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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
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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
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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
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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
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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
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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.
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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.
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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
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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.
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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.
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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.
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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.
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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
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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.
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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.
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Attention!
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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.
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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.
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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.
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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.
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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. +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.
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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.
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