Everything revolves around the ultimate availability of industrial drives.

Head office and Herne works Works Friedrichsfeld Works Penig Customer Centre Dresden

Suedstrasse 111 Laboratoriumstrasse 2 Thierbacher Strasse 24 Bautzner Strasse 147 a

D-44625 Herne D-46562 Voerde D-09322 Penig D-01099 Dresden

Phone +49 (0) 2323-940-230 Phone +49 (0) 2871-92-2441 Phone +49 (0) 37381-6-1437 Phone +49 (0) 351-81407-31

Fax +49 (0) 2323-940-333 Fax +49 (0) 2871-92-1490 Fax +49 (0) 37381-6-1488 Fax +49 (0) 351-81407-32

Alarm with data

arrow via

e-mail / SMS

Automatic condition

monitoring

Variation in status

condition

Machine with measu-

rement location

Service data bank in

web technology

Diagnostic

expert

Machine

alarm

via e-mail

+ SMS

... for the utmost

availability of your

industrial drives

The decisive momentum

Six benefits for your drive systemsMomentums for utmostavailability

2

Strategy Page 2

Customer benefits Page 3

Care & maintenance

management Page 4/5

Condition

monitoring Page 6/7

Replacement parts and

replacement gear units Page 8/9

Inspection /

maintenance /

field service Page 10

Job work /

heat treatment Page 11

Contents

FLENDER SERVICE offers you services covering the

condition-oriented care and maintenance of drives

which are aimed at a clearly defined goal, namely to

ensure utmost availability. Therefore, we have deve-

loped a service range that finds a solution to any

requirement and which is as comprehensive as

scarcely any other.

The main benefit of our service programme is the

following: the realisation of all messures, such as

inspection, maintenance, field service and repair

work, under our care and maintenance management

system. Our condition-oriented care & maintenance

programme gives you a clear picture of the current

condition of your drives, thanks to our dedicated

diagnostic specialists and the use of our test & mea-

surement systems e.g. our GearController®. We can

supply spare parts and replacement gear units at

short notice, if requested, and will, therefore, be

happy to assist you in your spare part management.

Last but not least, you can take advantage of our

all-inclusive solutions from one source, which we

prepare within the framework of a close working

relationship with our partners. It goes without

saying that we can simply do more to ensure the

ultimate availability of your drives.

Reliability

FLENDER SERVICE is always there in the right

place at the right time whenever you need us. Call

our hotline which is available 24 hours a day.

Services

Our services are the key to ensuring the ultimate

availability of your drive systems. In addition to

preventive measures, such as our inspection servi-

ce, we also provide technical reports on failure

causes as well as expert reports and assistance in

managing claims for damages against insurance

companies.

Making plant fail-safe

FLENDER SERVICE makes your plant fail-safe by

applying condition monitoring technology and con-

dition-oriented care & maintenance programs to

your operating systems. Wear induced defects can

be identified at an early stage by our mobile

or stationary telediagnostic test systems

GearController®.

Plant availability

With the aid of FLENDER SERVICE you can signifi-

cantly increase the useful service life of your

production plant. We work together with the custo-

mer to develop far-sighted servicing concepts so

that plant availability can be improved even further.

Upgrading of plant

Raise the productivity and cost effectiveness of

your drive systems by way of re-engineering and

retrofit measures.

Know-how transfer

Train your employees to identify defects early on.

The FLENDER ACADEMY seminars follow an inno-

vative training concept which ensures that the method

for transferring know-how meets the requirements

in the field. Employees who have once completed the

training programme become independent "teachers"

by means of the "train the trainer" concept. They pass

on what they have learnt to other members of your

staff.

3

Strategy Customer benefits

Condition monitoring

Knowing what moves and how

Condition monitoring

6

Flexible technology, concrete results

7

Making an exact drive diagnosis is a prerequisite

for condition-oriented care & maintenance.

Ultramodern test & measurement technology ena-

bles us to identify failure patterns precisely. Our

know-how is the foundation for reliably analysing

the test values in detail. Then, in a joint effort with

the customer, we reflect on possible drive modifi-

cations and submit concrete suggestions, which

are designed to prevent the damage recurring in

the future.

Machinery diagnosis

Our diagnostic and inspection services deliver a

transparent picture of the current condition of your

drives. Measurements are taken with the plant run-

ning. This means we measure the status condition

of a drive under operating conditions with no need

for time consuming and costly disassembly. Based

on our experience, you will then receive our clear

recommendations for actions to be taken under a

condition-oriented care & maintenance program.

Condition monitoring

Condition monitoring is a FLENDER SERVICE spe-

ciality. This embraces mobile and stationary testing

tools for condition-oriented care & maintenance. For

gear and bearing diagnoses we consistently use

our GearController®, however you can also rely on

us to carry out "typical measuring tasks", such as

measurements of tem-

perature, torque and

sound.

GearController®

By using GearController® systems it is possible to

collect information about the operating and run-

ning conditions of gear units and rotating machines

and to identify variations of the vibration behaviour

over the time the units have been in operation.

Depending on the drive and gear unit type, pre-set

test modules are activated in the test system, and

test results are read out and stored in a database.

The GearController® works on the basis of traffic

light frequency spectra. Frequency components

which are significant are checked and analysed as

to variations. The experience we have accumulated

in worldwide applications is at your disposal for

forecasting residual service lifetimes.

Remote access to stationary GearController®

systems is possible via the Internet. As inadmissible

variations arise, the GearController® sends out the

appropriate data sets by E-mail on a worldwide

basis. The advantage is that the data and not the

expert will "travel", and you can avoid an impending

crash by a scheduled outage of your plant.

Refer to www.flender-cm.de for product information.

FLENDER SERVICE offers you the followingoptions:

• mobile diagnostic test systems with specialistson-site

• temporary telediagnostic test systems on a rentalbasis

• permanent machine diagnosis based on statio-nary GearController® systems

• special analyses such as torque measurements

• video monitoring of processes

• consulting and training

GEAR UNIT TYPE MODEL

CAVEX worm gear units e.g., CKOP, CKUP, COHP, CUHP, ....

DURUBLOC helical and bevel-helical gear units with power splitting

feature models BN S... and BN K...

DURUNORM helical and bevel-helical gear units including allied ranges

REDUREX helical and bevel-helical gear units including allied ranges

SKET-gear units helical and bevel-helical gear units

STANDARD WGW / TGW helical and bevel-helical gear units with through-hardened gears

TGL-gear units helical and bevel-helical gear units models TGL 21810 to 21818

UNIRED planetary gear units models PE... and PZ...

Line of business MODEL

Gear units for railway Flender helical (AS...), bevel (AKO...) and bevel-helical

vehicles (AKE.../AKW...) gear units for trams, metros, LRVs and locomotives

Penig production before 1990 for locomotives and trains

Mining gear units FKP, KPL, PZA models and others

Crane gear units models NKS..., NKK... and DKS... as TGL 34611

Marine gear units L & S / Flender marine gear units

Mill gear units models KML and KMP as SBH and SBHK

Agitator gear units models SROA, SRON, SRVN, XSLH, XKB H, -L, -N

and TGL 22109

Special type gear units e.g. bucket wheel gear units and slewing gear units, press gear units,

mixer and calender gear units

Special design ranges e.g. conveyor gear units models TGL 18049 and TGL 37088, cooling tower

drive models KV and KSV, baseplate-mounted models KSHK, KBHK and KCHK

and others

Replacement gear unitsSpare parts

8 9

No matter what sort of original replacement parts

or gear units you need, whether they be from the

range of Flender GmbH, TGW Thyssen Getriebe-

und Kupplungswerke, WGW Westdeutsche

Getriebewerke GmbH or Flender Getriebewerk Penig

(FGWP) – FLENDER SERVICE is your contact. These

are our strengths:

• Short delivery times and great availability of

replacement parts, thanks to corporate-wide

stock-keeping

• Wide variety of designs (e. g., case-hardened,

nitrided or through-hardened gear components)

from the works-own production line

Please take advantage of our extensive know-how

in servicing industrial, marine and LRV gear units.

If component supplies have to be accompanied by

acceptance certificates or have to meet special

quality requirements, we can deal with it at short

notice.

Each and every industrial gear unit, even if supplied

by a third-party, can be supplied within a very brief

period for replacement on the basis of the dimen-

sions taken or according to drawing specifications.

By the way, if we have nothing in stock that suits

your individual needs - no problem. Our years of

experience in mechanical power transmission

engineering allow us to develop an optimum soluti-

on for any application.

Spare parts management

Under the spare parts pool management you can

assign our company responsibility for keeping your

drives up and running. If so requested, we will sup-

port your spare parts management (manufacture,

stock-keeping etc.) and rectify problems within a

defined period.

For third-party gear units we can supply every

industrial gear unit for replacement on basis

of dimensions taken or according to drawing

specifications.

Spare parts and replacement gear units at aglanceThe right solution in stock

Job work/heat treatment

This is the sort of maintenance you have been looking for

Inspection/maintenance/field service

10

We rely on optimum preparation

11

Inspection and maintenance

The purpose of any inspection is to identify and

assess the current plant condition by means of

measurements and functional tests. Depending on

the findings, our maintenance system ensures that

the required condition of your drives is maintained

by means of a regular action plan including e. g.,

re-adjustment, parts addition, lubrication and

cleaning.

FLENDER SERVICE will be happy to provide mainte-

nance and inspection services at any time within

the framework of a maintenance agreement.

Inspection and maintenance agreements

Optimum maintenance is, last but not least, a mat-

ter of regular application. Therefore, FLENDER SER-

VICE offers you maintenance agreements which are

tailored to your individual needs and define the

inspection and maintenance work to be carried out.

We discuss things with you and make agreements

that take into account the maintenance procedures

so far employed. The aim is to achieve targeted,

condition-related and, especially, cost-effective

maintenance of your drives.

Job work

For order-based work from FLENDER SERVICE, you

can choose from the following methods for the

manufacture of gear components used in all fields of

power transmission equipment: either according to

your drawings, the specimen provided or according

to individual dimensions taken. Any manufacturing

method connected with the gear is possible in our

workshops. Our speciality is through-hardened and

case-hardened spiral bevel gear wheels, which are

produced to the Klingelnberg-Hypoid-Palloid

system and are lapped, with ground tooth flanks or

HPG-S (hard-cut) type. Our in-process quality con-

trol system is applied to every work cycle up to the

final inspection.

Skeleton maintenance agreements with a warranty

clause

Again, these agreements are matched to your indi-

vidual needs and requirements and they ensure

that the down-times of your production facilities

are reduced to a defined minimum. A skeleton

maintenance agreement specifies and guarantees

that necessary replacement parts and service

engineers are provided as required.

Field service

Our specialised service engineers have a diverse

range of tasks, including the installation and moun-

ting of the drive on the job site and the alignment

according to the manufacturer's specifications

and/or recommendations. FLENDER SERVICE is

also your reliable partner for the commissioning,

checking of all operating parameters as well as care

& maintenance work. This also applies to industrial

gear units, LRV gear units, marine or special type

gear units.

Heat treatment

Capability and punctual delivery - they are the most

important parameters in our heat treatment shop in

the Herne works. The service range incorporates:

case-hardening, through-hardening, gas nitriding,

metallographic analyses, structure and hardness

analyses, heat treatment samples.

Please consult us for concrete information on how

FLENDER SERVICE can take care of the ultimate

availability of your drives: ++49 (0)2323 940 - 230.

Call our 24 hour-a-day Hotline 0172 - 28 10 100.

Everything revolves around the ultimate availability of industrial drives.

Head office and Herne works Works Friedrichsfeld Works Penig Customer Centre Dresden

Suedstrasse 111 Laboratoriumstrasse 2 Thierbacher Strasse 24 Bautzner Strasse 147 a

D-44625 Herne D-46562 Voerde D-09322 Penig D-01099 Dresden

Phone +49 (0) 2323-940-230 Phone +49 (0) 2871-92-2441 Phone +49 (0) 37381-6-1437 Phone +49 (0) 351-81407-31

Fax +49 (0) 2323-940-333 Fax +49 (0) 2871-92-1490 Fax +49 (0) 37381-6-1488 Fax +49 (0) 351-81407-32

Alarm with data

arrow via

e-mail / SMS

Automatic condition

monitoring

Variation in status

condition

Machine with measu-

rement location

Service data bank in

web technology

Diagnostic

expert

Machine

alarm

via e-mail

+ SMS

... for the utmost

availability of your

industrial drives

The decisive momentum