4300 W.

BRYN MAWR AVENUE CHICAGO, IL 60646 USA

TEL. (773) 478-9700 FAX (773) 478-8689


OWNERS MANUAL



CMB MIXER/BLENDER



CUSTOMER: CECINAS SAN JORGE
MODEL: CMB-8000
SERIAL NO.: P5126-09-I-1036A




CONTENIDO
SECCIN 1 INTRODUCCIN................................................................................... 5
Acerca de este Manual .................................................................................................... 5
Guas de Seguridad......................................................................................................... 5
Garanta........................................................................................................................... 6
Introduccin a la Mezcladora.......................................................................................... 6
Descripcin de la Operacin y mecanismos de la Mezcladora....................................... 7
SECCION 2 USO DE LA MEZCLADORA/BATIDORA.......... 8
Instrucciones de Operacin e Instalacin....................................................................... 8
Instalacin....................................................................................................................... 8
Inspeccin antes de puesta en marcha........................................................................ 8
Configuracin del Equipo......................................................................................... 10
Prueba de puesta en marcha...................................................................................... 13
Llenado de la Mezcladora/Batidora.............................................................................. 15
Directrices de Operacin............................................................................................... 15
Descarga de la mezcladora............................................................................................ 16
SECCION 3 MANTENIMIENTO............................................................................. 17
Procedimientos de Mantenimiento............................................................................... 17
Ensamble y Desensamble de sellos de ejes................................................................... 17
Reemplazo del empaque del sello............................................................................. 20
Agitadores..................................................................................................................... 21
Lubricacin de rodamientos de agitadores............................................................... 21
Alineamiento del Agitador........................................................................................ 22
Componentes de Unidad Motriz................................................................................... 22
Mantenimiento del Reductor de Engranes................................................................ 22
Mantenimiento de Motor Elctrico........................................................................... 23
Alineacin de las poleas............................................................................................ 24
Tensin de las correas............................................................................................... 25
Reemplazo de correas............................................................................................... 27
Reemplazo de Rodamientos de Agitador.................................................................. 27
Reemplazamiento de Eje Piloto................................................................................ 31
Mantenimiento Sistema Neumtico.............................................................................. 32
Mantenimiento de Filtro-Regulador-Lubricador (F-R-L)......................................... 32
Cilindros Neumticos................................................................................................ 34
Ajuste del flujo de aire del cilindro........................................................................... 34
Ensamble y desensamble de los cilindros................................................................. 35
Mantenimiento de Compuerta de Descarga.................................................................. 36
Seguro mecnico....................................................................................................... 37
Ajuste del seguro mecnico...................................................................................... 38
Reemplazo del empaque de las compuertas de descarga.......................................... 38
Instrucciones de lubricacin......................................................................................... 40
REV. B: 4/28/03

2
Operacin en presencia de polvo, agua o vapores corrosivos.................................. 40
Tipo de grasa............................................................................................................. 40
Programa de lubricacin........................................................................................... 41
Mantenimiento del sistema hidrulico.......................................................................... 41
SECCION 4 - LIMPIEZA E HIGIENIZACION......................................................... 43
SEC
Di
SE

Fi
Fig
Figu
Fi
Figu
Figu
Figu
Figu
Figu
Figu
Figu
Fi
Figu
Figu
Figu
Figu
Fi
Figu
Figu
Figu
Fi
Figura 22: D
Mantenimiento preventivo............................................................................................ 42
Mantenimiento diario recomendado......................................................................... 42
Mantenimiento semanal recomendado..................................................................... 42
Mantenimiento trimestral recomendado................................................................... 42
Mantenimiento semestral requerido.......................................................................... 42
Limpieza del sello del eje............................................................................................. 43
Limpieza de los agitadores y paletas............................................................................ 44
Limpieza de las compuertas.......................................................................................... 44
CIN 5 - LOCALIZACIN DE FALLAS........................................................... 45
agnstico de la localizacin de fallas........................................................................ 45
Solo para unidades equipadas con roco de agua.......................................................... 46
Solo para equipos equipadas con unidad Hidrulica.................................................... 46
CCION 6 PARTES DE REPUESTO.................................................................... 48
INDICE............................................................................................................................ 49
TABLA OF FIGURAS
gura 1: Ensamble de Mezcladora (Lado Motriz)............................................................. 6
ura 2: Ensamble de Mezcladora (Descargando a un Cargador de Tornillo Cozzini).... 7
ra 3: Lineas de Aire..................................................................................................... 8
gura 4: Ensamble de Reductor......................................................................................... 9
ra 5: Cilindros de Compuertas de Descarga................................................................ 9
ra 6: Estructura con patas Ajustables......................................................................... 10
ra 7: Estructura con bases para montaje.................................................................... 10
ra 8: Conectando alimentacin de aire a mezcladora................................................ 11
ra 9: Lubricacin de Rodamientos de Agitadores..................................................... 11
ra 10: Sensores de Proximidad sobre Rejilla equipada de rocio de agua.................. 12
ra 11: Conexin de suministro de agua y medidor.................................................... 12
gura 12: Correcta rotacin de agitadores en la mezcladora........................................... 14
ra 13: Agitador rozando la pared del tanque durante la puesta en marcha................ 14
ra 14: Palanca de Sellos (posicin cerrada)................................................................18
ra 15: Palanca de Sellos (posicin abierta).................................................................18
ra 16: Ensamble de bloque de Sellos..........................................................................18
gura 17: Ensamble de bloque de sellos (lado de descarga)............................................19
ra 18: Ensamble de Sellos...19
ra 19: Desensamble de Sellos.... ................................................................................20
ra 20: Lubricacin de Rodamientos de Agitadores ...21
gura 21: Rodamiento de Agitadores en lado de descarga............................................ 222
etalle de Reductor .23
REV. B: 4/28/03

3
Figu
Figu
Figu
Fi
Fi
#8)..
Figu
Figu
Figu
Figura 31: Ensamble de lado de descarga tipico............................................................... 31
Fi
Fi
Fi
Fi
Fi
Fi
DIBUJ OS Y LISTA DE PA
ra 23: Detalles de Motores..........................................................................................24
ra 24: Ensamble de Poleas .........................................................................................25
ra 25: Motor con polea y placas de tensin................................................................26
gura 26: Tensores de Poleas ..........................................................................................26
gura 27: Ensamble de Partes de Reductor ( Rodamiento, pieza
..............................27
ra 28: Chumacera de Agitador, lado de reductor29
ra 29: Reemplazo de rodamientos de agitador del lado de descarga..........................30
ra 30: Rodamientos de Agitador lado de descarga y Eje Piloto.................................30
Figura 32: Ensamble de Filtro/regulador/lubricador ........................................................ 32
gura 33: Detalle de tapn de drenado del F-R-L y tazn de engrasado........................ 33
gura 34: Desemblado de Filtro/Regulador/Lubricador.................................................. 33
gura 35: Cilindros de Compuerta de Descarga.............................................................. 34
Figura 36: Control de flujo de cilindros de aire/ valvula de control y tornillo de ajuste.. 35
Figura 37: Seccin transversal tipica de cilindro de aire.................................................. 35
gura 38: Lado de Descarga de Mezcladora................................................................... 36
gura 39: Compuerta de Descarga de Mezcladora.......................................................... 37
gura 40: Seguro Mecnico en compuerta de descarga (cerrado)................................... 37
Figura 41: Seguro Mecnico en compuerta de descarga (abierto).................................... 38
Figura 42: Empaque de compuerta de descarga............................................................... 39
Figura 43: Palanca de sellos en posicin cerrada.............................................................. 44
igura 44: palanca de sellos en posicin abierta............................................................... 44 F

RTES INCLUIDAS
Ensamble General
Lado de Descarga
Lado de Reductores
Diagrama de Control Neumtico de Mezcladora
Ensamble de sello hermtico
REV. B: 4/28/03

4

SECCIN 1 INTRODUCCIN
Acerca de este Manual
Este manual est dirigido a los tcnicos y al personal de mantenim
reparacin y el mantenimie
iento responsable de la
nto rutinario del equipo. Se recomienda familiarizarse con los
componentes de la unidad motriz y leer los dibujos o esquemas tcnicos. El manual trata
sobre la operacin mecnica y el mantenimiento del equipo as como de las ilustraciones
de los subsistemas que componen la mezcladora.

Guas de Seguridad
Como parte de su obligacin y compromiso con cada uno de sus clientes, Cozzini ha
dado todos los pasos posibles para hacer de la mezcladora/batidora Cozzini un equipo
libre de cualquier riesgo conocido, que pueda causar lesiones o lastimar a cualquier
persona que pueda operarlo. Se han hecho todos los esfuerzos para cumplir con todas las
secciones pertinentes de los Estndares de seguridad y salud ocupacional publicados por
el Departamento de trabajo de los Estados Unidos (United States Department of Labor).

Dondequiera que usted vea este smbolo en el manual, por favor siga las guas de
seguridad cuando opere la maquina.


Mantenga las manos lejos de las compuertas de descarga y de los agitadores en
todo momento. Hay una pequea demora entre el momento en que se oprime el
botn de PARO y el momento en que el agitador llega a detenerse por completo.
mezcladora/batidora por ningn motivo mientras la mquina Nunca ingrese a la
est en operacin. Si la maquina no est en operacin y es necesario ingresar a
la mquina, asegrese de que la energa haya sido desconectada y que se hayan
seguido todos los procedimientos de bloqueo y paro.
e PARE (STOP) de la caja de control est equipado Para su seguridad, el botn d
con un dispositivo adicional de seguridad. Este dispositivo evitar que la
mquina arranque accidentalmente. Este dispositivo fue diseado para su
seguridad y se debe usar durante todas las operaciones de limpieza y cualquier
operacin fuera de servicio.
El botn de control a dos-manos esta diseado para operar los agitadores
cuando una o ambas compuertas de descarga estn abiertas y la rejilla esta
cerrada. Esto asegura que ambas manos del operador estn en el panel de
control y no en la mquina. No desconecte o modifique este dispositivo de
seguridad importante.
No obstruya ni retire ningn aviso de advertencia que est adherido a la
mquina. Si algn aviso de advertencia se daa, se pierde o se vuelve ilegible,
por favor ordene reemplazarlo inmediatamente
No opere la mquina sin todas las protecciones y cubiertas en su posicin
correcta.
No use esta mquina para ningn propsito diferente al de su aplicacin como
procesador de alimentos.
REV. B: 4/28/03

5
No se introduzca en esta mquina bajo ninguna circunstancia.
No sobrecargue la mquina. Trabaje la mquina a su capacidad recomendada.
No opere la mquina hasta que usted haya cumplido con todas las reglas y
regulaciones locales de seguridad.
No desconecte ni anule ningn interruptor de seguridad por ninguna razn
Preste atencin en todo momento. No opere esta mquina de manera negligente.


Garanta
Es poltica de Cozzini garantizar todo equipo fabricado por Cozzini por un perodo de 1
ao a partir de la fecha de facturacin. Todos los componentes no fabricados pero
vendidos por Cozzini estn cubiertos por la garanta de fabricacin del proveedor. Todas
las garantas se aplican siempre y cuando el producto haya sido operado bajo las
condiciones normales especificadas por los procedimientos y guas de mantenimiento
ilustradas en este manual. El no seguir los procedimientos y guas de mantenimiento
como se

El uso en este equipo de partes que no
especifica en este manual anular todas las garantas del producto.
estn aprobadas como repuestos autorizados
por el vendedor anular todas las garantas.

Introduccin a la Mezcladora

Figu 1



ra : Ensamble de Mezcladora (lado de Motores)
Medidor de Agua (sol
equipos con roco de a
o
gua)
Palanca de
apoyo de Rejilla
Motor
Rejilla
Guarda Lado
de Descarga

Lineas de
Aire
Solamente l
la mezclado
evante
ra en la
estructura.
Palanca de
de Agitador
Sello
es
REV. B: 4/28/03

6




Figura 2: Ensamble de Mezcladora (descargando dentro de un Cargador de Tornillo Cozzini)
mecanismos de la Mezcladora
La Mezcladora/Batidora Cozzini se llena con carne, especias y otros aditivos y
en una mezcla homognea en el tanque de proceso durante una cantidad pred
de tiempo. Un par de agitadores revuelven el producto dentro del tanque. Un motor y un
reductor de engranajes conducen cada agitador por medio de un sistema m de
poleas y correas. Los sellos en ambos extremos de los ejes de los agitadores impiden al
producto gotear fuera de la unidad.

Del lado de la descarga del mezclador, dos compuertas de descarga se abren
descargar el producto de carne mezclada en una carrito u otro receptculo. Un cilindro
neumtico abre y cierra cada compuerta. Despus que el proceso de mezcla se
el producto puede transferirse entonces a otra mquina para embutido o emulsificacin.

Unidades equipadas con roco de agua en la rejilla tienen una capacidad adic
permite agregar una cantidad predeterminada de agua a la receta de la mezcla e
verterlo mediante un volteador u otros medios.
Descripcin de la Operacin y
los mezcla
eterminada
ecnico
para
completa,
ional que
n lugar de
Cilindros
compuert
de
as de
descarga
Eje de Rejilla
Guarda Pos
para compu
de descarga
terior
ertas
.
REV. B: 4/28/03

7

SECCION 2 USO DE LA MEZCLADORA/BATIDORA
ones de Operacin e Instalacin Instrucci
IMPORTANTE: Revise cualquier dao que pueda tener su mezcladora/batidora al
momento de recibirla. Es importante que usted informe cualquier dao
inmediatamente de tal manera que se pueda hacer el reclamo correspondiente al
transportista.
Instalacin
Inspeccin antes de puesta en marcha
IMPORTANTE: Al descargar su mezcladora, manjela con cuidado, dejarla caer o
golpearla puede daarla seriamente y desalinear los reductores, motores y
agitadores. No arrastre la mquina en el piso. Vea la Fig. 1 para la manera
apropiada de levantar la mezcladora.
Inspeccione estos elementos cuando reciba la mquina (Figura 3 a la Figura 5):
1. Revise abolladuras en el
cuerpo.
2. Revise si hay dao en el
sistema neumtico.
Figura 3: Lineas de Aire


REV. B: 4/28/03

8

Figura 4: Ensamble unidad motriz

Figura 5: Cilindros de Compuertas de Descarga

4. Revise si hay dao en
los Reductores
5. Revise si hay dao e
los motores
n
5. Inspeccione los
pistones neumticos
3. Revise el nivel de
aceite del reductor
REV. B: 4/28/03

9

Configuracin del Equipo
Paso 1. Si la mquina esta provista de estructura con patas ajustables (Figura 6), usted
debe nivelar la maquina al piso. Si la mezcladora tiene bases de montaje (Figura 7),
nivele el mezclador con calzas y aplique una lechada alre hay un
bastidor separado, la Mezcladora deber soldarse o atornillarse a este despus de que ha
sido fijado en el sitio. Si es posible, instalar la mezcladora con una ligera pendiente, 1/4"
a 1/2", para que el agua fluya a un desage durante el proceso de limpieza e
higienizacin..

dedor de las bases. Si
Figura 6: Estructura de patas ajustables

Figura 7: Estructura con bases de montaje

IMPORTANTE: Si se han provisto celdas de carga electrnicas, no realice ninguna
soldadura en la mquina una vez que las celdas de carga se han instalado, las
corrientes parsitas por la soldadura podran causar dao a las partes electrnicas.

Paso 2. Los reductores de velocidad han sido llenados de aceite antes del embarque para
su conveniencia. Asegure que el aceite en los reductores est al nivel del tapn (vea
Figura 4). Para instrucciones de lubricacin adicionales de los reductores, refirase a pag.
21.
Paso 3. Conecte la energa elctrica a la mezcladora/batidora refirindose a los
diagramas elctricos suministrados con el equipo. Los diagramas esquemticos ilustran
la rotacin de los agitadores con relacin a los controles de botn que estn identificados
en la caja de control.

Paso 4. Proporcione el suministro -125 PSI, pero a no menos de
las compuertas de descarga y la rejilla de la
ezcladora (Figura 8).
de aire idealmente a 100
80 psi, a la caja de control neumtico para
m
REV. B: 4/28/03

10

Figura 8: Conectando el suministro de aire a la mezcladora

Paso 5. Engrase los rodamientos de los agitadores antes de operar la mquina. Durante el
transporte y la instalacin se puede haber acumulado polvo, agua y suciedad.
1. Aplique grasa grado alimento por las graseras de cada rodamiento de los
agitadores para purgar la grasa vieja (Figura 9).
2. Contine engrasando hasta que observe salir grasa nueva por el rodamiento.

Figura 9: Lubricacin de rodamientos de agitadores.

Conexin de
Aire principal
Grasera en la chumacera
del agitador
REV. B: 4/28/03

11
Paso 6. Solo para unidades equipadas con roco de agua: Inspeccione la articulacin de
la rejilla de la mezcladora para asegurarse que el sensor de proximidad detecte la oreja
del enrejando cuando esta se baja sobre el tanque (Figura 10). El sensor puede daarse si
el enrejando choca con l mientras se esta cerrando.
Sensor de Proximidad
debe estar despejado
para detectar la oreja de
la rejilla

0: Sensor de proximidad en equipos con rejilla con roco Figura 1 de agua

Conecte la mezcladora a una lnea de alimentacin de agua limpia (Figura 11).

Conecte al
suministro de agua
Oreja de la rejilla
para sensor de
proximidad
Figura 11: Conexin a suministro de agua y medidor

Paso 7. Para mezcladoras accionadas hidrulicamente solamente: La mquina viene
con su propia unidad de poder hidrulica; las instrucciones siguientes aplican::

eramente por encima de la marca
l aceite
adicional se requiere para llenar las lneas que van a los motores hidrulicos. Use
El depsito de aceite se debe llenar a un nivel lig
superior del visor de nivel de aceite localizado a un lado del depsito. E
REV. B: 4/28/03

12
el aceite como se recomienda en las instrucciones de la unidad hidrulica
incluidas con la unidad.

A. Gire manualmente el motor elctrico/bomba hidrulica. En unidades con
acoplamiento motor/bomba inaccesibles, retire la cubierta del ventilador del
motor y gire el ventilador. Si no gira libremente, revise la alinea
y el motor con su indicador de alineacin. Haga la alineacin dentro de .003 pulg.
(0.08 mm) de la lectura del indicador.

Asegrese de que la rotacin del motor corresponda a la direccin de la flecha
marcada en la carcasa del motor o de la bomba pulsando el control del motor
elctrico.

Donde se usen vlvulas solenoides direccionales, las solenoides deben estar
conectadas a una fuente de control adecuada.

Si se provee un intercambiador de calor, conctelo a una fuente
fra.

Refirase al manual de mantenimiento de unidad hidrulica incluido con el manual del
a y localizacin de
llas.
Prueba de puesta en marcha.
Una vez la mquina esta instalada y conectada a la energa elctrica, realice una prueba
de puesta en marcha para ver si la unidad est trabajando correctamente..
1. Baje la rejilla sobre el tanque.
2. Encienda la mezcladora y accione los agitadores durante 1-2 minutos. En el modo
de mezcla los agitadores deben estar girando uno hacia el otro, como se muestra
en la Figura 12 en el lado izquierda.
3. Escuche si hay cualquier sonido raro o ruidos como molie
IMPORTANTE: Despus de soltar el botn de PARO (STOP), pero antes de
cin de la bomba
de agua limpia,
equipo. El cual tiene sus propias instrucciones de puesta en march
fa

ndo o raspando.
cambiar la rotacin de los agitadores, hay un perodo de demora. ste es el tiempo
que las paletas del agitador necesitan para detenerse completamente. Asegrese de
permitir a los agitadores detenerse antes de invertir la rotacin.
4. Accione los agitadores brevemente en modo inverso. Los agitadores deben estar
girando hacia afuera entre ellos como en el lado derecho de la Figura 12.
REV. B: 4/28/03

13


Figu 1

5. Despus de accionar los agitadores, revise las paredes laterales del tanque para


13). Refirase a Seccin 5 - Localizacin de Fallas en este manual para


ra 2: Rotacin correcta de agitadores en mezcladora
ver si cualquier rozamiento tuvo lugar entre los agitadores y la pared del tanque.
Aparecer como una marca de la raspadura luminosa dentro del tanque (Figura
diagnsticos detallados si esto ocurre..

Figura 13: Rozamiento de agitadores en paredes del tanque durante la puesta en marcha

Rozamiento de agitador
sobre la pared lateral
Revise raspaduras en
el fondo del tanque
Rotacin en sentido inverso Rotacin en modo de Mezcla
REV. B: 4/28/03

14
IMPORTANTE: Los agitadores deben girar suavemente y en las direcciones
apropiadas en los modos de operacin (refirase al manual elctrico). Revise que
los motores elctricos no consumen excesiva corriente de mas a su valuacin de
rango de carga y que los rodamientos del agitador y los sellos del eje no se
sobrecalienten.
6. Solo modelos provistos de roco de agua: Calibre el medidor de agua. Para
hacer esto, siga las instrucciones especficas provistas en el manual para su
modelo en particular de medidor.
7. Si la prueba de puesta en marcha se realiza exitosamente, el mezclador debe estar
en buenas condiciones de operacin. Si hubiera cualquier problema, refirase a
Seccin 3 - Mantenimiento y Seccin 5 - Localizacin de Fallas este manual para
un diagnstico detallado..

lena a/Batidora
a mezcladora/batidora puede ser cargada mediante un volteador o mediante un
iento. La mezcladora debe llenarse a
n nivel ligeramente por encima del agitador. La capacidad de trabajo de la mezcladora
sta
agit

L do de la Mezclador
L
transportador directamente en el tanque de procesam
u
e basada en el volumen del tanque, llenando ligeramente sobre la parte superior del
ador, y la densidad del producto de 55 lbs. por pie cbico (881.1 kg/m3).
PRECAUCION: La Mezcladora Cozzini no debe llenarse ni operarse a una
capacidad mayor a la capacidad nominal del equipo.

Directrices de Operacin
Para mezclar lotes de 2/3 o menos de la capa dor, opere
los agitadores en el modo INVERSO.
Asegrese que la rejilla este en su lugar antes de intentar operar la mezcladora.

Para una mezcladora accionada hidrulicamente, se aplican las siguientes instrucciones:
No encienda los motores elctricos si el depsito no est lleno con el fluido
hidrulico
Al poner en marcha inicialmente, la bomba hidrulica debe ser cebada pulsando el
motor elctrico El nivel de ruido de la unidad de energa debe disminuir despus
de unos pocos impulsos a medida que se log ecuadamente. Si
la bomba no ceba despus de algunos impulsos, refirase a su manual de la
unidad hidrulica en busca de posibles fallas.

Note: Es necesario operar la mezcladora/batidora descargada por lo menos una
cidad nominal del mezcla
ra cebar la bomba ad
hora para lubricar los motores hidrulicos suficientemente.

REV. B: 4/28/03

15
Descarga de la mezcladora
a descargar la mezcladora, ponga una tina bajo el lado de descarga, debajo de las
puertas. Abra las compuertas de descarga para permitir que el producto fluya hacia
era. Operando los agitadores mientras s esta descargando acelera el proceso d
carga. El producto
Par
com
afu e la
des en la mezcladora puede descargarse de varias formas, como se
describe en el manual del control elctrico.
Mantenga las manos lejos de las compuertas de descarga y de los agitadores en
todo momento. Hay una pequea demora entre el momento en que se oprime el botn y el
momento en que el agitador se detiene por completo.



























REV. B: 4/28/03

16
SECCION 3 MANTENIMIENTO
as
ia a esta seccin para las explicaciones
detalladas del ensamblado de componentes y los procedimientos de mantenimiento.

ves americanas estndar y llaves
Allen.

Procedimientos de Mantenimiento
La siguiente seccin cubre los procedimientos de mantenimiento rutinario y de
reparacin que se puedan necesitar al montar, ajustar o analizar fallas de la mquina. L
otras secciones de este manual hacen referenc
La mezcladora/batidora no requiere ninguna herramienta especial para su reparacin. Se
recomienda al personal de mantenimiento que tenga lla
Antes de hacer cualquier trabajo de mantenimiento en cualquier componente,
siempre siga los procedimientos de bloqueo/paro en planta


Ensamble y Desensamble de sellos de ejes
ara limpieza de rutina, los sellos de los ejes deben sacarse fuera del tanque para lavarse.
uando sea necesario desmontar el bloque de sellos y revisar o reemplazar los empaques,
ga las instrucciones e ilustraciones siguientes.
P
C
si
REV. B: 4/28/03

17
Figura 15: Palanca de sellos de Ejes
(posicin abierta)
Figura 14: Palanca de sellos de Ejes
(posicin cerrada)

Figura 16: Ensamble de bloque de sellos de Hermeticidad

Pza. DESCRIPCION
1 CAJ A DEL SELLO (LA FRONTAL Y LA POSTERIOR PUEDEN DIFERIR.)
2 PERNO DE SELLOS
3 EMPAQUE (CORTADO A LA MEDIDA)
4 SELLO DE BORDE (CORTADO A LA MEDIDA)
5 ABRAZADERA DE CAJ A DE SELLOS

REV. B: 4/28/03

18

Figura 17: Ensamble de bloque de sellos (lado de descarga)

Herramientas necesarias: desarmador plano/estrado, llaves de 9/16

1. Desconecte la energa de la mezcladora/batidora.
2. J ale el asa de palanca de sellos y mueva el ensamble de sellos hacia afuera del
tanque (Figura 14 a la Figura 17).
3. Abra el bloque de sellos usando un destornillador plano/estriado para soltar la
abrazadera (Figura 18 y Figura 19).
4. Con una llave de 9/16", afloje el perno retenedor del sello en cada lado para
separar las mitades de la caja de sellos.

Figura 18: Ensamble de bloque de sellos
Bloque de sellos
(separado en
dos mitades)
Abrazadera
Perno de retencin de
bloque de sellos
Abrazadera
Ranura para perno
de retencin
Empaque
Bloque de sellos
(dos mitades)
REV. B: 4/28/03

19

Sellos de labio
Empaque
Abrazadera
Figura 19: Desensamble de bloque de sellos
5. Retire el empaque y el sello de labio interior.
tos han sufrido desgaste o
8. o debe mirar hacia el tanque. Coloque la otra
oque

Reemplazo del empaque del sello
El empaque del sello hace presin contra la pared del tanque cuando el sello est
asegurado en su sitio. El material del empaque est disponib sea
necesario cambiar el empaque, siga estas instrucciones:

Herramientas necesarias: cinta mtrica, cuchillo, adhesivo transparente de Loctite o
Goma loca (Crazy Glue)
Retire el empaque usado del conjunto del sello. Corte el empaque si no est roto y
estrelo en lnea recta.
1. Tome el empaque nuevo y estrelo en lnea con el em compararlos.
2. Corte los extremos de la tira de empaque a aproxima bos empaques
(viejo y nuevo) deben tener la misma longitud.
nuevo en el bloque del sello antes de engomar los
extremos..
4. Si el ajuste es bueno, tome los dos extremos y pguelos con un adhesivo claro y
permanente..


6. Reemplace el empaque y el sello de labio interior si es
deterioro (al menos cada 3 meses).
Ensamble de nuevo los sellos del bo 7. rde divididos y el empaque. Los sellos de
borde deben quedar mirando hacia el tanque para sellar hermticamente.
El empaque frontal en la caja del sell
mitad de la caja del sello y ajuste la brida alrededor de todo el conjunto del bl
del sello.
le por pies. Cuando
paque usado para
damente 45. Am
3. Pruebe el ajuste del empaque
REV. B: 4/28/03

20
Agitadores
Los agitadores revuelven el producto dentro del tanque. Los ejes estn accionados
mediante un motor y un reductor de engranajes por medio de un sistema de bandas y
poleas. Las chumaceras a cada lado del tanque soportan a los agitadores. La seccin
siguiente se refiere a los procedimientos de mantenimiento comunes para los agitadores.

Lubricacin de rodamientos de agitadores
Los rodamientos de rodillos esfricos se han lubricado antes de su embarque.
Re-engrselos cada semana con Grasa Texaco Cygnus #2 o una equivalente.

Herramientas necesarias: pistola de grasa
1. Aplique grasa grado alimenticio dentro de la grasera en cada uno de las
chumaceras de los agitadores para purgar la grasa vieja (Figura 20).
2. Contine engrasando hasta que observe salir grasa nueva por el rodamiento.

Grasera en la chumacera
del agitador

Figu


ra 20: Lubricacin de rodamiento de Agitador
REV. B: 4/28/03

21
Alineamiento del Agitador

Figura 21: Rodamiento de Agitador en el lado de descarga
Cada rodamiento del agitador est montado en una mnsula con calzas para lograr la
alineacin vertical correcta. Hay tambin un perno de ajuste lateral con una tuerca para
permitir la alineacin horizontal (Figura 21). Para a , se necesita
ajustar la posicin de los rodamientos.

Herramientas necesarias: llaves inglesas estndar
1. Afloje (no los quite)los pernos de montaje que sostienen el ensamble de la chumacera.
2. Gire la cabeza del tornillo de ajuste lateral localizada al lado de la chumacera. Cuando
se gira, el tornillo va empujando la chumacera.
3. Una vez que se ha logrado la posicin deseada de la chumacera, apriete tuerca en el
tornillo de ajuste para asegurar esa posicin..
4. Re-apriete los pernos que sostienen el ensamble de la chumacera.
5. Repita este procedimiento en el lado opuesto.


Componentes de Unidad Motriz
linear los ejes del agitador
Antes de hacer cualquier trabajo de mantenimiento en los componentes de la
unidad motriz, siempre siga los procedimientos de bloqueo/paro en-planta.

M
(A
antenimiento del Reductor de Engranes
plica a todas las mezcladoras, excepto aqullas con sistema motriz de motor
hidrulico)
Los reductores de velocidad han sido lubricados antes de su embarque. El nivel de aceite
debe verificarse regularmente y debe cambiarse cada seis meses o ms frecuentemente
dependiendo del ciclo de servicio de su mquina.

Placa calzadora
Tornillo de ajuste
lateral
Pernos de Montaje
Tuerca
REV. B: 4/28/03

22
Revise el aceite destornillando el tapn de nivel con una llave Allen. Debe haber aceite
en el tornillo (Figura 22) cuando este se saca. El aceite debe llenar casi la mitad del
interior de la caja de engranajes. Agregue el aceite llenndolo a tr
localizado encima de la caja de engranajes. Para las especificaciones del lubricante
refirase al manual del fabricante del reductor incluido con este m

avs del respirador
anual.

Figura 22: Detalle de Reductor de engranes
o llenadas con grasa por el fabricante. No
se requiere engrasado peridico. Si un motor se desmonta, la cmara de rodamiento, as
como l
grasa T
fabrica nto de
bricacin especial.
Mantenimiento de Motor Elctrico
El motor tiene balineras blindadas que han sid
a cmara de la campana exterior detrs del rodamiento, debe reensamblarse con
exaco Cygnus #2 o una equivalente (Figura 23). Refirase al manual del
nte de motor para los detalles del ensamble de motor y cualquier requerimie
lu

IMPORTANTE: En algunos motores los rodamientos son lubricados con grasa a
base de poliurea que no es compatible con las grasas a base de litio. Mezclar grasas
de poliurea y de litio puede causar prdida del lubricante y llevar a una falla del
rodamiento o del motor. Refirase al manual del fabricante del motor en lo que
respecta a lubricantes compatibles.


Respirador/Llenador de aceite
Tapn de nivel de aceite
REV. B: 4/28/03

23

Grasera
Figura 23: Detalles de Motor

Alineacin de las poleas
Las poleas superiores e inferiores deben estar localizadas en el mismo punto sobre sus
respectivos ejes (Figura 24). Esto permite que las correas tensionen uniformemente sobre
el mismo plano. Cuando las poleas no estn alineadas adecuadamente, usted puede notar
un olor a caucho quemado cerca de los componentes de la unidad de conduccin. Para
revisar la alineacin de las poleas, siga estas instrucciones:
.

Herramientas necesarias: llaves de boca fija, nivel o regla, mazo de goma
1. Siga el procedimiento de bloqueo/paro de seguridad antes de llevar a cabo
cualquier trabajo en la mquina.
f inar si
mo plano.
el buje de una polea para permitir moverla
2. Coloque el nivel o la regla en la cara
ambas estn a nivel sobre el mis
rontal de cada polea para determ
3. Si existe alguna desalineacin, afloje
sobre el eje.
4. Deslice la polea hacia adelante o hacia atrs hasta que se logre la nivelacin.
5. Ajuste el buje de la polea.
REV. B: 4/28/03

24

Polea superior
(conducida)
Polea in erior f
(conductora)
Figura 24: Ensamble de poleas

Tensi
La
mm) cu leas. Una correa tensionada
inad
estn localizadas un par de platinas equipadas de tensores.
.

Herramientas: regla, llaves de boca fija (2)
1. Desconecte la energa, siga el procedimiento de bloqueo/paro de seguridad para la
mezcladora.
2. Afloje las 4 contratuercas de un lado de la platina para aumentar o disminuir el
espacio entre las platinas (Fig. 28 y 29).
3. Una vez que se logre la tensin deseada de la correa, ajuste las tuercas para evitar
que la platina se mueva.
n de las correas
correa est tensionada correctamente cuando cede slo aproximadamente (12.7
ando se hace presin en ella entre las dos po
ecuadamente puede causar deslizamiento y desgaste prematuro. Encima del motor
REV. B: 4/28/03

25

Figura 25: Motor con polea y placas de tensin


Figura 26: Detalle de los tensionadores de polea

Placas de tensin
de las correas
Correas
Tensionadores de las correas
Igual espacio en todos los
tensionadores cuando l
tensin es correcta.
a
Contratuercas
REV. B: 4/28/03

26
Reemplazo de correas
Cuando la parte superior de una correa est por debajo de la superficie del d
exterior de la polea, la correa se ha desgastado y debe ser reemplazada. Las
mezcladora siempre
imetro
correas de la
se deben reemplazar en juegos completos..

Herramientas necesarias: llaves de boca fija, regla
1. Desconecte la energa, siga el procedimiento de bloqueo/paro de seguridad para la
mezcladora.
2. Retire la cubierta para tener acceso a las correas conductoras.
3. Afloje la tensin de las correas levantando los cuatro tornillos del motor
conductor (Fig. 26).
4. Cuando las correas estn suficientemente flojas, retrelas de la polea.
5. Coloque las correas nuevas.
6. Tensione las correas nuevas bajando los pernos del motor y ajustando las
contratuercas.
7. Revise que el eje del motor est paralelo al eje del reductor arriba de l. Los 4
pernos de la placa de tensin del motor deben tener la misma longitud expuesta
para que el eje est correctamente orientado (Fig. 26).
eemplazo de Rodamientos de Agitador
Para reemplazar los rodamientos del agitador en el lado motriz se requiere un desmontaje
extenso (Figura 27). En el lado de descarga los rodamientos son ms rpidamente
accesibles. Cuando se cambian los rodamientos del agitador, siempre cambie ambos
lados de la unidad..

R
11
7
5
1
2
4
6
3
9
8
10

Figura 27: Ensamble de Unidad Motriz tpica (Rodamiento de Agitador es la pieza 8)




REV. B: 4/28/03

27
PZA. DESCRIPCION
1 MOTOR ELECTRICO
2 BASE DE MOTOR
3 ADAPTADOR DE BASE DE MOTOR
4 REDUCTOR DE ENGRANES
5 POLEA DEL MOTOR
6 POLEA DEL REDUCTOR
7 CORREAS EN V
8 CHUMACERA DE AGITADOR
9 SELLO POSTERIOR DE EJ ES
10 CERROJ O, -TURN LOCK
11 ENSAMBLE DE EJ E DE AGITADOR

Para reemplazar el rodamiento del agitador del lado motriz, siga estas instrucciones:

a energa, siga el procedimiento de bloqueo de seguridad para la
mezcladora.
2. En el lado de motores, retire las siguientes partes en este orden:
Correas
Poleas
Reductor de Engranes
Guardamotores
Chumaceras de Agitador
3. Una vez que se accede a los rodamientos del agitador, afloje los opresores que
sostienen los collarines en ambos lados de la chumacera (Figura 28).

Herramientas necesarias: Llaves Allen, Llaves inglesa de boca fija, martillo de
goma, pasta anti-friccin
1. Desconecte l
REV. B: 4/28/03

28

Opresores de
collarines en ambos
lados de chumacera
Pernos de montaje
de chumacera
Fi a o de motor
4. Desatornille los pernos de la chumacera.
ra
er
8. Reinstale l s dentro de las chumaceras. Reinstale las placas calzas,
apriete los ntaje de la chumacera y opresores de collarines.
9. Realine la h i es necesario. (Ver pag.22).
10. Reensambl o idad motriz:

Para reemplazar los rodamientos de agitadores del lado de descarga, siga estas
instrucciones refirindose a la Figura 29 y Figura 30.

Herramientas necesarias: Llaves Allen, Llaves inglesa de boca fija, martillo de
goma, pasta anti-friccin
1. Desconecte la energa, siga el procedimiento de bloqueo de seguridad para la
mezcladora.
2. Retire los cilindros neumticos de las compuertas de descarga de enfrente de la
chumacera.
3. Una vez que se accede a los rodamientos del agitador, afloje los opresores que
sostienen los collarines en ambos lados de la chumacera (Figura 29).
gur 28: Chumacera de Agitador del lad
5. Retire el rodamiento de rodillos esfricos dentro de la chumacera. En la mayo
de los casos, la carcasa se puede reutilizar a menos que est daada. Si se coloca
toda la carcasa, asegrese de conservar las calzas de cada rodamiento ya que s
necesario realinearlos.
6. Aplique pasta anti-friccin al eje del agitador.
7. Reemplace el rodamiento interior o todo el conjunto de la chumacera si es
necesario.
os rodamiento
o pernos de m
s c umaceras del agitador s
e la un e l s componentes d
Guardamotores
Reductor
Poleas
Correas conductoras
REV. B: 4/28/03

29


Figura 29: Reemplazando los rodamientos del agitador del lado de descarga
dentro de la chumacera. En la mayora
a menos que est daada.
6.
7. to interior o todo el conjunto de la chumacera si es
lzas,
ernos de montaje de la chumacera y opresores de collarines.
10.
4. Retire el rodamiento de rodillos esfricos
de los casos, la carcasa se puede reutilizar
5. Asegrese de conservar las calzas de cada rodamiento ya que ser necesario
realinearlos.
Aplique pasta anti-friccin al eje corto del agitador .
Reemplace el rodamien
necesario..
8. Reinstale los rodamientos dentro de las chumaceras. Reinstale las placas ca
apriete los p
9. Realine las chumaceras del agitador si es necesario. (Ver pag.22).
Reinstal los cilindros neumticos y conecte las lneas de aire.


0: Chumacera de Agitador del lado de descarga y Eje piloto Figura 3
Retire el cilindro cuando
cambia los rodamientos
Opresor de collarin
Pernos de
Montaje
Eje corto
(piloto)
Ensamble de
e sellos bloque d
Pernos de Montaje
Eje corto
Placas de Calza
Rodamiento interno
REV. B: 4/28/03

30

Reemplazamiento de Eje Piloto
El Eje Corto, tambin conocido como Eje Piloto, esta localizad
de la mezcladora (pieza 4 en la Figura 31). Se sostiene por la chu
desliza dentro del eje del agitador (pieza 6) en el otro.
o en el lado de descarga
macera de un lado y se

Figura 31: Ensamble del lado de descarga tpico
PIEZA DESCRIPCION
1 CHUMACERA
2 CILINDRO NEUMATICO DE COMPUERTA DE DESCARGA
3 FLASHING LIGHT
4 EJ E PILOTO DE AGITADOR
5 SELLO FORNTAL DE EJ E
6 ENSAMBLE DE AGITADOR
7 EMPAQUE DE COMPUERTA

Para reemplazar el eje piloto del agitador::

Herramientas necesarias: Llave Allen, Llaves inglesas, martillo de g nti-
friccin, gra o soporte para el eje del agitador del lado del eje piloto
1. Desconecte la energa, siga el procedimiento de bloqueo de seguridad para la
mezcladora.
2. Retire los cilindros neumticos de las compuertas de descarga d
chumacera..
3. Utilice una gra o algn otro medio de izaje o un apoyo pa im
oma, pasta a
e enfrente de la
ra pedir que el eje
del agitador caiga o se incline cuando se retire el eje piloto. Esto podra doblar o
daar el eje del agitador.
REV. B: 4/28/03

31
4. Una vez que se accede a los rodamientos del agitador, afloje los opresores que
lados de la chumacera (Figura 30).
7. Retire el eje piloto.
8. Aplique pasta anti-friccin al nuevo eje piloto que entra en el eje del agitador y
aplicar algo alrededor del rea de la chumacera.
9. Reinstale el bloque de sellos.
10. Coloque la chumacera, junto con las placas de calza y opresores de collarines.
11. Restaure el cilindro de la compuerta de descarga
12. Ejecute una prueba corta con el agitador girando. Aline la chumacera si es
necesario (vea pag.21)

Mantenimiento Sistema Neumtico
Mantenimiento de Filtro-Regulador-Lubricador (F-R-L)
Para mantener la confiabilidad de los cilindros y vlvulas, es importante mantener el
sistema neumtico limpio. Hay un tapn de drenado al fondo del filtro de aire y un tazn
lubricador (Figura 32 & Figura 33). Abra estos cada semana para permitir el drenado de
sedimentos.

sostienen los collarines en ambos
5. Retire los pernos de montaje de la chumacera y saque la chumacera del eje.
6. Retire el bloque de sellos (ver pag.17 para las instrucciones de ensamble y
desensamble).

Empuje hacia abajo para
bloquear (posicin cerrada)
Regulador de aceite
ajustado a 1-2
gotas/minuto
Conexin principal de aire
Figura 32: Ensamble de Filtro/Regulador/Lubricador
REV. B: 4/28/03

32

Figura 33: Detalle de tapn de drenado y depsito de aceite del F-R-L

Figura 34: Desensamble del Filtro/Regulador/Lubricador
El filtro/lubricador puede desensamblarse y limpiarse si es necesario (Figura 34).

1. Antes de desensamblar, cierre el suministro de aire de la planta, aplastando el
botn amarillo (Figura 34).
2. Desensamble el filtro/lubricador desenroscando la trampa de agua y el depsito de
aceite.
3. Limpie todas las partes con metanol y splelas con aire comprimido. Limpie los
tazones plsticos y los visores solamente con jabn comn.
4. Reemplace el filtro del lubricador por uno limpio.
Herramientas necesarias: ninguna
T rampa de agua
Salida de aire cerrada
Tubo de lubricante
Regulador de aceite
Llene el depsito de
aceite cada semana
Tapn de Drenado
Depsito de aceite
REV. B: 4/28/03

33
5. Ensamble nuevamente y llene el lubricador con aceite lubricante liviano Mobil
DTE.
El lubricante usado en el lubricador debe cumplir los siguientes requisitos:
Viscosidad de 100-150 SUS (Segundo Universal de Saybolt) a 100 F
ndice alto de viscosidad: ms de 90.
Compatible con el empaque Buna-N
Antiespumante
Estabilidad a la oxidacin (ms de 2000 en prueba ASTM [So
para el Ensayo de Materiales] D943
Rango de anilina 180-210

Cilindros Neumticos
Los cilindros neumticos no requieren mantenimiento regular. Si los sellos se desgastan y
requieren ser cambiados, existen juegos de sellos de reemplazo. Refi
partes neumticas incluidas con este manual para los juegos de sellos aplicables al
Si una compuerta de descarga abre o cierra ms rpidamente que la otra
ajustar el flujo de aire para igualar los cilindros neumticos (Figura 35).
ciedad Americana
rase a la lista de las
tamao del cilindro en particular.
Ajuste del flujo de aire del cilindro
, es necesario


Vlvula de flujo/control
Ajuste de
h
Vlvula de flujo/control
orquilla
Figura 35: Cilindros de compuertas de descarga

Herramientas necesarias: Destornillador (paleta), llave inglesa de boca fija
1. Cierre el suministro de aire a la unidad.
2. Revise las vlvulas de flujo/control de cada uno de los cilindros para ver si estn
ajustados aproximadamente a la misma velocidad. Gire los tornillos de ajuste
ranurados de cada uno si es necesario (Fig. 36). Esto garantiza que la cantidad de
aire que va a cada cilindro sea la misma.
REV. B: 4/28/03

34

Tornillo ranurado de
el control
del flujo de aire
ajuste para
Figura 36: Vlvula de flujo/control y tornillo de ajuste del cilindro de aire
ste con una llave
de boca fija en el punto plano para controlar la cantidad expuesta de rosca del eje
del pistn. Ambos cilindros deben tener el mismo nmero de hilos de rosca en el
eje del pistn expuestos por la horquilla.
4. Cuando est ajustada adecuadamente, la cubierta debe subir y
la misma velocidad a ambos lados de la mquina..

Ensamble y desensamble de los cilindros












Figura 37
El cilindro de aire necesita ser desensamblado para cambiar los sellos internos. Refirase
a la Fig. 37 para ver el ensamble tpico de un cilindro de aire.

3. Otro ajuste que se hace es en el eje del pistn de la horquilla. Aju
bajar suavemente a




: Seccin transversal tpica del cilindro de aire
REV. B: 4/28/03

35

Herramientas necesarias: llaves de boca fija
1. Cierre el suministro de aire a la unidad.
2. Retire el cilindro de las horquillas de la cubierta y del fondo.
3. Desenrosque la tapa del extremo del eje del cilindro girando ales
de l. Esto le permitir jalar hacia afuera el pistn y tener acceso a los sellos tipo
anillo O internos.
4. Desenrosque el extremo inferior del cilindro con una llave. Esto proporcionar
acceso al anillo O del fondo.

Mantenimiento de Compuerta de Descarga
Las compuertas de descarga estn localizadas en el lado de la mquina opuesto a los
componentes de la unidad conductora. Las compuertas proporcionan una salida para el
producto mezclado y permiten el desage del tanque durante la limpieza. Cada compuerta
es accionada por un cilindro neumtico. Alrededor de las partes mviles hay una
proteccin para evitar lesiones pero al mismo tiempo permite una limpieza completa
las caras hexagon
(Figura 38).

Figura 38: Lado de descarga de la mezcladora
Palanca de sellos
Guarda de Compuertas
de descarga
(2) Cilindros de accionamiento
de compuerta de descarga
REV. B: 4/28/03

36

Figura 39: Compuerta de descarga de la mezcladora
Seguro mecnico
Las compuertas de descarga tienen un seguro mecnico a cada lado para evitar que la
compuerta se abra en caso de prdida de la presin de aire hacia los cilindros. El seguro
mecnico consiste en un tensor y un pivote que actan contra la compuerta de descarga
(Figura 39 y Figura 40)

Figura 40: Seguro mecnico en la compuerta de descarga (cerrada)
Cuando la compuerta est cerrada, el tensor ebe estar perpendicular a la compuerta.
d debe escuchar un fuerte "chasquido" cuando
los cilindros cierran la compuerta y ponen el seguro mecnico en posicin. En caso de
que el cilindro neumtico falle, la fuerza del producto empujando contra la compuerta de
descarga se encontrar con una fuerza igual y opuesta del tensor. Esto sostendr el
producto dentro del tanque y la placa pivote no se mover.

Eje del Cilindro de aire
Tensor perpendicular
a la compuerta
Contratuercas
Placa pivote
Ajuste del
extremo del eje
Horquilla
d
Cuando est ajustada adecuadamente, uste
REV. B: 4/28/03

37

La compuerta de descarga se abre cuando el cilindro de aire se retracta hacia arriba y
levanta el pivote (Fig. 41). El seguro no sostendr la compuerta en esta posicin.
.
Pivote posicin
arriba

Figura 41: Seguro mecnico en la compuerta de descarga (abierta)

Ajuste del seguro mecnico
Si el seguro no est manteniendo la compuerta cerrada o si no est pe
la compuerta se cierra, usted necesita ajustar las contratuercas del ten
Fig. 40 de la pgina anterior.
Herramientas necesarias: llaves de boca fija (2)
1. Asegrese que la compuerta est en posicin cerrada.
2. Cierre el suministro elctrico y de aire a la mezcladora.
3. Retire los pernos que sostienen la horquilla del cilindro de aire a la placa pivote.
4. Usando las llaves, ajuste igualmente ambos lados del tensor p tar o
disminuir la distancia entre el pivote y el punto de enlace en el otro extremo del
tensor.
5. Reinstale la horquilla del cilindro a la placa pivote.
6. En este punto, puede ser necesario ajustar la tuerca en el extr l
cilindro neumtico.
7. Restablezca la energa a la unidad y pruebe la operacin de lo
las compuertas de descarga. Si usted escucha el "chasqu o" sor
ajustado correctamente.
salga del tanque. El
mpaque alrededor de las compuertas (Figura 42) necesita ser reemplazado cuando
rpendicular cuando
sor. Refirase a la
ara aumen
emo del eje de
s cilindros de aire de
y observa el ten id
perpendicular a la compuerta, el seguro mecnico est
Si es necesario, ajuste la velocidad del flujo de aire en los cilindros neumticos, vea
pag.34.

Reemplazo del empaque de las compuertas de descarga
El empaque alrededor de las compuertas de descarga (Cozzini #12-004-0002)
proporciona un sello hermtico para evitar que el producto se
e
REV. B: 4/28/03

38
empiece a salirse o cuando el dao sea evidente. Cuando sea necesario cambiar el
empaque de la compuerta, siga estas instrucciones.
No intente cambiar el empaque con la compuerta adherida a la mezcladora.


Empaque de compuerta
#12-004-0002
Retire el perno
Retire el perno
Figura 42: Empaque de la compuerta de descarga
Herramientas necesarias: llaves de boca fija, cinta para medir, cuchillo, adhesivo
oma loca (Crazy Glue) y sellador de silicn
o se muestra en la
e trabajo aparte.
7.
10.
el
uevo empaque.

Prisma transparente de Loctite o G
transparente
1. Coloque las compuertas de descarga en posicin abierta.
2. Cierre el suministro de energa y de aire hacia la mezcladora.
3. Desprenda la compuerta de descarga retirando los 2 pernos com
Figura 42. Lleve la compuerta de descarga a un lugar d
4. Retire el silicn que sostiene el empaque y retire el empaque viejo de la
compuerta.
5. Raspe cualquier residuo de silicn que haya en la compuerta.
6. Corte el empaque si no est roto y estrelo en lnea recta.
Tome el empaque nuevo y tindalo en lnea con el empaque viejo para
compararlos.
8. Corte los extremos de la tira de empaque aproximadamente a 45. Mdalos para
confirmar que ambos empaques (viejo y nuevo) tienen la misma longitud.
Pruebe el ajuste del e 9. mpaque nuevo en la ranura de la compuerta antes de
engomar los extremos. No estire demasiado la tira de empaque.
Si el ajuste es bueno, tome los dos extremos y pguelos al mismo nivel con un
adhesivo claro y permanente.
11. Aplique un poco de silicn en la ranura del empaque de la compuerta e instale
n
12. Cuando el silicn est seco, reinstale la compuerta en la mezcladora.
13. Revise que el seguro est ajustado correctamente (ver pag.37).



REV. B: 4/28/03

39
Instrucciones de lubricacin

Operacin en presencia de polvo, agua o vapores corrosivos
Bajo estas condiciones, los rodamientos deben contener tanta grasa como la velocidad lo
permita. Un rodamiento lleno de grasa con un ligero escape consecuente protege mejor
contra la entrada de materiales extraos.

Si el exceso de grasa en el rodamiento produce sobrecalentamiento, retire las graseras
para permitir el escape del exceso de grasa. Los rodamientos vienen engrasados de
fbrica y estn listos para funcionar.

Temperatura de operacin
Las temperaturas anormales de los rodamientos pueden ser indicac
lubricacin. La temperatura normal puede oscilar desde fra o tibia al tacto hasta el
punto de muy caliente al tacto durante ms de unos pocos segundos, dependiendo del
tamao del rodamiento, la velocidad y las condiciones circundantes.

La temperatura normal y una ligera indicacin de grasa en la superficie del sello
indican una lubricacin adecuada.
aada de una fuga excesiva de grasa indica
mente si el rodamiento parece tener un ruido, indica muy poca lubricacin.

Tip
La
Lubriqu le con el
lub
in de una mala
Una temperatura inusualmente alta acomp
demasiada lubricacin.
Una alta temperatura sin indicacin de grasa en la superficie del sello,
particular
o de grasa
grasa Texaco Cygnus #2 es ideal para las condiciones normales de operacin.
e nuevamente con la grasa Texaco #2 o con una grasa que sea compatib
ricante original y que sea adecuada para el servicio de rodamientos.
REV. B: 4/28/03

40

Programa de lubricacin
Punto de lubricacin Lubricante Intervalo
Rodamiento del motor
elctrico
Grasa Cygnus #2*
(USDA H1)
Reparar
Reductor Ver manual del fabricante
Rodamientos del agitador Grasa Cygnus #2*
(USDA H1)
1 Semana
Lubricador neumtico Aceite lubricante liviano
Mobil
1 Semana
DTE

*IMPORTANTE: En algunos motores los rodamientos son lubricados con grasa a
base de poliurea que no es compatible con las grasas a base de litio. Mezclar grasas
de poliurea y de litio puede causar prdida del lubricante y llevar a una falla del
rodamiento o del motor. Refirase al manual del fabricante del motor en lo que
respecta a lubricantes compatibles.

Sistemas Hidrulicos solamente: Al cambiar el aceite en el sistema de la bomba
hidrulica Use aceite Texaco Cygnus #46 para las mquinas que trabajan a temperatura
ambiente por debajo de los 50 F (10 C). Use aceite Texaco Cygnus #68 para las
mquinas que trabajan a temperatura ambiente por encima de los 50 F (10 C).

ntenimiento del sistema hidrulico Ma
ladoras con unidad motriz hidrulica)
to es,

temperatura del sistema se debe mantener por debajo de 140 F (60 C.), ya que el
sobrecalentamiento descompondra el aceite hidrulico y formara lodo. Es obligatorio
establecer y seguir un programa regular de cambio de los elementos del filtro y de
limpieza de los filtros de succin. Los procedimientos especficos de mantenimiento
dependen del tipo particular de sistema hidrulico suministrado con su mezcladora.

(Aplicable a Mezc
Es importante que el fluido hidrulico sea mantenido en condiciones adecuadas, es
libre de contaminacin por qumicos o partculas. Abra peridicamente el tapn de
drenaje localizado en la parte inferior del depsito para drenar cualquier condensacin de
humedad, lodo o producto que se hayan acumulado ah. Durante la operacin, la
IMPORTANTE: Si la mezcladora/batidora trabaja ms de 8 horas al da, o est bajo
condiciones ms severas de lo normal, los intervalos de mantenimiento se deben ajustar
convenientemente.

Use aceite Texaco Cygnus #46 para las mquinas que trabajan a temperatura ambiente
por debajo de los 50 F (10 C). Use aceite Texaco Cygnus #68 para las mquinas que
trabajan a temperatura ambiente por encima de los 50 F (10 C).

Refirase al manual del sistema hidrulico que se incluye con su mezcladora equipada
con unidad hidrulica. El manual contiene informacin especfica sobre los componentes
y los requisitos de mantenimiento.
REV. B: 4/28/03

41

Mantenimiento preventivo
La nto preventi a referencias a los
eccin ara instruc talladas sobre cada
.
i recomienda ampli mie tos. Mantenga una tabla
seccin de Mantenimie vo proporcion tpicos
correspondientes de la S
operacin
3- Mantenimiento p ciones de
Cozzin amente seguir estos procedi n
para los operarios y el per nto. Esta t numerar todos sonal de mantenimie abla debe e
los pasos de mantenimiento y sus intervalos y debe requerir de una firma al lado de
cada tarea cuando se lleve e tod edimientos de a cabo. Esto garantiza qu os los proc
mantenimiento preventivo se hayan llevado a cabo a sus intervalos requeridos.

Mantenimiento diario recomendado
1. Revise que todas las guardas de seguridad estn puestas y funcionando: Rejillas
del tanque, Guarda de Compuertas de descarga.
2. Revise que no haya condensacin en los controles e interruptores de segurida
3. Revise que los sellos de los ejes d
d.
e los agitadores no tengan seas de desgaste o
estn daados (pag.17)
2. Revise las chumaceras de los agitadores y lubrquelas con grasa Texaco Cygnus
o de las poleas. (pag.24)

lico,
compuertas; ajuste si es necesario. (pag.37)
e
Inspeccione todas las mangueras y
1. El nivel de aceite de los reductores se debe revisar regularmente y el aceite se

Mantenimiento semanal recomendado
1. Revise que el filtro/regulador/lubricador tenga el nivel de aceite adecuado
(pag.32)
#2 si es necesario. (pag.21)
3. Revise se estn daadas las correas y el alineamient
4. Inspeccione la condicin de los empaques de las compuertas de descarga (pag.38)
5. Para las unidades Hidrulicas solamente: Revise el filtro de retorno hidru
reemplcelo de ser necesario.
6. Para las unidades hidrulicas solamente: Revise si el aceite del depsito
hidrulico tiene alguna contaminacin. Cambie el aceite y los filtros si es
necesario.

Mantenimiento trimestral recomendado
1. Revise la alineacin correcta de los cilindros neumticos y los seguros de las
2. Revise la hermeticidad del cierre de las compuertas de descarga y la condicin d
los empaques de las compuertas . (pag.38)
4. Reemplace sellos y empaques. (pag.17)
5. Para las unidades hidrulicas solamente:
acoples hidrulicos.

Mantenimiento semestral requerido
debe cambiar cada seis meses o ms frecuentemente, dependiendo del ciclo de
trabajo de la mquina. Esto no se aplica a los sistemas motrices hidrulicos.
REV. B: 4/28/03

42

SECCION 4 - LIMPIEZA E HIGIENIZACION
ntiene compuestos de curado o de adobo, estos pueden corroer el equipo si no


Limpie la mezcladora/batidora tan pronto como sea posible despus de cada uso. Si el
producto co
se limpia total y adecuadamente.
Antes de empezar cualquier procedimiento de limpieza o higiene, el motor debe
ser colocado en posicin de apagado (off). Siempre siga los procedimientos de
bloqueo/paro de seguridad de la planta.
En la m
escarga
Rejilla
evantarse a la posicin totalmente
abie versal
posterio

IM ua directamente sobre el panel de control. Solo
ezcladora, limpie las siguientes partes diariamente:
Tanque de mezcla
Paletas de los agitadores
Conjuntos de sello
Compuertas de d
La rejilla sobre el tanque de la mezcladora debe l
rtacon la espiga de seguridad que contacta directamente con el elemento trans
r.
PORTANTE: Nunca roce ag
limpie manualmente.

Lim
Par . Para
lim
1. idad
agitadores girando en cualquier modo.
e de la mezcladora (Figura 43 y
pieza del sello del eje
a la limpieza de rutina diaria, los sellos de los ejes no necesitan ser desmontados
piar los sellos del eje del agitador:
Cierre las compuertas de descarga y la rejilla de seguridad. Arranque la un
con ambos
2. Baje la palanca para retirar el sello del tanqu
Figura 44). Esto le permitir tener acceso completo para limpiar el rea de los
sellos de los ejes con una manguera de agua a alta presin.
Para cerrar los sellos de los ejes despus de u 3. na limpieza completa, mueva la
palanca de los sellos de regreso a su posicin original.
REV. B: 4/28/03

43

ra 43: Palanca de los sellos (cerrada) Figu
Figura 44: Palanca de los sellos (abierta)
Si los s o reemplcelos. Ver la Seccin 3 - Mantenimiento,
pag.17 para una explicacin detallada del ensamble y desensamble de los sellos.


ell s aparecen daados,
NOTA: e ble o desensamble cualquier superficie de sello. T nga cuidado cuando ensam
Una fuga causado por los sellos o superficies de sello daados puede causar prdida
del producto.

impiez L a de los agitadores y paletas
git agitadores y paletas se han limpiado completamente, abra la
r que salga todo el exceso de agua y producto de la
Para limpiar los agitadores, cierre la rejilla de seguridad y encienda los agitadores en
cualquier modo. Use una manguera de alta presin para rociar las paletas de los
adores. Una vez que los a
compuerta de descarga para permiti
mezcladora/batidora.

A travs de la rejilla de DVERTENCIA: No introduzca su brazo o manos a
seg s en uridad intentando quitar cualquier exceso de producto del agitador o sus paleta
ningn el momento durante este procedimiento de limpieza. No inserte ninguna parte d
cuerpo y puede producir en la compuerta de descarga. Esto es sumamente peligroso
una lesin seria.

Limpieza de las compuertas
Para limpiar las compuertas de descarga, pngalas en posicin abierta. Usando una
manguera de alta presin, limpie completamente las compuertas, por dentro y por fuera.
Usted puede rociar con la manguera hacia arriba desde la guarda de seguridad o rociar
con la manguera desde arriba hacia las compuertas de descarga.



REV. B: 4/28/03

44
ADVERTENCIA: No gire los agitadores en ningn momento durante este
procedimiento de limpieza. Nunca introduzca ninguna parte de su cuerpo en las
compuertas de descarga. Esto es extremadamente peligroso y puede resultar en lesiones
graves.

SECCIN 5 - LOCALIZACIN DE FALLAS
Diagnstico de la localizacin de fallas
Estos son los problemas comunes encontrados durante la operacin de la mezcladora y
las ibles caus
probabilidad de ocurrencia. Para llevar a cabo las operaciones de m
necesarias, refirase al t to.

R A
sugerencias para solucionarlos. Las pos as se enumeran por orden de
antenimiento
pico correspondiente descrito en la Seccin 3 - Mantenimien
OBLEMA: EL AGITADOR ROZA EN EL CUERPO DE LA MEZCLADOR P
POSIBLES CAUSAS:
A Agitadores desalineados aline las chumaceras (pag.22)
B Desgaste excesivo de los rodamientos. Cambie los rodamientos (pag.27)
C s tornillos de las chumaceras . estn flojos. Ajuste lo necesario. Lo
D El eje del agitador est torcido.
E Eje gastado en el lado de la descarga Reemplcelo (pag.31)

PROBLEMA: EL PRODUCTO SE SALE POR LOS SELLOS
POSIBLES CAUSAS:
A Los sellos estn instalados incorrectamente (ver la pg. 16 para todos l
detalles
os
del ensamblaje de los sellos)
B Dentro de la caja del sello hay un sello de borde y un empaque. Es necesario
que ambos estn instalados.
C La abrazadera del sello no est ajustada adecuadamente
D Los sellos estn gastados y necesitan ser reemplazados

PROBLEMA: OLOR A CAUCHO QUEMADO CERCA DE LA UNIDAD
MOTRIZ
POSIBLES CAUSAS:
A Correas flojas y no tensionadas correctamente (pag.25)
B Correas desgastadas o daadas: reemplcelas inmediatamente (pag. 27)
C Poleas desalineadas que causan que las correas se rocen unas a ot
Verifique la alineacin de la polea. (pag.24)
ras.

PROBLEMA: FUGA DE PRODUCTO POR LAS COMPUERTAS DE
DESCARGA
POSIBLES CAUSAS:
A El empaque alrededor de la compuerta esta daada o incorrectamente
instalado. (pag.38)
REV. B: 4/28/03

45
B El seguro mecnico necesita ajustarse (pag.37)

PROBLEMA: PARTES DEL PRODUCTO SIN MEZCLAR
POSIBLES CAUSAS:
A La mezcladora esta sobrecargada o por debajo de su capacidad. Cuando el
nivel del producto es demasiado alto, es inseguro operar el equipo. El
volumen de la mezcladora debe llenarse a un nivel ligeramente sobre la
cima de los agitadores.

Solo para unidades equipadas con roco de agua
PROBLEMA: SALIDA DE AGUA REDUCIDA
POSIBLES CAUSAS:
A Bobina de vlvula pegada en la posicin cerrada impide entrada de agua
B Obstruccin u obstculo en el conducto de agua

E AGUA DE LOS ROCIADORES EN LA REJILLA PROBLEMA: NO SAL
POSIBLES CAUSAS:
A La vlvula de agua de la lnea esta cerrada
B La bobina de la vlvula esta pegada en la posicin cerrada. Reemplace la
bobina si es necesario.

o S lo para eq
ido en mezcladoras
OBLEMA:
uipos equipadas con unidad Hidrulica
Refirase al manual del sistema hidrulico adicional que viene inclu
ulica. Este contiene la informacin sobre los componentes y los provistas de unidad hidr
uisitos de m req

antenimiento especficos
PR TEMPERATURA DE ACEITE ALTA
POSIBLES CAUSAS:
A El ajuste de la vlvula de alivio est muy bajo.
B Mal funcionamiento de la bomba
C Suministro de agua inadecuado a travs del intercambiador de calor
D La bomba tiene excesivo desgaste.

PROBLEMA: EL SISTEMA HIDRULICO EST PRODUCIENDO RUIDO
CESIVO. EX
POSIBLES CAUSAS:
A La bomba puede estar cavitando.
B El fluido puede estar muy fro para fluir.
C El filtro de succin puede estar obstruido.
D Revise la manguera de succin. Puede haber colapsado.
E El respirador del tanque puede estar obstruido.
F Se puede estar formando vapor
G El nivel del depsito de aceite puede estar muy bajo.
H ando el tipo o la cantidad equivocada de fluido Se puede estar us
REV. B: 4/28/03

46
hidrulico.
I Los acoples pueden estar desalineados.
J Los acoples pueden estar flojos.
K La bomba puede estar daada o gastada.

PROBLEMA: PRESIN HIDRULICA INADECUADA
POSIBLES CAUSAS:
A a. La bomba no est cebad
B La bomba est daada o gastada.
C Mal funcionamiento de la vlvula de alivio.
D Mal funcionamiento de la vlvula de control direccional.


PROBLEMA: Y FLUJO. FLUJO DEL PRODUCTO BAJO O NO HA
POSIBLES CAUSAS:
A La bomba est cavitando.
B Aireacin del fluido.
C La bomba est desgastada o daada.
D Mal funcionamiento del compensador de presin
E a no es la adecuada. La rotacin de la bomb



















REV. B: 4/28/03

47
SECCION 6 PARTES DE REPUESTO
siguiente es e mantener disponibles as como
cantidades r los componentes pueden variar
un modelo a rtes incluidas en el manual para
s nmeros de parte especficos para su unidad.
La
las
una lista de partes de repuesto que se deb
ecomendadas. Los nmeros de parte para
otro. Refirase a los dibujos y listas de pa de
lo
REV. B: 4/28/03

48
INDICE
Agitadores, 14
Barra del pistn, 35
Base de montaje, 10
Bloqueo/Paro, 22, 24, 25, 27
Reductor de engranes, 22
Roco de agua, 7, 12
Rodamientos, 21, 27
Capacidad de Mezcladora, 15
Caja del reductor, 9,10, 23
Celdas de carga, 10
Cilindros neumticos, 7, 30, 35
Compuerta de Descarga, 7,16, 36, 37, 38
Correas, 25, 26, 27
Chumacera, 11, 29, 30
Eje piloto, 30,31
Engrasado, 11, 21, 40
Empaque de compuerta de descarga, 38, 39
Empaque de sellos, 18, 19, 20
Filtro/lubricador, 32,33
Garanta, 6
Guas de Seguridad, 5
Inspeccin, 8
J uego de sellos, 36
Lubricador, 32, 33
Mantenimiento hidrulico, 41
Mantenimiento Preventativo, 42
Mantenimiento semanal, 42
Medidor de agua, 12
Motor, 23
Nivel de aceite, 23, 34
Palanca de sellos, 18, 36
Patas ajustables, 10
Poleas, 24, 25, 26
Prueba de puesta en marcha, 13
Rotacin de Agitador, 14
Rozamiento de Agitadores, 14
Seguro, 38
Sellos, 17, 19, 20
Sensor de proximidad, 12
Sistema hidraulico, 41
Suministro de aire, 11,
Tapn de drenado, 33
Temperaturas del rodamiento, 40
Tensin de correas, 25
Unidad de potencia hidraulica, 12
Vlvulas flujo/control, 34, 35















REV. B: 4/28/03

49

CONTENTS

SECTION 1 INTRODUCTION.................................................................................... 5
About This Manual ......................................................................................................... 5
Safety Guidelines............................................................................................................ 5
Warranty......................................................................................................................... 6
Getting to Know the Mixer............................................................................................. 6
Mixer Operation and Mechanical Overview................................................................... 7
SECTION 2 USING THE MIXER/BLENDER.......................................................... 8
Installation and Operating Instructions........................................................................... 8
Installation....................................................................................................................... 8
Inspection Before Startup........................................................................................... 8
Equipment Setup......................................................................................................... 9
Start-Up Test............................................................................................................. 13
Filling the Mixer/Blender ............................................................................................. 14
Operating Guidelines.................................................................................................... 15
Unloading the Mixer..................................................................................................... 15
SECTION 3 MAINTENANCE................................................................................... 15
Maintenance Procedures............................................................................................... 15
Shaft Seal Assembly and Disassembly......................................................................... 16
Replacing the Seal Gasket........................................................................................ 18
Agitators........................................................................................................................ 18
Agitator Bearing Lubrication.................................................................................... 19
Agitator Alignment................................................................................................... 20
Drive Components........................................................................................................ 20
Gear Reducer Maintenance....................................................................................... 20
Electric Motor Maintenance..................................................................................... 21
Pulley Alignment...................................................................................................... 22
Belt Tensioning......................................................................................................... 23
Belt Replacement...................................................................................................... 25
Agitator Bearing Replacement.................................................................................. 25
Stub Shaft Replacement............................................................................................ 28
Pneumatic System Maintenance................................................................................... 29
Filter-Regulator-Lubricator (F-R-L) Maintenance................................................... 29
Pneumatic Cylinders................................................................................................. 31
Adjusting Air Cylinder Flow Rate............................................................................ 31
Cylinder Assembly and Disassembly....................................................................... 33
Discharge Door Maintenance....................................................................................... 33
Mechanical Interlock................................................................................................ 34
Adjusting the Mechanical Interlock.......................................................................... 36
Discharge Door Gasket Replacement....................................................................... 36
Lubrication Instructions................................................................................................ 37
Operation In The Presence Of Dust, Water Or Corrosive Vapors............................ 37
REV. E: 8/2/04

2
Operating Temperature............................................................................................. 37
Type of Grease.......................................................................................................... 37
Lubrication Schedule................................................................................................ 38
Hydraulic System Maintenance.................................................................................... 38
Preventative Maintenance............................................................................................. 39
Required Daily Maintenance.................................................................................... 39
Required Weekly Maintenance................................................................................. 39
Required 3-Month (90-Day) Maintenance................................................................ 39
Required 6-Month Maintenance............................................................................... 39
SECTION 4 - SANITATION AND CLEANING......................................................... 40
Cleaning the Shaft Seals............................................................................................... 40
Cleaning of the Agitator and Paddles........................................................................... 41
Cleaning The Doors...................................................................................................... 41
SECTION 5 TROUBLESHOOTING........................................................................ 42
Troubleshooting Diagnostics........................................................................................ 42
Water Spray-Equipped Units Only............................................................................... 42
Hydraulic-Equipped Units Only................................................................................... 43
SECTION 6 SPARE PARTS ...................................................................................... 44
INDEX.............................................................................................................................. 45

TABLE OF FIGURES
Figure 1: Mixer assembly (drive end)................................................................................. 6
Figure 2: Mixer assembly (shown discharging into Cozzini screw loader)........................ 7
Figure 3: Pneumatic lines.................................................................................................... 8
Figure 4: Drive assembly.................................................................................................... 9
Figure 5: Discharge door cylinders..................................................................................... 9
Figure 6: Frame with adjustable feet................................................................................ 10
Figure 7: Frame with mounting pads................................................................................ 10
Figure 8: Connecting the air supply to mixer................................................................... 11
Figure 9: Agitator bearing lubrication.............................................................................. 11
Figure 10: Proximity switches on water spray equipped grating...................................... 12
Figure 11: Water supply connection and meter................................................................ 12
Figure 12: Correct agitator rotation in mixer.................................................................... 13
Figure 13: Agitator rubbing tank wall during startup....................................................... 14
Figure 14: Shaft seal lever (locked).................................................................................. 16
Figure 15: Shaft seal lever (open)..................................................................................... 16
Figure 16: Watertight seal block assembly....................................................................... 16
Figure 17: Seal block assembly (discharge end)............................................................... 17
Figure 18: Assembled seal block...................................................................................... 17
Figure 19: Disassembled seal block.................................................................................. 18
Figure 20: Agitator bearing lubrication............................................................................ 19
Figure 21: Agitator bearing on discharge end................................................................... 20
Figure 22: Gear reducer detail .......................................................................................... 21
REV. E: 8/2/04

3
Figure 23: Motor detail ..................................................................................................... 22
Figure 24: Pulley assembly............................................................................................... 23
Figure 25: Motor with pulley and tensioning plates......................................................... 24
Figure 26: Pulley tensioning standoff detail .................................................................... 24
Figure 27: Typical drive end assembly (Agitator bearing is item 8)................................ 25
Figure 28: Drive end agitator bearing............................................................................... 26
Figure 29: Replacing the discharge side agitator bearing................................................. 27
Figure 30: Discharge end agitator bearing and stub shaft................................................. 28
Figure 31: Typical discharge end assembly...................................................................... 28
Figure 32: Filter/regulator/lubricator assembly................................................................ 30
Figure 33: Close-up of F-R-L drain cock and oiler bowl ................................................. 30
Figure 34: Disassembled filter/regulator/lubricator.......................................................... 31
Figure 35: Discharge door cylinders................................................................................. 32
Figure 36: Air cylinder flow control/check valve and adjustment screw......................... 32
Figure 37: Typical air cylinder cross-section.................................................................... 33
Figure 38: Discharge end of mixer................................................................................... 34
Figure 39: Discharge door on mixer................................................................................. 34
Figure 40: Mechanical interlock on discharge door (closed)............................................ 35
Figure 41: Mechanical interlock on discharge door (open).............................................. 35
Figure 42: Discharge door gasket..................................................................................... 36
Figure 43: Seal lever closed.............................................................................................. 41
Figure 44: Seal lever open................................................................................................ 41

DRAWINGS & PART LISTS INCLUDED
General Assembly
Discharge End
Drive End
Mixer Pneumatic Control Diagram
Watertight Seal Assembly
REV. E: 8/2/04

4

SECTION 1 INTRODUCTION
About This Manual
This manual is intended for service technicians and personnel responsible for repair and
routine maintenance of the equipment. Familiarity with drive components and reading
technical drawings or schematics is recommended. The manual addresses mechanical
operation and maintenance as well as illustrations of subsystems that comprise the mixer.

Safety Guidelines
As part of its obligation and commitment to each of its customers, Cozzini has taken
every step possible to make the Cozzini Mixer/Blender free from any recognized hazards,
which may cause harm or injury to anyone who may operate this equipment.

Wherever you see this sign in the manual, please follow the prescribed safety
guidelines when operating the machine.


Keep hands away from the discharge openings and the agitators at all times.
There is a short delay from the time the STOP button is pushed and the agitators
actually come to a complete stop.
Never reach into the mixer/blender for any reason during operation. If the
mixer/blender is not in operation and there is a reason you need to reach in the
machine, ensure the power has been disconnected and all locked out/tagout
procedures have been followed.
For your safety, on the control box the STOP button is equipped with an added
safety-locking device. This will prevent the machine from any accidental startup.
This was designed for your safety and should be used during all cleaning
operation and for any downtime.
The two-handed push button control feature is designed to operate the agitators
when one or both discharge doors are opened and the grating is closed. This
ensures both hands of the operator are on the control panel and not in the
machine. Do not disconnect or modify this important safety feature.
Do not obstruct or remove any warning signs that are attached to the machine. If
warning signs become damaged, lost or illegible, please order replacement signs
immediately.
Do not operate the mixer without guards and covers fully in place.
Do not use for any application other than its intended use.
Do not enter mixer tank for any reason.
Do not overload the machine. Run equipment at its recommended capacity.
Do not operate the machine until you have complied with all local safety rules
and regulations.
Do not disconnect or override any safety interlocking switches for any reason.
Pay attention at all times. Do not operate this machine in a careless manner.

REV. E: 8/2/04

5
Warranty
Cozzini, Inc. and its subsidiaries (Cozzini Group) warrant all equipment it manufactures
for a period of one (1) year from date of final invoice. All components not manufactured
but sold by Cozzini Group are covered under the original manufacturers warranty. All
warranties apply provided the equipment is operated under normal conditions specified
by the procedures and maintenance guidelines illustrated in the equipment manual.
Cozzini Group shall not be liable for any other damages, direct, indirect or consequential.
Cozzini Group will only be liable to the extent of repairing or replacement of the original
equipment and will, under no circumstances, is liable for product loss. Failure to follow
procedures and maintenance guidelines as specified will void all product warranties. Use
of any replacement parts on this equipment that are not approved by Cozzini Group as
authorized replacement parts shall void all warranties.

Use of any parts on this equipment that are not approved by Seller as authorized
replacement parts shall void all warranties and guarantees.

Getting to Know the Mixer

Figure 1: Mixer assembly (drive end)
Water meter (water spray
equipped models only)
Grating
Discharge end
guarding
Pneumatic
lines
Agitator seal
lever
Lift mixer under
frame only
Motor
Grating
support lever






REV. E: 8/2/04

6

Grating pivot
Discharge door
cylinder
Discharge doors
behind guarding
Figure 2: Mixer assembly (shown discharging into Cozzini screw loader)
Mixer Operation and Mechanical Overview
The Cozzini mixer/blender is filled with meat, spices and other additives and blends them
into a homogenized mixture in the processing tank for a predetermined amount of time. A
pair of agitators stir the product inside the tank. A motor and gearbox drives each agitator
by means of a belt and pulley mechanical system. Seals on both ends of the agitator
shafts prevent product from leaking out of the unit.

At the discharge end of the mixer, two discharge doors open to release the blended meat
product into a cart or another receptacle. A pneumatic cylinder opens and closes each
door. After mixing is completed, the product can then be transferred to another machine
for stuffing or emulsification.

Units equipped with water spray on the grating have an added feature that allows a
predetermined amount of water to be added to the mixture recipe instead of pouring it in
from a dumper or other means.
REV. E: 8/2/04

7

SECTION 2 USING THE MIXER/BLENDER
Installation and Operating Instructions
IMPORTANT: Check for damage immediately upon receipt of the Mixer/blender. It
is important to report any damage immediately so that an appropriate claim can be
filed with the freight carrier.

Installation
Inspection Before Startup
IMPORTANT: When unloading your Mixer/Blender, handle with care as dropping
or jarring can seriously damage the bearings and misalign drive motors and
agitators. Do not draglift the machine into place. See Fig. 1 for the proper way of
lifting a mixer.
Inspect these items on the mixer when it arrives (Figure 3 thru Figure 5):
Figure 3: Pneumatic lines
1. Check body for dents
2. Check all pneumatic lines
for damage


REV. E: 8/2/04

8

Figure 4: Drive assembly

Figure 5: Discharge door cylinders
3. Check gearbox oil
level
5. Check motors for
damage
4. Check gearboxes for
damage
5. Inspect air
cylinders

Equipment Setup
Step 1. If the mixer frame has adjustable feet (Figure 6), you must level the unit on the
floor. If the mixer has mounting pads (Figure 7), level the mixer with shims and apply
REV. E: 8/2/04

9
grout around the plates. If there is a separate underframe, the Mixer Blender must be
welded or bolted to it after it has been set in place. If possible, place the mixer on a slight
slope, 1/4 to 1/2, so that water will flow to a drain during the cleaning and sanitation
process.

Figure 6: Frame with adjustable feet

Figure 7: Frame with mounting pads

IMPORTANT: If electronic load cells have been provided, do not perform any
welding on the machine once the load cells have been installed. Any stray welding
currents could cause damage.

Step 2. The gear reducers have been filled with oil prior to shipment for your
convenience. Ensure that the oil in the gear reducers is at the level plug (see Figure 4).
For further lubrication instructions on the gearboxes, refer to p.20.

Step 3. Connect the electrical power to the mixer/blender by referring to the electrical
diagram provided in the electrical manual for this machine. The drawing illustrates the
agitator rotation in relationship to the push button controls that are labeled accordingly on
your control box.

Step 4. Provide house air supply ideally at 100-125 PSI, but not less than 80 psi, to the
pneumatic control box for discharge doors and grating (Figure 8).
REV. E: 8/2/04

10

Main air
connection
Figure 8: Connecting the air supply to mixer

Step 5. Grease agitator bearings before running machine. Dirt, water and grime may have
accumulated during shipping and installation.
1. Pump food-grade grease into fitting on each of the agitator bearings to purge out
the old grease (Figure 9).
2. Keep greasing until you see new, clean grease coming out of the bearing.

Grease fitting on
agitator bearing
Figure 9: Agitator bearing lubrication

REV. E: 8/2/04

11
Step 6. For units equipped with water spray only: Check the swivel on the tank
grating to make sure that the proximity switch clears the tab when the grating is lowered
over the tank (Figure 10). The sensor can be damaged if the grating collides with it while
coming down.

Grating
prox
switch tab
Prox switches
must clear tab
on grating
Figure 10: Proximity switches on water spray equipped grating

Connect the mixer to a supply of clean water (Figure 11).

Connect to
water supply
Figure 11: Water supply connection and meter

Step 7. For a hydraulically driven mixer/blender only: The machine comes with its
own hydraulic power unit; the following instructions apply:

The hydraulic reservoir should be filled to a level slightly above the high mark on
the oil level sight gauge, located on the side of the reservoir). The extra oil
REV. E: 8/2/04

12
provides the volume of fluid required to fill the lines to the hydraulic motors. Use
the oil as recommended on the enclosed hydraulic power unit instructions.

Rotate the electric motor/hydraulic pump by hand. On units with inaccessible
motor/pump couplings, remove the motor fan grating and the rotate the fan. If it
does not turn freely, check the alignment of the pump and motor. Align to within
.003 inches (.08mm) total indicator reading.

Make sure the motor rotation corresponds to the arrow-mark on the motor or
pump housing by jogging the electric motor control.

Where solenoid directional valves are used, the solenoids should be connected to
an appropriate control source.

If a heat exchanger is provided, connect it to a source of cool, clean water.

Refer to the separate hydraulics maintenance manual included with the equipment
manual. It has its own startup and troubleshooting instructions.

Start-Up Test
Once the machine is set up and connected to power, run a start-up test to see if the unit is
running correctly.
1. Lower the grating over the tank.
2. Turn on the mixer and run the agitators for 1-2 minutes. In mix mode the agitators
should be turning toward each other, as shown in Figure 12 on the left.
3. Listen for any unusual sounds or noises such as grinding or scraping.
IMPORTANT: After depressing the STOP button, but prior to changing the rotation
of the agitators, there is a dwell period. This is the time the agitator paddles need to
come to a complete stop. Be sure to allow the agitators to stop before reversing
rotation.
4. Run the agitators briefly in reverse mode. The agitators should be turning away
from each other as on the right side in Figure 12.

Figure 12: Correct agitator rotation in mixer
REV. E: 8/2/04

13
5. After running the agitators, check the side walls of the tank to see if any rubbing
took place between the agitators and the tank wall. It will appear as a bright
scrape mark inside of the tank (Figure 13). Refer to Section 5- Troubleshooting in
this manual for further diagnostics if this occurs.

Agitator
rubbing on
side wall
Check bottom of
tank for scrapes
Figure 13: Agitator rubbing tank wall during startup
IMPORTANT: The agitators should run smoothly and in the proper directions in all
operating modes (refer to electrical manual). Check that the electric motors do not
draw current in excess of their no-load rating and that the agitator bearings and shaft
seals do not overheat.
6. Water spray-equipped models only: Calibrate the water meter. To do this,
follow the specific instructions provided in the manual for your particular model
of meter.
7. If the start-up test ran successfully, the mixer should be in good working order. If
there were any problems, refer to Section 3 - Maintenance and Section 5 -
Troubleshooting in this manual for further diagnostics.

Filling the Mixer/Blender
The mixer/blender unit can be loaded from a dumper or conveyor, directly into the
processing tank. The mixer should be filled to a level slightly above the agitator.
The working capacity of the mixer is based on the tub volume, filled slightly above the
top of the agitator, and the product density of 55 lbs. per cubic foot (881.1 kg/m
3
).
REV. E: 8/2/04

14
CAUTION: The Cozzini mixer/blender should not be filled or operated at a
capacity higher than its rated load.

Operating Guidelines
For blending batches of 2/3 or less than the rated capacity of the mixer, operate
the agitators in REVERSE mode.
Make sure that the grating is in place before attempting to operate the
mixer/blender.
For a hydraulically driven Mixer Blender, the following instructions apply:
Do not start the electric motors unless the reservoir is filled with hydraulic fluid.
On initial start-up, the hydraulic pump must be primed by jogging the electric
motor. The noise level of the power unit should decrease after a few jogs as the
proper priming is achieved. If the pump fails to prime after a few jogs, refer to
your hydraulics manual for troubleshooting.
Note: It is necessary to operate the mixer/blender unloaded at least one hour to
sufficiently lubricate the hydraulic motors.

Unloading the Mixer
To unload the mixer, place a vat under the discharge end, below the doors. Open the
discharge doors to allow the product to flow out. Running agitators while discharging
will accelerate the unloading process. The product in the mixer/blender may be unloaded
in various modes, as described in the electrical controls manual.
Keep hands away from the discharge openings and the agitators at all times. There
is a short delay between the time that the STOP button is pushed and the time that the
agitators actually come to a complete stop.
SECTION 3 MAINTENANCE

Maintenance Procedures
The following section covers routine maintenance and repair procedures that may be
required to perform when setting up, adjusting or troubleshooting the machine. The other
sections of this manual refer to this section for thorough explanations of each component
assembly.

The mixer/blender does not require any special tools for servicing. Standard American
open-end wrenches and Allen keys are recommended for maintenance personnel.
Before doing any maintenance work on any components, always follow in-
plant lockout/tagout procedures.
REV. E: 8/2/04

15


Shaft Seal Assembly and Disassembly
For routine cleaning, the shaft seals should be pulled away from the tank to wash down.
When it is necessary to take apart a seal block and check or replace the gaskets, follow
the directions and illustrations below.
Figure 14: Shaft seal lever (locked) Figure 15: Shaft seal lever (open)

Figure 16: Watertight seal block assembly

ITEM DESCRIPTION
1 SEAL HOUSING (FRONT AND REAR MAY DIFFER)
2 SEAL BOLT
3 GASKET (CUT TO SIZE)
REV. E: 8/2/04

16
4 LIP SEAL (CUT TO SIZE)
5 SEAL HOUSING CLAMP


Clamp
Seal block (split
intwohalves)
Seal block
retaining bolt
Figure 17: Seal block assembly (discharge end)

Tools required: flat-blade screwdriver, 9/16 wrenches

1. Lock out power to the mixer/blender.
2. Pull the seal lever handle and move the seal assembly away from the tank (Figure
14 thru Figure 17).
3. Open the seal block by using the flat-bladed screwdriver to release the clamp
(Figure 18 & Figure 19).
4. With a 9/16 wrench, loosen the seal-retaining bolt on each side to separate seal
housing halves.

Slot for retaining
bolt
Clamp
Seal block
(two halves)
Gasket
Figure 18: Assembled seal block
REV. E: 8/2/04

17

Split lip seal
Gasket
Clamp
Figure 19: Disassembled seal block
5. Remove the gasket and internal lip seal.
6. Replace gasket and internal split lip seal as the seals become worn or damaged (at
least every 3 months).
7. Re-assemble the split lip seal and gasket. The open side of the split lip should face
toward the tank for a watertight seal.
8. The front gasket pressed in the seal housing should face the tank. Assemble the
other half of the seal housing and tighten clamp around entire seal block
assembly.

Replacing the Seal Gasket
The seal gasket presses against the wall of the tank when the seal is locked in place. The
gasket material is available by the foot. When the gasket needs to be replaced, follow
these directions:

Tools required: tape measure, utility knife, Loctite clear Prism adhesive or Crazy
Glue
1. Remove the old gasket from the seal assembly. Cut the gasket if it is not broken
and lay it out in a straight line.
2. Take the new gasket material and line it up beside the old gasket for comparison.
3. Cut the ends of the gasket strip at approximately 45. The old and new gaskets
should be the same length.
4. Test-fit the new gasket in the seal block before gluing the ends.
5. If the fit is good, take the two ends and join them with a clear, permanent
adhesive.

Agitators
The agitators stir the product inside the tank. The shafts are driven by a motor and
gearbox by means of a belt and pulley system. Bearings at each end of the tank support
REV. E: 8/2/04

18
the agitators. The following section addresses common maintenance procedures for the
agitators.

Agitator Bearing Lubrication
The spherical roller bearings have been lubricated prior to shipment. Regrease every
week with Texaco Cygnus Grease #2 or an equivalent.

Tools required: grease gun
1. Pump food-grade grease into fitting on each of the agitator bearings to purge out
the old grease (Figure 20).
2. Keep greasing until you see new, clean grease coming out of the bearing.


Grease fitting on
agitator bearing
Figure 20: Agitator bearing lubrication


REV. E: 8/2/04

19
Agitator Alignment

J am nut
Lateral
adjustment screw
Mounting bolt
Shim plate
Figure 21: Agitator bearing on discharge end
Each agitator bearing is mounted on a bracket with shims underneath to attain correct
vertical alignment. There is also a lateral adjustment bolt with a jam nut to allow
horizontal alignment (Figure 21). To align the agitator shafts, the bearing position needs
to be adjusted.

Tools required: open-end wrenches
1. Loosen (but not remove) mounting bolts holding the pillow block assembly.
2. Turn the head of the lateral adjustment screw located beside the bearing. As it
turns, the screw pushes the pillow block bearing assembly.
3. Once the desired position of the bearing is attained, tighten the jam nut on the
adjustment screw to lock in the position.
4. Re-tighten the bolts holding the pillow block bearing.
5. Repeat this procedure on the opposite end.


Drive Components
Before doing any maintenance work on drive components, always follow in-
plant lockout/tagout procedures.

Gear Reducer Maintenance
(Applies to all mixer blenders, except those with direct drive hydraulic motors)
Gear reducers have been filled with oil prior to shipment. The oil level should be checked
regularly and changed every six months or more frequently depending on the duty cycle
of your machine.

Check oil by unscrewing the level plug with an Allen key. There should be oil on the
screw (Figure 22) when it is pulled out. The oil should fill about one-half of the gearbox
REV. E: 8/2/04

20
inside. Add oil by filling it through the breather located on top of the gearbox. For
lubrication specifications refer to the gearbox manufacturers manual included with this
manual.


Breather/filler
Oil level plug
Figure 22: Gear reducer detail
Electric Motor Maintenance
The motor has shielded ball bearings packed by the manufacturer. No periodic greasing
is needed. If a motor is taken apart, the bearing housing, as well as the chamber in the
end bell behind the bearing, should be repacked with Texaco Cygnus Grease #2 or an
equivalent (Figure 23). Refer to the motor manufacturers manual on motor assembly
details and any special lubrication requirements.

IMPORTANT: On some motors the bearings are lubricated with polyurea based
grease that is not compatible with lithium-based greases. Mixing polyurea and
lithium greases may cause a loss of lubricant and lead to bearing or motor failure.
Refer to the motor manufacturer manual provided regarding compatible lubricants.


REV. E: 8/2/04

21

Grease fitting
Figure 23: Motor detail

Pulley Alignment
The upper and lower pulleys should be located at the same point on their respective shafts
(Figure 24). This allows the belts to track evenly on the same plane. When pulleys are not
aligned properly, you may notice an odor of burning rubber around the drive components.
To check pulley alignment, follow these directions.

Tools required: open-end wrenches, level or straightedge, rubber mallet
1. Lock out / tag out before starting any work on the machine.
2. Apply level or straightedge to front face of each pulley to determine if both are
level on the same plane.
3. If there is misalignment, loosen the bushing on a pulley to allow it to move on the
shaft.
4. Slide pulley forward or backward until a level state is achieved.
5. Tighten pulley bushing.
REV. E: 8/2/04

22

Upper (driven)
pulley
Lower (drive)
pulley
Figure 24: Pulley assembly

Belt Tensioning
The belt is correctly tensioned when it gives only about when pushed between the two
pulleys. An improperly tensioned belt can cause slippage and wear prematurely. Pair of
plates, separated by standoffs, are located above the motor.

Tools: straightedge, (2) open-end wrenches
1. Disconnect power, lock out / tag out mixer
2. Loosen 4 jam nuts on one side of the plate in order to increase or decrease the
spacing between the plates (Figure 25 & Figure 26).
3. Once the desired belt tension adjustment is achieved, tighten the nuts to prevent
the plate from moving.
REV. E: 8/2/04

23

Belt tensioning
plates
Drive belts
Figure 25: Motor with pulley and tensioning plates


Belt tensioning standoffs
Spacing equal on all
standoff bolts when
properly tensioned
J am nuts
Figure 26: Pulley tensioning standoff detail

REV. E: 8/2/04

24
Belt Replacement
When the top of a belt is below the surface of the outer diameter of the pulley, it is worn
and need to be replaced. The belts on the mixer should always be replaced as a full set.

Tools required: open-end wrenches, straightedge
1. Disconnect power, lock out / tag out mixer.
2. Remove cover to gain access to drive belts.
3. Loosen tension on belts by raising four bolts on drive motor (Figure 26).
4. Once the belts have enough slack, remove them from the pulley.
5. Replace with new belts.
6. Re-tension the belts by lowering the motor bolts and tightening jam nuts.
7. Check that the motor shaft is parallel to the gearbox shaft above. All 4 bolts on
the motor tensioning plate should have the same amount of length exposed for the
shaft to be correctly oriented (Figure 26).

Agitator Bearing Replacement
To replace the agitator bearings on the drive end requires extensive disassembly (Figure
27). On the discharge end the bearings are more readily accessible. When changing
agitator bearings, always change both sides of the unit.
11
7
5
1
2
4
6
3
9
8
10

Figure 27: Typical drive end assembly (Agitator bearing is item 8)
ITEM DESCRIPTION
1 ELECTRIC MOTOR
2 MOTOR BASE
3 MOTOR BASE ADAPTER
4 GEAR REDUCER
5 SHEAVE -- MOTOR
REV. E: 8/2/04

25
6 SHEAVE GEAR REDUCER
7 V-BELTS
8 PILLOW BLOCK AGITATOR BEARING
9 REAR SHAFT SEAL
10 LATCH, -TURN LOCK
11 AGITATOR SHAFT ASSEMBLY

To replace the agitator bearing on the drive end, follow these directions:

Tools required: Allen keys, open-end wrenches, rubber mallet, anti-seize paste
1. Disconnect power and lock out/tag out mixer.
2. On the drive end, remove the following parts in order:
Drive belts
Pulley
Gear reducer
Drive guard enclosure
Agitator pillow block bearing
3. Once the agitator bearings are accessible, loosen setscrews holding the collars on
both sides of the bearing (Figure 28).

Pillow block
bearing bolts
Setscrew
collar on
both sides
of bearing
Figure 28: Drive end agitator bearing
4. Unscrew the pillow block bolts.
5. Remove spherical bearing inside of pillow block. In most cases, the housing can
be re-used unless it is damaged. If the entire housing gets replaced, be sure to
keep the shims for each bearing since they will need to be realigned.
6. Apply anti-seize paste to agitator shaft.
7. Replace the bearing insert or entire pillow block if needed.
REV. E: 8/2/04

26
8. Reassemble bearings inside pillow blocks. Restore the shim plates, tighten the
bearing bolts and setscrew collars.
9. Realign agitator bearings if necessary. (See p.20).
10. Reassemble drive components:
Drive guard enclosure
Gear reducer
Pulley
Drive belts

To replace the discharge side agitator bearings, follow these directions and refer to Figure
29 & Figure 30.

Tools required: Allen keys, open-end wrenches, rubber mallet, anti-seize paste
1. Disconnect power and lock out/tag out mixer.
2. Remove discharge door pneumatic cylinder in front of bearing.
3. Once the agitator bearings are accessible, loosen setscrews holding the collars on
both sides of the bearing (Figure 29).


Shim plate
Remove cylinder when
changing bearing
Stub shaft
Mounting bolts
Figure 29: Replacing the discharge side agitator bearing
4. Remove spherical bearing inside of pillow block. In most cases, the housing can
be re-used unless it is damaged.
5. Save any shim plates under the pillow block since those will need to be restored
later.
6. Apply anti-seize paste to the stub shaft.
7. Replace the bearing insert or entire pillow block if needed.
8. Reassemble bearings inside pillow blocks. Restore the shim plates, tighten the
bearing bolts and setscrew collars.
9. Realign agitator bearings if necessary. (See p.20).
10. Restore the pneumatic cylinder and reconnect air lines.

REV. E: 8/2/04

27

Mounting
bolt
Seal block
assembly
Figure 30: Discharge end agitator bearing and stub shaft

Stub Shaft Replacement
The stub shaft, also known as the pilot shaft, is located on the discharge end of the
mixer (item 4 in Figure 31). It is held by the pillow block bearing on one side and slips
into the keyed end of the agitator shaft (Item 6) on the other.

Figure 31: Typical discharge end assembly
ITEM DESCRIPTION
1 PILLOW BLOCK BEARING
2 DISCHARGE DOOR AIR CYLINDER
3 FLASHING LIGHT
Stub or
pilot shaft
Bearing insert
Setscrew collar
REV. E: 8/2/04

28
4 AGITATOR PILOT SHAFT
5 FRONT SHAFT SEAL
6 AGITATOR ASSEMBLY
7 DOOR GASKET

To replace the agitator stub shaft:

Tools required: Allen keys, open-end wrenches, rubber mallet, anti-seize paste, hoist
or support for agitator shaft end
1. Disconnect power and lock out/tag out mixer.
2. Remove discharge door cylinder in front of the pillow block bearing.
3. Use an overhead hoist or some other means of support to keep the agitator shaft
from falling or tilting when the stub shaft will be removed. This can bend or
damage the agitator shaft.
4. Once the agitator bearing is accessible, loosen setscrews holding the collars on
both sides of the bearing (Figure 30).
5. Remove bearing mounting bolts and slide bearing off of shaft.
6. Remove seal block assembly (see p.16 for disassembly and assembly
instructions).
7. Pull off the stub shaft.
8. Apply anti-seize paste to the new stub shaft end going into the agitator shaft and
apply some around the area of the bearing.
9. Replace seal block.
10. Replace pillow block bearing, along with shim plate(s) and setscrew collars.
11. Restore discharge door cylinder.
12. Run a short test with the agitator turning. Align the bearing if necessary (see
p.20).

Pneumatic System Maintenance
Filter-Regulator-Lubricator (F-R-L) Maintenance
To maintain the reliability of the cylinders and valves, it is important to keep the air
system clean. There are drain cock at the bottom of the air filter and lubricator bowls
(Figure 32 & Figure 33). Open these every week to allow sediment to drain.

REV. E: 8/2/04

29

Oil regulator set to 1-2
drops/minute
Push down to lock out
(shown locked)
Main air connection
Figure 32: Filter/regulator/lubricator assembly

Oil bowl
Drain cock
Figure 33: Close-up of F-R-L drain cock and oiler bowl
REV. E: 8/2/04

30

Oil regulator
Air locked out
Fill bowl with oil
weekly
Oiler tube
Water trap
Figure 34: Disassembled filter/regulator/lubricator
The filter/lubricator should be disassembled and cleaned as needed (Figure 34).

Tools required: none
1. Before disassembly, lock out the plant air supply by pushing down on yellow tab
(Figure 34).
2. Disassemble the filter/lubricator by unscrewing water trap and oil bowl.
3. Clean all the parts with methanol and blow them out with compressed air. Clean
the plastic bowls and sight glass with a household soap only.
4. Replace the lubricator filter with a clean one.
5. Reassemble and fill the lubricator with Mobil DTE Light Lubricating Oil.
The lubricant used in the lubricator should meet these requirements:
Viscosity of 100-150 SUS at 100 F
High viscosity index: over 90.
Compatible with Buna-N rubber
Anti-foaming
Oxidation stability (over 2000 on ASTM D943 test)
Aniline range 180-210

Pneumatic Cylinders
The pneumatic cylinders operating the discharge doors require no regular maintenance.
Rebuild seal kits are available if seals are worn and need to be replaced. Refer to the
pneumatic parts lists included with this manual for seal kits applicable to your particular
cylinder size.

Adjusting Air Cylinder Flow Rate
If one discharge door opens or closes faster than the other, it is necessary to adjust the
airflow to equalize the pneumatic cylinders (Figure 35).
REV. E: 8/2/04

31

Flow/check valve
Clevis
adjustment
Flow/check valve
Figure 35: Discharge door cylinders

Tools required: screwdriver (flat blade), open-end wrench
1. Lock out air supply to unit.
2. Check the flow control/check valves on each of the cylinders to see if they are set
to the same approximate rate. Turn the slotted screw adjustments on each if
necessary (Figure 36). This ensures the amount of air going to each cylinder is the
same.

Slotted
adjustment screw
controls air flow
Figure 36: Air cylinder flow control/check valve and adjustment screw

3. Another adjustment is on the piston rod at the clevis (Figure 35). Adjust the flat
on the rod with an open-end wrench to control the amount of exposed piston rod
REV. E: 8/2/04

32
threads. Both cylinders should have the same number of exposed threads on the
piston rod by the clevis.
4. When properly adjusted, the discharge doors should open and close smoothly at
the same rate on both sides of the machine.

Cylinder Assembly and Disassembly
STD. O-RING
(MOVING &
STATIC SEALS)
WRENCH FLATS
STAINLESS STEEL
PISTON ROD
MOUNTING PILOT
CONCENTRIC w.
PISTON ROD
HARD DRAWN SEAMLESS
BRASS TUBING
HIGHLY FINISHED I.D.
POSITIVE LOCKING
SPECIAL LOCK NUT
HIGH TENSILE ALUM. ALLOY
MACHINED BAR STOCK
SELF LUBRICATING
BRONZE BEARING

Figure 37: Typical air cylinder cross-section
An air cylinder needs to be disassembled in order to change the seals inside. Refer to
Figure 37 for a typical air cylinder assembly.

Tools required: Open-end wrenches
1. Lock out air supply to unit.
2. Remove cylinder from clevis on the cover and bottom.
3. Unscrew the cap on the rod end of the cylinder by turning the flats on it. This will
allow you to pull out the piston and access the internal o-ring seals.
4. Unscrew the bottom end of the cylinder with a wrench. This will provide access
to the o-ring on the bottom.

Discharge Door Maintenance
The discharge doors are located on the side of the machine opposite the drive
components. The doors provide an exit for mixed product and allow the tub to drain
during cleaning. An air cylinder operates each door. Guarding around the moving parts is
there to prevent injury but allow clean-through at the same time (Figure 38).
REV. E: 8/2/04

33

Seal lever
Discharge door
actuating cylinders (2)
Discharge door
guarding
Figure 38: Discharge end of mixer

Figure 39: Discharge door on mixer
Mechanical Interlock
The discharge doors have a mechanical interlock on each side to prevent the door from
opening in case of a loss of air pressure to the cylinders. The mechanical interlock
REV. E: 8/2/04

34
consists of a turnbuckle and pivot acting against the discharge door (Figure 39 & Figure
40)

Air cylinder rod
Figure 40: Mechanical interlock on discharge door (closed)
Clevis
Rod end
adjustment
Pivot plate
J am nuts (2)
Turnbuckle
perpendicular to door
When the door is closed, the turnbuckle should be perpendicular to the door. When
properly set, you should hear a loud pop when the cylinder locks the door and puts the
mechanical interlock in position. If the pneumatic cylinder should fail, the force of the
product pushing out against the discharge door will be met with equal force from the
turnbuckle. This will hold back the product inside the tank and the pivot plate will not
move.

The discharge door opens when the air cylinder retracts upward and causes the pivot to
rise (Figure 41). The interlock will not hold back the door in this position.

Pivot higher
Figure 41: Mechanical interlock on discharge door (open)

REV. E: 8/2/04

35
Adjusting the Mechanical Interlock
If the interlock is not keeping the door shut or if it is not perpendicular when the door is
shut, you need to adjust the jam nuts on the turnbuckle. Refer to Figure 40 on the
preceding page.
Tools required: open-end wrenches (2)
1. Make sure the door is in the closed position.
2. Lock out electrical and air supply to the mixer.
3. Remove the bolt holding the air cylinder clevis to the pivoting plate.
4. Using the wrenches, adjust both sides of the turnbuckle equally to increase or
decrease the distance between the pivot and the linkage point on the other end of
the turnbuckle.
5. Re-attach the cylinder clevis to the pivot plate.
6. At this point, it may also be necessary to adjust the nut on the rod end of the
pneumatic cylinder.
7. Restore power to the unit and test the air cylinder operation on the discharge
doors. If you hear the pop and see the turnbuckle is perpendicular to the door,
then the mechanical interlock is set correctly.
If it is necessary to adjust the airflow rate on the pneumatic cylinders, see p.31.

Discharge Door Gasket Replacement
The gasket around the discharge doors (Cozzini #12-004-0002) provides a tight seal to
keep product from leaking out of the tank. The gasket around the doors (Figure 42) needs
to be replaced when it begins to leak or when damage is visible. Check the condition of
the gasket on a weekly basis. If the door gasket needs to be replaced, follow these
directions.
Do not try to change the gasket with the door attached to the mixer.


Remove bolt
Remove bolt
Door gasket
#12-004-0002
Figure 42: Discharge door gasket
Tools required: open-end wrenches, measuring tape, utility knife, Loctite clear Prism
adhesive or Crazy Glue, clear silicone sealant
1. Put the discharge doors in the open position.
REV. E: 8/2/04

36
2. Lock out power and air to the mixer.
3. Detach the discharge door by removing the 2 bolts as shown in Figure 42. Take
the discharge door to a separate workstation.
4. Cut away the silicone holding the gasket and remove the old gasket from the door.
5. Scrape out any remaining silicone on the door.
6. Cut the gasket if it is not broken and lay it out in a straight line.
7. Take the new gasket material and line it up beside the old gasket for comparison.
8. Cut the ends of the gasket strip at approximately 45. Measure to confirm the old
and new gaskets are the same length.
9. Test-fit the new gasket in the door groove before gluing the ends. Do not
overstretch gasket strip.
10. If the fit is good, take the two ends and join them flush with a clear, permanent
adhesive.
11. Apply a bead of silicone in the door gasket groove and install the new gasket.
12. When the silicone is dry, re-install the door to the mixer.
13. Check that the interlock is set correctly (see p.34).

Lubrication Instructions

Operation In The Presence Of Dust, Water Or Corrosive Vapors
Under these conditions, the bearings should contain as much grease as speed will permit.
A bearing full of grease with consequent slight leakage best protects against entry of
foreign material.

If excess grease in the bearing causes overheating, remove grease fittings to permit
excess grease to escape. The bearings have been greased at the factory and are ready to
run.

Operating Temperature
Abnormal bearing temperatures may indicate faulty lubrication. Normal temperature
may range from cool to warm to touch up to a point too hot to touch for more than a
few seconds, depending on bearing size, speed and surrounding conditions.

Normal temperature and a slight showing of grease at the seal surface indicate proper
lubrication.
Unusually high temperature accompanied by excessive grease leakage indicates too
much grease.
High temperature with no grease showing at the seal surface, particularly if the
bearing seems noisy, indicates too little grease.

Type of Grease
Texaco Cygnus #2 grease is suitable for normal operating conditions. Relubricate with
Texaco #2 grease or grease which is compatible with original lubricant and suitable for
roller bearing service.
REV. E: 8/2/04

37

Lubrication Schedule
Point of Lubrication Lubricant Interval
Electric Motor Bearing Texaco Cygnus Grease #2*
(USDA H1)
Overhaul
Gear Reducer See manufacturers manual
Agitator Bearings Texaco Cygnus Grease #2
(USDA H1)
1 Week
Pneumatic Lubricator Mobil DTE Light
Lubricating Oil
1 Week

*IMPORTANT: On some motors the bearings are lubricated with polyurea based
grease, which is not compatible with lithium-based greases. Mixing polyurea and
lithium greases may cause a loss of lubricant and lead to bearing or motor failure.
Refer to the motor manufacturer manual provided regarding compatible lubricants.

Hydraulic systems only: When changing oil in the hydraulic pump system, use oil based
on the room temperature. Mixers operating in an ambient temperature of under 50 F
(10 C) should use Texaco Cygnus Oil #46. Mixers operating in environments over 50
F should use Texaco Cygnus Oil #68.

Hydraulic System Maintenance
(Applicable to hydraulic driven Mixer Blenders)
It is very important that the hydraulic fluid be maintained in proper condition, that is, free
of chemical and particle contamination. The drain plug in the bottom of the reservoir
should be opened periodically to drain off any moisture condensation, sludge or emulsion
that might collect there. During operation, the system temperature should be kept below
140 F (60 C.), since any overheating will break down the hydraulic oil and form sludge.
Setting up and adhering to a regular schedule for changing the filter elements and
cleaning the suction strainer is mandatory. Specific maintenance procedures depend on
the particular type of hydraulic system supplied with your mixer/blender.

IMPORTANT: If operating conditions are more than an 8-hour day, or more severe
than normal, then maintenance intervals should be adjusted accordingly.

Mixers operating in an ambient temperature of under 50 F (10 C) should use Texaco
Cygnus Oil #46. Mixers operating in environments over 50 F should use Texaco
Cygnus Oil #68.

Refer to the hydraulic system manual that is included with your hydraulically equipped
mixer unit. It contains information on specific components and maintenance
requirements.

REV. E: 8/2/04

38
Preventative Maintenance
The Preventative Maintenance section provides references to corresponding topics in
Section 3- Maintenance for detailed instructions on each operation.
Cozzini strongly recommends following these procedures. Keep a chart for operators
and maintenance personnel. This chart should list all maintenance steps and their
intervals and should require a signature next to each task upon completion. This
ensures that all Preventative Maintenance procedures have been completed at their
required intervals.

Required Daily Maintenance
Check to see that all safety guards are in place and operational: tank grating,
discharge door guarding, and flashing lights.
Check interior of electric control boxes and safety limit switches for condensation.
Check the agitator shaft seals for any sign of wear, damage or missing gaskets (p.16).

Required Weekly Maintenance
Clean filter/regulator/lubricator and refill oil bowl (p.29)
Check the agitator pillow block bearings and lubricate with Texaco Cygnus Grease
#2 as needed. (p.19)
Check drive belts for wear and check pulley alignment. (p.22)
Inspect the condition of the discharge door gasketing. (p.36)
Check the oil level in gearbox. Add oil, drain/refill if necessary. Refer to the gearbox
manual included for oil specifications.
Hydraulic units only: Check hydraulic return filter, replace as needed.
Hydraulic units only: Check hydraulic reservoir for oil contamination. Replace oil
and filter as needed.

Required 3-Month (90-Day) Maintenance
Check pneumatic door cylinders and mechanical interlocks for proper alignment;
adjust if necessary. (p.34)
Check discharge doors for closing tightness and the condition of door gasket. (p.36)
Replace seals and gaskets. (p.16)
Hydraulic units only: Inspect all hydraulic hoses and fittings.

Required 6-Month Maintenance
Change the oil in the gearbox every six months or more frequently depending on the
duty cycle of your machine. This does not apply to direct-drive hydraulic motors.


REV. E: 8/2/04

39

SECTION 4 - SANITATION AND CLEANING

Clean the mixer/blender as soon as possible after every use. If the product contains
curing or pickling compounds, it can corrode the equipment if it is not properly and
thoroughly cleaned.

Before beginning any cleaning or sanitation procedures, the motor should
be in the off position. Always follow in-plant lockout/tagout procedures.
On the mixer, clean the following parts daily:
Mixing tank
Agitator paddles
Seal assemblies
Discharge doors
Grating
The grating over the mixer tank should be raised to the fully open position with the safety
tangs making direct contact with the back cross-member.

IMPORTANT: Never spray any water directly on control panels. Hand wash only.

Cleaning the Shaft Seals
For daily routine cleaning, the shaft seals do not need to be disassembled. To clean the
agitator shaft seals:
1. Close the discharge doors and the safety grating. Start the unit with both agitators
turning in any mode.
2. Pull down on the seal lever to pull the seal away from the mixer tank (Figure 43
& Figure 44). This will allow you to have full access to clean the shaft seal area
with a high-pressure water hose.
3. To close the shaft seal after thoroughly cleaning it, move the seal lever back to the
original position to close.
REV. E: 8/2/04

40

Figure 43: Seal lever closed
Figure 44: Seal lever open

If the seals appear damaged, replace as needed. See Section 3 - Maintenance, p.16 for
a detailed explanation of seal assembly and disassembly.

NOTE: Use caution whenever assembling or disassembling any seal surfaces. A
leak due to damaged seals or seal surfaces may cause loss of product.

Cleaning of the Agitator and Paddles
To clean the agitators, close the safety grating and the run the agitators in any mode. Use
a high-pressure hose to spray off the agitator paddles. Once the agitator shafts and
paddles have been thoroughly cleaned, open the discharge doors to drain water and
product out of the mixer tank.

WARNING: Do not extend your arm or hand through the safety grating in an
attempt to remove any excess product from the agitator or its paddles at any time during
this cleaning procedure. Do not insert any part of the body in the discharge door. This is
extremely dangerous and can result in serious injury.

Cleaning The Doors
To clean the discharge doors, put the doors in the open position. Using a high-pressure
hose, thoroughly clean the doors, inside and out. You can spray the hose upward from
under the safety guarding, or spray the hose from above, down at the discharge doors.

WARNING: Do not run the agitators at any time during this cleaning procedure.
Never insert any part of your body in the discharge door. This is extremely dangerous
and can result in serious injury.

REV. E: 8/2/04

41
SECTION 5 TROUBLESHOOTING
Troubleshooting Diagnostics
These are common problems encountered while operating the mixer/blender and
suggestions for resolving them. The possible causes are listed in the order of probability
of occurrence. To perform the maintenance operations required, refer to the
corresponding topic addressed in Section 3 - Maintenance.

PROBLEM: THE AGITATOR RUBS ON THE MIXER/BLENDER BODY
POSSIBLE CAUSES:
A Misaligned agitators align bearings (p.20)
B Excessively worn bearings replace bearings (p.25)
C Loose screws on pillow block bearings. Tighten as needed.
D Bent agitator shaft
E Worn stub shaft on the discharge end replace (p.28)

PROBLEM: PRODUCT IS COMING OUT OF THE SEAL(S)
POSSIBLE CAUSES:
A Seals are installed incorrectly (see p.16 for all seal assembly details)
B Within the seal housing is a lip seal and a gasket. Both need to be installed
C The seal clamp is not properly tightened
D Seals are worn and need to be replaced

PROBLEM: ODOR OF BURNING RUBBER NEAR DRIVE UNIT
POSSIBLE CAUSES:
A Loose belts not tensioned correctly (p.23)
B Worn or damaged belts: replace promptly (p.25)
C Misaligned pulleys causing belts to rub together. Check pulley alignment.
(p.22)

PROBLEM: PRODUCT LEAKING AT DISCHARGE DOORS
POSSIBLE CAUSES:
A Gasket around door is damaged or incorrectly installed. (p.36)
B Mechanical interlock needs to be adjusted (p.34)

PROBLEM: DEAD SPOTS OR UNMIXED REGIONS IN PRODUCT
POSSIBLE CAUSE:
A Mixer capacity underfilled/overfilled. When the product level is too high,
the equipment is unsafe to operate. Tub volume should be filled to a level
slightly above the top of the agitators.

Water Spray-Equipped Units Only
PROBLEM: REDUCED WATER OUTPUT
POSSIBLE CAUSES:
A Valve coil stuck in closed position prevents metering of water
REV. E: 8/2/04

42
B Obstruction or blockage in water piping

PROBLEM: NO WATER COMING OUT OF SPRAYERS ON GRATING
POSSIBLE CAUSES:
A Water valve shut off down the line
B Valve coil stuck in the closed position. Replace coil if necessary.

Hydraulic-Equipped Units Only
Refer to the separate hydraulic system manual that is included with a hydraulically
equipped mixer unit. It contains information on the components and specific maintenance
requirements.

PROBLEM: HIGH OIL TEMPERATURE
POSSIBLE CAUSES:
A Relief valve setting is too low
B Malfunction of the pump
C Inadequate water supply through the heat exchanger
D Excessively worn pump

PROBLEM: THE HYDRAULIC SYSTEM IS MAKING EXCESSIVE NOISE
POSSIBLE CAUSES:
A The pump may be cavitating
B The fluid may be too cold to flow
C The suction strainer may be clogged
D Check the suction hose. It may have collapsed
E The tank breather may be clogged
F Vapor may be forming
G The reservoir level may be too low
H The wrong type or amount of hydraulic fluid may have been used.
I The couplings may be misaligned
J The couplings may be loose
K The pump may be worn or damaged

PROBLEM: INADEQUATE HYDRAULIC PRESSURE
POSSIBLE CAUSES:
A Pump not primed
B Damaged or worn pump
C Malfunctioning relief valve
D Malfunctioning directional control valve

REV. E: 8/2/04

43

PROBLEM: LOW OR NO PRODUCT FLOW
POSSIBLE CAUSES:
A Pump cavitation
B Fluid aeration
C Worn or damaged pump
D Malfunctioning pressure compensator
E Improper pump rotation

SECTION 6 SPARE PARTS
The following is a list of spare parts to keep on hand as well as recommended quantities.
The part numbers for the components may vary from model to model. Refer to the
drawings and part lists included in the manual for specific part numbers for your unit.

REV. E: 8/2/04

44
8000 LB MIXER/BLENDER RECOMMENDED SPARE PARTS
CUSTOMER: CECINAS SAN J ORGE
MODEL: CMB-8000
SERIAL #: P5126-09-I-1036A
PART # DESCRIPTION QTY ON HAND
03-007-0037 Master link, drive chain 2
03-011-0004 Guard latch 4
03-011-0005 Guard latch key 2
03-001-0084B Pillow block bearing (discharge end) 2
03-001-0091B Pillow block bearing (drive end) 2
05-001-0015 Air cylinder, 2 x 7 1
05-001-0126 Air cylinder seal kit, 2 2
05-002-0206 Solenoid valve, 2-station 24 V 2
05-002-0022 Solenoid valve 24 V 2
05-002-0009 Electrical coil, 24 V 1
12-002-0005 Lip seal (rear drive end) 8
12-002-0001 Lip seal (front discharge end) 8
12-004-0002 Gasket (cut to fit) 20 ft
INDEX
adjustable feet, 9
agitator bearing, 20, 26, 27, 28, 29
agitator bearings, 11, 14, 19, 25, 26, 27
agitator rotation, 10, 13
Agitator rubbing, 14
agitators, 15
air cylinder, 33
air filter, 29
air supply, 10, 11, 31, 32, 33, 36
bearing temperatures, 37
bearings, 42
belt tension, 23
belts, 42
capacity, 14, 15
cylinders, 32, 33
DEAD SPOTS, 42
discharge door, 15, 27, 29, 31, 33, 35,
37, 39, 41
Discharge door gasket, 36
discharge doors, 5, 7, 10, 31, 33, 34, 36,
39, 40, 41
door gasket, 36, 37, 39
drain cock, 29
dwell period, 13
filter, 31
filter/lubricator, 31
flow control/check valves, 32
gasket, 18, 42
gear reducer, 10
gearbox, 7, 10, 18, 20, 25, 39
grease, 11, 19, 21, 37, 38
hydraulic power unit, 12
hydraulic system, 38, 43
hydraulics maintenance, 13
Inspection, 8
interlock, 36
load cells, 10
lockout/tagout, 15, 20, 40
lubricator, 29, 31
Mixer capacity, 42
motor, 40
mounting pads, 9
oil level, 12, 20, 39
pillow block bearing, 20, 26, 28, 29
pillow block bearings, 42
pilot shaft, 28
piston rod, 32
Pneumatic Cylinders, 31
Preventative Maintenance, 39
proximity switch, 12
pulleys, 22, 23, 42
safety guidelines, 5
seal gasket, 18
seal kits, 31
seal lever, 16, 17, 40
seals, 39, 41
Seals, 42
shaft seals, 14, 16, 40
split lip seal, 18
start-up test, 13, 14
stub shaft, 27, 28, 29, 42
tools, 15
tub volume, 42
turnbuckle, 35
underframe, 10
UNMIXED REGIONS, 42
valves, 29
water meter, 14
water spray, 7, 12
Weekly Maintenance, 39
wrenches, 15

REV. E: 8/2/04

45

PARTS LIST FOR

MODEL CMB-8000
P5126
ITEM PART # DESCRIPTION
1 03-002-0819 GEARMOTOR 30HP, 380V/3 PH/50 HZ
2 MBXPN312C GEARBOX MOUNTING PLATE
3 03-004-0648 DRIVE SPROCKET
4 03-004-0596 DRIVEN SPROCKET
5 03-007-0017 CHAIN
5A 03-007-0037 CHAIN CONNECTING MASTER LINK
6 03-001-0091B PILLOW BLOCK BEARING
6A MBXPX401C REAR SHAFT SEAL (SEE SEAL ASSEMBLY DWG.)
7 03-011-0004 GUARD LATCH
7A 03-011-0005 GUARD LATCH KEY
8 VMXPX700D AGITATOR ASSEMBLY (COMPLETE)
Refer to Dwg. No. MBXPN304A

PARTS LIST FOR

MODEL CMB8000
P5126
ITEM PART # DESCRIPTION
1 03-001-0084B PILLOW BLOCK BEARING
2 05-001-0015 AIR CYLINDER 2 X 7
2A 05-001-0126 AIR CYLINDER SEAL KIT
3 FLASHING LIGHT (REFER TO ELECTRICAL MANUAL)
4 VMRIX711B AGITATOR PILOT SHAFT
5 FRONT SHAFT SEAL (SEE SEAL ASSEMBLY DWG.)
6 VMXPX700D AGITATOR ASSEMBLY (COMPLETE)
7 12-004-0002 GASKET (CUT TO SIZE)
Refer to Dwg. No. MBXXM100A

PARTS LIST FOR
MODEL CMB8000
P5126
ITEM PART # DESCRIPTION
1 05-001-0015 AIR CYLINDER 2 X 7
1A 05-001-0126 AIR CYLINDER SEAL KIT 2"
2 05-003-0003 FLOW CONTROL VALVE
3 05-002-0206 VALVE ASSEMBLY 2-STATION / 2-SOLENOID / 2-POSITION 24 V
3A 05-002-0022 SOLENOID VALVE - 24 VOLT
3B 05-002-0009 ELECTRICAL COIL - 24 VOLT
4 05-006-0008 FILTER / REGULATOR / LUBRICATOR WITH SHUT-OFF VALVE
4A 05-006-0013 FILTER
4B 05-006-0014 REGULATOR
4C 05-006-0015 LUBRICATOR
4D 05-006-0016 SHUT-OFF VALVE
Refer to Dwg. No. MBXXZ302A

PARTS LIST FOR

MODEL CMB8000
WATER TIGHT SHAFT SEALS
DISCHARGE END
ITEM PART # DESCRIPTION
1 98-SS404W01B SEAL HOUSING - FRONT
2 98-SPXXX422A SEAL BOLT
4 12-002-0001 LIP SEAL - FRONT
5 06-006-0008 SEAL HOUSING CLAMP - FRONT
6 98-SPXXX432A SEAL LOCK
DRIVE END
ITEM PART # DESCRIPTION
1 98-SS300W01B SEAL HOUSING - REAR
2 98-SPXXX422A SEAL BOLT
3 12-004-0002 GASKET - REAR
4 12-002-0005 LIP SEAL - REAR
5 06-006-0011 SEAL HOUSING CLAMP - REAR
6 98-SPXXX432A SEAL LOCK
Refer to Dwg. No. SSXXMW01A
Ensamblado y desensamblado de los cilindros

BIM-1010/2002/01 1 www.nord.com
BIM-1010/2002
UNICASE

Helical Inline Gearboxes

Installation and Maintenance Instructions
Retain These Safety Instructions For Future Use
INSPECTION OF UNIT
Thoroughly inspect the equipment for any shipping and handling damage before accepting shipment from the freight company. If any of the
goods called for in the bill of lading or express receipt are damaged or the quantity is short, do not accept until the freight or express agent
makes an appropriate notation on your freight bill or express receipt. If any concealed loss or damage is discovered later, notify your freight
carrier or express agent at once and request him to make an inspection. We will be very happy to assist you in collecting claims for loss or
damage during shipment; however, this willingness on our part does not remove the transportation companys responsibility in reimbursing
you for collection of claims or replacement of material. Claims for loss or damage in shipment must not be deducted from the NORD Gear
invoice, nor should payment of the NORD Gear invoice be withheld awaiting adjustment of such claims, as the carrier guarantees safe
delivery.
If considerable damage has been incurred and the situation is urgent, contact the nearest NORD Gear Sales Office for assistance. Please
keep a written record of all communications.
RECORD NAMEPLATE DATA
Locate the gear reducer nameplate and record all nameplate data for future reference.
SK ________________________________________________________ S/N _________________________________
RATIO ______________ MAX TORQUE ____________________ RPM ______________ MTG. POS ______________
STORAGE
PROPER STORAGE UNTIL INSTALLED
Keep unit in a dry, temperature controlled area. If stored other
than said, long term storage methods must be applied to the unit
including complete fill with lubricant. Protect machined surfaces
and rotate shafts periodically. Prior to putting unit into service,
drain lubricant and refill to proper level as determined by the
mounting position.
PROPER HANDLING OF THE UNIT
Exercise care to prevent damage to the unit when moving. Lift
onIy at designed Iifting points. Do not attach other machinery and
lift by the unit lifting points. The lifting points are to be used to lift
the unit only. Insure that adequate safety measures are taken to
protect personneI during transportation. Protect the mounting
surface from damage.
CDN
USA
BIM-1010/2002/01 2 www.nord.com
INSTALLATION OF UNIT
To ensure Iong service and dependabIe performance, an encIosed gear drive must be rigidIy supported and the shafts accurateIy aIigned.
The foIIowing describes the minimum precautions required to accompIish this end.
FOUNDATION
The responsibiIity for the design and construction of the
foundation Iies with the user. The foundation must be adequate
to withstand normaI operating Ioads and possibIe overIoads whiIe
maintaining aIignment to attached system components under
such Ioads.
MOUNTING POSITION
UnIess a unit is specificaIIy ordered for incIined mounting, the
foundation must be IeveI and fIat. The Iubrication system may
not operate properIy if the unit is not mounted in the position for
which it is designed. It may be desirabIe to eIevate the
foundation to faciIitate oiI drainage.
CONCRETE FOUNDATION
If a concrete foundation is used, steeI mounting pads and boIts of
sufficient size to distribute the stress into the concrete shouId be
grouted into the foundation.
STEEL FOUNDATION
If a structuraI steeI foundation is used (i.e. wide fIange beams or
channeIs), a base pIate or soIe pIate of suitabIe thickness shouId
be used and shouId extend under the entire unit.
FLANGE MOUNTED UNITS
If a structuraI steeI foundation is used (i.e. wide fIange beams or
channeIs), a base pIate or soIe pIate of suitabIe thickness shouId
be used and shouId extend under the entire unit. If a buIk head
pIate is used it shouId be of proper strength to minimize buckIing
distortions.
FIange PiIot AK or AK1 toIerance
Metric (mm)
> 50 80 = +0.012/-0.007
> 80 120 = +0.013/-0.009
> 120 180 = +0.014/-0.011
> 180 230 = +0.016/-0.013
> 230 315 = +0.000-0.032
> 315 400 = +0.000/-0.036
> 400 500 = +0.000/-0.040
Inch
> 1.969 3.150 = +0.005/-0.0003
> 3.150 4.724 = +0.005/-0.0004
> 4.724 7.087 = +0.006/-0.0004
> 7.087 9.055 = +0.006/-0.0005
> 9.055 12.402 = +0.000/-0.0013
> 12.402 15.748 = +0.000/-0.0014
> 15.748 19.685 = +0.000/-0.0016
BOLT STRENGTH
BoIt size, strength and quantity shouId be verified to insure proper
torque reaction capacity whatever the mounting arrangement.
PRIME MOVER MOUNTING
AIign the prime mover to the reducer-input shaft using shims
under the feet. Make sure that the feet are supported. DoweI the
prime mover to its foundation.
SHAFT CONNECTIONS
When connecting shafts to either the input or output of the
reducer, consider the foIIowing instructions.
FITS
CIearance or interference fits for coupIing hubs shouId be in
accordance with ANSI/AGMA 9002-A86 or as follows.
Output and Input shaft Diameter toIerance
Metric (mm)
18 = +0.012/+0.001
> 18 30 = +0.015/+0.002
> 30 50 = +0.018/+0.002
> 50 80 = +0.030/+0.011
> 80 120 = +0.035/+0.013
> 120 180 = +0.040/+0.015
Inch
1.750 = +0.0000/-0.0005
> 1.750 = +0.0000/-0.0010
Output and Input shaft DriII and tap shaft end
Metric (mm)
16 = M5
> 16 21 = M6
> 21 24 = M8
> 24 30 = M10
> 30 38 = M12
> 38 50 = M16
> 50 85 = M20
> 85 130 = M24
Inch
0.438 = #10-24 x 0.4 deep
> 0.438 0.813 = -20 x 0.6 deep
> 0.813 0.938 = 5/16-18 x 0.7 deep
> 0.938 1.125 = 3/8-16 x 0.9 deep
> 1.125 1.375 = 1/2-13 x 1.1 deep
> 1.375 1.875 = 5/8-11 x 1.4 deep
> 1.875 3.250 = 3/4-10 x 1.7 deep
> 3.250 = 1-8 x 2.2 deep
Outboard pinion and sprocket fits shouId be as recommended by
the pin sprockets with interference fits shouId be heated
according to the manufacturers recommendations, generaIIy
250F to 300F, (120C to 150 C) before assembIing to the shaft.
BIM-1010/2002/01 3 www.nord.com
WARNING:
LOCK OUT POWER before any maintenance is performed.
Make absolutely sure that no voltage is applied while work is
being done on the gearbox.
The Autovent releases built-up air pressure from
inside the gearbox (Max. pressure 2 psi).
LOCATION
CoupIing hubs shouId be mounted fIush with the shaft ends,
unIess specificaIIy ordered for overhung mounting. Pinions,
sprockets and sheaves shouId be mounted as cIose as possibIe
to the unit housing to minimize bearing Ioads and shaft
defIections.
COUPLING ALIGNMENT
Shaft coupIings shouId be instaIIed according to the coupIing
manufacturers recommendations for gap, anguIar and paraIIeI
aIignment. In many instaIIations, it is necessary to aIIow for
thermaI and mechanicaI shaft movement when determining shaft
aIignment. The coupIing manufacturers recommendations
shouId be foIIowed.
AXIAL DISPLACEMENT
The gap between shaft ends shouId be the same as the specified
coupIing gap unIess overhung mounting of the coupIing hub is
specified. The coupIing gap and shaft gap must be sufficient to
accommodate any anticipated thermaI or mechanicaI axiaI
movement.
ANGULAR ALIGNMENT
Insert a spacer or shim stock equaI to the required coupIing gap
between the coupIing hub faces and measure the cIearance using
feeIer gauges. Repeat this at the same depth at 90-degree
intervaIs to determine the amount of anguIar misaIignment.
PARALLEL ALIGNMENT
Mount a diaI indicator to one coupIing hub, and rotate this hub,
sweeping the outside diameter of the other hub. The paraIIeI
misaIignment is equaI to one-haIf of the totaI indicator reading.
Another method is to rest a straight edge squareIy on the outside
diameter of the hubs at 90-degree intervaIs and measure any
gaps with feeIer gauges. The maximum gap measurement is the
paraIIeI misaIignment.
CHECKING ALIGNMENT
After both anguIar and paraIIeI aIignments are within specified
Iimits, tighten aII foundation boIts secureIy and repeat the above
procedure to check aIignment. If any of the specified Iimits for
aIignment are exceeded, reaIign the coupIing.
SPROCKET OR SHEAVE ALIGNMENT
AIign the sheaves or sprockets square and paraIIeI by pIacing a
straight edge across their faces. AIignment of bushed sheaves
and sprockets shouId be checked after bushings have been
tightened. Check horizontaI shaft aIignment by pIacing a IeveI
verticaIIy against the face of the sheave or sprocket. Adjust beIt
or chain tension per the manufacturers specified procedure.
OUTBOARD PINION ALIGNMENT
AIign the pinion by adjusting the gear tooth cIearance according
to the manufacturers recommendations and checking for
acceptabIe outboard pinion tooth contact. The foundation boIts
may have to be Ioosened and the unit moved sIightIy to obtain
this contact. When the unit is moved to correct tooth contact, the
prime mover shouId be reaIigned.
RECHECK ALIGNMENT
After a period of operation, recheck aIignment and adjust as
required.
1. Properly install unit on a rigid foundation
adequateIy supported
secureIy boIted into pIace
IeveIed so as not to distort the gear case
2. Properly install couplings suitabIe for the application and
connected equipment.
3. Ensure accurate aIignment with other equipment.
4. Furnish and install adequate machinery guards as needed to
protect operating personneI and as required by the
appIicabIe standards of the OccupationaI Safety and HeaIth
Administration (OSHA), and by other appIicabIe safety
reguIations;
5. Ensure that driving equipment is running in the correct
direction before coupling to reducers with backstops
(designed to operate onIy in a specific direction) or
machinery designed to operate only in one direction.
CHANGES IN PERFORMANCE SPECIFICATIONS
Owner has the responsibiIity to consult with NORD GEAR if such
items such as applied Ioads, operating speeds or other operating
conditions have changed.
START-UP
1. Ensure that switches, aIarms, heaters, coolers and other
safety and protection devices are instaIIed and operational
for their intended purpose.
2. Verify that the installed mounting position is the same as the
nametag mounting position. If not, adjust the oil level
accordingly and relocate the vent plug, fill plug and drain
plug according to the mounting position. See following.
AUTOVENT PLUG
The Autovent plug is brass in color and will be located at the
highest point on the gearbox. It operates like a check-valve to
allow the reducer to relieve internal pressure while preventing
lubricant contamination during cooling. A spring presses a ball or
plunger against a machined orifice until pressure exceeds 2 psi.
Above 2 psi the air is allowed to escape depressurizing the
gearcase. When internal pressure drops below 2 psi, the
autovent re-seals closing the unit to the outside environment.
After shutdown, the reducer cools along with the air inside the
reducer. The unit will temporarily maintain a slight vacuum until
normalization occurs. NORD Gear supplies an Autovent as a
standard feature.
BIM-1010/2002/01 4 www.nord.com

Two types of plugs for maintenance
FILL LEVEL & DRAIN PLUGS
The drain plugs are metric socket head cap screws. They will be
located at the lowest part of the gearbox for ease of draining. The
fill level plug is a hex head cap screw. It will be located between
the Autovent and drain plug. Both types of plugs will have gaskets
included to prevent oil from leaking.
LUBRICANT
AII NORD reducers are shipped from the factory properIy fiIIed
with Iubricant and all plugs are installed according to the mounting
position given on the reducer nametag. Acceptable oil fill level is
within inch of the bottom of the fill plug threads.
OPERATION AND MAINTENANCE CHECKLIST
1. Operate the equipment as it was intended to be operated
2. Do not overIoad.
3. Run at correct speed.
4. Maintain Iubricant in good condition and at proper IeveI.
5. Dispose of used Iubricant in accordance with appIicabIe
Iaws and reguIations.
6. AppIy proper maintenance to attached equipment at
prescribed intervaIs recommended by the manufacturer.
7. Perform periodic maintenance of the gear drive as
recommended by NORD.
BIM-1010/2002/01 5 www.nord.com
MOUNTING POSITIONS
These charts detail the mounting positions for horizontal and vertical mounting. The Autovent, oil fill plug and drain plug are indicated on each
mounting position picture. The factory set mounting position and plug locations match that shown on the gearbox nametag. For mounting
orientations other than shown consult NORD Gear.
BIM-1010/2002/01 6 www.nord.com
BIM-1010/2002/01 7 www.nord.com
MAINTENANCE
Mineral lubricant should be changed every 10,000 service hours or after two years. For synthetic oils, the lube should be changed every
20,000 service hours or after four years. In case of extreme operating (e.g. high humidity, aggressive environment or large temperature
variations), shorter intervals between changes are recommended.
OIL SPECIFICATIONS
NORD supplies aII reducers fiIIed with oiI from the factory. Consult the sticker adjacent to the fill plug to determine the type of lubricant
installed at the factory. Standard lubricant is ISO VG220 mineral-based oil. However, some units have special lubricants designed to operate
in certain environments or to extend the service life of the lubricant. If in doubt about which lubricant is needed, contact NORD Gear.
STANDARD OIL ISO VG220
Ambient Temperature FormuIation
Oil
Manufacturer Oil Brand Name
Origin of
Gearbox Assembly
20 to 104F (-5 to 40C) MineraI Texaco Meropa 220 NORD USA
20 to 104F (-5 to 40C) MineraI SheII OmaIa EP 220 NORD Canada
OPTIONAL LUBRICANTS
Ambient Temperature FormuIation
Oil
Manufacturer Oil Brand Name
Origin of
Gearbox Assembly
14 to 176F (-10 to 80C) Synthetic Texaco PinnacIe EP680 NORD USA
14 to 176F (-10 to 80C) Synthetic SheII OmaIa HD 680 NORD Canada
-13 to 140F (-25 to 60C) Synthetic Texaco PinnacIe EP220 NORD USA
-13 to 140F (-25 to 60C) Synthetic SheII OmaIa HD 220 NORD Canada
-40 to 50F (-40 to 10C) Synthetic Texaco PinnacIe EP32 NORD USA
-40 to 50F (-40 to 10C) Synthetic SheII OmaIa HD 32 NORD Canada
20 to 104F (-5 to 40C) Food Grade Chevron FM ISO 220 NORD USA
20 to 104F (-5 to 40C) Synthetic Food Grade OilJAX MagnapIate 85W140-FG NORD Canada
5 to 125F (-20 to 50C) FIuid Grease MobiI MobiIux EP023 NORD USA
-30 to 140F (-35 to 60C) Synthetic FIuid Grease MobiI MobiIith SHC 007 NORD USA
-30 to 140F (-35 to 60C) Synthetic FIuid Grease SheII TiveIa compound A NORD Canada
STANDARD BEARING GREASE NLGI 2EP Iithium
Ambient Temperature FormuIation
Grease
Manufacturer Grease Brand Name
Origin of
Gearbox Assembly
-20 to 140F (-30 to 60C) MineraI Texaco MuItifak EP2 NORD USA
-20 to 140F (-30 to 60C) MineraI SheII Cypernia RA/C3 NORD Canada
OPTIONAL BEARING GREASE
Ambient Temperature FormuIation
Grease
Manufacturer Grease Brand Name
Origin of
Gearbox Assembly
-58 to 230F (-50 to 110C) Synthetic Texaco Starfak 2202 NORD USA
-58 to 230F (-50 to 110C) Synthetic SheII Aero SheII NORD Canada
5 to 230F (-20 to 110C) Food Grade LubripIate SIF 1 NORD USA
BIM-1010/2002/01 8 www.nord.com
LUBRICANT CAPACITY
Each reducer has the oil level and oil quantity adjusted according to the mounting position shown in the tables. When replacing the oil, consult
the tables below to determine the proper amount of oil to be installed according to the reducer size and mounting position. Note that this is
approximate and the final level will be adjusted when the reducer is installed. Acceptable oil fill level is within inch of the bottom of the fill
plug threads.
LUBRICATION CAPACITY HELICAL INLINE GEARBOXES
Horizontal position Vertical position
single reduction Mounting position
B 3 B 6 B 7 B 8 B 5 B 5I B 5II B 5III V 1 V 3 V 5 V 6
quarts 0.26 0.37 0.37 0.58 0.32 0.53 0.42 0.42 0.32 0.37 0.42 0.53
SK 11E
liters 0.25 0.35 0.35 0.55 0.30 0.50 0.40 0.40 0.30 0.35 0.40 0.50
quarts 0.63 1.06 1.06 1.27 0.53 1.16 0.95 0.95 0.74 1.48 1.06 1.27
SK 21E
liters 0.60 1.00 1.00 1.20 0.50 1.10 0.90 0.90 0.70 1.40 1.00 1.20
quarts 1.16 1.80 1.80 2.32 0.85 1.74 2.11 2.11 1.16 1.37 2.43 2.85
SK 31E
liters 1.10 1.70 1.70 2.20 0.80 1.65 2.00 2.00 1.10 1.30 2.30 2.70
quarts 1.80 2.75 2.75 3.49 1.06 2.96 3.49 3.49 1.69 2.75 2.64 2.75
SK 41E
liters 1.70 2.60 2.60 3.30 1.00 2.80 3.30 3.30 1.60 2.60 2.50 2.60
quarts 2.32 3.59 3.59 4.97 1.90 4.33 4.02 4.02 3.17 3.70 4.23 4.65
SK 51E
liters 2.20 3.40 3.40 4.70 1.80 4.10 3.80 3.80 3.00 3.50 4.00 4.40
double reduction
Mounting position
B 3 B 6 B 7 B 8 B 5 B 5I B 5II B 5III V 1 V 3 V 5 V 6
quarts 0.16 0.42 0.42 0.74 0.26 0.63 0.53 0.53 0.63 0.63 0.63 0.63
SK 02
liters 0.15 0.40 0.40 0.70 0.25 0.60 0.50 0.50 0.60 0.60 0.60 0.60
quarts 0.26 0.53 0.53 0.90 0.37 0.95 0.63 0.63 0.95 0.90 0.79 0.79
SK 12
liters 0.25 0.50 0.50 0.85 0.35 0.90 0.60 0.60 0.90 0.85 0.75 0.75
quarts 0.53 1.43 1.43 2.11 0.74 2.11 1.64 1.64 1.90 2.11 1.90 1.90
SK 22
liters 0.50 1.35 1.35 2.00 0.70 2.00 1.55 1.55 1.80 2.00 1.80 1.80
quarts 0.95 2.11 2.11 3.17 1.37 3.49 2.54 2.54 3.28 3.06 3.06 2.64
SK 32
liters 0.90 2.00 2.00 3.00 1.30 3.30 2.40 2.40 3.10 2.90 2.90 2.50
quarts 1.37 3.38 3.38 4.76 1.90 4.76 3.91 3.91 4.23 4.65 4.54 6.13
SK 42
liters 1.30 3.20 3.20 4.50 1.80 4.50 3.70 3.70 4.00 4.40 4.30 5.80
quarts 2.64 5.39 5.39 7.19 3.17 6.55 5.92 5.92 7.82 7.19 7.19 7.40
SK 52
liters 2.50 5.10 5.10 6.80 3.00 6.20 5.60 5.60 7.40 6.80 6.80 7.00
quarts 6.87 15.85 15.85 13.74 7.40 14.79 16.91 16.91 19.55 15.85 16.91 15.85
SK 62
liters 6.50 15.00 15.00 13.00 7.00 14.00 16.00 16.00 18.50 15.00 16.00 15.00
quarts 9.51 24.30 24.30 19.02 10.57 19.55 24.30 24.30 29.59 24.30 27.47 24.30
SK 72
liters 9.00 23.00 23.00 18.00 10.00 18.50 23.00 23.00 28.00 23.00 26.00 23.00
quarts 14.79 33.81 33.81 28.53 15.85 30.64 36.46 36.46 47.55 39.10 46.49 36.98
SK 82
liters 14.00 32.00 32.00 27.00 15.00 29.00 34.50 34.50 45.00 37.00 44.00 35.00
quarts 26.42 54.95 54.95 49.66 27.47 49.66 54.95 54.95 82.42 77.14 80.31 77.14
SK 92
liters 25.00 52.00 52.00 47.00 26.00 47.00 52.00 52.00 78.00 73.00 76.00 73.00
quarts 38.04 75.02 75.02 69.74 42.27 69.74 76.08 76.08 109.90 85.59 107.78 83.48
SK 102
liters 36.00 71.00 71.00 66.00 40.00 66.00 72.00 72.00 104.00 81.00 102.00 79.00
triple reduction
Mounting position
B 3 B 6 B 7 B 8 B 5 B 5I B 5II B 5III V 1 V 3 V 5 V 6
quarts 0.32 0.63 0.63 0.85 0.53 0.95 0.85 0.85 1.16 0.86 0.95 1.32
SK 03
liters 0.30 0.60 0.60 0.80 0.50 0.90 0.80 0.80 1.10 0.81 0.90 1.25
quarts 0.63 0.74 0.74 1.16 0.85 1.27 1.00 1.00 1.27 1.27 1.27 1.32
SK 13
liters 0.60 0.70 0.70 1.10 0.80 1.20 0.95 0.95 1.20 1.20 1.20 1.25
quarts 1.37 1.69 1.69 2.43 2.64 1.59 2.96 2.96 2.96 2.75 2.48 2.54
SK 23
liters 1.30 1.60 1.60 2.30 2.50 1.50 2.80 2.80 2.80 2.60 2.35 2.40
quarts 1.69 2.43 2.43 3.38 2.01 3.70 2.75 2.75 4.65 3.59 4.44 3.06
SK 33
liters 1.60 2.30 2.30 3.20 1.90 3.50 2.60 2.60 4.40 3.40 4.20 2.90
quarts 3.17 3.80 3.80 5.49 3.70 5.28 4.33 4.33 6.45 6.02 6.97 5.92
SK 43
liters 3.00 3.60 3.60 5.20 3.50 5.00 4.10 4.10 6.10 5.70 6.60 5.60
quarts 4.76 6.34 6.34 8.14 5.49 7.40 7.08 7.08 9.40 8.88 9.19 9.19
SK 53
liters 4.50 6.00 6.00 7.70 5.20 7.00 6.70 6.70 8.90 8.40 8.70 8.70
quarts 10.57 13.74 13.74 11.62 11.62 12.68 14.79 14.79 19.02 14.79 16.91 15.32
SK 63
liters 10.00 13.00 13.00 11.00 11.00 12.00 14.00 14.00 18.00 14.00 16.00 14.50
quarts 14.79 21.13 21.13 18.49 14.79 19.02 21.13 21.13 29.06 23.78 28.53 21.13
SK 73
liters 14.00 20.00 20.00 17.50 14.00 18.00 20.00 20.00 27.50 22.50 27.00 20.00
quarts 23.25 34.87 34.87 27.47 24.30 28.53 35.93 35.93 42.27 35.93 39.10 32.76
SK 83
liters 22.00 33.00 33.00 26.00 23.00 27.00 34.00 34.00 40.00 34.00 37.00 31.00
quarts 42.27 51.78 51.78 46.49 42.27 46.49 51.78 51.78 78.19 73.97 76.08 73.97
SK 93
liters 40.00 49.00 49.00 44.00 40.00 44.00 49.00 49.00 74.00 70.00 72.00 70.00
quarts 58.12 70.80 70.80 58.12 58.12 62.34 70.80 70.80 104.61 82.42 102.50 75.02
SK 103
liters 55.00 67.00 67.00 55.00 55.00 59.00 67.00 67.00 99.00 78.00 97.00 71.00
Note: Filling quantities are approximate figures. Oil level must be checked according to oil level plug after final installation.
Acceptable oil fill level is within inch of the bottom of the fill plug threads For mounting angles not shown, consult factory.
BIM-1010/2002/01 9 www.nord.com
SPARE PARTS LISTS
BIM-1010/2002/01 10 www.nord.com
SPARE PARTS LISTS
BIM-1010/2002/01 11 www.nord.com
NOTES
BIM-1010/2002/01 12 www.nord.com
TROUBLE SHOOTING
PROBLEM WITH THE REDUCER POSSIBLE CAUSES SUGGESTED REMEDY
Overloading
Load exceeds the capacity of the
reducer
Check rated capacity of reducer, replace
with unit of sufficient capacity or reduce
load
Insufficient lubrication
Check lubricant level and adjust up to
recommended levels
Excessive lubrication
Check lubricant level and adjust down to
recommended levels
Runs Hot
Improper lubrication
Wrong lubrication
Flush out and refill with correct lubricant as
recommended
Weak mounting structure
Inspect mounting of reducer. Tighten loose
bolts and/ or reinforce mounting and
structure
Loose foundation bolts
Loose hold down bolts Tighten bolts
Worn RV Disc
Overloading unit may result in
damage to disc
Disassemble and replace disc. Recheck
rated capacity of reducer.
May be due to lack of lubricant
Replace bearing. Clean and flush reducer
and fill with recommended lubricant. Failure of Bearings
Overload Check rated capacity of reducer.
Runs Noisy
Insufficient Lubricant
Level of lubricant in the reducer not
properly maintained.
Check lubricant level and adjust to factory
recommended level.
Overloading of reducer can cause
damage.
Replace broken parts. Check rated capacity
of reducer.
Internal parts are broken
Key missing or sheared off on input
shaft.
Replace key.
Output Shaft
Does Not Turn
Coupling loose or disconnected.
Properly align reducer and coupling.
Tighten coupling.
Worn Seals Caused by dirt or grit entering seal.
Replace seals. Autovent may be clogged.
Replace or clean.
Overfilled reducer.
Check lubricant level and adjust to
recommended level.
Autovent clogged.
Clean or replace, being sure to prevent any
dirt from falling into the reducer.
Oil Leakage
Improper mounting position, such as
wall or ceiling mount of horizontal
reducer.
Check mounting position. Name tag & verify
with mounting chart in manual.
Instrucciones de funcionamiento
y mantenimiento
Istruzioni duso e manutenzione
Manual de Operao e Manuteno
B 1010
09/2001
E I P
Guarde estas indicaciones de seguridad
Queste istruzioni di sicurezza devono essere osservate
Estas instrues de segurana devem ser observadas
Reductores de ruedas helicoidales monobloque
Riduttori a ingranaggi cilindrici
Redutores de Engrenagens Helicoidais
Instalacin, preparacin
Los cncamos de transporte en el reductor
estn previstos para soportar el peso del
accionamiento
Dimensionar los fundamentos de forma
suficiente y ejecutarlos exentos de
vibraciones
Montar el reductor o el motor reductor
firmemente y sin apretar excesivamente
Prever suficiente ventilacin
Utilizar rosca interior de serie segn DIN
332 para el montaje de elementos de unin
sobre el eje
Evitar golpes en los ejes (desperfecto de
cojinetes!)
Unir mquina y engranaje en lo posible con
acoplamientos elsticos
Antes de la conexin montar los elementos
accionados y asegurar la chaveta
Para reductores de eje hueco con brazo de
reaccin, utilizar amortiguadores o mazas
de caucho

Conexin elctrica
Conectar el motor segn el esquema de
conexin
Asegurar que la tensin y la frecuencia de
red coincidan con los datos que aparecen
en la placa de caractersticas
Conectar de forma segura el conductor
protector
Corregir un eventual sentido de giro
incorrecto cambiando las 2 fases
Cerrar a prueba de polvo y agua los
boquetes de entrada de cables y la caja de
terminales en s
Prevenir sobrecargas y fallos de una fase
mediante interruptor de proteccin
Ajustar el interruptor protector del motor al
valor de corriente nominal
Esquemas de conexin en la ltima pgina

Puesta en marcha
Durante tiempos de almacenaje
prolongados tomar medidas de precaucin
especiales (vase Almacenaje prolongado
en la hoja de normas de fbrica)
Verificar la posicin del tornillo indicador de
nivel de aceite segn las tablas de posicin
de montaje del respectivo catlogo
Controlar el nivel de aceite
Quitar el tapn de cierre antes de la puesta
en marcha (sobrepresin!); si se diera el
caso, montar tornillo de descarga de aire a
presin
Primer relleno normal: vase tabla de
lubricantes
Los motores refrigerados por aire estn
diseados para soportar temperaturas
ambiente de - 20C hasta +40C, as como
alturas de emplazamiento 1.000 m sobre
el nivel del mar
No se admite el empleo en mbitos Ex
(riesgo de explosin), en tanto no haya sido
expresamente previsto para este fin

Advertencia
Es requisito indispensable que los trabajos
fundamentales de planificacin de la
instalacin, as como el transporte, el
montaje, la instalacin, la puesta en marcha,
el mantenimiento y las reparaciones sean
ejecutados por personal cualificado o bien,
controlados por tcnicos especializados en la
materia. Al realizar trabajos en el motor
reductor se ha de estar absolutamente seguro
de que no hay ninguna tensin conectada, y
que el motor est asegurado contra conexin
ulterior.

Advertencia
Anomalas no conformes con el
funcionamiento normal (mayor consumo de
energa, temperaturas, vibraciones, ruidos,
etc., o disparo de los dispositivos de
vigilancia) son indicios para suponer que la
funcin es defectuosa. En todo caso, el
personal de mantenimiento encargado deber
ser informado inmediatamente al respecto, a
fin de evitar desperfectos que por su parte
pueden causar directa o indirectamente
graves daos personales o materiales.

En caso de duda, Desconectar
inmediatamente la mquina correspondiente!
Installazione e Preparazione
golfari sul motoriduttore
adeguati al peso del gruppo motore
dimensionare adeguatamente le fondazioni
ed eseguirle esenti da vibrazioni.
montare i riduttori o i motoriduttori
saldamente e senza serrare
eccessivamente.
prevedere una ventilazione adeguata
utilizzare filettature interne di serie conformi
alla DIN 332 per sollevare gli elementi di
collegamento sugli alberi.
evitare di urtare gli alberi (i cuscinetti
potrebbero subire danni).
utilizzare il pi possibile giunti elastici per
connettere macchina e riduttore.
prima di prowedere allavviamento, serrare
gli elementi condotti o assicurare la
chiavetta.
in caso di riduttori pendolari con braccio di
reazione, utilizzare un tampone in gomma.


Allacciamento elettrico
eseguire lallacciamento del motore secondo
lo schema elettrico.
verificare che la tensione di rete e la
frequenza corrispondano ai dati sulla
targhetta.
realizzare un collegamento sicuro del
conduttore di protezione.
correggere il senso di rotazione
eventualmente errato scambiando 2 fasi.
sigillare a tenuta di polvere e di acqua le
aperture per i cavi non necessarie e la
scatola morsettiera stessa.
prevenire il sovraccarico e la mancanza di
fase con interruttori di protezione.
impostare linterruttore di protezione del
motore sulla corrente nominale.
schema elettrico nellultima pagina.

Messa in funzione
in caso si prevedano tempi di stoccaggio
prolungati, necessario prendere misure
particolari (vedere opuscolo norme interne
Stoccaggio per periodi prolungati)
stabilire la posizione del tappo di livello
dellolio secondo le tabelle delle forme
costruttive del catalogo corrispondente.
verificare il livello dellolio.
prima della messa in funzione, liberare dallo
spinotto di plastica il tappo di sfiato
(sovrappressione), eventualmente montare
tappi di sfiato a pressione.
prima carica normale: vedere la tabella dei
lubrificanti.
i motori raffreddati ad aria sono progettati
per temperature ambiente comprese fra
-20C e + 40C e per altezze di montaggio
di 1.000 m sul livello del mare.
non ammesso il loro impiego in ambienti
con pericolo di esplosione se non sono
espressamente previsti a tale scopo.


Attenzione
Si d per scontato che i lavori fondamentali di
progettazione dellimpianto e gli interventi di
trasporto, montaggio, installazione, messa in
funzione, manutenzione e riparazione siano
eseguiti da personale qualificato o siano
controllati da personale responsabile. Quando
si eseguono interventi sul motoriduttore,
accertarsi che sia completamente esente da
tensione e renderlo sicuro contro il
riavviamento.



Attenzione
Eventuali variazioni rispetto al normale
funzionamento (aumento della potenza
assorbita, delle temperature, insorgere di
oscillazioni, rumorosit, ecc.) fanno
presuporre che il funzionamento sia
imperfetto. In tali casi per evitare linsorgere di
guasti che, direttamente o indirettamente,
potrebbero causare gravi danni alle persone o
alle cose, si deve avvisare tempestivamente il
personale addetto alla manutenzione.


In caso di dubbio, interrompere
immediatamente lalimentazione!
Preparo da instalao
Utilizar os olhais de iamento para elevao
e transporte das unidades.
Dimensionar as bases de fundao com
rigidez adequada e livres de vibraes.
Montar a unidade rigidamente e ajustada.
Prever a ventilao suficiente.
Utilizar os furos roscados (DIN 332) para
instalao de elementos de transmisso aos
eixos.
Evitar choques nos eixos (danos aos
rolamentos)
A unio entre os eixos de acionamento e da
mquina acionada devem,
preferencialmente, ser feitos por
acoplamentos elsticos.
Dispositivos que operem solidrios ao eixo
de sada devem ser acoplados antes da
instalao do motor.
Utilizar brao de torque com amortecedores
de borracha nas unidades de eixo oco.


Ligao eltrica
Efetuar a ligao do motor conforme
diagrama.
Assegurar-se que tenso e frequncia
coincidem com dados de plaqueta do motor.
Execute um correto aterramento da
instalao.
Caso se queira inverter o sentido de rotao
deve-se inverter duas das tres fases.
Furos e tampa da caixa de ligao devem
ser mantidos fechados e apertados.
Instalar chaves de proteo contra
sobrecarga e falta de fase.
Ajustar o dispositivo de proteo do motor
para a corrente nominal.
Veja diagramas de ligao na ltima pgina.



Posta em marcha
Em caso de armazenagem por longos
perodos seguir procedimento especial
(conforme procedimento Armazenagem por
longos perodos.
Cheque a posio do bujo de nvel de leo
conforme tabelas constantes do catlogo.
Cheque o nvel do leo.
Antes da posta em marcha retire o pino
plstico que protege o respiro (se houver).
Se no especificado em contrrio, a
primeira carga de leo conforme tabela de
lubrificantes.
Motores ventilados a ar so apropriados
para operar em temperatura ambiente entre
20C e +40C e altitudes inferiores a
1.000m.
A utilizao de motores em ambientes
explosivos proibida, a menos que
expressamente indicados para tal operao
(obedecer normalizao especfica).
Ateno
requisito indispensvel que todos os
trabalhos relativos mquina, desde o
projeto, transporte, montagem, instalao,
posta em marcha, manuteno e reparos
devam ser executados por pessoal qualificado
e/ou supervisionados por pessoal
especializado. Deve-se garantir que, durante
os trabalhos de manuteno e reparos o
equipamento esteja eletricamente desligado,
e que no haja possibilidade de ligao
acidental durante o servio.
Ateno
Qualquer anomalia no funcionamento normal
(maior consumo de potncia, elevao de
temperatura, vibraes, rudos, etc.) ou
disparos de alarmes pelos dispositivos de
proteo, so sinais de irregularidades de
funcionamento. Nestes casos, informar
imediatamente o pessoal responsvel pela
manuteno para prevenir que a evoluo do
problema gere consequncias piores e venha
a causar danos fsicos ou materiais.
Em caso de dvida, desligue
imediatamente a mquina.
Mantenimiento
MOTOR
Eliminar las acumulaciones de polvo
(sobrecalentamiento!)
Desmontar, limpiar y engrasar los
rodamientos
Se ha de observar que aprox. 1/3 de todo el
espacio libre en torno al cojinete est relleno
con grasa
Para el tipo de lubricante, vase la tabla de
abajo

ENGRANAJE
Verificar el nivel de aceite con regularidad
Cambiar el lubricante cada 10.000 horas de
servicio o a ms tardar despus de 2 aos
Plazos dos veces mayores para lubricantes
sintticos
Acortamiento de intervalos de lubricacin bajo
condiciones de servicio extremas (humedad
de aire elevada, entorno agresivo y grandes
fluctuaciones de temperatura)
Complementar el cambio de lubricante con la
limpieza a fondo del engranaje




No mezclar lubricantes sintticos con
lubricantes minerales! Esto tambin se aplica
para la evacuacin de los lubricantes!
Manutenzione
MOTORE
eliminare gli accumuli di polvere
(surriscaldamento)
smontare, pulire e ingrassare i cuscinetti a
rotolamento
accertarsi che tutto lo spazio vuoto attorno al
cuscinetto sia riempito con grasso per circa
1/3
per i tipi di lubrificanti vedere sotto


RIDUTTORE
controllare regolarmente il livello dellolio
sostituire il lubrificante ogni 10.000 ore di
funzionamento o, al pi tardi, dopo 2 anni,
contemporaneamente pulire e ingrassare i
cuscinetti riempiti con grasso.
associare il cambio del lubrificante ad una
pulizia approfondita del riduttore.
con i tempi sintetici i tempi raddoppiano,
con gli oli sintetici i tempi raddoppiano, gli
intervalli fra le sostituzioni di lubrificante si
accorciano in caso di condizioni di esercizio
estreme (elevata umidit dellaria, ambiente
aggressivo ed elevate oscillazioni di
temperatura)

Non mescolare i lubrificanti sintetici con quelli
minerali, nemmeno in fase di smaltimento!
Manuteno
MOTOR
Remover o acmulo de poeira
(superaquecimento).
Retire os rolamentos para limpeza e nova
lubrificao.
Cerca de 1/3 do rolamento deve estar
uniformemente preenchido por graxa.
Tipo recomendado de graxa conforme tabela
de lubrificantes.


REDUTOR
Checar regularmente o nivel do leo.
Substituir o lubrificante aps cada 10.000
horas de operao ou no mximo a cada2
anos.
Coordenar a troca do lubrificante com a total
limpeza interna do redutor.
O intervalo de troca ser duplicado se forem
utilizados lubrificantes sintticos.
Se em condies extremas de operao (alta
umidade, ambiente agressivo, grandes
variaes de temperatura) reduzir o intervalo
de troca de lubrificante.
Nunca misturar lubrificantes sintticos e
minerais, seja para completar o nvel ou aps a
drenagem.
CANTIDAD DE LUBRICANTE [cm
3
] QUANTITA DOLIO [cm
3
] QUANTIDADE DE LUBRIFICANTE [cm
3
]
Posicin horizontal
Disposizione orizzontale
Posio horizontal
Posicin vertical
Disposizione verticale
Posio vertical
Reductores de ruedas helicoidales Riduttori a ingranaggi Redutores de engrenagens helicoidais
reduccin simple cilindrici ad una riduzione Reduo nica
B 3 B 6 B 7 B 8 B 5 B 5I B 5II B 5III V 1 V 3 V 5 V 6
SK 11 E
SK 21 E
SK 31 E
SK 41 E
SK 51 E
250
600
1.100
1.700
2.200
350
1.000
1.700
2.600
3.400
350
1.000
1.700
2.600
3.400
550
1.200
2.200
3.300
4.700
300
500
800
1.000
1.800
500
1.100
1.650
2.800
4.100
400
900
2.000
3.300
3.800
400
900
2.000
3.300
3.800
300
700
1.100
1.600
3.000
350
1.400
1.300
2.600
3.500
400
1.000
2.300
2.500
4.000
500
1.200
2.700
2.600
4.400
Reductores de ruedas helicoidales Riduttori a ingranaggi Redutores de engrenagens helicoidais
reduccin doble cilindrici a due riduzioni Reduo dupla
B 3 B 6 B 7 B 8 B 5 B 5I B 5II B 5III V 1 V 3 V 5 V 6
SK 02
SK 12
SK 22
SK 32
SK 42
SK 52
SK 62
SK 72
SK 82
SK 92
SK 102
150
250
500
900
1.300
2.500
6.500
9.000
14.000
25.000
36.000
400
500
1.350
2.000
3.200
5.100
15.000
23.000
32.000
52.000
71.000
400
500
1.350
2.000
3.200
5.100
15.000
23.000
32.000
52.000
71.000
700
850
2.000
3.000
4.500
6.800
13.000
18.000
27.000
47.000
66.000
250
350
700
1.300
1.800
3.000
7.000
10.000
15.000
26.000
40.000
600
900
2.000
3.300
4.500
6.200
14.000
18.500
29.000
47.000
66.000
500
600
1.550
2.400
3.700
5.600
16.000
23.000
34.500
52.000
72.000
500
600
1.550
2.400
3.700
5.600
16.000
23.000
34.500
52.000
72.000
600
900
1.800
3.100
4.000
7.400
18.500
28.000
45.000
78.000
104.000
600
850
2.000
2.900
4.400
6.800
15.000
23.000
37.000
73.000
81.000
600
750
1.800
2.900
4.300
6.800
16.000
26.000
44.000
76.000
102.00
600
750
1.800
2.500
5.800
7.000
15.000
23.000
35.000
73.000
79.000
Reductores de ruedas helicoidales Riduttori a ingranaggi Redutores de engrenagens helicoidais
reduccin triple cilindrici a tre riduzioni Redu!o tripla
B 3 B 6 B 7 B 8 B 5 B 5I B 5II B 5III V 1 V 3 V 5 V 6
SK 03
SK 13
SK 23
SK 33 N
SK 43
SK 53
SK 63
SK 73
SK 83
SK 93
SK 103
300
600
1.300
1.600
3.000
4.500
10.000
14.000
22.000
40.000
55.000
600
700
1.600
2.300
3.600
6.000
13.000
20.000
33.000
49.000
67.000
600
700
1.600
2.300
3.600
6.000
13.000
20.000
33.000
49.000
67.000
800
1.100
2.300
3.200
5.200
7.700
11.000
17.500
26.000
44.000
55.000
500
850
2.500
1.900
3.500
5.200
11.000
14.000
23.000
40.000
55.000
900
1.200
1.500
3.500
5.000
7.000
12.000
18.000
27.000
44.000
59.000
800
950
2.800
2.600
4.100
6.700
14.000
20.000
34.000
49.000
67.000
800
950
2.800
2.600
4.100
6.700
14.000
20.000
34.000
49.000
67.000
1.100
1.200
2.800
4.400
6.100
8.900
18.000
27.500
40.000
74.000
99.000
800
1.200
2.600
3.400
5.700
8.400
14.000
22.500
34.000
70.000
78.000
900
1.200
2.350
4.200
6.600
8.700
16.000
27.000
37.000
72.000
97.000
1.000
1.250
2.400
2.900
5.600
8.700
14.500
20.000
31.000
70.000
71.000
La carga normal del reductor es de aceite mineral. Aceite sinttico se suministra con recargo.
La carica normale del riduttore effettuata con olio minerale. E disponibile anche olio sintetico con un supplemento di prezzo.
Normalmente os redutores so fornecidos com leo mineral, podendo tambem ser fornecidos com leo sinttico com custo adicional
NOTA / NOTA / OBSERVAO:
Las cantidades de aceite especificadas son valores aproximados. Verificar el nivel de aceite con ayuda del tornillo indicador.
Le quantit di olio sono indicative. Verificare il livello dellolio utilizzando l apposito tappo di livello.
As quantidades de leo recomendadas so aproximadas, devendo-se controlar sempre o nvel do leo atravs do bujo indicador.
Nota:
Esta tabla indica lubricantes comparables de distintos
fabricantes. Dentro de una viscosidad y tipo de lubricante se
puede cambiar el fabricante de aceite. Al cambiar la
viscosidad o el tipo de lubricante, se tendr que consultar con
nosotros, de lo contrario no podremos asumir ninguna
garanta por la capacidad de funcionamiento de nuestros
engranajes reductores.
Nota:
Questa tabella elenca i lubrificanti compatibili di diversi
fornitori. Avendo la stessa classe di viscosit e tipo di
lubrificante il fornitore pu essere scelto liberamente. Nel
caso in cui si desideri cambiare viscosit contattare la NORD
altrimenti non potremo assicurare il buon funzionamento del
riduttore e di conseguenza la garanzia non sar valida.
Observaes:
Esta tabela mostra os lubrificantes similares de diferentes
fornecedores. Respeitando-se a classe de viscosidade e tipo
de lubrificante, o fornecedor pode ser escolhido livremente.
A eventual troca por lubrificante de caractersticas tcnicas
diferentes deve ocorrer atravs de nossa autorizao
expressa, caso contrrio implicar na perda da garantia.
Tipos de lubricante / Tipo di lubrificante / Tipo de lubrificante
Temp. ambiental
Temp. ambiente
Temp. ambiente


0 ... 40C
ISO VG 680
Degol BG 680
Degol BG 680
plus
-- Alpha SP 680 Falcon
CLP 680
-- Renolin
CLP 680
CLP 680 Plus
Klberoil
GEM 1-680
Mobilgear:
- 636
- XMP 680
Optigear
BM 680
Shell
Omala 680
Tribol
1100/680
ISO VG 220
- 5 ... 40C (normal)
Degol
BG 220
BG 220 plus
Energol
GR-XP
220
Alpha SP 220
Alpha MW220
Alpha MAX 220
Falcon
CLP 220
Spartan
EP 220
Renolin CLP 220
Renolin CLP 220
Plus
Klberoil
GEM 1-220
Mobilgear
630
Mobilgear
XMP 220
Optigear
BM 220
Shell
Omala 220
Tribol
1100 / 220
ISO VG 100
- 15 ... 25C
Degol
BG 100
BG 100 plus
Energol
GR-XP
100
Alpha SP 100
Alpha MW 100
Alpha MAX 100
Falcon CLP
100
Spartan
EP 100
Renolin CLP 100
Renolin CLP 100
Plus
Klberoil
GEM 1-100
Mobilgear:
- 627
- XMP 110
Optigear
BM 100
Shell
Omala 100
Tribol
1100 / 100
Tipo de
lubricante
Tipo di lubrif.
Tipo de lubrif.
Aceite mineral
Olio minerale
leo mineral
ISO VG 15
- 45 ... - 15C *
Vitamol
1010
Bartran
HV 15
Hyspin AWS 15
Hyspin SP 15
Hyspin ZZ 15
Astron
HVLP 15
Univis J13 Renolin B 15 HVI Isoflex MT
30 rot
Mobil DTE
11 M
Ultra 10 Shell Tellus
T 15
Tribol
943 AW 22
-5 ... 60C
ISO VG 680
Degol
GS 680
Energol
SG-XP 680
-- -- -- Renolin PG 680 Klbersynth
GH-6-680
Glygoyle
HE 680
Optiflex
A 680
Shell Tivela
S 680
Tribol
800 / 680
Aceite sinttico
Olio sintetico
leo sinttico
ISO VG 220
-25 ... 80C *
Degol
GS 220
Enersyn
SG-XP 220
Alphasyn
PG 220
Polydea
PGLP 220
Glycolube
220
Renolin PG 220 Klbersynth
GH-6-220
Glygoyle
HE 220
Optiflex
A 220
Shell
Tivela WB
Tivela S 220
Tribol
800/ 220
ISO VG 680
-5 ... 40C
-- -- -- -- -- Plantogear CLP
680
-- -- -- -- -- Aceite
biodegradable
Olio
biodegradabile
leo
biodegradvel
ISO VG 220
-5 ... 40C
Degol
BAB 220
Biogear
SE 220
Carelub
GES 220
Ergon ELP
220
-- Plantogear CLP
220
Klberbio
GM2-220
-- Optisynt
BS 220
-- Tribol BioTop
1418 / 220
-5 ... 40C
ISO VG 680
-- -- -- -- -- Bel-Ray No-Tox
Synt.Worm Gear
Oil 680
Klberoil
4 UH1-680
Klbersynth
UH1 6-680
-- Optileb
GT 680
Shell
Cassida
Fluid GL680
Tribol
FoodProof
1800 / 680
Eural
Gear 220
-- Vitalube
GS 220
-- Gear Oil
FM 220
Bel-Ray No-Tox
Gear Oil 90
Klberoil
4 UH1-220
Mobil DTE
FM 220
Optileb
GT 220
Shell Cassida
Fluid GL220
Tribol
FoodProof
1810 / 220
Aceite compat. c.
prod. alim.
1)
Olio per ambienti
alimentari
1)
leo p/ ind.
Alimentcia ISO VG 220
-25 ... 40C
Synt.Gear Oil 220 Klbersynth
UH1 6-220
oder
1800 / 220
Grasa sinttica
fluida
Grasso sintetico
Graxa sinttica
fluida
- 25 ... 60C
Aralub
BAB EP0
Enersyn
GSF
Alpha Gel 00 -- Fliefett
S 420
Renolit LX-PG 00 Klbersynth
GE 46-1200
Klbersynth
UH1 14-1600
1)
Glygoyle
Grease 00
Obeen
UF 00
Tivela
Comp. A
Tivela GL 00
Tribol
800 / 1000
Tipos de lubricante para rodamientos antifriccin / Tipo di lubrificante per cuscinetti / Tipos de lubrificantes para rolamentos
Tipo de
lubricante
Type of
lubricant
Tipo de
lubrificante
Temp. ambiental
Temp. ambiente
Temp. ambiente




- 30 ... 60C
(normal)
Aralub
HL 2
Energrease
LS 2
Spheerol AP
2 LZV-EP
Glissando 20 Grasa
universal
Beacon2
Renolit FWA 160 Klberplex
BEM 41-132
Mobilux 2 Longtime
PD 2
Shell
Alvania R2
Tribol
4020/220-2
Grasa (a base de
aceite mineral)
Grasso (olio
minerale di base
Graxa (base leo
mineral)
* - 50 ... 40C
Aralub
SEL 2
-- Spheerol
EPL2
-- -- Renolit JP 1619 -- -- Longtime
PD 1
Shell Alvania
RL 2
Tribol
3785
Grasa sinttica
Grasso sintetico
Graxa sinttica
* - 25 ... 80C
Aralub
SKL 2
-- Product
783/46
Discor B EP
2 LF
Beacon
325
Renolit S 2
Renolit HLT 2
Isoflex Topas
NCA 52
Isoflex Topas
NB 52
Mobiltemp
SHC 32
Optitemp
LG 2
Aero Shell
Grease
16 oder 7
Tribol
3499
Grasa
biodegradable
Biodegradable
Grease
Graxa
biodegradvel
- 25 ... 40C
Aralub
BAB EP 2
BP Bio-
grease EP 2
Biotec Dolon E EP 2 -- Plantogel 2 S Klberbio
M 32-82
Schmierfett
UE 100 B
EF 584 Shell
Alvania
RLB 2
Molub-Alloy
BioTop 9488
Grasa compat. c.
prod. alim
1)
Grasso
biodegradabile
1)
Graxa p/ ind.
Alimentcia
1)
- 25 ... 40C
Eural
Grease EP 2
BP
Energrease
FM 2
Vitalube HT
Grease 2
Tamix FRA 1 Carum
330
Renolit
G 7 FG 1
Klbersynth
UH1 14-151
Mobil-
grease
FM 102
Obeen
UF 2
Shell Cassida
RLS 2
Molub-Alloy
Food-Proof
823-2 FM
* En caso de temperaturas ambiente inferiores a -30 C y superiores a 60 C se tendrn que utilizar retenes de un material de calidad especial
* Con temperature ambiente sotto 30C e sopra approssimativamente i 60C consigliabile usare anelli di tenuta speciali
* Para temperaturas ambientes inferiores a 30C e superiores a 60C devem ser utilizados retentores especiais.
1)
Aceites + grasas aprobados para la industria alimenticia segn la norma H1 / FDA 178.3570
1)
Lubrificanti per ambienti alimentari con USDA-H1 approvato da FDA 178.3570
1)
Lubrificantes aprovados para a indstria alimentcia pelo FDA 178.3570
B 3
B 6
B 7
B 8
B 5
B 5 I
B 5 II
B 5 III
SK 11 E - SK 51 E
SK 02 - SK 52
SK 03 - SK 53
SK 62 - SK 103
SK 63 - SK 103
SK 62 - SK 102
SK 62 - SK 102
SK 63 - SK 103
SK 62 - SK 102
SK 63 - SK 103
POSICIONES DE MONTAJE
POSIZIONI DI MONTAGGIO
FORMAS CONSTRUTIVAS
Posicin horizontal
Disposizione orizzontale
Posio horizontal
SK 63 - SK 103
SK 62 - SK 102
Motor trifsico con rotor en cortocircuito
Motore trifase con rotore in corto circuito
Motor trifsico de rotor em gaiola
I) Placa de terminales
Morsettiera
Placa de bornes
II) Interruptor
Interruttore
Contator
Posicin vertical
Disposizione verticale
Posio vertical
SK 11 E - SK 51 E
SK 02 - SK 03 -
SK 52 SK 53
SK 62 - SK 103
V1 *
V3
V5 *
* Posiciones de montaje V1 o V5 con depsito de compensacin del aceite (vase catlogo G1000)
* Posizione di montaggio V1 o V5 con unit di espansione lubrificante (vedi catalog G 1000)
* Formas construtivas V1 ou V5 com cmara de expanso (veja catlogo G1000)
Esquemas de conexin / Schemi di collegamento / Diagramas eltricos
V6
Smbolos:
Simboli:
Smbolos:
Ventilacin
Sfiato
Bujo de respiro
Nivel de aceite
Livello dellolio
Nvel de leo
Salida de aceite
Tappo di scarico
dellolio
Bujo de dreno
Fijacin
Superficie di montaggio
Superfcie de montagem
SK 63
SK 63
Motor trifsico con rotor en cortocircuito, conexin Dahlander
Motore trifase con motore in corto circuito, collegamento Dahlander
Motor trifsico de dupla rotao, ligao Dahlander
Motor trifsico de polos conmutables, dos bobinas separadas
Motore trifase a poli commutabili, due avvolgimenti separati, due velocita
Motor trifsico de dupla rotao, bobinagens independentes
inferior - velocidad - superior
inferiore - numero dio giri - superiore
baixa - rotao - alta
inferior - velocidad - superior
inferiore - numero dio giri - superiore
baixa - rotao - alta




















Operating and Maintenance Instructions

These safety instructions must be kept in a safe place

B 1091
Status: 06.03




Three-phase Asynchronous Motors Standard Design
SK 63./. SK 132./.

Explosion-proof Motors with Type of Protection "e"
SK 63./. ED SK 132./. ED

Dust Explosion-proof Motors
(Zone 21)
SK 63./. 2D SK 132./. 2D

Dust Explosion-proof Motors
(Zone 22)
SK 63./. 3D SK 132./. 3D
GB
Page -2- B1091-D


































1. General information
These Operating Instructions must be read before you transport, assemble, commission, maintain or repair NORD
motors.
All persons who are involved with such tasks must observe these Operating Instructions.
All safety instructions provided in these Operating Instructions must be strictly observed for reasons of personal
protection and protection of property.

Information and instructions provided in the manual supplied, safety and commissioning information and all other
manuals must be observed.

This is absolutely essential in order to avoid hazards and damage!
Any applicable national, local and system-specific regulations and requirements must also be observed!

Custom designs and design variants may differ on technical details. If any points are not clear, it is
urgently recommended that you consult the manufacturer stating the type designation and motor number
or have the maintenance work performed by NORD.
Qualified staff are persons who, owing to their training, experience, instruction received, and their knowledge of
relevant standards, accident prevention regulations and the appropriate operating conditions, are entitled to
perform the activities necessary in order to put the motor into operation.
That also calls for knowledge of First Aid and local rescue facilities.

CONTENTS Page

1. General information ...........................................................................................2
2. Description..........................................................................................................3
2.1 Range of application.............................................................................................3
2.2 Design and method of operation..........................................................................3
3. Operation.............................................................................................................4
3.1 Transport, storage................................................................................................4
3.2 Installation ............................................................................................................4
3.3 Balancing, output components.............................................................................4
3.4 Alignment..............................................................................................................4
3.5 Electrical connection ............................................................................................5
3.6 Checking insulation resistance.............................................................................5
3.7 Commissioning.....................................................................................................5
4. Maintenance/servicing.......................................................................................6
5. Motors with type of protection Increased Safety EExe..................................7
6. Motors for protection against dust explosion.................................................9
6.1 General .................................................................................................................9
6.2 Safety instructions ................................................................................................9
6.3 Commissioning instructions/range of application.................................................9
6.4 Design and method of operation........................................................................10
6.5 Minimum cross-sections of protective earth wires .............................................10
6.6 Inverter operation ...............................................................................................10
6.7 Maintenance.......................................................................................................10
7. Spare parts drawing and spare parts list ......................................................11
B1091-D Page -3-


It is assumed that the work for transport, assembly, installation, commissioning, maintenance and repair will be
performed by qualified staff.
The following points in particular must be observed:
Specifications and information about permissible use, assembly, connection, ambient and operating
conditions, which are included in the catalogue, the order documentation and any other product
documentation
The local, system-specific regulations and requirements
Expert use of tools, hoisting equipment and transport equipment
Use of personal safety equipment

For reasons of simplicity the Operating Instructions cannot contain all detailed information about possible design
variants so they cannot take into consideration every imaginable case of installation, operation or maintenance.

For this reason these Operating Instructions essentially only contain such instructions as are required for normal
use by qualified staff.
To prevent malfunctions it is necessary that the specified maintenance and inspection work be performed by
appropriately trained staff.
If the Operating Instructions are lost for any reason, a copy can be obtained from NORD.


2. Description
2.1 Range of application

Use of the motors:

The motors may only be used for their intended purpose.
The motors are designed with at least IP 55 protection (for degree of protection see rating plate). They can be
installed in a dusty or moist environment.
The necessary degree of protection and any additional precautions required always depend on the operating and
environmental conditions.
For outdoor installation and vertical designs, e.g. V1 or V5 with shaft pointing down, NORD recommends using the
option of the double fan hood.
The motors must be protected against intense sunlight, e.g. by means of a protective roof.
The insulation is tropic-proof.

Ambient temperature: -20...+40 C
Installation altitude: 1,000 m


2.2 Design and method of operation

Motor designs:

Standard NORD 3-phase AC motors are self-cooled (with fan), cooling method IC 411.
In the case of foot-mounted motors in frame sizes 63S/.. to 90L/.. the feet are cast onto the motor housing.
In the case of foot-mounted motors in frame sizes 100L/.. to 132M/.. the feet are bolted onto the motor
housing.
In the case of brake motors the brake operating instructions also have to be observed!

Page -4- B1091-D



3. Operation
Work may only be performed if the system is disconnected from the mains supply.


3.1 Transport, storage
For transport use all the hoisting lugs fitted to the motor!
The hoisting lugs are designed for the weight of the motor; do not attach any additional loads!
To transport machine sets (e.g. gear unit attachments) only use the hoisting lugs and pins provided!
Machine sets must not be hoisted by attaching to individual machines!
To prevent damage to the motor, the motor must always be lifted with suitable hoisting equipment. The antifriction
bearings should be replaced if the time between delivery and motor commissioning under favourable conditions
(storage in dry, dust-free and vibration-free rooms) is more than 4 years. Under unfavourable conditions that time is
reduced considerably. It may be necessary to treat unprotected, machine surfaces (flanging surface, shaft end; ...)
with corrosion inhibitor. If necessary, check the insulation resistance of the winding, see section 3.6.
Changes in normal operation (higher power consumption, higher temperatures or higher vibrations, unusual noises
or smells, response from the monitoring system, etc.) indicate that operation is impaired. To avoid personal injury
and damage to property, the maintenance staff responsible must be informed about the change immediately.
In case of doubt switch off the motor without delay, as soon as the status of the system permits.


3.2 Installation
After installation, tighten up or remove any hoisting lugs that have been screwed in!
Smooth running: accurate alignment of the coupling as well as a well-balanced drive assembly
(coupling, pulleys, fan, ...) are essential for smooth, vibration-free running.
If may be necessary to completely balance the motor with the output assembly.
The top section of the terminal box and the orientation of the terminal box can be rotated 4 x 90 degrees.


3.3 Balancing, output components

Fitting and removing output assemblies (coupling, pulleys, gear, ...) must be performed with a suitable device.

The rotors are balanced with half key balancing as standard.

When fitting output assemblies to the motor shaft observe the appropriate type of balancing!
The output assemblies have to be balanced in accordance with DIN ISO 1940!
Take the general precautions necessary for providing the output assemblies with shock protection.
If a motor is put into operation without an output assembly, prevent the key from being flung out. This also applies if
a second shaft end is fitted. Alternatively, remove the key.


3.4 Alignment

Especially if there is a direct coupling, align the shafts of the motor and the driven machine with one another axially
and radially.
Any inaccurate alignment can lead to bearing damage, excessive vibrations and shaft breakage.

B1091-D Page -5-


3.5 Electrical connection

Feed the connecting leads into the terminal box with cable glands. The terminal box must be sealed so that it is
dust-tight and water-tight. The mains voltage and mains frequency must agree with the figures on the rating plate.
5% voltage deviations or 2% frequency deviations are permissible without any reduction in performance. The
connections and arrangement of the terminal board jumpers must conform to the circuit diagram provided in the
terminal box. Connect the protective earth lead to that protective earth terminal.

Provide the ends of the connecting leads with cable lugs or curved ring eyes and connect them to the terminal
board. That also applies to the protective earth connection and the external bonding lead.
For tightening torques at the screw connections of electric terminals and the terminal board connections (apart
from terminal strips) refer to the table below:

Tightening torques for terminal board connections

Thread diameter M4 M5 M6

Tightening torque (Nm) 0.6 1.2 1.8 2.5 2.7 4.0
If the machine has an auxiliary heater, it must not be switched on during operation.


3.6 Checking insulation resistance

Before putting the motor into operation for the first time, after a lengthy period of storage or standstill (approx. 6
months), the insulation resistance of the winding has to be determined. During and directly after measurement the
terminals carry hazardous voltages in some cases and must not be touched.

Insulation resistance
The insulation resistance of new, cleaned, repaired windings against the housing and against one another is >200
M Ohm.

Measurement
In the case of windings up to an operating voltage of 400 V the insulation resistance against the housing must be
measured with a DC voltage of 500 V. At operating voltages up to 725 V measure with a DC voltage of 1000 V.
When doing this the temperature of the windings should be 25C 15C.

Checking
If, in the case of a new, cleaned winding or a repaired motor which has been stored or shut down for any lengthy
period, the insulation resistance of the winding against the housing is less than 50 MOhm, the cause may be
moisture. The windings will then have to be dried.
After any lengthy period of operation the insulation resistance may drop. As long as the measured value does not
fall below the critical insulation resistance of < 50 MOhm, the motor may continue to be operated. If the value falls
below the critical level, the cause must be established and if necessary, the windings or winding sections must be
repaired, cleaned or dried.


3.7 Commissioning
Note:
Electromagnetic compatibility
Emitted interference: If torques are not equal (e.g. drive of a piston compressor) a non-sinusoidal motor current is
bound to develop, the harmonics of which may cause impermissible mains influence and hence impermissible
emitted interference.
If power is fed via an inverter, different levels of emitted interference will occur, depending on the design of inverter
(type, suppression, manufacturer). It is absolutely essential that the EMC information provided by the inverter
manufacturer be observed. If the manufacturer recommends a screened motor supply lead, screening will be most
effective if it is electrically connected to a large area of the metal terminal box of the motor (with EMC cable gland
made of metal). In the case of motors with built-in sensors (e.g. PTC thermistors) interference voltages can occur
on the sensor line, caused by the inverter.
Interference immunity: In the case of motors with built-in sensors (e.g. PTC thermistors) the user himself must
ensure adequate interference immunity by making a suitable selection of sensor signal line (possibly with
screening, interfacing as with motor supply lead) and the analysing instrument. Prior to commissioning always
observe the information and instructions in the operating manuals for inverters as well as all other sets of
instructions. After attaching the motors, check them to make sure they are operating properly! In the case of brake
motors also check that the brake operates properly.

Page -6- B1091-D



4.0 Maintenance/servicing

Safety precautions
Before commencing any work on the motor or device, but especially before opening covers in front of live
components, always isolate the motor electrically according to the regulations. Apart from the main circuits also
isolate any additional or auxiliary circuits.

The standard "5 safety rules", e.g. according to DIN VDE 0105, are:
Isolate electrically
Prevent equipment from being switched on again
Check that there is no voltage
Earth and short-circuit
Cover any adjacent live components or prevent access with barriers
The above precautions may only be withdrawn when the maintenance work has been completed and the motor is
fully assembled.
Inspect the motors properly at regular intervals. In particular look out for any physical damage, ensure that cooling
passages are free, listen for any unusual noises, and ensure that electrical connections are performed in a proper
manner.
With the exception of standardised, commercial or equivalent parts the only spare parts which may be used are
genuine spare parts!

NOTE: Inasmuch as motors are provided with enclosed condensation ports, they must be opened from time to time
so that any accumulated condensation can drain off. Condensation ports are always positioned at the lowest point
of the motor. When installing the motor ensure that the condensation holes are at the bottom.

Bearing changes, grease filling
The period for changing bearings in operating hours [h] on IEC motors with coupling drive is as follows, under
normal operating conditions and with the motor installed horizontally, depending on coolant temperature and motor
speed:

25C 40C
Up to 1,800 rpm

approx. 40,000 h approx. 20,000 h
Up to 3,600 rpm

approx. 20,000 h approx. 10,000 h

In the case of direct gearbox attachment or under special operating conditions, e.g. vertical motor, substantial
vibrations or shock loads, frequent reversing, etc. the above-mentioned operating hours will be reduced
considerably.

The motor must be subjected to a general overhaul every 5 years!

The motors have deeper groove ball bearings with cover disks (2Z design) or shields (2RS design). In the case of
frame sizes 63-100 the ball bearings are fitted with normal bearing clearance and in the case of frame sizes 112
and 132 with increased bearing clearance (C3). The filling of grease in the ball bearings is sufficient for the entire
service life. Antifriction bearings have to be pulled off with a suitable device. Any soiling of the bearings must be
removed!
The shaft seal seats on the shaft must not be damaged in any way whatsoever. Minute scores will cause a
leakage.

Before fitting, heat antifriction bearings uniformly to approx. 80 -100C.
Avoid any hard knocks (e.g. with a hammer, ...).
Also replace any worn sealing elements (e.g. shaft seal, ...).
If shaft seals are fitted without a spring, the spare part must also be inserted without a spring.
When fitting shaft seals apply plenty of antifriction bearing grease; particularly at the sealing lip.
B1091-D Page -7-


General overhaul

For this purpose the motor must be dismantled. Perform the following work:
Clean all parts of the motor
Inspect all parts of the motor for damage
Replace all damaged parts
Replace all antifriction bearings
Replace all gaskets and shaft seals

The general overhaul must be performed in a specialised workshop with appropriate equipment and by qualified
staff. We urgently recommend having the general overhaul performed by NORD Service.


5. Motors with type of protection Increased Safety EExe

These motors are subject to the following supplementary or specific information.

Explosive gas mixtures or concentrations of dust in conjunction with hot, live and moving parts on electrical
machinery can cause serious or lethal injuries.

The motors are suitable for use in Zone 1 and conform to equipment group II, category 2G.

The marking is

0102 II 2G EEx e II along with the temperature class.

If the motor is connected to a gearbox, the Ex marking of the gearbox must also be observed.

The increased hazard in explosive areas calls for particularly careful compliance with the general safety and
commissioning instructions. The staff responsible must be trained regarding correct use of motors in explosive
areas.

Explosion-proof electrical machines comply with the standards in series EN 60034 (VDE 0530) as well as EN
50014 and 50019. It is the degree of explosion risk which determines zone classification. DIN EN 60079, Part 10,
provides information on this. It is the user who is responsible for zone classification.

If motors are not certified for explosive areas, it is prohibited to use them in explosive areas.

Cable entries must be approved for explosive atmospheres. Ports which are not used must be closed off with
approved blind plugs.
When connecting up the installation lines to the motor terminals and the protective earth lead must be laid with U-
shaped lines under the respective terminals so that the wire clamps and the terminal studs are subjected to uniform
loading and are not deformed under any circumstances. Alternatively, the connections can be made with a cable
lug.

When connecting up always ensure that the permissible clearance distances of 10 mm and the permissible
creepage distances of 12 mm between live components and housing potential and between individual live
components are observed.

Before the terminal box is closed, make sure that all the nuts on the terminals and the screw on the protective earth
terminal are tight. The terminal box gaskets and the seals on the cable gland must be fitted properly and must not
be damaged in any way.

If the shaft end is at the top, e.g. designs IMV3 or IMV6, and the motor has EExe protection, the user/installer must
fit a cover which prevents foreign bodies from falling into the motor fan hood (see DIN EN 50014). It must not
impair cooling of the motor by its fan. A handwheel at the second shaft end is not permitted. If the shaft end is at
the bottom, e.g. designs IMV1 or IMV5, the motors are generally provided with a protective roof on the fan hood.
The motors are designed for continuous duty and normal, non-recurring start-ups in which no substantial start-up
heat develops.




Page -8- B1091-D


Area A in EN 60034-1 (VDE 0530 Part 1) - voltage 5%, frequency 2%, characteristic, mains symmetry - must
be observed so that the development of heat remains within the limits permitted. Any major deviations from the
ratings can caused an impermissible increase in the development of heat in the electric machine.
The motor temperature class stated on the rating plate must at least conform to the temperature class of any
combustible gas that may be emitted.

Each machine must be protected against impermissible development of heat by a current-dependent delayed
protective switch tested for operation by an appointed body, with phase-failure protection in compliance with VDE
0660 or an equivalent system in all phases. The protective system must be set to the rated current. If windings are
connected in a delta circuit the trips must be connected in series with the winding phases and set to 0.58 times the
rated current. If such a configuration is not possible, additional precautions will be necessary (e.g. thermal machine
protection).
If the rotor jams, the protective system must shut down within the t
E
-time specified for the respective temperature
class.
Electric machines for heavy starting (ramp time > 1.7 x t
E
-time) must be protected by a start-up monitoring system
in accordance with the provisions of the EC type test certificate.
Thermal machine protection by means of direct thermal monitoring of the winding with PTC thermistor temperature
sensor is permissible if it is certified and stated on the rating plate.
Do not connect any voltage higher than 2.5V to the PTC thermistor temperature sensor!
If the only protection is a PTC thermistor temperature sensor, a performance-tested, certified PTC tripping unit from
an appointed body must be used. The PTC tripping unit must be provided with the following marks concerning the
degree of protection:


II (2) G

In Germany reference is made to DIN 57165/VDE 0165 and ElexV for setting up electrical installations in
explosive areas! In other countries the appropriate national regulations must be observed!

Operation in conjunction with an inverter must be explicitly certified. It is absolutely essential that the separate
manufacturer's instructions be observed. For EExe protection the motor, inverter and protective systems must be
identified as belonging together and the permissible operating data must be defined on the joint EC type test
certificate. The levels of voltage peaks generated by the inverter may be subjected to unfavourable influences by
the connecting cable installed between the inverter and the electric machine. In the system comprising inverter-
cable-electric machine the maximum figure for voltage peaks at the connecting terminals on the machine must not
be less than the figure specified in the separate manufacturer's instructions. In addition, the EMC Directive must
also be observed.

Any repairs must be performed by NORD or accepted by an officially recognised independent expert. The work
must be identified by means of an additional repair plate. With the exception of standardised, commercial and
equivalent parts, the only spare parts which may be used are genuine spare parts (see spare parts list): this
particularly applies to seals and connecting parts.
In the case of motors with closed condensation holes the threads of the plugs must be recoated with Loctite 242 or
Loxeal 82-21 after condensation has been drained off. As soon as that has been done the plugs must be
reinserted. Checking of electrical connections must be performed at regular intervals.
The connection terminals, protective earth terminal and equipotential bonding terminal must be inspected to make
sure they are firm. When doing so, check to make sure that the cable entry, cable gland and terminal box gaskets
are in good condition.

All work on electric machines must be performed with the machine vertical and with all terminals disconnected from
the mains.

If installation resistance is being measured the motor must be removed. Measurement must not be performed in
the explosive area. As soon as measurement has been completed discharge the connecting terminals again by
shorting them in order to prevent any spark discharges occurring in the explosive area.


6. Three-phase asynchronous motors for use in Zone 21 and Zone 22
6.1 General

Motors in categories 2D and 3D are subject to the supplementary or specific information below!

6.2 Safety instructions

The increased risk in areas with combustible dust calls for strict observation of the general safety and
commissioning instructions. Explosive concentrations of dust can, if ignited by hot or sparking objects, cause
explosions which result in serious to lethal injuries to persons as well as considerable damage to property.
It is absolutely imperative that the persons responsible be trained for the correct use of motors in explosive areas.

6.3 Commissioning instructions / range of application

In accordance with their markings the motors are suitable for use in Zone 21 (category 2D) or Zone 22 non-
conductive dust (category 3D). If the motors are to be suitable for inverter operation, this must be stated when
placing the order. The motors must be protected against overheating by means of suitable monitoring devices! The
amount of dust settling must not exceed 5 mm! The motors are designed for voltage and frequency range A of EN
60034 Part 1.
Motors for use in Zone 21 and Zone 22 with the mark TF may be monitored thermally by a built-in PTC in
conjunction with a suitable tripping unit, as sole protection.
If the motor is marked TFX, the PTC thermistor may only be used as extra protection in addition to the motor
protection switch.

The marks are:
0102
II 2 D T 125C for Zone 21

Certificate number:


II 3 D T 125C for Zone 22 (non-conductive dust)

If the motor is connected to a gearbox, the Ex marking on the gearbox must be observed in addition!

Electrical equipment for use in areas with combustible dust conform to the standards EN 50281-1-1, EN 60034 as
well as EN 50014. The degree of explosion risk determines zone classification. The user/employer is responsible
for zone classification (Directive 1999/92/EC).
If the certificate is supplemented with an X, special rules in the EC type test certificate have to be observed. If
standards motors are not certified for explosive areas, it is prohibited to use them in explosive areas.
For Zone 21 the cable entries must be approved for explosive applications (degree of protection at least IP 66) and
prevented from becoming loose on their own. Any ports not used must be closed off with approved plugs (degree
of protection at least IP 66).
For Zone 22 the cable entries must at least satisfy the requirements of IP 55 protection. Any ports not used must
be closed off with blind plugs (minimum degree of protection IP 55).
Any opening of the motor in order to connect electric cables or perform other work must not take place in an
explosive atmosphere. The voltage must always be switched off before opening and precautions must be taken to
prevent equipment from being switched on again!

If the shaft end is at the top, e.g. designs IMV3 or IMV6, the user/installer must fit the cover to the motors which
prevents foreign bodies from falling into the motor fan hood (see DIN EN 50 281-1-1). It must not impair cooling of
the motor by its fan. A handwheel at the second shaft end is not permitted. If the shaft end is at the bottom, e.g.
designs IMV1 or IMV5, the motors are generally provided with a protective roof on the fan hood for Zone 21.
Unless the test certificate or the rating plate provides different information as regards mode of operation and
tolerances, electric machines are designed for continuous duty and normal, non-recurrent start-ups in which no
substantial start-up heat develops. The motors may only be used for the mode of operation stated on the rating
plate
It is absolutely imperative that the installation specifications be observed!






B1091-D Page -9-
Page -10- B1091-D

6.4 Design and method of operation

The motors are self-cooled. Shaft seals are fitted both at the drive end and at the ventilation end.
Motors for Zone 21 and for the Zone 22 have a metal fan. The motors have IP 55 protection (Zone 22 - non-
conductive dust) or IP 66 (Zone 21). The surface temperature does not exceed 125C under normal operating
conditions.

6.5 Minimum cross-sections of protective earth wires

Cross-section of the live wire
for installation S in mm
2

Minimum cross-section of the associated
protective earth wire S
P
in mm
2

S 16
16 < S 35
S > 35
S
16
0.5 S

When connecting a wire to the external earthing system the cross-section must be a minimum of 4 mm
2
.

6.6 Converter operation

Each rating plate on converter-compatible motors states the maximum frequency which must not be exceeded.
Motors for inverter operation are generally equipped with 3 PTC thermistors. The PTC thermistor tripping unit must
be selected according to the valid standard. The temperatures at the points of cable entry are 120C max. Suitable
cables must be used for that temperature.

The levels of the voltage peaks generated by the inverter may be subjected to unfavourable influences by the
connecting cable installed between the inverter and the electric machine! This must be taken into consideration in
configuration!

The EMC regulations must be observed!


6.7 Maintenance

Always switch off the voltage before opening and take precautions to prevent the equipment from being
switched on again!
Important! Inside the motor temperatures may occur which are higher than the maximum permissible
surface temperature of the housing. Consequently, the motor must not be opened in an explosive dusty
atmosphere!
Perform a regular check on the motors to ensure that they are reliable!

Impermissibly high levels of dust must not be allowed to accumulate! If the motor is not reliable, it must not be used
any longer!
When the ball bearings are being changed the shaft seals must also be replaced. Use shaft seals made of NBR
specified by NORD. Only genuine parts may be used as spare parts, with the exception of standardised,
commercial and equivalent parts. This particularly applies to seals and connecting parts. In the case of terminal
box parts and spare parts for external earthing the parts must be ordered according to the spare parts list in the
Operating Instructions.
Gaskets, shaft seals and cable glands must be checked regularly to make sure they are in good working order!

Maintenance of dust protection for the motor is of prime importance with regard to protection against
explosion.


7. Spare parts drawing and spare parts list















































Item No. Description Item No. Description
900 Rotor with shaft
902 End shield at drive end
902.1 Cheese-head screw
902.2 Hexagon nut
904 Shaft seal
905 Bearing at drive end
906 Ball bearing shim
907 Terminal box frame
907.1 Chassis connection terminal wire clamp
907.2 Oval-head screw
908 Terminal box lid
908.1 Cheese-head screw
909 Terminal box frame gasket
910 Terminal box lid gasket
911 Terminal board
911.1 Cheese-head screw
911.5 Spring lock washer
912 Mini-terminal
912.1 Oval-head screw
913 Spacer
913.1 Cheese-head screw
913.2 Spring lock washer
916 Stator with winding
916.1 Equipotential bonding terminal
916.2 Spring pin
918 Key
924 Screw-on foot (BG 100-132)
924.1 Hexagon bolt
924.2 Spring lock washer
924.3 Hexagon nut
929 Bearing at ventilation end
932 End shield at ventilation end
932.1 Cheese-head screw
932.2 Hexagon nut
933 Shaft seal
939 Fan
940 Fan hood
940.1 Oval-head screw
940.2 Countersink screw B3
941 Key
942 947 Circlip
948 Circlip
952 Clamping bush
953 Cable gland
955 Blind plug
956 Blind plug
980 Protective roof
988 Ring seal
989 Rating plate
989.1 Oval-head screw
B1091-D Page -11-
BadgerMeter,Inc.
Installation &
Operation Manual
Bulletin No. IOM-067-03
Part No. 53400-067
March 2000

Model Industrial RCDL

Nutating Disc Meters
GENERAL DESCRIPTION
2
Table 1 - Configuration and Specification Data for Model RCDL Disc Meters
DIMENSIONS (INCHES)
Meter Flow Laying Center Line Register Transmitter Approximate
Meter Size Range Housing End Length to Base Height Height Weight
Model Inches GPM Material Connections A B C D Pounds
M 25 5/8 1/2 - 25 BZ or PL NPT - Male 7.5 1.7 3.3 4.4 5
1 - 25
M 25 3/4 1/2 - 30 BZ or PL NPT - Male 7.5 1.7 3.3 4.4 5
1 - 30
M 35 3/4 3/4 - 35 BZ NPT - Male 9.0 1.7 3.6 5.0 6
M 40 1 3/4 - 50 PL NPT - Male 10.75 1.9 3.8 5.5 5
M 70 1 1 - 70 BZ NPT - Male 10.75 2.3 4.2 5.6 12
5 - 70
M 120 1 1/2 2 - 120 BZ NPT - Female 12.62 2.4 4.6 6.0 20
10 - 120
M 170 2 2 - 170 BZ NPT - Female 15.25 2.9 5.1 6.5 30
BZ = Bronze; PL = Plastic
Model 25, Model 70 and Model 120 are available with optional corrosion resistant internals; temperature limit with this option
is increased on the bronze housing model to 250 F.
METER OPTIONS/SPECIFICATIONS
A A
B
C
B
D
C
B
A
E
D
Badger's RCDL positive displacement meters are one of the
most cost effective methods in metering industrial fluids.
The RCDL meter's simple but efficient design assures high
accuracy and repeatability over the entire meter flow range.
Available in five sizes, 1/2" through 2" for flows up to 170
GPM, these meters are extremel y rugged and rel i abl e.
Maintenance is seldom required, but if necessary, takes
onl y a few mi nutes. Al l parts are desi gned and bui l t of
materials to meet your application, providing you with long
life and a trouble-free, precision flow meter.
To complement the RCDL meter line, Badger offers a com-
plete line of accessories that includes totalizers, electrome-
chanical and electronic transmitters, rate of flow indicators
and batch/process controllers.
The metering principle, known as positive displacement, is
based on the conti nuous fi l l i ng and di schargi ng of the
measuring chamber. Controlled clearances between the
disc and the chamber insure precise measurement of each
volume cycle. As the disc nutates, the center spindle rotates
a magnet, whose movement is sensed through the meter
wal l by a fol l ower magnet or by vari ous sensors. Each
revolution of the magnet is equivalent to a fixed volume of
fluid, which is converted to any engineering unit of measure
for totalization, indication or process control.
Figure 1.
Liquid flowing through the meter chamber (A) causes a disc
(B) to nutate or wobble. This motion, in turn, results in the
rotation of a spindle (C) and drive magnet (D). Rotation is
transmi tted through the wal l of the meter to a second
magnet (E) or varied style of sensor pickup.
MODEL 25, 35 & 70 MODEL 120 & 170
Meter with Transmitter Meter with Register
Corrosion
Resistant Internal
Corrosion
Resistant Internal
Corrosion
Resistant Internal
Corrosion
Resistant Internal
3
Any special instructions required for the installation and/
or electrical connection of any meter-mounted or free-
standing accessory devices such as registers, pulse trans-
mitters, and remote batch controllers, will be provided as
a supplement to this manual.
A. Please read the following instructions to become fa-
miliar with the requirements and the recommended proce-
dures involved.
CAUTION: The meter must be operated in an application
within the specified temperature range to obtain opti-
mum accuracy and prevent damage to any internal
components.
1. Verify the fluid operating temperature range is com-
patible with the materials of construction of the
meter received.
CAUTION: The life of the meter will be impaired if it is
operated at flow rates in excess of those indicated in the
product specifications.
2. If any solid material is present in the liquid, instal-
lation of a strainer is recommended upstream of the
meter.
3. Locate the meter installation with consideration for
sufficient space for cleaning and maintenance of
the meter.
B. Review the overall dimensions (including laying length
requirements) of the meter as listed in Table 1 of this
manual on page 2. If necessary, consideration may also
need to be given for height dimensions including the meter
mounted accessory. Then proceed as follows:
1. Measure the overall length of the meter with the
connection pieces attached to the inlet and outlet
spuds of the meter.
INSTALLATION
2. Be sure to provide this proper gap length in the
facility piping.
CAUTION: Excess gap length may cause excessive
strain on connection assemblies.
3. Remove the connections and install one connection
piece in each end of the facility pipe gap provided in
step #2. Allow for the gaskets at the inlet and the
outlet spuds of the meter.
4. Install the meter making sure that the flow arrow
marking on the meter housing is in the correct
relationship to the direction of the fluid flow in the
system.
5. Tighten the meter connections.
Note instructions on packaging from connection assem-
bly when tightening.
6. To relieve any possible strain on the facility piping
that might be caused by the weight of any of the
large size meters, it is recommended that consider-
ation be given to incorporating a meter support to
be placed under the housing of the meter.
To ensure that the meter has been properly installed and
operational:
A. Slowly open the upstream valve to apply fluid pressure
to the meter. Check the connections for any possible
leakage. Retighten the connections as required.
B. Perform a functional test of the meter utilizing the
adjustment and calibration procedures that are included
later in this manual.
Upon receipt of meter, perform the following:
NOTE: If damage to the shipping container is evident,
request the carrier to be present when meter is un-
packed.
A. Carefully open the shipping container. Remove all the
cushioning material surrounding the meter and carefully
lift the meter from the container.
Retain all of the packing material for possible use in
reshipment or storage of the meter.
B. Visually inspect the meter and the accessory device
for any physical damage such as scratches, loose or
broken parts, or any other damage that may have occurred
during shipment of the product.
NOTE: If damage is found upon receipt of the equipment,
request inspection by the carrier's agent within 48 hours
of the delivery. Then file a claim with the carrier. A claim
for the equipment damaged in transit is the responsibil-
ity of the customer.
UNPACKING AND INSPECTION
In general, the operation of a Model RCDL disc meter is
either manually controlled or accessory controlled. Manual
operation applies to the applications employing hand-
operated valves or other manually activated, flow-regulat-
ing devices that are not functionally controlled by a meter
accessory. Accessory controlled operation applies to ap-
plications when a meter accessory provides a signal out-
put to activate and/or deactivate a valve or other flow
control device.
CAUTION: Valves controlling the fluid flow through the
meter should be opened and closed slowly to prevent
shock loads that may damage the meter measuring
element.
A. MANUAL OPERATION. The following procedures are
for use in simple metering applications where the flow of
fluid is controlled by hand-operated valves located up-
stream and downstream of the meter.
1. Slowly open the upstream valve to apply fluid to the
meter.
2. Slowly open the downstream valve to initiate the
metering operation.
3. Adjust downstream valve so the flow rate of the
fluid does not exceed the maximum continuous
flow rate specification of the meter. (Refer to Table
1 of this manual.)
NOTE: On meters with an accessory device providing a
totalizing indicator, the flow rate of the fluid can be
checked by timing the number of gallons registered in
one minute.
4. To stop metering, slowly close downstream valve;
then close upstream valve.
B. ACCESSORY CONTROLLED OPERATION. Operating
procedures for accessory controlled applications are de-
pendent on the specific function of that accessory em-
ployed and its electrical interconnection with a flow control
device or devices. Refer to the bulletin or bulletins cover-
ing the applicable accessories for specific operating in-
structions (included as a supplement to this manual when
required.)
SHUTDOWN INSTRUCTIONS
If the meter is to be shut down for an extended period of
time, it is recommended that the measuring chamber of
the meter be thoroughly flushed out to prevent the settling
out of undissolved solids or the accumulation of corrosive
deposits.
4
GENERAL OPERATING INSTRUCTIONS MAINTENANCE
PREVENTIVE MAINTENANCE
Preventive maintenance consists of periodic inspection and
cleaning procedures. The procedures should be performed
at regular intervals and any defects discovered should be
corrected before further operation of the meter.
PERIODIC INSPECTION
A. Visually inspect meter and accessory for missing hard-
ware, loose connections, broken register glass, damaged
wiring, or other signs of wear or deterioration. Repair or
replace components as required.
B. Verify proper flow rate and pressure for meter. A loss in
pressure, with the resulting flow rate decrease, may indicate
the meter screen is clogged and requires cleaning.
CLEANING
Cl ean al l dust, di rt, grease, moi sture, or other forei gn
material from exterior of meter and applicable accessory.
CALIBRATION CHECK AND ADJUSTMENT
The following instructions are provided to assist in perform-
ing on-site calibration check and/or adjustment.
ACCURACY TEST
A. Place a test tank of known volume at output of meter.
B. Fill test tank to calibrated level. Make test run at same
flow rate to be used i n actual operati on.
C. Record quantity indicated on applicable accessory.
D. Repeat test three times and average recorded results.
E. Perform the following calculations to determine percent
of accuracy of meter-accessory combination.
Qty. Indicated on Accessory
x 100 = Meter Accuracy
Actual Quantity in Test Tank
Example 1.
95 Gallons
x 100 = 95% Accuracy
100 Gallons
The meter-mounted accessory is slow and reading low so it
must be speeded up by a calibration adjustment.
Example 2.
104 Gallons
x 100 = 104% Accuracy
100 Gallons
In this example, the meter accessory is fast and running
high so it must be slowed down by calibration adjustment.
5
CHANGE GEAR CALIBRATION
If the accuracy test of a meter-accessory combination indi-
cates that adj ustment i s requi red and change gears are the
medium; proceed as follows:
A. Remove applicable Driver (Accessory) change gear and
Driven (Meter) change gear.
NOTE: The number of t eet h and out si de di amet er i s
stamped on each gear.
Figure 3 - Change Gear Locations on
Model RCDL Meters
B. Calculate ratio of existing change gears as follows:
No. of Teeth on Accessory Change Gear
Ratio =
No. of Teeth on Meter Change Gear
C. Calculate new change gear ratio required by multiplying
the ratio of existing change gears by the percent-of-meter
accuracy determined in the accuracy test.
Example
42 Teeth
Existing Change Gear Ratio = = .976
43 Teeth
Meter Accuracy = 95%
95
Corrected Change Gear Ratio = .976 x = .927
100
D. If change gear charts are available, select a new change
gear combination that matches corrected change gear ratio.
If new gears are not available, submit order for corrective
change gears to nearest Badger Meter Representative or
contact the Industrial Division of Badger Meter, Inc.
NOTE: When ordering, specify serial number of meter,
meter model and size, accessory device employed, num-
ber of teeth and diameter of existing change gears, and
corrected change gear ratio required.
E. Observe the position of old change gears on spindles
before removing. Install new change gears on meter and
accessory spindles and assemble accessory to meter. Care
should be taken to obtain full mesh when assembling acces-
sory to meter gear train adapter. Note position information
from old gears.
ELECTRONIC CALIBRATION
If electronic scaling is the accessory medium for calibration,
see accessory technical brief for instructions.
Meter (Driver)
Change Gear
Accessory (Driven)
Change Gear
Accessory
Device
Magnetic Drive
Gear Train
Adapter
SERVICING
The following instructions are for removal, inspection and
installation of meter parts/assemblies. Refer to applicable
illustrated parts list for part numbers of components and
ordering information. Accessory service and repair proce-
dures are provided in literature specific to that device.
METER ASSEMBLY
These procedures are for disassembly of the meter:
A. Shut off fluid flow to meter. Place container under meter
and relieve fluid pressure in the meter by uniformly loosen-
ing bolts (bronze meter) or retaining ring (plastic meter).
Fluid will run out into container.
B. Remove bolts or retaining ring while holding housing
bottom in place. Remove housing bottom. Chamber assem-
bly may drop from housing as bottom is removed.
C. I f chamber assembl y i s out , set asi de. I f not , f i rst
remove chamber strap and then chamber assembly.
D. Remove meter screen. Inspect screen for dirt and cor-
rosion. Clean or replace as necessary.
E. Inspect the chamber assembly:
1. Check the disc in the chamber assembly for warpage,
cracks or wear. A severely worn disc can cause over
delivery of the fluid being metered.
2. Check the thrust roller and thrust roller insert for
excessive wear.
After inspection, clean or replace the chamber assembly
as necessary. If chamber is worn or corroded, it is always
recommended that the entire chamber and disc assembly be
replaced.
F. Re-install housing chamber assembly, screen, chamber
strap and bottom as follows:
1. Assemble screen in proper location.
2. Locate chamber assembly in proper orientation. Add
chamber strap.
3. Position housing bottom with the correct seal. (Re-
placement of seal is always recommended.)
4. Assemble bolts or retaining ring and tighten.
ALTERNATIVE DISASSEMBLY METHOD FOR SERVICE
Loosen connection pieces slightly. Turn meter upside down,
putting gravity on your side. This will help eliminate the
possibility of the chamber assembly and/or screen compo-
nent dropping during disassembly and causing damage.
RECALIBRATION
After repair or replacement of a meter component or assem-
bly, perform the calibration check and adjustment proce-
dure to ensure that the meter is properly calibrated and will
operate in accordance with published specifications.
1 Shroud Assembly, Plastic
(Cover, top and roll pin, no btm.)
2 Register Assembly, U.S. Gallons
Register Assembly, Liters/M3
3 Shroud Assembly, Plastic
(Cover, top, btm., roll pin)
4 Pulse Transmitter Register RTR
7 Coupling (Series 76 Register)
8 Change Gear, Driver
9 Change Gear, Driven
10 Retaining Ring
11 Gear Train (234:1)
11 Gear Train (30:1)
12 Housing, Mach.
13 Gear Train Assy. (234:1)
13 Gear Train Assy. (30:1)
Item No. Part Description
6
Models 25 and 40
Industrial Disc Meters Thermoplastic
Item No. Part Description
14 Housing Bottom "O" Ring Seal
15 Housing Bottom
16 Retaining Ring
17 Connection Assembly, 1/2" Plastic
Connection Assembly, 3/4" Plastic
Connection Assembly, 1" Plastic
Connection Assembly, 1/2" Bronze
Connection Assembly, 3/4" Bronze
Connection Assembly, 1" Bronze
18 Housing 5/8" x 1/2", 7 1/2" LL
Housing 5/8" x 3/4", 7 1/2" LL
Housing 1" x 1", 10 3/4" LL
19 Chamber and Disc Assembly, Plastic
Chamber and Disc Assembly, LCP
20 Chamber Retainer Strap
21 Screen
Item No. Part Description
7
Models 25, 35, 40, 70, 120 and 170
5/8" - 2" Industrial Disc Meters Bronze
Item No. Part Description
15 Chamber Retainer Strap
16 Spring Clip (High Temp. Only)
(Model 25, 70 and 120 Only)
17 Screen
18 Housing Gasket , Buna N
Housing Gasket, Viton
19 Housing Bottom
19A Washers (6 needed)
20 Housing Bolt
21 Conn. Assembly (2) 1/2"
Conn. Assembly (2) 3/4"
Conn. Assembly (2) 1"
Conn. Assembly (2) 1 1/2"
Conn. Assembly (2) 2"
22 Conn. Washer (1) 1/2"
Conn. Washer (1) 3/4"
Conn. Washer (1)
23 Housing Top
24 Bottom Seal "O" Ring
1 Shroud Assembly, Plastic .
(Cover, top & roll pin) (No btm.)
2 Register Assembly, Gallons
Register Assembly, Liters/M3
3 Shroud Assembly, Plastic
(Cover, top, btm. & roll pin)
4 Pulse Transmitter Register RTR
7 Coupling (Series 76 Reg.)
8 Change Gear, Driver
9 Change Gear Driven
10 Retaining Ring
11 Gear Train (234:1)
11 Gear Train (30:1)
12 Housing, Mach.
13 Gear Train Assy. (234:1)
13 Gear Train Assy. (30:1)
14 Chamber & Disc Assy., Std.
Chamber & Disc Assy., LCP

BadgerMeter,Inc.
P. O. Box 245036 Milwaukee, WI 53224-9536
Telephone: (414) 355-0400
Fax: (414) 355-7499
Due to continuous research, product improvements
and enhancements, Badger Meter reserves the right to
change product or system specifications without notice.
All rights reserved.
BadgerMeter,Inc.
Technical
Brief
Bulletin No. ITB-072-08
December 1999

FEATURES

Accuracy: 1.5% over full range

Repeatability: 0.5%

Wide flow range

Rugged bronze or thermoplastic housing

Maximum Operating Temperature

Plastic Housing: 100F
Bronze Housing: 120F
Models 25, 70 and 120; Bronze: 250F Option

Maximum Operating Pressure: 150 PSI

Easily maintained without removing from line

Durable components for minimal maintenance

Wide range of compatible accessories

Direct replacement for SC-ER

Model Industrial RCDL
Nutating Disc Meter (Bronze and Thermoplastic)
GENERAL
Badger's RCDL positive displacement meters are one of
the most cost effective methods in metering industrial fluids.
The RCDL meter's simple but efficient design assures high
accuracy and repeatability over the entire meter flow range.
Available in sizes, 1/2" through 2" for flows up to 170 GPM,
these meters are extremely rugged and reliable. Mainte-
nance is seldom required, but if necessary, takes but a few
minutes. All parts are designed and built of materials to
meet your application, providing you with long life and a
trouble-free, precision flow meter.
To complement the RCDL meter line, Badger offers a
complete line of accessories that includes totalizers, elec-
tromechanical and electronic transmitters, rate of flow indi-
cators and batch/process controllers.
OPERATION
The metering principle, known as positive displacement, is
based on the continuous filling and discharging of the
measuring chamber. Controlled clearances between the
disc and the chamber insure minimum leakage for precise
measurement of each volume cycle. As the disc nutates, the
center spindle rotates a magnet, whose movement is sensed
through the meter wall by a follower magnet or by electronic
sensors. Each revolution of the magnet is equivalent to a fixed
volume of fluid, which is converted to any engineering unit of
measure for totalization, indication or process control.
Liquid flowing through the meter chamber (A) causes a disc
(B) to nutate or wobble. This motion, in turn, results in the
rotation of a spindle (C) and drive magnet (D). Rotation is
transmitted through the wall of the meter to a second
magnet (E) which operates the transmitter.
BadgerMeter,Inc.
P. O. Box 245036 Milwaukee, WI 53224-9536
Telephone: (414) 355-0400
Fax: (414) 355-7499
Due to continuous research, product improvements
and enhancements, Badger Meter reserves the right to
change product or system specifications without notice.
All rights reserved.
B C Flow Rates - Gallons
Meter A Meter Center Hot Water Approx.
Size Housing Meter Length Line Cold Liquids Chemicals & Oils Weight
Inches Material Length w/ Conn. To Base 32F to 120F 32F to 250F (BZ) Pounds
32F to 100F (PL)
5/8 BZ or PL 7-1/2 12-7/16 1-3/8 1/2 - 25 1 - 25 5
3/4 BZ or PL 7-1/2 12-5/8 1-3/8 1/2 - 30 1 - 30 5
3/4 BZ 9 14-1/8 1-3/4 3/4 - 35 N/A 6
1 PL 10-3/4 16-3/16 2-1/4 3/4 - 50 N/A 5
1 BZ 10-3/4 16-5/8 2-1/4 1 - 70 5 - 70 12
1-1/2 BZ 12-5/8 19-3/4 2-5/8 2 - 120 10 - 120 20
2 BZ 15-1/4 22-7/8 3-3/8 2 - 170 N/A 30
BZ = Bronze; PL = Plastic N/A = Not available in High Temperature / Chemical option.
Connection set assemblies available, all having NPT threads.
HEIGHT DIMENSIONS (INCHES) (D) WITH REGISTER AND ACCESSORIES
With With With
With Non Resetable With MS-ER1 With ECA 258 Series 76
Meter Size Register Transmitter Transmitter Transmitter Register Registers
5/8 & 5/8 x 3/4 5-3/4 7-3/8 11-1/4 9-3/8 8 15-1/4
3/4 6-1/8 7-3/4 11-5/8 9-3/8 8-3/8 15-5/8
1 & 1 x 1-1/4 7-1/2 9-1/8 13 11-3/16 9-3/4 17
1-1/2 9-1/8 10-3/8 14-1/4 12-3/4 11 18-1/4
2 10-3/4 12-1/4 16-1/8 14-3/8 12-7/8 20-1/8
PERFORMANCE
Accuracy: 1.5%
Repeatability: 0.5%
Max. Operating Pressure: 150 PSI
Meter
Model
M25
M25
M35
M40
M70
M120
M170
Dimensions in inches (Without Register)
PRESSURE LOSS CHART
Industrial Disc Meters
Rate of Flow in Gallons Per Minute
Model 25, 35 & 70
Model 120 & 170
SPECIFICATIONS
MATERIALS OF CONSTRUCTION
High Temp.
Cold and/or
Liquid Chemical Units
Units Models 25, 70 & 120
Housing: BZ or PL BZ - 250F
PL - 100F
Chamber: Noryl LCP
Disc: SAN LCP
Crossbar: Nylon Ultem
Magnetic Assembly: Nylon Ultem
Chamber Retainer: Polyethylene Metal Clip
Screen: Polypropylene None
BadgerMeter,Inc.
Repair Parts
Bulletin No. IRP-104-05
Part No. 53401-104
January 2000
Models 25, 35, 70, 120 and 170
5/8" - 2" Industrial Disc Meters Bronze
BadgerMeter,Inc.
P.O. Box 245036 Milwaukee, WI 53224-9536
Telephone: (414) 355-0400
Fax: (414) 355-7499
All rights reserved.
Due to continuous research, product improvements
and enhancements, Badger Meter reserves the right to
change product or system specifications without notice.
Model 25 Model 35 Model 70 Model 120 Model 170
1/2" Top Top
& 3/4" 1" Load Load
Item Description 3/4" 1 1/2" 2"
1 Shroud Assembly, Plastic.................... 62416-001 62416-001 62416-001 62416-001 62416-001
(Cover, top & roll pin) (No btm.)
2 Register Assembly, (up to 120F)
U.S. Gallons ............................. 33626-002 33626-060 33626-068 33626-011 33626-057
Cubic Meters ............................ 33626-007 33626-062 33626-070 33626-014 33626-059
Register Assembly, (up to 250F)
U.S. Gallons ............................. 58932-002 -------------- 58932-007 58932-017 --------------
Liters ........................................ 58932-005 -------------- 58932-009 58932-018 --------------
3 Shroud Assembly, Plastic.................... 62696-001 62696-001 62696-001 62696-001 62696-001
(Cover, top, btm. & roll pin)
3a Screw, Tamper-Resistant ....................... 62335-001 62335-001 62335-001 62335-001 62335-001
3b TORX

Seal Screw Driver & Bit (Stubby) .. 62658-001 62658-001 62658-001 62658-001 62658-001
3c TORX

Seal Screw Driver & Bit (Long) ..... 62658-003 62658-003 62658-003 62658-003 62658-003
4 Pulse Transmitter / Register, RTR......... Please advise meter size, model and unit of measure.
7 Coupling (Series 76 Reg.) .................. 56646-001 56646-001 56646-001 56646-001 56646-001
8 Change Gear, Driver .......................... -------------- -------------- -------------- -------------- --------------
9 Change Gear Driven .......................... -------------- -------------- -------------- -------------- --------------
10 Retaining Ring................................... 1013-000 1013-000 1013-000 1013-000 1013-000
11 Gear Train (234:1).............................. 56065-004 56065-004 56065-004 56065-004 56065-004
11 Gear Train (30:1)............................... 56065-005 56065-005 56065-005 56065-005 56065-005
12 Housing, Mach.................................. 58091-002 58091-002 58091-002 58091-002 58091-002
13 Gear Train Assy. (234:1) .................... 56066-004 56066-004 56066-004 56066-004 56066-004
13 Gear Train Assy. (30:1) ..................... 56066-005 56066-005 56066-005 56066-005 56066-005
14 Chamber & Disc Assy., Std.................. 33334-009 33334-029 33334-016 33334-017 33334-028
Chamber & Disc Assy., LCP
(Coated Magnet) Viton Seals ................ 58908-006 -------------- 63079-002 63175-002 --------------
Chamber & Disc Assy., LCP
(Coated Magnet) EPR Seals ................. 58908-010 -------------- -------------- -------------- --------------
15 Chamber Retainer Strap ..................... 58540-001 58540-001 56188-001 -------------- 56188-001
(Low Temp. Only)
16 Spring Clip (High Temp. Only)(2 Reqd.) 62695-001 -------------- 62695-002 62695-002 --------------
17 Screen (Low Temp. Only).......................34333-001 59805-001 56182-001 62172-001 59720-001
18 Housing Gasket , EPR .................... 11071-033 59782-001 58769-001 59239-001 59722-001
(Low Temp. Only)
Housing Gasket, Viton........................ 11071-045 -------------- 58769-002 62171-002 --------------
19 Housing Bottom.................................. 62635-001 59784-001 59733-001 -------------- --------------
19A Washers (6 needed)..............................-------------- -------------- 24991-044 -------------- --------------
20 Housing Bolt.......................................62777-001 62777-001 59733-001 55029-089 55029-089
21 Conn. Assembly (2) 1/2"..................... 7557-002 -------------- -------------- -------------- --------------
Conn. Assembly (2) 3/4"..................... 7559-002 7559-002 -------------- -------------- --------------
Conn. Assembly (2) 1" ....................... -------------- -------------- 7561-002 -------------- --------------
Conn. Assembly (2) 1 1/2".................. -------------- -------------- -------------- 7563-000 --------------
Conn. Assembly (2) 2" ....................... -------------- -------------- -------------- 7564-000 7564-000
22 Conn. Washer (1) 1/2" ....................... 11012-001 -------------- -------------- -------------- --------------
Conn. Washer (1) 3/4" ....................... 14143-000 14143-000 -------------- -------------- --------------
Conn. Washer (1) .............................. -------------- -------------- 18177-000 1331-000/ 1359-000
1359-000
23 Housing Top....................................... -------------- -------------- -------------- 62176-001 59719-001
ORDER INFORMATION: This repair parts bulletin shows an exploded view of the product with specific reference to those items
available for replacement. The item number and part number may change at any time; therefore, it is important when placing an
order that a complete description of the part, meter size, model and serial number be provided.