JUPITER2200-01 1233-SA Eng

TECHNISCHE SERVICEANLEITUNG
TECHNICAL SERVICE INSTRUCTION
MANUALE DI ASSISTENZA TECNICA
JUPITER 2200
Ma.Nr.: 1233
JU2200-01_SA00-V00_eng-DB.doc
Service Instruction
JUPITER 2200
Index
1. Specification of machine
( JU2200-01_SA10-V00_eng.doc )
2. Safety instructions
( JU2200-01_SA20-V01_eng.doc )
3. Maintenance and Service

( JU2200-01_SA30-V06_eng.doc )
4. Spare parts
( JU2200-01_SA40-V05_eng.doc )
5. Documentation of components
( JU2200-01_SA50-V00_eng.doc )
6. Electrical diagrams
( JU2200-01_SA60-V00_eng.doc )
7. Supplement
( JU2200-01_SA70-V01_eng.doc )
JU2200-01_SA01-V07_eng-IHV_1512+1513-MUT.doc
AUTHOR`S RIGHT
The author`s right of this Operating, Maintenance and Service Instruction, which is
exclusive determined for using by authorised and trained personnel of the operator
of the machine or plant, remains to the following company:
LINDNER Recyclingtech GmbH
The reproduction, distribution and utilization of this document as well as the

communication of its contents to others without explicid authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the
event of a grant of a patent, utility model or design.
Company address:
Lindner - Recyclingtech GmbH

Villacher Straße 48, A-9800 Spittal/Drau
Phone: +43 4762 2742-0, Fax 2742-32
E-mail: office@lindner-recyclingtech.com
Internet: www.lindner-recyclingtech.com
Urheberrecht_eng.doc
Service Instruction
JUPITER 2200
Index
1. Specification of machine
1.1. Technical description .................................................................................... 2 / 5
1.1.1. Function .............................................................................................................. 2 / 5

1.1.2. Schematic presentation.................................................................................. 2 / 5
1.2. Use According to Specifications ............................................................... 3 / 5
1.2.1. Areas of Application.......................................................................................... 3 / 5

1.2.2. Guarantee ........................................................................................................ 3 / 5
1.3. Dimension drawing ........................................................................................ 4 / 5
1.4. Technical data .................................................................................................. 5 / 5
JU2200-01_SA10-V00_eng.doc Rev.: 00 / 18.02.2009 page 1 of 5

Service Instruction
JUPITER 2200
1.1. Technical description
1.1.1. Function
The material to be reduced enters the cutting area (2) by means of a generous sized in-feed hopper
(1). A massive hydraulic in-feed device (3) pushes the material towards a slowly running milling rotor
(4). The thus compressed material is cut between the counter-knife (5) and the cutters, which are
installed in spiral formation on the rotor. The reduced material is pressed through the sickle-shaped
clamps (6) or the screen (option), when necessary cut on the upper strike-off (7) and then falls down
into the evacuation assembly (8). Having achieved the forward motion the in-feed device (3) returns
in order to transport more material. Granular size (reduced material) can be varied by using
exchangeable sickle-shaped clamps (6), where the disrtances are variable or screens (option) with
different perforations and exchangeable cutters. Evacuation of the granular material can be
performed by means of a screw conveyor, a conveyor belt or a patented cradle chain conveyor (8)
from Lindner.
The Foreign parts flap (9) (backwards covering of the plant) can be swung out outside or inside the
machine hydraulically in order to guarantee easy access to the rotor (4) and to the cutting area (2).
By opening the maintenance door (10) there can be an easy access to the screen space (11) which
contains the sickle-shaped clamps (6). The screen unit (option) can be driven out hydraulically.
1.1.2. Schematic presentation
1 3
7 9
4
5
10
6
11
8

Service Instruction
JUPITER 2200
1.2. Use According to Specifications
1.2.1. Areas of Application
The JUPITER 2200 machine is exclusively designed for shredding contractually agreed upon materials.
Any use above and beyond this is deemed to be not according to specifications.
The following types of materials have been contractually agreed upon:
Requirements
Material
Material charge
Residual moisture
Input density
Input granulation
Transfer rate
Output
granulation
Material removal
Production times
Attention:
For safety reasons the following materials must not be feeded to the shredder machine
in no case:
• materials with low flash point, which cause danger of fire

(for example varnish residues or solvent)
• materials, which couse danger of explosion (gas, vapour, flammable dust)
• materials, which release radioactive radiation
1.2.2. Guarantee
If materials are processed that are not contractually agreed upon, the
manufacturer is absolved of any liability and guarantee for safety and
the functioning of the machine. This is entirely at the risk of the operator!

Service Instruction
JUPITER 2200
1.3. Dimension drawing

see following page!

Service Instruction
JUPITER 2200
1.4. Technical data

see following page!

Operating Instruction
1. 4. Technical data
Type of machine: JUPITER 2200 Ma.Nr.: 1233
1.4.1. General data:
Number of cutters 24 pcs Year of construct 2009

Cutter form 145x145x47 EX-protection No
Screen perforation sickle cass. 104 mm Noise level > 85 dB(A)
Material discharge by customer Varnish RAL 5015/RAL 2000
Weight of machine 30 tons Rotor-Revolutions 51 rpm
Climatic conditions 5-55°C/40-80%rel.hu. Rotor-cooling no
1.4.2. Drive: Three phases current motor (2x)

Manufacture Schorch Construction form B3
Capacity 110 kW Size 315M
Revolutions 980 rpm Voltage / frequency 3x400 V / 50 Hz
Terminal box top Frequency converter No
1.4.3. Transmission: Countershaft gear (2x)

Transmission Belt drive I = 1:5,4 Transmission Belts 2x KB3-8V-
Motor / countershaft Motor / countershaft 2360/5994LA - 115200
Transmission Belt drive I = 1:3,54 Transmission Belts 4x 5-8V Red Power
Countershaft / rotor Countershaft / rotor 2000/5080LA - 95961
Product - Type -
Gear lubricant - Filling volume - litre
Safety clutch RK-75 Setting by manufact. 28 kNm
1.4.5. Hydraulic unit:

Manufacture / type Dorninger – Heavy Duty 1
Capacity 65 l/min
Oil tank 400 l Castrol Vario HDX VG46
Inward pressure 160 bar
Outward pressure 80 bar
1.4.5.1. Drive of hydraulic unit:

Capacity 11 kW Voltage / frequency 3x400/660 V / 50 Hz
Revolutions 1450 rpm Size B35
1.4.6. Hydraulic cylinders

In-feed device (2x) Foreign parts flap (2x) Screen device (2x)
Manufacture / type Dorninger 105155, Dorninger 65937, Dorninger 65426,
80/56x470 R/L 63/36x685 50/28x700
Cylinder- / diameter 80/56 mm 63/36 mm 50/28 mm
of bar
Stroke 470 mm 685 mm 700 mm
Service Instructions
JUPITER 2200
Index
2. Safety instructions
2.1. Definitions and Identification Symbols ........................................................ 2
2.1.1. Definitions..................................................................................................................2
2.1.2. Identification Symbols .............................................................................................. 2
2.2. Operational Safety ............................................................................................. 4
2.2.1. General Measures....................................................................................................4

2.2.2. Choice of Personnel ................................................................................................4
2.2.3. Operating States ......................................................................................................5
2.2.4. Specific Hazards.......................................................................................................6
2.2.5. Machine Labelling .................................................................................................... 8
2.3. Residual Hazards .................................................................................................. 9
2.3.1. Nipping Hazard ........................................................................................................9

2.3.2. Danger through unexpected starting (screen area) ....................................... 10
2.3.3. Feed Area .............................................................................................................. 11
2.3.4. Interfaces Between Machine Components...................................................... 11
2.3.5. Interfaces to Neighbouring System Components ............................................ 11
2.3.6. Spontaneous ignition of remaining material ..................................................... 11
2.3.7. Danger through rotating components (rotor run-out)..................................... 12
JU2200-01_SA20-V01_eng.doc Rev.: 01 / 18.02.2009 Page 1 of 12

JUPITER 2200
2.1. Definitions and Identification Symbols
2.1.1. Definitions
• Hazardous Zone
A hazardous zone is any area around the machine / system in which there is a hazard for persons. This
hazard may be caused by parts being hurled out of the machine.
• Cutting Space
The cutting space of a machine is the area in which the shredding takes place. It ranges from the
rotor shaft to the upper edge of the feed opening.
• Disruptive Materials
Disruptive materials are unshreddable materials that could cause damage to or a total breakdown of
the machine or system and are not part of proper use.
• Operator
The operator is responsible for using authorised and trained personnel to operate, maintain, and
service the machine / system.
• User
The user may only operate the machine / system following adequate instructions by the operator,
whereby the operator’s guide must be observed.
2.1.2. Identification Symbols
The following symbols indicate safety-relevant places in the operator’s guide:
• Warning of hazards
There is a direct hazard for the life and health of persons.

Access is only permitted for authorised and trained personnel.
• Warning of hazards from electrical current / voltage
There is a direct hazard for the life and health of persons by coming into contact with
live components.
Work is only permitted for trained and qualified personnel (electricians).

JUPITER 2200
• Notice about proper operation of the machines
The machine or system must be handled properly.

This information must be observed to avoid destroying or damaging the machine or
system components.
• Notice about bans
There are bans for operating personnel so that safety is guaranteed during the various
operating states of the machine / system (e.g. no open fire or smoking).
• Notice about using personal protection equipment
There is a rule about using personal protection equipment during different operating
states of the machine / system (e.g. wearing safety glasses).
• Notices about using fire extinguishing equipment
It is necessary to install fire extinguishing equipment that is to be used in case of

emergency. Here, the local fire protection regulations must be observed (e.g. pointer
to a fire extinguisher).
• Notice about hazards from working materials
There are hazards coming from working materials (e.g. a hazard to the environment).

JUPITER 2200
2.2. Operational Safety
2.2.1. General Measures

In order to guarantee the operational safety and functioning (risks reduction) of the machine / system,
the machine / system may only be used for the purposes given by the manufacturer (also see 1.2).
The manufacturer assumes no liability for the safety and functioning of the machine / system for
misuse, modifications, and the use of non-original parts in the shredder and other system components.
The operator must make sure that the machine / system is integrated into the plant’s internal safety
management system (employee safety assessment, fire protection, first aid).
The operator’s guide must be kept with the machine / system and be accessible to
operating, maintenance, and service personnel.
Any safety equipment and safety notices attached to the machine / system may not
be removed or rendered inoperative due to modifications to the machine.
In case of emergency (accident), there must be adequate precautions taken for first
aid (first aid kit, emergency shower) on the premises.
2.2.2.Choice of Personnel
• Responsibility of the Operator
The operator of the machine / system must make sure that all users have been trained by the
manufacturer / supplier of the machine / system. This also applies to users, who weren’t working with
the machine / system at the time of the first training. The training must be documented by means of
an acceptance and training confirmation (see enclosure 7).
The operator of the machine / system must make sure that only authorised and trained
personnel are called on for operating as well as maintaining, repairing, and servicing
the machine / system. The responsibilities for the various jobs on the machine / system
must be clearly defined and complied with. Unclear competence may endanger
safety of the users.
Youths under 18 years of age may not operate the machine / system!

JUPITER 2200
• Responsibility of the User
The user must check whether safety equipment is in the correct position and can fulfil its function (see
2.2.1). Only then may the user start-up the machine.
If there are any unauthorised persons in the work area of the shredding machine / system, the user
must request that they leave. If they don’t comply, the operator must be informed.
2.2.3. Operating States
• Transport and Installation
To transport the machine and other system components, use the transport straps that are for
this purpose and hoist it using a crane (see Installation and Transport). Do not stand under
the raised load, or move under it, even briefly.
• Start-up and Operation
Before starting-up the machine / system, walk around it. At that time, check that all
protective devices have been properly installed.
Before starting-up the machine / system, make sure that no one is in the hazardous
zone of the machine and the all persons are in safety.
When the machine is running, operating personnel and all persons in the hazardous
zone of the machine / system, must wear hard hats as well as safety glasses because of
the possibility of parts being hurled out (label on the machine).
The system components have edges and corners. In order to avoid injury, be careful during operation and
when handling the machine.
Due to serious danger for the lives of persons, the following activities are not permitted
when the machine is running (see label):
climbing on the machine

looking into and reaching into the cutting space
putting material into the hopper by hand
• Dismantling, Disposal
Only trained and qualified personnel may dismantle system components. Components
and auxiliary materials (hydraulic oil, transmission oil) must be disposed of according to
national environmental and employee safety regulations.

JUPITER 2200
• Maintenance and Service
The service intervals and work specified by the manufacturer must be complied with
unconditionally and may only be performed by authorised and trained personnel. If
anything is unclear, contact the specialists at the manufacturer.
For any installation, assembly, service, repair, or dismantling work, the machine / system
must be shut down and the power supply must be interrupted (main switch set to “OFF”
with the safety lock locked, press and block the EMERGENCY-OFF key-switch, and if
available, unplug the power cable )
In general, safety shoes must be worn for any service work. Use any other necessary
protective equipment (gloves, ear protection, hard hat, filter mask) as required.
Heavy machine parts (>25kg) as screens, counter knife slides and clamping parts must
not be lifted only from one person. There must be used appropriate cranes and lifting
devices. For transportation there are muonted transport eyes or screwed on shackles.
2.2.4. Specific Hazards
• Fire and Explosion
In case of fire, there must be adequate fire extinguishing equipment (fire extinguisher,
hydrants) close to the machine before starting it up. These areas must be marked and
operating personnel must be familiar with their usage.
Smoking and handling open fire or spark-generating materials are not permitted in the
area around the machine / system (fire hazard when shredding easily flammable
materials).
Areas where there is a danger of explosion (if any) must be identified separately. Any
components of the machines / systems must be rendered explosion-proof according
relevant regulations.
To avoid spontaneous ignition by heated-up material, the cutting chamber has to be

completely emptied before longer shutdowns of the machine.

JUPITER 2200
• Electrical Equipment
Work on electrical equipment may only be performed by authorised and trained

personnel (electricians) as well as after contacting the company Lindner
Recyclingtech. Here, the applicable national safety regulations must be observed
(ÖVE, VDE, ...).
• Laser radiation
Laser beams can endanger the eyes and the skin. When laser beams are used for
measurements (for example level measurements) there must be taken safety
precautions in accordance to the used laser class (for example laser class 2: do not
look into the laser beam). The danger areas are marked.
• Hydraulics
Only authorised and trained personnel or employees of Lindner Recyclingtech may perform work on
hydraulic systems.
Hydraulic oil can endanger your health and the environment. Therefore, when
changing the oil, be sure to avoid any contact with the eyes or skin (use protective
equipment). For disposal, observe the relevant environmental protection regulations.
• Working Material
When shredding products that generate a great deal of dust, use a filter mask. Any
existing vacuum equipment must be used and checked for proper operation.
When working with oils and greases as well as other chemical materials, observe the
available safety data sheets.
Make sure that you avoid any contact with the eyes or skin (use protective
equipment). If it comes into contact with your eyes, contact a doctor. For skin contact,
wash with sufficient water and soap. Take first aid measures.
• Noise Generation
The amount of noise generated by the machine / system is dependent on the specific
material being shredded and on the position of the operator. It may exceed 85 dBA. In
this case, use ear protection (danger of hearing damage).
• Tripping and Falling
Only use specifically placed ladders, stairways, and platforms for working at an higher
level. Safety devices (grates, railings, protective cages) may not be removed.

JUPITER 2200
• Magnetic Fields
Magnetic drums with strong magnetic fields are installed for the metal cutting bands.
This is a hazard for persons and working materials.
Observe the instructions in the operator’s guide in the areas of strong magnetic fields
(no access for persons with pacemakers, keep away electronic equipment and
storage media).
2.2.5. Machine Labelling
1.......... Rule: wear hard hat, safety

glasses and noise protection
4
2.......... Service and safety
information
3.......... Prohibition sign: no climbing 8
on the housing
4.......... Model plate, CE Marking
5.......... Information about
protection of material 1
hopper and discharge
6 ......... Maintenance instructions
for central lubrication
7.......… Information about 2
protection of danger
points inside cutting area
8.......… Information about
protection after opening
the foreign parts flap

JUPITER 2200
2.3. Residual Hazards

The machine was manufactured according to the state of the art and legal safety regulations
(guidelines, harmonised standards; for technical guidelines see declaration of conformity, 3.4), which
demand very low safety risk. However, if there is improper handling, there still may be unexpected
hazards. Therefore, you must strictly comply with the safety requirements (see 2.1, 2.2). If for any reason
there is any lack of clarity in operating or using the machine, contact the manufacturer and discuss
the problem.
2.3.1. Nipping Hazard

The residual hazard from nipping in the cutting space as well as in the
compacting equipment (HNDE) of the shredder can’t be completely excluded
by means of structural measures. The areas are appropriately marked off
(limited access) and labelled.
View of the cutting

space showing the
hazardous areas on the
rotor.
Labelling of the
hazardous areas at
the hydraulic pusher
(both sides)

JUPITER 2200
2.3.1.1 Labelling
Information about protecting the hazardous zones in the cutting space is provided using labels on the
machine.
Labelling at the machine
2.3.2. Danger through unexpected starting (screen area)

The maintenance doors must be fastened with bolts during operation of the machine. When working
inside the screen area of the machine (normally not more than 1x/shift) there must be ensured sein,
that the machine is protected against unexpected starting.
Before opening the maintenance doors switch off the main switch and make sure it
cannot be switched on again Wiedereinschalten sichern (safety lock)!
The key must be held in safe custody from an authorized person!
2.3.2.1. Labelling
machine.
Screw fastening of the

maintenance door

JUPITER 2200
2.3.3. Feed Area
The feed areas of all conveyor belts are protected to avoid catching parts of
the body and clothing. The protective cover must not be removed.
2.3.4. Interfaces Between Machine Components

Combining the individual machine components into one functioning system may result in hazardous
zones which were not there when considering the individual components.
These hazardous zones are normally adequately protected. If that is not possible, then special
attention will be drawn to these hazards.
2.3.5. Interfaces to Neighbouring System Components
The provider of the overall system is responsible for the safety-related inspection
(protection, employee training) of the interfaces to system areas for which
Lindner Recyclingtech is not responsible.
2.3.6. Spontaneous ignition of remaining material
During the shredding of some materials high temperatures may arise inside the
cutting chamber. Before a longer shutdown of the shredder, the cutting
chamber must be completely emptied in order to avoid spontaneous ignition of
heated-up remaining material.

JUPITER 2200
2.3.7. Danger through rotating components (rotor run-out)

After the machine is cut out, the rotor is still rotating for a certain time - especially at star-delta
connection. During this period maintenance doors must remain bolted. During servicing works in the
screening area of the shredder (usually not more than once per shift), it must be ensured that the
machine has completely stopped and that it is secured against sudden restart.
Open maintenance door only after machine has completely stopped (perform visual
inspection at the fan wheel of the electric motor)!
2.3.7.1. Labelling
machine.
Screw fastening of the

maintenance door
!!! A C H T U N G !!!
Die Wartungstür darf erst
nach dem
vollständigen Stillstand
der Maschine
geöffnet werden
(Optische Kontrolle)!
Visual inspection at
the fan wheel of the
electric motor

Service Instruction
JUPITER 2200
Index
3. Maintenance and Service

3.1. Information................................................................................................................. 2
3.1.1. Safety Information................................................................................................... 2

3.1.2. General Information ................................................................................................. 2
3.2. Replacement of the knives ................................................................................. 3
3.3. Replacement of the counter knives ............................................................... 5
3.4. Replacement of the scrapers ............................................................................ 7
3.5. Changing of the Screens / screen cassette with sickles....................... 11
3.6. Maintenance of V-belts...................................................................................... 13
3.6.1. Installation and storage ....................................................................................... 13

3.6.2. Pretension of the power transmission belts........................................................ 14
3.6.3. Controlling the Pretension of the power transmission belts ............................... 16
3.7. Safety coupling (RK-75) ..................................................................................... 18
3.7.1. Maintenance......................................................................................................... 18
3.7.2. Readjustment ........................................................................................................ 18
3.7.3. Disc replacement ................................................................................................. 19
3.7.4. Adjustment instructions .......................................................................................... 20
3.8. Maintenance Tools ............................................................................................... 22
3.9. Hard facing of wear parts ................................................................................. 23
3.9.1. Hard facing of rotor and knife supports – wearing protection ....................... 23
3.9.2. Hard facing of counter-knife skids – Wearing protection ................................ 25

Service Instruction
JUPITER 2200
3.1. Information
Before performing the maintenance work (described in 3.2 to 3.8), the following information must be
observed.
3.1.1. Safety Information
Safety information must be observed (see 2.2. Operational Safety).

Before starting work, shut the machine down and secure it from restarting.
Use suitable protective equipment for the job.
Only allow work to be done by instructed and trained personnel.
3.1.2. General Information
• The work given in 3.2 to 3.8 may only be performed by specially trained personnel, or alternatively by
service personnel of LINDNER Recyclingtech.
Personnel, who are solely familiar with operating the machine/ system, may not perform the work
given in 3.2 to 3.8.
• The given work is based on using the machine / system according to specifications. For any usage
above and beyond this, LINDNER Recyclingtech assumes no responsibility for performing service and
maintenance
• Generally, the machine must be completely inspected once a year for cracks, deformation, or
alternatively changes compared to its new condition. If necessary, it will be repaired by a qualified
technician from LINDNER Recyclingtech (see service plan in the operator’s guide).
• Damaged Screws, washers and screw nuts have to be eplaced against new parts immediately (see
chapter 4, spare parts list B)
IMPORTANT!
Removed or demaged protection devices must be remounted immediately after
finishing the maintenance and repair activities!

Service Instruction
JUPITER 2200
3.2. Replacement of the knives
The safety information for service and maintenance must be observed (see 2.2
Operational Safety).
1) Hydraulic pusher unit (HPU) has to be in his end position. Swing out the Foreign parts flap (FPF) to
the inner maintenance position (see 5.3.10), insert safety lever for FPF according to picture D. The
HPU is now supported by the FPF and can additionally be secured with a locking plate (see
picture E)
2) Switch off the machine and protect it against starting again.
Knife changing: picture A
3) Loose screw fastening (1,2) and remove thread bushing (4)
4) Pull knife (3) forwards and turn it or replace it by a new part.

Each knife can be used 4 times. To guarantee an optimal fit to the knife bad, the knives have to
be turned according picture A3-A4. From the first using side A they have to be turned 180° to side
B. The third side will be mounted by turning over and turning the knife by 90°. For side D the knives
have to be turned 180°.
Attention: armoured knives can be used only on 1 side!
Attention: At designated use of the machine (material as to agreement) the radius on

the worn edge must not reach over the knife thickness (max. 47mm) at the end of life
(see picture A3)!
5) Before inserting the knives (3) again there have to be cleaned the V-milling at the rotor and the
support area at the Knife bed (5). Only the knife beds have to be daubed with ceramic paste.
6) Insert knives (3) in V-milling und insert thread bushing (4) into the hole.
Caution: Only use original LINDNER knives. If the wrong counter knives are used serious
damage can be caused to the machinery by unfavourable clamping!
After each change of the knives (1) the Plain washers (2) and after each second
change of the knives (1) the Hexagon socket screws (1) and thread bushings (4) have
to be replaced.
7) Fasten Knive (3) with hexagon socket screw (1) (fastening torque 1000 Nm)
8) For checking the knife gap and for changing the knife position the rotor can be turned forward by
hand (without frequency converter) or by pressing two-hand control buttons – see manual 5.3.8
9) After finishing the knives changing place back the protection elements and swing in the FPF to the
Operating position (see operating manual 5.3.10)
10) Before starting the machine again, the rotor has to be gradually turned all over forward by hand
(without FU) or by pressing two-hand control buttons. This step is necessary to guarantee that the
knifes have been changed correctly so that the knives won't collide with the counter knives or the
scrapers!
11) Tools needed for the knife change:

Torque wrench for 760-2000Nm with insert for hexagon socket SW22 (for Pos. 1)

Service Instruction
JUPITER 2200
IMPORTANT: There is to clean the whole depth of the inner hexagonal of all inner
hexagonal screws to prevent deformations. For each mounting all parts, base surfaces
and especially the screws have to be cleaned. The screws have to be coated with
ceramic paste to prevent seizing.
Ceramic paste: 605 anti seize ceramic Fa. Moly Slide
Picture A1:
4 3 5 2 1 1000 Nm
Picture A2: knife without wear Picture A3: knife with max. wear
side D
side B
4 3 5 1,2 side C side A
Picture A4: D C
A
C
D
A, B

Service Instruction
JUPITER 2200
3.3. Replacement of the counter knives
1. Hydraulic pusher unit (HPU) has to be in his end position. Swing out the Foreign parts flap (FPF) to
picture E)
2. Switch off machine and ensure it cannot be switched on again.
Changing of counter knife: picture B
3. Loosen hexagon head screw (5) and lift off supporting plate (4).
Attention:
Heavy Parts (eg. counter knife slide, supporting plate) must be carried and transported
together with a second person or with a lifting device (crane or fork lift).
4. Turn counter knife (2) or replace it with new one. If the counter knife (2) can only be lift off strongly,
the hexagon socket screws (3) can be used for pressing them ubwards. The counter knife can be
used up to 2 times.
5. Before re-inserting the counter knife (2) clean the counter knife slide (1), the counter knife (2) and
the hexagon socket screw (5), check all parts for damage and if the hexagon socket screws (3)
are fixed strongly.
If the support of the counter knife (2) is no longer optimal, the counter knife slide (1) should be
replaced. (Damaged counter knife slides can lead to counter knife fractures)!
6. Insert counter knife (2) on counter knife slide (1)
Caution: Only use original LINDNER counter knives. If the wrong counter knives are used
serious damage can be caused to the machinery by unfavourable clamping! After
each change of the counterknife the hex. socket screws (5) must also be replaced.
7. The cutting gap to the counter knife (2) is set by means of the counter knife slide (1).
The counter knife slide (1) is supported from behind by the adjustment screw (6) and locked with
the hexagon screw (7). When the lock screw (7) is opened the counter knife (2) can be moved
forwards, or by the lock screw (7) backwards (possible when machine is running). The set cutting
gap should not exceed 0.8mm.
The counter knife (2) can also be adjusted while the machine is running. To do so, the lock screw
(7) has to be opened and unscrewed a little bit. Then the adjustment screw (6) (no.: 2 per counter
knife) will be tightened slowly and alternately until contact noise with the knives can be heard.
After finishing the adjustment process, the lock screw (7) has to be fastened again.
Caution: The adjustment process of the counter knives might only be started if the
machine is empty! After noticing the first contact noise stop screwing on – otherwise
there can be caused knife damages! To prevent damaging of the fine thread of the
adjustment screws (6) there must not be used a percussion screw driver for adjustment!
8. Fasten clamping bar (4) with the hexagon socket screw (5): Tightening torque: 1000 Nm.
For checking the cutting gap the rotor can be turned manually (without FU) or by using the 2-hand
control-buttons (see manual 5.3.8)!

Service Instruction
JUPITER 2200
9. After counter knife change has been completed reset the safety elements and swing in the
Foreign parts flap to the position in operation (see Operating instruction, 5.3.10)
10. Before the machine is switched on again, the rotor must be turned forwards step by step by hand
(without FU) or by using the 2-hand control-buttons (see manual 5.3.8). This is necessary to ensure
that the counter knives have been correctly installed and do not collide with the knives!
For ensuring an optimum shredding process, the maximum output capacity and the
maximum lifetime of the knives, it is absolutely necessary (for almost all material types)
to keep the cutting gap as small as possible by adjusting the counter knives.
13. Tools needed for a counter knife change:

Torque wrench 1000Nm with insert for hexagon socket SW22 / SW19 and hexagon SW46 / SW55.
hexagonal screws to prevent deformations. For each mounting all parts, base surfaces
and especially the screws have to be cleaned. The screws have to be coated with
ceramic paste to prevent seizing.
Ceramic paste: 605 anti seize ceramic Fa. Moly Slide
Picture B: 1000 Nm
5 4 3 1 2

Service Instruction
JUPITER 2200
3.4. Replacement of the scrapers
1. Hydraulic pusher unit (HPU) has to be in his end position. Swing out the Foreign parts flap (FPF) to
picture E)
2. Switch off machine and ensure it cannot be switched on again.
Changing of scrapers: picture C
3. Loosen hexagon socket screws (3) and lift off the clamping bar (2)
Attention: After loosening the hexagon socket screws (3) the scraper (1) is no longer
fastened und can move forwards itself!
4. Turn Scraper (1) around (possible up to 4 times) or replace it with a new one. The scraper can be
used up to 4 times.
5. Before re-inserting the scraper (1) check the supporting surface for damage. If the support of the
scraper (1) is no longer optimal, it must be repaired. (Damaged scraper supports can lead to
scraper fractures).
6. Insert Scraper (1) backwards to support screws (6) and support plate (5). Fasten clamping bar (2)
slightly with the hexagon socket screws (3).
Achtung: Only use original LINDNER scraper. If the wrong scrapers are used serious
damage can be caused to the machinery by unfavourable clamping (no guarantee)!
After each change of the acrapers the hex. socket screws (3) and plain washers (4)
must also be replaced.
7. Adjust cutting gap: The cutting gap can be adjusted by the support screws (6) and should be
between 0.3 and 3mm. After successful adjustment of the cutting gap the support screws (6)
must be countered by the hexagon nut (7).
8. Fasten hexagon socket screws (3) at tightening torque (1400 Nm).

For checking the cutting gap the rotor can be turned manually (without FU) or by using the 2-
hand control-buttons (see manual 5.3.8)!
9. After counter knife change has been completed reset the safety elements and swing in the
Foreign parts flap to the position in operation (see Operating instruction, 5.3.10)
10. Tools needed for a scraper change:

Torque wrench for 1400Nm with insert for hexagon socket SW22 and hexagon SW46.

Service Instruction
JUPITER 2200
hexagonal screws to prevent deformations.
Each time scrapers are installed all parts, the supporting surfaces and in particular the
bolts are to be cleaned. The screws have to be coated with a ceramic paste to
prevent seizing.
Ceramic paste: 605 Anti Seize Ceramic Fa. Moly Slide
1400 Nm
3,4
6,7
Picture C: 1

Service Instruction
JUPITER 2200
Bild D:
Sketch D:
Schizzo D:
Sicherungshebel
Safety lever
Leva di sicurezza
Betriebsstellung
Position in
operation
Sicherungshebel
Safety lever
Leva di sicurezza
Störstoffentnahme
Removal of foreign
parts

Service Instruction
JUPITER 2200
Sicherungshebel
Safety lever
Leva di sicurezza
Wartungsstellung
innen
Maintenance
position inwards
Bild E:
Sketch E:
Schizzo E:
Sicherheits-Verriegelung für
HNDE
Safety locking for HPU
Sprangatura di sicurezza
per HPU

Service Instruction
JUPITER 2200
3.5. Changing of the Screens / screen cassette with sickles
Brefore opening the maintenance doors the machine must be in stoppage und be
protected against putting into opreation (Main switch locked).
The shredding machine can be eqquipped with a hydraulic movable screen cassette (option), which
contains changeable screen inserts (option) or welded sickle-shaped clamps.
1. Switch off machine and ensure it cannot be switched on again (see Operating Instr. 5.3.5).
Attention:
Before loosening the Hexagon head screws (2) of the screen cassette it is neccesary to
operate Switch M / Screen close (position II) at the Operator panel for a short time (see
Operating Instruction 5.3.16).
2. Loosen the Hexagon head screws (7) and open the maintenance door (1), then loosen the
Hexagon head screws (2) on the upper side of the screen cassette (3) and the Hexagon head
screws (6) on the outside of the screens (5).
3. Close the maintenance door (1) and fasten the Hexagon head screws (7) (410Nm). Now the
screen cassette (3) can be moved down hydraulically to the stop position ( Oper. Instr. 5.3.16).
4. Loosen the Hexagon head screws (7), open the maintenance door (1) again and loosen the
Hexagon head screws (4) at the inner side of the Screen inserts (5). After this the screen insert (5)
can be turned upwards, carried out and turned around or replaced by a new one, if necessary.
Attention:
The screen inserts must be carried and transported together with a second person or
with a lifting device (crane or fork lift).
5. Fasten the Screen inserts (5) again with the Hexagon head screws (4) (410Nm). Close the
maintenance door (1) and fasten the Hexagon head screws (7) (410Nm), then move up the
screen cassette (3) hydraulically to the upper end position (see Oper. Instr. 5.3.16).
6. Loosen the Hexagon head screws (7) and open the maintenance door (1), then fasten the
Hexagon head screws (2) on the upper side of the screen cassette (3) again (710Nm).
7. Fasten the Hexagon head screws (6) on the outer side of the screen inserts (5) (410Nm).
8. After the maintenance door (1) has been closed and fastened with the Hexagon head screws
(7) (410Nm), the maschine can be put into operation again.
9. Tools needed for changing the screen inserts:

Torque wrench for 410Nm / 710Nm with insert for hexagon socket SW30 / SW36
IMPORTANT: When changing the screen, you may find unshredded material inside the
screen space, which then falls into the discharge device. If this could cause
problems for the following systems, then remove this material.
At every installation, all components, the contact surfaces, and in particular the
screws must be cleaned and coated with a ceramic paste against seizing up.
Ceramic paste: 605 Anti Seize Ceramic, Moly Slide

Service Instruction
JUPITER 2200
Changing the screens – pictures:
7 (2x)
2 (8x)
2 3
(12x)
3 6 (3x)
4 (3x)

Service Instruction
JUPITER 2200
3.6. Maintenance of V-belts
3.6.1. Installation and storage
Motors with Vee-belts that have been placed in correct geometrical position for optimal efficiency
guarantee a maximum of operational safety and long duration. Years of practise have shown that
unsatisfactory terms of wear are, more often than not, due to mistakes made durning installation or
maintenance. To prevent this we advise careful attention to the following installation and
maintenance instructions.
• Pulleys
The grooves must conform to standard and be clean. 1°

• Pitching
Shafts and pulleys must be aligned before installation. The maximum recommended
deviation of the pulley alignment is 1°.
• Multiple Groove Motors
Vee-belts for multiple groove motors must be measured in batches. Attention must
be paid to the batch tolerance according to the valide norms.
• Installation of the Vee-belts
Before installation the axle space must be erduced to allow the Vee-belts to be placed in the grooves
without tension. Installation by force using either tools or screwdrivers is not permissible as this can lead
to often invisible damage to the high quality tautness of the belts os to the covering material.
• Storage- General Information
Vee-belts that are stored professionally remain unchanged over several years. When however
conditions are not favourable or the treatment false most rubber products lose their physical
characteristics. These changes can be caused by oxygen, ozone, extreme temperatures, light damp
or solvents.
• Storage
The Vee-belts must be stored without tension, pressure or any other deformation as this produces
permanent deformation as well as tears. The storage room should be dry and free of dust. Damp
storage rooms are not suitable, most favourable is humidity under 65%. Storage temperatures should
be between +15°C and 25°C.
Vee-belts should be protected from the light, especially direct sun light and strong artificial lighting
with high ultraviolet content like, for example, fluorescent tupes installed without a shade.

Service Instruction
JUPITER 2200
3.6.2. Pretension of the power transmission belts
Belt pretensioning and checking are carried out by means of the length addition value
1. Place the power transmission belts on the drive unit and tighten briefly so that they fit in the belt
pulley.
2. Remove the tension on the power transmission belts completely.
3. Mark the measuring distance “M” on the slack strand length (M=1000mm).
4. The power transmission belts are now tightened until the length changes by the length addition
value “A”. The drive is thus correctly pretensioned.
If the drive is retightened, the belts must be loosened again so that they can be measured again
when not under tension. The procedure described under items 3 to 4 is then to be followed again.
M=1000mm

Service Instruction
JUPITER 2200
Tabelle Längenadditionswert
Table length addition value
Tabelle per i valori di incremento lunghezza
Keilriemen Motor – Vorgelege

Belt motor – countershaft
Cinghia trapezoidale Motore - Riduttore
Rotordrehzahl Riemen- Riemen- A A

Keilriemen
Antrieb Rotor- scheibe scheibe (Erstmontage) (Nachspannen)
Belt
Drive revolutions Belt Belt (Initial fitting) (Retightening)
Cinghia (Primo (Ritensiona-
Motore N. giri rotore pulley pulley
trapezoidale montaggio) mento)
(50Hz) Puleggia Puleggia
2x KB3-8V /
160kW 58 rpm 355 mm 1700 mm 5,8 mm 3,9 mm
2360/5994 La
160kW 87 rpm 355 mm 1700 mm KB5-8V/2360/5994 La 6,5 mm 4,4 mm
2x KB3-8V/
132kW 51 rpm 315 mm 1700 mm 4,9 mm 3,3 mm
2360/5994 La
2x KB3-8V/
110kW 51 rpm 315 mm 1700 mm
2360/5994 La
4,9 mm 3,3 mm X
Keilriemen Vorgelege - Rotor

Belt countershaft – rotor
Cinghia trapezoidale Riduttore - Rotore
Rotordrehzahl Riemen- Riemen- A A

Keilriemen
Belt
Motore N. giri rotore pulley pulley
4x 5-8V/2000/5080
160kW 58 rpm 395 mm 1400 mm 8,4 mm 5,6 mm
La, Red Power II
160kW 87 rpm 395 mm 1400 mm 4x5-8V/2000/5080 La 6,6 mm 4,4 mm
4x 5-8V/2000/5080
132kW 51 rpm 395 mm 1400 mm 8,6 mm 5,7 mm
La, Red Power II
4x5-8V/2000/5080 La
110kW 51 rpm 395 mm 1400 mm
Red Power II
8,6 mm 5,7 mm X

Service Instruction
JUPITER 2200
3.6.3. Controlling the Pretension of the power transmission belts
Belt pretension and checking by frequency meter:
Safety information:
Before measurement begins, switch off the drive machine to ensure that
neither the drive shaft nor the driven shaft are caused to rotate
unintentionally. The relevant safety instructions should also be observed.
Operating instructions:
An A for "active" appears on the display after the device is switched on. An M appears to indicate
when the machine begins measuring. Hold the measurement head over the belt to be checked. The
microphone can be detached from the measurement head if the space is narrow. Start the belt
vibrating with your finger or by tapping it.
Measurement with measurement evaluation begins when a constant frequency is reached. This is
indicated by an LED and acoustic signal. Another signal is emitted after the measurement has been
evaluated and the result is displayed in Hz. A goes out and a number between 1 and 4 appears. This
number represents the number of successful measurement cycles. A statistical value is determined
when there are two to four measurements. If an E appears after the number, then one of the
measurement results was outside of the tolerance range. If 1 of E appears it is recommended that the
measurement should be repeated after the A reappears.
The measurement frequency (Hz) should be compared with the set value (Hz). You should reduce or
increase the belt tension depending on the measurement results until the set value is reached.
The result is displayed for two minutes. After this the machine automatically switches off. To restart the
device press the on switch. To clear the display, press the Reset-key.
Special information:
If no measurement takes place despite numerous taps on the belt, this may have the following
causes:
The belt vibrates outside of the specified frequency range

Remedy: Change the belt tension
The belt can only vibrate slightly
Remedy: Increase the amplitude of vibration, tap the belt harder
When Low Batt appears you should replace the battery. We recommend removing the battery if the
device is not used for a long period.
About the drive mechanism: No more than one belt pulley should be fixed when measurement takes
place. All other pulleys should rotate freely. When installing a new belt, a number of rotations should
be carried out prior to measurement.

Service Instruction
JUPITER 2200
Tabelle Messfrequenz
Table Measurement Frequency
Tabelle per la misura della frequenza
Keilriemen Motor – Vorgelege

Belt motor – countershaft
Cinghia trapezoidale Motore - Riduttore
Rotordrehzahl Riemen- Riemen- f (Hz) f (Hz)

Keilriemen
Belt
Motore No. giri rotore pulley pulley
2x KB3-8V /
160 kW 58 rpm 355 mm 1700 mm 26,4 23,2
2360/5994 La
160kW 87 rpm 355 mm 1700 mm KB5-8V/2360/5994 La 27,3 23,9
132kW 87 rpm 355 mm 1700 mm KB5-8V/2360/5994 La 27,3 23,9
2x KB3-8V/
132kW 51 U/min 315 mm 1700 mm 24,6 21,6
2360/5994 La
2x KB3-8V/
110kW 51 rpm 315 mm 1700 mm
2360/5994 La
24,7 21,6 X
110kW 87 rpm 355 mm 1700 mm KB5-8V/2360/5994 La 27,3 23,9
Keilriemen Vorgelege - Rotor

Belt countershaft – rotor
Cinghia trapezoidale Riduttore - Rotore
Rotordrehzahl Riemen- Riemen- f (Hz) f (Hz)

Keilriemen
Belt
Motore No. giri rotore pulley pulley
4x 5-8V/2000/5080
160 kW 58 rpm 395 mm 1400 mm 35,9 31,5
La, Red Power II
160kW 87 rpm 395 mm 1400 mm 4x5-8V/2000/5080 La 31,1 27,3
132kW 87 rpm 395 mm 1400 mm 3x5-8V/2000/5080 La 31,1 27,2
4x 5-8V/2000/5080
132kW 51 U/min 395 mm 1400 mm 32,8 28,7
La, Red Power II
4x5-8V/2000/5080 La
110kW 51 rpm 395 mm 1400 mm
Red Power II
32,8 28,8 X
110kW 87 rpm 395 mm 1400 mm 3x5-8V/2000/5080 La 31,0 27,2

Service Instruction
JUPITER 2200
3.7. Safety coupling (RK-75)

As a protection against overload of the macjhines and drives there are used safety couplings. The
exactly mode of operation (operation and maintenance) is bescribed in chapter 5.4.
Important
Before installing and starting up the product, please read these installation and
operating instructions carefully. Hints and danger warnings should be given particular
attention.
Any failure to comply with, or misinterpretation of these installation and operating
instructions shall invalidate any product liability and warranty, the same applies to any
dismantling of or alteration to our product.
Safety instructions
Our product may only be installed and started up by trained personnel.

Repair works may only be carried out by the manufacturer or by trained personnel.
If faulty operation is suspected, the product or the machine in which it is installed must
be immediately stopped and LINDNER or an authorised
LINDNER representative must be informed.
3.7.1. Maintenance
Under normal operating conditions separate maintenance of the safety coupling (friction clutch) is
not required. The inspection to be made as part of machine maintenance should include the
following:
The set torque values should be checked and if necessary adjusted.
Check easy movement of the fine threads of the adjustment nuts.

(Relubricate if necessary e.g. with ceramic paste)
Remove external dirt and corrosion.
Check the bearings for damage and if necessary fill up the grease supply of the roller bearings.
3.7.2. Readjustment
Coupling wear is caused by worn discs whose thickness is reduced leading to a lower torque as a
result of decreasing spring preloading.
Outer disc: new: 9.5mm Wear limit: 8mm
Inner disc: new: 14mm Wear limit: 11mm
Readjustment is necessary if the coupling no longer achieves the set torque and is carried out by
retightening the adjustment nuts according to the setting instructions up to the preset marking.

Service Instruction
JUPITER 2200
Disk spring column:

Layering of disc springs, readjustment
1mm x12 = 5.000Nm
Detail marking spring punch:
3.7.3. Disc replacement
1) Secure the clutch housing (17) against axial movement by supporting it on the housing wall of the
shredder.
2) Expansion of the Disk spring column
3) Disassemble the spring support (16):
a) The bearing (3) is fixed on the hub and must not be removed separately. By loosening the bolts
(15) the pressure disc is pressed off the disc assembly using the preloaded spring plunger (5),
until the cup spring columns are unloaded and no longer exert any pressure.
b) Remove housing bolts (15) and pull off spring support (16).
When handling the pressure disc it should be ensured that the fine threads on the cup spring
sleeves are not damaged.
Attention:
As the spring support weighs approx. 85 kg, it should be secured against
dropping down before removing the bearing bush (e.g. by suspending on a
crane hook.)

Service Instruction
JUPITER 2200
4) Removal of the discs.
5) Internal cleaning of the clutch and inspection of the hub gear teeth and the spacer tube (14) for
damage. If the parts are so badly nicked on the faces of the discs that a disc cannot move
perfectly, optimal adjustment is no longer guaranteed and the parts must be replaced.
6) Insertion of new discs, beginning with the outer disc (steel).

Alternately one outer and one inner disc are now inserted.
4 pcs. outer discs made of steel
3 pcs. inner discs with welded-on sintered-coating plates and inner gearing
7) Installation of the spring support (16). Before installation the ball bearing (8) is to be given an
adequate grease supply
8) Tightening of the housing bolts M20x200, 8.8 (15). Tightening torque: 415Nm
9) Setting of the required torque (see Table 1).
Pictures see Spare part list (D)
3.7.4. Adjustment instructions
The torque is adjusted on the adjustment nuts (4) of the spring columns, using adjustment tool
Id.No 47017.
The spring columns are designated with numbers from 1-12. By turning the adjustment nut in a
clockwise direction the spring preloading is increased, by turning in an anti-clockwise direction the
spring preloading is reduced.
The spring plunger (5) has markings (rings) on which the spring preloading is to be checked.
The upper edge of the uppermost ring marks the zero position for each spring column. (see detail
markings spring punch)
One turn of the adjustment nut causes the spring preloading to increase by one millimetre, this
corresponds exactly to the width of one marking.
If all 12 spring columns are preloaded by 1mm the torque increases by 5 kNm.
It is essential to avoid damage to the fine thread of the adjustment sleeve and the
adjustment nut. Remove dirt such as metal chips or other solid grainy particles from
the disc springs.

Service Instruction
JUPITER 2200
The torque values can be set according to the following table:
Table 1 Spring column Torque:

Nr.:
Marking 1 2 3 4 5 6 7 8 9 10 11 12
2 * * * * * * * * * * * * 10.000 Nm
3 * * * * * * 12.500 Nm
3 * * * * * * * * * * * * 15.000 Nm
4 * * * * * * 17.500 Nm
4 * * * * * * * * * * * * 20.000 Nm
5 * * * * * * 22.500 Nm
5 * * * * * * * * * * * * 25.000 Nm
6 * * * * * * 27.500 Nm
6 * * * * * * * * * * * * 30.000 Nm
7 * * * * * * 32.500 Nm
7 * * * * * * * * * * * * 35.000 Nm
8 * * * * * * 37.500 Nm
8 * * * * * * * * * * * * 40.000 Nm
9 * * * * * * 42.500 Nm
9 * * * * * * * * * * * * 45.000 Nm
10 * * * * * * 47.500 Nm
10 * * * * * * * * * * * * 50.000 Nm
11 * * * * * * 52.500 Nm
11 * * * * * * * * * * * * 55.000 Nm
12 * * * * * * 57.500 Nm
12 * * * * * * * * * * * * 60.000 Nm
13 * * * * * * 62.500 Nm
13 * * * * * * * * * * * * 65.000 Nm
14 * * * * * * 67.500 Nm
14 * * * * * * * * * * * * 70.000 Nm
15 * * * * * * 72.500 Nm
15 * * * * * * * * * * * * 75.000 Nm
16 * * * * * * 77.500 Nm
16 * * * * * * * * * * * * 80.000 Nm
17 * * * * * * 82.500 Nm
17 * * * * * * * * * * * * 85.000 Nm

Service Instruction
JUPITER 2200
3.8. Maintenance Tools

The following maintenance tools are necessary for the work described in 3.1 – 3.7:
No. Units Tool Data Order No. Comment

1 1 Socket wrench 1“ 75357 Gedore
handle with slider
2 1 Socket wrench short (200mm), 1 “ 75362 Gedore
extender
3 1 Socket wrench 1“ to 3/4 “ 85136 Gedore
adapter element
4 1 Socket wrench SW 55 (M36), 85685 Gedore
insert hexagonal, 1 “
insert hexagonal, 3/4 “
insert hexagonal, 3/4 “
9 1 Socket wrench SW22 (M30), 95006 Gedore
insert socket, 1 “
12 2 Open ended SW55, DIN984 115580 Gedore
wrench
13 1 Frequency Optibelt TT Mini 75558 Optibelt
measuring device
14 1 Wrench for safety - 47017 -
coupling
15 1 Socket wrench SW 46 (M30), 49118 -
insert extended socket, 1 “
16 1 Torque wrench Gedore 140-760 Nm - Not included
17 1 Torque wrench Gedore 760-2000 Nm - Not included

Service Instruction
JUPITER 2200
3.9. Hard facing of wear parts
3.9.1. Hard facing of rotor and knife supports – wearing protection
3.9.1.1. General
To avoid overwearing of rotor at sealing ring area and knife supports at knife bolting area, these areas
have to be hard faced regularly.
3.9.1.2. Wearing inspection
Admissible wearing has to be determined at the following positions:
a) Rotor: Armoured weld seam at outer edge (near sealing ring) and on upper side
b) Knife support: Armoured weld seam on upper side
Inspection interval when knives are replaced: e.g. 600 hours.
Armoured weld seam on

whole circumference at
outer edge of rotor (near
sealing ring)

whole circumference at
outer edge of rotor (near
sealing ring)

upper side of knife support

Service Instruction
JUPITER 2200
3.9.1.3. Hard facing
If admissible values at inspection measuring as to 3.9.1.2. have dropped below, following positions on
upper side of rotor and knife support have to be hard faced (see pictures obove):
a) Rotor: Armoured weld seam at outer edge (near sealing ring) and on upper side
(seam height app 4mm)
b) Knife support: Armoured weld seam on upper side (seam height app 4mm)
IMPORTANT: Hard facing has to follow before dissappearing of the old weld
seam in order to avoid mixing of electrode and core material
(lower wearing properties)!
3.9.1.4. Operating material required
Preferably: Filling wire electrode E+C TerroMatec AN 4660

(Attention: filling wire suited welding set required!)
Alternatively: Inert-gas welding wire DUR650
Data sheets see below SA, 5.8!

Service Instruction
JUPITER 2200
3.9.2. Hard facing of counter-knife skids – Wearing protection
3.9.2.1. General
To avoid overwearing of counter-knife skid at the area of front edge (rotor side), these areas have to
be hard faced regularly.
3.9.2.2. Wearing inspection

Admissible wearing has to be determined by optical recognition at the following positions of skid:
Counter-knife skid: Armoured weld seam at routings on front side – counter knife
Inspection interval when counter knives are replaced. e.g. 600 hours.
Armoured weld seam at

routing on front side
3.9.2.3. Hard facing

If admissible values at optical inspection as to 3.9.2.2. have dropped below, following positions on
front side of counter knife skid have to be hard faced (see picture):
Counter-knife skid: Armoured weld seam at routings on front side – counter knife (seam
height appr. 7mm, two-layer)
IMPORTANT: Hard facing has to follow before dissappearing of the old weld
seam in order to avoid mixing of electrode and core material
(lower wearing properties)!
3.9.2.4. Operating material required
see 3.9.1.4

Service Instruction
JUPITER 2200
Index
4. Spare parts list
4.1 . Rotor bearing (A) .............….…...............................................…..........………….. 2 / 16
4.2 . Cutting unit (B) .............................................................................................……… 4 / 16
4.3 . Driving unit (C) .......................................................................................…………… 8 / 16
4.4 . Friction coupling (D) ............................................................................................. 12 / 16
4.5 . Transmission gear bearing (E) ......................…................................................ 14 / 16
4.6 . Sealing HPU (F) ........................................................................................................ 16 / 16
JU2200-01_SA40-V05_eng.doc Rev.: 05 /18.02.2009 page 1 of 16

Ersatzteilliste Rotorlagerung
Spare part list Rotor bearing
JUPITER 2200 A
Pos. Nr. Stück Bezeichnung - Norm Bestell Nr.
Bezeichnung Description
Pos. no. Quantity Description - standard Order no.
1 2 Lagergehäuse Bearing casing - 34056
2 12 Innensechskantschraube M24x150 Hex. socket cap screw M24x150 DIN912, 8.8 105125
3 24 Keilsicherungsscheibe NL24 Plain washer NL24 DIN 25201 (Fa. Nord Lock) 75883
4 2 Lagerdeckel Bearing cover - 34057
5 12 Innensechskantschraube M24x80 Hex. socket cap screw M24x80 DIN912, 8.8 15169
6 2 Pendelrollenlager Spherical roller bearing 23148BK.MB 105121
7 2 Abziehhülse Withdrawal sleeve AH3148 105122
8 2 Wellenmutter Nut - 44395
9 4 Wellendichtring AS260x300x20 Oil seal DIN3760 105126
10 8 Innensechskantschraube M10x35 Hex. socket cap screw M10x35 DIN912, 10.9 / Ma=50Nm 125568
11 2 Festring Fixing ring - 34059
12 6 Gewindestift Core pin DIN 913 15771
13 4 Räumblech (Option) Cleaning plate (option) - 36158
14 6 Dichtring (Gehäuse) Sealing ring (casing) - 34163
15 22 Sechskantschraube M16x30 Hexagon head screw M16x30 DIN 933, 8.8 5876
17 2 Sechskantmutter M16 Hexagon nut M16 DIN 934, 8. 15064
18 8 Dichtring (Rotor) Sealing (rotor) - 34162
19 40 Sechskantschraube M20x45 Hexagon head screw M20x35 DIN 933,8.8, Ma=300Nm 5893

Ersatzteilliste
Spare part list

JUPITER 2200 A

Ersatzteilliste Schnitteinheit
Spare part list Cutting unit
JUPITER 2200 B
R1 1 Rotor Rotor - 39851
M1 24 Messer Knife - 38326
M2 24 Gewindehülse M30 Thread bushing - 31275
M3 24 Innensechskantschraube M30x160 Hexagon socket screw M30x160 DIN912, 8.8 85083
M4 24 Keilsicherungsscheibe NL30 Plain washer NL30 DIN 25201 (Fa. Nord Lock) 75884
M5 24 Messerhalter Knife bed - 31274
M6 48 Zylinderstift 10m6x40 Cylindrical pin 10m6x40 DIN6325 35951
A1 6 Abstreifkamm Scraper - 34152
A2 6 Klemmleiste Clamping bar - 33785
A3 30 Innensechskantschraube M30x120 Hexagon socket screw M30x120 DIN912, 8.8, 1400 Nm 105270
A4 30 Keilsicherungsscheibe NL30 Plain washer NL30 DIN 25201 (Fa. Nord Lock) 75884
A5 6 Stützblech Support plate - 39056
A6 12 Sechskantschraube M30x120 Hexagon head screw M30x120 - 34409
A7 12 Sechskantmutter M30 Hexagon head nut M30 DIN 934, 8 25405
G1 6 Gegenmesserschlitten Counter knife slide - 33818
G2 6 Gegenmesser Counter knife - 31272
G3 12 Innensechskantschraube M24x45 Hexagon socket screw M24x45 DIN 6912,8.8 29793
G4 6 Klemmteil geschweisst Clamping part welded - 39845
G5 18 Innensechskantschraube M30x200 Hexagon socket screw M30x200 DIN912, 10.9, 1000 Nm 115638
G6 12 Einstellschraube S40x3 Adjusting screw S40x3 - 42628
G7 6 Sechskantschraube M30x140 Hexagon head screw M30x140 DIN 933, 8.8 105216
G8 6 Scheibe 31-HV Plain washer 31-HV DIN 6916 75953
G9 12 Schmutzabstreifer W1-32-PB Dirt skimmer W1-32-PB - 125033
G10 12 Gewindehülse S40x3 Thread bushing S40x3 - 41602
G11 12 Sicherungsring 65x2,5 Retaining ring 65x2,5 DIN 471 15276

JUPITER 2200 B
S1 4 Siebblech (Option) Screen plate (option) - 34017-X
S2 12 Sechskantschraube M20x60 (Option) Hexagon head screw M20x60 DIN 933, 8.8 85318
S3 24 Scheibe 21-HV (Option) Plain washer 21-HV DIN 6916 45850
S4 8/12 Sechskantschraube M24x70 Hexagon head screw M24x70 DIN 933, 8.8 5662
S5 8/12 Scheibe 25-HV Plain washer 25-HV DIN 6916 65788
S6 12 Sechskantschraube M20x55 (Option) Hexagon head screw M20x55 DIN 933, 8.8 5895
S7 16/10 Innensechskantschraube M24x150 Hexagon socket screw M24x150 DIN912, 8.8 15670
S8 16/10 Keilsicherungsscheibe NL24 Plain washer NL24 DIN 25201 (Fa. Nord L.) 75883
S9 1 Siebkassette mit Sicheln Screen cassette with sickles 61/83/104/148mm 44389-X
S10 8/2 Aufnahmelasche Mounting strap - 34025
S11 6 Innensechskantschraube M24x60 Hexagon socket screw M24x60 DIN912, 8.8 15659
S12 2+2 Aufnahmelasche mit Haken Mounting strap with hook - 60789+60790
S13 1+1 Aufnahmelasche Mounting strap - 60801+60802
S14 2 Achse Axle - 34032
S15 3 Achse Axle - 47750

JUPITER 2200 B
Screen cassette with sickles M3,4 R1 A1 A2
(welded) A6
M5,6 A7
M2 A3,4
M1 A5
G2 S4,5
S9
G4
G5
G1,3
G6-9
G10,11
S11,8 S7,8 S15 S12,13 S14 S7,8 S10


JUPITER 2200 B
Screen cassette with screen plates

(changeable, option) A6
(Rotor shown from Type METEOR) A7
A2
A3,4
S4,5
G5 S2,3
G3
G10,11 S9
G6 S1
G7,8 S6,3
G9 S7,8

Ersatzteilliste Antriebseinheit
Spare part list Driving unit

JUPITER 2200 C

1 8 Nivellierelement Level ISO-4-80 75038
2 2 Hydraulikzylinder Hydraulic cylinder LC250 80/56x470 GZ 105155
5 2 Hydraulik: Blasenspeicher Hydraulic: accumulator Siehe/see/vedere 5.1 115650-2.1
6 2 Pendelrollenlager Self-aligning roller bearing 23120ES.TVPB 95138
7 2 Achse Axle - 33630
8 2 Gleitbuchse PM 10080 DX Bushing - 75263
9 2 Riemenscheibe, Rotor (NW 1400) Pulley, rotor - 32849
10 24 Sechskantschraube M24x100 Hexagonal head screw DIN 931, 10.9 75329
11 24 Scheibe 25-HV Plain washer DIN 6916 65788
12 2 Riemenscheibe (NW395) Pulley - 32873
13 8 Innensechskantschraube M30x180 Hexagon socket screw M30x180 DIN912, 8.8 85317
15 2 Riemenscheibe (NW1700/1270) Pulley (NW1700/1270) - 33588/29272
16 2 Nabe mit Flanschring Hub with flange ring - 33589
17 2 Scheibe Ø180 Plain washer Ø180 - 16503
18 2 Sechskantschraube M42x2x110 Hexagon head screw M42x2x110 - 27146
19 2 Scheibe M42 Plain washer M42 DIN 125-A 55661
22 2 Riemenscheibe, Motor (NW315/355) Pulley, motor - 34042/32002/40994
23 2 Klemmscheibe Ø90 Clamping ring Ø90 - 7247

JUPITER 2200 C
25 2 Scheibe M20 Plain washer M20 DIN 125-A 15196
26 2 E-Motor Electric motor 132kW, 980 1/min, BG315, B3 85166-1/85166-4
110kW, 980 1/min, BG315, B3 85174-1/85174-4
27 4 Kraftband Power belt KB 3-8V, 2360/5994 115200
KB 3-8V, 2000/5080 85074
28 8 Kraftband Power belt KB 5-8V, 2000/5080 Red Power 2 95961
29 2 Drehzahlgeberaufnahme Tachometer support - 39316
30 3 Induktiver Näherungsschalter Proximity switch IGM 201 125025+115180
31 1 Impulsrad Pulse wheel - 30290
32 12 Impulsrad (Segment) Pulse wheel (segment) - 40567
33 2 Rutschkupplung (Option) Friction coupling (option) RK-75 42177-2
34 2 Induktiver Näherungsschalter-HNDE Proximity switch-HPU XS7-C40PC440-24VDC 115181


JUPITER 2200 C
6,7
34
15
8
26 8
3
1 3
1
22 1
Darstellung ohne Antriebseinheit

Ersatzteilliste
Spare part list
JUPITER 2200 C
15 17-19 16 20,21 28 12 13,14 6,7 2
27 22 23-25 26 1 29 30 31 33 9 10,11

Ersatzteilliste Sicherheitskupplung RK-75
Spare part list Friction coupling RK-75

JUPITER 2200 D
Quantit
Pos. no. Description - standard Order no.
y
1 1 Kupplungsnabe Clutch hub - 42164
2 1 Rillenkugellager 6048M Bearing DIN625 115021
3 1 Rillenkugellager 61848 Bearing DIN625 125037
4 12 Einstellhülse Adjusting nut - 42173
5 12 Federstempel Spring tappet - 42168
6 12 Tellerfeder-Hülse Plate spring-sleeve - 42174
7 384 Tellerfedern 50x20,4x2,5 Plate spring UN9308 75595
8 1 Sicherungsring 240x5 Retaining ring DIN471 125039
9 2 Nilos-Ring 61848-240 Nilos-ring - 125036
10 2 Nilos-Ring 6048-240 Nilos-ring - 125035
11 4 Druckscheibe (Außenlamelle) Outside disc - 42172
12 3 Innenlamelle Inside disc - 42178
13 1 Verschleißscheibe Wear plate - 42171
14 16 Distanzrohr Distance sleeve - 42170
15 16 Innensechskantschraube M20x200 Hexagon socket screw M20x200 DIN 912, 8.8 125779
16 1 Federträger Compression plate - 42163
17 1 Gehäuse / Trägerflansch Flange - 42162
18 12 Stützscheibe S42x52 Support disc DIN 988 115031
19 1 Passfeder 40x22x140 Fitting key 40x22x140 DIN 6885-A 75337

Ersatzteilliste Sicherheitskupplung RK-75
Spare part list Friction coupling RK-75

JUPITER 2200 D

19

Ersatzteilliste Vorgelegelagerung
Spare part list Transmission gear bearing

JUPITER 2200 E

Quantit
y
1 2 Lagergehäuse Bearing casing - 29229
2 2 Lagerdeckel Bearing cover - 29230
4 12 Federring A12 Spring washer DIN127 15213
5 2 Pendelrollenlager Spherical roller bearing 23032ESK.TVPB 35545
6 2 Spannhülse Adaptor sleeve H3032 85171
7 4 Wellendichtring AS140x170x15 Oil seal AS140x170x15 DIN3760-NBR 85172
8 2 Festring Fixing ring - 11684

Ersatzteilliste
Spare part list

JUPITER 2200 E

Ersatzteilliste Abdichtung HNDE
Spare part list Sealing HPU

JUPITER 2200 F

Quantit
y
1 2 Dichtgummi, seitlich Rubber joint, lateral - 31341
2 2 Lochleiste, seitlich Perforated plate, lateral - 34340
3 1 Dichtgummi, vorne Rubber joint, in front - 34342
4 1 Lochleiste, vorne Perforated plate, in front - 34343
6 12 Scheibe A12 Plain washer A12 DIN 125-A 15193
5,
6

JUPITER 2200
Index
5. Documentation of components
5.1. Hydraulic unit ............................................................................................................ 2
5.2. Electric motor ............................................................................................................ 3
5.3. V-belts .......................................................................................................................... 4
5.4. Safety clutch ............................................................................................................. 5
5.5. Central lubrication .................................................................................................. 6
5.6. Safety data sheets ................................................................................................. 7
5.7. Others components .............................................................................................8

JUPITER 2200
5.1. Hydraulic unit

Bill of Material
Material: R996554245 Description: PUMP PLATE
Prod. Order: Division: MFM

Customer: EPU
PUMPEN,HEAVY DUTY,
Purchase Order: Item descr.: MICROMAT,VORMONT
REV. Tech.Pos. Component No. Component Data Brand Quantity

Unit
3.0 R996V57029 PUMP PLATE 1 PC
PUMPENPLATTE NG10,3-SAE1
MBV-LINDNER
mit O-Ring 32,92x3,53
3.1 0532002014 PRESSURE RELIEF VALVE 1 PC
DRUCKBEGR.VENTIL
RD-----
3.2 1810361022 NOZZLE 1 PC
DUESE 0,9 1/16-27NPTF
3.21 1810361020 NOZZLE 1 PC

DUESE 1,0 1/16-27NPTF
3.3 0811402017 PILOT VALVE 1 PC

DBETX-1X/180G24-8NZ4M
RD29161
3.4 R900710686 THROTTLE VALVE 1 PC
DROSSELVENTIL NFDC-LAN
3.5 R900561280 DIRECTIONAL SPOOL VALVE -DIRECT OPER. 1 PC

4WE 6 EA6X/EG24N9K4
RD23178
4WE 10 E3X/CG24N9K4
RD23327
R900002414 THREADED FASTENER 2 PC
VERSCHRAUBUNG AB20-12/GE 22 LR-ED A3C
AB20-12
MONTIERT in T und T1
This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth.
It may not be reproduced or given to third parties without ist consent
Page: 1/1
Bill of Material
Material: R996563089 Description: H400-AKP45-11KW HD5
Sales Order: 2261498 Item: 300
Required Qty: 1
Prod. Order: 11424037 Division: EPU
Customer: LINDNER Recyclingtech
B090069 HYDR PUMP UNIT
Purchase Order: KA22354/M1512 Item descr.: H400-AKP45-11KW HD5

Unit
7-6174-11-C Hydraulic Flow sheet
1-1844-10-C Assembly Drawing
1.1 R996538471 CONTAINER 1 PC
BEHAELTER NG400 DIN ANC ST
STAHL
1.31 R900543908 LOCK 2 PC
VERSCHLUSS AB40-19/324A-AL/M-6
AB40-19
1.32 R901034648 BALL VALVE 1 PC
KUGELHAHN AB21-33/ G 1-010
AB21-33
1.41 R900013663 OIL GAUGE 1 PC
OELSTANDANZEIGER AB31-21/127T
AB31-21
R900710555 PLATE 1 PC
SCHILD AB31-21/ 400L-SKALA
AB31-21
1.42 R996409670 FLOAT SWITCH 1 PC
SCHWIMMERSCHALTER 61-0-M3 L=300MM,
1.51 R996407434 AIR FILTER 1 PC

LUFTFILTER PI 0126 MIC MIT SIEB
M2-1
1.52 R901025413 RETURN FILTER 1 PC
ABZFR-S0160-10-1X/M-DIN
RD50088
Filterelement 01025295
1.522 R901025339 CLOGGING INDICATOR 1 PC
ABZFV-E1SP -M12X1-1X/-DIN
RD50086+50088
1.53 R996549512 HYDRAULIC HOSE 1 PC
AB23-10/2SC20-EFR22L-EFR22L45-1200
D2-11
AB23-10/2SC20-EFR22L-EFR22L90-1100
D2-11
1.541 R900064238 PIPE 1 PC
ROHR AB23-04/GE-22LR L= 325 A3C
AB23-04
Bill of Material
Required Qty: 1

Unit
1.61 R900028241 THERMOSTAT 1 PC
THERMOSTAT AB31-14/1-1A
AB31-14
2.1 R910967365 AXIAL-PISTON PUMP 1 PC
A A10VSO 45 DFR1/31R-VPA12N00

AB23-10/2SC16-EFR18L-EFR18L90-1100
D2-11
2.12 R900064237 PIPE 1 PC
AB23-04
AB23-10/2SC06-EFR08S-EFR08S90-700
D2-11
R900026554 PIPE 1 PC
ROHR AB23-03/SAE1 1/2 L= 750
AB23-03
R900869992 ASSEMBLY KIT 1 PC
BAUSATZ AB12-03/B 48,3-NBR
AB12-03
2.2 R996410222 ELECTRIC MOTOR 1 PC
ABZEK B35-160M-4-B0-11,0/13,20
AB42-30
2.21 R900022416 HUB 1 PC
NABE AB33-22/KD 42-42
AB33-22
2.22 R900087807 RING GEAR 1 PC
ZAHNKRANZ AB33-22/KD 42-98 SH A
AB33-22
2.23 R900011342 HUB 1 PC
NABE AB33-22/KD 42-25
AB33-22
2.24 R900026361 PUMP CARRIER 1 PC
AC PBR 100AS2H/A 350/204-1X/DH-AL
AB33-37
R900028248 DAMPING BAR 2 PC
DAEMPFUNGSSCHIENE DSM 160 M
Bill of Material
Required Qty: 1

Unit
3.0 R996554245 PUMP PLATE 1 PC
PUMPEN,HEAVY DUTY,MICROMAT,VORMONT
SBL-LINDNER
4WE 6 J6X/EG24N9K4
RD23178
3.9 R99650A152 STACKING ASSEMBLY SUBPLATE 1 PC
VERKETTUNGSPLATTE ML6-2,2FACH,ALU
MBL-BR-AT
3.91 R996410284 SET OF SCREWS 1 PC
SCHRAUBENSATZ 2XM6 1XM8 L=136

4WE 6 E67-6X/EG24N9K4/T06
RD23178
3.12 R900152067 ORIFICE 1 PC
BLENDE 1,2/8,0X4,0 WE6
3.14 R900347495 CHECK VALVE SANDWICH PLATE 1 PC

Z2S 6-1-6X/
RD21548
4.0 R900024095 PRESSURE GAUGE 1 PC
MANOMETER AB31-13/063-0250
AB31-13
4.1 R996405849 PRESSURE HOSE 1 PC
DRUCKSCHLAUCH 110-BB-BB-01.50
4.3 R996516789 NON-RETURN VALVE 1 PC

RUECKSCHLAGVENTIL RHV 28 LRED A3C 0,2
D6-1
AB23-10/2SC16-EFR20S-EFR20S90-910
D2-11
DRV 12 -1-1X/V
RD32502
Bill of Material
Required Qty: 1

Unit
EXTRA
DRV 10 -1-1X/V
RD32502
40.0 R996545623 PRESSURE RELIEF VALVE 2 PC
PRESET 200 bar
RPEC-LAN
40.1 R996409066 VALVE HOUSING 2 PC
FAW
60.0 531603600 HAD1,4-250-1X/50Z08C-1N111-CE 2 PC
DIAPHRAGM-TYPE ACCUMULATOR
RD50150
R901236762 OIL-AIR COOLER 1 PC
BNK6.6-60-2,2-IB5
Bill of Material
Required Qty: 1


Unit
7-6174-11-C Hydraulic Flow sheet
1-1844-10-C Assembly Drawing
1.1 R996538471 CONTAINER 1 PC
BEHAELTER NG400 DIN ANC ST
STAHL
1.31 R900543908 LOCK 2 PC
VERSCHLUSS AB40-19/324A-AL/M-6
AB40-19
1.32 R901034648 BALL VALVE 1 PC
KUGELHAHN AB21-33/ G 1-010
AB21-33
1.41 R900013663 OIL GAUGE 1 PC
OELSTANDANZEIGER AB31-21/127T
AB31-21
R900710555 PLATE 1 PC
SCHILD AB31-21/ 400L-SKALA
AB31-21
1.42 R996409670 FLOAT SWITCH 1 PC
SCHWIMMERSCHALTER 61-0-M3 L=300MM,
1.51 R996407434 AIR FILTER 1 PC

LUFTFILTER PI 0126 MIC MIT SIEB
M2-1
1.52 R901025413 RETURN FILTER 1 PC
ABZFR-S0160-10-1X/M-DIN
RD50088
Filterelement 01025295
1.522 R901025339 CLOGGING INDICATOR 1 PC
ABZFV-E1SP -M12X1-1X/-DIN
RD50086+50088
AB23-10/2SC20-EFR22L-EFR22L45-1200
D2-11
AB23-10/2SC20-EFR22L-EFR22L90-1100
D2-11
Bill of Material
Required Qty: 1


Unit
1.541 R900064238 PIPE 1 PC
AB23-04
1.61 R900028241 THERMOSTAT 1 PC
THERMOSTAT AB31-14/1-1A
AB31-14
2.1 R910967365 AXIAL-PISTON PUMP 1 PC
A A10VSO 45 DFR1/31R-VPA12N00

AB23-10/2SC16-EFR18L-EFR18L90-1100
D2-11
2.12 R900064237 PIPE 1 PC
AB23-04
AB23-10/2SC06-EFR08S-EFR08S90-700
D2-11
R900026554 PIPE 1 PC
ROHR AB23-03/SAE1 1/2 L= 750
AB23-03
R900869992 ASSEMBLY KIT 1 PC
BAUSATZ AB12-03/B 48,3-NBR
AB12-03
2.2 R996410222 ELECTRIC MOTOR 1 PC
ABZEK B35-160M-4-B0-11,0/13,20
AB42-30
2.21 R900022416 HUB 1 PC
NABE AB33-22/KD 42-42
AB33-22
2.22 R900087807 RING GEAR 1 PC
ZAHNKRANZ AB33-22/KD 42-98 SH A
AB33-22
2.23 R900011342 HUB 1 PC
NABE AB33-22/KD 42-25
AB33-22
Bill of Material
Required Qty: 1


Unit
2.24 R900026361 PUMP CARRIER 1 PC
AC PBR 100AS2H/A 350/204-1X/DH-AL
AB33-37
R900028248 DAMPING BAR 2 PC
DAEMPFUNGSSCHIENE DSM 160 M
3.0 R996554245 PUMP PLATE 1 PC

PUMPEN,HEAVY DUTY,MICROMAT,VORMONT
SBL-LINDNER
4WE 6 J6X/EG24N9K4
RD23178
3.9 R99650A152 STACKING ASSEMBLY SUBPLATE 1 PC
VERKETTUNGSPLATTE ML6-2,2FACH,ALU
MBL-BR-AT
3.91 R996410284 SET OF SCREWS 1 PC
SCHRAUBENSATZ 2XM6 1XM8 L=136

4WE 6 E67-6X/EG24N9K4/T06
RD23178
3.12 R900152067 ORIFICE 1 PC
BLENDE 1,2/8,0X4,0 WE6
3.14 R900347495 CHECK VALVE SANDWICH PLATE 1 PC

Z2S 6-1-6X/
RD21548
4.0 R900024095 PRESSURE GAUGE 1 PC
MANOMETER AB31-13/063-0250
AB31-13
4.1 R996405849 PRESSURE HOSE 1 PC
DRUCKSCHLAUCH 110-BB-BB-01.50
4.3 R996516789 NON-RETURN VALVE 1 PC

RUECKSCHLAGVENTIL RHV 28 LRED A3C 0,2
D6-1
Bill of Material
Required Qty: 1


Unit
AB23-10/2SC16-EFR20S-EFR20S90-910
D2-11
DRV 12 -1-1X/V
RD32502
EXTRA
DRV 10 -1-1X/V
RD32502
40.0 R996545623 PRESSURE RELIEF VALVE 2 PC
PRESET 200 bar
RPEC-LAN
40.1 R996409066 VALVE HOUSING 2 PC
FAW
60.0 531603600 HAD1,4-250-1X/50Z08C-1N111-CE 2 PC
DIAPHRAGM-TYPE ACCUMULATOR
RD50150
R901236762 OIL-AIR COOLER 1 PC
BNK6.6-60-2,2-IB5
Lindner-Recyclingtech GmbH
Recommended oil types Villacher Straße 48,
for utilization A-9800 Spittal/Drau
Phone: +43 4762 2742-0, Fax: -32
in hydraulical plants. office@lindner-recyclingtech.com
Recommended oil types:
Sound operation, working reliability and lifetime of hydraulical plants highly depend on the
utilization of appropriate hydraulic oils.
We recommend to use hydraulic oils based on mineral oils according to standard DIN 51524,
part 2.
The viscosity shall lie between 25 and 50 mm² at a temperature of 50° C.
Operational viscosity 12 – 100 mm² / s-Maximum viscosity 320 mm²/s at short notice while
start-up. Temperature range –10° C to + 70° C.
As far as information on other hydraulic fluids is concerned, we ask you to contact us.
TRADE MARKS of HYDRAULIC OILS:
Producer Designation Producer Designation

VITAM 4128 Eni Agip
VITAM 4243 GROUP Prezis BR-Fluid46
VITAM GF46M
Avilub Hydraulic
HMW46 HLP AF 46
Avilub Hydraulic
DD 46
Renolin MWB 46
Energol HLP-46S FUCHS Renolin B15
Renolin ZAF B
Renolin ZAF D
Renolin ZAF MB
Vario HDX 46
Hyspin SP 46 KLÜBER Lamora HLP 46
Castrol HLP-D-46SF
LUBRICATION
Actis X HLPD 46
Astron X HLP MB 46 ML HLPD 46 B
Elfolna SP 46 Mobil HLPD 46

Mobilfluid 423
Shell Hydrauliköl
(aceite hidraulico) MW46 Wintershall Wiolan HX 46 S
BASF
Tribol Tribol 772 ZEPF ZX-10HELP
.
Unil
Deutschland UNIL HYD HFF REPSOL Telex E-46
GmbH.
Bremen
Erstellt: J. Steiner 28.06.2004

JUPITER 2200
5.2. Electric motor

ELECTRICAL MACHINES, DRIVE SYSTEMS AND INSTALLATIONS
Operating Manual IP55
■ Three-phase-low-voltage machine
with squirrel-cage rotor
■ Explosion-safe Three-phase
low-voltage machine
with squirrel-cage rotor
GB
1
Table of Contents
Chapter Page
1 Safety Instructions
1.1 General Instructions .......................................................................... 6
1.2 Symbols ............................................................................................ 6
1.3 Safety Regulations ........................................................................... 7
1.4 Regulations, Standards .................................................................... 7
1.5 Conditions of Connection ................................................................. 7
1.6 Inscriptions, Warning Signs .............................................................. 8
1.7 Working on the Electrical machine ................................................... 8
2 Important Instructions
2.1 Stipulated Usage .............................................................................. 9
2.2 General Instructions .......................................................................... 9
2.3 Installation ....................................................................................... 10
2.4 Ventilation ....................................................................................... 10
2.5 Electromagnetic Compatibility ........................................................ 11
2.6 Feet Anchoring Holes ..................................................................... 11
2.7 Condensation Drain Holes ............................................................. 11
3 Transportation
3.1 Safety Instructions ........................................................................... 12
3.2 Lifting Eyes ..................................................................................... 12
3.3 Securing Procedures for Transportation ......................................... 12
3.4 Transport Damage .......................................................................... 13
4 Assembly and Commissioning

4.2 Mechanical ..................................................................................... 15
4.2.1 Transmission Components ............................................................. 15
4.2.2 Machine Base ................................................................................. 17
4.2.2.1 Assessment Criteria for Vibration ................................................... 17
4.2.3 Alignment ........................................................................................ 18
4.2.3.1 Angular Alignment .......................................................................... 18
4.2.3.2 Parallel Alignment .......................................................................... 18
4.2.3.3 Combined Angular and Parallel Alignment ................................... 19
4.2.4 Additional devices .......................................................................... 19
4.3 Electrical ......................................................................................... 20
4.3.1 Insulating Resistance ..................................................................... 20
4.3.2 Voltage and Circuit ......................................................................... 20
4.3.3 Connection ..................................................................................... 21
4.3.4 Terminal Box Position (Side) .......................................................... 23
4.3.5 Direction of Rotation ....................................................................... 23
4.3.6 Y/D -start ......................................................................................... 24
4.3.7 Electrical machine Protection ......................................................... 24
2
Table of Contents
Chapter Page
5 Maintenance
5.2 Cleaning ......................................................................................... 26
5.3 Ball and Roller Bearing Maintenance ............................................ 26
5.3.1 Ball and Roller Bearing with Permanent Lubrication ..................... 27
5.3.2 Lubrication ...................................................................................... 27
5.3.3 Lubricant ......................................................................................... 27
5.4 Bearing Seals ................................................................................. 28
5.5 Bearing Change - Shaft Height ...................................................... 29
5.5.1 Dismantling Procedure for Drive and
Non-drive Side Deep Groove Ball Bearings .................................. 29
5.5.2 Assembly Procedure for Drive and
Non-drive Side Deep Groove Ball Bearing .................................... 31
5.5.3 Dismantling Procedure for Drive Side Cylindrical Roller Bearing . 33
5.5.4 Assembly Procedure for Drive Side Cylindrical Roller Bearing .... 35
5.5.5 Dismantling Procedures for Non-drive Side
Angular Contact Ball Bearing ......................................................... 37
5.5.6 Assembly Procedures for Non-drive Side
Angular Contact Ball Bearing ......................................................... 39
5.6 Maintenance plan ........................................................................... 41
6 Trouble shooting
6.2 Malfunctions, Electrical ................................................................... 43
6.3 Malfunctions, Mechanical ............................................................... 44
7 Repair Instructions
7 Repair Instructions .......................................................................... 45
8 Stipulated Usage in Explosive Areas

8.1 Electrical machines for the use of device group II
for category 2 (zone 1) .................................................................... 46
8.1.1 Assembly ........................................................................................ 46
8.1.2 Installation ....................................................................................... 47
8.1.3 Connection ..................................................................................... 47
8.1.4 Protective Measures against Impermissible Heating ..................... 48
8.1.5 Maintenance and Repair ................................................................ 49
8.1.6 Spare Parts ..................................................................................... 49
3
Table of Contents
Chapter Page
for category 3 (zone 2) .................................................................... 50
8.2.1 Assembly ........................................................................................ 50
8.2.2 Installation ....................................................................................... 50
8.2.3 Connection ..................................................................................... 51
8.2.4 Protective Measures against Impermissible Heating ..................... 51
8.2.5 Maintenance and Repair ................................................................ 52
8.2.6 Spare Parts ..................................................................................... 53
9 Spare Parts
9.1 Order Details ................................................................................... 54
9.2 Exploded View ................................................................................ 54
10 Instructions for Electrical machines Which Are To Be Stored

10.1 Storage Site .................................................................................... 56
10.2 Securing the Machine for Transportation ........................................ 56
10.3 Checks before Commissioning ...................................................... 57
10.3.1 Bearings .......................................................................................... 57
10.3.2 Insulating Resistance ..................................................................... 57
4
Model Sizes 180M-315L
Squirrel-cage rotors,
Type BC7, BD7, DA7, EA7, KA7, KB7, KC7, KE7, KH7
Example, Diag. 1
Three-phase-squirrel-cage motor with squirrel-cage rotor
Basic model KA7
Diag. 1: Model size 180M-315L - Type KA7
5
Safety Instructions
1 Safety Instructions
1.1 General Instructions
Read the operating manual before transportation, assembly, commissioning,
maintenance and repair, and comply with its instructions!
1.2 Symbols
In this operating manual 5 symbols are used which must receive special attention:
Instructions concerning safety and the guarantee:

The possibility of personal injury is included here.
Warns of electrical voltage.
Points out that damage to the electrical machine and / or auxiliary

fittings can occur.
☞ Indicates useful advice and explanations.
Ex Additional instruction for electrical machines of device group II for

category 2 (zone 1) or device group II for category 3 (zone 2).
6
Safety Instructions
1.3 Safety Regulations

Observe
– the safety regulations,
– accident prevention regulations,
– guide lines and acknowledged technical rules,
cited in this operating manual!
Non-compliance with safety regulations will result in the endangering of personnel

and damage to the machine.
1.4 Regulations, Standards

When working on the electrical machine observe all valid accident prevention
regulations and generally acknowledged technical rules!
• Accident prevention regulations laid down by the professional associations
– „General Regulations (VBG 1)“
– „Electrical Plant and Operational Means (VBG 4)“
• Harmonized European standards EN 60034
• VDE requirements
DIN VDE 0105 Requirements for the Operation of High-Voltage Plant
DIN EN 60079 The Installation of Electrical Plant in Explosive
or VDE 0165 Environments
• ElexV or Ev VO Ordinance regarding Electrical Plant in

Explosive Areas
7
Safety Instructions
1.5 Conditions of Connection

Observe the regulations and conditions of connection laid down by the local
electrical supply utility when connecting the electrical machine to the mains
supply!
All work on the electrical machine’s electrical connections may only be

carried out by electricians (as defined in DIN VDE 0105 and IEC 364)!
Pay attention to the earthing when installing drives with IGBT convertors; espe-
cially make sure that there is no potential difference between the drive aggregate,
engine and convertor. Make sure that the cables are correctly installed and that the
earth connection has minimum induction.
1.6 Lettering, warning signs

Instructions attached to the electrical machine (e.g. rotation-direction arrows,
instruction signs, lettering and warning signs) must be observed and kept legible.
1.7 Work activities to the electrical machine

For safety reasons, only qualified personnel may carry out maintenance and
repair activities
Qualified personnel are those persons who, on account of their professional
training, experience and instruction, have sufficient knowledge of
– safety regulations,
– guide lines and acknowledged technical rules
(e.g. VDE requirements, DIN standards).
The qualified personnel must
– be able to assess the work assigned to them and recognize and avoid
possible dangers.
– be authorized by those responsible for the safety of the plant to carry out
the required work.
8
Important Instructions
2 Important Instructions
2.1 Stipulated Usage
This operating manual is valid for surface-cooled electrical machines designed for
low-voltage use and of protection type IP 55 in accordance with EN 60034 - Part V.
Higher protection types are specified on the rating plate (e.g. IP 68).
In explosive environments only electrical machines which possess a registered
explosion protection type may be used.
Ex For electrical machines of device group II for category 2 (zone 1) or

group II (zone 1) and of device group II for category 3 (zone 2) or group II
(zone 2) apply also the data in Sections 8.1 and 8.2.
Any other usage which goes above and beyond that stipulated is considered to be
non-stipulated. Any other or further use shall be regarded as non-intended. We
cannot be held liable for any damage or downtime that is caused by installation
errors, non-observance of this manual or unprofessional repairs.
2.2 General Instructions

Use of this operating manual alleviates safe and proper transportation, assembly,
commissioning, maintenance and repair of the electrical machine.
We reserve the right to make technical changes to the electrical means discussed
in this operating manual.
Illustrations and drawings presented in this operating manual are simplified
portrayals. On account of improvements and changes it is possible that the
illustrations do not agree exactly with the electrical machine operated by you.
Technical specifications and dimensions are not binding, and any possible claim
cannot be based there upon.
We reserve all copyright to this operating manual and the drawings and other
documents contained there in.
9
The manufacturer accepts no liability for damages,
• which arise during the period covered by the guarantee as a result of

– negligent maintenance,
– improper operation,
– faulty installation,
– wrong or inexpert connecting of the electrical machine.
• which result directly or indirectly either from unilateral changes to the machine
by the user or from non-compliance with the manufacturer’s recommendations.
• which arise from the use of spare parts / accessories not recommended or
supplied by the manufacturer.
2.3 Installation
The machines may be operated at heights of ≤ 1000 m above sea level, at coolant
temperatures of -20 to +40°C. Exceptions are specified on the rating plate.
2.4 Ventilation
The distance between the air intake and any driven appliances, covers etc., must
be at least 1/4 of the diameter of the air intake aperture. Air stream flow is from the
non-drive side to the drive side.
The exhausting air stream must not be directly sucked in again.

Keep the air intake and exit apertures free from dirt.
For a position other than horizontal, prevent solid objects from falling into
the ventilation aperture install a suitable cover. The motor cooling must not
be affected by such a cover.
Electric motors with an external ventilator may only be operated while the
external ventilator is active. (For the connection data of the external ventila-
tor, see the rating plate.)
10
2.5 Electromagnetic Compatibility

The electrical machines correspond at least to EN 50081 Part 2 (electromagnetic
compatibility, generic commission standart part 2: industrial environment) in
accordance with VDE 0839 Part 81-2. This suffices for the operation of electrical
machines in industrial areas.
2.6 Feet Anchoring Holes (Diag.2)

Electrical machines with axial heights of 180, 225 and 315 each have only one
housing length.
22 0M
18
31 S5
31 5S
5M
22 0L
18
31 5M
31 5L
5M
Diag.2: Feet anchoring holes
2.7 Condensation Drain Holes
Prevent the condensate-drainage holes from becoming blocked
Ex Only open these drain holes for the purpose of drainage, close again
afterwards.
11
Transportation
3 Transportation
3.1 Safety Instructions
When raising and transporting the machine observe the applicable

accident prevention regulations and any generally acknowledged
technical rules!
• Accident prevention regulations
– General Regulations (VBG 1),
– Cranes (VBG 9),
– Load Suspension Device in the Lifting Gear Industry (VBG 9a)
• DIN standards
– DIN 15003 Lifting Gear, Load Suspension Devices
– DIN 7540 Eye-Hooks, Goods Class 5
– DIN 82101 Shackles
3.2 Lifting Eyes
Only suspend electrical machines from the lifting eyes provided.

Check that the twisted-in ring screws are firmly tightened
Do not subject to additional loads. The load eyelets have been designed for
the weight of the electrical machine only.
Other supplementary lifting eyes which may possibly be available, e.g. on
fan hoods, cooler fittings etc., are only suitable for the lifting of the respec-
tive individual parts.
3.3 Securing Procedures for Transportation

Before shipment, use transport safeguards to protect electrical machines with
cylinder-roller bearings from bearing damage.
Remove this device before commissioning and pack the securing hole with
the plug supplied. Use the transportation securing device again if further
transportation is required.
12
Transportation
Securing Procedures for Transportation,

Examples
• Rod fixing:
2 – Undo bolts (1) and remove the rod
fixing (2).
– Screw in and tighten the shorter bolts
1
supplied.
• Clamp fixing:
– Undo bolts (3) and remove transporta-
4 3 tion shackle (4).
– Stop up the threaded hole with the
plug.
☞ The machine is fitted either with a

clamp fixing or a rod fixing.
Diag. 3: Example securing Procedures
for Transportation
The plug is attached to the information
plate (drive shaft).
3.4 Transport Damage

Document any transport damage and immedi-
ately inform the transport company, insurance
company and the manufacturer!
13
Assembly and Commissioning
4 Assembly and Commissioning

During assembly and commissioning observe the following:

– safety instructions pages 6-8
– important instructions pages 9-11!
Installation activities may only be carried out by qualified personnel

who - based on their training, experience and instructions - have
sufficient knowledge of:
– guide lines and acknowledged technical rules
The qualified personnel must

– be able to assess the work assigned to them and recognize and
avoid possible dangers.
– be authorized by those responsible for the safety of the plant to
carry out the required work.
☞ It is recommended that you request the assistance of the manufacturer’s

assembly personnel.
14
4.2 Mechanical
4.2.1 Transmission Components
Only use flexible couplings;

Rigid couplings may be applied only after consultation with
the manufacturing factory.
Should a machine with two shaft ends have no drive element fitted on one
of these shaft ends, ensure that the unused key cannot spin off the shaft.
If the machine is of balance type „H“ then the key should be shortened by
half!
If a machine with two shaft ends on one shaft end does not have a drive
take-off element, the unused feather key must be secured against ejection.
Note that in rotor alignment mode ‘H’ (see rating plate), this feather key
must be shortened by 50%.
Ex Use only drive belts that are not electrostatically charged.
Each rotor is dynamically balanced according to its balance type with a full, a half
or no key and, in accordance with ISO 8821, is labelled thus:
F = full key,
H = half key,
N = no key.
Rotors balanced with a full key → balance the drive component with open
key way.
Rotors balanced with a half key → balance the drive component in a

ungrooved state.
• Align the power take-off element in accordance with the alignment mode of the
rotor. If the power take-off element is shorter, the part of the feather key that
protrudes from the power take-off element and over the shaft contour must be
finished (e.g.) or covered with a suitable ring of a corresponding length.
• Before fitting the drive component onto the shaft remove the anti-corrosion film
on the shaft end with a suitable cleaning agent (e.g. naphtha).
Do not use emery or rub down the shaft to remove the protective film!
15
• Lightly grease or oil all seating

surfaces and fit the drive element.
In order not to damage the rolling

bearing, use a suitable device to
pull the power take-off element on
(see Fig. 4) or off (see Fig. 5).
If necessary, heat the power take-
off element in accordance with the
shrink dimension as indicated by
the manufacturer.
Avoid hard blows and knocks

when fitting the drive component.
Diag.4: Fitting with a centre bore
The bearings and / or the shaft will
be damaged and the manufactur-
er’s guarantee will be null and
void.
Diag.5: Dismantling
16
4.2.2 Machine Base

Suitable supports for the electrical machine are support faces that guarantee the
shock-free, low-vibration and rigid-coil operation of the machine and which will
support the increased forces in short-circuited situations.
All the electrical machine feet must lie on an even, level plane in order to
avoid stress in the housing.
The fastening elements of the electrical machines must be firmly tightened

and locked in order to prevent them from becoming loose during operation.
Use washers with a large surface area in order to make the support surface
sufficiently large.
Wrong installation can lead to resonances in rotary frequency and double

mains frequency range.
In order to avoid damage to electrical machines in an idle state (stand-by

operation) the following maximum rates of vibration must not be exceeded.
Idle Time Rate of Vibration
up to 500 hrs 0,4 mm/s
more than 500 hrs 0,2 mm/s
4.2.2.1 Assessment Criteria for Vibration
With regard to vibration at the site location, the assessment criteria laid down in
DIN ISO 3945 are to be complied with.
For rigid foundations the following measured values on the bearing housing can
be considered as limiting values:
– 5.5 mm/s for the alarm,
– 11 mm/s for switch-off.
☞ If the vibration values vary between warning and deactivation, only con-
tinue to operate the electrical machine while observing it or alert the
manufacturer.
17
4.2.3 Alignment
• Align the electrical machine precisely

in accordance with the already
aligned driven appliance.
• Clamp on the dial gauges firmly. Carry

out measurements at four measuring
points, each separated by 90° whilst
simultaneously turning both halves of
the coupling.
E 4.2.3.1 Angular Alignment (Diag.7)

Diag.7: Angular alignment Compensate for any differences by
inserting plates. Ensure that any residual
inaccuracy, in reference to a measured
radial diameter of 200 mm, does not
exceed 0.03 mm.
4.2.3.2 Parallel Alignment (Diag.8)
Compensate for any differences by re-

positioning or by inserting suitable plates
so that the residual inaccuracy does not
exceed 0.03 mm. Adjust the axial air gap
between the two halves of the coupling
E (dimension „E“) in accordance with the
specifications given by the coupling
Diag.8: Parallel alignment manufacturer.
Check alignment when the ma-

chine is in an operationally warm
state.
4.2.3.3 Combined Angular and Parallel

Alignment (Diag.9)
Diag.8 shows a method of combining both

measurements which is relatively simple
in concept. The dial gauges are placed in
the corresponding holes of the flat bars
(which are screwed or clamped on) and
E are then fixed by means of, for example,
Diag.9: Combined angular / parallel grub screws.
alignment
18
4.2.4 Additional devices
In order to protect the electrical machine various accessories may be fitted or

attached subject to order, e.g.:
– temperature sensor for monitoring windings and bearings,

– space heater,
– measuring nipple for bearing monitoring.
– Speed-count (RPM) monitor.
19
4.3 Electrical
All work on the electrical machine’s electrical connections must only be

4.3.1 Insulating Resistance
Do not touch the connection terminals either during or after measuring.

The terminal connections can carry high voltages! After carrying out
the check earth the terminal connections briefly (5 seconds).
• Using a hand generator (max. D.C. voltage = 630V) measure the insulating
resistance of each individual phase to earth. Continue measuring until the
measured value is constant.
☞ The insulating resistance of new windings is > 100 MΩ.

Dirty and damp windings have considerably lower resistance values.
A coil is regarded as sufficiently dry and clean if the insulation resistance at 75 °C

is at least 1MW je 1kV (see table).
If the values drop below the table values, the coil must be dried or cleaned. The
coil temperature must not exceed 75 °C.
Rated voltage Windings temperature Operational

when cold temperature
UN 15°C 25°C 35°C 75°C

0,5 kV 30 M Ω 15 M Ω 8MΩ 0,5 M Ω
1,0 kV 60 M Ω 30 M Ω 15 M Ω 1,0 M Ω
Dry the coil using the space heater or another heater or by applying an
alternating voltage of 5-6% of the rated voltage (make a delta circuit) to the
stator connection clamps U1 and V1.
20
☞ Insulation resistance values are temperature dependent.

Guide values: a coil temperature increase or decrease of 10 k leads to the
insulation resistance value being halved or doubled.
Remove the condensate water plug before drying the coil. Reclose it tightly once
the condensate water openings have been dried.
4.3.2 Voltage and Circuit
Observe the circuit details given on the rating plate and compare the rated voltage
to the mains voltage.
The permitted fluctuation in mains voltage amounts to ±5%. Exceptions are
specified on the rating plate.
4.3.3 Connection
Connect the connection cables in accordance with the applicable

regulations of the local electricity supply utility and in accordance with:
– the DIN VDE requirements,
– the safety regulations,
– the accident prevention regulations.
• Connect mains feeds with care, so that the contact force required for an
electrical connection will be maintained over a long period (→ table on
tightening torques, terminal layout and special arrangement of securing nuts
see Illustration).
In addition to operating conditions, the firmness of the electrical connections
should be checked.
21
If no other precise specifications have been made, the following tightening

torques are valid for normal connections of securing screws and nuts used for
electrical connections.
Tightening torques (Nm with a tolerance of ±10%)
for thread sizes of
M5 M6 M8 M10 M12 M16 M20 M24
2 3 6 10 15,5 30 52 80
Manually tighten the nut against the isolator screw
In electrical connecting work, the permitted torque is usually limited

by the bolt material and / or the loading capacity of the insulators.
☞ All electrical machines have a connection diagram on the inner side of the
terminal box cover.
Match the cross-sectional area of the connecting cable to the rated current
strength.
To avoid tension in the terminal connections fit the cable so it is not pulling
from the connectors.
Take care that there are no foreign bodies, dirt and / or dampness present
in the terminal box.
To guarantee the protective type when sealing the terminal box, use
original seals.
Seal any unused cable feed apertures so that they are dust- and water-
tight. The closing caps included in the delivery serve only as a transport
safeguard; they do not form a tight seal.
22
4.3.4 Terminal Box Position (Side)
For electrical machines up to and including model size 315M - with normal output -
it is possible to change the side terminal box position at a later date from RIGHT to
LEFT or vice versa.
For such a change within the guarantee period the prior agreement of
the manufacturer is required. Clarify any change to the position of the
connection box with the manufacturer.
4.3.5 Direction of Rotation
Under normal conditions the electrical machines are suitable for operation in both
directions of rotation. Exceptions are indicated on the rating plate with a corre-
sponding directional arrow. For each respective direction of rotation the following
stator connections are given:
Connection of L1, L2, L3 Direction of rotation viewed on the

drive side
U1 - V1 - W1 right (cw)
W1 - V1 - U1 left (ccw)
In machines with two shaft ends, the information concerning the direction of
rotation refers to the driven side of the shaft end.
• Check the direction of rotation by quickly switching the electrical machine (which has
been connected in accordance with the regulations) „On / Off“ in its uncoupled state.
Before checking the direction of rotation or carrying out any trial operation (without
drive element), always lock the feather key/keys.
Reversal of direction of rotation:
Type of switch-on and winding Measures
Direct switch-on and pole-shift motors Exchange twosupply-cable conductors

with separate windings on the motor terminal board.
Star or delta connection and pole-shift Exchange two supply-cable

motors with DAHLANDER winding conductors at the incoming supply to
the contactor combination.
Only the person who is actually checking the direction of rotation may
remain in the danger zone of the machine/operating machine. When
checking the direction of rotation, observe DIN VDE 0105.
23
4.3.6 Y/D -start
To avoid unpermitted transient current and torque impacts, the cross-over

from Y to ∆ may only be effected if the start current of the Y stage has
decayed, or if the run-up has ended.
During the run-up phase the machine should only be switched off in an
emergency, in order to protect the switchgear and the machine itself.
4.3.7 Electrical machine Protection
• Connect the built-in semi-conductor temperature sensor to the trigger mecha-

nism in accordance with the circuit diagram.
• Any possibly required continuity check of the temperature sensor should only
be carried out using a measuring bridge (max. 5V).
In order to achieve total thermal

protection of the machine, fit a
supplementary thermally-delayed
overload protector (→ Diag.10).
Safety fuses alone tend to just
protect the mains supply and not
the electrical machine.
Ex Electrical machines of devices

group II category 2 (zone 1) or of
group II (zone 1) and category 3
(zone 2) or of group II (zone 2) are
governed also by the information
in Section 8.1 or 8.2.
M
+
Diag. 10: Protection using over-current relay,
thermistor protector and fuse.
24
Maintenance
5 Maintenance
Maintenance work (except for greasing work) is only to be carried out

when the machine is standing idle.
Ensure that the machine is safeguarded against accidental switch-on

and is labelled with a corresponding warning sign.
Observe the safety regulations and accident prevention regulations of

the corresponding manufacturer when using oils and greases, cleaning
agents and spare parts!
Maintenance work on the machine’s electrical power supply or to the

electrical auxiliary / control supplies may only be carried out by electri-
cians in compliance with DIN VDE 0105.
Ensure that the machine is switched so that it is not live.
Lock the machine against reactivation and indicate such by placing a

warning sign on/by the switch.
Ascertain that the machine is not live!
Earth and short-circuit!
Cover or cordon off any neighbouring parts which are still live!
Ensure that the auxiliary power circuits e.g. space heater etc., are
switched so as not to be live.
25
Maintenance
5.2 Cleaning
Do not wash down the machine with water or other liquids.
• Check the whole cooling airway for dirt annually.
• In the event of severe dirt deposits dismantle the electrical machine and
remove the deposits using suitable cleaning agents (e.g. superheated steam).
• Finally dry the winding and measure the insulating resistance.
☞ During these procedures observe the specifications on page 20 given

under 4.3.1 Insulating resistance.
5.3 Ball and Roller Bearing Maintenance

– Monitor bearing temperature during operation.
– Check the bearing for noise when running.
– Greasing of ball and roller bearings.
– Renewing the bearings.
• Should a rise in temperature or running noises occur during operation,

switch off the electrical machine immediately in order to avoid any
resulting damage. Inform the manufacturer’s service department.
• Dismantle the bearing and check for damage (→ page 28 – 39).
• Should there be darkly coloured, matt- or polished-effect areas on the

bearing, fit a new bearing.
☞ The operational safety of the electrical machine is dependent upon mainte-

nance of the lubrication schedule.
For the type of grease, see the rating or lubricating plate.
The standard versions of electrical machines have a relubricating device

with grease-quantity regulator.
Initial lubrication of the bearing is carried out at our factory. The lubricating
schedule and lubricant volumes are specified on the rating plate.
In the basic model the electrical machines are fitted with a button head
grease nipple, M10 x 1, in accordance with DIN 3404.
26
Maintenance
5.3.1 Ball and Roller Bearing with Permanent Lubrication

Under normal operating conditions 2-pole electrical machines are maintenance
free for around 10,000 operational hours, more-pole electrical machines for
20,000, however, in both cases at the most 3-4 years. At this juncture the ball and
roller bearing and bearing cover should be washed out with a suitable cleaning
agent. If necessary, renew the bearing. Half-fill with grease both the hollow spaces
between the rollers and the roller track, and the grease chamber. Lightly smear the
shaft bushes in the bearing covers or bearing shields with grease.
It is not possible to wash out and lubricate sealed-for-life bearings (2RS and
2Z bearings). Purchase new bearings from the manufacturer.
Use forcing screws or a suitable device for dismantling the bearings.
5.3.2 Lubrication
If grease exit holes are closed with plugs (IP54 drive end), remove the plugs
before commissioning. Seal holes with grease.
If there are no grease-relief holes (degree of protection IP55), after 3-4 years the
bearing covers or endshields, respectively, must be removed and the spent grease
must be disposed of.
Only carry out lubricating work when the machine is running:

Be careful of moving parts!
☞ Observe the lubricant specification given on the rating or lubricant plate.

• Clean the grease nipple and apply the corresponding amount of grease (using
the correct grade of grease) by means of a grease gun. To achieve this weight
the grease gun both before and after use.
5.3.3 Lubricant
For the type of grease, see the rating or lubricating plate.
For basic model electrical machines the bearing can be re-filled (without cleaning)
using lithium-saponified ball and roller bearing grease K3k in accordance with
DIN 51825, for example, SKF LGMT3, Shell Alvania G3, Esso Beacon 3 etc..
Carefully clean the bearings when switching to a type of grease with

another soap basis, as indicated on the rating plate, since the rolling-
bearing greases used must satisfy the following conditions:
– Drop point approx. 190°C
– Ash content 4%
– Water content 0.3%
☞ Changing over to a grade of grease with a different saponification base

requires consultation with the machine manufacturer.
27
Maintenance
5.4 Bearing Seals (Diag.11)

1
without grease
• Before fitting new felt rings into the
x bearing cover, soak them in high-
viscosity oil heated to 80°C.
The shaft must slide easily in the felt
greased
ring and be completely sealed radially.
• Lightly grease the running faces.
2 • Push on the sealing rings (3) and

V-rings (1), e.g. using a screwdriver
whilst simultaneously turning the shaft
(→ Diag.12).
3
When fitting V-rings onto flat
sealing surfaces the dimension „X“
must be maintained.
greased
Non-compliance will lead to
+ 0.5 overheating or destruction of the
2 V-ring, or will result in a bad seal.
4
V-ring type Fitting dimensionX

(mm)
V-25 to V-38 9,0 -0,3
V-40 to V-65 11,0 -0,3
V-70 to V-100 13,5 -0,5

Diag. 11: 1 V-ring
2 Felt ring V-110 to V-150 15,5 -0,5
3 Neoprene sealing ring
4 Labyrinth ring
x
• Before installation, heat the labyrinth
rings (4) to approx. 60-80 °C and push
them towards the bearing cover;
observe the remaining axial gap
(2+05 mm).
Diag.12: V-type sealing ring
28
Maintenance
5.5 Bearing Change - Shaft Height (AH) 180 to 315
The prior agreement of the electrical machine manufacturer is required for

bearing changes undertaken within the warranty period!
5.5.1 Dismantling Procedure for Drive and Non-drive Side Deep Groove Ball
Bearings (® Diag.13)
(For drive side cylindrical roller bearing, see 5.5.3)
1. Unscrew the grease nipple (20.1), loosen screws (20.2), remove fan hood (20).
2. Loosen the circlip (19) and pull it off. Pull off the fan (18) using a pulling tool
(metal fans should be heated up in this procedure).
3. Loosen screws (2.1), (2.2), (16.1) and (16.2). Pull off the bearing shields (2)
and (16), together with the bearing seals (1) and (17), taking care not to tilt
them.
Take off the compensation washer (3) – only present on electrical machines
≤ AH225.
4. Loosen and pull off the spring clips (4) and (15) – only present on electrical
machines AH250. Pull off the collar oilers (5) and (14). (Collar oilers fitted in
electrical machines of the range AH180 to AH225 have holes in the hub
section which can be used for pulling off).
5. Loosen and pull off the securing ring (13).
6. By using a pulling tool and heating the inner ring slightly, remove the deep
groove ball bearings (6) and (12).
Remove the pressure springs (9) – only present on electrical machines
AH250.
7. Pull off the inner bearing covers (8) and (10) together with the seals (7) and
(11).
8. The rotor remains in the stator housing.
29
Maintenance
8
7
6
5
20.1 4
3
2
20.1
1
9
20
18 19
2.1 2.2 17
16
15
14 16.2 20.2
13
16.3
12
16.1
11
10
Diag. 13: Bearing change AH180 to AH315
30
Maintenance
5.5.2 Assembly Procedure for Drive and Non-drive Side Deep Groove Ball
Bearing (® Diag.13)
(For drive side cylindrical ball and roller bearing, see 5.5.4).
All securing screws must be fitted with the spring washers provided
(DIN 6796).
1. Clean off the bearing seats with a suitable cleaning agent, check for any
damage and measure the shaft with a micrometer after it has cooled.
2. Remove the old grease from the inner bearing covers (8) and (10), wash them
out using a suitable cleaning agent and allow to dry.
Fill the bearing covers (8) and (10) with new grease (use the correct type of
grease) then push them onto the shaft along with bearing seals (7) and (11).
Cover the compression springs (9) in the bearing-cover holes (8) with the
same grease.
3. Heat the new bearing in an oil bath (or using inductive means – de-magnetize
afterwards) to a temperature of 80°-90°C.
To ensure proper fitting push the heated bearings (6) and (12) onto their
shaft seating and press them against the shaft shoulder for approx. 10
secs.
Once they have cooled down, fill the hollow bearing space with new grease
(use the correct type of grease).
4. Push on the circlip (13) and secure it. Push on the collar oilers (5) and (14).
Push on and tighten up the spring clips provided (4) and (15).
5. Remove the old grease from the bearing cover (2) and (16), wash out using a
suitable cleaning agent and allow to dry. Place the compensation washer
provided in position on the bearing shield hub.
6. For easy assembly screw in two studs (A) – about 100 mm long – into the
threaded holes in the inner bearing cover (8) and (10).
Push on the bearing shields (2) and (16) and screw down tightly using screws
(2.2) and (16.2), together with mounting plate 16.3).
Tighten up screws (2.1) and (16.1) (at this stage the studs (A) must be re-
moved).
7. Fit the bearing seal (1) and (17) as described on page 27.
8. Fit the plastic fan (18) using a winding tool (metal fans should be heated up
and pushed on), push on and secure the circlip (19).
Place the fan hood (20) in position and tighten up the screws (20.2).
Screw in the grease nipple (20.1).
31
Maintenance
8
7
6
5
20.1 4
3
2
20.1
1
9
20
18 19
2.1 2.2 17
16
15
14 16.2 20.2
13
16.3
12
16.1
11
10
32
Maintenance
5.5.3 Dismantling Procedure for Drive Side Cylindrical Roller Bearing

(® Diag.14)
(For non-drive side deep groove ball bearing, see 5.5.1)
1. Loosen screws (2.1.1) and pull off the bearing cover (2.1) together with the
bearing seal (1.1).
2. Loosen and pull off the spring clip (4.1) – only present on electrical machines
AH250. Pull off the collar oiler (5.1) (on electrical machines AH180 to AH225
the collar oilers have holes in their hub section which can be used for pulling
off).
3. Loosen screws (3.1.1) and pull off the bearing shield (3.1). Press the outer
bearing ring (6.1) out of the bearing shield hub.
4. Using a welding torch quickly heat up the inner bearing ring (6.2) and force off
using, for example, a screwdriver.
5. Pull off the bearing cover (8.1) together with the bearing seal (7.1).
33
Maintenance
8.1
7.1
6.1
20.1 5.1
4.1
3.1
2.1 20.1
1.1 6.2
20
18 19
2.1.1 3.1.1 17
16
15
14 16.2 20.2
13
16.3
12
16.1
11
10
34
Maintenance
5.5.4 Assembly Procedure for Drive Side Cylindrical Roller Bearing

→ Diag.14)
(→
(For non-drive side deep groove ball bearing, see 5.5.2).
All securing screws must be fitted with the spring washers provided (DIN
6796).
1. Clean off the bearing seats with a suitable cleaning agent. Check for any
damage and measure the shaft with a micrometer after it has cooled .
2. Remove the old grease from the inner bearing cover (8.1), wash it out using a
suitable cleaning agent and allow to dry.
Fill the bearing cover (8.1) with new grease (use the correct type of grease)
then push it onto the shaft along with the bearing seal (7.1).
3. Heat the new inner bearing ring (6.2) in an oil bath (or using inductive means -
de-magnetize afterwards) to a temperature of 80°-90°C.
To ensure proper fitting push the heated inner bearing ring (6.2) onto its
shaft seating and press it against the shaft shoulder for approx. 10 secs.
Lightly grease inner bearing ring (6.2) after cooling.
4. Wash out the hub of the bearing shield (3.1) using a suitable cleaning agent
and allow to dry.
5. Press the bearing outer ring (6.1) into the end-shield hub and fill the hollow
bearing spaces with new grease (use the correct type of grease).
6. For easy assembly screw in a stud (A) – about 100mm long – into the threaded
hole located in the bearing cover (8.1). Push on the bearing shield (3.1) and
tighten up using the screws (3.1.1).
7. Push on the collar oiler (5.1), push on and tighten up the spring clip (4.1)
provided.
8. Remove the old grease from the bearing cover (2.1), wash out the cap using a
suitable cleaning agent, allow it to dry. Push the bearing cover (2.1) onto the
shaft and tighten up using screws (2.1.1) (in doing this remove stud [A]).
9. Fit the bearing seal (1.1) as described on page 27.
35
Maintenance
8.1
7.1
6.1
20.1 5.1
4.1
3.1
2.1 20.1
1.1 6.2
20
18 19
2.1.1 3.1.1 17
16
15
14 16.2 20.2
13
16.3
12
16.1
11
10
36
Maintenance
5.5.5 Dismantling Procedures for Non-drive Side Angular Contact Ball

Bearing (O-layout) (® Diag.15)
(For drive side cylindrical roller bearing, see 5.5.3 and for drive side
deep groove ball bearing, see 5.5.1).
1. Unscrew the grease nipple (20.1), loosen the screws (20.2) and take off the fan
hood (20).
2. Loosen and pull off the circlip (19). Pull off the fan using a pulling tool (to
facilitate this operation, metal fans should be heated up).
For designs fitted with labyrinth seals (1):
Screw studs into the threaded holes (2) and, using the studs, pull the seal from
the shaft end.
For designs fitted with rotary seals:
The rotary shaft seal is pulled off together with the bearing cover (4).
3. Undo the bearing cover securing screws (5) and pull off the bearing cover.
4. Undo the securing screw (shaft nut [6]).
5. Undo the shaft nut (6) with a hook spanner and pull it off the shaft end.
6. Pull off the collar oiler (7), taking care not to damage the torque device (8).
7. If applicable, undo the temperature sensor which is fitted on the outer surface
of the bearing shield.
8. Undo the securing screws (12) of the bearing shield (9).
9. Pull the bearing shield off the shaft end by means of a pulling tool.
10. Push back the inner bearing cover (10).
11. Pull the angular contact ball bearing (11) from the rotor shaft using a pulling
tool.
12. If the angular contact ball bearing is tightly seated, heat it up slightly (without
heating the rotor shaft) and pull off using a pulling tool.
37
Maintenance
8.1
7.1
6.1 20.1
20.1 5.1
20
4.1
3.1
2.1
6.2 18 19
1.1
1
3.1.1 20.2
2.1.1 12
6 13
8 2
7
11 5
10
38
Maintenance
5.5.6 Assembly Procedures for Non-drive Side Angular Contact Ball

Bearing (O-layout) (® Diag.15)
(For drive side cylindrical roller bearing, see 5.5.4, and for drive side
deep groove ball bearing, see 5.5.2)
1. Clean off the bearing seats with a suitable cleaning agent, check for damage
and measure the shaft with a micrometer after it has cooled.
2. Clean all individual parts of the bearing assembly. Check the felt ring seals in
the inner bearing cover (10) and renew if necessary.
3. Completely fill the greasing spaces of the inner bearing cover with the speci-
fied grease (→ rating plate) and push the inner bearing cover onto the shaft.
4. Heat up the angular contact ball bearing (11) in an oil bath or using inductive
means (de-magnetize afterwards) to a max. 100°C.
Do not heat the angular contact ball bearing with a naked flame.
5. Without tilting it, push the angular contact ball bearing onto the rotor shaft and
right up to the stop.
Note the fitting position.
6. Apply grease to the angular contact ball bearing.

7. Push the collar oiler (7) against the angular contact ball bearing and take care
that the torque device (8) locates in the grooves of the shaft and collar oiler
(nose under the inner bearing ring).
8. Screw on the shaft nut (6) and tighten using a hook spanner.
9. Lock the shaft nut with the securing screw.
10. Screw in at least two studs (A) into the threaded holes of the inner bearing cover.
11. Push the bearing shield over the rotor and studs and in front of the angular
contact ball bearing.
12. Using the studs, pull the bearing shield onto the outer ring of the angular
contact ball bearing.
Blows and knocks during the pulling on operation will damage the
angular contact ball bearing.
Do not tilt the bearing shield and bearing when they are being pulled on.
13. Tighten the securing screws (12) for the bearing shield and the angled stay
(13) to the inner bearing cover.
14. Push the bearing cover (4) against the bearing shield (9) and tighten down
using the proper screws (5).
39
Maintenance
15. For designs fitted with a rotary shaft seal, push the new rotary shaft seal onto
the bearing cover (4).
16. For designs fitted with a labyrinth sealing ring (1), heat the labyrinth sealing
ring up to approx. 60°-80°C and push it against the bearing cover (4).
17. To raise the effectiveness of the labyrinth sealing ring we recommend that a
small amount of grease be applied into the labyrinth opening.
18. Apply a film of grease to the contact surfaces of the rotary shaft seals in the
outer bearing cover.
19. Pull on the plastic fan (18) using a pulling tool (metal fans should be heated up
and then pulled on), push on the circlip (19) and secure, fit the fan hood (20),
tighten using screws (20.2). Screw in the grease nipple (20.1).
8.1
7.1
6.1 20.1
20.1 5.1
20
4.1
3.1
2.1
6.2 18 19
1.1
1
3.1.1 20.2
2.1.1 12
6 13
8 2
7
11 5
10
40
Maintenance
5.6 Maintenance plan
COMPONENT DAILY WEEKLY EVERY 3 ANNUALLY EVERY 5 YEARS

MONTHS
Bearing For lubrication - bearing change,

deadlines see check shaft seals,
rating plate replace if
necessary;
- remove old
grease;
Heat exchanger Check Clean Clean

Airways
Driven Check alignment Check alignment and Check alignment and

appliance and that the make sure that that machine is
(Observe the machine is secure machine is secure secure; Change
manufacturer´s grease / oil
specifications)
Terminal box Clean internally; Re- Clean internally; Re-

Earth tighten screws tighten screws
Stator winding Measure insulating Check that feed

resistance cables are not torn,
that they are firmly
seated,check keys;
measure insulating
resistance
Auxiliary Record Check function Check function

monitoring measurement
connections data
Motor as a Pay attention Re-tighten screws Dismantle rotor;

whole to operating check that the rotor
noise and plates, fan and stator
quiet running plates are firmly
seated; Check that
rotor bars are not
broken; Clean
41
Trouble shooting
6 Trouble shooting

A faulty electrical machine may only be repaired by qualified personnel at the
request of the person responsible for the installation.
When determining the cause of a malfunction take into consideration all facets of the
electrical machine (driven appliance, foundations, type of set-up, switchgear etc.).
Inform the manufacturer when damage occurs during the warranty period.
Request the manufacturer to provide service personnel. Tel.: +49 (0) 180/5003274
When determining the cause of a malfunction, or when rectifying the

malfunction, observe the following:
– DIN VDE 0105,

– Accident prevention regulations, VBG 1, VBG 4!
Ensure that the machine is switched so as not to be live.
Lock it against reactivation and designate such by placing a warning

sign next to the activation switch.
Earth and short-circuit!
Cover or cordon off any neighbouring parts which are live!
Ensure that the auxiliary circuits, e.g. space heater etc., are switched
so as not to be live.
42
Trouble shooting
6.2 Malfunctions, Electrical
ELECTRICAL MALFUNCTION CHARACTERISTICS

- Motor does not start
- Motor runs, but with difficulty
- Droning noise when starting
- Droning noise during operation
- Droning noise in time to the doubled induction frequency
- Rapid rise in temperature when running without load
- Rapid rise in temperature when running under load
- Rapid rise in temperature of individual winding sectors
POSSIBLE CAUSES OF REMEDIAL MEASURES
MALFUNCTION
l l l l Overload Reduce load
l Interruption of a phase in the feed Check switch and feeds
l l l l Interruption of a phase in the feed Check switch and feeds
after switching on
l l Mains voltage too low,Frequency too Check mains supply state
high
l Mains voltage too high,Frequency Check mains supply state
too low
l l l l l Stator winding connected up wrongly Check the winding circuitry
l l l l l Winding or phase break in the stator Determine winding and insulating
winding resistances; Overhaul after
consulting the manufacturer
l Asymmetry in short-circuit cage Overhaul after consulting the
manufacturer
l wrong direction of rotation of motor Swap the mains connections U and
W
l Insufficient cooling due to dirty Clean the airways,Check seals
airways
l Voltage too high, hence eddy current Do not exceed 105% of the rated
loss too high voltage
43
Trouble shooting
6.3 Malfunctions, Mechanical
MECHANICAL MALFUNCTION CHARACTERISTICS

– Rubbing noise
– Rapid rise in temperature
– Strong vibration
– Bearings overheating
– Bearing noise
POSSIBLE CAUSES OF REMEDIAL MEASURES
MALFUNCTION
l Rotating parts rubbing Determine cause, readjust parts *
l Air feed choked, filter dirty, if applicable, Check airways, clean filter, if necessary,
wrong direction of rotation replace fan *
l Rotor out of balance Uncouple rotor and re-balance *
l Rotor out of true, shaft distorted Consult the manufacturer
l Faulty alignment Align machine group, check coupling
l Driven appliance out of balance Re-balance coupled machine
l Impact from the driven appliance Check the coupled machine
l Noisy gearbox Repair the gearbox
l Resonance with foundations After consultation, alter the rigidity of the
foundations
l Changes in the foundations Determine the cause of the change, if
applicable, eliminate; align machine anew
l Too much grease in the bearings Remove excess grease
l Bearing dirty Clean or renew bearing *
l Ambient temperature > 40°C Use grease which is suitable for high
temperatures*
l l Felt rings pressing on the shaft Replace felt rings
l l Insufficient lubrication Grease according to instructions
l l Bearing corroded Renew bearing *
l l Too little play in the bearing Fit a bearing with more play *
l Too much play in the bearing Fit a bearing with less play *
l Areas of rubbing on bearing track Renew bearing *
l Furrows on the bearing Renew bearing, avoid shocks when the
machine is standing idle
l Coupling pressing or pulling Align the machine more accurately
l Too much belt tension Reduce drive belt tension
l l Bearing twisted or skew Check the bearing hub bore *
* if necessary, inform the manufacturer
44
Repair Instructions
7 Repair Instructions
Only carry out repair work when the machine is standing idle.
Ensure that the machine is switched so as not to be live.

Lock it against reactivation and designate such by placing a warning
sign next to the activation switch.
Cover or cordon off any neighbouring parts which are live!
Ensure that the auxiliary circuits, e.g. space heater etc., are switched
so as not to be live!
Repair activities may only be carried out by qualified personnel who -

based on their training, experience and instruction - have sufficient
knowledge of:
– guidelines and acknowledged technical rules
Such qualified personnel must

– be able to assess the work assigned to them, and to recognise and
avoid possible dangers.
– be authorized by those responsible for the safety of the machine /
plant to carry out the required work and activities.
Repair work carried out within the warranty period requires the prior
agreement of the electrical machine manufacturer.
☞ We recommend that only original replacement parts be used for overhauls.
45
Stipulated Usage in Explosive Areas
8 Stipulated Usage in Explosive Areas
• Electrical machines for the use of device group II

for category 2 (zone 1) or group II (zone 1):
– Type of ignition protection Ex II2 G EEx e II (EN 50014/50019)
or EEx e II T.
• Electrical machines for the use of device group II

for category 3 (zone 2) or group II (zone 2):
– Suitability for use in zone 2 under VDE 0165
– Type of ignition protection EEx nA II EN 50021 (IEC 79-15)

for category 2 (zone 1)
With regard to explosion-protected low voltage machines fitted with short-circuit rotor
of the ignition protection type „Raised Safety e“ in accordance with EN 50014/50019,
the following is valid as a supplement to the operating manual:
☞ The machines may be used in explosive spaces and operating plant in

accordance with the stipulations laid down by the responsible monitoring body
(for ignition protection type and temperature class ® rating plate)
The competent supervisor official is responsible for establishing the degree of
explosion danger posed by an operating site.
8.1.1 Assembly
☞ When assembling machines which are explosion protected observe the

safety requirements, instructions and descriptions contained in chapter
4 „Assembly and Commissioning“.
46
8.1.2 Installation
For national installation, i.e. installation within the area of jurisdiction of VDE
requirements, observe the following requirements and ordinances:
– DIN EN 60079 or DIN VDE 0165 - ‘Establishment of electrical installation in
explosive areas’ and
– ElexV or ExVO - „Ordinance on electrical Plant in Areas with a Risk of
Explosion“
For installation in other countries the respective relevant national regulations are
applicable.
Machines fitted with external fans should be installed so that the inflow
and outflow of cooling air is not obstructed.
For a position than horizontal, prevent solid objects from falling into the
ventilation aperture install a suitable cover.
In construction forms with a shaft end pointing downwards, a protective

cover must have been fitted on the ventilation opening in the factory.
8.1.3 Connection
Compare the mains voltage with the data on the rating plate. Adapt the dimensions
of the connection cables to the rated amperage under DIN VDE 0100 and while
observing the ambient temperature. Connect machines according to the wiring
diagram inside the connection cabinet.
Freely arrange the connection leads in the terminal box, so that the earth lead is
longer than the others and that the insulation of the feeds is not damaged.
Insulate the cable ends so that the insulation reaches the terminal itself (≤ 5mm).
Use form-flush securing elements or industrial stickers to protect allowed pipe
entries against rotation. Standardly supplied entry-screw connections may only be
used with permanently installed pipes.
Stop up any unused cable feeds apertures with the special plugs provided.
47
8.1.4 Protective Measures against Impermissible Heating
Protect each machine against impermissible heating on all phases by using a

current-dependent cut-out switch or equivalent device corresponding to
DIN EN 60439-5. When used on electrical machines the protective device should
be set to the rated current so that the current will also be switched off (within the tE-
time period specified for the respective temperature class) if the rotor is blocked.
This requirement is considered to be fulfilled if the trigger time, which can be
deduced from the characteristic trigger curve (initial temperature 20°C) for the
I
relationship A/IN, is no greater than that heating time tE specified for the relevant
temperature class.
Protect ∆-connection windings against phase failure. To do this connect the trigger
or relay in series with the winding strands and set to 0.58 of the rated current. If
such a wiring arrangement is not possible, then additional protective measures
are required besides the use of cut-out switches.
Protecting the windings solely by means of direct temperature monitoring (using
temperature sensors) is only permissible if this has been specially authorized and
is specified on the rating plate.
The thermal engine protection comprises temperature sensors under DIN 44081
or DIN 44082, guaranteeing the explosion protection only in connection with
activation devices, allowed by a testing body accredited in the EU and bearing test
mark (e.g.) PRB 3.53 - PTC/A.
Pole-reversible engines for each speed-count stage require separate, mutually
locked, approved protective devices.
Unless otherwise certified, the electrical machines may only be used for continu-
ous operation and only for normal, infrequently repeated commissionings, in
which no appreciable commissioning heating occurs.
Use a starter monitor to protect electrical machines which start slowly (starting time
>= 1.7 • tE - time) in accordance with the information of the conformity or construc-
tion-sample test certificate.
Should the certificate number of an explosion-protected machine be supple-
mented by a „B“ or an „X“, then special measures are to be carried out in corre-
spondence with the test certificate.
48
8.1.5 Maintenance and Repair
☞ When repairing and maintaining explosion-protected machines observe

the safety requirements, instructions and descriptions contained in
chapters „5 Maintenance“, and „7 Repairs“!
When maintaining, repairing and / or altering plant where there is a risk

of explosion, observe the requirements of the „Ordinance on electrical
Plant in Areas with a Risk of Explosion“ (ElexV or ExVO)!
Maintenance or repair affecting the explosion protection (especially all repair
activities to the stator and rotor coils, terminals and ventilation system) should be
carried out by the manufacturer.
When carrying out maintenance, repair or adjustment activities, designate the
machine by means of an additional shield, on which
– date,
– company carrying out the work and
– type and extent of the maintenance, repair or alteration.
In addition, this work must be inspected by a recognized expert and then
authorized by his written confirmation of checking.
8.1.6 Spare Parts
With the exception of standard, off-the-shelf parts (roller bearings etc.), only
original replacement parts may be used.
Please note chapter „9 Spare Parts“, when ordering parts.
49
8.2 Electrical machine for the use of device group II

for category 3 (zone 2)
Explosion-protected 3-phase asynchronous machines with short-circuit rotor of

ignition-protection type EEx nA II under EN 50021 (IEC 79-15). Suitability for the
use of device group II for category 3 is governed by the following supplement to
the operating manual:
☞ The machines may be used in explosive spaces and operating plants in

accordance with the stipulations laid down by the responsible monitor-
ing body (for ignition protection type and temperature class ® rating
plate)
The competent supervisor official is responsible for establishing the degree of
explosion danger posed by an operating site.
8.2.1 Assembly
☞ When assembling machines which are explosion protected observe the

safety requirements, instructions and descriptions contained in chapter
4 „Assembly and Commissioning“.
8.2.2 Installation
For national installation, i.e. installation within the area of jurisdiction of VDE
requirements, observe the following requirements and ordinances:
– DIN EN 60079 or VDE 0165- „Setting up electrical Plant in Areas
with a Risk of Explosion“ and
– ElexV or ExVO - „Ordinance on electrical Plant in Areas with a
Risk of Explosion“
For installation in other countries the respective relevant national standards and
regulations governing set-up are applicable.
Machines fitted with external fans should be installed so that the inflow
and outflow of cooling air is not obstructed.
For a position other than horizontal, prevent solid objects from falling
into the ventilation aperture install a suitable cover.
Models equipped with a downward-facing shaft end are already fitted with
a protective cover over the ventilation aperture by the manufacturer.
50
8.2.3 Connection
Compare the mains supply voltage with the specifications given on the rating
plate. Power cable dimensions should accord to VDE 0100 and be suitable for the
rated current strength taking into account an ambient temperature.
Connect up the machines in accordance with the circuit diagrams located in the
terminal box.
Freely arrange the connection leads in the terminal box, so that the earth lead is
longer than the others and that the insulation of the feeds is not damaged. Clamp
the cable ends in such a way that the minimum air gaps are maintained.
Use form-flush securing elements or industrial stickers to protect allowed power
entries against rotation. Standardly supplied entry-screw connections may only be
used with permanently installed pipes.
Unused cable-entry opening must be closed off by plugs that are allowable for the
purpose.
8.2.4 Protective Measures against Impermissible Heating
Protect each machine against impermissible heating on all phases by using a

current-dependent cut-out switch or equivalent device corresponding to VDE 0660.
When used on electrical machines the protective device should be set to the rated
current so that the current will also be switched off (within the tE-time period
specified for the respective temperature class) if the rotor is blocked.
This requirement is considered to be fulfilled if the trigger time, which can be
deduced from the characteristic trigger curve (initial temperature 20°C) for the
I
relationship A/IN, is no greater than that heating time tE specified for the relevant
temperature class.
Protect ∆-connection windings against phase failure. To do this connect the trigger
or relay in series with the winding strands and set to 0.58 of the rated current. If
such a wiring arrangement is not possible, then additional protective measures
are required besides the use of cut-out switches.
Protecting the windings solely by means of direct temperature monitoring (using
temperature sensors) is only permissible if this has been specially authorized and
is specified on the rating plate.
51
The thermal engine protection comprises temperature sensors under DIN 44081
or DIN 44082, guaranteeing the explosion protection only in connection with
activation devices, allowed by a testing body accredited in the EU and bearing test
mark (e.g.) PRB 3.53 - PTC/A.
Pole-reversible engines for each speed-count stage require separate, mutually
locked, approved protective devices.
Unless otherwise certified, the electrical machines may only be used for continu-
ous operation and only for normal, infrequently repeated commissionings, in
which no appreciable commissioning heating occurs.
Use a starter monitor to protect electrical machines which start slowly (starting time
>= 1.7 • tE - time) in accordance with the information of the conformity or construc-
tion-sample test certificate.
Should the certificate number of an explosion-protected machine be supple-
mented by a „B“ or an „X“, then special measures are to be carried out in corre-
spondence with the test certificate.
8.2.5 Maintenance and Repair
☞ When repairing and maintaining explosion-protected machines observe

the safety requirements, instructions and descriptions contained in
chapters „5 Maintenance“, and „7 Repairs“!
When maintaining, repairing and / or altering plant where there is a risk

of explosion, observe the requirements of the „Ordinance on electrical
Plant in Areas with a Risk of Explosion“ (ElexV or ExVO)!
Maintenance or repair affecting the explosion protection (especially all repair
activities to the stator and rotor coils, terminals and ventilation system) should be
carried out by the manufacturer.
When carrying out maintenance, repair or adjustment activities, designate the
machine by means of an additional shield, on which
– date,
– company carrying out the work and
– type and extent of the maintenance, repair or alteration.
In addition, this work must be inspected by a recognized expert and then
authorized by his written confirmation of checking.
52
8.2.6 Spare Parts
With the exception of standard, off-the-shelf parts (roller bearings etc.), only
original replacement parts may be used.
Please note chapter „9 Spare Parts“, when ordering parts.
53
Spare Parts
9 Spare Parts
9.1 Order Details
☞ Be sure to specify the electrical machine type and number (→ rating plate)
and give a precise description of the part (part number if applicable) when
ordering spare parts.
When ordering replacement bearings, take note not only of the bearing
type but also the engraved symbol which gives the bearing model (this can
be read off from the fitted bearing, e.g. C3 or C4)!
9.2 Exploded View, IP55, Model Size 180M-315L

1 Sealing ring DS, outer or labyrinth seal
2 Bearing shield DS
3 Grease nipple
4 Compensating washer
5 Spring clip, DS and shaft nut
6 Collar oiler DS
7 Roller bearing DS
8 Sealing ring DS, inner
9 Bearing cover, DS inner
10 Stator housing IMB3 with plates and winding
11 Terminal box, complete
12 Rotor with plates and winding
13 Key
14 Bearing cover NS, inner
15 Sealing ring NS, inner
16 Roller bearing NS
17 Circlip for NS bearing
18 Collar oiler NS
19 Spring clip NS and shaft nut
20 Bearing shield NS
21 Bush
22 Lubricating pipe
23 Sealing ring NS, outer or labyrinth
24 Fan
25 Circlip for fan
54
Spare Parts
26 Securing angle-plate
27 Fan hood
28 Flange bearing shield
29 Stator housing without mounting feet, compl.
11
30 Fan hood with protective cover
10
9
8
7
6
3 5
4
2
3
1
27
24 25
21 23
22
20
19
18
17
16
15 26
14
30
12
13 11
29
3
28
Diag. 16: Exploded view, IP55, model size 180M-315L.
55
Instructions for Electrical machines Which Are To Be
Stored
10 Instructions for Electrical machines Which Are To Be Stored
☞ Electrical machines which will be stored for long periods of time before use
are to be dealt with as follows:
10.1 Storage Site

Store the machine (complete with its transportation packing) in a dry place which can
be heated and which is free from shock, and protect it from mechanical damage.
After long periods of standing (more than 1 year) check the bearings for
corrosion damage. Even the smallest amount of corrosion damage can
reduce the bearing’s serviceable life.
10.2 Securing the Machine for Transportation

If the electrical machine is fitted with cylindrical roller bearings, fix the rotor by
means of a suitable transportation securing device (for protection against scoring
of the rotor by shock see chapter 3.3).
If the electrical machines are despatched on vibration dampers, then they should
not be removed during the period of standing.
If drive sprockets, couplings etc. are already assembled onto the shaft ends, then
fit the transportation securing devices where possible or place the machine onto
vibration dampers.
Any further transportation should only be carried out using transportation

securing devices or by placing the machine onto vibration dampers.
56
Stored
10.3 Checks before Commissioning
10.3.1 Bearings
After long periods of standing (> 1 year) check the bearings. For dismantling and
assembly of the bearings → pages 28-40.
The slightest corrosion damage will considerably reduce the lifespan of

the bearing.
The specifications for type / amount of grease can be taken from the rating
plate or lubricating plate (on the electrical machine). Observe the specifica-
tions given in the operating instructions on page 26, Bearing Lubrication,
Lubricants. The measures specified above can be ignored if the period of
standing has been relatively short (< 1 year) and storage has been carried
out in the proper manner.
10.3.2 Insulating Resistance
All work on the electrical machine’s electrical connections may only be

Do not touch the connection terminals either during or after measure-

ment. The connection terminals can carry high-voltages! After check-
ing, earth the connection terminals for a short time (5 seconds).
• Using a hand generator (max. DC voltage = 630V), measure the insulating

resistance of each individual phase to earth continuously until the measured
value is constant.
☞ The insulating resistance of new windings is > 100 MΩ. Dirty and damp
windings demonstrate considerably lower resistance values.
57
Stored
A coil is regarded as sufficiently dry and clean if the insulation resistance at 75 °C
is at least 1MW je 1kV (see table).
If the values drop below the table values, the coil must be dried or cleaned. The
coil temperature must not exceed 75 °C.
Rated voltage Windings temperature Operational

when cold temperature
UN 15°C 25°C 35°C 75°C

0,5 kV 30 M 15 M 8M 0,5 M
1,0 kV 60 M 30 M 15 M 1,0 M
Dry the coil using the space heater or another heater or by applying an
alternating voltage of 5-6% of the rated voltage (make a delta circuit) to the
stator connection clamps U1 and V1.
☞ Insulation resistance values are temperature dependent. Guide values: a

coil temperature increase or decrease of 10 k leads to the insulation
resistance value being halved or doubled.
Remove the condensate water plug before drying the coil. Reclose it tightly once
the condensate water openings have been dried.
58
SCH 12.01 / S7.4.2 en
SCHORCH Elektrische Maschinen und Antriebe GmbH

Breite Straße 131
D-41238 Mönchengladbach
Telefon +49 (0) 2166-925-0
Telefax +49 (0) 2166-925-100
E-mail: mail@schorch.de
Internet: http://www.schorch.de
JUPITER 2200
5.3. V-belts

optibelt
Products & Applications
Installation
& Maintenance
www.optibelt.com
Problem –
Cause –
Remedy
Drive solutions
with Optibelt products
Installation and
Maintenance Instructions
Safety: Before the beginning of any maintenance work, make sure that all
machine components are in a safety position and that they cannot be
changed during maintenance work. The safety instructions of the machine
manufacturers must be observed.
optibelt KS V-grooved pulleys with taper bushes

The V-grooved pulleys are to be checked for damages and correct execution before
the initial installation.
Taper bushes, tightening torques for screws

Size Key Number Tightening
width of screws torque
(Nm)
TB 1008, 1108 3 2 5.7
TB 1210, 1215, 1310, 1610, 1615 5 2 20.0
TB 2012 6 2 31.0
TB 2517 6 2 49.0
TB 3020, 3030 8 2 92.0
TB 3525, 3535 10 3 115.0
TB 4040 12 3 172.0
TB 4545 14 3 195.0
Horizontal alignment of shafts

Motor and machine shafts may have to be aligned with a machine spirit level.
Note!
Maximum shaft deviation 0.5°
Vertical alignment of V-grooved pulleys

The alignment of the V-grooved pulleys is to be checked before and after the tighening
of the taper bushes by means of a guide rail.
Note!
Check whether the pulley face width of the V-grooved pulleys is evenly dimensioned. A
possible existing deviation of the pulley face width has to be taken into consideration
correspondingly. With a symmetrical pulley face construction the distance to the guide
rail to the smaller face width is half of the deviation.
2
Installation and
Maintenance Instructions
Note: These installation and maintenance instructions apply with

appropriate modifications also to Optibelt timing belts and ribbed belts.
For details see corresponding technical manuals.
Initial installation
V-belts should be installed without using force. Installation using screwdrivers, crow-
bars etc. causes internal and external damage to the belt. V-belts installed by force
may in some instances only work for a few days. Correct installation of the belt saves
time and money.
If installation allowance is limited, it may be necessary to fit the belts to the pulleys
and then attach them to the shafts.
Belt tension
Belt tension values should follow Optibelt recommendations. Align the motor parallel
up to the stated belt tension. Carry out several belt revolutions and check static belt
tension again. Experience has shown that belt tension needs to be checked again after
0.5 to 4 hours and then corrected, if necessary. For further information on tensioning
gauges and how to use them see page 5.
Permissible shaft misalignment Pulley

diameter
Maximum permissible
centre distance
After tightening to the correct initial installation dd1, dd2 X1, X2
tension, the distances X1 and X2 between the two 112 mm 0.5 mm
pulleys dd1 and dd2 and the guide rail at shaft 224 mm 1.0 mm
level should be measured. The distances measured 450 mm 2.0 mm
should ideally fall below the maximum permissible 630 mm 3.0 mm
values for the distance X from the table, depen- 900 mm 4.0 mm
1100 mm 5.0 mm
ding on the pulley diameters dd. According to 1400 mm 6.0 mm
pulley diameter, the interim values for X are to be 1600 mm 7.0 mm
interpolated.
Inspections
We recommend that the drive should be inspected regularly, e.g. after 3 to 6 months.
V-grooved pulleys should be checked for wear and tear and overall condition. As an
aid, you are advised to use the Optibelt section and pulley groove template.
** section and pulley groove template **

3
Installation and Maintenance Instructions
V-Grooved Pulleys with Taper Bushes
Installation
1. All shiny surfaces such as bore and
end envelope of cone of the taper
bush as well as conical bore of the
pulley should be clean and free
of grease. Fit the taper bush into
the hub and align with all holes.
The half-tapped holes should be
aligned with the half plain bored
holes.
2. Stud screws (TB 1008-3030) or

fillister head screws (TB 3525 to
5050) should be slightly oiled and
screwed in but not fully tightened.
5. Using a socket wrench according to DIN 911, tighten the stud
3. Clean and degrease the shaft. Position the pulley with the taper screws or the fillister socket screws evenly to the torque values
bush in the correct place on the shaft. See information about given in the table below.
V-grooved pulley alignment.
6. After a short run (0.5 to 1 hour), check the tightening torque
values of the screws and tighten if necessary.
4. If a key is used, place this first into the keyway of the shaft.
Make sure there is a tolerance between the key and the bore 7. Fill the empty bush bores with grease to prevent foreign matter
keyway. from entering.
Installation
Size Size
TB 1008-3030 TB 3525-5050
When V-grooved pulleys with taper bush are being replaced, the following points should be noted:
1. Loosen all screws. According to bush size, completely unscrew one or two screws,
grease them and screw them into the proof test bores.
2. Tighten the screw or screws evenly until the bush comes out of the hub and the pulley
can move freely on the shaft.
3. Remove pulley with bush from the shaft.
Belt tension
Size Size
TB 1008-3030 TB 3525-5050
4
Belt Tension
optibelt Tension Testers
Optibelt Optikrik tension gauges optibelt TT 3

frequency
tension
rubber finger loop pressure pad
pocket clip tester
indicator arm
V-belt
pressure spring
This gauge serves as a simplified method Instructions for use

of reading off the belt tension. 1. The gauge is placed in the middle
This simplified tensioning method should between the two pulleys on the back
be used for example when technical data of the belt, in the case of belt sets ide-
are not known and, therefore, the opti- ally on the centre belt. (First, press the
mum tension cannot be calculated. The indicator arm fully onto the scale.)
diameter of the smaller driver pulley and 2. Lay the gauge loosely on the belt to
the belt section have to be determined be measured and press a finger slowly
only. onto the pressure surface.
The Optibelt tension gauge is used to 3. Try not to touch the gauge with more
read off the belt tension. By reducing or than one finger during the measuring
increasing the belt tension the desired process.
value can be obtained. 4. Once you hear or feel a definite click,
For different tension values, Optikrik 0, immediately release pressure and the
I, II, III with corresponding measurement indicator arm will remain in the meas-
ranges are available. ured position.
5. Carefully lift the gauge without moving
the indicator arm. Read off the belt
tension (see diagram). Read off the
measurement at the exact point where
the top surface of the indicator arm
crosses the scale.
6. Reduce or increase the belt tension ac-
cording to the measurement result until This optibelt TT 3
it is within the desired tension level. frequency tension tester is used
for tension checking of drive
belts by means of frequency
measurement. Measurements
are in Hertz (Hz).
When belt parameters are
entered, tension is indicated in
Newton (N).
Advantages of the tester:

● Non-contact, repetition sure
measurement
● Large measurement range
from 10-600 Hz
● High accuracy of measurement
● Quality assessment
of the measurement results
● Storage in a data base
● Easy to use
● Universal measuring head for
comfortable measuring
● Data communication via PC
5
Belt Tension
optibelt V-Belts
Section Diameter of the Static belt tension

small pulley [N]
de RED POWER II Standard SUPER TX M=S

wrapped
Initial New Initial Operation Initial Operation

[mm] installation installation installation after installation after
up existing start-up start-up
new belts belts
≤ 71 250 200 200 150 250 200

SPZ; 3V/9N; > 71 ≤ 90 300 250 250 200 300 250
XPZ; 3VX/9NX > 90 ≤ 125 400 300 350 250 400 300
> 125 *
≤ 100 400 300 350 250 400 300

SPA; > 100 ≤ 140 500 400 400 300 500 400
XPA > 140 ≤ 200 600 450 500 400 600 450
> 200 *
≤ 160 700 550 650 500 700 550

SPB; 5V/15N; > 160 ≤ 224 850 650 700 550 850 650
XPB; 5VX/15NX > 224 ≤ 355 1000 800 900 700 1000 800
> 355 *
≤ 250 1400 1100 1000 800 1400 1100

SPC; > 250 ≤ 355 1600 1200 1400 1100 1600 1200
XPC > 355 ≤ 560 1900 1500 1800 1400 1900 1500
> 560 *
≤ 50 90 70 120 90
Z/10; > 50 ≤ 71 – – 120 90 140 110
ZX/X10 > 71 ≤ 100 140 110 160 130
> 100 *
≤ 80 150 110 200 150

A/13; > 80 ≤ 100 – – 200 150 250 200
AX/X13 > 100 ≤ 132 300 250 400 300
> 132 *
≤ 125 300 250 450 350

B/17; > 125 ≤ 160 – – 400 300 500 400
BX/X17 > 160 ≤ 200 500 400 600 450
> 200 *
≤ 200 700 500 800 600

C/22; > 200 ≤ 250 – – 800 600 900 700
CX/X22 > 250 ≤ 355 900 700 1000 800
> 355 *
* Tension values for these pulleys must be calculated. The tension values (static belt tension) shown are guideline values
when accurate drive data is not available. They are calculated
Tension gauges: for maximum power transmission capability per belt.
Optikrik 0 Range: 70 – 150 N
Optikrik I Range: 150 – 600 N Calculation basis
Optikrik II Range: 500 – 1400 N Wedge belts belt speed v = 5 to 42 m/s
Optikrik III Range: 1300 – 3100 N Classical V-belts belt speed v = 5 to 30 m/s
Procedure Example
1. Look for the applied section in the column. 1. Optibelt V-belt standard section SPZ
2. For this purpose take the smallest pulley diameter in the 2. Smallest pulley diameter in drive 100 mm
drive system. 3. Static belt tension – tension initial installation 350 N
3. You can read the corresponding static tension from the table. 4. Static belt tension – tension in operation 250 N
4. Check static tension with the tension gauge as described.
6
Belt Tension
optibelt Ribbed Belts
Section Diameter Static tension Tmax [N]

of the Initial Operation Initial Operation Initial Operation Initial Operation Initial Operation
small pulley installation after installation after installation after installation after installation after
de start-up start-up start-up start-up start-up
[mm]
4 PH 8 PH 12 PH 16 PH 20 PH
≤ 25 90 70 150 130 250 200 300 250 400 300
PH > 25 ≤ 71 110 90 200 150 300 250 350 300 450 350
> 71 *
4 PJ 8 PJ 12 PJ 16 PJ 24 PJ
≤ 40 200 150 350 300 500 400 700 550 1000 800
PJ > 40 ≤ 80 200 150 400 350 600 500 800 650 1200 1000
> 80 ≤ 132 250 200 450 350 700 550 900 700 1300 1000
> 132 *
4 PK 8 PK 10 PK 12 PK 16 PK
≤ 63 300 250 600 450 700 600 900 700 1200 900
PK > 63 ≤ 100 400 300 800 600 1000 700 1200 900 1500 1200
> 100 ≤ 140 450 350 900 700 1100 800 1300 1000 1600 1300
> 140 *
6 PL 8 PL 10 PL 12 PL 16 PL
≤ 90 800 600 1000 800 1300 1000 1500 1200 1900 1500
PL > 90 ≤ 140 1000 700 1300 1000 1600 1300 1900 1500 2500 1900
> 140 ≤ 200 1100 800 1400 1100 1900 1400 2100 1600 2800 2100
> 200 *
Procedure Example
1. Look for the applied section in the column. 1. Optibelt RB ribbed belt section 4 PJ
2. For this purpose take the smallest pulley diameter in the 2. Smallest pulley diameter in drive db 100 mm
drive system. 3. Static belt tension – tension first installation 250 N
3. You can read the corresponding static tension in the table. 4. Static belt tension – tension after start-up 200 N
4. Check the static tension with the tension gauge as described.
Belt Tension
optibelt Timing Belts
For tension values of Optibelt timing belts please consult the corresponding
technical manuals or contact our engineers from the applications engineering dept.
7
Problems – Causes – Remedies
V-Belts
Problem Possible causes Remedies
Belt breaks after short running Forceful mounting, therefore, Apply unforced mounting according to
period (belt torn) damaging the tension cord instructions
Drive blocked Remove the cause
Ingress of foreign matter Fit a guard
during operation
Drive underdimensioned, Check drive conditions and remachine
insufficient number of belts
Excessive wear on Tension too low Check tension and retension

belt edges Starting torque too high Check drive conditions and remachine
Worn pulley grooves Replace pulleys
Wrong belt/groove section Adjust belt and groove sections
Wrong groove angle Remachine or replace pulleys
Pulleys do not align Allign pulleys
Small pulley diameter below Increase pulley diameter
recommended minimum (new drive design),
use Optibelt special execution or
Optibelt SUPER TX M=S
Belt slips or catches on protruding parts Remove protrusions or realign drive
Cuts and splits Outside idler pulley in use the Note Optibelt recommendations e.g.
at the base of the belt arrangement and diameter of which does increase diameter. Increase size of
(brittleness) not comply with our recommendations existing idler. Use Optibelt RED POWER II
or Optibelt special execution.
Abnormal belt slip Retension drive according to installation
instructions. Check drive conditions and
redesign, if necessary. Redesign using
minimum pulley diameters.
Pulley diameter too small Use Optibelt special execution or
Optibelt SUPER TX M=S.
Ambient temperature too high Ensure good ventilation, protect belts
from direct heat. Use Optibelt XHR
special execution (extra heatresistant) or
use Optibelt SUPER TX M=S or belt with
aramid cord construction.
Ambient temperature too low Warm area surrounding drive and
belt before use. Use Optibelt special
execution.
Chemical influences Protect drive from contamination.
Use Optibelt special execution.
8
V-Belts
Belt swelling or softening Contamination by oil, grease, chemicals Protect drive from contamination.
Use raw edge SUPER TX M=S or special
execution “05”. Clean pulley grooves
with petrol or alcohol before using new
belts!
Belts turn over Wrong belt/groove section Realign belt and groove section
correctly
Pulleys do not align Realign pulleys
Pulley grooves severely worn Replace pulleys
Tension too low Retension drive
Excessive vibrations Use inside idler pulley on drive slack
side or Optibelt KB Kraftbands
Foreign matter in pulley grooves Remove foreign matter and protect drive
Severe belt vibration Drive overloaded (underdimensioned) Check drive conditions and redesign
Centre distance far larger than Reduce shaft centre distance; use inside
recommendations idler pulley on the drive slack side.
Use Optibelt kraftbands.
High shock loads Use Optibelt kraftbands.
Use inside idler pulley.
Use Optibelt special execution.
Belt tension too low Correct tension
Unbalanced V-grooved pulleys Balance pulleys
Belts cannot Allowance of centre distance too low Modify drive to allow more take-up
be retensioned according to Optibelt recommendations
Excessive belt stretching, due to Recalculate drive design and modify
underdimensioned (and overloaded) drive
Wrong belt length Use shorter belt length
Excessive running noise Poor drive alignment Realign pulleys

Belt tension too low Check tension and retension
Drive overloaded Check drive conditions and redesign
if necessary
Uneven belt stretching Worn or badly machined pulley grooves Replace pulleys
Used belts mixed with new belts on the Fit completely new set of belts
same drive
Belts from different manufacturers used on Use belts in sets from one manufacturer
the same drive only – Optibelt S=C PLUS,
Optibelt SUPER TX M=S,
Optibelt RED POWER II
If further problems arise, contact our engineers from the applications engineering dept. Detailed technical data are necessary for specific assistance.
9
Ribbed Belts
Unusual wear and Tension too low Correct tension

tear of ribs
Ingress of foreign matter during operation Fit a guard
Pulleys do not align Align pulleys
Pulleys defective Remachine or replace pulleys
Wrong rib /pulley section Align rib and pulley section
Break of ribbed belts Ribbed belt slips or catches on Remove protruding parts; realign drive
after short running time protruding parts
(belts torn)
Drive blocked Remove cause
Effects of oil, grease, chemicals Protect drive from environmental

influences
Cuts and splits in the ribs Effects of an outside idler pulley Comply with Optibelt recommendations
(brittleness) the arrangement and diameter of e.g. increase diameter; use an inside
which does not comply with our idler pulley on the drive slack side
recommendations
Pulley diameter too small Ensure minimum pulley diameter
Ambient temperature too high Remove source of heat, protect belts from
direct heat. Improve air ventilation
Ambient temperature too low Warm up ribbed belt before use
Abnormal belt slip Retension drive according to installation

instructions. Check drive conditions and
redesign if necessary
Chemical influences Protect drive from contamination
10
Ribbed Belts
Severe vibrations Drive underdimensioned Check drive conditions and modify

if necessary
Shaft centre distance far bigger than Reduce shaft centre distance.
recommendations Install idler pulley on drive slack side.
High shock loads Use idler pulley
Tension too low Correct tension
V-grooved pulleys not balanced Balance pulleys
Ribbed belts cannot be Adjustment allowance of shaft centre Correct range of adjustment according
retensioned distance too small to Optibelt recommendations
Excessive stretching caused by Recalculate drive design and modify

underdimensioned drive
Incorrect ribbed belt length Install shorter ribbed belt length
Excessive running noise Pulleys do not align Align pulleys
Tension too low or too high Check tension
Ribbed belts swelling Effects of oil, fat, chemicals Protect drive from foreign matter
and softening
Clean pulleys with petrol or alcohol
before using new ribbed belts.
11
Timing Belts
Belt teeth shearing off Belt kinked before or during installation Do not kink belts
(belt break) Overloading Install wider belts or larger pulleys
Number of engaging teeth too small Increase diameter of small pulley or
choose wider belts
Foreign matter in the drive Remove foreign matter and
protect drive
Tension too high Correct tension
Severe wear on Incorrect belt tension Correct tension

the tooth edge in use Overloading Install wider belts with higher power
Drive underdimensioned transmission capability / increase size
of timing belt or pulley
Tooth pitch selection error Check section and replace if necessary
Defective timing belt pulleys Replace timing belt pulleys
Unusual wear of sides Incorrect shaft parallelism Realign shafts

of belt Defective flanged pulleys Replace flanged pulleys
Alteration of shaft centre distance Reinforce bearings and/or casing
Excessive lateral run-off Incorrect shaft parallelism Realign shafts

Timing belt pulleys not aligned Realign pulleys
Shock load pressure when belt tension is Reduce belt tension
too high
12
Timing Belts
Excessive wear at the bottom Belt tension too high Reduce tension
of the notches Drive underdimensioned Increase size of timing belts
and/or pulleys
Defective timing belt pulleys Replace timing belt pulleys
Tears in longitudinal direction Defective flanged pulleys Replace flanged pulleys

Belt runs up to the flanged pulley Realign pulleys/shafts; correct tension
Effects of foreign matter during operation Remove foreign matter;
fit protective guard
Cutting error during cutting of sleeve Check cutting adjustment and
sleeve/belt guide setting
Flanged pulleys coming off Timing belt pulleys not aligned Realign timing belt pulleys
Very strong lateral pressure of timing belt Realign shafts
Incorrect installation of flanged pulleys Install flanged pulleys correctly
Excessive running noise Incorrect shaft alignment Realign shafts

Belt tension too high Reduce tension
Pulley diameters too small Increase diameter of pulleys
Overloading of timing belt Increase width of belt or tooth
engagement
Belt width too large at high speed Reduce width of belt by selecting larger
belt sections
13
Timing Belts
Apparent lengthening of belt Storage too soft Correct belt tension;

increase and secure storage firmness
Abnormal wear of Unsuitable working material Use harder working materials

timing belt pulleys Incorrect engagement of teeth Replace timing belt pulleys
Insufficient hardness of surface Use harder material or carry out surface
hardening
Brittleness of Ambient temperature higher than +85 °C Choose extra heat resistant quality
top surface Incompatible radiation Protect or install suitable belt quality
Tears in the top surface Ambient temperature Install cold resistant belt quality
below – 30 °C
Softening of the top surface Effects of incompatible substances Protect or install suitable belt quality
and/or chemicals
14
Problem – Cause – Remedy
Sources of Error
Correct belt arrangement in Belt too big/ Belt section too small/ Worn V-grooved pulley
the V-grooved pulley pulley groove too small pulley section too big
•
•
•
• •
• • • • • • • • •
• •
•
•
Tension too low Installation by force Vertical angle deviation of the Kinked belt
shafts
Aligned pulleys on axially parallel shafts Axial misalignment of pulleys Horizontal angle deviation
of the shafts
The Optibelt offer is aimed exclusively at specialist distributors. Optibelt recommends that its products be used exclusi-
vely according to the instructions in the Optibelt documentations. Optibelt will not be held responsible if the products
are used in any application for which the were not designed or manufactured. Optibelt would also like to point out its
General Terms of Business.
15
Installation, Maintenance and Storage
Drives with Optibelt V-belts that have ● Idler pulleys / guide pulleys ● Light
been correctly installed in terms of ge- Idler pulleys and guide pulleys are to V-belts should be protected from light,
ometry and performance guarantee be avoided. If they have to be used, especially from direct sunlight and
high operational safety and maximum the recommendations of our manual from strong artificial light with a high
durability. must be followed. ultra-violet content (ozone formation),
Practice has shown that unsatisfactory e.g. naked neon tubes. The ideal form
service life is often caused by installa- ● Maintenance of lighting is with normal light bulbs.
tion and maintenance errors. In order to We recommend regular checks of the
prevent these, we recommend that you V-belt drives. This includes checking ● Ozone
carefully follow the below mentioned in- the tension and, if necessary, correct- To counteract the harmful effects of
stallation and maintenance instructions: ing it. If in the case of multi-groove ozone, the store-rooms must not con-
drives one or more V-belts fail, a new tain any ozone-producing items e.g.
● Safety V-belt set must be mounted. V-belts fluorescent light sources, mercury
Before the beginning of any mainte- from different manufacturers must not vapour lamps, high-voltage electri-
nance work, make sure that all ma- be combined to form a belt set. Before cal equipment etc. Combustion gases
chine components are in a safety posi- mounting new V-belts, the condition of and vapours that can cause the
tion and that they cannot be changed the V-belt pulleys must be checked. production of ozone as a result of
during maintenance work. The safety Optibelt V-belts do not require any photo-chemical processes should be
instructions of the machine manufac- special care. Belt wax and belt spray avoided or eliminated.
turers must be observed. should not be used.
● Pulleys ● Dampness
The grooves must be produced accord- ● Storage – general Damp store rooms are unsuitable.
ing to standard and must be clean. Correctly stored V-belts maintain their Efforts should be made to ensure that
quality and properties over a period no condensation occurs. The relative
● Alignment of several years (also see DIN 7716). air humidity should ideally be under
Shafts and pulleys must be correctly In unfavourable storage conditions 65 %.
aligned before installation. and when incorrectly treated, most
We recommend that the maximum rubber products change their physi- ● Storage
deviation of the pulley alignment cal properties. Such changes can be V-belts should be stored without ten-
should not exceed 1/2°. caused for example by the effects of sion, i.e. without pulling, pressure or
oxygen, ozone, extreme tempera- other deformations, as tension and
● Multi-groove drives tures, light, dampness or solvents. permanent deformations can lead to
V-belts for multi-groove drives must formation of cracks.
usually be measured in sets. The belt ● Store-room If V-belts are placed on top of each
set tolerance according to the valid The store-room should be dry and free other, it is advisable not to exceed a
standard should be noted here. Opti- of dust. stacking height of 300 mm in order to
belt S=C PLUS and Optibelt SUPER TX V-belts should not be stored together avoid permanent deformations. If for
M=S V-belts, however, can be com- with chemicals, solvents, fuel, lubri- reasons of space the belts are sus-
bined into sets without measuring. cants, acids etc. pended, the diameter of the mandrel
should be at least 10 times the height
● Installation of the V-belts of the belt.
Before installation, the shaft centre ● Temperature In the case of
distance is to be reduced so that the The recommended storage tempera- optibelt S=C PLUS,
belts can be placed in the grooves ture should be +15 °C to + 25 °C. optibelt RED POWER II and
without force. Forced installation Lower temperatures do not generally optibelt SUPER TX M=S,
using crow-bars, screwdrivers etc. is cause damage to V-belts. However, there is no need to store
not permitted under any circum-stanc- as they become very stiff as a result of in sets as these belts can be
es, as this damages – often not visible cold, they should be brought up to a combined into sets without
– the high-quality, low-stretch tension temperature of about + 20 °C before measuring.
cord or the cover fabric. operation. This will help to prevent
breaks and tears. ● Cleaning
● Belt tension Radiators and radiator pipes should Cleaning of dirty V-belts should be
After the calculated shaft loading has be screened. The distance between done with a glycerine-spirit mixture
been obtained, the tension of the belts the radiators and the stored goods in the proportion of 1 : 10. Petrol,
should be checked. We recommend must be at least 1 m. benzene, turpentine etc. should not
that you use our Optibelt tension gaug- be used. Sharp-edged objects, wire
© Arntz Optibelt Gruppe 317221/0607Hux
es for this purpose. The drive should brushes, sandpaper etc. should not be
be observed during the first hours of used under any circumstances as this
operation, and experience shows that can cause mechanical damage to the
it will need to be retensioned after V-belts.
running for a period from 0.5 to 4
hours under full load. This restores
tension to the original level.
Optibelt GmbH
P.O. Box 10 0132 • D-37669 Höxter/Germany • Tel. +49 (0) 52 71 - 6 21 • Fax +49 (0) 52 71 - 9762 00
info@optibelt.com • www.optibelt.com
16
JUPITER 2200
5.4. Safety clutch

JUPITER 2200
5.5. Central lubrication

User’s Manual
Operating Instructions and Service Parts List
1.1A-78001-A96
Central Lubrication Pumps Helios Junior
1184a96
Subject to modifications
Page 1 of 7
ss.LUBAC*Lindaustr. 28*A 4820 Bad Ischl*Tel.:++43(06132)23741*Fax++43(06132)25237*info@sslubac.com

User’s Manual
1.1A-78001-A96
• Before putting the pump into operation, read carefully these operating instructions
• Observe the safety instructions
• Keep these operating instructions on the site where the pump will be in operation.
Safety Instructions Appropriate Use

The central lubrication pump type Helios Junior (HJ) is a hand-
operated high-pressure pump used for the supply of lubricating
greases in centralized lubrication systems.
The maximum values mentioned in the technical data must not
be exceeded.
Technical Data
• All the components of the connected centralized lubrication
system must be designed for maximum system pressure. Type HJ2 HJ2A
• Repairs may only be carried out by qualified, skilled person- Number of outlets: 1 2
nel using only original spare parts. Lubricant output per lever
movement: 2 cm³ 2x1 cm³
• Do not touch internal parts of the reservoir while the pump is Operating pressure: 300 bar
in operation. Max. pressure: 500 bar
Hand force at max. pressure: 300 N
• Refill the pump reservoir in time with clean lubricant. Suitable lubricants: grease up to NLGI-
grade 3
• The manufacturer is not liable for damages due to inadequa- acc. to DIN 51818
te handling. (as a function of the ambient temp.)
Threaded connection: G 1/4"
Pump types Reservoir capacity: 3 dm³
(all types have a 3-dm³ reservoir): Weight empty: 8,7 kg 8,9 kg
HJ2 L-30 Part. no. 603-40558-3 left-hand hand lever

1 outlet
Accessories
HJ2 R-30 Part. no. 603-40558-4 right-hand lever,
Order the check valves required for the pump outlet separately
1 outlet
and in accordance with the number and diameter of the tube
HJ2AL-30 Part. no. 603-40558-1 left-hand hand lever
line(s):
2 outlets
HJ2AR-30 Part. no. 603-40558-2 right-hand hand lever
Check valve for tube: Ø 6 mm: GERV 6-SG 1/4AVC
2 outlets
Part. no. 223-13052-1
Check valve for tube: Ø 8 mm: GERV 8-L G 1/4AVC
If necessary, the hand lever may be changed from one side to
Part. no. 223-13052-2
the other.
Check valve for tube: Ø 10 mm: GERV 10-LG1/4AVC
Part. no. 223-13052-3
Description of Operation
The central lubrication pump type HJ is equipped with 2 delivery
pistons which are moved forward and backward via a hand le-
ver. As a result, they alternately suck in the lubricant from the
reservoir and dispense it to the outlets. In the case of the HJ
pump the lubricant output of the two pistons is combined to one
outlet.
The lubricant output of 1 cm³ per each lever movement is rea-
ched when a full movement - forward or backward -is carried out
from stop to stop.
The movement of the lever leads to a rotation of the stirring

paddle in the reservoir.
The rotation of the stirring paddle causes the lubricant to be
homogenized, vented and dispensed to the suction boreholes.
Page 2 of 7

User’s Manual
1.1A-78001-A96
Examples of Application
4085a196 4085a96
Fig. 1: HJ2A with 2 outlets, used as a supply pump in a progressive system Fig. 2: HJ2 with 1 outlet, used as a supply pump in a progressive system with one
main metering device
4086a96
Fig. 3: HJ2 witht 1 outlet, used as a supply pump in a small two-line system
Installation and Operating Instructions
Installation site requirements
• even, solid and vibration-free surface

• protected from dust and dirt
• protected against atmospheric influences
• Sufficient space for operating the hand lever and for refilling
the lubricant reservoir
Position of installation: reservoir vertical

Page 3 of 7

User’s Manual
1.1A-78001-A96
Putting into Operation
Before putting the pump into operation, fill the reservoir with lub- • Do not touch the internal parts of the
ricant. grease reservoir while the pump is in
operation.
• Risk of injury due to the stirring paddle.
Attention
• When filling the reservoir, pay attention that no foreign partic- • All the components connected to the sy-
les or dirt enter the reservoir. stem installed downstream of the pump
• Always refill the reservoir in time. and on which the hydraulic pump pressu-
• Avoid contamination in the pump area. re has an influence (e.g. change-over val-
ve, metering devices, tube lines, tube fit-
tings, hoses) must be designed for maxi-
mum system pressure.
Maintenance and Repair
Before undertaking any repair on the

pump, observe the following:
• Loosen the pressure connection fittings • Repairs may only be carried out by qualified, skilled person-
in order to decrease the pressure in the nel using original spare parts.
system. Risk of injury due to lubricant
splashing under out high pressure. • Provided that the pump dispenses only clean lubricant, it does
not need any particular maintenance. Clean and lubricate the
drive parts (swivels) and the ratchet gear, if necessary.
Troubleshooting
• Fault: Pump does not supply lubricant
• Cause: • Remedy:
• Reservoir empty • Refill the reservoir with lubricant and cycle the pump until
grease is dispensed from the pressure line connection
without air bubbles.
• Suction borehole clogged • Check the suction boreholes for foreign particles and
remove them, if any.
• Fault: No pressurization in the system
• Check valve defective or clogged • Replace the check valve
• Pump piston worn • Replace the pump housing assy (item 27)
• Fault: System blocked
• Bearing, lines or progressive metering devices clogged. • Find out the cause of the blockage and eleminate to it:
see: progressive metering device malfunctioning
• Change-over valve malfunctioning • see: change-over valve malfunctioning or description of
system
Page 4 of 7

User’s Manual
1.1A-78001-A96
Dimensioned Drawing HJ2L (HJ2R mirror-image)
4087b96
P1: Pressure connection for all types

P2: Pressure connection for HJ2A
R: Return line connection for HJ2
Page 5 of 7

User’s Manual
1.1A-78001-A96
Spare Parts Drawing
4088b96
Page 6 of 7

User’s Manual
1.1A-78001-A96
Spare Part List
Item. Designation Qty. Part. no.
1 Stirring paddle 1 403-20180-1

2 Reservoir 3 dm³ 1 503-30034-1
3 Bearing pin 10x59 1 403-20172-1
4 Side bar, short 32x12x3 4 403-20171-1
5 Washer Ø 5,3 11 209-13077-3
6 Pin without head Ø4,9x25 5 302-17366-2
7 Retaining washer 11 211-12504-1
8 Side bar, long 73x12x3 2 403-20175-1
9 Spacer sleeve 12x9,8 1 403-20176-1
10 Stud bolt 1 403-20177-1
11 Drive lever 1 403-20169-1
12 Washer B 15,0 1 209-13077-8
13 Retaining washer A15x1 1 211-12164-4
14 Hex. socket head screw M 5x12 3 201-12016-4
15 Hex. socket head screw M 5x8 6 201-12017-6
16 Sealing ring Ø 67 x Ø 83 x 1 1 306-17846-1
17 Tooth lock washer I 5,3 8 210-12161-9
18 Cylinder roller 8 405-24314-1
19 Ratched wheel 1 403-20086-1
20 Drive ring 1 403-20174-1
21 Compression ring 6,4x1x11 8 300-17203-1
22 Brake drum 1 403-20190-1
23 Shaft 1 403-20178-1
24 Feather key 5x5x20 1 214-12174-2
25 Flange 1 403-20168-1
26 Sealing ring Ø 10 x Ø 12 x 1 1 306-18752-1
27 Pump housing assy. HJ2, 1 outlet 1 503-30181-1
Pump housing assy. HJ2A,2 outlets 503-30182-1
28 Hexagon screw M 10 1 207-12136-1
29 Washer 10,0 1 209-12150-3
Page 7 of 7

JUPITER 2200
5.6. Safety data sheets

Page 1/4
Material Safety Data Sheet
According to 91/155 EEC
Printing date 23.03.2006 Reviewed on 23.03.2006
1 Identification of the substance/preparation and of the company/undertaking

· Product details
· Trade name: MICROLUBE GL 261
· Article number: 020195
· Application of the substance / the preparation Grease
· Manufacturer/Supplier:
KLÜBER LUBRICATION MÜNCHEN KG
Geisenhausenerstrasse 7
D-81379 München
Tel.: 0049 (0) 897876-0
Fax: 0049 (0) 897876-333
· Further information obtainable from: Material Compliance Management
· Information in case of emergency: 0011 49 89 7876 700
2 Composition/information on ingredients
· Chemical characterization
· Description:
mineral oil
special lithium soap
UV indicator
· Dangerous components: Void
· Additional information: For the wording of the listed risk phrases refer to section 16.
3 Hazards identification
· Hazard description: Not applicable.
· Information concerning particular hazards for human and environment:
The product does not have to be labelled due to the calculation procedure of the "General
Classification guideline for preparations of the EU" in the latest valid version.
· Classification system:
The classification is according to the latest editions of the EU-lists, and extended by company and
literature data.
4 First-aid measures
· After inhalation: Supply fresh air; consult doctor in case of complaints.
· After skin contact: Wash off with soap and plenty of water.
· After eye contact:
Rinse opened eye for several minutes under running water. If symptoms persist, consult a doctor.
· After swallowing: If symptoms persist consult doctor.
5 Fire-fighting measures
· Suitable extinguishing agents:
Water haze
Foam
(Contd. on page 2)
GB
DR
Page 2/4
Trade name: MICROLUBE GL 261
(Contd. of page 1)
Fire-extinguishing powder
Carbon dioxide
· For safety reasons unsuitable extinguishing agents: Water with full jet
· Special hazards caused by the substance, its products of combustion or resulting gases:
In case of fire, the following can be released:
Carbon monoxide (CO)
Hydrocarbons
· Protective equipment:
Do not inhale explosion gases or combustion gases.
Standard procedure for chemical fires.
· Additional information
Cool endangered receptacles with water spray.
Dispose of fire debris and contaminated fire fighting water in accordance with official regulations.
6 Accidental release measures

· Person-related safety precautions: Not required.
· Measures for environmental protection: Do not allow to enter sewers/ surface or ground water.
· Measures for cleaning/collecting:
Pick up mechanically.
Dispose of the material collected according to regulations.
· Additional information: No dangerous substances are released.
7 Handling and storage

· Handling:
· Information for safe handling: No special measures required.
· Information about fire - and explosion protection: No special measures required.
· Storage:
· Requirements to be met by storerooms and receptacles:
Store in cool, dry conditions in well sealed receptacles.
· Information about storage in one common storage facility:
Store away from foodstuffs.
Store away from oxidizing agents.
· Further information about storage conditions: None.
8 Exposure controls/personal protection

· Additional information about design of technical facilities: No further data; see item 7.
· Ingredients with limit values that require monitoring at the workplace:
The product does not contain any relevant quantities of materials with critical values that have to be
monitored at the workplace.
· Additional information: The lists valid during the making were used as basis.
· Personal protective equipment:
· General protective and hygienic measures:
Immediately remove all soiled and contaminated clothing
Avoid close or long term contact with the skin.
Be sure to clean skin thoroughly after work and before breaks.
· Respiratory protection: Not required.
· Protection of hands: Preventive skin protection by use of skin-protecting agents is recommended.
· Eye protection: Not required.
GB
(Contd. on page 3)
DR
Page 3/4
(Contd. of page 2)
9 Physical and chemical properties

· General Information
Form: Pasty
Colour: Yellow-brown
Odour: Product specific
· Change in condition
Drip point: > 220°C (DIN ISO 2176)
· Flash point: not applicable
· Danger of explosion: Product does not present an explosion hazard.
· Density at 20°C: ~ 0.89 g/cm³
· Solubility in / Miscibility with
water: Insoluble.
10 Stability and reactivity

· Thermal decomposition / conditions to be avoided:
No decomposition if used and stored according to specifications.
· Materials to be avoided: oxidizing agents
· Dangerous reactions No dangerous reactions known.
· Dangerous decomposition products: none under normal use
11 Toxicological information
· Additional toxicological information:
Prolonged skin contact may cause skin irritation and/or dermatitis.
12 Ecological information
· Ecotoxical effects:
· Behaviour in sewage processing plants: The product can be mechanically separated.
· General notes: Do not allow product to reach ground water, water course or sewage system.
13 Disposal considerations
· Product:
· Waste disposal key:
For this product no waste disposal key according the European Waste Catalogue (EWC) can be
determined, as only the purpose of application defined by the user enables an allocation. The waste
code number has to be determined in accordance with the local waste disposer.
· Uncleaned packaging:
· Recommendation:
Empty contaminated packagings thoroughly. They may be recycled after thorough and proper
cleaning.
14 Transport information
· Land transport ADR/RID (cross-border)
· ADR/RID class: -
· Maritime transport IMDG:
· IMDG Class: -
(Contd. on page 4)
GB
DR
Page 4/4
(Contd. of page 3)
· Air transport ICAO-TI and IATA-DGR:

· ICAO/IATA Class: -
· Transport/Additional information:
Not classified as dangerous according to the above specifications.
15 Regulatory information
· Labelling according to EU guidelines:
The product is not subject to classification according to the calculation methods of the "General
Classification Guideline for Preparations of the EU" as issued in the latest valid version.
16 Other information
This information is based on our present knowledge. However, this shall not constitute a guarantee
for any specific product features and shall not establish a legally valid contractual relationship.
· Department issuing MSDS: Material Compliance Management
· Contact: +49(0)897876-1564
GB
DR
SAFETY DATA SHEET
1. Identification of the substance/preparation and of the company/undertaking

Product name Vario HDX
SDS # DE-18758, BE-01103
Product Use Hydraulic fluid. Lubricants.
Supplier Castrol Industrie GmbH

Erkelenzer Straße 20,
D-41179 Mönchengladbach
Germany
Telefon: +49 (0)2161 909-319

Telefax: +49 (0)2161 909-392
EMERGENCY TELEPHONE + 49 (0) 30-19240 (Poison Centre Berlin)
NUMBER
2. Composition/information on ingredients
Highly refined mineral oil and additives.
This product does not contain any hazardous ingredients at or above regulated thresholds.
3. Hazards identification
This preparation is not classified as dangerous according to Directive 1999/45/EC as amended and adapted.
Effects and symptoms
Eyes May cause mild eye irritation.
Skin Prolonged or repeated contact can defat the skin and lead to irritation and/or dermatitis.
Inhalation Inhalation of oil mist or vapours at elevated temperatures may cause respiratory irritation.
Ingestion Ingestion may cause gastrointestinal irritation and diarrhoea.
4. First-aid measures
Eye Contact In case of contact, immediately flush eyes with a copious amount of water for at least 15 minutes. Get
medical attention if irritation occurs.
Skin contact Wash skin thoroughly with soap and water or use recognised skin cleanser. Remove contaminated
clothing and shoes. Wash clothing before reuse. Clean shoes thoroughly before reuse. Get medical
attention if irritation develops.
Inhalation If inhaled, remove to fresh air. Get medical attention if symptoms appear.
Ingestion Do NOT induce vomiting unless directed to do so by medical personnel. Never give anything by mouth to
an unconscious person. If large quantities of this material are swallowed, call a physician immediately.
5. Fire-fighting measures
Extinguishing Media
Suitable In case of fire, use water fog, foam, dry chemical or CO2 extinguisher or spray.
Not Suitable Do not use water jet.
Hazardous decomposition These products are carbon oxides (CO, CO2).
products
Unusual fire/explosion Hazards This material is not explosive as defined by established regulatory criteria.
Special fire-fighting procedures None identified.

Protection of fire-fighters Fire fighters should wear self-contained positive pressure breathing apparatus (SCBA) and full turnout
gear.
Product Name Vario HDX Product Code DE-18758 Page: 1/4
Version 1 Date of issue 31 October 2002 Format Germany Language
( BUILD 5.0 ) ( ENGLISH )

6. Accidental release measures
Personal Precautions Immediately contact emergency personnel. Keep unnecessary personnel away. Use suitable protective
equipment (Section 8). Follow all fire fighting procedures (Section 5).
Environmental precautions and If emergency personnel are unavailable, contain spilled material. For small spills add absorbent (soil may
cleanup methods be used in the absence of other suitable materials) scoop up material and place in a sealed, liquid-proof
container for disposal. For large spills dike spilled material or otherwise contain material to ensure runoff
does not reach a waterway. Place spilled material in an appropriate container for disposal. Minimize
contact of spilled material with soils to prevent runoff to surface waterways. See Section 13 for Waste
Disposal Information.
Personal Protection in Case of a Splash goggles. Full suit. Boots. Gloves. Suggested protective clothing might not be sufficient; consult a
Large Spill specialist BEFORE handling this product.
7. Handling and storage

Handling Wash thoroughly after handling.
Storage Keep container tightly closed. Keep container in a cool, well-ventilated area.
VCI Storage class (Lagerklasse) 10
8. Exposure controls/personal protection

Ingredient Name Occupational Exposure Limits
Highly refined mineral oil ACGIH (United States).
TWA: 5 mg/m3 8 hour(s). Form: Oil mist, mineral
STEL: 10 mg/m3 15 minute(s). Form: Oil mist, mineral
Control Measures Provide exhaust ventilation or other engineering controls to keep the airborne concentrations of vapours
below their respective occupational exposure limits.
Hygiene measures Wash hands after handling compounds and before eating, smoking, using lavatory, and at the end of day.
Personal protective equipment
Respiratory system None required; however, use of adequate ventilation is good industrial practice.
Skin and body Avoid prolonged or repeated contact with skin.
Hands Wear protective gloves if prolonged or repeated contact is likely. Consult your local supplier of personal
protective clothing regarding the choice of material.
Eyes Safety glasses with side shields.
9. Physical and chemical properties

Autoignition temperature >230 °C
Flash point 204 °C (CLOSED CUP)
Explosion Limits LOWER: 0.6 %
UPPER: 6.5 %
Physical state Liquid.
Boiling point / range >250 °C
Density <1 g/cm3 at 20 °C
Vapour pressure <0.75 mmHg
Solubility Insoluble in cold water
Viscosity kinematic at 40°C: 43 cSt
kinematic: 8 cSt at 100°C
10. Stability and reactivity

Incompatibility with Various Reactive with oxidizing agents.
Substances
Hazardous Polymerization Will not occur.

11. Toxicological information
Chronic toxicity
Carcinogenic effects No component of this product at levels greater than 0.1% is identified as a carcinogen by ACGIH, the
International Agency for Research on Cancer (IARC) or the European Commission (EC).
12. Ecological information

Persistence/degradability Inherently biodegradable
Mobility Nonvolatile. Liquid. Insoluble in water.
Environmental hazards Not classified as dangerous.
13. Disposal considerations

Disposal Consideration / Waste Avoid contact of spilled material and runoff with soil and surface waterways. Consult an environmental
information professional to determine if local, regional or national regulations would classify spilled or contaminated
materials as hazardous waste. Use only approved transporters, recyclers, treatment, storage or disposal
facilities.
Unused product
European Waste Catalogue 13 01 10 mineral based non-chlorinated hydraulic oils
(EWC)
Used/contaminated product
European Waste Catalogue 13 01 10 mineral based non-chlorinated hydraulic oils
(EWC)
Packaging
European Waste Catalogue 15 01 10* packaging containing residues of or contaminated by dangerous substances
(EWC)
However, deviation from the intended use and/or the presence of any potential contaminants may require an
alternative waste disposal code to be assigned by the end user.
14. Transport information

Not classified as hazardous for transport (ADR, RID, UN , IMO, IATA/ICAO).
15. Regulatory information

Label Requirements
Risk Phrases This product is not classified according to the EU regulations.
EU Regulations Classification and labelling have been performed according to EU directives 1999/45/EC and 67/548/EEC
as amended and adapted.
Other Regulations
Inventories AUSTRALIAN INVENTORY (AICS): Not determined.
CANADA INVENTORY (DSL): Not determined.
CHINA INVENTORY (IECS): Not determined.
EC INVENTORY (EINECS): In compliance.
JAPAN INVENTORY (ENCS): Not determined.
KOREA INVENTORY (ECL): Not determined.
PHILIPPINE INVENTORY (PICCS): Not determined.
US INVENTORY (TSCA): Not determined.
Additional Warning Phrases Safety data sheet available for professional user on request.
Ordinance on Combustible No.
Liquids (VbF)
Technical instruction on air Class III
quality control

Hazard class for water 1
(WGK)
16. Other information

HISTORY
Date of issue 31/10/2002.
Date of previous issue 01/08/2002.
Prepared by Product Stewardship
Notice to Reader
The information given is based on current knowledge. Products are described in terms of their safety data. The data does not signify any
warranty with regard to the products' properties.
The product should only be used for the stated application or applications. Use of the product for applications other than as stated in the sheet
may give rise to risks not mentioned in this sheet.
Further information relating to the use of the product can be obtained from the technical datasheets.

JUPITER 2200
5.7. Other components

+++++++++++++++++--tm
XS7-C / XS8-C
Inductive proximity sensors / Détecteurs de proximité inductifs XS7/8- C40•C44• XS7/8- C40•P2••
Induktive Näherungsschalter / Detectores de proximidad inductivos
Interruttori di prossimità induttivi / Detectores de proximidade indutivos
DANGER / PELIGRO / DANGER

HAZARDOUS VOLTAGE TENSION PELIGROSA TENSION DANGEREUSE
Disconnect all power Desenergice el equipo Couper l'alimentation avant Listing and Certification :
before servicing equipment. antes de realizarle servico. de travailler sur cet appareil. Applicable on proximity switches
Electric shock will result Una descarga eléctrica Une électrocution
in death or serious injury. podrá causar la muerte entrainera la mort ou bearing the UL and CSA marks only.
o lesiones serias. des blessures graves. Enclosure : Type 12, 4X indoor use only
Mechanical installation XS7/8-C40•C44• XS7/8-C40•P2••

Mise en œuvre mécanique 40/1.57 40/1.57
Mechanische Installation
Instalación mecánica
25/0.98 20/0.79
25/0.98 20/0.79
Messa in opera meccanica 40/1.57
40/1.57
Instalação mecânica
2x5,3 x 7 2x5,3 x 7
mm / in 2x0.2x0.28 2x0.2x0.28
117/4.61
117/4.61
L2 L1 L1
60/2.36
60/2.36
LED LED
2xØ5,3 2xØ5,3
2xØ0.2 2xØ0.2
13P 13P
16/0.63 = 30/1.18 = 16/0.63 = 30/1.18 =

24/0.94 40/1.57 24/0.94 40/1.57
41/1.61 41/1.61
d1
e1 e2 e3
h
Sn e1 ≥ e2 ≥ e3 ≥ d1 ≥, h ≤
XS7-C40 15 / 0.59 40 / 1.57 80 / 3.15 45 / 1.77 40 / 1.57, 40 / 1.57
XS7-C40••••9 20 / 0.79 120 / 4.72 240/ 9.45 60/ 2.36 40 / 1.57, 40 / 1.57
XS8-C40 20 / 0.79 80 / 3.15 160 / 6.30 60 / 2.36 200 / 7.87, 40 / 1.57
XS8-C40••••9 40 / 1.57 160 / 6.30 320 / 12.60 120/ 4.72 200 / 7.87, 40 / 1.57
Head orientation
Orientation de la tête
Ausrichtung des Kopfteils
Orientación de la cabeza
Orientamento della testa
Orientação da cabeça
Te
Te
Te Te Te Te Te
1 2
Installation precautions Indication, Signalisation

Précautions de mise en œuvre Funktionsanzeige, Señalización
Vorsicht bei der Inbetriebnhame Segnalazione, Sinalização
Precautión de instalatión
Consigli di messa in opera XS7/8-C
Precaução de instalação NO L1
NC L1
HT L1 L1
W914119180111 A08 1/2
XS7/8-C•C44•
GN YW
≥ 100 / 3.94 L2 L1
Power Output
HT
YW/L1 Yellow Jaune Gerb Amarillo Giallo Amarelo

GN/L2 Green Vert Grün Verde Verde Verde
MIT detection Tome 1 / chap. 6 / page 1 12/2001
+++++++++++++++++--tm
XS7-C / XS8-C
Electrical installation XS7/8-C40PC440/449 XS7-C40KPM40 XS7/8-C40D•210 XS7/8-C40MP230 (*) XS7/8-C40FP260 (*)
Mise en œuvre électrique + 1(NO), 3(NC) 5 +/– 5 XUZ-E08 5 XUZ-E08
Elektrische Installation 1 +
4 (NO) 2
Instalación eléctrica PNP PNP
Messa in opera elettrica 2 (NC) 4
6 –/+ 6 6
Instalação elétrica –
3
– 3(NO), 1(NC)
NO NO NO NO NO NO
XS7/8-C40NC440/449
2 x 1,5 mm2 + 1(NO), 3(NC)
4 Max. 1 NC NC NC NC NC NC
8 +
3 NPN NPN
7 4 (NO) 2
2
2 (NC)
1 6 3 4 –
5 – 3(NO), 1(NC)
Voltage limits (1) a 10...58 V a 10...38 V a 10...58 V z 20...264 V c 20...264 V

Load switching capacity (2) 0...200 mA 0...200 mA 1,5...100 mA a 5...200 mA, 5...500 mA
c 5...300 mA
Voltage drop (3) ≤2V ≤ 2,6 V ≤4V ≤ 5,5 V ≤ 5,5V
Leakage current (4) – – ≤ 0,5 mA ≤ 0,8 mA / 24 V, ≤ 1,5 mA
≤ 1,5 mA / 120 V
Current consumption (5) ≤ 10 mA ≤ 15 mA – – –
Operating temperature - 25 ... + 70 °C / 0 ... + 50 °C / - 25 ... + 70 °C /

Température de fonctionnement - 13 ... + 158 °F - 32 ... + 122 °F - 13 ... + 158 °F
Betriebstemperatur
Temperatura de funcionamiento
Temperatura di funzionamento
Temperatura de funcionamento
(1) Limite de tension / Betriebsspannung / Límites de tensión / Limiti di tensione / Limites de tensão (*) Without shor t circuit protection
(2) Courant commuté / Schaltstrom / Intensidad conmutada / Corrente commuta / Corrente comutada Non protégés court-circuit
(3) Tension de déchet / Spannungsfall (Ausgang durchgesteuert) / Tensión residual / Caduta di tensione / Tensão de defeito Ohne Kurzschlußschutz
(4) Courant résiduel / Reststrom (Ausgang gesperrt) / Intensidad residual / Corrente residual / Corrente residual No proteción cortocircuito
(5) Courant consommé / Leerlaufstrom / Intensidad consumida / Corrente consumata / Corrente consumida Non protetto corto-circuito
Não protecção curto-circuito
Programmable NO / NC
Programmation NO / NC
Programmierbar NO / NC
Programable NO / NC NO NO
Programmabile NO / NC
Programáveis NO / NC
NC NC
NO
NC
NO
NC
W914119180111 A08 2/2
12/2001 MIT detection Tome 1 / chap. 6 / page 1

Inductive proximity switches
IGM201
IGK3012-BPKG/M/US
Metal thread M18 x 1
Plug and socket
Increased sensing range

gold-plated contacts
e1 type approval
Sensing range 12mm [nf]

non-flush mountable
Electrical design DC PNP

Output normally open
Operating voltage [V] 10...36 DC

Current rating [mA] 100
Short-circuit protection pulsed
Reverse polarity protection yes
Overload protection yes
Voltage drop [V] < 2.5
Current consumption [mA] < 10
Certain sensing range [mm] 9.72

Environmental Inspection Rating Vibration Test (EN 60068-2-6 Fc):
20 g acceleration; from 10 to 3000 Hz at -20 °C and 50 °C; 50 cycles per
frequency; 1 octave per minute in each of 3 mutually perpendicular axes.
Shock Test (EN 60068-2-27 Ea):

100 g acceleration; 11 ms half sine wave pulse shape with 3 shocks in each
direction along the three coordinate axis at -40 °C and 85 °C.
Continuous Shock Test (EN 60068-2-30 Eb):

40 g acceleration; 6 ms with 4000 shocks in any direction along the 3
coordinate axis at -20 °C and 50 °C.
Rapid Temperature Change Test (EN 60068-2-14 Na):

Sensor is alternately put in -40 °C environment for 30 minutes and 85 °C
environment for 30 min. The tranfer between environments must occur in less
than 10 seconds. Test is repeated for 50 cycles.
Salt Spray Test (EN 60068-2-52 Kb):

Severity level 5 (4 test cycles)
Real sensing range [mm] 12 ± 10 %
Switch-point drift [% / Sr] -10...10
Hysteresis [% / Sr] 1...20
Switching frequency [Hz] 200
mild steel = 1 / stainless steel approx. 0.7 / brass approx. 0.5 / Al approx. 0.45 /
Correction factors
Cu approx. 0.35
ifm electronic gmbh · Teichstraße 4 · D-45127 We reserve the right to make technical alterations without prior notice. — GB - IGM201 - 1/2 — 23.05.2003
Essen
IGM201
Operating temperature [°C] -40...85
Protection IP 67 / IP 69 K
EMC Automotive area
Noise emission and noise interference according to the
automotive directive 95/54/EC (e1 type approval)
Noise interference according to DIN ISO 11452-2: 100
V/m
Conducted interference according to ISO 7637-2
Pulse 1 2 3a 3 b 4 5
Severity level IV IV IV IV IV IV
Failure criterion C C A A A C
CD: 4 kV / AD: 8
EN 61000-4-2:
kV
10 V/m
EN 61000-4-3:
(80...1000 MHz)
EN 61000-4-4: 2 kV
Mains line to
EN 61000-4-5:
line: 0.5 kV
10 V (0.15...80
EN 61000-4-6:
MHz)
class
EN 55011:
B
Housing material housing: stainless steel; active face: PBT
Function display
Switching status LED yellow (4 x 90°)
Connection M12 connector; gold-plated contacts
Wiring
Accessories (included) 2 lock nuts

ifm electronic gmbh · Teichstraße 4 · D-45127 — We reserve the right to make technical alterations without prior notice. — GB - IGM201 - 2/2 — 23.05.2003
Essen
Service Instruction
JUPITER 2200
Index
6. Electrical diagrams

Service Instruction
JUPITER 2200
Index
7. Supplement
7.1. Training confirmation .......................................................................................... 2

EINSCHULUNGSBESTÄTIGUNG
DER MASCHINE / ANLAGE
Kunde: Auftragsnummer:
Anlage besteht aus:
Die Einschulung brachte folgendes Ergebnis:
Datum: ________________ von: _______________ bis: __________________
Einschulungsort: _________________________________________________________
Durchgeführt von: _________________________________________________________
Die Einschulung erfolgte anhand der Betriebs- und Serviceanleitung.
Die Betriebs- und Serviceanleitung wurde ____ fach übergeben.
Auf Besonderheiten der Maschine und die davon ausgehenden Gefahren wurde ausdrücklich
hingewiesen.
Das eingeschulte Personal ist ab nun in der Lage, die Maschine/Anlage selbstständig zu
betreiben und zu warten. Der Auftraggeber bestätigt, dass der Auftragnehmer die vertraglich
vereinbarten Leistungen vollständig und zeitgerecht erbracht hat.
Die Einschulung gilt hiermit als erfolgt.
Nachfolgend angeführtes Personal wurde eingeschult und bestätigt hiermit, dass die Schulung
verstanden wurde und alle Fragen beantwortet wurden.
Name Unterschrift
Einschulungsbestätigung m Zusatz de-02.doc Rev: 02 / 02.04.2007 Seite 1 von 3

Anhand der Betriebs-, Wartungs- und Serviceanleitung wurde das Bedienpersonal in

folgenden Punkten unterwiesen:
durch nicht
1. Allgemein Referenz gef. zutr. Bemerkung
1.1. Bestimmungsgemäße Verwendung BA+SA, 1.2.
Sicherheitshinweise (Kennzeichnung, BA+SA,
1.2. Betriebssicherheit, Restgefahren) 2.1 - 2.3
1.3. Transport und Aufstellung BA, 4.1 - 4.3
2. Inbetriebnahme und Betrieb

Funktionsweise, Bedienelemente
2.1. (Hauptschalter, NOT-AUS, Pulte) BA, 5.3
2.2. Automatik Start / Stop der Maschine BA, 5.3
2.3. Programmtypen (Bedarf, Auswahl) BA, 5.4
Handsteuerung bei Wartungen für:
HNDE, Rotor, Siebkassette,
2.4. Ausschwenkwand/Störstoffklappe BA, 5.3
2.5. Bedienung des Bedienpultes OP7 BA, 5.4
Meldungen am Bedienpult OP7:
2.6. Ausgaben, Störungen, Warnungen BA, 5.4
2.7.
2.8.
2.9.
3. Wartungstätigkeiten
3.1. Wartungstätigkeiten mechanisch
Schmierung der Maschine
3.1.1. (Zentralschmierung, Schmierplan) BA, 6.4 Fettsorte beachten!
3.1.2. Rotormesser: Einstellung, Wechsel SA, 3.2
3.1.3. Gegenmesser: Einstellung, Wechsel SA, 3.3
3.1.4. Abstreifkamm: Einstellung, Wechsel SA, 3.4
3.1.5. Siebeinheit: Kontrolle + Wechsel, SA, 3.5
3.1.6. Antriebsriemen: Spannung prüfen SA, 3.6 Frequenzmessgerät
Dichtringe BA, 6.2
3.1.7. (Rotor, Gehäuse, Siebraum, Filzringe) SA, 3.9 Filzringe nur bei KOMET
3.1.8 Gehäuseöffnung reinigen BA, 6.2 bei MICROMAT, VEGA
Sicherheitskupplung:
3.1.8 Funktion, Einstellung SA, 3.7
Drehmomentstütze:
3.1.9 Verschraubung, Gummipuffer BA, 6.2 Bei Antrieb mit Getriebe
3.1.10
3.1.11
3.1.12
3.1.13
3.1.14
3.1.15

Wartungstätigkeiten durch nicht

3.2. Hydraulik+Getriebe Referenz gef. zutr. Bemerkung
3.2.1 Hydraulik. Funktionsweise SA, 5.1
Hydraulikeinstellungen: Öl- u. Luftfilter,
3.2.2 Niveau, Öltemperatur, Öldruck SA, 5.1
3.2.3 Hydraulikleitungen: Verschraubungen SA, 5.1
3.2.4 Hydraulik: Fülldruck Blasenspeicher SA, 5.1
3.2.5 Hydraulik: Ölprobe bzw. Ölwechsel SA, 5.1 Öltype beachten
3.2.6 Getriebe: Ölwechsel SA, 5.3 Öltype beachten
3.2.7
3.2.8
3.2.9
Wartungstätigkeiten
3.3 Elektrische Ausrüstung
Schaltschrank: Wartungsarbeiten
3.3.1 (Reinigung, Batterie SPS, FI-Schalter) -
3.3.2 Schaltschrank: Gefahrenpotentiale -
3.3.3 E-Motoren: Reinigung -
2.4.4 E-Motoren: Schmierung BA, 6.4 Fettsorte beachten
2.4.5 Füllstandsmelder: Reinigung -
Schaltschränke: Öffnen nur durch
2.4.6 Fachpersonal erlaubt (Staubschutz) BA, 6.3.6 Aufkleber beachten
Verschraubungen prüfen für: Anschluss
2.4.7 E-Motor, Schienen für Hauptstromkreise BA, 6.4
Schaltschrank:
2.4.8 Schützkontakte kontrollieren BA, 6.4 bei Stern/Dreieck Antrieb
2.4.9
2.4.10
2.4.11
2.4.12

Service Instruction
JUPITER 2200
7.1. Training confirmation

The training of the employees must take place by using the following blank und must be confirmed
from every involved person with its signature (see following page).

JUPITER2200-01 1233-SA Eng

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

JUPITER2200-01 1233-SA Eng

Uploaded by

Copyright:

Available Formats

TECHNISCHE SERVICEANLEITUNG

TECHNICAL SERVICE INSTRUCTION

MANUALE DI ASSISTENZA TECNICA

3. Maintenance and Service

LINDNER Recyclingtech GmbH

The reproduction, distribution and utilization of this document as well as the

Lindner - Recyclingtech GmbH

1.1.1. Function .............................................................................................................. 2 / 5

1.2. Use According to Specifications ............................................................... 3 / 5

1.2.1. Areas of Application.......................................................................................... 3 / 5

1.3. Dimension drawing ........................................................................................ 4 / 5

1.4. Technical data .................................................................................................. 5 / 5

JU2200-01_SA10-V00_eng.doc Rev.: 00 / 18.02.2009 page 1 of 5

1.1. Technical description

1.1.2. Schematic presentation

JU2200-01_SA10-V00_eng.doc Rev.: 00 / 18.02.2009 page 2 of 5

1.2. Use According to Specifications

1.2.1. Areas of Application

The following types of materials have been contractually agreed upon:

• materials with low flash point, which cause danger of fire

JU2200-01_SA10-V00_eng.doc Rev.: 00 / 18.02.2009 page 3 of 5

1.3. Dimension drawing

JU2200-01_SA10-V00_eng.doc Rev.: 00 / 18.02.2009 page 4 of 5

1.4. Technical data

JU2200-01_SA10-V00_eng.doc Rev.: 00 / 18.02.2009 page 5 of 5

Number of cutters 24 pcs Year of construct 2009

1.4.2. Drive: Three phases current motor (2x)

1.4.3. Transmission: Countershaft gear (2x)

1.4.5. Hydraulic unit:

1.4.5.1. Drive of hydraulic unit:

1.4.6. Hydraulic cylinders

2.2. Operational Safety ............................................................................................. 4

2.2.1. General Measures....................................................................................................4

2.3. Residual Hazards .................................................................................................. 9

2.3.1. Nipping Hazard ........................................................................................................9

JU2200-01_SA20-V01_eng.doc Rev.: 01 / 18.02.2009 Page 1 of 12

2.1. Definitions and Identification Symbols

2.1.2. Identification Symbols

The following symbols indicate safety-relevant places in the operator’s guide:

There is a direct hazard for the life and health of persons.

• Warning of hazards from electrical current / voltage

JU2200-01_SA20-V01_eng.doc Rev.: 01 / 18.02.2009 Page 2 of 12

• Notice about proper operation of the machines

The machine or system must be handled properly.

• Notice about bans

• Notice about using personal protection equipment

• Notices about using fire extinguishing equipment

It is necessary to install fire extinguishing equipment that is to be used in case of

• Notice about hazards from working materials

JU2200-01_SA20-V01_eng.doc Rev.: 01 / 18.02.2009 Page 3 of 12

2.2. Operational Safety

2.2.1. General Measures

• Responsibility of the Operator

JU2200-01_SA20-V01_eng.doc Rev.: 01 / 18.02.2009 Page 4 of 12

• Responsibility of the User

2.2.3. Operating States

• Transport and Installation

• Start-up and Operation

climbing on the machine

JU2200-01_SA20-V01_eng.doc Rev.: 01 / 18.02.2009 Page 5 of 12

• Maintenance and Service

2.2.4. Specific Hazards

• Fire and Explosion