 7 8
6 9 10 11 9 11
10
8 2
26 13 12
27
13 12 1
1 Date of manufacture (coded, e.g. S01) 14 Phase number and type of current of the motor
2 Weight m [kg] (only if>30kg) (e.g.: 3Mot. or 1Mot.)
3 Order No. / consecutive No. 15 Connecting symbol to DIN 40900 T6/IEC 617-6
4 Type - Size 16 Rated voltage U [V]
5 Power rating: T2 [Nm] 17 Rated current Ι [A]
6 Type of construction 18 Rated frequency f [Hz]
7 Total ratio i 19 Rated speed n [1/min] (1/min=1/60s)
8 Speed n2 [1/min] (1/min=1/60s) 20 Rated power P [kW]
9 Oil grade, e.g.: 21 Duty type (if 0 S1)
CLP-oil DIN 51517/3 (mineral oil) 22 Power factor cos ϕ
or PGLP-oil (synthetic oil) 23 Type of protection to IEC 34-5 or IEC 529
10 Oil viscosity: ISO VG-class to 24 Thermal class Th. Cl.
DIN 51519 / ISO 3448 25 Regulation taken as basis (Standard)
11 Oil quantity [l] (1l=1dm3≈1kg) e.g.: IEC 34 or EN 60034 or VDE 0530
12 Free field for additional data 26 EC symbol (CE) or other marking (CSA,
e.g. commission number (customer’s request) NRTL/C, UL, etc.) if applicable
13 max. ambient temperature TUmax. [°C] 27 Brake data
Data on the weight and sound pressure of the various drives will be found under 3.4 and 3.5.
Further technical data will be found in the drawings and the gear unit documentation.
Page 6 of 47 BA S295 EN 06.97

3.2 Mounting positions
S The drives may only be operated in the mounting position specified on the rating plate. This will ensure
the correct quantity of lubricant.
S The designations of the mounting positon correspond to IEC 34-7ΙΙ.
Marking: Oil level
Oil filling
Housing ventilation
Oil drain plug
3.2.1 Gear units and gear motors S. 01
Foot mounted B3-00/ B6-01 Foot mounted B8-00/ B6-03 Foot mounted B3-01/ B6-02
Flange mounted B5-01 Flange mounted B5-03 Flange mounted B5-02
Shaft mounted H-01 Shaft mounted H-02 Shaft mounted H-03
Foot mounted B6-00/ B8-01 Foot mounted V5-00/ V5-01 Foot mounted V6-00/ V6-01
Flange mounted B5-00 Flange mounted V1-00 Flange mounted V3-00
B A
A B
Execution “A” resp. “B” is the position for the shaft.
BA S295 EN 06.97 Page 7 of 47

3.2.2 Gear units and gear motors S. 06, S. 11
Foot mounted B3-00 Foot mounted B8-00 Foot mounted B3-01

Foot mounted B6-00 Foot mounted V5-00 Foot mounted V6-00

B A
A B
Foot mounted B6-01 Foot mounted B6-03 Foot mounted B3-01

(vertical) SC (vertical) SC (vertical) SC
Foot mounted B8-01 Foot mounted V5-01 Foot mounted V6-01

(vertical) SC (vertical) SC (vertical) SC
B A
A B
Page 8 of 47 BA S295 EN 06.97

3.2.3 Gear units and gear motors C. 10
B A
A B
BA S295 EN 06.97 Page 9 of 47

3.2.4 Gear units and gear motors C 21 - C 122, C. 21 - C. 122
*
*
B A
A B


A
B
B
A
* on opposite side
Page 10 of 47 BA S295 EN 06.97

3.2.5 Tandem gear unit - compound helical gear unit
horizontal operating position vertical operating position
Main
gear unit
A
A
Main
gear unit * A
* Main
gear unit
* on opposite side
In horizontal operating position, the housing recess of the 2. gear unit in
Attention! general points downwards.
S Types Z10 and ZF10 are only equipped with one plug screw at point ’A’.
3.3 Oil quantities
The exact oil quantities are specified on the rating plates of the drives.
The quantities in litres listed in the following are reference values.
The gear units should always be filled up to the oil level
Attention! (see Section LEERER MERKER “Startup”).
3.3.1 Type S. 01
Type Mounting position

B3-00 B3-01 V5-00
S 01
B6-01 B6-00 V5-01
SC 01
B6-03 B6-02 V6-00
SP 01
B8-00 B8-01 V6-01
B5-01 B5-00 V1-00/ B V1-00/ A
SF 01
B5-03 B5-02 V3-00/ A V3-00/ B
H-01 H-03 H-05
SA 01
H-02 H-04 H-06
H-01 H-03 H-05/ B H-05/ A
SAF 01
H-02 H-04 H-06/ A H-06/ B
0.1 0.14 0.14 0.18 0.18
3.3.2 Type S. 06, S. 11
Mounting position
S SC SF SAF
B3-00 B3-01 B5-00 H-01
Type B6-00 B6-01 B5-01 H-02
B6-02 B6-03 B5-02 H-03
B8-00 B8-01 B5-03 H-04
V5-00 V5-01 V1-00/ A V1-00/ B H-05/ B H-05/ A
V6-00 V6-01 V3-00/ B V3-00/ A H-06/ A H-06/ B
S. 06 0.16 0.16 0.16 0.2 0.16 0.2
S. 11 0.25 0.25 0.25 0.3 0.25 0.3
BA S295 EN 06.97 Page 11 of 47

3.3.3 Type C. 10

B3-00 B6-03 B3-01
B6-00 B8-00 B6-02
C 10 B6-01 V5-00
CP 10 B8-01 V5-01
V6-00
V6-01
B6-01 B6-02 B3-01
CC 10 B8-01 V5-01
V6-01
B5-00 B5-02
CF 10 B5-01 V1-00/ B V1-00/ A
B5-03 V3-00/ A V3-00/ B
H-01 H-03
CA 10 H-02 H-05
H-04 H-06
H-01 H-03
CAF 10 H-02 H-05/ B H-05/ A
H-04 H-06/ A H-06/ B
0.15 0.16 0.18 0.2 0.22 0.25
3.3.4 Type C 21 - C 122, C. 21 - C. 122
Mounting position
Type B3-00 B8-00 B3-01 B6-00 V5-00 V6-00
B6-01 B6-03 B6-02 B8-01 V5-01 V6-01
C 21 0.6 0.7 0.9 0.8 0.7 0.7
C 41 0.8 1.2 1.4 1.1 0.9 0.9
C 61 1.6 2.7 3.1 2.5 2.1 2.1
C 81 2.7 3.8 5.3 3.7 3.1 3.1
C 102 5.5 8 11.5 8.5 7 7
C 122 13 15.5 25 15 13 13
Mounting position
Type V1-00/ A V3-00/ A
B5-01 B5-03 B5-02 B5-00
V1-00/ B V3-00/ B
CF 21 0.6 0.7 0.9 0.8 0.7 0.7
CF 41 0.8 1.2 1.4 1.2 0.9 0.9
CF 61 1.6 2.7 3.6 2.5 2.2 2.2
CF 81 2.7 3.9 5.5 5.4 3.2 3.2
CF 102 4 8.5 10 8.5 6.3 6.3
CF 122 8.5 16 21 15.5 13 13

CAZ, CAF,
CAD, CAZS,
CAFS, CADS H-01 H-02 H-03 H-04 H-05 H-06
C. 21 0.6 0.7 0.9 0.8 0.7 0.7
C. 41 0.7 1.2 1.4 1.2 0.9 0.9
C. 61 1.6 2.4 3.1 2.4 2 2
C. 81 2.7 3.8 5.3 5.2 3.2 3.2
C. 102 4 6.5 8.5 7 5.5 5.5
C. 122 8.5 12.5 19.5 15 12.5 12.5
Page 12 of 47 BA S295 EN 06.97

3.3.5 Worm gear unit with attached helical gear unit or gear motor
In horizontal operating position, the housing recess of the 2. gear unit in
Attention! general points downwards.
Mounting position
Type B3-00 B8-00 B3-01 B6-00 V5-00 V6-00
B6-01 B6-03 B6-02 B8-01 V5-01 V6-01
0.6+0.2 0.7+0.2 0.9+0.4 0.8+0.3 0.7+0.2 0.7+0.2
C 21 - Z 10
C.
0.8 0.9 1.3 1.1 0.9 0.9
0.8+0.2 1.4+0.2 1.4+0.4 1.1+0.3 0.9+0.2 0.9+0.2
C 41 - Z 10
C.
1 1.6 1.8 1.4 1.1 1.1
0.8+0.5 1.4+0.5 1.3+1.2 1.1+0.8 0.9+0.5 0.9+0.5
C 41 - D/Z 30
C.
1.3 1.9 2.5 1.9 1.4 1.4
1.6+0.2 2.7+0.2 3.1+0.4 2.5+0.3 2.1+0.2 2.1+0.2
C 61 - Z 10
C.
1.8 2.9 3.5 2.8 2.3 2.3
1.6+0.5 2.7+0.5 3.1+1.2 2.5+0.8 2.1+0.5 2.1+0.5
C 61 - D/Z 30
C.
2.1 3.2 4.3 3.3 2.6 2.6
2.7+0.5 3.8+0.5 5.3+1.2 3.7+0.8 3.1+0.5 3.1+0.5
C 81 - D/Z 30
C.
3.2 4.3 6.5 4.5 3.6 3.6
5.5+0.8 8+0.8 11.5+2 8.5+1.7 7+0.8 7+0.8
C 102 - D/Z 40
C.
6.3 8.8 13.5 10.2 7.8 7.8
13+0.8 15.5+0.8 25+2 15+1.7 13+0.8 13+0.8
C 122 - D/Z 40
C.
13.8 16.3 27 16.7 13.8 13.8
Mounting position
Type V1-00/ A V3-00/ B
B5-01 B5-03 B5-02 B5-00
V1-00/ B V3-00/ A
0.6+0.2 0.7+0.2 0.9+0.4 0.8+0.3 0.7+0.2 0.7+0.2
CF 21 - Z 10
0.8 0.9 1.3 1.1 0.9 0.9
0.8+0.2 1.2+0.2 1.4+0.4 1.2+0.3 0.9+0.2 0.9+0.2
CF 41 - Z 10
1 1.4 1.8 1.5 1.1 1.1
0.8+0.5 1.2+0.5 1.6+1.2 1.2+0.8 0.9+0.5 0.9+0.5
CF 41 - D/Z 30
1.3 1.7 2.8 2 1.4 1.4
1.6+0.2 2.7+0.2 3.6+0.4 2.5+0.3 2.2+0.2 2.2+0.2
CF 61 - Z 10
1.8 2.9 4 2.8 2.4 2.4
1.6+0.5 2.7+0.5 3.6+1.2 2.5+0.8 2.2+0.5 2.2+0.5
CF 61 - D/Z 30
2.1 3.2 4.8 3.3 2.7 2.7
2.7+0.5 3.9+0.5 5.5+1.2 5.4+0.8 3.2+0.5 3.2+0.5
CF 81-
81 D/Z 30
3.2 4.4 6.7 6.2 3.7 3.7
4+0.8 8.5+0.8 10+2 8.5+1.7 6.3+0.8 6.3+0.8
CF 102 - D/Z 40
4.8 9.3 12 10.2 7.1 7.1
8.5+0.8 16+0.8 21+2 15.5+1.7 13+0.8 13+0.8
CF 122 - D/Z 40
9.3 16.8 23 17.2 13.8 13.8
4+0.8 8.5+0.8 10+2 8.5+1.7 6.3+0.8 6.3+0.8
CF 102 - D/Z 40
4.8 9.3 12 10.2 7.1 7.1
8.5+0.8 16+0.8 21+2 15.5+1.7 13+0.8 13+0.8
CF 122 - D/Z 40
9.3 16.8 23 17.2 13.8 13.8
BA S295 EN 06.97 Page 13 of 47

CAZ, CAF, CAD,
CAZS, CADS,
CAFS H-01 H-02 H-03 H-04 H-05 H-06
0.6+0.2 0.7+0.2 0.9+0.4 0.8+0.3 0.7+0.2 0.7+0.2
C 21 - Z 10
C.
0.8 0.9 1.3 1.1 0.9 0.9
0.7+0.2 1.2+0.2 1.4+0.4 1.2+0.3 0.9+0.2 0.9+0.2
C 41 - Z 10
C.
0.9 1.4 1.8 1.5 1.1 1.1
0.7+0.5 1.2+0.5 1.6+1.2 1.2+0.8 0.9+0.5 0.9+0.5
C 41 - D/Z 30
C.
1.2 1.7 2.8 2 1.4 1.4
1.6+0.2 2.4+0.2 3.1+0.4 2.4+0.3 2+0.2 2+0.2
C 61 - Z 10
C.
1.8 2.6 3.5 2.7 2.2 2.2
1.6+0.5 2.4+0.5 3.1+1.2 2.4+0.8 2+0.5 2+0.5
C 61 - D/Z 30
C.
2.1 2.9 4.3 3.2 2.5 2.5
2.7+0.5 3.8+0.5 5.3+1.2 5.2+0.8 3.2+0.5 3.2+0.5
C 81-
C. 81 D/Z 30
3.2 4.3 6.5 6 3.7 3.7
4+0.8 6.5+0.8 8.5+2 7+1.7 5.5+0.8 5.5+0.8
C 102 - D/Z 40
C.
4.8 7.3 10.5 8.7 6.3 6.3
8.5+0.8 12.5+0.8 19.5+2 15+1.7 12.5+0.8 12.5+0.8
C 122 - D/Z 40
C.
9.3 13.3 21.5 16.7 13.3 13.3
Page 14 of 47 BA S295 EN 06.97

3.4 Weights
The weight of the drive is shown on the rating plate of the gear unit or the gear motor, if higher than 30 kg;
it can always be found in the shipment documents.
When there are several rating plates on one drive, the value on the main gear unit is decisive.
The weight given refers to the delivery condition of the product ex FLENDER-HIMMELWERK.
3.5 Sound power level
The A-qualified sound power levels LWA of a selection of gear units in Figure 3.5 were determined
according to DIN EN 21680 measured with testing apparatus to DIN IEC 651.
The sound is dependent upon speed, power rating and ratio.

The MOTOX worm gear motors mostly lie within the dark range. Gear units with very small ratios,
high power rating and high input speed may lie in the hatched range.
If no proper measuring system can be established when measuring again at the place of use, the
measurement on the FLENDER-HIMMELWERK test rigs are valid.
110
Sound power level LWA [dB]
100
90
80
70
60
0.2 0.5 1 2 5 10 20 50 100 160

Mechanical power rating P [kW]
Figure 3.5
S External noises
Noises which are not generated by the gear unit but are emitted by the gear unit are not taken into
consideration.
Noises which are emitted by input and output machines as well as by the foundation are not taken into
consideration either, even if they were transmitted to that point by the gear unit.
General guidelines concerning the influence of noise on people should be

taken into consideration.
BA S295 EN 06.97 Page 15 of 47

4. Incoming goods, handling and storage
4.1 Incoming goods
The contents of the shipment are listed in the shipping documents. The shipment should be checked
for completeness and shipping damage immediately on receipt. If necessary, a loss advice should be
written out in the presence of the forewarder, otherwise repairing the damage without costs will not be
possible.
Damaged drives must not be put into operation.
4.2 Handling
The drive is shipped in assembled state. Ancillary equippment (such as for example pipes and valves)
are shipped packed separately.
The packing of the gear unit will differ, dependent on the method of shipment and size. The packing,
unless otherwise agreed contractually, complies with HPE Packing Guidelines.
The symbols shown on the packing should be noted. Their significance is as follows:
This side up Fragile Keep dry Protect Centre of gravity Use no Sling here
Goods from heat hooks
When handling and loading and unloading of the drive, excercise special care
Attention! to avoid damage due to the use of force.
The drive should be lifted by the largest eye bolt present, this is usually the eye
bolt on the gear.
Check fixture of the eye bolt, tighten if necessary.
Eye bolts on the motor may only be used for
- handling of the motor alone or
- as an additional support for reaching a horizontal mounting position of the
drive.
The permissible attaching weight is to be observed:
d3 d3 [mm] 36 45 54 63 72 90 108
M M8 M 10 M 12 M 16 M 20 M 24 M 30
[kg] 140 230 340 700 1200 1800 3600
Highest load exercised by the drive to be attached in kg with tension ↑ in the direction
M of the screw axis.
Use additional suitable lifting devices (ropes or similar) for transport or

Attention! installation in order not to exceed the max. load in the direction of the eye bolt
axis.
When attaching with several chains and ropes, two ropes must already be
sufficient to support the complete load. Lifting devices such as ropes and
similar should be secured against slipping.
The threads in the shaft ends must not be used for attaching eye bolts for
Attention! handling.
Transport fixtures, if present, should be removed and stored or be made

Attention! noneffective according to additional notes.
For further transport reuse or make effective again.
Page 16 of 47 BA S295 EN 06.97

4.3 Storage
The drives should be stored in dry rooms with minimum temperature fluctuations in their positions of
use on a horizontal wooden support and covered.
The storage area must be free of vibrations (shocks) as otherwise the

Attention! anti-friction bearings may be damaged.
It is not permissible to stack drives on top of one another.
The gear units are provided with internal preservation, the free shaft ends and the flange surfaces are
provided with a protective coating.
Note: Unless agreed to the contrary by contract, a warranty period of 6 months is given for
the standard preservation. The warranty period starts to run on the date of delivery
of the gear unit.
In the case of prolonged interim storage (> 6 months) check preservation and renew it, if necessary
(see Section 7. “Startup”).
The contractually agreed external coating (type, structure, colour) was carefully applied by spray
painting. See 5.10 for the resistances of the coating.
Note: Do not damage the coating!
Mechanical (scratches), chemical (acids, alkaline solutions) or thermal (sparks,
welding beam, heat) damage leads to corrosion and to the failure of the external
protection.
If stored in the open, the drive should be covered with special care and it
Attention! should be ensured that neither moisture nor foreign matter are allowed to
collect on the gear unit.
BA S295 EN 06.97 Page 17 of 47

5. Technical description
5.1 General description
The gear units are supplied as single- or two-stage worm gear units. The gear units are suitable for the
different mounting positions taking into consideration the oil level.
5.2 Housings
The gear unit grey cast iron housings are stable, vibration dampening and are designed for continuous
operation.
A high centre distance precision is achieved by the single-piece design of the housing which avoids a
punctual overload of the tooth flanks. Furthermore, the high precision guarantees a favourable bearing
load as well as good noise characteristics.
5.3 Toothed components
In case of double-stage worm gear units, the toothed gear unit parts of the 1st reduction stage are
hardened. For the 2nd stage as well as for single-stage gear units, the worm is hardened and ground,
the gear is made from high-quality bronze. Due to the high quality of the gearing as well as the flank-
and profile-corrected involute gearing, the noise level of the gear unit is minimized and the flank capacity
is optimized.
5.4 Lubrication
The components of the tooth system are adequately supplied with lubricant by splash lubrication. This
ensures that the gear units are especially maintenance-free.
Attention! See Section 10. “Maintenance and repair” for trouble-free operation.
5.5 Bearings
All shafts are mounted in anti-friction bearings. Lubrication of the anti-friction bearings is effected by
splash lubrication assisted by the gear wheels. Bearings which are not supplied with lubricant hereby
are enclosed and grease lubricated (lifetime lubrication).
5.6 Shaft seals
Radial shaft seal rings at the shaft outlet prevent lubricant from escaping from the housing and dirt
entering the housing. In case of higher ambient temperatures (60°C-100°C), shaft seal rings from
temperature resistant material are used.
5.7 Cooling
The gear units do not require any additional cooling. The generously dimensioned housing surface is
sufficient for dissipating the heat loss in case of free convection.
The surface of the gear unit or the gear motor should be kept free of dirt
Attention! (see Section 10. “Maintenance and repair“).
5.8 Couplings
As a rule, flexible couplings should be provided for the input drive and output drive sides of the gear
unit.
If rigid couplings or other input drive and output drive elements are used which give rise to additional
radial and/or axial forces (for example gear wheels, belt pulleys, etc.), this must be agreed on by
contract.
Couplings with peripheral speeds at the outside diameter up to 30 m/s must

Attention! be statically balanced. Couplings with peripheral speeds above 30 m/s require
dynamic balancing.
The special Operating Instructions should be noted for operation of the couplings.
Page 18 of 47 BA S295 EN 06.97

5.9 Backstop
The gearboxes can be provided with a mechanical backstop for certain requirements. During operation,
this permits rotation in the specified direction only. This direction is marked by a corresponding direction
of rotation arrow.
The backstop incorporates centrifugally operated grippers. When the gear unit is rotating in the
specified direction, the inner ring and the cage with the grippers rotate, the outer ring remaining
stationary. From a certain speed of rotation, the grippers lift off and the back stop now operates without
wear.
The backstops are lubricated ready for duty, they don’t need to be serviced.
To prevent damage to or destruction of the backstop, it is essential to ensure

Attention! that the motor is not run against the locked backstop.
Please observe the notes on the gear.
5.10 Coats of paint
All coats of paint are applied carefully by spray painting in the most modern painting plants.
Paint Typical area Overpaint- Chem. phys. Temperature Remark

system of use ability resistance resistance
Standard 1-layer With plastic lacquer Good resistance to Standard coat of
Plastic coat of lacquer or synthetic resin cleaning agents, oil lacquer with
for the internal lacquer and benzine, resistant –40°C to 100°C excellent adhesive
area, in the open to short-time attack by characteristics
with roof, i.e. diluted acid and up to 140°C for a
Standard: suitable alkaline solution (≤3%), short time
RAL 7011 protection against not resistant to solvent
sun and
continuous
atmospheric
influence
Standard 2-layer After preceeding Excellent resistance to: Standard coat of
2K- coat of lacquer grinding with: oil, grease, benzine, lacquer for cooling
especially for 2K-PUR lacquer water, sea water and –40°C to 150°C tower and agitator
PUR installation in the 2K-Epoxy lacquer cleaning agent; good drive or if sea
open or in case of resistance to water resistance
increased atmospheric influences below deck or
Standard: demands on and diluted acid and similar is required
corrosion alkaline solution (≤3%);
RAL 7031 protection good mechanical
resistance to abrasion
High-quality coat After preceeding Excellent resistance to 2K-Epoxy lacquer
2K- of lacquer for the grinding with: weak acid and alkaline “chalks” in case of
external area or 2K-PUR lacquer solution (≤5%), oil, –40°C to 150°C installation in the
Epoxy in case of attacks 2K-Epoxy lacquer grease, benzine, open (does not
by diluted acid 2K-AC lacquer cooling emulsion, salt, effect the quality),
Standard: and alkaline solvent; tough and high gloss with
RAL 7035 solution (v5%) scratch-resistant good mechanical
coating film resistance
For overpainting: Excellent with: Good resistance to Adhesive agent
Primed adhesive agent plastic lacquer, cleaning agent, to salt with excellent
for all common synthetic resin spraying and resistant –40°C to 150°C adhesive
paint systems, lacquer, to oil and benzine characteristics and
temporary 2K-PUR lacquer, good corrosion
RAL 7032 corrosion 2K-Epoxy lacquer, protection
protection SH lacquer,
2K-AC lacquer
For overpainting: Excellent with: Components from
Un- (adhesive agent) plastic lacquer, grey cast iron
temporary synthetic resin (–40°C to 150°C) dip-primed,
lacquered corrosion lacquer, oil paint, components from
protection bitumenous paint, steel primed or
2K-PUR paint galvanised,
2K-Epoxy paint components from
Al and plastic
untreated
Note: As a precaution against misunderstandings, we would like to point out that the
recommendation does not imply any release in the sense of a warranty for the quality
of the paint provided by your supplier. Each paint manufacturer must warrant the
quality of his product himself.
BA S295 EN 06.97 Page 19 of 47

6. Installation
6.1 General information on installation
During installation, the safety notes in Section 2. “Safety notes” should be observed.
Installation should be carried out by specialist personnel with extreme care. Damage caused by
improper execution results in the exclusion of our liability.
Right at the planning stage, it should be ensured that there is adequate space around the gear unit for
installation and subsequent care and maintenance.
Adequate space for air intake should be left for drives with fan.
The drives may overheat if positioned in strong direct sunlight. Provide
Attention! appropriate protective devices such as cover, roof or similar!
Before commencing installation, adequate hoist equipment must be provided for lifting the drives.
No welding work must be carried out on the drive. The drives must not be used
Attention! as ground points for welding work. Components of the tooth system and
bearings may be destroyed by welding.
Note: Use shoulder studs of property class 8.8 or higher for mounting the drives.
All mounting possibilities assigned to the respective mounting position

Attention! should be used.
6.2 Drives with foot mounting

6.2.1 Foundation
The foundation must be flat.

Note: The flatness of the gear unit support must not exceed the following values:
for gear units up to size 81 ≤ 0.1 mm
for gear units above to size 81 ≤ 0.2 mm
It should be executed in such a way that no resonance vibrations occur and no vibration can be
transmitted from adjacent foundations. Steel structures on which the gear unit is installed must be
torsionally rigid. They are to be designed corresponding to weight and torque, taking into account the
forces acting on the gear unit.
When mounting the gear unit on a concrete foundation, using foundation blocks, suitable recesses
should be provided in the foundation.
When alignment has been completed, slide rails should be grouted to the concrete foundation.
6.2.2 Installation of gear units with foot mounting
When making use of the highest possible output torque or shearing forces besides the foot mountings
by studs or bolts of property class 8.8. suitable additional positive connections such as e.g. cylindrical
grooved pins, dowel pins, spring type straight pins or fitting pipes should be provided. These measures
are also necessary for dynamically loaded screw connections.
In some cases headed screws can’t be used, due to lack of space for insertion. If in doubt, please
contact us giving the type of gear.
Do not use spring rings, serrated lock washers, spring washers or tooth lock
Attention! washers, plate springs or idler pulleys as substitute for the above mentioned
positive connections.
The gear unit housings must not be distorted when tightening the fastening
Attention! screws.
Note: See 10.2.4 for tightening torques.
Note: Gear units which require the use of a hoist due to their weight should be attached
according to 4.2.
Page 20 of 47 BA S295 EN 06.97

6.3 Installation of input drive and output drive elements on gear unit shafts
Elements such as running wheels, chain sprockets and gear wheels, couplings and belt pulleys, etc.
should be installed on the gear unit shafts using a fitting device.
Note: Deburr elements to be fitted in the bore and keyway area.
Recommendation: 0.2 x 45°
Centre bores according to DIN 332 are provided in the shaft faces which are used in this case.
Description of the assembly work
S Remove corrosion protective coating from the shaft ends and flanges with benzine or solvent, or
remove protection skin if existing.
Ensure adequate ventilation. Do not inhale vapours. Do not smoke.

Explosion hazard.
Under any circumstances, ensure that benzine or solvent does not contact the
Attention! shaft seals.
S Fit input drive and output drive elements on the shaft ends and secure them, if necessary.
If couplings are used which are to be fitted after heating, the Operating Instructions of the coupling in
question should be observed.
Under no circumstances must the part to be installed be driven onto the shaft
Attention! by hammer blows as this may cause damage to bearings, housing, shaft and
circlips.
Example of a fitting device for installing couplings or

hubs on gear unit or motor shaft ends.
If possible, the thrust bearing on the fitting device can
be obmitted.
Hub Hub
Correct assembly arrangement of gear wheel or

chain sprocket in order to keep the load of the shaft
or bearing by shearing forces as low as possible.
wrong right
BA S295 EN 06.97 Page 21 of 47

6.4 Shaft mounting gear units with hollow shaft and parallel key
6.4.1 Assembly
S Remove the anticorrosive paint from the hollow shaft and from the machine shaft with benzine.
Attention! When doing so, the benzine must never contact the shaft seals.

Explosion hazard.
S Check the hollow and machine shaft for damaged seats or edges. Rework parts with a suitable tool
and clean them again, if necessary.
Apply a suitable lubricant to the contact surfaces to avoid fitting rust, e.g. grease H 443 HD88,
manufacturer Calypsol.
6.4.1.1 Fitting
S Fit the drive by means of nut and threaded spindle. The support is realized by the hollow shaft.
When doing so, the hollow shaft must be in line with the machine shaft to avoid
Attention! canting.
In case of flange-mounted drives, the hollow shaft must not be distorted

Attention! neither axially nor radially since the bearings may break down due to the
exces-sive load.
1 3 2 6 7 4 5
1 Machine shaft 5 Threaded spindle

2 Hollow shaft 6 Locking ring
3 Parallel key 7 Disc
4 Hexagon nut
Pos.4 and Pos.5 are not part of the scope of supply

A hydraulic lifting device may be used instead of the nut and threaded spindle shown in the drawing.
6.4.1.2 Axial safety device

Secure the hollow shaft axially on the machine shaft (e.g. locking ring, disc, set screw). See Table 6.4.2
for tightening torque TA of the set screw.
Page 22 of 47 BA S295 EN 06.97

6.4.2 Disassembly
Before disassembly, a sufficiently dimensioned load suspension device
Attention! should be mounted under the drive before driving out the machine shaft.
The pulling-off device should be slightley pretensioned so that the drive does
not fall into the pulling-off device when loosening the drive from the insertion
shaft.
S Remove axial safety device of the hollow shaft.
S In case of formation of fitting rust at the seat surfaces, use penetrating oil so that the gear unit can
be pulled off more easily.
S Drive out the machine shaft by means of disc Pos.13, threaded piece Pos.12 and parallel key Pos.11
as well as threaded spindle Pos.8 - Pos.10.
Pull off the gear unit by means of the device according to Figure 6.4.2 after a sufficient reaction time
of the penetrating oil.
Attention! Make sure that there is no canting during pulling off.
13 12 11 10 9 8
Figure 6.4.2
8 Threaded spindle 11 Parallel key

9 Hexagon nut 12 Threaded piece
10 Hexagon nut 13 Disc
Pos.8 - Pos.13 are not part of the scope of supply

Suggested design for components Pos.11 - Pos.13:
u b12
s11
∅d11
∅d10
t
d10 b11 b10
d10 t TA
Type b10 b11 b12 d11 s11 u
–0.5 max [Nm]
6 15 10 24.9 15 M10x1.5 28 8 16
C 21
C.
6 15 10 29.9 20 M10x1.5 33 8 16
6 15 10 29.9 20 M10x1.5 33 8 16
C 41
C.
6 15 5 34.9 24 M12x1.5 38 10 28
7 20 7 39.9 28 M16x1.5 43 12 69
C 61
C.
7 20 7 44.9 34 M16x1.5 48.5 14 69
7 20 10 49.9 36 M16x1.5 53.5 14 69
C 81
C.
10 24 10 59.9 45 M20x1.5 64 18 138
10 24 10 59.9 45 M20x1.5 64 18 138
C 102
C.
10 24 5 69.9 54 M20x1.5 74.5 20 138
10 24 5 69.9 54 M20x1.5 74.5 20 138
C 122
C.
10 24 5 89.9 70 M24x1.5 95 25 237
Table 6.4.2
BA S295 EN 06.97 Page 23 of 47

6.5 Shaft mounting gear unit with hollow shaft and multi-spline gearing
6.5.1 Assembly

Explosion hazard.
Apply a suitable lubricant to the contact surfaces to avoid fitting rust, e.g. grease H 443 HD88,
manufacturer Calypsol.
6.5.1.1 Mounting
Attention! canting.

exces-sive load.
1 2 5 6 3 4

2 Hollow shaft 5 Locking ring
3 Hexagon nut 6 Disc
Pos.3 and Pos.4 are not part of the scope of supply

Secure the hollow shaft axially on the machine shaft (e.g. locking ring, disc, set screw). See Table 6.4.2
for tightening torque TA of the set screw.
Page 24 of 47 BA S295 EN 06.97

6.6 Shaft mounting gear unit with hollow shaft and shrink disc
6.6.1 Assembly

Explosion hazard.
The bore of the hollow shaft as well as the machine shaft must be absolutely
Attention! free of grease in the area around the shrink disc seat.
The safety of the torque transmission depends on it to a great extent.
Dirty solvents and cleaning rags are unsuitable for degreasing.
6.6.1.1 Mounting
Attention! canting.

exces-sive load.
1 2 5 3 4

2 Hollow shaft 5 Disc
3 Hexagon nut
Pos.3 - Pos.5 are not part of the scope of supply
The hollow shaft is axially secured on the machine shaft by means of a shrink disc connection.
BA S295 EN 06.97 Page 25 of 47

6.6.2 Shrink disc type HSD
6.6.2.1 Assembly of the shrink disc
The shrink disc is delivered ready for installation.
Attention! Do not disassemble the shrink disc before first clamping.
The bore of the hollow shaft as well as the machine shaft must be absolutely
Attention! free of grease in the area around the shrink disc seat.
The safety of the torque transmission depends on it to a great extent.
Dirty solvents and cleaning rags are unsuitable for degreasing.
4 3
greased
5
absolutely
free of grease
2
1 Machine shaft 4 Outer race

2 Hollow shaft 5 Clamping screw
3 Inner race
Note: In the area around the shrink disc seat, the outer surface of the hollow shaft may be
greased.
Never tighten the clamping screws before the machine shaft is installed, too,
Attention! as otherwise the oil shaft will be plastically deformed.
The clamping screws are to be tightened in several turns one after the other until the front surfaces of
the outer and inner race are flush.
Note: The correct clamping state can thus be checked visually.
Attention! Tightening of all clamping screws Pos.5 one after the other (not “crosswise”).
1 12
2 11
3 10
4 9
5 8
6 7
Page 26 of 47 BA S295 EN 06.97

To avoid overloading the individual screws, the max. tightening torque (see
Attention! Table 6.6.2.1) must not be exceeded, what is more important is that the faces
are flush. If this flushness cannot be reached during clamping, the tolerance
of the insertion shaft should be checked.
max. tightening torque per screw

(with µ = 0.1)
Clamping
Cl i screw Property class Property class
thread 10.9 12.9
Nm Nm
M 6 12 14.5
M 8 29 35
M 10 58 70
M 12 100 121
M 14 160 193
M 16 240 295
M 20 470 570
Table 6.6.2.1: max. tightening torques of the clamping screws
Re-install the protective cover afterwards.
6.6.2.2 Disassembly of the shrink disc

The clamping screws are to be loosened in several turns one after the other.
If the outer race does not come off the inner race by itself, some clamping screws can be unscrewed
and screwed into the neighbouring forcing threads.
Unclamping is then possible without any problem.
Pull off the shrink disc of the hollow shaft.
6.6.2.3 Cleaning and lubricating the shrink disc

Loosened shrink discs do not have to be taken apart and lubricated again before being re-clamped.
The shrink disc is only to be disassembeled and cleaned when it is dirty.
When connecting, only the inner sliding surfaces of the shrink disc are to be
Attention! lubricated again.
A solid grease with a friction coefficient of m = 0,04 in accordance with the table below is to be used.
Lubricant Commercial form Manufacturer

Molykote 321 R (Lubricating paint) Spray DOW Corning
Molykote Spray (Powder spray) Spray DOW Corning
Molykote G Rapid Spray or paste DOW Corning
Aemasol MO 19 P Spray or paste A. C. Matthes
Molykombin UMFT 1 Spray Klüber Lubrication
Unimoly P 5 Powder Klüber Lubrication
Table 6.6.2.3: Lubricants for shrink disc cleaning
BA S295 EN 06.97 Page 27 of 47

6.7 Attachment of standard motors
6.7.1 Attachment to coupling lantern with BIPEX coupling
Note: The special Operating Instructions should be observed for the operation of the
couplings.
S Fit coupling half Pos.2 onto the motor shaft end observing 6.3.
Secure the coupling half against axial shifting with grub screw Pos.4.
Attention! Distance dimension z12 according to Table 6.7.1 should be kept.
Note: Dimension z12 applies to the standard assignment of the coupling. In case of a
special assignment, the dimension should be taken from the corresponding special
dimension drawing.
S Insert elastic element Pos.3 into coupling half Pos.1.

S Flange motor to coupling lantern and fasten it by means of screws Pos.5 according to the prescribed
tightening torque, Table 10.2.4.
Note: Bei Aufstellung des Antriebs im Freien oder bei höherer Schutzart (w IP 55):
Flansch, Schrauben (Pos.5) und evtl. vorhandene Verschlußstopfen (Pos.6) oder
eingebaute Elemente, z.B. Näherungsschalter, mit Dichtmasse abdichten.
1 3 2 4 z12
6 5
1 Coupling half 4 Grub screw

2 Coupling half 5 Hexagon head screw
3 Elastic element 6
Motor size 63 71 80 90 100 112 132 160 180 200 225 250 280 315
z12 [mm]
4 4 19 25 33 21 40 56 56 45 73 73 63 62
for IEC B5-flange
143TC 182TC 213TC 254TC 284TC 324TC 364TC

Motor size 42C 48C 56C - - - - - - -
145TC 184TC 215TC 256TC 286TC 326TC 365TC
z12 [mm]
14 14 30 30 37 40 46 56 68 68
for Nema-TC-motor
Table 6.7.1
Page 28 of 47 BA S295 EN 06.97

6.7.2 Attachment to coupling lantern with clamping ring
S Remove mounting plugs Pos.1 and Pos.2.
S To fasten the clamping ring align input shaft and clamping ring of the gear unit to the mounting bores
(Pos.1 and 2) by rotating.
S Flange motor to coupling lantern and fasten it by means of screws Pos.3 according to the prescribed
torque, Table 10.2.4.
Note: Bei Aufstellung des Antriebs im Freien oder bei höherer Schutzart (w IP 55):
Flansch, Schrauben (Pos.3) und Montagestopfen (Pos.1 und Pos.2) mit Dichtmasse
abdichten.
S Screw the grub screw Pos.4 onto the key Pos.5 until a light resistance is felt, then unscrew half a turn
(Wrench size SW1, see table 6.7.2).
S To stop the shafts from turning, use a wrench in the grub screw Pos.4 through bore Pos.1.
S Tighten hexagon socket screw Pos.6 according to the prescribed torque, Table 6.7.2 (wrench size
SW2 see Table 6.7.2).
S Tighten grub screw Pos.4.
S Cover mounting bores with plugs Pos.1 and Pos.2.
5 4 1
1 Mounting plug
2 Mounting plug
3 Hexagon head screw
4 Grub screw
5 Parallel key
6 Hexagon socket screw
6 2 3
Motor size 63 71 80 90 100 112 132 160 180 200

Torque [Nm] 7 7 7 7 12 12 12 29 29 59
SW1 [mm] 2 2 2 2.5 3 3 3 3 3 4
SW2 [mm] 4 4 4 4 5 5 5 6 6 8
143TC 182TC 213TC 254TC 284TC

Motor size 56C - - - - -
145TC 184TC 215TC 256TC 286TC
Torque [Nm] 7 7 12 12 29 29
SW1 [mm] 2 2 3 3 3 3
SW2 [mm] 4 4 5 5 6 6
Table 6.7.2
BA S295 EN 06.97 Page 29 of 47

6.8 Motor base plate
The motor base plate serves for supporting a foot mounted IEC standard motor which is mainly used
for driving a V-belt drive.
Note: Incorrect belt tension results in belt breakages and damage to the bearing.
Attention! The appropriate Operating Instructions for V-belt drives should be observed.
Do not re-adjust the motor base plate in downward mounting position as it may
slip out of the holder.
S Loosen grub screw (4x) Pos.1.
S From motor size 225 on, hexagon nuts Pos.4 and Pos.5 of the support should be loosened.
S The height can be adjusted by turning hexagon nut Pos.2.
S Tighten grub screws Pos.1 after adjusting the correct height.
S From motor size 225 on, tighten hexagon nuts Pos.4 and Pos.5.
When tightening the hexagon nuts Pos.4 and Pos.5 the motor base plate Pos.3
Attention! must not be forced into a different position or be distorted.
5 4 3
1 1 1
1 1 1
1 Grub screw 4 Hexagon nut

2 Hexagon nut 5 Hexagon nut
3 Motor base plate
Suggestion for fixing a protective device:

For connecting a protective device, screw the grub screws Pos.1 out of the bores and replace them
by suitable longer grub screws (DIN 916). These grub screws serve for clamping the columns and as
fastening threads of a protective device.
Page 30 of 47 BA S295 EN 06.97

6.9 Torque arm for shaft mounting gear unit
The torque arm serves for compensating the reaction torque and the weight of the drive, if necessary.
Note: In principle, it should be observed that the torque arm does not cause any
unpermissibly high constraining forces (e.g. in case of rough running of the driven
shaft). On the other hand, dangerously high suddenly applied torques can result from
an excessive play when changing the gear or reversing.
Suggested assembly of the worm gear unit with torque arm:
The torque arm can be mounted in different positions

due to the available bore division.
Note: The bush of the torque arm must run in bearings on both sides.
Properties of the rubber elements:

Basic material: Caoutchouc: 60°Shore A
thermal stability: –45°C to +70°C
The rubber elements must not come into contact with solvents, oils, greases
Attention! and fuels.
BA S295 EN 06.97 Page 31 of 47

7. Startup
7.1 Measures before startup
7.1.1 Startup without long term preservation
S MOTOX drives are delivered with the appropriate lubricants ready for operation depending on the
specified conditions of use.
In case of gear units which require housing ventilation, the necessary venting
Attention! screw is supplied separately. Before starting up the gear unit, the venting
screw should replace the corresponding plug screw.
It should be inserted at the point marked with this symbol (see 3.2).
7.1.2 Startup in case of long term preservation
7.1.2.1 Long term preservation up to 18 months
Attention! Before starting up the gear unit, it should be filled with lubricant (see 7.1.3).
7.1.2.2 Long term preservation up to 36 months
The gear unit is completely filled with oil. Before the startup, the oil level
Attention! should be corrected according to the type of construction.
The oil level should be reduced to the level marked with this symbol
(see 7.2).
Any oil escaping should be removed immediately with oil binding agent in an
environmentally compatible way.
7.1.3 Filling with lubricant
S Screw out venting screw or venting filter or plug screw at the highest point (see 3.2 for point of
ventilation).
Fill gear unit up with fresh oil using a filling filter (max. filter coarseness 60 µm).
Attention! The quantity of oil depends on the mounting position!
Note: Recommendations on the oil to be used should be taken from

Section 10. “Maintenance and repair”.
Data, such as oil grade, oil viscosity and oil quantity required will be found on the rating
plate (see Section 3. “Technical data”).
Attention! Finally, check the oil level (see 7.2).
7.1.4 Drive with backstop
Secure drive unit to prevent accidental startup.

Affix notice at the switch-on point.
Attention! Check the direction of rotation before putting into service!
E.g. by manually turning the input shaft or the motor. Check the motor direction of rotation according
to the phase sequence, swap two supply leads if necessary.
Page 32 of 47 BA S295 EN 06.97

7.2 Oil level check
S Shut down the gear unit by shutting off the drive unit.

Note: In case of tandem gear units, each single gear unit should be inspected separately.
Check oil level with the oil cooled down.
Even after a short run, oil needs a longer ‘rest’ in order to release possible air bubbles.
7.2.1 Checking the oil level in the gear unit housing
Screw out the plug screw at the point marked with this symbol .
Note: If the oil level is correct, a small amount of oil may flow out, the oil must at least come
up to the lower edge of the bore.
Oil level
For drives with only one plug screw, checking the oil level is not possible.
7.2.2 Oil sight glass (Special feature)
S If equipped with an oil sight glass, the oil level must be visible within the area of the sight glass.
7.2.3 Dipstick (Special feature)
S Check oil level with dipstick:
The oil level must be between the lower and upper mark of the dipstick.
7.3 Shutdown

Note: If shut down for a considerable period of time, the gear unit should be run briefly at
intervals of three weeks. If shut down for a period exceeding six months, the gear unit
should be preserved (see 7.4 and 7.5).
7.4 Preservation with gear oil
S Long term preservation up to 36 months.
Completely top up the gear unit with the filled oil grade.
BA S295 EN 06.97 Page 33 of 47

7.5 External preservation procedure
S Clean surfaces.
Cleaning the drive with a high-pressure cleaning device is not permissible.
Attention! Do not use sharp-edged tools.
S Smear shaft seal rings with grease for protection against preservatives.
S Coating: check, in case of damage have it repaired by an expert.
S Apply preservatives.
Protection time Preservative Layer thickness Remarks

name
Wax base long preservation,

up to 12 months Tectyl 846 K19 approx. 50 µm sea water resistant,
tropic-proof, benzine-soluble
Table 7.5: External preservation of shaft ends and other bright metal surfaces
8. Operation
8.1 General operating data
During operation, the gear units should be checked for
S excessive operating temperature (In continuos duty, the gear unit is suitable for a
temperature of 100°C when using a synthetic oil
(polyglycole).
Short-term temperatures of 110°C are permissible,
see also Section 10. “Maintenance and repair”).
S any changes in gear unit noises

S possible oil leakage at the housing and the shaft seals.
If irregularities are detected during operation, the drive assembly should be

Attention! shut off immediately. The cause of the malfunction should be determined with
the aid of the Troubleshooting Table (Section 9. “Disturbances, reasons and
remedy”).
The Troubleshooting Table lists possible malfunctions, their causes and
suggestions for their remedy.
If the cause cannot be determined or there is no facility for repair with suitable
equipment, we recommend calling in one of our service fitters
(see Section LEERER MERKER “Spare parts stock, service addresses”).
Page 34 of 47 BA S295 EN 06.97

9. Disturbances, reasons and remedy
9.1 General information on malfunctions
Note: Malfunctions occuring during the warranty period which necessitate repair of the gear
unit may only be repaired by FLENDER-HIMMEL service personnel. Even after the
warranty period has elapsed, we recommend our customers to consult our Service
Division concerning malfunctions whose cause cannot be clearly ascertained.
Malfunctions Causes Remedy

Temperature rise at bearing Oil level in gear unit housing too Check the oil level at room
points low temperature;
top up if necessary.
Oil is overaged Check when last oil change was

carried out;
change oil if necessary.
See Section 10.
Bearing(s) defective Call in FLENDER-HIMMEL

Service.
Check bearing(s);
replace if necessary.
Excessive operating Oil level in gear unit housing too Check the oil level at room
temperature high temperature;
correct oil level if necessary.
Oil is overaged Check when last oil change was

carried out;
change oil if necessary.
See Section 10.
Oil is very dirty Change oil.

See Section 10.
Fan cowl of the motor and/or Clean fan cowl and surface of
drive is very dirty the drive.
Backstop does not run freely Call in FLENDER-HIMMEL

Service.
Repair backstop,
replace if necessary.
Change in gear unit running Damage to tooth systems Call in FLENDER-HIMMEL
noises Service.
Check toothed components;
if necessary replace damaged
components.
Excessive bearing play Call in FLENDER-HIMMEL

Service.
Adjust bearing play.
Bearing defective Call in FLENDER-HIMMEL

Service.
Replace defective bearings.
External loading on input and Correct loading to nominal data

output too high e.g. correct belt tension.
BA S295 EN 06.97 Page 35 of 47

Malfunctions Causes Remedy
Loud noises in the region of the Gear unit mounting has Tighten bolts/nuts at
gear unit mounting loosened recommended tightening
torque.
Replace damaged bolts/nuts.
Noticeable lubricant leakage Wrong mounting position/oil Correct mounting position
level according to rating plate,
check oil level.
Inadequate sealing of housing Call in FLENDER-HIMMEL

cover or joints Service.
Seal again.
Radial shaft seal defective Call in FLENDER-HIMMEL

Service.
Replace radial shaft seal.
Drive does not start or starts Lubricant viscosity incorrect Fill in correct lubricant.
under great effort
Oil level in the gear unit housing Check oil level at room
too high temperature,
drain oil if necessary.
External loading on output too Correct loading to nominal data.

high
Brake of motor is not released Check switching/connection of

brake, correct if necessary.
Drive works against the back- Call the customer service!

stop Change the direction of rotation
of the motor or the backstop.
Check the backstop.
Drop in speed or torque Belt tension too low Correct belt tension.
Replace belt if necessary.
Play on input and output too Elastic element worn Replace elastic element;
high call in FLENDER-HIMMEL
Service if necessary.
Positive connection worn out by Call in FLENDER-HIMMEL

overload Service.
Page 36 of 47 BA S295 EN 06.97

10. Maintenance and repair
10.1 General information on maintenance
Note: All maintenance and repair work should be carried out with due care and only by
thoroughly trained personnel.
The notes in Section 2. “Safety notes” should be observed.
The periods listed in Table 10.1 are largely dependent on the conditions of use
Attention! of the gear unit. For this reason, it is only possible to give average periods
which refer to a
daily operating time of 24 h

duty factor of ED 100 %
input drive speed of 1500 1/min
max. oil temperature of 100°C.
Note: Under different operating conditions, the periods should be adjusted accordingly.
Measures Causes Remedy

Observe/check gear unit noise from time to time, more often
for changes during operation if possible
Observe/check oil temperature from time to time, more often

during operation if possible
Check oil level monthly see 7.2
Check gear unit for leakage monthly
Initial oil change after startup after approx. 2000 operating see 10.2.1
hours, at the latest after 3 years
Subsequent oil changes every 3 years or see 10.2.1

10000 operating hours
Clean vent plug every 3 months see 10.2.2
Clean drive according to the degree of see 10.2.3

contamination
Check all fixing screws for at least once a year see 10.2.4
tightness
Carry out complete inspection at least once a year see 10.2.5

of gear unit
Table 10.1: Maintenance and repairs
BA S295 EN 06.97 Page 37 of 47

10.2 Description of maintenance and repairs
10.2.1 Carrying out oil changes
When changing the oil the gear unit should always be filled with the oil grade
Attention! previously in use. Mixing oils of different grades is not permissible. In
particular, synthetic oils may not be mixed with mineral oils or different
synthetic oils. When changing over from mineral oil to synthetic oil or from
synthetic oil with a particular base to synthetic oil with another base, the gear
unit must be flushed through thoroughly with the new oil grade.
When changing the oil, the housing must also be cleaned thoroughly by flushing with oil to remove oil
sludge, abraded particles and residues of old oil. For this purpose, the same oil grade should be used
as is in use for operation of the gear unit. Viscous oils should be warmed beforehand. Only when all
residues have been removed, the fresh oil may be poured in.
Note: The oil should be drained off after shutdown, while the gear unit is still warm.
S Place a suitable collection receptacle under the oil drain plug of the gear unit housing.
S Unscrew the vent plug on top of the housing.

S Unscrew oil drain plug and drain oil off into the receptacle.
There is a risk of scalding from the hot oil emerging.
Wear protective gloves.
S Screw in oil drain plug.
Note: Check condition of seal ring, use new seal ring if necessary.
Attention! Fill gear unit up with fresh oil using a filling filter (max. filter coarseness 60 µm)
Note: Recommendations on the oil to be used should be taken from

Section 10. “Maintenance and repair”.
Data, such as oil grade, oil viscosity and oil quantity required will be found on the rating
plate (see Section 3. “Technical data”).
S Check oil level (see 7.2).
Page 38 of 47 BA S295 EN 06.97

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

Explosion hazard.
10.2.3 Cleaning the drive
Keep drives free of dirt and dust, etc. in order to ensure a sufficient heat dissipation.
Cleaning the drive with a high-pressure cleaning device is not permissible.

Attention! Do not use sharp-edged tools.
10.2.4 Checking all fixing screws for tightness
S Check all fixing screws for tightness with a torque wrench
Thread size Property class min. Tightening torque

M6 8.8 10 Nm
M8 8.8 25 Nm
M 10 8.8 50 Nm
M 12 8.8 90 Nm
M 16 8.8 210 Nm
M 20 8.8 450 Nm
M 24 8.8 750 Nm
M 30 8.8 1500 Nm
M 36 8.8 2500 Nm
Table 10.2.4: Tightening torques
Note: Unserviceable screws should be replaced by new ones of the same property class
and type.
10.2.5 Inspection of the drive
The drive should be checked annually and with the aid of an inspection plan according to the possible
criteria listed in Section 9. “Disturbances, reasons and remedies”.
In addition, the drive should be checked according to the criteria described in Section 2. “Safety notes”,
e.g. check tight fit of the protective devices.
Any damage of the coating should be repaired by an expert.
BA S295 EN 06.97 Page 39 of 47

10.3 Lubricants
Oil selection should always be determined by the oil viscosity (ISO VG class) specified on the rating
plate of the gear unit. The viscosity class is valid for the operating conditions agreed on by contract.
Under different operating conditions, it will be necessary to consult us at FLENDER-HIMMEL.
We have compiled a Lubricant Table of the lubricants suitable for the gear unit (see Table 10.3).
We are acquainted with the composition of these lubricants and know that, in accordance with the latest
technology, they possess values in respect of loadability, corrosion protection, load carrying capacity
with micro-pitting, as well as compatibility with seals and internal coating on which the design of the gear
unit has been based.
Thus, we recommend that our customers should select a lubricant from this Table, taking in account
the viscosity class stated on the rating plate.
The lubricants listed have no approval according to USDA -H1/-H2 (United
States Department of Agriculture) and are as such not, or only limited
approved, for use in the food or pharmaceutical industry.
The lubricants are not, or only limited biologically decomposeable. They are
usually according to the Classes 2 or 1 of hazard for water.
If lubricants are necessary according to these classifications, please contact
the factory.
If the gearboxes are filled with special lubricants from the factory for the cases
given above, this can be seen on the name plate e.g.: CLP-H1 VG220 or CLP
E VG220.
Note: As a precaution against misunderstandings, we would like to point out that the
recommendation does not imply any release in the sense of a warranty for the quality
of the lubricant provided by your supplier. Each lubricant manufacturer must warrant
the quality of his product himself.
If for any reason you deem important, you do not follow our recommendation, you yourself will assume
the responsibility for the technical suitability of the lubricant.
In order to assist you to minimize the technical risk in such cases, we recommend that you consult us
at FLENDER-HIMMEL.
S In the case of synthetic oils not listed in Table 10.3, the corrosiveness of the oil to our internal coating
should also be checked. A check of this nature is carried out by us at cost (cost on request).
Page 40 of 47 BA S295 EN 06.97

Designatio
Examples of lubricants
n
Lubricant according
to
DIN 51502
OIL Degol Enersyn Polydea GLYCO- Renodiol Syntheso Glygoyle TIVELA TRIBOL Optiflex
PGLP GS460 SG-XP PGLP46 LUBE PGP460 D460EP HE460 OIL 800/460 A460
ISOVG46 460 0 460 SD
Syntheti
y 0
c Oils
2) OIL Degol Enersyn Polydea GLYCO- Renodiol Syntheso Glygoyle TIVELA TRIBOL Optiflex
PGLP GS220 SG-XP PGLP22 LUBE PGP220 D220EP 30 OIL 800/220 A220
ISOVG22 220 0 220 WB
0
Lithium saponified Aralub Energrease Glissan- BE- Renolit CEN- Mobilux ALVANIA MOLUB Wiolub Longtime
anti-friction bearing HL3, LS3, do ACON FWA220, TRO- 3, R3, ALLOY LFK2 PD2
greases NLGI 3/2 HL2 LS2 30, 3 FWA160 PLEX 2 R2 BRB527
20 GLP402
Table 10.3: Lubricant selection

Synthetic lubricants (polyglycols) in accordance with designation PGLP as per DIN 51 502. These oils
are distinguished by their high ageing resistance and favourable effect on the efficiency of the gear unit.
They are suitable for the following operating temperatures:
PGLP ISO VG 220: –35°C bis +100°C
PGLP ISO VG 460: –15°C bis +100°C
The maximum temperatures can be exceeded by 10K for a short time.
Note: If the operating temperature of the drive exceeds or undershoots the limit values, the
oil selected should be checked for suitability by consulting FLENDER-HIMMEL.
Oils marked with a can also be utilized when using Freudenberg shaft seal rings of Viton 83
FKM 575 or 75 FKM 585.
The drives will be only be provided by Flender-Himmelwerk with this form of sealing in this previously
agreed special case. They can be recognised by the stamp “BAUM” or “BAUMSL” on the front.
BA S295 EN 06.97 Page 41 of 47

11. Spare parts stock, service addresses
11.1 Stocking spare parts
Maintaining a stock of the most essential replacement and wearing parts on site will ensure that the
drive is serviceable at all times.
We assume warranty only for original spare parts supplied by us.
We would like to explicitly draw attention to the fact that spare parts and
Attention! accessories not supplied by us have not been tested and approved by us
either. Fitting and/or use of such products can therefore under certain
circumstances adversely effect structurally specified properties of the drive
and will thus impair active and/or passive safety. No form of reliability or
warranty will be assumed by FLENDER-HIMMELWERK GmbH for damage
caused by the use of non-original spare parts and accessories.
Please note that special production and supply specifications frequently exist for components and we
will always offer spare parts in accordance with the latest technology and the latest legal requirements.
When ordering spare parts, the following data should be stated:

Order No. (see rating plate 3 )
Type designation (see rating plate 4 )
Part No. (six-digit ident. No. or three-digit pos. No. from the spare parts list)
Quantity
11.2 Spare parts and Customer Service addresses

FLENDER-HIMMEL Germany
FLENDER-HIMMEL Europe
FLENDER-HIMMEL International
Page 42 of 47 BA S295 EN 06.97

FLENDER - HIMMEL Germany
Internal Sales Tübingen (Advice, Sales, Spare parts) Customer Service

Telephone 07071/707-499 / -285 / -435 Flender-Himmelwerk GmbH
Fax 07071/707-475 / -324 72072 Tübingen
Tel. 07071/707-384
Fax 07071/707-485
Sales office Berlin Sales office Hannover

Egellsstraße 21, D-13507 Berlin Marktplatz 2, D-30853 Langenhagen
Tel.: (030) 4301-0 D-30839 Langenhagen
Fax: (030) 4301-2712 Tel.: (0511) 77189-0
Fax: (0511) 77189-89
Sales Region Telephone / Fax Mobil Telephone Sales Region Telephone / Fax Mobil Telephone
Dresden 0351 / 4596603 0172 / 2846219 Hamburg / Hannover 04103 / 970444 0172 / 2819599
Magdeburg 0391 / 5439279 0172 / 2819762 Braunschweig / Kassel 05153 / 963174 0172 / 2837340
Thüringen 035934 / 4451 0172 / 2919771 Bielefeld 05181 / 82543 0172 / 2867002
Berlin 030 / 4544067 0172 / 2822196 Schl.-Holstein / Bremen 040 / 6064256 0172 / 2819746
Sales office Herne

Südstraße 111, D-44626 Herne
D-44607 Herne
Tel.: (02323) 940-0
Fax: (02323) 940-950 / -940 / -960 / -951
Sales Region Telephone / Fax Mobil Telephone
Bocholt 02871 / 38690 0172 / 2819615
Bocholt 02852 / 3992 0172 / 2819786
Wuppertal 02361 / 108984 0172 / 2838334
Köln 0221 / 729073 0172 / 2819783
Düsseldorf 02871 / 221201 0172 / 2823950
Dortmund 0234 / 263335 0172 / 2867003
Your contact in Tübingen: Tel.: 07071 / 707-326 Fax: 07071 / 707-475
Sales office Stuttgart Sales office München

Breitwiesenstraße 27, D-70565 Stuttgart Liebigstraße 15, D-85757 Karlsfeld
D-70504 Stuttgart D-85750 Karlsfeld
Tel.: (0711) 78054-51 Tel.: (08131) 9003-0
Fax: (0711) 78054-50 Fax: (08131) 9003-33
Sales Region Telephone / Fax Mobil Telephone Sales Region Telephone / Fax Mobil Telephone
Heilbronn 07941 / 34221 0172 / 2819759 Würzburg 09331 / 7020 0172 / 2819777
Frankfurt 06241 / 44598 0172 / 2819650 Würzburg 0931 / 408090 0172 / 2819669
Freiburg 07641 / 3244 0172 / 2819755 Augsburg 089 / 7459429 0172 / 2819736
Saarbrücken 06897 / 84930 0172 / 2819765 Nürnberg 09643 / 8242 0172 / 2819739
Tübingen 07473 / 6288 0172 / 2819749 München 08139 / 99314 0172 / 2844016
Mannheim 0621 / 896625 0172 / 2819646
Ludwigshafen 06224 / 929551 0172 / 2846218
Stuttgart I 07162 / 24910 0172 / 2819660
Stuttgart II 07032 / 75968 0172 / 2822274
Your contact in Tübingen: Tel.: 07071 / 707-469 Fax: 07071 / 707-475
Further partners in the Flender Group:
FLENDER ENGINEERING & SERVICE D-44607 Herne - Südstraße 111, D-44625 Herne
ANTRIEBSTECHNIK GMBH Tel.: (02323) 940-0 - Tx.: 8229868 - Fax: (02323) 940-200
A. FRIEDR. FLENDER AG D-46393 Bocholt - Alfred-Flender-Straße 77, D-46395 Bocholt

Tel.: (02871) 92-0 - Tx.: 813841 - Fax: (02871) 922596
LOHER AG D-94095 Ruhstorf - Hans-Loher- Straße 32, D-94099 Ruhstorf

Tel.: (08531) 390 - Tx.: 8531806 - Fax: (08531) 39437
A. FRIEDR. FLENDER AG Thierbacher Straße 24, D-09320 Penig

GETRIEBEWERK PENIG Tel.: (037381) 60 - Tx.: 322661 - Fax: (037381) 80286
FLENDER GUSS GMBH Obere Hauptstraße 228-230, D-09228 Wittgensdorf

Tel.: (03722) 64-0 - Tx.: 322352 - Fax: (03722) 64-3112
BA S295 EN 06.97 Page 43 of 47

FLENDER - HIMMEL Europe
AUSTRIA GREECE SWEDEN
Flender Ges.m.b.H. F : Mangrinox S.A. Z Flender Svenska AB Z
Industriezentrum Nö-Süd 14 Grevenon Str. Ellipsvägen 11
Strasse 4, Objekt 14, Postfach 132 GR-11855 Athens S-141 75 Huddinge
A-2355 Wiener Neudorf Tel. 00301-3412427 Tel. 46-8-4495770
Tel. 02236-64570 Tx. 214909 Fax 46-8-4495690
Tx. 79141 Fax 00301-3459928
Fax 02236-64570-10
SWITZERLAND
ITALY Flender ATB-Loher F :
BELGIUM & LUXEMBOURG Flender Cigala S.p.A. J : Zeughausstr. 48
N.V. Flender Belge S.A. F : Via Privata da Strada Provinciale, 215 CH-5600 Lenzburg
Cyriel Buyssestraat 130 I-20040 Caponag (Mi) Tel. 062-8857600
B-1800 Vilvoorde Tel. 02-95742371 Fax 062-8857676
Tel. 02-2531030 Fax 02-95743887
Tx. 22449
Fax 02-2530966 TURKEY
THE NETHERLANDS Flender Güc Aktarma Sistemler San.F:
Flender ATB-Loher F : ve Tic. Ltd. STI
DENMARK Lage Brink 5-7 Imes Sanayi Sitesi
FLENDER AS Z : NL-7317 BD Apeldoorn E Blok 502. sokak No.22
Sydmarken 46 Tel. 055-5275000 TR-81360 Dudullu-Istanbul
DK-2860 Soborg Fax 055-5218011 Tel. 0216-3643413
Tel. 0045-7025-3000 Fax 0216-3645913
Fax 0045-7025-3001
NORWAY
ATB Norge F : UNITED KINGDOM & EIRE
EAST EUROPEAN COUNTRIES G. Bauknecht A.S. Flender-Himmelwerk Ltd. J :
A. Friedr. Flender AG F Frysjavn 40 Thornbury Works, Leeds Road
Beratungszentrale Osteuropa N-0884 Oslo GB-Bradford BD3 7EB West Yorkshire
Industriezentrum Nö-Süd Tel. 02-2021036 Tel. 01274-657700
Strasse 4, Objekt 14, Postfach 132 Tx. 71062 Tx. 517543
A-2355 Wiener Neudorf Fax 02-2021050 Fax 01274-669836
Tel. 02236-64570
Tx. 79141
Fax 02236-64570-23 SPAIN & PORTUGAL
Flender Ibérica S.A. F
Poligono Industrial San Marcos
FINLAND Calle Morse, 31 (Parcela D-15)
Flender Oy F E-28906 Getafe/Madrid
Korppaanmäentie 17 CL 6 Tel. 00349-1-6836186
FIN-00300 Helsinki Fax 00349-1-6834650
Tel. 09-4361366 Simet Ltda.
Fax 09-4361410 Apartado 5.111
P-1703 Lissabon
Tel. 01-254565
FRANCE Tx. 42213
Flender France S.A.R.L. F :
3, Rue Jean Monnet
Zone des Côtes
F-78990 Elancourt
B.P. 5
F-78312 Maurepas Cedex
Tel. 1-30663900
Tx. 699715
Fax 1-30663513
BRANCH OFFICES:
Flender S.A.R.L.
25, Boulevard Joffre
F-54000 Nancy
Tel. 038-3308590
Fax 038-3308599
Flender S.A.R.L.
36, Rue Jean Broquin
F-69006 Lyon
Tel. 0472-839520
Fax 0472-839539
J Subsidiary, Manufacturing,
Sales and Stock
F Subsidiary, Sales and Stock
Z Distributer
: Assembly Centre
Page 44 of 47 BA S295 EN 06.97

FLENDER - HIMMEL International
AFRICA AMERICA AUSTRALIA
ALGERIA & TUNESIA BRAZIL AUSTRALIA
Simetra Flender S.A.R.L. F Flender Brasil Ltda. J : Flender (Australia) Pty. Ltd. F:
3, Rue Jean Monnet Rua Quartoze Nr. 60, Caixa Postal 296 9 Nello Place
Zone des Côtes 32211-970 Contagem-MG Wetherill Park
F-78990 Elancourt Tel. 031-3692000 N.S.W. 2164
B.P. 5, Fax 031-3311893 Sydney
78312 Maurepas Cedex Tel. 02-97562322
Tel. 1-30663900 BRANCH OFFICES: Tx. AA27742
Tx. 699715 Rua Aratans, 1.455 Fax 02-97564892
Fax 1-30663513 Planalto Paulista
04081-005-São Paulo-SP BRANCH OFFICES:
Tel. 011-5365211 20 Eskay Road, South Oakleigh
EGYPT Fax 011-5301252 Melbourne
Farid Hassanen & Co. Z Victoria 3167
81, Matbaa Ahleia Street CANADA Tel. 03-95790633
Boulac-Cairo, A.R.E. Flender Power Transmission Inc. F : Tx. 38437
Tel. 5751489 215 Shields Court, Units 4-6 Fax 03-95790417
Tx. 22936, 22125 Markham, Ontario L3R8V2
Fax 5751383 Tel. 905-3051021 20 Brookes Street, Bowen Hills
Fax 905-3051023 Brisbane
Workshop and Service: Qld. 4006
13, Selim Oma Street BRANCH OFFICES: Tel. 07-32522711
Boulac-Cairo, A.R.E. Flender Power Transmission Inc. Tx. 41203
Tel. 764656, 774897 Bay # 3, 6565 40th Street S.E. Fax 07-32523150
Tx. 22936, 22125 Calgary, Alberta T2C - 2J9
Fax 769741 Tel. 403-543-7744 1 Dampier Road
Fax 403-543-7745 Welshpool, Perth
W.A. 6106
MOROCCO Colombia Tel. 09-4518355
S.M.E.M. Z Flender de Colombia Tx. 93712
15, Boulevard du Fouarat A.G.P. Representaciones Ltda. Fax 09-4583582
Casablanca Carrera 68 Nr. 16-80 Piso 4.
Tel. 2-240253, 2-240271 CIPRES TRADE CENTER
Tx. 26923M Bogota - Colombia NEW ZEALAND
Tel. 91-3460561 R.R. Fisher & Co.Ltd. Z
Fax 91-3460415 13, Spring Street
SAUDI ARABIA/U.A.E./KUWAIT Papatoetoe
Ticos-International Z CHILE New Zealand
General Trading Co. Sargent S.A. Z : Tel. 09-2784059
P.O. Box 2191 Av. Pdte. Bulnes 205, Casilla 166 D Tx. 2458
Ajman Santiago
Tel. 428716 Tel. 02-6991525
Fax 428730 Fax 02-6983989
MEXICO
SOUTH AFRICA Flender de Mexico, S.A. de C.V. F
Flender Power Transmission (Pty.)Ltd.F: Vista Hermosa No.23
No.8 Greenfield Park Col. Romero Vargas
Cnr. Furnace Street & Quality Road Adpo. Postal 2-85
Isando, Kempton Park Tv1. Puebla, Pue.C.P. 72131
P.O. Box 8358, Elandsfontein 1406 Tel. 22310951, 22310844
Tel. 011-3922850/1/2/3/4/5 Fax 22310913
Tx. 4-28445
Fax 011-3922434 USA
Flender Corporation J :
BRANCH OFFICE: 950 Tollgate Road, P.O. Box 1449
P.O. Box 28283 F : Elgin, Illinois 60120
Bothasig, Cape Town 7406 Tel. 847-9311990
Unit No.3 Marconi Park Tx. 285394
No.9 Marconi Cresent Fax 847-9310711
Montague Garden
Tel. 021-5515003 VENEZUELA
Fax 021-523824 F. H. Transmissiones S.A. Z :
Urb. Buena Vista
Calle Johan Schafer o Segunda Calle
Edif. F.H.T. (frente a Lab. Boehringer)
Municipio Sucre, Petare Edo. Miranda
Caracas - Venezuela
Tel. 0058-2-215261
Fax 0058-2-211838
Sales and Stock
Z Distributer
: Assembly Centre
BA S295 EN 06.97 Page 45 of 47

ASIA
ASEAN KOREA
Flender Singapore Pte. Ltd. F : Sung Ji Trading Co. Z :
BLK 2033 Bukit Batok Street 23 No.211, Ma Yeol
Nr.01-302 Gochuk Ind. Market 103-4
Singapore 659538 Gochuk Dong
Tel. 0065-5663412 Kuro-Ku, Seoul/Korea
Fax 0065-5625773 Tel. 02-688-8367, 8368
Fax 02-688-8368
PEOPLE’S REPUBLIC OF CHINA

Beijing Flender Mechanical & Electrical MALAYSIA
Engineering Co. Ltd. F : German Transmission Z :
No. C-411, Office Building, Machinery SDN. BHD.
Beijing Lufthansa Center Prime Subang Industrial Park
No. 50, Liangmaqiao Road No.3 Block C, Lot 757
Chao Yang District Jl Subang 6, off Persiaran Subang
Beijing 100016 P.R.C. 47500 Petaling Jaya
Tel. 0086-10-64622151-54 Selangor, Malaysia
Fax 0086-10-64622143 Tel. 03-7336023
Fax 03-7336259
INDIA
Flender Macneill Gears Limited. J PAKISTAN
2, St. Georges Gate Road, 5 th Floor O.T.C. Z
Calcutta-700022 114 Alama Iqbal Road
West Bengal - India Lahore-5
Tel 33-223-0164/-0545/-0846 Tel. 42-869398
Fax 33-223-0830 Tx. 44914
Fax 42-305291
Flender Macneill Gears Ltd.
Southern Region Office
41, Nelson Manickam Road PHILLIPPINE
Aminjikarai OTEC Material Handing Inc. Z :
Chennai - 600029 P.O. Box 2199
Tel. 44-4810476/4810478/4810479 Equitable Bank Bldg. Room 401
Fax 44-4810473 Corner Paseo de Roscas Sen Gil. 406
Puyut Ave.
New Dehli Makati 3117, Metro Manila
Tel. 11-6250104 Phillippines
Fax 11-6250221 Tel. 2-878551
Fax 2-8187158
Bombay
Tel. 22-7657227
Fax 22-7657228 TAIWAN
A. Fried. Flender AG
Taiwan Branch J:
INDONESIA No. 5, Alley 17, Lane 194, HuanHo St.,
P. T. Guna Elektro FZ: Hsichih, Taipei Hsien, Taiwan, R. O. C.
Jl. Terusan Arjuna 50 Tel. 02-26932441-3
Jakarta Barat 11510 Fax 02-26943611
P.O. Box 2280, Jakarta 10022
Tel. 0062-21-5655010
Fax 0062-21-5655030 THAILAND
Smith Technology Co. Ltd. Z :
128/75 Phyathai Plaza Building
JAPAN 7th. Fl., Phyathai Road
Flender Ishibashi MFG. Co. Ltd. J Rajthevee
(Nogata Industrial Park)4636-15 Bangkok 10400
Oaza Kamitonno Tel. 02-2165831/3
Nogata-Shi, Fukuoka-ken Fax 02-2165799
822 Japan
Tel. 09492-6-3711
Fax 09492-6-3902
Sales and Stock
Z Distributer
: Assembly Centre
Page 46 of 47 BA S295 EN 06.97

12. Declaration by the manufacturer
Declaration by the manufacturer

as defined by EC machinery directive 89/392/EEC Annex II B
We hereby declare that the
Gear units and gear motors of types
S 01
S 06, S 11
C 10
C... 21 - C... 122
described in these operating instructions are meant for being installed in a machine and
that their putting into operation is prohibited until it has been ascertained that the
machine, in which these components will be installed, corresponds to the regulations of
the EC directive 89/392/EEC (original version) incl. all further amendments.
All the harmonised standards published by the EC-Commission in the official journal of
the European Community applicable for our products are either totally or partly observed
with this manufacturers declaration.
These are especially:
EN 292-1 EN 294 EN 60204-1
EN 292-2 EN 349
Tübingen, the 30.05.1997

(Manager of Standards Department)
BA S295 EN 06.97 Page 47 of 47

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Operating Instructions

Worm gear units

FLENDER-HIMMELWERK GmbH, Bahnhofstr., D-72072 Tübingen

4. Incoming goods, handling and storage 16

Page 2 of 47 BA S295 EN 06.97

9. Disturbances, reasons and remedy 35

10. Maintenance and repair 37

11. Spare parts stock, service addresses 42

12. Declaration by the manufacturer 47

BA S295 EN 06.97 Page 3 of 47

Postfach 1709 , D-72007 Tübingen

Bahnhofstr. , D-72072 Tübingen

Page 4 of 47 BA S295 EN 06.97

2.1 Safety notes

2.1.1 Notes and symbols in the Operating Instructions

BA S295 EN 06.97 Page 5 of 47

3.1 General technical data

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

Page 6 of 47 BA S295 EN 06.97

Marking: Oil level

Oil drain plug

3.2.1 Gear units and gear motors S. 01

Execution “A” resp. “B” is the position for the shaft.

BA S295 EN 06.97 Page 7 of 47

Foot mounted B3-00 Foot mounted B8-00 Foot mounted B3-01

Foot mounted B6-00 Foot mounted V5-00 Foot mounted V6-00

Foot mounted B6-01 Foot mounted B6-03 Foot mounted B3-01

Foot mounted B8-01 Foot mounted V5-01 Foot mounted V6-01

Execution “A” resp. “B” is the position for the shaft.

Page 8 of 47 BA S295 EN 06.97

Execution “A” resp. “B” is the position for the shaft.

BA S295 EN 06.97 Page 9 of 47

Flange mounted B5-01 Flange mounted B5-03 Flange mounted B5-02

Flange mounted B5-00 Flange mounted V1-00 Flange mounted V3-00

Page 10 of 47 BA S295 EN 06.97

horizontal operating position vertical operating position

Type Mounting position

3.3.2 Type S. 06, S. 11

BA S295 EN 06.97 Page 11 of 47

Type Mounting position

3.3.4 Type C 21 - C 122, C. 21 - C. 122

Type Mounting position

Page 12 of 47 BA S295 EN 06.97

BA S295 EN 06.97 Page 13 of 47

Page 14 of 47 BA S295 EN 06.97

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

0.2 0.5 1 2 5 10 20 50 100 160

General guidelines concerning the influence of noise on people should be

BA S295 EN 06.97 Page 15 of 47

Damaged drives must not be put into operation.

The permissible attaching weight is to be observed:

Use additional suitable lifting devices (ropes or similar) for transport or

Transport fixtures, if present, should be removed and stored or be made

Page 16 of 47 BA S295 EN 06.97

The storage area must be free of vibrations (shocks) as otherwise the

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

BA S295 EN 06.97 Page 17 of 47

5.1 General description

5.3 Toothed components

5.6 Shaft seals

Couplings with peripheral speeds at the outside diameter up to 30 m/s must

Page 18 of 47 BA S295 EN 06.97

To prevent damage to or destruction of the backstop, it is essential to ensure

Paint Typical area Overpaint- Chem. phys. Temperature Remark