Service Sm2000 en

Repair Manual for Cutter Mill type SM 2000
©Retsch GmbH & Co.KG , 42781 Haan , Rheinische Str.36 , GermanyDoc. No. GB 98.721.9998
1. Rectification of malfuctions (troubleshooting)................... 3
2. Description of repairs ................................................... 3
3. Replacing the fuses on the controller .............................. 3
4. Replacing the safety door catch ..................................... 4
5. Replacing the motor..................................................... 4
6. Replacing the controller with operator control .................. 5
7. Replacing the grooved ball bearing with conical sleeve ...... 5
8. Replacing the indexable inserts...................................... 6
9. Replacing the cutter bars .............................................. 6
10. Replacement and setting of the tensioning pins .............. 6
11. Replacing the rotor and the felt washer ......................... 7
12. Technical data ........................................................... 8
Parts list, Section 1.......................................................... 9
Parts list, Section 1 (continued)......................................... 10
Teileliste Teil 2 Normteile.................................................. 10
Parts list, Section 3.......................................................... 11
Spare part assemblies...................................................... 11
List of spare parts for 2 years’ operation ............................. 12
Recommended stock of spare parts.................................... 12
Dimensional chart for SM2000 with standard hopper ............ 13
Drawings, Part 1 ............................................................. 14
Drawings, Part 2 ............................................................. 15
Drawings, Part 3 ............................................................. 16
Drawings, Part 4 ............................................................. 17
Parts lists and drawings for the accessories ......................... 18
Standard hopper ............................................................. 18
Filter unit ....................................................................... 19
Accessory box................................................................. 20
Long material hopper ....................................................... 20
Cutter roller with slide...................................................... 21
Circuit diagrams .............................................................. 22
Circuit diagram for 1x220/230V......................................... 22
Circuit diagram for 3x440V ............................................... 25
Circuit diagram for 1x220/230V AE=J................................. 27
Circuit diagram for 3x440V AE=J ....................................... 30
Modifications .................................................................. 31
20.10.2006 2 ©Retsch GmbH & Co.KG Doc. No. GB 98.721.9998

1. Rectification of malfuctions (troubleshooting)
Fault Cause Remedy
1. No power 1. Check external connection
LEDs do not light up 2. Main switch not ON 2. Turn main switch ON
3. Fuses on the controller defective 3. Replace fuses –see section 3
4. Controller defective 4. Replace controller – see
section 6
5. Thermal relay has tripped 5. Switch the machine off and allow
Motor does not run 6. Fuses on the controller defective the motor to cool down
7. Motor defective 6. Replace the fuses – see section 3
7. Replace the motor – see section 5
8. Fuses on the controller defective 8. Replace the fuses – see section 3
Door cannot be opened 9. Safety door catch defective 9. Replace the safety door catch –
see section 4
2. Description of repairs
Note: We recommend you to have the repairs described in
sections 4, 6, 7 and10 performed at our works or by the local
authorised agent.
3. Replacing the fuses on the controller

Tools required:
1 Phillips screwdriver size 2
Spare parts required:
3x fuses, 1A, slow blow, 6.3x32mm long
Retsch Art. no. 05.699.0050
Procedure:
• Disconnect the machine from the power supply.
• Remove screws 91 from the right hand side panel.
• Carefully tilt side panel 1 over.
• Replace the fuses.
• Assemble by reversing the above procedure.

4. Replacing the safety door catch
Tools required:
1 Allen key, 2.5 mm AF
1 x safety door catch
Procedure:
• Remove screws 98 from the right hand side panel 2.
• Remove side panel 2.
• Remove the fastening screws98 for the safety catch 36.
• Carefully draw the safety door catch off.
• Detach the wiring connections from the safety door catch.
• Replace the safety door catch.
• Restore the wiring connections as shown in the circuit
diagram.
5. Replacing the motor

Tools required:
1 Allen key, 8 mm AF
1 Screwdriver, 5 x 80
1 Hexagon socket wrench, 7 mm AF
1 Hexagon socket wrench, 8 mm AF
1 Open jawed spanner, 16/17 mm AF
1x motor
Retsch Art. no.: See parts list, item 401-419
Procedure:
• Open the door and housing top.
• Only then disconnect the machine from the power supply.
• Remove cheese head screw 84 for the rotor.
• Draw off the rotor with cheese head screw M10x130
DIN912.
• Open the motor terminal box K.
• Release the connecting cable and draw it off the motor
• Unscrew the hexagon nuts 88.
• Replace the motor. The motor weighs approx. 62kg.
• Reconnect the wiring as shown in the circuit diagram.
• Ensure that the motor turns in the correct direction:
counter-clockwise.
Tightening torque for rotor screw 84 = 14Nm
Tightening torque for nuts 88 = 16Nm

6. Replacing the controller with operator control
Tools required:
1 Hexagon socket wrench, 5.5 mm AF
1x controller with operator control
Retsch Art. no.: See parts list
Procedure:
• Remove screws 91 from the right hand side panel 1.
• Carefully tilt side panel 1 over.
• Remove the ribbon cable from the operator control to the
controller.
• Remove the hexagon nuts B on the operator control.
• Replace the operator control.
• Release the cable connections on the controller.
• Unscrew hexagon nuts A on the controller.
• Replace the controller.
• Restore the cable connections as shown in the circuit
diagram.
7. Replacing the grooved ball bearing with conical sleeve

Tools required:
1x grooved ball bearing with conical sleeve
1x door seal Retsch Art. no. 03.241.0061
Procedure:
• Open the door.
• Switch the machine off.
• Remove the countersunk screws 100.
• Remove seal 25.
• Use two cheese head screws M4x20 DIN912 to push
washer 15 out.
• Press the grooved ball bearing and conical sleeve out.
• Lightly oil the outer ring of the ball bearing.
• Press the ball bearing in.
• Glue in a new seal with Technicoll 8050.
• Refit washer 15.

8. Replacing the indexable inserts
Tools required:
1 special key 41 included in the supply
18x indexable inserts with screws
Procedure:
• Switch the machine off at the main switch.
• Remove the old indexable inserts.
• Fit new indexable inserts.
• Tighten the indexable inserts well. (10Nm)
• Check the cutting gap: never less than 0.3 mm.
9. Replacing the cutter bars

Tools required:
4x cutter bars
Procedure:
• Switch the machine off.
• Remove the central screws 83.
• Replace the cutter bars.
• Check the cutting gap with a feeler gauge: never less than
0.3 mm.
• Adjust the gap if necessary by releasing set screws 86.
Tightening torque for screw 83 = 7Nm.
10. Replacement and setting of the tensioning pins

Tools required:
1 Screwdriver, 5 x 80
1 Open jawed spanner, 16/17 mm AF
2x tensioning pins
Procedure:
• Switch the machine off at the main switch.
• Release hexagon nut 79 and/or set screw 85 lösen, and
unscrew the tensioning pin.
• Fit a new tensioning pin.
See next page for settings.

Settings:
Tensioning pin in the housing top
• Release set screw 85.
• Turn the tensioning pin:
clockwise = tighter
counter-clockwise = looser
The tensioning pin is correctly set when the housing top is free
of play and the handwheel easily engages in the “CLOSED”
position.
• Retighten set screw 85.
Tensioning pin in the door

• Release hexagon nut 79.
• Turn the tensioning pin:
clockwise = tighter
counter-clockwise = looser
The tensioning pin is correctly set when the housing top is free
of play and the handwheel easily engages in the “CLOSED”
position.
• Retighten hexagon nut 79.
11. Replacing the rotor and the felt washer

Tools required:
1 Cheese head screw M10x130 DIN912
1x rotor Retsch Art. no. 22.608.0005
for 750-835min-1
1x rotor Retsch Art. no. 22.608.0006
for 1430-1690min-1
1x felt washer Retsch Art.Nr. 03.182.0024
Procedure:
• Only then disconnect the machine from the power supply.
• Remove cheese head screw 84 for the rotor.
• Draw off the rotor with cheese head screw M10x130
DIN912
• Remove countersunk screws 99.
• Remove washer 11.
• Replace the felt washer.
Tightening torque for screw 84 = 14Nm.

12. Technical data
Drive Standard 3-phase motor or

single phase AC motor
Mains voltage required see type plate ± 5%
Rated power 1500 Watt
Protection - motor IP 54
Speed of three phase motor 750min-1 at 50Hz - 835min-1 at 60Hz
Speed of AC motor 1430min-1 at 50Hz - 1690min-1 at 60Hz
Activation ⇒ Main switch A ( ON-OFF)
Start ⇒ Sensor key B green
Stop Sensor key C red
Deblocking door and housing Central catch D
Open door Sensor key E blue
Overload protection Temperature sensor in motor
Fuses, external At site supply in accordance with motor current

(see type plate on motor) for each phase
Fuses, internal 3x 1A, slow blow, on the controller

Art. No. 05.699.00050
Noise level 66 dBA under no load

75-92 dBA when milling, up to
98 dBA
Dimensions 550 x 600 x 1805 mm (w x d x h)
Weight 95-130 kg

Parts list, Section 1
Item Code Qty. Article no. Designation
1 1 03.009.0026 Cover for electronics enclosure
2 1 03.009.0027 Cover for safety door switch
3 1 01.011.0023 Collecting tank, 5 litre
4 1 03.013.0001 Cover disk for handwheel
5 1 03.009.0028 Cover for housing top
6 1 03.042.0214 Pin for door
7 1 03.042.0215 Pin for housing top-bottom
8 2 03.061.0001 Collar for door- housing bottom
9 1 05.106.0012 Cable gland for power cable
10 2 05.106.0023 Cable gland for motor cable
11 1 03.111.0001 Sealing ring for grinding chamber – motor shaft
12 1 03.111.0002 Seal for connector or item 5
13 1 05.112.0027 Reducer for motor terminal box
14 E 1 05.114.0040 O-ring for 5 litre collecting tank
15 E 1 03.143.0037 Insert for door
16 1 03.149.0001 Electronics enclosure
17 1 05.181.0069 Pressure spring for central catch
18 E 1 03.182.0024 Felt washer for motor shaft
19 1 03.183.0012 Flange for collecting tank
20 E 1 03.183.0013 Flange for motor
21 1 03.222.0053 Housing bottom
22 1 03.222.0059 Housing top
23 1 05.225.0016 Handle for door
24 E 2 03.241.0055 Rubber seal for housing top-bottom
25 E 1 03.241.0061 Rubber seal for door
26 1 03.268.0003 Handwheel for central catch
27 E 1 05.274.0001 Main switch
28 E1 1 03.363.0001 Conical sleeve
29 1 03.108.0033 Pressure piece
30 4 03.043.0003 Spacer bushing for operator control
31 4 03.265.0119 Sleeve for centring pin
32 E2/E3 1 03.608.0035 Rotor disk no.1
33 E2/E3 5 03.608.0036 Rotor disk no. 2 – no. 6
34 E1 1 05.617.0018 Grooved ball bearing for door
35 1 03.622.0001 Notched disk for central catch
36 E 1 05.656.0001 Safety catch 220V-50/60Hz
37 E 2 03.657.0001 Tensioning pin for central catch
38 1 03.658.0001 Slotted pin for central catch
39 E 1 05.719.0001 Closing block for safety catch
41 1 05.728.0023 Key for indexable inserts
42 1 03.731.0326 Caution! Mains Plug label
43 1 03.731.0327 OPEN-CLOSE handwheel label
44 1 03.731.0328 OPEN-CLOSE housing label
46 1 01.747.0040 Connector
47 1 03.005.0009 Stop for housing bottom-top
48 1 03.796.0003 Door
49 1 03.798.0009 Keyboard membrane
50 1 03.800.0001 Keyboard mounting
51 1 03.824.0041 Subframe

Parts list, Section 1 (continued)
Pos. Code Qty. Article no. Designation
52 2 03.867.0005 Catch hook
54 4 03.937.0001 Centring pin for door – housing top/bottom
55 2 03.112.0069 Spacer ring for door – housing bottom
56 3 05.022.0001 Cap for electronics enclosure cover
59 E2/E3 1 05.728.0015 Allen key for item 5
61 4 05.753.0021 Plug for subframe
62 4 05.005.0006 Foot (stop buffer), subframe
64 1 05.731.0051 Label (arrow) for direction of rotation
65 1 05.727.0041 Cable tie
Teileliste Teil 2 Normteile

70 1 08.935.0002 Straight pin 5m6x10 DIN7
71 2 08.933.0035 Cheese head screw M3x12 DIN84
73 6 08.701.0012 Washer A3,2 DIN125
75 4 08.701.0018 Washer A6,4 DIN125
76 4 08.701.0001 Washer A8,4 DIN125
77 E2/E3 5 08.181.0001 Spring washer A8 DIN127
78 3 08.181.0007 Spring washer A10 DIN127
79 1 08.642.0018 Hexagon nut BM10 DIN439
80 3 08.221.0025 Set screw M10x35 DIN551
81 E2/E3 4 08.933.0144 Cheese head screw M6x10 DIN6912
82 7 08.933.0016 Cheese head screw M6x16 DIN 912
85 3 08.221.0001 Set screw M6x10 DIN914
86 8 08.221.0040 Set screw M6x20 DIN915
88 7 08.642.0008 Hexagon nut M10 DIN934
89 4 08.643.0042 Countersunk screw M3x10 DIN966
93 1 08.521.0008 Fitting key 4x4x8 DIN6885
94 E2/E3 5 08.703.0001 Woodruff key 5x6,5 DIN6888
102 2 08.181.0014 Spring washer A12 DIN127
106 4 08.642.0004 Hexagon nut M3 DIN7985

Parts list, Section 3
401 E 1 05.441.0264 Motor 1.5KW 3x400-440V-50Hz 750min-1
402 E 1 05.441.0259 Motor 1.5KW 3x290/500V-50Hz 750min-1
407 E 1 05.441.0241 Motor 1.5KW 1x240V-50Hz 1430min-1
414 E 1 05.441.0251 Motor 1.5KW 3x400-440V-50Hz 1430min-1
421 E 4 03.720.0001 Cutter bar in stainless steel
426 E 18 05.908.0001 Indexable inser
431 E 1 05.748.0076 Controller with operator control for
220-440V
432 E 1 05.748.0079 Controller with operator control for
200V
435 E2 1 03.901.0041 Shaft for rotor disks for 750-835min-1
436 E3 1 03.901.0042 Shaft for rotor disks for 1430-1690min-1
450 1 05.731.0037 Type plate
Legend to Code : E ⇒ Spare part
E1 ⇒ Spare parts with the same number may only be replaced together
Spare part assemblies

E1 = Art. no. 22.363.0001 Conical sleeve with grooved ball bearing
E2 = Art. no. 22.608.0005 Rotor with rotor disks and
indexable inserts for 750-835min-1
E2 = Art. no. 22.608.0006 Spare part assembly: rotor with rotor disks and
indexable inserts for 1430-1690min-1

List of spare parts for 2 years’ operation
( 8 hour single shift service / 30% duty cycle ^ 1320 operating hours )
Item Qty. Article no. Designation
14 1 05.114.0040 O-ring for 5 litre collecting tank
18 1 03.182.0024 Felt washer for motor shaft
24 2 03.241.0055 Rubber seal for housing top-bottom
25 1 03.241.0061 Rubber seal for door
421 4 03.720.0001 Cutter bar in stainless steel
426 18 05.908.0001 Indexable insert
Recommended stock of spare parts
14 1 05.114.0040 O-ring for 5 litre collecting tank
18 1 03.182.0024 Felt washer for motor shaft
24 2 03.241.0055 Rubber seal for housing top-bottom
25 1 03.241.0061 Rubber seal for door
421 4 03.720.0001 Cutter bar in stainless steel
426 18 05.908.0001 Indexable insert
431 1 05.748.0076 Controller with operator control for
220-440
432 1 05.748.0079 Controller with operator control for
200V

Dimensional chart for SM2000 with standard hopper

Drawings, Part 1

Drawings, Part 2

Drawings, Part 3

Drawings, Part 4
Only dismantle the operator control and the controller at the screws and nuts marked A and
B.
When undertaking repairs remove only the hex nuts and cap screws indicated with the letter
A or B.

Parts lists and drawings for the accessories
Standard hopper
Art.No. 01.747.0040
1 2 05.070.0008 Knob
2 1 05.042.0194 Pin
3 1 05.108.0029 Pressure piece
4 1 05.225.0016 Gripf
5 1 02.381.0002 Flap with chute
6 1 03.398.0004 Top plate
7 1 03.361.0044 Clamping pin
8 1 03.725.0018 Wooden slide
9 1 02.725.0019 Metal slide
10 1 03.731.0330 Label
11 1 02.747.0040 Connector
12 2 08.933.0006 Cheese head screw M4x8 DIN 84
13 2 08.701.0006 Washer A4.3 DIN 125
14 2 08.643.0001 Countersunk screw M6x12 DIN 7991
17 1 08.701.0001 Washer A8.4 DIN 125

Filter unit
Art.No. 22.187.0001
1 1 05.114.0040 O-ring
2 1 03.186.0025 Filter frame
3 1 03.604.0072 Ring, lower
4 1 03.604.0073 Ring, upper
5 2 05.867.0026 Catch
6 2 05.867.0027 Catch hook
7 8 08.933.0011 Countersunk screw M3x6 DIN 963-A2

Accessory box
Art.No. 22.905.0001
1 1 03.222.0276 Casing in painted steel
2 2 08.933.0011 Flat head screw M5x10 DIN 84-A2
Long material hopper

Art.No. 22.408.0001
1 1 03.111.0181 Seal in Vulkollan
2 1 02.725.0021 Slide in beech
3 1 03.785.0134 Hopper in stainless steel with support plate and cheese
head screws M6x12 DIN85-A2

Cutter roller with slide
Art.No. 22.722.0001
1 1 02.608.0033 Rotor disks 1-6 with indexable inserts
1.1 18 03.361.0045 Clamping block
1.2 1 03.608.0033 Rotor disk no.1
1.3 5 03.608.0034 Rotor disks nos..2-6
1.4 1 03.901.0040 Shaft
1.5 18 05.908.0001 Indexable insert
1.6 18 08.933.0056 Cheese head screw M4x12 DIN912-8.8vz
1.7 4 08.933.0144 Cheese head screw M6x10 DIN6912-8.8vz
1.8 5 08.703.0001 Woodruff key 5x6,5 DIN6888
2 1 02.725.0020 Slide for cutter roller

2.1 1 05.225.0016 Grip
2.2 1 03.361.0044 Clamping pin
2.3 1 03.398.0004 Top plate
2.4 1 03.725.0020 Slide with rail and plate
2.5 2 08.643.0001 Countersunk screw M6x12 DIN7991-A2
2.6 2 08.643.0039 Countersunk screw M6x45 DIN7991-A2
3 1 08.933.0065 Cheese head screw M6x20 DIN912-8.8vz

(extractor screw)

Circuit diagrams
Circuit diagram for 1x220/230V
SM 2000
START
STOP
Legend :
A1 = Main switch
A2 = Controller
A3 = Door switch
A4 = Motor
A5 = Central earth in electronics enclosure

Legend :
A1 = Main switch
A2 = Controller
A3 = Door switch
A4 = Motor

Legend :
A1 = Main switch
A2 = Controller
A3 = Door switch
A4 = Motor

Circuit diagram for 3x440V
Legend :
A1 = Main switch
A2 = Controller
A3 = Door switch
A4 = Motor

for machines with letter “A” following the serial number
SM 2000
START
STOP
Legend :
A1 = Main switch
A2 = Controller
A3 = Door switch right
A4 = Motor
A7 = Door switch left

Circuit diagram for 1x220/230V AE=J
for machines with letter “J” following the serial number
Legend :
A1 = Main switch
A2 = Controller
A4 = Motor

Legend :
A1 = Main switch
A2 = Controller
A4 = Motor

Legend :
A1 = Main switch
A2 = Controller
A4 = Motor

Circuit diagram for 3x440V AE=J
Legend :
A1 = Main switch
A2 = Controller
A4 = Motor

Modifications
1.) from 29.09.2006

The devices bear the revision mark "H" behind the serial number on the rating plate.
Safety Lock Part No. 05.656.0001

Glued with Loctite 243
2.) from 20.10.2006

The devices bear the revision mark "I" behind the serial number on the rating plate.
old = with revision mark "H" behind the serial number on the rating plate.
New = with revision mark "I" behind the serial number on the rating plate.
117 118
Pos. Stck. Art. Nr. Benennung Abmess. DIN Material
117 1 03.266.0225 Halteblech St1203 verzinkt
118 4 03.716.0005 Schwingmetalldämpfer 20x15

3.) 2007
The devices bear the revision mark "J" behind the serial number on the rating plate.
New = with revision mark "J" behind the serial number on the rating plate.
Pos. Stck. Art. Nr. Benennung Abmess. DIN Material

10 2 05.106.0023 Cable gland PG11
119 1 03.112.0117 Reducer 1.4301
120 1 05.703.0214 Switch
121 1 03.042.0321 Pin for Door, left 1.4305K
122 4 08.701.0005 Washer A5,3 125 St-A2K
123 4 08.933.0159 Cheese head screw M5x45 912 8.8-A2K
124 1 05.112.0092 Reducer M20x1,5 – PG11
125 1m 05.707.0060 Protective cable sleeve NW12

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Repair Manual for Cutter Mill type SM 2000

20.10.2006 2 ©Retsch GmbH & Co.KG Doc. No. GB 98.721.9998

3. Replacing the fuses on the controller

20.10.2006 3 ©Retsch GmbH & Co.KG Doc. No. GB 98.721.9998

5. Replacing the motor

20.10.2006 4 ©Retsch GmbH & Co.KG Doc. No. GB 98.721.9998

7. Replacing the grooved ball bearing with conical sleeve

20.10.2006 5 ©Retsch GmbH & Co.KG Doc. No. GB 98.721.9998

9. Replacing the cutter bars

10. Replacement and setting of the tensioning pins

20.10.2006 6 ©Retsch GmbH & Co.KG Doc. No. GB 98.721.9998

Tensioning pin in the door

11. Replacing the rotor and the felt washer

20.10.2006 7 ©Retsch GmbH & Co.KG Doc. No. GB 98.721.9998

Drive Standard 3-phase motor or

Mains voltage required see type plate ± 5%

Rated power 1500 Watt

Speed of three phase motor 750min-1 at 50Hz - 835min-1 at 60Hz

Speed of AC motor 1430min-1 at 50Hz - 1690min-1 at 60Hz

Activation ⇒ Main switch A ( ON-OFF)

Start ⇒ Sensor key B green

Stop Sensor key C red

Deblocking door and housing Central catch D

Open door Sensor key E blue

Overload protection Temperature sensor in motor

Fuses, external At site supply in accordance with motor current

Fuses, internal 3x 1A, slow blow, on the controller

Noise level 66 dBA under no load

Dimensions 550 x 600 x 1805 mm (w x d x h)

20.10.2006 8 ©Retsch GmbH & Co.KG Doc. No. GB 98.721.9998

20.10.2006 9 ©Retsch GmbH & Co.KG Doc. No. GB 98.721.9998

Teileliste Teil 2 Normteile

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Spare part assemblies

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Long material hopper

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2 1 02.725.0020 Slide for cutter roller

3 1 08.933.0065 Cheese head screw M6x20 DIN912-8.8vz

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20.10.2006 30 ©Retsch GmbH & Co.KG Doc. No. GB 98.721.9998

1.) from 29.09.2006

Safety Lock Part No. 05.656.0001

2.) from 20.10.2006

20.10.2006 31 ©Retsch GmbH & Co.KG Doc. No. GB 98.721.9998

Pos. Stck. Art. Nr. Benennung Abmess. DIN Material

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