®
www.CAVEX-GmbH.de
Instruction manualBA 6611 CAVEX EN 12.11
CAVEX®- worm gear units
of the models CS..
Sizes 63 to 630Instruction manual
CAVEX GmbH & Co. KGTübinger Straße 2D-72131 OfterdingenTelephone: +49 (0) 74 73 95 546 - 0Telefax: +49 (0) 74 73 95 546 - 88
®
www.CAVEX-GmbH.de
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 Type CSUW 6 1.2.2 Type CSOW 71.2.3 Type CSFW 81.2.4 Type CSDA 91.2.5 Type CSUA 101.2.6 Type CSOA 111.2.7 Type CSFA 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 6611 CAVEX EN 12.11
4 / 43BA 6611 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 part storage, customer service .1111.1 Spare part storage 3711.2 Spare part lists 3811.2.1 Type CS.W and CS.A 3811.3 Spare part drawings 39
39Type CS.W 63-80 and CS.W 100-2501.3.1111.3.2 Type CS.W 280-630 40
41Type CS.A 63-80 and CS.A 100-250 3.3.1111.3.4 Type CS.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 6611 CAVEX EN 12.11
6 / 43
BA 6611 CAVEX EN 12.11
1.2 Dimension tables
1.2.1 Type CSUW
Output shaft on side A, B or both sides; drive shaft in position a, b, c or d1); installation position SU, SO, SR, SL, VO or VU
Drive shaft in position ”a” shall be preferred; on size 63 only position ”a” is possible.
®
SideA
SideB A B
Ansicht X
X
SU
B
ASO
SR SL VO VU
A
B
B
A
B
A
A B
B A
d
b
c
a
a
a
aa
aa
a b cd1 l1 d1 l1
d2 e3 e4 E E1 G1 G2 h1 h2 H l2 m1 m2 m3 sa b ci1 < 3.6 i1 > 3.6
d2 e3 e4 E E1 G1 G2 h1 h2 H l2 m1 m2 m3 sSize
mm
63 80 100
146 175 216
140168200
20 24 28
16 k616 k622 k6
30 30 35
14 k614 k618 k6
30 30 35
28 m6 38 m6 48 m6
69 82 98
119140168
63 80100
50 50 63
168 182 220
72 86102
113125153
126 155 190
208 252 309
50 65 80
115 140 170
120145170
–––
121515
120 140 160
254 290 324
235260295
32 36 40
22 k628 m628 m6
35 40 40
18 k622 k622 k6
35 40 40
55 m6 65 m6 70 m6
114126143
194220244
120140160
63 80 80
241 286 304
120132150
168195210
225 255 290
364 416 472
95105120
200 230 260
200225255
–––
191919
180 200 225
364 396 440
325350380
45 50 55
35 m635 m642 m6
50 50 60
28 m628 m638 m6
50 50 60
80 m6 90 m6100 m6
159171188
272294323
180200225
100100125
350 368 419
165178195
240250290
320 350 390
522 573 638
140160180
290 315 350
280295325
–––
242428
250 280 315
480 525 590
415450490
60 65 70
42 m648 m648 m6
60 70 70
38 m642 m642 m6
60 70 70
110 n6120 n6140 n6
204222244
354387430
250280315
125160160
442 506 539
212230252
305360375
430 480 530
703 786 870
200220240
385 430 480
355385420
–––
283535
355 400 450
665 748 855
535585562
78 85 92
55 m655 m670 m6
80 80100
48 m648 m660 m6
80 80100
150 n6170 n6190 n6
266291322
478526596
355400450
200200250
620 662 784
275300332
440460540
595 660 740
97710861270
260290320
540 605 750
460510495
––
560
424235
500 560 630
95510501175
616678750
100110120
70 m685 m685 m6
100120120
60 m675 m675 m6
100120120
210 n6230 n6255 n6
355389429
663733815
500560630
250315315
838 9571022
365400440
565665700
815 9101015
141015601745
350390430
840 9201030
540600660
630700780
424248
6 / 43
BA 6611 CAVEX EN 12.11
1.2 Dimension tables
1.2.1 Type CSUW
Output shaft on side A, B or both sides; drive shaft in position a, b, c or d1); installation position SU, SO, SR, SL, VO or VU
Drive shaft in position ”a” shall be preferred; on size 63 only position ”a” is possible.
®
SideA
SideB A B
Ansicht X
X
SU
B
ASO
SR SL VO VU
A
B
B
A
B
A
A B
B A
d
b
c
a
a
a
aa
aa
a b cd1 l1 d1 l1
d2 e3 e4 E E1 G1 G2 h1 h2 H l2 m1 m2 m3 sa b ci1 < 3.6 i1 > 3.6
d2 e3 e4 E E1 G1 G2 h1 h2 H l2 m1 m2 m3 sSize
mm
63 80 100
146 175 216
140168200
20 24 28
16 k616 k622 k6
30 30 35
14 k614 k618 k6
30 30 35
28 m6 38 m6 48 m6
69 82 98
119140168
63 80100
50 50 63
168 182 220
72 86102
113125153
126 155 190
208 252 309
50 65 80
115 140 170
120145170
–––
121515
120 140 160
254 290 324
235260295
32 36 40
22 k628 m628 m6
35 40 40
18 k622 k622 k6
35 40 40
55 m6 65 m6 70 m6
114126143
194220244
120140160
63 80 80
241 286 304
120132150
168195210
225 255 290
364 416 472
95105120
200 230 260
200225255
–––
191919
180 200 225
364 396 440
325350380
45 50 55
35 m635 m642 m6
50 50 60
28 m628 m638 m6
50 50 60
80 m6 90 m6100 m6
159171188
272294323
180200225
100100125
350 368 419
165178195
240250290
320 350 390
522 573 638
140160180
290 315 350
280295325
–––
242428
250 280 315
480 525 590
415450490
60 65 70
42 m648 m648 m6
60 70 70
38 m642 m642 m6
60 70 70
110 n6120 n6140 n6
204222244
354387430
250280315
125160160
442 506 539
212230252
305360375
430 480 530
703 786 870
200220240
385 430 480
355385420
–––
283535
355 400 450
665 748 855
535585562
78 85 92
55 m655 m670 m6
80 80100
48 m648 m660 m6
80 80100
150 n6170 n6190 n6
266291322
478526596
355400450
200200250
620 662 784
275300332
440460540
595 660 740
97710861270
260290320
540 605 750
460510495
––
560
424235
500 560 630
95510501175
616678750
100110120
70 m685 m685 m6
100120120
60 m675 m675 m6
100120120
210 n6230 n6255 n6
355389429
663733815
500560630
250315315
838 9571022
365400440
565665700
815 9101015
141015601745
350390430
840 9201030
540600660
630700780
424248
7 / 43
1.2.2 Type CSOW
Output shaft on side A, B or both sides; drive shaft in position a, b, c or d1);installation position SU, SO, SR, SL, VO or VU
SideA
SideB
Mounting with pin screws and nuts
AB
View X
X
A B
SU
B
A
B ASO
A
B
SR SL VO VU
B
A
B
A
d
b
c
a
a
a
aa
aa
a b cd1 l1 d1 l1
d2 l2 e3 e4 E E1 G1 G2 h1 h2 H m1 m2 m3 sSize
a b ci1 < 3.6 i1 > 3.6
d2 l2 e3 e4 E E1 G1 G2 h1 h2 H m1 m2 m3 s
mm
63 80 100
146 175 216
140168200
20 24 28
16 k616 k622 k6
30 30 35
14 k614 k618 k6
30 30 35
28 m6 38 m6 48 m6
50 65 80
69 82 98
119140168
63 80100
50 50 63
168 182 220
72 86102
113 150 182
100120145
226 275 335
115 140 170
120145170
–––
121515
120 140 160
254 290 324
235260295
32 36 40
22 k628 m628 m6
35 40 40
18 k622 k622 k6
35 40 40
55 m6 65 m6 70 m6
95105120
114126143
194220244
120140160
63 80 80
241 286 304
120132150
227 255 300
170195220
395 450 510
200 230 260
200225255
–––
191919
180 200 225
364 396 440
325350380
45 50 55
35 m635 m642 m6
50 50 60
28 m628 m638 m6
50 50 60
80 m6 90 m6100
m6
140160180
159171188
272294323
180200225
100100125
350 368 419
165178195
325 370 400
245270300
565 620 690
290 315 350
280295325
–––
242428
250 280 315
480 525 590
415450490
60 65 70
42 m648 m648 m6
60 70 70
38 m642 m642 m6
60 70 70
110 n6120 n6140 n6
200220240
204222244
354387430
250280315
125160160
442 506 539
212230252
455 487 560
330367405
760 847 935
385 430 480
355385420
–––
283535
355 400 450
665 748 855
535585562
78 85 92
55 m655 m670 m6
80 80100
48 m648 m660 m6
80 80100
150 n6170 n6190 n6
260290320
266291322
478526596
355400450
200200250
620 662 784
275300332
610 705 730
455505530
105011651270
540 605 750
460510495
––
560
424235
500 560 630
95510501175
616678750
100110120
70 m685 m685 m6
100120120
60 m675 m675 m6
100120120
210 n6230 n6255 n6
350390430
355389429
663733815
500560630
250315315
838 9571022
365400440
845 8951045
595650730
141015601745
840 9201030
540600660
630700780
424248
1) Drive shaft in position ”a” shall be preferred; on size 63 only position ”a” is possible.
®
BA 6611 CAVEX EN 12.11
8 / 43
1.2.3 Type CSFW
Flange on side A, B or both sides; output shaft on side A, B or both sides; drive shaft in position a, b, c or d1); installation position SU, SO, SR, SL, VO or VU
2)
2)
SideB
SideA
Hole pattern for size and nuts Mounting with pin screws
BA
View X
X
A BSU
B
A
B A
SO
SR SL VO
A
B
VU
B
A
B
A
d
b
c
a
a
a
aa
aa
cd1 l1 d1 l1
d l dd4
e e e e E E g G G k s zSize
ci1 < 3.6 i1 > 3.6
d2 l2 d3h8
e1 e2 e3 e4 E E1 g3 G1 G2 k s z
mm
63 80 100
7 8 9
16 k616 k622 k6
30 30 35
14 k614 k618 k6
30 30 35
28 m6 38 m6 48 m6
50 65 80
188 218 266
150 180 220
63 75 90
82 97119
69 82 98
119140168
63 80100
50 50 63
76 90107
168 182 220
72 86102
170 200 245
5 x 9 7 x 9 7 x 11
3.544
120 140 160
101112
22 k628 m628 m6
35 40 40
18 k622 k622 k6
35 40 40
55 m6 65 m6 70 m6
95105120
315 360 410
260 305 340
105115130
139161182
114126143
194220244
120140160
63 80 80
125138157
241 286 304
120132150
290 335 380
7 x 13.5 7 x 13.5 7 x 17.5
555
180 200 225
131415
35 m635 m642 m6
50 50 60
28 m628 m638 m6
50 50 60
80 m6 90 m6100 m6
140160180
450 490 540
380 420 465
140150165
202223248
159171188
272294323
180200225
100100125
172185202
350 368 419
165178195
420 460 505
7 x 17.5 7 x 17.512 x 17.5
555
250 280 315
16.518
19.5
42 m648 m648 m6
60 70 70
38 m642 m642 m6
60 70 70
110 n6120 n6140 n6
200220240
590 665 730
515 575 640
180200215
273306340
204222244
354387430
250280315
125160160
220238260
442 506 539
212230252
555 625 690
12 x 17.512 x 2212 x 22
666
355 400 450
2122.524
55 m655 m670 m6
80 80100
48 m648 m660 m6
80 80100
150 n6170 n6190 n6
260290320
825 9101025
725 805 905
240260290
382426530
266291322
478526596
355400450
200200250
286312345
620 662 784
275300332
780 865 975
12 x 2612 x 2616 x 26
666
500 560 630
25.527
28.5
70 m685 m685 m6
100120120
60 m675 m675 m6
100120120
210 n6230 n6255 n6
350390430
115012701405
101511251260
315350385
595650730
355389429
663733815
500560630
250315315
380415456
838 9571022
365400440
109512101345
16 x 3316 x 3316 x 33
666
1) shaft in position ”a” shall be preferred; on size 63 only position ”a” is possible.
2) Flange only possible at this location
®
BA 6611 CAVEX EN 12.11
8 / 43
1.2.3 Type CSFW
Flange on side A, B or both sides; output shaft on side A, B or both sides; drive shaft in position a, b, c or d1); installation position SU, SO, SR, SL, VO or VU
2)
2)
SideB
SideA
Hole pattern for size and nuts Mounting with pin screws
BA
View X
X
A BSU
B
A
B A
SO
SR SL VO
A
B
VU
B
A
B
A
d
b
c
a
a
a
aa
aa
cd1 l1 d1 l1
d l dd4
e e e e E E g G G k s zSize
ci1 < 3.6 i1 > 3.6
d2 l2 d3h8
e1 e2 e3 e4 E E1 g3 G1 G2 k s z
mm
63 80 100
7 8 9
16 k616 k622 k6
30 30 35
14 k614 k618 k6
30 30 35
28 m6 38 m6 48 m6
50 65 80
188 218 266
150 180 220
63 75 90
82 97119
69 82 98
119140168
63 80100
50 50 63
76 90107
168 182 220
72 86102
170 200 245
5 x 9 7 x 9 7 x 11
3.544
120 140 160
101112
22 k628 m628 m6
35 40 40
18 k622 k622 k6
35 40 40
55 m6 65 m6 70 m6
95105120
315 360 410
260 305 340
105115130
139161182
114126143
194220244
120140160
63 80 80
125138157
241 286 304
120132150
290 335 380
7 x 13.5 7 x 13.5 7 x 17.5
555
180 200 225
131415
35 m635 m642 m6
50 50 60
28 m628 m638 m6
50 50 60
80 m6 90 m6100 m6
140160180
450 490 540
380 420 465
140150165
202223248
159171188
272294323
180200225
100100125
172185202
350 368 419
165178195
420 460 505
7 x 17.5 7 x 17.512 x 17.5
555
250 280 315
16.518
19.5
42 m648 m648 m6
60 70 70
38 m642 m642 m6
60 70 70
110 n6120 n6140 n6
200220240
590 665 730
515 575 640
180200215
273306340
204222244
354387430
250280315
125160160
220238260
442 506 539
212230252
555 625 690
12 x 17.512 x 2212 x 22
666
355 400 450
2122.524
55 m655 m670 m6
80 80100
48 m648 m660 m6
80 80100
150 n6170 n6190 n6
260290320
825 9101025
725 805 905
240260290
382426530
266291322
478526596
355400450
200200250
286312345
620 662 784
275300332
780 865 975
12 x 2612 x 2616 x 26
666
500 560 630
25.527
28.5
70 m685 m685 m6
100120120
60 m675 m675 m6
100120120
210 n6230 n6255 n6
350390430
115012701405
101511251260
315350385
595650730
355389429
663733815
500560630
250315315
380415456
838 9571022
365400440
109512101345
16 x 3316 x 3316 x 33
666
1) shaft in position ”a” shall be preferred; on size 63 only position ”a” is possible.
2) Flange only possible at this location
®
BA 6611 CAVEX EN 12.11
®
9 / 43
1.2.4 Type CSDA
Torque support on side A or B in position 1, 2 or 3; with or without end plate; drive shaft in position a, b, c or d1); installation position SU, SO, SR, SL, VO or VU
SideB
SideA
Cover plate Detail
XEnd plate
BA
View X
X
A BSU
B
ASO
B A
A
B
SR SL VO VU
B
A
B
A
1
2
3
d
b
c
a
2
1
3
3
2
1
1
2 3 3 2
1
2 3
2 3
1
1
a
a
a
a
a
a
c1 c2d1 l1 d1 l1
d6D2 D5
e1 e2 e4 e E E1 f g4 G1 G2L
L2 nP
sSize
c1 c2i1 < 3.6 i1 > 3.6
d6H7 H8
e1 e2 e4 e5 E E1 f g4 G1 G2min. max.*
L2 nmin.
s
mm
63 80 100
161620
81010
16 k616 k622 k6
30 30 35
14 k614 k618 k6
30 30 35
32 40 40
30 40 50
162020
63 75 90
82 97119
119140168
73 89102
63 80100
50 50 63
223
62 74 88
168 182 220
65 80 93
94114136
102124147
115139.
5165
140 180 225
101214
M 10M 16M 16
120 140 160
202525
121415
22 k628 m628 m6
35 40 40
18 k622 k622 k6
35 40 40
50 50 65
60 65 75
252532
105115130
139161182
194220244
115127142
120140160
63 80 80
334
101113126
241 286 304
106118132
155173194
167186212
187208.
5235.
5
270 315 360
161820
M 20M 20M 20
180 200 225
323240
161718
35 m635 m642 m6
50 50 60
28 m628 m638 m6
50 50 60
65 80 80
85 95105
324040
140150165
202223248
272294323
154165182
180200225
100100125
445
138148163
350 368 419
144155170
212228250
233250276
259278307
405 450 505
222528
M 20M 24M 24
250 280 315
404050
202224
42 m648 m648 m6
60 70 70
38 m642 m642 m6
60 70 70
80100100
115125140
405050
180200215
273306340
354387430
197213233
250280315
125160160
555
178192212
442 506 539
185200220
272293322
301326357
335363397
560 630 710
303236
M 24M 24M 30
355 400 450
506060
273033
55 m655 m670 m6
80 80100
48 m648 m660 m6
80 80100
120120150
160180200
606075
240260290
382426530
478526596
256279308
355400450
200200250
556
233256282
620 662 784
242265292
354387425
394433480
438481532
800 9001010
404548
M 30M 30M 30
500 560 630
757590
363840
70 m685 m685 m6
100120120
60 m675 m675 m6
100120120
150170170
220240270
759090
315350385
595650730
663733815
336370406
500560630
250315315
666
310351377
838 9571022
320352388
465510560
528583650
585643713
112012601420
505663
M 30M 36M 36
* Lmax is only applicable when using the dismounting disc
1) Drive shaft in position ”a” shall be preferred; on size 63 only position ”a” is possible.
BA 6611 CAVEX EN 12.11
®
10 / 43
1.2.5 Type CSUA
Cover plate on side A or B; with or without forcing-off disc Drive shaft in position a, b, c or d1); installation position SU, SO, SR, SL, VO or VU
Cover plate dismounting disc
SideB
SideA
BA
B
A
SUBA
Ansicht X
X
SO
AB
A
B
SR SL VO VU
B
A
B
A
a
a
a
a b c c2d1 l1 d1 l1 D2
D3 e4 e E E1 G1 G2 h1 h2 H m1 m2 m3L
L1P
sSize
a b c c2i1 < 3.6 i1 > 3.6 H7
D3 e4 e5 E E1 G1 G2 h1 h2 H m1 m2 m3min. max.*
L1min.
s
mm
63 80 100
146 175 216
140168200
20 24 28
81011
16 k616 k622 k6
30 30 35
14 k614 k618 k6
30 30 35
30 40 50
M 12M 20M 20
119140168
73 89102
63 80100
50 50 63
168 182 220
65 80 93
113125153
126 155 190
208 252 309
115 140 170
120145170
–––
94114136
102124147
105.5
128152
101214
121515
120 140 160
254 290 324
235260295
32 36 40
121415
22 k628 m628 m6
35 40 40
18 k622 k622 k6
35 40 40
60 65 75
M 24M 24M 24
194220244
115127142
120140160
63 80 80
241 286 304
106118132
168195210
225 255 290
364 416 472
200 230 260
200225255
–––
155173194
167186212
173192.
5218.
5
161820
191919
180 200 225
364 396 440
325350380
45 50 55
161718
35 m635 m642 m6
50 50 60
28 m628 m638 m6
50 50 60
85 95105
M 24M 30M 30
272294323
154165182
180200225
100100125
350 368 419
144155170
240250290
320 350 390
522 573 638
290 315 350
280295325
–––
212228250
233250276
240258285
222528
242428
250 280 315
480 525 590
415450490
60 65 70
202224
42 m648 m648 m6
60 70 70
38 m642 m642 m6
60 70 70
115125140
M 30M 30M 36
354387430
197213233
250280315
125160160
442 506 539
185200220
305360375
430 480 530
703 786 870
385 430 480
355385420
–––
272293322
301326357
311337369
303236
283535
355 400 450
665 748 855
535585562
78 85 92
273033
55 m655 m670 m6
80 80100
48 m648 m660 m6
80 80100
160180200
M 36M 36M 36
478526596
256279308
355400450
200200250
620 662 784
242265292
440460540
595 660 740
97710861270
540 605 750
460510495
––
560
354387425
394433480
407447495
404548
424235
500 560 630
955105
01175
616678750
100110120
363840
70 m685 m685 m6
100120120
60 m675 m675 m6
100120120
220240270
M 36M 42M 42
663733815
336370406
500560630
250315315
838 9571022
320352388
565665700
815 910101
5
141015601745
840 9201030
540600660
630700780
465510560
528583650
544600668
505663
424248
* Lmax is only applicable when using the dismounting disc
1) Drive shaft in position ”a” shall be preferred; on size 63 only position ”a” is possible.
BA 6611 CAVEX EN 12.11
®
10 / 43
1.2.5 Type CSUA
Cover plate on side A or B; with or without forcing-off disc Drive shaft in position a, b, c or d1); installation position SU, SO, SR, SL, VO or VU
Cover plate dismounting disc
SideB
SideA
BA
B
A
SUBA
Ansicht X
X
SO
AB
A
B
SR SL VO VU
B
A
B
A
a
a
a
a b c c2d1 l1 d1 l1 D2
D3 e4 e E E1 G1 G2 h1 h2 H m1 m2 m3L
L1P
sSize
a b c c2i1 < 3.6 i1 > 3.6 H7
D3 e4 e5 E E1 G1 G2 h1 h2 H m1 m2 m3min. max.*
L1min.
s
mm
63 80 100
146 175 216
140168200
20 24 28
81011
16 k616 k622 k6
30 30 35
14 k614 k618 k6
30 30 35
30 40 50
M 12M 20M 20
119140168
73 89102
63 80100
50 50 63
168 182 220
65 80 93
113125153
126 155 190
208 252 309
115 140 170
120145170
–––
94114136
102124147
105.5
128152
101214
121515
120 140 160
254 290 324
235260295
32 36 40
121415
22 k628 m628 m6
35 40 40
18 k622 k622 k6
35 40 40
60 65 75
M 24M 24M 24
194220244
115127142
120140160
63 80 80
241 286 304
106118132
168195210
225 255 290
364 416 472
200 230 260
200225255
–––
155173194
167186212
173192.
5218.
5
161820
191919
180 200 225
364 396 440
325350380
45 50 55
161718
35 m635 m642 m6
50 50 60
28 m628 m638 m6
50 50 60
85 95105
M 24M 30M 30
272294323
154165182
180200225
100100125
350 368 419
144155170
240250290
320 350 390
522 573 638
290 315 350
280295325
–––
212228250
233250276
240258285
222528
242428
250 280 315
480 525 590
415450490
60 65 70
202224
42 m648 m648 m6
60 70 70
38 m642 m642 m6
60 70 70
115125140
M 30M 30M 36
354387430
197213233
250280315
125160160
442 506 539
185200220
305360375
430 480 530
703 786 870
385 430 480
355385420
–––
272293322
301326357
311337369
303236
283535
355 400 450
665 748 855
535585562
78 85 92
273033
55 m655 m670 m6
80 80100
48 m648 m660 m6
80 80100
160180200
M 36M 36M 36
478526596
256279308
355400450
200200250
620 662 784
242265292
440460540
595 660 740
97710861270
540 605 750
460510495
––
560
354387425
394433480
407447495
404548
424235
500 560 630
955105
01175
616678750
100110120
363840
70 m685 m685 m6
100120120
60 m675 m675 m6
100120120
220240270
M 36M 42M 42
663733815
336370406
500560630
250315315
838 9571022
320352388
565665700
815 910101
5
141015601745
840 9201030
540600660
630700780
465510560
528583650
544600668
505663
424248
* Lmax is only applicable when using the dismounting disc
1) Drive shaft in position ”a” shall be preferred; on size 63 only position ”a” is possible.
BA 6611 CAVEX EN 12.11
®
11 / 43
BA 6611 CAVEX EN 12.11
1.2.6 Type CSOACover plate on side A or B; with or without forcing-off disc Drive shaft in position a, b, c or d1); installation position SU, SO, SR, SL, VO or VU
Cover plate
Mounting with pin screws and nuts
SideA
SideB
dismounting disc
B A
X
View X
SU
A B
B
A
A
B
B ASO
SR SL VO VU
B
A
B
A
c
d
b
a
a
aa
aa
a b c cd1 l1 d1 l1 D2
D e e E E G G h h HL
m m m LP
sSize
a b c c2 i1 < 3.6 i1 > 3.6 H7D3 e4 e5 E E1 G1 G2 h1 h2 H
min. max.*m1 m2 m3 L1 min.
s
mm
63 80 100
146 175 216
140168200
20 24 28
81011
16 k616 k622 k6
30 30 35
14 k614 k618 k6
30 30 35
30 40 50
M 12M 20M 20
119140168
73 89102
63 80100
50 50 63
168 182 220
65 80 93
113 150 182
100120145
226 275 335
94114136
102124147
115 140 170
120145170
–––
105.5
128152
101214
121515
120 140 160
254 290 324
235260295
32 36 40
121415
22 k628 m628 m6
35 40 40
18 k622 k622 k6
35 40 40
60 65 75
M 24M 24M 24
194220244
115127142
120140160
63 80 80
241 286 304
106118132
227 255 300
170195220
395 450 510
155173194
167186212
200 230 260
200225255
–––
173192.
5218.
5
161820
191919
180 200 225
364 396 440
325350380
45 50 55
161718
35 m635 m642 m6
50 50 60
28 m628 m638 m6
50 50 60
85 95105
M 24M 30M 30
272294323
154165182
180200225
100100125
350 368 419
144155170
325 370 400
245270300
565 620 690
212228250
233250276
290 315 350
280295325
–––
240258285
222528
242428
250 280 315
480 525 590
415450490
60 65 70
202224
42 m648 m648 m6
60 70 70
38 m642 m642 m6
60 70 70
115125140
M 30M 30M 36
354387430
197213233
250280315
125160160
442 506 539
185200220
455 487 560
330367405
760 847 935
272293322
301326357
385 430 480
355385420
–––
311337369
303236
283535
355 400 450
665 748 855
535585562
78 85 92
273033
55 m655 m670 m6
80 80100
48 m648 m660 m6
80 80100
160180200
M 36M 36M 36
478526596
256279308
355400450
200200250
620 662 784
242265292
610 705 730
455505530
1050
1165127
0
354387425
394433480
540 605 750
460510495
––
560
407447495
404548
424235
500 560 630
955105
01175
616678750
100110120
363840
70 m685 m685 m6
100120120
60 m675 m675 m6
100120120
220240270
M 36M 42M 42
663733815
336370406
500560630
250315315
838 957102
2
320352388
845 895104
5
595650730
1410
1560
1745
465510560
528583650
840 9201030
540600660
630700780
544600668
505663
424248
* Lmax is only applicable when using the dismounting disc 1) Drive shaft in position ”a” shall be preferred; on size 63 only position ”a” is possible.
1.2.7 Type CSFA
Cover plate on side A or B; with or without forcing-off disc Drive shaft in position a, b, c or d1); installation position SU, SO, SR, SL, VO or VU
SideA
SideB
Cover plate
Hole pattern for Size
Flange cover
dismounting disc
A B
X
View X
SU
A
A B
B
B A
SO
SR SL VO
B
A
VU
A
B
A
B
d
b
c
a
a
a
aa
aa
c c2d1 l1 d1 l1
d3d4 D2
D3 g3 G1 G2 e1 e2 e4 e E E1 kL
L1P
s zSize
c c2i1 < 3.6 i1 > 3.6
d3h8 H7
D3 g3 G1 G2 e1 e2 e4 e5 E E1 kmin.max.*
L1min.
s z
mm
63 80 100
131518
81011
16 k616 k622 k6
30 30 35
14 k614 k618 k6
30 30 35
145 175 217
95 125 155
30 40 50
M 12M 20M 20
63 75 90
168 182 220
65 80 93
63 75 90
82 97119
119140168
73 89102
63 80100
50 50 63
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
22 k628 m628 m6
35 40 40
18 k622 k622 k6
35 40 40
258 302 338
190 225 260
60 65 75
M 24M 24 M 24
104116129
241 286 304
106118132
105115130
139161182
194220244
115127142
120140160
63 80 80
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
35 m635 m642 m6
50 50 60
28 m628 m638 m6
50 50 60
379 416 462
295 330 375
85 95105
M 24M 30M 30
142152167
350 368 419
144155170
140150165
202223248
272294323
154165182
180200225
100100125
350 385 430
212228250
233250276
240258285
222528
8 x M 16 8 x M 1612 x M 16
555
250 280 315
374043
202224
42 m648 m648 m6
60 70 70
38 m642 m642 m6
60 70 70
510 574 638
420 465 530
115125140
M 30M 30M 36
181196216
442 506 539
185200220
180200215
273306340
354387430
197213233
250280315
125160160
480 535 600
272293322
301326357
311337369
303236
12 x M 1612 x M 2012 x M 20
566
355 400 450
464852
273033
55 m655 m670 m6
80 80100
48 m648 m660 m6
80 80100
720 804 906
600 680 770
160180200
M 36M 36M 36
238260287
620 662 784
242265292
240260290
382426530
478526596
256279308
355400450
200200250
680 760 860
354387425
394433480
407447495
404548
12 x M 2412 x M 2416 x M 24
666
500 560 630
556063
363840
70 m685 m685 m6
100120120
60 m675 m675 m6
100120120
1014
1126125
8
860 965109
0
220240270
M 36M 42M 42
314346382
838 957102
2
320352388
315350385
595650730
663733815
336370406
500560630
250315315
960107
0120
0
465510560
528583650
544600668
505663
16 x M 3016 x M 3016 x M 30
666
* Lmax is only applicable when using the dismounting disc
1) Drive shaft in position ”a” shall be preferred; on size 63 only position ”a” is possible.
BA 6611 CAVEX EN 12.11
®
12 / 43
®
13 / 43
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
Sizea3 b3 h3 m3 m4 m7 s3 t
Sizea4 b4 h4 m5 m6 m8 s3 t
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
BA 6611 CAVEX EN 12.11
®
14 / 43
1.2.9 Worm gear unit with shrink disc
Dimensions for shaftSlide 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
BA 6611 CAVEX EN 12.11
®
15 / 43
1.2.10 Installation IEC-Motor
1)
IEC-standard motor,construction type
B5, V1 or V3
BIPEX-coupling Model BWN
Drilling(mm)
IEC-standard motor,construction type
B5, V1 or V3
BIPEX-coupling Model BWN
Drilling(mm)
Size
a g gMotor side Gear side
Size
a g gMotor side Gear side
Sizea1
mm
g5
mm
g6≈
mmSize
Teil ∅ Teil∅
i1 <3.6
∅i1 >3.6
Sizea1
mm
g5
mm
g6≈
mmSize
Teil ∅ Teil∅
i1 <3.6
∅i1 >3.6
63718090
160200200
240252252
462,5 495,5 524
B 43B 43B 43
111
141924
222
161616
141414
200
90100/112
132160
200250300350
482494516552
754 799/842,5
931,51051
B 62B 62B 72A 97
1111
24283842
2222
35353535
28282828
80718090
160200200
254266266
476,5 509,5 538
B 43B 43B 43
111
141924
222
161616
141414
225
100/112132160180
250300350350
557577613613
862/905,5
992,51112AA
AB 72B 72A 97AB 97
1112
28384248
2221
42424242
38383838
100
718090
100/112
160200200250
297309309331
519,5552,5581
636/679,5
B 43B 53B 53B 62
1111
14192428
2222
22222222
18181818
250
100/112132160180
250300350350
580600636636
885/928,5
1015,5
1135AA
AB 72B 72A 97AB 97
1112
28384248
2221
42424242
38383838
120
718090
100/112
160200200250
318330330352
540,5573,5602
657/700,5
B 43B 53B 53B 62
1211
14192428
2222
22222222
18181818
280
100/112132160180200
250300350350400
654674710710713
959/1002,5
1084,5
1209AAAA
AB 84AB 84AB 97B 97AB 112
11112
2838424855
22221
4848484848
4242424242
140
8090
100/112132
200200250300
382382402424
625,5 654 707/750,5
839,5
B 62B 62B 62AB 72
1112
19242838
2221
28282828
22222222
315
100/112132160180200
250300350350400
687707743743746
992/1035,5
1122,5
1242AAAA
AB 84AB 84AB 97B 97AB 112
11112
2838424855
22221
4848484848
4242424242
160
8090
100/112132
200200250300
400400420442
643,5 672 725/768,5
857,5
B 62B 62B 62AB 72
1112
19242838
2221
28282828
22222222
355
132160180200225
300350350400450
801834834837867
1216,5
1333AAAA
1614,5
AB 112AB 112AB 112B 112AB 127
11112
3842485560
22221
5555555555
4848484848
180
90100/112
132160
200250300350
764781498534
736 781/824,5
913,51033
B 62B 62B 72A 97
1111
24283842
2222
35353535
28282828
400
132160180200225
300350350400450
843876876879909
1258,5
1375AAAA
1656,5
AB 112AB 112AB 112B 112AB 127
11112
3842485560
22221
5555555555
4848484848
Couplings bored with ISO-tolerance field H7, fitted key groove according to DIN 6885 part 1 and adjusting screw
BA 6611 CAVEX EN 12.11
The dimensions may vary slightly depending on the motor model. They are applicable to motors without additional installations
1.3 Ventilation, oil level, oil drainage, oil quantities and weights
M5 = additional oil drain with respective position of the primary gear stage
A1 B1
M3M2B4
B7B2
B5
B6
B3
M1
2M3MA4
A7A2
A5
A6
A3
M5
M4
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
⊗ ⊗ ⊗ ⊗ ⊗ ⊗
CSUW A A1 B2 1) B3 B3 M4 A1 B4 M1 A1 A1 M1 B4 M4 M5 M3 M3 B7 M4CSUWCSUA B / beiderseits B1 A2 1) A3 A3 M4 B1 B1 M1 A4 A4 M1 B1 M4 M5 M3 M3 A5 M4
CSOW A B4 B2 1) B6 B6 M4 B4 B4 M2/3 A4 A4 M2/3 B4 M4 M5 M3 M3 B7 M4CSOWCSOA B / beiderseits A4 A2 1) A6 A6 M4 A4 B4 M2/3 A4 A4 M2/3 B4 M4 M5 M3 M3 A5 M4
CSFW 2)
CSFAA A1 B2 1) B6 B6 M4 A1 B4 M1 A1 A1 M1 B4 M4 M5 M3 M3 B7 M4
CSFACSDA B / beiderseits B1 A2 1) A6 A6 M4 B1 B1 M1 A4 A4 M1 B1 M4 M5 M3 M3 A5 M4
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 CSUW , CSOW, CSFW Model CSUA, CSOA, CSFA, CSDA ModelSize
, , Installation location Installation location
SU SO SR/SL VO/VU SU SO SR/SL VO/VU CS.W CS.A
63 1 1.2 1 1.8 1 1.1 0.9 1.7 21 21
80 1.6 2.4 1.6 2.9 1.6 2.2 1.4 2.7 31 31
100 2 4.4 3 5.6 2 4.1 2.7 5.2 54 52
120 2.7 7 4.7 8.5 2.7 6.5 4.2 8 77 74
140 4.5 11.5 7.5 13.5 4.5 10.5 7 12.5 112 107
160 6 15.5 10 18 6 14.5 9.5 17 147 142
180 8 22 14.5 27 8 21 13.5 25 205 195
200 10 28 18 34 10 27 17 32 255 245
225 15 40 26 48 15 37 25 45 340 320
250 18 53 32 61 18 49 31 56 430 410
280 23 70 45 80 23 66 43 76 600 570
315 28 90 60 102 28 84 57 96 780 740
355 43 130 90 145 43 122 87 137 1160 1110
400 55 175 115 195 55 165 110 185 1530 1470
450 85 270 173 293 85 258 160 280 2200 2130
500 107 360 226 390 107 345 210 375 2920 2840
560 158 510 330 560 158 490 310 540 4100 4000
630 200 680 430 750 200 655 405 725 5400 5280
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BA 6611 CAVEX EN 12.1116 / 43
1.3 Ventilation, oil level, oil drainage, oil quantities and weights
M5 = additional oil drain with respective position of the primary gear stage
A1 B1
M3M2B4
B7B2
B5
B6
B3
M1
2M3MA4
A7A2
A5
A6
A3
M5
M4
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
⊗ ⊗ ⊗ ⊗ ⊗ ⊗
CSUW A A1 B2 1) B3 B3 M4 A1 B4 M1 A1 A1 M1 B4 M4 M5 M3 M3 B7 M4CSUWCSUA B / beiderseits B1 A2 1) A3 A3 M4 B1 B1 M1 A4 A4 M1 B1 M4 M5 M3 M3 A5 M4
CSOW A B4 B2 1) B6 B6 M4 B4 B4 M2/3 A4 A4 M2/3 B4 M4 M5 M3 M3 B7 M4CSOWCSOA B / beiderseits A4 A2 1) A6 A6 M4 A4 B4 M2/3 A4 A4 M2/3 B4 M4 M5 M3 M3 A5 M4
CSFW 2)
CSFAA A1 B2 1) B6 B6 M4 A1 B4 M1 A1 A1 M1 B4 M4 M5 M3 M3 B7 M4
CSFACSDA B / beiderseits B1 A2 1) A6 A6 M4 B1 B1 M1 A4 A4 M1 B1 M4 M5 M3 M3 A5 M4
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 CSUW , CSOW, CSFW Model CSUA, CSOA, CSFA, CSDA ModelSize
, , Installation location Installation location
SU SO SR/SL VO/VU SU SO SR/SL VO/VU CS.W CS.A
63 1 1.2 1 1.8 1 1.1 0.9 1.7 21 21
80 1.6 2.4 1.6 2.9 1.6 2.2 1.4 2.7 31 31
100 2 4.4 3 5.6 2 4.1 2.7 5.2 54 52
120 2.7 7 4.7 8.5 2.7 6.5 4.2 8 77 74
140 4.5 11.5 7.5 13.5 4.5 10.5 7 12.5 112 107
160 6 15.5 10 18 6 14.5 9.5 17 147 142
180 8 22 14.5 27 8 21 13.5 25 205 195
200 10 28 18 34 10 27 17 32 255 245
225 15 40 26 48 15 37 25 45 340 320
250 18 53 32 61 18 49 31 56 430 410
280 23 70 45 80 23 66 43 76 600 570
315 28 90 60 102 28 84 57 96 780 740
355 43 130 90 145 43 122 87 137 1160 1110
400 55 175 115 195 55 165 110 185 1530 1470
450 85 270 173 293 85 258 160 280 2200 2130
500 107 360 226 390 107 345 210 375 2920 2840
560 158 510 330 560 158 490 310 540 4100 4000
630 200 680 430 750 200 655 405 725 5400 5280
®
BA 6611 CAVEX EN 12.1116 / 43
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17 / 43
BA 6611 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 <70 <70 73 75 79 82 87
750 <70 <70 <70 <70 <70 71 76 81 85
Table 1.2: Measurement surfaces - Sound pressure level LpA in dB(A)
2. General information
2.1
2.2
Attention!
CAVEX GmbH & Co. KGTübinger Straße 2D-72131 Ofterdingen
Telephone: +49 (0) 7473 95 546-13Telefax: +49 (0) 7473 95 546-88
E-Mail: [email protected] Internet: www.CAVEX-GmbH.de
Measurement surfaces – Sound pressure level
The measurement surfaces – sound pressure level of the CAVEX® gear unit according to DIN 45635 is applicable on a measurement surface in 1 m distance from the gear surface with a minimum of 30% nominal capacity.
The measurement surfaces – sound pressure levels stated in Table 1.2 are taken from the quality control statistic evaluations. It can be expected that the CAVEX® gear unit does not exceed these noise levels. If no clear conditions can be created on site for technical measurement during remea-surements, the measurement on the CAVEX GmbH & Co. KG testing benches is applicable.
Introduction
The present instruction manual is included in the delivery of the gear unit and should always be kept close to the gear unit.
The CAVEX® gear unit described here is constructed according to the recognized safety-technical rules and corresponds to the technical status at the time this instruction manual was printed.
In the interest of further development we reserve the right to conduct those changes on the individual components and accessories that are deemed beneficial for the increase of performance and safety with the maintenance of the essential features.
Copyright
The copyright to this instruction manual remains with CAVEX GmbH & Co. KG.
The instruction manual may not be used in part or in whole without authorization and without our consent for competitive purposes or made available to third parties.
Please contact our factory in case of technical questions:
Every person who is involved in the assembly, operation, maintenance and repair of the gear unit must have read and understood the instruction manual, and adhere to it. We are not liable for damage and operational defects that occur due to non-adherence to the instruction manual.
or contact one of our customer service addresses. A list of our customer service offices is available on the website www.cavex-gmbh.de
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18 / 43
3. Safety information
3.1
3.2
3.3
BA 6611 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.
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18 / 43
3. Safety information
3.1
3.2
3.3
BA 6611 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 6611 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.
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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 6611 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 6611 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
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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 6611 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 6611 CAVEX EN 12.11
The gear is a two-level gear with a helical prestage gear and a main gear as worm-gear speed redu-cer with CAVEX® toothing.
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.
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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 6611 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 6611 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.
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
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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 6611 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 6611 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.
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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 6611 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 6611 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 6611 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 6611 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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7.4 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. +100°C 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 6611 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 6611 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.
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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 6611 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.
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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
Further oil changes
Lubrication of the bearing
Renew grease in the bearings
Clean ventilation screw
Clean ventilator and casing
Check fixing screws for tightness
continuously
every 3 months
after approx. 1000-2000 operating hours
after approx. 6000-12000 operating hours, at the latest after 5 years
see plates with exact instructions for the grease nipple
after approx. 10000 to 15000 operating hours, at the latest after 5 years
if contaminated
if contaminated
during every oil change
in case of change see Table 9.1
see Items 7.1. and 10.2.1
see Items 7.1. and 10.2.1
see Item 10.2.2
see Item 10.2.2
see Item 10.2.3
see Item 10.2.4
Table 10.1: Maintenance intervals
All maintenance and service work shall be performed carefully and only by specially trained personnel.
The adherence to the warranty conditions also includes the adherence to the inspection intervals.
BA 6611 CAVEX EN 12.11
Oil level at least up to the middleof oil level window, maximum to the upper edge of the oil window or to the lower edge of the oil level opening for a cold gear unit in standstill
10.2 Description of the maintenance and service work
When using cleaning agents and lubricants, adhere to the relevant regula-tons and guidelines, for example according to ISO 14001, and the laws of the countries and states. Follow the instructions of the manufacturer of the clea-ning agents and lubricants.
10.2.1 Oil change
Secure the drive aggregate against unintentional start up. Attach an informa-tion plate to the on-off switch.
Burning hazard due to hot oil. Before performing any work, wait until the oil has cooled to below +30 °C.
Remove excess oil immediately in an environmentally friendly manner using oil binding agents.
The oil quantity and the location of the lock elements depend on the installati-on position, see Item 1.3 “Ventilation, oil level, oil drainage, oil quantities and weights”.
During an oil change, the gear unit should be filled with the previously used oil. Mixing oils of different types is not permissible. Only use lubricants according to the lubricant table in Chapter 10 or according to the lubricant table on the website of CAVEX GmbH & Co. KG.
The oil must be drained immediately after the device was turned off, while the oil is still warm. The oil must be able to drain long enough to remove sludge, abrasion and remaining oil. Shimmering bronze abrasion in the oil is not harmful.
In case of double gear units, inspect each unit separately.
Surrounding conditions that deviate from the normal surrounding conditions (high surrounding temperatures, high humidity, aggressive surrounding media) shorten the change intervals. In this case, please contact CAVEX GmbH & Co. KG to determine individual intervals for lubricants change.
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BA 6611 CAVEX EN 12.1134 / 43
Information:
Information:
Information:
Attention!
Attention!
10.2.2 Grease
The permissible roller bearing greases are listed in the lubricants table Chapter 10 and in the lubricants table on the website CAVEX GmbH & Co. KG.
When lubricating, do not mix greases of different soaps.
10.2.3 Clean ventilator and casing
• Shut down the gear unit by switching off the drive aggregate and secure it against rotation.
Secure the drive aggregate against unintentional start up. Attach informati-on plate to the activation location
• Remove possible corrosion, if present.
Cleaning with a pressure cleaning device is not permissible.
10.2.4 Check fixing screws for tightness
• Shut down the gear unit by switching off the drive aggregate and secure it against rotation.
Secure the drive aggregate against unintentional start up. Attach an informa-tion plate to the on-off switch.
Check all fixing screws for tightness and tighten if necessary. The tightening torques for the tightening screws are listed in the relevant tables.
Screws that can no longer be used must be replaced with new screws of the same strength class and design.
10.3 Lubrication
The oil of the different lubricants is listed in the following table. Our homepage at www.cavex-gmbh.com always shows you the newest specifications about all lubricants allowed by CAVEX GmbH & Co. KG.
If you decide not to follow our recommendation due to a reason that is important to you, you assume responsibility for the technical adequacy of the lubricant.
Therefore, we recommend that our customers select a lubricant from the table with consideration of the VG-class stated on the type plate.
Using gear oils that do not correspond to the above stated quality requirements may void our warranty obligation. We explicitly state that every oil manufacturer resp. oil supplier is responsible for the quality of his product.
The oil viscosity class stated on the rated plate of the gear unit is always decisive for the oil selection. When using a different viscosity or a different gear oil than recommended here the operator assumes responsibility for the technical adequacy of the lubricant.
Follow the instructions on the type plates and in the instruction manuals of the gear units!
Information:
Information:
Attention!
Attention!
Attention!
Attention!
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BA 6611 CAVEX EN 12.1135 / 43
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BA 6611 CAVEX EN 12.11
Lubricant
Viscosity ISO-VG
DIN 51519at 40 °C(mm2/s)
VG 1000
VG 680
Polyglycols VG 460
(PG-oil) VG 320
VG 220
VG 150
RENOLIN PG 1000
RENOLIN PG 680
RENOLIN PG 460
RENOLIN PG 320
RENOLIN PG 220
RENOLIN PG 150
Renolit GP2 PETAMO GHY 133N Tribol 4020/220-2
Tribol 3785Renolit GP3
Renolit H443-HD88
Rolling bearing greases
Klübersynth GH6-1000
Klübersynth GH6-680
Klübersynth GH6-460
Klübersynth GH6-320
Klübersynth GH6-220
Klübersynth GH6-150
Tribol 800/1000
Tribol 800/680
Tribol 800/460; Tribol 1300/460
Tribol 800/320
Tribol 800/220; Tribol 1300/220
Tribol 800/150
10.3.1 Oil types
• Synthetic oils (Polyglycols) Polyglycols approx. –20 °C to +100 °C (short term +110 °C).
Information: The upper and lower usage temperatures (flashpoint, pour point) of individual gear oils may deviate strongly from the stated values. These and further data and characteristics of the gear oils are listed in the technical data sheets of the oil manuf-acturers.
37 / 43
BA 6611 CAVEX EN 12.11
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11. Spare parts
11.1 Spare part storage
To order spare parts, please use the spare parts list and spare parts drawing.
We only provide a warranty for original spare parts that we deliver.
We explicitly state that spare parts we did not supply are also not inspected and approved by us. The installation and/or usage of such products may negatively alter constructively determined characteristics of the CAVEX® -gear unit and thus impede the active and/or passive safety. Any liability and warranty by CAVEX GmbH & Co. KG are excluded for damage occurring due to the usage of non-original-spare parts.
The following data shall be stated in spare part orders:
Ident-No. of the gear unit (see type plate)
Part-No. (from spare part list)
Quantity (from spare part list)
Attention!
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BA 6611 CAVEX EN 12.1138 / 43
11.2 Spare part lists
11.2.1 Type CS.W and CS.A
Spare parts
CS.W CS.A
Part-No.
Designation 63–
80
100–
250
280–
630
63–
80
100–
250
280–
630
10 Shaft x x x
15 Shaft sealing ring x x x x x x
28 Dowel screw x x x x
29 Hexagonal nut x x x x
30 Disc x x x x
42 Roller bearing x x x x x x
43 Worm x x x x x x
44 Wheel rim x x x x x x
45 Nave x x
45 Hollow shaft x x x
50 Shaft sealing ring x x x x x x
52 Nilos ring x x x x x x
60 Roller bearing x x x x x x
61 Roller bearing x x x x x x
63 Groove nut x x
74 Shrink disc x x x
114 Shaft sealing ring x x x x x x
141 Roller bearing x x x x x x
142 Roller bearing x x x x x x
143 Pinion shaft x x x x x x
144 Spur gear x x x x x x
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BA 6611 CAVEX EN 12.1138 / 43
11.2 Spare part lists
11.2.1 Type CS.W and CS.A
Spare parts
CS.W CS.A
Part-No.
Designation 63–
80
100–
250
280–
630
63–
80
100–
250
280–
630
10 Shaft x x x
15 Shaft sealing ring x x x x x x
28 Dowel screw x x x x
29 Hexagonal nut x x x x
30 Disc x x x x
42 Roller bearing x x x x x x
43 Worm x x x x x x
44 Wheel rim x x x x x x
45 Nave x x
45 Hollow shaft x x x
50 Shaft sealing ring x x x x x x
52 Nilos ring x x x x x x
60 Roller bearing x x x x x x
61 Roller bearing x x x x x x
63 Groove nut x x
74 Shrink disc x x x
114 Shaft sealing ring x x x x x x
141 Roller bearing x x x x x x
142 Roller bearing x x x x x x
143 Pinion shaft x x x x x x
144 Spur gear x x x x x x
11.3 Spare part drawings
11.3.1 Type CS.W 63-80 and CS.W 100-250
A, B, E = Alignment disc
614360144114 05242551341
142 2544240501141
E
A B
B
CS.W 63 - 80
A, B, E = Alignment disc (B only for size 100)
142 242544540501141
302928
614360144114 052451341
E
AB
B
CS.W 100 - 250
BA 6611 CAVEX EN 12.11
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40 / 43
11.3.2 Type CS.W 280-630
A, E = Alignment disc
142 242544540501141
302928
614360144114 054251143
E
A
63
BA 6611 CAVEX EN 12.11
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11.3.2 Type CS.W 280-630
A, E = Alignment disc
142 242544540501141
302928
614360144114 054251143
E
A
63
BA 6611 CAVEX EN 12.11
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11.3.3 Type CS.A 63-80 and CS.A 100-250
A, B, E = Alignment disc
142 25442405141 45
E
A B
B
470551163406441411341
CS.A 63 - 80
A, B, E = Alignment disc (B only for size 100)
142 254405141 45
E
AB
B
42
302928
470551163406441411341 42
CS.A 100 - 250
BA 6611 CAVEX EN 12.11
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11.3.4 Type CS.A 280-630
A, E = Alignment disc
142 254405141 45
E
A
42
302928
470551163406441411341 4263
BA 6611 CAVEX EN 12.11
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11.3.4 Type CS.A 280-630
A, E = Alignment disc
142 254405141 45
E
A
42
302928
470551163406441411341 4263
BA 6611 CAVEX EN 12.11
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Bankverbindung:BW-Bank TübingenKto.-Nr.: 2 654 856(BLZ 600 501 01)Ust-IdNr.: DE277096258
Gerichtsstand:Registergericht Stuttgart HRA 726424Pers. haftende Gesellschaft CAVEX Verwaltungs-GmbHAmtsgericht Stuttgart HRB 737611Geschäftsführer: Dr.-Ing. Peter Leoni
G e r m a n D r i v e Te c h n o l o g y
CAVEX GmbH & Co. KGTübinger Straße 2D-72131 OfterdingenTel.: +49 (0) 74 73 95 546 - 0Fax: +49 (0) 74 73 95 546 - 88
Kontakt: [email protected]
Mehr erfahren Sie unter
w w w. C AV E X - G m b H . d e
Jens Heilemann Andy Schäfer
Declaration of Incorporationaccording to Directive 2006/42/EG, Appendix II, Part 1, Section B
chief operating officerHead of design & development
The manufacturer
CAVEX GmbH & Co. KGTübinger Straße 2D-72131 Ofterdingen
declares as follows:
The declaration refers to CAVEX-worm gear units models CS.. of size 63 to 630. The previously stated gear units are the incomplete machines in terms of directive 2006/42/EG.
The special technical documents according directive 2006/42/EEC, appendix VII B, are prepared.
The general safety and health protection requirements according directive 2006/42/EG, appendix I, are applied and followed.
1.1.1., 1.1.2., 1.1.3., 1.1.5., 1.2.6., 1.3.1., 1.3.2., 1.3.3., 1.3.4., 1.3.6., 1.3.7., 1.3.8.1., 1.4.1., 1.4.2.1.,1.5.1., 1.5.2., 1.5.3., 1.5.4., 1.5.5., 1.5.6., 1.5.7., 1.5.8., 1.5.9., 1.5.10., 1.5.11., 1.5.13., 1.5.14., 1.5.15.,1.6.1., 1.6.2., 1.6.5., 1.7.1., 1.7.1.1., 1.7.1.2., 1.7.3., 1.7.4., 1.7.4.1., 1.7.4.2., 1.7.4.3.
The manufacturer agrees to hand over upon special request to individual state officies the special documents according directive 2006/42/EG, appendix VII B. The documents will be transferred in electronic form.
The incomplete machine CAVEX-worm gear unit of the models CS.. of size 63 to 630 may only be taken intooperation if it was determined that the machine into which the incomplete machine CAVEX-worm gear unit ofthe models CS.. of size 63 to 630 is to be installed corresponds to the directive 2006/42/EG.
The following person is authorized to prepare the relevant technical documents:Jens Heilemann, head of design & development, CAVEX GmbH Co. KG, Tübinger Straße 2,D-72131 Ofterdingen
D-72131 Ofterdingen, 20.3.2012
www.CAVEX-GmbH.de
CAVEX GmbH & Co. KGTübinger Straße 2D-72131 OfterdingenTel.: +49 (0) 74 73 95 546 - 0Fax: +49 (0) 74 73 95 546 - 88
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