KPAV125

Installation, Operation and
Maintenance Manual
(Pulverizer GearBox-
GearBox-KPAV 125
125)
25)
Preface ............................................................................................................................................ I
0 Identification ........................................................................................................... 0.1

0.1 Manufacturer ............................................................................................................. 0.1
0.2 Product Identification ................................................................................................. 0.1
0.3 Operating Instructions ................................................................................................ 0.4
0.4 Personnel .................................................................................................................. 0.7
0.5 Conformity ................................................................................................................. 0.7
1 Intended Use, Warranty, Safety Information ........................................................ 1.1

1.1 Appropriate Use ......................................................................................................... 1.2
1.2 Warranty and Liability ................................................................................................ 1.4
1.2.1 Terms and Conditions of Warranty ................................................................. 1.4
1.2.2 Service 1.5
1.3 Information on Transport............................................................................................ 1.5
1.4 Information for the Distribution Company of the overall Plant ..................................... 1.6
1.5 Obligation of the Owner/Operator .............................................................................. 1.8
1.6 Personnel Training ..................................................................................................... 1.9
1.7 Information concerning Operation ............................................................................ 1.10
1.8 Notes for the Operator ............................................................................................. 1.11
1.9 Information concerning Service Jobs ....................................................................... 1.10
1.10 Obligation of the Personnel ...................................................................................... 1.14
1.11 Residual Risks caused by incorrect Behaviour of the Personnel .............................. 1.14
1.12 Qualification of the Personnel .................................................................................. 1.15
1.13 Areas to be occupied by Personnel.......................................................................... 1.15
1.14 Personal Protective Equipment ................................................................................ 1.15
1.15 Safety Devices ......................................................................................................... 1.16
1.16 Warning Signs on the Gear Unit .............................................................................. 1.17
1.17 Hazards caused by Electric Current ......................................................................... 1.18
1.18 Hazards caused by Operating Media ....................................................................... 1.19
1.19 Disposal and Recycling............................................................................................ 1.21
1.20 Danger Areas of the Gear Unit................................................................................. 1.22
2 Technical Data ........................................................................................................ 2.1

2.1 Performance Data – Main Gear Unit .......................................................................... 2.1
2.1.1 Coupling Main Drive ....................................................................................... 2.1
2.2 Weights ..................................................................................................................... 2.2
2.2.1 Weight - Oil system ........................................................................................ 2.2
2.3 Energy and Media Requirement ................................................................................ 2.3
2.3.1 Oil Main Gear Unit .......................................................................................... 2.3
2.3.2 Electricity - Oil system .................................................................................... 2.3
Translation of the original instructions – Industrial gear unit – KPAV 125 - HKC01090000039 –VRM i
2.3.3 Water - Oil system .......................................................................................... 2.3
2.4 Packing Level ............................................................................................................ 2.4
2.5 Mill ............................................................................................................................. 2.4
2.6 Languages of the Operating Instruction ..................................................................... 2.4
3 Technical Description ............................................................................................ 3.1

3.1 Gear Unit ................................................................................................................... 3.1
3.1.1 Main Components .......................................................................................... 3.1
3.1.2 Functional Description .................................................................................... 3.7
3.1.3 Displays on the Gear Unit ............................................................................... 3.9
3.2 Gear Unit Lubrication: Oil System and Monitoring.................................................... 3.10
3.2.1 Functional Description of the Oil System ...................................................... 3.11
3.2.2 Low-Pressure Lubricating Circuit .................................................................. 3.12
3.2.3 Low-Pressure Lubricating Circuit: Monitoring Devices .................................. 3.15
3.3 Components for the KPAV Gear Unit (Options) ....................................................... 3.18
3.3.1 Main Coupling .............................................................................................. 3.18
4 Packing, Conservation, Transport and Storage .................................................. 4.1

4.1 Packing ...................................................................................................................... 4.1
4.2 Conservation ............................................................................................................. 4.2
4.2.1 Internal Conservation ..................................................................................... 4.2
4.2.2 Long-Term Preservation (Optional) ................................................................ 4.3
4.2.3 External Conservation .................................................................................... 4.4
4.3 Transport ................................................................................................................... 4.5
4.3.1 Transport of the Gear Unit in a Crate.............................................................. 4.5
4.3.2 Transporting the Gear Unit wrapped in Film ................................................... 4.6
4.3.3 Lift Gear Unit .................................................................................................. 4.7
4.3.4 Setting Down the Gear Unit ............................................................................ 4.8
4.4 Storage ...................................................................................................................... 4.9
4.5 Long-Term Preservation (Option) .............................................................................. 4.9
5 Setting Up and Connecting ................................................................................... 5.1

5.1 Foundation................................................................................................................. 5.3
5.2 Accessories ............................................................................................................... 5.3
5.3 Preparing Gear Unit for Installation ............................................................................ 5.4
5.3.1 Unpacking ...................................................................................................... 5.4
5.4 Installation ................................................................................................................. 5.6
5.4.1 Transporting Gear Unit to Set-Up Location ..................................................... 5.6
5.4.2 Aligning Gear Unit .......................................................................................... 5.6
5.4.3 Fastening Gear Unit to Foundation ................................................................. 5.7
5.4.4 Grounding Connection / Potential Equalization ............................................... 5.7
5.4.5 Connecting the Oil System ............................................................................. 5.8
Translation of the original instructions – Industrial gear unit – KPAV 125 - HKC01090000039 –VRM ii
5.4.6 Removing Inside Preservation Oil................................................................... 5.9
5.4.7 Filling Gear Unit with Oil ............................................................................... 5.11
5.4.8 Aligning and Connecting Drive Motor ........................................................... 5.14
5.4.9 Aligning and Installing Grinding Bowl............................................................ 5.17
5.4.10 Connecting Sensors ..................................................................................... 5.18
5.4.11 Setting Up and Connecting Components ...................................................... 5.19
6 Initial Commissioning, Checking and Decommissioning ................................... 6.1

6.1 Restart the Gear Unit ................................................................................................. 6.2
6.2 Service Instruction after Initial Commissioning ........................................................... 6.3
6.3 Operate Gear Unit ..................................................................................................... 6.6
6.4 Shutting Down Gear Unit ........................................................................................... 6.7
6.4.1 Decommissioning up to 6 Months ................................................................... 6.8
6.4.2 Permanent Shutting Down/ Decommissioning ................................................ 6.8
7 Maintenance and Repair ........................................................................................ 7.1

7.1 Safety Information...................................................................................................... 7.2
7.2 Qualification of the Personnel .................................................................................... 7.4
7.3 Service Plan Gear Unit .............................................................................................. 7.5
7.3.1 Service Overview - Gear Unit and Couplings .................................................. 7.5
7.3.2 Service Measures - Gear Unit and Couplings ................................................. 7.7
7.4 Service Plan Oil System .......................................................................................... 7.12
7.4.1 Service Overview - Oil System ..................................................................... 7.12
7.4.2 Service Measures - Oil System .................................................................... 7.13
7.5 Double Oil Filter: Cleaning and Exchanging of the Filter Insert ................................ 7.16
7.6 Dismantling the Pumps ............................................................................................ 7.17
7.7 Service Plan Main Coupling (BOKU-N Coupling) (Option) ....................................... 7.17
8 Oil Change .............................................................................................................. 8.1

8.1 Checking Oil Quality .................................................................................................. 8.3
8.2 Drain Oil .................................................................................................................... 8.4
8.2.1 Activities before Filling the Machine woth new Oil .......................................... 8.5
8.3 Filling with Oil ............................................................................................................ 8.6
8.3.1 Report - for filling of fresh oil ........................................................................... 8.9
8.3.2 Check list - for filling of fresh oil (option) ....................................................... 8.10
9 Trouble shooting .................................................................................................... 9.1

9.1 Gear Unit ................................................................................................................... 9.3
9.2 Oil System ................................................................................................................. 9.4
10 Spare Parts ........................................................................................................... 10.1
Translation of the original instructions – Industrial gear unit – KPAV 125 - HKC01090000039 –VRM iii
11 Disposal / Recycling ............................................................................................ 11.1
Appendix
Appendix A – Drawings
Appendix B – Components - Gear Units (Options)
Appendix C – Components - Oil System
Appendix D – Lubricant KPAV Gear Unit
Appendix E – Flushing procedure
Appendix F – Operating Instructions
Translation of the original instructions – Industrial gear unit – KPAV 125 - HKC01090000039 –VRM iv
Preface
Preface
Dear reader,
Thank you for choosing one of our products.
Please read this operating manual carefully before commissioning your

gear unit. In particular, observe the safety information in the text and in
chapter 1 "Basic safety information for operation of the gear unit".
These are the conditions for:

 Safe transport,
 Safe commissioning,
 Trouble-free operation,
 Safe execution of service jobs.
We are gladly available for any questions that are not answered in this
manual. Please call us; the Hyosung. Co service will be available for help.
We are happy to receive any ideas or improvements concerning this

operating manual.
We wish you success and good work results!
Hyosung Gear Solution Design Team.
Translation of the original instructions – Industrial gear unit – KPAV 125 - HKC01090000039 –VRM
0 Identification
0 Identification
0.1 Manufacturer
Manufacturer: Hyosung Corporation(Licenced Renk)

Street: 303, Gongdan-ro
Location: Seongsan-gu, Changwon-si, Gyeongsangnam-do
Telephone: +82 (0)55 282-0141
Fax: +82 (0)55 570-0522
Email: sales@hyosung.com
Internet: www.hyosungpni.co.kr
0.2 Product Identification
The industrial gear unit KPAV is delivered in the following version:
Construction size:
KPAV 125 Options:
– KTR coupling to connect the drive motor with the gear unit.
Translation of the original instructions – Industrial gear unit – KPAV 125 - HKC01090000039 –VRM 0.1
0 Identification
Information
The nameplate is attached on the gear unit casing.
Name plate
Fig. 0.1: Nameplate
0 Identification
0.3 Operating Instructions
Date produced: 2016.12 / 2017.04
Change index: Index Change Date Name
Number and language English Paper Digital(CD-ROM)
Customer 1
Information
The operating manual is an integral part of the gear unit. It must always
be kept in the vicinity of the gear unit/overall plant and must always be
available for consultation by the personnel.
Copyright:
Reproduction and copying of this document, and disclosure and use of its
contents are strictly prohibited unless expressly authorized.
Non-compliance will result in a claim for damages. All rights reserved in
case of registration of patent or design patent.
These operating instructions have been produced in accordance with the

product-specific and application-related requirements derived from laws,
rules, regulations, technical standards, guidelines, directives and contracts.
This operating manual contains information for the distributing company of

the overall plant as well as for the owner/operator of the gear unit concerning
 The required safety information,
 Layout and functioning of the gear unit,
 The safety switching to be integrated into the control system of the
overall plant (with corresponding performance level),
 Initial commissioning and service,
 Spare parts lists and
 Supplier documentation.
0 Identification
All persons, who are commissioned to work on the gear unit, must have read
and understood the complete operating instructions, and in particular, the
"Safety information" section.
The additional instructions for devices and units in the gear unit going be-
yond this description and which are not part of the scope of supply of Hy-
osung. Co are likewise to be complied with. The safety-related stipulations
and accident prevention regulations are to be complied with in the same way.
In this manual, warning information is indicated by pictograms. Information is

preceded by signal words that indicate the scope of risk.
To avoid accidents and damage to persons or property, always follow the
information. Always act with extreme caution.
Below, the pictograms used in this manual and their meaning are listed.
DANGER!
Imminent danger to body and life!
WARNING!
Possible danger to body and life!
ATTENTION!
Possible injury or property damage!
DANGER!
Danger caused by electric current!
0 Identification
Note!
Information on the professional and proper handling of the gear unit.
Ignoring this information may cause destruction of the gear unit or materi-
al damage in its surroundings.
Information
Useful hints!
Information
For further information please read the technical documents of the gear
unit and the data sheets!
0 Identification
0.4 Personnel
ATTENTION!
Only trained and instructed personnel may operate the gear unit. Addi-
tional requirements, qualifications and skills are listed in each chapter.
0.5 Conformity
The design of the industrial gear unit KPAV complies with the relevant
regulation of the EU directives listed in the attached installation declaration.
The manufacturer declares that the gear unit is an incomplete machine in the
sense of the machine directive. The gear unit is designed exclusively for
installation in a plant, machine or incomplete machine and therefore does
not comply with all requirements of the machine directive.
The essential requirements of the machine directive applied and observed
are included in the installation declaration.
Initial commissioning of the gear unit including all options is not permitted
until it has been established that the plant or machine into which the gear
unit is installed complies with all essential requirements of the machine di-
rective.
The special technical documents according to appendix B have been gener-
ated.
1 Intended Use, Warranty, Safety Information
ATTENTION!
Residual risks!
The gear unit has been designed and manufactures with utmost care. Its
use can nevertheless constitute a hazard to the life and limb of the user or
third parties, or can cause damage to the gear unit and other material
assets.
In operation and use, there are residual risks caused by structurally una-
voidable hazard situations.
This manual indicates general residual risks and hazard points.
 In addition to the safety instructions described below, all safety in-

structions pointed out in the following paragraphs of this manual
applies!
Note!
Information on professional and proper handling of the gear unit:
Persons assigned to work on and with the gear unit agree:
 to observe the local regulations on work safety and accident pre-
vention,
 to read this manual including all its warning instructions before be-
ginning their work.
1.1 Appropriate Use
The industrial gear unit KPAV including its peripheral components is de-
signed for use in vertical roller mills. The initial rotating speed is reduced in
the gear unit by means of a bevel wheel stage and a vertical planetary stag-
es; the initial torque is increased correspondingly.
The owner/operator agrees

 The gear unit must only be used for the purpose for which it is in-
tended and only when it is in perfect technical condition.
Malfunctions that impair its safety must be rectified at once.
Intended use also includes:

 Observation of all safety instructions,
 Observation of the inspection and service conditions,
 Operate gear unit only in combination with the additional oil supply
system.
The gear unit may only be operated at the location agreed upon in the con-
tract and only by trained and authorised specialised persons while complying
with all the safety information included in this operating manual. Safe and
trouble-free operation can only be assured in the event of appropriate use in
accordance with the details given in these operating instructions.
Warning!
The gear unit KPAV is not approved for use in explosive zones.
Possible Misuse
Improper use can lead to hazards. Examples of improper use are, e.g.:
 Transport of the gear unit with oil filling

 Suspension of the gear unit from the bottom attachment points,
 Commissioning, driving, starting-up or rotating of the gear unit by
secondary drives or in any other way, e.g.
– without sufficient oil filling of the gear unit or of the oil system,
– without operating or properly operated oil system,
– without running lubricating oil pumps,
 Operation of the gear unit outside its dimension and capacity data,
 Exceeding of the maximum oil temperature,
 Operation below the minimum oil pressure,
 Operation without installed protective devices,
 Improper operation,
 Improper rectification of malfunctions,
 Operation of the gear unit by personnel that was not instructed,
 Non-compliance with the care and maintenance measures,
 Operation of the gear unit with different types of oil than those rec-
ommended by Hyosung. Co.
 Changes occurring in the gear unit caused by malfunctions that affect

safety (e.g. higher noise level, higher vibrations, strong resonances,
higher operating temperatures than in normal operation etc.) Must be
rectified immediately.
 The changes must be reported to the person in charge of the opera-
tor of the overall plant.
 The personnel must be obliged to do so.
 After service jobs have been completed, all tools, work materials and
operating aids, etc. must be removed from the work area of the gear
unit.
PROHIBITED!
 Interventions jeopardising the safety of the gear unit are not
permissible!
 Driving and rotating the gear unit without connection to the
oil system is prohibited!
1.2 Warranty and Liability
As a rule, the Hyosung. Co “General Terms of Sale and Delivery” as well as

the concluded contract apply. Furthermore, claims under warranty or out of
liability in the event of personal injury or damage to property are excluded if
they are due to one or more of the following causes:
 Inappropriate operation of the gear unit.

 Operation of the gear unit outside the specified capacity limits.
 Operation of the gear unit without safety and protective devices or
safety and protective devices that defective or not in position.
 Damage to the plant caused by inappropriate use, improper commis-
sioning, installation/dismantling, service or maintenance of the gear
unit.
 Ignoring of the safety regulations and information in this manual con-
cerning the life cycles of the gear unit.
 Improperly executed maintenance jobs.
 Structural modification of the gear unit not released by Hyosung. Co.
 Disaster situations caused by impact of foreign bodies or acts of God.
1.2.1 Terms and Conditions of Warranty
The terms of conditions of warranty that had been contractually agreed upon
between Hyosung. Co and the owner/operator of the gear unit shall apply.
Structural Changes to the Gear Unit
As soon as add-ons or conversions or performance-relevant modifications
are made to the gear unit that are not approved of by Hyosung. Co in writing
 Warranty for this gear unit is voided,
 The installation declaration provided by Hyosung. Co loses its validity.
Only use spare parts and consumables released by Hyosung. Co.
1.2.2 Service
Please contact the service section of Hyosung. Co if you have any questions
or problems (service address cf. cover sheet).
1.3 Information on Transport
 Only use lifting gear of an adequate load and lifting capacity in

transport.
 Never stand underneath suspended loads.
 The gear unit may only be lifted at the lifting and attachment points
provided for that purpose.
 The gear unit must be secured against slipping, transported and set
down.
1.4 Information for the Distribution Company of the over-

all Plant
 The gear unit may only be connected to the supply lines that have
been designed and intended for such a purpose.
Grid disconnection devices

 All motors (including auxiliary motors) must be equipped with suitable
grid disconnection devices which are used to disconnect them from
the power supply on all poles and to secure them against switching
on.
Distancing protective equipment

 All exposed rotating parts of the main drive motor (not scope of deliv-
ery of Hyosung. Co), of the KTR coupling and the positioning drive
must be covered by means of distancing protective devices in a way
that the requirement of EN 953 and EN ISO 13857 are fulfilled.
Emergency stop installations

 The distributing company of the overall plant is obliged to install at
least one emergency stop installation (emergency switch) for the
main emergency stop circuit of the overall plant. When this switch is
triggered all hazardous movements of all motors must stop (i.e. main
drive motor, and the positioning drive). However, oil system must not
be switched off. The following performance level according to EN ISO
13849-1 must be reached:
Note!
Safety chain: Emergency stop switch --> safety relay --> safe switch-
ing off of all components: PLr= d.
 The distributing company of the overall plant is obliged to install an-

other emergency stop circuit for switching off the oil system. The
emergency stop circuit must shut down the gear unit first and after
that the oil system so that lubrication of the gear unit is ensured until
it has come to a standstill. The following performance level according
to EN ISO 13849-1 must be reached:
Note!
Safety chain: Emergency stop switch --> safety relay --> safe switch-
ing off oil system: PLr= d.
Failure of power supply

Hyosung. Co recommends to the distributing company of the overall plant
that the electronic control system is set up in a way that all control com-
mands are automatically set to zero position in case of power failure. Unin-
tentional switching on as soon as the power returns must be excluded. After
a power failure the industrial gear unit must be restarted.
1.5 Obligation of the Owner/Operator
The owner/operator agrees
 To assign only such persons to working on the gear unit who are,
– Familiar with the local regulations concerning work safety and
– With accident prevention,
– Who have been instructed in activities on an with the gear unit
and
– Who have read and understood this manual.
 To examine in regular intervals that his personnel work on and with
the gear unit in a safety-conscious way,
 That adjusted lighting is available for working on the gear unit
 To keep this manual in legible condition near the gear unit for the
personnel assigned to work on and with the gear unit,
 To keep all safety and warning signs on the plant in legible condition,
 In addition to the operating manual, all general, legal and miscellane-
ous binding regulations for accident prevention and protection of the
environment, must be observe, e.g.
– Setting up of hydraulic systems (gear unit, oil system) over a
sump or a similar installation that has sufficient capacity and a
suitable construction to collect oil spilled from the containers as a
result of an accident or the hydraulic systems must be set up on
an impermeable surface,
– handling of hazardous substances
 Carry out regular training,
 Provide the necessary personal protective equipment, e.g. safety
boots, protective goggles, hearing protection, protective gloves,
 Ensure that the supervisors in the company check that personal pro-
tective equipment is used by the personnel.
1.6 Personnel Training
Training must emphasize the dangers involved and safety precautions. In-
structions must be provided in regular intervals and repeated at least every
year, in case of minors twice every year.
It is recommended that the owner/operator should obtain confirmation in
writing that the persons concerned are familiar with the contents of the oper-
ating instructions. This knowledge is one of the prerequisites to protect per-
sons against dangers, avoid errors and allow the gear unit to be operated
safely and without errors. In the last resort, the owner/operator or the per-
sonnel authorized by him are responsible for operation without accidents.
The personnel must have a solid knowledge of the following areas:
 Layout and functioning of the gear unit and the oil unit,
 Information in the operating manual and in all documentation of the
components,
 Intended use of the gear unit,
 Function of safety and protective installations,
 Behaviour and action in the event of dangers and emergencies.
1.7 Information concerning Operation
Gear unit
 Operation of the gear unit outside its dimension and capacity data is
prohibited.
 Starting up or rotating the gear unit by means of gear unit motor, by
other devices even manually is only permitted if sufficient oil filling
of the gear unit, of the oil system and ongoing lubrication is en-
sured.
 It is necessary to ensure the functional safety of the oil unit required
for lubrication of the gear unit.
 In case of changes in the gear unit that may affect safety (increased
noise level, resonances, higher temperatures than normal, etc.) oper-
ation is not permitted.
 Switching points set by the manufacturer on monitoring and control
instruments such as, temperature or pressure switches, thermostats,
level switches, valves, regulators, etc., may not be changed.
 Do not touch the hot surfaces of the case, pipes and tanks of the hy-
draulic system during operation.
 Protective gloves must be worn at all times when carrying out any
work on the gear unit.
 None of the alarms may be ignored or suppressed. They indicate that
there is a problem in the gear unit or oil unit and the cause must be
searched for at once or the error dealt with.
 In parallel to this, any changes are to be reported at once to the own-
er/operator of the unit, and the personnel must be required to do this.
 If the unit is switched off for safety reasons, the gear unit may only be
switched on again once the reason for the problem has been dealt
with.
Oil system
 Never switch on the heating elements (immersion heaters) if there is
no oil in the tank. The heating elements must always be completely
immersed in the lubricating oil.
 The oil level must be above the minimum marking on the oil level dis-
play of the container (cf. document "Technical data oil system" in the
appendix of this operating manual).
 The maximum permissible oil temperature for the lubricating oil used
(cf. "Oil circuit diagram" or "Installation drawing" in appendix A of this
operating manual) in continuous operation must not be exceeded.
 Avoid any contact with the hot lubricating oil. Take higher surface
temperatures into account as well when the outside temperatures are
higher.
 The maximum permissible oil temperature for the lubricating oil in the
container (measured at the thermometer (5), cf. "Oil circuit diagram"
in appendix A of this operating manual) must not be exceeded.
 The minimum oil pressure of 0.7 in the lubricant line at the gear unit
inlet must be maintained at all times.
 The minimum oil inlet pressure (cf. "Oil circuit diagram" or "Installa-
tion drawing" in appendix A of this operating manual) must be en-
sured.
1.8 Notes for the Operator
 In order to avoid hazards and to ensure optimal performance, no

modifications or conversions may be made to the gear unit.
 Any changes in the operating values without the approval of Hyosung.
Co can lead to damage to the gear unit as a result.
 Unauthorized persons are not to be allowed to have access to the
gear unit.
1.9 Information concerning Service Jobs
The owner/operator as well as the service personnel must ensure that during
service and maintenance work on the gear unit...
 The overall plant is switched to zero-potential and that the power

supply is secured against unintentional switching on.
 All auxiliary drives are also switched to zero-potential and secured,
 The special regulations for maintenance work are observed during...
– Work on pressure-conducting parts of the gear unit,
– Work on live parts of the gear unit.
 Activities with dismantled protective devices may be carried out

– Only by properly trained,
– Specialists authorised to this work,
– Under the necessary supervision of the supervisor in the compa-
ny and
 When the job is completed all protective devices must be immediately
and properly installed,
 The local regulations for works safety are observed,
 Only trained specialised personnel with appropriate qualification is
assigned,
 Hazards caused by operating media (oils, greases) are avoided,
 Laws and local regulations for environmental protection are observed,
in particular during…
– Transport and storage of operating media,
– Disposal of operating and cleaning media.
The owner / the service personal must be strictly adhered following:
 It is necessary to ensure the functional safety of the oil unit required

for lubrication of the gear unit.
 Starting up or rotating the gear unit by means of gear unit motor, by
positioning drive or other devices even manually is only permitted if
sufficient oil filling of the gear unit, of the oil system and ongo-
ing lubrication is ensured.
 Welding work on the tanks may only be carried by trained welders.
Comply with the test certificate regarding sealing of the tanks.
 Set up a suitable earth when carrying out welding work to prevent
damage due to electric current passing through the gear unit. If the
scope of delivery includes a grounding cable it should be used for this
purpose. The suitability of the cross section and the contact must be
guaranteed.
 When carrying out repair work, all the relevant parts of the gear unit
must be suspended, supported or dismantled.
 Repairs may only be made using original parts from the manufacturer.
Any use of components from other manufacturers or of other types
that have not been explicitly approved by the manufacturer of the
gear unit is forbidden.
 The lubricating oil system must be fully depressurized before any
work is done on the pipes or components of this system.
 Before switching the gear unit on again after service or inspection ac-
tivities, check whether all safety devices that were dismantled have
been replaced and are functional.
 Comply with the relevant environmental regulations when draining oil.
 The information provided by the manufacturer on the relevant prod-
ucts must be followed when using solvents and other aggressive ma-
terials.
 Solvents or petrol must never touch or penetrate the gear unit!
1.10 Obligation of the Personnel
Persons assigned to work on and with the gear unit agree

 To observe the local regulations on work safety and accident preven-
tion,
 To have read and understood this manual and to observe all the in-
structions.
Furthermore, the personnel must observe:

 There must be no fire or naked flame in the vicinity of the gear unit.
 Smoking, eating and drinking in the vicinity of the gear unit is not al-
lowed.
 All safety instructions in this operating manual and in all documents of
the components must be observed and complied with.
The personnel must follow the measures listed below to ensure safety at
work during the corresponding work steps:
 Wear protective work clothing, change out of dirty clothing,
 Wear a protective helmet, protective gloves, protective shoes and
protective glasses,
 Keep tanks closed,
 Not wear any loose clothing or jewellery.
1.11 Residual Risks caused by incorrect Behaviour of the

Personnel
 For all activities carried out on the gear unit please note that excess
physical stress increases the risk of accidents.
 Therefore always use suitable equipment to facilitate all activities,
minimising the risk of accidents this way.
 Please note that there is danger of crushing during any manual work
on and with the gear unit.
1.12 Qualification of the Personnel
 There is danger to life and limb for untrained personnel if they use the
gear unit improperly or for uses for which it was not intended.
 The gear unit may only be transported, installed, operated and ser-
viced by instructed and authorised personnel. For operation, setting
and for service activities responsibilities of the personnel must be
clearly defined.
 Personnel to be instructed may only work on the gear unit if super-
vised by an experienced person. It must be ensured that only per-
sonnel assigned to do so works on the gear unit.
1.13 Areas to be occupied by Personnel
The areas to be occupied by personnel (work and service areas) cannot be

clearly separated for the industrial gear unit KPAV with oil system. The gear
unit operates practically without personnel; personnel is only required in the
operating range of the gear unit and the oil system for carrying out service,
maintenance, inspection and cleaning activities.
1.14 Personal Protective Equipment
DANGER!
Working on the gear unit is only permitted if the personnel is using
the prescribed personal protective equipment!
Therefore, as necessary and required by regulations, use of personal pro-
tective equipment, e.g. hearing protection, slip-proof safety boots, protec-
tive goggles and protective gloves is mandatory!
The personnel must not wear open long hair, loose-fitting clothes or jewellery
(including rings).
This may cause the risk of injury e.g. due to snagging or inrunning nip.
1.15 Safety Devices
DANGER!
Danger of life caused by dangerous gear unit components in case of
open/removed protective devices!
Opening/removing of protective devices does not automatically switch off
the gear unit.
 For operation of the gear unit, ensure that all protective covers are
installed professionally and closed! This applies especially for sep-
arating protective devices of positioning drive.
 Removing or disabling protective devices is not allowed during op-
eration of the gear unit.
 In case of service and repair activities, protective devices may only
be removed if the gear unit or the plant was switched off before
and brought into a save condition.
 The same applies for opening of any inspection hole covers on the
gear unit. Before opening the inspection hole covers, gear unit and
all auxiliary drives must be switched to zero-potential and secured.
 If movements are necessary, this may only be done if supervised
by a supervisor in the company. All required measures for precau-
tion must be met.
 Any protective devices that have failed or are not functional must
be reported to the supervisor in the company immediately. He will
decide on further procedures.
Before starting the gear unit, all potentially hazardous, freely rotating and live
parts must be
 Secured by means of properly installed protective devices and
 Checked by the personnel for functionality.
Before commissioning, the operator of the overall plant must, with regard to
the gear unit
 Equip it with passive and active protective devices.
At least once per day (shift),

 check the gear unit for visible damage and for function of the protec-
tive devices.
1.16 Warning Signs on the Gear Unit
The following warning signs are visibly and protected from soiling attached to
the gear unit. They must always be kept in legible condition.
Read the operating instructions carefully.
Use hand protection (M06)
Warning of Hot Surface (W26)
Warning of space/zone under excess pressure (W63)
Use eye protection (M01)
Use hearing protection (M03)
Warning of hot fluids and steams (W47)
Warning of inrunning nip (on inspection hole covers) (W30)
The mandatory sign concerning wearing personal protective equipment and

the prohibitions signs prescribed by the authorities must be affixed at the
access points to the overall plant.
This signage is the responsibility of the manufacturer of the overall plant!
1.17 Hazards caused by Electric Current
DANGER!
Danger of life due to electric shock!
Imminent danger arises for life and health of the person concerned when
touching live parts.
 Switch the overall electrical equipment to zero-potential when car-
rying out service work on the gear unit.
 Secure the gear unit against switching on while the activities are
carried out!
ATTENTION!
Work on the electrical equipment must only be done by an authorised
qualified electrician, in accordance with electrical engineering regulations.
The designation qualified electrician must comply with the definition of the
corresponding European standards.
 For any work on the electrical system of the gear unit (parts under
electric voltage) the gear unit must first be switched to zero poten-
tial and secured against unintentional switching on. For this pur-
pose, the distributing company of the overall plant is obliged to
provide a main or power switch or repair switch or other de-
vices for grid power disconnection for switching off the gear
unit.
The person responsible for the job carries the key of the padlock
with him.
 In addition, a warning sign "Do not switch on! Work in the dan-
ger zone!" is set up.
 The potential equalisation of the gear unit must be designed with
at least half the cross section of the outside conductor.
 Have a qualified specialist immediately...
– Fasten loose cable connections,
– Exchange defective cables for new ones.
 After completing the jobs and before switching the voltage back on
the supervisor in charge ensures that this is possible without caus-
ing harm to persons or installations. Before switching on, all per-
sons concerned must receive timely and clear warning.
DANGER!
Danger due to electric shock on frequency converters!
The power section of a frequency inverter may still be live up for some
time after disconnection from the mains. Inverter terminals, motor supply
cables, and motor terminals may be dangerously live, too!
 Touching exposed or unconnected terminals, cables, or parts
of the device may lead to serious injuries or even death!
1.18 Hazards caused by Operating Media
DANGER!
Danger that persons are exposed to dangerous fluids or vapours!
If service or inspection jobs make it necessary to enter the inside of the
gear unit while it still contains oil mist the gear unit must cool down, be
switched off and secured against switching on.
Warning!
Observe the safety data sheets of the operating media used (e.g.
lubricating oils, media for preservation and de-preservation) when
carrying out maintenance work and fault clearance!
Note!
All requirements and EU safety data sheets of the relevant manufacturer
concerning the storage, handling, use and disposal of all operating mate-
rials and cleaning agents used in connection with the gear unit are to be
followed.
Information concerning use of operating materials and cleaning

agents:
 Never use any materials whose properties are unknown. If applicable,
contact the manufacturer.
 Always use only the tank or containers that had been approved for
the relevant substance. The tanks and containers are to be marked
accordingly.
 In case of contact with auxiliary / operating materials and cleaning
agents the following measures must be taken with regard to the re-
spective medium:
– After skin contact, clean the skin off with soap and water.
– After eye contact, flush the eyes under running water for at least
10 minutes and contact a doctor.
– After inhalation, provide fresh air or oxygen and contact a doctor.
– Observe safety data sheet, especially regarding additional infor-
mation!
Disposal of operating material

Operating materials, cleaning agents and their containers are not to be dis-
posed of in household waste or allowed to penetrate into the sewage system
or the ground. They must be disposed of properly and in compliance with
international, national and regional laws and local regulations. This applies in
particular...
 For filter and oil change,

 Work carried out on lubrication systems and installations,
 Media for preservation, de-preservation and cleaning.
1.19 Disposal and Recycling
ATTENTION!
Hyosung. Co does not assume liability for damage on the gear unit
caused by use of unsuitable operating materials!
Note!
When handling oils, greases and other chemical substances, the safety
regulations applicable in the country of use are to be followed!
Processing residue and lubricant must not enter the sewage system or
domestic waste. These substances must be disposed of in a way that
complies with the applicable regulations for environmental protection.
Also observe the information in the paragraph "Instructions concerning
use of operating material and cleaning agents" in this chapter.
1.20 Danger Areas of the Gear Unit
DANGER!
There is a general hazard caused by:
 Danger of burning
 Danger of crushing or impacts
 Danger of falling, tripping or slipping
These hazards should be expected particularly in case of errors and dur-
ing service and maintenance work on the gear unit.
DANGER!
Hazards caused by material wear!
If the gear is stored by the operating/distributing company for more than
12 months, long-term preservation - inside and outside - is absolutely
necessary! This will prevent corrosion damage on components.
 Before delivery, Hyosung. Co carries out inside and outside
preservation of the gear unit. In case of storage ≥ 12 months it is
necessary to carry out long-term preservation for the inside of the
gear unit.
 Inform the Hyosung. Co service minimum 3 months before! After
that, you will receive the document "Long-term preservation of the
gear unit KPAV" with the necessary information and to install com-
ponents.
 The gear unit must be serviced regularly and checked for wear or
leakage. The operating personnel take care to notice leaking flu-
ids.
DANGER!
If a job makes it necessary to open the gear unit, it must be ensured
through the system that rotation of the gear unit is impossible. As a
rule, any work on the gear unit including positioning drive may only
be carried out when they stand still. The secured parts must first be
checked to ensure that they are not live, grounded, and adjacent live
parts must be insulated.
DANGER!
Danger that when the flashpoint of the lubricating oil is exceeded
and sparks are generated at the same time, deflagration may occur
in the gear unit!
Before opening an inspection hole cover, especially in case you suspect
damage on a bearing, wait until the oil has cooled down. Always observe
this waiting period!
DANGER!
Danger that when opening inspection hole covers of the axial bear-
ing space large quantities of oil may escape from the gear unit!
Dismantle inspection hole covers of the axial bearing space only after the
oil of the gear unit has been drained and no oil level is displayed in the oil
inspection glass.
DANGER!
Danger that persons slip and fall, e.g. as a result of escaped lubricat-
ing oil!
 Hoses and cables must be laid in a way that they do not constitute
a tripping hazard for personnel.
 When exchanging oil and hoses, a suitable container must be
available to collect leaking oil.
 Personnel on the plant take care to notice leaking oil to avoid slip-
ping and falling.
 Leaking oil must be absorbed immediately by means of suitable
auxiliary substances.
2 Technical Data
2 Technical Data
Information
The following data are also included in the technical drawings in appen-
dix A.
2.1 Performance Data – Main Gear Unit
Continuous rating P = 850 kW

Drive unit rpm n1 = 990 rpm
Output rpm n2 = 34.5 rpm
Step-down i = 28.69
Load on the axial bearing - static Fstat = 2,290 kN
Load on the axial bearing - dynamic Fdyn = 5,900 kN
Bearing design, all main bearings roller bearing
permitted nominal torque on drive shaft T = 13,000 Nm
main drive
2.1.1 Coupling Main Drive
Manufacturer KTR
Manufacturer drawing SH1-DHI-P1HFC-M-M01-DAS-1002-09
Operating Instructions – Industrial gear unit - KPAV 125 - HKC01090000039 –VRM 2.1
2 Technical Data
2.2 Weights
Gear unit (total weight without oil filling) approx. 18,000 kg

Housing approx. 7,118 kg
Output stage approx. 6,572 kg
(Output flange + planetary stage)
Axial-thrust bearing, 13 circular pads approx. 2,315 kg
○ Axial bearing, weight per pad approx. 60 kg
Bearing cover, installed (bearing, bevel approx. 1,208 kg
gear shaft and bevel gear rim)
Eccentric cartridge complete , mounted approx. 485 kg
with bevel pinion shaft + bearings
Inspection cover, bolt, etc. approx. 320 kg
Main coupling approx. 173 kg
2.2.1 Weight - Oil system
Oil system, without filling approx. 14,500 kg
2 Technical Data
2.3 Energy and Media Requirement
Information
The following data are also included in the technical drawings in appendix
A.
2.3.1 Oil Main Gear Unit
Mineral oil ISO VG 320 CLP (observe appendix D "Lubricant - KPAV gear
unit"!)
Oil filling, total approx. 960 l
thereof in the
○ oil tank (oil system) approx. - l
○ Axial bearing area approx. 220 l
○ Casing bottom part approx. 660 l
○ Lines / Pipes approx. 80 l
2.3.2 Electricity - Oil system
Motor 400 V, 50 Hz, 3-phases

Capacity lubricating oil pump motor P = 11 kW
Rating, heating P = - kW
2.3.3 Water - Oil system
Oil cooler, cooling capacity P = 50,740 kcal/hr

Cooling water, inlet temperature max. tmax = 36.1 °C
Cooling water throughput Q = 124 l/min
Operating pressure min. p = 1.5 bar
Max. permissible pressure p = 10 bar
2 Technical Data
2.4 Packing Level
Gear unit: Steel Packing or Wood Packing
Oil system: Wood Packing
2.5 Mill
KPAV 125
2.6 Languages of the Operating Instruction
Hardcopy : - copy (English)

CD : 1 copy
3 Technical Description
The industrial gear unit KPAV is a bevel gear planetary gear unit for use in
vertical roller mills.
3.1 Gear Unit
The rotating speed is reduced in the gear unit by means of a bevel wheel
stage and a vertical planetary stage; each increases the torque.
3.1.1 Main Components
Fig. 3.1: Components with roller bearing (the legend only describes the main com-
ponents!)
Item Designation Item Designation

1301 Casing 1725 Coupling Ring
1101 Thrust Bearing Cover 2001 Coupling Sleeve
1110 Bearing Cover 2201 Planet Carrier
1620 Bevel Pinion 2110 Planet Pin
2501 Roller Bearing (#23236) 2505 Roller Bearing (#23238)
2502 Roller Bearing (#31330) 2115 Planet Gear
1601 Eccentric Cartridge 2010 Sun Pinion
1801 Bevel Gear Shaft 1302 Annulus
2503 Roller Bearing (NU230) 2506 Roller Bearing (NU1064)
2504 Roller Bearing (#32038) 2101 Planet Carrier
1802 Bevel Gear Hub 2420 Fixation Disc
1810 Bevel Gear Rim 2401 Thrust Plate
1710 Bearing Bush 2601 Thrust Pad
Bevel pinion shaft

The drive shaft is driven by an electric motor. Motor and drive shaft are con-
nected by means of a coupling.
Fig. 3.2: Drive shaft main drive [1]
The drive shaft of the main drive [1] must be driven clockwise (looking onto
the gear unit).
Output flange
The drive flange rotates clockwise. The drive is the interface to the roller mill.
Fig. 3.3: Output flange [2]
Case and inspection hole lid
Fig. 3.4: Air vent [1] and inspection hole lid [2], [3],[4]
1 Air vent
2 Inspection hole cover, 4x on circumference
3 Inspection hole cover, 2x on circumference
The air vents [1] ensure pressure balance in the gear unit. The inspection
hole covers [2] and [3] are used when servicing and repairing the gear unit.
Gear unit types

All gear unit types are lubricated and cooled during operation by means of
pressure lubrication.
All bearings except the guide bearing and the thrust bearing of the drive
flange are roller bearings. The guide bearing for KPAV 140 and bigger is a
sleeve bearing.
The axial bearing for the drive flange is always a sleeve bearing.
Depending on the type of the bearings, lubricating oil is supplied via sepa-
rate low-pressure lubricating oil circuits. The low-pressure lubricating circuit
supplies all roller bearings, the axial bearing area, and the gear teeth of the
gear unit with lubricating oil.
Lubricating oil circuit
lubricating
pressure
circuit
Low-
Bearing
Bearing / gear teeth/ axial bearing area X

Axial bearing pads hydrodynamic X
Tab. 3.1: Lubricating oil circuits
Oil circuit - oil system / gear unit

To enable operation, the oil temperature must be at least 20° C.
The connections [1], [2] and [3] are used to connect the gear unit to the low-
pressure lubricating circuit of the oil supply system.
In ongoing operation, the cooled lubricating oil is mixed with warm oil behind
the oil cooler.
Tooth and oil sprinklers inside the gear unit spray the teeth of the gear
wheels with oil.
In the axial bearing area oil pump up and flows through overflows back into
the lower part of the casing.
The oil level in the axial bearing area of the gear unit is displayed in the oil
inspection glass [4]. This oil is drained via the draining valve [8] on the axial
bearing area. To drain the oil from the lower part of the casing the draining
valve [5] is used.
From the oil return line [6] the oil flows back into the oil system.
Oil filling - oil system / gear unit

1. Set and connect the Gearbox, LO unit and all the Suction/Supply
Pipes according to Mill Gearbox Arrangement drawing.[SH1-DHI-
P1HFC-M01-DAS-1002-01]
2. Fill oil into the oil tank through the filling hole[8] until the oil level
gauge[7] reaches 350mm.
3. Start the oil pump and run for few minutes, through this operation the
oil will fill up the Suction/Supply Pipe and upper oil Tank, meanwhile
the oil level of the lower oil tank will drop below 350mm.
4. Fill oil into the oil tank through the filling hole until the oil level reach-
es 350mm again.
5. Repeat the step 3 and 4 for 1 or 2 times.
5
1 6
3 2 7 8
Fig. 3.5: Connections to oil system, oil level display and oil drain
1 Pressurised oil connection bevel gear stage 4 Oil inspection glass

2 Pressurised oil connection planetary stage 5 Oil draining valve
3 Pressurised oil connection axial bearing area 6 Oil return line
7 Oil level gauge 8 Oil filling hole
Fig. 3.6: Oil drain on axial bearing area
9 Oil draining valve for axial bearing area
3.1.2 Functional Description
The industrial gear unit KPAV is a bevel gear planetary gear unit for use in
vertical roller mills (e.g. for cement production or power plants). The rotating
speed is reduced in the gear unit by means of a bevel wheel stage and a
vertical planetary stages; each increases the torque.
The casing of the gear unit (fig. 3.1 and 3.2, pos. 100) is a welded construc-
tion from SS400.
The drive shaft is on the side of the gear unit.
The bevel gear stage deflects the drive direction by 90° and reduces the
rotational speed.
The planetary stage consists of a sun pinion, three planet wheels installed
inside the planet carrier and a ring gear. The sun pinion rotates, the planet
wheels rotate around the sun pinion and the ring gear stands still. In the
planetary stage rotational speed is further reduced and torque increased.
For power transmission in the gear unit, the bevel gear shaft with sun drives
the planets of the first planetary stage. The planet carrier is connected with
the output flange onto which later the grinding bowl is installed.
The drive flange is supported by axial bearings.
The overall bearing of the drive flange is designed in a way that it can ab-
sorb the static loads arising from the weight of the mill as well as the static
and dynamic forces arising as a result of the grinding process.
Plant layout
The overall roller mill line must be controlled and regulated by a higher-level
control system. Safety- and control-relevant sensor signals and regulation of
the energy supply, e.g. for the oil system and the immersion heater must be
incorporated in it.
Fig. 3.7: Simplified plant layout
Information
The exact design layout of the gear unit can be seen in the assembly
drawing in appendix A.
Torque flow in the gear unit

The drive motor creates a torque about the hori-
zontal axis

The bevel gear stage increases the torque, di-
verts it and reduces the rotating speed

The planetary stage increase the torque and
reduces the rotating speed
Flow of forces in the gear unit

The forces of the grinding rollers are directed into the foundations via drive
flange, axial bearing pads and casing.
3.1.3 Displays on the Gear Unit
An oil inspection glass is installed in the upper part of the gear unit. It shows
the filling level of the gear oil in the axial bearing area.
Note!
The search numbers of the display in brackets are listed in the oil circuit
diagram and/or the outside piping plan in appendix A of this operating
manual.
Further Displays
Display Function Description

Oil inspection Oil level display Shows the oil level in the axial bearing
glass area.
Thermometer Temperature dis- Oil temperature at the gear unit inlet
play
Pressure Pressure display Oil pressure at the gear unit inlet
gauge
3.2 Gear Unit Lubrication: Oil System and Monitoring
Note
The gear unit lubrication and monitoring of the oil unit can vary according
to the configuration of the gear unit. As a rule, the oil circuit diagram gen-
erated for the order at hand applies.
Fig. 3.8: Oil system
Information
The exact design layout of the oil system is included in the technical doc-
umentation of the manufacturer in appendix C.
3.2.1 Functional Description of the Oil System
For lubrication the gear unit has a separate oil system. It consists chiefly of
an oil container and the stored lubricating oil as well as pump-driven oil cir-
cuits.
Actual lubrication of the gear unit is done by the low-pressure circuit .
The low-pressure lubricating circuit supplies all plain and roller bearings, the
axial bearing area and the gear teeth of the gear unit with lubricating oil.
Also the low-pressure circuit is responsible for supplying the axial bearing
pads with lubricating oil.
The lubricating oil flows down and collects at the bottom of the gear unit
casing. From here it flows back into the oil container of the oil system.
If oil system and gear unit are positioned on the same level, the lubricating
oil is pumped back from the gear unit into the container of the oil system.
To reach the minimum temperature in cold environment, several immersion

heaters are installed in the oil container. These heat up the lubricating oil in
the oil system. At oil temperature of 25° C operation of the gear unit is ena-
bled. The gear unit can now be started.
The immersion heaters switch off automatically as soon as the oil tempera-
ture in the oil container reaches 35° C. When the temperature in the con-
tainer drops to ca. 30° C, the immersion heaters start up again.
As an additional safety function there are two temperature limiter installed.
The immersion heaters are switched off at 80°C.
During operation, the oil in the gear unit heats up. Behind the cooler (on the
oil system), the oil reaches a temperature of 50° C when entering the gear
unit.
Corresponding switch points for safety and control-relevant operating status-
es must be defined in the control system for the overall plant.
Note!
The required switch points are included in the document "Technical data
oil system" and "Oil circuit diagram" in appendix.
For further information also refer to the logic diagram in the appendix.
In ongoing operation, the cooled lubricating oil is mixed with warm oil behind
the oil cooler.
The gear unit must be switched off immediately in case of a failure of the oil
system. Therefore all relevant lubricating points are monitored by sensors.
These are either on the actual lubricating points or in the pressure-side flow
lines.
Note
The starter units required for switching of the motors are not part of the
scope of supply of Hyosung. Co.
3.2.2 Low-Pressure Lubricating Circuit
Mode of functioning
The low-pressure lubricating circuit supplies all the bearings and gear teeth
of the gear unit with lubricating oil. The low-pressure circuit has the following
main components.
Main components
Oil pump :
An oil pump sucks up the oil required for lubrication and cooling from the oil
tank or from the lower part of the case of the gear unit. A non-return valve is
installed in the pressure line on the delivery side so that the oil pump unit
can be dismantled for maintenance and repair without losing a large amount
of oil. The non-return valve also prevents the oil from flowing back from the
pipes and units into the oil tank when the pump stops.
Double oil filter :
The oil that has been conveyed by the oil pump flows to the double oil filter
and on to the oil cooler. In normal operation of the oil unit (maintenance cir-
cuit in operation), only a very small amount of dirt particles collect in the
double oil filter due to the fine filtering in the maintenance circuit(option). It
therefore serves purely as a safety filter. Dirt only collects as a rule in the
double filter if the maintenance circuit is not in operation, for example, after a
failure or when starting the gear unit from cold.
In normal operation the double filter must be switched such that entire quan-
tity of oil is passed through only the one filter container and the other filter
container is available for use and in a cleaned state. The switchover device
is set to the middle position and the oil is passed through both filter sets
when starting up with oil that is cold and therefore more viscous so as to
reduce the pressure drop in the filter. Switch over to normal operation at the
latest when the operating temperature has been reached.
Oil cooler :
The details of the cooling capacity of the oil cooler and the throughput of
cooling water are given in the technical data (see section "Technical Data").
It is necessary to ensure that the specified throughput of cooling water is
maintained under all circumstances so that the cooler can provide optimum
cooling performance.
The cooling capacity of the cooler cannot be specified exactly due to varying
ambient influences. Under normal conditions it is set as at an oil temperature
of less than 50 °C at the oil outlet of the cooler and at the oil inlet in the gear
unit. For the oil inlet temperature of this gear unit type the following values
apply (cf. "Technical data of the oil system" in appendix C).
– Ideal value: between 40 °C and 50 °C
– Upper tolerance limit: 60 °C up to the "Alarm" temperature

– Lower tolerance limit: <40 °C (only while the unit is starting up)
Attention!
Danger of damage to the components of the gear unit. The oil inlet
temperature may not exceed the "Alarm" temperature. The drive mo-
tor must be switched off automatically at the maximum permissible
oil temperature.
Function of the temperature regulating valve (Option) behind the oil cooler:
– Constant oil inlet temperature in the gear unit under varying loads
– Constant oil inlet temperature in the gear unit under varying cooling water
temperatures
– Quickly reaches the operating temperature when starting up
With the aid of an adjusting device in the valve, the amount of oil passing
through the oil cooler and the bypass pipe is split such that an almost con-
stant oil temperature can be set.
Note
If the valve is defective, the temperature can be set by hand by an emer-
gency control.
Oil pipe:
The pressure pipe is divided into several branches before it enters the gear
unit. The following components are lubricated and cooled by means of these
branches:
– Gear teeth
– Bearing
– Axial bearing area
A non-return valve is built into the supply line to the thrust bearing that pre-
vents a drop in the level of oil in the axial bearing area if a pump fails while
the unit is being shut down.
Pressure limiting valve :
For safety reasons, a pressure limiting valve is built into the pressure line
between the oil pump and the double oil filter. It protects the downstream
units, filters, coolers, etc., against excessively high pressure when the oil is
cold and the oil pump unit against overloading by allowing only part of the
amount conveyed by the pump to pass into the gear unit lubrication. The
excess oil flows into the oil tank via the pressure limiting valve. The amount
of the overflow is reduced as the oil warms up. The valve is closed once the
operating temperature is reached. If the pressure line is completely blocked,
the pressure limiting valve can divert the entire output from the pump into the
oil tank.
A dirty pilot valve in the pressure limiting valve can lead to excessive pres-
sure in the system. The secondary valve in the pressure limiting valve brings
about the opening of the valve in such a case. This increases the operational
security of the unit. The pilot valve must be cleaned at once if the secondary
valve is actuated.
3.2.3 Lubricating Circuit: Monitoring Devices
Attention!
Danger of damage to the components of the oil unit and the gear
unit through malfunctions.
If an alarm signal is given in the oil system, it is necessary to search
immediately for the cause of the alarm and to correct it within a max-
imum of 5 hours (for example, oil temperature too high, oil pressure
or throughput too low). The gear unit drive motor is stopped auto-
matically if the error is not corrected within 5 hours. Damage can
occur in the oil system (for example, by sucking in air if the oil level
is too low).
Attention!
Danger of accidents due to defective or blocked monitoring devices.
Danger of damage to the components of the oil unit and the gear
unit through defective or disconnected monitoring devices.
All the cut-off valves to the manometers and pressure switches must
be open without fail during operation of the oil unit (set in the oper-
ating position). They may only be moved out of the operating posi-
tion for brief periods during operation of the oil unit (for example, to
monitor or to replace a device).
Note
All relevant operating parameters and limit values are included in "Tech-
nical data oil system" (cf. chapter 2).
Difference pressure measuring for monitoring the filters

Important components:
– Pressure gauge : Displays the oil pressure after the oil pump and before
the oil filter.
– Pressure gauge : Displays the oil pressure after the oil cooler and at the
inlet in the gear unit.
Function:
If the manometers show pressures that differ from those given in the tech-
nical data, this is due to a pressure drop in the filter or the cooler. A major
discrepancy indicates that the filter is becoming increasingly dirty. Depend-
ing on the degree of soiling, it is necessary to either clean or replace the filter
(cf. chapter 7 "Service and maintenance").
In addition to the manometers and, a visual and electrical dirt indication dis-
play is installed on the filter:
– Sight field blue  Filter is clean
– Sight field increasingly red  Increasing degree of dirtiness
Once a predefined differential pressure has been reached, the red field co-
vers around 70 % of the marking in the sight field and the electrical dirtiness
display gives an alarm signal. The double oil filter must then be switched
(this can be done while the plant is running), the dirty filter insert removed
and cleaned or replaced.
Attention!
Danger of damage to the filter components when switching from one
filter unit to the other!
Observe chapter 7 "Service and maintenance" and the instructions
of the filter manufacturer.
Oil pressure monitoring after the oil cooler

– Pressure switch or pressure transformer : Initiates an alarm signal on
dropping to the set pressure.
– Pressure switch or pressure transformer : Switches off the drive motor
and the high-pressure pump motors when the minimum pressure is
reached(option).
Monitoring of the oil temperature
Note
The measuring transformer and the associated contact and display in-
struments do not as a rule belong to the scope of supply of Hyosung. Co.
– Temperature switch/ Resistance thermometer: Start up of the lubricating

oil pump motor on exceeding a set value for the oil temperature in the oil
collector tank.
– Thermometer : Reads the oil temperature in the oil tank.
– Thermometer : Reads the oil temperature at the inlet to the gear unit.
Note
The cooling by the oil cooler can be monitored by comparing the oil tem-
perature in the oil tank and at the inlet to the gear unit.
– Resistance thermometer in the pressure line after the oil cooler at the
inlet to the gear unit .
The following 4 switching points must be monitored and triggered as appli-

cable with the measured values determined by the above thermometer:
Switching point Function

Maximum permissible Stops the gear unit drive motor.
oil temperature
Increased oil tempera- An immediate search for the cause of the alarm
ture must be made when an alarm signal is given
and the error must be corrected within 5 hours
at the most. The gear unit drive motor must be
stopped automatically if the error is not correct-
ed within 5 hours.
Activation of the filter Suppression of the alarm signal that is given by
dirtiness monitoring the pressure drop in the filter when the oil is
cold.
– 1, 2 or 4 resistance thermometers in the axial thrust bearing: Tempera-

ture monitoring.
The following 2 switching points must be monitored and triggered as appli-

cable with the measured values determined by the 1, 2 or 4 resistance ther-
mometers:
Switching point Function

Maximum permissible Stops the gear unit drive motor.
axial bearing tempera-
ture
Increased axial bear- If an alarm signal is given, the cause must be
ing temperature searched for and corrected immediately.
The error must have been found within 5 hours
at the most, otherwise the drive motor is to be
switched off manually.
Note
A contact device, for example, can be used to monitor and trigger the
switching points. The device is not provided as a rule by Hyosung. Co. In
addition, the contact device can be used for temperature remote display.
Monitoring of the oil level:
– Level monitoring in the oil tank or in the lower part of the gear unit : Trig-
gers an alarm signal if the oil level drops below a specified level and
switches off the immersion heaters.
3.3 Components for the KPAV Gear Unit (Options)
Information
Information on components for KPAV gear units cf. appendix B.
3.3.1 Main Coupling
The KTR coupling is installed between gear unit and drive motor as a con-
necting element.
4 Packing, Conservation, Transport and Storage
Information
The shipping company receives drawings and documents from Hyosung.
Co. These show the centre of gravity and the lifting points of the gear unit.
4.1 Packing
The gear unit is packed according to the customer's order.
Generally Hyosung. Co will

 Shrink-wrap it, without frame or
 Pack it in a crate and deliver it with steel frame
The oil system, the pipes (between the gear unit and oil system) and the
components are packed in a separate crate.
Packaging stages and storage conditions are listed in the following table.
Packing Parts Method/ packing Duration of stor-

level spectrum items age/place of storage
Packing with pad-

Gear unit max. 12 months from
Steel Pack- ding and filling ma-
data of packing, in a
ing terials as required,
closed room
on a steel flame
Packing with pad-

Lube oil system
ding and filling ma-
Wooden Piping terials as required,
Packing Main coupling on a pallet, wooden
supernut frame, boarding,
crate
Tab. 4.1: Packing levels
4.2 Conservation
When supplied, the gear unit is preserved inside and outside.
 Inside preservation is done by Hyosung. Co during the test run with

"Antirust 1013" and
 outside preservation with "Antirust 720"
The Antirust 1013 anti-corrosion protective oil is completely dissolved as a

rule in the oil used for actual operation during the initial commissioning.
For de-preservation, the corrosion protection agent Antirust 720 is removed

with benzene.
DANGER!
Danger caused by materials and substances!
 Wear your personal protective equipment when preserving and de-
preserving the gear unit.
 Wear protective gloves and tightly fitting protective goggles.
 Observe the local regulations concerning environmental protection!
 Observe the relevant safety data sheets!
4.2.1 Internal Conservation
When supplied, the gear unit is preserved inside.
Note!
If the gear unit is out of operation for a longer period or if it is to be
stored (for longer than stipulated according to the packaging de-
gree), you will have to carry out inside preservation (long-term
preservation)!
 For long-term preservation (inside) use the operating oil recommend-

ed by Hyosung. Co - ISO VG 320 (Mineral Oil, according to specifica-
tion).
 Have compatibility of the operating oil ISO VG 320 with the corrosion
protection oil Antirust 1013 confirmed by the supplier of the operating
oil.
 Observe the safety data sheet of the preservation agent!
4.2.2 Long-Term Preservation (Optional)
For information concerning long-term preservation, please contact our Hy-

osung. Co service ahead of time. You will then receive the necessary com-
ponents and detailed documentation.
Attention!
Use of preservation agents that are not approved may cause corrosion
damage on the inside of the gear unit.
Note!
 Inform Hyosung. Co if you want to decommission and store the
gear unit permanently. Hyosung. Co will specify the measures to
be taken for inside and outside preservation and storage in case of
permanent decommissioning.
4.2.3 External Conservation
When supplied, the gear unit is preserved outside.
Note!
If you store the gear unit for longer than stipulated according to packaging
instruction, carry out outside preservation!
 Preserve all outside unvarnished parts that are exposed to the danger of
corrosion during storage using the corrosion protection grease Antirust
720.
 Wear protective gloves and protective goggles.
 Apply Antirust 720 with a brush and
 Ensure that the film is evenly applied
 Observe the safety data sheet of the preservation agent used.
Attention!
Danger of damage to the gear unit.
The specified duration of corrosion protection is only guaranteed as long
as the film-like covering is not broken.
4.3 Transport
DANGER!
Danger caused by falling heavy parts!
The industrial gear unit and any separate components are very heavy (cf.
information in chapter 2.2 "Weights" in the technical data).
 Never step under suspended heavy loads.
 Transport the gear unit only if you have the required qualification
and permission to operate lifting gear.
 Lift the gear unit only on the devices intended for this purpose.
 The gear unit must be secured against slipping, attached at the
provided attachment points transported and put down.
 Ensure that your lifting equipment is suitable for lifting the weight.
Only use lifting gear and ropes or cables of an adequate load and lift-
ing capacity in transport.
4.3.1 Transport of the Gear Unit in a Crate
In individual cases the gear unit is transported in a special crate on steel

frame, which must be lifted by means of crane.
The gear unit has defined attachment points which are used for lifting it. Cf.
also chapter 4.3.3 "Lifting the gear unit".
Information
The shipping company receives drawings and documents from Hyosung.
Co; they show the centre of gravity and the attachment points of the gear
unit.
4.3.2 Transporting the Gear Unit wrapped in Film
DANGER!
Danger caused by improper lifting and setting down!
 Never pull ropes or other lifting equipment over the drive casing.
Ensure that the corrosion protection is not damaged.
 Never fasten ropes or other lifting equipment on the drive shaft.
 Never use the drive shaft for lifting or tying down.
This way you can ensure that the drive shaft and its bearings are not
damaged.
 Never pull the gear unit across the floor to transport it.
Ensure that the bottom surface of the gear unit is not damaged.
Attention!
Ensure that the packing foil is not damaged during transport and storage.
4.3.3 Lift Gear Unit
Attention!
The ropes or cables from which the gear unit is to be suspended may only
pass over the guide plates intended for this purpose (see Fig. 4.1, [2]).
Ensure that the ropes or cables do not run over parts that have been at-
tached and not over the output flange.
The ropes for lifting the gear unit are suspended from the marked eye holes
of the ribs (cf. fig. 4.1, [1]). The ropes are to be arranged in a way that they
run over the guide plates. The suspension holes are likewise to be used for
lashing down.
Note!
Lifting with hydraulic lifting equipment (machine lifter) should only
be done at the rib cutouts (cf. fig. 4.1, [3]).
- Lift Hole size : ¢ 60 mm
- Shackles(Screw Pin Anchor) : Nominal size ¢ 35.05 mm, 12ton
Fig. 4.1: Lifting of the gear unit
1 Suspension holes
2 Guide plates
Lifting the gear unit

Information
Weight of the industrial gear unit and its optional components cf. chapter
2.2 "Weights" in the technical data.
 Lift the gear unit only on the eye hole intended with suitable lifting gear.
 Ensure that the ropes run vertically over the guide plates (cf. drawing fig.
4.1).
If the ropes run too diagonally or, if the guide plates are missing the drive
flange and the corrosion protection of the gear unit will be damaged.
 If the gear unit is packaged in a crate, observe the centres of gravity on

the crate marked in red.
4.3.4 Setting Down the Gear Unit
 Ensure that the surface is dry, level and stable.
 Ensure a suitable sub-structure is available, e.g. a base frame that is

firmly anchored in the concrete with prepared bearing surface.
This way you will prevent damage to the bottom surface of the gear unit.
 Secure the gear unit against slipping while it is transported.
 For transport, tie the gear unit down only using the eye holes.
4.4 Storage
If the gear unit is to be out of operation for a longer period or if it to be put in

storage, it must be treated with a conservation agent both inside and out.
Contact Hyosung. Co beforehand, regarding longer periods of storage and
use of preservation agents.
Note!
 Follow the instructions for transporting and setting down the gear
unit in paragraph 4.3.1 "Lifting the gear unit" and paragraph 4.3.2
"Setting down the gear unit".
 Also follow the necessary packaging stages according to table 4.1
under paragraph 4.2.2 "External preservation" before putting the
gear unit into storage.
 Store the gear unit only in the scope of the contractually agreed
ambient conditions:
This way, you can ensure a long service life of your gear unit and prevent
corrosion damage.
Storage and conservation of the oil system

The oil unit and outside pipe are treated inside and outside with a conserva-
tion agent and packed in accordance with the stipulations of the sales con-
tract.
The pipes between the gear unit and the oil unit are packed in a separate
crate.
If the oil unit is to be stored out in the open under a cover, the protection
against corrosion must be effective for 12 months.
Information
Further information is included in the documentation of the oil sys-
tem in the appendix.
4.5 Long-Term Preservation (Option)
Note!
For information concerning long-term preservation, please contact
our Hyosung. Co service.
Hyosung. Co will specify the measures to be taken for long-term preser-
vation and storage in case of permanent decommissioning.
5 Setting Up and Connecting
DANGER!
Danger caused by falling heavy parts!
The industrial gear unit and any separate components are very heavy (cf.
information in chapter 2.2 "Weights" in the technical data).
 All installation and dismantling work on the gear unit and gear unit
components may only be carried out with sufficiently dimensioned
lifting gear.
 Ensure that your lifting equipment is suitable for lifting the weight.
 Never step under suspended heavy loads.
 Transport the gear unit only if you have the required qualification
and permission to operate lifting gear.
 Lift the gear unit only on the devices intended for this purpose.
DANGER!
Danger caused by improper lifting and setting down!
 Never pull ropes or other lifting equipment over the drive casing.
Ensure that the corrosion protection is not damaged.
 Never pull the gear unit across the floor to transport it. Ensure that
the bottom surface of the gear unit is not damaged.
DANGER!
Risk of contamination with dirt and hence a danger of damage to the
gear unit!
Pay attention to cleanliness during all installation and dismantling work on
the gear unit and gear components. Do not allow dirt or foreign particles
to get into the openings of the gear unit or into other parts (e.g. pipes,
hoses).
DANGER!
 Never open terminal boxes or electrical equipment unless you
are a trained electrician.
 Switch off immersion heaters in the oil system and secure them
against switching on before you begin commissioning, mainte-
nance and repair activities on the gear unit.
 Always have zero-potential checked by a trained electrician before
you work on or near parts of the electrical system.
DANGER!
Warning!
Benzene must never penetrate or touch the gear unit!
 Use benzene only for removing grease from outside, unfinished
components.
 After that, dry off the benzene from the de-greased components so
that no residue is left.
Warning!
Hyosung. Co recommends that a mechanic from Hyosung Co. is
present during setup, inspection of the installed gear unit and first-
time start-up at the site of installation.
Note!
General information on setting up the gear unit:
 Screws and other connecting elements as well as securing ele-
ments must be replaced if damaged during disassembly.
 After major and extended repair work an oil change is recom-
mended (cf. chapter 7 "Service plan gear unit").
 After assembly, check alignment of the gear unit (cf. 5.2.1 "Align
gear unit").
 Close pipe openings on gear unit and pipes.
 Install grinding bowl and drive flange without contamination.
 Tighten the screws on the drive flange for fastening the grinding
bowl evenly.
 The maximum permissible axial run-out is ±0.1 mm over a radius
of 200 mm and the total deviation may not exceed ±0.06 mm.
 The gear unit, drive and power output components must be in-
stalled correctly and prepared in accordance with the operating in-
structions.
5.1 Foundation
 The gear unit is to be installed on a strong, vibration-free, flat founda-

tion.
 What meets this purpose is a base frame that has been firmly an-
chored into concrete and has a prepared surface.
 After it has been aligned, the gear unit is to be fixed in place with
strong tapered pins and bolted to the base frame.
 In operating condition, the drive shaft to be connected to the main
drive motor must align to the drive shaft of the motor precisely.
Information
Required information for installation is included in the installation drawing
in the appendix.
5.2 Accessories
The valves, pressure switches, manometers and the parts of the pipes are
shipped at the same time in separate packing as applicable by Hyosung. Co
for transport reasons.
They must be cleaned thoroughly before assembly and installation.
If subsequent changes are made to the pipes (only with the approval of Hy-
osung. Co), the pipes concerned must be cleaned thoroughly (pickled).
Ensure during the cleaning and installation that no foreign bodies (waste
cotton, paper, wood, etc.) get into the pipes.
5.3 Preparing Gear Unit for Installation
5.3.1 Unpacking
 Remove the transport packaging.
Fig. 5.1: Gear unit with film transport packaging(Reference)
De-preserving
Prior to putting into service of the gear unit the corrosion protection com-
pound of inner and outer preservation must be removed.
The Antirust 1013 anti-corrosion protective oil is completely dissolved as a

rule in the oil used for actual operation during the initial commissioning.
For de-preservation, the corrosion protection agent Antirust 720 is removed

with benzene.
DANGER!
 Wear your personal protective equipment when de-preserving the
gear unit.
Warning!
components.
5.4 Installation
The gear unit forms the basis for the grinding bowl.
When the gear unit is set up and aligned the grinding tools are aligned to-
wards it.
5.4.1 Transporting Gear Unit to Set-Up Location
 Take the gear unit to the intended set-up location (cf. also chapter 4.3.2,
"Transporting the gear unit").
 Set the gear unit down precisely onto the base frame.
5.4.2 Aligning Gear Unit
ATTENTION!
The gear unit must be aligned at an even temperature.
 Ensure that during alignment the temperature is unchanged.
 Avoid direct sun radiation during alignment.
This way, the gear unit will stay in its precise alignment. This is a condi-
tion for low-wear operation later.
 Align the gear unit exactly horizontal on both axles.
5.4.3 Fastening Gear Unit to Foundation
 Fix the gear unit to the base frame using tapered pins (cf. installation
drawing in the appendix).
 Bolt the gear unit to the base frame.
5.4.4 Grounding Connection / Potential Equalization
Note!
The gear unit casing has a grounding connection (25 mm2).
When connecting the gear unit to the overall plant, the distributing com-
pany of the overall plant must ensure that potential equalisation is exe-
cuted by a cable that has at least half the cross section of the outside
conductor.
Fig. 5.2: Grounding connection
1 Grounding connections on the base plate of the gear unit casing
 Connect the grounding connection to the customer-provided PE-

connection of the overall system.
5.4.5 Connecting the Oil System
DANGER!
Danger caused by improper connection!
 Ensure that the oil lines are connected vibration-free.
This way you can prevent them from breaking during operation and hot oil
from splashing out.
Note!
Ensure that
 the oil lines are free from dirt and
 that no foreign particles penetrate into the oil lines and the gear
unit.
This way you prevent damage to toothings and bearings and avoid a con-
siderably longer rinsing procedure of the oil system / the gear unit.
Connecting oil lines

 Align the oil lines and the oil system towards the connections of the gear
unit.
 Screw the oil lines of the oil system to the connections on the gear unit.
 Replace defective seals with clean, new seals.
Information
Alignment of oil lines and oil system must be carried out to the customer-
specific installation drawings.
5.4.6 Removing Inside Preservation Oil
DANGER!
Danger caused by tripping and falling!
 Absorb spilled or leaked oil immediately.
This will prevent that you or others slip and fall.
 Drain the remaining inside preservation oil before you fill in the lubricat-
ing oil for operation.
 Dispose of the drained oil according to the local regulations.
 Observe the information in the safety data sheet.
Gear unit
 Open
– the Ball valve of the axial bearing area at the top end of the gear unit
and
– the ball valve at the bottom end of the gear unit.
 Collect the residual oil in suitable containers.
 Close the ball valves.
Oil system
 Open the ball valve at the bottom part of the oil unit.
 Catch the residual oil in suitable containers.
 Close the ball valve.
After long-term preservation
Information
If you have filled several 1000 litres of the operating oil ISO VG 320 into
the gear unit for long-term preservation,
 drain this oil.
 Collect the draining inside preservation oil in a container.
 Dispose of drained oil according to the local regulations.
 Remove the special attachments for long-term preservation.
 Also read the separate instructions "Long-term preservation indus-
trial gear unit KPAV" chapter 10 "Removing inside / long-term
preservation" already in your possession.
Note!
Depending on ambient and oil temperature, it may take several hours to
drain in the oil.
5.4.7 Filling Gear Unit with Oil
DANGER!
Filling oil system with oil
Information
Instructions for filling the oil system with operating oil are included in the
operating manual of the manufacturer of the component in appendix C of
this operating manual.
Filling gear unit / oil system

For commissioning the gear unit, the oil system must be filled with the oper-
ating oil ISO VG 320.
Note!
 Only fill clean oil into the gear unit / oil system.
 Use only approved gear oil for filling.
 Filter the oil through a 10 µm fine filter when filling the oil system.
This way you will prevent damage to the toothings and the bearings in the
gear unit.
Information
Information about the permitted operating oil is included in the document
"Lubricants chart" in appendix D.
Operating steps for filling the gear unit / the oil system with operat-
ing oil ISO VG 320:
1. Fill the oil container of the oil system through the maintenance circuit
pump(Option) with the prescribed operating oil.
2. Switch on the lubricating oil pump to fill the axial bearing area, the
bottom part of the gear unit and the components.
ATTENTION!
Damage to the pump due to a lack of lubricating oil!
It is essential that the oil pumps are wetted with oil before they are started
up for the first time.
3. Re-fill oil into the oil container of the oil system. Here, the oil in the oil
display should be between "normal" and "maximum".
ATTENTION!
Damage to the pumps by sucking in air!
When starting up the oil pump for the first time, the axial bearing area, the
gear unit casing and the components are filled.
 Ensure when doing this that the oil level is sufficient for operation
of the pump.
 Dry-running of the pump must be avoided.
4. If the oil level is below "normal" top up operating oil.
5. Rinse the oil system / the gear unit with the prescribed operating oil
for at least 4 hours. (cf. document "Lubricants chart" in the appendix
of this operating manual).
6. By connecting the maintenance circuit pumps(Option) the oil is

cleaned prior to the first start-up of the gear unit.
7. During the rinsing process, check the dirt indication display of the fil-
ters.
8. Depending on the degree of soiling, clean or change the filter inserts

(cf. documentation of the filter manufacturer in the appendix).
9. Continue the rinsing process until the filters are free from soiling.
Note!
If the filter units do not remain clean after a considerably long rinsing peri-
od, the operating oil must be changed and cleaned outside the gear unit.
This danger occurs during considerable introduction of dirt during
transport or during assembly.
The rinsing process must then be repeated.
 After filling, check the oil level in the oil inspection glass of the axial bear-
ing area.
The oil is not yet distributed in the gear unit. Therefore the oil level
should be above the maximum display [1].
Fig. 5.3: Oil inspection glass
1 Max. oil level

2 Oil inspection glass
 Check the gear unit for leaks.
 Inform the Hyosung. Co service if you discover leaks.
5.4.8 Aligning and Connecting Drive Motor (Option)
ATTENTION!
 Check that the version of the motor has an axial bearing.
If the motor is without axial bearing, the coupling must have an axial back-
lash limitation!
Aligning drive motor

To ensure that the drive shaft of the gear unit is exactly aligned with the drive
shaft of the main motor, they must be checked for concentricity and axial
run-out with the measuring set-up according to fig. 5.5.
Fig. 5.4: Measuring set-up for checking concentricity and axial run-out
Coupling type Trueness of running Axial run-out

Elastic coupling 0.05 mm 0.05 mm
Tab. 5.1: Permissible tolerances
For r ≠ 200 mm the run-out tolerance changes proportionally to the meas-

ured radius r.
 Align the drive shaft of the main drive motor to the input shaft of the gear
unit.
The values specified in table 5.1 must be observed, even if the coupling
manufacturer permits larger values. No axial forces are to be transmitted
into the gear unit via then coupling when it is in operation.
 Align the main drive motor by shifting and lifting until the required align-
ment exactness has been reached.
Information
For axial alignment, observe the information in the operation / operating
manual of the coupling manufacturer.
Checking rotational direction by means of the label
Fig. 5.5: Rotational direction gear unit input shaft
The prescribed rotational direction of the drive motor is marked by a direction

arrow on the gear unit.
 Do not yet connect the drive motor or the coupling shaft to the gear unit.
 First, check the rotational direction of the drive motor.

 To do so, briefly start the drive motor.
 If necessary, change the rotational direction of the drive motor.
Connecting
ANTIRUST 1013
Fig. 5.6: De-grease shaft end gear unit input shaft
DANGER!
 Wear your personal protective equipment when de-preserving the
gear unit.
 Before connecting, de-grease the shaft end of the gear unit input shaft
as long as the coupling has not yet been fixed.
 Use benzene to do so.

 Then dry off the benzene so that no residue is left.
 Now connect drive motor and coupling to the gear unit drive shaft.
Warning!
components.
DANGER!
Danger caused by open rotating shafts!
 Never operate the gear unit without protective covers!
This will prevent injuries caused by open rotating shafts.
5.4.9 Aligning and Installing Grinding Bowl
Information
Installation of the grinding bowl to the gear unit drive flange must be car-
ried out according to the customer-specific installation drawings.
ATTENTION!
Other than the static axial forces, no other forces may affect the gear unit.
5.4.10 Connecting Sensors
DANGER!
Danger due to electric arcing!
 Carry out work on the power supply only if you are a trained and
qualified specialist for this type of work.
Ensure that all parts of the gear unit casing are grounded.
Fig. 5.7: Connecting sensors
1 Sensor strip
Information
The connections for the sensors are in a terminal box on the gear unit.
Note!
Observe when connecting sensors
 The plans in appendix A of this operating manual
– Oil Circuit Scheme,
– Technical data of the gear unit and the oil system,
– Outer piping plan,
– Terminal diagram,
– Installation drawing.
 Information concerning setting values and switching functions in
table 1 in the document "Technical data oil system" in appendix C
of this operating manual.
 Table 2 "Electrical values" in the document "Technical data oil
system" in appendix C.
 The information in the diagram for gear unit cabling in appendix
A.
5.4.11 Setting Up and Connecting Components
When the gear unit

 is aligned,
 fixed to the foundation and connected,
 ready-to-operate,
the optional components can be
 set up
 and connected.
DANGER!
For the components, please observe
 Proper use,
 Observation of the capacity limitations,
 Information in chapter 1.4 of this manual, e.g.
 The prescribed safety chains and performance levels,
 Grounding according to the specified cross section,
 The specified EN standards
 Installation of the emergency stop and power grid disconnection
devices.
Information
Instructions for setting up / installation or attaching and connecting of the
components
 KTR coupling
Are included in the documents of the suppliers in the appendix of this op-
erating manual.
Note!
The gear unit casing has a grounding connection (25 mm2).
When connecting the gear unit to the overall plant, the distributing com-
pany of the overall plant must ensure that potential equalisation is exe-
cuted by a cable that has at least half the cross section of the outside
conductor.
DANGER!
Please observe the following safety instructions
 It is mandatory that in normal operation
– The maintenance / positioning drive is electrically locked,
– The protective hoods on the main coupling and on the
maintenance / positioning drive are installed and
– A device prevents attaching the chain.
 During attaching / removing the chain it must be ensured that

– The main motor and the maintenance / positioning drive is
locked and
– The chain lock is in the upper position
 When driving the maintenance / positioning drive it must be en-
sured that
– The main motor is locked
– The chain guard hood including main coupling protection are
installed and
– The chain lock is in the upper position.
ATTENTION!
 All safety chains, safety terminal switches and safeguards must be
realised by the operating company of the overall plant.
 When driving the maintenance / positioning drive, the overall oil
system, in particular the oil pump and the high-pressure radial pis-
ton pump must be switched off.
 For the maintenance / positioning drive, the permitted drive mo-
ment must never be exceeded. Due to the large gear ratio, a low
motor capacity may generate large moments.
Normal operation of the main gear unit

During normal operation, a chain lock or the coupling protection prevent
attachment of the chain. At the same time, a safety switch locks the mainte-
nance / positioning drive.
6 Initial Commissioning, Checking and Decommissioning
DANGER!
 Never operate the gear unit without protective covers.
DANGER!
Danger caused by splashing hot oil!
 Never open an inspection hole cover while the gear unit and the
overall plant are operating.
DANGER!
Danger caused by crushing and inrunning nip!
 Always operate the gear unit with closed inspection hole covers.
Ensure that no injuries are caused by rotating parts of the gear unit.
DANGER!
Danger caused by hot surfaces!
 Always wear personal protective equipment (protective goggles
and protective gloves) when working on the gear unit.
6.1 Restart the Gear Unit
 Switch on the control system of the mill.
Information
 Observe the instructions in the operating manual of the plant
control system.
Note!
The start-up temperature must be reached!
 Before starting the gear unit, run the oil system for at least 10
minutes!
This way, the heated lubricating oil is pumped through the gear unit in
order to build up a lubricating film in the gear unit. This will ensure that no
damage is incurred to the gear unit by dry-running.
 Check the lubricating oil supply.
 Check the limit values.
 Test the switch points defined for measuring vibrations according to ta-
ble 1 in the document "Technical data oil system" (cf. appendix C of this
operating manual).
Note!
Listen for unusual noise from the gear unit!
 Inform Hyosung. Co if you discover unusual noises.
Note!
Check for leaks!
 Check the oil connections for leaks.
 Repair any leaks on screw connections and flanges.
 Replace defective seals.
 Inform Hyosung. Co if you discover leaks in different places than
screw connections and flanges.
6.2 Service Instruction after Initial Commissioning
 After initial commissioning, carry out the following service activities:
Intervals:
1 = Every 3-4 hours

2 = First day after start-up
3 = First 3 days after start-up
4 = 400-600 operating hours
Service overview after initial commissioning
Every 3-4 hours

First day after start-up
First 3 days after start-up
400-600 operating hours
Service element
Gear unit
Axial thrust bearing: Check oil level on in-
X X X X
spection glass
Connection lines: Check for leakage X X X X
Gear unit to foundation: Check fastening X X X
Couplings and gear units: Check alignment X X
Air filter: Checking for permeability X
Oil system
Filter dirt side oil sample: Carry out Oil
X
Analysis
Filter: check for contamination X X X X
Oil level: Check oil level on oil level indica-
X X X X
tor
Connection lines: Check for leakage X X X X
Air filter: Checking for permeability X
Tab. 6.1: Service overview: Gear unit and the oil system after initial commis-
sioning
Service jobs on the gear unit after initial commissioning
Location Work Consumables / notes / reference Interval Interval Interval Interval

1 2 3 4
Axial thrust Check oil level in the axial pressure bear- When the gear unit is in operation the oil in-
bearing ings by visual inspection of the oil inspec- spection glass should be filled more halfway
tion glass. with oil; in case of standstill of the gear unit, the
oil should be visible up to halfway of the oil
inspection glass.
X X X X
If the oil level is lower this may indicate an er-
ror in the oil system. Risk of dry-running. In-
form the Hyosung. Co service!
Connection Check hoses, pipes and seals for leakage,
lines replace if necessary or repair by tightening X X X X
the screw connection.
Gear unit to Check the fastening of the gear unit on the Cf. operating manual of the gear unit, chapter
X X X
foundation foundation; renew faulty connections. "Align gear unit".
Couplings and Check for correct alignment and adjust if Cf. service instructions of the component man-
X X
gear unit necessary. ufacturer.
Air filter Check for permeability and renew if nec- Filter for renewing cf. spare parts list of this
X
essary. operating manual.
Service jobs on the oil system after initial commissioning
Location Work Consumables / notes / reference Interval Interval Interval Interval

1 2 3 4
Filter dirt side Take oil sample from the filter dirt side and The record of the oil sample serves as a refer-
carry out an oil analysis in a certified la- ence for quality analysis, according to the ser- X
boratory. vice intervals.
Filter Checks filter elements (double oil filter and Cf. service instructions of the component man-
fine filter) for contamination. ufacturer.
X X X X
If metal shavings or grit are discovered inform
the Hyosung. Co service immediately.
Oil level Visual inspection of the oil level. Cf. service instructions of the component man-
ufacturer.
The oil level must always be within the limit
values in order to prevent and damage caused
X X X X
by the immersion heater and an error of the oil
system.
Changes of the oil level may indicate leakage,
water penetration or an error in the oil system.
Connection Check hoses, pipes and seals for leakage,
lines replace if necessary or repair by tightening X X X X
the screw connection.
Air filter Check for permeability and renew if nec- Filter for renewing cf. spare parts list of this
X
essary. operating manual.
6.3 Operate Gear Unit
DANGER!
Danger caused by darting flames!
 During operation, keep away from the air vents.
Mechanical damage of the bearings or other parts of the gear unit may
generate ignition sources in the gear unit. As a result, the oil-air mixture in
the gear unit may ignite and escape as a dating flame from the air vent.
DANGER!
 Never operate the gear unit without protective covers.
DANGER!
Danger caused by crushing and inrunning nip!
 Always operate the gear unit with closed inspection hole covers.
Ensure that no injuries are caused by rotating parts of the gear unit.
DANGER!
DANGER!
Danger of fire or explosion!
 Never open an inspection hole cover while the gear unit and the
overall plant are operating.
Deflagration may occur if overheated parts are inside the casing and air
or oxygen is added through the open inspection hole cover.
Note!
Monitor the functions of the control system of the overall plant.
6.4 Shutting Down Gear Unit
Note!
The gear unit still runs on for a few rotations when the mill is switched off
normally.
 Switch off main drive motor.
 Leave the oil system in operation until the gear unit has come to a
standstill and has cooled down.
Note!
After the gear unit is switched off, the oil unit must remain in operation for
around another 30 minutes to ensure that the lubrication of the gear teeth
and bearings is preserved and no heat builds up.
The gear unit / oil temperature is then <40°.
Note!
 In case of shorter standstill periods (up to 10 hours) the oil pump
should continue to run in order to keep the oil at a minimum oper-
ating temperature (ca. 25 °C) so that the gear unit can be started
up at any time.
 The oil unit must be put into operation around every 14 days in the
event of longer periods of shutdown. The oil pump must run ap-
proximately every 30 minutes with fresh oil so that all the lubrica-
tion points are provided with fresh oil.
 In the case of longer periods of shutdown (over 6 months) or if
there is no oil supply, then the gear unit must be given a conserva-
tion treatment as described in the details on protection against cor-
rosion.
 For information concerning long-term preservation, please contact
our Hyosung. Co service ahead of time. You will then receive the
necessary components and detailed documentation.
6.4.1 Decommissioning up to 6 Months
Note!
 Run the gear unit at low rotational speed and low load every four
weeks. This way you can prevent deterioration in storage inside
the gear unit.
 To do so, first switch on the oil system. Wait until the correct tem-
perature to enable operation (25°C) is reached. This way lubrica-
tion of the gear unit is ensured.
6.4.2 Permanent Shutting Down/ Decommissioning
Note!
 Inform Hyosung. Co if you want to decommission and store the
gear unit permanently.
 For information concerning long-term preservation, please contact
our Hyosung. Co service ahead of time. You will then receive the
necessary components and detailed documentation.
7 Maintenance and Repair
Careful and regular service and maintenance are necessary in order to rec-
ognise faults on the gear unit in time and repair them. Such faults may cause
extensive damage.
Upon request, the Hyosung. Co service department offers service manage-
ment that includes training as well as provision of spare parts.
Service jobs must be documented. Keep the corresponding documents so
that they are available to the Hyosung. Co service personnel.
Note!
Availability of spare parts
 Check availability of spare parts ahead of time before beginning
service jobs.
 Note the delivery time of spare parts
 Ensure that spare parts are stored and preserved correctly.
 Renew preservation if necessary.
Note!
In addition, observe the service and maintenance information in the at-
tached instructions of the components' manufacturers.
 Observe the prescribed service intervals!
7.1 Safety Information
DANGER!
Danger of life as a result of unprofessional service or repair of the
gear unit!
 Repairs on/in the gear unit are to be carried out only by Hyosung
Co. service personnel.
 Unauthorised opening and unprofessional manipulation may result
in danger of life or material damage; in consequence, warranty will
be lost.
DANGER!
Danger of life due to electric shock!
touching live parts. Please observe the following safety rules:
 Switch the electrical equipment of the gear unit to zero-potential on
all poles when carrying out maintenance work.
 Secure electrical disconnection against unintentional switching on.
 Verify that there is no voltage on the components switched to zero-
potential.
DANGER!
Danger when opening the inspection hole cover! Possible danger of
deflagration caused by sudden inflow of air / oxygen!
 Inspection hole covers may only be opened by trained service per-
sonnel.
 Wear personal protective equipment.
 Shut down the gear unit.
 Secure the gear unit and the connected components against
switching on.
 Let the gear unit cool down.
DANGER!
Danger of life caused by rotating parts!
touching rotating parts:
 Wait until all rotating parts have come to a standstill, including
secondary drives.
 Secure them against unintentional start-up!
DANGER!
Danger of life caused by hot parts!
Imminent danger arises for the health of the person concerned when
touching hot parts of the gear unit:
 Wait until the surface and the other parts of the gear unit are
cooled down and only hand-warm.
DANGER!
Never open an inspection hole cover while the plant is operating.
DANGER!
Absorb spilled or leaked oil immediately. This will prevent that persons
slip and fall.
DANGER!
Danger of life caused when protective devices are not installed!
Ensure that after service and maintenance jobs ...
 All protective devices are installed properly,
 No tools, packaging material or other loose parts remain on/inside
the gear unit,
 All danger information of this plant documentation are observed,
 The local safety and accident prevention regulations are observed.
Note!
Observe the prescribed service intervals!

After initial commissioning, carry out service jobs according to service plan.
This will help to maintain the function of the gear unit and ensure a long
service life.
7.2 Qualification of the Personnel
Qualification of the personnel for service and maintenance jobs is defined as

follows:
Level Description
A0 Specialist - personnel on site
A1 Service personnel – Hyosung. Co recommends that ser-
vice personnel of the owner/operator are trained by a spe-
cialist from Hyosung. Co.
A2 Hyosung. Co service
DANGER!
Danger of caused by unqualified personnel!
Repairs on the gear unit are to be carried out only by specialised Hy-
osung. Co service personnel.
The necessary specialised knowledge cannot be taught in this operating
manual.
7.3 Service Plan Gear Unit
Note!
This service plan is a recommendation and describes the minimum scope
of service jobs.
Monitoring of vibrations (roller bearings) is recommended by Hyosung Co.
Capturing of data is only possible if sensors are included in the scope of
delivery and have been installed by Hyosung. Co.
If you decide in favour of retrofitting, please contact the Hyosung. Co ser-
vice.
Temperature monitoring of the plain and axial bearing is always included
in the Hyosung. Co scope of delivery.
7.3.1 Service Overview - Gear Unit and Couplings
continuously
every time after an alarm
weekly
monthly
after 1000 operating hours
yearly
after 2 years
after 6 years
20000 operating hours
Service element Service level

Vibrations: Gear unit case X A1
Vibrations: Bearing X A1
Vibrations: Gear teeth X A1
Gear unit inlet oil pressure X A0
Gear unit oil temperature X A0
Axial thrust bearing X A0
Pipes, hoses, seals
X X A0
(outside)
Air filter X A0
Output flange X A0
Filter dirt side, oil sample X A1
Gear oil – oil change X A1
Casing and added-on parts X A0
continuously
weekly
monthly
yearly
after 2 years
after 6 years

Components of measuring
equipment, X A1
instruments
Fixing X A0
Alignment of gear X A1
Gear teeth X A2
External hoses X A0
General inspection
Bearings, internal seals,
X A2
internal hoses, consuma-
bles
Outside components cou-
X A1
pling elements
KTR coupling X A0
Tab. 7.1: Service overview: Gear units and couplings
7.3.2 Service Measures - Gear Unit and Couplings
Gear unit
Location Work Consumables / notes / reference Qualifica- Interval

tion
Case Measuring of vibrations, Vibrations of the gear unit should be monitored inside
Archiving records or outside on the casing.
A1 continuously
Short-term or long-term changes of vibrations may
indicate improper operation or damage.
Bearing Measuring of vibrations (roller bearings) Vibrations on the bearings of the gear unit should be
and temperatures (plain bearings), measured inside or outside the gear unit near the
Archiving records bearings.
Short-term or long-term changes of vibrations may A1 continuously
Hyosung. Co will provide information on the specific
gear frequencies.
Gear teeth Measuring of vibrations / frequencies, Vibrations on the toothed parts of the gear unit should
Archiving records be measured inside or outside the gear unit near the
bearings. A1 continuously
Short-term or long-term changes of vibrations may
Gear unit inlet Check the oil pressure Reference values cf. document "Technical data oil
Oil pressure system" and "Oil circuit diagram".
Deviating oil pressure values may indicate malfunc- A0 continuously
tion of components of the oil system, leakage, errors
in the gear unit.
Translation of the original instructions – Industrial gear unit – KPAV 125 -HKC01090000039 –VRM 7.7

tion
Gear unit oil tempera- Check the oil temperature Reference values cf. document "Technical data oil
ture system" and "Oil circuit diagram"
Deviating oil temperature values may indicate mal- A0 continuously
function of components of the oil system, leakage,
errors in the gear unit.
Axial thrust bearing Check oil level in the axial pressure bear- When the gear unit is in operation the oil inspection
ings by visual inspection of the oil inspec- glass should be filled more halfway with oil; in case of
tion glass standstill of the gear unit, the oil should be visible up
to halfway of the oil inspection glass. A0 weekly
If the oil level is lower this may indicate an error in the
oil system. Risk of dry-running.
Inform the Hyosung. Co service!
Pipes, Visual inspection and check for: Apply corrosion protection Antirust 1013 for outside
Hoses, – Leak, unvarnished parts with a brush.
Seals – Dirtiness,
(outside) – Rust and
– Damage
weekly
and
– Faultless fastening A0
every time after an
If necessary: alarm
– replace,
– clean,
– Renew corrosion protection
– Faultless fastening
Air filter Check for permeability and renew if nec- Filter for renewing, cf. spare parts list of this operating
A0 monthly
essary. manual.

tion
Output flange Measure of the distance (gap) of drive A deviating value may indicate a malfunction of the oil
flange to upper edge of the gear unit cas- system or wear of the axial pressure bearings. A0 2000 operating hours
ing and compare to initial value (marked x) Inform the Hyosung. Co service!
Filter dirt side Take oil sample from the filter dirt side and If oil quality declines the interval for oil analysis must
Oil sample carry out an oil analysis in a certified la- be shortened and, if necessary, a full oil change pre- A1 2000 operating hours
boratory. pared.
Gear oil Full oil change! Mineral oil ISO VG 320
Exchange of all the gear oil unless the oil See operating instructions, chapter “Oil change”. A1 20000 operating hours
analysis permits a longer utilisation period.
Casing and Check components for: Apply corrosion protection Antirust 1013 for outside
added-on parts – Damage, unvarnished parts with a brush.
– Rust and
– Faultless fastening.
A0 4000 operating hours
If necessary:
– replace,
– clean,
– Renew corrosion protection.
Components of Function check of all components and in- Cf. operating manuals of the components’ manufac-
measuring equip- struments of the measuring equipment. In turers.
ment, case of faulty function, exchange compo-
Instruments nent.
Fixing Check the fastening of the gear unit on the See operating instructions, chapter “Align gear unit”.
foundation; renew faulty connections.
Alignment of gear Check alignment of gear unit and adjust in See operating instructions, chapter “Align gear unit”.
A1 yearly
case of deviations.

tion
Gear teeth Visual inspection of all toothed parts by Endoscope
means of endoscope through the inspec- Observe safety information for opening the inspection
tion hole cover. hole cover!
Inspection Plan service jobs ahead of time and inform the A2 yearly
– Of the tooth contact pattern Hyosung. Co service!
– For rust and
– Abrasion of inside parts.
External hoses Exchange hoses. Recommended intervals for exchange BGR (Federal
Institute for Geosciences and Natural Resources)
237:
– Normal requirements: 6 years of operating time
A0 2 years
including maximally 2 years storage time
– Increased requirements: 2 years operating
time (e.g. increased utilisation times, multi-shift
operation)
Bearing, General inspection! Hyosung. Co recommends carrying out general
Internal seals, Visual inspection of all toothed and rotat- inspection at the same time that the bearings are
Internal hoses, ing components. Check all components for exchanged. This reduces the period of downtime.
Consumables cracks and hairline fissures. In order to guarantee availability of the spare 80 000
parts, service jobs must be planned at least 18 A2
– Exchange bearings operating hours
– Exchange consumables months in advance.
– Exchange all seals
– Exchange hoses
Couplings

tion
Outside coupling Check for correct alignment and adjust if Cf. service instructions of the component manufac-
elements necessary. turer.
KTR coupling Check elastic transmission elements for Cf. service instructions of the component manufac-
wear and deformation and exchange if turer. A0 4000 operating hours
necessary.
7.4 Service Plan Oil System
Note!
 For the following service suggestions, read the service and
maintenance instructions of the manufacturer of the oil system!
 Observe the relevant service intervals prescribed there.
 In case of malfunction of the oil system, inform the manufacturer of
the oil system.
7.4.1 Service Overview – Oil System
continuously
weekly
monthly
yearly
after 2 years
after 6 years

Oil sample X A1
Oil level X X A0
Oil filter dirt indication display – visual X X A0
Motors, pumps, couplings X X A0
Pipes, hoses, seals X X A0
Air filter X X A0
Filter X X A0
Immersion heater X A0
Components of measuring equipment,
X A1
instruments
Oil cooler X A1
Hoses X A0
General inspection
Inspection and replacement of compo- X A2
nents
Tab. 7.2: Service overview: Oil system
7.4.2 Service Measures – Oil System

tion
Filter dirt side Take oil sample from the filter dirt side and If oil quality declines the interval for oil analysis must
Oil sample carry out an oil analysis in a certified la- be shortened and, if necessary, a full oil change pre- A1 2000 operating hours
boratory. pared.
Oil level Visual inspection of the oil level Cf. service instructions of the component manufac-
turer.
The oil level must always be within the limit values in
order to prevent and damage caused by the immer- A0 weekly
sion heater and an error of the oil system.
Changes of the oil level may indicate leakage, water
penetration or an error in the oil system.
Oil filter-dirt indica- Check degree of contamination and check Cf. service instructions of the component manufac- weekly
tion-display – Visual monitoring turer. and
A0
– Electrical monitoring Changes of the degree of contamination indicate that Every time after an
the filter element must be cleaned or replaced. alarm
Motors, pumps, cou- Check for Cf. service instructions of the component manufac- weekly
plings – Unusual noises of motors, pumps, turer. and
A0
couplings and suspensions. Cf. also chapter 7.7. every time after an
alarm

tion
Pipes, Visual inspection and check for: Cf. operating manuals of the components’ manufac-
Hoses, – Leak, turers.
Seals – Dirtiness,
– Rust,
– Damages and
weekly
and
– Faultless fastening. A0
every time after an
If necessary: alarm
– replace,
– clean,
– renew corrosion protection,
– rework fastening.
Air filter Check for permeability and renew if nec- Cf. operating manuals of the components' manufac-
A0 monthly
essary. turers.
Filter Check filter elements for contamination. Cf. operating manuals of the components' manufac-
turers. 1000 operating hours
Cf. also chapter 7.5 (double oil filter) and chapter 7.6 and
A0
(fine filter). every time after an
If metal shavings or grit are discovered inform the alarm
Hyosung. Co service immediately.
Immersion heater Check function and exchange if neces- Cf. operating manuals of the components' manufac-
sary. turers.
Components of Function check of all components and in- Cf. operating manuals of the components' manufac-
measuring equip- struments of the measuring equipment. In turers.
ment, case of faulty function, exchange compo-
Instruments nent.

tion
Oil cooler Check and clean Check the pipe side (water side) and clean if neces-
sary.
Built-up dirt may cause destruction of the oil system A1 yearly
and reduced service life the gear unit.
Order new seal in time!
Hoses Exchange hoses Recommended intervals for exchange BGR (Federal
Institute for Geosciences and Natural Resources)
237:
– Normal requirements: 6 years of operating time
A0 2 years
including maximally 2 years storage time
– Increased requirements: 2 years operating
time (e.g. increased utilisation times, multi-shift
operation)
Inspection and re- General inspection! Cf. operating manuals of the components' manufac-
placement of compo- Check and replace all relevant all relevant turers.
nents components of the oil system Hyosung. Co recommends carrying out general
inspection at the same time that the general in-
80 000
spection of the gear unit is carried out. This re- A2
operating hours
duces the period of downtime.
In order to guarantee availability of the spare
parts, service jobs must be planned at least 18
months in advance!
7.5 Double Oil Filter: Cleaning and Exchanging of the Fil-

ter Insert
DANGER!
Danger of injury due to hot oil under pressure!
For cleaning and changing a double oil filter insert the respective filter pot
must be pressureless. A corresponding warning sign is to be applied to
the oil unit during the work.
Note!
Cleaning and exchanging are to be done in accordance with the operating
and service instructions of the manufacturer (cf. "Operating and service
instructions of the oil system" in appendix C of this operating manual).
All required working steps for cleaning and exchanging a filter insert are
included in the operating and service instructions of the components' manu-
facturer.
ATTENTION!
Danger of damage to the filter components when switching from one
filter unit to the other!
Avoid pressure surges in the filter when switching from one filter unit to
the other. See the instructions from the filter maker if necessary. Equalize
the pressure before switching over by operating the pressure equalization
valve until the second filter has also been filled with oil.
Always follow the instructions from the filter maker.
Depending on the degree of contamination it is recommended to replace the

filter inserts after several cleaning processes.
The cleaning intervals can be lengthened correspondingly if the filter inserts
and elements are changed in accordance with the stipulations.
7.6 Dismantling the Pumps
ATTENTION!
Danger of injury due to hot oil under pressure!
All the systems must have been completely depressurized before carrying
out any work on the pumps.
The oil pumps for the low-pressure lubricating circuit as well as for the
maintenance circuit(Option) can be dismantled without draining a larger
amount of oil. The associated cutoff valve is to be closed and the pump dis-
mantled. Once the pump has been removed, the connection points must be
closed up again and made tight.
7.7 Service Plan Main Coupling (KTR Coupling) (Option)
Information
Information concerning service of the KTR coupling cf. documentation of
the components' manufacturer.
8 Oil Change
8 Oil Change
A careful oil change will contribute significantly towards increasing the oper-
ating safety and reliability as well as the service life of both the gear trans-
mission and its new oil filling. It must be ensured that no contaminants such
as foreign matter, water or other liquids can enter the gear transmission in
the course of the oil change.
To remove the initial wear of the gearbox the gear oil change should be per-
formed after the first 500 hours of gearbox operation. Oil analysis is required
every 3 months (or 2000 hours) and if there is no problem with the oil condi-
tion, it can be used continuously. However, do not use the oil for more than 2
years. Refer to Oil change & Flushing procedure. (Appendix F)
Labour safety and environmental protection
Information
All jobs necessary for oil change must be carried out carefully by special-
ised personnel trained to do so.
DANGER!
 Wear your personal protective equipment when draining oil from
the gear unit or oil container or filling it.
DANGER!
 Have oil binding agents and cleaning agents ready.
Note!
General information:
 Drain the old operating oil before you fill in new operating oil.
8 Oil Change
ATTENTION!
The oil recommended by Hyosung. Co is ISO VG 320, according to the
lubricant specification and the list of permitted lubricants (current version
available from the Hyosung. Co service).
Ensure that a sufficient quantity of the prescribed oil ISO VG 320 is avail-
able.
DANGER!
Danger of contamination due to escaping oil!
Do not allow any oil to get into the sewage system or the ground when
filling up / draining oil. The oil must be collected up and disposed off in an
environmentally-approved manner or handed in for recycling.
8 Oil Change
8.1 Checking Oil Quality
Note!
 Have each oil sample analysed in a certified laboratory.
 File the oil analysis records in a way that they are available to the
Hyosung. Co service at any time.
Take an oil sample:

 Before every oil change take an oil sample of the oil at operating tem-
perature from the dirt side of the coarse filter (3).
 Remove the closing screw.
 Open the ball valve.
 Remove the oil sample as specified by the laboratory.

 Close the ball valve.
 Insert closing screw again.
ATTENTION!
If the oil no longer complies with the specifications or if water is in the oil,
the gear unit must be inspected by a specialist from Hyosung. Co.
 Inform the Hyosung. Co service!
8 Oil Change
8.2 Drain Oil
ATTENTION!
An oil level above the "max" mark may point to ingress of foreign liquid
(e.g., water or the like). An oil level below the "min" mark may indicate a
leak.
Both conditions are untypical and may result in transmission failure.
Before filling with fresh operating oil, the cause must be clarified and recti-
fied if necessary.
 Shut down the gear unit and secure it against unauthorised switching on.
 Check and document the oil level on the oil level display of the oil con-
tainer.
 Carry out visual inspection for possible leakages on gear unit and oil
container.
 If a leak is discovered, identify and remedy the cause before refilling.
 The oil change should be performed as soon as possible after the gear
unit has been switched off so as to prevent any particles from re-settling.
ATTENTION!
Scalding injury!
To avoid scalding injury, the temperature of the oil being drained should
not be substantially higher than 50°C!
Draining of the oil tank is done by manual control of the electric motor of the
maintenance circuit pump (Option).
1. Remove the ventilation filter on the oil container.
2. Close the pressure-side shut-off valve.
3. Open the pressure-side shut-off valve.
4. To do so, remove the blanking flange from the draining flange.
5. Install the pipe for oil draining by means of a suitable flange.
6. Switch the electric motor of the maintenance circuit pump on manual-

ly. The oil is drawn from the oil container and pumped into the provid-
ed container.
7. Remove the pipe for oil draining.
8 Oil Change
8. Close the draining flange with the blanking flange.
9. Open the pressure-side shut-off valve fully.
10. Check the pressure-side shut-off valve to ensure it is fully open.
11. Re-install the ventilation filter.
The remaining oil from the axial bearing area is drained through the ball
valve at the upper part of the gear unit.
The remaining oil from the gear unit casing is drained through the ball valve
at the bottom part of the gear unit cf. outside piping diagram).
The components of the oil system (e.g. filter, cooler etc.) are to be drained
through the appropriate valves.
8.2.1 Activities before Filling the Machine with new Oil
 Inspect the drained oil visually (appearance, colour, contamination,

etc.).
 Inform the Hyosung. Co service if severe contamination is discov-

ered (e.g. water, metallic particles, sludge).
 Check the magnet screw on the oil filter for metallic abrasive parti-
cles.
 Clean the screw.
 Inform the Hyosung. Co service if you suspect increased wear.
 Clean or exchange the existing oil filters and seals.
8 Oil Change
8.3 Filling with Oil
 Compare the drained oil quantity with the value specified on the type
label. If the drained oil quantity is considerably (> 500 litres) lower, there
should be clear residual quantities in the gear unit or in the components.
 Verify that the used oil from the axial bearing area, the lower part of the
gear unit and the components has been drained.
 If necessary, repeat the steps as described in 8.3.
ATTENTION!
Oil capacity data on nameplates are given as a guide!
Note!
As a rule, the gear unit is filled with operating oil of the previously used
product.
For changing the type of oil, the Hyosung. Co service must be informed
ahead of time.
ATTENTION!
Hyosung. Co recommends keeping a sample of the fresh oil before filling.
8 Oil Change
DANGER!
 Wear your personal protective equipment when filling oil into the
gear unit.
ATTENTION!
 Fresh oil may contain impurities.
 Therefore, fill oil through a 10 µm filter.
 It is recommended that the oil be preheated to between 35 °C and
40 °C to this end.
ATTENTION!
 During the filling process, continuously check the gear unit for
leaks.
The filling of the oil tank is done by manual control of the electric motor of
the maintenance circuit pump (Option).
1. Close the suction-side shut-off valve.
2. Open the pressure-side shut-off valve.
3. To do so, remove the blanking flange from the filling flange.
4. Install the pipe for oil draining by means of a suitable flange on the
filling flange.
5. Switch the electric motor on manually. The oil is drawn from the fresh
oil container and pumped into the oil container after it has passed the
maintenance circuit filter.
6. Switch on the lubricating oil pump to fill the axial bearing area, the
bottom part of the gear unit and the components.
7. Check the oil level on the oil inspection glass of the axial bearing area
and on the oil filling level display of the oil container. Here, the oil lev-
el must be up the marking "maximum".
8. Remove the pipe for oil filling.
9. Close the filling flange with the blanking flange.
10. Open the suction-side shut-off valve fully.
8 Oil Change
11. Check the pressure-side shut-off valve to ensure it is fully open.
12. After a short operating time (ca. 10 min) and a resting time of 5 min
check the oil level again: If necessary, top up oil.
Check the fresh oil visually for the following parameters:

– Homogeneity,
– Absence of solid foreign matter and water,
– Colour and appearance according to the oil manufacturer's product
specific data.
Note!
 After filling the gear unit with fresh oil, check the oil level after 1, 2
and 5 days and correct it if necessary.
 After 1, 2, and 5 days, then weekly, check the oil filters for depos-
its.
 Clean or replace dirty filters.
Debris remaining in the system may have become detached, ob-
structing the filters.
Note!
It is recommended to take an oil sample from the transmission after about
5 operating hours following each oil change. This sample should be doc-
umented and retained for future examination.
8 Oil Change
8.3.1 Report - for filling of fresh oil
Plant: ....................................................................... Gear unit: .................................................................
Date: .............................. Operating hours: ....................... Last oil change: .............................................
Oil to be used according to nameplate: .................................. Quantity according to nameplate: ................ l
Condition prior to oil change
Name of oil: ....................................................... Oil filling level: ...............................................................
Transmission / oil supply system free of leaks? yes □ no □ Filter dirty? yes □ no □
Operating temperature: ...................... °C
Other special observations made: ..................................................................................................................
Old oil
Designation of the old oil sample: .......................... Laboratory No.: ........................................................
Quantity: ........................ l Visual description: ..........................................................................................
Transmission / oil supply system
Deposits? yes □ no □
Visual description: ..........................................................................................................................................
Fresh oil
Name of oil: ....................................................................................................................................................
Designation of the fresh oil sample: ....................................... Laboratory No.: ........................................
Filled through filter? yes □ no □ Filter unit: ......................... µm Quantity filled: .............................. l
Visual description of the oil: ............................................................................................................................
Gear unit / oil supply system flushed before filling with fresh oil? yes □ no □ with: .............................
Special observations: .....................................................................................................................................
Designation of the 5-hour oil sample: ............................................... Laboratory No.: ..............................
Report issued by: .............................................................................. Department: ...................................

Name
8 Oil Change
8.3.2 Check list - for filling of fresh oil (option)
Service instruction for gear unit and com- Oil filter insert cleaned or replaced. Seals
1. ponents was read? 18. exchanged if necessary?
Specialised personnel for filling of fresh Open ball valves / closing screws closed
2. oil on site? 19. again?
Personal protective equipment available

3. 20. Fresh oil checked visually?
and used?
Drive shut down and protected against

4. 21. Oil filling open, closed?
switching on?
Report for completing after filling in fresh Maintenance circuit pump unit switched
5. oil available? 22. on?
Fresh oil filled in through fine filter to

6. Sufficient quantity of fresh oil available? 23. marking "maximum" on the oil level dis-
play of the oil container?
Lubricating oil pump switched on, axial
Sufficiently large collecting containers for
7. 24. bearing area and gear unit casing filled
old oil available?
with oil?
After at least 5 min of resting time
Are oil absorbent and cleaning agents checked if the oil has been filled to mark-
8. available? 25. ing "maximum" on the oil level display of
the oil container?
Sufficient space for filling of fresh oil

9. 29. Oil added or drained? Oil level OK?
available?
Visual inspection of the gear unit done

10. 30. Oil filling closed, open?
and leaks repaired?
11. Used oil cooled down below 50°C? 31. Report after filling in fresh oil completed?
Used oil disposed of according to the

12. Oil sample of old oil taken and recorded? 32. local regulations?
Oil sample of fresh operating oil taken

13. Ventilation filter on oil container removed? 33. after ca. 5 hours and recorded?
Oil binding agent and cleaning agent dis-

Collecting container placed below oil
14. 34. posed of according to the local regula-
drain?
tions?
CAREFULLY OPEN closing screws / ball

15. 35. Gear unit taken into operation again?
valves! SCALDING INJURY!
Check filter according to degree of con-

Used oil completely drained, even from all
16. 36. tamination, after one week of operation at
components?
the latest; clean or replace.
Gear unit and components (outside)

17. cleaned?
9 Troubleshooting
9 Troubleshooting
DANGER!
Always wear personal protective equipment (protective goggles and pro-
tective gloves) when working on the gear unit.
DANGER!
Never open an inspection hole cover while the gear unit / plant is operat-
ing.
DANGER!
 Never open terminal boxes or electrical equipment unless you
are a trained electrician.
 Switch off immersion heaters and secure them against switching
on before you begin maintenance and repair jobs on the gear unit.
 Always have zero-potential checked by a trained electrician before
you work on or near parts of the electrical system.
Note
Also observe the operating manuals for oil system and drive motors if the
control system for the overall plant indicates an error message.
 Take the gear unit out of operation.
 To do so, switch off drive motors.
 Leave the oil system in operation until the gear unit has come to a
standstill and has cooled down. The temperature is then <40°.
 Check ...
– Contacts.
– Cables and connections,
– Sensors and electrical interfaces.
9 Troubleshooting
ATTENTION!
Whenever a problem occurs, it is necessary to determine the cause of the
problem and likewise correct it.
Note!
Inform Hyosung. Co if the control system of the plant indicates errors
typical for the gear unit.
Errors typical for the gear unit are e.g.:
– Increased vibrations,
– Unusual noises from the inside of the gear unit,
– Increased temperature values.
Note!
Check for leaks!
Inform Hyosung. Co if you discover leaks in different places of the gear
unit than screw connections and flanges.
9 Troubleshooting
9.1 Gear Unit
Note!
Please contact the service department of Hyosung. Co if problems occur in the gear unit that
cannot be remedied with the methods listed below (address/phone cf. chapter "Identification").
Seq.
Error Possible cause Measures
No.:
1 Noticeable and unusual Bearing or gear teeth dam- Request a Hyosung. Co fitter
noises in the gear unit aged and service the parts
Bad alignment Check the alignment
(Cf. chapter 5.4.2 "Align gear
unit")
Foreign bodies in the gear unit Request a Hyosung. Co fitter
to remove the foreign bodies,
determine and correct the
damage
9 Troubleshooting
9.2 Oil System
Note!
Please contact the service department of Hyosung. Co if problems occur in the oil system that
cannot be remedied with the methods listed below (address/phone cf. chapter "Identification").
Seq.
No.:
1 Lubricating oil temperature No cooling water supply Correct
too high the cooling water supply
Too little cooling water Increase the amount of cool-
ing water
Cooling water temperature too Check the inlet and outlet
high temperature
Check the cooling water sup-
ply
Clean the oil cooler
Thermostat defective Replace thermostat
Cooler has air in it Bleed the cooler
Temperature regulator defec- Check the setting or
tive (if there is one) replace the regulator
2 Lubricating oil temperature Immersion heaters switched Switch on the immersion
too low on too late heaters
If necessary, check the re-
sistance thermometer and
temperature limiter
Heating switched on too late Wait until oil has heated up,
Wait for pump start,
Wait for enable main motor
start
Gear unit has not come up to Wait
temperature
Resistance thermometer de- Replace resistance ther-
fective mometer
Temperature regulator defec- Check the setting or replace
tive (if there is one) the regulator
9 Troubleshooting
Seq.
No.:
3 Lubricating oil pressure too Filter dirty Switch over the double filter
low Clean or replace the filter in-
sert (the filter must be depres-
surized to do this)
Pressure limiting valve set Set the oil pressure at the
incorrectly pressure limiting valve correct-
ly
Pressure limiting valve dam- Service valve, replace spring
aged
Suction line blocked Clean the suction line
Pump sucks in air Oil level too low (add oil as
necessary)
Check the suction line
Correct the error (if necessary,
tighten up the flange screws)
Oil foams strongly Have the oil examined,
change the oil if necessary
Leak in the pressure line (at Tighten up the flange screws
the flanges or pipes) or replace the seals or pipes
Lubricating oil temperature too see seq. no. 1
high
Oil viscosity too low Check the viscosity
Fill with the correct oil,
(see Lubrication stipulations in
Appendix)
Pump damaged Service the pump
4 Lubricating oil pressure too Gear unit has not come up to Wait
high temperature
Lubricating oil lines blocked at Look for and clean the
the gear unit blocked lines
Oil viscosity too high Check the viscosity
Fill with the correct oil,
(see Lubrication stipulations in
Appendix)
9 Troubleshooting
Seq.
No.:
5 Oil consumption too high Oil drain screw is leaking Tighten screws,
Pipes are leaking seal anew
Shaft outlet at the gear unit is Replace seals

leaking (if there is one)
Cooler leaking Replace the cooler insert
Oil loss on additional compo- Check additional components,
nents rectify defects
Filter leaking Seal filter
Gear unit case leaking Check gear unit casing, inform
Hyosung. Co service and rec-
tify defects
6 Unusual or increased filter Pipe lines contaminated Clean the pipes
residues
Gear teeth worn Check alignment
Bearings (roller bearings) Re-align gear unit (cf. chapter
damaged (steel, metallic grey, 5.4.2 "Align gear unit") and
magnetic; non-ferrous metal) inform the Hyosung. Co ser-
Bearing (plain bearings) dam- vice.
aged (bearing metal)
For gear units with plain bear- Inform Hyosung. Co service
ings: Plain bearings damaged concerning checking, repairing
(Babbit metal, white) or replacing bearings
Lubricating oil dirty Oil change (see chap. 8)
Pump damaged (steel, metal- Service or replace the pump
lic grey, magnetic)
10 Spare Parts
10 Spare Parts
Note!
Only OEM consumables and spare parts of Hyosung. Co are permitted
for use.
Use of different parts is not permitted.
If different parts are used,
 our guarantee is invalidated as well as
 any kind of any claim for damages
Since unexpected risks may arise.
11 Disposal / Recycling
11 Disposal / Recycling
Note!
 Always observe the regionally and internationally valid regulations
for waste disposal.
 In cases of uncertainty, ask your waste manager or your supervi-
sor.
 Ensure that the gear oil is completely removed from the gear unit.
 Have the gear unit dissembled into transportable parts by special-
ists trained to do so.
Dispose of components according to the local regulations.
 Dispose of parts containing oil or lubricant, cleaning cloths and

used oil according to the regulations.
 Never dispose of electronic components together with household

waste.
 Dispose of electronic waste only by using the container provided
for this purpose.
Appendix A Drawings
Appendix A Drawings
Designation Drawing-no. Index

Mill gearbox – Arrangement SH1-DHI-P1HFC-M-M01-DAS-1002-01
Mill gearbox – Outline SH1-DHI-P1HFC-M-M01-DAS-1002-02
Mill gearbox – Assembly SH1-DHI-P1HFC-M-M01-DAS-1002-03
Mill gearbox – LO unit Assembly SH1-DHI-P1HFC-M-M01-DAS-1002-04
Mill gearbox – LO System Schematic SH1-DHI-P1HFC-M-M01-DAS-1002-05
Mill gearbox – LO Instrument List SH1-DHI-P1HFC-M-M01-DAS-1002-06
Mill gearbox – Terminal box wiring 1 SH1-DHI-P1HFC-M-M01-DAS-1002-07
Mill gearbox – Terminal box wiring 2 SH1-DHI-P1HFC-M-M01-DAS-1002-08
Mill gearbox – Input Coupling SH1-DHI-P1HFC-M-M01-DAS-1002-09
Translation of the original instructions – Industrial gear unit – KPAV 125 -HKC01090000039 –VRM A.1
Appendix B Components - Gear Units (Options)
Appendix B Components - Gear Units (Options)
Coupling main drive

MANUFACTURER KTR
TYPE REVOLEX
SIZE 150-D
INSTRUCTION FOR INSTALLRATION, OPERATION AND SERVICE
Translation of the original instructions – Industrial gear unit – KPAV 125 HKC01090000033,4 –VRM B.1
Appendix C Accessory Parts - Oil System
Appendix C Accessory Parts - Oil System
Information
The documents for the oil supply system are on our digital documentation
CD.
Technical data oil system
Information
Cf. document "Technical data oil system" (oil system and oil circuit dia-
gram in appendix A).
Operating and Maintenance Instructions for the Oil System

The technical datasheet provides an overview about the components. The
documents are provided by the manufacturer of the oil system; they are
binding for initial commissioning, usage and service of the oil system.
The Hyosung. Co information concerning the oil lubrication system has to be
mentioned, too.
Translation of the original instructions – Industrial gear unit – KPAV 125 HKC01090000039 –VRM C.1
Appendix D Lubricant - KPAV Gear unit
ATTENTION!
Danger of damage to the machine!
A suitable lubricant must always be selected in coordination with Hy-
osung. Co.
ATTENTION!
Hyosung. Co recommends ISO VG 320 oil.
In addition to this recommendation, please observe
 the respective lubricant specification and
 the list of approved lubricants.
The current version is available from the Hyosung. Co service.
Area of application
Note!
The following must be noted when selecting lubricants:
 The specified ISO-VG 320 relates to a constant ambient tempera-
ture of 10 to 40 °C.
 It is necessary to consult Hyosung. Co service regarding tempera-
tures above or below this reference temperature in the case of
pressure-lubricated gear units.
 Option: In the case of immersion-lubricated gear units the next
smallest or next largest class should be chosen regarding temper-
atures above or below this reference temperature. The pour point,
i.e. the temperature where a viscous liquid turn solid must not be
above the normal start-up temperature.
Information
You can get further information on the specifications of the relevant lubri-
cants also from the corresponding oil companies.
Translation of the original instructions – Industrial gear unit – KPAV 125 -HKC01090000039 –VRM D.1
Notes
ATTENTION!
Operational safety of the gear unit is only guaranteed if the recommended
intervals for oil change are observed. The correct composition of the lub-
ricants must be proven with oil samples and their examination concerning
possible sediments in certified laboratories.
ATTENTION!
Do not mix different types of lubricant without consulting the lubricant
manufacturers concerned beforehand.
The compatibility of the selected lubricant with the conservation and test
operation oils used by Hyosung. Co must be assured by the manufacturer
of the lubricants concerned.
Information
The required viscosity class ISO VG320 and the type of the oil are speci-
fied in the installation drawing or on the type label on the gear unit.
Information
The oil quantity required in item2.3.1 is theoretical value however, con-
sidering the oil loss during installation and initial operating, we recom-
mend the customer to prepare the oil about 10% more.
Lubricant analysis
ATTENTION!
In principle, the lubricant should be changed after three years (the latest
however after 20,000 hours of operation).
Subsequent intervals of the oil change always depend on the test results
of the lubricant analysis.
Note!
 Have the oil analysis carried out in a neutral, certified laboratory.
 Observe the following points:
– File the oil analysis records in a way that they are available to
the Hyosung. Co service at any time.
– Take a comparative sample before changing the oil (current
operating oil / new oil)
– Approval for further use of the examined oil, possibly with
shorter test intervals
Appendix E Part Manual
Appendix E Part Manual
Translation of the original instructions – Industrial gear unit – KPAV 125 HKC01090000039 –VRM E.1
Appendix F Flushing procedure
1. Objective
The purpose of this process is to set up the Oil Flushing
procedure of the Rotary Machine and also to remove debris
of the Oil Tank and Piping system.
2. Work Scope
This process will be applied to Forced Circulation Lube Sys-
tem which Oil Tank is attached.
This process complies with AGMA 6010 and 9005 (refer to
attached documents)
3. Guide Lines
3.1. Oil Flushing for Rotary Machine should be followed by
this process.
3.2. Oil Flushing operators should be well-acquainted with
this process.
3.3. Commissioning Dept. and operators should attend the
test and check whether the Oil Flushing is complied
with this process.
4. Responsibility
4.1 Commissioning Department
4.1.1 Commissioning Team Leader
Commissioning Team Leader should review and ap-
prove this process and also supervise the test.
4.1.2 Commissioning Manager
Commissioning Manager should check test progress
and if revision of process is needed, orders the revision
and manage it.
4.1.3 Facility Department should support the commission-
ing test.
4.1.4 Commissioning Leader

Commissioning Leader should check the operating sta-
tus and supervise the test is complied with process
4.1.5 Commissioning Operator
Commissioning Operator should be well-acquainted with
this process, if needed; operator test facility cooperated
with Construction Department. If there are any problems,
he must report to Team Leader immediately.
4.2 Construction Department has responsibility of prelimi-

nary inspection and if there is no problem, operates the
test comply with the process
5. Definition
Terms in this process are used commonly understood.
5.1 Flushing time
Decision of Flushing is based on check through the In-
spection Cover/ Filter / Sludge on the bottom of tank or
Oil Cleanliness inspection.
Oil Flushing or Facility Flushing including removal of
sludge can be decided, based on the condition of inner
system.
Besides regular maintenance, flushing must be per-
formed in cases of below.
Filter damaged/failure
New or Repaired Facility: In case of New Facility,
the flushing work should be performed after 500hrs
or four(4) weeks of operation whichever occurs
first based on AGMA 9005
After replacing the entire oil
Long time after the facility stopped.
After cooler is damaged.

In case of that the different types of oil are mixed.
Microbial Contamination: microbe can be broken in
while the rainy season and can make sediments
Find the abnormal signs: If rapid deterioration oc-
curs as follows during operation, perform an anal-
ysis of the oil, it is necessary to consider the oil
change and flushing.
* In the case of direct determination by the color, it is neces-

sary to compare the new oil of existing reference color, it is
always performed an analysis of the oil because there may
be difference in the oil Maker.
5.2 Caution
In case of Facility Integration Flushing, removal of Seal
or Gasket can be the source of Leakage and also Fault
Assembly.
a. During the flushing not exceed the maximum supply
pressure
Pump max. pressure: 10bar
Recommended supply pressure: 7bar
b. Should be using oil degasifier when the new oil injected
into the oil tank. (Not clean, even though new oil)
5.3 Flushing Degree

Flushing Degree varies based on the applications, who
associated facility can decide and manage it. Flushing
can be managed through the before/after Oil Cleanli-
ness Analysis and below table.
After oil flushing, the oil grade must be NAS 9 grade
(18/15), (AS4059 Class9) or better. If the oil cleanliness
does not meet above grade, repeat the flushing 2 or 3
times.
If the oil cleanliness is exceed NAS 11 grade, must re-
peat the
flushing or change the new oil.
Target of oil contamination: NAS 9 grade (18/15)

Warning of oil contamination: NAS 11grade (20/17)
Table1. AS4059 Cleanliness coding system
Table2. NAS 9 grade = ISO Contaminated code 18/15
6. References
- Oil Flushing Flow chart
- ANSI/AGMA6113-B16
- ASTM D6244-98
7.0 Procedure
7.1 Preparation Items
7.1.1 Circuit Diagram, Oil, Pump, Tank, Filter and Gear-
box.
7.1.2 Flushing Filter Replacement
(1) FLUSHING FILTERS ELEMENT
HYDAC 0660 R 005 BN4HC_5 MICRON
When replacing a filter to remove the top cover of the fil-
ter at the non-driving side, the oil drain through filter
drain port and then the filter has been replaced.
When filter replacement, be careful not flowing contami-
nated oil into the gearbox
(2) Direction of the handle of the filter is adjusted to non-

driven side. As described above, the two filters to be re-
placed.
7.2 General Items
7.2.1 Flushing can be performed to main pipes and
branch pipes after combine the gearbox and Lubrica-
tion system.
7.2.2 If there is no significant to report, flushing can be
complied with this process, related drawings, and
specification.
7.2.3 Close the bypass of pressure switch.
7.2.4 Clean and attach of the Valves
(1) Cooler and Filter must be fully cleaned and check
the debris in the inner of it.
(2) If you do not have relevant experience is not recom-
mended for separate cleaning. After Normal life cycle
(10 years), it is recommended if applicable.
7.3 Flushing Procedure

7.3.1 Flushing
(1) Procedure
a. Apply the Regular Oil
- Manufacture: Mobil
- Mobilgear 600XP 320 or equivalent specifications
- Oil filling quantity for the flushing : abt.960 liter
b. Heat the Oil until 60～80℃ using the Electric Heater.
c. Turn on the Pump to circulate the Oil. If oil tempera-

ture is raising to the proper level, tap pipes with rubber
hammer. (Hammerings parts are Welded parts, Genu
parts, rising part, long and horizontal part, Not hammer-
ing parts are Cast Iron Parts, Fitting and Valves)
(2) Checklist during the Flushing.

a. After 6 hrs of operation, sample the Oil using the
clean bottle.
b. Use HYDAC 0660 R 005 BN4HC_5 MICRON for
strainer.
c. Record the amount of filth from the Filter and amount
of sampling oil.
d. Flushing duration must be over 6hrs. (but it can be
extend or reduced based on the oil condition)
e. check the Filter element of exchange it if the pressure
difference is over 2.5 bar during the flushing
f. Special check points Filter, Bottom of the Cooler
g. Because Valve has uneven surface, it is needed to be
checked on the filth
h. Bottom portion of Standpipe, end of main oil supply
pipe are needed to be checked on the filth
(3) Filling the additional New Oil : 200~300 liter
- If the oil level has decreased during the flushing pro-
cess
(4) Sample the oil after 2 hrs of operation, and inspect
the Cleanliness, Viscosity and amount of moisture.
(6) If inspection results meet the spec. Check the Filter
element and Filter housing.
(7) Exchange to the 25 Micron Filer which is applied to
main product. (HYDAC 0660_R 025 W/HC)
(8) Start to Commissioning test.
7.3.2 Inspection and Decision

(1) Inspection is performed to verify the effectiveness of
flushing and to decide the time of completion
(2) Inspection Interval
At the Early stage, Inspection is performed every 6 hr

and after filth was reduced, Inspection is performed eve-
ry 2~6 hrs.
(3) Inspection Procedure
Stop the Pump after record Oil Temperature and
Pressure
Close the Return Opening Side Valve and remove
the Filter
Classify the collected filth and record it
Optimal grade of Flushing Oil can comply with AS-
4059 which is in Appendix 1, S-4059. It is Class 9
If the inspection results meet the Spec., performed
Commissioning Test.
If one of 3 results after Inspection not meet the
Spec., repeat the flushing from the proce-
dure(Appendix 8.1).
If the water content and viscosity value are not
satisfied continuously after inspection, it should be
considered to apply a Purifier application or
Change the oil to New oil.
If there are other problems, contact the manufac-
turer.
8. Appendix & check sheet form

8.1 Oil Flushing Flow Chart
8.2 Allowable Contamination Level
8.3 NAS Grade of cleanliness
8.4 AGMA 6010-F97, 9005-E02
8.5 Oil Flushing Check Sheet
8.6 Oil Flushing Check list
8.7 Inspection for Oil Flushing
[Appendix 1]
Oil Flushing Flow Chart
FILL GEARBOX & LO-UNIT WITH OIL

(NEW OIL REFUEL : ISO VG320)
CHANGE THE FINE FILTER_5MICRON

(HYDAC 0660 R 005 BN4HC_5MICRON)
OPERATING OF LUBE.OIL SYSTEM

(NO OPERATION GEARBOX)
Repetition
℃~80℃
6HOURS(60℃ ℃) 2~3 times
SAMPLING OF OIL
(CHECK THE OIL CLEANLINESS)
(2)
DYNAMIC VISCOSITY (1)
(3)
NAS 9 GRADE CONTAMINATION
WATER CONTENT
NO (4) NO
YES
DONE
CHANGE THE FILTER_25MICRON

(HYDAC 0660_R 025 W/HC)
COMMISSIONING TEST
1) Contamination: Cleanliness [NAS 9] or [18/15_ISO4406-99]

2) Dynamic Viscosity (cSt@40℃ ℃): 288 ~ 352 [ISO 3448]
3) Water content: Max. 500 ppm [AGMA6010]
4) If the water content and viscosity value are not satisfied continuously
after inspection, it should be considered to apply a Purifier application
or Change the oil to New oil.
[Appendix 2]
AS4059 Cleanliness coding System
[Appendix 3]
NAS GRADE OF CLEANLINESS
[Appendix 4]
ANSI/AGMA 6010-F97
AMERICAN NATIONAL STANDARD
9.6 Maintenance of lubrication system

Lubricants must be free of solid contaminants such as dirt
and wear particles, free of water, and contain sufficient addi-
tives to maintain their original performance. The best way to
maintain lubricant performance is by regular oil changes.
Refer to ANSI/AGMA 9005-D94, clause 6.
9.6.1 Initial lubricant maintenance
The lubricant in a new gear drive should be drained after
500 hours or four (4) weeks of operation, whichever occurs
first.
The gear case should be thoroughly cleaned with a com-
mercial grade of flushing oil that is compatible with the seals
and operating lubricant. The original lubricant can be used
for refilling if it has been filtered through a filter of 30 mi-
crons or less, it is free of water, and the original additive
strength is maintained; otherwise, new lubricant must be
used.
Lubricants should not be filtered through fuller’s earth or any
filters which remove lubricant additives.
9.6.2 Subsequent oil change interval
Under normal operating conditions, the lubricant should be
changed every 2500 operating hours or six months,
whichever comes first. Conditions that may require more
frequent oil change periods include:
ambient conditions of extreme dust, dirt, moisture

and chemical particles or fumes;
sustained lubricant sump temperatures approach-
ing 200°F;
duty cycle or ambient conditions causing large and

rapid sump temperature changes;
seasonal ambient temperature changes causing
changes in recommended lubricant.
Extending the change period recommended may
be preferred based on type of lubricant, amount of
lubricant,
system down time, or environmental impact of
used oil. This can be done through proper imple-
mentation of
a comprehensive lubricant testing program. As a
minimum, the program should include testing for:
changes in appearance and odor;
lubricant viscosity (oxidation);
water concentration;
contaminant concentration;
sediment and sludge;
additive concentration and condition.
In the absence of more specific limits, the guide-
lines listed as follows may be used to indicate
when to change oil:
water content greater than 0.05% (500 ppm);
However, it’s recommended to keep within 250ppm.
iron content exceeds 150 ppm;
silicon (dust/dirt) exceeds 25 ppm;
viscosity changes more than 15%.
These tests should be performed on the initial charge of the

gear unit to establish a base line for comparison.
Subsequent test intervals should be established based on
the unit manufacturer’s and lubricant supplier’s recommen-
dations.
9.6.3 Cleaning and flushing

The lubricant should be drained while the gear drive is at
operating temperature.
The drive should be cleaned with a flushing oil.
9.6.4 Used lubricants
Used lubricant and flushing oil should be completely re-
moved from the system to avoid contaminating the new
charge.
9.6.5 Cleaning with solvents
The use of a solvent should be avoided unless the gear
drive contained deposits of oxidized or contaminated lubri-
cant
which cannot be removed with a flushing oil. When persis-
tent deposits necessitate the use of a solvent, a flushing oil
should then be used to remove all traces of solvent from the
system.
9.6.6 Inspection
The interior surfaces should be inspected where possible,
and all traces of foreign material removed.
The new charge of lubricant should be added and circulated
to coat all internal parts.
[ANSI/AGMA 9005-E02, Industrial Gear Lubrication]
F.1 Initial lubricant change period

The initial start-up and operating oil of a new gear drive
should be thoroughly drained after a period of 500 operating
hours or four weeks, whichever occurs first. The importance
of a thorough gear case cleaning with flushing oil to remove
particle matter during the first lubricant change cannot be
overemphasized. Consult the manufacturer if this is intend-
ed to be a fill for life application.
F.2 Subsequent lubricant change interval

Under normal operating conditions, the lubricants should be
changed every 2500 operating hours or six months, which-
ever occurs first. Extending the change periodmay be ac-
ceptable based on the type of lubricant, amount of lubricant,
system down time, or environmental consideration of the
used lubricant. This can be done by proper implementation
of a comprehensive monitoring program. Such a program
may include examining for:
change in appearance and odor;

lubricant viscosity;
lubricant oxidation, e.g., total acid number;
water concentration;
contaminants concentration;
percentage sediment and sludge;
Additive depletion.
New lubricant specification should be used to es-
tablish a base line for comparison. Follow unit
manufacturer and lubricant
Supplier’s recommendations for appropriate sub-
sequent testing intervals.
F.3 Cleaning and flushing

When the gear drive reaches normal operating temperature,
lubricant should be drained immediately after shutdown.
The drive should be cleaned with flushing oil. Flushing oil
must be clean and compatible with the operating oil. Oils
specially blended for flushing, or clean operating oil are
commonly used for flushing.
F.3.1 Cleaning with solvents

The use of a solvent should be avoided unless the gear
drive contains deposits of oxidized or contaminated lubri-
cant which cannot be removed with a flushing oil. When
persistent deposits
necessitate the use of a solvent, a flushing oil should then
be used to remove all traces of solvent from the system.
CAUTION: When solvents are used, consult the unit manu-
facturer to assure compatibility with paint, seals, sealant and
other components.
F.3.2 Used lubricants
Used lubricant and flushing oils should be completely re-
moved from the system to avoid contaminating the new
charge, and properly disposed.
CAUTION: Care must be exercised not to mix lubricants
with different additive chemistry.
F.3.3 Inspection
The interior surfaces of the gear drive should be inspected,
where possible, and all traces of foreign material removed.
The new charge of lubricant should be added and circulated
to coat all internal parts.
F.4 Protective coatings
For gearing which may be subjected to extended shipment
or storage periods, consideration should be given to apply-
ing a protective coating formulated to prevent rusting. These
coatings must be compatible with the lubricant to be used in
service and all other components.
CAUTION: Some lubricants may foam due to reaction with
rust preventatives. If necessary, flush out residues from the
unit.
F.5 Filtration
Gear drives with pressurized oil systems should have a filter
on the pressure side of the system to remove contamination
Particles. As a guideline, in the absence of specific manu-
facturer’s recommendations, the filter should be no coarser
than 50 μm(microns) absolute for gear drives with ball or
roller bearings, and 25 mm absolute for gear drives with
journal bearings.
In addition, a screen may be used on the suction side to
protect the pump.
This should be in combination with a filter and must have a
coarse mesh to avoid flow restriction.
CAUTION: Lubricants should not be filtered through fuller’s
earth or other types of filters which could remove the addi-
tives of the original formulation.
F.6 Gear tooth wear
There are numerous modes of damage associated with
gear teeth. See ANSI/AGMA 1010-E95. Proper selection,
application, and maintenance of lubricants is therefore es-
sential to avoiding premature wear.
If premature wear occurs, lubricant selection should be re-
viewed.
[Appendix 5]
[Appendix 6]
[Appendix 7]
1 Storage and preservation, KPAV gear units ................................... 1.2
1.1 General ..................................................................................... 1.2
1.2 Preservation............................................................................. 1.3
1.2.1 Information on safety ...................................................... 1.3
1.2.2 Long-term preservation VCI ........................................... 1.4
1.2.3 De-preservation ............................................................ 1.12
1.3 Preservation after installation.............................................. 1.16
1.3.1 Special Maintenance Work........................................... 1.16
1.3.2 Connecting outside bolting area ................................... 1.17
1.3.3 Checking Flexibe hose(or Expansion Joint) Lines ....... 1.18
1.3.4 Alignment of the Flexible coupling ............................... 1.19
1.3.5 Oil Change and Inspection ........................................... 1.20
2 Decommissioning, dismantling and disposal .............................. 2.22
2.1 Information on safety ............................................................ 2.22
2.2 Decommissioning ................................................................. 2.23
2.2.1 Shut-down up to 10 hours ............................................ 2.23
2.2.2 Shut-down longer than 2 weeks ................................... 2.24
2.2.3 Tank type Lubrication unit(optional) ............................. 2.25
2.3 Dismantling ............................................................................ 2.26
2.4 Disposal ................................................................................. 2.27
End of the chapter……………………..2.27
Storage and preservation, KPAV gear units 1.1

1 Storage and preservation, KPAV gear units
1.1 General
Note!
Material damage due to transport and storage!
if the labels/information on the packaging unit and the shipping docu-
ments/this documentation are not observed, material damage to the
parts/component groups of the gear unit system may be incurred.
The marking/information on the packaging units and in the shipping doc-
uments/this documentation must be observed.
When storing the gear unit system in the packaging units of HYOSUNG,
observe the specifications for duration of storage and storage place ac-
cording to the packaging level (cf. chapter "Transport and packaging").
If the gear unit system is to be stored outside or after expiration of the
packaging level, it is necessary to carry out a preservation routine (cf.
section "Preservation").

1.2 Preservation
In case of storage, continuous preservation of the gear unit system must be

ensured. In general, storage of wood packaging should be indoor or outdoor
with waterproof condition.
Definition of preservation types
Corrosion
Preservation type Execution
protection
Inside preservation 12 months
Long-term preservation VCI
External preservation 12 months
Inside preservation Up to 5 years
Long-term preservation RK5
External preservation 12 months
Table 9 - 1 Table title
Information
Warranty for the durability of preservation can only be assumed if
long-term preservation was carried out by HYOSUNG service
personnel.
1.2.1 Information on safety
DANGER!
Possible risks when working on/with the gear unit system!
Ignoring of safety information in the chapter "Basic safety information"
and of the agreed accident prevention regulations when working on and
with the gear unit system will result in imminent danger for life and health
of the persons concerned.
Read and observe the safety information in the chapter "Basic safety in-
formation" and the agreed accident prevention regulations before and
while working on and with the gear unit system.
Warning!
Danger when handling hazardous substances!
When handling lubrication oils, preservatives and operating supplies dan-
ger for life and health of the persons concerned arises (e.g. suffocating
hazard, acid burns on limbs).
The following instructions must be observed:
 Observe all the safety information and instructions in the safety
data sheets of the products used.
 Wear your personal protective equipment, e.g. protective clothing,
protective gloves, and tight-fitting protective goggles.
 Ensure sufficient ventilation and do not inhale fumes. If sufficient
ventilation is not possible, wear breathing protection.
 Ensure that there are no sources of ignition.

1.2.2 Long-term preservation VCI
1.2.2.1 Recommended preservatives
Note!
Risk of material damage from mixing or contamination of
lubricating oils, preservatives or consumables!
Damage, faults or foam formation may result in the lubricating oil circuit of
the gear unit system if differing lubricating oils, preservatives or consum-
ables are mixed or contaminated.
 The compatibility of different types of lubricating oils, preservatives
or consumables can only be specified by the respective lubricant
supplier.
 Always use new and pure lubricating oils, preservatives or con-
sumables.
 Avoid contamination in the lubricating oil circuit of the gear unit
system.
HYOSUNG shall not assume liability or provide warranty for damage,
faults, contaminated lubricating oil or foaming lubricating oil resulting
from this.
Recommended
Type Preservation Purpose
preservative
Type 1 Inside preservation Highly fluid, wetting and water-repelling FUCHS Anticorit
DFW corrosion protection oil (de-watering DFW 9301 or simi-
fluid) for spraying all components of the lar specification
inside area.
Type 2 Inside preservation Due to the VCI corrosion protection oil FUCHS
(Volatile Corrosion Inhibitor), designated for Anticorit VCI UNI IP
spraying into the gear unit, a permanent 30 or similar speci-
protective atmosphere is created in the fication
closed interior.
Type 3 Outside preservation Corrosion protection of the outside unfin- FUCHS Anticorit
ished parts BW366 or similar
specification
Type 4 Outside preservation Protection of the shaft seals Multi-purpose
grease or similar
specification
Table 1 - 2 Recommended preservatives
Type Required quantity / stated consumption

Type 1 Ca. 5-10 litres for spraying
Type 2 30 litres
Type 3 Ca. 5 kg, consumption = 0.06 kg/m2
Type 4 ca. 5 kg
Table 1 - 3 Required quantities, preservative

Note!
Environmental pollution caused by improper use and dis-
posal of operating supplies!
All lubricants, preservatives or operating supplies must be collected in a
suitable vessel and disposed of in an environmentally responsible way or
recycled. Always observe the regulations for waste disposal that are valid
in the company and in the region.
1.2.2.2 Carry out long-term preservation
The following conditions for long-term preservation must be met:

 Ensure that the gear unit has been taken out of operation and
is secured against starting up.
 Ensure that components already mounted on the gear unit
system are secured in a way that
- That no mechanical forces affect the gear unit.
- That no vibrations affect the gear unit.
 Ensure that the connecting pipes on the gear unit are not
mounted (delivered condition).
 Ensure that during transport and storage the gear unit system
is not subjected to individual / continuous impacts or vibra-
tions.
 Make sure that the gear unit system is set up and stored dur-
ing preservation work in an enclosed, dry and frost-free build-
ing with protection from the elements.
 Make sure that the gear unit system is set up and stored in the
storage period protected from the elements under a roof or
with a covering tarpaulin.
 Make sure that the gear unit system does not come into direct
contact with water.
 Make sure that the gear unit system is stored in a horizontal
and stable position.
 Make sure that the corrosion protection agent used is compat-
ible with the lubricating oil used in the gear unit system. To
do this, consult the manufacturer of the lubricating oil in use.
 The following documents must have been read and under-
stood:
- the operating manual for the gear unit system.
- the relevant safety data sheets for the lubricating oils,
preservatives and consumables.
- these instructions on long-term preservation.
 The preservative agent must be applied by trained specialist
staff.
 Follow the instructions for actions for internal preservation and
then the instructions for external preservation.
 When carrying out work for long-term preservation, wear your
personal protective equipment, such as safety goggles,
protective gloves, oil-resistant safety shoes and safety
clothing.

Inside preservation
Warning!
danger for life and health of the persons concerned arises
(e.g. suffocating hazard, acid burns on limbs).
 Allow any excess residual oil inside the gear unit to drain through
the ball valve (1) and "oil return" connection (2) into a suitable
collection vessel.
Then close the openings again oil-tight.
Figure 1 - 1 Darin Valve and Oil return

 Dispose of the oil according to the local regulations.
 Open all "small" inspection holes (1) at the axial bearing area
and all "large" inspection holes (2) on the gearbox housing.
Figure 1 - 2 Inspection holes
 Suction out any oil remaining inside the gear unit.

 Spray the tooth flanks, the gearwheels, the shafts and the
interior walls with highly fluid, corrosion protection oil (type 1)
through the inspection holes.
All component groups must be coated with a thin film.
 Fill 5 litres of VCI corrosion protection oil (type 2) into each of
the
 two oppositely positioned "small" inspection holes at the axial
bearing area.
10 litre total volume of VCI corrosion protection oil (type
2).
 Fill 10 litres of VCI corrosion protection oil (type 2) into each of
the two oppositely positioned "large" inspection holes on the
gear unit sump.
20 litre total volume of VCI corrosion protection oil (type
2).
 Close and bolt the open inspection holes on the gearbox
housing.
When installing, ensure that the position of the seal is correct
and that all screws are available. Damaged seals must be
replaced.
 Close all inspection holes and gearbox openings on the gear
unit air- and oil-tight.

Air and oil-tight sealing of the inside of the casing
ensures that the outgassed VCI active agents of the
corrosion protection oil remain in the atmosphere inside
the gear unit. The VCI active agents precipitate as an
anti-corrosion agent onto the blank metal surfaces.

Outside preservation
Note!
Damage due to cleaning solvent in the gear unit or on
finished parts.
The cleaning solvent used for cleaning may only be used on the exterior
unfinished parts. Cleaning solvent must never enter the gear unit or
touch finished parts.
 Use cleaning solvent to remove dirt and grease from all out-
side bare parts (e.g. shafts).
 Apply corrosion protection wax (type 3) with a brush on all
outside bare parts so that they are covered (thrust ring, cou-
pling shafts etc.).
 Allow a drying time of 2 – 5 hours.
 After the drying time check the applied wax layer for full cov-
erage and correct layer thickness on all bare parts.
 Cover all coated surfaces with oil paper.
 Press multi-purpose grease (type 4) all around into the clean
and dry gap of the labyrinth (output side) with a grease gun.

Figure 1 - 3 Labyrinth
 Cover the gap of the labyrinth with foil paper.

 Close all shaft connections and air vents on the gear unit air-
and oil-tight.
 Air and oil-tight sealing of the inside of the casing ensures that the
outgassed VCI active agents of the corrosion protection oil remain
in the atmosphere inside the gear unit. The VCI active agents
precipitate as an anti-corrosion agent onto the blank metal surfaces

Figure 1 - 4 Shaft connections and air vents (2x)
Information
If the gear unit system is to be protected from external mechanical
damage by means of packaging the mechanical requirements and
the weather conditions on site must be considered:
• Wooden crate for protection of shafts, thrust ring and

instrumentation
• Shrink film
• Tarpaulins

1.2.2.3 Carry out long-term preservation
To check long-term preservation, the following activities must be

carried out according to schedule and documented:
Note!
Loss of the preservation
If the durability period of preservation ends or if one or several inspection
holes or openings in the casing are opened, the long-term preservation
must be renewed.
Do not open inspection holes or openings in the casing during long-term
preservation.
Activity Qual.- Interval

Place
Notes / consumables / references level1) Days OH
 Check the gear unit for leaks, in particular at
the pipe connection points and inspection
holes
Re-establish tightness and dispose of the dis-
Inside
charged oil according to local regulations. If the A 30 --
preservation
quantity of leaked oil is suspicious in relation to the
quantity of the VCI corrosion protection oil (type 2)
filled into the gear unit, long-term preservation must
be renewed.
 Check the applied corrosion protection layer
for full coverage and for correct layer thick-
Outside ness on all uncoated surfaces.
A 30 --
preservation If the corrosion protection layer (type 3) is dam-
aged, outside preservation must be renewed on the
unfinished surfaces where necessary.
 Carry out visual inspection for possible corro-
sion damage of the entire gear unit (inside and
outside area).
 Thoroughly remove any corrosion damage.
Renew  Carry out another long-time preservation VCI
B 365 --
preservation according to this documentation.
When carrying out the work, observe the relevant
safety information and dispose of the preservation
material according to the local environmental regu-
lations.
Table 1 - 4 Scheduled activities for checking long-term preservation

1.2.3 De-preservation
Warning!
When handling lubrication oils, preservatives and operating supplies dan-
ger for life and health of the persons concerned arises (e.g. suffocating
hazard, acid burns on limbs).
Note!
Risk of material damage from mixing or contamination of
lubricating oils, preservatives or consumables!
Damage, faults or foam formation may result in the lubricating oil circuit of
the gear unit system if differing lubricating oils, preservatives or consum-
ables are mixed or contaminated.
 The compatibility of different types of lubricating oils, preservatives
or consumables can only be specified by the respective lubricant
supplier.
 Always use new and pure lubricating oils, preservatives or con-
sumables.
 Avoid contamination in the lubricating oil circuit of the gear unit
system.
HYOSUNG shall not assume liability or provide warranty for damage,
faults, contaminated lubricating oil or foaming lubricating oil resulting from
this.

Packaging level
1 Ball valve, axial bearing area 3 Blank flange

2 Ball valve, gear unit sump
Table 1 - 5 Gearbox housing ball valves
 Allow any residual corrosion inhibiting oil inside the gear unit
to drain off through the ball valves of the axial bearing area
(1) and housing sump (2) into a suitable collection vessel.
 Close the ball valves on the axial bearing area (1) and on the
housing sump (2) again oil-tight.
 Remove the blank flange (3) from the gearbox housing.
 Use an oil suction device to extract any excess residual oil
from the gear unit sump.
 Attach the blank flange (3) oil-tight to the gearbox housing
Information
Minor residual quantities of oil remaining from the packaging
stage are normally dissolved in the lubricating oil during the com-
missioning:
 Remove the corrosion protection agent used for external preserva-

tion on the shafts with cleaning solvent.

Long-term preservation VCI
1 Ball valve, axial bearing area 3 Blank flange

2 Ball valve, gear unit sump
Table 1 - 6 Gearbox housing ball valves
 Allow any residual corrosion inhibiting oil inside the gear unit
to drain off through the ball valves of the axial bearing area
(1) and housing sump (2) into a suitable collection vessel.
 Close the ball valves on the axial bearing area (1) and on the
housing sump (2) again oil-tight.
 Remove the blank flange (3) from the gearbox housing.
 Use an oil suction device to extract any excess residual oil
from the gear unit sump.
 Attach the blank flange (3) oil-tight to the gearbox housing
Information
Minor residual quantities of oil remaining from the packaging
stage are normally dissolved in the lubricating oil during the com-
missioning:
 Remove the corrosion protection agent used for external preserva-

tion on the shafts with cleaning solvent.

Long-term preservation RK5
The required equipment with documentation for long-term

preservation RK5 can be optionally obtained from HYOSUNG
SERVICE.

1.3 Preservation after installation
1.3.1 Special Maintenance Work
DANGER!
DANGER!
Danger caused by improper connection!
 Ensure that the oil lines are connected vibration-free.
This way you can prevent them from breaking during operation and hot oil
from splashing out.
Note!
Ensure that
 the oil lines are free from dirt and that no foreign particles
penetrate into the oil lines and the gear unit.
This way you prevent damage to tooth and bearings and avoid a consid-
erably longer rinsing procedure of the oil system / the gear unit.

1.3.2 Connecting outside bolting area
 All exposed bolt areas should be inspected at least once every three
months.
 Replace defective seals, bolts, nust with clean, new seals.
Information
Alignment of oil lines and oil system must be carried out to the customer-
specific installation drawings.
All screws of the main flange, connecting the torque support, the ring gear
and the housing with each other, have to be checked after 6 and 12 months
after start-up. Afterwards intervals of at least 12 months have to be kept.
The tightening torques specified in table 1-7. apply to the fastening screws.
This may be used as a guide. The tightening torques applies to bolts with an
untreated surface and light oil.
Tightening Torque Tightening Torque

Thread Size
(Strength Class 8.8) (Stainless Steel, dry condition)
M10 49 Nm 42 Nm
M12 86 Nm 73 Nm
M16 210 Nm 180 Nm
M20 410 Nm 370 Nm
M24 710 Nm 603 Nm
M30 1450 Nm
M36 2530 Nm
Table 1 - 7 Tightening Torque Guide
Damaged bolts must be replaced with new bolts of the same type and grade.

1.3.3 Checking Flexibe hose(or Expansion Joint) Lines
 The period of use of the hose lines must not exceed 6 years from the
manufacturing date stamped on them. To deviate from this, the
period of use can be determined in accordance with available test
and empirical values, particularly taking into account the conditions
of use.
 Even when correctly stored and subjected to permissible loads,
hoses and hose lines are subject to a natural ageing process. This
limits their period of use.
 The operator of the system must ensure that hose lines are replaced
at suitable intervals of time, even if no defects which may affect
their safe operation are identifiable on them.
 Hose lines must be inspected for safe working condition by an expert
before the work equipment is first put into operation and thereafter
at least once a year.
 If during inspections faults are found, these must be rectified
immediately or suitable countermeasures taken.
 Uniquely identify each hose and document its checks, maintenance
and replacement.

1.3.4 Alignment of the Flexible coupling
The alignment of the coupling must be checked before driving the

gearbox again.
ATTENTION!
 Check that the version of the motor has an axial bearing.
If the motor is without axial bearing, the coupling must have an axial back-
lash limitation!
Information
For axial alignment, observe the information in the operation / operating
manual of the coupling manufacturer.
DANGER!
 Never operate the gear unit without protective covers!

1.3.5 Oil Change and Inspection
A careful oil change will contribute significantly towards increasing the oper-
ating safety and reliability as well as the service life of both the gear trans-
mission and its new oil filling. It must be ensured that no contaminants such
as foreign matter, water or other liquids can enter the gear transmission in
the course of the oil change.
To remove the initial wear of the gearbox the gear oil change should be per-
formed after the 500 hours or four (4) weeks of operation, whichever
occurs first of gearbox operation. Oil analysis is required every 3 months
or 2000 hours of operation, whichever occurs first and if there is no
problem with the oil condition, it can be used continuously. However, do not
use the oil for more than 2 years. Refer to Oil change & Flushing proce-
dure
Labour safety and environmental protection
Information
All jobs necessary for oil change must be carried out carefully by special-
ised personnel trained to do so.
DANGER!
 Wear your personal protective equipment when draining oil from
the gear unit or oil container or filling it.
DANGER!
 Have oil binding agents and cleaning agents ready.
Note!
General information:
 Drain the old operating oil before you fill in new operating oil.

ATTENTION!
Ensure that a sufficient quantity of the prescribed oil ISO VG 320 is avail-
able.
DANGER!
Danger of contamination due to escaping oil!
Do not allow any oil to get into the sewage system or the ground when
filling up / draining oil. The oil must be collected up and disposed off in an
environmentally-approved manner or handed in for recycling.

2 Decommissioning, dismantling and disposal
2.1 Information on safety
DANGER!
Possible risks when working on/with the gear unit system!
Ignoring of safety information in the chapter "Basic safety information"
and of the agreed accident prevention regulations when working on and
with the gear unit system will result in imminent danger for life and
health of the persons concerned.
Read and observe the safety information in the chapter "Basic safety
information" and the agreed accident prevention regulations before and
while working on and with the gear unit system.
Note!
Material damage due to unqualified personnel
Drain the old operating oil before you fill in new operating oil.
Dispose of the drained oil according to the local regulations.
Observe the information in the safety data sheet.
Replace defective seals.
Decommissioning, dismantling and disposal 1.22

2.2 Decommissioning
2.2.1 Shut-down up to 10 hours
Note!
Damage on the gear unit system due to corrosion!
In case of longer periods of standstill (> 14 days) corrosion
damage may occur on the gear unit system.
In case of longer periods of standstill the instructions for handling
described in the section "Decommissioning" must be observed.
The following instructions must be observed when the system is shut

down up to 10 hours:
Bring the gear unit to a standstill using a shut-down routine for the
overall plant.
 Do not switch off the oil supply system so that the gear unit system
can be started up again easily.
 The oil supply system is kept at a minimum temperature of approx.
25°C.

2.2.2 Shut-down longer than 2 weeks
Note!
Damage on the gear unit system due to corrosion!
In case of longer periods of standstill (> 2 weeks) corrosion damage may
occur on the gear unit system.
In case of longer periods of standstill suitable measures must be taken to
protect against possible corrosion.
The following instructions must be observed when the system is shut

down longer than 2 weeks:
 Bring the gear unit to a standstill using a shut-down routine for the
overall plant.
 Switch off the oil supply system after a waiting time of 30 minutes.
This way, lubrication of the gearing and of the bearings is
maintained and backup heat does not develop in the gearbox
housing.
Start the gear unit system every 2 weeks in accordance with the
following instructions:
 Switch on the oil supply system and wait until the minimum
temperature has been reached.
 Pump the lubricating oil through the gear unit system for approx.
3…4 hours.
This supplies all lubrication points with an adequate amount of
lubricating oil.
 Run the gear unit under no load conditions for 5…10 minutes while
th e lubricating oil supply unit is operating. (Recommendation)
This wets all gearing and sliding surfaces with an adequate
amount of lubricating oil. In addition, regular operation of the
heaterless electric motor can prevent malfunctions.
 Bring the gear unit to a standstill again using a shut-down routine for
the overall plant.
 Switch off the oil supply system after a waiting time of 30 minutes.
This way, lubrication of the gearing and of the bearings is
maintained and backup heat does not develop in the gearbox
housing.
 Drain the oil to the gear box and suction pipe drain port every 2
months in units of 1...2 liters.
This way helps to remove moisture from the bottom of the
lubricant. Refer to the installation drawing and maintenance
manual for the location of the drain port.
 The lubricant must be inspected before the load operation of the
gearbox according to the flushing manual.

 It is recommended to replace the air vent with dehumidification func-
tion when the operation is stopped for more than 12months. For de-
tailed specifications, please contact Hyosung Co.
 When restarting normal operation, be sure to check the initial instal-
lation conditions in the maintenance and operating manual.
2.2.3 Tank type Lubrication unit(optional)
In addition to section 2.2.2, the following instructions for handling must be

observed when dismantling the gear unit system:
 According to Table 1-7, Check the lubrication unit’s bolts every

three months. Damaged bolts must be replaced with new bolts of
the same type and grade.
 Check the piping connections and flange for leakage. If leakage is
detected, action is required immediately. In some cases, bolts and
gaskets may need to be replaced.

2.3 Dismantling
The following instructions for handling must be observed when dismantling

the gear unit system:
Work for dismantling the gear unit system may only be carried out
by qualified specialized personnel.
 Take the gear unit system out of operation (cf. Section
"Decommissioning").
 Before beginning the activities to dismantle the gear unit system,
ensure that it has been shut down Is secured against starting up
 Always follow the regulations for waste disposal valid regionally and
in the company.
 If in doubt, ask your waste manager or your supervisor. Ensure that
the lubricant is completely removed from the gear unit system.
 Have the gear unit dissembled into transportable parts by specialists
trained to do so.
 Dispose of the parts/component groups of the gear unit system
according to the regulations:
- Dispose of parts containing oil or lubricant, cleaning cloths and
- Dispose of electronic parts/component groups in a collecting
container set up for this purpose.

2.4 Disposal
The following essential instructions for handling must be observed when

disposing of the gear unit system:
 Work for disposing of the gear unit system may only be carried out
by qualified specialized personnel.
 Take the gear unit system out of operation (cf. Section
"Decommissioning").
 Dismantle the gear unit system (cf. section "Dismantling").
 Always follow the regulations for waste disposal valid regionally and
in the company.
 If in doubt, ask your waste manager or your supervisor. Ensure that
the lubricant is completely removed from the gear unit system.
 Have the gear unit dissembled into transportable parts by specialists
 trained to do so.
 Dispose of the parts/component groups of the gear unit system
according to the regulations:
- Dispose of parts containing oil or lubricant, cleaning cloths and
- Dispose of electronic parts/component groups in a collecting
container set up for this purpose.

KPAV125

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Installation, Operation and

0 Identification ........................................................................................................... 0.1

1 Intended Use, Warranty, Safety Information ........................................................ 1.1

2 Technical Data ........................................................................................................ 2.1

3 Technical Description ............................................................................................ 3.1

4 Packing, Conservation, Transport and Storage .................................................. 4.1

5 Setting Up and Connecting ................................................................................... 5.1

6 Initial Commissioning, Checking and Decommissioning ................................... 6.1

7 Maintenance and Repair ........................................................................................ 7.1

8 Oil Change .............................................................................................................. 8.1

9 Trouble shooting .................................................................................................... 9.1

10 Spare Parts ........................................................................................................... 10.1

Thank you for choosing one of our products.

Please read this operating manual carefully before commissioning your

These are the conditions for:

We are happy to receive any ideas or improvements concerning this

We wish you success and good work results!

Hyosung Gear Solution Design Team.

Manufacturer: Hyosung Corporation(Licenced Renk)

0.2 Product Identification

The industrial gear unit KPAV is delivered in the following version:

Fig. 0.1: Nameplate

0.3 Operating Instructions

Date produced: 2016.12 / 2017.04

Change index: Index Change Date Name

Number and language English Paper Digital(CD-ROM)

These operating instructions have been produced in accordance with the

This operating manual contains information for the distributing company of

In this manual, warning information is indicated by pictograms. Information is

1 Intended Use, Warranty, Safety Information

This manual indicates general residual risks and hazard points.

 In addition to the safety instructions described below, all safety in-

1.1 Appropriate Use

The owner/operator agrees

Intended use also includes:

 Transport of the gear unit with oil filling

 Changes occurring in the gear unit caused by malfunctions that affect

1.2 Warranty and Liability

As a rule, the Hyosung. Co “General Terms of Sale and Delivery” as well as

 Inappropriate operation of the gear unit.

1.2.1 Terms and Conditions of Warranty

Only use spare parts and consumables released by Hyosung. Co.

1.3 Information on Transport

 Only use lifting gear of an adequate load and lifting capacity in

1.4 Information for the Distribution Company of the over-

Grid disconnection devices

Distancing protective equipment

Emergency stop installations

 The distributing company of the overall plant is obliged to install an-

Failure of power supply

1.5 Obligation of the Owner/Operator

The owner/operator agrees

1.6 Personnel Training

The personnel must have a solid knowledge of the following areas:

1.7 Information concerning Operation

1.8 Notes for the Operator

 In order to avoid hazards and to ensure optimal performance, no

1.9 Information concerning Service Jobs

 The overall plant is switched to zero-potential and that the power

 Activities with dismantled protective devices may be carried out

The owner / the service personal must be strictly adhered following:

 It is necessary to ensure the functional safety of the oil unit required

1.10 Obligation of the Personnel

Persons assigned to work on and with the gear unit agree