instruction manual - cavex · instruction manual ba 6611 cavex en 12.11 ... gear tooth geometry....

®

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.


6 / 43


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


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.

®


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

®


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

®


®

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



®

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




®

10 / 43

1.2.5 Type CSUA


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




®

11 / 43


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


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




®

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


Sizea3 b3 h3 m3 m4 m7 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





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

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


®

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


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

®

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

®

17 / 43


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

®

18 / 43

3. Safety information

3.1

3.2

3.3


Environmental protection

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

Intended usage

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

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

General obligations

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

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

– ensure the operational safety of the gear unit

and

– exclude downtimes and environmental influences due to incorrect operation.

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

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

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

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

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

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

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

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

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

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

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

®

18 / 43

3. Safety information

3.1

3.2

3.3


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!

®


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

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

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

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

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

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

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

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

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

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

®

20 / 43

4.3 Storage of the gear unit

4.4 Standard corrosion protection

4.5 Type plate

Attention!

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


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


®

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.


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


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!

®


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.

23 / 43

®

24 / 43

Information:

Version B:

5.7 Assembly of IEC-Motors

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

6. Assembly

6.1 General assembly information

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

6.2. Description of the assembly

Attention!

Attention!


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!

®


• 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

®

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!


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.


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

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

®

28 / 43

Information:

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

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

tensioningscrew thread

M 8 29

M 10 58

M 12 100

M 14 160

M 16 240

M 20 470

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

Subsequently, mount the protective cover.

6.4.5 Disassembly of the shrink disc

6.4.6 Cleaning and lubrication of the shrink disc

Attention!

Attention!

Attention!

Attention!


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


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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®

30 / 43

7. Start up


7.1 Oil filling

Attention!

Attention!


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


7.1 Oil filling

Attention!

Attention!


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


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.


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32 / 43

9. Faults, causes and solution


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


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.



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.


Clean ventilator cover and gear unit casing

New lubrication.See Chapter 10.



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32 / 43

9. Faults, causes and solution


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


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




Tighten screws / nuts with prescribed torque.

Replace damages screws / nuts.

Fill with permissible oil

Check oil level at room temperatureif necessary correct oil level



Clean ventilator cover and gear unit casing

New lubrication.See Chapter 10.



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33 / 43

10. Maintenance and service


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.


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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36 / 43


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






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


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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


52 Nilos ring x x x x x x



63 Groove nut x x

74 Shrink disc 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


28 Dowel screw x x x x

29 Hexagonal nut x x x x

30 Disc 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


52 Nilos ring x x x x x x



63 Groove nut x x

74 Shrink disc 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


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39 / 43

40 / 43

11.3.2 Type CS.W 280-630

A, E = Alignment disc

142 242544540501141

302928

614360144114 054251143

E

A

63


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40 / 43

11.3.2 Type CS.W 280-630


142 242544540501141

302928

614360144114 054251143

E

A

63


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41 / 43

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


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11.3.4 Type CS.A 280-630


142 254405141 45

E

A

42

302928

470551163406441411341 4263


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42 / 43

11.3.4 Type CS.A 280-630


142 254405141 45

E

A

42

302928

470551163406441411341 4263


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42 / 43

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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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