Docu B-02497

Project No.
B-02497-100-01
B-02496-100-01
Client documentation : 902005907
Edition: 07/05 Machine type: DK 3,00
Cover Sheet
SONTH O FEN
1. Operating Instructions .................................... 902001099

Client Documentation
2. Technical Documents ..................................... 902005904
3. Spare Parts List ............................................... 902005906
Twin-Shaft Batch Mixer

SONTH O FEN
BHS-Sonthofen GmbH Hans-Böckler-Str. 7 87527 Sonthofen

Spare Parts: Tel. ++49 8321/802 144 - 146 Fax ++49 8321/802 120
902001099-001 A
Edition: 08/01 DKX
Cover Sheet
SONTH O FEN
1. Information for User ........................................ 900359300

Operating Instructions
2. General Safety Instructions ............................ 900359400
3. Delivery and Intermediate Storage ................. 900369400
4. Machine Description ....................................... 900359700
5. Erection and Electric Connection .................. 900359800
6. Starting and Operation.....................................900359900
7. Servicing and Inspection............................ .... 900360100
8. Lubrication........................................................900401500
9. Maintenance......................................................900360500

SONTH O FEN D...
BHS-Sonthofen Maschinen- und Anlagenbau GmbH Hans-Böckler-Str. 7 D-87527 Sonthofen
Spare Parts: Phone +49 (0)8321 / 802 144 - 802 146 Fax +49 (0)8321 / 802 120
Edition: 08/97 900359300-00E C
Information for User

SONTH O FEN
1. Instruction to Owner and Operators .......................... 2

2. Guarantee and Liability............................................... 3
3. Copyright ..................................................................... 4
Machines and Plants

SONTH O FEN
BHS-Sonthofen GmbH Hans-Böckler-Str. 7 D-87527 Sonthofen

Machines and Plants
SONTH O FEN
Information for User - 900359300-00E C
1. Instruction to Owner and Operators

Employ only
• instructed
• trained
• reliable
bd00038
personnel for operation, maintenance and repair.

The operating instructions belong into the hands of the
operating and maintenance personnel. The instructions
contain important information the knowledge of which is
indispensable for the operating and maintenance
personnel to prevent maloperation, errors and portentous
omissions.

Ask the operating and maintenance personnel to confirm that they will apply
and observe the operating, maintenance and safety instructions.

Use the machine/plant only for the proper use specified by the
manufacturer.
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2. Guarantee and Liability

As a matter of principle, our "General Terms and Conditions for Sale and
Delivery" shall apply, which have been sent to you on conclusion of the
contract, at the latest.

Claims for guarantee and liability for damage to people and property are
excluded when they can be attributed to the following causes:
• Operation of the machine/plant with defective safety devices or removed

safety and protective devices.
• Improper intermediate storage, erection, starting, and operation of the

machine/plant.
• Professionally improper operation and maintenance of the machine/plant.
• Improper use of the machine/plant.
• Faulty feeding and discharge conditions.
• Unauthorized structural changes on the machine/plant.
• Unauthorized change of the driving conditions (power and speed).
• Poor surveillance of the parts which are subject to wear.
• Cases of disaster through influences of foreign bodies and force majeure.
• Professionally improper repair under your own responsibility.
• Use of spare parts which are not of BHS original.
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3. Copyright

The copyright in the Operating Instructions remains with the manufacturer
of the machine/plant.

These operating instructions are destined for operating, maintenance,
monitoring, and repair personnel.

The instructions include specifications and technical documentation which
must not be reproduced, distributed, used for purposes of competition or
handed over to any third party, neither completely nor partially, without
authorization.

Infringements may be prosecuted.
4-4
Edition: 07/05 900359400 - 900359400-006 - K
General Safety Instructions

SONTH O FEN
1. Basic Safety Requirements ........................................ 3

2. Warning Notes and Warning Signs ............................ 4
2.1 Signs in the Operating Instructions .................................... 4
2.2 Signs on Machines and Plants (Examples) ........................ 5
3. Use of the Machine/Plant ............................................ 6
3.1 Proper Use............................................................................. 6
3.2 Improper Use ......................................................................... 6
3.3 Dangers and Troubles .......................................................... 6
4. Organizational Measures ............................................ 7
4.1 Operating Instructions.......................................................... 7
4.2 Supplements to the Operating Instructions........................ 7
4.3 Working in Compliance with Safety Regulations............... 8
4.4 Unauthorized Modifications ................................................. 8
5. Personnel Requirements ............................................ 9
5.1 Selection and Qualification .................................................. 9
5.2 Responsibility for operation ................................................ 9
5.3 Responsibility for assembly ................................................ 9
6. Safety Equipment on the Machine/Plant.................. 10
6.1 Safety Measures for Machine/Plant Motors ...................... 10
6.2 Main Switch ......................................................................... 10
6.3 Repair Switch ...................................................................... 10
6.4 Emergency-Off Switch........................................................ 10
6.5 Protection of Access or Maintenance Hatches ................ 11
6.6 Safety Devices..................................................................... 11
6.7 Working and Maintenance Platforms, Catwalks............... 11
6.8 Safety Precautions when Explosions in the Machine Cannot
be Completely Ruled Out by the Operator........................ 12
7. Requirements for Machine/Plant Operation ............ 13
7.1 Safety Instructions.............................................................. 13
7.2 Safety Measures.................................................................. 13
8. Requirements for Working at the Machine/Plant .... 14
8.1 Safety Instructions.............................................................. 14
8.2 Safety Measures.................................................................. 14
9. Particular Dangers .................................................... 16
9.1 Electric Power Supply ........................................................ 16
9.2 Repair................................................................................... 16
9.3 Process Materials................................................................ 17
Machines and Plants

SONTH O FEN

Edition: 07/05 900359400 - 900359400-006 - K
General Safety Instructions

SONTH O FEN
9.4 High-pressure water, steam, hydraulics ........................... 17

9.5 Radiation Protection ........................................................... 18
9.5.1 Necessary Handling Permit ....................................................... 18
9.5.2 Instructions for Radiation Protection ....................................... 18
9.5.3 Radiological Safety Officer........................................................ 18
9.6 Safety Instructions on Operation in Explosion Risk Areas
According to ATEX ............................................................. 19
9.6.1 Combination of Components, Devices to Machines/Plants..... 19
9.6.2 Installation of protection against contact for couplings and V-belt
drives .......................................................................................... 19
9.6.3 Monitoring technical parameters .............................................. 19
9.6.4 Preventing Sparks from Outside Strikes .................................. 20
9.6.5 Unauthorised Reconstruction and Spare Part Manufacturing. 20
10. Mobile Machines/Plants ............................................ 21
11. Safety regulations of the German Employers' liability
insurance association for the quarrying industry... 22
Machines and Plants

SONTH O FEN

Machines and Plants
SONTH O FEN
General Safety Instructions 900359400
1. Basic Safety Requirements

Persons who are responsible for the
• operation
• maintenance
• repair
• assembly
of the machine/plant have to,
- read and observe the safety instructions carefully
- use safety equipment
bd00038
- execute safety-technical requirements
- know and observe the customer documentation
which are described hereafter.
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2. Warning Notes and Warning Signs
2.1 Signs in the Operating Instructions

In these operating instructions all regulations, rules, and instructions
concerning safety have been marked by warning signs and in addition by
headings such as “NOTE!”, “ATTENTION!”, or “DANGER!”.

NOTE!
this heading refers to operating and maintenance instructions which must
bd00023
absolutely be followed and observed.

ATTENTION!
bd00023
indicates operating and maintenance procedures which must be strictly
adhered to in order to prevent damage to and destruction of the
machine/plant and other property.

DANGER!
indicates operating and maintenance procedures which must be strictly
adhered to in order to protect life and limb of persons.
bd00023

NOTE!
Only if ATEX compliant safety precautions have been agreed for the scope
of supply, the following ATEX danger signs shall apply as indicated in the
bd00023
respective chapters of the operation manual.

NOTE!
indicates ATEX conforming measures that need to be observed under all
circumstances.

ATTENTION!
indicates ATEX conforming measures that need to be precisely observed in
order to prevent damage to and destruction of the machine/plant and loss of
other assets.

DANGER!
indicates ATEX conforming measures that need to be precisely observed in
order to protect life and limb of persons.
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2.2 Signs on Machines and Plants (Examples)

DANGER!
Be on alert while mixing tools are rotating!

DANGER!
No access for unauthorized persons! ATTENTION
DANGEROUS AREA!
Trained service
personnel only
No access for
unauthorized persons!
Trained service
personnel only

DANGER!
Keep away from loading area!

DANGER!
Falling hazard!

DANGER!
Risk of getting pinched!

DANGER!
Slippery surface!
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3. Use of the Machine/Plant
3.1 Proper Use

The machine/plant may be used for its intended purpose only! The proper
use of the machine/plant has been clearly stated in
• the group “Machine description”

• the Technical Specification.
• the Order Acknowledgement
Any other use, or any use beyond those specifications, is regarded as

improper use. The manufacturer will not be liable for any damage involved.
The risk will be solely with the operator.
The proper use also includes adhering to the operating instructions, and the
inspection and maintenance instructions.

The machine/plant shall be used in technically perfect condition only; be
always aware of safety and danger!
3.2 Improper Use

It is dangerous and not allowed to use the machine/plant improperly and not
to specification.

The machine/plant will not be reliable if it is not serviced to the maintenance
instructions, or if it is not serviced at all.

The machine/plant must not be operated by unauthorized personnel!
3.3 Dangers and Troubles

The machine/plant has been manufactured according to the state of the art
and the recognized safety regulations. Nevertheless, its use may cause
danger for life and limb of its operator or other persons, or can cause
damage to the machine/plant and other property.

Malfunctions in the machine/plant which may affect the safety must be
eliminated immediately!
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4. Organizational Measures
4.1 Operating Instructions

One copy of the operating instructions must always be kept ready on hand
at the site.

NOTE!
The personnel working at the machine/plant must
know the operating instructions in particular the chapters concerning

bd00023
safety
During work it will be too late.
This applies especially to personnel working only occasionally at the

machine/plant, e.g. for maintenance and repair work.
4.2 Supplements to the Operating Instructions

Observe the generally valid safety regulations and provisions of the
competent trade association, and other obligatory regulations for accident
prevention and environmental protection.

Such responsibilities can also concern e.g. the handling of dangerous
materials or the availability and use of protective equipment, as well as road
traffic regulations

Observe the regulations concerning special company conditions, including
responsibilities for supervision and notification, e.g. with regard to
organization of work, working sequences, and personnel employed.

Make sure that the dates for possible recurrent safety checks of the
machine/plant components by experts of technical surveillance association,
trade association, or other authorities will be observed.
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4.3 Working in Compliance with Safety Regulations

The machine/plant must always be operated in its proper condition and for
its proper use as specified.

Mind all safety and danger indications at the machine/plant and keep them
all in legible condition! For example:
• warning and instruction signs

• rotational direction arrow on the motor
• type label

If necessary or specified by regulations, your personnel must wear personal
safety clothing, or use protective equipment, during maintenance and repair
work.

The personnel must not wear loose and long hair, loose clothing, or jewelry
(including rings). There will be danger of injury by being pulled in or getting
caught!

When carrying out maintenance work, an adequate tooling equipment is
absolutely necessary!

ATTENTION!
Any maintenance or repair work on machines and plants located in a
hazardous area must only be performed with the express approval of
the person in charge of the plant.
For any work requiring electric or pneumatic tools and welding work
special permits must be obtained.
4.4 Unauthorized Modifications

In case of changes in the operating performance stop machine/plant and
report the trouble to the competent authority/person!

Any modifications, attachments and conversions on the machine/plant
which may affect the safety and function must not be made!

Any changes of program (software) for programmable control functions on
the machine/plant are permitted only after approval by the manufacturer!
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5. Personnel Requirements
5.1 Selection and Qualification

Work on/with the machine/plant must be made by reliable personnel only.
Mind the legal minimum age! Make sure that only instructed personnel will
work at the machine/plant.

Employ only trained and instructed personnel and clearly define the
responsibilities of the personnel for operation, set-up and shut-down,
maintenance, and repair!

Authorities, responsibilities, and the supervision of the personnel need to be
precisely determined by the operator. In case the personnel does not have
the necessary knowledge, they need to be instructed and trained. This can
be done if necessary on behalf of the operator of the machine by the
manufacturer/supplier.

Furthermore the operator must make sure that the contents of the operating
manual are fully understood by the personnel.

Personnel just being trained, instructed or generally educated may work at
the machine/plant only under the constant supervision of an experienced
person!

We recommend that the support and services offered by BHS technicians
be called upon for planning, assembly, commissioning, and service tasks.

NOTE!
Maintenance and repair work on electrical, mechanical, hydraulic and
pneumatic equipment at the machine/plant shall be carried out only by a
qualified expert having special knowledge and experience in the respective
bd00023 field and working in accordance with the existing regulations.
5.2 Responsibility for operation

Define the responsibility of the machine/plant foreman, also with regard to
road traffic regulations, and enable him to refuse the instructions of any
third person if those instructions are contradictory to safety.
5.3 Responsibility for assembly
NOTE!
If the assembly of the machine/plant is not included in the BHS scope of
supply, the BHS specialist will be responsible only for supervising the
assembly sequence. He is not responsible for observing the respective
statutory provisions, training, instruction and watching the assembly
bd00023
personnel. Assembly shall be organized by the respective company.
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6. Safety Equipment on the Machine/Plant
6.1 Safety Measures for Machine/Plant Motors

As electric safety measures motor fuse protections, protective motor
switches, possibly posistor temperature probes, and fault current circuit
breakers are to be provided.
6.2 Main Switch

It must be possible to shut off the supply of electric energy to the
machine/plant by means of a lockable main switch in the control cabinet.
6.3 Repair Switch

For each machine/plant there must be an all-pole, lockable switch-off unit, in
its immediate neighbourhood or on the machine/plant itself; the switch
positions “Ein” (ON) and “Aus” (OFF) must be clearly visible.

Starting the machine/plant from any other point must be possible only when
switch position “Ein” (ON) is in permissive position.

The electric connection of the repair switch must be made in a way that it is
in any case in the supply line (4-wire) before the star-delta combination in
the control cabinet. Thus it is ensured that, even with double-motor drives
connected in parallel, both motors are switched off by means of one repair
switch.
6.4 Emergency-Off Switch

For each machine/plant there must be a noticeable red emergency-off
switch in its immediate vicinity or on the machine/plant itself, by which in
case of danger the machine/plant drive and the material supply to the
machine/plant can be switched off.
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6.5 Protection of Access or Maintenance Hatches

The access or maintenance hatches must be protected by one of the
following means:
• Electric safety limit switch and electromagnetic locking unit
• Combined switch for limit and locking connection
• Mechanical safety locks
- The safety limit switches must be connected to the control in a way
that the machine/plant cannot be started if the access or
maintenance hatches are open.
The locking unit must be connected to the control in a way that, when
the machine/plant has been switched off, the access or maintenance
hatches can be opened only after the moving parts have come to
complete standstill.
The time to be set on the time lag relay of the locking unit should at
least correspond to the coasting period of the moving parts.
- The keys for the safety locks must be kept under lock and key by the
person responsible for the machine/plant.
6.6 Safety Devices

For V-belt drives, couplings and working cylinders, safety devices are
provided that are constructed according to the prevailing regulations for the
prevention of accidents.
6.7 Working and Maintenance Platforms, Catwalks

If these are necessary for operation reasons, then they must be designed in
a way that they meet the requirements to be expected. They must be of

adequate size.
When there is risk of falling, safety devices must be provided in accordance
with the prevailing regulations for the prevention of accidents.
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6.8 Safety Precautions when Explosions in the Machine

Cannot be Completely Ruled Out by the Operator

DANGER!
While the machine and the plant is in operation persons and vehicle
must keep a sufficiently great safety distance from the machine/plant.
Depending on the hazard posed by the product to be treated, the
bd00023 safety distance must be scaled large enough so that there is no
danger from an expanding flame wall, shock wave, and flying debris.

The operator is committed to assess the hazard involved.

Do not allow dust to accumulate in the entire machine and plant area.
Vacuum off accumulations of dust.

Suitable measures for explosion pressure discharge, explosion isolation,
explosion suppression

Suitable measures for preventing further expansion of flame walls and
shock waves in the feed units, dust extraction systems, and other plant
components.
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7. Requirements for Machine/Plant Operation
7.1 Safety Instructions

Observe the instructions and measures specified in the Operating
Instructions, they apply to automatic as well as hand operation!

Prior to switching on and starting the machine/plant make sure that nobody
will be endangered by the starting of the machine/plant!

Any method of operation that may affect safety must be avoided!

Mind the control indications during the starting and stopping operations!

Do not switch off or remove any extraction or ventilation equipment when
machine/plant is running!
7.2 Safety Measures

Set selector switch to Automatic or Manual Operation!

Take measures to ensure that machine/plant will be operated in safe and
proper condition only! Operate the machine/plant only if all safety and
protection equipment, e.g. detachable protection devices, emergency-off
devices, sound insulations, extraction systems are existing and operative!

In case of malfunctions, stop and secure the machine/plant immediately!
Have all malfunctions rectified as soon as possible!

At least once per shift check machine/plant for any defect or failure that can
be detected from outside! Report any deviations (also in operating
performance) immediately to the responsible office/person! If necessary,
stop and secure the machine/plant immediately!
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8. Requirements for Working at the

Machine/Plant
8.1 Safety Instructions

The instructions and measures specified in the Operating Instructions for
maintenance, inspection, and operation must be observed and adhered to!

The adjusting, maintenance, inspection, and repair actions (including
replacement of wearing and machine parts) specified in the Operating
Instructions must be observed and carried out in compliance with the safety
instructions!

Inform the operating personnel prior to commencing any repair and
maintenance work, and appoint a supervisor!

For all work on the machine/plant concerning operation, change of control
functions, conversion of the machine/plant and its safety equipment, as well
as inspection, maintenance, and repair, the instructions regarding safety,
starting and stopping operations, and proper repair must be observed and
adhered to!

Any fuel and process materials, as well as replaced parts must be discarded
in a safe and environmentally harmless way.
8.2 Safety Measures

Protect a wide area - when applicable - around the repair location!

When the machine/plant has been completely switched off for inspection,
maintenance or repair work, it must be secured against unexpected
restarting:
• Lock the main switch (also repair switch) and take key along.
• Attach warning sign at the main switch.

Clean the machine/plant prior to commencing maintenance and repair work!
Prior to cleaning, e.g. with water or steam jet (low pressure) or other
cleaning agents, cover or - if necessary - tape up all openings or devices,
into which water / steam / cleaning agent must not penetrate for reasons of
safety or proper function.
• Electric motors, switches, valves, and switch cabinets are particularly
susceptible!
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• Only dry cleaning for all dosing and feeding devices for dry aggregates!
• Do not use aggressive cleaning agents!
• ATTENTION!
Plastic parts shall be cleaned only with a solvent-free, moist cloth
(static charges).
Only use ATEX compliant cleaning agents.
• Electric devices and installations without the necessary protection must not
be treated with water or steam jet.

After the machine/plant has been cleaned, remove again all coverings and
tape seals completely!

After having cleaned air and oil lines, check them for leakage, loose
connections, abraded spots, and damage!
Any defects detected must be repaired immediately!

If the dismantling of safety devices is required during maintenance and
repair work, those safety devices must be installed again after the
completion of the work and their proper function be tested!

Machine parts and large assemblies must be carefully fixed to the lifting
devices and secured during replacement so that they will be no source of
danger. Suitable and technically faultless lifting devices as well as load
carrying means with adequate capacity must be used only.

Do not stay or work under suspended parts!

Experienced persons only must be engaged for the slinging of loads or the
guiding-in of crane drivers! The guider must be within sight of the crane
driver or be in speech contact with him.

In case of assembly or repair work above body height use the intended or
other safe ladders or work platforms.

Do not use machine parts as climbing aids!

Keep all handles, steps, railings, landings, platforms, and ladders free from
dirt, snow and ice!

When working at greater heights use guard rails!

Bolt connections loosened during maintenance and repair work must be
tightened again after completion of the work, taking into consideration any
specified tightening torques (see technical documentation)!
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9. Particular Dangers
9.1 Electric Power Supply

ATTENTION!
Work on electrical installations or equipment must be carried out only by an
electrician or by instructed personnel under the supervision of an electrician
in accordance with the rules of the electrical engineering industry.
bd00023

The electrical equipment of the machine/plant must be inspected and
checked regularly. Any defects such as loose cable connections or scorched
cables must be analysed and repaired immediately!
9.2 Repair

Repair work on machine/plant to be carried out only after explicit approval!

NOTE!
Work on electric, hydraulic, pneumatic, mechanic equipment must be
executed only by persons who have special technical knowledge in the
respective field and observe the prevailing rules!
bd00023

Prior to commencing repair, depressurize any system, sections and pipes
for compressed oil or air which must be opened. For example, spurting oil
may cause injuries or fire! The oil must be properly collected and discarded.

ATTENTION!
Any maintenance or repair work on machines and plants located in a
hazardous area must only be performed with the express approval of
the person in charge of the plant.
For any work requiring electric or pneumatic tools and welding work
special permits must be obtained.

Prior to commencing welding and flame-cutting work, clean the working
place of all dust and grease, and remove all flammable material around it.
Make sure that adequate ventilation is provided; there may be fire or
explosion hazard!

During electric welding disconnect or remove the electronic insert cards to
avoid possible damages by welding current. Also ensure very good bonding
around the welding point (remove dirt and paint).

During electric welding on the machine/plant, which has to be done in moist
areas, there is danger of electric shock!
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• Make sure that the welder's place is properly isolated, otherwise welding
work must not be carried out under those circumstances!

When working in confined spaces observe any prevailing national
regulations!
9.3 Process Materials

When handling oil, fats and other chemical substances mind the applicable
safety regulations for the respective product.

Be careful when handling hot process materials; risk of burning or scalding!
9.4 High-pressure water, steam, hydraulics

The applicable safety regulations must be observed for hose lines and
connections, particularly with regard to the durability, checking and
changing of hose lines. It is imperative to adhere to the checking and
changing intervals.
BGI 572 – Information leaflet regarding safe use of hose lines.

At control system level it is necessary to make sure that no hazards
whatsoever are capable of occurring as a result of unintentional start-up.

ATTENTION!
Before starting any work on the system, always make sure that the electrical
bd00023 power is switched off and can't be switched on again!

Accumulators must be completely depressurised before removing valves
and pipe runs.

Valve and equipment fastening screws must only be re-tightened in a non-
pressurised state.

Screw unions must only be re-tightened in a non-pressurised state.

Pre-filling an accumulator on the gas side must only be done using the
prescribed medium.

Leaks from the unit, pipe runs and user may cause significant damage to
the environment
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9.5 Radiation Protection
9.5.1 Necessary Handling Permit

For the operation of a plant using Gamma rays a handling permit is
required. Apply for this permit to the respective authorities in your country.
Among other things a certificate of qualification is required, which can be
obtained by attending special courses.
9.5.2 Instructions for Radiation Protection

The aim of radiation protection is the behaviour which reduces to a
minimum any danger through radioactive material. It is important to
consider the radiation protection principles, i.e. who operates a plant or
installation with ionizing radiation is obliged to
• avoid any unnecessary radiation exposure or contamination of

persons, goods or environment
• to keep any radiation exposure or contamination of persons,

goods or environment as low as possible under consideration of
the state of art and science, and all circumstances of the
respective case, even if below the limits fixed by the radiation
protection prescription.

International limits for maximum radiation exposure have been fixed in
order to rule out harms to health. By the installation of measuring
instruments and the design of radiation shielding is made sure that with
expert behaviour the radiation exposure is in any case below the maximum
admissible value. The law for radiation protection determines for humans
working near technical installations with gamma radiation the limits as max.
annual dose (see Encl. X, Table X1 of StrlSchV).

In case an area of radiation protection is formed outside the radiation
shielding it must - if accessible - be marked and provided with barriers.
9.5.3 Radiological Safety Officer

The radiological safety officer is the competent person at the plant. He has
to care that the radiation protection regulations are obeyed. The lacking
human organ to notice radiation is replaced by measures as there are
measuring instruments, calculations and objective estimation.

Special occurrences, e.g. fires or explosions, which could reduce the safety
and function of radiometric measuring devices have to be notified to him
immediately. He has to introduce the necessary measures.
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9.6 Safety Instructions on Operation in Explosion Risk Areas

According to ATEX
9.6.1 Combination of Components, Devices to Machines/Plants

If the machine/plant is combined to a complete machine/plant by
mechanical or electrical components, then the single device may be
considered as conforming to the respective device category according to
EC directive 94/9/EC only if all included components conform to it.

NOTE!
This regulation has special importance when using machines that conform
to a device category according to 94/9/EC, but are driven by a motor that
does not meet these criteria. In such a case it could be that the Ex sign is
attached to the machine, but the device may not be employed in explosion
risk areas because of the motor, which is not Ex validated. It is the
obligation of the operator to ensure that all components used in the
machine/plant conform with guideline 94/9/EC.
9.6.2 Installation of protection against contact for couplings and V-belt

drives

Protections against contact to be used in explosion risk areas need to meet
certain criteria:
• Either a material should be used that does not cause sparks, or a

• steel-sheet construction that is designed in such a way that
contact by the rotating parts and the protection against contact is
ruled out in case of possible faults (e.g. deformation by stepping
on the protection against contact).
9.6.3 Monitoring technical parameters

The following parameters need to be monitored regularly by the operator
when machines are run in areas where there is a risk of explosion:
• leaking seals
• storage temperatures if necessary
• oil level in the gearbox
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9.6.4 Preventing Sparks from Outside Strikes

DANGER!
The operator must take precaution that no external strikes can hit the
machine case when the machine is operated in an explosion risk area.
This prevents sparks from being caused by striking.
9.6.5 Unauthorised Reconstruction and Spare Part Manufacturing

NOTE!
The operator assumes responsibility for safety when he reconstructs or
changes the machine/plant unauthorised.
The warranty given by BHS-Sonthofen GmbH is cancelled in such a
case.

Original spare parts and accessories authorised by the manufacturer serve
safeness. Using other parts can cancel the manufacturer's liability for
resulting consequences.
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Machines and Plants
SONTH O FEN
10. Mobile Machines/Plants

The following refers to machines/plants that frequently change sites.

Use only lifting devices and load carrying means with adequate capacity
and experienced guiders for the process of loading.

Sling, lift with lifting devices and load the machine/plant only in accordance
with the Operating Instructions, Group: Delivery and Intermediate Storage.

Only use suitable vehicles with sufficient capacity for transport!

The load must be reliably protected with the recommended or delivered

devices against lengthwise and crosswise slipping; the suitable sling points
must be used!

Use warning signs in case of surpassing the loading gauge!

Before recommissioning carefully mount those parts or part groups which

had to be dismantled for reasons of transport!

For recommissioning proceed only in accordance with the operating

instructions.
21 - 22
Machines and Plants
SONTH O FEN
11. Safety regulations of the German

Employers' liability insurance association
for the quarrying industry

The following accident prevention regulations issued by the German

employers' liability insurance association for the quarrying industry must be
observed for mounting and dismounting the plant.
• General safety regulations
• Ladders and steps
• Silos
• Provision of safety and/or health signs at work
• Health hazardous mineral dust
• Noise
• Specialists for occupational safety
• Exposure to carcinogens
• Occupational medical prevention
• Excavators, loaders, graders, scraping implements and special earthwork
machines
• Track railways
• Works in the area of rail tracks
• Continuous conveyors
• Winches, lifting and pulling machines
• Cranes
• Lifting tackles
• Building elevators
• Lifting platforms
• Vehicles
• Industrial trucks
• Power trucks
• Electrical systems and equipment
• Compressors
• Grinding and brushing tools

• Grindstones and grinding machines
• Metalworking
• Metalworking; shears
• Metalworking; grindstones, grinding and polishing wheels; grinding
and polishing machines
• Machines and plants for processing of wood and similar materials
• Welding, cutting and allied processes
• Use of liquid gas
• Construction work
• First aid
22 - 22
Edition: 07/98 900369400-00E E
Delivery and Intermediate Storage

SONTH O FEN
1. Condition as Supplied ................................................ 2

1.1 Scope of Supply .................................................................... 2
1.2 Degree of Dismantling .......................................................... 2
1.3 Readiness for Operation ...................................................... 2
2. Transport ..................................................................... 3
2.1 Mode of Despatch ................................................................. 3
2.2 Method of Packing ................................................................ 3
2.3 Dimensions and Weight ....................................................... 4
2.4 How to Suspend for Transport............................................. 4
2.5 Loading .................................................................................. 4
2.6 Handling................................................................................. 4
3. Intermediate Storage................................................... 5
3.1 Storage................................................................................... 5
3.2 Preservation Measures for Intermediate Storage .............. 5
3.3 Preservation Measures for Drive Elements ........................ 6
3.3.1 Parts with revolving seat ............................................................. 6
3.3.2 Gearboxes .................................................................................... 6
3.3.3 Motors........................................................................................... 6
3.3.4 Pneumatic Cylinders, Valves, Grease Pump Unit ...................... 6
3.3.5 Hydraulic Cylinders, Hydraulic Unit............................................ 7
3.4 Preservation Measures for the Control ............................... 7
3.5 Preservation Measures for Plant Components from sub-
suppliers ................................................................................ 7
4. Intermediate Storage after Commissioning............... 8
4.1 Extended Standstill in a Building ........................................ 8
4.2 Extended Standstill in the Open Air .................................... 8
5. Measures after Intermediate Storage ......................... 9
5.1 Gearboxes and Oil-Filled Units ............................................ 9
5.2 Motors .................................................................................... 9
6. Warranty Claims ........................................................ 10
Machines and Plants

SONTH O FEN

Machines and Plants
SONTH O FEN
Delivery and Intermediate Storage - 900369400-00E E
1. Condition as Supplied
1.1 Scope of Supply

The scope of supply corresponds to the order acknowledgement, and
shipping advice, respectively, which also includes the data of packages.

On arrival the supply must be checked for
• completeness
• transport damages
• missing parts

Any defects must immediately be advised to the carrier.
The carrier is obliged to establish a written damage report and provide this
to the competent insurance company, or to the one who has arranged the
insurance, respectively.
1.2 Degree of Dismantling

Normally, the machine/plant will be delivered in assembled condition.
It will, however, be possible to supply it dismantled into various

subassemblies.

The degree of dismantling depends on
• the transport conditions

• the local condition on site
• the available lifting gears
1.3 Readiness for Operation

Test run at the manufacturer's works irrespective of the later condition of
delivery and degree of dismantling.

No test run for plants which cannot be test assembled.
2 - 10
Machines and Plants
SONTH O FEN
2. Transport
2.1 Mode of Despatch

The mode of despatch depends on
• the ways of transport

• the instructions of the customer

Transport possibilities are
• truck
• railway
• ship

The required mode of despatch will be agreed with the customer well in time
prior to despatch.
2.2 Method of Packing

The way of transport is also decisive for the method of packing.

The method of packing,
• whether unpacked,
• in container,
• or case,
will correspond - unless otherwise specially agreed upon - to the

recommendations HPE, established by the "Deutscher Bundesverband
Holzmittel, Paletten, Exportverpackung e.V." and the "Verein Deutscher
Maschinenbauanstalten".

The method of packing is mentioned in the order acknowledgement.

The pictographs on the packages must be observed, e.g.:
Top Fragile Keep dry Keep

away
from heat
Hand hooks Centre of

Sling
3 - 10
Machines and Plants
SONTH O FEN
2.3 Dimensions and Weight

Transport dimensions and weight of the machine/plant see Technical
Specification and Technical Documentation: "Installation drawing"

Exact shipping weight see shipping documents.
2.4 How to Suspend for Transport

ATTENTION!
Loading, without packing:
Suspend the machine on provided lifting eyes.
Angle of pull of the lifting chains and ropes to
bd00023 the horizontal not less than 45°!

For suspension mind distortion of
the machine/plant. No damages due
to distortion must result.

bd00035 When packed in cases
When slinging the lifting chains and ropes, use the points marked on the
cases by pictographs.
2.5 Loading

Secure the load against sliding during transport.

The loading area must be even and possibly torsion-proof.
2.6 Handling

The machine/plant must be transported cautiously in order to prevent
damage due to brutal force or careless loading and unloading.

NOTE!
Transport damages must be advised in writing to the carrier and the
insurance company (see scope of supply).
bd00023
For transport the goods must be secured against sliding.
4 - 10
Machines and Plants
SONTH O FEN
3. Intermediate Storage
3.1 Storage

Requirements regarding the place of storage for the machine/plant:
• protected
• free of mechanical vibrations (shaking)
• free of dust and the influence of moisture
• free from chemical attack
• lower temperature limit: -30°C
• even and fortified erection surface

Method of Intermediate Storage:
• best in a moderately heated building

• avoid unprotected storage in the open air, if
inevitable it should be
- for a short period of time

- with protective measures against atmospheric influences, e.g.
mounting of a flat wooden roof with a plastic tarpaulin on top
- place the machine/plant workmanlike on an even and fortified surface, if
necessary, place the machine/plant on squared beams
- protect plastic material or rubber parts from sunshine.
3.2 Preservation Measures for Intermediate Storage

Execute, if no special preservation measures have been agreed
contractually.

External preservation for storage in protected, dry and moderately heated
buildings (for storage longer than approx. 5 months):
• spraying of all bolt connections, links, pedestal bearings and blank swivel
parts with penetrating or rust preventing spray oil, respectively, (rubber
components, e.g. the V-belts, springs and coupling elements must not be
sprayed)
• repetition of the external preservation depends on the requirements (but at
latest after 12 months)

External preservation for protected storage in open air:
• for storage under roof in the open air spraying with oil for the first time at
the beginning of such storage
• repetition of the external preservation depends on the requirements (but at
latest after 6 months).
5 - 10
Machines and Plants
SONTH O FEN
3.3 Preservation Measures for Drive Elements
3.3.1 Parts with revolving seat

Turn every 3 months by hand by 2-3 revolutions. Thus bearings will
internally again be provided with and preserved by lubricant.
3.3.2 Gearboxes

After 6 months' storage to be completely filled with oil.

The type and make of oil must correspond to the oil filled in already (see
spare parts list or contact the machine supplier).
3.3.3 Motors

When stored in moderately heated rooms, no preservation

For storage in the open air wrap in plastic foil (a bag with desiccating agent,
e.g. Branogel, is to be enclosed)

If the motors have closed condensation holes, any condensation water that
has accumulated in the motor must be drained.

For motors which will probably be stored for more than 2 years before actual
commissioning, the following additional measures must be made at the
beginning of the storage period:
• The shaft entry and the junction box cover must be sealed by means of
roller bearing grease.
• If the motor shaft is rotated prior to commissioning, the destroyed protecting
layer of grease must be renewed.
• Desiccating agent, such as Branogel, must be put into the junction box.
• The roller bearings must be regreased with special grease "Staburags NBU
8 EP", in case of long time of exposure.
3.3.4 Pneumatic Cylinders, Valves, Grease Pump Unit

When stored in moderately heated rooms and under roof in the open air (in
the summer months) no preservation measures will be required.

When stored under roof in the open air, the pneumatic cylinders and valves,
as well as grease pump unit must be covered with plastic foil before the
beginning of winter a bag with desiccant agent,e.g. Branogel must be
enclosed
6 - 10
Machines and Plants
SONTH O FEN
3.3.5 Hydraulic Cylinders, Hydraulic Unit

When stored in moderately heated rooms and under roof in the open air (in
the summer months), no preservation measures will be required.

When stored under roof in the open air the hydraulic tank must be
completely filled with oil before the beginning of winter. Make sure that the
oil to be refilled (brand and type) corresponds to the oil already filled in. In
case of doubt, contact the machine manufacturer.

The hydraulic unit and the hydraulic cylinders must additionally be covered
with plastic foil and bags with desiccant agent, e.g. Branogel must be
enclosed.

During each intermediate storage the hand pump, if existing, with the
control valves must be actuated several times every 3 months.
3.4 Preservation Measures for the Control

see Technical Documentation: Operating Instructions of the manufacturer.
3.5 Preservation Measures for Plant Components from sub-

suppliers

see Technical Documentation: Operating Instructions of the manufacturer.
7 - 10
Machines and Plants
SONTH O FEN
4. Intermediate Storage after Commissioning
4.1 Extended Standstill in a Building

The location is moderately heated and dry.

Clean the machine/plant internally and externally, let it dry.

External preservation with liquid oil. Do not spray rubber parts (e.g. V-belts)!

Repeat preservation measures after appr. 9 months.

Supplementary Notes:
• see Intermediate Storage of this group
• see Technical Documentation

For re-commissioning see group: Commissioning and Service.
4.2 Extended Standstill in the Open Air

Protect the machine/plant against atmospheric influences.

Shutdown will not last more than 2 years.

Protect machine/plant with a wooden roof and plastic tarpaulin from rain and
sunshine.

Clean the machine/plant internally and externally, let it dry.

External preservation with liquid oil. Do not spray rubber parts (e.g. V-belts)!

With rotating machine/plant completely fill all bearings and seals with
grease.
With stopped machine/plant fill the motor bearings with grease.
The shaft entries and junction box covers must be sealed by means of roller
bearing grease, see group: Lubrication

Fill all gearboxes and oil aggregates with the corresponding type of oil.

Every 3 months the rotating parts must be turned once by hand (e.g. on the
V-belt drive) and, if exists, the hand pump on the hydraulic aggregate be
operated appr. 5 times.
The destroyed protecting layer of grease on the shaft entries must be
renewed.

Additionally cover the bearing points on machine/plant and motor with
plastic foil.

NOTE!
• see Intermediate storage

• see Technical Documentation: separate Operating Instructions.
bd00023
8 - 10
Machines and Plants
SONTH O FEN
5. Measures after Intermediate Storage
5.1 Gearboxes and Oil-Filled Units

Oil renewal in all gearboxes and units. Prior rinsing is necessary.

Check shaft sealing rings and other rubber seals for ageing. Unfavourable
storage conditions may cause the rubber components to age prematurely.

During commissioning pay particular attention to the shaft sealing rings and
replace them immediately if they are slightly leaking.

NOTE!
Commissioning after prolongates production interruption see group:
Commissioning and Operation.
bd00023
see Technical Documentation: separate Operating Instructions.
5.2

Motors
NOTE!
see Technical Documentation.
9 - 10
Machines and Plants
SONTH O FEN
6. Warranty Claims

Any damages occurring inside and outside on the machine/ plant, which
must be attributed to improper intermediate storage, are no longer subject
to warranty.
10 - 10
D...
Edition: 09/01 900359700-003 F
Machine Description
SONTH O FEN
Operating Instructions 1. General View................................................................ 2

2. Design .......................................................................... 3
2.1 Basic Equipment ................................................................... 3
2.2 Additional Equipment (optional).......................................... 4
3. Mode of Operation....................................................... 5
3.1 Feeding of the Mixer ............................................................. 5
3.2 Discharge of the Mixer.......................................................... 5
3.3 Mixing Capacity..................................................................... 6
3.4 Sense of Rotation of the Mixing Shafts............................... 6
Twin-Shaft Batch Mixers

SONTH O FEN D...
Spare Parts: Phone +49 (0)8321 / 802 144 - 802 146 Fax +(0)49 8321 / 802 120
Twin-Shaft Batch Mixer D...
SONTH O FEN
Machine Description - 900359700-003 F
1. General View
14 13 12 10 11
2, 3
4
9
5
8
6
1 Trough sealing
2 Bearings
3 Mixing shafts
4 Mixing tools
5 Supporting claws
6 Discharge door/flap operation
7 Discharge hopper
8 Discharge door /Discharge flap
9 Mixer drive
10 Mixing trough, trough wearing parts
11 Filter, airbag (optional)
12 Steam blowing (optional)
13 Trough cover
14 Water spraying
2-6
SONTH O FEN
2. Design
The mixer has been designed according to the modular principle and may thus be
supplied in different executions
2.1 Basic Equipment

Mixing Trough
• welded design
• 4 supporting claws for fixing in the steel structure or on convenient concrete
foundation
• 4 suspension eyes
• exchangeable wear protection for front and bottom sides
• symmetric wearing elements, exchangeable to each other, with patented
design and increased service life
• special lining (ceramic, rubber, plastic material, composite sheets, etc.) is
possible

Mixing tools
• 2 horizontal mixing shafts with self-aligning roller bearings

• mixing arms arranged in helical line, which is advantageous for the mixing
process and energy saving
• central and lateral arms of special steel casting
• mixing technically optimised design of mixing arms
• mixing blades and exchangeable wearing elements made of highly wear
resistant special hard casting
• special blades (plastic/steel, composite sheet, etc.) are possible.

Mixing Trough Sealing
• reliable axial face sealing

Discharge Door /Discharge Flap in the trough bottom
• revolving seating
• adjustable sealing ledges

Discharge Door/ Discharge Flap Operation
• opening and closing via pneumatic cylinder, or optional, via hydraulic

cylinder
• protective hood over the working cylinders
3-6
SONTH O FEN

Mixer Drive
• Slip on drive units, consisting of:
- slip-on worm gear

- torque support
- motor console
- motor
- V-belt drive
• synchronisation of drive unit via coupling

• speed control (optional)
• small mixers are provided with single motor drive, bigger ones
with double motor drive
• protective hoods on V-belt drive and synchronous coupling
• A drive unit can be installed on each lateral side at selected mixer
sizes.
2.2 Additional Equipment (optional)

Trough Cover
• welded design
• electrically protected maintenance doors
• water spraying
- admission of metered water quantity

- used and clean water design
• central entries for aggregates and binders

• connecting sleeve for filter and airbags

High-Pressure Cleaning Plant
• mixer cleaning to reduce manual attendance
• nozzles installed in the trough cover
• high-pressure aggregate with control

Central Grease Lubrication or oil-air
• Different variants of design
- for the 4 lubricating points of the inner sealing chamber of the
mixing trough
- all lubricating points of the mixer
- oil or grease lubrication or combinations interval control and manual
release optional
Exact descriptions see group: Lubrication
• Installation of the lube unit on the mixing trough or near the mixer

Device for Steam Blowing
to produce heated concrete
• steam lances on both sides in the upper trough area
4-6
SONTH O FEN
3. Mode of Operation

The Twin-Shaft Batch-Mixer is, from the function's point of view, a
batch mixer, e.g. for fresh concrete, to which aggregates, binding
agent, water and special additives are supplied from above in certain
feeding intervals.

The counter-rotating and synchronously running mixing shafts,
equipped with the mixing tools, effect true compulsory mixing.

In the mixing trough the material is compulsorily mixed horizontally
and vertically, and moved in a circle by the rotating tools, working in
opposite direction. This results in optimum homogeneity of the mix
within shortest possible mixing time.
3.1 Feeding of the Mixer

The mixer can be fed in automatic or manual operation. For the most
important instructions for mixer feeding refer to Commissioning and
Operation
3.2 Discharge of the Mixer

Discharge of the mixer can be made in automatic or manual operation.

The mixer discharges through a discharge door/ flap with adjustable
opening positions directly into the discharge hopper. The width of the
opening and the opening time depend on the vehicles to be charged
(truck mixers or trucks) and the concrete consistency.For the most
important instructions for mixer discharge refer to Commissioning
and Operation
5-6
SONTH O FEN
3.3 Mixing Capacity

The efficency of the mixer depends on the volume of the product to be
mixed during feeding and during the mixing process and on the
amount of filling.
The admissible values are indicated in the technical specification.

The required settings of feeding time and sequence as well as
discharge time are plant-specific parameters. Basically, all ingedients
of the mix must be metered individually (e.g. steel fibers isolated to
prevent balling of the fibers)

It may be necessary to reduce the degree of filling or to reinforce the
drive unit in case of:
- high share of fines in the mix

- very stiff consisteny
- using chemical additives
- Using special additives (such as steel fibers)
- Feeding sequences deviating from the recommended specifications
(see group Commissioning and Operation)
- Mixing special products

In order to avoid machine overload the proportions of the mix design
should be changed.
• selectively with reduced degrees of filling and

• under observation of the current consumption/drive power
3.4 Sense of Rotation of the Mixing Shafts

The synchronously rotating mixing
shafts are moving in
counterrotation and the sense of
rotation of both mixing shafts must
be such that the mixing tools
between both shafts run upward,
according to the sketch on the right.
6-6
Edition: 07/03 900359800-00E D
Assembly and Electric Connection

SONTH O FEN
1. General Instructions.................................................... 2
2. Assembly Instructions ................................................ 3
2.1 Mechanical work ................................................................... 3
2.2 Testing operations before tightening the mixer fixing
screws.................................................................................... 4
2.3 Transport safety .................................................................... 4
2.3.1 Safety of the discharge door ....................................................... 4
2.3.2 Safety of the discharge flap......................................................... 5
2.4 Welding work......................................................................... 5
3. Electric Connection..................................................... 6
3.1 General prescriptions ........................................................... 6
3.2 Mixer motor............................................................................ 6
3.2.1 Check and adjust direction of rotation of mixing shafts ........... 7
3.2.2 Checking the direction of rotation in case of a double-motor
drive .............................................................................................. 7
3.2.3 Checking the direction of rotation in case of a four-motor drive
...................................................................................................... 7
3.3 Access/maintenance doors in the trough cover ................ 8
3.4 Hydraulic drive ...................................................................... 8
3.5 Central lubrication ................................................................ 8

SONTH O FEN D...
SONTH O FEN
Assembly and Electric Connection - 900359800-00E D
1. General Instructions

For safety instructions and safety requirements see
• Group: User Information

• Group: General Safety Instructions

The erection has a decisive influence on the optimum operation of the
machine.

NOTE!
Because of many years' experience it is recommended to ask the expert
personnel of the machine manufacturer for erection. This is not only useful
for warranty reasons, but also for qualified advice and control, such as
bd00023
• Detection of transport damages

• Checking of test instructions and measures during erection
• Advices for the operation of the machine

After an extended period of storage and before proper use of the machine,
see group: Delivery and Intermediate Storage.
2-8
SONTH O FEN
2. Assembly Instructions
2.1 Mechanical work

Technical Documentation: Installation Drawing
• connecting dimensions
• machine weight
• static and dynamic load indications

ATTENTION!
Open loading.
• Only attach the machine to the special eyelets.
bd00023
• The pull direction of the suspension gear to
the horizontal may not fall below an angle of
45°!

During suspension avoid excessive distortion
of the machine/plant in order to prevent
bd00035
damages.

Erection
• horizontal and even

• on sufficiently dimensioned steel or concrete foundation

ATTENTION!
Welding work
• connect the ground cable always directly near the treated

bd00023
component
• welding current must never flow through the rolling bearings

Good accessibility for the following maintenance and repair work:
• opening of maintenance doors in the trough cover

• change of mixing arms
• mixing shaft dismantling and mounting
• removal and installation of wearing parts
• maintenance work on the drive
• cleaning of the mixing trough interior space

For space requirements see Technical Documents: Installation Drawing.
3-8
SONTH O FEN
2.2 Testing operations before tightening the mixer fixing

screws

The mixing tools should be rotated several times by hand on the V-belt
drive to make sure that the lateral arms do not touch the front wall. Should
this be the case, the mixing trough has got distorted while it has been
placed on the steel structure. in this case, shims must be inserted under the
supporting claws of the mixer.

Check the synchronizing coupling at the mixer drive (between both gear
units) in vertical and horizontal direction for true alignment. If any
unacceptable alignment errors are found, these must be attributed to
uneven installation of the mixer, see group: Maintenance and Inspection.

Procedure for Mixer Alignment:
• drive in slim steel wedges between supporting claws of

the mixer and steel structure
• repeated checks of the above mentioned controls

Good alignment has been achieved when the lateral arms no longer touch
the front walls and when the misalignment of the synchronizing coupling has
been reduced to admissible tolerances.

NOTE!
Proper alignment of the mixer will prevent failures of the discharge door/
flap and the mixer drive.
bd00023
2.3 Transport safety
2.3.1 Safety of the discharge door

ATTENTION!
The discharge door is locked by socket pin safety.

Loosening of locking
bd00023
• release locking screw (4)

• pull socket pin (2) from
locking pipe (3)
• insert socket pin (2) in
safekeeping eye (1)

DANGER!
For all repair work, e.g. replacement

of wearing parts (mixing blades, tiles,
bd00023 etc.) or machine parts, insert the dis-
charge door safety in reverse order to
avoid accidents in the zone of the bd00022
discharge door.
4-8
SONTH O FEN
2.3.2 Safety of the discharge flap

ATTENTION!
Mixers with discharge flap have in the reach of the discharge hopper a
transport safety.

bd00023
DANGER!
After connecting the discharge flap control (pneumatic
or hydraulic) close the discharge flap so that the transport safety can
be dismantled without danger of jamming or squeezing.
bd00023

DANGER!
For all work during which the discharge flap cannot be held safely in all
positions because of missing pressure in the cylinders or disconnected
current, the discharge flaps open due to dead weight up to the cg position.
bd00023
For jamming effect the flap could stop even before reaching the cg position.
To work in the mixer, convenient safety measures (e.g. maintenance

scaffolds under the mixer, safety belt for the fitter) must be taken.
bd00028
2.4 Welding work

DANGER!
connected the ground cable always directly near the
treated component

bd00023
welding current must never flow through the rolling bearings!
5-8
SONTH O FEN
3. Electric Connection
3.1 General prescriptions

DANGER!
Admissible connected load (service/control voltage and frequencies) of
motors, valves, limit switches, locking switches, central lubricating unit,
bd00023
must be observed, as otherwise damages and malfunctions may occur!

NOTE!
The regulations of the local electric supply company must be observed.

bd00023 Regulations (e.g. EN 57100 (VDE 0100), or EN 60204 (VDE 0113) must be
observed.
3.2 Mixer motor

Motor data see Technical Specification and Technical Documentation.

DANGER!
Check if motor bearing safety has been unlocked/ removed.

bd00023 When connecting the mixer motor firmly tighten all cable connections and
also check proper fit of all cables inside the mixer.

For electrical installation consider that the mixer operates continuously at
100% connecting time.

It is required that the nominal filling the mixer starts under load.
• Therefore, besides of the normal start in star-triangle (to start the

mixer at no load), a switch for direct start under load must be
provided in the control.
• The time lag relay of the star-triangle combination has to be set to 2.5 – 3.0
sec.

The design of the electric installation for the mixer motor must be adjusted
to the a.m. loads.

Full motor protection via thermistors with posistor temperature probes.

We recommend to install in the control desk an ammeter for the mixer
motor.
6-8
SONTH O FEN
3.2.1 Check and adjust direction of rotation of mixing shafts

Check the direction of rotation of mixing shafts at no-load operation.

The mixing tools must rotate towards the discharge door.
3.2.2 Checking the direction of rotation in case of a double-motor drive
ATTENTION!
Prior to starting the motors together first start each motor separately and
check the direction of rotation.
bd00023
Only when both motors are rotating in the same direction as the mixing
shafts they are allowed to be started simultaneously!
3.2.3 Checking the direction of rotation in case of a four-motor drive
ATTENTION!
Check direction of motor rotation only after V-belts have been removed.
bd00023
Only when all motors are rotating in the correct direction, they are allowed to
be started simultaneously!
ATTENTION!
When starting the mixer after having installed all V-belts, turn on all
motors simultaneously!
bd00023
Looking onto the Looking onto the

motor shaft motor shaft
Looking onto the Looking onto the

motor shaft motor shaft
7-8
SONTH O FEN
3.3 Access/maintenance doors in the trough cover

DANGER!
The access/maintenance doors are protected by a safety limit switch and a
safety locking switch, see group: General Safety Instruction, Item: Safety
Installation on the machine/plant - Safety of Access/ Maintenance doors.
bd00023

Before commissioning, correctly connect the safety limit switch and the
safety locking switch and check their function.

Data for the safety limit switch and the safety locking switch
(electromagnetic locking unit) see Technical Documentation.
3.4 Hydraulic drive

see Technical Documentation
3.5 Central lubrication

8-8
Edition: 07/03 900359900-003 J
Commissioning and Operation

SONTH O FEN
2. Checks prior to Starting.............................................. 5
2.1 Erection of the Mixer............................................................. 5
2.2 Screw Connections............................................................... 5
2.3 Mixing Trough ....................................................................... 5
2.4 Discharge Door / Discharge Flap......................................... 6
2.5 Mixing Tools .......................................................................... 6
2.6 Drive ....................................................................................... 6
2.7 Lubrication............................................................................. 7
3. Function Tests without Load...................................... 8
3.1 Controls before Connection of the Machine....................... 8
3.2 Controls after Connection with empty Machine ................. 8
3.3 Discharge Door or Discharge Flap(s).................................. 9
3.3.1 Discharge Door/ Flap Operation, Pneumatic .............................. 9
3.3.2 Discharge Door/ Flap Operation, Hydraulic................................ 9
3.4 Central Lubrication ............................................................. 10
3.5 Hydraulic Couplings ........................................................... 10
3.6 Electric Switch Gears ......................................................... 10
4. Commissioning and Continuous Operation............ 11
4.1 Break-in Regulations for slip-on Gear Units..................... 11
4.2 Break-in Regulations before Commissioning the Mixer,
after change of Trough Lining ........................................... 11
4.3 Mixer Feeding ...................................................................... 11
4.3.1 General Instructions .................................................................. 11
4.3.2 Correct feeding........................................................................... 12
4.3.3 Sequence of feeding .................................................................. 13
4.4 Discharge of Mixer .............................................................. 14
4.4.1 Discharge into Truck Mixers...................................................... 14
4.4.2 Discharge on to Trucks.............................................................. 14
4.5 Continuous Operation ........................................................ 15
4.6 Replacement Gear Units..................................................... 15
4.7 Temperature check on Hydraulic Aggregate.................... 15
4.8 Mixing Operation................................................................. 15
4.8.1 Automatic Operation.................................................................. 15
4.8.2 Manual Operation....................................................................... 16
4.8.3 Stopping the Mixer ..................................................................... 16
4.9 Extraordinary Operating Conditions ................................. 17
4.9.1 Extended Mixing Time ............................................................... 17
4.9.2 Operation in Winter.................................................................... 17
4.9.3 Heavy-Load Starts with full Mixer ............................................. 17

SONTH O FEN D...
Edition: 07/03 900359900-003 J
Commissioning and Operation

SONTH O FEN
4.9.4 Heavy-Load Start with Overfilled Trough (Emergency Start) .. 17

Operating Instructions 4.9.5 Emergency Standstill during Mixing Operation ....................... 18
4.9.6 Mechanical Defect ...................................................................... 18
4.9.7 Power Failure - Manual Opening of Discharge Door................ 18
4.9.8 Actions prior to and after Extended Standstill ......................... 19
5. Failures and Malfunctions ........................................ 20
5.1 Safety and Protective Devices ........................................... 20
5.2 Trouble Shooting in case of anomalous Operating
Performance ........................................................................ 20

SONTH O FEN D...


SONTH O FEN
Starting and Operation - 900359900-003 J

For Safety Instructions and Safety Requirements refer to:
• Group: Information for User


Commissioning are all operating conditions for which a machine is used for
the fist time or reused after an extended interruption; refer to group:
Delivery and Intermediate Storage.

The initial operation has a decisive influence on the optimum performance
of the machine/plant.

NOTE!
Because of manifold influences, we strongly recommend to ask for expert
personnel of the machine manufacturer for commissioning. This is necessary
not only for warranty reasons, but also serves to provide expert advice and
bd00023 control, such as:
• Detection of assembly defects and errors made during the erection of the
machine
• Checking of test instructions and measures during starting
• Additional advices for the operation of the machine (starting, feeding,
mixing, discharge, etc.)

Follow the information signs on the machine !

DANGER!
disconnect the machine immediately if
• there are high vibrations

bd00023
• important safety defects are found
• hazards result from escaping materials
• critical operating conditions, e.g. overload, are to be expected

ATTENTION!
If the emergency switch has been operated:
• clarify the reason

bd00023 • remedy the reason
before restarting the machine.

The control measures for starting have to be executed before
• the fist commissioning

• further starts after extended standstill (winter break or repair work)
3 - 22
SONTH O FEN

ATTENTION!
For control measures in/on the machine and with dismantled protective
devices
• repair switch "STOP" and locked

bd00023
• keep key safe against unauthorized access
• install information sign "Maintenance Work" on the repair switch.

ATTENTION!
For control measures that necessitate a stay inside the machine, install the
discharge door/flap safety device, refer to group: Maintenance.
bd00023
4 - 22
SONTH O FEN
2. Checks prior to Starting
2.1 Erection of the Mixer

For assembly and connection of the machine refer to group: Assembly and
Electric Connection.
2.2 Screw Connections

All screws at the mixing trough, mixing tools, mixer drive and discharge
door/flap, etc. must be checked for tight fit and tightened if necessary !
For screw tightening moments refer to Technical Documentation.
2.3 Mixing Trough

Check:
• horizontal alignment of the casing
• distortion of mixing trough by measuring the radial displacement on the

synchronizing coupling, refer to group: Maintenance and Inspection.
• tight connection of input and outlet components (e.g. trough cover)
• correct and safe installation of all feed and discharge devices
• correct seating of wear lining so that mixing plates cannot get caught
• if all rotating and moved parts (e.g. V-belt drive) have protective devices
installed
• if all doors and covers are closed and locking screws, quick acting closures,
resp., are a tight and safe fit
• correct installation of safety limit switches and safety locking switches on the
maintenance doors
• all screw connections, screw tightening moments: refer to Technical

Documentation
• weld seams (visual crack control)
5 - 22
SONTH O FEN
2.4 Discharge Door / Discharge Flap

Correct removal of maintenance and transport safety devices off the
discharge door /flap(s), refer to group: Assembly and Electric Connection.
2.5 Mixing Tools

Check:
• if mixing tools are correctly fixed

• gap width of blade outer edges to the mixing trough (appr. 3 mm)
• if mixing shaft if rotating freely
2.6 Drive
Check:

V-Belt Drive
• V-belt tension - refer to Technical Documentation

• Correct seating and alignment of V-belts between drive pulley and driven
pulley
• Tight fit of the Taper-Lock Collets, the end disk of the V-belt pulleys, resp.,
refer to Technical Documentation: Screw Tightening Moments

Guards of V-belt drive(s) and synchronizing coupling for proper attachment
and condition.

ATTENTION!
Motor
bd00023 • remove motor safety, refer to Technical Documentation: three-phase motor

• motor connected loads
• sense of rotation, refer to group: Erection and Electric Connection
• motor with re-lubricating device: as a precaution lubricate both bearings
immediately before the first commissioning (with rotating motor)
• commissioning after extended standstill, refer to group: Delivery and
Intermediate Storage

Synchronizing Coupling
• Alignment refer to group: Erection and Electric Connection and

group: Maintenance and Inspection.
6 - 22
SONTH O FEN
2.7 Lubrication

Check:
• Oil level in the gearboxes with stopped mixer
- oil level till the center of the sight glass (straight bevel gear)
- oil level till approx. 20 mm below the upper edge of the overflow
connection (worm gear)
• leakage on all hose and line connections for oil, grease and
compressed air supply, retighten if necessary
• oil level in the oil tank (hydraulic aggregate)

the oil level must reach the centre of the sight glass
• grease level in the grease tank (lube pump)

the tank must be filled completely
7 - 22
SONTH O FEN
3. Function Tests without Load
3.1 Controls before Connection of the Machine

Foreign matters must not enter the machine

Disconnect Material Input

Machine empty, without load
• Free turning of V-belt drive by hand
3.2 Controls after Connection with empty Machine

No-load operation: 20 - 30 min.

Switch-over time from star to triangle: 2.5 - 3 sec.
refer to group: Erection and Electric Connection

Sense of Rotation Mixing Shafts
refer to group: Assembly and
Electric Connection
bd00023
bd00025

Unbalance of Mixing Shafts

remarkable Running Noise of
motor, gearbox, bearings,
mixing tools
Remark:
A swivelling running noise in the rhythm of the mixing shaft speed
(overrunning noise) is harmless. Reason: unbalance of the mixing tools.

Tightness of all hose connections

Function and adjustment of all Control Units on the mixer
emergency switch, limit switch, locking unit, ...)

Emergency Switch
for safety favourable installation and function
8 - 22
SONTH O FEN
3.3 Discharge Door or Discharge Flap(s)

DANGER!
When performing adjustment work at the discharge door or discharge flap
operation make sure that nobody is inside the mixing trough.
bd00023

Functional check of discharge door /flap position
• final positions "open" and "closed"

• intermediate positions "1/2 open" or "1/3 open" and "2/3 open"

Reset limit switches, if necessary.
For contactless inductive proximity switches the correct switching distance
is of appr. 5-7 mm.
3.3.1 Discharge Door/ Flap Operation, Pneumatic

DANGER!
bd00023

Air pressure: 8 bars required.

Check of Tightness
on all hose and line connections, e.g. apply soapy water on the connections.

Adjust Maintenance Unit
it comprises: water separator, pressure governor and oil atomizer and it will
supply prepared, i.e. dewatered and oiled compressed air for the pneumatic
cylinders, refer to group: Maintenance and Inspection.

Pneumatic Cylinders
• check function by opening and closing them several times.

• if necessary, readjust final damping.
• refer to group: Maintenance and Inspection.
3.3.2 Discharge Door/ Flap Operation, Hydraulic

DANGER!
bd00023

ATTENTION!
Check and adjust function of hydraulic unit, refer to Technical Documentation.
bd00023
9 - 22
SONTH O FEN
3.4 Central Lubrication

Installation and functional test as per design (grease or oil/air lubrication)
refer to Technical Documentation.

Check grease outlet on axial face seal in mixing trough.

Check tightness on all hose and line connections.
3.5 Hydraulic Couplings

Check Performance during mixing operation.
If an increased temperature (appr. 70°C, 158°F, res p.) is found during
continuous operation, check the oil filling.

Refer to Technical Documentation
3.6 Electric Switch Gears

Functional testing and adjustment of all switchgears on the mixer.

Check function of Safety Limit Switches and Locking Units at the access
hatches of the trough cover. For instructions on the functional test refer to
Group: Maintenance and Inspection.

Check function of Repair and Emergency Switches on the mixer.

Setting of Overspeed Monitor and check proper functioning.
• The mixer drive must be switched off, if speed drops to 10-15% below idling
speed.
• Start bridging is to be set to 10 seconds.
• Functional test: Slowly turn up the knob for precise impulse adjustment at
idling. When reaching the idling speed the mixer motor will be switched off.
The switch-off point under load is 10-15 % below the idling speed.
• For explanations on the overspeed monitor refer to Technical
Documentation.

Voltage Control (cos -monitor) for mixer motor. The value to be set
corresponds to the power factor (cos) of the motor in no-load operation.
10 - 22
SONTH O FEN
4. Commissioning and Continuous Operation
4.1 Break-in Regulations for slip-on Gear Units

No-Load Operation: 30 minutes (without mix)

Break-In Rhythm
1st batch filling = appr. 1/2 nominal filling 60 sec.
2nd batch filling = appr. 1/2 nominal filling 60 sec.
3rd filling = nominal filling 60 sec.
This break-in rhythm must be repeated 20 times.
4.2 Break-in Regulations before Commissioning the Mixer,

after change of Trough Lining
ATTENTION!
The first 10 mixing operations shall be run with very liquid concrete
consistencies and a particle size of max. 4 mm. Thus; the tiles of the trough
lining are backfilled with concrete laitance, which will give additionally support
bd00023
to the tiles after hardening.
After this start-up procedure clean the mixer carefully to not rinse out the
backfilling of the trough lining and allow it to harden
4.3 Mixer Feeding

4.3.1 General Instructions

ATTENTION!
Before starting make sure that the mixer and feeding units are free from
foreign matters which could cause a blockade of the mixing tools.
bd00023

NOTE!
Keep the data agreed by the Technical Specification and the Order
Acknowledgement:
bd00023
- throughput
- type of feed material
- size of feed material
- drive power
• Deviations only after agreement with the machine manufacturer!
• For proper feeding and feeding sequence refer to Technical Documentation.
• Insert Material feeding only if mixing tools have reached the operating
speed.
• Feeding unit
In regular intervals, special during breaking-in, check for obstruction.
11 - 22
SONTH O FEN
4.3.2 Correct feeding

binder aggregates
water
water
1) Position and direction of binder and

aggregate inlets are decisive for short
mixing times and good mixing. They, moreover, will avoid deposits on the
mixing tools.
Recommended arrangement of the feeding devices refer to Technical
Documents, installation drawing
a) The water spraying system consists in a

U-shaped pipe with rows of holes and nozzles.
Liquid admixtures should be added to the water.
b) The rubber tube fixed on the cement inlet must be cut parallel to the
mixing shaft so that it will be slightly touched by the mixing blades at
any revolution (self-cleaning).
12 - 22
SONTH O FEN
4.3.3 Sequence of feeding

Feeding of the additive scale and intermediate vessel must be effected
such that during discharge the coarser fractions enter the mixer at first
followed by the finer fractions (sands)

Feeding of the mixer with aggregates, binders and water must be made in a
determined and timed sequence.

The Twin-Shaft Batch Mixer normally does not require dry mixing times.
The water will generally be called off together with the aggregates or 1-2
seconds later.

It is important that the aggregates are advanced against the binder. When
calling off the binder 80-90 % of the aggregates must already be in the
mixing trough.
aggregates
water
Wasser
binder
filling period mixing time
13 - 22
SONTH O FEN
4.4 Discharge of Mixer

The discharge of the mixer is made through a discharge hopper on to the
transport vehicles or receiving points

NOTE!
It must be assured that with nominal filling capacity and stiff consistency of
the mix approx. 95-96 % of the mixing trough is emptied. If this is not the
case the discharge time must be extended.
bd00023
Instructions on discharge door and discharge flap actuation for various
discharge situations refer to Technical Instructions.
4.4.1 Discharge into Truck Mixers

c) On Twin-Shaft Batch Mixers with "standard discharge door or
discharge flap" an intermediate position "1/2 open" is provided, as a
rule. For exception, however, two intermediate positions "1/3 open"
and "2/3 open" may be provided .
d) On Twin-Shaft Batch Mixers with "large discharge door" two

intermediate positions "1/2 open" and "2/3 open" are provided, as a
rule.

Note:
Control of these intermediate positions, and their holding times, should be
bd00023
adapted to the receiving capacity of the truck mixer, and to the consistency.
Mix Discharge
½ open open
Discharge time
1/3 open 2/3 open open
Discharge time
4.4.2 Discharge on to Trucks

On Twin-Shaft Batch Mixers with "standard and large discharge doors"
discharge will directly take place through the discharge opening "open";
intermediate positions are not used.
14 - 22
SONTH O FEN
4.5 Continuous Operation

Upon termination of the break-in rhythm, start of continuous operation with
nominal filling, refer to Technical Specification.

Temperature check of slip-on gear units
• The external temperature on the slip-on gear units must be measured by

contact thermometer in the input shaft area during the first 10 full load
operating hours after commissioning.

ATTENTION!
Depending on the load, normal gear temperatures are in continuous
operation appr. 25°C to 45°C (77°F to 113°F) higher than the respective
ambient temperature, however the maximum temperature of 90°C (194°F)
must not be exceeded. If higher temperatures are found, reduce the batch
bd00023
filling to half the nominal filling and inform the mixer manufacturer
immediately.
4.6 Replacement Gear Units

When the mixer drive is equipped with a new slip-on gear unit, the break-in
regulations must be repeated.
4.7 Temperature check on Hydraulic Aggregate

refer to Technical Documentation: Operating Instructions for Hydraulic
Aggregate.
4.8 Mixing Operation
4.8.1 Automatic Operation

The mixer drive runs continuously, only for pauses it is switched-off by
hand.

The automatic control function and functional control of a mixing cycle
comprises:
• feeding
• mixing
• discharge

The mix components for each mixing batch will be prepared automatically.

The first mixing cycle begins with time lag after switching the mixer on with
control functions "Discharge door/ flap closed", "Aggregate scale open".

All other control functions for calling water and binder, for mixing and
discharge time, run off program controlled.
15 - 22
SONTH O FEN

The first mixing cycle will be completed with the function message
"Discharge door/flap closed".
For several batches in succession, the cycles are automatically controlled.
They begin each time when electrical interlocking is released by the
message that all weigh- batchers are full and the discharge door/flap is
closed.
4.8.2 Manual Operation

The mix components for each mixing batch can be provided either by
automatic or manual actuation.

After switching on the mixer the mixing cycle begins with the control
function "Discharge door/ flap closed", "Aggregate scale open".

All other control functions for calling water and binder, for mixing and
discharge time, run off program controlled.

The mixing cycle will be completed with the function message "Discharge
door/flap closed".
4.8.3 Stopping the Mixer

Stopping is made as follows:
• stop weighing of mix components.
• open discharge door/ flap and empty the mixing trough with mixing tools
running.
• cut off mixer drive, central lubrication and hydraulic unit.
• prior to short production breaks (45-60 min.) clean the interior of the trough
and discharge door/ flap with a high-pressure water jet, if the mix requires
this. Thus, deposits of mix may far-reachingly be avoided.
• prior to extended interruption and at shift end, clean the mixer - refer to
group: Maintenance and Inspection.
• relubricate inner axial face seal.

DANGER!
Check initial tension of V-belts at every shift end. Re-tension, if
necessary, refer to Technical Documentation.
With slipping V-belts risk of fire and poisoning.

bd00023
• For further notes refer to group: Maintenance and Inspection.
16 - 22
SONTH O FEN
4.9 Extraordinary Operating Conditions
4.9.1 Extended Mixing Time

Mixing times of more than 2 minutes mean:
• increased wear
• additional thermal stress on the drive, specially with stiff mix consistency.
4.9.2 Operation in Winter

NOTE!
If the ambient temperature is appr. -10°C (14°F) th e mixer must be idling for a
minimum of 30 minutes prior to commencing the work.

bd00023 If the temperatures drop even lower, the gear units and motors should
additionally be heated from outside with hot air by means of fan heaters.
4.9.3 Heavy-Load Starts with full Mixer

NOTE!
Star-Delta Starting
• On mixer drives with hydraulic couplings, starting under heavy

bd00023 load with nominal batch filling of the mixer is always made in star-
delta connection.
• Switching over from star to delta in 2.5 - 3 seconds.

NOTE!
Direct Starting
On mixer drives without hydraulic couplings, starting under heavy load with
nominal batch filling of the mixer is always made in delta connection (direct
bd00023
starting).
4.9.4 Heavy-Load Start with Overfilled Trough (Emergency Start)

NOTE!
With overfilling by a second batch due to control failure
• open discharge door or flap

bd00023
• empty the mixing trough and, if required, rinse with water.

Clearing of the mixing trough may be accelerated by jerkily starting of the
mixer drive, but only when both mixing shafts have become visible.
However, observe that the type of heavy-load start depends on the design
of the mixer drive.
17 - 22
SONTH O FEN

If the mixer drive does not draw through for clearing the mixing trough,
• the duration of switching on the motors must not exceed 2 seconds

• the frequency of switching-on is limited to max. 3 times one after the other.
4.9.5 Emergency Standstill during Mixing Operation

ATTENTION!
if the emergency switch has been actuated, restart the machine only after
bd00023
• clarifying the reason
• elimination of the reason

As a rule, this means that the mixing trough if left filled with mix.

NOTE!
If, within a short period of time (appr. 10 min.), e.g. with concrete mix, the
cause of the standstill cannot be eliminated, the discharge door/flap must
bd00023
immediately be opened and the mix be discharged.
4.9.6 Mechanical Defect

Knock out the bolt of the fork head connection discharge door/flap -
pneumatic/hydraulic cylinder.

Swing out sideways the pneumatic/ hydraulic cylinder.

Open discharge door/flap by means of a bar (lever action).

DANGER!
Discharge door/flap could open suddenly !
bd00023
4.9.7 Power Failure - Manual Opening of Discharge Door

NOTE!
In case of a power failure manual opening has to be done according to the
existing discharge door operation.
bd00023
Manual opening of the discharge door/flap should be trained before an
emergency occurs already; in case of an emergency it will be too late !
18 - 22
SONTH O FEN
Manual Opening of Discharge Door with Pneumatic Actuation
• Discharge door/flap can be actuated on one or both sides with pneumatic

cylinders, where the compressed air for either side will be controlled by a
5/3 ways solenoid valve.
• Each solenoid valve has two manual emergency controls for switching
functions "open" and "close", which will be actuated by turning or pressing.
• Procedure for opening:
- Turn or press manual emergency actuation "open" on the 5/3 ways

solenoid valve. When two valves are provided, both must be
actuated simultaneously.
- The compressed air available in the compressor will be sufficient for
actuation.
- When the trough is empty the manual emergency actuations should
be returned to their zero positions.

Manual Opening of Discharge Door with Hydraulic Actuation
refer to Technical Documentation: "Operating instructions for hydraulic unit"
4.9.8 Actions prior to and after Extended Standstill

Actions prior to extended standstill
refer to group: Delivery and Intermediate Storage

Commissioning after extended standstill
refer to group: Starting and Operation
19 - 22
SONTH O FEN
5. Failures and Malfunctions
5.1 Safety and Protective Devices

Group: Information for User
Group: General Safety Instructions

DANGER!
Removed protective devices are a considerable factor of risk and must
be mounted again on completion of the work.

bd00023
To find the causes of failures with running machine, the existing
safety and protective devices must not be removed.
5.2 Trouble Shooting in case of anomalous Operating

Performance
Symptom Reason Action
Running noise on motor - Bearing defective - Replace bearing

- Fan blade grazes at fan hood - Align or replace deformed
fan blade
Mixer does not start when - Motors are running in - Change sense of rotation of
empty (often during opposite directions in case one motor (observe correct
commissioning) of two-motor drive rotation of mixing shafts!)
- Hydraulic clutch without oil - Refill oil
Periodic running noise on gear - Overriding noise in the - None - harmless
units when idling gearing, caused by
unbalance of the mixing
tools
Running noise on gear units - Bearing damage or - Contact BHS
when idling beginning gearing damage
Running noise on hydraulic - Bearing damage - Replace bearing
coupling(s) filling - Too much oil - Check oil
Unsteady running of mixer - Bearing damage of - Replace bearng
drive hydraulic coupling
- Cement sticking to coupling - Clean hydraulic coupling
and V-belt pulley and V-belt pulley
Discharge door/flap closes - Damping on cylinders too - Adjust damping harder.
abruptly screw soft. Turn adjusting to the right.
- Throttle back valve opened - Reset.
too far
20 - 22
SONTH O FEN
Discharge door/flap jams when - Sealing gap too big - Reset sealing ledges.
closing - Damping on cylinders too - Adjust damping softer.
hard Turn adjusting screw to the
- Water in the pneumatic left.
cylinder. - Dewater compressed air.
- Air in the hydraulic cylinder. - Remove water from
cylinder.
- Deaerate pipes.
-
Discharge door (pneumatic) - Stones jammed between Attention:
does not open discharge door ledge and Depressurize
drum protection pneumatic cylinders
- Release screws at pedestal

bearings of discharge door
drum and lower discharge door
by approx. 2 mm.
- Pressure of pneumatic supply - Increase pressure of the

line below 8 bar pneumatic line
Intermediate positions for - Cylinders, valves or line - Replace cylinder seals and
discharge door/flap overrun connections are leaking. valves.
- Tighten connections or
replace sealing rings.
- Limit switch defective. - Replace limit switch.
Mixer stops - V-belt tension insufficient.

- Not enough oil in hydraulic - Re-tension V-belts.
coupling - Check oil filling.
- Electrical reason. - Check electric supply,
- Wrong feeding of mixer fuses, voltage, etc.
resp. proportioning - Check feeding of mixer and
proportioning quantity
Formation of deposits on - Wrong feeding of mixer, - Set cement and aggregate

mixing shafts, mixing tools and e.g. cement called too early, call correctly.
trough cover water called too late,
aggregate and cement inlet - Maybe change inlet
not optimal situation.
- Cement inlet pipe without - Mount rubber hose.
rubber hose.
Clogging in the discharge - First intermediate discharge - Reduce first intermediate

hopper position (e.g. for stiff discharge position.
concrete) too big (capacity
of truck mixer insufficient)
Loud mixing noise - Blade gap too big - Readjust lateral and central
blades
21 - 22
SONTH O FEN
-
Excessive wear on mixing and - Blade gap too big. - Readjust lateral and central
wearing tools - Sealing gap on discharge blades.
door/flap too large. - Reset sealing ledges.
- Mixing time too long. - Reduce mixing time.
- Broken and abrasive - Optimize feeding and
additives. discharge in order reduce
time
Cement slurry leaking outside - Axial face seal damaged - Replace axial face seal
at mixing shaft sealing due to insufficient
lubrication
Hydraulic clutch drains oil - Overload of coupling due to - Open discharge door and
surcharge or starting with remove material (refer to
full mixer starting under load with
surcharged mixer)
- Increased slipping because - Check oil filling
of insufficient oil filling
22 - 22
DKX
Edition: 02/04 900360100-00E F
Servicing and Inspection

SONTH O FEN
f1. General Instructions.................................................... 2

2. Service and Inspection Plan ....................................... 4

SONTH O FEN D...
Twin-Shaft Batch Mixer D
SONTH O FEN
Servicing and Inspection - 900360100-00E F

Safety instructions and safety requirements see


ATTENTION!
Start control and maintenance operations and open covers, doors, guards and
other machine parts only if
• repair switch is position "OFF" and locked by key

•
bd00023
key is kept safely against unauthorized use
• warning sign "Maintenance Work" is installed on the repair switch
• slow down period of moving machine parts is over.

DANGER!
before starting, check the machine and eliminate dangers:
• protective devices must be installed

bd00023 • casing must be closed and secured
• tools in and on the machine must be removed
• danger for maintenance work around the machine and
on machines in the process line

NOTE!
Insufficient or poor maintenance and servicing increase susceptibility to
trouble and repair and reduce guaranty performance.
bd00023

NOTE!
The following Maintenance and Inspection Table applies for:
• single shift operation

bd00023
• treatment of mixes which cause normal wear

NOTE!
The user has to determine, correct, resp., the Maintenance and Inspection
Table according to his operating conditions.
bd00023
The Maintenance and Inspection Table can deviate from the following plan
if:
• very abrasive material is treated

• the exploitation is carried out under unfavourable climatic conditions
• the machine is operated in several shifts

ATTENTION!
Electrical installation, control cabinets, motors, gears, auxiliary units
such as centralized lubrication, drives, hydraulic and pneumatic
bd00023
installations may not be cleaned by pressure washers.
2-8
SONTH O FEN

NOTE!
After removal, replace fixing elements, e.g. screws, nuts, bolts, by new ones
of identical quality (material, strength) and design.
bd00023
For tightening torques of screw connections see Technical Documentation.

NOTE!
Even after commissioning it is for all screw connections on the mixer
imperative to survey further on tight fitting and, if necessary, to retighten
with the respective tightening torque. All moving parts, e.g. drive, mixing
tools, discharge door/ flap, have specially to be monitored.
bd00023

Mind information signs on the machine!

DANGER!
Install a safeguard against rotation!
If for maintenance operations personnel is in the mixing space, all
mixing shafts and the discharge door/discharge flap must be
safeguarded against rotation:
• put wedges between the mixing blades and trough walls or

• put one wedge on each side of the V-belt pulley on the gearbox to
block the V-belt drive (only with installed synchronous coupling!)
bd00023 • install discharge door/discharge flap safety device, refer to group:
Maintenance.

After termination of the maintenance operations remove the safeguard
against rotation.
3-8
SONTH O FEN
2. Service and Inspection Plan

Checking period
hours
from to Item Subassembly Maintenance unit Scope of control or maintenance
h h
8 10 Drive V-belts
(new) - Check V-belt tension
- Short inspection algorithm and retightening
until there are no more setting phenomena
8 10 Hydraulic plant Aggregate - see Technical Documentation
8 10 Mixer Trough interior

Mixing tools - Cleaning of mixing trough in
Discharge dependence of mix properties
door/flap - Short intermediate Cleaning is more
Trough cover efficient and cheaper than one cleaning at
shift end.
- Cleaning with press-water jet (50-80 bar)
- At cleaning open and close discharge
door/flap several times.
- With wet mixes after cleaning the trough
interior, mixing tools, discharge door/flap,
trough cover spray with concrete solvent.
- Electric devices (motor, solenoid valve,
limit switch, pumps, etc.) do not pressure
clean with steam or water jet.
- Let V-belts dry.
Note
Only fill floating ring seal with grease after
having cleaned the interior of the trough
8 10 Central Pump - Functional test

lubrication Control - Tightness
grease Pipings - see Technical Documentation
40 50 Drive Gearbox - Gearbox temperatures measured with

contact thermometer at drive shaft:
25 °C - 45 °C higher than ambiance
maximum temperature 90 °C
40 50 Drive Motor - Noise

Gearbox - Unbalance
Coupling - Wear
- Correct fixing
- Grease, oil leakage
- Temperature
- Clean cooling ribs
- Further indications see Technical
Documentation
4-8
SONTH O FEN
Checking period
hours
h h
40 50 Drive V-belts - For prolongated use check tension see
Technical Documentation.
- Replace V-belts not individually, but in sets
only (assorted lengths).
40 50 Discharge - Functional test
door/flap
40 50 Discharge Cylinders - Check:
door/flap Tightness
operation Correct fixing
- Functional test

Open and close several times
If end position is jerkily reached end
damping „E“ of the cylinders is set too

hard. Turn the setscrew left to set it
softer.
If the end of a stroke is indicated by a
metallic blow end damping „E“ must be

harder. Turn the setscrew right to set it
harder.
- After having adjusted the damping, tighten
the counter nut of the setscrews.
bd00015
40 50 Discharge Pedestal bearings - Clean outside

door/flap
40 50 Discharge Limit switch - Functional test
door/flap solenoid valve - Switching position
operation - Eliminate defects
40 50 Discharge Hydraulic plant - see Technical Documentation
door/flap
40 50 Discharge Hydraulic cylinder - Check:
door/flap Function
Tightness
Correct fixing
Open and close several times
40 50 Mixer Feeding - Feeding sequence

Discharge - Trough discharge (95-96 %)
5-8
SONTH O FEN
Checking period
hours
h h
40 50 Mixing tools Mixing blade - Remove cement adherences.
Mixing arm - Check wear condition, see Technical
Mixing shaft Documentation
- Replace used parts, if necessary
- Tight fit of mixing arms on shaft (screw
tightening torque see Technical
Documentation)
- Tight fit of mixing blades on arms.
- Gap between mixing blades and trough
wall approx. 5 mm.
- Adjust mixing blades, if necessary
40 50 Mixing trough Wearing tiles - Check wear condition, replace if

Dust cover necessary.
Wearing ring - Parts items see spare parts list
40 50 Trough cover Safety limit switch - Functional test:
With open access hatches of the trough
cover it must not be possible to start the
mixer.
40 50 Trough cover Safety locking - Functional test:
switch This switch locks the access hatches of the
trough cover while the mixer is running.
Locking ends only with the electric signal
„mixer switched off“.
40 50 Trough cover - Wear
- Correct fixing of feed devices.
200 300 Drive Synchronous - Check rubber elements for cracks.
coupling - If cracks are found, replace rubber
Typ: MCF elements immediately.
- Check alignment.
- ATTENTION!
Before uncoupling the synchronous
coupling secure mixing shafts against
twisting. The correct position of mixing
tools is marked on the shaft ends.
Before and after coupling check correct
mixing tools position.
- Check mismatch a in two planes with a
ruler, max. mismatch ± 1 mm
bd00014
6-8
SONTH O FEN
Checking period
hours
h h
200 300 Antrieb Bellows coupling - In case of drives with 4 gears, one side is
equipped with a bellows coupling.
- Check alignment
- ATTENTION!
If the coupling on the opposite side is also
loosened before decoupling the
synchronous coupling, secure mixer spiral
against twisting. The right mixer position
is identified at the mixer spiral ends.
Check the right mixer position before and
after coupling.
- Check eccentricity a with ruler in two
levels, max. misalignment: ± 1 mm
200 300 Drive Synchronous - Check circumferential backlash, if it
coupling exceeds 3 mm, replace rubber set.
Type: N-Eupex - Check alignment.
- ATTENTION!
Before uncoupling the synchronous
coupling secure mixing shafts against
twisting.
The correct position of mixing tools is
marked on the shaft ends. Before and after
coupling check correct mixing tools
position.
gap: s = 2 - 4 mm
check mismatch in two planes with a
ruler: amax = ± 0,15 mm

circum. Backlash: v
max = 3 mm
tighten locking screws f.
bd00024
200 300 Dischare Sealing gap - Check:

door/flap Sealing function
Wear
- Readjust sealing, if necessary

200 300 Mixing trough - Wear check
- Deformations
- Untight junctions
200 300 Protective hoods Drive - All-round protection of rotating and moved
V-belt drive parts against touching
Pneumatic/ - Safe fixing
Hydraulic - Cleaness
cylinders
7-8
SONTH O FEN
Checking period
hours
h h
1.000 1.500 Hydraulic plant Return filter - Check
Air filter - Change if necessary
- see Technical Documentation
1.500 2.000 Hydraulic plant Hand pump - Operate
1.500 2.000 Central grease Grease tank - Clean
lubrication - see Technical Documentation
4.000 5.000 Drive Motor - Antifriction bearings to be checked and
cleaned by motor specialist
- Replace bearings, if necessary.
8-8
DKX
Edition: 11/04 900401500-009 L
SONTH O FEN
Lubrication
1. General Instructions...................................................... 2
2. Lubrication Versions..................................................... 3
2.1 Manual grease lubrication of all lubrication points.............. 3
2.2 Central lubrication-grease, manual grease lubrication of all
lubrication points .................................................................... 3
2.3 Central lubrication- grease with control unit, manual grease
lubrication of subordinate lubrication points ....................... 3
2.4 Central lubrication-grease with control unit to supply all
lubrication points .................................................................... 3
2.5 Central lubrication oil-air with control unit, manual grease
lubrication of subordinate lubrication points ....................... 4
2.6 Central lubrication-oil-air with control unit, combined with
grease pump with control unit to supply all lubrication
points 4
3. Lubrication chart ........................................................... 6

SONTH O FEN

Spare parts: Tel. 08321 / 802 144 - 802 146 Fax 08321 / 802 120
Twin-Shaft Trough Mixer DKX
SONTH O FEN
Lubrication - 900401500-009 L

Safety Instructions and Safety Requirements see:
• Group: User Information

NOTE!
Insufficient or poor lubrication increases susceptibility to malfunctions and
repair and affects the warranty clause.
bd00023
Specific lubrication charts may deviate from the following chart if:
• operation is made under unfavourable climatic conditions
• low-consistency mixtures are processed
• high-temperature products are mixed
• the machine works in multi-shift operations
• if strongly abrasive materials are processed (adjustment of
sealing gap)

NOTE!
The user has to determine and, if necessary, amend the Lubrication Chart
to suit individual operating conditions.
bd00023

Observe indicating labels on the machine!

Lubricants, such as oils and greases must be stored in clean, closed
recipients (tins, cans, hobbocks, barrels) to prevent entry of dust and
moisture, and to keep the oxidation effect of the air as low as possible. The
place of storage should be dry and cool.

The delivery devices (grease presses, oil cans ...) must also be clean (free
from dust and moisture)!

NOTE!
Lubrication work must always be carried out after cleaning the mixer,
otherwise the lubricants might get rinsed off or washed away again!
bd00023
Hardened mix components at the inner mixing trough seal may cause
the destruction of the axial face seal!
NOTE!
For any accessory units and maintenance equipment attached to the
machine, such as gear unit, fluid coupling, oil-air central lubrication,
hydraulic system, only use recommended lubricants, see: Technical
bd00023
Documents. .

NOTE!
Using a central lubrication system shall not release you from carrying out
inspections! In case of a machine breakdown the manual lubrication stated
bd00023
in the lubrication chart under item 2.1 refers.

When using central lubrication systems make regular checks to verify
whether warning signals (e.g. grease tank empty) are shown and
transmitted correctly to the control unit.
2 - 11
SONTH O FEN
2. Types of Lubrication
2.1 Manual grease lubrication of all lubrication points

All lubrications points are greased by hand.

With the new mixer line, the most important lubrication points are combined
on two central points.
2.2 Central lubrication-grease, manual grease lubrication

of all lubrication points

to supply grease to the inner sealing chamber of the mixing shaft seal
during operation of the mixer!

NOTE!
After cleaning the mixer, greasing of these lubricating points must still be
effected manually.
bd00023

Use if a particularly high share of low-viscosity concrete types shall be
mixed.
2.3 Central lubrication- grease with control unit, manual

grease lubrication of subordinate lubrication points

to supply lubricant to the internal sealing chamber of the mixing shaft seal
during operation of the mixer!

NOTE!
These lubrication points are greased after cleaning the mixer. The
lubrication process is actuated manually through the pump control unit.
bd00023

The personnel is relieved from the most time-consuming lubrication
process.
2.4 Central lubrication-grease with control unit to supply

all lubrication points

to supply lubricant to all important grease lubrication points during operation
of the mixer!

Depending on the design, the system may consist of two pumps or one
pump.
bd00023
3 - 11
SONTH O FEN

NOTE!
Lubrication of the inner grease chamber after cleaning of the mixer is
effected by manual actuation of the lubrication process via the pump control
unit.

Owing to this system the machine requires very little maintenance in the
field of lubricant supply.
Subject to correct integration of the control unit and maintenance of the
system the working reliability of the machine and service life of the parts is
increased.
2.5 Central lubrication oil-air with control unit, manual

grease lubrication of subordinate lubrication points

to supply the internal sealing chamber of the mixing shaft seal with an oil-air
mixture.

NOTE!
Lubricating the internal sealing chamber after cleaning of the mixer is to be
bd00023
ensured by a slowing down time of the oil-air application to the sealing
points.
Slowing down time: approx. 30 min

NOTE!
The oil filling devices and oil storage tanks must enable an absolutely
bd00023
contamination-free transfer of the oil into the storage vessel.

Lubricant consumption is very small as compared to grease lubrication.
2.6 Central lubrication-oil-air with control unit, combined

with grease pump with control unit to supply all
lubrication points

to supply the internal sealing chamber of the mixing shaft seal with an oil-air
mixture.

to supply all important grease lubrication points with lubricant during
operation of the mixer!

The system comprises a central oil-air lubrication unit and a central grease
lubrication unit.
4 - 11
SONTH O FEN

NOTE!
Lubricating the internal sealing chamber after cleaning of the mixer is to be
ensured by a slowing down time of the oil-air application to the sealing
points.
Slowing down time: approx. 30 min
bd00023

NOTE!
The oil filling devices and oil storage tanks must enable an absolutely
contamination-free transfer of the oil into the storage vessel.

bd00023 Lubricant consumption is very small as compared to grease lubrication

Owing to this system the machine requires very little maintenance in the
field of lubricant supply.
Subject to correct integration of the control unit and maintenance of the
system the working reliability of the machine and service life of the parts is
increased.
5 - 11
SONTH O FEN
3. Lubrication chart
2 2
1 1
6
1. Internal sealing chamber of the mixing shaft seal

Sealing point to the interior space of the mixing trough – most highly stressed
sealing point.
Grease filling prevents mix components from entering the sealing chamber
bd00023
– red lubricating nipples
2. External sealing chamber of mixing shaft seal
Supplies sliding faces of the seal with grease – yellow lubricating nipples
3. Hinges of discharge door operation
4. Gear oil level
5. Motor bearing
6. Mixing shaft bearing – blue lubricating nipples
7. Discharge door bearing – blue lubricating nipples
8. Ball joints at the torque support
9. Limit switches / hinges at the trough cover
6 - 11
SONTH O FEN Lubrication - 900401500-009 L
Inspection Type of lubrication

period
from until Pos. Subassembly Maintenance Scope of inspection and Amount
2.1
2.2
2.3
2.4
2.5
2.6
unit maintenance work of
grease
h h g
8 10 X X X X X X Discharge door lubrication unit - oil level
operation - oil temperature
hydraulic - check lines and screw
(option) connections for oil leakages
- see Technical Documents
8 10 1 X X Mixing trough inner sealing - clean lubricating nipples

seal chamber of - regrease until clean grease
shaft sealing comes out on the inside of the
mixing trough
- NOTE!
bd00023 Fill grease into the sealing
chamber only after having
cleaned the interior of the trough
8 10 1 X X X Mixing trough internal sealing - actuate the central lubrication at
seal chamber of the control unit
shaft sealing - Check (commissioning phase)
whether clean grease comes out
on the inside of the mixing trough
bd00023 - NOTE!
Fill grease into the sealing
chamber only after having
cleaned the interior of the trough
7-11

period
2.1
2.2
2.3
2.4
2.5
2.6
grease
h h g
8 10 X X X X Central lubrication / - proper function unless the
lubrication control unit devices are integrated in the
control unit of the plant.
(warning signals see Technical
Documents
-
8 10 X X X X Central grease vessel - check grease level, refill if
lubrication necessary
grease
8 10 X X Central oil tank - check oil level, refill if necessary
lubrication
oil-air
40 50 2 X X X X Mixing trough external sealing - clean grease nipples
seal chamber of - regrease until clean grease
shaft seal comes out on the outside
(labyrinth design)
40 50 2 X X X X Mixing trough external sealing - clean grease nipples 10
seal chamber of - regrease
shaft seal
(shaft sealing ring
design)
40 50 3 X X X X X X Discharge door hinges - oil
operation pneumatic - spray (e.g. using MoS2-spray)
pneumatic cylinder
8-11

period
2.1
2.2
2.3
2.4
2.5
2.6
grease
h h g
40 50 3 X X X X Discharge door hinges - clean grease nipples 5
operation hydraulic - regrease
hydraulic cylinder
(option)
40 50 4 X X X X X X Drive gear unit - check:

•gear oil level, refill oil if required
•gear temperature
200 300 7 X X X X Discharge door/ pedestal bearing - clean greasenipple 5

discharge flap - regrease
200 300 X X X X X Central lubrication unit(s), - proper connection of lines

lubrication lines - tightness
- function
200 300 X X Mixing trough internal sealing - check slowing-down time to spray
seal chamber of the oil-air mix (until approx. 30
shaft sealing minutes after the mixing trough
cleaning has ended)
9-11

period
2.1
2.2
2.3
2.4
2.5
2.6
grease
h h g
200 300 1 X X Mixing trough internal sealing - check whether clean grease
seal chamber of comes out on the inside of the
shaft sealing mixing trough
- NOTE!
Owing to wear in the labyrinth are
the amount of grease may
bd00023
increase during the service life.
The cycle time of the pump must
then be adapted accordingly
(see Technical Documents).
200 300 X X X X X X Discharge door lubrication unit - First oil change

operation (oil type and amount see
hydraulic Technical Documents)
(option)
200 300 6 X X X X Mixing shaft - clean grease nipples 20
bearings - regrease
200 300 8 X X X X Drive ball joints on - clean grease nipples 5

torque support - regrease
200 300 9 X X X X X X Trough cover limit switches - oil
hinges
200 300 X X X X X X Discharge door lubrication unit - check return line filter, replace if
operation required
hydraulic - check air filter, replace if required
(Option)
10-11

period
2.1
2.2
2.3
2.4
2.5
2.6
grease
h h g
1000 1500 X X X X X X Drive gear unit - first oil change
(oil type and amount see
Technical Documents)
-
1500 2000 5 X X X X X X Drive motor bearing - clean lubricator nipples 45
with regreasing - regrease
device
6000 9000 4 X X X X X X Drive gear unit - oil change
10000 15000 X X X X X X Drive fluid coupling - oil change
(option) (oil type and amount see
Technical Documents)
20000 22000 5 X X X X X X Drive motor bearings - rinse bearings
without - replace defective bearings
regreasing - change grease (see maintenance
device instructions on motor)
20000 22000 X X X X X X Discharge door lubrication unit - oil change

operation - see Technical Documents
hydraulic
(option)
11-11
DKX
Edition: 07/03 900360500-00E H
Maintenance
SONTH O FEN
2. Discharge Door Safety ................................................ 4
3. Discharge Flap Safety ................................................. 5
4. Trough Wearing Parts ................................................. 6
5. Wearing parts of the Discharge Door ........................ 7
6. Replacement of Cylinder Protection .......................... 8
7. Replacement of Pedestal Bearings ............................ 9
8. Wearing Parts of Discharge Door Flap .....................10
9. Replacement of Discharge Door or Discharge Flap.11
10. Replacement of Cylinders..........................................12
11. Replacement of Cylinder Seals .................................13
12. Replacement of Mixing and Lateral Blades ..............14
13. Replacement of Mixing Arms ....................................15
14. Replacement of V-Belts on externally arranged V-
Belt Drive ....................................................................17
15. Replacement of V-belts on internally arranged V-
Belt Drive ....................................................................18
16. Replacement of Motor(s)............................................19
17. Replacement of Slip-On Gear Units ..........................20
18. Repair on Slip-On Gear Units ....................................22
19. Replacement of Rubber Components in
Synchronous Couplings ............................................23
20. Replacement of Mixing Shafts...................................24
20.1 Non-adjustable axial face seal................................................... 25
20.2 Adjustable axial face seal .......................................................... 26
21. Replacement of Mixing Shaft Bearings.....................28
22. Replacement of Axial Face Seals ..............................29

SONTH O FEN

Twin-Shaft Batch Mixer DKX
SONTH O FEN
Maintenance - 900360500-00E H

Safety instructions and Safety Requirements see


NOTE!
Start control and maintenance operations and open covers, doors, guards
and other machine parts only if
bd00023
• repair switch is on position "OFF" and locked by key

• key is kept safely against unauthorized use
• warning sign "Maintenance Work" is installed on the repair switch
• slow down period of moving machine parts is over

DANGER!
before starting, check the machine and eliminate dangers:
• protective devices must be installed

bd00023
• casing must be closed and secured
• tools in and on the machine must be removed
• danger for maintenance work around the machine and
on machines in the process line

Insufficient or poor maintenance and servicing increase susceptibility to
trouble and repair.

The user has to determine in dependance to his operating conditions:
• Period and extension of maintenance + servicing work

• Maintenance and Inspection Table

NOTE!
Execution of maintenance and servicing work:
• Replacement of wearing parts and simple repair work (e.g. case sealing) by
bd00023
qualified personnel of the user
• Comprehensive repairs always with the support of expert personnel of the

mixer manufacturer

For welding work refer to Group: Assembly and Electric Connection
2 - 30
SONTH O FEN

DANGER!
If for maintenance operations personnel is in the mixing space, the
mixing shafts must be safeguarded against rotation:
bd00023
• put wedges between the mixing blades and trough walls or

• each one wedge on both sides of the V-belt pulley on the gearbox to
block the V-belt drive (only with mounted synchronous coupling!)

After termination of maintenance operations, remove the safeguard
against rotation.

IMPORTANT!
In case the electric connections of the drive motors had been removed for
repair work then:
• refer to group: Assembly/Electric Connection for checks necessary

bd00023
prior to energizing and sense of rotation.

Replace fixing elements, e.g. screws, nuts, bolts, by new ones of identical
quality (material, strength) and design.

For tightening torques of screw connections see Technical Documentation.

NOTE!
For figures for Maintenance Instructions see Spare Parts List.
bd00023
3 - 30
SONTH O FEN
2. Discharge Door Safety

ATTENTION!
The discharge door is arrested with a socket pin.

Installation of the locking:
bd00023
• Take socket pin (2) from

the keeping eye (1)
• Insert socket pin (2) into
locking tube (3)
• Tighten locking screw (4).

DANGER!
The discharge door must be fastened
with the socket pin during all repair and
maintenance works executed on the
bd00023
mixer, e.g. when replacing wearing parts
(mixing blades, tiles, etc.) or machine bd00022
parts. It serves to avoid accidents in
the discharge door zone.
4 - 30
SONTH O FEN
3. Discharge Flap Safety

DANGER !
For all work during which the discharge flap cannot be held safely in
all positions because of missing pressure in the cylinders,
bd00023 disconnected current, resp., the discharge flaps open due to dead
weight up to the cg position. For jamming effect the flap could stop
even before reaching the cg position.
To work in the mixer, convenient safety measures (e.g. maintenance

scaffolds under the mixer, safety belt for the fitter) must be taken.
bd00028
5 - 30
SONTH O FEN
4. Trough Wearing Parts

ATTENTION!
Switch off the machine.
• Repair switch to position "OFF" and locked by key

• Keep key safely against unauthorized use
bd00023
• Put warning sign "Maintenance Work" on repair switch
• Wait for slow-down period of moving machine parts

ATTENTION!
Wait for immobilization of mixing shaft (check on the mixing shaft between
bd00023
bearing case and machine housing) and opening of locking unit.

DANGER!
see Discharge Door/Flap Safety

bd00023 DANGER!
bd00023
• put wedges between the mixing blades and trough walls

• or each one wedge on both sides of the V-belt pulley on the gearbox to

Remove wear lining by unscrewing the fastening elements, preferably by
means of an impact screw driver

Clean the stripped inner trough surfaces, remove any deposits of the mix.

Mount the new parts, or old parts with one-side wear, which, however, must
be mounted the other way round.

Tighten screw connections.

Steps of more than 3 mm at the joints of the mounted plates or tiles must be
evenly ground.

When replacing discharge door covers, discharge door ledges, wearing
ledges and wearing plates make sure that discharge door/flap remains
floating.

ATTENTION!
against rotation.
bd00023

NOTE!
see group: Starting and Operation - Break-in Prescriptions before strarting
the mixer, after change of trough lining, resp.
bd00023
6 - 30
SONTH O FEN
5. Wearing parts of the Discharge Door

ATTENTION!

bd00023 • Keep key safely against unauthorized use

ATTENTION!
bd00023

DANGER!
bd00023

DANGER!
To work on the Discharge Door remember:
• to avoid unauthorized starting of the discharge door

• to take precautions against getting squeezed
• to work under the mixer only with permissible maintenance scaffolds
• see Discharge Door Safety

Remove lateral discharge door covers and discharge door ledges along
discharge door.

Remove fastening nuts on the lower side of the discharge drum, remove
cylinder protection and clean the supporting faces on the discharge door
cylinder

Mount the new cylinder protection, discharge door ledges and discharge
door cover.

Make sure that the discharge door remains floating.

DANGER!
against rotation.
bd00023
7 - 30
SONTH O FEN
6. Replacement of Cylinder Protection

ATTENTION!


DANGER!
To work on the Discharge Door remember:
• to avoid unauthorized starting of the discharge door

• to take precautions against getting squeezed
bd00023 • to work under the mixer only with permissible maintenance scaffolds
• see Discharge Door Safety

Remove lateral discharge door covers and discharge door ledges along
discharge door.

Remove fastening nuts on the lower side of the discharge drum, remove
cylinder protection and clean the supporting faces on the discharge door
cylinder

Mount the new cylinder protection, discharge door ledges and discharge
door cover.

Remove socket-pin safety from the discharge door.

Make sure that the discharge door remains floating.
8 - 30
SONTH O FEN
7. Replacement of Pedestal Bearings

NOTE!
This repair should not be executed by the user alone, but always with the
assistance of an expert of the mixer manufacturer, who will make available
also the necessary tools and technical documentation.
bd00023

ATTENTION!

bd00023

ATTENTION!
bd00023 bearing case and machine housing) and opening of locking unit.

ATTENTION!
bd00023
Discharge door/flap can turn or open. Secure opposite side at first.

Remove discharge door/flap operation and lever.

Secure discharge door/flap against falling down.

Release setscrew on the bearing tension ring and open by means of
beating in anticlockwise direction.

After removing the pedestal bearing fastening screws, take bearing off in
axial direction.

Mount new bearing, fasten tension ring by beating in clockwise direction
and tighten setscrew.

Remount lever and discharge door/flap operation.
9 - 30
SONTH O FEN
8. Wearing Parts of Discharge Door Flap

ATTENTION!


ATTENTION!
bd00023
see Discharge door safety!

Remove wearing ledges along discharge flap.

Release fastening elements on the lower side of the discharge flap, remove
flap wearing parts and clean supporting faces on the flap.

Mount new flap wearing parts and wearing ledges.

Make sure that the discharge flap remains floating!
10 - 30
SONTH O FEN
9. Replacement of Discharge Door or

Discharge Flap

NOTE!
bd00023

ATTENTION!

bd00023

ATTENTION!

bd00023 DANGER!
see Discharge Door Safety /Discharge Flap Safety

Removal is always to be made downwards.

Remove discharge hopper under the mixer or swing it downward.

Remove discharge door or discharge flap operation or drive.

Hang up lifting cables to the left and to the right around the axles.

Release screw connections on pedestal bearings and lower discharge door
or flap.

Remove sealing and wearing ledges in the mixing trough and clean
supporting faces.

Install new discharge door(s) of flap(s).

Same proceeding as for removal, however in reverse order.

Mount new sealing and wearing ledges.

Make sure that the discharge door/flap remains floating!
11 - 30
SONTH O FEN
10. Replacement of Cylinders

ATTENTION!

bd00023

ATTENTION!
bd00023

If possible, remove cylinder when the piston rod is drawn in. Arresting of the
discharge door or flap lever is necessary. Thus the mounting length remains
fixed.

Unscrew hose lines and bolts (on cylinder and piston rod side).

When mounting the new cylinder observe the correct mounting length and
alignment. The bolts must be well greased!
12 - 30
SONTH O FEN
11. Replacement of Cylinder Seals

ATTENTION!


ATTENTION!
bd00023

NOTE!
The required spare part kits should be kept on stock or ordered well in time
from the mixer manufacturer.
bd00023
For replacing the cylinder seals, dismantle the cylinder.
13 - 30
SONTH O FEN
12. Replacement of Mixing and Lateral Blades

ATTENTION!

•
bd00023
Keep key safely against unauthorized use

ATTENTION!

bd00023
see Discharge Door Safety /Discharge Flap Safety.

Clean mixing tools and remove deposits of the mix, particularly in the area
of the blade fastening nuts.

Release fastening nuts. If this is not possible, then burn away
hexagon nuts.

Remove blades and clean supporting faces on the mixing arm. Remove
deposits of mixed material.

NOTE!
Mount new mixing and lateral blades with simultaneous setting of the radial
and axial blade gap.
Minimum gap width = 2 mm in radial and axial direction.
bd00023

Setting of the blade gap with simultaneous rotation of the mixing tools by
hand and check of the blade gap. The narrowest radial blade gaps should
always be measured at the upper blade entry, at the trough wear
protection.

Upon adjustment of all mixing and lateral blades the screw connections
must be firmly tightened and the mixing tools rotated by hand on the V-belt
drive. If the blades touch the wear protection they must be reset

For tightening torques refer to Technical Documentation

ATTENTION!
Make sure that all blade screws are firmly tightened. Blade screws which
are not firmly tightened will cause loosening of the blades. This will cause
blocking of the mixing tools, bending of the mixing shafts and, finally high
bd00023 repair costs.
14 - 30
SONTH O FEN
13. Replacement of Mixing Arms

ATTENTION!


ATTENTION!
bd00023

DANGER!
bd00023


DANGER!
bd00023
Clean mixing tools and remove deposits of the mix, particularly in the area
of the fastening elements.

Release fastening nuts. If this is not possible, then burn away fixing
screws in the gap between arm hub and counterpiece.

Remove mixing arm and counterpiece and clean shaft supporting face.
Remove deposits of mixed material

Install new mixing arm, counterpiece and mixing blade.

NOTE!
The screw connection for fastening the mixing arm consists of hexagon
bolt, hexagon nut and spherical disk, the latter being placed under the
bd00023
hexagon nut.

For tightening torques see Technical Documentation.

ATTENTION!
Make sure, that all mixing arms and blade fastening screws are firmly
tightened.
bd00023
15 - 30
SONTH O FEN

After mounting the new mixing arms, the mixing tools must be rotated by
hand on the V-belt drive. If the blades touch the wear protection, then they
must be reset.

ATTENTION!
Blade screws which are not firmly tightened will cause loosening of the
blades. This will cause blocking of the mixing tools, bending of the mixing
bd00023
shafts and finally, high repair costs.

ATTENTION!
against rotation.
bd00023
16 - 30
SONTH O FEN
14. Replacement of V-Belts on externally

arranged V-Belt Drive

ATTENTION!

bd00023

ATTENTION!
bd00023
Remove V-belt protection device.

Release V-belts by displacement of the motor rocker.

Remove V-belts and mount new set of V-belts.

Only use high-capacity narrow V-belts, see Spare Parts List.

Tension V-belts and mount V-belt protection device!

For V-belt tension see Technical Documentation.
17 - 30
SONTH O FEN
15. Replacement of V-belts on internally

arranged V-Belt Drive

ATTENTION!

•
bd00023

ATTENTION!
bd00023

Remove V-belt protection device.

Safeguard mixing shafts against rotation:
• Put wedges between the mixing blades (of both mixing shafts) and the
trough walls.

For MFC coupling: remove rubber components by means of cranked double
ratchet ring spanner.

For N-Eupex coupling: release screws on claw ring and move claw ring
horizontally until uncoupled. Release screws on female part of coupling,
remove female part.

Release V-belts by displacement of the motor rocker.

Remove V-belts and mount new set of V-belts.

Only use high-capacity V-belts, see Spare Parts List.

Observe the instructions for coupling and uncoupling, refer to Group:
Maintenance and Inspection.

Couple synchronous coupling again. Same proceeding as for uncoupling,
however in reverse order.

Check correct adjustment of mixing tools to each other!

Tension V-belts and mount V-belt protection device.

against rotation.

For V-belt tension see Technical Documentation.
18 - 30
SONTH O FEN
16. Replacement of Motor(s)

NOTE!
bd00023 also the necessary tools and technical documentation.

ATTENTION!
All electric work must be executed only by admitted specialists!

bd00023
ATTENTION!

bd00023

ATTENTION!
bd00023

Remove V-belt guard, detention V-belts and remove V-belts.

Remove motor V-belt pulley and hydraulic coupling, resp.
Hydraulic coupling see Technical Documentation.

Place a lifting device over the motor to be removed. Then put two ropes
around the motor at the drive and the fan side, hang them into the lifting
device and pull until the ropes are uniformly tight.

Remove motor fastening screws. Afterwards attach a second lifting device
laterally at the motor and by pulling at an angle put the motor in its lowering
position. Then lower the motor onto the platform.

Mount the new motor. Same proceeding as for removal, but in reverse
sequence.

Mount the motor V-belt pulley, or hydraulic coupling, resp. Check alignment
of V-belt pulleys to each other. Move motor in axial direction, if necessary.
Hydraulic coupling see Technical Documentation.

Attach and tension V-belts. Mount V-belt guard.

IMPORTANT!
Check before switching on, rotational direction, refer to Group
bd00023
assembly/electrical connection
19 - 30
SONTH O FEN
17. Replacement of Slip-On Gear Units

NOTE!
bd00023 also the necessary tools and technical documentation.

ATTENTION!

bd00023

ATTENTION!
bd00023

DANGER!
bd00023


Dismount motor and V-belts.

DANGER!
Before releasing the torque support and the synchronous coupling, secure
the gear unit to be removed against tilting to the side.
bd00023

Suspend the gear unit vertically upward by means of a lifting device.

Loosen drive support by knocking out a bolt on the hinge head.
The bolt has been bonded by means of metal adhesive, e.g. Loctite;
therefore heat the butt straps shortly to approx. 180-200 °C.

Turn drive support (turnbuckle with hinge head) downwards.

Separate synchronizing coupling.

After removing the gearbox cover and end disk, attach extracting device
with light metal hollow piston cylinder (Lukas) and extract the gear unit by
actuating the piston hand pump. If no Lukas cylinder is available then insert
several spacer pieces instead of the cylinder into the extracting device and
withdraw the gear unit by hand by uniform tightening of all 4 nuts.
20 - 30
SONTH O FEN

ATTENTION!
When setting down the gear unit make sure that no oil will come out of the
ventilation system.
bd00023

After removal clean the shaft by means of benzine and emery cloth, and
apply some grease.

The mounting of the slip-on gear unit to the shaft is made by hand by
means of a threaded spindle.
• Thread diameter = M 24 for mixer sizes 1,25 - 4,0 m³

• Thread diameter = M 36 for mixer sizes 5,0 - 6,0 m³

Mount the motor, put on and tension V-belts.

Mount drive support again, provide bolt with metal adhesive, e.g. Loctite,
install it and put on V-belts.

Remount synchronous coupling:

Remove the safeguard against rotation.

ATTENTION!
Bring the mixing tools into their correct position to each other:
• The marking at the shaft ends must agree to the marking on the hollow
bd00023 shafts of the gear units.
• Correct position of the two lateral arms at the drive end, see Spare Parts
List, Group: Mixing Tools.

Couple synchronous coupling.

Adjust coupling alignment in two planes:
• vertically: by adjusting the turnbuckle

• horizontally: by placing a fitting ring between gear unit and spacer bushing

Screw end disk and gearbox cover on, fill gear oil in.

Prior to starting, rotate the mixing tools one full revolution by hand on the V-
belt drive to check the adjustment of the mixing tools.

IMPORTANT!
Check before switching on, rotational direction, refer to Group
assembly/electrical connection

Mount protective guards.
21 - 30
SONTH O FEN
18. Repair on Slip-On Gear Units

NOTE!
As a matter of principle the replacement of bearings must be carried out by
expert personnel of the mixer or gearbox manufacturer. Special knowledge
and technical documentation is required.
bd00023

ATTENTION!

•
bd00023

ATTENTION!
bd00023

The sealing rings may be replaced by the operator, provided that the
sealing lip has not left traces of running-in on the sealing faces of the shaft.
22 - 30
SONTH O FEN
19. Replacement of Rubber Components in

Synchronous Couplings

ATTENTION!

bd00023

ATTENTION!
bd00023

Remove V-belt protecting device.

Uncouple synchronous coupling.

For MFC coupling: remove rubber components by means of cranked double
ratchet ring spanner and mount new rubber components.

For N-Eupex coupling: Release screws on claw ring and move claw ring
horizontally until uncoupled. Press out rubber components by means of a
screw driver and press in new rubber components.

Instructions for coupling and uncoupling must be observed, refer to Group:
Maintenance and Inspection, Maintenance and Inspection Plan.

Couple synchronous coupling again. Same proceeding as for removal, but
in reverse sequence.

Tension V-belts and mount V-belt protection device.

IMPORTANT!
Adjustment of mixing tools see Spare Parts List
Check if mixing tools are rotating freely.
bd00023
23 - 30
SONTH O FEN
20. Replacement of Mixing Shafts

NOTE!
bd00023

ATTENTION!


ATTENTION!

bd00023

Remove slip-on gear units, see Replacement of slip-on Gear Units.

Dismount mixing tools.

Remove bearing cover, dust cover and wearing rings on either side.

Support shaft in the trough on both sides.

Pull off bearing bodies with self-aligning roller bearings by means of jacking
screw.

Release and pull-off locating ring and shaft bush.

Remove shaft to the side.

Mount new shaft as well as seals, bearing bodies, bearings and bearing
cover
• Mounting instructions:
see: Replacement of Axial Face Seals
see: Replacement of Mixing Shaft Bearings
• The following illustration shows the design of the shaft sealing.
24 - 30
SONTH O FEN
20.1 Non-adjustable axial face seal

The shaft bush (2) is fixed on the mixing shaft (1) in its axial position to the
connecting flange (3). The bipartite axial face seal (5) is seated in the
locating ring (4) and the shaft bush (2) by means of O-rings. For the proper
functioning of the axial face seal it is important that it is prestressed in
installed condition Therefore mind the following proceeding for assembly:
• Before mounting the split ring seals (8 + 9) the mixing shaft must be aligned
and dimension 's' between shaft bush (2) and mixer housing must be set. s
= 2 ± 0,5 mm.
• In case of deviations levelling plates are slipped onto the shaft, or

corresponding rework is required on shaft bush (2).
• With locating ring (4) pulled out, the distance X measured between contact
surface of connecting flange (3) and shaft bush (2) must be checked.
Correct distance (X):
for mixer sizes: 1,25 - 1,67 m³ X = -5 ± 0,5 mm (set back)

1,85 - 3,0 m³ X = 7 ± 0,5 mm
3,5 - 4,0 m³ X = 10 ± 0,5 mm
5,0 - 7,0 m³ X = 3 ± 0,5 mm
Check of gap size 'z' between dust cover (8) and wearing ring (9) z = 2,0 ±
0,5 mm.
If the gap size is inferior, it is to be adjusted by means of shims (shim to
DIN 127 or tooth lock washer to DIN 17222) between dust cover (8) and
shaft bush (2) depending on the deviation.

When replacing the drive side seals mount slip-on gear, refer to: replacing
of the gearbox (for mixing tool position refer to spare part list).

IMPORTANT!
bd00023
build-up
25 - 30
SONTH O FEN
20.2 Adjustable axial face seal

The shaft bush (2) is
fixed on the mixing
shaft (1) in axial
position to the
connecting flange (3).
The bipartite axial face
seal (5) is seated in the
locating ring (4) and the
shaft bush (2) by
means of O-rings. For
poper functioning of the
axial face seal it is
important that it is
prestressed in installed
condition. Therefore
mind the following
proceeding for
assembly.

Dismount the locating ring (4).

Clean locating ring and shaft bush; then check if parts are still ok.

You should be able to mount the axial face seals with O-rings in the locating
ring applying slight pressure only, to get a pretension to hold the rings.

The sealing faces must be smooth without any grooves!

ATTENTION!
Dimension X must be mediated on the drive side and opposite drive side
depending on the mixer size.
bd00023
• Mixer size: 1.85 to 3.00

calculated nominal size: X = 7 mm
Y must be set and fixed by means of the forcing screws (7) in dependence
on the measured value X (refer to table).
X measured 5 5.25 5.5 5.75 6 6.25 6.5 6.75 7 7.25 7.5 7.75 8 8.25 8.5 8.75 9
Y measured 5 5.25 5.5 5.75 6 6.25 6.5 6.75 7 7.25 7.5 7.75 8 8.25 8.5 8.75 9

X measured 8 8.25 8.5 8.75 9 9.25 9.5 9.75 10 10.25 10.5 10.75 11 11.25 11.5 11.75 12
Y measured 3 3.25 3.5 3.75 4 4.25 4.5 4.75 5 5.25 5.5 5.75 6 6.25 6.5 6.75 7
26 - 30
SONTH O FEN

X measured 1 1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75 4 4.25 4.5 4.75 5
Y measured 3 3.25 3.5 3.75 4 4.25 4.5 4.75 5 5.25 5.5 5.75 6 6.25 6.5 6.75 7

Check if O-ring (10) and sealing ring (11) have been inserted correctly.

Check gap size between dust cover (8) and wearing ring (9):
z = 2.0 ± 0.5 mm.
If the gap size is inferior, it is to be adjusted by means of shims (shim to
DIN 127 or tooth lock washer to DIN 17222) between dust cover (8) and
shaft bush (2) depending on the deviation.

When replacing seals on the drive side, mount slip-on gear unit;
refer to: replacing of the gearbox (for setting of mixing tools refer to spare
part list).

IMPORTANT!
bd00023
27 - 30
SONTH O FEN
21. Replacement of Mixing Shaft Bearings

NOTE!
bd00023

ATTENTION!

bd00023

ATTENTION!
bd00023
In case of drive side bearing, remove slip-on gear unit proceeding see
Replacement of slip-on Gear Units.

Support shaft on both sides of the trough.

Then unscrew bearing cover and bearing body and withdraw bearing body
with self-lager aligning roller bearing by means of jacking screw.

Clean bearing body, bearing cover and shaft.

Mount again bearing body, self-aligning roller bearing and bearing cover.

Remount slip-on gear unit and adjust correct position of mixing tools, see
Replacement of Mixing Arms.
28 - 30
SONTH O FEN
22. Replacement of Axial Face Seals

NOTE!
bd00023

ATTENTION!

bd00023

ATTENTION!
bd00023

In case of drive side seal, remove slip-on gear unit, see: Replacement of
slip-on Gear Units.

Support shaft on both sides of the trough.

Then unscrew bearing cover and bearing body and with-draw bearing body
together with self-aligning roller bearing by means of jacking screw.

Before removing the fixed bearing or replacing the shaft seal on the fixed
bearing side (non-drive end) measure alignment between gear coupling
halves and note down.

Support the shaft in the trough, unscrew and withdraw locating ring.

Dismount axial face seals.

Clean locating ring and shaft bush, check if parts are OK

Builds-up - see fig. Replacement of Mixing Shafts - must still exist, so the
axial face seals with O-rings can only be mounted with corresponding
pressure.

Sealing faces must be smooth without any striae.

Insert new axial face seals and mount locating ring, bearing body and
bearing cover. Check distance between contact surface of locating ring and
shaft bush.

IMPORTANT!
Correct distance measure refer to: Replacement of Mixing Shafts
29 - 30
SONTH O FEN

Readjust the alignment measured on the gear coupling (only applicable
when replacing the seals on the non-drive end).

In case of drive side seal replacement mount slip-on gear unit and adjust
correct position of mixing tools, refer to Replacement of slip-on Gear Units.
30 - 30
DK 3,00
Edition: 07/05 902005904 - 600004470-000 - B
Cover Sheet
SONTH O FEN
1. Technical Specification................................... 902005844

Technical Documents
2. Installation Drawing ........................................ 902003760
3. Danger Analysis .............................................. 900421800
4. Control Instructions Wearing Parts................ 900302500
5. Control Instructions Central Arm ................... 900421900
6. Tensioning Torque .......................................... 900356300
7. Pre-tension of V-belts ..................................... 900361200
8. Lubricant Oil .................................................... 900360600
9. Lubricant Grease ............................................. 900360700
10. Cavex Worm Gear Units.................................. 900026000
11. Three-Phase Motors ........................................ 900484100

12. Motion Controls ............................................... 900016800
13. Central Lubrication Grease............................. 902001861

SONTH O FEN

Spare Parts Tel. ++49 8321 802 144, 145, 146 Fax ++49 8321 802 120
600003620-000 - A
Technical Specification 1) 902005844
issue 07/05
Twin Shaft Batch Mixer
SONTH O FEN DK 3,00 page 1-2
Process Data
Batch volume compacted concrete 3,00 m3

dry charge 4,50 m3
Batch weight max. 7200 kg
mixing cycles per

Truck mixer discharge3) hour 43
compacted concrete 129 m3/h
mixing cycles per

Open truck discharge4) hour 52
compacted concrete 156 m3/h
Mixture2) ready-mixed concrete, RCC, wet mortar
Aggregate size from/to 0 - 150 mm
Technical Data
Mixer motor drive power 2 x 55 kW
Discharge door operation kind pneumatic

number of cylinders 4
number of solenoid
valves 2
number of limit
switches 4
Machine weight 9800 kg
Dimensions refer to installation drawing

2)
upon request special versions f.i. for:
- concrete for prefabricated components

- concrete with particular chemical additives
- concrete with high cement content
- concrete with high content of fines
- concrete with low water content
- concrete with higher aggregate size than indicated above
3)
30 sec. mixing time and truck mixer input performance of 0,12m 3 fresh concrete per sec.
4)
30 sec. mixing time and compactability v > 1,25
1) Any deviations from the technical specification will be specified in the respective offer or order acknowledgement.
600003620-000 - A
Technical Specification 1) 902005844
issue 07/05
Twin Shaft Batch Mixer
SONTH O FEN DK 3,00 page 2-2
Basic scope of supply

Mixing trough - welded design made by means of gauges and fixtures
- 4 supporting consoles
- 4 suspension eyes
- replaceable wear protection for trough and frontal walls
- symmetrical, interchangeable wear parts
- wearing tiles of patented shape with increased service life made
of special hard casting Sontid (option)
Discharge door - one-piece, torsion-proof casting

- lined with replaceable wearing parts
- adjustable sealing ledges
- regreasable bearings
Discharge door operation - with cylinders and solenoid valves

- limit switch for closed, intermediate and open positions
- installation of pneumatic lines inside the machine
Mixing trough seal / Mixing - sturdy, adjustable axial face seal with grease chamber
shaft bearings - working safety owing to physical separation of mixing trough
seal and mixing shaft bearing
- mixing shafts with self-aligning roller bearings for high service
life
Mixing tools - 2 horizontal mixing shafts

- intensive mixing motion due to the asymmetrical, helical
arrangement of the mixing tools
- mixing tools arranged at a 90° angle for excellent mixing results
at reduced energy
- central and lateral arms made of special cast steel
- optimal shape of mixing arms
- adjustable mixing blades
- mixing blades made of highly wear-resisting special hard
casting Sontid.
Drive - with 2 worm gears designed for extremely shock loaded mixing
operation
- threephase motors, V-belt drive and gear unit assembled on
one torque support forming the drive unit
- drive units slipped on freely to the mixing shafts to avoid excess
gear loads.
- synchronisation of the gear units by means of a highly flexible
coupling
- protective hoods over V-belt drive and synchronous coupling in
conformity with CE regulations.
- overspeed governor (Option)
- hydraulic couplings (Option)
Testing - running without load for several hours

- recorded acceptance of performance
Painting - two priming coats on sand-blasted surface

- single top coat to RAL
1) Any deviations from the technical specification will be specified in the respective offer or order acknowledgement.
Technical Documents 900421800-00E C
Danger Analysis Edition 28.08.97

SONTH O FEN Residual risk when installing a
Twin-Shaft Trough Mixer Page 1-2
The following hazards are not covered by the mixer scope of

supply.
This list of measures will not release from studying and

bd00023
observing the operating manual as well as other instructions.
EN Hazards Subassembly/ Measures

12151 Component
4.1.1 Squeezing Trough cover - Trough cover shall not allow any access to
4.1.2 Shearing (mixing tools), mixing tools during mixing process or when
4.1.4 Pulling-in or getting mixing trough cover machine is running.
caught - Access and maintenance hatches are
protected by means of locking unit against
opening of the mixing trough as long as the
mixing tools are still running.
- When opening the maintenance hatches a limit
switch is actuated preventing the mixer from
starting again.
- Easily accessible emergency switches in the
mixer area.
- Openings to observe the mixing process are to
be provided with non-removable plexiglass
covers (for mixes developing dust or gases) or
close-mesh grids
- Material feeding devices must be connected
such to the mixer that no access to the mixing
room is possible.
- Electrical locking of the machine to prevent that
the mixer will be started and the mixer
discharge be actuated inadvertently.
- After integration into the steel structure, it is to
be checked whether there is any access and
thus danger of squeezing and shearing in the
mixer discharge area..
Bk
Technical Documents 900421800-00E C
Danger Analysis Edition 28.08.97

SONTH O FEN Residual risk when installing a
Twin-Shaft Trough Mixer Page 2-2
EN Hazards Subassembly/ Measures

12151 Component
4.1.10 Catapulting of parts Trough cover - Corresponding design of the trough cover and
or material Discharge door the material feeding devices.
Discharge flap - Electrical locking of the machine to prevent that
material can be fed during maintenance works.
- Mounting of a suitable delivery hopper for a
guided and safe material discharge out of the
mixer.
- Opening of trough cover for discharge subject
to supervision.
- Measures to identify the hazardous area.
4.2 Electrical hazard Drive - Professional connection of cables to terminal

Safety limit switch, boxes of mixer motors
safety locking - Safe, waterproof locking of terminal boxes
unit (electro- - Safe mounting and guiding of feed lines
magnetic) at the - Checking of cables for damages
trough cover - Mounting of emergency switches in the area of
the machine and control system
- Fault current circuit breakers or system with
similar protection.
4.7 Hazards by working Trough cover - Dust-tight trough cover
material Delivery hopper - Sealing of access and maintenance hatches
- Sealing of material delivery points to the mixer
- Mounting of suction devices and filters, resp.
- Mounting of a suitable delivery hopper for a
guided and safe discharge of the material out of
the mixer.
- Sealing of the mixer outlet area for mixes
developing dust or gases, resp.
4.10 Failure of the Mixer - The following points must be observed for
system integration of the mixer:
• power failure
• failure of control units
• incorrect software
• incorrect installation
Bk
Technical Documents 900302500-00E D
Edition 05/03
Instructions on Inspecting Wearing Parts
SONT H O FEN from Twin-Shaft Batch Mixer Page 1-5
ATTENTION:
All wearing parts in the mixing trough must be checked at monthly intervals.
Wearing parts must be changed before they start to damage the base structure of the mix-
ing trough, discharge gate or discharge door.
bd00023
NOTE:
The useful life of wearing parts may vary widely. This will be governed by different pa-
rameters, such as charging situation, type and nature of additives, consistency of the
materials being mixed and not least by the gap between the mixing tools and the anti-
bd00023
wear lining which must be as close as possible.
1. Mixing trough protection
1.1 Sheet metal plates

Although these plates can be reversed and are economical to use, plate
thickness in the wear zone must not be allowed to fall below 3 mm.
1.2 Tiles of special hard cast material

These can be used to replace the metal plates without corrective work. Tiles last
approximately 3 times longer than metal plates. The tiles must be renewed
when they have worn down to a thickness about 6 mm (risk of breaking). As a
rule, you will only need to replace the lower rows.
1.3 Ceramic / steel tiles

These can be used to replace the metal plates or hard cast tiles without the need for
corrective work.
Ceramic tiles with a steel base structure last at least twice as long as hard cast tiles and can
be worn down as far as the steel base structure.
Plastic-type mixing blades should be selected.
1.4 Ceramic lining cemented directly in place

Special measures are required for installing this ceramic lining. Please consult our
Customer Service Department for further details. Plastic mixing blades must be se-
lected for this lining type as well.
Edition 05/03
2. Trough end-wall protection
2.1 Sheet metal plates

Although individual segments may be reversed, plate thickness in the wear-
ing zone must not be allowed to fall below 6 mm.
2.2 Tiles of special hard cast material

For casting reasons, the segments are of different design.
2.3 Sealing plates and lateral wearing

plates for the discharge doors
In view of the necessity for the discharge doors to form a tight seal, these
metal plates must only be allowed to wear down to such an extent that
adjusting the sealing plates still ensures that the discharge doors form a
tight seal at the sides.
To adjust the sealing plates, refer to spare parts list.
2.4 Ceramic / steel tiles

The tiles are the same shape as the sheet metal plates, and are otherwise structured as described in
1.3.
2.5 Ceramic lining cemented directly in place

As described in 1.4.
3. Mixing blades, central
3.1 Mixing blades of special hard cast material

must be adjusted at the latest when the distance from the trough protection in the lower part of the
mixing trough has reached 10 mm.
The normal radial gap setting is approx. 2 mm at the narrowest point.
Turn mixer and check the gap widths.
Edition 05/03
3.2 Plastic mixing blades

must be checked frequently to ensure that the gap setting remains as small as possible since any
major gap will result in increased wear, particularly at the plastic edge facing the trough protection.
As far as the radial gap setting is concerned, the plastic blade may contact the trough lining at the
tightest point.
Turn mixer and check gap widths and points of contact.
For type: LESX or DKX For type: LES or DK
4. Mixing arms, lateral

4.1 are provided with mixing blades and lateral plates of special-hard cast material that can be ad-
justed in both the axial and radial direction, permitting compensation for wear on the scraping edges.
The arm protection must not be spaced more than 5 mm from the end-wall. The normal radial and axial
gap setting is approx. 2 mm at the tightest point.
Turn mixer and check gap widths.
4.2 provided with mixing blades and lateral plates in plastic must be frequently checked to ensure
that the gap setting remains as small as possible since any major gap will result in increased wear,
particularly at the plastic edge facing the trough and end-wall protection. These plastic blades and
plates can also be adjusted in both the axial and radial direction, and may contact the anti-wear lin-
ing when the gap is adjusted to the tightest setting.
Turn mixer and check gap widths and points of contact.
With ceramic lining the distance between arm protection and end-wall should be as small as possible
(although there must be no contact) and may be adjusted by fitting a washer between arm protection
and side arm.
For type: LESX or DKX For type: LES or DK For type: LESX or DKX
For type: LES or DK
Mixing arms, left Mixing arms, left Mixing arms, rigth
Mixing arms, right
Edition 05/03
ATTENTION!
Small gap widths -> low wear
Large gap widths -> high wear
bd00023
5. Mixing arms, central
Refer to Technical Documentation for details on checking for wear: Instructions on

inspecting central arm.
6. Cylinder protection at discharge gate
This must be renewed when it has worn down as far as the base structure
at the beater arms. To do this, the closed discharge gate must be secured
by the locking bolt, refer to Operating Instructions, Group: General Safety
Instructions.
7. Discharge door protection
This must be renewed when it has worn down at any point as far as the base
structure or can no longer be held in place by the countersunk screws.
8. Gate strips and sealing strips
must be replaced when it is not longer possible to move them closer than 1 mm
to the discharge door, anti-wear plates or gate cylinder at the fixing slots. (Dis-
charge gate or discharge door can then no longer be sealed.)
9. Gate cover
Service life can be almost doubled by turning the gate cover.

Edition 05/03
10. Dust cover of special hard cast material
This serves as the inner end cover for the shaft seal. Wear is governed by the
radial parallelism of the gap with the end-wall protection. Change the dust cover
when the gap exceeds 5 mm.
11. Dust cover wearing ring of special hard cast ma-

terial
This is positioned between dust cover and end-wall tile and must be changed
when renewing the dust cover.
Technical Documents 9004219000000E A
Edition 07.03.97
Control Instructions – Central Arm
SONTH O FEN DKX 2,0 – 3,0 Page 1-1
ATTENTION!
If, due to wear, the cross-section at the weakest point has reached the dimension
indicated, the mixing arm can no longer be used and must be replaced for safety
bd00023
reasons.
Bk
Technical Documents 900356300-00E G
Edition 09/03
SONT H O FEN Tensioning Torque
Page 1-2
1. Tensioning torque for bolt connections - general
Dimension
M8 M 10 M 12 M 16 M 20 M 24 M 27 M 30
Property class 8.8
Nm
1)
21 42 72 174 340 580 855 1160
Property class 8.8
and hexagon all-metal
nut with clamping
part Nm 27 52,5 87,5 206 394 660 949 1268
1) + 2)
Property class 10.9

Nm
1)
29 58 100 245 476 821 1201 1636
Property class 8.8
and NORD LOCK
self-locking washers
Nm 24 48 82 200 391 667 1018 1334
1)
Property class A 4
stainless steel screw 402,2 549
Nm 15,3 31,0 52,0 126 245 235 Friction Friction
4) + 3) µ = 0,14 µ = 0,14
ges ges
1) Specification are suitable for the friction µges = 0,10

For non treated surface with MoS2-paste (Molykote) lubricated and cadmium electroplated surface non oiled or slightly oiled.
2) Hexagon all-metal nut with clamping part - DIN 6925 - property class 8
3) up to M 20 cold rolled, as of M 22 cut
4) Specification are suitable for the friction µges = 0,12

For non treated surface with MoS2-paste (Molykote) lubricated and cadmium electroplated surface non oiled or slightly oiled.
1.1 Installation of the NORD-LOCK self-locking lock washers
As shown in Fig. 1-4 the lock washers are installed in pairs with the inclined plane to one anothers.
Upon tightening the washer pair is braced against the supporting surface, and the radial ribs on the
outside of the lock washer pair enter a positive engagement.
B ild 1 B il d 2 B il d 3 B ild 4
bd00043
Technical Documents 900356300-00E G
Edition 09/03
SONT H O FEN Tensioning Torque
Page 2-2
2. Tensioning torque for bolt connections used in Taper-Lock spring

collets
Type of Taper Lock 2012 2517 3020 3525

spring collet 2017 2525 3030 3535 4040 4545 5050
Tensioning Torque
Nm
5)
31 48 90 113 170 192 271
3. Tensioning torque for bolt connections used in tensioning sets
Part no. Tensioning Torque

(see List of Spare 5)
Parts) Nm
9101316 235
9101817 145
9101857 145
9101875 145
9102452 235
9102702 84
9102993 43
9103347 18
9103390 84
9105196 145
9105505 83
9105775 84
9106125 365
9106126 720
9107976 43
9302124 145
9303941 70
5) Specification are suitable for the friction no. µges = 0,14 B

Bolts are slightly oiled.
Technical Documents 900361200-00E F
Version 01/05
SONTH O FEN Determining the V-belt Initial Tension
Page 1-8
1. Preliminary Work............................................................................................... 2
2. Procedure for Determining Initial V-belt Tension............................................ 2
2.1 Optikrik Initial Tension Measuring Device.................................................................... 2
2.2 Determining Initial Tension Using Length Addition Factor ........................................ 3
2.3 Measuring the initial tension by using a tension gauge (spring balance type) ........ 5
3. Tables ................................................................................................................ 6
3.1 Table 1 Static Strand Force (N)...................................................................................... 6
3.2 Table 2 Length Addition Factor per 1000 mm Belt Length ......................................... 7
3.3 Table 3 Deflection forces using the spring balance principle .................................... 8
Bk
Version 01/05
Page 2-8
1. Preliminary Work
− Determining the V-belt profile and the diameter of the small V-belt pulley
− Determining the static strand force (N) at initial assembly or for V-belts that have been run-in
(table 1)
− Selecting an appropriate method for determining the initial tension of the V-belt
a) Inspection procedure using “Optikrik” device for measuring initial tension, can be
used for all shaft centre distances but not for power belts
b) Length addition factor
2. Procedure for Determining Initial V-belt Tension

2.1 Optikrik Initial Tension Measuring Device
The Optikrik II measuring device – with a measuring range from 500 to 1400 N – is available as an
option (order no. 920001545).
It is not suitable for measuring power belts.
View
1 Display arm
2 Rubber finger loop
3 Pressure area
4 Pocket clip
5 Belt
6 Compression spring
Bk
Version 01/05
Page 3-8
1. Place the measuring device in the middle between the two pulleys along the
back side of the belt. If a set of belts is being used, it should be placed on
the middle belt, if possible.
(Push the display arm fully into the scale area beforehand)
2. Lay the device loosely along the belt to be measured and slowly apply
pressure to the pressure area (3) with one finger.
3. Avoid contacting the device with more than one finger during the measuring
process.
4. As soon as you hear or feel a distinct ‘click’, immediately stop applying

pressure and the display arm will remain at the measured position.
5. Carefully pick up the device without moving the display arm. Read the value
for the static strand force at the intersection between the upper edge of the
display arm and the scale area.
6. Decrease or increase the belt tension depending on the measurement

result until you are within the desired tension range.
The required strand force is given in table 1.
2.2 Determining Initial Tension Using Length Addition Factor
This procedure is appropriate for single belts and power belts.
1 Take the value for the strand force from table 1
2 The measurement section “M” of the power belt or single belt is measured
in the slack state along the cover plate of the power belt or the back of the
single belt.
The measurement can also be made on the drive side with no tension
applied.
Bk
Version 01/05
Page 4-8
3 Procedure:
a) Lay the power or single belts on the drive and tension them briefly in
order to adapt the belt to the pulley profile.
b) Next, slacken the power or single belts completely.
c) Mark the measurement section “M” along the open strand length
(min. 1000 mm)
WARNING: The larger the measurement section, the better
the measurement accuracy
Measurement distance min. 1000 mm
4 Compute the length addition factor A using the formula
MxR
A =----------------
1000 mm
R = elongation factor or stretched distance from table 2
5 The power or single belts are placed under tension until they have stretched
to the value computed in step 4. This places the proper initial tension on the
drive.
6 If the drive is restretched, the belts have to be loosened first so that they
can be measured and marked in the slack state. Next, proceed as
described in steps 3 to 5.
Bk
Version 01/05
Page 5-8
2.3 Measuring the initial tension by using a tension gauge (spring balance type)
1. Measure the span length
2. Use the bottom ring to set the deflection force a calculated by using the
formula a= t/100 on the distance scale.
The top ring should be at zero on the deflection scale.
Press on a V-belt or a power belt with the tension tester (approx. in the
center of the distance t) until the lower O-ring (adjusted to deflection a) is at
the same level as the unstressed belt next to it (see illustration).
3. Read the deflection force on the top part of the tension gauge. The movable
O-ring marks this point to facilitate reading.
Please take the reading on the top side of the ring (bring the ring to its initial
position before using the tension gauge again)
Deflection force (kg) 4. Compare the deflection force to the values indicated in the table under
section 3.3. If the measured deflection force reads lower than desired, the
drive must be tightened, if the value reads higher the drive must be
Deflection loosened.
distance (mm)
When tensioning power belts multiply the deflection (see table 3.3) by the number of straps of the
power belt. When using the tension gauge place a metal rod or small plate on the back of the belt,
so all straps are deflected uniformly.
The device can be ordered through our spare part department.

For the order number please refer to the spare parts list: Drive
Bk
Version 01/05
Page 6-8
3. Tables
3.1 Table 1 Static Strand Force (N)
Diameter Static Strand Force Static Strand Force

V-belt Profile of Small in N in N
V-belt Pulley At Initial Assembly After Run-in Phase
<160 650 500
>160 <224 700 550
>224 <355 900 700

SPB
XPB
375 1100 850
400 1200 900
<250 1000 800
>250 <355 1400 1100

SPC
XPC
>355 <560 1800 1400
<160 850 650
>160 <224 900 700
Power Belt >224 <355 1200 900

SPB
<355 >375 1400 1100
400 1600 1200
Bk
Version 01/05
Page 7-8
3.2 Table 2 Length Addition Factor per 1000 mm Belt Length
Elongation Factor or Stretched Distance

Static in mm
Strand Force V-belt Profile
SPB SPC
400 2.0
450 2.4
500 2.7
550 3.1
600 3.4 2.0
650 3.8 2.2
700 4.1 2.4
800 4.8 2.8
850 5.2 3.1
900 5.5 3.3
1000 6.2 3.7
1100 6.9 4.1
1200 7.6 4.5
1200 8.3 5.0
1400 9.0 5.4
1500 9.87 5.8
1600 10.4 6.3
1700 11.1 6.8
Bk
Version 01/05
Page 8-8
3.3 Table 3 Deflection forces using the spring balance principle
Profile Diameter Recommended

small deflection force
pulley in daN*
mm min. max.
160 – 200 2,9 4,4
SPB/5V 212 – 280 3,6 5,0
300 - 400 3,8 5,8
250 - 355 5,1 7,5

SPC
375 - 530 6,0 9,0
112 - 118 2,4 3,6

125 - 140 2,7 4,1
150 - 170 3,0 4,7
XPB/5VX
180 - 200 3,6 5,3
212 - 280 3,8 5,5
300 - 400 4,1 6,4
*
1 daN = 1,02 kg
Bk
Technical Documents 900360600-00E J
Edition 05/05
SONT H O FEN Lubricant Oil
Page 1-2
Service unit Fluid coupling Gear unit

for Oil-Air
Lubrication
Oiler Part of V-belt Part of coupling Spur gear

Worm gear
pulley
Spindle oil VG 10 Gear oil VG 220 Hydraulic oil VG Synthetic gear oil Mineral gear oil
to DIN 51524 to DIN 51517 22 to DIN 51524 VG 460 PG to VG 320 CLP to
and DIN 51517 DIN 51502 DIN 51502
Degol Vitam Degol Degol

ARAL
BG 220 GF 22 GS 460 BG 320
Omala Omala
SHELL Morlina 10 Tellus S 22 Tivela S 460
Oil 220 Oil 320
BP Energol Energol Energol Enersyn Energol

HLP-HM 10 GR-XP 220 HLP-HM 22 SG-XP 460 GR-XP 320
MOBIL Mobilgear 630 Mobil Glygoyle Mobilgear

DTE 22 HE 460 632
CASTROL Hyspin Optigear Optiflex Optigear

AWS 10 BM 220 A460 BM 320
ESSO Nuto Spartan Nuto Glycolube Spartan

H 10 EP 220 H 22 460 EP 320
KLÜBER Klüberoil Syntheso Klüberoil

GEM 1-220N D 460 EP GEM 1-320N
FUCHS RENOLIN
PG 460
BECHEM STAROIL BERUSYNTH

NR 22 EP 460
Technical Documents 900360600-00E J
Edition 05/05
SONT H O FEN Lubricant Oil
Page 2-2
Hydraulic unit
Ambient Ambient
temperature temperature
above + 30 °C 0 bis + 30 °C
Hydraulic oil VG Hydraulic oil VG
68 to DIN 51524 46 to DIN 51524
ARAL Vitam Vitam

GF 68 GF 46
SHELL Tellus S 68 Tellus S 46
BP Energol Energol
HLP-HM 68 HLP-HM 46
MOBIL Mobil Mobil

DTE 26 DTE 25
CASTROL Hydro E 68 Hydro E 46
ESSO Nuto Nuto

H 68 H 46
Technical Documents 900360700-00E I
Edition 05/05
SONT H O FEN Lubricant Grease
Page 1-1
For all bearings and seals with For hauling Articulations

grease nipples, as well as for ropes and limit
automatic lubrication systems switches
a) Temperature of b) Temperature of Attention: Penetrating or

The
lubricating lubricating rust preventing
percentage
bd00023
points up to points above content of solid grease with MoS2

60 °C 60 °C lubricants such as addition
graphite, MoS2…
shall not exceed 5 %
by weight.
Aralub Aralub
ARAL
HL 2 HTR 2
SHELL Alvania RL 2
Energrease Energrease
BP
LS 2 HTG
MOBIL Mobilux EP 2
Optimol-Spray
CASTROL Olit 2 EP Optitemp HT 2 EPL
SHF
ESSO BEACON EP 2 NORVA HT 2
Prinz- Aero-Line
Schulte MPG 1000 E
Elkalub-Spray
ELKALUB GLS 135/N2 GLS 962/N2 GLL 10/N2
FLC 367
DOW Molykote
CORNING Polygliss N
BECHEM HIGH-LUB L2
900026000 D
BA 6610TU EN 03.04
CAVEX® Worm-Gear Units Type
C..
Sizes 63 to 630
FLENDER TÜBINGEN GMBH ⋅ Bahnhofstr. 40-44 ⋅ D-72072 Tübingen

Telefon +49 (0) 70 71 - 707 0 ⋅ Fax +49 (0) 70 71 - 707 400 ⋅ http://www.flender.com
E-mail: sales-motox@flender-motox.com
A company of the Flender group
Contents

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BA 6610TU EN 03.04
2 / 46
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BA 6610TU EN 03.04
3 / 46
1. Technical data
1.1 Rating plate

The rating plate of the CAVEX® gear unit shows the following technical data.
1 Company logo and production location 8 Output speed n2
2 Special information 9 Input speed n1
3 Order no. - Serial no. 10 Transmission ratio i
4 Type / Size 11 Oil type / Viscosity of oil in VG class for main

gear unit
5 Output torque T2 in Nm 12 Quantity of oil in litres for main gear unit
6 Input torque T1 in Nm 13 Operating Instructions number
7 Duty factor 14 Special information
Further data are given in the supply agreement and in these operating instructions.
A standard gear unit has the dimensions indicated

for its type and size in the following dimension tables.
BA 6610TU EN 03.04
4 / 46
1.2 Dimension tables
1.2.1 Type CUW
Output shaft on side A, B or on both sides;

mounting position SU, SO, SR, SL, VO or VU
Side Side
A B
SU SR SL VO VU
A B
B A
A B
SO X
B B
A A
B A View X
a b c d1 l1 d2 l2 e3 e4 E G1 G3 G2 h1 h2 H m1 m2 m3 s
Size
mm
63 146 140 20 18 k6 35 28 m6 50 69 119 63 85 122 72 63 126 208 115 120 – 12
80 175 168 24 22 k6 40 38 m6 65 82 140 80 102 143 86 75 155 252 140 145 – 15
100 216 200 28 28 m6 50 48 m6 80 98 168 100 124 171 102 90 190 309 170 170 – 15
120 254 235 32 32 m6 55 55 m6 95 114 194 120 145 197 120 105 225 364 200 200 – 19
140 290 260 36 38 m6 60 65 m6 105 126 220 140 165 224 132 115 255 416 230 225 – 19
160 324 295 40 42 m6 70 70 m6 120 143 244 160 184 248 150 130 290 472 260 255 – 19
180 364 325 45 48 m6 80 80 m6 140 159 272 180 205 276 165 140 320 522 290 280 – 24
200 396 350 50 55 m6 90 90 m6 160 171 294 200 223 298 178 150 350 573 315 295 – 24
225 440 380 55 60 m6 100 100 m6 180 188 323 225 245 327 195 165 390 638 350 325 – 28
250 480 415 60 65 m6 105 110 n6 200 204 354 250 270 358 212 180 430 703 385 355 – 28
280 525 450 65 70 m6 110 120 n6 220 222 387 280 318 392 230 200 480 786 430 385 – 35
315 590 490 70 75 m6 120 140 n6 240 244 430 315 355 434 252 215 530 870 480 420 – 35
355 665 535 78 80 m6 130 150 n6 260 266 478 355 395 482 275 240 595 977 540 460 – 42
400 748 585 85 90 m6 145 170 n6 290 291 526 400 432 530 300 260 660 1086 605 510 – 42
450 855 562 92 100 m6 160 190 n6 320 322 596 450 485 600 332 290 740 1270 750 495 560 35
500 955 616 100 110 n6 175 210 n6 350 355 663 500 540 668 365 315 815 1410 840 540 630 42
560 1050 678 110 120 n6 190 230 n6 390 389 733 560 590 738 400 350 910 1560 920 600 700 42
630 1175 750 120 135 n6 210 255 n6 430 429 815 630 655 820 440 385 1015 1745 1030 660 780 48
With a vertical worm shaft the note on the diagram in item 1.3 must be observed.
BA 6610TU EN 03.04
5 / 46
1.2.2 Type CFW
Flange on side A or B; output shaft on side A, B or both sides;

Side Side
A B
Fastening with studs and nuts

Hole pattern on size
SU A B SR SL VO VU
B A
A B
SO
X
B B
A A
B A View X
c d1 l1 d2 l2 d3 d4 e1 e2 e3 e4 E g3 G1 G3 G2 k s z
Size
mm
63 7 18 k6 35 28 m6 50 188 150 h8 63 82 69 119 63 76 85 122 72 170 5x 9 3.5
80 8 22 k6 40 38 m6 65 218 180 h8 75 97 82 140 80 90 102 143 86 200 7x 9 4
100 9 28 m6 50 48 m6 80 266 220 h8 90 119 98 168 100 107 124 171 102 245 7 x 11 4
120 10 32 m6 55 55 m6 95 315 260 h8 105 139 114 194 120 125 145 197 120 290 7 x 13.5 5
140 11 38 m6 60 65 m6 105 360 305 h8 115 161 126 220 140 138 165 224 132 335 7 x 13.5 5
160 12 42 m6 70 70 m6 120 410 340 h8 130 182 143 244 160 157 184 248 150 380 7 x 17.5 5
180 13 48 m6 80 80 m6 140 450 380 h8 140 202 159 272 180 172 205 276 165 420 7 x 17.5 5
200 14 55 m6 90 90 m6 160 490 420 h8 150 223 171 294 200 185 223 298 178 460 7 x 17.5 5
225 15 60 m6 100 100 m6 180 540 465 h8 165 248 188 323 225 202 245 327 195 505 12 x 17.5 5
250 16.5 65 m6 105 110 n6 200 590 515 h8 180 273 204 354 250 220 270 358 212 555 12 x 17.5 6
280 18 70 m6 110 120 n6 220 665 575 h8 200 306 222 387 280 238 318 392 230 625 12 x 22 6
315 19.5 75 m6 120 140 n6 240 730 640 h8 215 340 244 430 315 260 355 434 252 690 12 x 22 6
355 21 80 m6 130 150 n6 260 825 725 h8 240 382 266 478 355 286 395 482 275 780 12 x 26 6
400 22.5 90 m6 145 170 n6 290 910 805 h8 260 426 291 526 400 312 432 530 300 865 12 x 26 6
450 24 100 m6 160 190 n6 320 1025 905 h8 290 530 322 596 450 345 485 600 332 975 16 x 26 6
500 25.5 110 n6 175 210 n6 350 1150 1015 h8 315 595 355 663 500 380 540 668 365 1095 16 x 33 6
560 27 120 n6 190 230 n6 390 1270 1125 h8 350 650 389 733 560 415 590 738 400 1210 16 x 33 6
630 28.5 135 n6 210 255 n6 430 1405 1260 h8 385 730 429 815 630 456 655 820 440 1345 16 x 33 6
BA 6610TU EN 03.04
6 / 46
1.2.3 Type COW
Output shaft on side A, B or on both sides;

Side Side
B A
Fastening with studs and nuts
SU SR SL VO VU
B A
A B
A B
SO
B A X
B
A
View X
a b c d1 l1 d2 l2 e3 e4 E G1 G3 G2 h1 h2 H m1 m2 m3 s
Size
mm
63 146 140 20 18 k6 35 28 m6 50 69 119 63 85 122 72 163 100 226 115 120 – 12
80 175 168 24 22 k6 40 38 m6 65 82 140 80 102 143 86 200 120 275 140 145 – 15
100 216 200 28 28 m6 50 48 m6 80 98 168 100 124 171 102 245 145 335 170 170 – 15
120 254 235 32 32 m6 55 55 m6 95 114 194 120 145 197 120 290 170 395 200 200 – 19
140 290 260 36 38 m6 60 65 m6 105 126 220 140 165 224 132 335 195 450 230 225 – 19
160 324 295 40 42 m6 70 70 m6 120 143 244 160 184 248 150 380 220 510 260 255 – 19
180 364 325 45 48 m6 80 80 m6 140 159 272 180 205 276 165 425 245 565 290 280 – 24
200 396 350 50 55 m6 90 90 m6 160 171 294 200 223 298 178 470 270 620 315 295 – 24
225 440 380 55 60 m6 100 100 m6 180 188 323 225 245 327 195 525 300 690 350 325 – 28
250 480 415 60 65 m6 105 110 n6 200 204 354 250 270 358 212 580 330 760 385 355 – 28
280 525 450 65 70 m6 110 120 n6 220 222 387 280 318 392 230 647 367 847 430 385 – 35
315 590 490 70 75 m6 120 140 n6 240 244 430 315 355 434 252 720 405 935 480 420 – 35
355 665 535 78 80 m6 130 150 n6 260 266 478 355 395 482 275 810 455 1050 540 460 – 42
400 748 585 85 90 m6 145 170 n6 290 291 526 400 432 530 300 905 505 1165 605 510 – 42
450 855 562 92 100 m6 160 190 n6 320 322 596 450 485 600 332 980 530 1270 750 495 560 35
500 955 616 100 110 n6 175 210 n6 350 355 663 500 540 668 365 1095 595 1410 840 540 630 42
560 1050 678 110 120 n6 190 230 n6 390 389 733 560 590 738 400 1210 650 1560 920 600 700 42
630 1175 750 120 135 n6 210 255 n6 430 429 815 630 655 820 440 1360 730 1745 1030 660 780 48
BA 6610TU EN 03.04
7 / 46
1.2.4 Type CDA
Torque reaction arm in position 1, 2, 3 or 4 **; torque reaction arm on side A or B

with or without end plate; mounting position SU, SO, SR, SL, VO or VU
2 Side Side
A B
4 1
** With motor attachment,
position 4 not possible
End cover Detail

End plate
X
SU SR SL VO VU
2 A B
B A 4 1
4 1
2 3 2 3
3 A B 4
1
SO 1 1
3 X
B B
2 3 3 2
4 1
A A View X
2 B A 4 4
D2 D5 L P
c1 c2 d1 l1 d6 e1 e2 e4 e5 E f g4 G1 G3 G2 L2 n s
Size H7 H8 min. max.* min.
mm
63 16 8 18 k6 35 32 30 16 63 82 119 73 63 2 62 85 122 65 95 102 115 140 10 M 10
80 16 10 22 k6 40 40 40 20 75 97 140 89 80 2 74 102 143 80 114 124 139.5 180 12 M 16
100 20 11 28 m6 50 40 50 20 90 119 168 102 100 3 88 124 171 93 136 147 165 225 14 M 16
120 20 12 32 m6 55 50 60 25 105 139 194 115 120 3 101 145 197 106 155 167 187 270 16 M 20
140 25 14 38 m6 60 50 65 25 115 161 220 127 140 3 113 165 224 118 173 186 208.5 315 18 M 20
160 25 15 42 m6 70 65 75 32 130 182 244 142 160 4 126 184 248 132 194 212 235.5 360 20 M 20
180 32 16 48 m6 80 65 85 32 140 202 272 154 180 4 138 205 276 144 212 233 259 405 22 M 20
200 32 17 55 m6 90 80 95 40 150 223 294 165 200 4 148 223 298 155 228 250 278 450 25 M 24
225 40 18 60 m6 100 80 105 40 165 248 323 182 225 5 163 245 327 170 250 276 307 505 28 M 24
250 40 20 65 m6 105 80 115 40 180 273 354 197 250 5 178 270 358 185 272 301 335 560 30 M 24
280 40 22 70 m6 110 100 125 50 200 306 387 213 280 5 192 318 392 200 293 326 363 630 32 M 24
315 50 24 75 m6 120 100 140 50 215 340 430 233 315 5 212 355 434 220 322 357 397 710 36 M 30
355 50 27 80 m6 130 120 160 60 240 382 478 256 355 5 233 395 482 242 354 394 438 800 40 M 30
400 60 30 90 m6 145 120 180 60 260 426 526 279 400 5 256 432 530 265 387 433 481 900 45 M 30
450 60 33 100 m6 160 150 200 75 290 530 596 308 450 6 282 485 600 292 425 480 532 1010 48 M 30
500 75 36 110 n6 175 150 220 75 315 595 663 336 500 6 310 540 668 320 465 528 585 1120 50 M 30
560 75 38 120 n6 190 170 240 90 350 650 733 370 560 6 341 590 738 352 510 583 643 1260 56 M 36
630 90 40 135 n6 210 170 270 90 385 730 815 406 630 6 377 655 820 388 560 650 713 1420 63 M 36
* Lmax applies only if the forcing-off disk is used
BA 6610TU EN 03.04
8 / 46
1.2.5 Type CUA
End cover on side A or B; with or without forcing-off disk;
Side Side
A B
End cover Forcing-off disk
SU SR SL VO VU
A B
B A
A B
SO
X
B B
A A
B A View X
D2 H L P
a b c c2 d1 l1 D3 e4 e5 E G1 G2 G3 h1 h2 L1 m1 m2 m3 s
Size H7 min. max.* min.
mm
105.
63 146 140 20 8 18 k6 35 30 M 12 119 73 63 85 65 122 63 126 208 94 102 115 120 – 10 12
5
80 175 168 24 10 22 k6 40 40 M 20 140 89 80 102 80 143 75 155 252 114 124 140 145 – 12 15
128
100 216 200 28 11 28 m6 50 50 M 20 168 102 100 124 93 171 90 190 309 136 147 170 170 – 14 15
152
173
120 254 235 32 12 32 m6 55 60 M 24 194 115 120 145 106 197 105 225 364 155 167 192. 200 200 – 16 19
140 290 260 36 14 38 m6 60 65 M 24 220 127 140 165 118 224 115 255 416 173 186 5 230 225 – 18 19
160 324 295 40 15 42 m6 70 75 M 24 244 142 160 184 132 248 130 290 472 194 212 218. 260 255 – 20 19
5
180 364 325 45 16 48 m6 80 85 M 24 272 154 180 205 144 276 140 320 522 212 233 240 290 280 – 22 24
200 396 350 50 17 55 m6 90 95 M 30 294 165 200 223 155 298 150 350 573 228 250 258 315 295 – 25 24
225 440 380 55 18 60 m6 100 105 M 30 323 182 225 245 170 327 165 390 638 250 276 285 350 325 – 28 28
250 480 415 60 20 65 m6 105 115 M 30 354 197 250 270 185 358 180 430 703 272 301 311 385 355 – 30 28
280 525 450 65 22 70 m6 110 125 M 36 387 213 280 318 200 392 200 480 786 293 326 337 430 385 – 32 35
315 590 490 70 24 75 m6 120 140 M 36 430 233 315 355 220 434 215 530 870 322 357 369 480 420 – 36 35
355 665 535 78 27 80 m6 130 160 M 36 478 256 355 395 242 482 240 595 977 354 394 407 540 460 – 40 42
400 748 585 85 30 90 m6 145 180 M 36 526 279 400 432 265 530 260 660 1086 387 433 447 605 510 – 45 42
450 855 562 92 33 100 m6 160 200 M 36 596 308 450 485 292 600 290 740 1270 425 480 495 750 495 560 48 35
955
500 616 100 36 110 n6 175 220 M 36 663 336 500 540 320 668 315 815 1410 465 528 544 840 540 630 50 42
105
560 678 110 38 120 n6 190 240 M 42 733 370 560 590 352 738 350 910 1560 510 583 600 920 600 700 56 42
0
630 750 120 40 135 n6 210 270 M 42 815 406 630 655 388 820 385 1015 1745 560 650 668 1030 660 780 63 48
1175
BA 6610TU EN 03.04
9 / 46
1.2.6 Type CFA
Flange cover on side A or B; with or without forcing-off disk;

Side Side
A B
End cover
Forcing-off disk
Flange cover
Hole pattern on size
SU SR SL VO VU
A B
B A
A B
SO X
B B
A A
View X
B A
d4 D2 L P
c c2 d1 l1 d3 D3 e1 e2 e4 e5 E g3 G1 G2 G3 k L1 s z
Size h8 H7 min. max.* min.
mm
63 13 8 18 k6 35 145 95 30 M 12 63 82 119 73 63 63 85 65 122 130 94 102 105.5 10 6xM 8 3
80 15 10 22 k6 40 175 125 40 M 20 75 97 140 89 80 75 102 80 143 160 114 124 128 12 8 X M 8 3.5
100 18 11 28 m6 50 217 155 50 M 20 90 119 168 102 100 90 124 93 171 195 136 147 152 14 8 X M 10 3.5
120 20 12 32 m6 55 258 190 60 M 24 105 139 194 115 120 104 145 106 197 235 155 167 173 16 8 X M 12 4
140 22 14 38 m6 60 302 225 65 M 24 115 161 220 127 140 116 165 118 224 275 173 186 192.5 18 8 X M 12 4
160 25 15 42 m6 70 338 260 75 M 24 130 182 244 142 160 129 184 132 248 310 194 212 218.5 20 8 X M 16 5
180 28 16 48 m6 80 379 295 85 M 24 140 202 272 154 180 142 205 144 276 350 212 233 240 22 8 X M 16 5
200 31 17 55 m6 90 416 330 95 M 30 150 223 294 165 200 152 223 155 298 385 228 250 258 25 8 X M 16 5
225 34 18 60 m6 100 462 375 105 M 30 165 248 323 182 225 167 245 170 327 430 250 276 285 28 12 X M 16 5
250 37 20 65 m6 105 510 420 115 M 30 180 273 354 197 250 181 270 185 358 480 272 301 311 30 12 X M 16 5
280 40 22 70 m6 110 574 465 125 M 30 200 306 387 213 280 196 318 200 392 535 293 326 337 32 12 X M 20 6
315 43 24 75 m6 120 638 530 140 M 36 215 340 430 233 315 216 355 220 434 600 322 357 369 36 12 X M 20 6
355 46 27 80 m6 130 720 600 160 M 36 240 382 478 256 355 238 395 242 482 680 354 394 407 40 12 X M 24 6
400 48 30 90 m6 145 804 680 180 M 36 260 426 526 279 400 260 432 265 530 760 387 433 447 45 12 X M 24 6
450 52 33 100 m6 160 906 770 200 M 36 290 530 596 308 450 287 485 292 600 860 425 480 495 48 16 X M 24 6
101 960
500 55 36 110 n6 175 4 860 220 M 36 315 595 663 336 500 314 540 320 668 107 465 528 544 50 16 X M 30 6
560 60 38 120 n6 190 1126 965 240 M 42 350 650 733 370 560 346 590 352 738 0 510 583 600 56 16 X M 30 6
630 63 40 135 n6 210 125 1090 270 M 42 385 730 815 406 630 382 655 388 820 120 560 650 668 63 16 X M 30 6
8 0
BA 6610TU EN 03.04
10 / 46
1.2.7 Type COA
End cover on side A or B; with or without forcing-off disk;
Side Side
B A
End cover Forcing-off disk Fastening with studs and nuts
SU SR SL VO VU
B A
A B A B
SO
B A X
B B
A View X A
D2 L P
a b c c2 d1 l1 D3 G1 G3 G2 e4 e5 E h1 h2 H m1 m2 m3 L1 s
Size H7 min. max.* min.
mm
63 146 140 20 8 18 k6 35 30 M 12 85 122 65 119 73 63 163 100 226 115 120 – 94 102 105.5 10 12
80 175 168 24 10 22 k6 40 40 M 20 102 143 80 140 89 80 200 120 275 140 145 – 114 124 128 12 15
100 216 200 28 11 28 m6 50 50 M 20 124 171 93 168 102 100 245 145 335 170 170 – 136 147 152 14 15
120 254 235 32 12 32 m6 55 60 M 24 145 197 106 194 115 120 290 170 395 200 200 – 155 167 173 16 19
140 290 260 36 14 38 m6 60 65 M 24 165 224 118 220 127 140 335 195 450 230 225 – 173 186 192.5 18 19
160 324 295 40 15 42 m6 70 75 M 24 184 248 132 244 142 160 380 220 510 260 255 – 194 212 218.5 20 19
180 364 325 45 16 48 m6 80 85 M 24 205 276 144 272 154 180 425 245 565 290 280 – 212 233 240 22 24
200 396 350 50 17 55 m6 90 95 M 30 223 298 155 294 165 200 470 270 620 315 295 – 228 250 258 25 24
225 440 380 55 18 60 m6 100 105 M 30 245 327 170 323 182 225 525 300 690 350 325 – 250 276 285 28 28
250 480 415 60 20 65 m6 105 115 M 30 270 358 185 354 197 250 580 330 760 385 355 – 272 301 311 30 28
280 525 450 65 22 70 m6 110 125 M 30 318 392 200 387 213 280 647 367 847 430 385 – 293 326 337 32 35
315 590 490 70 24 75 m6 120 140 M 36 355 434 220 430 233 315 720 405 935 480 420 – 322 357 369 36 35
355 665 535 78 27 80 m6 130 160 M 36 395 482 242 478 256 355 810 455 1050 540 460 – 354 394 407 40 42
400 748 585 85 30 90 m6 145 180 M 36 432 530 265 526 279 400 905 505 1165 605 510 – 387 433 447 45 42
450 855 562 92 33 100 m6 160 200 M 36 485 600 292 596 308 450 980 530 1270 750 495 560 425 480 495 48 35
109
955 5
500 616 100 36 110 n6 175 220 M 36 540 668 320 663 336 500 595 1410 840 540 630 465 528 544 50 42
105 121
560 678 110 38 120 n6 190 240 M 42 590 738 352 733 370 560 650 1560 920 600 700 510 583 600 56 42
0 0
630 750 120 40 135 n6 210 270 M 42 655 820 388 815 406 630 730 1745 1030 660 780 560 650 668 63 48
1175 136
0
BA 6610TU EN 03.04
11 / 46
1.2.8 Worm-gear unit with additional mounting surfaces
Size 63 - 400 Size 450 - 630
Mounting surfaces Mounting surfaces

a3 x b3 a4 x b4
a3 b3 h3 m3 m4 m7 s3 t a4 b4 h4 m5 m6 m8 s3 t
Size Size
mm mm mm mm
63 146 91 78 110 71 – M 10 19 63 146 110 126 114 89 – M 10 19
80 175 110 93 133 86 – M 12 21 80 175 130 155 140 109.5 – M 12 21
100 216 131 115 163 105 – M 12 23 100 216 160 190 170 133 – M 12 23
120 254 155 135 190 125 – M 16 25 120 254 183 225 194 151.5 – M 16 25
140 290 172 156 220 140 – M 16 26 140 290 204 255 220 172 – M 16 26
160 324 189 177 245 155 – M 16 27 160 324 223 290 240 187.5 – M 16 27
180 354 210 197 275 170 – M 20 30 180 364 245 320 268 209.5 – M 20 30
200 396 222 217 300 182 – M 20 31 200 396 260 350 280 219 – M 20 31
225 440 246 242 335 200 – M 24 38 225 440 280 390 300 234.5 – M 24 38
250 480 266 267 370 220 – M 24 40 250 480 305 430 340 265.5 – M 24 40
280 525 296 298 400 240 – M 30 45 280 525 345 480 430 290 – M 30 45
315 590 325 331 450 265 – M 30 45 315 590 370 530 480 310 – M 30 45
355 665 363 373 510 295 – M 36 55 355 665 415 595 540 350 – M 36 55
400 748 403 416 570 335 – M 36 55 400 748 445 660 605 375 – M 36 55
Mounting surfaces Mounting surfaces

a3 x b3 a4 x b4
a3 b3 h3 m3 m4 m7 s3 t a4 b4 h4 m5 m6 m8 s3 t
Size Size
mm mm
450 855 562 530 750 495 560 35 92 450 855 562 740 750 495 560 35 92
500 955 616 595 840 540 630 42 100 500 955 616 815 840 540 630 42 100
560 1050 678 650 920 600 700 42 110 560 1050 678 910 920 600 700 42 110
630 1175 750 730 1030 660 780 48 120 630 1175 750 1015 1030 660 780 48 120
BA 6610TU EN 03.04
12 / 46
1.2.9 Worm-gear unit with shrink disk
Protective cover Connection dimensions for shaft

Sliding bush
Shrink disk
The protective cover must be ordered separately
Shrink disk d7 d8 d9 d10 f1 G2 G4 l3 l4 l5 l6 l7
Size T2max D
Type
Nm mm mm mm mm mm mm mm mm mm mm mm mm mm
63 HSD 36 - 32 630 72 28 30 30 37 1 65 95 160 21 24 25 13
80 HSD 50 - 32 1400 90 39 40 40 48 0.5 80 112 192 25 28 30 13
100 HSD 68 - 32 2200 115 50 55 51 64 1 93 129 222 27 30 30 14
120 HSD 80 - 32 4600 141 60 65 61 75 1 106 144 250 29 32 32 16
140 HSD 90 - 32 6400 155 65 70 66 80 2 118 166 284 35 38 40 16
160 HSD 100 - 32 9700 170 75 80 77 90 2 132 184 316 40 43 45 16
180 HSD 110 - 32 14000 185 85 90 87 100 2 144 202 346 45 48 50 18
200 HSD 125 - 32 21200 215 95 100 97 110 2 155 216 371 48 51 50 19
225 HSD 140 - 32 29800 230 105 110 107 120 2 170 238 408 53 56 60 20
250 HSD 155 - 32 40000 263 115 120 117 130 2 185 257 442 57 60 60 20
280 HSD 165 - 32 51000 290 125 130 127 140 2 200 280 480 63 66 65 22
315 HSD 185 - 32 79000 320 140 150 142 160 2 220 317 537 78 82 80 23
355 HSD 200 - 32 95000 340 155 160 157 170 2 242 340 582 78 82 80 23
400 HSD 240 - 32 148000 405 175 180 177 190 2 265 385 650 98 102 100 27
450 HSD 260 - 32 215000 430 200 205 202 215 2 292 425 717 112 116 120 30
500 HSD 280 - 32 279000 460 220 225 222 235 2 320 467 787 125 130 135 31
560 HSD 320 - 32 346000 520 240 245 242 255 2 352 507 859 134 140 145 33
630 HSD 340 - 32 489000 570 270 275 272 285 2 388 558 946 148 155 160 34
BA 6610TU EN 03.04
13 / 46
1.2.10 Attachment of IEC motor
1) The dimensions may vary slightly according to the make of the motor.
They apply to motors without additional equipment.
IEC standard motor, BIPEX coupling type BWN IEC standard motor, BIPEX coupling type BWN
assembly option assembly option
Bore Bore
B5, V1 or V3 (mm) B5, V1 or V3 (mm)
Size Size
a1 g5 g6 Gear unit a1 g5 g6 Gear unit
Motor side Motor side
Size ≈ Size side Size ≈ Size side
mm mm mm Part ∅ Part ∅ mm mm mm Part ∅ Part ∅
132 300 420 820 AB 112 1 38 2 55
71 160 162 370 B 43 1 14 2 18 160 350 450 970 AB 112 1 42 2 55
80 200 174 410 B 53 1 19 2 18
63 200 180 350 450 1030 AB 112 1 48 2 55
90 200 174 450 B 53 1 24 2 18 200 400 450 1080 B 112 1 55 2 55
100/112 250 196 520 B 62 1 28 2 18 225 450 480 1170 AB 127 2 60 1 55
160 350 482 1000 AB 112 42 2 60
80 200 198 430 B 62 1 19 2 22 1
180 350 482 1060 AB 112 48 2 60
90 200 198 470 B 62 1 24 2 22 1
80 225 200 400 482 1110 B 127 55 2 60
100/112 250 218 540 B 62 1 28 2 22 225 450 512 1210 B 127 1 60 2 60
132 300 240 640 AB 72 2 38 1 22 1
250 550 512 1240 B 127 65 2 60
160 350 512 1030 AB 127 1 42 2 65
90 200 238 510 B 53 1 24 2 28 180 350 512 1090 AB 127 1 48 2 65
100/112 250 250 570 B 62 1 28 2 28 200 400 512 1140 AB 127 1 55 2 65
100 250
132 300 272 680 AB 72 2 38 1 28 225 450 542 1240 B 127 1 60 2 65
160 350 308 830 A 97 1 42 2 28 250 550 546 1270 B 142 1 65 2 65
280 550 546 1460 B 142 1 75 2 65
180 350 569 1150 AB 142 1 48 2 70
100/112 250 276 600 B 62 1 28 2 32
200 400 569 1200 AB 142 1 55 2 70
132 300 298 700 AB 72 2 38 1 32
120 280 225 450 599 1290 AB 142 1 60 2 70
160 350 334 860 A 97 1 42 2 32 250 550 599 1320 B 142 1 65 2 70
180 350 334 920 AB 97 2 48 1 32
280 550 599 1500 B 142 1 75 2 70
200 400 616 1240 AB 142 1 55 2 75
100/112 250 303 630 AB 72 1 28 2 38 225 450 646 1340 AB 142 1 60 2 75
132 300 323 730 B 72 1 38 2 38
140 315 250 550 646 1370 B 142 1 65 2 75
160 350 359 880 A 97 1 42 2 38
280 550 646 1550 B 142 1 75 2 75
180 350 359 940 AB 97 2 48 1 38
315 660 681 1650 B 162 1 80 2 75
100/112 250 332 660 AB 72 1 28 2 42 200 400 671 1300 AB 162 1 55 2 80
132 300 352 760 B 72 1 38 2 42 225 450 701 1390 AB 162 1 60 2 80
160 160 350 388 910 A 97 1 42 2 42 355 250 550 701 1420 AB 162 1 65 2 80
180 350 388 970 AB 97 2 48 1 42 280 550 701 1600 B 162 1 75 2 80
200 400 391 1020 AB 112 2 55 1 42 315 660 731 1700 B 162 1 80 2 80
132 300 386 790 AB 84 1 38 2 48 200 400 729 1360 AB 182 1 55 2 90
160 350 419 940 AB 97 1 42 2 48 225 450 759 1450 AB 182 1 60 2 90
180 180 350 419 1000 B 97 1 48 2 48 400 250 550 759 1480 AB 182 1 65 2 90
200 400 422 1050 AB 112 2 55 1 48 280 550 759 1660 AB 182 1 75 2 90
225 450 452 1150 AB 127 2 60 1 48 315 660 789 1760 B 182 1 80 2 90
Couplings finish-bored with ISO tolerance field H7, parallel keyway to DIN 6885 Part 1 and set screw.
BA 6610TU EN 03.04
14 / 46
1.3 Ventilation, oil level, oil drain, oil quantity and weights
A1 M1 B1
M2 M3 M3 M2
B4 A4
M6 M7 M7 M6
B5 B7 A5 A7
B2 A2
B3 A3
B6 A6
140 180 225 280 355 450 560

Size 63 80 100 120
160 200 250 315 400 500 630
X (mm) 60 70 82 95 110 135 160 190 210 240 280
With a vertical worm shaft a gap X high must be provided

above the gear unit on M6 and M7.
Position of ventilation Position of oil level Position of oil drain

f ⊗ F
Type Output on side Mounting position
SU SO SR SL VO VU
f ⊗ F f ⊗ F f ⊗ F f ⊗ F f ⊗ F f ⊗ F
CUW A A1 B2 1) B3 B3 B2 A1 B4 M1 A1 A1 M1 B4 M6 B5 M7 M7 B7 M6
CUA B / both sides B1 A2 1) A3 A3 A2 B1 B1 M1 A4 A4 M1 B1 M6 A7 M7 M7 A5 M6
COW A B4 B2 1) B6 B6 B2 B4 B4 M2/3 A4 A4 M2/3 B4 M6 B5 M7 M7 B7 M6

COA B / both sides A4 A2 1) A6 A6 A2 A4 B4 M2/3 A4 A4 M2/3 B4 M6 A7 M7 M7 A5 M6
CFW 2) A A1 B2 1) B6 B6 B2 A1 B4 M1 A1 A1 M1 B4 M6 B5 M7 M7 B7 M6
CFA
CDA B / both sides B1 A2 1) A6 A6 A2 B1 B1 M1 A4 A4 M1 B1 M6 A7 M7 M7 A5 M6
1) With sizes 63 and 80: B5 instead of B2 or A5 instead of A2
2) On CFW the flange is designated as output
Average weights,
Average oil quantities in litres
excluding oil, in kg
Type CUW, COW, CFW Type CUA, COA, CFA, CDA
Type
Size Mounting position Mounting position
SU SO SR/SL VO/VU SU SO SR/SL VO/VU C.W C.A
63 0.6 0.8 0.7 1.1 0.6 0.7 0.6 1 15 15
80 1.2 1.8 1.3 2.2 1.2 1.6 1.1 2 25 25
100 1.3 3.3 2.3 4.2 1.3 3 2 3.8 42 40
120 2 5.5 4 7 2 5 3.5 6.5 65 62
140 3 9 6 11 3 8 5.5 10 90 85
160 4.5 12.5 8.5 16 4.5 11.5 8 15 125 120
180 5.5 17 12 22 5.5 16 11 20 170 160
200 7.5 23 16 29 7.5 22 15 27 220 210
225 10 32 21 39 10 29 20 36 290 270
250 13 44 27 52 13 40 26 47 380 360
280 15 58 35 66 15 54 33 62 520 490
315 20 78 50 88 20 72 47 82 700 660
355 28 110 71 124 28 102 68 116 1030 980
400 40 155 95 174 40 145 90 164 1400 1340
450 55 220 133 243 55 208 127 232 1980 1910
500 77 310 186 340 77 295 178 325 2700 2620
560 108 430 260 475 108 410 250 455 3700 3600
630 150 600 360 665 150 575 348 640 5000 4880
BA 6610TU EN 03.04
15 / 46
1.4 Measuring-surface sound-pressure level
The measuring-surface sound-pressure level is according to DIN 45635 that measured on a measuring
surface at a distance of 1 m from the surface of the CAVEX® gear unit at at least 30 % of rated output.
The measuring-surface sound-pressure levels specified in Table 1.2 derive from statistic evaluations
conducted by our quality control department. The CAVEX® gear unit may be expected not to exceed
these noise levels. If repeat measurements on site do not yield clear results with regard to measuring
technology, the measurement obtained on FLENDER TÜBINGEN GMBH test stands will apply.
Size 63 - 80 100 - 120 140 - 160 180 - 200 225 - 250 280 - 315 355 - 400 450 - 500 560 - 630
n1
Type LpA dB(A)
1/min
3000 79 83 86
C.. 1500 <70 <70 73 75 79 82 87

750 <70 <70 <70 <70 <70 71 76 81 85
Table 1.2: Measuring-surface sound-pressure level LpA in dB(A)
2. General instructions
2.1 Introduction
These Operating Instructions (BA) are an integral part of the gear unit supplied and must be kept in its
vicinity for reference at all times.
All persons involved in the installation, operation, maintenance and repair of
Caution! the gear unit must have read and understood these Operating Instructions and
must comply with them. We accept no responsibility for damage or disruption
caused by disregard of these Instructions.
The CAVEX® gear unit described here has been manufactured in compliance with the recognised
safety regulations and the state of technical development applying at the time these operating
instructions were printed.
In the interest of technical progress we reserve the right to make changes to the individual assemblies
and accessories which we regard as necessary to preserve their essential characteristics and improve
their efficiency and safety.
2.2 Copyright
The copyright to these Operating Instructions is held by FLENDER TÜBINGEN GMBH.
These Operating Instructions must not be wholly or partly reproduced for competitive purposes, used
in any unauthorised way or made available to third parties without our agreement.
Technical enquiries should be addressed to the following works
FLENDER TÜBINGEN GMBH

Postfach 1709 ⋅ D-72007 Tübingen
Bahnhofstr. 40-44 ⋅ D-72072 Tübingen

Telefon +49 (0) 70 71 - 707 0
Fax +49 (0) 70 71 - 707 400
E-mail: sales-motox@flender-motox.com
http://www.flender.com
24 h Service Hotline +49 (0) 172 - 7 32 29 55
or to one of our customer-service addresses. A list of our customer-service addresses is given in section
11, ”Spare parts, customer-service addresses”.
BA 6610TU EN 03.04
16 / 46
3. Safety instructions
3.1 Proper use
S The CAVEX® gear unit has been manufactured in accordance with the latest state of technological
development and is delivered in a condition for safe and reliable use. Unauthorised changes,
additions and modifications which reduce reliability and safety are not permitted. This applies equally
to safety features designed to prevent accidental contact.
S The CAVEX® gear unit may be used and operated only in accordance with the conditions laid down
in the service and supply contract.
3.2 Obligations of the user
S The user must ensure that all persons involved in the installation, operation, maintenance and repair
of the gear unit have read and understood these Operating Instructions and comply with them at all
times in order to:
– avoid injury or damage to the user and third parties,
– ensure the safety and reliability of the unit,
and
– avoid disruptions and environmental damage through incorrect use.
S During transport, assembly, installation, disassembly, operation and maintenance of the unit the
relevant safety and environmental regulations must be complied with.
S The gear unit should be operated, maintained or repaired only by authorised, trained and qualified
personnel.
S The gear unit must not be cleaned with high-pressure cleaning equipment.
S All work on the coupling must be carried out with great care and with due regard to safety.
S All work on the gear unit must be carried out only when it is at a standstill. Secure the drive unit to
prevent unintentional switch-on! A notice should be attached to the start switch stating clearly that
work is in progress.
S No welding work should be done on the gear unit.

The gear unit must not be used as an earthing point for welding operations. Toothed parts and
bearings may be irreparably damaged by welding.
S If any changes (e.g. overheating or unusual noises)are noticed on the gear unit during operation, the
drive unit must be switched off immediately.
S Exposed rotating parts must be fitted with guards to prevent physical contact.
S If the CAVEX® gear unit is intended for installation in plant or machinery, the manufacturer of such
plant or machinery must ensure that the regulations, pointers and descriptions contained in these
operating instructions are incorporated in his own instructions.
S Notices attached to the CAVEX® gear unit, e.g. rating plate, direction arrows, etc., must be observed.
They must be kept free from dirt and paint at all times. Missing plates must be replaced.
S All spare parts must be obtained from FLENDER TÜBINGEN GMBH.
3.3 Environmental protection
S When changing oil, the used oil must be collected in suitable containers. Any oil spillage must be
removed immediately.
S Preservative agents should be stored separately from used oil.
S Used oil, preservative agent, oil-binding agents and oil-soaked cloths must be disposed of in
accordance with environmental legislation.
BA 6610TU EN 03.04
17 / 46
3.4 Special dangers
S Depending on operating conditions, the surface of the CAVEX® gear unit may heat up considerably.
Danger of burns!
S When changing oil, take care to prevent scalding by hot oil.
3.5 Warnings and symbols used in these Operating Instructions (BA)
This symbol indicates safety measures which must be observed to avoid personal
injury.
This symbol indicates safety measures which must be observed to avoid damage to
Caution! the gear unit.
Note: This symbol indicates general operating instructions which are of particular
importance.
4. Transport, handling and storage
Note: Observe the ”Safety instructions” in section 3.

4.1 Scope of supply
The products supplied are listed in the despatch papers. Check immediately on receipt to ensure that
all the products listed have actually been delivered. Parts damaged during transport or missing parts
must be reported in writing immediately.
4.2 Transport and handling
When handling FLENDER products, use only lifting and handling equipment
of sufficient load-bearing capacity!
Different forms of packaging may be used, depending on the size of the CAVEX® gear unit and method
of transport. Unless otherwise agreed, the packaging complies with the HPE Packaging Guidelines.
The symbols marked on the packaging must be observed at all times. These have the following
meanings:
bild-transport
This way Fragile Keep Keep Centre of Use no Attach

up dry cool gravity hand hook here
The gear unit must always be transported with due care to avoid danger to
persons and the gear unit.
If, for example, the free shaft ends are knocked, this may damage the gear unit.
To transport and handle the gear unit, suitable means of attachment (e.g. eye
Caution! bolts) must be screwed into the tapped holes provided for this purpose on the
upper side of the housing.
Do not use the front threads at the shaft ends to attach eye bolts for transport.
4.3 Storing the gear unit

The gear unit must be stored on a vibration-free base in a place protected from the weather.
Do not stack gear units on top of one another.
If the gear unit is being stored out of doors, it must be particularly carefully
Caution! covered, and care must be taken that neither moisture nor foreign material can
collect on the unit.
BA 6610TU EN 03.04
18 / 46
4.4 Standard preservation
The shaft ends have been provided with a rust-preventive paint coating. It is resistant to seawater and
tropical conditions for a period of 12 months.
The properties of the outer paint coat are as follows: Resistant to acids, weak alkalis, solvents,
atmospheric action, temperatures up to 120 °C (temporarily up to 140 °C) and to tropical conditions.
All grease lubrication points are provided with suitable lubricant, and the gear unit has been initially filled
by us with synthetic oil (long-term lubrication).
If initial filling has not been expressly requested, the internal parts of the gear unit are treated with
preservative. This preservative is sufficient for normal transport conditions (including overseas
transport) and for a period of 6 months until initial start-up.
For longer periods of storage (> 6 months) we advise regular checking and, if necessary, renewal of
the internal and external preservation.
5. Technical description
5.1 General
The gear unit is a CAVEX® worm-gear unit. It is outstanding for its quiet running and high efficiency.
5.2 Identification marking
Colour codes for ventilation, oil level and oil drainage:

Ventilation and oil filling: yellow f
Oil level and lubrication points: red '

Oil drain: white l
On gear units with a backstop the direction of rotation is indicated by an arrow.
5.3 Fan
On worm gear units fitted with fans the fan is mounted on the high-speed worm shaft of the gear unit
and protected by a fan cover against accidental contact. The fan sucks air through the grid on the cover
and blows it along the air ducts on the side of the gear housing. This removes heat from the housing.
Caution! Make sure that the air intake at the fan cover is not obstructed.
The cooling effect is considerably reduced if the fan cover or the surface of the gear housing, particularly
in the area of the worm, is dirty (see section 10, ”Maintenance and repair”).
BA 6610TU EN 03.04
19 / 46
5.4 Couplings
As a rule, flexible couplings must be provided for the input and output drive sides of the gear unit.
If rigid couplings are to be used, the manufacturer’s approval must be obtained, as otherwise additional
radial and axial forces may cause problems.
The special operating instructions should be observed for operation of the couplings.
5.5 Shrink disk

In the case of a shaft-mounted gear unit with hollow shaft in shrink disk version, a shrink disk should
be used as a frictional clamping connection between the gear unit hollow shaft and the driven machine.
5.6 Backstop
For certain requirements, the gear unit is fitted with a mechanical backstop.
Note: This permits only the correct direction of rotation during the operation of the unit.
The direction of rotation is marked by an arrow on the input side of the gear unit.
There are two different designs:
Design A:
The backstop is mounted in the bearing cover on the fan side. The backstop is mounted oiltight on an
adapter flange on the gear unit and integrated in its oil-circulation system.
Note: If the direction of rotation is subsequently to be changed and this will involve major
engineering work, FLENDER TÜBINGEN GMBH must be consulted.
Design B:
This design is specified when it is expected that the direction of rotation will later be changed and no
fan is required for the gear unit.
The backstop is not integrated into the oil circuit. A separate lubrication system is not necessary.
To prevent damage to or destruction of the backstop, it is essential to ensure
Caution! that the motor is not run in opposition to the locked backstop.
5.7 Attachment of IEC Motors

When attaching IEC motors, the Operating Instructions for the motor are to be observed.
No motor with a speed exceeding the speeds specified for the gear unit must
Caution! be used, as this may cause damage to the gear unit.
BA 6610TU EN 03.04
20 / 46
6. Assembly
6.1 General information on assembly and installation

Installation or attachment must take place without putting undue stress on the gear unit.
The air feed for cooling the CAVEX® gear unit must not be impaired.
A means of monitoring the oil level must be provided.
Foundations and connections must be designed and constructed so as to prevent vibration being
transmitted from adjacent components and assemblies.
The unit must be carefully aligned with the motor on the input and output sides. Possible strain
deformations due to operating forces must be taken into account.
Fastening bolts or nuts must be tightened to the prescribed torque. For the tightening torque, refer to
the relevant tables. Bolts of the minimum strength class 8.8 must be used.
If external forces are acting upon the gear unit, it is advisable to prevent displacement by means of
lateral stops.
To ensure proper lubrication, the installation position specified in the order must always be observed.
6.2 Description of assembly

S Remove anti-corrosive paint from the shaft ends and connecting surfaces with cleaning medium.
Adequate ventilation must be ensured, when using cleaners containing

solvent additives. If necessary, the flammability of the cleaning medium must
be noted.
Cleaning media must not be allowed to get under the sealing lips of the shaft
Caution! sealing rings.
S Pull couplings and similar add-on parts onto the shaft ends and secure them.
If these are to be heated before mounting, the manufacturer of the parts must be consulted for the
correct joining temperatures.
Unless otherwise specified, the components may be heated inductively, with a burner or in a furnace.
Take precautions to avoid burns from hot components!
The gear unit shaft ends have tapped holes in their end faces to aid the pulling on of couplings, washers,
gears, etc.
The components to be mounted must be fitted with the aid of suitable
Caution! equipment to prevent the shaft bearings from being damaged by axial joining
forces.
Always use suitable lifting equipment.
When fitting the components, care must be taken that the shaft sealing rings
and shaft running surface are not damaged.
Never use force or knock the couplings into position, as this will damage the
Caution! rolling bearings, locking rings, etc.
Caution! The operating instructions for the part to be attached must be observed.
BA 6610TU EN 03.04
21 / 46
6.3 Fitting a shaft-mounted gear unit with parallel key
6.3.1 Preparatory work

To assist demounting, we recommend providing a connection for pressure oil on the end of the driven
machine shaft. For this a hole must be drilled through to the hollow shaft bore.
1 Pressure oil connection
The driven machine shaft end must be provided with a parallel key to DIN 6885 Part 1 Form A and should
have a centring feature to DIN 332 Form DS (with thread) in its end face.
Check the hollow and machine shafts to ensure that seats and edges are not
Caution! damaged.
If necessary, rework the parts with a suitable tool and clean them again.
Note: Protection of the cleaned contact surfaces with a suitable lubricant to prevent fretting
corrosion (e.g. Altemp Q Paste NB 50 by Messrs. Klüber).
6.3.2 Assembly
The hollow-shaft gear unit can be mounted on the machine shaft by means of an end plate and locking
ring, if these parts have been delivered with the gear unit.
Note: By repositioning the end plate and using a suitable bolt the end plate can be used as
a forcing-off disk.
1 4
2
3
3
2
4
1 End cover 3 Bolt

2 End plate (forcing-off disk) 4 Locking ring
Only on types fitted with a torque reaction arm may the hollow shaft be pulled
Caution! up against a machine shaft collar, as otherwise the bearings will be put under
undue stress.
The hollow shaft must be precisely aligned with the machine shaft to avoid
Caution! canting.
BA 6610TU EN 03.04
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6.4 Fitting a shaft-mounted gear unit with shrink disk
6.4.1 Preparatory work
The hollow shaft bore and outside diameter of the machine shaft must be
Caution! thoroughly cleaned in the area of the shrink disk seat.
Both surfaces must be completely grease-free.
This is essential for safe and reliable torque transmission. Do not use
contaminated solvents or dirty cloths to remove grease.
S Remove anti-corrosive paint from the shaft ends and connecting surfaces with cleaning medium.
Adequate ventilation must be ensured, when using cleaners containing
solvent additives. If necessary, the flammability of the cleaning medium must
be noted.
Cleaning media must not be allowed to get under the sealing lips of the shaft
Caution! sealing rings.
Never use force or knock the couplings into position, as this will damage the
Caution! rolling bearings, locking rings, etc.
Caution! The operating instructions for the part to be attached must be observed.
6.4.2 Fitting
S Fitting with integrated sliding bush
S Fit the drive unit by means of the nut and threaded spindle. The counter force is provided by the hollow
shaft.
The hollow shaft must be exactly aligned with the machine shaft to avoid
Caution! canting.
On flange-mounted gear units the hollow shaft must not be put under undue
Caution! axial and radial stress, as the bearings may fail through excessive load.
1 6 2 5 3 4
1 Machine shaft 4 Threaded spindle

2 Hollow shaft 5 Washer
3 Hexagon nut 6 Sliding bush
Note: Parts 3, 4 and 5 are not included in the delivery.
Instead of the nut and threaded spindle shown in the diagram, other types of equipment, e.g. hydraulic
pulling-off equipment (type Lucas) may be used.
6.4.3 Axial securing device
The hollow shaft is axially secured on the machine shaft by means of a shrink disk connection.
BA 6610TU EN 03.04
23 / 46
6.4.4 Assembly of shrink disk
The shrink disk is delivered ready for installation.
Caution! It must not be dismantled before tensioning for the first time.
4 3
A
5
B
2
A Greased B Absolutely grease-free
1 Machine shaft 4 Outer ring

2 Hollow shaft 5 Tensioning bolt
3 Inner ring
Note: The outer surface of the hollow shaft may be greased in the area of the shrink-disk
seat.
Never tighten the tension bolts before the machine shaft has been fitted, as this
Caution! cause plastic deformation of the hollow shaft.
The tension bolts must be tightened one after the other, working round several times, until the front
faces of the outer and inner ring are in alignment.
Note: This allows the tension condition to be checked visually.
Caution! Tightening all the tension bolts (5) one after the other (not diagonally).
BA 6610TU EN 03.04
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To avoid overloading the individual bolts, the maximum tensioning torque (see
Caution! table 6.1) must never be exceeded; the alignment of the end faces has priority.
If this alignment is not achieved when tensioning, the tolerance of the stub
shaft must be checked.
Max. tensioning
torque
Tensioning-bolt per bolt
thread Strength class
10.9
Nm
M 8 29
M 10 58
M 12 100
M 14 160
M 16 240
M 20 470
M 24 820
Table 6.1: Maximum torques for tensioning bolts
Then replace the protective cover.
6.4.5 Removing the shrink disk
Loosen the tensioning bolts gradually one after the other, working round several times.
If the outer ring does not release from the inner ring, several tensioning bolts can be removed and then
screwed into adjacent forcing threads.
The rings can then be released without difficulty.
Pull the shrink disk off the hollow shaft.

6.4.6 Cleaning and greasing the shrink disk
Released shrink disks do not have to be dismantled and re-greased before being re-tensioned.
The shrink disk should only be dismantled and cleaned if it is dirty.
Following cleaning, only the inner sliding surfaces of the shrink disk should
Caution! be re-greased.
A solid lubricant as specified in the following table must be used.
Lubricant Form Manufacturer

Molykote 321 R (lubricating paint) Spray DOW Corning
Molykote Spray (powder spray) Spray DOW Corning
Molykote G Rapid Spray or Paste DOW Corning
Aemasol MO 19 P Spray or Paste A. C. Matthes
Molykombin UMFT 1 Spray Klüber Lubrication
Unimoly P 5 Powder Klüber Lubrication
Table 6.2: Lubricants for shrink disks after their cleaning
BA 6610TU EN 03.04
25 / 46
6.5 Torque support
On gear units with a torque reaction arm the torque is effectively supported by bolts and links (see
drawing below) to keep the gear unit free of undue stress on the machine shaft.
90 ° ± 20 °
Note: If the machine shaft is deformed, the resulting displacement of the coupling on the
drive shaft must be noted.
6.6 Attachment of motors
Note: For attaching the motor, the specific operating instructions must be observed.
6.6.1 Attachment to motor bell housing with a coupling
Note: The special operating instructions must be observed for mounting the couplings.
BA 6610TU EN 03.04
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7. Start-up

7.1 Oil filling
Check the oil level before starting up. The oil must be put in until it is at least
Caution! up to the middle of the sight glass or at most up to the upper edge of the oil
sight glass or the lower edge of the oil level hole (shown in red). The upper
screw plug (marked yellow) must be replaced with the breather screw supplied
along with the unit.
7.1.1 Gear unit with oil filling
In this case the gear unit is filled with synthetic lubricant (polyglycol) by us before despatch.
7.1.2 Gear unit without oil filling
If the CAVEX® gear unit has been ordered without an oil filling, the oil must be put into the gear unit
before starting up.
The oil quantity indicated on the rating plate is a reference value. When putting in the oil, the oil must
be allowed sufficient time to distribute so that the final oil level can be determined.
Various lubricants are indicated in the lubricant table (see section 10) according to the oil manufacturers’
recommendations. Equivalent brands of non-foaming oil by other manufacturers may also be used. It
is important to use the type of oil (synthetic or mineral oil) specified on the nameplate. However, we
cannot guarantee that a selected lubricant is completely suitable.
Always select the gear oil in accordance with the viscosity class indicated on
Caution! the rating plate on each gear unit. If other viscosities are used, thicker oils are
preferable to thinner ones.
7.2 Grease lubrication of bearings
Rolling bearings located above the oil level are filled with grease.
7.3 Built-in and add-on parts
On CAVEX® gear units with special additional attachments (e.g. pumps, filter oil coolers,
spring-pressure brakes, multi-disk clutches, etc.) the special operating instructions for these parts must
be observed.
7.3.1 Gear units with backstop
Before start-up, check whether the backstop can be turned manually in the free-running direction
without exerting undue force. Observe the direction-of-rotation arrows on the housing.
To avoid damaging or breaking the backstop, it is essential to ensure that the
Caution! motor is not run in opposition to the locked backstop.
Built-in or attached backstops are lubricated automatically.
BA 6610TU EN 03.04
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7.4 Electrical connection (on CAVEX® gear units with attached motor)
With each motor we provide a circuit diagram in the terminal box showing how the motor is to be
connected up. Care must be taken on connecting up that the supply voltage corresponds to that
indicated on the rating plate.
As a safeguard against overload and two-phase operation, the use of a motor safety switch is
recommended. The over-current relay must in each instance be set to the correct rated current
assigned to the respective rated voltage (see rating plate). Earthing or protective conductors must be
connected to the earthing terminal provided.
If the motor rotates in the wrong direction, 2 phases of the power cable must be interchanged.
Work on the terminal box and current-carrying parts must always be carried
out only by specially trained personnel.
Observe special safety regulations.
7.5 Start-up
On starting up care must be taken that the breather screw with its cap is fitted; if necessary, remove
plastic screw stopper or screw plug.
The gear unit must then be run on intermittent load, i.e. run on normal load for a few minutes, alternating
with breaks several times the length of the operating cycle. The duty cycle can gradually be increased
up to normal operation, while at the same time monitoring the operating temperature. Operating
temperatures up to approx. 100 °C are permissible.
8. Operation
During operation the CAVEX® gear unit must be monitored for:
S excessive operating temperature

S changes in gear noise
S possible oil spillage

If there are any irregularities during operation, the cause of the malfunction
Caution! should be determined with the aid of the Troubleshooting Table (Section 9).
This table contains a list of possible faults, their causes and suggested
remedies.
If the cause cannot be identified or the unit repaired with the facilities available,
you are advised to contact one of our customer-service offices for specialist
assistance (see section 11).
BA 6610TU EN 03.04
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9. Faults, causes and remedy

9.1 General information on faults and malfunctions
Note: Faults and malfunctions occurring during the guarantee period and requiring repair
work on the gear unit must be carried out only by FLENDER TÜBINGEN GMBH
Customer Service.
We recommend continuing to use our Customer Service even after expiry of the
guarantee period.
To remedy faults and malfunctions, the gear unit must always be taken out of
service.
Secure the drive unit to prevent it from being started up unintentionally.
Attach a warning notice to the start switch.
9.2 Possible faults
Malfunctions Causes Remedy
Changes in gear noise Excessive bearing play Contact Customer Service.
Bearing defective Contact Customer Service.
Damage to gear teeth Contact Customer Service.
Fastening has worked loose Tighten bolts / nuts to prescribed

torque.
Replace damaged bolts / nuts.
Operating temperature too high Oil level in gear-unit housing too Check the oil level at room
high or too low temperature and, if necessary,
adjust oil level
Oil too old Change oil. See section 10.
Oil badly contaminated Change oil. See section 10.
Suction opening in cover and/or Clean fan cover and housing

housing clogged by dirt
The grease filling of the bearings is Fresh grease lubrication.

too old See section 10.
Bearing defective Contact Customer Service.
Backstop not running freely Contact Customer Service.
Oil leak Radial shaft sealing rings defective Replace radial shaft sealing rings
Table 9.1: Faults, causes and remedies
BA 6610TU EN 03.04
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10. Maintenance and repair

10.1 General notes on maintenance
Note: Maintenance and repair work must be done with care by trained and qualified
personnel only.
Adherence to the inspection intervals is part of the guarantee conditions.
Measures Periods Remarks

Monitor oil temperature, continuously if changed, see tab. 9.1.
gear unit noise and
leaktightness
Check oil level every 3 months Oil level at least up to the middle
of the oil sight glass or at most up
to the upper edge of the oil sight
glass or the lower edge of the oil
level hole when the gear is cold
and out of operation
First oil change after approx. 1 000-2 000 (300-600) see items 7.1.2 and 10.2.1
operating hours
subsequent oil changes after approx. 6 000-12 000 see items 7.1.2 and 10.2.1
(2 000-4 000) operating hours, but at
the latest after 5 years (18 months)
Relubrication of the bearings see notices with precise instructions see item 10.2.2
on the force-feed lubrication nipples
Renew grease in the after approx. 10 000-15 000 see item 10.2.2
bearings operating hours
or at the latest after 5 years
Cleaning the breather screw if dirty
Clean fan and housing if dirty see item 10.2.3
Checking tightness of with every oil change see item 10.2.4

fastening bolts
Table 10.1: Inspection intervals
Note: The times shown in brackets apply to mineral oils.
BA 6610TU EN 03.04
30 / 46
10.2 Description of maintenance and repair work
10.2.1 Changing the oil

Secure the drive unit to prevent it from being started up unintentionally. Attach
a warning notice to the start switch.
Danger of scalding from the hot oil emerging. Before starting any work wait
until the oil has cooled down to 30 °C.
Remove any oil spillage immediately and in compliance with environmental

requirements with an oil-binding agent.
The oil quantity and the position of the locking elements depend on the
Caution! mounting position; refer to Item 1.3 “Ventilation, oil level, oil drain, oil quantity
and weights”.
When changing the oil, re-fill the gear unit preferably with the same type of oil.
Caution! Never mix different types of oil or oils made by different manufacturers. Only
lubricants appearing in the Flender List must be used; refer to Item 10.3.1 “Oil
types”. In particular synthetic oils must never be mixed with mineral oils.
Note: The oil must be drained off immediately after shutting down the gear unit and while
the oil is still warm. The oil must be given sufficient time to drain off in order to remove
oil sludge, abraded metal and oil residues. If iridescent abraded bronze particles
appear in the oil, this is not in any way harmful.
Note: As a rule synthetic oil is used as lubricant. As an option mineral oil is available. Details
such as oil type, oil viscosity and required quantity are given on the rating plate; refer
to Item 1.1 “Rating plate”. Refer to Item 10.3 “Lubricants” for details regarding
compatibility.
Note: In case of double gear units every single unit is to be considered separately.
Note: In case of ambient conditions deviating from the normal ambient conditions (high
ambient temperatures, high relative humidity, aggressive ambient media), the
changing intervals should be shorter. In such cases contact the customer service of
FLENDER TÜBINGEN GMBH for determining the individual lubricant change
intervals.
BA 6610TU EN 03.04
31 / 46
10.2.2 Greases
Rolling bearing greases to be used are listed in the lubricant table (see section 10).
Caution! When relubricating, do not mix greases of different soap bases!
10.2.3 Clean fan and housing
S Stop gear unit by deactivating the drive unit, and secure from turning
S Remove any corrosion.
Caution! The gear unit must not be cleaned with high-pressure cleaning equipment.
10.2.4 Checking tightness of fastening bolts
S Stop gear unit by deactivating the drive unit, and secure from turning

Check all fastening bolts for tightness and, if necessary, tighten.
For the tightening torques for the fastening bolts, refer to the relevant tables.
Note: Damaged bolts must be replaced with new bolts of the same type and strength class.
10.3 Lubricants
For its gear units, FLENDER TÜBINGEN GMBH approves only CLP oils which contain ingredients to
DIN 51517-3 for improvement of corrosion protection, resistance to ageing, and which reduce wear in
mixed-friction areas.
Note: For the various makes of oil to be used, refer to the following table.
The latest information on all greases approved at A. Friedr. Flender AG can be found
at any time on our Internet homepage at http://www.flender.com.
Should you, for an important reason of your own, not wish to follow our recommendation, you assume
responsibility for the technical suitability of the lubricant used.
We therefore advise our customers to select one of the lubricants listed in the table, taking into account
the VG class specified on the nameplate.
Note: The use of gear oils which do not comply with the above quality requirements, may
invalidate our product guarantee. Every oil manufacturer or supplier of oil is
responsible for the quality of his product.
Always select the gear oil in accordance with the viscosity class indicated on the rating plate on the gear
unit. If a different viscosity is selected, or oil of a type other than those recommended in these
instructions, the operator assumes the responsibility for its technical suitability. In order to minimise the
technical risk in such a case, we advise the use of a CLP oil of the above quality which should be
accompanied by a statement of suitability by the oil manufacturer.
Always comply with the information given on the rating plates and the written
Caution! instructions for the gear units.
BA 6610TU EN 03.04
32 / 46
10.3.1 Oil types
S Mineral oils (MIN-oil)

S Polyglycol (PG-oil)
S Physiologically safe oils approved in accordance with USDA H1 (PHY-oil).

The synthetic oils have a wider temperature range and a higher viscosity index (i.e. a flatter
viscosity-temperature gradient) than the mineral oils. Guideline values for temperature range:
mineral oils approx. - 10 °C to + 90 °C (short term + 100 °C);

polyglycols approx. - 20 °C to + 100 °C (short term + 110 °C);
Note: The upper and lower temperatures (flash point, pour point) for using certain gear oils
may deviate widely from the figures indicated. For these and other data and properties
of the gear oils, refer to the technical-data sheets published by the oil manufacturers.
Viscosity
ISO-VG
Lubricant DIN 51519
at 40 °C
(mm2/s)
VG 1000 Energol GR-XP 1000
VG 680 Degol BG 680 Energol GR-XP 680
Mineral oils VG 460 Degol BG 460 Energol GR-XP 460
(MIN-oil) VG 320 Degol BG 320 Energol GR-XP 320
VG 1000 Degol GS 1000
BERUSYNTH
VG 680 Degol GS 680 GEAR VSG 680 EP 680 Enersyn SG-XP 680
BERUSYNTH
Polyglycol VG 460 Degol GS 460 GEAR VSG 460 EP 460 Enersyn SG-XP 460
BERUSYNTH
(PG-oil) VG 320 Degol GS 320 GEAR VSG 320 EP 320 Enersyn SG-XP 320
BERUSYNTH
BERUSYNTH
Rolling bearing Energrease

3 Aralub HL3 LS 3
greases
(MIN-WF) 2 Aralub HL2
Energrease
LS 2
Mineral oil base
1
Lithium saponification
BA 6610TU EN 03.04
33 / 46
Viscosity
ISO-VG
Lubricant DIN 51519
at 40 °C
(mm2/s)
VG 1000
Klüberoil
VG 680 Falcon CLP 680 SPARTAN EP 680 GEM1 - 680
Klüberoil
Mineral oils VG 460 Falcon CLP 460 SPARTAN EP 460 GEM1 - 460
Klüberoil
(MIN-oil) VG 320 Falcon CLP 320 SPARTAN EP 320 GEM1 - 320
Klüberoil
Klüberoil
SYNTHESO
VG 1000 Polydea PGLP 1000 RENOLIN PG 1000
D 1000 EP
SYNTHESO
D 680 EP
SYNTHESO
Polyglycol VG 460 Polydea PGLP 460 GLYCOLUBE 460 RENOLIN PG 460
D 460 EP
SYNTHESO
(PG-oil) VG 320 Polydea PGLP 320 RENOLIN PG 320
D 320 EP
SYNTHESO
VG 220 Polydea PGLP 220 GLYCOLUBE 220 RENOLIN PG 220
D 220 EP
SYNTHESO
D 150 EP
Rolling bearing Renolit FWA 160
3 Glissando 30 BEACON 3 Renolit H 443-HD 88
greases
(MIN-WF) 2 Glissando 20
Renolit H 443-HD 88 CENTOPLEX
Renolit FWA 220 GLP 402
Mineral oil base
1
Viscosity
ISO-VG
Lubricant DIN 51519
at 40 °C
(mm2/s)
VG 1000 Optigear BM 1000
VG 680 Mobilgear 636 Optigear BM 680 Ersolan 680

Mobilgear XMP 680

Mineral oils Mobilgear XMP 460
Mobilgear 632
(MIN-oil) VG 320 Mobilgear XMP 320
Optigear BM 320 Ersolan 320

Mobilgear XMP 220

Mobilgear XMP 150
Mobil Glygoyle
VG 1000 HE 1000 Optiflex A 1000
Mobil Glygoyle
VG 680 HE 680 Optiflex A 680
Mobil Glygoyle
Polyglycol VG 460 HE 460 Optiflex A 460 Shell Tivela S
Mobil Glygoyle
(PG-oil) VG 320 HE 320 Optiflex A 320
Mobil Glygoyle HE 220

VG 220 Optiflex A 220 Shell Tivela WB
Mobil Glygoyle 30
VG 150 Mobil Glygoyle 22 Optiflex A 150 Shell Tivela WA
Rolling bearing Alvania RL 3

3 Mobilux 3
Alvania G 3 1)
greases
(MIN-WF) 2 Mobilux 2
Longtime PD 2
Energrease LS 3 Wiolub LFK 2
Olista Longtime 2
Mineral oil base
1
1) Li, Ca saponification
BA 6610TU EN 03.04
34 / 46
Viscosity
ISO-VG
Lubricant DIN 51519
at 40 °C
(mm2/s)
VG 1000 Tribol 1100 / 1000
VG 680 Tribol 1100 / 680
Mineral oils VG 460 Tribol 1100 / 460
(MIN-oil) VG 320 Tribol 1100 / 320
VG 220 Tribol 1100 / 220
VG 150 Tribol 1100 / 150
VG 1000 Tribol 800 / 1000
VG 680 Tribol 800 / 680
Polyglycol VG 460 Tribol 800 / 460
(PG-oil) VG 320 Tribol 800 / 320
VG 220 Tribol 800 / 220
VG 150 Tribol 800 / 150
VG 1000
Tribol FoodProof
VG 680 1800 / 680 2)
Physiologically Tribol FoodProof
VG 460 1800 / 460 2)
safe oils
Tribol FoodProof
VG 320 1800 / 320 2)
(PHY-oil)
Tribol FoodProof
VG 220 1800 / 220 2)
VG 150
Rolling bearing 3
greases
(MIN-WF) 2
Tribol 4020/220-2
Tribol 3785 3)
Mineral oil base
1 Tribol 3785 3)
2) PG-Oil
3) Mixture of mineral oil and PAO
BA 6610TU EN 03.04
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11. Spare parts, customer-service addresses
11.1 Stocking spare parts

When ordering spare parts, refer to the spare-parts list and spare parts drawing.
We guarantee only original spare parts supplied by us.
Please note that spare parts and accessories not supplied by us have also not
Caution! been tested and approved by us. The installation and/or use of such products
may therefore impair essential characteristics of the CAVEX® gear unit,
thereby posing an active or passive risk to safety. FLENDER will assume no
liability or guarantee for damage caused by spare parts and accessories not
supplied by FLENDER TÜBINGEN GMBH.
When ordering spare parts, always state the following:

Identity no. of gear unit (see rating plate)
Part no. (from spare parts list)
Quantity (from spare parts list)
BA 6610TU EN 03.04
36 / 46
11.2 Spare parts lists
11.2.1 Types C.W and C.A
Spare parts
C.W C.A
Part
Description 63 100 280 63 100 280
no.
– – – – – –
80 250 630 80 250 630
10 Shaft x x x
14 Shaft seal x x x x x x
28 Close fitting screw x x x x
29 Hexagon nut x x x x
30 Washer x x x x
42 Anti-friction bearing x x x x x x
43 Worm shaft x x x x x x
44 Wheel rim x x x x x x
45 Wheel centre x x
45 Hollow shaft x x x
52 NILOS ring x x x x x x
63 Slotted nut x x
74 Shrink disk x x x
BA 6610TU EN 03.04
37 / 46
11.3 Spare parts drawings
11.3.1 Type C.W 63-80 and C.W 100-250
10 50 42 44 52
A B
14 60 43 61 15 52 42 50
C.W 63 - 80
A, B = Shim
30
29
10 50 42 45 44 28 52
B
A
14 60 43 61 15 42 50
C.W 100 - 250
A, B = Shim (B only on size 100)
BA 6610TU EN 03.04
38 / 46
11.3.2 Type C.W 280-630
30
29
10 50 42 45 44 28 52
14 60 43 61 63 15 42 50
A = Shim
BA 6610TU EN 03.04
39 / 46
11.3.3 Type C.A 63-80 and C.A 100-250
50 42 45 44 52
A B
14 60 43 61 15 50 74
C.A 63 - 80
A, B = Shim
30
29
50 42 45 44 28 52
B
A
14 60 43 61 15 42 50 74
C.A 100 - 250
A, B = Shim (B only on size 100)
BA 6610TU EN 03.04
40 / 46
11.3.4 Type C.A 280-630
30
29
50 42 45 44 28 52 50
14 60 43 61 63 15 42 74
A = Shim
BA 6610TU EN 03.04
41 / 46
11.4 Spare-part and customer-service addresses
FLENDER TÜBINGEN GMBH Germany
FLENDER TÜBINGEN GMBH Postfach 1709 ⋅ D-72007 Tübingen

Bahnhofstr. 40-44 ⋅ D-72072 Tübingen
Telefon +49 (0) 70 71 - 707 0 ⋅ Fax +49 (0) 70 71 - 707 400
E-mail: sales-motox@flender-motox.com ⋅ http://www.flender.com
24 h Service Hotline +49 (0) 172 - 7 32 29 55
Sales Office
Bocholt D-46393 Bocholt
Alfred-Flender-Str. 77, D-46395 Bocholt
Tel. +49 (0) 2871 - 92 0 ⋅ Fax +49 (0) 2871 - 92 14 35
E-mail: vz.bocholt@flender.com
Stuttgart D-70472 Stuttgart

Friolzheimer Str. 3 ⋅ D-70499 Stuttgart
Tel. +49 (0) 7 11 - 7 80 54 51 ⋅ Fax +49 (0) 7 11 - 7 80 54 50
E-mail: vz.stuttgart@flender.com
München D-85750 Karlsfeld

Liebigstr. 14 ⋅ D-85757 Karlsfeld
Tel. +49 (0) 81 31 - 90 03 0 ⋅ Fax +49 (0) 81 31 - 90 03 33
E-mail: vz.muenchen@flender.com
Berlin Schlossallee 8 ⋅ D-13156 Berlin

Tel. +49 (0) 30 - 91 42 50 58 ⋅ Fax +49 (0) 30 - 47 48 79 30
E-mail: vz.berlin@flender.com
FLENDER SERVICE GMBH D-44607 Herne ⋅ Südstr. 111 ⋅ D-44625 Herne

Tel. +49 (0) 23 23 - 940 0 ⋅ Fax +49 (0) 23 23 - 940 333
E-mail: infos@flender-service.com ⋅ http://www.flender-service.com
24 h Service Hotline +49 (0) 17 22 81 01 00
A. Friedr. Flender AG D-46393 Bocholt ⋅ Alfred-Flender-Str. 77 ⋅ D-46395 Bocholt
Tel. +49 (0) 28 71 - 92 0 ⋅ Fax +49 (0) 28 71 - 92 25 96
E-mail: contact@flender.com ⋅ http://www.flender.com
LOHER GMBH D-94095 Ruhstorf ⋅ Hans-Loher-Str. 32 ⋅ D-94099 Ruhstorf
Tel. +49 (0) 85 31 - 3 90 ⋅ Fax +49 (0) 85 31 - 3 94 37
E-mail: info@loher.de ⋅ http://www.loher.de
A. Friedr. Flender AG Obere Hauptstr. 228-230 ⋅ D-09228 Chemnitz / Wittgensdorf
Flender Guss Tel. +49 (0) 37 22 - 64 0 ⋅ Fax +49 (0) 37 22 - 94 1 38
E-mail: flender.guss@flender-guss.com ⋅ http://www.flender-guss.de
A. Friedr. Flender AG Thierbacher Str. 24 ⋅ D-09322 Penig
Getriebewerk Penig Tel. +49 (0) 3 73 81 - 60 ⋅ Fax +49 (0) 3 73 81 - 8 02 86
E-mail: ute.tappert@flender.com ⋅ http://www.flender.com
A. Friedr. Flender AG Industriepark Bocholt ⋅ Schlavenhorst 100 ⋅ D-46395 Bocholt
Kupplungswerk Mussum Tel. +49 (0) 28 71 - 92 28 68 ⋅ Fax +49 (0) 28 71 - 92 25 79
E-mail: couplings@flender.com ⋅ http://www.flender.com
A. Friedr. Flender AG Am Industriepark 2 ⋅ D-46562 Voerde
Werk Friedrichsfeld Tel. +49 (0) 28 71 - 92 0 ⋅ Fax +49 (0) 28 71 - 92 25 96
E-mail: contact@flender.com ⋅ http://www.flender.com
WINERGY AG Am Industriepark 2 ⋅ D-46562 Voerde
Tel. +49 (0) 28 71 - 92 4 ⋅ Fax +49 (0) 28 71 - 92 24 87
E-mail: info@winergy-ag.com ⋅ http://www.winergy-ag.com
BA 6610TU EN 03.04
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FLENDER TÜBINGEN GMBH Europe
ALBANIA / MACEDONIA / SERBIA-MONTENEGRO Flender Graffenstaden SA RUSSIA
A. Friedr. Flender AG 1, rue du Vieux Moulin F & F GmbH
Branch Office FR - 67400 Illkirch-Graffenstaden Tjuschina 4-6
c/o G.P. Inzenjering d.o.o. B.P. 84 RU - 191119 St. Petersburg
III Bulevar 54 / 19 FR - 67402 Illkirch-Graffenstaden Tel. +7 (0) 8 12 - 3 20 90 34
YU - 11070 Novi Beograd Tel. +33 (0) 3 - 88 67 60 00 Fax +7 (0) 8 12 - 3 40 27 60
Fax +33 (0) 3 - 88 67 06 17
Tel. +381 (0) 11 - 60 44 73 E-mail: flendergus@mail.spbnit.ru
E–mail: flencomm@flender-graff.com
Fax +381 (0) 11 - 3 11 67 91
E-mail: flender@eunet.yu SLOVAKIA
GREECE
Flender Hellas Ltd. A. Friedr. Flender AG
AUSTRIA 2, Delfon str. Branch Office
Flender Ges.m.b.H. GR - 11146 Athens Vajanského 49, P.O. Box 286
Industriezentrum Nö-Süd Tel. +30 210 - 2 91 72 80 SK - 08001 Presov
Str. 4, Objekt 14, Postfach 132 Fax +30 210 - 2 91 71 02 Tel. +421 (0) 51 - 7 70 32 67
AT - 2355 Wiener Neudorf E-mail: flender@otenet.gr Fax +421 (0) 51 - 7 70 32 67
Tel. +43 (0) 22 36 - 6 45 70 E-mail: micenko.flender@nextra.sk
Fax +43 (0) 22 36 - 6 45 70 10
Mangrinox S.A.
E-mail: office@flender.at SPAIN
14, Grevenon str.
http://www.flender.at Flender Ibérica S.A.
GR - 11855 Athens
Tel. +30 210 - 3 42 32 01 Poligono Industrial San Marcos
BELGIUM & LUXEMBOURG Fax +30 210 - 3 45 99 28 Calle Morse, 31 (Parcela D-15)
N.V. Flender Belge S.A. E-mail: mangrinox@otenet.gr ES - 28906 Getafe, Madrid
Cyriel Buyssestraat 130 Tel. +34 (0) 91 - 6 83 61 86
BE - 1800 Vilvoorde Fax +34 (0) 91 - 6 83 46 50
HUNGARY
Tel. +32 (0) 2 - 2 53 10 30 E-mail: f-iberica@flender.es
A. Friedr. Flender AG
Fax +32 (0) 2 - 2 53 09 66 http://www.flender.es
Branch Office
E-mail: sales@flender.be
Bécsi Út 3-5
SWEDEN
HU - 1023 Budapest
BOSNIA-HERZEGOVINA / CROATIA / SLOVENIA Tel. +36 (0) 1 - 3 45 07 90
Flender Scandinavia
A. Friedr. Flender AG Äsenvägen 2
Fax +36 (0) 1 - 3 45 07 92
Branch Office, 44339 Lerum
E-mail: jambor.laszlo@axelero.hu
c/o HUM - Naklada d.o.o. Tel. +46 (0) 302 - 1 25 90
Mandroviceva 3 Fax +46 (0) 302 - 1 25 56
HR - 10000 Zagreb
ITALY E-mail: kontakt@flenderscandinavia.com
Tel. +385 (0) 1 - 2 30 60 25 Flender Cigala S.p.A. http://www.flenderscandinavia.com
Fax +385 (0) 1 - 2 30 60 24 Parco Tecnologico Manzoni, Palazzina G
E-mail: flender@hi.hinet.hr Viale delle industrie, 17 SWITZERLAND
IT - 20040 Caponago (MI)
Flender AG
Tel. +39 (0) 02 - 95 96 31
BULGARIA Zeughausstr. 48
Fax +39 (0) 02 - 95 74 39 30
A. Friedr. Flender AG CH - 5600 Lenzburg
E-mail: info@flendercigala.it
Branch Office Tel. +41 (0) 62 - 8 85 76 00
c/o Auto - Profi GmbH Fax +41 (0) 62 - 8 85 76 76
Alabin Str. 52, 1000 Sofia THE NETHERLANDS E-mail: info@flender.ch
Tel. +359 (0) 2 - 9 80 66 06 Flender Nederland B.V. http://www.flender.ch
Fax +359 (0) 2 - 9 80 33 01 Lage Brink 5-7
E-mail: sofia@auto-profi.com NL - 7317 BD Apeldoorn TURKEY
Postbus 1073 Flender Güc Aktarma Sistemleri
CZECH REPUBLIC NL - 7301 BH Apeldoorn Sanayi ve Ticaret Ltd. Sti.
A. Friedr. Flender AG Tel. +31 (0) 55 - 5 27 50 00 IMES Sanayi, Sitesi, E Blok 502, Sokak No. 22
Branch Office Fax +31 (0) 55 - 5 21 80 11 TR - 81260 Dudullu - Istanbul
Hotel DUO, Teplicka 17 E-mail: sales@flender.nl Tel. +90 (0) 2 16 - 4 66 51 41
CZ - 19000 Praha 9 Fax +90 (0) 2 16 - 3 64 59 13
Tel. +420 (0) 2 - 83 88 23 00 Bruinhof B.V. E-mail: cuzkan@flendertr.com
Fax +420 (0) 2 - 83 88 22 05 Boterdiep 37 http://www.flendertr.com
E-mail: flender_pumprla@hotelduo.cz NL - 3077 AW Rotterdam
Postbus 9607 UKRAINE
NL - 3007 AP Rotterdam A. Friedr. Flender AG
DENMARK
Tel. +31 (0) 10 - 4 97 08 08 Branch Office
Flender Scandinavia A/S
Fax +31 (0) 10 - 4 82 43 50 c/o DIV - Deutsche Industrievertretung
Rugmarken 35 B
E-mail: info@bruinhof.nl Prospect Pobedy 44
DK - 3520 Farum
http://www.bruinhof.nl UA - 252057 Kiev
Tel. +45 (0) - 70 22 60 03
Fax +45 (0) - 44 99 16 62 Tel. +380 (0) 44 - 4 46 80 49
E-mail: kontakt@flenderscandinavia.com NORWAY Fax +380 (0) 44 - 2 30 29 30
http://www.flenderscandinavia.com Please refer to E-mail: flender@div.kiev.ua
Flender Scandinavia A/S
ESTHONIA / LATVIA / LITHUANIA Rugmarken 35 B UNITED KINGDOM & EIRE
Flender Branch Office 3520 Farum Flender Power Transmission Ltd.
Addinol Mineralöl Marketing OÜ Tel. +45 (0) - 70 22 60 03 Thornbury Works, Leeds Road
Suur-Söjamäe 32 Fax +45 (0) - 44 99 16 62 GB - Bradford, West Yorkshire BD3 7 EB
EE - 11415 Tallinn / Esthonia E-mail: kontakt@flenderscandinavia.com Tel. +44 (0) 12 74 - 65 77 00
Tel. +372 (0) 6 - 27 99 99 http://www.flenderscandinavia.com Fax +44 (0) 12 74 - 66 98 36
Fax +372 (0) 6 - 27 99 90 E-mail: flenders@flender-power.co.uk
E-mail: flender@addinol.ee POLAND http://www.flender-power.co.uk
http://www.addinol.ee A. Friedr. Flender AG
Branch Office
FINLAND Przedstawicielstwo w Polsce ul. Wyzwolenia 27
Flender Oy PL - 43 - 190 Mikolów
Ruosilantie 2 B Tel. +48 (0) 32 - 2 26 45 61
FI - 00390 Helsinki Fax +48 (0) 32 - 2 26 45 62
Tel. +358 (0) 9 - 4 77 84 10 E-mail: flender@pro.onet.pl
Fax +358 (0) 9 - 4 36 14 10 http://www.flender.pl
E-mail: webmaster@flender.fi
http://www.flender.fi PORTUGAL
Rodamientos FEYC, S. A.
FRANCE R. Jaime Lopes Dias, 1668 CV
Flender s.a.r.l. PT - 1750 - 124 Lissabon
3, rue Jean Monnet - B.P. 5 Tel. +351 (0) 21 - 7 54 24 10
FR - 78996 Elancourt Cedex Fax +351 (0) 21 - 7 54 24 19
Tel. +33 (0) 1 - 30 66 39 00 E-mail: info@rfportugal.com
Fax +33 (0) 1 - 30 66 35 13
E-mail: sales@flender.fr ROMANIA
A. Friedr. Flender AG Branch Office
SALES OFFICES: 98 - 106, Soseaua Mihai Bravu
Flender s.a.r.l. Sector 2, Bloc D 16, Sc 1, Apartament 4
36, rue Jean Broquin 021331 Bucuresti - 2
FR - 69006 Lyon Tel. +40 (0) 21 - 4 91 10 08
Tel. +33 (0) 4 - 72 83 95 20
Fax +40 (0) 21 - 4 91 10 08
Fax +33 (0) 4 - 72 83 95 39
E-mail: sales@flender.fr E-mail: flender@fx.ro
BA 6610TU EN 03.04
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FLENDER TÜBINGEN GMBH International
AFRICA Flender Brasil Ltda. VENEZUELA

Rua Campos Salles, 1095 - sala 04 - Centro F. H. Transmissiones S.A.
EGYPT 14015-110 - Ribeirão Preto - SP Urbanización Buena Vista
Sons of Farid Hassanen Tel. +55 (0) 16 - 6 35 15 90 Calle Johan Schafer o Segunda Calle
81 Matbaa Ahlia Street Fax +55 (0) 16 - 6 35 11 05 Municipio Sucre, Petare
EG - Boulac 11221, Cairo E-mail: flender.ribpreto@uol.com.br VE - Caracas
Tel. +20 (0) 2 - 5 75 15 44
Tel. +58 (0) 2 12 - 21 52 61
Fax +20 (0) 2 - 5 75 17 02
CANADA Fax +58 (0) 2 12 - 21 18 38
E-mail: hussein@sonfarid.com
Flender Power Transmission Inc. E-mail: fhtransm@telcel.net.ve
215 Shields Court, Units 4-6 http://www.fhtransmisiones.com
NORTH AFRICAN COUNTRIES CA - Markham, Ontario L3R 8V2
Please refer to Flender s.a.r.l. Tel. +1 (0) 9 05 - 3 05 10 21
3, rue Jean Monnet - B.P. 5 Fax +1 (0) 9 05 - 3 05 10 23
FR - 78996 Elancourt Cedex E-mail: flender@ca.inter.net
Tel. +33 (0) 1 - 30 66 39 00
http://www.flenderpti.com
Fax +33 (0) 1 - 30 66 35 13
E-mail: sales@flender.fr
SALES OFFICE:
SOUTH AFRICA Flender Power Transmission Inc.
34992 Bernina Court
Flender Power Transmission (Pty.) Ltd.
CA - Abbotsford-Vancouver
Cnr. Furnace St & Quality Road
B.C. V3G 1C2
P.O. Box 131
ZA - Isando 1600 Johannesburg
Tel. +1 (0) 6 04 - 8 59 66 75 ASIA
Fax +1 (0) 6 04 - 8 59 68 78
Tel. +27 (0) 11 - 5 71 20 00
E-mail: tvickers@rapidnet.net BAHRAIN / IRAQ / JORDAN / LYBIA / OMAN /
Fax +27 (0) 11 - 3 92 24 34
E-mail: sales@flender.co.za QATAR / U.A.E. / YEMEN
http://www.flender.co.za CHILE Please refer to A. Friedr. Flender AG
Sergent S.A. Middle East Sales Office
SALES OFFICES: Av. Pdte. Bulnes 205, Casilla 166 D IMES Sanayi, Sitesi, E Blok 502, Sokak No. 22
Flender Power Transmission (Pty.) Ltd. CL - Santiago TR - 81260 Dudullu - Istanbul
Unit 3 Marconi Park Tel. +56 (0) 2 - 6 99 15 25 Tel. +90 (0) 2 16 - 4 99 66 23
9 Marconi Crescent, Montague Gardens Fax +56 (0) 2 - 6 98 39 89 Fax +90 (0) 2 16 - 3 64 59 13
P.O. Box 3729 E-mail: secventas@sargentagricola.cl E-mail: meso@flendertr.com
Chempet 7442, Cape Town
Tel. +27 (0) 21 - 5 51 50 03 COLOMBIA BANGLADESH / SRI LANKA
Fax +27 (0) 21 - 5 52 38 24 A.G.P. Representaciones Ltda. Please refer to Flender Limited
E-mail: sales@flender.co.za Flender Liaison Office Colombia No. 2 St. George’s Gate Road, 5 th Floor, Hastings
Av Boyaca No 23A, 50 Bodega UA 7-1 Kolkata - 700022
Flender Power Transmission (Pty.) Ltd. CO - Bogotá Tel. +91 (0) 33 - 22 23 05 45
Unit 3 Goshawk Park Tel. +57 (0) 1 - 5 70 63 53 Fax +91 (0) 33 - 22 23 08 30
Falcon Industrial Estate Fax +57 (0) 1 - 5 70 73 35 E-mail: flender@flenderindia.com
P.O. Box 1608 E-mail: aguerrero@agp.com.co
ZA - New Germany 3620, Durban http://www.agp.com.co INDIA
Flender Limited, Head Office
Tel. +27 (0) 31 - 7 05 38 92 No. 2 St. George’s Gate Road, 5 th Floor, Hastings
Fax +27 (0) 31 - 7 05 38 72 MEXICO Kolkata - 700022
E-mail: sales@flender.co.za Flender de Mexico S.A. de C.V. Tel. +91 (0) 33 - 22 23 05 45
17, Pte, 713 Centro Fax +91 (0) 33 - 22 23 08 30
Flender Power Transmission (Pty.) Ltd. MX - 72000 Puebla E-mail: flender@flenderindia.com
9 Industrial Crescent, Ext. 25 Tel. +52 (0) 2 22 - 2 37 19 00
P.O. Box 17609 Fax +52 (0) 2 22 - 2 37 11 33 Flender Limited
ZA - Witbank 1035 E-mail: szugasti@flendermexico.com Industrial Growth Centre
Tel. +27 (0) 13 - 6 92 34 38 http://www.flendermexico.com Rakhajungle, Nimpura
Fax +27 (0) 13 - 6 92 34 52 Kharagpur - 721302
E-mail: sales@flender.co.za SALES OFFICES: Tel. +91 (0) 32 22 - 23 33 07
Flender de Mexico S.A. de C.V. Fax +91 (0) 32 22 - 23 33 64
Flender Power Transmission (Pty.) Ltd. Lago Nargis No. 38, Col. Granada E-mail: works@flenderindia.com
Unit 14 King Fisher Park, Alton MX - 11520, Mexico, D.F.
Cnr. Ceramic Curve & Alumina Allee Tel. +52 (0) 55 - 52 54 30 37 SALES OFFICES:
Fax +52 (0) 55 - 55 31 69 39 Flender Limited
P.O. Box 101995
E-mail: info@flendermexico.com Eastern Regional Sales Office
ZA - Meerensee 3901, Richards Bay
No. 2 St. George’s Gate Road, 5 th Floor, Hastings
Tel. +27 (0) 35 - 7 51 15 63 Kolkata - 700022
Fax +27 (0) 35 - 7 51 15 64 Flender de Mexico S.A. de C.V.
Tel. +91 (0) 33 - 22 23 05 45
E-mail: sales@flender.co.za Ave. San Pedro No. 231-5, Col. Miravalle Fax +91 (0) 33 - 22 23 08 30
MX - 64660, Monterrey, N.L. E-mail: ero@flenderindia.com
Tel. +52 (0) 81 - 83 63 82 82
Fax +52 (0) 81 - 83 63 82 83 Flender Limited
AMERICA E-mail: info@flendermexico.com Western Regional Sales Office
ARGENTINA Plot No. 23, Sector 19 - C, Vashi
Chilicote S.A. PERU Navi Mumbai - 400705
Avda. Julio A. Roca 546 Potencia Industrial E.I.R.L. Tel. +91 (0) 22 - 27 65 72 27
C 1067 ABN Buenos Aires Passaje Los Pinos No. 156 - Of.905 Fax +91 (0) 22 - 27 65 72 28
Miraflores - Lima 18 E-mail: wro@flenderindia.com
Tel. +54 (0) 11 - 43 31 66 10
Fax +54 (0) 11 - 43 31 42 78 P.O. Box Av. 2 de Mayo No. 679
Of. 108 - Miraflores, Casilla No. 392, PE - Lima 18 Flender Limited
E-mail: chilicote@chilicote.com.ar Southern Regional Sales Office
Tel. +51 (0) 1 - 2 42 84 68
Fax +51 (0) 1 - 2 42 08 62 41 Nelson Manickam Road, Aminjikarai
ARGENTINA / BOLIVIA / CHILE / ECUADOR / Chennai - 600029
E-mail: cesaram@potenciaindustrial.com.pe
PARAGUAY / URUGUAY http://www.potenciaindustrial.com.pe Tel. +91 (0) 44 - 23 74 39 21
Flender Cono Sur Limitada Fax +91 (0) 44 - 23 74 39 19
Avda. Galvarino Gallardo 1534 E-mail: sro@flenderindia.com
USA
Providencia, CL - Santiago
Flender Corporation Flender Limited
Tel. +56 (0) 2 - 2 35 32 49 950 Tollgate Road
Fax +56 (0) 2 - 2 64 20 25 Northern Regional Sales Office
P.O. Box 1449 209-A, Masjid Moth, 2nd Floor (Behind South Extension II)
E-mail: flender@flender.cl US - Elgin, IL. 60123 New Delhi - 110049
http://www.flender.cl Tel. +1 (0) 8 47 - 9 31 19 90 Tel. +91 (0) 11 - 26 25 02 21
Fax +1 (0) 8 47 - 9 31 07 11 Fax +91 (0) 11 - 26 25 63 72
BRASIL E-mail: flender@flenderusa.com E-mail: nro@flenderindia.com
Flender Brasil Ltda. http://www.flenderusa.com
Rua Quatorze, 60 - Cidade Industrial INDONESIA
32211-970, Contagem - MG Flender Corporation Flender Singapore Pte. Ltd. Representative Office
Tel. +55 (0) 31 - 33 69 21 00 Service Centers West Perkantoran Puri Niaga II
Fax +55 (0) 31 - 33 69 21 66 4234 Foster Ave. Jalan Puri Kencana Blok J1, No. 2i
E-mail: vendas@flenderbrasil.com US - Bakersfield, CA. 93308 Kembangan, ID - Jakarta Barat 11610
Tel. +1 (0) 6 61 - 3 25 44 78 Tel. +62 (0) 21 - 5 82 86 24
SALES OFFICES: Fax +1 (0) 6 61 - 3 25 44 70 Fax +62 (0) 21 - 5 82 86 23
Flender Brasil Ltda. E-mail: flender1@lightspeed.net E-mail: bobwall@cbn.net.id
Rua James Watt, 142 - conj. 142 - Brooklin Novo
04576-050, - São Paulo - SP
Tel. +55 (0) 11 - 55 05 99 33
Fax +55 (0) 11 - 55 05 30 10
E-mail: flesao@uol.com.br
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FLENDER TÜBINGEN GMBH International
IRAN Flender Power Transmission (Tianjin) Co., Ltd. AUSTRALIA

Cimaghand Co. Ltd. Guangzhou Office
No. 13, 16th East Street, P.O. Box 15745-493 Rm 2802, Guangzhou International, Electronics Tower AUSTRALIA
Beyhaghi Ave., Argentina Sq., IR - Tehran 15156 403 Huanshi Road East Flender (Australia) Pty. Ltd.
Tel. +98 (0) 21 - 8 73 02 14 CN - Guangzhou - 510095
9 Nello Place, P.O. Box 6047, Whetherill Park
Tel. +86 (0) 20 - 87 32 60 42
Fax +98 (0) 21 - 8 73 39 70 N.S.W. 2164, AU - Sydney
Fax +86 (0) 20 - 87 32 60 45
E-mail: info@cimaghand.com Tel. +61 (0) 2 - 97 56 23 22
E-mail: guangzhou@flenderprc.com.cn
Fax +61 (0) 2 - 97 56 48 92
ISRAEL Flender Power Transmission (Tianjin) Co., Ltd. E-mail: sales@flender.com.au
Greenshpon Engineering Works Ltd. Chengdu Office http://www.flender.com.au
Haamelim Street 20 G-6 / F, Guoxin Mansion, 77 Xiyu Street
P.O. Box 10108, IL - 26110 Haifa CN - Chengdu - 610015 SALES OFFICES:
Tel. +972 (0) 4 - 8 72 11 87 Tel. +86 (0) 28 - 86 19 83 72 Flender (Australia) Pty. Ltd.
Fax +972 (0) 4 - 8 72 62 31 Fax +86 (0) 28 - 86 19 88 10 Suite 3, 261 Centre Rd.
E-mail: sales@greenshpon.com E-mail: chengdu@flenderprc.com.cn AU - Bentleigh, VIC, 3204
http://www.greenshpon.com Melbourne
Flender Power Transmission (Tianjin) Co., Ltd. Tel. +61 (0) 3 - 95 57 08 11
JAPAN Shenyang Office Fax +61 (0) 3 - 95 57 08 22
Rm. 2-163, Tower I, City Plaza, Shenyang
Flender Japan Co. Ltd. E-mail: sales@flender.com.au
206 Nanjing Street (N), Heping District
WBG Marive East 21 F
Shenyang 110001
Nakase 2 - 6, Mihama-ku, Chiba-shi Tel. +86 (0) 24 - 23 34 20 48 Flender (Australia) Pty. Ltd.
Chiba 261 - 7121 Fax +86 (0) 24 - 23 34 20 46 Suite 5 - 1407 Logan Rd.
Tel. +81 (0) 43 - 2 13 39 30 E-mail: shenyang@flenderprc.com.cn Mt. Gravatt
Fax +81 (0) 43 - 2 13 39 55 AU - QLD 4122, Brisbane
E-mail: contact@flender-japan.com Flender Power Transmission (Tianjin) Co., Ltd. Tel. +61 (0) 7 - 34 22 23 89
Xi’an Office Fax +61 (0) 7 - 34 22 24 03
KOREA Rm. 302, Shanzi Zhong Da, E-mail: sales@flender.com.au
Flender Ltd. International Mansion, 30 Southern Road
7th Fl. Dorim Bldg., 1823 Bangbae-Dong Xi’an 710002 Flender (Australia) Pty. Ltd.
Seocho-Ku, KR - Seoul 137-060 Tel. +86 (0) 29 - 7 20 32 68 Suite 2, 403 Great Eastern Highway
Tel. +82 (0) 2 - 34 78 63 37 Fax +86 (0) 29 - 7 20 32 04 AU - W.A. 6104, Redcliffe - Perth
Fax +82 (0) 2 - 34 78 63 45 E-mail: xian@flenderprc.com.cn Tel. +61 (0) 8 - 94 77 41 66
E-mail: sales@flender-korea.com Fax +61 (0) 8 - 94 77 65 11
PHILIPPINE E-mail: sales@flender.com.au
KUWAIT Flender Singapore Pte. Ltd. Representative Office
South Gulf Company 28/F, Unit 2814, The Enterprise Centre NEW ZEALAND
Al-Reqai, Plot1, Block 96 6766 Ayala Avenue corner Please refer to Flender (Australia) Pty. Ltd.
P.O. Box 26229, KW - Safat 13123 Paeso de Roxas, Makati City 9 Nello Place, P.O. Box 6047, Whetherill Park
Tel. +965 (0) - 4 88 39 15 Tel. +63 (0) 2 - 8 49 39 93 N.S.W. 2164, AU - Sydney
Fax +965 (0) - 4 88 39 14 Fax +63 (0) 2 - 8 49 39 17 Tel. +61 (0) 2 - 97 56 23 22
E-mail: adelameen@hotmail.com E-mail: roman@flender.com.ph Fax +61 (0) 2 - 97 56 48 92
E-mail: sales@flender.com.au
LEBANON SAUDI ARABIA
Gabriel Acar & Fils s.a.r.l. South Gulf Co.
Dahr-el-Jamal Al-Khobar, Dahran Street
Zone Industrielle, Sin-el-Fil Middle East Trade Center
B.P. 80484, Beyrouth 3rd floor, Flat # 23
Tel. +961 (0) 1 - 49 82 72 P.O. Box 20434
Fax +961 (0) 1 - 49 49 71 SA - 31952 Al-Khobar
E-mail: gacar@beirut.com Tel. +966 (0) 3 - 8 87 53 32
Fax +966 (0) 3 - 8 87 53 31
MALAYSIA E-mail: adelameen@hotmail.com
Flender Singapor Pte. Ltd., Representative Office
37 A - 2, Jalan PJU 1/39, Dataran Prima SINGAPORE
MY - 47301 Petaling Jaya, Selangor Darul Ehsan Flender Singapore Pte. Ltd.
Tel. +60 (0) 3 - 78 80 42 63 13 A, Tech Park Crescent
Fax +60 (0) 3 - 78 80 42 73 SG - Singapor 637843
E-mail: flender@tm.net.my Tel. +65 (0) - 68 97 94 66
Fax +65 (0) - 68 97 94 11
PAKISTAN E-mail: flender@singnet.com.sg
Please refer to A. Friedr. Flender AG http://www.flender.com.sg
D - 46393 Bocholt
Tel. +49 (0) 28 71 - 92 22 59 SYRIA
Fax +49 (0) 28 71 - 92 15 16 Misrabi Co & Trading, Mezzeh Autostrade Transportation
E-mail: ludger.wittag@flender.com Building 4/A, 5th Floor
P.O. Box 12450, SY - Damascus
PEOPLE’S REPUBLIC OF CHINA Tel. +963 (0) 11 - 6 11 67 94
Flender Power Transmission (Tianjin) Co., Ltd. Fax +963 (0) 11 - 6 11 09 08
Shuang Hu Rd.-Shuangchen, Rd. West, Beichen Economic E-mail: ismael.misrabi@gmx.net
Development Area (BEDA)
CN - Tianjin - 300400 TAIWAN
Tel. +86 (0) 22 - 26 97 20 63 A. Friedr. Flender AG, Taiwan Branch Company
Fax +86 (0) 22 - 26 97 20 61 1 F, No. 5, Lane 240, Nan Yang Street, Hsichih
E-mail: flender@flendertj.com TW - Taipei Hsien 221
http://www.flendertj.com Tel. +886 (0) 2 - 26 93 24 41
Fax +886 (0) 2 - 26 94 36 11
Flender Power Transmission (Tianjin) Co., Ltd. E-mail: flender_tw@flender.com.tw
Beijing Office
C-415, Lufthansa Center
50 Liangmaqiao Road, Chaoyang District THAILAND
CN - Beijing - 100 016 Flender Singapore Pte. Ltd. Representative Office
Tel. +86 (0) 10 - 64 62 21 51 23/F M Thai Tower, All Seasons Place
Fax +86 (0) 10 - 64 62 21 43 87 Wireless Road, Phatumwan
E-mail: beijing@flenderprc.com.cn TH - Bangkok 10330
Tel. +66 (0) 2 - 6 27 91 09
Flender Power Transmission (Tianjin) Co., Ltd. Fax +66 (0) 2 - 6 27 90 01
Shanghai Office E-mail: christian.beckers@flender.th.com
Unit 1101 - 1102, Harbour Ring Plaza
No. 18 Xizang Zhong Road VIETNAM
CN - Shanghai - 200001 Flender Singapore Pte. Ltd. Representative Office
Tel. +86 (0) 21 - 53 85 31 48 Suite 6/6A, 16F Saigon Tower, 29 Le Duan Street, District.1
Fax +86 (0) 21 - 53 85 31 46 Ho Chi Minh City, VN - Vietnam
E-mail: shanghai@flenderprc.com.cn Tel. +84 (0) 8 - 8 23 62 97
Fax +84 (0) 8 - 8 23 62 88
Flender Power Transmission (Tianjin) Co., Ltd.
Wuhan Office E-mail: flender@hcm.vnn.vn
Room 1503, Jianyin Building
709 Jianshedadao
CN - Wuhan - 430015
Tel. +86 (0) 27 - 85 48 67 15
Fax +86 (0) 27 - 85 48 68 36
E-mail: wuhan@flenderprc.com.cn
BA 6610TU EN 03.04
45 / 46
12. Declaration by the manufacturer
Declaration by the manufacturer
in accordance with EC Engineering Guideline 98/37/EC, Appendix II B

We hereby declare that the
CAVEX® Worm-Gear Units Type

C..
Sizes 63 to 630
described in these Operating Instructions are intended for incorporation in a machine, and that it is
prohibited to put them into service before verifying that the machine into which they are incorporated
complies with the EC Guidelines 98/37/EC.
This Manufacturer’s Declaration takes into account all the unified standards applying to our products
in part or in whole published by the European Commission in the Official Journal of the European
Community
These include in particular:

- EN 292-1
- EN 292-2
- EEN 294
- EEN 349
- EN 60204-1
Tübingen, 01.03.2004 (Head of Works Standards)
BA 6610TU EN 03.04
46 / 46
N – R 435 en 09.03
for totally enclosed fan–cooled (TEFC) and internally cooled (ODP)
three–phase motors with squirrel cage
for low voltage, with antifriction bearings
BN.A–071 to BN.A–315
A..A–071..–.. to 800..–..
J..A–160..–.. to 800.. –..
LOHER GmbH
P.O. Box 1164 • 94095 RUHSTORF
Hans–Loher–Str. 32 • 94099 RUHSTORF
GERMANY
Phone +49 8531 39–0 • Fax +49 8531 32895
E–Mail: info@loher.de
http://www.loher.de
Table of contents
Page
1. Safety and commissioning instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4. Installation and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
6. Additional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7. Three–phase motors as centrifugal drive for heavy starting . . . . . . . . . . . . . 18
8. Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9. Storage instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
10. Faults and remedies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
11. Operating instructions for brake motors with spring–loaded
single–disk brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
12. EC Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Appendix 1; Grease life and grease quantities . . . . . . . . . . . . . . . . . . . . . . . 30
Appendix 2; Alignment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Subject to modifications
Loher GmbH 2003
All rights reserved
N–R 435 en 09.03 Page 1 of 31

Safety and commissioning instructions
1. Safety and commissioning instructions

1.1 Warning symbols in these instructions
The symbols are used in these operating instructions to point out to particular dangers.
This symbol refers to a dangerous situation which can cause fatal or serious injuries or
considerable damage to property.
Danger
This symbol refers to a possibly dangerous situation which can cause injuries and damage to
property if it is not avoided.
1.2 General
Low voltage motors have dangerous, live and rotating parts, and probably hot surfaces. All work for transport,
connection, commissioning and maintenance is to be made by qualified, responsible specialists (EN
50110–1/VDE 0105 Part 1, IEC 60364 must be observed). An inadequate behaviour can cause severe dam-
ages to persons and property.
1.3 Specified use

These low voltage motors are meant for use in industrial plants. They are in accordance with the standards of
the series EN 60034 (VDE 0530).
Air–cooled types are suitable for ambient temperatures from –20°C (–4°F) to +40°C (+104°F) as well as alti-
tudes ≤ 1000 m above sea level. It is imperative to observe differing data on the rating plate. The conditions at
the site of application must comply with all indicated data on the rating plate.
Low voltage motors are components to be installed into machines in accordance with
Directive 89/392/EEC.
Commissioning is not allowed as long as the conformity of the end product with this directive is not estab-
lished (EN 60204–1 has also to be observed).
1.4 Transport, storage

The carrier is immediately to be informed on damages found upon delivery; commissioning must not be
admitted, if required. Screwed–in eye bolts are to be tightened. They are suitable for the weight of the low volt-
age motor, no additional loads are allowed to be attached. If required, sufficiently dimensioned means of trans-
port (e.g. rope guides) are to be used. Prior to commissioning the transport locking devices are to be re-
moved. Reuse for further transports. For storage of low voltage motors, take care of a dry, dustfree and
low–vibration (veff v 0.2 mm/s) ambience (bearing damages with motor at standstill).
Before commissioning the insulation resistance is to be measured. In case of values v 1kΩ per Volt of the
rated voltage the winding must be dried. Observe the ”Storage instructions”.
Page 2 of 31 N–R 435 en 09.03

1.5 Installation
Take care of an even ground, suitable fastening of feet or flange and an exact alignment for direct coupling.
Avoid that structure–dependent natural frequencies occur within the rotary frequency and the double mains fre-
quency. Turn rotor by hand, listen to abnormal frictioning noises. Check direction of rotation before coupling
(Observe section ”Electrical connection”).
Pulleys and couplings are only allowed to be installed or removed with suitable devices (Heating!) and to be
covered with protection against accidental contact. Avoid inadmissible belt tensions (Tech. List). The bal-
ance of the low voltage motor is indicated on the shaft end face or on the rating plate (H = half key, F = full
key). In case of a half key (H), the coupling must also be balanced with a half key. In case of any protruding
and visible part of the key take care of the mass balancing.
If required, make the necessary pipe connections. Mounting types with the shaft end facing upwards are to be
provided with a cover by the customer, avoiding that foreign bodies fall into the fan.
Ventilation must not be hindered and the

outgoing air – also from adjacent units – must
not be directly sucked in again.
1.6 Electrical connection

All work is only allowed to be done by qualified personnel with the low voltage motor and driven machine at
standstill, electrically dead and locked against restart.
This is also applicable to auxiliary circuits (e.g. space heater).
Check de–energizing!
A non–observance of the tolerances indicated in EN 60034–1/VDE 0530, part 1 – voltage " 5%, frequency "
2%, curvature, symmetry – will result in an excessive heating and is influencing the electromagnetic compatibil-
ity. Observe data on the rating plate as well as wiring diagram in the terminal box.
Observe connection and differing data on the rating plate as well as the wiring data in the terminal box.
Connection is to be made in such a way that a durably safe, electrical connection is maintained (no uncovered
wire ends); especially provided cable end equipment is to be used. A safe earthing is to be made.
The minimum air gaps between uninsulated and live parts themselves and to earth must not be lower than the
following values: 8 mm at UN v 550 V, 10 mm at UN v 750 V, 14 mm at UN v 1000 V.
The terminal box must be free of foreign bodies, dirt as well as humidity. Unused cable entries and the box it-
self are to be sealed against dust and water. For trial operation without driving elements the key is to be se-
cured. For low voltage motors with brake it is to be checked before putting into operation, if the brake is per-
fectly functioning.
N–R 435 en 09.03 Page 3 of 31

1.7 Operation
Vibration severities veff ≤ 3.5 mm/s (PN ≤ 15 kW) and 4.5 mm/s (PN > 15 kW) are not critical in coupled oper-
ation. In case of changes compared with normal operation – e.g. higher temperatures, noises, vibrations –
the cause is to be found, if required, consult the manufacturer. Even for trial operation the safety devices are
not allowed to be put out of function. In case of doubt switch off the low voltage motor.
In case of heavy dirt accumulation, the air ducts must be cleaned at regular intervals.
Bearings with regreasing devices are to be regreased with low voltage motor running. Risk of accidents! Pay
attention to rotating parts. Observe saponification class! If grease drainholes are sealed with a plug, remove
these plugs before putting into operation. Boreholes have to be sealed with grease. Replacement of bearings
in case of permanent lubrication see Appendix 1 or motor documentation.
1.8 Warranty
The Warranty is only applicable if all of these instructions for safety and putting into operation as well as the
following paragraphs of the operating instructions and the directions for possible additional units are strictly ob-
served.
Page 4 of 31 N–R 435 en 09.03

Description
2. Description
2.1 Overall construction and design

Mounting arrangement acc. to EN 60034–7: see dimension drawing or rating plate
Mounting dimensions for surface cooling (TEFC) up to frame size 315 M acc. to
DIN 42 673 (foot mounted)
DIN 42 677(flange mounted)
from frame size 315 L acc. to dimension drawing,
all frame sizes acc. to IEC 60072–1 or IEC 60072–2: see dimension drawing
Mounting dimensions for internal cooling (ODP) up to frame size 315 M acc. to
DIN 42 672 (foot mounted)
DIN 42 676 (flange mounted)
from frame size 315 L acc. to dimension drawing,
all frame sizes acc. to IEC 60072–1 or IEC 60072–2: see dimension drawing
Connection designations acc. to

DIN VDE 530 part 8
IEC 60034 – 8: see wiring diagram
Enclosure acc. to
EN 60034 – 5: see rating plate
Cooling acc. to EN 60034–6:

IC 411 surface cooling or hollow–fin cooling
IC 511 tube cooling
IC 01 internal cooling
IC 611 internal cooling with mounted–on air–to–air heat exchanger
IC 81 W internal cooling with air–water circuit cooler
IC 71 W water jacket cooling
Details of the motor design are indicated in the valid technical catalogues.
2.2 Bearings
The motors are equipped with grease–lubricated antifriction bearings. The standard version of the
bearings in surface–cooled motors up to frame size 280 and in internally cooled motors up to frame
size 225 is permanently lubricated.
The bearings of totally enclosed fan–cooled (TEFC) motors from frame size 315 and the internally
cooled open–drip proof (ODP) motors from frame size 250 are equipped with regreasing devices
and automatic grease quantity control.
N–R 435 en 09.03 Page 5 of 31

Description
2.3 Cooling
2.3.1 Surface cooling (TEFC) for the Type A..A–...–.. except A.WA–132..–.. to A.WA–560..–..
Design for fin–, hollow–fin– or tube cooling, where an external fan takes in the cooling air through
the openings in the fan cover and presses the air over the surface or through the cooling tubes of
the stator housing. In case of hollow–fin or tube cooling the heat dissipation is supported by a
closed cooling air circuit inside the motor.
2.3.2 Internal cooling for the Type J..A–... except JNWA–... and JNRA–...
In case of motors with enclosure IP 23 the cooling air (ambient air) is taken in by internal fans
through air inlet openings, is led over the heat–generating elements in the motor and is blown out
through air outlets.
2.3.3 Internal cooling with mounted–on air–water heat exchanger for the Type JNWA–...
The motors are equipped with air–water circuit coolers. The cooling air led through the heat ex-
changer and motor is recooled in the heat exchanger and the heat loss is dissipated through the
cooling water. The heat exchangers are provided with special ribbed tubes.
2.3.4 Internal cooling with mounted–on air–to–air heat exchanger for the Type JNRA–...
The motors are equipped with air–to–air heat exchanger. The cooling air led through the heat
exchanger and motor is recooled in the heat exchanger and the heat loss is dissipated through
the cooling medium air.
2.3.5 Water jacket cooling for the Type A.WA.–132..–.. to A.WA.–560..–..
The stator housing has a double casing. For water channelling it is sub–divided by spirals where
the cooling water passes through. This results in a good heat dissipation. Additionally, this reduces
the danger that suspended matters carried along in the water can deposit.
2.4 Motor frame

2.4.1 Construction for surface cooling (TEFC), hollow–fin cooling or tube cooling
(Type A..A–...–.. except A.WA–132..–.. to A.WA–560..–..)
Depending on the frame size the stator frame and end shields are made of grey cast iron or steel.
The fan cover is made of sheet steel. The stator frame surface is provided with cooling fins, hollow
fins or tubes and attached terminal box.
2.4.2 Construction for internal cooling (ODP) for the Type J..A–... except JNWA–... and
JNRA–...
Depending on the frame size the stator frame and end shields are made of cast iron or steel. The
stator frame has an even surface with attached terminal box. There are distance fins between sta-
tor jacket and stator pack allowing the internal cooling.
2.4.3 Construction for internal cooling with air–water heat exchanger for the Type JNWA–...
The stator frame and end shields are of steel. The stator frame surface is plain with
mounted–on terminal box. Between the stator jacket and the stator core there are spacing ribs
making possible the internal cooling. An air–water circuit cooler is mounted onto the ventilation
openings.
2.4.4 Construction for internal cooling with air–to–air heat exchanger for the Type JNRA–...
Like for the internal cooling with air–water heat exchanger, however, an air–to–air heat ex-
changer is mounted onto the ventilation openings.
2.4.5 Construction for water jacket cooling (Type A.WA.–132..–.. to A.WA.–560..–..)
Stator frame and end shields are made of grey cast iron or steel.
The stator housing is designed as double casing, through which the cooling water is led.
The housing is provided with inlet and outlet for the cooling water.
Page 6 of 31 N–R 435 en 09.03

Description
2.5 Stator winding

The stator winding is executed in insulation class (see rating plate) acc. to EN 60034–1. High–qual-
ity enamelled wires, suitable surface insulating materials and the type of insulation provide a high
level of mechanical and electrical stability with a high utilization factor and a long service life.
If required, the winding heads are sealed with a silicon–rubber compound. This sealing offers
special advantages in combination with the insulation classes F and H, when the motors are oper-
ated under severe starting– and braking conditions. Furthermore, the sealing provides an in-
creased mechanical short circuit resistance and the motor inside (in case of surface cooling) is pro-
tected against condensed water.
2.6 Rotor
The rotor in motors of small frame sizes is equipped with a squirrel cage made of aluminium die
cast, in case of larger frame sizes and for special starting– and braking conditions a brazed rotor
version is also available. The rotor is dynamically balanced.
The balance is indicated on the shaft end or the rating plate, see Paragraph 4.1 ”Installation”.
The motors in standard design meet the requirements of vibration level N
acc. to DIN EN 60034–14 / IEC 60034–14, in special cases level R (reduced) or S (special).
2.7 Terminal boxes

If required, additional terminals for the monitoring devices are available inside the
terminal box. On special order an additional terminal box will be installed for larger motors (see
dimension drawing).
The number of available terminals is indicated in the wiring diagrams.
2.8 Monitoring devices

Monitoring devices are only available on special request. See wiring diagram.
N–R 435 en 09.03 Page 7 of 31

Transport
3. Transport
For handling during transport the stator construction of the motor is equipped with lifting eyes,
where the lifting hooks can be fixed.
Check whether screwed lifting eyes are securely tightened.
Lift motors only by using these lifting eyes. Several lifting eyes must always be used
together.
Lifting of the motors on other parts (e.g. shaft ends) is not permitted, since this might result in
considerable damages.
The lifting eyes are only suitable for the motor weight. Additional loads attached to the
motor must never be lifted using these eyes.
3.1 Check before installation

Check whether the motor has been damaged during transport. If the packing is damaged to such
an extent that a motor damage is to be assumed, the packing should be removed in the presence
of a representative agent of the carrier.
3.2 Bearing lock

(for motors with cylindrical roller bearings only.)
The rotor of the motor is locked in order to avoid damages to bearings caused by vibrations
at standstill:
– by red marked locking screws in the bearing cap
– or by a transport locking mechanism fixed to the shaft end.
Before the motor is mounted, the locking screws must be loosened by 10 mm and the transport
locking device must be removed (see instruction plate on the motor).
After this, it must be possible to turn the shaft by hand.
We recommend loosening of the bearing lock only after the drive element has been fitted.
The transport locking mechanism has to be reused for further transports.
Prevent failures and thus avoid damages to persons and property.
The person responsible for the installation has to make sure, that
– safety– and operating instructions are available and observed
– operating conditions and technical data acc. to the order are observed
– protective equipment is used
– specified maintenance work is carried out.
Page 8 of 31 N–R 435 en 09.03

Installation and commissioning
4. Installation and commissioning
A most careful mounting and alignment of the motors on an absolutely even surface is impera-
tive to avoid distortions when the screws are being tightened. For machines which are to be
coupled it must be paid attention to a careful alignment. See Appendix 2 for alignment check.
As elastic as possible couplings should be used.
The motors with surface cooling (TEFC), hollow–fin cooling or tube cooling , internal
cooling or internal cooling with air–to–air heat exchanger
(for all indicated types except Type A.WA.–... and JNWA–...)
Maximum permissible coolant temperature (ambient temperature on site) acc. to EN 60034–1/IEC
60034–1 is 40°C (104°F) and a permissible altitude up to 1000 m above mean sea level (other va-
lues see rating plate).
Care must be taken that the cooling air can flow without hindrance into the air inlet openings and
freely pass through the air outlet openings and cannot be directly sucked in again. Suction and
outlet openings must be protected from obstructions and coarse dust.
The motors with water jacket cooling (Type A.WA.–132..–.. to A.WA–560..–..)

Before commissioning of water–cooled motors, the troublefree function of the cooling–water circuit
must be guaranteed. It must be ensured that the motor will only be switched on when the cooling–
water circuit is in operation. It must be kept functioning until the motor comes to standstill after
switching–off. Inlet and outlet openings are found on the motor housing.
The cooling water circuit is to be monitored. Normally, the motor is equipped with PTC thermistor
sensors, which switch off the motor if the cooling–water circuit fails. If the housing is provided with
vent plugs for the water chamber, venting is to be made for the first filling and thereafter at regular
intervals.
Only clean, non–aggressive cooling water is to be used. Admissible content of suspended solids
is max. 10mg/l
A most careful mounting and alignment of the motors on an absolutely even surface is impera-
tive to avoid distortions when the screws are being tightened. For machines which are to be
coupled it must be paid attention to a careful alignment. See Appendix 2 for alignment check.
As elastic as possible couplings should be used.
The inlet temperature of the cooling water should be at least 20 °C (68 °F).
Temperatures below 20 °C (68 °F) result in higher formation of condensation water and motor fail-
ure. Admissible inlet and outlet temperature, maximum pressure and the required amount of cool-
ing water are indicated on the motor plates.
The motors are only allowed to be operated at a coolant temperature over 0 °C (32 °F). For lower
temperatures it is required to add an antifreeze due to reduced cooling effect. Consultation with
the motor manufacturer is required.
N–R 435 en 09.03 Page 9 of 31

The motors with mounted–on air–water heat exchanger for the Type JNWA–..
Before commissioning of the motors, the troublefree function of the cooling–water circuit must be
guaranteed. It must be ensured that the motor will only be switched on when the cooling–water
circuit is in operation. It must be kept functioning until the motor comes to standstill after switching–
off.
Admissible inlet and outlet temperature, maximum pressure and the required amount of cooling
water are indicated on the motor plates.
4.1 Mounting
Fitting of pulleys or couplings.
First the shaft end should be cleaned (not with emery cloth) and then greased. Pulley or coupling
should be fitted only with the aid of a fitting device. For this purpose the threaded centering hole
in the shaft end can be used. Insert a threaded bolt into the threaded hole. Then place the steel
washer, the diameter of which is large enough to cover the hub borehole of the pulley or coupling.
The pulley and coupling is to be fitted onto the shaft end by means of a nut or a suitable hydraulic
device.
The fitting of the drive elements by means of hammer blows is not permitted because of
the risk of bearing damages.
When replacing the bearings those must only be removed and reinstalled by means of suit-
able devices using the shaft centering. Only original spare parts must be used.
The rotor of the motor is dynamically balanced. Balance is indicated on the shaft end face or the
rating plate (H = half key, F = full key). Take care of the balance for installation of the driving el-
ement!
The balancing of the transmission elements to be fitted must be adapted to the rotor balancing.
In case of half key balancing any protruding and visible part of the key has to be removed.
The motor must only be mounted and operated according to the specified mounting arrangement
(see rating plate).
Page 10 of 31 N–R 435 en 09.03

4.2 Connection, insulation resistance

Connection must only be made by an expert and in accordance with the valid safety regulations.
The relevant installation– and operating instructions as well as national and international rules have
to be observed.
Observe data on the rating plate!

Compare type of current, mains voltage and frequency!
Check wiring diagram!
Observe rated current for setting of the protective switch!
Connect motor in accordance with the wiring diagram provided in the terminal box!
The motor must be protected against excessive heating, e.g. by means of a motor protective
switch.
For earthing the motor is provided with an earthing terminal, which depending on the mounting ar-
rangement is either located on the frame resp. on the flange end shield. In addition all motors have
a protective conductor terminal inside the terminal box.
As protection against dust and humidity unused cable entries in the terminal box must have a tor-
sionproof seal. All terminal screws and nuts have to be securely tightened to avoid excessive
transition resistances (see paragraph 4.6).
Protective measures are to be taken.
In case of terminal boards with U–shaped terminal washers the

conductors to be connected have to be bent in U–shape and
placed underneath the terminal washers. See sketch!
In case of motors with terminal boxes which have ground surfaces between cover and base a thin
grease film is to be applied for sealing and against corrosion.
After longer storage periods or standstill (see page 18) the insulation resistance of the winding must
be measured phase against phase and phase against ground before putting into operation.
Humid windings might cause creeping currents, arcing and ruptures. In case of values ≤ 1 kΩ per
Volt of rated voltage measured at a winding temperature of 20 °C (68 °F) the winding must be dried.
Cable–, lead entries and connecting cables must be suitable for ambient temperatures occur-
ring.
4.3 Rotational direction and designation of the terminals acc. to

DIN VDE 0530–8/IEC 60034–8
4.3.1 In standard design surface cooled (TEFC) motors up to frame size 355 and internally cooled
(ODP) motors up to frame size 315 are suitable for both directions of rotation.
Motors suitable for one rotational direction only are identified by an arrow on the motor for the
correct direction. Terminals U1, V1, W1 connected to phase L1, L2, L3 (in alphabetical se-
quence or natural sequence) always result in clockwise rotation. This rule applies to all motors,
even if they are not suitable for clockwise direction.
N–R 435 en 09.03 Page 11 of 31

4.3.2 Change of rotational direction:

For DOL (direct on–line) starting and in pole–changing motors with separate windings the di-
rection of rotation can be reversed by exchanging two mains conductors on the terminal board
of the motor.
For motors with star/delta starting and pole–changing motors with Dahlander winding, 2 (two)
mains conductors at the input to the motor switch have to be exchanged.
For a machine with one shaft end only or with two shaft ends of different diameters, that rota-
tional direction of the rotor is considered as the direction of rotation, being noticed by anybody
when looking at the front end or thicker shaft end.
4.3.3 With forced ventilation the direction of rotation is separately marked by an arrow on the forced
ventilation itself.
4.4 Air–water heat exchanger

(motors with air–water heat exchanger of the type JNWA–...)
For connection and commissioning the instructions for air–water heat exchangers must be con-
sidered.
Admissible inlet and outlet temperature, maximum pressure and the required amount of cooling
water are indicated on the motor plates.
4.5 Check before commissioning

– Check whether the bearing lock has been removed!
See Paragraph 3.2 ”Bearing lock”!
– Observe data on the rating plate!
– Check whether voltage and frequency of the motor comply with the mains data!
– Check whether the rotational direction is correct and for inverter operation, that the
limit speed is not exceeded!
– Check whether the motor is protected as specified in the regulations!
– Check and make sure that in case of star/delta–starting, because of the risk of
inadmissible operational loads, the switching from star to delta can only be
executed after fading of starting current of the star step!
– Check whether the electrical connections are securely tightened and whether the
monitoring devices are correctly connected and adjusted!
– Check coolant temperature!
– Check whether the additional equipment – if any – is functioning.
– In case of water–cooled motors, check whether the cooling water circuit is in operation!
– Check whether the cooling air inlet openings and cooling surfaces are clean!
– Check whether protective measures have been taken: earthing!
– Check whether the motor is securely fixed!
– In case of a belt drive, check the belt tension!
– Check whether the cover of the terminal box is closed and whether the cable
entries are properly sealed.
– For forced–ventilated motors it is to be checked, whether the forced ventilation is
functioning and in operation when the main motor is in operation.
Page 12 of 31 N–R 435 en 09.03

4.6 Tightening torques for screwed joints

4.6.1 General
If no other data are indicated the following torque limits (screw and nut) are applicable.
Note: Screws which become unusable have to be replaced by
new ones of the same strength class and type.
4.6.2 Screwed joints for electrical connections
Thread Tightening torque [Nm] Thread Tightening torque [Nm]

M4 1.2 M 12 15.5
M5 2 M 16 30
M6 3 M 20 52
M8 6 M 24 80
M10 10 M 30 150
4.6.3 Screwed joints strength class 8.8 and A4–70

Tightening torques for screws of the strength class 8.8 and A4–70 (A4–80) only in components
with higher strength (e.g. grey cast iron, steel).

M4 2.3 M 14 105
M5 4.6 M 16 160
M6 7.9 M 20 330
M8 19 M 24 560
M10 38 M 30 1100
M 12 66 M 36 1900
4.6.4 Screwed joints strength class 5.6

Tightening torques for screws of the strength class 5.6, 4.6, A2 or for screws in components
with lower strength (e.g. aluminium).

M4 1.1 M 14 49
M5 2.1 M 16 75
M6 3.7 M 20 150
M8 8.9 M 24 260
M10 18 M 30 520
M 12 30 M 36 920
N–R 435 en 09.03 Page 13 of 31

Maintenance
5. Maintenance
The responsible for the facility must ensure that the specified maintenance work
is made adequately.
5.1 Bearings and greasing
5.1.1 The bearings in totally enclosed fan–cooled (TEFC) motors up to frame size 280 and of inter-
nally cooled open drip–proof (ODP) motors up to frame size 225 are permanently lubricated. In
case of differences this is marked by indication plates on the motor.
For normal coolant temperatures (see EN 60034–1 or page 2 of these instructions) motors
are greased in our plant, which under normal operating conditions must only be replaced after
several years (see Appendix 1).
5.1.2 Bearings of totally enclosed fan–cooled (TEFC) motors from frame size 315 (upon customer
request also for the range from frame size 160 to 280) and of internally cooled open drip–proof
(ODP) motors from frame size 250 as well as the water–cooled motor with air–water circuit
cooler are equipped with regreasing devices and automatic grease quantity control. The re-
greasing of the bearings is done by means of a grease gun through the nipples provided on the
end shields.
Overfilling of the bearing chambers is not possible since in case of an extended regreasing the
used grease will be thrown off by a rotating disk in the outer grease chamber through an aper-
ture in the end shield (or into a grease collecting chamber).
Regreasing during operation only!

Regreasing intervals, grease quantity and grease quality are indicated on the instruction plates at
the motor. Regreasing, however, is to be made at least once a year.
If the motor is equipped with grease removal rams, the used grease must be removed after re-
greasing by pulling the ram at the bearing several times to the stop, with the motor in operation.
If the motor is equipped with grease collecting chambers, these chambers are to be dismounted
at motor standstill acc. to the intervals on the instruction plate and the used bearing grease is to
be removed. If this is not done, the grease piles up and the bearings are overheated.
Extending the regreasing intervals endangers the bearing and might risk a deterioration of the
sealing provided by the grease and thus the ingress of dust into the bearing. If the motors have
not been operated for a longer period we recommend even for new motors to regrease the bearings
before putting into operation, especially if due to congealing grease in the bearing there are noises
which are caused by vibrations of the bearing cage. In the course of running–in increased bearing
noises might occur for a short period. The bearing noise is not critical as long as the operating tem-
perature of the bearing is not yet reached and if the noise is caused by the dynamic viscosity of
the bearing grease.
The temperature of the bearings is continuously to be checked. Up to an ambient temperature of

40 °C/104 °F a heating–up of 80 K is acceptable if the recommended grease quality is used.
Page 14 of 31 N–R 435 en 09.03

Maintenance
We would like to point out that the grease quantity regulation can only work properly if the grease
types specified by us are used. Decisive is the plate fixed on the motor!
Only use antifriction bearing grease as specified for regreasing on the motor plate, i.e. for the ambi-
ent temperature range from –25°C (–13°F) to +70°C (+158°F) lithium based grease (e.g Shell Al-
vania RL3), for the ambient temperature range from –60°C (–76°F) to +80°C (+176°F) special
grease (e.g. Klüber Isoflex Alltime SL2). Admissible ambient temperature for the motors: See
Paragraph 1.3.
Motors for special operating conditions are supplied with a separate greasing plate stating the
grease quality to be used as well as the regreasing intervals.
Relubrication with grease of a different saponification basis. e.g. sodium saponified grease,
might cause a deterioration and elimination of the grease effect and thus a total damage of the
bearings.
In case of 2 and 4 pole motors it might happen that by the use of unsuitable grease the grease
quantity regulation fails and when pressing new grease into the bearings they get abnormally hot
due to overfilling. In such cases the bearings have to be cleaned thoroughly by using cold–degreas-
ing agent, and be refilled with suitable grease.
5.1.3 Avoidance of mechanical damages (bearing damages)

All machines have to be checked at regular intervals for mechanical damages.
Special attention must be paid that the intervals for bearing replacement and regreasing inter-
vals or grease change intervals as well as oil change intervals to be specified by the user are
observed.
When the rated service life is reached the bearings should either be replaced or it is to be
proven by an inspection that there are no mechanical damages.
– For bearings which are not regreasable it is ensured that the rated service life will only be
reached clearly after achieving the grease service life of the bearings.
– The calculated rated service life of the bearings can be seen in the data sheet of the ma-
chine, if it was specified particularly or for structural reasons specified for an individual case.
– For machines which are exposed to forces applied externally (e.g. belt force or axial load
from the driven machine) the bearing service life is a minimum of 20.000 hours for the full load
indicated in the technical list.
– All of the other machines have a rated bearing service life of at least 40.000 hours.
– For bearings with separate oil supply the user is to watch suitably that the lubrication is main-
tained.
N–R 435 en 09.03 Page 15 of 31

Maintenance
5.2 Terminal locations, terminals, ventilating passages

Depending on the operating conditions, the following should be done at certain intervals
checking the cleanliness of terminal locations and terminals
– checking of the electrical connections with regard to tightness
– cleaning of the ventilating passages.
Both the cooling air inlets and the cooling surfaces must be protected against obstruction and
contamination.
– If required, the water chambers are to be flushed and cleaned from deposits.
Never use sharp–edged tools for cleaning.
5.3 Air–water heat exchanger

(Motors with air–water heat exchanger of the Type JNWA–...)
For maintenance please consider the instructions for the air–water heat exchangers.
Page 16 of 31 N–R 435 en 09.03

Additional equipment
6. Additional equipment
On special order only.
6.1 Temperature monitoring *)

The temperature sensors for monitoring e.g. of the stator winding temperature, the bearings, the
coolant must be connected to the additional terminals in the main terminal box or by one or several
terminal boxes.
The temperature sensors have to be connected according to the relevant connection diagram. For
connection the specifications and instructions acc. to Paragraph 4.2 ”Connection” are applicable.
6.2 Electronic speed monitoring *)

This one is essentially consisting of the slot–type initiator and the control segment. The electronic
speed monitoring is maintenance–free.
6.3 Space heater *)

Heating capacity and connection voltage: See special plate on the motor. The space heater has
to be connected to the terminals provided in the main terminal box or by an additional terminal box
acc. to the relevant connection diagram.
For connection the specifications and instructions acc. to Paragraph 4.2 ”Connection” are appli-
cable.
An operation of the space heater is only allowed when the motor is switched off. The space heater
must never be switched on during motor operation.
6.4 Forced ventilation *)

Observe direction of rotation! (see arrow for directional rotation.)
Forced ventilation is to be connected acc. to the wiring diagram inside the terminal box.
During operation of the main motor the forced ventilation must be switched on!
The forced ventilation is dissipating the heat loss during operation of the main motor. When switch-
ing off the main motor a temperature–dependant follow–up run of the forced ventilation is required.
6.4.1 To be checked when commissioning the main motor:

Check whether the forced ventilation works and is in operation when the main motor is
switched on!
*) On special order only
N–R 435 en 09.03 Page 17 of 31

Three–phase motors as centrifugal drive
for heavy starting
7. Three–phase motors as centrifugal drive for heavy starting

Special requirements for a safe application (Type AW.A–...–..)
For mounting and removal of the motor the corresponding operating instructions of the centrifuge
must be observed.
Starting– and braking conditions of the motor in accordance with the corresponding operating in-
structions must be observed.
Even for trial operation the control and safety devices as well as the motor monitoring (thermal
motor protection, speed monitoring and others) are not allowed to be put out of function.
The motor must only be mounted and operated according to the specified mounting arrangement.
Any other application is prohibited.
It has to be secured that the servicing personnel is informed at once or the electrical machine is
immediately stopped to find the causes, if contrary to the rated operation higher temperatures, no-
ises, vibrations etc. occur.
Direction of rotation:
The centrifuge is only suitable for one direction of rotation. The relating arrow on the centrifuge
must be observed.
Bearing and greasing:
For permanently lubricated motors (also see bearing and greasing data sheet on request) the
grease life, grease quantities and grease qualities as indicated in Appendix 1 of these operating
instructions are applicable. Motors with regreasing device are equipped with an automatic grease
quantity control. Regreasing intervals, grease quantity, grease quality and the exact bearing type
are indicated on the motor plate or in the bearing– and greasing data sheet to be requested.
A lack of regreasing, an extension of the regreasing intervals or the use of a wrong grease quality
might endanger the bearing. This can result in a deterioration of the bearing and the motor shaft,
also entailing consequential damages on the centrifuge.
For this reason it is recommendable to maintain an inspection– and maintenance plan where re-
greasing and possible bearing replacements are documented.
Replacement of bearing:
See safety instructions, section ”Operation”.
The service life of the bearings depends on many influences. Therefore, the operation of the low–
voltage motor has continuously to be checked and the intervals for bearing replacement to be de-
termined accordingly.
Page 18 of 31 N–R 435 en 09.03

Spare parts
8. Spare parts
When ordering spare parts or components please state the type, serial number of the motor.
Both data can be taken from the rating plate.
Standard version:
N–R 435 en 09.03 Page 19 of 31

Spare parts
Version with forced ventilation and electronic speed monitoring:
1.00 Stator, complete 4.34 Resilient preloading ring, NDE

1.03 Stator core with winding 4.36 Grease guide disk, NDE
1.06 Stator housing 4.38 Centrifugal disk, NDE
1.10 Mounting feet, unmachined (1 pair) 4.42 Felt packing ring, NDE
4.44 Outside gasket, NDE
2.00 Rotor, complete (balanced) 4.46 Inner gasket, NDE
3.01 End shield, DE 5.01 External fan, complete

3.02 Flange shield, DE 5.10 Fan cover, complete
3.08 Flange disk, DE 5.14 Protective grid, complete
3.21 End shield, NDE 5.30 Spring fastener
5.60 Motor for forced ventilation
4.01 Bearing, DE 5.65 Front shim
4.05 Bearing, NDE
4.10 Outside bearing cap, DE 6.03 Base of terminal box
4.12 Inner bearing cap, DE 6.04 Upper part of terminal box
4.14 Resilient preloading ring, DE 6.05 Terminal box cover
4.16 Grease guide disk, DE 6.07 Bushing plate
4.18 Centrifugal disk, DE 6.08 Cable gland, lower part
4.22 Felt packing ring, DE 6.09 Cable clamp
4.24 Outside gasket, DE 6.10 Cable entry
4.26 Inner gasket, DE 6.11 Cable gland, upper part
4.30 Outside bearing cap, NDE 6.15 Terminal board, complete
4.32 Inner bearing cap, NDE 6.16 Bushing terminal
Page 20 of 31 N–R 435 en 09.03

Spare parts
6.17 Accessory terminal

6.20 Clamping
6.28 Cable gasket
7.01 Slot–type initiator

7.02 Mounting angle
7.11 Bolted connection
7.12 Segmental disk
7.16 Metal tube
The parts shown are available in different sets depending on type, size, mounting and enclosure. They are available
from our works. All other parts such as bolts, spring washers etc. are available anywhere.
When ordering spare parts, please state:
Spare part designation

Motor type
Serial number
Example:
3.01 End shield, DE
ANLA–200LB–08
8 386 388
1. Einlagerungsvorschriften
N–R 435 en 09.03 Page 21 of 31

Storage instructions
9. Storage specifications
9.1 For motors which have to be stored for a period of up to 2 years, the fol-
lowing is to be observed:
9.1.1 Storage
9.1.1.1 The motors are to be stored dry, dustfree and at room temperature. In this case no special
packing is required. Otherwise the motors must be packed into plastic foil with humidity–ab-
sorbing substances (e.g. Branogel) or into an air–sealed foil. Protective cover against sun and
rain is to be provided.
9.1.1.2 In order to avoid secondary failures at the bearings caused by vibrations at standstill, for
example by adjacent running machines, the motors are only allowed to be stored in vibration-
less rooms.
9.1.1.3 For transport the TEFC, ODP and water–cooled motors with roller bearings have to be
equipped with a bearing lock at the driving end. It is to remain locked until commissioning resp.
to be reinstalled after an inspection or a trial operation. A locking device is not necessary and
not available, if the bearing is axially preloaded.
9.1.1.4 On motors with sealed condensation water drain holes it might be necessary to have the con-
densation water flow out. Afterwards the boreholes are to be sealed again.
9.1.2 Commissioning
9.1.2.1 Before commissioning the insulation resistance of the winding must be measured by qualified
personnel phase against phase and phase against mass. Damp windings may cause leakage
currents, arcing and ruptures. In case of values ≤ 1 kΩ per Volt of rated voltage measured at a
winding temperature of 20 °C (68 °F) the winding must be dried. Drying is possible by feeding
of the winding with single phase a.c. current. The voltage has to be adjusted in a way that the
recommended values of the heating current in accordance with Illustrations a) and b) are not
exceeded.
The temperature should reach approx. 80 °C (176 °F) and be active for several hours. Drying
is also possible in a drying kiln.
Page 22 of 31 N–R 435 en 09.03

Recommended heating circuits and maximum heating currents
a) D b) Y
IMAX = 65 % Ir IMAX = 75 % Ir
9.1.2.2 On motors with bearing lock this one has to be removed before commissioning.
9.1.2.3 Antifriction bearings, lubrication

If adequately stored for a longer time it can be assumed that within 2 years the lubricating
grease in the bearings is not affected. Motors with permanent lubrication can be put into oper-
ation after having checked the insulation resistance of the winding and a short trial run.
For motors with insulation class F a lithium–saponified antifriction bearing grease with a drip-
ping point of at least 180 °C (356 °F) is used for normal ambient temperatures.
For the motors with insulation class H and certain special motors, the used special lubricating
grease is indicated on an instruction plate attached to the motor.
9.1.2.4 For motors with a regreasing device it is advisable to regrease both bearings shortly after com-
missioning at running motor.
Grease type, grease quantity and regreasing intervals are marked on an additional plate at-
tached to the motor.
The data for grease service life with regreasing intervals can surely be expected for motors in
enclosure IP 55. The bearing is protected against the ingress of fine dust and of water in all
directions, e.g. for outdoor installation without additional protection.
For motors with enclosure IP 44 and IP 54 these data apply with the restriction that the envi-
ronmental load by dust and water is not exceeding the limits of DIN EN 60034–5 with tests ac-
cording to DIN EN 60034–5.
9.1.3 For motors which are transported and stored in assembled condition with the machine
to be driven the following must be observed:
9.1.3.1 Storage
The free shaft ends must be greased before installation of the motors as well as all of the other
blank metal parts, e.g. foot– and flange surfaces or supporting faces of terminal boxes and
covers.
As protection against dust and humidity, grease seals with antifriction bearing grease are to be
installed at the shaft opening.
b) A humidity–absorbing substance (e.g. Branogel) is to be filled into the terminal boxes of the
motors.
c) The machines are to be stored dry, dustfree and at room temperature.
d) For further measures the specifications according to the items 9.1.1.2 – 9.1.1.4 are appli-
cable.
A bearing lock is not necessary, if the bearings are preloaded by means of belt drive (9.1.1.3).
N–R 435 en 09.03 Page 23 of 31

9.1.3.2 Commissioning
Before commissioning the humidity–absorbing substance (e.g. Branogel) is to be removed from
the terminal boxes and the measures according to 9.1.2 are to be performed.
9.1.3.3 For outdoor storage it is additionally to be observed:

Protective cover against the influence of sun and rain is to be provided, exchange of air must
be possible to avoid condensation water.
After 2 months it must always be checked if the protective measures acc. to 9.1.3.1a are still
given and functioning.
9.2 For motors which are stored for more than 2 up to 4 years before com-
missioning additionally applies:
9.2.1 Storage
9.2.1.1 The manufacturer must be informed on the storage time in the purchase order.
9.2.1.2 Shaft opening and terminal box cover are to be provided with grease seals of antifriction bear-
ing grease. The motor shafts are not allowed to be rotated, as otherwise the protective grease
coating is destroyed. If a movement of rotating parts is unavoidable, the protective grease
coating has to be renewed.
9.2.1.3 A humidity–absorbing substance (e.g. Branogel) must be in the terminal boxes.
9.2.1.4 Due to the long standstill the antifriction bearings must be greased with the special grease
”Staburags NBU 8 EP”.
9.2.2 Commissioning
9.2.2.1 Before commissioning the humidity–absorbing substance (e.g. Branogel) is to be removed from
the terminal boxes and the measures according to 9.1.2 are to be performed.
9.2.2.2 Antifriction bearings, lubrication

Motors with regreasing device must be relubricated immediately after commissioning with
about the double grease quantity, until the used grease has been thrown out. Further greasing
can then be made with the bearing grease indicated on the lubrication plate. During the run-
ning–in period increased bearing noises may occur, which are not dangerous, when the operat-
ing temperature of the bearing has not been reached and is caused due to the dynamic viscos-
ity of the bearing grease.
Page 24 of 31 N–R 435 en 09.03

9.3 If motors (not Type A.WA–... and JNWA–...) are stored at temperatures till
–50°C (–58 °F) the following must be observed in addition to the instruc-
tions according to point 9.1. and 9.2:
9.3.1 The standard antifriction bearing grease for the motors as per catalogue is suitable for
operating temperatures between –30 °C (–22 °F) and +130 °C (+266 °F). Temperatures till –50
°C (–58 °F) are harmless for the antifriction bearing grease, when the motors are at standstill
or stored. (For an operation at –50 °C (–58 °F) a special grease, e.g. Klüber Isoflex Alltime
SL2, is available for the bearings).
9.3.2 Motors with regreasing device are to be relubricated with the double grease quantity when put
into operation.
9.4 If motors with direct water jacket cooling or with air–water cooler (Type
A.WA–... or JNWA–... )
are stored at temperatures up to –20 °C (–4 °F) the following must be ob-
served in addition to the instructions of point 9.1 and 9.2:
The water has to be removed completely from the air–water coolers.
In any case the coolers have to be dried completely with hot air of max. 60 °C (140 °F) and
then to be sealed.
Motors with coolers have to be stored in a dry and dustfree room.
At commissioning the motors with regreasing device have to be relubricated with the double
grease quantity.
9.5 Further to these storage instructions all data of these operating instruc-
tions are to be considered.
The manufacturer’s warranty is only applicable if all of the above men-
tioned items are strictly observed.
N–R 435 en 09.03 Page 25 of 31

Faults and remedies
10. Faults and remedies
Fault Possible causes Remedy

Bearing is too hot Bearing noise*) Motor runs
unevenly
Too much grease in bearing Remove excess grease
Bearing dirty Replace bearing
Belt tension too high Reduce belt tension
Coupling forces are pulling or Realign motor, correct coupling

pushing
Coolant temperature above 40°C Adjust temperature of cooling air

(104°F)
Not enough grease in the bearing Grease according to specifications
Motor incorrectly mounted Check mounting type of motor
Bearing grease dark coloured Check bearing currents
Scoring at bearing inner race, e.g. Replace bearing, avoid vibrations

caused by motor start with locked at standstill
bearing
Unbalance caused by coupling Exact balancing
Motor fastening unstable Check fastening
*) If remedies described are insufficient, we recommend to replace the bearings.
Fault Possible causes Remedy

High Protective
Motor does Motor is too
decrease in device
not start hot
speed triggers
Countertorque too high Check motor– and load torque
Mains voltage too low Check mains conditions
Phase interruption Check mains supply
Observe wiring diagram and rating

Wrong winding connection
plate
Overload Compare data on rating plate
Too many starts per hour Observe rated duty type
Check ventilation passages, check

Insufficient ventilation
direction of rotation
Check cooling water inlet and

Insufficient cooling
outlet temperature
Ventilation passages or water Clean

chambers dirty
Short–circuit of winding or terminal

Measure insulation resistance
board
Starting time exceeded Check starting conditions
Page 26 of 31 N–R 435 en 09.03

Operating instructions for brake motors
with spring–loaded single–disk brake
11. Operating instructions for

brake motors with spring–loaded single–disk brake (Type AB.A–...–..)
Description
The maintenance–free brake is rest current–operated and in released condition it is operable in any fitted position
as long as required and is suitable for both directions of rotation. The asbestos–free brake linings are highly wear–
resistant.
Attention! The friction surfaces must not get into contact with oil or grease.
Air gap adjustment

Air gap ”SLü” is adjusted according to Table 1. If a readjustment should be required, the correct air gap ”SLü” is restor-
able by turning the readjusting bushes (4).
If the motor is designed with a manual release, it must be observed that dimension ”S” between the self–locking
nuts and the armature disk is equally adjusted on both sides. If the air gap ”SLü” is required to be readjusted, how-
ever, nothing may be changed on the manual release.
N–R 435 en 09.03 Page 27 of 31

Operating instructions for brake motors
with spring–loaded single–disk brake
Braking torque adjustment

As delivered the brake is adjusted to the rated braking torque. A reduction of the braking torque is possible by
unscrewing the adjusting ring (1) up to Dimension ”O1”.
For braking torque adjustment it is required to remove the fan cowl (3). In case of the design with manual re-
lease part (2) must be unscrewed before.
Reduction of braking torque per detent according to Table 1
Table 1: Lenze brakes Type BFK 458
Brake size 06 08 10 12 14 16 18 20 25
Rated braking torque [Nm] 4 8 16 32 60 80 150 260 400
SLü [mm] 0.2 0.2 0.2 0.3 0.3 0.3 0.4 0.4 0.5
S [mm] 1.0 1.0 1.0 1.5 1.5 1.5 2.0 2.0 2.5
Reduction per detent [Nm] 0.2 0.35 0.8 1.3 1.7 1.6 3.6 5.6 6.2
O1 max [mm] 4.7 4.7 7.6 9.6 11 10 14.9 16.4 18.3
Please request the operating and maintenance instructions for spring–loaded single–disk brakes, if required.
Page 28 of 31 N–R 435 en 09.03

EC Declaration of Conformity
12. EC Declaration of Conformity
N–R 435 en 09.03 Page 29 of 31

Appendix 1
Grease life and grease quantities

for antifriction bearings of three–phase motors with squirrel cage for low voltage and permanent lubrication.
Grease life for permanent lubrication 1) Grease

operation hours at rated speed 1/min: quantities in g
per bearing for
Frame size Horizontal mounting (IM B) permanent
3600 3000 1800 1500 1200 v 1000 lubrication
63 4
71 5
33000
80 9
33000
90 11
100 15
112 24000 33000 25
33000
132 33000 33000 50
160 70
24000
180 80
200 17000 60
225 70
250 17000 90
24000
280 12000 24000 120
Vertical mounting (IM V)

3600 3000 1800 1500 1200 v 1000
63 4
33000
71 5
24000
80 33000 9
33000
90 24000 11
33000
100 15
17000 33000
112 25
132 17000 50
160 24000 70
180 12000 24000 80
200 60
12000
225 24000 70
250 17000 24000 90
9000 17000
280 9000 120
The indicated grease life is applicable for an ambient temperature of max. 40 °C (104 °F).
For a temperature rise of 10 °C (50 °F) each the grease life is to be reduced by factor 0.7 of the chart value
(max. 20 °C/68 °F = factor 0.5).
At an ambient temperature of 25 5C (77 5F) the double grease life can be expected, however, 33000
operating hours at a maximum.
1) Independently of the operation hours the antifriction bearing grease resp. the bearing (2Z bearings) have to
be replaced after 3–4 years at the latest.
Page 30 of 31 N–R 435 en 09.03

Appendix 2
Servicebericht / Service report Seite /

Page
Überprüfung der Ausrichtung / ...
Alignment check
Servicenr. / Service No.: Bestellnr. / Order No.:
Typ / Type: Seriennr./ Serial No.:
Kupplungstyp / Coupling type: Durchmesser / Diameter:
Empfohlene Ausrichtgenauigkeit / Recommended accuracy for alignment*

Drehzahl / Speed Parallelversatz / Parallel offset Winkelversatz / Angular offset
(rpm) (1/100 mm) 1/100 mm pro / 1/100 mm each
750 9 9
1500 6 5
3000 3 2.5
Gemessene Werte an der Kupplung / Measured values at the coupling

Parallelversatz / Offset Winkelversatz / Angular offset
Messung /
Measure-
ment
Bemerkungen / Comments
* Falls keine Werte vom Kupplungshersteller vorgeschrieben sind / If no values were specified by the coupling manufacturer
N–R 435 en 09.03 Page 31 of 31

Satz MediCom – Druck LOHER 09.03 Printed in Germany
LOHER GmbH
P.O. Box 1164 • 94095 RUHSTORF
Hans–Loher–Str. 32 • 94099 RUHSTORF
GERMANY
Phone +49 8531 39–0 • Fax +49 8531 32895
E–Mail: info@loher.de
http://www.loher.de
Rotational Speed
Monitor MS24-112-R
9 10 11 12 13 14 15 16
1-channel
+ + AU
Power Pwr
MS24-112-R
Pulse indication
Switching status
Limit value factor Test Factor min-1 AU [s]
10 18 15 20
Test button 1 100
12 10
25
24
6 5 30
Limit value 1,5 30 0,1
Start-up time delay Power Over
1 2 3 4 5 6 7 8
2
2
• 1-channel rotational speed monitor

Example for signal
• Overspeed or underspeed detection evaluation from the 16 8
hazardous area
15 7
14 6
• For use with sensors conforming Hazardous
area 13 5
to EN 60947-5-6 (NAMUR),
4 12 4
3-wire pnp sensors and signal 8
3 11 3
sources with pulse levels from BU
2 +7 10 + (+) 2
10...30 VDC BN A (NC) 5
1+ 9 (-) 1
NAMUR
MK13-P-Ex0 MS2...
• Relay output with one SPDT contact
• Monitoring ranges from

1.5...3000 min-1 (3 ranges) The device features three overlapping button is pressed, the output relay remains
measuring ranges and can be easily energised.
• Optional start-up time delay adapted to the application. A 3-position
switch serves to adjust the required The unit operates on the digital pulse
• Sealed relay with hard gold measuring range. Then the switch point principle. This method provides a fast
plated contacts is adjusted by means of the front panel response and is ideal for applications with
potentiometer. relatively low speed.
• Universal supply voltage
(20...250 VUC) The test button enables adjustment of the For underspeed monitoring, a built-in start-
switch point during installation without up time delay (AU) is available. During the
disabling the output relay. When the test start-up time delay, the output relay will be
+15 V
15
The rotational speed monitor MS24-112-R 8
AU +15 V Overspeed
may be connected to 3-wire pnp sensors, 16
7
min-1
sensors according to EN 60947-5-6 14
Test
1
Factor
10
100
12
18
24
10
AU [s]
15 20
25
6 5 30 6
II I
(NAMUR) or voltage sources with a signal 1,5 30 0,1
13 13
5
level between 10 and 30 VDC. pnp
£ 250 VAC/
120 VDC
BN 12 + £2A
4 £ 500 VA/60 W
BU
Linking terminals 7/8 selects the 11 BK 11
3
Pwr
overspeed monitoring mode. If the preset NAMUR
BN 10 +
µP
2
limit value is exceeded, the relay is de- BU GN
Power
9 ()
energised. Leaving terminals 7/8 open 1
activates the underspeed monitoring

mode. If the speed is below the preset limit
value, the relay is de-energised.
Hans Turck GmbH & Co.KG • D–45466 Mülheim/Ruhr • Tel. 0208/4952-0 • Fax 0208/4952-264 • E-Mail: turckmh@mail.turck-globe.de • www.turck.com 2 – 27 /0304
Rotational Speed Monitor MS24-112-R
energised to prevent that the system is Type MS24-112-R

brought to a stop when the input rate is Ident-no. 0518003
less than the preset limit value. The start-
up time delay is triggered under two Supply voltage U B 20...250 VUC
conditions: upon connection of a potential- Line frequency (AC) 40...70 Hz
free contact between terminals 15 and 16 Power consumption ≤3W
while the device is powered; or by linking Galvanic isolation between input circuit, output circuit and supply
terminals 15 and 16 first and then applying voltage for 250 Vrms, test voltage 2.5 kVrms
power to the device.
Rotational speed monitoring overspeed/underspeed
The switching state of the output relay is Speed range 1.5...3000 min-1 (3 ranges)
indicated by the yellow LED; the device – Range 1 1.5...30 min-1
operation is indicated by a green LED. If an – Range 2 15...300 min-1
input pulse is present, the respective – Range 3 150...3000 min-1
yellow LED lights. Input frequency ≤ 60 000 min-1
Pause duration ≥ 0.2 ms
Pulse duration ≥ 0.2 ms
Hysteresis approx. 10 %
Start-up time delay 0.1…30 s (front panel potentiometer)
Repeat accuracy ≤ 0.1 %
Temperature drift ≤ 0.005 %/K
75 Clearences and creepage distances

– Input circuit to output circuit ≥ 4 mm
– Input circuit to power supply ≥ 4 mm
110
50 Input circuits NAMUR or (3-wire, pnp)
NAMUR input according to EN 60947-5-6, terminals 9/10
– Operating characteristics U0 = 8.2 V; Ik = 8.2 mA
– Switching threshold 1.4 mA ≤ Ie ≤ 1.8 mA
3-wire input pnp, terminals 11…13
– Operating characteristics U ≤ 15 VDC; I ≤ 30 mA
– "ON" signal 0…5 VDC
– "OFF" signal 10...30 VDC
Output circuits
Relay output 1 relay output
– Number of contacts 1 SPDT contact, silver-alloy + 3 µm Au
– Switching voltage ≤ 250 V
– Switching current ≤2A
– Switching capacity ≤ 500 VA/60 W
LED indications
– Power green
– Switching status yellow
– Pulse indication yellow
Housing 50 mm wide, Polycarbonate/ABS

Mounting panel mounting or snap-on clamps
for top-hat rail (DIN 50022)
Connection 2 x 8 self-lifting pressure plates
Connection profile ≤ 2 x 2.5 mm2 or 2 x 1.5 mm2
with wire sleeves
Degree of protection (IEC 60529/EN 60529) IP20
Operating temperature -25…+60 °C
2 – 28 /0304 Hans Turck GmbH & Co.KG • D–45466 Mülheim/Ruhr • Tel. 0208/4952-0 • Fax 0208/4952-264 • E-Mail: turckmh@mail.turck-globe.de • www.turck.com
Technical Documents 902001861-003 C
Edition 03/04
SONTH O FEN Central Lubrication Grease
Page 1-5
Lubrication Pump PMF/GMF
Bk
Edition 03/04
Page 2-5
1. Design and Functional Characteristics

The motor driven grease lubrication pump, type GMF-B/../…/M/0/4/0/0/0/0/0/6/K/D. Installed at the
mixer continuously supplies grease through the lubrication pipes to the four shaft seals of the mixer.
Each pump outlet is provided with a pressure reducing valve (10) and a pipe filling nipple (11).
The pump motor drives the vertical pump shaft via a worm gear (7; 8).
A thrust ring (6) where the pump elements (9) are hinged to is rotating eccentrically with this pump
shaft. Due to the eccentricity of the thrust ring (6) each feed piston makes a forcibly actuated, constant
pressure and intake stroke with each revolution of the pump shaft.
An agitator blade (3) is connected to the pump shaft pressing the lubricating grease into the pump
housing – where the pump elements are – and simultaneously reducing the air bubbles.
The grease level control in the vessel (1) is effected through a secondary piston (4) by means of a le-
vel switch (5).
The pump is not provided with a filling nipple, therefore the grease must be filled into the vessel from
the top.
1 vessel
2 housing
3 agitator blade
4 secondary piston
5 level switch
6 thrust ring
7 worm gear
8 worm
9 pump element
10 pressure reducing valve
11 pipe filling nipple
12 hoses or pipes
2. Assembly and Electric Connection

The grease lubrication pump must be placed such that the pump elements are well accessible and re-
placeable. Before connecting the lubrication pipes to the pump outlets, they must be blown through by
air in order to remove impurities in the pipes. The electric control of the pump motor (P = 0.18 kW) is
made in parallel to the mixer drive motor, i.e. mixer and pump are switched on and off simultaneously.
Sense of rotation of pump motor to the left or to the right. For the control of the grease level in the vessel
the level switch (5) must be electrically connected such that a light or horn signal will be released when
the lower piston position (mininium grease level) is reached.
Bk
Edition 03/04
Page 3-5
Bk
Edition 03/04
Page 4-5
3. Commissioning and Operation

Prior to first starting the pump must be filled with appr. 1.5 1 of mineral gear oil (ISO-VG 150 to 460) up
to the agitator blade (3); subsequently the vessel is to be filled up with lubricating grease.
NOTE: Use only clean lubricating greases saponified an a lithium base with EP additives (to prevent
bleeding) of consistency group 2 (refer to operating instructions of mixer, subassembly: maintenance
and inspection, or technical documentation.
Then let the pump run until the lubricating grease comes out of the pump outlets without any air bubbles.
This may take less or more than one hour. For this purpose, the hose pipes (12) behind the pipe filling
nipples (11) must be detached. lf no grease is supplied at one outlet, then check if the tappet of the
pump element (9) is hinged in the thrust ring (6). Correct installation of the pump element according to
the illustration opposite: with supply piston inclined to the top and pulled out to appr. 2/3 of its length. In
order to maintain the position of the piston during suspension, it will be advantageous to pull the piston
out of the cylinder, fill the cylinder with grease and push in the piston to appr. 1/3 of its
length.
Attention: Piston and cylinder must not be exchanged; they are honed to each other.
bd00023
lf grease comes out at all pump outlets, then all hoses,(12).are to be connected. After retightening of the
hose pipes grease must be manually pressed into all pipe filling nipples (11) until it comes out again in-
side of the mixing trough between dust cover and wearing ring.
3.1 Regreasing intervals
NOTE!
Each time after cleaning the interior of the mixing trough the inner chambers of
the axial face seals must be regreased through the pipe filling nipples (11) while
bd00023 the mixer is in operation until fresh grease comes out inside of the mixing
trough.
3.2 Refilling of vessel
Please observe instructions given under section 4!
It is important to refill the vessel (1) with grease immediately when an empty
signal is indicated, i.e. minimum grease level. lf this is neglected, however, the
bd00023
grease supply will fail within a very short period of time causing the destruction
of the shaft seals at the mixer.
Attention:
Fill in 1.5 l of gear oil first, and then fill up the vessel with grease.
During refilling ensure that no dirt particles or other foreign material can enter
the vessel.
bd00023
Bk
Edition 03/04
Page 5-5
4. Maintenance
Please observe the following instructions before carrying out any repair or refilling work.
bd00023
• Switch off drive motor and secure against inadvertent restarting.

Hazard of getting injured by agitator blades !
• Depressurize pump and system by disconnecting the pressure connections.

Hazard of lubricant being ejected under high pressure.
• Repair work must be carried out by qualified staff only using original spare parts.
• Provided that only lubricant is supplied the pump will need no special care. The internal
drive components and pump elements are located in midst the lubricant to be supplied
and are therefore lubricated automatically.
• Depending on the operating time and working pressure they are subject to natural wear
and must be replaced.
5. Attachments
BHS Doc. No. Description

902001919 Pressure Control Valve
902001920 Spare parts list
Bk
900026000 D
Pos Stck Material Materialkurztext 1 Abm./Typ Werkstoff Vorschrift Gewicht
1,00 1 900382800 notice HINWEIS ERSATZTEILLISTE MASCHINEN MASCHINEN/ANLA 0,0
2,00 1 902003860 trough wearing parts TROGVERSCHLEISSTEILE DKX 3,00 0,0
3,00 1 902001692 discharge door ENTLEERSCHIEBER DK 3,00 0,0
4,00 1 902001106 discharge door operation ENTLEERSCHIEBERBETAETIG. DKX 3,00 0,0
5,00 1 902001694 mixing shaft with bearing MISCHWELLE M.LAGERUNG DK 3,00 0,0
6,00 1 902004539 mixing mechanism MISCHWERK DK 3,00 0,0
7,00 1 902005905 mixer drive ANTRIEB Z.MISCHER DK 3,00 0,0
8,00 1 900516900 lubrication pipe SCHMIERLEITUNG ZENTR.SCHM. DKX 1,85-3,00 0,0
9,00 1 902003399 central lubrication ZENTRALSCHMIERUNG FETT WOERNER 0,0
ENDE DE R ERSATZTE ILSTÜCKLISTE!
DK 3,00 SPARE PARTS LIST

SPARE PARTS LIST
902005906 ERSATZTEILLISTE
Druck: 21.07.2005 11 : 14
Seite 1
Condition for continuous function and readiness for use of the machine/plant is that the most important spare and wearing
parts are kept on stock.
Our guarantee covers only original spare parts, which have been supplied by us.
With your spare parts order please indicate the following:
see:
Werk no. spare parts list, nameplate, client’s
documentation cover sheet
Year of construction nameplate, client’s documentation
cover sheet
No. of spare parts item part no. required denomination

(f. e. 90 XXXXX) quantity
Deviations from the above indication make the treatment of your order difficult and can lead to wrong deliveries.
Dept.: Spare Parts / After-Sales Service BHS-Sonthofen GmbH ++49 83 21 / 80 21 44

++49 83 21 / 80 21 45
Postfach 1164 ++49 83 21 / 80 21 46
D-87515 Sonthofen
Hans-Böckler-Str. 7 FAX ++49 83 21 / 80 21 20
D-87527 Sonthofen
Notices for List of Spare Parts

900382800-00E D SONT H O FEN
Stand Datum Name Bemerkung
1,00 2 200001622 fixing angle BEFESTIGUNGSWINKEL 19,6
2,00 8 100224800 front tile STIRNWANDKACHEL AUSSEN 32,6
3,00 4 100224900 front tile STIRNWANDKACHEL LINKS 27,0
4,00 4 100225000 front tile STIRNWANDKACHEL RECHTS 27,0
5,00 4 100225100 front tile STIRNWANDKACHEL MITTE 13,0
7,00 16 100455700 trough tile external WANNENKACHEL AUSSEN 9,8
8,00 48 100455600 trough tile internal WANNENKACHEL INNEN 9,8
9,00 16 100595000 trough sheet upper part WANNENBLECH OBEN 17,4
11,00 6 200001354 discharge door ledge SCHIEBERLEISTE 6,9
12,00 4 200001238 discharge door cover SCHIEBERABDECKUNG 19,8
14,00 152 100240700 countersunk screw SENKSCHRAUBE 0,1
15,00 16 500136300 hexagon bolt 6KT-SCHRAUBE M16X 45 8.8, VERZ. DIN 933 0,1
16,00 20 101148800 countersunk screw SENKSCHRAUBE KOMPL. 0,2
17,00 188 503041600 hexagon nut 6KT-MUTTER M16 8, VERZ. DIN 934 0,0
18,00 188 503351600 disk SCHEIBE 17 ST VZ.-140 DIN 125 0,0
19,00 36 503361600 spring ring FEDERRING A 16-VSK FST/DACROM DIN 128* 0,0
20,00 4 100067600 front sheet left STIRNWANDBLECH LI 63,3
21,00 4 100067700 front sheet right STIRNWANDBLECH RE 63,3
22,00 2 100067800 front sheet centre STIRNWANDBLECH MITTELST 27,6
DKX 3,00 TROUGH WEARING PARTS

SPARE PARTS LIST
902003860 TROGVERSCHLEISSTEILE
Druck: 21.07.2005 11 : 15
Seite 1
1,00 1 101079600 discharge door cylinder SCHIEBERWALZE 468,0
2,00 8 101079700 roller protection WALZENSCHUTZ 13,0
3,00 1 100543400 discharge door bolt SCHIEBERBOLZEN 18,0
4,00 1 100543300 discharge door bolt SCHIEBERBOLZEN 18,0
5,00 2 100859800 spacer block DISTANZSTUECK 6,5
6,00 2 910004900 pedestal bearing STEHLAGER 7,8
7,00 2 506117000 gib key NASENKEIL 25X14X110 C45K DIN 6887 0,4
8,00 4 500032400 hexagon bolt 6KT-SCHRAUBE M20X130 8.8, VERZ. DIN 931 0,4
12,00 16 100578200 countersunk screw SENKSCHRAUBE 0,1
13,00 16 503001600 hexagon nut 6KT-MUTTER M16 8 DIN 934 0,0
14,00 16 503321600 spring ring FEDERRING A 16-VSK FST DIN 128 * 0,0
15,00 4 503441900 disk SCHEIBE 21 ST-VZ DIN 7349 0,1
DK 3,00 DISCHARGE DOOR

SPARE PARTS LIST
902001692 ENTLEERSCHIEBER
Druck: 21.07.2005 11 : 15
Seite 1
1,00 2 100988300 lever HEBEL 11,0
2,00 4 100988800 thrust bearing console GEGENLAGERKONSOLE 5,0
3,00 2 100216400 fixing angle BEFESTIGUNGSWINKEL 4,0
4,00 1 100435300 fixing HALTERUNG 0,8
5,00 1 100436400 fixing HALTERUNG 0,8
6,00 1 100370300 contact lever KONTAKTHEBEL RECHTS 0,2
7,00 1 100370200 contact lever KONTAKTHEBEL LINKS 0,2
8,00 4 504310200 pneumatic cylinder PNEUMATIKZYLINDER 20,3
9,00 4 504311800 fork joint GABELGELENK 2,0
10,00 4 504313800 suspension fixture AUFHAENGEBEFESTIGUNG 5,9
11,00 8 504321400 reducing screw fitting REDUZIERVERSCHRAUBUNG 0,1
12,00 4 504326300 screw fitting VERSCHRAUBUNG >STECK< 0,1
14,00 2 504325000 connection element VERBINDUNGSELEMENT 0,0
15,00 2 504324200 connecting piece VERBINDUNGSSTUECK 0,0
17,00 8 503512900 sealing ring DICHTRING A 27X32 AL DIN 7603 0,0
18,00 2 541501500 hose SCHLAUCH 12/8,0 (AD/ID) 2 500,000 POLYURETHAN
19,00 4 504337400 bolt BOLZEN M. 2 SPLINTLOCH 0,8
21,00 8 505406800 split-pin SPLINT 6,3X 40 ST VZ DIN 94 0,0
22,00 2 506114900 gib key NASENKEIL 18X11X 80 C45K DIN 6887 0,2
27,00 2 504316900 solenoid valve MAGNETVENTIL 5/3 WEG.ISO2 0,7
28,00 2 504316600 base plate GRUNDPLATTE F. 5/3-WEGEV. 0,3
29,00 4 504339200 wall outlet/plug LEITUNGSDOSE/STECKER 0,0
DKX 3,00 DISCHARGE DOOR OPERATION

SPARE PARTS LIST
902001106 ENTLEERSCHIEBERBETAETIG.
Druck: 21.07.2005 11 : 15
Seite 1
30,00 4 504316000 silencer GERAEUSCHDAEMPFER 10 BAR 0,1
32,00 2 100411100 screwed hose nozzle EINSCHRAUB-SCHLAUCHTUELLE 0,1
34,00 4 500173100 hexagon bolt 6KT-SCHRAUBE M 5X 25 8.8, VERZ. DIN 933 0,0
36,00 4 503422500 disk SCHEIBE 5,3 ST, VERZ. DIN 9021 0,0
37,00 4 919900400 proximity switch NAEHERUNGSSCHALTER IND. 0,0
38,00 4 503335500 tooth lock washer SCHNORR-SICHERUNG 5 FST VZ - 0,0
39,00 1 504338400 spare parts package ERSATZTEILPAKET 1,2
DKX 3,00 DISCHARGE DOOR OPERATION

SPARE PARTS LIST
902001106 ENTLEERSCHIEBERBETAETIG.
Druck: 21.07.2005 11 : 15
Seite 2
1,00 2 200002027 mixing shaft MISCHWELLE 400,0
2,00 2 100989500 shaft bush WELLENBUCHSE 8,0
3,00 4 100709700 retaining ring AUFNAHMERING 9,0
4,00 8 100260400 dust cover STAUBDECKEL 1,6
5,00 2 100991700 distance sleeve DISTANZBUCHSE 4,2
6,00 2 100003800 bearing cover LAGERDECKEL 4,3
7,00 2 100003900 bearing box LAGERKOERPER 24,0
8,00 2 504306600 laminum adjusting ring LAMINUM-PASSRING 0,1
9,00 4 504302000 axial face seal GLEITRINGDICHTUNG 1,2
10,00 6 507079100 shaft sealing ring WELLENDICHTRING C150X180X15 0,2
11,00 4 101059500 sealing ring DICHTUNGSRING 0,0
12,00 2 506768000 self-aligning roller brg. PENDELROLLENLAGER 23026 5,6
13,00 8 100260300 wearing ring SCHLEISSRING 2,5
14,00 2 100004000 shaft bush WELLENBUCHSE 9,0
15,00 2 100004300 end disk SCHLUSSCHEIBE 2,0
16,00 2 100004600 bearing cover LAGERDECKEL 7,0
17,00 2 100004400 bearing box LAGERKOERPER 24,0
19,00 4 507085000 shaft sealing ring WELLENDICHTRING C140X180X15 0,0
20,00 2 506770000 self-aligning roller brg. PENDELROLLENLAGER 23124 7,7
27,00 24 500505600 cheese head screw ZYLINDERSCHRAUBE M10X 20 8.8 DIN 912 0,0
DK 3,00 MIXING SHAFT WITH BEARING

SPARE PARTS LIST
902001694 MISCHWELLE M.LAGERUNG
Druck: 21.07.2005 11 : 15
Seite 1
31,00 16 500223000 hex.bolt full dog point 6KT-SCHRAUBE MIT ZAPFEN BM12X 60 8.8 VZ DIN 561 0,1
33,00 2 500122600 hexagon bolt 6KT-SCHRAUBE M24X 65 8.8 DIN 933 0,3
34,00 2 503346400 lock washer SICHERUNGSSCHEIBE M 24 ST VZ DIN 25201 0,0
35,00 2 100965100 feather key PASSFEDER 1,0
36,00 4 506008800 feather key PASSFEDER A10X 8X 50 C45K DIN 6885 0,0
DK 3,00 MIXING SHAFT WITH BEARING

SPARE PARTS LIST
902001694 MISCHWELLE M.LAGERUNG
Druck: 21.07.2005 11 : 15
Seite 2
1,00 2 200002954 lateral arm SEITENARM RECHTS KPL 66,0
2,00 1 902003286 components EINZELTEILE SEITENARM RE DK 2,25 0,0
3,00 2 200002932 lateral arm SEITENARM LINKS KPL 57,5
4,00 1 902003287 components EINZELTEILE SEITENARM LI DK 2,25 0,0
5,00 2 200002945 lateral arm SEITENARM LINKS KPL 55,8
6,00 1 902003288 components EINZELTEILE SEITENARM LI DK 2,25 0,0
7,00 12 200002720 central arm MITTELARM KPL 55,2
8,00 1 902003289 components EINZELTEILE MITTELARM DK 2,25 0,0
9,00 18 100005500 counterpart GEGENSTUECK 16,0
10,00 72 500014500 hexagon bolt 6KT-SCHRAUBE M24X110 8.8 DIN 931 0,5
11,00 72 503435700 spherical disk KUGELSCHEIBE C 25 ST DIN 6319 0,0
12,00 72 503002400 hexagon nut 6KT-MUTTER M24 8 DIN 934 0,1
13,00 28 200003702 filling-up piece FUELLSTUECK 55 BREIT 5,6
14,00 4 200003703 filling-up piece FUELLSTUECK 65 BREIT 6,2
15,00 16 500532300 cheese head screw ZYLINDERSCHRAUBE M 8X 35 A4-70 DIN 912 0,0
16,00 16 500532711 cheese head screw ZYLINDERSCHRAUBE M. VOLLGEWINDE M 8X 60 A4-70 DIN 912 0,0
DK 3,00 MIXING MECHANISM

SPARE PARTS LIST
902004539 MISCHWERK
Druck: 21.07.2005 11 : 15
Seite 1
1,00 1 200002948 lateral arm SEITENARM RECHTS 39,7
2,00 1 101104900 lateral blade SEITENSCHAUFEL RECHTS 13,6
3,00 1 101105200 lateral plate SEITENPLATTE RECHTS 9,2
4,00 4 101021900 mixing blade screw MISCHSCHAUFELSCHRAUBE 0,4
5,00 2 101119200 shim UNTERLAGE 0,3
6,00 1 100313100 arm protection right ARMSCHUTZ RECHTS 1,0
DK 2,25 COMPONENTS
SPARE PARTS LIST
902003286 EINZELTEILE SEITENARM RE
Druck: 21.07.2005 11 : 15
Seite 1
1,00 1 200002931 lateral arm SEITENARM LINKS 34,9
2,00 1 101102500 lateral blade SEITENSCHAUFEL LINKS 10,7
3,00 1 101104600 lateral plate SEITENPLATTE LINKS 7,4
5,00 2 101119200 shim UNTERLAGE 0,3
8,00 1 100260600 arm protection left ARMSCHUTZ LINKS 2,0
DK 2,25 COMPONENTS
SPARE PARTS LIST
902003287 EINZELTEILE SEITENARM LI
Druck: 21.07.2005 11 : 15
Seite 1
1,00 1 200002931 lateral arm SEITENARM LINKS 34,9
2,00 1 101102500 lateral blade SEITENSCHAUFEL LINKS 10,7
3,00 1 101104600 lateral plate SEITENPLATTE LINKS 7,4
5,00 2 101119500 wear protection VERSCHLEISSCHUTZ 0,5
DK 2,25 COMPONENTS
SPARE PARTS LIST
902003288 EINZELTEILE SEITENARM LI
Druck: 21.07.2005 11 : 15
Seite 1
1,00 1 200002719 central arm MITTELARM 40,8
2,00 1 200003739 central blade MITTELSCHAUFEL 13,0
4,00 1 101118100 wear protection VERSCHLEISSCHUTZ 0,5
DK 2,25 COMPONENTS
SPARE PARTS LIST
902003289 EINZELTEILE MITTELARM
Druck: 21.07.2005 11 : 15
Seite 1
1,00 1 910416700 cavex gearbox CAVEX-GETRIEBE I=37,00 965,0
2,00 1 910416800 cavex gearbox CAVEX-GETRIEBE I=37,00 965,0
3,00 1 100609400 coupling KUPPLUNG MCF 28,0
4,00 2 200000641 coupling hub KUPPLUNGSNABE 11,0
5,00 10 910304800 rubber element KREUZSTOLLEN 0,3
6,00 40 500175200 hexagon bolt 6KT-SCHRAUBE M 6X 30 8.8, VERZ. DIN 933 0,0
7,00 1 100611300 torque support right DREHMOMENTSTUETZE RE 151,0
8,00 1 100611400 torque support left DREHMOMENTSTUETZE LI 151,0
9,00 2 100612800 bearing block ABSTUETZBOCK 3,1
10,00 1 100303100 trestle BOCK 4,2
11,00 2 100296000 turnbuckle SPANNSCHLOSS 0,9
12,00 4 100484000 bolt BOLZEN M.KOPF 0,5
13,00 2 100613000 end disk SCHLUSSCHEIBE 1,0
14,00 1 919900500 overspeed governor DREHZAHLWAECHTER 0,0
15,00 1 919900000 three-phase motor DREHSTROMMOTOR NR. 1 0,0
16,00 1 919901600 three-phase motor DREHSTROMMOTOR NR. 2 0,0
17,00 2 910412500 fludex coupling FLUDEX-KUPPLG. BOHRG.65H7 91,0
18,00 2 505763500 v-belt pulley tl KEILRIEMENSCHEIBE TL SPB 450X6 38,0
19,00 2 505796000 tensioning bush tl SPANNBUCHSE TAPER-LOCK NR. 4040 7,3
20,00 12 910339400 v-belt KEILRIEMEN DIN 7753 0,0
21,00 120,0 509507300 lubricating oil SCHMIEROEL SYNTHETISCH VG460 ISO-VG460 - 1,0
22,00 18,0 509502600 hydraulic oil HYDRAULIKOEL VG22 ISO-VG22 - 0,9
23,00 1 919901500 proximity switch NAEHERUNGSSCHALTER IND. 0,0
24,00 1 561100100 terminal box KLEMMENKASTEN 102 006 2000 ALU
25,00 2 910160200 joint head GELENKKOPF RE 1,1
26,00 2 910160300 joint head GELENKKOPF LI 1,1
27,00 2 910161800 hexagon nut 6KT-MUTTER 9 SMN 28 DIN 936 0,2
28,00 2 910161900 hexagon nut 6KT-MUTTER 9 SMN 28 DIN 936 0,2
29,00 2 910121500 fusible plug SCHMELZSICHERUNGSSCHRAUBE 140 GRAD 0,0
DK 3,00 MIXER DRIVE

SPARE PARTS LIST
902005905 ANTRIEB Z.MISCHER
Druck: 21.07.2005 11 : 15
Seite 1
32,00 6 500343400 dowel screw PASSCHRAUBE M24X 55 8.8-A DIN 609 0,3
39,00 2 503346400 lock washer SICHERUNGSSCHEIBE M 24 ST VZ DIN 25201 0,0
40,00 6 503322400 spring ring FEDERRING A 27-VSK FST DIN 128 * 0,0
45,00 16 503424000 disk SCHEIBE 22 ST, VERZ. DIN 9021 0,1
49,00 2 501645900 threaded pin GEWINDESTIFT M10X25 45H DIN 914 0,0
50,00 1 920001545 measuring instrument MESSGERAET KEILRIEMENSPANNUNG OPTIBELT 0,0
51,00 1 910669400 measuring instrument MESSGERAET KEILRIEMEN-SPANN.PRUEFER 0,0
DK 3,00 MIXER DRIVE

SPARE PARTS LIST
902005905 ANTRIEB Z.MISCHER
Druck: 21.07.2005 11 : 15
Seite 2
1,00 1 508502500 angle WINKEL A4.SYMB.A 1/8 W 400-05ZN EN 10242 0,0
4,00 20 910451000 straight screwed socket GERADER EINSCHRAUBSTUTZEN ST,VZ ERMETO 0,0
5,00 2 910692400 straight screwed union GER.EINSCHR.VERSCHRAUBUNG ST,VZ ERMETO 0,0
6,00 10 507636500 conical lubr. head KEGELSCHMIERNIPPEL AR1/4 5.8 DIN 71412 0,0
7,00 2 507514300 elbow-type screw fitting WINKELEINSCHR.VERSCHRBG. GL 8 ST/A3C DIN 2353 0,0
8,00 2 508161400 taper nipple ROHRDOPPELNIPPEL R 1/4 X 80 ST33 DIN 2982 0,1
9,00 2 508500200 angle WINKEL A1.SYMB.A 1/4 W 400-05ZN EN 10242 0,0
10,00 2 910691800 hose pipe SCHLAUCHLEITUNG 1SN-DN 6 0,3
DKX LUBRICATION PIPE

SPARE PARTS LIST
900516900 SCHMIERLEITUNG ZENTR.SCHM.
Druck: 21.07.2005 11 : 15
Seite 1
1,00 1 910230300 grease pump FETTSCHMIERPUMPE 18,0
2,00 4 910230500 pressure control valve DRUCKBEGRENZUNGSVENTIL 150 BAR 0,2
3,00 4 507550300 t-screw fitting T-VERSCHRAUBUNG QL 8 ST/A3C DIN 2353 0,1
4,00 4 508156200 sleeve MUFFE RP 1/4 ST DIN 2986 0,0
5,00 8 910451000 straight screwed socket GERADER EINSCHRAUBSTUTZEN ST,VZ ERMETO 0,0
6,00 7 507544300 angular screw joint WINKELVERSCHRAUBUNG KL 8 ST/A3C DIN 2353 0,1
7,00 4 508161200 taper nipple ROHRDOPPELNIPPEL R 1/4 X 60 ST33 DIN 2982 0,0
8,00 4 500503500 cheese head screw ZYLINDERSCHRAUBE M 8X 16 8.8 DIN 912 0,0
9,00 4 910795000 conical lubr. head KEGELSCHMIERNIPPEL ST/VERZ 0,0
DKX CENTRAL LUBRICATION

SPARE PARTS LIST
902003399 ZENTRALSCHMIERUNG FETT
Druck: 21.07.2005 11 : 15
Seite 1

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Project No.

1. Operating Instructions .................................... 902001099

3. Spare Parts List ............................................... 902005906

Twin-Shaft Batch Mixer

BHS-Sonthofen GmbH Hans-Böckler-Str. 7 87527 Sonthofen

1. Information for User ........................................ 900359300

3. Delivery and Intermediate Storage ................. 900369400

4. Machine Description ....................................... 900359700

5. Erection and Electric Connection .................. 900359800

6. Starting and Operation.....................................900359900

7. Servicing and Inspection............................ .... 900360100

Twin-Shaft Batch Mixer

Information for User

1. Instruction to Owner and Operators .......................... 2

Machines and Plants

BHS-Sonthofen GmbH Hans-Böckler-Str. 7 D-87527 Sonthofen

1. Instruction to Owner and Operators

personnel for operation, maintenance and repair.

2. Guarantee and Liability

• Operation of the machine/plant with defective safety devices or removed

• Improper intermediate storage, erection, starting, and operation of the

• Professionally improper operation and maintenance of the machine/plant.

• Improper use of the machine/plant.

• Faulty feeding and discharge conditions.

• Unauthorized structural changes on the machine/plant.

• Unauthorized change of the driving conditions (power and speed).

• Poor surveillance of the parts which are subject to wear.

• Cases of disaster through influences of foreign bodies and force majeure.

• Professionally improper repair under your own responsibility.

• Use of spare parts which are not of BHS original.

General Safety Instructions

1. Basic Safety Requirements ........................................ 3

Machines and Plants

BHS-Sonthofen GmbH Hans-Böckler-Str. 7 D-87527 Sonthofen

General Safety Instructions

9.4 High-pressure water, steam, hydraulics ........................... 17

Machines and Plants

BHS-Sonthofen GmbH Hans-Böckler-Str. 7 D-87527 Sonthofen

1. Basic Safety Requirements

of the machine/plant have to,

- read and observe the safety instructions carefully

- use safety equipment

- know and observe the customer documentation

which are described hereafter.

2. Warning Notes and Warning Signs

2.1 Signs in the Operating Instructions

2.2 Signs on Machines and Plants (Examples)

3. Use of the Machine/Plant

3.1 Proper Use

• the group “Machine description”

Any other use, or any use beyond those specifications, is regarded as

3.2 Improper Use

3.3 Dangers and Troubles

4.1 Operating Instructions

know the operating instructions in particular the chapters concerning

During work it will be too late.

This applies especially to personnel working only occasionally at the

4.2 Supplements to the Operating Instructions

4.3 Working in Compliance with Safety Regulations

• warning and instruction signs

4.4 Unauthorized Modifications

5.1 Selection and Qualification

5.2 Responsibility for operation