Instruction manual - CAVEX · Number of the instruction manual Special data 2 9 8 7 Serial number 3...

44
® www.CAVEX-GmbH.de Instruction manual BA 6610 CAVEX EN 12.11 CAVEX ® - worm gear units of the models C.. Sizes 63 to 630 Instruction manual CAVEX GmbH & Co. KG Tübinger Straße 2 D-72131 Ofterdingen Telephone: +49 (0) 74 73 95 546 - 0 Telefax: +49 (0) 74 73 95 546 - 88

Transcript of Instruction manual - CAVEX · Number of the instruction manual Special data 2 9 8 7 Serial number 3...

  • www.CAVEX-GmbH.de

    Instruction manualBA 6610 CAVEX EN 12.11

    CAVEX- worm gear units

    of the models C..

    Sizes 63 to 630Instruction manual

    CAVEX GmbH & Co. KGTbinger Strae 2D-72131 OfterdingenTelephone: +49 (0) 74 73 95 546 - 0Telefax: +49 (0) 74 73 95 546 - 88

  • Profit from CAVEX in many ways:

    Continuous range of worm gear units up to 360,000 Nm in 18 sizes

    Specially high torques and efficiencies and long lifetime due to unique gear tooth geometry

    High ratios

    High overload capability

    Rugged design

    Low noise levels

    Custom and sector-specific solutions

    In conformance with ATEX

    A worm gear is not just a worm gear. CAVEX proves this over and over again. For more than 50 years. In a wide range of industrial sectors world-wide. The decisive advantage over conventional worm gears is their unique gear tooth geometry.

    Intelligent gear tooth geometryThe name CAVEX is well-known and is made up of the Latin word concavus, the worm profile, and convexus, the worm wheel profile. Thanks to the worm teeth with concave flank profile (hollow-flank worm) coupled with convex-shaped worm wheels, CAVEX Worm Gear Units are far superior to compa-rable gear units of the same size. Gear tooth pairing ensures better flank meshing and an extremely low specific gear flank pressure (Hertzian pres-sure). The result: higher torques of up to 360,000 Nm, excellent efficienci-es of up to 95% and a significantly longer lifetime as a result of lower wear.

    Complete CAVEX range CAVEX GmbH & Co. KG offers you a complete range of CAVEX Worm Gear Units in 18 sizes from 100 to 360,000 Nm. From single-stage or multi-sta-ge units, in a wide variety of standard versions, as sector-specific solutions or adapted to your specific requirements.

    Unique when it comes to efficiency, torque and lifetime

    Conventional Worm Gear CAVEX

  • 3 / 43

    Index of Content

    1. Technical Data 51.1 Type plate 51.2. Dimension tables 61.2.1 Model CUW 6 1.2.2 Model CFW 71.2.3 Model COW 81.2.4 Model CDA 91.2.5 Model CUA 101.2.6 Model CFA 111.2.7 Model COA 121.2.8 Worm gear units with additional mounting surfaces 131.2.9 Worm gear units with shrink disc 14 1.2.10 Assembly IEC-motor 151.3 Ventilation, oil level, oil drainage, oil quantities and weights 161.4 Measurement surfaces Sound pressure level 17

    2. General information 172.1. Introduction 172.2. Copyright 17

    3. Safety information 183.1. Intended usage 183.2. General obligations 183.3. Environmental protection 18 3.4. Special dangers 193.5. Warnings and symbols used in this instruction manual 19

    4. Transport and storage 194.1. Scope of delivery 194.2. Transport 19 4.3. Storing the gear unit 204.4. Standard corrosion protection 204.5. Rating plates 204.6 Coatings 214.6.1 General information 214.6.2 Painted version 214.6.3 Primed version 22

    5. Technical description 235.1 General information 235.2 Labelling 235.3 Ventilator 235.4 Couplings 235.5 Shrink disc 235.6 Backstop 235.7 Assembly of IEC-motors 24

    6. Assembly 246.1 General assembly information 246.2 Description of the assembly 246.3 Assembly of a shaft-mounted gear unit with fitted key 256.3.1 Preparation 256.3.2 Assembly 26

    BA 6610 CAVEX EN 12.11

  • 4 / 43BA 6610 CAVEX EN 12.11

    62Assembly of a shaft-mounted gear unit with shrink disc 4.66.4.1 Preparation 266.4.2 Mounting 266.4.3 Axial securing 27

    72Fitting of the shrink disc 4.4.6825 Removal of the shrink disc .4.6826 Cleaning and lubrication of the shrink disc .4.6

    6.5 Torque support 296.6 Assembly of motors 29

    92Assembly to motor lantern with coupling 1.6.6

    03Start up .77.1 Oil filling 307.1.1 Gear unit with oil filling 307.1.2 Gear unit without oil filling 30

    032 Greasing of bearings .77.3 Built-in parts and accessories 30

    031 Gear unit with backstop .3.77.4 Electrical connection (on CAVEX gear units with assembled motor) 137.5 Start up 31

    8. Operation 31

    23. Faults, causes and solutions 9231 General fault information .9

    9.2 Possible defects 32

    33Maintenance and service .0133General maintenance specifications 1.0143Description of maintenance and service work 2.01

    10.2.1 Oil change 3410.2.2 Greases 35

    53Clean ventilator and casing 3.2.0153Check fixing screws for tightness 4.2.01

    10.3 Lubrication 3510.3.1 Oil types 36

    37Spare parts.1111.1 Spare part lists 3811.1.1 Model C.W and C.A 3811.2 Spare part drawings 39

    39Model C.W 63-80 and C.W 100-250 1.2.1111.2.2 Model C.W 280-630 40

    41Model C.A 63-80 and C.A 100-250 3.2.1111.2.4 Model C.A 280-630 42

    34Declaration of Manufacturer.21

  • 5 / 43

    1. Technical data

    1.1 Type plate

    The type plate of the CAVEX gear unit includes the following technical data.

    1 Company logo

    Production date

    Serial number

    Model / Size

    Output torque T2N in Nm

    Output torque T2max in Nm

    Input speed n1 in min-1

    Ratio

    Oil type/Oil viscosity in ISO VG Category for the main gear unit

    Oil quantity in litres for the main gear unit

    Number of the instruction manual

    Special data

    2

    9

    8

    7

    Serial number

    3

    104

    115

    126

    Further data is listed in the delivery contract and in this instruction manual.

    The dimensions of the following measurement tables for the listed models and sizes are applicable to a standard gear unit.

    BA 6610 CAVEX EN 12.11

  • 6 / 43

    BA 6610 CAVEX EN 12.11

    1.2 Measurement tables

    1.2.1 Model CUW

    Output shaft on side A, B or both sides;Installation position SU, SO, SR, SL, VO or VU

    SideA

    SideB

    SU

    B

    A

    A B

    View X

    X

    B A

    SO

    SR SL VO

    A

    B

    B

    A

    B

    A

    VU

    a b c d1 l1 d2 l2 e3 e4 E G1 G3 G2 h1 h2 H m1 m2 m3 sSize

    mm

    63 80 100

    146 175 216

    140 168 200

    20 24 28

    18 k6 22 k6 28 m6

    35 40 50

    28 m6 38 m6 48 m6

    50 65 80

    69 82 98

    119 140 168

    63 80 100

    85 102 124

    122 143 171

    72 86 102

    63 75 90

    126 155 190

    208 252 309

    115 140 170

    120 145 170

    12 15 15

    120 140 160

    254 290 324

    235 260 295

    32 36 40

    32 m6 38 m6 42 m6

    55 60 70

    55 m6 65 m6 70 m6

    95 105 120

    114 126 143

    194 220 244

    120 140 160

    145 165 184

    197 224 248

    120 132 150

    105 115 130

    225 255 290

    364 416 472

    200 230 260

    200 225 255

    19 19 19

    180 200 225

    364 396 440

    325 350 380

    45 50 55

    48 m6 55 m6 60 m6

    80 90100

    80 m6 90 m6100 m6

    140 160 180

    159 171 188

    272 294 323

    180 200 225

    205 223 245

    276 298 327

    165 178 195

    140 150 165

    320 350 390

    522 573 638

    290 315 350

    280 295 325

    24 24 28

    250 280 315

    480 525 590

    415 450 490

    60 65 70

    65 m6 70 m6 75 m6

    105110120

    110 n6120 n6140 n6

    200 220 240

    204 222 244

    354 387 430

    250 280 315

    270 318 355

    358 392 434

    212 230 252

    180 200 215

    430 480 530

    703 786 870

    385 430 480

    355 385 420

    28 35 35

    355 400 450

    665 748 855

    535 585 562

    78 85 92

    80 m6 90 m6100 m6

    130145160

    150 n6170 n6190 n6

    260 290 320

    266 291 322

    478 526 596

    355 400 450

    395 432 485

    482 530 600

    275 300 332

    240 260 290

    595 660 740

    97710861270

    540 605 750

    460 510 495

    560

    42 42 35

    500 560 630

    95510501175

    616 678 750

    100110120

    110 n6120 n6135 n6

    175190210

    210 n6230 n6255 n6

    350 390 430

    355 389 429

    663 733 815

    500 560 630

    540 590 655

    668 738 820

    365 400 440

    315 350 385

    815 9101015

    141015601745

    840 9201030

    540 600 660

    630 700 780

    42 42 48

    In the case of a vertical worm gear shaft follow the instructions in the figure under Point 1.3.

  • 6 / 43

    BA 6610 CAVEX EN 12.11

    1.2 Measurement tables

    1.2.1 Model CUW

    Output shaft on side A, B or both sides;Installation position SU, SO, SR, SL, VO or VU

    SideA

    SideB

    SU

    B

    A

    A B

    View X

    X

    B A

    SO

    SR SL VO

    A

    B

    B

    A

    B

    A

    VU

    a b c d1 l1 d2 l2 e3 e4 E G1 G3 G2 h1 h2 H m1 m2 m3 sSize

    mm

    63 80 100

    146 175 216

    140 168 200

    20 24 28

    18 k6 22 k6 28 m6

    35 40 50

    28 m6 38 m6 48 m6

    50 65 80

    69 82 98

    119 140 168

    63 80 100

    85 102 124

    122 143 171

    72 86 102

    63 75 90

    126 155 190

    208 252 309

    115 140 170

    120 145 170

    12 15 15

    120 140 160

    254 290 324

    235 260 295

    32 36 40

    32 m6 38 m6 42 m6

    55 60 70

    55 m6 65 m6 70 m6

    95 105 120

    114 126 143

    194 220 244

    120 140 160

    145 165 184

    197 224 248

    120 132 150

    105 115 130

    225 255 290

    364 416 472

    200 230 260

    200 225 255

    19 19 19

    180 200 225

    364 396 440

    325 350 380

    45 50 55

    48 m6 55 m6 60 m6

    80 90100

    80 m6 90 m6100 m6

    140 160 180

    159 171 188

    272 294 323

    180 200 225

    205 223 245

    276 298 327

    165 178 195

    140 150 165

    320 350 390

    522 573 638

    290 315 350

    280 295 325

    24 24 28

    250 280 315

    480 525 590

    415 450 490

    60 65 70

    65 m6 70 m6 75 m6

    105110120

    110 n6120 n6140 n6

    200 220 240

    204 222 244

    354 387 430

    250 280 315

    270 318 355

    358 392 434

    212 230 252

    180 200 215

    430 480 530

    703 786 870

    385 430 480

    355 385 420

    28 35 35

    355 400 450

    665 748 855

    535 585 562

    78 85 92

    80 m6 90 m6100 m6

    130145160

    150 n6170 n6190 n6

    260 290 320

    266 291 322

    478 526 596

    355 400 450

    395 432 485

    482 530 600

    275 300 332

    240 260 290

    595 660 740

    97710861270

    540 605 750

    460 510 495

    560

    42 42 35

    500 560 630

    95510501175

    616 678 750

    100110120

    110 n6120 n6135 n6

    175190210

    210 n6230 n6255 n6

    350 390 430

    355 389 429

    663 733 815

    500 560 630

    540 590 655

    668 738 820

    365 400 440

    315 350 385

    815 9101015

    141015601745

    840 9201030

    540 600 660

    630 700 780

    42 42 48

    In the case of a vertical worm gear shaft follow the instructions in the figure under Point 1.3.

    7 / 43

    BA 6610 CAVEX EN 12.11

    1.2.2 Model CFW

    Flange on side A or B; Output shaft on side A, B or both sides; Installation position SU, SO, SR, SL, VO or VU

    X

    SideB

    SideA

    Hole pattern for size Fastening with studs and nuts

    SU

    SO

    SR SL VO VU

    A

    B

    B

    A

    A

    B

    A

    B

    A B

    B A View X

    Sizec d1 l1 d2 l2 d3 d4 e1 e2 e3 e4 E g3 G1 G3 G2 k s z

    mm

    63 80 100

    7 8 9

    18 k6 22 k6 28 m6

    35 40 50

    28 m6 38 m6 48 m6

    50 65 80

    188 218 266

    150 h8 180 h8 220 h8

    63 75 90

    82 97119

    69 82 98

    119140168

    63 80100

    76 90107

    85102124

    122143171

    72 86102

    170 200 245

    5 x 9 7 x 9 7 x 11

    3.544

    120 140 160

    101112

    32 m6 38 m6 42 m6

    55 60 70

    55 m6 65 m6 70 m6

    95105120

    315 360 410

    260 h8 305 h8 340 h8

    105115130

    139161182

    114126143

    194220244

    120140160

    125138157

    145165184

    197224248

    120132150

    290 335 380

    7 x 13.5 7 x 13.5 7 x 17.5

    555

    180 200 225

    131415

    48 m6 55 m6 60 m6

    80 90100

    80 m6 90 m6100 m6

    140160180

    450 490 540

    380 h8 420 h8 465 h8

    140150165

    202223248

    159171188

    272294323

    180200225

    172185202

    205223245

    276298327

    165178195

    420 460 505

    7 x 17.5 7 x 17.512 x 17.5

    555

    250 280 315

    16.518

    19.5

    65 m6 70 m6 75 m6

    105110120

    110 n6120 n6140 n6

    200220240

    590 665 730

    515 h8 575 h8 640 h8

    180200215

    273306340

    204222244

    354387430

    250280315

    220238260

    270318355

    358392434

    212230252

    555 625 690

    12 x 17.512 x 2212 x 22

    666

    355 400 450

    2122.524

    80 m6 90 m6100 m6

    130145160

    150 n6170 n6190 n6

    260290320

    825 9101025

    725 h8 805 h8 905 h8

    240260290

    382426530

    266291322

    478526596

    355400450

    286312345

    395432485

    482530600

    275300332

    780 865 975

    12 x 2612 x 2616 x 26

    666

    500 560 630

    25.527

    28.5

    110 n6120 n6135 n6

    175190210

    210 n6230 n6255 n6

    350390430

    115012701405

    1015 h81125 h81260 h8

    315350385

    595650730

    355389429

    663733815

    500560630

    380415456

    540590655

    668738820

    365400440

    109512101345

    16 x 3316 x 3316 x 33

    666

    In the case of a vertical worm gear shaft follow the instructions in the figure under Point 1.3.

  • BA 6610 CAVEX EN 12.11

    1.2.3 Model COW

    Output shaft on side A, B or both sides; Installation position SU, SO, SR, SL, VO or VU

    SideA

    SideB

    Fastening with studs and nuts

    UVOVLSRSUS

    SO

    B

    AA B

    B A

    A

    B

    B

    AView X

    X

    Sizea b c d1 l1 d2 l2 e3 e4 E G1 G3 G2 h1 h2 H m1 m2 m3 s

    mm

    63 80 100

    146 175 216

    140168200

    20 24 28

    18 k6 22 k6 28 m6

    35 40 50

    28 m6 38 m6 48 m6

    50 65 80

    69 82 98

    119140168

    63 80100

    85102124

    122143171

    72 86102

    163 200 245

    100 120 145

    226 275 335

    115 140 170

    120 145 170

    121515

    120 140 160

    254 290 324

    235260295

    32 36 40

    32 m6 38 m6 42 m6

    55 60 70

    55 m6 65 m6 70 m6

    95105120

    114126143

    194220244

    120140160

    145165184

    197224248

    120132150

    290 335 380

    170 195 220

    395 450 510

    200 230 260

    200 225 255

    191919

    180 200 225

    364 396 440

    325350380

    45 50 55

    48 m6 55 m6 60 m6

    80 90100

    80 m6 90 m6100 m6

    140160180

    159171188

    272294323

    180200225

    205223245

    276298327

    165178195

    425 470 525

    245 270 300

    565 620 690

    290 315 350

    280 295 325

    242428

    250 280 315

    480 525 590

    415450490

    60 65 70

    65 m6 70 m6 75 m6

    105110120

    110 n6120 n6140 n6

    200220240

    204222244

    354387430

    250280315

    270318355

    358392434

    212230252

    580 647 720

    330 367 405

    760 847 935

    385 430 480

    355 385 420

    283535

    355 400 450

    665 748 855

    535585562

    78 85 92

    80 m6 90 m6100 m6

    130145160

    150 n6170 n6190 n6

    260290320

    266291322

    478526596

    355400450

    395432485

    482530600

    275300332

    810 905 980

    455 505 530

    105011651270

    540 605 750

    460 510 495

    560

    424235

    500 560 630

    95510501175

    616678750

    100110120

    110 n6120 n6135 n6

    175190210

    210 n6230 n6255 n6

    350390430

    355389429

    663733815

    500560630

    540590655

    668738820

    365400440

    109512101360

    595 650 730

    141015601745

    840 9201030

    540 600 660

    630700780

    424248

    In the case of a vertical worm gear shaft follow the instruction in the figure under Point 1.3.

    8 / 43

  • BA 6610 CAVEX EN 12.11

    1.2.3 Model COW

    Output shaft on side A, B or both sides; Installation position SU, SO, SR, SL, VO or VU

    SideA

    SideB

    Fastening with studs and nuts

    UVOVLSRSUS

    SO

    B

    AA B

    B A

    A

    B

    B

    AView X

    X

    Sizea b c d1 l1 d2 l2 e3 e4 E G1 G3 G2 h1 h2 H m1 m2 m3 s

    mm

    63 80 100

    146 175 216

    140168200

    20 24 28

    18 k6 22 k6 28 m6

    35 40 50

    28 m6 38 m6 48 m6

    50 65 80

    69 82 98

    119140168

    63 80100

    85102124

    122143171

    72 86102

    163 200 245

    100 120 145

    226 275 335

    115 140 170

    120 145 170

    121515

    120 140 160

    254 290 324

    235260295

    32 36 40

    32 m6 38 m6 42 m6

    55 60 70

    55 m6 65 m6 70 m6

    95105120

    114126143

    194220244

    120140160

    145165184

    197224248

    120132150

    290 335 380

    170 195 220

    395 450 510

    200 230 260

    200 225 255

    191919

    180 200 225

    364 396 440

    325350380

    45 50 55

    48 m6 55 m6 60 m6

    80 90100

    80 m6 90 m6100 m6

    140160180

    159171188

    272294323

    180200225

    205223245

    276298327

    165178195

    425 470 525

    245 270 300

    565 620 690

    290 315 350

    280 295 325

    242428

    250 280 315

    480 525 590

    415450490

    60 65 70

    65 m6 70 m6 75 m6

    105110120

    110 n6120 n6140 n6

    200220240

    204222244

    354387430

    250280315

    270318355

    358392434

    212230252

    580 647 720

    330 367 405

    760 847 935

    385 430 480

    355 385 420

    283535

    355 400 450

    665 748 855

    535585562

    78 85 92

    80 m6 90 m6100 m6

    130145160

    150 n6170 n6190 n6

    260290320

    266291322

    478526596

    355400450

    395432485

    482530600

    275300332

    810 905 980

    455 505 530

    105011651270

    540 605 750

    460 510 495

    560

    424235

    500 560 630

    95510501175

    616678750

    100110120

    110 n6120 n6135 n6

    175190210

    210 n6230 n6255 n6

    350390430

    355389429

    663733815

    500560630

    540590655

    668738820

    365400440

    109512101360

    595 650 730

    141015601745

    840 9201030

    540 600 660

    630700780

    424248

    In the case of a vertical worm gear shaft follow the instruction in the figure under Point 1.3.

    8 / 43 9 / 43BA 6610 CAVEX EN 12.11

    1.2.4 Model CDA

    Torque support in position 1, 2, 3 or 4 **; torque support on side A or B with or without end plate; installation position SU, SO, SR, SL, VO or VU

    SideB

    SideA

    ** During motor installation position 4 not possible

    Cover plate End plate

    Detail X

    B

    A

    SUBA

    B

    A

    B

    A

    A

    B

    AB

    SO

    SR SL VO VU

    View X

    X

    1

    2

    3

    4

    2

    14

    3

    3

    14

    2

    1

    32

    4

    1

    23

    4

    1

    32

    4

    4

    32

    1

    c c d l dD2 D5

    e e e e E f g G G GL

    L nP

    sc1 c2 d1 l1 d6H7 H8

    e1 e2 e4 e5 E f g4 G1 G3 G2min. max.*

    L2 nmin.

    sSize

    mm

    63 80 100

    161620

    81011

    18 k6 22 k6 28 m6

    35 40 50

    32 40 40

    30 40 50

    162020

    63 75 90

    82 97119

    119140168

    73 89102

    63 80100

    223

    62 74 88

    85102124

    122143171

    65 80 93

    95114136

    102124147

    115139.5165

    140 180 225

    101214

    M 10M 16M 16

    120 140 160

    202525

    121415

    32 m6 38 m6 42 m6

    55 60 70

    50 50 65

    60 65 75

    252532

    105115130

    139161182

    194220244

    115127142

    120140160

    334

    101113126

    145165184

    197224248

    106118132

    155173194

    167186212

    187208.5235.5

    270 315 360

    161820

    M 20M 20M 20

    180 200 225

    323240

    161718

    48 m6 55 m6 60 m6

    80 90100

    65 80 80

    85 95105

    324040

    140150165

    202223248

    272294323

    154165182

    180200225

    445

    138148163

    205223245

    276298327

    144155170

    212228250

    233250276

    259278307

    405 450 505

    222528

    M 20M 24M 24

    250 280 315

    404050

    202224

    65 m6 70 m6 75 m6

    105110120

    80100100

    115125140

    405050

    180200215

    273306340

    354387430

    197213233

    250280315

    555

    178192212

    270318355

    358392434

    185200220

    272293322

    301326357

    335363397

    560 630 710

    303236

    M 24M 24M 30

    355 400 450

    506060

    273033

    80 m6 90 m6100 m6

    130145160

    120120150

    160180200

    606075

    240260290

    382426530

    478526596

    256279308

    355400450

    556

    233256282

    395432485

    482530600

    242265292

    354387425

    394433480

    438481532

    800 9001010

    404548

    M 30M 30M 30

    500 560 630

    757590

    363840

    110 n6120 n6135 n6

    175190210

    150170170

    220240270

    759090

    315350385

    595650730

    663733815

    336370406

    500560630

    666

    310341377

    540590655

    668738820

    320352388

    465510560

    528583650

    585643713

    112012601420

    505663

    M 30M 36M 36

    In the case of a vertical worm gear shaft follow the instructions in the figure under Point 1.3.

    * Lmax is only applicable when using the dismounting disc

  • 10 / 43

    BA 6610 CAVEX EN 12.11

    1.2.5 Model CUA

    Cover plate on side A or B; with or without dismounting disc; Installation position SU, SO, SR, SL, VO or VU

    SideA

    SideB

    Cover plate Dismounting disc

    X

    Ansicht X

    SUA B

    B

    B A

    A

    A

    B

    B

    A

    B

    A

    SO

    SR SL VO VU

    D2h

    H L Pa b c c2 d1 l1

    H7D3 e4 e5 E G1 G2 G3 h1 h2

    min. max.*L1 m1 m2 m3

    min.s

    Sizemm

    63 80 100

    146 175 216

    140168200

    20 24 28

    81011

    18 k6 22 k6 28 m6

    35 40 50

    30 40 50

    M 12M 20M 20

    119140168

    73 89102

    63 80100

    85102124

    65 80 93

    122143171

    63 75 90

    126 155 190

    208 252 309

    94114136

    102124147

    105.5128152

    115 140 170

    120145170

    101214

    121515

    120 140 160

    254 290 324

    235260295

    32 36 40

    121415

    32 m6 38 m6 42 m6

    55 60 70

    60 65 75

    M 24M 24M 24

    194220244

    115127142

    120140160

    145165184

    106118132

    197224248

    105115130

    225 255 290

    364 416 472

    155173194

    167186212

    173192.5218.5

    200 230 260

    200225255

    161820

    191919

    180 200 225

    364 396 440

    325350380

    45 50 55

    161718

    48 m6 55 m6 60 m6

    80 90100

    85 95105

    M 24M 30M 30

    272294323

    154165182

    180200225

    205223245

    144155170

    276298327

    140150165

    320 350 390

    522 573 638

    212228250

    233250276

    240258285

    290 315 350

    280295325

    222528

    242428

    250 280 315

    480 525 590

    415450490

    60 65 70

    202224

    65 m6 70 m6 75 m6

    105110120

    115125140

    M 30M 36M 36

    354387430

    197213233

    250280315

    270318355

    185200220

    358392434

    180200215

    430 480 530

    703 786 870

    272293322

    301326357

    311337369

    385 430 480

    355385420

    303236

    283535

    355 400 450

    665 748 855

    535585562

    78 85 92

    273033

    80 m6 90 m6100 m6

    130145160

    160180200

    M 36M 36M 36

    478526596

    256279308

    355400450

    395432485

    242265292

    482530600

    240260290

    595 660 740

    97710861270

    354387425

    394433480

    407447495

    540 605 750

    460510495

    560

    404548

    424235

    500 560 630

    95510501175

    616678750

    100110120

    363840

    110 n6120 n6135 n6

    175190210

    220240270

    M 36M 42M 42

    663733815

    336370406

    500560630

    540590655

    320352388

    668738820

    315350385

    815 9101015

    141015601745

    465510560

    528583650

    544600668

    840 9201030

    540600660

    630700780

    505663

    424248

    In the case of a vertical worm gear shaft follow the instruction in the figure under Point 1.3.

    * Lmax is only applicable when using the dismounting disc

  • 10 / 43

    BA 6610 CAVEX EN 12.11

    1.2.5 Model CUA

    Cover plate on side A or B; with or without dismounting disc; Installation position SU, SO, SR, SL, VO or VU

    SideA

    SideB

    Cover plate Dismounting disc

    X

    Ansicht X

    SUA B

    B

    B A

    A

    A

    B

    B

    A

    B

    A

    SO

    SR SL VO VU

    D2h

    H L Pa b c c2 d1 l1

    H7D3 e4 e5 E G1 G2 G3 h1 h2

    min. max.*L1 m1 m2 m3

    min.s

    Sizemm

    63 80 100

    146 175 216

    140168200

    20 24 28

    81011

    18 k6 22 k6 28 m6

    35 40 50

    30 40 50

    M 12M 20M 20

    119140168

    73 89102

    63 80100

    85102124

    65 80 93

    122143171

    63 75 90

    126 155 190

    208 252 309

    94114136

    102124147

    105.5128152

    115 140 170

    120145170

    101214

    121515

    120 140 160

    254 290 324

    235260295

    32 36 40

    121415

    32 m6 38 m6 42 m6

    55 60 70

    60 65 75

    M 24M 24M 24

    194220244

    115127142

    120140160

    145165184

    106118132

    197224248

    105115130

    225 255 290

    364 416 472

    155173194

    167186212

    173192.5218.5

    200 230 260

    200225255

    161820

    191919

    180 200 225

    364 396 440

    325350380

    45 50 55

    161718

    48 m6 55 m6 60 m6

    80 90100

    85 95105

    M 24M 30M 30

    272294323

    154165182

    180200225

    205223245

    144155170

    276298327

    140150165

    320 350 390

    522 573 638

    212228250

    233250276

    240258285

    290 315 350

    280295325

    222528

    242428

    250 280 315

    480 525 590

    415450490

    60 65 70

    202224

    65 m6 70 m6 75 m6

    105110120

    115125140

    M 30M 36M 36

    354387430

    197213233

    250280315

    270318355

    185200220

    358392434

    180200215

    430 480 530

    703 786 870

    272293322

    301326357

    311337369

    385 430 480

    355385420

    303236

    283535

    355 400 450

    665 748 855

    535585562

    78 85 92

    273033

    80 m6 90 m6100 m6

    130145160

    160180200

    M 36M 36M 36

    478526596

    256279308

    355400450

    395432485

    242265292

    482530600

    240260290

    595 660 740

    97710861270

    354387425

    394433480

    407447495

    540 605 750

    460510495

    560

    404548

    424235

    500 560 630

    95510501175

    616678750

    100110120

    363840

    110 n6120 n6135 n6

    175190210

    220240270

    M 36M 42M 42

    663733815

    336370406

    500560630

    540590655

    320352388

    668738820

    315350385

    815 9101015

    141015601745

    465510560

    528583650

    544600668

    840 9201030

    540600660

    630700780

    505663

    424248

    In the case of a vertical worm gear shaft follow the instruction in the figure under Point 1.3.

    * Lmax is only applicable when using the dismounting disc

    11 / 43

    BA 6610 CAVEX EN 12.11

    1.2.6 Model CFA

    Flange cover on side A or B; with or without dismounting discInstallation position SU, SO, SR, SL, VO or VU

    SideA

    SideB

    Cover plate Dismounting disc

    Flange cover

    Hole pattern for size

    SU

    A

    A BB

    SO

    SR SL VO

    B

    A

    VU

    A

    B

    A

    BX

    View XB A

    c c2 d1 l1 d3d4 D2

    D3 e1 e2 e4 e E g3 G1 G2 G3 kL

    L1P

    s zSize

    c c2 d1 l1 d3h8 H7

    D3 e1 e2 e4 e5 E g3 G1 G2 G3 kmin. max.*

    L1min.

    s z

    mm

    63 80 100

    131518

    81011

    18 k6 22 k6 28 m6

    35 40 50

    145 175 217

    95 125 155

    30 40 50

    M 12M 20M 20

    63 75 90

    82 97119

    119140168

    73 89102

    63 80100

    63 75 90

    85102124

    65 80 93

    122143171

    130 160 195

    94114136

    102124147

    105.5128152

    101214

    6 x M 8 8 X M 8 8 X M 10

    33.53.5

    120 140 160

    202225

    121415

    32 m6 38 m6 42 m6

    55 60 70

    258 302 338

    190 225 260

    60 65 75

    M 24M 24M 24

    105115130

    139161182

    194220244

    115127142

    120140160

    104116129

    145165184

    106118132

    197224248

    235 275 310

    155173194

    167186212

    173192.5218.5

    161820

    8 X M 12 8 X M 12 8 X M 16

    445

    180 200 225

    283134

    161718

    48 m6 55 m6 60 m6

    80 90100

    379 416 462

    295 330 375

    85 95105

    M 24M 30M 30

    140150165

    202223248

    272294323

    154165182

    180200225

    142152167

    205223245

    144155170

    276298327

    350 385 430

    212228250

    233250276

    240258285

    222528

    8 X M 16 8 X M 1612 X M 16

    555

    250 280 315

    374043

    202224

    65 m6 70 m6 75 m6

    105110120

    510 574 638

    420 465 530

    115125140

    M 30M 30M 36

    180200215

    273306340

    354387430

    197213233

    250280315

    181196216

    270318355

    185200220

    358392434

    480 535 600

    272293322

    301326357

    311337369

    303236

    12 X M 1612 X M 2012 X M 20

    566

    355 400 450

    464852

    273033

    80 m6 90 m6100 m6

    130145160

    720 804 906

    600 680 770

    160180200

    M 36M 36M 36

    240260290

    382426530

    478526596

    256279308

    355400450

    238260287

    395432485

    242265292

    482530600

    680 760 860

    354387425

    394433480

    407447495

    404548

    12 X M 2412 X M 2416 X M 24

    666

    500 560 630

    556063

    363840

    110 n6120 n6135 n6

    175190210

    101411261258

    860 9651090

    220240270

    M 36M 42M 42

    315350385

    595650730

    663733815

    336370406

    500560630

    314346382

    540590655

    320352388

    668738820

    96010701200

    465510560

    528583650

    544600668

    505663

    16 X M 3016 X M 3016 X M 30

    666

    In the case of a vertical worm gear shaft follow the instruction in the figure under Point 1.3.

    * Lmax is only applicable when using the dismounting disc

  • 12 / 43

    BA 6610 CAVEX EN 12.11

    1.2.7 Model COA

    Cover plate on side A or B; with or without dismounting disc; Installation position SU, SO, SR, SL, VO or VU

    SideA

    SideB

    Dismounting disc Fastening with studs and nutsCover plate

    SU

    A B

    A

    B

    SOB A

    SR SL VO VU

    X

    View X

    B

    A

    B

    A

    B

    A

    a b c c2 d1 l1D2

    D3 G1 G3 G2 e4 e E h1 h2 H m1 m2 m3L

    L1P

    sSize

    a b c c2 d1 l1H7

    D3 G1 G3 G2 e4 e5 E h1 h2 H m1 m2 m3min. max.*

    L1min.

    s

    mm

    63 80 100

    146 175 216

    140168200

    20 24 28

    81011

    18 k6 22 k6 28 m6

    35 40 50

    30 40 50

    M 12M 20M 20

    85102124

    122143171

    65 80 93

    119140168

    73 89102

    63 80100

    163 200 245

    100120145

    226 275 335

    115 140 170

    120145170

    94114136

    102124147

    105.5128152

    101214

    121515

    120 140 160

    254 290 324

    235260295

    32 36 40

    121415

    32 m6 38 m6 42 m6

    55 60 70

    60 65 75

    M 24M 24M 24

    145165184

    197224248

    106118132

    194220244

    115127142

    120140160

    290 335 380

    170195220

    395 450 510

    200 230 260

    200225255

    155173194

    167186212

    173192.5218.5

    161820

    191919

    180 200 225

    364 396 440

    325350380

    45 50 55

    161718

    48 m6 55 m6 60 m6

    80 90100

    85 95105

    M 24M 30M 30

    205223245

    276298327

    144155170

    272294323

    154165182

    180200225

    425 470 525

    245270300

    565 620 690

    290 315 350

    280295325

    212228250

    233250276

    240258285

    222528

    242428

    250 280 315

    480 525 590

    415450490

    60 65 70

    202224

    65 m6 70 m6 75 m6

    105110120

    115125140

    M 30M 30M 36

    270318355

    358392434

    185200220

    354387430

    197213233

    250280315

    580 647 720

    330367405

    760 847 935

    385 430 480

    355385420

    272293322

    301326357

    311337369

    303236

    283535

    355 400 450

    665 748 855

    535585562

    78 85 92

    273033

    80 m6 90 m6100 m6

    130145160

    160180200

    M 36M 36M 36

    395432485

    482530600

    242265292

    478526596

    256279308

    355400450

    810 905 980

    455505530

    105011651270

    540 605 750

    460510495

    560

    354387425

    394433480

    407447495

    404548

    424235

    500 560 630

    95510501175

    616678750

    100110120

    363840

    110 n6120 n6135 n6

    175190210

    220240270

    M 36M 42M 42

    540590655

    668738820

    320352388

    663733815

    336370406

    500560630

    109512101360

    595650730

    141015601745

    840 9201030

    540600660

    630700780

    465510560

    528583650

    544600668

    505663

    424248

    In case of a vertical worm gear shaft follow the instructions in the figure under Point 1.3.

    * Lmax is only applicable when using the dismounting disc

  • 13 / 43

    BA 6610 CAVEX EN 12.11

    1.2.8 Worm gear unit with additional mounting surfaces

    Sizes 63 - 400 Sizes 450 - 630

    Mounting surfaces a3 x b3

    Mounting surfaces a4 x b4

    a3 b3 h3 m3 m4 m7 s3 tSize

    a4 b4 h4 m5 m6 m8 s3 tSize

    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 a3 x b3

    Mounting surfaces a4 x b4

    Sizea3 b3 h3 m3 m4 m7 s3 t

    Sizea4 b4 h4 m5 m6 m8 s3 t

    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

  • 14 / 43

    BA 6610 CAVEX EN 12.11

    1.2.9 Worm gear unit with shrink disc

    Dimensions for shaft Slide bush

    The protective cover must be ordered separately

    Shrink disc

    Protective cover

    Shrink disc model d7 d8 d9 d10 f1 G2 G4 l3 l4 l5 l6 l7

    SizeModel

    T2max

    Nm

    D

    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

  • 15 / 43

    BA 6610 CAVEX EN 12.11

    1.2.10 Installation IEC-Motor

    1) The dimensions may vary slightly depending on the motor model. They are applicable to motors without additional installations

    Size

    IEC-standard motor,construction type

    B5, V1 or V3

    IEC-standard motor,construction type

    B5, V1 or V3

    BIPEX-coupling Model BWN

    Drilling(mm)

    Size

    BIPEX-coupling Model BWN

    Drilling(mm)

    Sizea1 g5 g6 Motor side Gear side

    Sizea1 g5 g6

    SizeMotor side Gear side

    mm mm mmSize

    Part Part mm mm mm Part Part

    63

    718090

    100/112

    160200200250

    162174174196

    384,5417,5

    446 501/544,4

    B 43B 53B 53B 62

    1111

    14192428

    2222

    18181818

    200

    132160180200225

    300350350400450

    420450450450480

    835,5 949

    AAAA1227,5

    AB 112AB 112AB 112B 112AB 127

    11112

    3842485560

    22221

    5555555555

    80

    8090

    100/112132

    200200250300

    198198218240

    441,5 470 523/566,5

    715,5

    B 62B 62B 62AB 72

    1112

    19242838

    2221

    22222222

    225

    160180200225250

    350350400450550

    482482482512512

    981AAAA1259,51343,5

    AB 112AB 112B 127B 127B 127

    1111

    4248556065

    22222

    6060606060

    100

    90100/112

    132160

    200250300350

    238250272308

    510 555/598,5

    687,5 807

    B 53B 62AB 72A 97

    1121

    24283842

    2212

    28282828

    250

    160180200225250280

    350350400450550550

    512512512542546546

    1011AAAA1289,51373,51423/1474

    AB 127AB 127AB 127B 127B 142B 142

    111111

    424855606575

    222222

    656565656565

    120

    100/112132160180

    250300350350

    276298334334

    581/624,5

    713,5 858AA

    B 62AB 72A 97AB 97

    1212

    28384248

    2121

    32323232

    280

    180200225250280

    350400450550550

    569569599599599

    AAAA1346,51430,51476/1527

    AB 142AB 142AB 142B 142B 142

    11111

    4855606575

    22222

    7070707070

    140

    100/112132160180

    250300350350

    303323359359

    608/651,5

    738,5 858 AA

    AB 72B 72A 97AB 97

    1112

    28384248

    2221

    38383838

    315

    200225250280315

    400450550550660

    616646646646681

    AA1393,51477,51523/1574

    1635/1735

    AB 142AB 142B 142B 142B 162

    11111

    5560657580

    22222

    7575757575

    160

    100/112132160180200

    250300350350400

    332352388388391

    637/680,5

    767,5 887 AAAA

    AB 72B 72A 97AB 97AB 112

    11122

    2838424855

    22211

    4242424242

    355

    200225250280315

    400450550550660

    671701701701731

    AA1448,51532,51578/1629

    1685/1805

    AB 162AB 162AB 162B 162B 162

    11111

    5560657580

    22222

    8080808080

    180

    132160180200225

    300350350400450

    386419419422452

    801,5 918

    AAAA1199,5

    AB 84AB 97B 97AB 112AB 127

    11122

    3842485560

    22211

    4848484848

    400

    200225250280315

    400450550550660

    729759759759789

    AA1506,51590,51636/1687

    1743/1863

    AB 182AB 182AB 182AB 182B 182

    11111

    5560657580

    22222

    9090909090

    Couplings bored with ISO-tolerance field H7, fitted key groove according to DIN 6885 part 1 and adjusting screw

  • 16 / 43

    BA 6610 CAVEX EN 12.11

    1.3 Ventilation, oil level, oil drainage, oil quantities and weights

    Size

    X (mm)

    100 120 140160180200

    225250

    280315

    355400

    60 70 82 95 110 135 160 190 210

    80 450500560630

    240 280

    63

    In the case of a vertical worm gear shaft, a distance of x must be kept free above the gear unit at M6 resp. M7.

    M1A1 B1

    M3M2

    M7M6

    2M3M

    6M7M

    B4

    B7B5

    B6

    B2

    B3

    A4

    A7A5

    A6

    A2

    A3

    Location of the ventilation Location of the oil level Location of the oil drainage

    Model Output on side

    Installation location

    SU SO SR SL VO VU

    CUW A A1 B2 1) B3 B3 B2 A1 B4 M1 A1 A1 M1 B4 M6 B5 M7 M7 B7 M6CUW

    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 M6COW

    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)CFA

    A A1 B2 1) B6 B6 B2 A1 B4 M1 A1 A1 M1 B4 M6 B5 M7 M7 B7 M6CFACDA B / both sides B1 A2 1) A6 A6 A2 B1 B1 M1 A4 A4 M1 B1 M6 A7 M7 M7 A5 M6

    1) For sizes 63 and 80: B5 instead of B2 resp. A5 instead of A2

    2) On CFW the flange is defined as output

    Average oil quantities in litres Average weightswithout oil in kg

    Model CUW, COW, CFW Bauart CUA, COA, CFA, CDA Model Size Installation location Installation location

    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

  • 16 / 43

    BA 6610 CAVEX EN 12.11

    1.3 Ventilation, oil level, oil drainage, oil quantities and weights

    Size

    X (mm)

    100 120 140160180200

    225250

    280315

    355400

    60 70 82 95 110 135 160 190 210

    80 450500560630

    240 280

    63

    In the case of a vertical worm gear shaft, a distance of x must be kept free above the gear unit at M6 resp. M7.

    M1A1 B1

    M3M2

    M7M6

    2M3M

    6M7M

    B4

    B7B5

    B6

    B2

    B3

    A4

    A7A5

    A6

    A2

    A3

    Location of the ventilation Location of the oil level Location of the oil drainage

    Model Output on side

    Installation location

    SU SO SR SL VO VU

    CUW A A1 B2 1) B3 B3 B2 A1 B4 M1 A1 A1 M1 B4 M6 B5 M7 M7 B7 M6CUW

    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 M6COW

    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)CFA

    A A1 B2 1) B6 B6 B2 A1 B4 M1 A1 A1 M1 B4 M6 B5 M7 M7 B7 M6CFACDA B / both sides B1 A2 1) A6 A6 A2 B1 B1 M1 A4 A4 M1 B1 M6 A7 M7 M7 A5 M6

    1) For sizes 63 and 80: B5 instead of B2 resp. A5 instead of A2

    2) On CFW the flange is defined as output

    Average oil quantities in litres Average weightswithout oil in kg

    Model CUW, COW, CFW Bauart CUA, COA, CFA, CDA Model Size Installation location Installation location

    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

    17 / 43

    BA 6610 CAVEX EN 12.11

    1.4

    Size 63 - 80 100 - 120 140 - 160 180 - 200 225 - 250 280 - 315 355 - 400 450 - 500 560 - 630

    Model n11/min LpA dB(A)

    3000 79 83 86

    C.. 1500

  • 18 / 43

    3. Safety information

    3.1

    3.2

    3.3

    BA 6610 CAVEX EN 12.11

    Environmental protection

    The relevant regulations and guidelines, for example ISO 14001, as well as the laws of the countries and states shall be followed. This is particularly applicable to the usage of lubricants, preservation and cleaning agents. The regulations of the manufacturers of the operating materials, auxiliary mate-rials and tools being used must be followed.

    Intended usage

    The CAVEX gear unit is constructed according to state-of-the-art technology and is delivered safe to operate. Unauthorized modifications, installations and modifications that influence the safety are not permitted. This also is applicable to safety installations that are installed as contact protection.

    The CAVEX gear unit may only be used and operated in the framework of the conditions defined on the delivery contract.

    General obligations

    The operator is to ensure that all persons working on the assembly, operation, maintenance and service and repair of the device have read and understood the instruction manual, and that they adhere to all items, in order to:

    avoid danger to life and limb of the user and third parties

    ensure the operational safety of the gear unit

    and

    exclude downtimes and environmental influences due to incorrect operation.

    The relevant occupational safety and environmental protection regulations shall be adhered to during transport, assembly and disassembly, operation and service and maintenance.

    The gear unit may only be operated, serviced and repaired by authorized, trained and instructed personnel.

    Cleaning the device with a pressure cleaning device is not permissible.

    All work shall be performed diligently and from the point of Safety.

    It is mandatory to work on the gear unit may only be performed at rest. The drive unit must be secured against unintentional start up. A sign indicating work is in progress on the gear unit must be applied to the activating switch of the gear unit.

    Welding work must not be performed on the gear unit. The gear units must not be used as ground point for welding work. Gear parts and bearings could be destroyed by welding.

    The drive aggregate must be switched off immediately if changes to the device are perceived during operation, such as for example an increased operating temperature or change of gear noises.

    Openly rotating drive parts must be secured against contact using appropriate safety measures.

    When installing the CAVEX gear unit in devices or units, the manufacturer of the devices or units is obligated to incorporate into his instruction manual the regulations, information and descriptions contained within this instruction manual.

    Information markings affixed to the CAVEX gear unit, such as for example the type plate, turning direction arrow etc. must be observed. They must be free from paint and dirt. Missing information plates must be replaced.

    Non-standard spare parts, such as bearings, radial shaft sealing rings, seals, screws, nuts, washers, sealing plugs, ventilation screws, oil level displays must always be obtained from CAVEX GmbH & Co. KG.

  • 18 / 43

    3. Safety information

    3.1

    3.2

    3.3

    BA 6610 CAVEX EN 12.11

    Environmental protection

    The relevant regulations and guidelines, for example ISO 14001, as well as the laws of the countries and states shall be followed. This is particularly applicable to the usage of lubricants, preservation and cleaning agents. The regulations of the manufacturers of the operating materials, auxiliary mate-rials and tools being used must be followed.

    Intended usage

    The CAVEX gear unit is constructed according to state-of-the-art technology and is delivered safe to operate. Unauthorized modifications, installations and modifications that influence the safety are not permitted. This also is applicable to safety installations that are installed as contact protection.

    The CAVEX gear unit may only be used and operated in the framework of the conditions defined on the delivery contract.

    General obligations

    The operator is to ensure that all persons working on the assembly, operation, maintenance and service and repair of the device have read and understood the instruction manual, and that they adhere to all items, in order to:

    avoid danger to life and limb of the user and third parties

    ensure the operational safety of the gear unit

    and

    exclude downtimes and environmental influences due to incorrect operation.

    The relevant occupational safety and environmental protection regulations shall be adhered to during transport, assembly and disassembly, operation and service and maintenance.

    The gear unit may only be operated, serviced and repaired by authorized, trained and instructed personnel.

    Cleaning the device with a pressure cleaning device is not permissible.

    All work shall be performed diligently and from the point of Safety.

    It is mandatory to work on the gear unit may only be performed at rest. The drive unit must be secured against unintentional start up. A sign indicating work is in progress on the gear unit must be applied to the activating switch of the gear unit.

    Welding work must not be performed on the gear unit. The gear units must not be used as ground point for welding work. Gear parts and bearings could be destroyed by welding.

    The drive aggregate must be switched off immediately if changes to the device are perceived during operation, such as for example an increased operating temperature or change of gear noises.

    Openly rotating drive parts must be secured against contact using appropriate safety measures.

    When installing the CAVEX gear unit in devices or units, the manufacturer of the devices or units is obligated to incorporate into his instruction manual the regulations, information and descriptions contained within this instruction manual.

    Information markings affixed to the CAVEX gear unit, such as for example the type plate, turning direction arrow etc. must be observed. They must be free from paint and dirt. Missing information plates must be replaced.

    Non-standard spare parts, such as bearings, radial shaft sealing rings, seals, screws, nuts, washers, sealing plugs, ventilation screws, oil level displays must always be obtained from CAVEX GmbH & Co. KG.

    19 / 43

    3.4 Special dangers

    3.5 Warnings and symbols in this instruction manual

    Information:

    4. Transport and storage

    Information: Follow the instructions in Chapter 3. Safety instructions.

    4.1 Scope of delivery

    4.2 Transport

    image-transport

    this side up fragile goods

    protect from moisture

    protectfrom heat

    centre of gravity No hooks fasten well

    Attention!

    Attention!

    BA 6610 CAVEX EN 12.11

    The transport of the gear unit must be conducted with adequate care to avoid personal injury and damage to the gear unit. For example, impacts on free shaft ends may lead to damage in the gear unit.

    To transport the gear unit, appropriate fastening means (for example eyebolts) must be screwed into the prepared threads on the top of the casing. The front threads in the shaft ends may not be used to attach eyebolts for transport.

    For transport, only use hoisting devices and load lifting installations with suffi-cient carrying capacity!

    Depending on the transport method and size the CAVEX gear unit is packaged differently. If not specifically agreed upon differently by contract, the packaging corresponds to the HPE packaging guidelines. The image instructions on the package shall be followed:

    The delivery content is listed in the shipping documents. Check that the delivery is complete upon receipt. Possible transport damage and/or missing parts must be reported in writing immediately.

    Depending on the operating condition, the CAVEX gear unit may generate high surface tempera-tures. Risk of burns!

    When changing the oil there is the risk of burns resulting from the escaping hot oil.

    This symbol indicates the safety measures that need to be followed to avoid perso-nal injury.

    This symbol indicates safety measures that need to be followed to avoid damage to the gear unit.

    This symbol indicates general operating instructions that need to be followed.

  • 20 / 43

    4.3 Storage of the gear unit

    4.4 Standard corrosion protection

    4.5 Type plate

    Attention!

    The type plate is made of aluminium. The data according to Point 1.1 is engraved into the anodized surface for permanent legibility. The type plate is riveted onto the gear unit casing.

    BA 6610 CAVEX EN 12.11

    The gear unit must be stored in a weather-protected location on a vibration-free surface.

    Stacking gear units on top of each other is not permissible.

    When storing a gear unit outside, the unit must be covered carefully. It must be ensured that moisture or dirt cannot settle onto the gear unit.

    The shaft ends, the drilling of the hollow shaft and the installation surface of the output flange are prepared with corrosion protection. It is seawater resistant and tropic-proof for a period of up to 12 months.

    All the greasing points are greased with the appropriate agents.

    The interior gear parts are corrosion protected. This protection is sufficient for normal transport conditions and a period of 6 months up to first start up.

    In case of longer intermediate storages (> 6 months) the interior and exterior corrosion protection must be inspected and renewed, if necessary. The gear unit is delivered without oil.

  • 21 / 43

    4.6. Coatings

    4.6.1 General information

    Information:

    4.6.2 Painted version

    Coating system Plastic 2K-PUR 2K-Epoxy

    Colours

    typ.Typical applicationarea

    Standard-1-layer-coatingfor interior areas

    Standard-2-layer-coating especially for

    usage outside resp. for the increased demands of corrosion protection

    High quality coatingfor exterior use resp.

    for stresses res-ulting from diluted acids and alkaline solutions ( 5%)

    Recoatability

    chem. phys.resistance

    Temperature resistance

    Remark

    Table 4.6.2: Painted version

    BA 6610 CAVEX EN 12.11

    The specifications concerning the possibility of repainting do not constitute an approval in the sense of a guarantee for the quality of the coating material delivered by your supplier.

    RAL 1003,1007, 1012,1023, 2000, 2004, 3000,5007, 5009, 5010, 5012,5015, 6011, 7001, 7011,7030, 7032, 7035, 9005,

    9006, black-matte

    RAL 1003, 1018, 2004, 5002, 5015, 6011, 7000, 7031, 9010, 9011,

    9016

    RAL 1003, 5015,6018, 7031, 7035

    2K-Epoxy-paint chalks when set installed outdoors

    (without influencing the quality), high shine

    with good mechanical resistance

    excellent resistance against: weak acids and lye ( 5%), oil,

    grease, fuel, coolant, salt, solvents; tough

    and scratchproof paint

    very good resistance against: oil, grease, fuel,

    water, seawater and cleaning agents; good

    resistance against: weather influences and

    diluted acids and lye ( 3%); not steam re-

    sistant lye ( 3%); good mechanical resistance

    against: abrasion

    after prior sanding down with: 2K-PUR paint,

    2K-Epoxy paint

    after prior sanding down with: 2K-PUR

    paint, 2K-Epoxy paint, 2K-AC paint

    Coverage after prior sanding down with: plastic paint resp.

    synthetic resin varnish; can be painted over

    after 3 days setting time

    good resistance against: cleaning agents, oil and fuel; resistant against:

    short term stresses with diluted acids and lye( 3%); not solvent resistant; not steam

    resistant

    Standard paint for cooling tower and

    agitator drive resp. when seawater resistance is needed below deck, or

    similar

    Standard paint with very good adhesive characte-

    ristic, not suitable for: storage outside, outdoor

    installation

    40 C ... +100 Cshort-term up to 140 C

    40 C ... +150 C 40 C ... +150 C

  • 22 / 43

    4.6.3 Primed version

    primedCoating system unpainted

    Standard colour anthracite brown -

    typ. area of usage

    Recoatability

    chem. phys. resistance -

    Temperature resistance 40 C ... +150 C (40 C ... +150 C)

    Remark

    Table 4.6.3: Primed version

    *)The type plate must be covered prior to painting.

    BA 6610 CAVEX EN 12.11

    for over painting*): Bonding agent for all common paint

    systems, temporary

    very good with: plastic paint, synthetic resin varnish, 2K-PUR paint, 2K-Epoxy paint, SH paint,

    2K-AC paint

    good resistance against: cleaning agents, good salt spray resistance; resistant

    against: oil and fuel

    Bonding agent with very good adhesive characteristics and

    good corrosion protection

    GG-parts immersion primed, St-parts primed or galvanized, Al- and plastic parts untreated

    very good with: plastic paint, synthetic resin varnish, oil paint, bitumen paint, 2K-PUR coating,

    2K-Epoxy coating

    for covering coating*):temporary corrosion protection

  • 5. Technical description

    5.1 General information

    Information: Follow the instructions in Chapter 3. Safety instructions.

    5.2 Identification

    Colour identification of ventilation, oil level and oil drainage:

    Ventilation and oil input:

    Oil level and lubrication positions:

    Oil drainage:

    On gear units with backstop, the rotation direction is indicated by an arrow.

    5.3 Ventilator

    5.4 Couplings

    5.5 Shrink disc

    5.6 Backstop

    For certain requirements the gear unit is equipped with a mechanical backstop.

    Information:

    Differentiation is made between two versions:

    Version A:

    Attention!

    BA 6610 CAVEX EN 12.11

    The gear unit is a single stage worm gear unit with CAVEX-teething.

    yellow

    red

    white

    On worm gear units equipped with ventilators, the ventilator is arranged on the fast running worm shaft of the gear unit and secured against unintentional contact by a ventilator cover. The ventilator sucks in air through the protective grid of the ventilator cover and leads it past the gear casing through the lateral air channels. This cools the air surrounding the gear casing.

    Contamination of the ventilator cover and the casing surface especially in the area of the worm drive significantly reduces the cooling effect (See Chapter 10. Maintenance and Service).

    As a general rule, elastic couplings should be installed for the drive and output of the gear unit.

    If rigid couplings are planned, approval must be obtained from the manufacturer. For the operation of the couplings, the special operating instructions of the couplings must be followed.

    For shaft-mounted gear units with hollow shaft in shrink disc version, a shrink disc Type HSD-32 is intended as frictional tension connection between the hollow gear shaft and the machine.

    The backstop is installed in the lid on the ventilator side. The backstop is installed oil-proof over an intermediate flange on the gear unit and is integrated in its oil circuit.

    Ensure that the air intake on the ventilator cover is not blocked.

    During operation, only the pre-determined direction is allowed. This is indicated by a directional arrow on the gear drive side.

    23 / 43

  • 24 / 43

    Information:

    Version B:

    5.7 Assembly of IEC-Motors

    When installing IEC-Motors, pay attention to the instruction manual of the motor.

    6. Assembly

    6.1 General assembly information

    Information: Follow the instructions in Chapter 3. Safety information.

    6.2. Description of the assembly

    Attention!

    Attention!

    BA 6610 CAVEX EN 12.11

    When using cleaning agents the relevant regulations and guidelines, for example according to ISO 14001, as well as the laws of the countries and states must be followed. Adhere to the regulations of the manufacturer of the cleaning agents.

    Agreement with CAVEX GmbH & Co. KG is necessary to change the rotation direction later on, as this is only possible with high level of technical effort.

    In order to avoid damage or destruction of the backstop, attention must be paid to ensure that the motor is not driven against the locked backstop!

    Any motor must not be used that exceeds the determined rotation speeds of the gear unit, as this may damage the gear unit.

    This version is intended if a later change of rotation direction is expected and no ventilator is required for the gear unit.

    The backstop is not integrated in the oil circuit. Separate lubrication is not necessary.

    The assembly must be performed such that the gear unit is not distorted during assembly and operation.

    The possibility of checking the oil level must be ensured.

    Foundations and connection constructions must be made such that no vibrations are transferred from neighbouring components and parts.

    A careful alignment to the output and drive side machine must be ensured, so that if necessary, elastic distortions due to the operating forces are taken into consideration if necessary.

    Fixing screws or nuts must be tightened with the determined torque. The tightening torque is listed in relevant tables. Screws with the minimum strength class 8.8 shall be used.

    If exterior forces influence the gear unit it is useful to prevent dislocation by lateral fixings.

    The cooling of the CAVEX gear units must not be influenced. Pay attention to free convection and open air flow during ventilator operation.

    To guarantee sufficient lubrication during operation, the installation position stated in the order placement must be adhered to.

    Remove corrosion protection paint on the shaft ends and connecting surfaces with cleaning agents.

  • Protect against burning by hot parts!

    Please follow the instruction manual of the part to be assembled.

    6.3 Assembly of a shaft-mounted gear with fitted key

    6.3.1 Preparation

    1

    1 Pressurized oil connection

    Information:

    Attention!

    Attention!

    Attention!

    Attention!

    BA 6610 CAVEX EN 12.11

    Mount couplings and similar connecting parts onto the shaft ends and secure them. If they are to be mounted warm, the necessary joining temperatures shall be requested from the manufacturer of the parts to be mounted.

    Warming can be performed, if not described otherwise, by induction, with a burner or in the oven.

    The gear shaft ends have thread drillings at the front ends with which couplings, disc, gears or similar can be mounted.

    For better disassembly we recommend installing a connection for pressurized oil at the shaft end of the machine. To do this, provide a drilled hole that ends at the turned end of the hollow shaft.

    The shaft end of the machine must be equipped with a fitted key according to DIN 6885 part 1 Form A and should have a centring device according to DIN 332 Form DS (with thread) on the front end.

    The parts to be mounted shall be assembled with help of suitable equipment to prevent damage of the shaft bearing due to axial joining force. The usage of appropriate hoisting devices must be ensured. Ensure that the shaft sealing rings and the surface of the shaft are not dama-ged when mounting the elements.

    Any fitting by impact or force is not permissible, as this may damage the rolling bearing, sealing rings and similar parts.

    Cleaning agents must not be allowed to penetrate beneath the sealing lips of the shaft sealing rings.

    Protection of the cleaned contact surfaces with an appropriate lubricant that prevents fretting corrosion.

    Check the hollow and machine shaft for damage to the intakes or edges. If necessary, refinish parts with an appropriate tool and clean them again.

    25 / 43

    Attention!

  • 26 / 43

    6.3.2 Assembly

    Information:

    1

    2

    3

    4

    4

    3

    2

    3142

    6.4 Assembly of a shaft-mounted gear unit with shrink disc

    6.4.1 Preparation

    Please follow the instruction manual of the part to be assembled.

    6.4.2 Mounting

    Attention!

    Attention!

    Attention!

    Attention!

    Attention!

    Attention!

    BA 6610 CAVEX EN 12.11

    Assembly of the hollow shaft gear unit onto the machine shaft can be performed with an end disc and securing ring, insofar these parts were included in the delivery.

    Cover plate End plate (Dismounting disc)

    Screw Securing ring

    By turning the end plate and using an appropriate screw, the end plate can be used as dismounting disc.

    When using cleaning agents, adhere to the relevant regulations and guide-lines, for example according to ISO 14001, as well as the laws of the countries and states. Follow the regulations of the manufacturer of the cleaning agent.

    Cleaning agents must not be allowed to penetrate beneath the sealing lips of the shaft sealing rings.

    Any lifting by impact or force is not permissible, as this can damage the rolling bearings, securing rings and similar parts.

    The hollow shaft may only be drawn against a machine shaft collar on models with torque support, as the bearings would be distorted on other models.

    The hollow shaft must be aligned with the machine shaft, so that jamming is prevented.

    Remove the corrosion protection coating on the shaft ends and connecting surfaces with a cleaning agent.

    Mounting with installed slide bush

    Mount drive with nut and threaded spindle. Support is given by the hollow shaft.

    The drilling of the hollow shaft and the exterior diameter of the machine shaft must be thoroughly cleaned in the area of the shrink disc position. Both surfaces must be absolutely free of grease.The safety of the torque transfer is highly dependant on this. Contaminated cleaning agents and cloths are inappropriate for degreasing the surfaces.

  • 27 / 43

    4321 56

    Machine shaftHollow shaft Hexagon nut

    Threaded spindle DiscSlide bush

    123

    456

    machine shaft hollow shaft interior ring

    exterior ring tensioning screw

    123

    45

    Information: Parts 3, 4 and 5 are not included in the scope of delivery.

    6.4.3 Axial securing

    6.4.4 Assembly of the shrink disc

    The shrink disc is delivered ready to install.

    It may not be disassembled prior to first tensioning.

    4

    1

    2

    3

    5

    A

    B

    A greased B absolutely free of grease

    Attention!

    Attention!

    Attention!

    The hollow shaft must be aligned with the machine shaft, so that jamming is prevented.

    On flange gear units, the hollow shaft may not be axially and radically distorted, as the bearings may fail due to excessive load.

    BA 6610 CAVEX EN 12.11

    Instead of the shown nut and threaded spindle you may also use a hydraulic puller.

    The axial securing of the hollow shaft on the machine shaft is performed by the shrink disc connection.

  • 28 / 43

    Information:

    Information: The control of the correct tightening status can thus be inspected visually.

    Tighten all tightening screws (5) in sequence (not crosswise).

    tensioningscrew thread

    M 8 29

    M 10 58

    M 12 100

    M 14 160

    M 16 240

    M 20 470

    M 24 820Table 6.1: Max. tightening torques of the tensioning screws

    Subsequently, mount the protective cover.

    6.4.5 Disassembly of the shrink disc

    6.4.6 Cleaning and lubrication of the shrink disc

    Attention!

    Attention!

    Attention!

    Attention!

    BA 6610 CAVEX EN 12.11

    max. tightening torque per screw

    strength class 10.9 Nm

    Subsequently, only the interior gliding surfaces of the shrink disc need to be lubricated again.

    When using cleaning agents and lubricants, adhere to the relevant regulations and guidelines, for example according to ISO 14001, and the laws of the countries and states. Pay attention to the regulations of the manufacturer of the cleaning agent and the lubricant.

    Loosened shrink discs do not need to be taken apart and greased again prior to renewed tensioning.

    Shrink discs only need to be disassembled and cleaned when they are dirty.

    The exterior surface of the hollow shaft can be greased in the area of the shrink disc location.

    Never tighten the tightening screws before the machine shaft is installed, as the hollow shaft will distort.

    In order to prevent overload of the individual screws the maximum tightening torque (see Table 6.1) may not be exceeded, the alignment of the front ends is priority. If this alignment is not achieved during tightening, check the tolerance of the insert shaft.

    The tightening screws can be tightened in several turns in sequence, until the front surfaces of the exterior and interior rings are aligned.

    The tensioning screws are loosened in several turns in sequence.

    If the exterior ring does not loosen off the interior ring by itself, unscrew some tightening screws and screw them into the neighbouring dismounting threads.

    Easy detensioning is then possible.

    Pull off the shrink disc from the hollow shaft.

  • 29 / 43

    6.5 Torque support

    90 20

    Information:

    6.6 Installation of motors

    Information:

    6.6.1 Installation on motor lantern with coupling

    Information:

    Use a solid material lubricant according to the following table.

    Lubricant

    Molykote 321 R (lubricant varnish)

    Molykote G Rapid

    Aema-Sol M 19 P

    Aema-Sol MO 84-K

    Table 6.2: Lubricants for shrink discs after their cleaning

    BA 6610 CAVEX EN 12.11

    On gear units with torque support, the support of the torque is achieved by bolts and brackets (see the following drawing). The gear unit must be mounted on the machine shaft without tension. The torque support must be achieved in a manner that the torque support is only tangentially and longitu-dinally stressed when the gear unit is operated. Adhere to the permissible angle for the assembly of the bracket on the torque support.

    In the case of misalignment of the machine shaft, attend to the coupling displace-ment on the drive shaft.

    Observe the special instruction manuals for the motors and the couplings for the installation of the motors and the couplings.

    Observe the special instruction manuals for the motors and the couplings for the installation of the motors.

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    7. Start up

    Information: Follow the instructions in Chapter 3. Safety instructions.

    7.1 Oil filling

    Attention!

    Attention!

    BA 6610 CAVEX EN 12.11

    Gear will be supplied without oil filling. Before initial operation, anti-corrosion agent must be discharged and gear must be filled with oil.

    When using cleaning agents and lubricants, adhere to the relevant regulations and guidelines, for example according to ISO 14001, as well as the laws of the countries and states. Follow the instructions of the manufacturer of the cleaning agent and lubricants.

    Prior to start up, check the oil level. The oil must be filled at least to the middle of the oil level window, as a maximum to the upper edge of the oil level window or up to the lower edge of the oil level opening. The upper locking screw must be replaced with the included ventilation screw.

    The oil viscosity to be maintained is listed on the rating plate of every gear unit. If other oils must be used, it is more permissible to use thicker oils than thinner oils. The only oils permissible for use are those listed in the lubricant table in Chapter 10, or according to the lubricant table on the website of CAVEX GmbH & Co. KG.

    7.2 Lubrication of bearings

    Bearings located above the oil level are equipped with grease filling.

    7.3 Installation and assembly parts

    7.3.1 Gear units with backstop

    Installed or assembled backstops are automatically lubricated.

    Attention!In order to avoid damage or destruction of the backstop, ensure that the motor is not driven in the locking direction of the backstop!

    Prior to start up, check whether the backstop can be turned in freewheeling without increased effort. The rotational direction arrows on the gear units must be adhered to.

    For CAVEX gear units with special additional installations (e.g. pumps, filter-oil cooler, spring-applied brakes, multi-disc clutch or similar) the specific operating instructions must be followed.

    The oil quantity stated on the type plate is a reference value. When filling the oil, wait until the oil has become evenly distributed and thus the final oil level is displayed.

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    7. Start up

    Information: Follow the instructions in Chapter 3. Safety instructions.

    7.1 Oil filling

    Attention!

    Attention!

    BA 6610 CAVEX EN 12.11

    Gear will be supplied without oil filling. Before initial operation, anti-corrosion agent must be discharged and gear must be filled with oil.

    When using cleaning agents and lubricants, adhere to the relevant regulations and guidelines, for example according to ISO 14001, as well as the laws of the countries and states. Follow the instructions of the manufacturer of the cleaning agent and lubricants.

    Prior to start up, check the oil level. The oil must be filled at least to the middle of the oil level window, as a maximum to the upper edge of the oil level window or up to the lower edge of the oil level opening. The upper locking screw must be replaced with the included ventilation screw.

    The oil viscosity to be maintained is listed on the rating plate of every gear unit. If other oils must be used, it is more permissible to use thicker oils than thinner oils. The only oils permissible for use are those listed in the lubricant table in Chapter 10, or according to the lubricant table on the website of CAVEX GmbH & Co. KG.

    7.2 Lubrication of bearings

    Bearings located above the oil level are equipped with grease filling.

    7.3 Installation and assembly parts

    7.3.1 Gear units with backstop

    Installed or assembled backstops are automatically lubricated.

    Attention!In order to avoid damage or destruction of the backstop, ensure that the motor is not driven in the locking direction of the backstop!

    Prior to start up, check whether the backstop can be turned in freewheeling without increased effort. The rotational direction arrows on the gear units must be adhered to.

    For CAVEX gear units with special additional installations (e.g. pumps, filter-oil cooler, spring-applied brakes, multi-disc clutch or similar) the specific operating instructions must be followed.

    The oil quantity stated on the type plate is a reference value. When filling the oil, wait until the oil has become evenly distributed and thus the final oil level is displayed.

    31 / 43

    7.4 Electrical connection (on CAVEX gear units with assembled motor)

    7.5 Start Up

    8. Operation

    Information: Follow the instructions in Chapter 3. Safety instructions.

    Attention!If irregularities occur during operation, the cause must be determined using the fault table (see Chapter 9.). The fault table contains possible faults, their causes and suggestions for solutions. If the cause cannot be determined resp. if it is not possible to repair the unit with own means, we recommend contacting CAVEX GmbH & Co. KG.

    Work on the terminals and live parts may generally only be performed by specially trained personnel. Follow the safety instructions.

    During operation, check the CAVEX gear unit for:

    high operating temperature

    different gear unit sounds

    possible oil leaks

    During start up, ensure that the ventilation screw with cap is installed; if necessary, remove the plastic screw cap or lock screw.

    Subsequently, the gear unit is to be operated initially in intermittent duty, meaning operated under normal operating stress for a few minutes, alternating with breaks lasting several times the length of the operating duration. The active periods can be gradually increased up to normal operation, where-by the operating temperature needs to be monitored. Operating temperatures of up to approx. +100C are permissible.

    We include a circuit diagram in the terminal box of every E-Motor showing how the motor must be connected. When connecting, ensure that the system voltage corresponds to that stated on the rating plate.

    In general, usage of a motor protection switch is recommended for protection against overload or phase failure. The overcurrent relay must be set to the correct rated input current assigned to the respective nominal voltage (see rating plate). Ground or protective wires must be connected with the included ground terminal.

    If the motor runs in the wrong rotation direction, 2 phases of the mains connection must be swapped over.

    BA 6610 CAVEX EN 12.11

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    9. Faults, causes and solution

    Information: Follow the instructions in Chapter 3. Safety instructions.

    9.1 General fault information

    Information:

    9.2 Possible defects

    Defects Causes Solution

    Different gear unit noises

    Increased operating temperature Oil filling with non-approved oil

    Oil level in the gear casing too high or too low

    Oil is old

    Oil is very contaminated

    Suction opening of the ventilation cover and/or gear unit casingseverely contaminated

    Grease filling of the bearings is old

    Bearing defective

    Backstop does not move freely

    Oil leak Radial-shaft sealing rings defective Change radial-shaft sealing rings

    Table 9.1: Fault information

    BA 6610 CAVEX EN 12.11

    Defects that occur during the warranty period and require repair of the gear unit may only be remedied by the CAVEX GmbH & Co. KG customer service. We also recommend using our customer service after the expiry of the warranty term.

    In general, the gear unit must be turned off during the repair of defects. Secure the drive aggregate against unintentional start up. Attach an informa-tion sign to the activation switch.

    Bearing tolerance enlarged

    Bearing defective

    Damage to the gears

    Gear unit mounting is loose

    Contact customer service.

    Contact customer service.

    Contact customer service.

    Tighten screws / nuts with prescribed torque.

    Replace damages screws / nuts.

    Fill with permissible oil

    Check oil level at room temperatureif necessary correct oil level

    Change oil. See Chapter 10.

    Change oil. See Chapter 10.

    Clean ventilator cover and gear unit casing

    New lubrication.See Chapter 10.

    Contact customer service.

    Contact customer service.

  • 32 / 43

    9. Faults, causes and solution

    Information: Follow the instructions in Chapter 3. Safety instructions.

    9.1 General fault information

    Information:

    9.2 Possible defects

    Defects Causes Solution

    Different gear unit noises

    Increased operating temperature Oil filling with non-approved oil

    Oil level in the gear casing too high or too low

    Oil is old

    Oil is very contaminated

    Suction opening of the ventilation cover and/or gear unit casingseverely contaminated

    Grease filling of the bearings is old

    Bearing defective

    Backstop does not move freely

    Oil leak Radial-shaft sealing rings defective Change radial-shaft sealing rings

    Table 9.1: Fault information

    BA 6610 CAVEX EN 12.11

    Defects that occur during the warranty period and require repair of the gear unit may only be remedied by the CAVEX GmbH & Co. KG customer service. We also recommend using our customer service after the expiry of the warranty term.

    In general, the gear unit must be turned off during the repair of defects. Secure the drive aggregate against unintentional start up. Attach an informa-tion sign to the activation switch.

    Bearing tolerance enlarged

    Bearing defective

    Damage to the gears

    Gear unit mounting is loose

    Contact customer service.

    Contact customer service.

    Contact customer service.

    Tighten screws / nuts with prescribed torque.

    Replace damages screws / nuts.

    Fill with permissible oil

    Check oil level at room temperatureif necessary correct oil level

    Change oil. See Chapter 10.

    Change oil. See Chapter 10.

    Clean ventilator cover and gear unit casing

    New lubrication.See Chapter 10.

    Contact customer service.

    Contact customer service.

    33 / 43

    10. Maintenance and service

    Information: Follow the instructions in Chapter 3. Safety instructions.

    10.1 General maintenance specifications

    Information:

    Measures Deadlines Remarks

    Monitor oil temperature, gear unitsounds and tightness

    Check oil level

    First oil change