Appendix 1000 A

APPENDIX A
MANUFACTURER SERVICE AND

MAINTENANCE PROCEDURES
RJ1000VT
60503
REVISION 1.0
BAKERY CONCEPTS INTERNATIONAL, LLC.

P.O. Box 234,
Enola, PA 17025
Phone (717) 732-8168
Fax (717) 732-8169
www.bakeryconcepts.net
© 2016 Bakery Concepts International, LLC - All Rights Reserved - Copy by Permission Only - Copyright Strictly Enforced
© 2016 Bakery Concepts International, LLC
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or
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assumed with respect to the use of the information contained herein. Moreover, because Bakery
Concepts International, LLC strives constantly to improve its high-quality products, the information con-
tained in this manual is subject to change without notice. We have taken every precaution in the prepa-
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O&M MANUAL ~ RAPIDOJET RJ1000VT
TABLE OF CONTENTS
1. PRESSURE PUMP MAINTENANCE�� 1
2. AUGER/AGITATOR MOTOR MAINTENANCE�� 10
2.1 OIL PLUG LOCATIONS �� 10
2.2 MANUFACTURES SERVICE AND MAINTENANCE ��11
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Phone (717) 732-8168
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PAGE iv www.bakeryconcepts.net
1. PRESSURE PUMP MAINTENANCE
D/G-04 Maintenance
NOTE: The numbers in parentheses are the Ref. Nos. on
the illustrations in the Parts Manual. Shutdown Procedure During
Freezing Temperatures
Daily Take all safety precautions to assure safe handling of the
Check the oil level and the condition of the oil. The oil level fluid being pumped. Provide adequate catch basins for fluid
should be 1/4 in. (6 mm) above the cast surface in the upper drainage and use appropriate plumbing from drain ports,
oil reservoir. etc., when flushing the pump and system with a compatible
Use the appropriate Hydra-Oil for the application (contact antifreeze.
Wanner Engineering if in doubt). 1. Adjust the discharge pressure regulating valve so the pump
CAUTION: If you are losing oil but don’t see any external runs under minimum pressure. Stop the pump.
leakage, or if the oil becomes discolored and contaminated, . Drain supply tank; open any draincocks in system piping and
one of the diaphragms (17) may be damaged. Refer to the collect drainage. Drain as much fluid from the pump manifold
Fluid-End Service Section. Do not operate the pump with and plumbing attached directly to the pump manifold by
a damaged diaphragm. loosening fittings or removing plugs or gauges.
3. Close draincocks in system piping and tighten or replace any
CAUTION: Do not leave contaminated oil in the pump
fittings, gauges or plugs.
housing or leave the housing empty. Remove contaminated
oil as soon as discovered, and replace it with clean oil. 4. Fill supply tank with enough antifreeze to fill system piping
and pump.
NOTE: Disconnect the system return line from the supply
Periodically tank and connect it to a separate reservoir.
Change the oil after the first 100 hours of operation, then 5. Start the pump and allow it to run until the system is filled with
change according to the guidelines below. When changing, antifreeze. NOTE: If the system has an air lock and the
remove the drain plug (60) at the bottom of the pump so all oil pump fails to prime, follow step 4 of the Initial Start-up
and accumulated sediment will drain out. Procedure to clear the air.
Hours Between Oil Changes @ Various 6. When mostly antifreeze is flowing from the system return line,
stop the pump. Connect the system return line back to the
Process Fluid Temperatures supply tank and circulate the antifreeze for a short period.
<90°F <139°F <180°F 7. It is also good practice to change the oil in the hydraulic
Pressure RPM (32°C) (60°C) (82°C) end before storage for an extended period. This will remove
<1500 psi (100 bar) <100 6,000 4,000 ,000 any accumulated condensation and sediment from the
<1800 3,000 ,000 1,500 oil reservoir. Drain and refill the hydraulic end with the
<500 psi (170 bar) <100 3,000 ,000 1,500 appropriate Hydra-Oil and operate the pump for a short period
<1800 1,500 — 1,000 to assure smooth performance.
NOTE: Minimum oil viscosity for proper hydraulic end

lubrication is 16-20 cST (80-100 SSU).
NOTE: Use of an oil cooler is recommended when process
fluid and/or hydraulic end oil exceeds 180°F (82°C).
CAUTION: Do not turn the drive shaft while the oil reservoir
is empty.
Check the inlet pressure or vacuum periodically with a gauge.
If vacuum at the pump inlet exceeds 7 in. Hg (180 mm Hg),
check the inlet piping system for blockages. If the pump inlet
is located above the supply tank, check the fluid supply level
and replenish if too low.
CAUTION: Protect the pump from freezing. Refer also to
the “Shutdown Procedure”.

9 D04-991-400A
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www.bakeryconcepts.net PAGE 1
D/G-04 Service (Fluid End)
W0072A
W0070
W0071
Bolt Torque Specifications

Ref. No. D-04 G-04
1 50 ft-lbs 70 Nm
17 10 in-lbs 110 Ncm
10 D04-991-400A
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PAGE 2 www.bakeryconcepts.net

NOTE: The number in parentheses are the Reference
numbers on the illustration at right and in the Parts
2. Inspect Valves (5-11)
Manual. The three inlet and three outlet valve assemblies are identical
(but face in opposite directions). Inspect each valve as
This section explains how to disassemble and inspect all easily
follows:
serviceable parts of the pump. Repair procedures for the
hydraulic end (oil reservoir) of the pump are included in a later a. Check the spring retainer (10), and replace if worn.
section of the manual. b. Check the valve spring (8). If shorter than a new spring,
replace it (do not stretch a used spring).
CAUTION: Do not disassemble the hydraulic end unless
c. Check the valve (7). If worn excessively, replace it.
you are a skilled mechanic. For assistance, contact Wanner
Engineering (TEL 61-33-5681 or FAX 61-33-6937) or the d. Remove the valve seat (6), O-ring (5), and dampening
distributor in your area. washer (11) (See note below). A seat puller is included
in the Wanner Tool Kit. Inspect all parts for wear. In all
CAUTION: The two capscrews (16) that screw through the instances, O-ring (5) should be replaced. Replace the
diaphragm plate in the pump housing hold the diaphragm plate valve seat and/or dampening washer if necessary.
over the hydraulic end of the pump. Do not remove them except
NOTE: On newer pump models, the dampening
when repairing the hydraulic end.
washer (11) is not used because the valve seat (6) is
thicker. When replacing the valve seat on an older
pump model which has dampening washers, do not
Tools and Supplies reinstall the dampening washers as the new valve
seat is thicker than the original.
• Straightedge (at least 6 in. long)
e. Reinstall the valve assemblies:
• Grease or petroleum jelly
• Clean the valve ports and shoulders with emery cloth,
• Torque wrench, rated to at least 50 ft-lbs (70 N-m) and lubricate them with lubricating gel or petroleum
• Emery cloth jelly.
• 1/-in. drive socket wrench • Install the O-ring (5) on the valve seat (6).
• 5/16-in. (8-mm) open-end wrench • Inlet (3 lower valves in the illustration below). Insert
• 5-mm hex Allen wrench the spring retainer (10) into the valve plate, then insert
• 8-mm hex bit socket (1/ inch drive) the spring, valve, Tetra seal, valve seat, and dampening
• Wanner D-04/G-04 Tool Kit, which includes the following: washer (8,7,9,6,11). A flat O-ring (Tetra seal, 9) goes
• Seat puller between the retainer and seat.
• Plunger holder • Outlet (3 upper valves in the illustration below).
Insert the dampening washer, valve seat, Tetra seal,
• Plunger guide lifter
valve, and spring, then the retainer. Install the flat O-ring
• Shaft rotator
(Tetra seal, 9) between the retainer and seat.
Service Procedures
1. Remove Manifold (3) and
Valve Plate (12)
a. Remove all eight capscrews (1) around the manifold.
Use an 8-mm hex Allen wrench.
b. Remove the manifold (3).
c. Inspect the manifold for warping or wear around the
inlet and outlet ports. If wear is excessive, replace the
manifold.
To check if the manifold is warped, place a straightedge
across it. A warped manifold should be replaced.
d. Remove the two socket-head capscrews (14) that hold
W0076
the valve plate to the pump housing. Use a 5-mm hex
Allen wrench.
e. Inspect the valve plate in the same manner as the
manifold, for excessive wear and/or warping. Replace if
necessary.
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3. Inspect and Replace 4. Flush Contaminant from
Diaphragms (17) Hydraulic End
a. Lift a diaphragm by one edge, and turn the pump shaft
until the diaphragm moves up to “top dead center”. This
(only if a diaphragm has ruptured)
will expose machined cross-holes in the plunger shaft a. With the valve plate and manifold still removed (see
behind the diaphragm. above), remove the oil drain cap (60) allow all oil and
b. Insert the plunger holder tool through one of the machined contaminant to drain out.
cross-holes, to hold the diaphragm up. (Don’t remove b. Fill the reservoir with kerosene or solvent, manually turn
the tool until the new diaphragm is installed in step “f” the pump shaft to circulate the kerosene, and drain.
below.) Dispose of this contaminated fluid properly.
c. Unscrew the diaphragm. Use a 5/16-in. (8-mm) open-end c. Repeat the flushing procedure (step “b” above).
wrench, and turn counterclockwise. d. Fill the reservoir with fresh oil, manually turn the pump
d. Inspect the diaphragm carefully. A damaged diaphragm shaft to circulate the oil, and drain again.
generally indicates a pumping system problem and e. Refill the reservoir. If the oil appears milky, there is
replacing only the diaphragm will not solve the larger still contaminant in the reservoir. Repeat the flushing
problem. Inspect the diaphragm for the following: procedure until the oil appears clean.
• Small puncture. Usually caused by a sharp foreign
object in the fluid, or by an ice particle. 5. Prime the Hydraulic Cells
• Diaphragm pulled away from the metal insert. a. With the pump horizontal, fill the reservoir with the
Usually caused by excessive inlet vacuum, or by appropriate Hydra-oil for the application.
overpressurization of the pump inlet.
b. All air in the oil within the hydraulic cell (behind the
• Outer diaphragm bead extruded. Usually caused by diaphragms) must be forced out by turning the shaft
overpressurization of the pump. — and thus pumping the piston. Use a glove when turning
• Diaphragm becoming stiff and losing flexibility. the shaft by hand.
Usually caused by pumping a fluid that is incompatible Turn the shaft until a bubble-free flow of oil comes
with the diaphragm material. from behind all the diaphragms. Watch the oil level in
• Cut diaphragm convolute. Usually caused by the reservoir: if it gets too low during priming, air will be
excessive inlet vacuum. drawn into the piston (inside the hydraulic end). This will
CAUTION: If a diaphragm has ruptured and foreign cause the pump to run rough, and you will have to start
material or water has entered the oil reservoir, do over again with priming the hydraulic cells.
not operate the pump. Check all diaphragms, then c. After the Hydra-Cells are fully primed, ensure that the
flush the reservoir completely (as outlined below) oil level is 1/4 in. (6 mm) above the cast surface in the
and refill it with fresh oil. Never let the pump stand upper oil reservoir.
with foreign material or water in the reservoir, or with d. Wipe excess oil from the diaphragm plate and
the reservoir empty. diaphragms.
e. Clean away any spilled oil.
f. Install a good or new diaphragm and tighten to 10 in.-lbs
(110 N-cm).
g. Repeat the above inspection procedure (and replacement,
if necessary) with the other two diaphragms.
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6. Reinstall Valve Plate (12) and
Manifold (3)
a. Reinstall the valve plate (1), with the valve assemblies
installed as outlined above, onto the diaphragm plate
(18) and alignment pins (9).
Tighten the two socket-head capscrews evenly and
snugly to compress the outer diaphragm beads and hold
the valve plate in place.
b. Reinstall the O-rings (4) on the front side of the valve
plate. Use petroleum jelly or lubricating gel to hold them
in place.
c. Reinstall the manifold onto the valve plate.
d. Insert all capscrews (1), with washers (), around the
edge of the manifold, and alternately tighten opposite
bolts until all are secure. Torque to 50 ft-lbs (70 N-m).
e. Recheck all bolts for tightness and proper torque.
13 D04-991-400A
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D/G-04 Service (Hydraulic End)
W0073A
14 D04-991-400A
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Phone (717) 732-8168
Fax (717) 732-8169

NOTE: The numbers in parentheses are the Ref. Nos. on
the illustrations in the Parts Manual.
2. Reassemble Pistons
a. Tip the pump so the pistons are vertical.
This section explains how to disassemble and inspect the
hydraulic end (oil reservoir) of the pump. b. Drop a ball (1) into the opening in the bottom of the
piston.
CAUTION: Do not disassemble the hydraulic end unless
c. Insert the valve plunger (4) into a valve cylinder ().
you are a skilled mechanic. For assistance, contact Wanner
Slide a spring (5) over the plunger, inside the valve
Engineering (TEL 612-332-5681 or FAX 612-332-6937) or
cylinder.
the distributor in your area.
d. Slide the assembled valve cylinder, plunger, and spring
Depending on the repair you are attempting, you may or may (-5) into the piston (0).
not have to remove the motor from a direct-drive pump/motor e. Insert the washer (6) over the plunger.
unit.
f. Using the snap-ring pliers, insert a snap ring (7) into
Internal piston components (1-7) can be serviced without the piston.
removing the motor or crankshaft. The motor and crankshaft g. Repeat the above procedure for the other two pistons.
must be removed to service the connecting rod (59), piston
housing (0), crankshaft (57), front bearing (68), back bearing
(56), or seal (54).
To Service Remainder of
Hydraulic End
Tools and Supplies
• Tools required for hydraulic end only: 1. Remove Pump Housing
• Snap-ring pliers a. Remove the manifold, valve plate, diaphragm plate,
• Small hook and diaphragms, as outlined in the Fluid-End Service
• 8-mm socket wrench Section.
b. Drain the oil from the pump housing by removing the
drain plug (60).
To Service Pistons Without c. Stand the pump on end, with the drive shaft up.
d. Remove the bolts (50) that secure the back cover (5)
Removing Motor or Crankshaft to the housing (78). Use an 8-mm socket wrench. Save
the O-rings (51).
1. Disassemble Pistons e. Remove the cover and the cover O-ring (53).
f. Remove the crankshaft (57) by pulling it through the
With the manifold, valve plate, diaphragm plate, and connecting rods (59).
diaphragms removed, and the oil drained from the pump
(see the Fluid-End Service Section):
a. Remove the snap ring (7) from one of the pistons, using
a standard snap-ring pliers.
2. Remove and Replace Pistons
b. Pull out the valve plunger (4). This also removes the To remove the pistons (0), first remove the connecting rod
washer (6) and spring (5). (59) and pin (58) by pressing the pin through the connecting
rod.
c. Insert a small hook through the center hole of the valve
cylinder (), and pull the cylinder out of the piston. Be Reverse the process to reinstall the piston.
careful not to damage the piston. Refer to Steps 5 and 6 below to replace the diaphragm and
d. Inspect all parts, and replace the O-ring and any other reassemble the pump.
parts that are worn or may be damaged.
e. Repeat steps “a” through “d” for the remaining pistons.
15 D04-991-400A
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3. Replace Shaft Seal 5. Reinstall Diaphragms
NOTE: Inspect the shaft seal (54) before continuing. If a. Screw the plunger guide lifter (from the Wanner Tool
it looks damaged in any way, replace it. Kit or Repair Kit) into the valve plunger (4). Pull out to
a. Press the back bearing (55) and seal (54) out of the cover expose the cross holes in the plunger. Rotate the shaft
(5). Discard the seal. until the piston is at top dead center.
b. Apply a coating of Loctite High-Performance Pipe b. Insert the plunger holder tool (from the Wanner Tool Kit),
Sealant with PTFE, or a comparable product, to the through the plunger hole — to hold the plunger away from
outer surface of a new seal and the inside surface of the the diaphragm plate (18), and to keep the plunger from
opening in the back cover (5) where the seal will rest. turning when the diaphragm is being installed.
c. Press the new seal into the back cover. c. Engage the diaphragm insert threads to the plunger
d. Inspect the bearing (55). If pitted or damaged, replace threads, and turn the diaphragm by hand until the insert
it. hits the shoulder of the valve plunger (4).
e. Apply a coating of Loctite Rc/609 Retaining Compound or d. Hold the plunger holder tool to secure the valve plunger,
comparable product to the outer surface of the bearing. and torque the diaphragm insert to 10 in.-lbs (110 N-cm)
Press the bearing into the back cover until it rests on the using a 5/16-in. (8-mm) open-end wrench.
shoulder. The shield on the bearing must face away from e. Repeat the above procedure for the plungers and
the back cover. diaphragms of the other two cylinders.
f. Fill the reservoir with fresh oil and prime the pump, as
outlined in the Fluid-End Service Section.
4. Reassemble Housing and
Back Cover 6. Reassemble Pump
a. Stand the pump on end. Reassemble the pump as outlined in the Fluid-End Service
b. With the pistons and connecting rods in place, reinstall Section.
the crankshaft by threading it through the connecting
rods.
c. Reinstall the back cover, cover O-ring, and bolts (with
their O-rings).
16 D04-991-400A
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D/G-04 Troubleshooting
Cavitation Pump Runs Rough
• Inadequate fluid supply because: • Worn pump valves
— Inlet line collapsed or clogged • Air lock in outlet system
— Clogged line strainer • Oil level low
— Inlet line too small or too long • Wrong weight of oil for cold operating temperatures (change
— Air leak in inlet line to lighter weight)
— Worn or damaged inlet hose • Cavitation
— Suction line too long • Air in suction line
— Too many valves and elbows in inlet line • Restriction in inlet/suction line
• Fluid too hot for inlet suction piping system. • Hydraulic cells not primed after changing diaphragm
• Air entrained in fluid piping system. • Foreign material in inlet or outlet valve
• Aeration and turbulence in supply tank. • Damaged diaphragm
• Inlet vacuum too high (refer to the Installation Section, Inlet • Fatigued or broken valve spring
Calculations).
Symptoms of Cavitation
Premature Failure of Diaphragm
• Excessive pump valve noise
• Frozen pump
• Premature failure of spring or retainer
• Puncture by a foreign object
• Volume or pressure drop
• Elastomer incompatible with fluid being pumped
• Rough-running pump
• Pump running too fast
• Premature failure of diaphragms
• Excess pressure
• Cavitation
Drop in Volume or Pressure

A drop in volume or pressure can be caused by one or more
of the following:
Water (or Process Fluid) in Oil
• Air leak in suction piping Reservoir
• Clogged suction line or suction strainer • Condensation
• Suction line inlet above fluid level in tank • Ruptured diaphragm
• Inadequate fluid supply • Hydraulic cell not properly primed af ter diaphragm
• Pump not operating at proper RPM replacement
• Relief valve bypassing fluid • Frozen pump
• Worn pump valve parts
• Foreign material in inlet or outlet valves
• Loss of oil prime in cells because of low oil level Strong Water (or Process Fluid)
•
•
Ruptured diaphragm
Cavitation
Pulsations
NOTE: Small pulsations are normal in single-acting pumps
• Warped manifold from overpressurized system
with multiple pumping chambers.
• O-rings forced out of their grooves from overpressurization
• Air leak in suction line strainer or gasket • Foreign object lodged in pump valve
• Cracked suction hose. • Loss of prime in hydraulic cell because of low oil level
• Empty supply tank • Air in suction line
• Excessive aeration and turbulence in supply tank • Valve spring (8) broken
• Cavitation • Cavitation
• Abrasives in the fluid • Aeration or turbulence in supply tank
• Valve incompatible with corrosives in the fluid
• Worn and slipping drive belt(s)
• Worn spray nozzle(s)
17 D04-991-400A
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D/G-04 Troubleshooting
Valve Wear
• Normal wear from high-speed operation
• Cavitation
• Abrasives in the fluid
• Valve incompatible with corrosives in the fluid
Loss of Oil
• External seepage
• Rupture of diaphragm
• Frozen pump
• Worn shaft seal
• Oil drain piping or fill cap loose.
• Valve plate and manifold bolts loose
• Pump housing porosity
Premature Failure of Valve

Spring or Retainer
• Cavitation
• Foreign object in the pump
• Spring/retainer material incompatible with fluid being
pumped
• Excessive inlet pressure.
18 D04-991-400A
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D/G-04 Warranty
Limited Warranty
Wanner Engineering, Inc. extends to the original purchaser
of equipment manufacturerd by it and bearing its name,
a limited one-year warranty from the date of purchase
against defects in material or workmanship, provided that
the equipment is installed and operated in accordance
with the recommendations and instructions of Wanner
Engineering, Inc. Wanner Engineering, Inc. will repair
or replace, at its option, defective parts without charge
if such parts are returned with transportation charges
prepaid to Wanner Engineering, Inc., 104 Chestnut
Avenue, Minneapolis, Minnesota 55403.
This warranty does not cover:

1. The electric motors (if any), which are covered by
the separate warranties of the manufacturers of these
components.
. Normal wear and/or damage caused by or related to
abrasion, corrosion, abuse, negligence, accident, faulty
installation or tampering in a manner which impairs normal
operation.
3. Transportation costs.
This limited warranty is exclusive, and is in lieu of any
other warranties (express or implied) including warranty
of merchantability or warranty of fitness for a particular
purpose and of any noncontractual liabilities including
product liabilities based on negligence or strict liability.
Every form of liability for direct, special, incidental or
consequential damages or loss is expressly excluded
and denied.
19 D04-991-400A
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Enola, PA 17025
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2. AUGER/AGITATOR MOTOR MAINTENANCE
2.1 OIL PLUG LOCATIONS
M1
H1/B5I
= Vent = Oil Level = Oil Drain
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2.2 MANUFACTURES SERVICE AND MAINTENANCE
5. Service and Maintenance
5. Service and maintenance

5.1 Service and maintenance intervals
Information –
Service and Maintenance Intervals Service and Maintenance Work see Section
At least every six months - Visual inspection 5.2

- Check for running noises 5.2
- Check oil level 5.2
- Re-grease 5.2
(applicable only to free drive shaft / Option W
and on agitator bearings / Option VL2 / VL3)
- Replace automatic lubricator (for operating 5.2
times < 8 h/day: a replacement interval for the
lubricant dispenser of 1 year is permissible)
(only with IEC/NEMA standard motors)
For operating temperatures up to 80°C - Change the oil 5.2
Every 10000 operating hours - Clean or replace the vent plug. 5.2
at least every 2 years
(The interval is double this if the unit is
filled with synthetic products)
For higher temperatures or extreme
operating conditions (high humidity,
aggressive environments and large
temperature fluctuations) the oil change
intervals must be halved.
Every 25000 operating hours, - Replace shaft sealing rings if worn 5.2
at least every 5 years - Re-lubrication of the bearings in the gear unit 5.2
At least every 10 years - General overhaul 5.2
5.2 Service and maintenance work

Servicing and maintenance work must only be performed by qualified specialist
personnel.
Installation and maintenance work must only be performed when gear units are at a
standstill. The drive must be isolated and secured to prevent accidental start-up.
Visual inspection
The gear unit must be checked for leaks. In addition, the gear unit must be inspected for external
damage and cracks in the hoses, hose connections and rubber buffers. Have the gear unit
repaired in case of leaks, e.g. dripping gear oil or cooling water, damage or cracks. Please contact
the NORD service department.
Note!
Shaft sealing rings are rubbing seals and have sealing lips made from an elastomer
material. These sealing lips are lubricated with a special grease at the factory. This
reduces the wear due to their function and ensures a long service life. An oil film in the
region of the rubbing sealing lip is therefore normal and is not due to leakage.
-22- B1000-GB-0713 www.nord.com
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Enola, PA 17025
Phone (717) 732-8168
Fax (717) 732-8169

Check for running noises
If the gear unit produces unusual running noises and/or vibrations, this could indicate damage to
the gear unit In this case the gear should be shut down and a general overhaul carried out.
Check the oil level

Section 6.1 describes the versions and the corresponding oil level screws. With double gear
units, the oil level must be checked on both units. The pressure vent must be at the position
marked in Section 6.1.
The oil level does not need to be checked on gear units without oil level screw (see Section 6.1).
Gear unit types that are not supplied full of oil must be filled before the oil level is checked. (see
“Changing the oil”)
Checking the oil level:

1. The oil level may only be checked when the gear unit is at a standstill and has cooled
down. The gear unit must be secured to prevent accidental switch-on.
2. The oil level screw corresponding to the version must be screwed out. (See Section 6.1)
Note!
At the first oil level check a small amount of oil may escape, as the oil level may be below the
lower edge of the oil level hole.
3. Gear units with oil level screw: The maximum oil level is the lower edge of the oil level hole.
The minimum oil level is 4 mm below the oil level hole. If the oil level is too low, this must be
corrected using the correct type of oil. An oil level glass is available instead of the oil level
screw
4. Gear units with an oil level vessel: The oil level must be checked in the oil level vessel with
the aid of the dipstick plug (thread G1 1/4). The oil level must be between the upper and
lower mark when the dipstick is completely screwed in (see Fig. 5-2). The oil level must be
corrected with the correct type of oil if necessary. These gearboxes may only be operated in
the configuration stated in Section 6.1.
5. The oil level screw or the cap screw with dipstick and all other loosened screws must be
correctly re-tightened.
Figure 5-2: Check the oil level with a dipstick
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Regreasing
Some gear unit designs (free drive shaft, Option W, agitator designs VL2 and VL3) are equipped
with a regreasing device.
For agitator versions VL2 and VL3, the vent screw located opposite to the grease nipple must be
unscrewed before regreasing. Grease should be injected until a quantity of 20-25g escapes from
the vent hole. After this, the vent plug must be reinserted and tightened.
For Option W and some IEC adapters, the outer roller bearing must be regreased with approx.
20-25g of grease via the grease nipple provided
Recommended grease: Petamo GHY 133N (see Section 6.4: Klüber Lubrication).
Replacing the automatic lubricant dispenser

Screw-off the cartridge case cover (2), (see Fig. 4-1). The lubrication dispenser (5) is screwed
out and replaced with a new component (Part No. 283 0100). Then activate (see Chapter 4.2)!
Changing the oil

The figures in Section 6.1 show the oil drain screw, the oil level screw and the pressure vent
screw for various designs.
Sequence:
1. Place the drip tray below the oil drain screw or the oil drain cock
2. Completely remove oil level screw, screwed sealing plug with dipstick if an oil level tank
is being used and oil drain screw.
Danger!
Warning: Hot oil!
3. Drain all the oil from the gear unit.

4. If the screw lock coating of the oil drain screw or oil level screw is damaged in the
thread, a new oil level screw must be used or the thread cleaned and coated with
securing lubricant, e.g. Loctite 242, Loxeal 54-03 prior to inserting. Check the sealing
ring for damage. Replace with a new sealing ring in case of damage.
5. Support the seal ring, insert the oil drain screw into the hole and tighten to the correct
torque! (See Section 6.2 for torque values)
6. Using a suitable filling device, refill with oil of the same type through the oil level hole
until oil emerges from the oil level hole. (The oil can also be filled through the pressure
vent screw or a sealing plug located higher than the oil level). If an oil level vessel is
used, fill the oil through the upper inlet (thread G1¼) until the oil level is set as described
in Section 5.2.
7. Wait at least 15 minutes, or at least 30 minutes if an oil level tank is used, and then
check the oil level. Proceed as described in Section 5.2.
Note!
The oil does not need to be changed on gear units without oil level screw (see Section 6.1).
These gear units are lubricated for life.
Standard helical gear units have no oil level screw. Here, the oil is topped up through the
pressure vent bolt using the quantities listed in the table in Section 6.5.
-24- B1000-GB-0713 www.nord.com
P.O. Box 234,

Enola, PA 17025
Phone (717) 732-8168
Fax (717) 732-8169

Cleaning or replacing the vent plug
Unscrew the vent screw and thoroughly clean it (e.g. with compressed air) and fit the vent screw
in the same place, If necessary, use a new vent screw with a new sealing ring.
Replacing the shaft sealing ring

Shaft sealing rings are rubbing seals made from an elastomer material and according to their
principle are subject to natural wear. The wearing life of shaft sealing rings depends on many
factors and cannot be calculated in advance. Once the shaft sealing ring has reached the end of
its service life, the oil film in the region of the sealing lip increases and a measurable leakage
with dripping oil occurs. The shaft sealing ring must then be replaced. To reduce the risk of
leaks due to worn shaft sealing rings we recommend that as a precaution, the shaft sealing rings
are replaced after every 25,000 operating hours or every 5 years. The space between the
sealing lip and the protective lip must be filled approximately 50% with grease on fitting
(recommended grease: PETAMO GHY 133N). Take care that after fitting, the new shaft sealing
ring does not run in the old wear track.
Re-lubricating bearings
For bearings which are not oil-lubricated and whose holes are completely above the oil level,
replace the roller bearing grease (recommended grease: PETAMO GHY 133N). Please contact
the NORD service department.
General overhaul
The gear units must be completely dismantled The following work must be carried out:
 Clean all gear unit components
 Examine all gear unit components for damage
 All damaged components must be replaced
 All roller bearings must be replaced
 Replace back stops if fitted
 Replace all seals, radial seals and Nilos rings
 Replace plastic and elastomer components of the motor coupling
The general overhaul must be carried out by qualified personnel in a specialist workshop with
appropriate equipment in observance of national regulations and laws. We recommend that the
general overhaul is carried out by the NORD service department.
www.nord.com B1000-GB-0713 -25-
P.O. Box 234,

Enola, PA 17025
Phone (717) 732-8168
Fax (717) 732-8169
P.O. Box 234,
Enola, PA 17025
Phone (717) 732-8168
Fax (717) 732-8169
www.bakeryconcepts.net

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Appendix 1000 A

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APPENDIX A

MANUFACTURER SERVICE AND

BAKERY CONCEPTS INTERNATIONAL, LLC.

2.2 MANUFACTURES SERVICE AND MAINTENANCE ������������������������������������������������������������������������11

BAKERY CONCEPTS INTERNATIONAL, LLC.

P.O. Box 234,

1. PRESSURE PUMP MAINTENANCE

NOTE: Minimum oil viscosity for proper hydraulic end

BAKERY CONCEPTS INTERNATIONAL, LLC.

D/G-04 Service (Fluid End)

Bolt Torque Specifications

BAKERY CONCEPTS INTERNATIONAL, LLC.

P.O. Box 234,

D/G-04 Service (Fluid End)

BAKERY CONCEPTS INTERNATIONAL, LLC.

P.O. Box 234,

D/G-04 Service (Fluid End)

BAKERY CONCEPTS INTERNATIONAL, LLC.

P.O. Box 234,

D/G-04 Service (Fluid End)

BAKERY CONCEPTS INTERNATIONAL, LLC.

P.O. Box 234,

D/G-04 Service (Hydraulic End)

BAKERY CONCEPTS INTERNATIONAL, LLC.

P.O. Box 234,

D/G-04 Service (Hydraulic End)

BAKERY CONCEPTS INTERNATIONAL, LLC.

P.O. Box 234,

D/G-04 Service (Hydraulic End)

BAKERY CONCEPTS INTERNATIONAL, LLC.

P.O. Box 234,

Drop in Volume or Pressure

BAKERY CONCEPTS INTERNATIONAL, LLC.

P.O. Box 234,

Premature Failure of Valve

BAKERY CONCEPTS INTERNATIONAL, LLC.

P.O. Box 234,

This warranty does not cover:

BAKERY CONCEPTS INTERNATIONAL, LLC.

P.O. Box 234,

2. AUGER/AGITATOR MOTOR MAINTENANCE

2.1 OIL PLUG LOCATIONS

= Vent = Oil Level = Oil Drain

BAKERY CONCEPTS INTERNATIONAL, LLC.

P.O. Box 234,

2.2 MANUFACTURES SERVICE AND MAINTENANCE

5. Service and Maintenance

5. Service and maintenance

At least every six months - Visual inspection 5.2

5.2 Service and maintenance work

-22- B1000-GB-0713 www.nord.com

BAKERY CONCEPTS INTERNATIONAL, LLC.

P.O. Box 234,

5. Service and Maintenance

Check the oil level

Checking the oil level:

Figure 5-2: Check the oil level with a dipstick

www.nord.com B1000-GB-0713 -23-

2.2 MANUFACTURES SERVICE AND MAINTENANCE ��11