Gertec Grout Pump 36974

GERTEC
Maschinen- und Anlagenbau GmbH
Instruction Manual
Grout Plant IS-60-50-M
Serial - No: 36974
Manufacturer:
GERTEC Maschinen- und Anlagenbau GmbH
Ludwig-Prandtl-Str. 1
D- 87448 Waltenhofen
Germany
Tel: +49 (0) 8303 929509-0
Fax: +49 (0) 8303 929509-99
info@gertec-gmbh.de
www.gertec-gmbh.de
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GERTEC
Table of Contents
1. Basic Safety Instructions................................................................................................................. 3
1.1. General............................................................................................................................................ 3
1.2. Instruction Manual........................................................................................................................... 3
1.3. Operator.......................................................................................................................................... 3
1.4. Expert.............................................................................................................................................. 3
1.5. Protective Equipment...................................................................................................................... 4
1.6. Safety Precautions.......................................................................................................................... 4
2. Description of the Grout Plant......................................................................................................... 5
2.1. Intended Use................................................................................................................................... 5
2.2. Principle of Operation...................................................................................................................... 5
2.3. Technical Specifications.................................................................................................................. 5
2.4. View of the Grout Plant.................................................................................................................... 6
2.5. View of the Plunger Pump............................................................................................................... 7
3. Transporting / Setting Up................................................................................................................. 8
3.1. Transporting.................................................................................................................................... 8
3.2. Setting Up........................................................................................................................................ 8
4. Operator Controls and Indicators................................................................................................... 9
4.1. Operator Controls on the Batch Mixer............................................................................................. 9
4.2. Operator Controls and Indicators on the Hydraulic Power Unit..................................................... 10
4.3. Operator Controls and Indicators on the Control Cabinet.............................................................. 11
5. Commissioning............................................................................................................................... 13
5.1. Prior to Commissioning................................................................................................................. 13
5.2. Connecting the Station.................................................................................................................. 13
5.3. Testing the Functioning of the Safety Switch................................................................................. 14
6. Operation......................................................................................................................................... 15
6.1. Settings.......................................................................................................................................... 15
6.2. Mixing Operation........................................................................................................................... 15
6.3. Pumping Operation........................................................................................................................ 15
6.4. Troubleshooting............................................................................................................................. 15
7. Ending Operation / Shutting Down............................................................................................... 17
7.1. Interruption of Operation................................................................................................................ 17
7.2. Ending Operation........................................................................................................................... 17
7.3. Ending Operation when there is Freeze Danger............................................................................ 18
7.4. Shutting Down............................................................................................................................... 18
8. Maintenance and Repair................................................................................................................ 19
8.1. General.......................................................................................................................................... 19
8.2. View of the Maintenance Points................................................................................................... 20
8.3. Scheduled Maintenance, Maintenance Work................................................................................ 20
8.3.1. Daily................................................................................................................................ 20
8.3.2. Weekly............................................................................................................................ 21
8.3.3. Monthly........................................................................................................................... 21
8.3.4. Annually.......................................................................................................................... 21
8.4. Consumables................................................................................................................................. 21
Appendices
A Spare Parts List
B Wiring Diagram
C Instruction Manual B 1021 - Gear Motor
D Declaration of Conformity
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GERTEC
1.Basic Safety Instructions
1.1.General
Improper handling and operation of the grout plant, any use for other than the intended purpose,
and/or additions or modifications to the station may endanger persons or cause damage to equipment
and property.
Therefore, the following safety instructions for transporting, setting up, commissioning, operating,
maintaining and repairing the grout plant must be strictly heeded.
In addition, all accident prevention codes of the trade associations, country-specific laws, rules and
regulations, as well as construction-site related provisions concerning personnel and machine safety
and environmental protection must be observed in handling the grout plant.
GERTEC cannot foresee every possible circumstance that might involve a potential hazard. Therefore,
when handling and using the Grout Plant, close attention must be paid to any potential hazards and to
any safety-relevant changes on the plant or in its surroundings and, if necessary, additional protective
measures, especially for ensuring personnel safety, must be taken.
1.2.Instruction Manual
The Grout Plant must be handled, transported, installed, operated, serviced and repaired in strict
compliance with this instruction manual.
Throughout this manual, attention is drawn to potential hazards by the “Attention“ sign.
In addition, special warning and advisory signs are posted on the plant.
-Carefully read the instruction manual before putting the machine into op-
eration.
-Do not put the machine into operation before all persons concerned
have read and understood this instruction manual.
This instruction manual must be kept readily available at the site where the Grout Plant is used.
1.3.Operator
Handling the Grout Plant (transporting, setting up, operating, maintaining, repairing, etc.) must be
entrusted only to persons who
- have been instructed in and trained for their respective task and are capable of performing it,
- are physically and mentally fit,
- have read and understood this instruction manual.
1.4.Expert
The performance of the expert inspection and the evaluation of safety-related issues regarding the
Grout Plant may be entrusted only to persons who
- are qualified for this by reason of their technical training and experience in dealing with such
machinery;
- have received specific instruction at the plant,
- are familiar with the applicable regulations and know how to apply them.
The expert must be appointed and instructed by the user of the plant.
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GERTEC
1.5.Protective Equipment
-Use the plant only with all protective covers attached or closed
and with all safety devices properly in place and functioning.
-Before removing any protective guards and devices (e.g. for main-
tenance, repair), disconnect the plant from its power source and
make sure it cannot be inadvertently reconnected/restarted.
-After completion of any installation, maintenance and repair work,
reinstall all protective guards and devices and make sure they are
functioning properly.
1.6.Safety Precautions
The most important safety precautions, particularly for the protection of personnel, are:
- The power supply to the plant must be protected by means of a suitable residual current
device (RCD).
- The plant must never be operated without effective protective guards and safety devices.
- The plant must not be used for any other than its intended purpose.
- Prior to any repair or maintenance work, especially before opening the control cabinet:
- Pull the AC power plug.
- Make sure it cannot be inadvertently reconnected.
- Make sure the equipment is actually de-energised.
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GERTEC
2.Description of the Grout Plant
2.1.Intended Use
The Grout Plant IS-60-50-M is especially suited for the mixing and injecting of cement grouts.
The Grout Plant must not be used for processing chemically aggressive and/or explosive materials.
Any functional or structural modifications to the plant and its integration in, or linking up with, other
equipment are permitted only after consultation with and express approval by GERTEC.
2.2.Principle of Operation
After having been mixed in the batch mixer, the cement grout is pumped to the agitator tank for
temporary storage. From there the grout slurry is withdrawn by means of the plunger pump and
delivered to the grouting site.
At first the water is batched into the batch mixer by means of a manual 3-way valve. Subsequently,
with the mixer motor running and the internal pumping line open, the solid is batched via the bag
dumping grate.
After the mixing time is over, actuation of the manual 3-way valve causes the grout to be pumped into
the agitation tank where a built-in agitator prevents it from setting.
The grout is sucked from the agitation tank by means of the infinitely variable flow rate plunger pump.
The maximum pumping pressure is infinitely variable.
2.3.Technical Specifications
Mixing capacity: (at 20 batches/h) 3.0 m³/h

Effective mixer volume: 150 dm³
Effective agitation tank volume: 300 dm³
Maximum pump delivery rate 50 dm³/min
Maximum pump delivery pressure 100 bar
Maximum solids grain size 2 mm
Discharge connection 3/4“ female thread
Water supply connection Storz C DIN 14306
Power supply connection CEE standard plug 32A; 5-pole
Voltage: 400 V; 50 Hz
Power input: 16 kW
Length: 2270 mm
Width: 830 mm
Height: 1800 mm
Weight: approx.. 820 kg
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GERTEC
2.4.View of the Grout Plant
FIG. 2-1
(1)Batch Mixer
(2)Agitation Tank
(3)Hydraulic Power Unit
(4)Plunger Pump (not visible, at rear side of hydraulic power unit)
(5)Electrical Control Cabinet
(6)Base Frame
(7)Central Lifting Eye
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GERTEC
2.5.View of the Plunger Pump
Hydraulic Cylinder
Lubrication Pot for Plunger
Discharge Valves
Discharge Connection
Suction Valves
Suction Connection
FIG. 2-2
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GERTEC
3.Transporting / Setting Up
3.1.Transporting
For lifting, the Grout Plant can be picked up at the following attachment points:
-With a crane at the central lifting eye,

With a fork lift underneath the base frame. Pay attention to the fork length.
-Use only the provided attachment points

-Use only suitable, flawless and tested hoisting equipment
and sling gear – Pay attention to the weight.
The unit must be fastened (lashed) on the transport vehicle in such way that it cannot shift, tip over, or
drop down due to heavy braking or road bumpiness.
-Proper loading and fastening of the load is the responsibility of the car-
rier, not of the driver of the transport vehicle.
3.2.Setting Up
The Grout Plant must be set up on a horizontal surface so that its base frame is evenly supported.
Absolute attention must be paid to sufficient stability. The floor surface must be paved or compacted in
order to prevent the station from subsiding.
Keep in mind that the bearing capacity of the subsoil is often diminished in the vicinity of excavations
and slope edges, thereby posing a risk of tipping and falling.
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GERTEC
4.Operator Controls and Indicators
4.1.Operator Controls on the Batch Mixer
FIG. 4-1
(1) Water Intake Valve

Hand lever parallel to pipe line – open, perpendicular to pipe line – closed.
(2) Batch Mixer Fill Level Gauge
Setting range: 50 to 150 litres.
(3) Manual 3-way valve for Internal Circulation/Emptying
- Hand lever pointing forward towards hose line = Emptying,
- Hand lever perpendicular to hose line towards control cabinet = Internal Circulation
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GERTEC
4.2.Operator Controls and Indicators on the Hydraulic Power Unit
Grout Pressure Hydraulic Pressure
(1)
Hand Wheel:
Flow Rate Adjustment
(2)
Hand Wheel:
Setting Pressure Limitation
Oil Filter Contamination Indicator
Oil Level Gauge
FIG. 4-2
1) Pump Flow Rate Adjustment

The flow rate of the plunger pump can be adjusted by turning the hand wheel.
Adjust only when the hydraulic pump is running.
2) Pressure Limitation Setting
The maximum discharge pressure of the plunger pump can be adjusted by turning the hand wheel.
Adjust only when the hydraulic pump is running.
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GERTEC
4.3.Operator Controls and Indicators on the Control Cabinet
2 1 4 3 5 6 7 8 11
10
13
12
FIG. 4-3
1) MIXER ON illuminated pushbutton

2) MIXER OFF pushbutton
3) AGITATOR ON illuminated pushbutton
4) AGITATOR OFF pushbutton
5) PUMP ON illuminated pushbutton
The hydraulic pump in the hydraulic power unit turns on and after a short starting time,
the plunger pump starts operating.
6) PUMP OFF pushbutton
The plunger pump stops operating, and the hydraulic pump automatically turns off
after a short run-on time (approx. 20 sec ).
7) GENERAL TROUBLE indicator light
It indicates trouble in the electrical control system. All drives stop and
cannot be restarted until that trouble has been eliminated.
8) WRONG PHASE SEQUENCE indicator light
The phase sequence in the power feed cable is wrong. The phase sequence can be
inverted in the power inlet plug. The station is ready for operation only after this
has been done.
9) PLUNGER UPWARD pushbutton
For maintenance purposes. Pressing the button turns on the hydraulic pump as described
under PUMP ON and the plunger moves upward as long as the pushbutton is being
pressed.
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GERTEC
10) PLUNGER DOWN pushbutton

by analogy with PLUNGER UP.
11) PLUNGER 1 - 0 - 2 selector switch
Switch position 0: Automatic operation.
Switches (5) PUMP ON and (6) PUMP OFF are active
Switch positions 1 and 2: Maintenance mode
Pushbuttons (9) PLUNGER UP and (10) PLUNGER UP are active
12) EMERGENCY STOP pushbutton
In case of suspected or evident danger, press EMERGENCY STOP pushbutton.
All drives stop.
To resume operation, release the EMERGENCY STOP pushbutton by twisting it slightly
and pulling it out; the control system is again ready for operation.
13) MAIN SWITCH
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GERTEC
5.Commissioning
5.1.Prior to Commissioning
-It is absolutely necessary that you are familiar with the machine,
the operator controls and indicators and the instruction manual.
Before the initial commissioning and subsequently every time before beginning operation, perform a
visual inspection of the unit. Check for the following:
-Date of the next expert inspection; if necessary, have first the expert inspection performed;
-Damage sustained during transport or prior use;
-Proper positioning and setup of the station (see section 3.2 Setting Up);
-Readyness for safe operation, especially whether all protective devices are in place and in
perfect working condition;
-Tightness of all screw and bolt connections; retighten, if necessary;
-Fill level of the hydraulic tank (see subsection 8.3.1 Scheduled Maintenance - Daily);
-Degree of contamination of the oil filter (see subsection 8.3.1 Scheduled Maintenance - Daily);
-Fill level and condition of the plunger lubricant
(see subsection 8.3.1 Scheduled Maintenance - Daily).
5.2.Connecting the Station
Mechanical Connection
(1) Water supply connection Storz C coupling

(2) Plunger pump discharge connection 3/4“ female thread
Electrical Connections
(3) Power Supply Feed CEE Standard Inlet Plug; 32 A; 5-pole;

400 V, 50 Hz
1)Make the water supply connection via the Storz C standard coupling
Be sure to observe the maximum pressure of 6 bar.
2)Make the 3/4" female thread plunger pump discharge connection.
-Be sure to use only suitable hose and coupling material.

-Be sure to observe the maximum pressure of 100 bar.
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GERTEC
3)Make the AC power supply connection via the the CEE standard connector.
-Before making the mains power connection, all mechanical protective

devices must be installed.
-The mains power supply must be provided with a proper residual current
device (RCD).
-The main switch must be in OFF position.
5.3.Testing the Functioning of the Safety Switch
1) Testing the functioning of the EMERGENCY STOP pushbutton at the Control Cabinet
-Set the main switch to ON

-Release the EMERGENCY STOP pushbutton, if it has been actuated.
-Press the MIXER ON pushbutton.
-Press the AGITATOR ON pushbutton.
-Press the PUMP ON pushbutton.
-Actuate the EMERGENCY STOP switch.
-All drives must stop.
-Release the EMERGENCY STOP pushbutton.
If the EMERGENCY STOP pushbutton is not functioning properly:

-Set the main switch OFF, pull the power plug and lock it or block it out
to prevent it from being inadvertently plugged in again.
-Have the defect corrected by qualified electrician.
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GERTEC
6.Operation
6.1.Settings
- Set the desired water batching quantity. To do so, twist the star knob to disengage the
indicator rod and shift it to the respective position on the litre scale, and then retighten the
star knob.
- The pump flow rate and pressure limitation can be set only when the pump is operating.
6.2.Mixing Operation
- Start by batching the water into the mixer. To do so, open the manual valve in the water
supply line and wait until the water level has reached the lower edge (round disk) of the
indicator rod. Close the manual valve.
- Set the manual 3-way valve to INTERNAL CIRCULATION.
- Press the MIXER ON pushbutton on the control cabinet to start the mixer:.
- Batch the desired quantity of solid material into the mixer via the bag dump grate.
- Wait for the end of the mixing time (about 60 sec)
- Empty the mixer by setting the manual 3-way valve to EMPTYING. Turn the hand lever by 90°
in clockwise direction.
- Press the AGITATOR ON pushbutton on the control cabinet to turn the agitator in the
agitation tank on.
- Turn off the mixer or proceed with the next batch.
6.3.Pumping Operation
- Turn the pump on by pressing the PUMP ON pushbutton on the control cabinet.
- Set the desired delivery flow rate of the pump by turning the hand wheel until the desired flow
rate is reached. Only possible while the pump is running.
- Set the delivery pressure limit of the pump: Run the pump against the closed discharge line.
Turn the hand wheel until the desired maximum pressure has been reached. (the pressure is
indicated on the pressure gauge). Open the discharge line (turn off the pump, if necessary)
and proceed with the pump operation.
6.4.Troubleshooting
1) Control cabinet: Operator controls not active.
Trouble: The operator controls at the control cabinet do not react when actuated
Cause: - No voltage
- EMERGENCY STOP has been actuated
- Trouble signalled by indicator light
Remedy: - Connect the mains power supply inlet plug.
- Set the main switch to ON
- Release the EMERGENCY STOP pushbutton
- Eliminate the indicated (trouble indicator lamp) trouble (see section 6.4
Troubleshooting, item 3)
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GERTEC
2) WRONG PHASE SEQUENCE indicator light is on
Trouble: The red WRONG PHASE SEQUENCE indicator light is on (see section 4.3
Operator Controls and Indicators on the Control Cabinet)
Cause: The power supply phase sequence is wrong.
Remedy: Unplug the power supply connection and use a screw driver to turn the phase
inverter in the station’s power inlet plug, and then connect again.
3) GENERAL TROUBLE indicator light is on
Trouble: The red GENERAL TROUBLE indicator light is on (see section 4.3 Operator
Controls and Indicators on the Control Cabinet)
Cause: - The EMERGENCY STOP pushbutton has been actuated.
- One or several motor protection switches have tripped.
Remedy: - Release the EMERGENCY STOP pushbutton.
- To localize and correct the trouble requires opening of the control cabinet.
The malfunction must be corrected by a qualified electrician.
-The control cabinet may be opened only by a qualified electrician.

-Before opening the control cabinet, turn the main switch off, pull the
mains power plug.
-Take proper precautions to prevent restarting.
4) The plunger pump stops during pump operation.
Trouble: The plunger pump stops running while it is switched on.

Cause: - The back pressure in the pump line is too high; the maximum pressure of
the pump is exceeded.
- The pressure limitation is set too low.
Remedy: - Eliminate clogging, if any, in the pump line.
- Increase the pressure limit, if possible
5) The plunger pump has intermittent discontinuities.
Trouble: Not every stroke causes pumping action

Cause: The ball valves do not close properly. Possible reasons:
- The ball seat is jammed by a foreign body
- The slurry contains lumps or set material
- The slurry to be pumped is too viscous
Remedy: - If possible, operate pump for a short time at maximum flow rate in order
to drive troublesome foreign bodies out of the seal seat.
- Open the twist lock at all valves and use a long object like a screw driver
to repeatedly lift the valve ball.
- Open the valves and remove any foreign bodies
6) The plunger pump is delivering nothing or too little even though the plungers are reciprocating
Trouble: Although the pistons are reciprocating, the piston pump does not deliver at all or
delivers too little; it generates no or insufficient pressure
Cause: - The ball valves do not close properly because of foreign bodies or wear.
- The plunger seals are damaged or worn out.
Remedy: - Proceed as in the case of the intermittent discontinuities.
- Replace the valve seats and balls if necessary
- Replace the plunger seal if necessary
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GERTEC
7.Ending Operation / Shutting Down
7.1.Interruption of Operation
In case of a longer lasting interruption of operation keep the setting time, if any, of the grout in mind.
If necessary, keep the unit running until it is empty, then flush it with clear water (see section 7.2)
7.2.Ending Operation
1) Empty and Clean the Batch Mixer

- Set manual flap valve to EMPTYING
- MIXER ON, wait until the mixer is empty.
- Mixer OFF
- Unscrew and remove bag dumping grate.
-Before opening the bag dumping grate, turn main switch off, pull the
mains plug.
-Take appropriate precautions to prevent that the plug is inadvertently
reconnected.
- Use clear water to spray off all residues and impurities inside the batch mixer.
- Screw the bag dumping grate on again.
- Set the manual 3-way valve to INTERNAL CIRCULATION.
- Press the MIXER ON pushbutton.
- After a short flush time, switch the manual 3-way valve from INTERNAL CIRCULATION to
EMPTYING.
- When the mixer is empty, set the manual 3-way valve again to INTERNAL CIRCULATION.
- Flush again with clear water and repeat the emptying process until only clear water exits
from the mixer.
2) Empty and Clean the Agitation Tank

- Press the PUMP ON pushbutton.
- When the agitation tank is empty, press PUMP OFF.
- Unscrew and remove the protective screen.
-Before opening the bag dumping grate, turn main switch off, pull the
mains plug.
-Take appropriate precautions to prevent that the plug is inadvertently
reconnected.
- Uncouple the pump suction line from agitation tank

- Use clear water to spray off all residues and impurities inside the agitation tank.
- Screw the protective grate on again.
- Reconnect suction coupling.
3) Flush the Pump

- Fill the agitation tank with clear water.
- Press the PUMP ON pushbutton
- Flush the pump with the discharge line open and with a high flow rate until all the water exiting
from it is clear.
4) Set the main switch to OFF.
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GERTEC
7.3.Ending Operation when there is Freeze Danger
- Proceed as described in section 7.2 Ending Operation.

- Uncouple the water intake line and open the water valve.
- Uncouple the internal circulation line at the manual 3-way valve and tilt it towards the floor.
- Set the manual 3-way valve to between INTERNAL CIRCULATION and EMPTYING:
- Set the hand lever to a slanted position of about 45°.
- Uncouple the suction line from the agitation tank.
- Open the twist locks on all four pump valves and use a long object like a screw driver
to lift the balls until no more liquid exits.
7.4.Shutting Down
- Proceed as described in section 7.3 Ending Operation when there is Freeze Danger.
- Close the twist locks
- Recouple the suction line to the agitation tank and the internal circulation line to the manual
3-way valve.
- Pull the mains plug.
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GERTEC
8.Maintenance and Repair
8.1.General
Proper maintenance and servicing and competent repair maintain the functionality of the plant and
thereby its efficiency and operational safety.
The instructions for maintenance and repair and all scheduled maintenance set out below must be
followed without exception. Failure to do so causes forfeiture of any warranty claim.
The following applies to all maintenance and repair work:

-All persons entrusted with these tasks must have read and understood these instructions, and they
must have been trained for, and be capable of, performing such work.
-It must be ensured that all repairs are carried out properly. In case of doubt, please call in GERTEC
expert personnel.
-For replacement of parts, only original GERTEC spare parts may be used.
-Any maintenance and repair work may be performed only with the main
switch on OFF and with the mains plug disconnected. Take proper
precautions to prevent inadvertent restarting.
-All personal protective gear required for performing these tasks, e.g.
hearing protectors, safety goggles, work gloves, etc. must be in perfect
condition and must be worn or used when and where it is appropriate.
-All further safety-related regulations and codes issued by competent
authorities, trade associations, technical inspection and control
associations, and all environmental protection regulations, etc. must also
be taken into account and complied with without any exception.
-Use only tools and devices that are suitable for the task and in perfect
working order.
8.2. View of the Maintenance Points
Filler neck for

hydraulic oil
Oil filter contamination

indicator
Oil level gauge
FIG. 8-1
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GERTEC
8.3.Scheduled Maintenance, Maintenance Work
After about 50 hours of operation: Check all screw and bolt connections for tightness. Retighten if
necessary.
8.3.1.Daily
1) Check the entire plant for defects or damage.

Visually inspect the plant and observe its pumping behaviour. In the event of any unusual
behaviour, determine the cause and shut the plant off if necessary (see section 6.4
Troubleshooting).
2) Check the oil level in the hydraulic tank.
Make sure the level is above the red line marking.
Top up hydraulic oil, if necessary (for oil type see section 8.4 Consumables)
3) Check the oil filter contamination indicator.
Make sure the indicator is in the green range. If the indicator is in the red range, change
the oil filter (oil filter: see Spare Parts List in Appendix A).
4) Check the fill level and the quality of the plunger lubricant.
In case of heavy contamination, drain the old lubrication oil and replace it with a fresh one.
(For lubricant type see section 8.4 Consumables).
(See also section 2.5 View of Plunger Pump.)
8.3.2.Weekly
8.3.3.Monthly
5) Check the oil level in the agitation tank gearbox; top up, if necessary. See also the pertinent
information in the appended instruction manual B 1021.
8.3.4.Annually
6) Expert inspection
-Due date: see decal on name/rating plate.
8.4.Consumables
1) Hydraulic Oil: Agip PRECIS HLP ISO VG 46 or other hydraulic oil of same quality that is compatible.
2) Lubricant Oil: Biologically degradable lubrication and adhesive oil
Waltenhofen, 30 June 2008
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GERTEC
Appendix A
Spare Parts List
- 21 -
GERTEC Maschinen- Injektionsstation
Ersatzteilliste 36974
und Anlagenbau GmbH grout plant
D-87448 Waltenhofen Spare Parts List 36974 Type: IS-60-50-M
Art.Nr. Menge Einheit Bezeichnung Deutsch designation

30004 1 Stck Verschlußstopfen 3/4'' plug 3/4"
30069 32 Stck Scheibe A10,5 washer A10,5 - St vz DIN125
30083 34 Stck Scheibe A13 washer A13
30099 16 Stck 6kt.Mutter M10 hexagon nut M10
30220 16 Stck 6kt.Schraube M10x25 hexagon screw M10x25
30845 1 Stck Storz-Festkupplung C/2'' storz coupling male thread C/2" AG
30846 1 Stck Storz-Saugkupplung C/LW50 suction coupling C/LW50
30849 1 Stck Absperrklappe DN40/PN16 shutting valve DN40/PN16
30856 2,2 m Gummi-Spiralschlauch LW50x6 rubber spiral hose LW50x6
30860 2 Stck Schlauchtülle LW19-3/4'' hose nozzle LW19-3/4" AG
30864 5 Stck Schlauchtülle LW50-2'' hose nozzle LW50-2" AG
30872 2 Stck Gewindeflansch DN40/PN16 threaded flange DN40/PN16
30882 1 Stck Winkel 90° 2 IG angle 90° 2 IG - St vz
30887 1 Stck Winkel 90° 3/4 IG-AG angle 90° 3/4 IG-AG
30919 1 Stck Winkel 45° 2 IG-AG angle 45° 2 IG-AG
30924 1 Stck Nippel 1 1/2''x 40 nipple 1 1/2"x 40
30934 2 Stck GBS-Schelle 28/18 GBS-clamp 28/18
31815 1 Stck Nippel 1''x 60 nipple 1"x 60 St vz
31824 1 Stck Nippel 2''x 80 nipple 2"x 80 - St vz
31892 1 Stck Deckplatte NW50 CM-150 cover plate NW50
31893 1 Stck Grundplatte NW50 base plate NW50
31897 1 Stck Doppelklappe NW50 trap NW50
32316 2 Stck Kugelhahn 3/4'' ball valve 3/4" with greasing
32317 1 Stck T-Verschraubung tee union
32318 3 Stck Verschraubung screw fitting
32319 0,92 m Gummi-Spiralschlauch LW19x4,5 rubber spiral hose LW19x4,5
32325 1 Stck Chargenmischer batch mixer CM-150
32657 1 Stck Red-Stück 1''-3/4'' reductionn fitting 1"-3/4"
32792 1 Stck Saug-Drucksieb NW100/DN50 filter NW100/DN50
33483 2 Stck Mörtelkupplung MT; 1'' coupling MT; 1" IG
33484 2 Stck Mörtelkupplung VT; 1'' coupling VT; 1" AG
33823 2 Stck Warnschild Deckel engl. warning sign cover engl
34511 1 Stck Red-Stück 2''-1 1/2'' reductionn fitting 2''-1 1/2''
34835 1 Stck Warnschild Transport englisch warning sign transportation english
36219 4 Stck Fuß Grundrahmen, Höhe 100 mm foot base plate IS-
36818 1 Stck Hydraulikaggregat hydraulic power pack
36831 1 Stck Hydraulikinstallation hydraulic installation
36846 1 Stck Grundrahmen base frame
36850 1 Stck Mörtelkupplung VT; 1 1/2'' IG coupling VT; 1 1/2" IG
GERTEC Maschinen- Injektionsstation
Ersatzteilliste 36974
und Anlagenbau GmbH grout plant
D-87448 Waltenhofen Spare Parts List 36974 Type: IS-60-50-M
36851 1 Stck Mörtelkupplung MT; 1 1/4'' coupling MT; 1 1/4" IG

36885 1 Stck Y-Stück DN32 Y-Fitting DN32
36887 1 Stck Elektroinstallation IS-60-40-M electric installation
36894 1 Stck Schild Öltank sign oil tank
36899 1 Stck Konsole PP-60 console PP-60
36938 1 Stck Rührwerksbehälter RB-300-R agitator tank
36977 1 Stck Typenschild IS-60-50-M type plate IS-60-50-M
36979 1 Stck Schildersatz IS- PP englisch sign set control cabinet IS-PP
36980 1 Stck Druckanzeige PP-60 pressure indicator PP-60
36981 1 Stck Schilder Plunger I + II, englisch sign plunger english
36992 1 Stck Doppelplungerpumpe PP-60 dublex plunger pump PP-60
37006 1 Stck V-Verschraubung v-union
37014 1 Stck Steuerschrank electrical control cabinet
37069 6 Stck Hydrauliköl TOTAL VG 46 Kan. 20l hydraulic oil TOTAL VG 46 tank 20l
GERTEC Maschinen- Ersatzteilliste 32325 Chargenmischer
und Anlagenbau GmbH batch mixer
D-87448 Waltenhofen Spare Parts List 32325
type:CM-150

30098 8 Stck Federring A10 spring ring A10
30103 3 Stck Scheibe A8,4 washer A8,4
30208 1 Stck Stopmutter M8_8 vz DIN985 Self-locking hexagon nut M8
30805 6 Stck Scheibe 10,5x25x4 washer 10,5x25x4
30807 1 Stck Scheibe 17x40x6 washer 17x40x6
30855 1 Stck Storz-Festkupplung C/1 1/2'' storz coupling male thread C/1 1/2"
30881 1 Stck Winkel 90° 1 1/2 IG angle 90° 1 1/2 IG
30890 1 Stck Winkel 90° 1 1/2 IG-AG angle 90° 1 1/2 IG-AG
30926 1 Stck Nippel 1 1/2''x 100_St vz nipple 1 1/2"x 100 - St vz
31743 1 Stck Muffenkugelhahn 1 1/2'' threaded ball valve 1 1/2"
31820 2 Stck Nippel 1 1/2''x 60 nipple 1 1/2"x 60
31842 1 Stck Mischbehälter IS-65-35-MB mixing container IS-65-35-MB
31849 1 Stck Sackaufgabegitter IS-65-40-MB sheetback emptying grid IS-65-40-MB
31862 1 Stck Mischrad IS-35-100-MB mixing wheel IS-35-100-MB
31863 1 Stck Mantel für Pumprad IS-35-100-MB jacket pump wheel IS-35-100-MB
31874 1 Stck Mischgehäuse IS-65-40-MB mixer housing IS-65-40-MB
31903 1 Stck Drehstrommotor 4kW three phase AC motor 4kW
31904 1 Stck Dichtung Mischgehäuse gasket mixer housing
32162 4 Stck Gummipuffer 50x30 Typ C rubber buffer 50x30 Typ C
32253 1 Stck Pumprad CM IS-90-60-M pump impeller CM IS-90-60-M
32260 1 Stck Motorplatte Mischer motor bedplate mixer
32261 1 Stck Motorabdeckung CM IS-90-60-M covering of motor CM IS-90-60-M
32293 1 Stck Mischerwelle IS-65-35-MB mixing shaft IS-65-35-MB
32294 1 Stck Mischerdeckel IS-65-35-MB mixing cover IS-65-35-MB
32326 1 Stck Füllstandsanzeige CM-150 level indicator CM-150
32327 1 Stck Winkelstück 2'' angle 2"
32351 2 Stck Schraube M10 screw M10
GERTEC Maschinen- Ersatzteilliste 32326 Füllstandsanzeige
und Anlagenbau GmbH level indicator
type:CM-150

31218 0,056 m Gewindestange M10 threaded rod M10
31882 1 Stck Skala 50 - 150Ltr scale 50 - 150 Ltr
32124 1 Stck T-Nutenstein 12mm tenon block 12mm
32353 1 Stck Laserzuschnitt Skalenplatte blank part scale plate
32354 1 Stck Sterngriff star grip
34260 1 Stck Stab Füllstandsanzeige CM-150 Filling Level Gauge CM-150
GERTEC Maschinen- Ersatzteilliste 36818 Hydraulikaggregat
und Anlagenbau GmbH hydraulic power pack
Type: IS-100-60

30098 4 Stck Federring A10 spring ring A10 - St vz DIN127
30204 2 Stck Stopmutter M3 Self-locking hexagon nut M3
30413 4 Stck Zyl.Schraube M4x45 alan cap screw M4x45
31032 1 Stck Einfüll-/Belüftungsfilter EB 80-10 filter filler/ventilation EB 80-10
31886 1 Stck Füllstandsanzeige optisch SF2 optical level indicator SF2
31891 2 Stck Dichtung Pumpenträger gasket pump carrier PT
32080 1 Stck Rücklauffilter return line filter
32451 1 Stck Zahnkranz Spidex ZK 38 gear rim Spidex ZK 38 92° Shore A
33194 1 Stck Druckbegrenzungsventil vorgesteuert pressure limitating valve
33218 1 Stck Reinigungsdeckel RD 350 cleaning cover RD 350-V324-6
33219 1 Stck Profildichtung D 268 NBR profile gasket D 268 NBR
34449 1 Stck Drehstrommotor 11 kW three phase AC motor 11 kW
34516 1 Stck Schild min sign min
36149 1 Stck Kupplungshälfte Spidex Alu A38 H7 half coupler Spidex Alu
36150 1 Stck Kupplungshälfte Spidex Alu A38.F half coupler Spidex Alu
36151 1 Stck Pumpenträger pump carrier with damping
36184 1 Stck Befestigungswinkel f. Schild min fixing bracket
36285 1 Stck Steuerblock NG 6 - Sunventile valve block NG 6
36496 1 Stck Manometerhalter hood IV-140-2
36743 1 Stck Verstellpumpe 23 cm³ Variable Displacement Pump
36744 1 Stck Zahnradpumpe 14 cm3/u gear pump 14cm3/u
36752 4 Stck Unterlegscheibe 6,4 washer for head screws 6,4
36793 1 Stck 4/3-Wegeventil NG 6 4/3 directional valve NG 06
36794 2 Stck Magnetspule CETOP 24VDC solenoid coil
36796 1 Stck Anschlussplatte NG 06 reworking connection plate NG 06
36799 1 Stck Ölbehälter IS-60-40-M oil pot IS-60-40-M
36909 2 Stck Ventilstecker SP-666 valve plug
GERTEC Maschinen- Ersatzteilliste 36831 Hydraulikinstallation
und Anlagenbau GmbH hydraulic installation
IS-60-40-M

30092 1 Stck Verschraubung screw connection
30968 0,25 m Rohr.21,3x2,6 pipe 1/2"
31023 2 Stck Winkel-Verschraubung knee fitting
31051 1 Stck Messleitung SMA3-300 measuring cable SMA3-300
31056 1 Stck Manometeranschluß manometer connection
31057 1 Stck Messanschluß measuring connector
31626 0,22 m Rohr.28x2 pipe 28x2 - St.37.4
33407 1 Stck Manometer 63 manometer 63; 0-250 bar; 1/4" rear
33773 1 Stck Reduzierstutzen reduction adaptor
35901 1 Stck Hydraulik-Flansch hydraulic flange
35969 1 Stck Hydraulik-Flansch hydraulic flange
36832 1 Stck HD-Schlauch DN 12 hydraulic hose DN 12
36916 2 Stck Rohrbogen 90° RB15x1,5 vz pipe bend 90° RB15x1,5
36918 4 Stck Winkelschottverschraubung straight screw connection
GERTEC Maschinen- Ersatzteilliste 36938 Rührwerksbehälter
und Anlagenbau GmbH agitator tank
D-87448 Waltenhofen Spare Parts List 36938 type:RB-300-R

30165 5 Stck Federring A12 spring ring A12 - St vz DIN127
30780 1 Stck Flachgetriebemotor 0,75 KW spur gear motor 0,75 KW
30806 1 Stck Scheibe 13x30x6 washer 13x30x6 - St vz DIN7349 - heavy
30807 1 Stck Scheibe 17x40x6 washer 17x40x6 - St vz DIN7349 - heavy
30891 1 Stck Winkel 90° 2 IG-AG angle 90° 2 IG-AG
31115 1,38 m Dichtungsprofil 10x5, NK 20 sealing section 10x5, NK 20
31826 1 Stck Nippel 2''x 150 nipple 2"x 150
32782 1 Stck Behälter RB-300 rund vessel agitator
32788 1 Stck Sichtgitter RB-300-R control grid agitator
32789 1 Stck Rührwerk Rübe RB-300-R agitator
32790 1 Stck Deckel Rübe RB-300-R cover agitator
32791 1 Stck Getriebemotorabdeckung RB-300 covering of gear motor RB-300
32794 1 Stck Wartungsdeckel Rübe RB-300-R maintenance cover agitator
32795 1 Stck Dichtung Wartungsdeckel RB-300 seal maintenance cover agitator RB-300
32956 1 Stck Passfeder A 8x30 DIN 6885 fitting key A 8x36
34513 1 Stck Blindstopfen 1'' blind plug 1"
36933 1 Stck Joch für zentrale Anhängung yoke for lifting eye
GERTEC Maschinen- Ersatzteilliste 36992 Doppelplungerpumpe
und Anlagenbau GmbH double plunger pump
Type: PP-60

30077 4 Stck O-Ring 50x3 o-ring 50x3
30107 2 Stck GEKA-Kupplung 3/4'' GEKA-coupling 3/4"
30108 2 Stck GEKA-Blindkupplung GEKA-cap coupling
30208 2 Stck Stopmutter M8 Self-locking hexagon nut M8
30805 4 Stck Scheibe 10,5x25x4 St vz DIN7349 washer 10,5x25x4 - St vz DIN7349
30944 4 Stck Stahlkugel D=36 valve ball D=36 mm
30945 4 Stck Ventilsitz KG 36 valve seat KG 36
30953 4 Stck Verschluß-Schraube 3/4'' screw plug 3/4"
31295 4 Stck Anschlußkabel connecting cable with plug
31683 2 Stck Führungsring KB guide ring KB
31710 4 Stck Ventilgehäuse KG 36 valve housing KG 36
31717 2 Stck Sauganschluß 1'' suction connection 1"
31767 0,496 m Rundschnur d=8 mm round cord d=8 mm
31773 4 Stck Induktiver Näherungsschalter inductive proximity switch
31775 2 Stck Ventilgrundplatte Druckseite KG36 valve base plate pressure side
36560 2 Stck Hydraulikzylinder 45/25-300 hydraulic cylinder 45/25-300
36699 2 Stck Plungerdeckel oben PP-60 cover plunger top PP-60
36701 6 Stck Stangendichtung T20 rod seal T20
36704 2 Stck Plungerdeckel unten kpl PP-60 plunger cover bottom complete
36705 2 Stck Plungermantel PP-60 hartverchromt plunger coat PP-60
36707 2 Stck Dichtungsträger D=60 seal support D=60
36709 2 Stck Schmierbad PP-60 lubrication bath PP-60
36713 4 Stck Spannleiste PP-60 clamp bar PP-60
36714 2 Stck Gehäuse PP-60 housing PP-60
36720 2 Stck Gehäusedeckel PP-60 housing cover PP-60
36736 1 Stck Drucksammler PP-60 pressure collector PP-60
36754 12 Stck Unterlegscheibe 10,5 washer for head screws 10,5
36755 8 Stck Unterlegscheibe 13 washer for head screws 13
36986 1 Stck Zylindergestell PP-60 cylinder frame PP-60
36988 2 Stck Flansch Kolbenstange PP-60 flange pump rod
36989 1 Stck Initiatorhalterung PP-60 initiator attachment
36990 1 Stck Frontabdeckung PP-60 covering front
36991 2 Stck Seitenabdeckung PP-60 covering beside
GERTEC
Appendix B
Wiring Diagram
- 22 -
0 1 2 3 4 5 6 7 8 9
GERTEC
Ludwig-Prandtl-Str. 1
D - 87448 Waltenhofen
Telefon: +49 8303 929509-0
description :IS-60-50-M
type :grout plant
drawing number :37014
manufacturer : Gertec
Maschinen- und Anlagenbau
work date: 20.Okt.2008 number of contents 11
2
Date 31.Jul.2008 =
grout plant Gertec Frontpage 37014
User. MOB +
Check. 20.Okt.2008 IS-60-50-M Bl. 1
Change Date Name Norm First. Created for Created by.
AT111008-225 11 Bl.
0 1 2 3 4 5 6 7 8 9
Table of contents Column X: an automaticly created page is manual changed ESSJ010E
Page Page designation Suppl. page field Date User X
1 Frontpage 31.07.2008
2 Table Of Contents 31.07.2008 X
3 Power supply M1, M2, M3, A1 31.07.2008
4 M4, M5, G1 31.07.2008
5 Pump, Mixer, Agitator 31.07.2008
6 LOGO - Inputs 31.07.2008
7 LOGO - Outputs 31.07.2008
8 LOGO - Outputs 31.07.2008
9 -X1 31.07.2008 X
10 -X2 31.07.2008 X
11 -X0.2 31.07.2008 X
1 3
Date 31.Jul.2008 =
grout plant Gertec Table Of Contents 37014
User. HGA +
Check. 20.Okt.2008 IS-60-50-M Bl. 2
AT111008-225 11 Bl.
0 1 2 3 4 5 6 7 8 9
380V AC, 50Hz L1/4.1

L2/4.1
L3/4.1
1 3 5 1 3 5 1 3 5
13 13 21 13 21
-Q1 14 -Q2 14 22 -Q3 14 22

20-25A 4.4 7-10A 1,8-2,5A
EW ?A EW ?A EW?A
2 4 6 2 4 6 2 4 6
-A1 12 14 22 24
4.4
1 3 5 1 3 5 1 3 5 1 3 5 4.5
-K1 -K2 -K3 L1 L2 L3
-Q0 11 21
8.6 5.5 5.7
2 4 6 2 4 6 2 4 6 2 4 6
Phase Monitoring Relay
PE PE PE PE
-X0.2 1 2 3 PE -X1 1 2 3 PE -X1 4 5 6 PE -X1 7 8 9 PE
4x4ý
-W2 4x2,5 400V -W2 -W3 4x1,5 400V
L1 L2 L3 N PE
-X0.1
U1 V1 W1 U1 V1 W1 U1 V1 W1
Power Supply M1 M2 M3
11,0 kW 4,0 kW 0,75 kW
PE PE PE
32A-CEE-connector
3x400V/N/PE/50Hz
Preceding fuse max. 32A
fault corrent breaker connect!!
Hydraulic Pump Mixer 4 kw Agiator 0,75kW
2 4
Date 31.Jul.2008 =
grout plant Gertec Power supply 37014
User. MOB +
Maschinen- und Anlagenbau M1, M2, M3, A1
Check. 20.Okt.2008 IS-60-50-M Bl. 3
AT111008-225 11 Bl.
0 1 2 3 4 5 6 7 8 9
3.9/L1
3.9/L2
3.9/L3
1 3 5
13 21
-Q4 14 22
2,2-3,2A
2 4 6
L+/5.0
-G1 -X2 1 -X2 2

L1 L2
-X2/2/6.3
-X2/1/6.2
400V AC
/24 DC
F2
1,6A 24 12
-A1
PE - + 3.8
21 11
1
-S0
emergency stop 2
PE1
13
-Q1
3.3
14
13 X1
-Q2 -H3 phase sequence-false

14 X2
13
-Q3
14
H-/5.0
L+/Not/5.0
-X2 14
-X2 8 -X2 15
-X2/15 /6.2
L-/5.0
3 5
Date 31.Jul.2008 =
grout plant Gertec M4, M5, G1 37014
User. MOB +
Check. 20.Okt.2008 IS-60-50-M Bl. 4
AT111008-225 11 Bl.
0 1 2 3 4 5 6 7 8 9
4.7/L+/Not L+/Not/6.0
4.6/L+ L+/6.0
-X2 3 -X2 10
-X2/3
1 1
-S2 -S4
2 2
6.4/
3 13 3 13
-K2 -K3
-S1 -S3
.5 .7
4 14 4 14
K2/6.0
1 A1 1 1 A1 1
-H1 -K2 U -H2 -K3 U

2 24V A2 2 2 24V A2 2
K-/8.0
-X2 16
-X2/16/6.3
4.7/H- H-/8.0
4.7/L- L-/6.0
1 2 3.5 1 2 3.7
3 4 3.5 3 4 3.7
5 6 3.5 5 6 3.7
13 14 .6 13 14 .8
Pump Mixer Agitator

4 6
Date 31.Jul.2008 =
grout plant Gertec Pump, Mixer, Agitator 37014
User. MOB +
Check. 20.Okt.2008 IS-60-50-M Bl. 5
AT111008-225 11 Bl.
0 1 2 3 4 5 6 7 8 9
5.9/L+/Not L+/Not/7.0
5.9/L+ L+/8.0
5.9/L- L-/7.0
-X2/4/6.5
-X2/15/4.5
-X2/16/5.2
-X2/18/7.1
-X2/1/4.6
-X2/2/4.6
-X2/3/5.1
-X2/4/6.1
-X2 6 -X2 11
1 2 1 2 1 2 1 2
-X2 4-X2 17
3 3
-B1 -B2 -B3 -B4 -S7 -S8
Piston1 Piston1 Piston2 Piston2 hand 4 hand 4
ontop down on top down up down
3 3 3 3
-X2 27 28 -X2 29 30
5.9/K2
-A3
L+ M I1 I2 I3 I4 I5 I6 I7 I8
LOGO - 24V
Inputs
5 7
Date 31.Jul.2008 =
grout plant Gertec LOGO - Inputs 37014
User. MOB +
Check. 20.Okt.2008 IS-60-50-M Bl. 6
AT111008-225 11 Bl.
0 1 2 3 4 5 6 7 8 9
-A3
LOGO - 24V
Outputs
Q1 M1 Q2 M2 Q3 M3 Q4 M4
-X2/18/6.5
A1 A2 A1 A2 A1 A2 A1 A2
-O1 -O2 -O3 -O4

Opto- Opto- Opto- Opto-
coupler coupler coupler coupler
13 14 13 14 13 14 13 14
-X2 23 24 25 26
A1 A1 A1 A1
-Y1 -Y2 -Y3 -Y4

Piston1 A2 Piston1 A2 Piston2 A2 Piston2 A2
up down up down
2x1ý 2x1ý 2x1ý 2x1ý
-X2 18 12 19 20 21 22
6.9/L+/Not L+/Not/8.0
6.9/L- L-/8.0
6 8
Date 31.Jul.2008 =
grout plant Gertec LOGO - Outputs 37014
User. MOB +
Check. 20.Okt.2008 IS-60-50-M Bl. 7
AT111008-225 11 Bl.
0 1 2 3 4 5 6 7 8 9
A3
LOGO
Expansion 4DI/4DO
(Q5) (Q6) (Q7) (Q8)

Q1 Q2 Q3 Q4
(I9) (I10) (I11) (I12) 1 2 1 2 1 2 1 2

L+ M I1 I2 I3 I4
3 1
-S5 -S6 -S9

Pump 4 Pump 2 Handbetrieb
on off li. / 0 / re.
-X2 5
X1 A1 1 X1
-H4 -K1 U -H5

X2 24V A2 2 X2
6.9/L+
7.8/L+/Not
7.8/L-
5.9/H-
5.9/K-
1 2 3.2
3 4 3.3
5 6 3.3
fault pump mode
7 9
Date 31.Jul.2008 =
grout plant Gertec LOGO - Outputs 37014
User. MOB +
Check. 20.Okt.2008 IS-60-50-M Bl. 8
AT111008-225 11 Bl.
0 1 2 3 4 5 6 7 8 9
ESSK003
3.2
3.3
3.3
3.3
3.5
3.5
3.5
3.5
3.7
3.7
3.7
3.7
Page/
path
Cable name Cable type
6
Connection
-K1
-K1
-K1
-K2
-K2
-K2
-K3
-K3
-K3
Target
design.
Strip designation
PE
PE
PE
Connection
-X1
Jumpers
1
PE
PE
PE
Terminal
number
M1 U1
M1 V1
M1 W1
M1 PE
M2 U1
M2 V1
M2 W1
M2 PE
M3 U1
M3 V1
M3 W1
M3 PE
Connection
Target
design.

1
PE
-W2
1
-W2.1
1
PE
-W3
Terminal diagram
Function text
Hydraulic Pump
Agiator 0,75kW
Mixer 4 kw
=
8 10
Date 31.Jul.2008 =
grout plant Gertec -X1 37014
User. MOB +
Check. 20.Okt.2008 IS-60-50-M Bl. 9
AT111008-225 11 Bl.
9
Terminal diagram ESSK003
Change
0
Strip designation
Date
-X2
Cable name
Cable name
Name
Norm
Date
User.
1
path
MOB
Page/
Target
number
Target
design.
Jumpers
design.
Terminal
Connection
Connection
Connection
Cable type
Cable type
Function text
Check. 20.Okt.2008
31.Jul.2008
1 -B1 1 1 + -G1 + 4.4
1 -B2 1 2 -A1 12 4.4

2
First.
1 -B3 1 3 5.1
1 -B4 1 4 -A3 L+ 6.1
IS-60-50-M
grout plant
1 A3 1 5 -S5 4 8.1
A3 L+ 6 -S7 3 6.5
8 -Q3 14 4.4
3
Mixer 10 -S2 1 1 5.5
Created for
11 -A3 I8 6.6
12 -O1 13 7.2
14 -G1 - 4.2
2 -B1 2 15 -H3 X2 4.5

4
2 -B2 2 16 5.1
Created by.
2 -B3 2 17 -A3 M 6.1
Gertec
18 -O1 A2 7.2
1 -Y1 A2 19 7.2

1 -Y2 A2 20 7.3
5
-X2
1 -Y3 A2 21 7.5
1 -Y4 A2 22 A3 M 7.6
2 -Y1 A1 23 -O1 14 7.2
2 -Y2 A1 24 -O2 14 7.3
2 -Y3 A1 25 -O3 14 7.5

6
2 -Y4 A1 26 -O4 14 7.6
3 -B1 3 27 -A3 I1 6.2
3 -B2 3 28 -A3 I2 6.3
3 -B3 3 29 -A3 I3 6.4
2 -B4 3 30 -A3 I4 6.5

7
37014
8
+
=
AT111008-225
9
Bl.
11
11
10
Bl.
0 1 2 3 4 5 6 7 8 9
ESSK003
3.1
3.1
3.1
3.1
Page/
path
6
Connection
-Q0
-Q0
-Q0
Target
design.
Strip designation
PE
Connection
-X0.2
Jumpers
1
PE
Terminal
number
L1
L2
L3
PE
Connection
-X0.1
-X0.1
-X0.1
-X0.1
Target
design.

1
PE
-W1
Terminal diagram
Function text
Power Supply
10
Date 31.Jul.2008 =
grout plant Gertec -X0.2 37014
User. MOB +
Check. 20.Okt.2008 IS-60-50-M Bl. 11
AT111008-225 11 Bl.
GERTEC Maschinen- Ersatzteilliste 37014 Steuerschrank
und Anlagenbau GmbH electrical control cabinet
Type: IS-60-50-M
Art.Nr. Menge Einheit Bezeichnung Deutsch designation component

31199 10 Stck Kabelverschraubung M12x1,5 cable gland M12x1,5
31201 2 Stck Kabelverschraubung M20x1,5 cable gland M20x1,5
31202 1 Stck Kabelverschraubung M25x1,5 cable gland M25x1,
31230 10 Stck Sechskantmutter M12x1,5 hexagon nut M12x1,5
31286 20 m Aderleitung 1,5 schwarz wire 1,5 black H07V-K
31452 1 Stck Tastmembrane touch key membrane S1
31571 4 Stck Ringzunge M6 contact stud M6
31575 4 Stck Ringzunge M8 contact stud M8
31614 20 Stck Aderendhülse 4x20 wire end ferrule 4x20;
31615 30 Stck Aderendhülse 2,5x18 wire end ferrule 2,5x18;
31752 1 Stck Schütz 3kW contactor 3KW K3
31918 1 Stck Leistungsschalter power switch 7-10 A/4kW Q2
31920 1,76 m Verdrahtungskanal wiring duct H=62/B=33
31923 1 Stck Schütz 4kW contactor K2
31928 1 Stck Überspannungsbegrenzer over-voltage limitation R2
31931 1 Stck Leistungsoptokoppler power optocoupler O1
31947 1 Stck Kontaktelement M22-CK01 contact element S0
31949 1 Stck Kontaktelement M22 contact element S1
31950 1 Stck Leuchtdrucktaste M22 light push bottom S1
Type: IS-60-50-M
31951 1 Stck Drucktaste M22 push bottom S2

31952 1 Stck Befestigungsadapter M22 fixing adapter S0
31952 1 Stck Befestigungsadapter M22 fixing adapter H3
31952 1 Stck Befestigungsadapter M22 fixing adapter H4
31954 1 Stck Tastenzusatzschildträger M22S label holder for pushbutton S1
31954 1 Stck Tastenzusatzschildträger M22S label holder for pushbutton H3
31954 1 Stck Tastenzusatzschildträger M22S label holder for pushbutton H4
31956 1 Stck Leuchtmelder M22 light indicator H3
31956 1 Stck Leuchtmelder M22 light indicator H4
31961 1 Stck LED-Element M22 LED-element S1
31961 1 Stck LED-Element M22 LED-element H4
31962 1 Stck Blindverschluß M22 blind cap
31964 1 Stck NOT-AUS-Taste pushbotton emergency stop S0
31966 35 Stck Reihenklemme 2,5 terminal block
31967 2 Stck Reihenklemme 2,5-PE terminal block
31969 9 Stck Reihenklemme 4 terminal block
31970 3 Stck Reihenklemme 4-PE terminal block 4-PE
32022 0,5 m Verdrahtungskanal H=62/B=61 wiring tunnel
32037 1,32 m Tragschiene 35x7,5 carrying rail
32040 5 m Aderleitung 2,5 wire 2,5 black H07V-K
32041 3 m Aderleitung 4,0 wire 4,0 black H07V-K
32043 30 m Aderleitung 0,75 wire 0,75 dark blue H05V-K
32047 2 m Aderleitung 4,0 wire 4,0 green/yellow H07V-K
32068 6 Stck Endhalter für Tragschiene E-UK end holder for bar E-UK
32069 3 Stck Klemmleistenmarker KLM clip ledge marker KLM
32126 1 Stck Hilfsschalter querlieg. auxiliary switch transverse Q1
Type: IS-60-50-M

32742 1 Stck LED-Element M22 LED-element H3
32971 1 Stck Schütz 11kW contactor K1
33026 1 Stck Schaltschrank 500x500x210 electrical control cabinet
33043 1 Stck Wahltaste M22 selector switch M22-WRK3 S9
33174 30 Stck Kabelbinder 100x2,5; PA-natur cable tie 100x2,5
33905 0 Stck WBS-Beschriftungskarte Legend Strip
33906 0 Stck WBS-Beschriftungskarte 1-10 Legend Strip 1-10
33934 4 Stck Abschlußplatte zu Klemme disconnecting plate type Wago
33978 1 Stck NOT-AUS Warnschild warning sign emergency stop; S0
34028 1 Stck Sockel für Steckrelais relay socket K4
34030 1 Stck Entstörmodul-LED 24 VDC recovery diode K4
34031 1 Stck Steckrelais, 1 W plug relay K4
34098 1 Stck Leistungsschalte power switch Q4
34129 15 Stck Steckbrücke 2-polig plug bridge 2 poles
34288 1 Stck Leistungsschalter 20-25 A/10kW power switch 20-25 A/10kW Q1
34538 8 Stck Abschlußplatte zu Klemme disconnecting plate
36984 1 Stck Erweiterungsmodul LOGO! module LOGO! A3
37041 1 Stck Phasenüberwachungsrelais phase monitoring relay A1
37042 1 Stck Gleichstromversorgung 400VAC electric(DC) power supply G1
37045 1 Stck Hauptschalter 3pol main switch 3-phase Q0
37046 1 Stck Leistungsschalter 1,8-2,5 power switch 1,8-2,5 A/0,75 kW Q3
37048 1 Stck Aufbaugerätestecker 32A, 5pol connector 32A, 5pol
37222 1 Stck Logikmodul LOGO 24 SIPLUS control module LOGO 24 SIPLUS A3
GERTEC
Appendix C
Instruction Manual B 1021 – Gear Motor
- 23 -
Betriebs- und Wartungsanleitung B 1021
Operating and Maintenance Instruction 08/2000
Notice de mise en service et dʼentretien DE GB FR

Flachgetriebe und NORDBLOC-Flachgetriebe
Helical Shaft Mounting Gearboxes and
NORDBLOC Helical Shaft Mounting Gearboxes
Réducteurs à arbres parallèles et
NORDBLOC Réducteurs à parallèles
Diese Sicherheitshinweise sind aufzubewahren

These safety instructions must be kept available
Ces instructions de sécurité doivent être observées
Getriebebau NORD
GmbH & Co. KG
D-22934 Bargteheide · P.O.Box 1262, D-22941 Bargteheide · Rudolf-Diesel-Straße 1
Tel. 0-45-32-/-401- 0 · Fax 0-45-32-/-401 - 253 · NORD Internet: http://www.nord.com
∆ Warnung ∆ Caution ∆ Avertissement
Es wird vorausgesetzt, daß die It is presumed that fundamental project work Il est impératif que les travaux fondamentaux
grundsätzlichen Planungsarbeiten der Anlage as well as all work with regard to transport, de l'installation, ainsi que tous les travaux de
sowie Transport, Montage, Installation, assembly, installation, starting-up, transport, montage, installation, mise en
Inbetriebnahme, Wartung und Reparaturen maintenance and repair is performed by exploitation, entretien et réparation soient
von qualifiziertem Personal ausgeführt bzw. qualified personnel or supervised by skilled accomplis par du personnel qualifié et
durch verantwortliche Fachkräfte kontrolliert labour taking overall responsibility. Make contrólés par des techniciens spécialisés
werden. Bei Arbeiten am Getriebemotor muß absolutely sure that no voltage is applied at all dans ce domaine. Avant toute intervention sur
garantiert sein, daß keinerlei Spannung while work is being done on the geared motor. le motoréducteur, il faut s'assurer que celui-ci
anliegt, und dieser gegen Wieder- Drive must also be secured against switching n'est plus sous tension et que la remise sous
einschaltung gesichert ist. on. tension soit interdite.
∆ Warnung ∆ Caution ∆ Avertissement
Veränderungen gegenüber dem Any deviation from normal operating Si en utilisation normale, des modifications de
Normalbetrieb (höhere Leistungsaufnahme, conditions (increased power consumption, fonctionnement apparaissent telles que
Temperaturen, Schwingungen, Geräusche temperature, vibrations, noise etc.) or warning puissance absorbée trop élevée, température
usw. oder Ansprechen der Überwachungs- signals by monitoring equipment suggest élevée, vibrations fortes, bruit intense etc. ou
einrichtungen) lassen vermuten, daß die malfunction. Inform the responsible en rapport avec les contrôles techniques, cela
Funktion beeinträchtigt ist. Zur Vermeidung maintenance personnel at once to prevent the laisse supposer que différentes fonctions de
von Störungen, die ihrerseits mittelbar oder trouble from getting worse and causing, l'appareil peuvent être détériorées. Pour éviter
unmittelbar schwere Personen- oder directly or indirectly, serious physical injury or ensuite des problèmes, qui pourraient
Sachschäden bewirken könnten, muß das material damage. entraîner de graves accidents corporels ou de
zuständige Wartungspersonal dann graves dégats matériels, le personnel
umgehend verständigt werden. d'entretien compétent doit immédiatement
être informé.
∆ Im Zweifelsfall die entspechenden Betriebs- ∆ In case of doubt disconnect the machine ∆ Si vous êtes dans le doute, coupez
mittel sofort abschalten! immediately! immédiatement l'alimentation
Aufstellung, Vorbereitung Preparing and performing installation Mise en place, préparation

− Transportösen am Getriebe sind für das − Lifting devices on the drive are designed to − Le matériel utilisé pour la manutention doit
Gewicht des Antriebs ausgelegt carry the drive weight tenir compte du poids de l'équipement
− Fundamente ausreichend bemessen und − the foundation (base) should be of adequate − prendre largement les dimensions des
schwingungsfrei ausführen size and vibration-proof embases et les réaliser exemptes de
− Getriebe oder -motor fest und ohne − install gear unit or geared motor rigid and vibrations
Verspannung montieren braceless − monter les réducteurs et motoréducteurs
− ausreichende Belüftung vorsehen − ensure sufficient ventilation solidement et sans haubanage
− serienmäßiges Innengewinde nach DIN 332 − make use of tapped hole (DIN 332) to suit − prévoir une aération suffisante
zum Aufziehen von Verbindungselementen fastening to the shaft end − prévoir le taraudage conforme à la norme
auf die Wellen benutzen − avoid shocks on shafts (bearing damage!) DIN 332 pour monter des accouplements
− Schläge auf die Wellen vermeiden − preferably use flexible coupling between sur les arbres d'entrée et de sortie
(Lagerbeschädigung!) output shaft and driven machine − éviter de donner des coups sur les arbres
− Maschine und Getriebe möglichst mit − fit output elements to shaft end or secure (cela pourrait détériorer le roulement!)
elastischen Kupplungen verbinden feather key before starting the motor − lier autant que possible la machine et le
− vor dem Einschalten Abtriebselemente − use torque arm with rubber buffer on shaft réducteur avec des accouplements
aufziehen bzw. Paßfeder sichern mounting gearboxes élastiques
− bei Aufsteckgetrieben mit Drehmoment- − avant la mise en service, enlever l'élément
stütze Gummipuffer verwenden d'accouplement ou/et fixer la clavette
− utiliser pour l'exécution arbre creux avec
bras de réaction une butée en caoutchouc
Elektrischer Anschluß Connection of motor Branchements électriques
− Motoranschluß nach Schaltbild vornehmen − Connect motor according to diagram − brancher le moteur selon le schéma
− Übereinstimmung von Netzspannung und − make sure that mains voltage/frequency are − s'assurer que la tension du réseau et la
Frequenz mit den Typenschild-Daten in accordance with nameplate information fréquence correspondent aux données
sicherstellen − make secure protective conductor conection inscrites sur la plaque signalétique
− Sichere Schutzleiterverbindung herstellen − if motor is running in reverse direction, − Le cable de raccordement doit être protégé
− evtl. falsche Drehrichtung korrigieren durch interchange two phases − corriger un éventuel mauvais sens de
Vertauschen von 2 Phasen − Close unused cable entrances holes and the rotation par une inversion de deux phases
− Nicht benötigte Kabeleinführungsöffnungen box itself in a dust- and watertight manner. − Les entrées de câbles non utilisées doivent
und den Kasten selbst staub- und − install protective switches to prevent être obturées, la boîte elle-même devant
wasserdicht verschließen overload and phase failure être fermée de façon à être étanche à l'eau
− Überbelastung und Phasenausfall durch − set motor protection switch to nominal et à la poussiére
Schutzschalter vorbeugen current − prévoir une protection électrique contre les
− Einstellen des Motorschutzschalters auf − wiring diagrams on the last page surcharges, court-circuit et défaut de phases
Nennstrom − régler la protection électrique suivant
− Schaltbilder auf der letzten Seite l'intensité nominale du moteur
− schéma de branchement à la derniére page
Inbetriebnahme Starting up Mise en fonctionnement

− bei längeren Lagerzeiten besondere − in case of long-time storage take special − si un stockage longue durée du réducteur
Vorkehrungen treffen (siehe Werknormblatt precautions (as provided in works standard est prévu, il faut prendre les dispositions
"Langzeitlagerung") sheet "Extended Storage") nécessaires (voir spécification "Stockage
− Lage der Ölstandschraube nach − check position of oil-level plug with help of longue durée")
Bauformtabellen des entsprechenden mounting position tables in applicable − vérifier que la vis de niveau d'huile
Kataloges feststellen catalogue corresponde à la position de montage du
− Prüfen des Ölstandes − check oil-level réducteur (voir catalogue)
− Entfernen des Verschlußstopfens vor − prior to starting-up, remove vent plug from − contrôler le niveau d'huile
Inbetriebnahme (Überdruck!), ggf. Druck- vent screw if necessary − enlever la mèche de la vis d'évent avant la
entlüftungsschraube montieren − if not specified otherwise, first oil filling as is mise en route (pour éviter une surpression)
− Normale Erstbefüllung: siehe Schmier- shown in list of lubricants ou fixer le clapet d'évent sur le réducteur
stofftabelle − air-cooled motors are designed for ambient − pour le premier remplissage voir le tableau
− Luftgekühlte Motoren sind für Umgebungs- temperautres between -20°C and +40°C and des lubrifiants
temperaturen von - 20°C bis +40°C sowie for installation at altitudes â 1.000 m above − les moteurs autoventilés sont dimensionnés
Aufstellungshöhen â 1.000 m über NN M.S.L. pour des températures ambiantes comprises
ausgelegt − Their use in hazardous areas is prohibited entre -20°C et +40°C, ainsi que pour une
− Der Einsatz im Ex-Bereich ist nicht zulässig, unless they are expressly intended for such altitude â 1000 mètres au-dessus du niveau
sofern nicht ausdrücklich hierfür vorgesehen use (follow additional instructions) de la mer
− Leur utilisation dans des atmosphères
explosives est interdite, à moins qu'elles ne
soient expressément prévues à cet effet
(respecter les indications supplémentaires)
Wartung Maintenance Entretien
MOTOR MOTOR DU MOTEUR
− Staubablagerungen entfernen (Überhitzung!) − remove dust deposit (overheating) − enlever la poussière du moteur
− Wälzlager ausbauen, reinigen und einfetten − dismount anti-friction bearings for cleaning (échauffement)
− Es ist zu beachten, daß der gesamte and refill with grease − démonter les roulements, les nettoyer et les
Freiraum um das Lager ca. 1/3 mit Fett − ensure that the bearing cage is packed to regraisser
gefüllt ist about 1/3 with grease, distribute evenly − la cage des roulements doit être remplie au
− Schmierstoffsorten siehe nächste Seite − select proper type of lubricating grease from 1/3 environ
following table − lubrifiant voir tableau ci-après
GETRIEBE GEARBOX DU REDUCTEUR
− regelmäßige Ölstandskontrolle − regular oil level check − vérifier régulièrement le niveau d'huile
− Wechseln des Schmierstoffes alle 10.000 − change lubricant every 10.000 working hours − vidanger le lubrifiant après 10.000 heures de
Betriebsstunden oder spätestens nach 2 or after two years at the latest. fonctionnement ou au plus tard après 2 ans
Jahren. − combine the lubricant change with thorough d'utilisation.
− Doppelte Fristen bei synthetischen Pro- cleaning of gear unit − profiter de la vidange pour effectuer un
dukten − lubricant changing intervals will be twice as nettoyage approfondi du réducteur
− Verkürzung der Schmierstoffwechselinter- long if synthetic products are used − pour des lubrifiants synthétiques, ce délai
valle bei extremen Betriebsbedingungen − extreme working conditions (high air peut être doublé
(hohe Luftfeuchtigkeit, aggressive Um- humidity, aggressive media and large − réduire les intervalles entre les vidanges
gebung und hohe Temperatur- temperature variations) call for reduced dans des conditions d'utilisation extrêmes
schwankungen) lubricant changing intervals (hygrométrie élevée, ambiance agressive ou
− Verbinden des Schmierstoffwechsels mit variations importantes des températures)
gründlicher Reinigung des Getriebes
Bei den Getrieben SK 0182 NB, SK 0282 NB The gearboxes SK 0182 NB, SK 0282 NB Pour le réducteurs SK 0182NB, SK 0282 NB
und SK 1382 NB mit Lebensdauer- and SK 1382 NB are supplied with lifetime- et SK 1382 NB lubrifiés à vie, ces
schmierung sind diese Arbeiten nicht lubrication. Therefore they do not require préconisations d’entretien ne sont pas
notwendig. the a.m. maintenance for gearboxes. nécessaires.
Δ Synthetische und mineralische Schmier- Δ Synthetic and mineral lubricants must not be Δ Des lubrifiants synthétiques et minéraux ne
stoffe nicht miteinander mischen! Das gilt auch mixed either for filling or for disposal! doivent pas étre mélangés! Ceci s'applique
für die Entsorgung der Schmierstoffe! également pour le retraitement des lubrifiants!
ÖLFÜLLMENGE [cm3] CAPACITY [cm3] QUANTITE DE LUBRIFIANT [cm3]

Bauform Waagerechte Anordnung
Horizontal position
Mounting Position horizontale
position
Flachgetriebe Helical Shaft Mounting Gearboxes Réducteurs à arbres paralléles
zweistufig double reduction à deux trains d‘engrenages
Positions de
montage 0182 NB 0282 NB 1282 2282 3282 4282 5282 6282 7282 8282 9282 10282 11282*
H1 400 700 900 1.650 3.150 4.700 7.500 17.000 25.000 37.000 74.000 90.000 165.000
H2 600 800 900 1.900 3.250 4.750 7.500 12.000 20.000 30.000 55.000 40.000 145.000
H3 500 900 950 1.800 3.150 4.700 7.200 14.000 21.000 31.000 59.000 82.000 140.000
H4 500 900 950 1.800 3.150 4.700 7.200 10.000 16.000 31.000 69.000 60.000 100.000
Bauform Senkrechte Anordnung
Vertical position
Mounting Position verticale
position Flachgetriebe Helical Shaft Mounting Gearboxes Réducteurs à arbres paralléles
zweistufig double reduction à deux trains d‘engrenages
Positions de
0182 NB 0282 NB 1282 2282 3282 4282 5282 6282 7282 8282 9282 10282 11282*
montage
H5 550 1.100 1.200 2.000 4.100 5.400 8.800 17.500 27.000 41.000 72.000 90.000 195.000
H6 550 1.000 1.300 2.400 4.100 6.100 8.800 14.000 21.000 33.000 70.000 90.000 160.000
Bauform Waagerechte Anordnung
Horizontal position
Mounting Position horizontale
dreistufig triple reduction à trois trains d‘engrenages
Positions de
1382 NB 2382 3382 4382 5382 6382 7382 8382 9382 10382 11382* 12382*
montage
H1 1.300 1.700 4.100 5.900 12.500 16.500 22.000 34.000 73.000 85.000 160.000 160.000
H2 1.400 1.900 3.300 4.900 6.700 9.600 16.000 25.000 45.000 73.000 140.000 140.000
H3 1.900 1.500 3.300 4.900 8.300 12.500 19.000 30.000 60.000 80.000 135.000 135.000
H4 2.000 1.500 3.300 4.900 8.300 14.000 23.000 35.000 65.000 80.000 155.000 155.000
Bauform Senkrechte Anordnung
Vertical position
Mounting Position verticale
dreistufig triple reduction à trois trains d‘engrenages
Positions de
1382 NB 2382 3382 4382 5382 6382 7382 8382 9382 10382 11382* 12382*
montage
H5 2.100 3.100 5.600 8.300 14.000 18.000 25.000 38.000 74.000 80.000 210.000 210.000
H6 2.300 2.600 4.100 6.800 12.000 13.000 20.000 32.000 70.000 80.000 155.000 155.000
* Die Getriebetypen SK 11282, SK 11382 und SK 12382 werden im Normalfall ohne Öl geliefert.
* Types SK 11282, SK 11382 and SK 12382 are supplied without lubricant as a standard.
* Les réducteurs SK 11282, SK 11382 et SK 12382 sont livrés sant huile.
Die Normalbefüllung der Getriebe ist Mineralöl. Synthetisches Öl ist gegen Mehrpreis lieferbar.
Standard lubricant for the gearboxes is mineral-oil. Synthetic oil is available at a surcharge.
Les réducteurs sont remplis d’huile minérale. Ils peuvent être remplis d’huile synthétique contre supplément de prix.
HINWEIS / REMARK / REMARQUE:

Ölfüllmengen sind ca.Angaben. Ölniveau anhand der Ölkontrollschrauben prüfen.
Filling quantities are approx. figures. Oil level must be checked according to oil-level plugs.
Les quantités d’huile sont données à titre indicatif. Vérifier la quantité d’huile grâce à la vis de niveau d’huile.
Hinweis: Note: Indication:
Diese Tabelle stellt vergleichbare Schmierstoffe unter- This table lists compatible lubricants of different suppliers. Ce tableau présente les lubrifiants comparables des
schiedlicher Hersteller dar. Innerhalb einer Viskosität und Within the same viscosity class and type of lubricant the différents fabricants. Si l'on respecte les critères de viscosité
Schmierstoffsorte kann der Ölhersteller gewechselt werden. supplier can be chosen freely. In case you change the et le type de lubrifiant, on peut uiliser n'importe quelle marque
Beim Wechsel der Viskosität bzw. der Schmierstoffsorte muß viscosity class resp. the type of lubricant you should contact d'huile après ne vidange. Afin de pouvoir garantir un bon
Rücksprache mit uns gehalten werden, da sonst keine us in advance as otherwise we cannot assure the proper fonctionnement de nos réducteurs, veuillez nous consulter
Gewährleistung für die Funktionstüchtigkeit unserer Getriebe function of our drive and the warranty becomes void. avant de remplacer un lubrifiant par un autre possédant des
übernommen werden kann. caractéristiques différentes de viscosité et de type.
Schmierstoffarten / Type of lubricant / Type de lubrifiant

Schmierstoffart Umgebungstemp.
Type of Ambient temp.
lubricant Temp. ambiante
Type de
lubrifiant
Mineralöl Schneckengetriebe Degol BG 680 -- Alpha SP 680 Spartan Renolin Klüberoil Mobilgear: Shell
Mineral oil 0 ... 40°C Degol BG 680 EP 680 CLP 680 GEM 1-680N - 636 Omala 680
Huile minérale ISO VG 680 plus CLP 680 Plus - XMP 680
Degol Energol Alpha SP 220 Spartan Renolin CLP 220 Klüberoil Mobilgear Shell
ISO VG 220 BG 220 GR-XP Alpha MW220 EP 220 Renolin CLP 220 GEM 1-220N 630 Omala 220
- 5 ... 40°C (normal) BG 220 plus 220 Alpha MAX 220 Plus Mobilgear
XMP 220
ISO VG 100 Degol Energol Alpha SP 100 Spartan Renolin CLP 100 Klüberoil Mobilgear: Shell
- 15 ... 25°C BG 100 GR-XP Alpha MW 100 EP 100 Renolin CLP 100 GEM 1-100N - 627 Omala 100
BG 100 plus 100 Alpha MAX 100 Plus - XMP 110
ISO VG 15 Vitamol Bartran Hyspin AWS 15 Univis J13 Renolin B 15 HVI ISOFLEX MT Mobil DTE Shell Tellus
- 45 ... - 15°C * 1010 HV 15 Hyspin SP 15 30 ROT 11 M T 15
Hyspin ZZ 15
Synthetisches Öl Schneckengetriebe Degol Energol -- -- Renolin PG 680 Klübersynth Glygoyle Shell Tivela
Synthetic oil -5 ... 60°C GS 680 SG-XP 680 GH 6-680 HE 680 S 680
Huile synthétique ISO VG 680
ISO VG 220 Degol Enersyn Alphasyn Glycolube Renolin PG 220 Klübersynth Glygoyle Shell
-25 ... 80°C * GS 220 SG-XP 220 PG 220 220 GH 6-220 HE 220 Tivela S 220
Biologisch Schneckengetriebe -- -- -- -- Plantogear 680 S -- --

abbaubares Öl ISO VG 680
Biodegradable oil -5 ... 40°C
Huiles ISO VG 220 Degol Biogear Carelub -- Plantogear 220 S Klübersynth -- Shell Omala
biodégradables -5 ... 40°C BAB 220 SE 220 GES 220 GEM 2-220 EPB220
Lebensmittel- Schneckengetriebe -- -- -- -- Geralyn Klüberoil Mobil Shell Cassida
1)
verträgliches Öl -5 ... 40°C SF 680 4 UH1-680N DTE-FM Fluid GL680
1)
Food-grad oil ISO VG 680 Klübersynth 680 Shell Cassida
Huiles pour UH1 6-680 Fluid WG680
environnement Eural -- Vitalube Gear Oil Geralyn Klüberoil Mobil DTE Shell Cassida
1)
alimentaire ISO VG 220 Gear 220 GS 220 FM 220 AW 220 4 UH1-220N FM 220 Fluid GL220
-25 ... 40°C Shell Cassida
Geralyn Klübersynth Fluid WG220
SF 220 UH1 6-220
Synth. Fließfett Aralub -- Alpha Gel 00 Fließfett Renolit Klübersynth Glygoyle Tivela GL 00
Synth. fluid - 25 ... 60°C BAB EP0 S 420 LST 00 GE 46-1200 Grease 00
grease Klübersynth
Graisse fluide UH1 14-
1)
synthétique 1600
Schmierstoffarten für Wälzlager / Type of lubricant for anti friction bearings / Type de librifiant pour roulements à rouleaux
Schmierstoffart Umgebungstemp.
Type of Ambient temp.
lubricant Temp. ambiante
Type de
lubrifiant
Fett Aralub Energrease Spheerol AP Mehr- Renolit FWA 160 Klüberplex Mobilux 2
(Mineralölbasis) - 30 ... 60°C HL 2 LS 2 2 LZV-EP zweckfett BEM 41-132
Grease (mineral (normal) Beacon2
oil basis) Aralub -- Spheerol -- Renolit JP 1619 -- -- Shell Alvania
Graisse (base * - 50 ... 40°C SEL 2 EPL2 RL 2
huile minérale)
Synthetisches Aralub -- Product Beacon Renolit S 2 ISOFLEX Mobiltemp Aero Shell
Fett * - 25 ... 80°C SKL 2 783/46 325 Renolit HLT 2 TOPAS SHC 32 Grease
Synthetic grease NCA 52 16 oder 7
Graisse
synthétique PETAMO
GHY 133 N
Biologisch Aralub BP Bio- Biotec -- Plantogel 2 S Klüberbio Schmierfett Shell
abbaubares Fett - 25 ... 40°C BAB EP 2 grease EP 2 M 72-82 UE 100 B Alvania
Biodegradable RLB 2
Grease
Graisse
biodégradables
Lebensmittelver- Eural BP Vitalube HT Carum Renolit Klübersynth Mobil- Shell Cassida
1)
trägliches Fett - 25 ... 40°C Grease EP 2 Energrease Grease 2 330 G 7 FG 1 UH1 14-151 grease RLS 2
Food-grade FM 2 FM 102
1)
grease
Graisse pour
environnement
1)
alimentaire
* Bei Umgebungstemperaturen unterhalb -30°C und oberhalb 60°C sind Wellendichtringe in besonderer Werkstoffqualität einzusetzen
* With ambient temperatures below -30°C and above approx. 60°C shaft sealing rings of a special material quality must be used
* Lors d’une température ambiante inférieure à -30°C ou supérieure à environ 60°C, il y a lieu d’utiliser des joints d’étanchéité spéciaux
1)
Lebensmittelverträgliche Öle + Fette nach Vorschrift H1 / FDA 178.3570
1)
Food grade lubricants with USDA-H1 approval FDA 178.3570
1)
Huiles pour environnement alimentaire + graisses suivant prescription H1 / FDA 178.3570
Hohlwelle mit Schrumpfscheibe - Montage - Demontage und Wartungshinweise
Hollow shaft with shrink-discs - Assembly - Dismantling suggestions and maintenance
Exécution des arbres creux avec frette de serrage - Montage - Démontage et entretien
Schrumpfscheibentyp, Sach-Nr. und Drehmomentangabe für Spannschrauben Spannflansche
Shrink-disc type, part-no. and torque of locking screws Locking hub Vollwelle der Maschine
Indication du type de frette et du couple de serrage et no. ident. disques de serrage Customers solid shaft
arbre plein machine
Wellenschaft und Hohlwellenbohrung

Spannschrauben DIN 931 (933) -10.9 Solid shaft and bore of hollow shaft
Locking screws DIN 931 (933) -10.9 arbre et alésage arbre creux
Vis de serrage DIN 931 (933) -10.9
FETTFREI
GREASE-FREE
SANS GRAISSE
Die Schrumpfscheiben werden vom Hersteller einbaufertig
geliefert. Sie sollen vor der Montage nicht mehr auseinander-
genommen werden. Hohlwelle des Getriebes
Hollow-shaft (Gearbox)
Shrink-discs are supplied ready for installation and should not be arbre creux du réducteur
taken apart before mounting.
Les frettes de serrage sont livrées prêtes à monter par le

fabricant et ne doivent donc pas être démontées avant le
montage. Zweimal halbgeschlitzter Innenring
Dual half-split Inner ring
deux bagues intérieures fendues
Montageablauf: Installation instructions: Procédure de Montage:

1. Entfernen der Transportsicherung zwischen den 1. Remove transportation spacers (if provided) located 1. Les éventuelles protections de transport placées entre
Flanschen, falls vorhanden. between outer collars. les surfaces de serrage doivent être retirées.
2. Anziehen der Spannschrauben (leicht von Hand) bis 2. Lightly handtighten locking screws to eliminate play 2. Les vis de serrage doivent être légèrement serrées à
das Spiel zwischen den Flanschen und dem Innenring between outer collars and inner ring. You should still la main, jusqu'à ce qu'il n'y ait plus de jeu entre les
beseitigt ist. Der Innenring muß noch leicht drehbar be able to easily turn inner ring. surfaces de serrage. L'anneau intérieur doit toutefois
sein. 3. Lightly lubricate the bore of the shrink-disc to facilitate pouvoir encore être tourné aisément.
3. Einfetten der Bohrung des Innenringes, dadurch easy mounting onto hollow-shaft of reducer. 3. L'alésage (D1) de la bague intérieure de la frette doit
leichte Montage der Schrumpfscheibe auf die 4. Fit shrink-disc onto hollow-shaft and mount hollow- être légèrement graissé. De la sorte, le montage de la
Getriebehohlwelle. shaft reducer onto solid shaft. frette sur l'arbre creux est facilité.
4. Aufsetzen der Getriebehohlwelle auf die 4. Positionner l'arbre creux réducteur sur l'arbre
Maschinenwelle. machine.
Maschinenwellenschaft und Hohlwellenbohrung Hollow- and solid shaft must be clean and L'arbre machine et l'arbre creux doivent absolument
müssen im Bereich der Schrumpfverbindung free from any lubricant. être e x e m p t - de - g r a i s s e - au niveau de la
a b s o l u t f e t t f r e i sein. Exception: Grease solid shaft at end where it will liaison par frette.
Die Maschinenwelle vor der Montage im Bereich, make contact with bronze bushing of the hollow- Préalablement au montage, l'arbre machine doit être
welche später Kontakt mit der Bronzebuchse der shaft when it is mounted. N e v e r g r e a s e the graissé à l'endroit du position-nement prévu de la
Hohlwelle hat, einfetten. Die Bronzebuchse nicht front of the solid shaft which makes contact under bague bronze de l'arbre creux. N e p a s g r a i s s
einfetten, um bei der Montage eine Befettung des the shrink-disc. Tighten locking screws only after e r la bague bronze, pour éviter un graissage du
Schrumpfsitzes zu vermeiden. mounting the hollowshaft onto the solid shaft. siège de la frette lors du montage.
5. Durch leichtes Anziehen der Spannschrauben 5. Now tighten locking screws only lightly to position 5. Serrer légèrement les vis de serrage de la frette, afin
positionieren sich die Spannflansche automatisch. outer collars. que les surfaces de serrage se positionnent
6. Festziehen der Spannschrauben der Reihe nach im 6. Use torque wrench and equally tighten all screws one automatiquement.
Uhrzeigersinn über mehrere Umläufe - nicht after another (never cross wise) in a clockwise or 6. Serrer les vis dans le sens des aiguilles d'une montre
überkreuz - 1/4 bis 1/2 Schraubenumdrehung pro counter clockwise sequence by approximately 1/4 to les unes après les autres, en plusieurs fois, en faisant
Umlauf.Die Spannschrauben mit einem Drehmoment- 1/2 turn until specified tightening torque (per table) is à chague fois d' 1/4 à 1/2 tour de vis. Ne pas serrer en
schlüssel bis zu dem auf der Schrumpfscheibe oder in reached. diagonale! Utiliser une clef dynamométrique pour le
der Maßtabelle angegebenen Anzugsdrehmoment serrage. Les couples de serrage sont indiqués sur les
anziehen. frettes, ou doivent être relevés sur les plans.
Demontageablauf: Removal: Procédure de démontage:

1. Spannschrauben der Reihe nach über mehrere 1. Loosen locking screws in sequence in several steps 1. Les vis de serrage doivent être desserrées dans
Umläufe lösen, pro Umlauf ca. 1/4 Umdrehung. by using approximately 1/4 turns. Danger - Do not l’ordre, les unes après les autres, en plusieures fois,
Spannschrauben nicht aus ihrem Gewinde entfernen - remove locking screws completely. avec environ 1/4 de tour par vis à chaque fois. Ne pas
Unfallgefahr!! 2. Loosen the outer collars from the double tapered inner sortir les vis du filetage. Risque d’accident!!
2. Die Spannflansche sind vom Konus des Innenringes ring. 2. Le plan de serrage doit être écarté du cône de la
zu lösen. 3. Remove hollow-shaft reducer from solid shaft. bague intérieure.
3. Abnehmen des Getriebes von der Maschinen- 3. Retirer le réducteur de l’arbre machine.
vollwelle.
Wartung der Schrumpfscheiben: Maintenance: Entretien des frettes de serrage:

Eine montierte Schrumpfscheibe ist wartungsfrei. War An installed shrink-disc is maintenance free. Before Une frette de serrage montée ne nécessite aucun
eine Schrumpfscheibe längere Zeit im Einsatz und reinstalling (after prolonged use) it should be taken apart entretien. Si une frette utilisée depuis un certain temps
wurde demontiert, dann ist sie vor der erneuten Montage and thorougly cleaned. Relubricate the taper of the outer est demontée, un nettoyage préalable à toute nouvelle
zu zerlegen und zu reinigen. Nach der Reinigung sind collars and of the inner ring with Molycote G-Rapid plus utilisation est nécessaire. Après nettoyage, les surfaces
die Kegelflächen (Konus) der Spannflansche und des or equivalent. Regrease screw threads and head contact coniques de serrage et la bague intérieure doivent être
Innenringes mit Molykote G-Rapid Plus oder area with mulitpurpose grease. enduites de Molykote G-Rapid Plus ou d’un type de
vergleichbarem Schmierstoff einzustreichen. Die graisse analogue. Les filetages et têtes de vis doivent
Schrauben sind im Gewinde und Kopfauflage mit être graissés normalement.
normalem Fett zu behandeln.
BAUFORMEN
MONTING POSITIONS
POSITIONS DE MONTAGE
Waagerechte Anordnung Horizontal position Position horizontale
SK 1282 - SK 11282 SK 1382 - SK 5382 SK 6282 - SK 11282 SK 1382 - SK 5382
SK 6382 - SK 11382 SK 6382 - SK 11382
SK 0282 NB SK 1282 - SK 5282

SK 1382 NB SK 0282 NB + SK 1382NB
H1 H2 H3 H4
Senkrechte Anordnung Vertical Position Position verticale

SK 1282 - SK 11282 SK 1382 - SK 5382 SK 1282 - SK 11282 SK 1382 - SK 5382
SK 6382 - SK 11382 SK 6382 - SK 11382
SK 0282 NB
SK 0282 NB
SK 1382 NB
SK 1382 NB
H5 * H6
Symbole: Entlütfung Ölstand Ölablaß Gummipuffer

Symbols: Vent plug Oil level Drain plug Rubber buffer
Symboles: Event Niveau d’huile Vidange Butées caoutchouc
* Bauform H5 mit Ölausgleichsbehälter (siehe Katalog G1000)
* Mounting position H5 with lubricant expansion unit (see catalogue G1000)
* Position de montage H5 avec réservoiur de compensation de niveau d’huile (voir catalogue G1000)
Die Getriebe SK 0182, SK 0282 NB und SK 1382 NB sind mit mineralischen Ölen befüllt. Es gibt keine Entlüftungs- oder Ölablaßschrauben.
Die Getriebe SK 1282 – SK 12382 sind ebenfalls mit Mineralöl befüllt. Diese Getriebe haben Entlüftungs-, Ölstand- und Ölablaßschrauben. (siehe Bauformen)
The Gear Units SK 0182, SK 0282 NB and SK 1382 NB are lubricated with mineral-oil. There are no vent or drain plug.
The standard-lubrication for sizes SK 1282 – SK 12382 is also mineral-oil. There are vent and drain plugs (see mounting positions).
Les réducteurs SK 0182, SK 0282 NB sont remplis d’huile minérale. Il n’y a aucune vis ni clapet d’évent.
Les réducteurs SK 1282 – SK 12382 sont remplis d’huile minérale (voir positions de montage).
Schaltbilder / Wiring diagrams / Schémas de branchement

Drehstrom-Motor mit Kurzschlußanker
Three phase squirrel-cage motor
Moteur triphasé à cage d’écureull
I) Klemmbrett
Terminal board
Plaque à bornes
II) Schalter
Switch
Démarreur
Drehstrom-Motor mit Kurzschlußanker, in Dahlander-Schaltung Drehstrom-Motor, polumschaltbar, zwei getrennte Wicklungen

Three phase squirrel-cage motor, Dahlander connection Three phase motor, polechanging, two separate windings, two speeds
Moteur triphasé à cage d’écrureull, couplage Dahlander Moteur triphasé à commutation de pôles, deux bobinages séparés,
deux vitesses
niedrige - Drehzahl - hohe niedrige - Drehzahl - hohe

low - speed - high low - speed - high
inférieure - vitesse - supérieure inférieure - vitesse - supérieure
www.nord.com
Mat.-Nr. 605 09 99 / 0108

GERTEC
Appendix D
Declaration of Conformity
- 24 -
EC Conformity Declaration GERTEC
in accordance with EC Machinery Directive 89/392/EEC Maschinen- und Anlagenbau GmbH
Hereby we,
GERTEC Maschinen- und Anlagenbau GmbH, Ludwig-Prandtl-Str.1, 87448 Waltenhofen, Germany
declare that the product described hereafter
Description : grout plant
Type: IS-60-50-M
Serial Number: 36974
Year of manufacture: 2008
has been designed and manufactured in compliance with the provisions of EC Machinery Directive
89/392 EEC. In particular, the following harmonised standards have been applied:
DIN EN 292 Safety of Machinery – Basic Concepts
DIN EN 294 Safety of Machinery – Safety Distances
DIN EN 60204 Safety of Machinery – Electrical Equipment of Machines
DIN EN 12151 Machinery and plant for the preparation of concrete and mortar –
Safety requirements
DIN EN 982 Safety of machinery – Safety requirements for fluid power systems and their
components – Hydraulics.
We point out that in case the machine described above is intended to be incorporated into or
combined with other machines / machine parts, it must not be put into service until the machinery
into which the machine described above is to be incorporated has been declared to be in conformity
with the requirements of Council Directive 89/392/EEC.
Place and Date of Issue: Signature GERTEC:
87448 Waltenhofen, Germany

april 28.07.2008
Managing Directors: Commercial Register No. VAT ID No. Sparkasse Allgaeu

Holger Gawryck Kempten HRB 7982 DE223180848 Bank Code 733 500 00
Reinhold Eggel Account 610134819

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GERTEC

Maschinen- und Anlagenbau GmbH

Grout Plant IS-60-50-M

Serial - No: 36974

1.Basic Safety Instructions

2.Description of the Grout Plant

Mixing capacity: (at 20 batches/h) 3.0 m³/h

2.4.View of the Grout Plant

2.5.View of the Plunger Pump

Lubrication Pot for Plunger

-With a crane at the central lifting eye,

-Use only the provided attachment points

4.Operator Controls and Indicators

4.1.Operator Controls on the Batch Mixer

(1) Water Intake Valve

4.2.Operator Controls and Indicators on the Hydraulic Power Unit

Grout Pressure Hydraulic Pressure

Oil Filter Contamination Indicator

Oil Level Gauge

1) Pump Flow Rate Adjustment

4.3.Operator Controls and Indicators on the Control Cabinet

1) MIXER ON illuminated pushbutton

10) PLUNGER DOWN pushbutton

5.2.Connecting the Station

(1) Water supply connection Storz C coupling

(3) Power Supply Feed CEE Standard Inlet Plug; 32 A; 5-pole;

2)Make the 3/4" female thread plunger pump discharge connection.

-Be sure to use only suitable hose and coupling material.

-Before making the mains power connection, all mechanical protective

5.3.Testing the Functioning of the Safety Switch

-Set the main switch to ON

If the EMERGENCY STOP pushbutton is not functioning properly:

1) Control cabinet: Operator controls not active.

2) WRONG PHASE SEQUENCE indicator light is on

3) GENERAL TROUBLE indicator light is on

-The control cabinet may be opened only by a qualified electrician.

4) The plunger pump stops during pump operation.

Trouble: The plunger pump stops running while it is switched on.

5) The plunger pump has intermittent discontinuities.

Trouble: Not every stroke causes pumping action

7.Ending Operation / Shutting Down

1) Empty and Clean the Batch Mixer

2) Empty and Clean the Agitation Tank

- Uncouple the pump suction line from agitation tank

3) Flush the Pump

4) Set the main switch to OFF.

7.3.Ending Operation when there is Freeze Danger

- Proceed as described in section 7.2 Ending Operation.

8.Maintenance and Repair

The following applies to all maintenance and repair work:

8.2. View of the Maintenance Points

Filler neck for

Oil filter contamination

Oil level gauge

8.3.Scheduled Maintenance, Maintenance Work

1) Check the entire plant for defects or damage.

-Due date: see decal on name/rating plate.

Waltenhofen, 30 June 2008

Spare Parts List

Art.Nr. Menge Einheit Bezeichnung Deutsch designation

36851 1 Stck Mörtelkupplung MT; 1 1/4'' coupling MT; 1 1/4" IG

Art.Nr. Menge Einheit Bezeichnung Deutsch designation

30069 8 Stck Scheibe A10,5 washer A10,5 - St vz DIN125