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FLENDER-GRAFFENSTADEN

P.O. BOX N° 84 - 67402 ILLKIRCH GRAFFENSTADEN CEDEX

TELEPHONE : +33 (0) 3 88.67.60.84.
FAX : +33 (0) 3 88.67.60.85.
E - MAIL : Flensav@flender-graff.com

OPERATING AND MAINTENANCE INSTRUCTIONS

GEARBOX WITH PARALLEL SHAFTS

TX80/3C
SPECIFICATION:RRO3710421

CUSTOMER REFERENCES :
NAME : NUOVO PIGNONE
ORDER N° : 439638946
JOB NAME : Frame 5 - 50Hz – IRAQ

F.G. REFERENCES :
OL N° : 4539506/20
FILE N° : 33769
MACHINE N° : 10911

A 09/10 FIRST ISSUE P.LOOS C.ZAEPFEL

Révision Date Revisions Written by Checked by Quality

assurance

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! guarantee.
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FLENDER-GRAFFENSTADEN

CONTENTS

1. TECHNICAL DESCRIPTION OF THE GEARBOX ........................................................................3

1.1. CASING ...........................................................................................................................................3
1.1.1. Lower casing .............................................................................................................................3
1.1.2. Upper casing..............................................................................................................................3
1.2. GEAR SET .......................................................................................................................................3
1.2.1. Toothing.....................................................................................................................................3
1.2.2. Material .....................................................................................................................................3
1.2.3. Oil seals......................................................................................................................................3
1.3. RADIAL BEARINGS......................................................................................................................3
1.4. THRUST BEARINGS .....................................................................................................................3
1.5. LUBRICATION...............................................................................................................................4
1.6. INSTRUMENTATION ...................................................................................................................4
2. PROTECTION - SHIPMENT.............................................................................................................4
2.1. STORAGE........................................................................................................................................4
3. INSTALLATION ON SITE...................................................................................................................4
3.1. FOUNDATIONS..............................................................................................................................4
3.2. ALIGNMENT ..................................................................................................................................5
3.3. HANDLING .....................................................................................................................................5
3.4. LEVELLING ...................................................................................................................................5
3.5. TOOTH CONTACT PATTERN....................................................................................................5
4. ASSEMBLY & DISMANTLING OF THE GEARBOX .....................................................................5
4.1. DISMANTLING ..............................................................................................................................5
4.2. ASSEMBLY .....................................................................................................................................6
5. OPERATION ..........................................................................................................................................6
5.1. OIL SYSTEM PREPARATION AND FLUSHING .....................................................................6
5.2. STARTUP ........................................................................................................................................6
5.3. CONTROL .......................................................................................................................................6
5.3.1. Oil pressure ...............................................................................................................................6
5.3.2. Temperatures ............................................................................................................................6
5.3.2.1. Oil outlet temperature .......................................................................................................6
5.3.2.2. Bearing temperatures ........................................................................................................6
5.3.3. Vibration amplitude .................................................................................................................6
5.4. SPECIFIC RECOMMANDATIONS.............................................................................................6
5.5. SHUTDOWN ...................................................................................................................................6
5.6. RESTART OF THE GEARBOX ...................................................................................................7
5.7. OPERATING INSTRUCTIONS IN CASE OF ANOMALIES...................................................7
5.7.1. Oil pressure fault ......................................................................................................................7
5.7.2. Temperature faults ...................................................................................................................7
5.7.3. Increase in vibration or noise level..........................................................................................7
6. MAINTENANCE AND SERVICING ON GEARBOX ......................................................................7
6.1. GÉNÉRAL .......................................................................................................................................7
6.2. EXTERNAL PARAMETERS TO BE MONITORED.................................................................8
6.2.1. Oil...............................................................................................................................................8
6.2.2. Stability of foundations/attachments.......................................................................................8
6.2.3. Vibrations ..................................................................................................................................8
6.2.4. Bearing temperatures ...............................................................................................................8
7. SPARE PARTS .......................................................................................................................................8
8. CORRESPONDENCE ...........................................................................................................................8
9. APPENDICES.........................................................................................................................................8

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FLENDER-GRAFFENSTADEN

1. TECHNICAL DESCRIPTION OF THE 1.2.2. Material

GEARBOX
The pinion and the wheel are of case-hardened alloy
steel. The gear teeth are surface hardened by case-
The gearbox is a speed reducer. hardening followed by tempering to obtain the
See data sheet in Appendix 01 required hardness to transmit the load.
Pinion shaft and wheel are forged.
1.1. CASING
The wheel shaft can be hollow to allow the passing of
The casing is made of welded steel plates. It is a quill shaft.
designed to keep rotating parts as well as journal and
thrust bearings in their correct positions under each 1.2.3. Oil seals
and every possible load situation. A stabilisation heat
treatment is done to reduce residual stresses. Oil tightness of shafts is obtained with two-parts
labyrinth seals in aluminium or bronze. The radial
A horizontal joint is separating the two parts of the clearance is determined according to bearing
casing. clearance.
1.1.1. Lower casing 1.3. RADIAL BEARINGS

 The lower casing is fitted on an base frame or
mounting base plate.
 It includes oil inlet and outlet flanges and also the
oil collector.
 Unit slinging and handling will be done with lifting
hooks fitted to the lower casing.
1.1.2. Upper casing
 The upper casing acts as bearing caps by
maintaining the high speed and the low speed
shaft line bearings.
 It has a visiting door wich can eventually have a
filter breather.
The following auxiliaries can be fixed to the casing :
Each shaft is fitted with two bearings. The radial
bearings are of the hydrodynamic type, and are
designed to guarantee satisfactory running. The
bearings are in two parts and made of steel with
antifriction coating. They can be dismounted easily.
Profile choice is done according to running conditions.
Possible types are OFFSET, 4 LOBES, LEMON,
CYLINDRICAL or TILTING PADS.
See modelisation drawing in Appendix 08.
The bearings are positioned in the casing with an anti-
rotation pin. The majority of our gearboxes are
equipped with an adjustable bearing to optimize the
tooth contact. This operation has to be carried out by
FLENDER GRAFFENSTADEN personnel.
1.4. THRUST BEARINGS

 turning gear, driven pump, LS and HS coupling
cover, measurement and control instrumentation.
1.2. GEAR SET
1.2.1. Toothing
The tooth profile is of the single or double helical type,
with tip and root relieve to optimize mesh conditions
and a supplementary tooth correction to optimise
tooth contact pattern under load.
When thrust bearings are needed, they are
dimensioned to support the axial thrust from the
toothing as well as external thrusts from the couplings.
Two types are being used : TAPERED LANDS or
TILTING PADS.
See modelisation drawing in Appendix 08.

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FLENDER-GRAFFENSTADEN

1.5. LUBRICATION 2.1. STORAGE

The unit is lubricated by forced oil circulation.
The bearings are lubricated by internal bores between
the bearing and the main collector.
The teeth are lubricated with calibrated nozzles.
When orifices are used, these must be correctly
marked before being removed.
The oil flow to the tank must be as direct as possible
with a slope greater than 5°. The diameter of the drain
pipe must be at least equal to the opening designed in
the casing.
The oil in use has to be conforme to the OIL
! TABLE in Appendix 04.
Short term storage : for 1 to 2 Medium term storage :
months at the most : 6 months :
The unit is delivered on a The machine will be
simple wood frame without delivered in a seal
packaging. watertight cover.
For a long term storage (after 6 months) :
! Contact FLENDER-GRAFFENSTADEN for
more informations.
The machine should be stored in a dry room
! without any large temperature variation.
FLENDER-GRAFFENSTADEN declines any

1.6. INSTRUMENTATION
! liability for the consequences of inadequate
storage if storage rules given here-above are
not respected.
For this chapter, please refer to the outline drawing
and wiring diagram in Appendix 08.

2. PROTECTION - SHIPMENT 3. INSTALLATION ON SITE

During reassembly after works testing, all internal

machined parts are given a coat of « Castrol SAFECOAT
DW 33 or similar ». Orifices are plugged or covered.
External machined parts are given a coat of
« MOLYDAL MULTI TP or similar » and shaft ends
are protected against physical damages.
For shipment, sprags or shipping clamps
provided to lock the rotating parts.
See diagram n° 01 in Appendix 02.
On reaching the final destination, the unit shall be
carefully inspected to detect any damage caused by
transportation. The internal protection oil applied in
the factory before dispatch must be kept until start up,
and will be eliminated by lube oil flow.
These operations are not included in the
! services provided by the gearbox
manufacturer.
3.1. FOUNDATIONS
are
The foundations must be built and calculated with
appropriate stiffness and damping to prevent
resonance phenomena. Take into consideration
gearbox data as given on the outline drawing. See
Appendix 08.
The base plate of the unit is machined flat and parallel
to the shafts. Any deformation in the casing due to
tightening will affect the teeth contact pattern.
It is useful to introduce shims 10 to 20 mm thick
between the foundations and the base plate of the unit
to facilitate any misalignment correction that may
prove necessary.

! Non compliance with the OPERATING AND MAINTENANCE INSTRUCTIONS, will lead to cancellation of our
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 ASSURANCE
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FLENDER-GRAFFENSTADEN
3.2. ALIGNMENT
 Remove transport protections, sprags and shipping
clamps before startup.
 If LS shaft is equipped with a quillshaft, leave
centering wedges in place during alignment.
Remove these parts before startup. Insert
! centering wedges again before handling LS
shaft.
 If the installation is to operate satisfactorily in
service, the different machines must be strictly
aligned according to the values given by FG.
Faulty alignment will lead to increased vibration
and noise levels on the gearbox and on the whole
shaft line. The best possible allowance must be
made for thermal expansion of the casing and
movement of the shafts in the bearings. The
design shaft positions for operation under full load
are indicated on the outline drawing Appendix
08.
 These positions are given as an illustration, and
serve to define the alignment criteria of the
different machines. To optimize performance, it is
recommended that alignment should be verified
with the machines "hot".
During alignment take into consideration §
! 3.4. LEVELLING.
3.3. HANDLING
Use slinging hooks provided on the lower casing,
never attach to any other location such as pipework,
components, etc...
See Appendix 06.
3.4. LEVELLING
The following operations have to be executed
! by qualified personnel.
 Levelling of the gearbox is done to obtain a correct
tooth contact pattern. The gearbox has to be
levelled within an admitted tolerance of  0.02
mm
/m. Use a precision bubble level on both sides of
the gearbox. See diagram n° 02 in Appendix 02.
 It is not necessary to remove upper casing during
levelling.
! Non compliance with the OPERATING AND MAINTENANCE INSTRUCTIONS, will lead to cancellation of our
guarantee.
Page : 5
 Control surfaces must be clean and without rust.
 If the surfaces are not clean or are damaged,
please contact FLENDER-GRAFFENSTADEN.
After each tooth contact control it is
! necessary to check the leveling.
3.5. TOOTH CONTACT PATTERN
After levelling and alignment but before coupling,
make a first tooth contact pattern check.
Open inspection door, and apply prussian blue to a
few teeth of the gearwheel. Turn a few times and slow
down pinion at the same time.
The obtained tooth contact pattern must be conform
with Appendix 08.
A control of tooth contact pattern after 1-2 hours of
running, under full load must be performed. Apply
« DYKEN RED »varnish to a few teeth of the pinion
(« DYKEN RED » can be obtained from FLENDER-
FRAFFENSTADEN customer support department).
Clean tooth flanks with a solvent before applying
« DYKEN RED » varnish. This method must reveal a
contact pattern along the whole length of the tooth.
4. ASSEMBLY & DISMANTLING OF
THE GEARBOX
During the warranty period, dismantling of
! the gearbox requires FLENDER-
GRAFFENSTADEN approval.
4.1. DISMANTLING
1. Remove all accessories.
2. Remove upper casing.
3. Remove probes and pipework.
4. Remove upper half-bearings.
5. Sling the shaft and lift it while maintaining it
horizontal, the lower half-bearings must remain in
the casing.
6. Protect probe tracks using adhesive paper or
equivalente.
7. Remove the lower half-bearings.
 ASSURANCE
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FLENDER-GRAFFENSTADEN

4.2. ASSEMBLY 5.3. CONTROL

1. The bearings have to be lubricated with clean oil. 5.3.1. Oil pressure
2. Two half bearings and their place in the casing Pressure switch adjustment must be conform to the
must have the same reference. values given in Appendix 03.
3. For thrust bearings, load faces of half bearings
must point in the same section. 5.3.2. Temperatures
4. When lowering a shaft into a thrust bearing, keep 5.3.2.1. Oil outlet temperature
shaft horizontal to avoid damage to thrust surface.
5. Install instrumentation and piping. If thermostats are installed on oil drain, they must be
setted as follows :
6. Internal screws and bots have to be locked.
 alarm at 10°C above normal full load temperature,
7. Tighten nuts on the gearbox with the tightening
torque indicated on the Assembly drawing in  shutdown at 5°C above alarm temperature.
Appendix 08.
5.3.2.2. Bearing temperatures
8. If one or more bearings were replaced you have to
recheck the tooth contact pattern. Defined temperature limits must not be exceeded to
After assembly and dismantling refer to § 3 protect white metal in the bearing. You have to
respect the temperature setting points given in
! INSTALATION ON SITE.
Appendix 03.

5. OPERATION 5.3.3. Vibration amplitude

5.1. OIL SYSTEM PREPARATION AND Shaft vibration - allowable limits

FLUSHING
Before startup, start the auxiliary oil pump. As soon as
the oil circulation is established the oil filter must be
cleaned frequently until it is completely clean. Since
the bearings and the teeth are connected to the same
circuit, it is recommend to provisionally place a metal
screen with 0.05 mm mesh at the input to the
collector on our unit. This precaution will avoid serious
incidents in the bearings due to foreign particles
coming from the pipes and carried by the oil.
! The metal screen must be removed as soon
as oil circuit flushing is finished.
5.2. STARTUP
Before starting rotations, lube oil pressure and
temperature must have reached minimum levels.
See tables in Appendix 03.
5.4. SPECIFIC RECOMMANDATIONS
In case of incident on site, repeat all
! controls mentioned in this manual.
 Degradation of lubrication oil : oil in service
deteriorates depending on many factors.
Laboratory analyses must be carried out
approximately every 2500 to 3000 hours.
 Check if oil is conform with § 6.2. EXTERNAL
PARAMETERS TO BE MONITORED.
 Extended shutdown : If a unit is stopped for a
longer period, we recommend that the lubrication
circuit be operated approximately once a week for
one hour. During this operation we recommend
that the shafts to rotate from time to time.

5.5. SHUTDOWN

There are no special instructions for shutdown. The

lubrication system must be operational until the unit is
completely stopped.

! Non compliance with the OPERATING AND MAINTENANCE INSTRUCTIONS, will lead to cancellation of our
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 ASSURANCE
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FLENDER-GRAFFENSTADEN
5.6. RESTART OF THE GEARBOX
Generally speaking the gearbox can be started up
immediatly after shut down. Respect startup
informations described § 5.2. STARTUP.
5.7. OPERATING INSTRUCTIONS IN CASE OF
ANOMALIES
The pressure, temperature and vibration
! should be recorded at all measurement
points. If these records are not available,
no warranty demands can be brought
against F-G.
Instructions to be followed on appearance of
alarm :
5.7.1. Oil pressure fault
If the pressure does not rise again and falls below the
shutdown pressure for more than 3 seconds the
installation must be stopped automatically. However,
the unit may operate temporarily when temperatures
are very closely monitored. See Appendix 03.
Possible causes :
 Oil level,
 Filter or cooler dirty,
 Incorrect pressure setting,
 Leak,
 Bearing wear,
 Oil quality.
If the nominal pressure cannot be reached, stop the
installation and lock for the reasons of the incident.
5.7.2. Temperature faults
If oil outlet temperature increases above the values
given in § 5.3.2.1. OIL OUTLET TEMPERATURE, the unit
may operate during a short time under constant
surveillance of bearing temperatures.
If there is a high temperature alarm it is necessary to
find out whether this is due to an individual fault
(bearing or thrust bearing) or to a general rise at all
the monitored points.
! Non compliance with the OPERATING AND MAINTENANCE INSTRUCTIONS, will lead to cancellation of our
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Page : 7
 individual rise : monitor the temperature rise
closely. If it stabilizes or returns to normal, the unit
can continue operating.
 general rise : check the oil pressure and
temperature. Check that the heat exchanger is
operating properly.
If no fault is found and if one or more temperatures
are near the shutdown value, the installation must be
stopped in time to avoid serious damage to the unit.
5.7.3. Increase in vibration or noise level
The main causes of variations in the vibration or noise
level are the following :
 misalignment,
 wear (bearing or thrust bearing),
 meshing fault,
 loose attached element (protective cover, etc...).
In all cases the origin of the change in noise or
vibration level must be found and eliminated as soon
as possible.
In case of warm startup a thermal unbalance can lead
to increased shaft vibrations. They will disappear once
the gearbox has reached nominal speed.
6. MAINTENANCE AND SERVICING ON
GEARBOX
6.1. GÉNÉRAL
The purpose is to describe the frequency and
operations necessary for correct maintenance of our
machines.
See maintenance table in Appendix 07.
There is also a table that describes the means to be
used to carry out these operations.
Finally, the causes of the most frequent incidents due
to “auxiliary equipment” are described.
Obviously, these are minimum recommendations.
Verifications should be made between programmed
maintenance work and after any incident that could
create abnormal operating conditions and/or any drift
in vibration and temperature measurements.
 ASSURANCE
OF QUALITY OPERATING AND MAINTENANCE INSTRUCTIONS Page : 8

FLENDER-GRAFFENSTADEN

6.2. EXTERNAL PARAMETERS TO BE 7. SPARE PARTS

MONITORED
When ordering spare parts, please indicate the
In order to optimize machine lifetime it is necessary to
following :
monitor the following parameters :
1. unit type and number,
6.2.1. Oil 2. the number of parts, their quantity, reference
number and designation,
1. flow,
3. the drawing number, if necessary.
2. temperature (inlet and outlet),
See spare parts list in APPENDIX 05.
3. pressure,
4. filtration,  Level 1 priority: * * Level 2 priority: *
5. « FZG » level (must be greater than 7, unless
mentioned otherwise),
8. CORRESPONDENCE
6. water content maxi. 50 ppm,
FLENDER-GRAFFENSTADEN BP 84
7. acidity,
67402
8. metal particles content.
ILLKIRCH GRAFFENSTADEN
6.2.2. Stability of foundations/attachments
 : +33 (0) 3 88 67 60 00
In particular, check that the casing is not twisted (joint
plane geometry).
Spare parts Technical support
6.2.3. Vibrations  : +33 (0) 3 88 67 60 19  : +33 (0) 3 88 67 60 31
FAX : +33 (0) 3 88 67 61 40 FAX : +33 (0) 3 88 67 60 85
In accordance with the limiting values specified in
instructions. See Appendix 03. E-mail : Flensav@flender-graff.com

6.2.4. Bearing temperatures

In accordance with values specified in the instructions.

See Appendix 03.

9. APPENDICES

A01 Machine characteristics data sheet

A02 Position of blocking parts & planeness of the joint plane
A03 Set values
A04 Oils table
A05 Spare parts list
A06 Technical instructions for accessories
A07 Maintenance table
A08 List of drawings

! Non compliance with the OPERATING AND MAINTENANCE INSTRUCTIONS, will lead to cancellation of our
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 GUIDE D’EXPLOITATION ET D’ENTRETIEN
ASSURANCE
DE LA QUALITE OPERATING AND MAINTENANCE INSTRUCTIONS A 01
BETRIEBS UND WARTUNGSVORSCHRIFTEN
FLENDER-GRAFFENSTADEN

FICHE CARACTERISTIQUE DE LA MACHINE

MACHINE KENNZEICHEN
GEAR DATA

CARACTERISTIQUES BETRIEBSDATEN GEAR DATA

Puissance de calcul Auslegeleistung Gear rated power : 31500 kW

Facteur de service Betriebs faktor Service factor : API 613/95>1.3
Vitesse PV Nenndrehzahl LW Rated speed LS : 5108 RPM
Vitesse GV Nenndrehzahl SW Rated speed HS : 1500 RPM
Rapport de vitesse Uebersetzungsverhaeltnis Speed ratio : 3.41

CONSTRUCTION KONSTRUKTIONSDATEN CONSTRUCTION FEATURES

Entraxe Achsabstand Centerlines distance : 800 mm

Masse totale Gesamtgewicht Total weight : 13400 kg
Masse carter supérieur Gehäuseoberteilgewicht Upper casing weight : 1540 kg
Masse carter inférieur Gehäuseunterteilgewicht Lower casing weight : 5120.5 kg
Masse mobile GV Gewicht Schnelldrehende Welle High speed shaft weight : 768.5 kg
Masse mobile PV Gewicht Langsamdrehende Welle Low speed shaft weight : 6361.7 kg

LUBRIFICATION SCHMIERUNG LUBRIFICATION

Huile, nature et viscosité Oelviskositaet Lube oil designation : 32 ISO VG

Filtration Filtrierung Filtering : 25 µm
Pression d’entrée Eintrittsdruck Inlet pressure : 1.72 bar act.
Température d’entrée nominale Normale Eintrittstemperatur Normal oil inlet temp. : 55 °C
Température d’entrée maximale Maximale Eintrittstemperatur Maximal oil inlet temp. : 79 °C
Débit Oelbedarf Oil flow : 490 l/mm
Quantité de chaleur à évacuer Abzufuehrende Waermemenge Calories to evacuate : 340 kW
 ASSURANCE
DE LA QUALITE OPERATING AND MAINTENANCE INSTRUCTIONS A 02
FLENDER-GRAFFENSTADEN

SKETCH N° 01 :

BOLT
SECONDARY MODEL
WITH PLATE
STEEL PLATE

SHAFT END

POSITION OF BLOCKING PARTS

SKETCH N° 02 :

PRECISION BUBBLE LEVEL ON STRAIGHT -

EDGE
0 02 t

CHECK PLANENESS OF THE JOINT PLANE

 ASSURANCE
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FLENDER-GRAFFENSTADEN

VALUES OF MONITORING AND PROTECTION SETPOINTS IN OPERATION

SHAFT VIBRATION [PTP µm]

Shaft line Alarm Shut down

LS 92 137
HS 72 107

During start-up, gears can exhibit a transient spike reading of vibration levels that will
exceed shut down settings. Therefore a Trip Multiplier is recommended in the control
system.

SHAFTS DISPLACEMENT (AXIAL) [mm]

Shaft line Alarm Shut down

LS ± ±
HS ± 0,40 ± 0,45

HOUSING VIBRATION (sensor in radial position)

Alarm Shut down

Overall value in mm/s RMS in
the frequency range 10 to 2500 7 11
Hz

Alarm Shut down

Overall value in g peak in the Acceleration not used
for protection shut
frequency range 2500 to 10000 18 down.
Hz (API670/4th§5.4.5.1)

OIL PRESSURE at gearbox inlet flange [bar]

Normal Alarm Shut down

1,7 1,2 0,9

JOURNAL BEARING AND THRUST BEARING TEMPERATURE

Measurement using rigid removable sensors Measurement using flexible sensors

Stabilization temperature +10°C Stabilization temperature +10°C
Alarm: Maximum 105°C Alarm: Maximum 125°C

Stabilization temperature +20°C Stabilization temperature +20°C

Shut down: Maximum 115°C Shut down: Maximum 130°C

OIL INLET TEMPERATURES [°C]

Minimum inlet temperature before start-up: 20

Nominal inlet temperature range: 55 to 72
Alarm: 72
Shut down: 79
 ASSURANCE
DE LA QUALITE
OPERATING AND MAINTENANCE INSTRUCTIONS A 04
FLENDER-GRAFFENSTADEN

LUBRICATING OIL RECOMMENDATIONS

Mineral oil : classification TSE and TGE (of ISO 6743-5)

Method Caractristics
Test

ISO VG ISO 3448 32 46

Viscosity Index ISO 2909 min. 95
Viscosity cST 100 °C ISO 3104 min. 5,1 min. 6,5
Flash point, °C ISO 2592 min. 210 min. 220
Pour point, °C ISO 3016 -10
Air release at 50 °C, minute DIN 51381 4 max.
Demulsibility at 54 °C, minute ISO 6614 40 / 40 / 0
Foam Seq I, ml/ml ISO 6247 10 / 0 max.
FZG damage load stage* DIN 51354 / 2 max. 5
RBOT, minute ASTM D2272 min. 450 *
Tost, h to IA=2 ISO7624 min. 4000
Acidity, TAN, mgKOH/g ISO 6618 0.2 max.

OPERATING CARACTERISTICS

Water content, ppm oil inlet max. 50

Min. temperature supply, °C oil inlet 20
Filtration BETA for 25 µm oil inlet (ISO 4572) min. 200
Normal supply temperature for
oil inlet 45 to 55 50 to 60
continuous operation °C

* : See 6.2.1. for special requirement.

 ASSURANCE
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A 05
SPARE PARTS LIST IRRO371042001-2101-2201-2301
FLENDER-GRAFFENSTADEN
Assembly drawing : 02R719-0
Outline drawing : 02M867-0
Spare parts
ITEM Number GEARING Type Drawing or Norm
DESIGNATION 1** 2*

A102 1 WHEEL SHAFT 04AB983-1 **

A104 1 WHEEL 04AB984-2 **

A105 1 WHEEL 04AB985-2 **

A130 1 QUILL SHAFT 04AB908-1 **

A200 1 PINION 04AB986-1 **

 ASSURANCE
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SPARE PARTS LIST IRRO371042002-2102-2202-2302
R-GRAFFENSTADEN

Spare parts
ITEM Number BEARINGS & THRUSTS BEARINGS Type Drawing or Norm
DESIGNATION 1** 2*

B110 1 BEARING EP 380 CY 190 RROO 05 F 887 - 3 **

B120 1 BEARING EP 380 CY 190 RROO 05 F 887 - 3 **

B210 1 TILTING PADS BEARING ASSEMBLY DN230 02 D 548 - 2 **

B220 1 BEARING EP 230 OF 230 RROO 05 F 448 - 3 **

B250 1 THRUST BEARING M8159 02 R 669 - 4 **

 ASSURANCE
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SPARE PARTS LIST IRRO371042003-2103-2203-2303
R-GRAFFENSTADEN

Spare parts
ITEM Number OIL SEAL Type Drawing or Norm
DESIGNATION 1** 2*

K110 1 OIL SEAL 03AG813-3 *

K210 1 OIL SEAL 03AG814-3 *

 ASSURANCE
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SPARE PARTS LIST
R-GRAFFENSTADEN

Spare parts
ITEM Number INSTRUMENTATION Type Drawing or Norm
DESIGNATION 1** 2*

L111 2 TEMPERATURE RTD'S PT100 DULEX 2x3 WIRES 08T111/05 **

L121 2 TEMPERATURE RTD'S PT100 DULEX 2x3 WIRES 08T111/05 **

L213 2 TEMPERATURE RTD'S PT100 DULEX 2x3 WIRES 08T111/05 **

L223 2 TEMPERATURE RTD'S PT100 DULEX 2x3 WIRES 08T111/05 **

L151 2 TEMPERATURE RTD'S PT100 DULEX 2x3 WIRES 08T165/12 **

L161 2 TEMPERATURE RTD'S PT100 DULEX 2x3 WIRES 08T165/12 **

L112 1 RADIAL VIBRATION PROBE *3301050212050205 **

L113 1 RADIAL VIBRATION PROBE *3301050212050205 **

L122 1 RADIAL VIBRATION PROBE *3301050212050205 **

L123 1 RADIAL VIBRATION PROBE *3301050212050205 **

L214 1 RADIAL VIBRATION PROBE *3301050212050205 **

L217 1 RADIAL VIBRATION PROBE *3301050212050205

L224 1 RADIAL VIBRATION PROBE *3301050212050205 **

L227 1 RADIAL VIBRATION PROBE *3301050212050205 **

L270/1 1 AXIAL VIBRATION PROBE *3301050212050205 **

L270/2 1 AXIAL VIBRATION PROBE *3301050212050205 **

L180 1 KEYPHASOR *3301050212050205 **

L480 11 PROXIMITOR *3301805105 **

L485 11 EXTENTION CABLE *3301300450005 **

L295 1 SEISMIC PROBE *3304000105 **

L295/1 1 EXTENTION CABLE *130539-15 **

 ASSURANCE
OPERATING AND MAINTENANCE INSTRUCTIONS
DE LA QUALITE A 07
MAINTENANCE BOARD
FLENDER-GRAFFENSTADEN

Operations to be done before : years 1 2 3 4 5 6 7 8 9 10

HOURS 200 8000 16000 24000 32000 40000 48000 56000 64000 72000 80000
Bearings (See also note A)
Visual inspection
Wear measurement
Dye penetration if necessary
Replace if : max clearance is reached
or there are any cracks
Toothing (See also note B)
Visual inspection (throuth the trap door)
Check the contact surface by checking
the ''Dyken red'' varnish
Mesure the backlash and check
the contact with methylene blue
Dye penetration or magnetic particle inspection
Replace if : wear to severe
presence of cracks
pitting, ect...
Seal
Visual inspection
Mesure clearance between shaft/oil seal
Replace if : too much clearance
presence of leaks
after installation of
new bearing shells
Coupling / Quill shaft
Dismantling, cleaning
Visual check : teeth for toothing coupling
spline for quill shaft / sleeve coupling
Replace if : severe wear marks
excessive clearance
breakage and / or deterioration
of toothing profiles
Casing
New compound on joint plane
Internal cleanliness check
Check of internal pipework
Levelling
Alignment
Inspection and any necessary modification
Aucillary equipment
Such as pumps, turning gear, clutchs etc...
in accordance with the specific See Appendix 06
instructions included in our manual
Note A : Bearing. In case clearance of bearings exceed maxi recommended 30%, it is absolutely necessary to
mount a set of spare bearings. Replacement of bearing may also be necessary in case
presence of inlet lubrication oil cannot be maintained. LS and HS thrust bearing pads have
to be replaces as soon as half of active area is tarnished.
Note B : Toothing. Control of tooth contact has be carried regulary through visiting door. Unilateral tooth
contact means that foundation gave way. Such a tooth contact is highly detrimental to good
quality of toothing especially in case of turbomachines which are therefore it is important to
identify the cause and find remedy for it at very short time.
 GUIDE D’EXPLOITATION ET D’ENTRETIEN
ASSURANCE OPERATING AND MAINTENANCE INSTRUCTIONS
DE LA QUALITE
BETRIEBS UND WARTUNGSVORSCHRIFTEN A 08
FLENDER-GRAFFENSTADEN
LIBRETTO D’USO E MANUTENZIONE
MANUAL DE USO Y DE MANTENIMIENTO

RECAPITULATIF DES PLANS / LIST OF DRAWINGS

LISTE DER ZEICHNUNGEN / RECAPITULACION DE LOS PLANOS / REPLOGIO DI PLANI

Plan d’assemblage
Assembly drawing
Montagezeichnung N° 02R719-0
Plano de ensamblaje
Piano d’assemblaggio
Plan d’encombrement + caractéristiques
Outline drawing + characteristics
N° 02M867-0
Einbauzeichnung + Technische Angaben
Plano di dimensiones + caracteristicas
Piano d’ingombrio + caratteristiche
Schéma de sortie de câble : Température
Wiring diagram : Temperature
Verkabelungsschema : Temperatur N° 27D894-3
Esquema de montaje del cable : Temperatura
Schema di uscita di cavo : Temperatura
Shéma de montage / câblage : Vibration
Wiring diagram : Vibration
Verkabelungsschema : Schwingung N° 27D895-3
Esquema de montaje / cableado : Vibracion
Schema di montaggio / cablaggio : Vibrazione
Portée dentures
Tooth contact pattern
Verzahnungstragbild N° 04AB981-4
Asiento de los dentados
Portata dentura