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TABLE OF CONTENTS
IDENTIFYING YOUR NEW MASABA MAGNUM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
POSITIONING YOUR MAGNUM FOR ROAD TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . 23
ADJUSTING CONVEYOR HEIGHT (MANUAL MODE) . . . . . . . . . . . . . . . . . . . . . . . . . 36
APPENDIX A. . . . . . . . . . . . . . . . . . . . . . . . . . . .Fenner Dunlop Belt Storage and Installation
APPENDIX B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flexco Bolt Solid Plate Belt Splice
APPENDIX C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fenner Dunlop Belt Tracking
APPENDIX D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fenner Dunlop Belt Maintenance
APPENDIX E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fenner Dunlop Troubleshooting
APPENDIX F . . . . . . . . . . . . . . Dodge Torque-Arm Shaft Mount Speed Reducer Lubrication
TABLE OF CONTENTS
APPENDIX G. . . . . . .Dodge Installation and Parts Replacement Manual for Speed Reducers
APPENDIX H. . . . . . . Dodge Instruction Manual for Torque-Arm Speed Reducer Backstops
APPENDIX I . . . . . . . . . . . . . . . . . . . . Dodge Instruction Manual for Mounted Ball Bearings
APPENDIX J . . . . . . . . . . . . . . . . . . . . . . . . . Dodge Instruction Manual for Type E Bearings
APPENDIX K. . . . . . . . . . . .Dodge Instruction Manual for S-2000 Spherical Roller Bearings
APPENDIX L . . . . . . . . . . Rexnord Instructions for 2000, 5000, 9000 Series Roller Bearings
APPENDIX M . . . . . . . . . . . . . . . . . . . . . .WEG Electric Motor Installation and Maintenance
APPENDIX N. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASABA Hydraulic System Service
APPENDIX O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASABA Hydraulic System Schematic
APPENDIX P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Allied Oil and Supply Material Safety
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MASABA, INC. (d/b/a MASABA Mining Equipment)
TERMS AND CONDITIONS
OFFER & ACCEPTANCE: MASABA, Inc. (“Seller”) acceptance of Buyer’s order to purchase products is expressly made conditional on assent to these
Terms and Conditions, which along with the Sales Order constitute a binding “Contract” between the parties. This Contract constitutes the complete and final agreement between Seller and Buyer for the products. Any additional or different terms or conditions contained in any document furnished by Buyer, including but not limited to, any purchase order or any acknowledgement, are deemed to be material and are herby objected to and rejected by Seller. If such agreement shall be deemed an offer or counter-offer by Buyer, Seller expressly rejects such offer or counter-offer and limits acceptance to these Contract terms and expressly objects to any different or additional terms proposed by Buyer. Any actually performance by Buyer or Seller thereafter shall be deemed a renewal of the offer contained in this Contract and acceptance of this Contract without change. In the event of a conflict between the terms of this Contract and the terms of any other document, the terms of this Contract shall control. This offer to purchase Seller’s products is valid for thirty (30) days form the date of the Sales Order.
PAYMENT TERMS: All prices specified in this Contract are FOB Seller’s designated location which constitutes delivery. All risk of damage to or loss of the products from any cause whatsoever shall pass to Buyer upon delivery, even if Seller arranges for shipment of the product. Unless otherwise expressly provide on the reverse hereof, payment shall be made within thirty (30) days form the earlier of the date of delivery or the date of an invoice, without discount. Any discount which may be expressly provide on the reverse hereof applies to the sale price of the products at the shipping point, and does not apply to any charges made for taxes, storage, loading or transportation. All payments shall be made in United States dollars. Interest will be charged at the rate of eighteen percent (18 %) per annum, or the maximum interest rate allowable by applicable law, whichever is lower, on all unpaid invoices. Buyer shall pay all taxes and charges of any nature imposed by any federal, state, or local governmental authority by reason of the sale or delivery of the products whether levied or assessed against Seller, Buyer, or the products. Such applicable taxes or charges, if not included in this Contract, shall be invoiced separately. If, in Seller’s opinion, reasonable doubt exists as to
Buyer’s financial condition, Seller may, at any time and without prejudice to any other remedies, suspend or terminate performance of any order, decline to ship, stop any material in transit, or require full or partial payment by Seller in advance.
DELIVERY: Any delivery of promise date indicated on the Sales Order is an estimate of the date Seller believes the products will be available for delivery, provided, however, Seller shall not be responsible for any delays in delivery.
WARRANTY:
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Limited Warranty; Exclusion of Third Party Components: Subject to the terms, conditions and limitations contained herein, Seller warrants only to the original Buyer that (a) Seller’s new equipment products and Seller’s new component products will not fail to operate in accordance with their respective specifications due to the defects in material or workmanship during the period which ends two (2) years form the date of delivery, normal wear and tear excluded, and (b)
Seller’s new equipment products will not incur a failure of their respective structural components (i.e. , trusses) due to defects in material or workmanship at any time during the period which ends five (5) years form the date of delivery, normal wear and tear excluded. The foregoing periods are sometimes referred to as
“original warranty periods.” THE FOREGOING LIMITED WARRANTY DOES NOT APPLY TO ANY PART, PORTION OR COMPONENT OF ANY
PRODUCT WHICH IS MANUFACTURED BY A THIRD PARTY (“Third -Party Component”).
DISCLAIMER OF ALL OTHER WARRANTIES, EXPRESS, IMPLIED OR STATUTORY: THE LIMITED WARRANTY SET FORTH IN THE FORE-
GOING PARAGRAPH IS THE SOLE AND EXCLUSIVE WARRANTY. WITH RESPECT TO THE PRODUCTS, SELLER MAKES NO OTHER EXPRESS
WARRANTY OF ANY KIND OR NATURE AS TO THE PRODUCTS OR THEIR PERFORMANCE EXCEPT FOR THOSE LIMITED WARRANTIES
EXPRESSLY SET FORTH IN THE FOREGOING PARAGRAPH AND SPECIFICALLY DISCLAIMS ANY AND ALL REPRESENTATIONS OR WAR-
RANTIES OF ANY KIND OR NATURE CONCERING THE PRODUCTS, INCLUDING, BUT NOT LIMITED TO, ANY REPRESTATIONS OR WAR-
RANTY THAT THE PRODUCTS COMPLY WITH ANY LAW, RULE OR REGULATION. SELLER MAKES NO WARRANTIES WITH RESPECT TO
ANY THIRD PARTY COMPONENT AND SELLER SPECIFICALLY SELLS SUCH THIRD-PARTY COMPONENTS “AS IS” WITHOUT ANY WAR-
RANTY. FURTHER, SELLER MAKES NO IMPLIED WARRANTY OF ANY KIND OR NATURE WITH RESPCT TO ITS PRODUCTS OR ANY
THIRD-PARTY COMPONENTS AND SPECIFICALLY DISCLAIMS ANY AND ALL IMPLIED WARRANTIES, INCLUDING, BUT NOT LIM-
ITED TO, ANY AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, NON-INFRINGE-
MENT, OR COMPLIANCE WITH ANY FEDERAL, STATE OR LOCAL LAW, RULE OR REGULATION. IN ADDITION, SELLER EXPRESSLEY
DISCLAIMS TO THE FULLEST ALLOWED BY LAW, RULE OR REGULATION ANY WARRANTY PROVIDED UNDER ANY FEDERAL, STATE OR
LOCAL LAW, RULE OR REGULATION.
Terms and Conditions of Warranty; Voiding of Warranty; Notice Requirements: The limited warranties set forth above shall be null and void if (a) any alternations or modifications are made to a product, (b) a product is not maintained in strict compliance with the maintenance requirements set forth in the maintenance manual for such product or otherwise provided to Buyer of such product, (c) any repairs are made to a product which are not authorized by Seller in writing, (d) any failure of a product to comply with the above limited warranty is not reported to Seller in writing within thirty (30) days of the date such failure first occurs, (e) a product is operated after the failure covered by warranty first occurs, (f) a product is used for any purpose other than for the purpose for which it was manufactured, (g) a product is not operated in strict compliance with the terms and conditions set forth in any operating manual for the product (including, but not limited to exceeding the load bearing capacity of the product), (h) a product is abused or damaged, (i) Buyer fails to deliver the product to Seller for inspection and testing if requested by Seller or Buyer disposes of the product or any part of component on or before the sixtieth (60 th
) day after sending a written claim to
Seller, or (j) such failure of the limited warranty results from a failure of any Third-Party Component.
Course of Dealing; Course of Performance; Usage of Trade: No course of dealing or course of performance of Seller with respect to the products sold under this Contract or with respect to any of its products to whomever sold and no usage of trade shall be considered in interpreting this Contract or any part thereof and none of the foregoing shall be considered a waiver or modification of any such terms, conditions, disclaimers, or limitation of the limited warranties or disclaimers contained in this Contract. No statement, whether written or oral, made by any employee, sales person, distributor, agent or contractor of Seller which is not set forth in this Contract shall be considered a representation or warranty with respect to any product, its specifications or its performance sand all such statements are hereby disclaimed.
Exclusive Remedies for Breach of Warranty: The sole and exclusive remedy for any failure of any product to comply with the limited warranty set forth above or any other warranty imposed upon Seller by law, if any, shall, at the election of Seller, in its sole discretion, be either (a) the repair or replacement of the product or component which failed to comply with such warranty or (b) the refund of the purchase price of the product. Buyer is responsible for all labor costs in connection with the repair or replacement of any equipment or component product; however, Seller will be responsible for its own labor performed in connection with any repair of equipment products at Seller’s location. Except as provideD below, any repair or replacement shall carry the same warranty as the original product but only for the remainder of the original warranty period. Buyer’s exclusive remedy with respect to any claim arising out of or as a result of Third-Party Component shall be against the third-party manufacturer.
Warranty Claims; Notice Requirement; Limited Time to ring Claims: Any and all claims under the above limited warranty shall be made to Seller only in writing and not later than thirty (30) days after the date the product first fails to comply with the above limited warranty but in no event later than the expiration of the original warranty period with respect to which the claim is being made. Any claim under the above limited warranty made after such period for making a claim shall be null and void. After receipt of written notice of the warranty claim, Seller shall determine whether to (a) repair or replace the product or part or (b)
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refund the purchase price of the product. Seller may require Buyer to return any product or part thereof which Buyer claims to be defective to Seller at Buyer’s cost for inspection as a condition to any claim under the above limited warranty. No product or part may be returned to Seller without Seller’s prior written authorization. If a product which is returned is determined by Seller in its sole discretion not to have failed to comply with the limited warranty, Buyer shall pay costs of removal, repair and/or replacement for such product. If a product which is returned is determined by Seller in its sole discretion to have failed to comply with the limited warranty, Seller shall pay for all repair and/or replacement costs for such product (or refund the purchase price if so elected by Seller) and Seller shall reimburse Buyer for the reasonable costs of shipping the product or component to Seller.
Limitation on Liability for Breach of Warranty and Other Claims: If the warranty and the remedy for any failure of any product to comply with any warranty are deemed for any reason to fail their intended purpose, Seller’s liability for any failure of any product to comply with any such warranty, together with any and all other liability, if any, arising out of or in connection with such product, including, but not limited to, all claims, whether in Contract, tort, or otherwise, arising out of, connected with, or resulting for the manufacture, sale, delivery, resale, repair, replacement, or use of the product, shall not exceed the purchase price for such product. In no event shall Seller be responsible or liable to Buyer or any third party under any circumstances for any indirect, consequential, special, punitive or exemplary, damages or losses, including, but not limited to, damages for loss of profits, goodwill, use of the product or any other equipment or other intangible losses which may be incurred in connection with the product regardless of the type of claim or the nature of the cause of action, even if Seller has been advised of the possibility of such damage or loss. Any and all claims that Buyer has against Seller, whether or not Buyer is aware of such claims, must be brought by Buyer within the applicable thirty (30) days after the date that such claim first arose, but in any event within the applicable warranty period set forth above. Any claim not brought by Buyer within the applicable thirty (30) day period shall be deemed null and void.
IMDEMNIFICATION: Buyer will indemnify and hold harmless Seller, its affiliates and their respective officers, directors, employees, agents and other representatives and defend any action brought against same with respect to any claims, judgments, actions, suites, demands, damages, liabilities, costs or expenses
(including, but not limited to, reasonable attorneys’ fees and legal expenses) associated with or arising from the ownership, use or operation of the products by
Buyer or any third party, including without limitation, product liability, an international, federal or state occupational safety and health statute, or any other governmental regulations or laws, and also with respect to any fault or negligence of the seller. If buyer fails to fulfill any of its obligations under this paragraph or any other part of this agreement, buyer agrees to pay seller's costs, expenses, and attorney fees incurred by seller to enforce or establish its rights under this paragraph or any other part of this agreement.
TERMINATION OF PERFORMANCE: Buyer may cancel its order only with the written consent of Seller and upon terms that will indemnify Seller for any loss, damage and expense arising from such cancellation. Seller may terminate this Contract pursuant to Sections 2 and/or 11 hereof, and in such event, Seller shall have no further reliability to produce or ship any products hereunder and shall have no liability for damages to Buyer or any third party.
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TECHNICAL ADVICE: No obligation or liability shall arise out of Seller’s rendering of technical advice in the connection with Buyers’ order or products.
Any technical advice furnished, or recommendation made by Seller or any employee or representative of Seller, concerning any use or application of any products or parts furnished under this Contract is believed to be reliable, but Seller makes no warranty, express or implied of results to be obtained. Buyer assumes all reasonability for loss or damage resulting form the handling or use of any such products or part is accordance with such technical advice or recommendation. The selection of the products ordered, or design of any customer products, shall be Buyer’s sole and ultimate responsibility, and Seller shall have no liability whatsoever for any design defects of custom products, or if the products ordered are unsuitable for Buyer’s intended use. Any advice or assistance provided by Seller to
Buyer in connection with Buyer’s selection or design of the products is at Buyer’s risk, and Seller makes no representation or warranty whatsoever in connection with such advice or assistance.
ASSIGNMENT: Buyer shall not assign its rights or obligations under this Contract without the prior written consent of Seller, which consent may be withheld for any reason in the sole discretion of Seller. Any attempt at such assignment by Buyer without the prior written consent of Seller shall be deemed null and void.
This Contract will be binding upon the parties hereto, and the successors and permitted assigns.
SECURITY INTEREST OF SELLER: Title to the products will not pass to Buyer until all required payments have been made to Seller. Until the purchase price and all other applicable costs and expenses are paid in full, Seller reserves a purchase money security interest in the products and the proceeds therefrom, and Seller thereby possesses the rights of a secured party under the Uniform Commercial Code. Upon Seller’s request, Buyer shall execute all necessary financing statements and other documents evidencing this security interest with the appropriate sate and local authorities. Seller is entitled to and is hereby granted reasonable access to Buyer’s locations as necessary to exercise its remedies as a secured party.
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GOVERNING LAW: This Contract shall be construed, interpreted, and governed by the laws of the State of South Dakota without regard to its conflict of laws principles. The exclusive forum for any disputes arising out of or relating to this Contract shall be any federal or state court sitting in the State of South Dakota.
The parties irrevocably consent to such exclusive jurisdiction in such courts and to the proper venue therein.
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FORCE MAJEURE: Seller does not assume the risk of and shall not be liable for failure to perform any obligation relating to the products caused by civil insurrection, war, fire, strike, labor disturbances, acts of God, acts or omissions of Buyer, acts or omissions of the United States Government, floods, epidemics, freight embargoes, shortages of fuel, energy or materials, failure of suppliers or subcontractors to satisfactorily meet scheduled deliveries, or any other cause beyond the reasonable commercial control of Seller
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NOTICES: Any notices, consents or other communications required or permitted under this Contract must be in writing and delivered personally, overnight air courier, registered or certified mail or facsimile. Unless otherwise stated in this Contract, notices, consents or other communication will be deemed received (a) on the date delivered, if delivered personally or by facsimile transmission; (b) on the next business day if sent via overnight air courier; or (c) three (3) business days after being sent, if sent by registered or certified mail.
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SEVERABILITY; WAIVER: The invalidity or unenforceability of any provision of this Contract shall not affect the validity or enforceability of any other provision of this Contract. No waiver of any of the provisions of this Contract shall be deemed, or shall constitute a waiver of any other provision, whether or not similar, nor shall any waiver constitute a continuing waiver. No waiver shall be binding unless executed in writing by the party making the waiver. The Section headings included herein are for the convenience of the parties only and no way alter, modify, amend, limit or restrict the contractual obligations of the parties.
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NO THIRD PARTY BENEFICIARIES; SETOFF: Nothing in this Contract is intended to, or shall, create any third-party beneficiaries, whether intended or incidental and neither party shall make any representations to the contrary. Seller shall have the right to deduct from any sums it owes to Buyer, and sums or the value of any obligation owed by Buyer to Seller.
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ENTIRE AGREEMENT: The terms set forth herein constitute the sole terms and conditions of the Contract between Buyer and Seller. Notwithstanding the foregoing or any other term of this Contract, to the extent this Contract conflicts with the terms or conditions of any written distributor agreement between the parties, the written distributor agreement shall control. No other warranty, term, condition or understanding, whether oral or written shall be binding upon Seller, unless hereafter expressed in writing, approved and signed by Seller.
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SURVIVAL: The provisions of Sections 3, 4, 5, and 7 through 16 shall survive the termination and performance of this Contract.
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SAFETY RULES
READ CAREFULLY BEFORE OPERATING EQUIPMENT
WHEEL LUGS MUST BE CHECKED AND RE-TORQUED AFTER FIRST 30 MILES
IMPORTANT
Wheel lugs must be properly torqued before using your conveyor in radial travel mode.
Safety must be a primary consideration when operating any type of machinery. Accidents are the result of carelessness or negligence on the part of the operator. The following safety considerations are not meant to cover every possible condition or situation that may occur.
Common sense and precaution must be practiced at all times when installing, operating and maintaining any MASABA machinery.
IMPORTANT
It is the responsibility of the owner to establish and maintain a safety training program that covers equipment operation and maintenance in accordance with all MSHA, OSHA, and local, state, and federal guidelines. All personnel operating this equipment MUST read and understand this Owner’s Manual and all warnings and safety precautions. Be aware of all posted warning, caution, or danger decals on your equipment. Compliance with these warnings is mandatory to prevent serious injury or death.
IMPORTANT
Guards and safety devices have been factory installed. Any additional guards or safety devices required to meet local, state or federal guidelines are the responsibility of the end user.
• ALWAYS RESPECT HEAVY MACHINERY FOR WHAT IT IS.
• ONLY QUALIFIED PERSONNEL MAY OPERATE OR MAINTAIN EQUIPMENT.
ALL PERSONNEL OPERATING THIS EQUIPMENT MUST READ AND UNDER-
STAND THIS OWNER’S MANUAL AND ALL WARNINGS AND SAFETY PRECAU-
TIONS.
• NEVER OPERATE ANY MACHINERY WITHOUT ALL GUARDS AND HOUSINGS
PROPERLY INSTALLED AND IN GOOD WORKING CONDITION. NEVER OPER-
ATE ANY EQUIPMENT WHILE UNDER THE INFLUENCE OF DRUGS OR ALCO-
HOL.
• NEVER LEAVE THE MACHINE RUNNING AND UNATTENDED.
• NEVER ATTEMPT TO ADJUST, LUBRICATE, REPAIR, MAINTAIN, ETC. ANY
MACHINERY WHILE IT IS MOVING OR OPERATING. ALWAYS USE “LOCK-
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OUT/TAGOUT” PROCEDURES ESTABLISHED BY YOUR COMPANY BEFORE
WORKING ON ANY EQUIPMENT.
• NEVER ATTEMPT TO RIDE ON A MOVING PIECE OF MACHINERY.
• DO NOT WALK ON MACHINERY GUARDS, GRATINGS, OR COVERS.
• DO NOT PLACE HANDS, FEET OR ANY PART OF THE BODY NEAR MOVING
PARTS.
• NEVER WEAR LOOSE CLOTHING, NECKTIES, OR JEWELRY AROUND MOV-
ING PARTS. LONG HAIR SHOULD BE SECURED UNDER A CAP OR HAT.
• ALWAYS WEAR EYE PROTECTION, HEARING PROTECTION, RESPIRATORS,
GLOVES, HARD HATS, SAFETY SHOES AND OTHER PROTECTIVE CLOTHING
WHEN REQUIRED. MATERIAL CAN AND WILL FALL OFF AT ANY POINT AND
CAN CAUSE SERIOUS INJURY.
• KEEP ALL OPERATING PERSONNEL ADVISED OF THE LOCATION AND
OPERATION OF ALL EMERGENCY STOPS AND CONTROLS. CLEAR ACCESS
MUST BE PROVIDED TO THESE STOPS AND CONTROLS MUST BE MAIN-
TAINED AT ALL TIMES.
• FREQUENT INSPECTIONS OF ALL EMERGENCY STOPS, CONTROLS,
GUARDS, GRATINGS OR COVERS MUST BE MAINTAINED AT ALL TIMES.
• ALWAYS FOLLOW “LOCKOUT/TAGOUT” PROCEDURES ETABLISHED BY
YOUR COMPANY WHEN PERFORMING ANY TYPE OF MAINTENANCE OR
REPAIR.
• BEFORE STARTING ANY EQUIPMENT, MAKE SURE THAT THE OPERATOR
HAS READ AND UNDERSTANDS ALL OPERATION AND SAFTEY GUIDELINES.
VERIFY THAT THE AREA AND EQUIPMENT ARE SAFE FOR OPERATION AND
ALL GUARDS ARE IN PLACE AND SECURE. OPERATORS MUST PERFORM A
PRE-OPERATION SAFETY INSPECTION.
• NEVER ALTER, MODIFY OR ATTEMPT TO USE THE CONVEYOR FOR ANY-
THING OTHER THAN ITS INTENDED USE.
HYDRAULIC SYSTEMS SAFETY (IF EQUIPPED)
• CHECK ALL HOSES FOR SIGNS OF WEAKNESS OR CRACKS BEFORE USING
EQUIPMENT.
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• CHECK FLOW DIAGRAM TO BE CERTAIN THE SYSTEM IS DEPRESSURIZED
BEFORE ATTEMPTING REPAIRS. SEE APPENDIX O FOR THE HYDRAULIC
SCHEMATIC.
• BE AWARE OF HEAT BUILDUP IN SYSTEM AND ALLOW COOLING BEFORE
BEGINNING REPAIR OR MAINTENANCE.
• SQUEEZE OR FLEX FLEXIBLE HOSES TO CHECK FOR PRESSURE BEFORE
LOOSENING FITTINGS.
• USE “WHIP-CHECKS” TO MOUNT AND SECURE HYDRAULIC LINES TO PRE-
VENT INJURIES FROM WHIPPING OR FLAILING HOSES.
GENERAL
Successful operation of a machine depends upon good maintenance. Machinery must be inspected regularly to make sure that all moving parts are in good operating condition and that all bolts are tight. During the first week of operation, check the bolts for tightness daily and then periodically thereafter. This procedure also applies to parts and components that have been disassembled and reassembled during normal maintenance periods.
Caution must be used when operating your equipment in high winds. If possible lower your conveyor to its lowest setting during periods of high wind. If lowering you conveyor is not possible, secure it to the ground at the axle. High winds can blow your conveyor over causing serious injury and equipment damage.
Statements used throughout this user manual to draw attention to important safety measures include but are not limited to the following:
IMPORTANT
IMPORTANT is used to identify a procedure that needs to be followed to prevent machine damage or personal injury.
The instructions that follow this level of warning draw attention to a safe operating procedure. If the instructions are ignored the possibility of personal injury may exist.
The instructions that follow this level of warning draw attention to the possibility of a serious hazard. Failure to follow these instructions may put an individual at risk of serious injury or death.
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The instructions that follow this level of warning are the most serious. Failure to follow these instructions will most likely result in serious injury or death.
SAFETY DECALS
The decals shown below are a representation of the types of decals you may find on your equipment. It is the responsibility of the operator to replace any worn, torn, hard to read or missing decals.
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IDENTIFYING YOUR NEW MASABA MAGNUM
CONVEYOR DEFINITIONS
Your MAGNUM Telescoping conveyor includes two conveyor systems. They are identified as follows:
• Main Conveyor: The main conveyor is the outer conveyor onto which material is initially fed.
• Extension Conveyor: The extension conveyor, also referred to as the stinger conveyor, is the inner conveyor which extends from within the main conveyor.
• Proximity Switches: There are several proximity switches on the MAGNUM Telescoping
Conveyor which are used to communicate the current state of certain components within the conveyor. There is a “Whisker Switch” located in the middle of the main frame that communicates to the PLC when the Extension/Stinger Conveyor is either fully extended or fully retracted. This switch also acts as a back up/safety switch to ensure the conveyor stops in the event of an encoder misread. If the “Whisker Switch” is engaged, the emergency horn will sound and the conveyor will immediately stop to prevent damage.
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• Rotary Encoders: Three (3) encoders are used on the MAGNUM conveyor to relay to the
PLC the conveyor’s position throughout the operating programs. Unlike many other telescoping conveyors, the MAGNUM allows the user to know exactly where the material discharge point is at all times (i.e. Left/Right, Up/Down, In/Out).
• Radial Travel Encoder: There is an encoder located at the tail of the MAGNUM Conveyor above the base plate. This encoder lets the PLC know where the conveyor is positioned within its radial arc. This encoder also tells the PLC program to shut down in the event that the conveyor’s drive wheels lose traction and spin in one place for a period of time.
• Extension/Stinger Conveyor Encoder: Another rotary encoder is located on the end of the
Track Technology drive shaft. This encoder relays to the PLC the extension/stinger conveyor’s travel location during the operation program.
• Hydraulic Lift Encoder: Another rotary encoder is located under one of the undercarriage lift cylinders. This encoder relays to the PLC the stroke position of the undercarriage lift cylinders.
• Material Flow Sensor: Each MAGNUM Telescoping conveyor is equipped with a Material
Flow Sensor which communicates to the PLC that material is no longer being fed onto the conveyor. When activated, the PLC will pause all radial and extension movement of the conveyor until material flow is restored. The Material Flow Sensor is located on a stand on top of
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the main conveyor towards the tail end of the MAGNUM. This feature ensures the most uniform pile possible.
• Pile Height Switch: The Pile Height Switch indicated in the photo below will need to be unclipped from its travel position on the conveyor before use. The Pile Height Switch, located at the head end of the extension/stinger conveyor, will tilt when discharged material reaches its height. This sends a signal to the PLC which automatically raises the conveyor a predetermined distance to allow for continued material flow.
• Optional Auxiliary Power Unit: Your MAGNUM Telescoping conveyor may have been purchased with an optional gas powered hydraulic pump. This pump has the option of fully extending the Extension/Stinger conveyor to transfer a significant amount of weight off the kingpin, allowing easier removal from the transport truck. A user can also operate the undercarriage lift cylinders, as well as operate the optional hydraulic landing jacks used to lift the
MAGNUM off the transport truck.
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• Undercarriage Lift Cylinder: During Operational Setup and Travel Preparation, these cylinders are used to raise and lower the conveyor undercarriage to allow the axles to swing into
Radial Travel Mode or Road Travel Mode.
SETTING UP YOUR MAGNUM
SITE PREPARATION
• Location of the MAGNUM is generally determined by the location of intake and discharge of material to be conveyed. Improper site conditions can adversely affect the operation and maintenance of your MAGNUM.
• The area around the MAGNUM should be kept clear and level to make the loading of the
MAGNUM and discharge of material as convenient as possible.
• The MAGNUM tail section must have adequate clearance all around to allow for maintenance and the removal of material spillage.
• The MAGNUM work site must have solid compacted ground with no more than one degree slope to ensure proper operation. This will prevent the MAGNUM from rolling down hill and will increase power travel operating life.
• The MAGNUM must be kept level to maintain balance and performance. If operated in nonlevel conditions, the frame could develop a permanent twist. Level should be checked across the main axle.
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UNLOADING YOUR MAGNUM
It is recommended that you unload your MAGNUM at the site it will be used. See page ten (10) for instructions on site preparation.
Your MAGNUM conveyor was delivered fully assembled and can be disconnected from the delivery truck at the designated site.
To disconnect your conveyor from the delivery truck:
1. Set the air brakes or block the wheels on the MAGNUM.
2. Lower the landing legs. Depending on the option you chose, these could be hydraulic or manually activated. If you have hydraulic landing legs you must start the gas powered motor located near the hydraulic control center to activate the hydraulic levers. Once you have the gas powered motor running, locate the hydraulic lever labeled “LANDING LEGS” and operate it in the corresponding direction.
Hydraulic landing legs can crush hands and feet. Make sure the area beneath the landing leg is clear before operating the hydraulic levers or manual crank. Failure to do so can result in serious injury.
3. Disconnect the air brakes from the tractor.
4. Disconnect the king pin from the tractor.
5. Drive tractor away from the MAGNUM.
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Be sure to inspect all lifting equipment for extreme wear or damage and maintain according to manufacturer’s guidelines.
If your conveyor was not delivered to the site of operation, you will need to carefully transport it to the desired location.
IMPORTANT
It is important to use the designated lifting eye for moving your conveyor. Failure to do so can result in equipment damage.
1. Attach a chain to the lifting eye located in the center of the conveyor tail.
2. Carefully lift the MAGNUM until the landing legs are off the ground.
3. With the MAGNUM supported by a chain, retract the landing legs. Depending on the option you chose, this will either be hydraulic or manual.
4. Carefully transport your MAGNUM to the desired operating location.
IMPORTANT
The MAGNUM Extension/Stinger conveyor must be returned to the “Home” position before moving. Failure to do so can result in equipment damage.
Your MAGNUM conveyor will need to be attached to the base plate, also referred to as the pivot stand, before operation. The base plate/pivot stand was shipped attached to the side of the MAG-
NUM tail.
5. Remove the base plate by removing the retention pin indicated below. Secure the base plate to the ground using the four (4) spikes shown on the right of the photo below. These spikes prevent the base plate/pivot stand from moving and affecting the encoder that will be installed later.
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6. Once the base plate/pivot stand is in place, pull the Fifth Wheel retention pins located on both sides of the tail and rotate the Fifth Wheel 90 degrees to accept the king pin.
7. Carefully lower the MAGNUM until the king pin rests on the center post of the base plate.
Make sure all personnel are kept clear of the MAGNUM tail section during installation.
Failure to do so can result in serious injury.
13
OPERATING YOUR MAGNUM
POWER CONNECTION
Proper “Lockout/Tagout” procedures should be followed before attempting to connect your conveyor to any power source. Failure to follow your company designed “Lockout/Tagout” procedure can result in serious injury or death.
Before operating your conveyor you will need to connect it to an external power supply. Be sure your power supply has the proper voltage. Improper voltage and/or power surges can damage the electronic systems and will void warranty.
IMPORTANT
It is important to inspect the power supply cord for cuts or other damage. Use of a damaged cord can result in equipment damage and/or personal injury.
The Power Lead Cord must be laid out along all five (5) cord holders on the MAGNUM frame so that the electrical lead is located at the tail of the conveyor. This will ensure that excess tension is not put on the cord or electrical panel during radial travel operation. The Power Lead Cord is
optional equipment.
CONVEYOR PREPARATION
Prior to running your MAGNUM for the first time perform the following tasks:
• Confirm that all shipping brackets and straps have been removed and that there are no obstructions to impede the operation of the conveyor belt.
14
• Always track belts prior to running material, belts may need to be adjusted once material starts running. See page 37 for belt tracking instructions.
• Minimize side load/feed of belt in hopper area to minimize tracking issues.
• Make sure material is being fed on the center of the belt as much as possible.
• Check all conveyor flashing to make sure it is in the proper position and fully tightened to reduce spillage.
• Check “V-Belts” on belt drive for proper tensioning. See page 44 for “V-belt” tensioning instructions.
• Check “Belt Cleaner” for proper tensioning.
15
POSITIONING YOUR MAGNUM FOR RADIAL TRAVEL
To prepare your MAGNUM for radial travel you will need to locate and start the gas powered motor on the side of the undercarriage.
LOWERING THE MAGNUM LIFTING JACKS
1. Once you have started the gas powered motor, locate the hydraulic levers labeled “LIFT
JACK LEFT” and “LIFT JACK RIGHT”.
Hydraulic lifting jacks can crush hands and feet. Make sure the area beneath the lifting jack is clear before operating the hydraulic levers. Failure to do so can result in serious injury.
2. Operate these levers one at a time in the “Down” direction to raise the conveyor.
IMPORTANT
It is important to operate each lever a little at a time, alternating from left to right frequently to keep the MAGNUM level as you raise it off the ground.
3. Lower the lifting jacks until both sets of wheels are slightly off the ground.
16
POSITIONING THE SWING AXLE FOR RADIAL TRAVEL
1. Remove the swing axle retention pin located on the inside of walking beam.
2. Place that retention pin in the open slot on the walking beam to prevent it from tilting while lifting the MAGNUM off the ground.
3. Remove the swing axle brace retention pin on the outside of the swing axle.
17
4. Manually swing the axle into the radial travel position. Once in the radial travel position, place the swing axle brace retention pin in the new position.
5. Repeat steps 4-6 on the opposite side of the MAGNUM.
6. Remove the pin in the pivoting walking beam indicated below.
7. Swivel the drive wheels until the second set of holes line up.
18
8. Replace the pin in the new set of holes indicated below.
9. Remove the retention pin that prevents the walking beam from tilting and place it in the swing arm brace for storage.
10. Repeat steps six (6) and seven (7) on the opposite side.
IMPORTANT
Before operating the conveyor in radial travel mode, the air brakes MUST be released.
Failure to do so will result in serious damage to power travel components.
Make sure the MAGNUM is on level ground or block the wheels so the conveyor cannot roll unexpectedly. Locate the air tank and open the release valve. When all air pressure has been released, close the valve.
19
Raise right and left Axle Jacks to lower the undercarriage back to the ground. Ensure that all personnel are clear from all equipment before lowering the MAGNUM.
INSTALLING OPTIONAL SAFETY STOPS
If you purchased the optional safety stops, they will need to be installed now. Use the following steps to setup your safety stops:
1. The optional safety stops were bolted to the undercarriage for shipping. You will need to remove the safety stops from the undercarriage.
20
2. Once you have the safety stops free from the undercarriage, each will need to be inserted into a receiver on the underside of the travel axle.
21
RADIAL POWER TRAVEL
Your MAGNUM conveyor was shipped with the radial power travel drive chain(s) removed. The chain(s) will need to be attached to allow for radial travel.
Be sure to follow your company lockout/tagout procedures before removing the drive chain safety guard and attempting to attach the drive chain. Failure to do so can result in serious injury.
1. Remove the bolts that hold the drive chain guard in place and remove the guard.
2. Wrap the chain around the upper and lower sprockets.
3. Bring the two ends of chain together and insert the connecting link.
4. Place the outer link plate over the connecting link and insert the retaining pins.
5. Check chain deflection by placing a straight edge against the chain and applying pressure to the chain. Adjust the motor mount tensioner or add/remove links as needed for proper chain tension. To properly tighten the chain, lift the wheels off the ground. It is important to
check both sides of the chain for tightness.
6. Replace the drive chain guard cover.
It is important to remove the drive chain before moving your MAGNUM to a new location.
Failure to do so may result in equipment damage.
22
POSITIONING YOUR MAGNUM FOR ROAD TRAVEL
To prepare your MAGNUM for road travel, use the following procedures:
1. Turn on the main power to the electrical panel and switch to “Manual Mode”.
2. Start the Hydraulic Pump by pressing the button indicated below.
23
3. Verify that the extension/stinger conveyor is fully retracted to its “Home” position. The extension/stinger conveyor can be retracted using the button indicated below.
4. Locate the hydraulic levers labeled “LIFT JACK LEFT” and “LIFT JACK RIGHT”.
Hydraulic lifting jacks can crush hands and feet. Make sure the area beneath the lifting jack is clear before operating the hydraulic levers. Failure to do so can result in serious injury.
5. Operate these levers one at a time in the “DOWN” direction to raise the conveyor.
IMPORTANT
It is important to operate each lever a little at a time, alternating from left to right frequently to keep the MAGNUM level as you raise it off the ground.
24
Lower the lifting jacks until both sets of wheels are slightly off the ground.
Be sure to follow your company lockout/tagout procedures before removing the drive chain safety guard and attempting to remove the drive chain. Failure to do so can result in serious injury.
6. Disengage the wheels by loosening the chain tightening mechanism on the power travel unit.
7. Remove the drive chain safety guard.
8. Remove the drive chain and place it in the storage box.
9. Remove the pin from the pivoting walking beam and swivel it into road travel position
10. Re-pin the pivoting walking beam in road travel position.
11. Remove the pin from the right swing axle support brace.
12. Move the right swing axle towards the undercarriage to road travel position.
25
13. Re-pin the swing axle to the undercarriage.
14. Repeat steps 6-13 on the opposite side of the MAGNUM.
26
MAGNUM OPERATION MODES
Your MAGNUM has three operational modes. They are defined as follows:
• MANUAL MODE: All functions of the conveyor are operated by interacting with the switches on the main electrical panel.
• AUTOMATED MODE: All functions of the conveyor are controlled by an automated program inside the “PROGRAMMABLE LOGIC CONTROLLER (PLC)”. See below for information on using the PLC.
• REMOTE MODE: Similar to Manual Mode except that all functions of the conveyor are operated by interaction with remote control (instead of main electrical panel). NOTE: The user can still interact fully with the switches on the main electrical panel.
PROGRAMMABLE LOGIC CONTROLLER (PLC)
A PLC is a digital computer used for automation of conveyor processes such as radial travel, conveyor extension, and raise/lower functions. The PLC is designed for multiple input and output arrangements, extreme temperature ranges, immunity to electrical noise, and resistance to vibration and impact. The PLC on the MAGNUM Telescoping conveyor is located inside the main electrical panel.
27
MASABA utilizes a 10” color touch screen interface to interact with the conveyor’s PLC.
MASABA’s PLC gives users the ability to easily set up automatic operations by enabling the user to enter values for several key operating parameters. There are four (4) default programs that can be set by the user based on your stockpiling preference.
An example of the input parameter screen for the most common program (Radial Windrow) is shown below. If the user has a question on a definition of these values, they can press and hold one of the input variables, i.e. Radial Distance (ft):
28
PLC INPUT DEFINITIONS
• RADIAL DISTANCE: Radial arc distance is measured at the tires. This value is entered into the PLC during the set up stage of “Automated Mode”. This distance communicates to the PLC how large of a radial pile you want to make.
• MINIMUM EXTENSION DISTANCE: The minimum extension distance refers to the minimum distance (from the fully retracted position) that you want the extension/stinger conveyor to travel when creating a pile in “Automated Mode”.
• MAXIMUM EXTENSION DISTANCE: The maximum extension distance refers to the maximum distance (from the fully retracted position) that you want the extension/stinger conveyor to travel when creating a pile in “Automated Mode”.
• ELEVATION DISTANCE: Time set that the conveyor will rise once the pile height switch has been activated. Each MAGNUM is set at a predetermined amount, but can be adjusted by calling MASABA and requesting instructions.
• MATERIAL DESEGREGATION: Desegregation of stockpiled material is very important in developing stockpiles for applications such as concrete or asphalt. The MAGNUM’s automated stockpiling configurations allow users to stockpile material in a desegregated manner.
A Fully Desegregated pile does not allow any overrun in the pile.
A Partially Desegregated pile allows overrun along the edges.
29
MANUAL & AUTO SYSTEM CONTROL
The manual system control allows the operator to control each individual function manually. The auto system control allows the operator to choose a program that will allow the machine to make windrows automatically. When operating the MAGNUM in “Manual Mode” (after setup or movements are complete), TURN THE HYDRAULIC PUMP SWITCH TO “OFF” on the electrical panel. Allowing the hydraulic pump to continuously run or “idle” when not in use may result in hydraulic pump failure.
PLC OPERATIONAL PROCEDURES
To begin using your MAGNUM conveyor, use the following procedures.
1. Make sure the MAGNUM conveyor is in the home position. The home position is defined as having the Extension/Stinger Conveyor in the fully retracted position, the Main Conveyor in the fully lowered position, and the undercarriage in the left most position.
2. The System Control switch must be set to “Auto”.
30
3. You should now see the home screen.
4. Touch anywhere on the home screen to access the Main Menu screen.
31
5. Touch New Stockpile Selection button. This brings up a decision screen to verify that new stockpile settings are desired.
6. Touch Yes to continue to the Stockpile Selector screen. On the Stockpile Selector screen, choose one of the four (4) options. Available options include Radial Windrow, Radial Con- ical, Inline Windrow, and Inline Conical.
32
Once selected the corresponding Stockpile screen appears.
Be sure to verify that all obstacles and personnel are clear of the MAGNUM travel area.
Failure to do so can result in equipment damage and/or serious injury.
7. Once desired parameters are set, touch Begin Cycle to start stockpile program. The MAG-
NUM is now ready to begin moving in cycle. The warning horn will sound for five (5) seconds prior to startup. When warning horn quits sounding, the extension/stinger conveyor will start moving. Three (3) seconds later, the main conveyor will start moving.
33
8. To stop a program at anytime during the cycle, touch Stop/Pause on the Stockpile Screen.
The wheel movement is paused immediately and the Resume Previous Program screen appears.
9. Follow the on screen prompts for moving the conveyor to its previous position.
10. Once the conveyor is in its previous position, the following screen will appear. This screen gives the operator the ability to Resume Cycle or Stop/Terminate Program.
34
The table below is provided to assist users during setup of the Traverse Distance or Radial Arc
Travel Distance. The Radial Distance, measured in feet, corresponds to the conveyor’s degree
(estimated) of radial arc represented in the table for each figure.
35
ADJUSTING CONVEYOR HEIGHT (MANUAL MODE)
Adjusting conveyor height can be done by either manually operating the switches on the electrical panel or through the use of the PLC.
Use the following procedures to adjust the conveyor height in Manual Mode:
1. On the electrical panel, turn the “OPERATION MODE” switch to the manual position.
2. Locate the switch labeled “MAIN CONVEYOR”. Operate this switch in the proper direction for the desired action.
36
MAINTENANCE
BELT TRACKING
Prior to running the conveyor loaded with material, the belt tracking should be checked. Belt training is the process of adjusting idlers to insure that the belt travels over the center of the idlers, return rollers, and pulleys.
DO NOT ATTEMPT TO TRAIN THE BELT BY ADJUSTING THE SCREW TAKE-UPS. The take-ups are used for belt tension, and to keep the tail pulley square with the frame.
A normal sequence of training is to start with the return run working toward the tail pulley and then follow with the top run in the direction of belt travel. The primary rule which must be kept in mind when tracking a conveyor belt is simply: “THE BELT MOVES TOWARD THAT END OF
THE ROLL/IDLER IT CONTACTS FIRST”.
The following steps should be taken to properly train the belt to run over the center of the pulleys, troughing idlers, and return rollers:
• Ensure that all frames are level. If the frames are not level, the belt will be forced to one side or the other.
• Square the tail pulley by measuring from a fixed point on both sides of the MAGNUM.
• Check the belt splice for squareness. The belt ends should be squared from a center line at least 15 feet long and accurately derived from center point measurements along the belt. Do not use the edge of the belt for reference.
37
• Square all troughing and return rollers with the frame and tighten the attachment bolts.
• Run the conveyor empty and at reduced speed if possible. Look for a side creep at any point along the frame. Check the return travel for side creep. Make adjustments where side creep occurs as follows:
The conveyor must be powered off before attempting to adjust any return rollers or idlers.
Failure to do so can result in serious injury.
1. The point of maximum side creep requires adjustment of a preceding roller when you are facing in the direction toward which the belt is moving.
2. Loosen the bolts and pivot the roller around its midpoint, making these adjustments in small increments. Tighten the bolts and make a test run after each adjustment to see the effect on side creep. If the point of maximum side creep changes, adjust the roller that precedes that new point.
3. Load the belt with material and continue testing until belt is running centered.
4. If the belt should show a side creep only at the splice point as it runs along the conveyor, rather than at one point, the splice is not square and should be re-done. See appendix B for detailed instructions on proper belt splicing.
38
OPTIONAL GREASE BANK SYSTEM
Your MAGNUM Telescoping Conveyor can be purchased with on optional Grease Bank System making servicing your conveyor much easier.
TROUBLESHOOTING BELT CONVEYORS
1. ALL PORTIONS OF CONVEYOR BELT RUNNING TO ONE SIDE AT A GIVEN POINT
ON STRUCTURE.
PROBLEM
One or more idlers immediately preceding trouble point not at right angles to direc- tion of belt travel.
One or more idler stands not centered under belt.
Belt runs off terminal pulley.
CORRECTION
Advance, in the direction of belt travel, the end of the idler toward which the belt has shifted.
Center them.
Buildup of material on idlers.
Structure not level and belt tends to shift to low side.
Check terminal pulley alignment.
Check alignment of idlers approaching terminal pulley.
Improve maintenance. Install brushes or other cleaning device.
Level Structure.
39
2. PARTICULAR SECTION OF BELT RUNS TO ONE SIDE AT ALL POINTS OF CON-
VEYOR.
PROBLEM
Belt not joined squarely.
CORRECTION
Square ends & re-splice.
Cambered belt.
Tension it or replace it.
3. CONVEYOR BELT RUNS TO ONE SIDE FOR LONG DISTANCE ALONG BED.
PROBLEM
Load being placed on belt off-center.
CORRECTION
Adjust chute and loading conditions so as to place in center.
Conveyor frame or structure crooked. Straighten it.
4. SEVERE WEAR ON PULLEY SIDE OF CONVEYOR BELT.
PROBLEM
Slippage on drive pulley.
Spillage of material between belt and pulley, or material builds up at loading point until belt is dragging.
Excessive tilt to troughing idlers.
CORRECTION
Increase tension if belt construction permits.
Lag drive pulley (groove if wet)
Improve loading conditions with chutes.
If belt loaded too full, increase belt speed or decrease feed.
Install plows or scrapers in front of tail pulley on return run.
Adjust to not more than 2 degrees from line perpendicular to belt.
Improve maintenance and lubrication.
Sticking idlers.
5. PRODUCT SLIPS ON INCLINE.
PROBLEM
Belt dirty.
Incline too steep.
6. COVER BLISTERS OR SAND BLISTERS.
CORRECTION
Clean it.
Decrease incline.
PROBLEM
Cover cuts or very small cover punctures
CORRECTION
Make spot repair with vulcanizer allow fine particles of sand to work or repair dough, after removing under the cover and cut cover away from and cleaning the carcass.
underneath blister area.
40
Oil either in material or from outside source.
Remove source of oil, if possible.
Check lubrication.
VENDOR SPECIFIC MAINTENANCE SCHEDULES
For maintenance schedules that are specific to the parts installed on your Masaba Conveyor, please refer to the corresponding appendix.
41
TROUBLESHOOTING MAGNUM CONVEYORS
1. WHEN IN INITIAL START UP IN AUTO MODE, CONVEYOR SYSTEM DOES NOT
START AFTER PRESSING START BUTTON.
PROBLEM
Extension conveyor not in Home Position
CORRECTION
Ensure Extension Conveyor is in fully retracted position. In Main Menu, press Bring Stinger Home.
Conveyor not in Auto Mode Change Mode Switch to Auto
2. WARNING HORN AND/OR LIGHT ACTIVATED.
PROBLEM
A system malfunction has occurred
Extension Conveyor has traveled too far past proximity switch at either tail end or head end of conveyor. Emergency switch has been activated.
CORRECTION
Identify malfunction by going to Main Menu, press the alarm log screen. This screen identifies the last ten (10) alarms. Once you have identified the problem, see next steps within this section.
Move mode switch to manual, turn on hydraulic pump, operate the Stinger extension control manually to navigate Stinger back to normal operating position.
Navigate user interface to Main Menu, press Bring
Stinger Home, Restart Program.
Wheel drives are spinning/no traction.
Shut down conveyor, move conveyor out of operating position and repack surface.
3. DURING NORMAL OPERATION, CONVEYOR SYSTEM SHUTS DOWN.
PROBLEM
Loss of power source.
CORRECTION
Check power leads to ensure proper connection.
Loss of drive wheel traction. If conveyor drive wheels spin out, conveyor program will stop system.
Ensure the conveyor work site has solid compacted ground with no more than one (1) degree slope. This will prevent the conveyor from rolling down hill and will increase power travel life.
4. DURING OPERATION, CONVEYOR DOES NOT TRAVEL PROPER RADIAL TRAVEL
DISTANCE.
PROBLEM
Radial Travel Encoder may not be functioning properly.
CORRECTION
Contact MASABA for assistance.
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INSTALLING/TENSIONING V-DRIVES
CHECK CONDITION OF SHEAVES
Before installing a new set of V-Belts, examine the sheaves. Dirty or rusty sheaves impair the drive’s efficiency and abrade the belts, which results in pre-mature failure. Worn sheaves shorten
V-Belt life by as much as 50%. If the grooves are worn to where the belt bottoms, slippage may result and burn the belts. If the sidewalls are “dished out”, the bottom shoulder ruins the V-Belts pre-maturely by wearing off the bottom corners.
The conveyor must be powered off before removing safety guards and must remain off while performing any maintenance function. Failure to do so can result in serious injury.
CHECK SHEAVE ALIGNMENT
Sheave adjustment should be checked by placing either a straight edge or a string line across the sheave face so that it touches all four points of contact.
Improper sheave alignment produces:
• Uneven wear on one side of the V-Belt
• The V-Belt to roll over in the sheaves
• Puts the entire load on one side of the V-Belt, stretching or breaking the cords on that side.
43
V-BELT INSTALLATION
Shorten the center distance of the drive until the V-Belts can be put on the sheaves without stretching. Stretching the V-Belts can cause internal damage to the belts. Center distance can be decreased by adjusting the belt tensioner shown below.
BELT SELECTION
For maximum service, replace V-Belt drives with a complete new matched set of belts. Never employ a used V-Belt as a replacement for one of a set of new V-Belts. Used belts normally are worn in cross-section and stretched, and will cause the new belts to accept its load. A new belt used with old belts will ride higher in the sheave, travel faster and operate at a much higher tension than the used belts. The cord center may be ruptured, allowing the new belt to elongate.
Shortly after this occurs it will cease to accept its full share of the load, leaving the drive underbelted. Belts of different manufactures should not be mixed for the same reasons.
GENERAL RULES OF TENSIONING
• IDEAL TENSION IS THE LOWEST TENSION AT WHICH THE BELT WILL NOT SLIP
UNDER PEAK LOAD CONDITIONS.
• CHECK TENSION FREQUENTLY DURING THE FIRST 24-48 HRS OF RUN-IN OPER-
ATION.
• OVER TENSIONING SHORTENS BELT AND BEARING LIFE.
• TENSION BELTS WHEN SLIPPING. NEVER APPLY BELT DRESSING AS THIS WILL
DAMAGE THE BELT AND CAUSE EARLY FAILURE.
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APPENDIX A
Conveyor Belt Storage and Installation
Conveyor Belt Storage and Installation
Receiving the Roll
Upon delivery, check the factory packaging for damage, punctures, etc. Make any appropriate claim against the carrier at that time.
Handling the Roll
Factory packaging is designed to protect your conveyor belt during normal shipping and handling. When a belt arrives, be careful unloading it. Don’t drop it or handle it roughly. This could break the packaging and cause the belt to telescope. Once a belt telescopes, it is almost impossible to re-roll.
Try not to roll it, but if you must, roll in the direction the belt is wound. Rolling a belt in the opposite direction can cause it to loosen and telescope.
The best way to move a belt is to slip a sturdy hoisting bar through the center core. Then, lift it with a sling or with strong cables. Be careful that these hoist cables don’t damage the outer wraps at the belt edges. Protect the edges with special
“spreader bars,” or short wooden planks. Never apply a sling around the circumference of a roll of belting. . .it isn’t safe!
You can also move a belt safely by laying the roll flat on a skid and hoisting the skid with a forklift. Just be sure the forks on the lift don’t come in contact with the belt itself.
Storage
When storing a new conveyor belt, leave it hoisted or stand it upright, preferably on a dry surface (do not lay the roll on its side). A wooden skid is best. Block it safely so it can’t accidentally roll.
Extreme temperature variations can have an adverse affect on a belt over long periods of time. The ideal storage range is between 50
°
F and 70
°
F.
Long exposure at temperatures even slightly below 40
°
F can harden or stiffen the compounds. If installed on a conveyor in this stiffened state, the belt may not train well until it adjusts or “warms up” to the system.
Neoprene, for example, is especially sensitive to low temperatures and should never be stored at less than 40
°
F. Stiffened neoprene belting is different than other constructions. It won’t loosen up until it’s had a lengthy exposure to relatively mild temperatures.
Temperatures over 90
°
F have an adverse effect, too, and should be avoided.
Sunlight and ozone can also deteriorate any exposed rubber over time. Store your belt out of the direct sunlight whenever possible.
Electrical generators or arc welders can sometimes generate ozone. It is best to store your belt some distance away from this type of equipment.
In general, it’s wise to keep any unused belt stored in its protective factory packaging until it’s ready for installation.
Used belt should be thoroughly cleaned and dried prior to storage.
A dry place out of direct sunlight is preferred for storage, excessive temperature variations or extremes being avoided. Belts should not be stored in excessively wet places or in areas where oils, gasoline, paint
2
Index Page
Index Page materials, acids and chemicals are also stored or used. Motor-control rooms, welding shops, and other places where ozone is generated should likewise be avoided. A belt should not be permitted to rest on a concrete floor. If it is necessary to lay a belt on the floor, use a pallet or a cradle.
Belts which are not endless should be stored in rolls. Once thoroughly cleaned and dried, it is good practice to dust a belt with tire talc or to insert kraft paper between the layers when rolling it up. Care should be taken not to roll a belt too tightly. Be sure the interior diameter of the roll is sufficiently large to avoid any possible carcass damage or warping.
The belt should be rolled evenly to avoid telescoping and warping. Excessive flexing or sharp bends of any sort are to be avoided. Rolls should not be stood on edge or leaned against a wall.
Small endless belts may be hung up on a dowel or a peg for storage. It is advisable to rotate the belt occasionally to avoid a constant flex or bend at one point. Larger endless belts may be stored flat, doubling them over as necessary. It is advisable when doubling a belt over to be sure that the edges of the belt are in line to avoid any warping. As above, it is good practice to rotate and repile the belt occasionally to avoid constant flexing or bending at any point.
Bends should be made as large as possible to avoid cracking the carcass.
Installation
Once the roll of belting has been transported to the point of installation it should be mounted on a suitable shaft for unrolling and threading onto the conveyor. Conveyor belting is normally rolled at the factory with the carrying side out. Consequently, in mounting the roll, the belt must lead off the top of the roll if it is being pulled onto the troughing or carrying idlers but off the bottom of the roll if it is being pulled onto the return idlers. The illustrations below represent suitable methods of mounting and stringing belt for each case.
Note: Temporary flat roll at bend point, as roll is pulled onto troughing idlers
Left: Temporary flat roll at bend point
Below: Threading through return strand
Reefing the Belt
No weight to be placed on top
In some cases, such as in the mines where head room does not permit maneuvering a roll, the belt may have to be pulled off the roll and reefed (Left). Extreme care should be exercised to see that the loops have large bends to avoid kinking or placing undue strain on the belt. No weight should ever be placed on the belt when it is in this position. Another method of handling belting under such conditions is to lay the roll on a turntable with a vertical spindle.
Keep bends large to prevent breaking carcass
3
Index Page
C O N V E Y O R B E L T I N G A M E R I C A S
21 Laredo Drive
Scottdale, Georgia 30079 • USA
Phone: (404) 297-3170
Fax: (404) 296-5165 www.fennerdunlopamericas.com
IS O 9001: 2000 C ertified
10/03
APPENDIX B
Installing Flexco
®
Bolt Solid Plate
Instructions for Installation
1. Square belt ends using centerline method. Cut belt ends using Flexco 840 Series Belt Cutter.
2. Support belt ends with wood plank. Nail
Flexco Templet in position with belt ends tight against lugs.
3. Spray templet holes with Flexco Silicone
Lubricant. Punch or bore bolt holes. Remove templet.
NOTE: A ½” square drive electric impact wrench with Flexco 5552 Quick Change
Chuck will speed hole boring operation.
5. Fold one belt end back and insert bolts in one row of holes.
6. Align bolts with templet teeth and place the other belt end over bolts. Remove templet.
7. Place top plates over bolts using bolt horn.
8. Start nuts on bolts by hand.
9. Cut Flexco-Lok® Tape 3-1/2 times the belt width and feed tape under top plates, under the bottom plates, then back under top plates.
10. Pull tape tight and hold in position by
en tighten all other plates.
11. Tighten all fasteners from edges to center.
Tighten all nuts uniformly.
Power Wrench used with an impact tool will speed this step considerably.
NOTE: A Flexco
12. Hammer plates in belt with wood block.
Retighten nuts.
13. excess bolt ends using two bolt
nish.
APPENDIX C
Belt Tracking
Index Page
Table of Contents
I.
Conveyor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Supporting Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pulleys, Rollers, Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Crowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Take-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
II.
Non Structural Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Neutral Belt Stresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Skew (Bow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Belt Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Square Belt Ends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
III.
General Training Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
IV.
Training Package or Unit Handling Belting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
V.
Training Bulk Haulage Belting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1
“Tracking” or training is defined as the procedure required to make the conveyor belt run “true” when empty and also when fully loaded.
Tracking conveyor belt should be approached from a systems point of view. We should first examine some of the components of the conveyor system and see how they effect belt tracking before we discuss the actual methods used to train a belt.
We also need to look at a few non-structural components such as conveyor house keeping, the belt itself and the splice, before we discuss recommended training procedures.
2
Index Page
Index Page
I. Conveyor Components
Supporting Structure
Crowns
The supporting structure is designed to hold conveyor sections firmly and in proper alignment. If it does not, for whatever reason, it is likely to have an effect on belt tracking. Support structure should be checked as a first step in belt tracking. Has a forklift run into the supporting structure and buckled it? Are the anchors firm?
Crowned pulleys for lightweight conveyor belt can be trapezoidal or radial shaped. Georgia Duck has products to accommodate both styles, however the amount of crown in either case should not exceed 1/8" per foot on the diameter, and should
not exceed 1/8" total. The rate of crown seems to be very important as well as the total amount of crown in the system.
Conveyor sections are bolted to the supporting structure. They should be “square” and “horizontal” (side to side). If the section is “racked” it must
be straightened. Measure diagonals across the frame. They should be equal. Repeat for total, assembled bed.
On short center conveyors, we recommend no crown on the drive (avoid crowns on drive in every case, unless the drive is an end pulley), and to crown the end pulleys. In a few cases we would also crown additional pulleys, but that will depend on the entire design and the amount of crown used.
Conveyor bed sections (slider or roller) must be properly aligned with no vertical off-set between sections. A taut line should be stretched over the top surface of the bed and adjustments made so that all points are in contact. The entire bed (and each section) must be horizontal (across the width). If they are not, the belt will be pulled by gravity and will “drift” toward the low side unless a compensating force of some kind is exerted on that belt.
Pulleys/Rollers/Idlers
Remember, for crowns to be effective, there must be enough free span/transition for the belt to elongate and conform. Pretension to get pulley crown conformation is very important, too much pretension can cause pulley deflection and bearing problems. Georgia Duck has specific carcass constructions to meet very short center, wide belt applications in the 1:1 ratio of length to width, and even less. Please consult factory if you have needs in this area.
All pulleys, snub rollers, carrying idlers, and return idlers must be square with the frame (perpendicular to belt center line), parallel to each other and level.
“Squaring” with the frame is a good preliminary adjustment. The final adjustment, however, requires that this “squaring” be done with the belt center line as the reference. All pulleys must be at right angles to the direction of belt travel (belt center line).
Crowned pulleys are not recommended for high
modulus bulk haulage belting. Steel Cord belting requires fully machined straight faced pulleys through out the system. If a crowned pulley is used on nylon, polyester or aramid style belting the crown should only be placed in a low tension area such as the tail on a conventional head drive conveyor. The tracking forces that the crown exhibits does not effect high modulus bulk haulage belting because the system lacks enough tension to make the crown effective. If you could exert enough tension on the belt to force the belt to conform to the crown, the belt would be subjected to excessive stretch and splice failure could result.
3
Index Page
Take-up
The take-up device in a conveyor belt system has three major functions:
1. To establish, and preferably to maintain a predetermined tension in the belt.
2. To remove the accumulation of slack in the belt at startup or during momentary overloads–in addition to maintaining the correct operating tension.
3. To provide sufficient reserve belt length to enable resplicing, if necessary.
Manual, as well as automatic, take-up devices are normally used in a typical conveyor belt system.
The manual or screw take-up consists of a tension pulley (frequently the tail) which can be moved to tighten the belt by means of threaded rods or by steel cables which can be wound on a winch.
These give no indication of the tension they establish and are adjusted by trial methods until slippage is avoided. They are unable to compensate for any length changes in the belt between adjustments and thus, permit wide variation in belt tension. Use is generally restricted to short and/or lightly stressed conveyors–widely used in unit handling.
The manual take-up must be such that when tension is applied to the pulley, the pulley remains at right angles to the direction of belt travel. Also the tension must be high enough to allow elastic recovery of elongation due to starting forces, load changes, etc.
Automatic take-ups depend upon suspending a predetermined weight (gravity), by activation of a torque motor, by hydraulic pressure, or by spring loading. These devices maintain a predetermined tension at the point of take-up regardless of length changes resulting from load change, start-up, stretch, etc. This permits running the belt at the minimum operating tension and should be used on all long length conveyors and moderate to highly stressed conveyors.
The automatic take-up alignment must be such that the pulley or pulleys are maintained at right angles to the direction of belt travel. In a gravity or spring loaded take-up, the carriage must be guided to maintain the pulley axis on a line perpendicular to the belt center line.
Adequate take-up is essential to satisfactory operation of a belt conveyor. The amount required depends on type of belting and on service conditions. Please refer to belt manufacturer for recommendations.
Normally, when a new belt has been properly installed and tensioned, the take-up roll or pulley
(automatic take-up) will be initially set at a position of 25% along the line of travel, leaving 75% of the take-up area available for elongation.
4
Index Page
II. Non Structural Components
Cleanliness
Cleanliness is essential to good belt tracking. A buildup (of whatever material) on pulleys and rolls can easily destroy the “perpendicularity” of the roll or pulley face. Foreign matter in essence creates a new roll or pulley crown–adversely affecting tracking.
Likewise, cleanliness is essential to slider bed operation. A buildup of foreign materials (or a roughened portion of the slider bed face) can very easily throw a belt off-center since this will result in a differential of warp tensions across the width of the belt. This can seriously effect training.
Scrapers can be applied directly to bend rolls at the take-up area, on a gravity take-up system, to keep the rolls free from build up. Ploughs installed prior to the tail roll, under the loading section, will prevent belt and pulley damage due to carry back.
Balanced/Neutral
It is extremely important that the final belt construction be “balanced” or “neutral” in terms of the internal stresses imparted to the belt during manufacture. Any unbalanced stress remaining in the belt will likely cause problems in tracking.
Typical belt carcass designs usually utilize a plain weave or twill weave. The “crimp” imposed upon the warp yarns (length-wise yarns) in these types of weaves, as well as the warp tension necessary at the loom are difficult to control. Unbalanced stresses can result. Georgia Duck has a patented tensioning system to minimize this problem.
The resulting “straight/balanced” carcass is kept straight by tensioning during the impregnation and curing steps of manufacture, resulting in a straight belt which is balanced and therefore, easy to track.
Camber
If unbalanced warp tensions exist in a conveyor belt, that belt will usually assume a “crescent” or
“banana” shape when laid flat upon a horizontal surface. This deviation from a straight line is hereby defined as “camber.”
To measure belt camber, it is recommended that the belt be unrolled on a flat surface like the warehouse floor, a flat horizontal driveway, etc. Next, one end of that belt should be grasped (and one end only) and the belt dragged in a perfectly straight line for approximately 10 feet. If the belt is too heavy for one man to move, then one end should be clamped to a forklift and the same procedure performed. At this point, the belt should lie flat. Unequal and unresolved warp tensions in the belt will cause it to assume a “crescent” or “banana” shape.
Camber is measured by drawing a taut line along one edge of the belt and measuring maximum deviation from that taut line to the belt at the point of maximum deviation. Compute % camber as follows:
% Camber =
Maximum Deviation (Inches)
Length of taut line (Inches) x 100
It is recommended that if the percent camber exceeds one-half of 1%, the belt manufacturer be contacted. In lightweight, unit/package handling
.25% is the maximum.
Camber can be instilled into a belt during the slitting operation if one of the slitting knives is dull. A dull slitting knife will tear the fill yarns (cross-wise yarns) rather than cut them. (While the belt is in roll form the side of the belt which had gone through the dull knife will exhibit a “fuzzy” appearance due to the torn fill yarns.) Usually this type of camber will be less than one-quarter of 1% and can be pulled out handily when the belt is properly tensioned.
5
Index Page
Skew (Bow)
The fill yarns (weft yarns) in the belt carcass will usually lie along the perpendicular to the belt center line. Any deviation from this perpendicular line by the fill yarn is hereby defined as “skew” or
“bow.”
A skewed pick in a plain weave or twill weave is cause for concern since it is generally indicative of unbalanced warp tensions and will usually go hand-in-hand with a significant camber.
In a straight warp or solid woven carcass design, however, skew is of little significance.
It is a cosmetic defect and is not indicative of a cambered belt.
Belt Tension
Belt tension must be great enough to prevent slippage between the drive pulley and belt. Tension must also be enough to cause the belt to conform to the crowns, if present.
Slippage will cause excessive wear to both drive pulley lagging and the belt. Further, an excessive heat buildup on the drive pulley lagging can result in rubber reversion. (Reversion is the softening of vulcanized rubber when it is heated too long or exposed to elevated temperatures. It is a deterioration in physical properties, and frequently results in tackiness.) Once the pulley lagging has reverted, it frequently will offset onto the bottom side of the conveyor belt which will then distribute the reverted rubber throughout the slider or roller bed of the system. The resulting tackiness between the bed and the belt will certainly drive horsepower consumption up; can actually result in a stalled system, and can cause severe tracking problems.
Square Ends
Accurate squaring of the belt ends prior to splicing is essential to belt tracking, and helps distribute stress evenly throughout the splice.
To properly square the belt ends, we recommend the center line method.
To establish the belt center line, start near the belt end as shown on the next page. Measure the belt width at seven points approximately 1 foot apart.
Divide each measurement in two and mark these center points as shown.
Using these seven “center points,” pop a chalk line to form the belt’s center line. Next, using a carpenter square or “T” square, draw a “cut line” across the width of the belt near the belt end as shown.
Repeat this for the other belt end.
Using the “cut line” as the guide, cut off the end of the belt with a sharp razor knife. Make sure that the cut is clean and vertical. This operation should then be repeated on the other end of the belt.
(Keep in mind that the final belt length may need to include an allowance for such things as diagonal splice, skive taper length, skive overlap, finger punching loss, fastener extension, etc.–depending upon what kind of splice is being performed.)
6
1 FOOT 1 FOOT 1 FOOT 1 FOOT 1 FOOT 1 FOOT
Index Page
BELT
END
BELT CENTER LINE
T-SQUARE
OR FRAMING SQUARE
MARKING OF CUT LINE AND OTHER
RIGHT ANGLE GUIDE LINES
7
CUT LINE
BELT
END
Index Page
An alternative method of squaring belt ends is called the “double intersecting arc” method.
First establish the center line as indicated previously. Once that center line has been established, pick a point on the center line and approximately 2 or 3 times the belt width from the belt end. An arc is now struck, as shown in the following sketch.
On bulk haulage belting, a nail can be used as the pivot point and an arc is struck with a steel tape.
Always mark the edge of the belt with the same side of the tape.
A second arc is now struck as shown. The pivot point in this case is on the center line and is close to the belt end. The arc length is slightly less than one-half of the belt width. Now draw a line from one pair of intersecting arcs to the other. This is the “cut line.” This line is perpendicular to the center line of the belt. The reason for this may be edge wear or damage or to eliminate slitting alignment errors.
Never assume both edges are straight and parallel.
PIVOT
APE
STEEL T
LONG ARC
PIVOT
Double Check Squareness
A
C
5’
5
CUT
LINE
D
B
PROVING ACCURACY OF SQUARED-CUT END
LENGTH OF DIAGONAL AB IS EQUAL TO LENGTH OF DIAG-
ONAL DC. ALSO AB AND DC INTERSECT ON THE BELT
CENTER LINE.
BELT
END
It is always a good idea to double-check the accuracy of the squared and cut end. Measure 5 feet along each edge from the end of the belt, then utilizing a tape measure, check the two diagonals.
They should be equal and further, should intersect on the belt center line.
NAIL
SHORTER
ARC
NAIL
CUT
LINE
ALTERNATIVE ARC METHOD OF SQUARING ENDS
JOINING OF THE POINTS WHERE THE ARCS INTERSECT
GIVES THE RIGHT ANGLE CUT LINE
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Index Page
III. General Tracking/ Training Procedures
Tracking the belt is a process of adjusting idlers, pulleys, and loading conditions in a manner that will correct any tendencies of the belt to run other than true.
A normal sequence of training is to start with the return run working toward the tail pulley and then follow with the top run in the direction of belt travel. Start with the belt empty. After tracking is completed, run the belt with a full load and recheck tracking.
Tracking adjustment is done while the belt is running and should be spread over some length of the conveyor preceding the region of trouble. The adjustment may not be immediately apparent, so permit the belt to run for several minutes and at least three full belt revolutions after each idler adjustment to determine if additional “tracking” is required.
After adjustment, if the belt has overcorrected, it should be restored by moving back the same idler, and not by shifting additional idlers or rollers.
If the belt runs to one side at a particular point or points on the conveyor structure, the cause will probably be due to the alignment, or leveling of the structure, or to the idlers and pulleys immediately preceding that particular area, or a combination of these factors.
If a section or sections of the belt run off at all points along the conveyor, the cause is possibly in the belt itself, in the belt not being joined squarely, or in the loading of the belt. With regard to the belt, this will be due to camber. Its condition should improve after it is operated under full load tension.
It is a rare occasion when a cambered belt (less than 1/2%) needs to be replaced.
These basic rules can be used to diagnose a belt running poorly. Combinations of these rules sometimes produce cases which do not appear clearcut as to cause, but if there is a sufficient number of belt revolutions, the running pattern will become clear and the cause disclosed. In those unusual cases where a running pattern does not emerge, it is quite likely that at some point the belt is running so far off that it is fouling structure or mounting brackets, bolts, etc. This results in highly erratic performance and can be a real problem. We would suggest that in this event the full tracking procedure be employed. It is quite likely that the erratic performance will be resolved in the process.
When replacing a used belt, go through the system and square and level all rollers, idlers, pulleys and bed before training a new belt.
Basic/Primary Rule of Tracking
The basic and primary rule which must be kept in mind when tracking a conveyor belt is simple,
“THE BELT MOVES TOWARD THAT END OF
THE ROLL/IDLER IT CONTACTS FIRST.”
The reader can demonstrate this for himself very simply by laying a small dowel rod or round pencil on a flat surface in a skewed orientation. If a book is now laid across the dowel rod and gently pushed by one’s finger in a line directly away from the experimenter, the book will tend to shift to the left or right depending upon which end of that dowel rod the moving book contacts first.
BOOK MOVES LIKE SO
PENCIL
BOOK
PUSH
9
Index Page
Pulley Crown on Lightweight and Monofilament Belt
A crowned pulley can be regarded as a special case of our primary rule of tracking as stated above. The right half of the belt is contacting the center of the pulley sooner than it contacts the right edge of that pulley and therefore will tend to move toward the center. The reverse is true of the left half of the belt. The two forces tend to balance one another by centering the belt.
In addition to this surface effect, however, there is a strong internal “balancing of warp tensions occurring.” Consider any warp yarn not directly on the center line. If the belt is forced off-center and this warp yarn is drawn toward the mid-point of the crown, tension will be increased on that yarn.
As the belt revolves and that yarn seeks to move back to its normal position, this tension will diminish. Yarns on both sides of the belt seek that position which results in the least stress to themselves, consistent with the physical structure across which they are stressed and consistent with their individual position within the matrix of the belt carcass.
Accordingly, the belt will shift on the crowned pulley until these stressing forces are balanced and minimized
–centering the belt.
Experiment has shown that a crown is most effective when it has a long unsupported span of belt approaching the pulley. The lateral position of the belt can be influenced by the crown more easily when there is a minimum of resistance being offered by a supporting slider bed or by supporting idlers.
Georgia Duck goes to great lengths to manufacture balanced carcass belts so that the belt will self center and track on the crown.
In most non-unit-handling conveyors this optimum condition does not exist on the top run and consequently, crown on the head pulley is of little value in training the belt. Further, it is a distinct detriment as far as lateral distribution of tension in the belt is concerned. Head pulleys therefore, should be uncrowned in normal circumstances. Tail pulleys and take-up pulleys which may have a fairly long approaching span without support can be crowned with some beneficial results.
The effectiveness of the crown is increased to a length of approximately 10 feet. Lengthening the unsupported span beyond 10 feet does not seem to increase the effectiveness of the crown.
Diminishing the length of the unsupported span on the other hand, does diminish the effectiveness of the crown. The shorter the unsupported span, the less effective the crown will be. Snub pulleys can reduce effectiveness by 50% or more.
We recommend a standard pulley crown of 1/16" on radius per foot of pulley face. This results in an increase in pulley diameter at a point 12" from the edge of the pulley of 1/8" above the edge diameter. A crown of 1/8" per foot should be considered maximum. Crowns may be trapezoidal or radius.
It is further recommended that the crown not be carried beyond a point 18" in from the edge of the pulley. If the pulley width is greater than 36" it is recommended that a trapezoidal pulley be used. In other words, that pulley will have a flat face in its center equivalent to the amount that the pulley width exceeds 36". Radius crowns work, but may take a few minutes longer to stabilize.
With the advent of CNC Machining, we see more use of radial crowns, but the same rule regarding maximum crown should apply. Special Note: The belt must stretch to conform to the crown or it will not be effective.
10
Index Page
Equipment Induced Camber
Camber can be induced into a perfectly straight belt by the roll or rolls preceding the camber. If the roll is cocked, the belt will react and will move toward that end of the roll which it contacts first.
This, of course, throws the belt off-center. If now, subsequent structural adjustments center that roll, the belt installation will be left with a cambered appearance. This camber may be removed by simply aligning the roll or rolls which are cocked.
Specific Training Sequence
Emergency
If the conveyor system, including the belt, has been designed, built and installed according to good engineering and manufacturing practice, the belt should track at start-up. There may be minor variations from the ideal because of manufacturing tolerance–this will simply result in a system in which the belt is not tracking absolutely perfectly, but one in which the belt can be operated without belt damage long enough for the tracking sequence to take place. Normally belt width is less than pulley face width and a small amount of belt movement will not cause any damage.
Occasionally, there may be a serious maladjustment or defect in the system which will throw the belt off to such a degree as to threaten belt damage. It may actually be necessary to station men at each end of the conveyor and physically force the belt back in line by means of a smooth, steel bar.
In extreme cases it may even be necessary to shut the conveyor down, make any adjustment indicated, and then restring and reposition the belt before start-up. In any case, it is extremely important to avoid belt damage. Once a belt is damaged, it will not necessarily recenter itself.
If the conveyor structure has been checked, appears to be true, and all rolls appear to be perpendicular to the system center line and severe belt tracking problems still persist, it is advisable to shut the system down and establish a belt center
line as a frame of reference. (Use the technique outlined previously in this discussion.) Now that a belt center line has been established. Use this line as the reference for the adjustment of each individual pulley, snubber, roll, etc. Once all rolls are perpendicular to the belt center line, the belt will track well enough so that the specific training sequence can commence.
(If it was necessary to establish the belt center line, double-check the system structure. Normally, the system center line and belt center line are equivalent. A variance suggests that something has been overlooked in examination of the structure, pulleys, idlers, etc.)
11
Index Page
IV. Training Belt on Package or
Unit Conveyors
At this point, let us assume that we have a system which is at least operating and with a belt running well enough so that it is not a danger of being damaged. For purposes of our study, let us use the hypothetical conveyor design which follows.
Keep in mind that we will follow the general training sequence previously outlined, namely:
1. Return run-working from head toward tail, low tension side.
be necessary to compromise and not cock the roll quite as much as we would like. (“Tracking” can be considered a physical embodiment of the art of compromise.)
For purpose of completeness, it should be noted that if one end of roll #2 is lower than the other, the belt will favor that side due to the pull of gravity.
This effect may, or may not, be masked by the tracking effect of roll #2.
2. Top run-working from tail toward head, high tension side.
3. First empty, then full; with belt running.
Idler #3 has little or no tracking effect due to the lack of unsupported span between itself and roll
#2. It can, however, be used to control the position of the belt since it does have a cambering effect.
Return Run
It is important to note at this point that virtually any adjustment you make to these rolls will be slight.
Considering the hypothetical conveyor system we have outlined (See Figure #1, page 13), our first consideration will be the first item in the return run–namely, the head pulley snubber (roll #1). From our previous discussion, it is obvious that cocking the head pulley snubber will have very little effect on the tracking since there is essentially no unsupported belt span available to allow the belt to react.
However, cocking snubber #1 will tend to throw a camber into the belt which will tend to throw the belt off-center and become apparent at roll #2.
Idler #4 is highly effective as a tracking roll because it does have a good unsupported belt span approaching it. It will induce very little, if any, camber to the belt because of its proximity to roll #5.
Roll #5 on this particular conveyor is our drive pulley and will be a high tension region for the belt.
This, coupled with the fact that there is little or no unsupported belt span between itself and roll #4, suggests that this is a poor tracking pulley and should not be crowned. This pulley should be squared to the belt center line and left there.
The same is true for roll #6–the snubber pulley.
The return idler #2 does have a sufficiently long unsupported span for belt reaction and therefore, cocking idler #2 in a horizontal plane, can have a beneficial tracking effect. (If after we have adjusted idler #2 to the point where the belt is centered on idler #2, examination shows a camber between rolls 1 and 2, this is an indication that roll #1 is not perpendicular to the belt center line and is imparting the camber to the belt in this section.)
Roll #7 will not be very effective for tracking purposes because of the short unsupported belt span, but can be a problem camber-wise if it is not perpendicular to the belt center line. This pulley should be square and left there.
If it is necessary to adjust roll #2 to an off-perpendicular position in order to center the belt on roll #2, this off-perpendicular position of roll #2 can cause a subsequent cambering effect. In this particular conveyor design, this cambering effect will be almost totally eliminated by the proximity of roll #3.
If the distance between roll #2 and roll #3 were
8 feet (let us say) this cambering effect could be pronounced. Under these circumstances it may
The take-up pulley (#8) does have potential for tracking, as well as for camber, due to the unsupported belt span between itself and rolls #7 and 9.
12
If, however, we adjust roll #8 so it is off-perpendicular in order to achieve a tracking effect on the belt as it approaches roll #8 from roll #7, that same adjustment will tend to impart camber to the belt as it leaves roll #8 and approaches roll #9. Accordingly, compromise is called for and roll #8 should be perpendicular to the belt center line. Unfortunately, this
13
Index Page
Index Page may not always be possible since roll #8 is a takeup roll and in this case, is spring-loaded. Roll #8 will move from time to time as tensions increase and decrease in the system due to the normal operating cycle. Good engineering practice dictates that roll #8 be constrained in some sort of carriage construction designed to keep it perpendicular to the belt center line at all times. However, there can be tolerance differences, corrosion effects, lack of lubrications, etc., as well as other problems which may, at least momentarily, throw the take-up roll off-square. To avoid the “mistracking effect” this would have, it would be a good idea to impart a self-aligning feature to the take-up roll by crowning it. Further, it is in a low tension portion of the belt circuit and does have a reasonably effective unsupported belt span preceding it.
tracking effect due to the fact that there is no unsupported belt span between itself and roll #10.
The snubber roll (#10) in this particular case has taken over the tracking function of the system. If, on the other hand, there were no roll #10, then the tail pulley would in truth have a tracking function and could effectively be crowned.
The tail pulley (#11) does have a marked cambering effect because of the long span between itself and roll #13. It’s true that this span is supported by a slider bed which tends to modify the cambering effect. However, since the loading point or points will occur somewhere on this section of the belt and probably quite close to the tail pulley, it is important that the tail pulley be squared relative to the center line so as to avoid any camber whatsoever.
Roll #9 can exert a reasonable amount of tracking force on the belt because of the unsupported belt span preceding it, but it can also exert a considerable cambering effect since the unsupported belt span between roll 9 and 10 is so large. Here again, compromise is called for–the ideal situation being to simply square pulley #9.
Roll #10 in this design is a snubber and is very important from a tracking point of view. First of all, it has a long unsupported belt span preceding it and therefore is capable of exerting a strong centering influence on the belt. Secondly, the position of this snubber means that it will feed the belt immediately onto the tail pulley and will, in essence, be responsible for positioning of the belt relative to loading. Roll #10 will obviously have little or no cambering effect.
Because of the importance of presenting the belt in a centered manner to the tail pulley, it might be wise to impart a self-aligning feature to roll #10 by crowning it. (Incidentally, this is also a low tension portion of the belt circuit.) Note that the crown will not be as effective as normal due to close proximity of roll #11.
The slider bed (#12) can have a marked effect on belt tracking. The slider bed must be level (side to side) since if it is not level the belt will tend to run toward the low side as it is being pulled by gravity.
Further, the slider bed needs to be clean and smooth. If it is rough on one side or it has a layer of gummy, sticky, reverted rubber on one side, it will tend to pull the belt toward that side. In this event, the slider bed should be thoroughly cleaned and buffed. The underside of the belt must also be cleaned ( do not use solvent based cleaners on belt).
Carrying idlers #13, #14 and #15 do have tracking and cambering effects based upon their distance from each other, and their distance relative to the slider bed and head pulley. The standard roller bed will have the carrying idlers so close together that individually the rolls will have very little tracking or cambering effects. If, however, they are all cocked in one direction, the effect can be marked. Accordingly, we would urge that carrying idlers not be used for tracking unless absolutely necessary and simply be squared relative to the belt center line.
Unless a snub pulley is needed to maintain belt within framework, a snub pulley doesn’t serve us well. The snub causes loss of tracking effectiveness with the tail, more belt flex and costs more. Avoid if at all possible.
The tail pulley (roll #11) should be perpendicular to the belt center line. In this particular design adjusting the tail pulley will have very little, if any,
14
The discharge pulley (#16) is located in a high tension portion of the belt circuit. Further, there is usually little or no unsupported belt span preceding it, which severely limits any tracking effect which can be obtained from the head pulley. Accordingly, it is good practice not to crown the head pulley nor use it for tracking adjustments. If you find that you must adjust the head pulley in order to center the belt, you will, in all likelihood, find that you have merely realigned an off-square head pulley.
Index Page
Empty/Full
As each adjustment is made on the individual components of the conveyor system, it is necessary to wait a few minutes, and for a minimum of 2 belt revolutions, in order to give the belt time to react and to observe the true effect of the adjustment you have made. If the belt has over-reacted, do not proceed to another adjustment until you first modify the original adjustment and again, observe its effect.
It is possible that once you have made the entire circuit of the conveyor that adjustments made in the latter part of the sequence may have modified or effected adjustments made earlier in the sequence. It is good practice to double-check by going through the entire sequence again, until the belt is tracking as you wish.
Now that the belt is tracking, the conveyor system should run fully loaded and the tracking sequence repeated.
Ideally, loading should be done in the center of the belt. Unfortunately, however, system parameters may prevent this. In this event, you may find it necessary to modify the original adjustments, so as to compensate for the off-center loading. Here again, compromise is called for. The belt must track empty, as well as full, with as little variation as possible. (Note: Expect some variation–full vs. empty.)
Reversible
In reversible conveyor systems, all idlers should be kept at right angles to the direction of belt travel and any correction necessary made with self-aligning idlers, designed for reversing operations.
It might be profitable to consider our hypothetical conveyor, if the belt were now reversed. (See
Figure #2, page 16.)
First of all, our sequence would be altered, since we would now start with roll #10, proceed to 9, 8, etc.
Roll #10 would now be functioning as the head pulley snubber. Any adjustment off the perpendicular of roll #10 would have little tracking effect, because there is no unsupported belt span between #11 and
#10. Further, such a deviation from the perpendicular would have a substantial cambering effect. Under the circumstances, therefore, it should be set perpendicular to the belt center line.
Our comments relative to roll #9 through #5 inclusive would be substantially the same as before.
Reaction of roll #4, however, would reverse. Previously, it had a tracking effect and no cambering effect. Now, the reverse is true–it has no tracking effect, but considerable cambering effect. Rolls #3 and 2, likewise, have reversed their actions on the belt. Accordingly, all 3 of these rolls should be left perpendicular to the belt center line.
Roll #1 is now the tail pulley snubber rather than the head pulley snubber. Here, again, it has reversed its role and will now exert a significant tracking effect and little cambering effect.
Roll #16 and roll #11 have now reversed positions and accordingly, comments made previously about roll #11 would apply to roll #16 and vice versa.
Comments made previously on items 12 through
15 would essentially hold under these particular conditions.
It is of course, recommended that rolls #11, 13, 14,
15 and 16 simply set perpendicular to the belt center line.
Finally, if this particular conveyor were to be used as a reversible conveyor, serious considerations should be given to replacing return rolls #2 and 3 with a single self-aligning roll. Further, there might be some advantage to crowning both snub rolls (#1 and #10). In this particular case, snub roll #1 would offer considerable tracking effect and would help center the belt on the tail pulley #16. When the belt is reversed, #1 would lose it’s tracking capability, but #10 would pick it up. Further, if #1 were indeed perpendicular to the belt line, it would not cause a camber problem. The same can be said for roll #10.
15
16
Index Page
Index Page
Short Center-Wide Belt
Conveyors
Short center-wide belt conveyors offer a special tracking challenge, simply because there usually is not enough belt length to stretch the necessary distance for crown conformation. If belt centers are
10 times belt width, these problems do not normally show up; below 5:1 ratio you must be aware of several factors: (1) Amount and type of crown,
(2) belt stress/strain curve, (3) tension on belt and
(4) location of crowns in the system.
Georgia Duck has products for lightweight material handling systems for length to width ratios of 1:1 and even below, but these are special and all details of conveyors must be discussed with a
Georgia Duck distributor or Georgia Duck representative.
Tracking Priority
Finally, we would like to suggest that when tracking a conveyor belt, number one priority should be given to adjusting return idlers followed by adjustment of snubber rolls. If there is no snubber on the tail pulley, then adjusting the tail pulley does become effective and should be used. The head pulley is normally a flat pulley and should be set on a perpendicular to the belt center line. The head pulley should be adjusted for tracking purposes only as a last resort.
17
Index Page
V. Training Bulk Haulage Belting
Training a heavy duty belt is similar in a lot of ways to training a light weight belt.
The major difference is that the troughed idlers on the carry side exert a natural gravitational training force. The edges of the belt that are turned up tend to gravitate toward the center of the conveyor, thereby exerting a powerful training action. Many bulk haulage conveyor operators do not attempt to add any other training devices to the carry side of the conveyor, as the troughers do a fine job by themselves.
As with training light weight belt, all major pulleys: head, tail, drive, snubs, bends, and take-up should be parallel, level and square. All idlers and pulleys need to be clean and functioning properly. All loading stations have to be centered so that product is introduced to the center of the belt. Any belt training idlers that are on the system must be in proper working order and be installed in the proper direction. The lagging on the drive pulley should be inspected and replaced, if the lagging is damaged or if the surface is smooth and hard, which can result in slippage. It is good practice to replace rubber lagging when a new belt is installed, particularly if the lagging is old, as the rubber tends to harden with age and become less effective.
The new belt may have some internal stresses from manufacturing; therefore, the best procedure for a new belt is to run it for a while before making any adjustments. This run-in period will relieve most manufacturing stresses that can occur during weaving, treating, calendering, assembly, curing, and slitting. Some belts, after installation, may run perfectly from the beginning. If the new belt will stay out of the frame on the return side, then run it empty for an hour or two, then begin introducing a load to the belt. The belt should be constantly inspected during this break-in period. Full belt contact with all carry side idlers is important due to the training forces that are present with the troughed idler sets.
As stated in the beginning of this brochure, crowned pulleys are not required for bulk haulage belting. Crowned pulleys may offer a minor contribution towards training when the crowned face is used on a low-tension pulley like the take-up or the tail pulley. The crown will have no effect if used on the high tension head pulley or drive pulley.
High modulus belt fabrics like nylon, polyester, and aramid do not respond to the centering forces of crowned pulleys; and in some cases, can actually have an adverse effect on the belt. Steel cord belts must have fully machined straight faced pulleys to operate around, because a crown will create adverse stresses in the belt and in the splice.
The theory of training a heavy duty belt is to feed the carry side square, use the troughers to keep the belt centered through the discharge, then train the empty belt on the return (slack side).
Self-training idlers should be on 100' centers on the return side, unless the conveyor is out of square, then 50' centers may be required in areas where the frame is out of square. The locations of the self-trainers are very important, as they can not function properly if installed in the wrong place.
The first self-training idler on the return should be placed about 30' behind the head. This allows the training idler to align the belt coming out of the head
(into the trainer). . .then 30' past the trainer. Selftraining idlers do not work when placed too close to a terminal pulley, snub, bend or take-up. These pulleys have more belt wrap than the training idler, which off-sets any training forces that the idler has.
You need at least 30' of free run on each side of the training idler to make it effective. On slow-moving belts, 20' of free area on each side will work. At 800' per minute, the self-training idler should be placed 40' from a major pulley. The trainers can then be spread out over the return. If the takeup is 80' behind the head, place one self-trainer between the head and take-up areas, after the takeup area (20' to 40'); then place the trainers on 100' centers back to within 20' to 40' of the tail. If the self-training return idlers are still not effective, shim the return trainers up to present the trainer with more belt surface area. Equally effective is to use the next size up return run self-trainer–a 5" dia. to a
6" dia. trainer. A good rule of thumb is never skew an idler that has over 90° of wrap, to ensure that the high modulus belt fabric will not be stretched out of square. This method will train the slack side belt,
18
Index Page feed the tail square, then run true on the carry side because of the centering forces from the troughers.
Self-training troughing idlers should not be shimmed up because the additional pressure that is created on the belt in the idler gap area can cause premature belt failure in the idler junction area.
Another approach to training the slack side of long centered conveyors is the use of 2 roll “V” return idlers. With this type idler (generally 10°), gravity becomes the training force, and the belt edges are not subject to wear from the vertical arms on selftrainers. It should be noted that due to the small degree of angle with this type of return idler, if the frame is severely out of square the belt can run out of the “V” and into the return frame.
The most important part of the tracking is not to use major pulleys for training; and to allow the trainer to have slack belt feeding into and out of the trainer.
Bi-Directional Belts
Bi-directional belts should only use carry side troughers that are vertical and do not have any tilt added in. All return run self-trainers should be of the bi-directional type.
In areas along the carry side where the frame is not level and true, the following additional training method can be used. Each individual idler stand can be tilted in the line of travel by placing a washer under the rear legs of the idler stand. This forward tilt is not to exceed 2° from vertical. This is
NOT to be done with reversing conveyors. The negative side of this training method is that excessive wear on the pulley cover and on the idler can result since the idler is no longer rotating on an axis 90° to the belt path.
2°
Maximum
Direction of travel
Bi-directional hardware, such as pulleys, top side idlers and return side idlers must be level, parallel and square.
When pulling the load towards the drive pulley, the tight side is on the carry side and the slack side is on the return. When pulling from the return side, ie., pushing the load, the tight side is on the return and the slack side is on the carry side.
The slack side of the belt will have more catenary, ie., loose belt, to drape over the idlers than the tight side; therefore the idlers on the slack side will have a more influential training effect than idlers on the tight side, ie., less drape over the idler.
Therefore it is mandatory that all idlers be level and square.
Skewing an idler on the tight side will allow certain training advantages. When the conveyor reverses, this same idler is now on the slack side, and will have more catenary, or drape, and will now have a greater influence than before.
Washer Top idler stand
Feeder Belts
Short centered feeder belts should be doublechecked for squareness with a steel tape. The two terminal pulleys need to be parallel, level and square.
The reader should also keep in mind another potential problem, when trying to train a bi-directional bulk haulage conveyor. A carry side trougher, when skewed, will have minimum effect when the belt is run empty and pulled over the idler. This same trougher with a load being pulled over it, now becomes even more influential, due to the weight on the belt forcing the belt down on the idler. If you now push the belt in the opposite direction with a load on it, this same idler has an even greater training effect.
All training should be done on the return, or slack side. On a short conveyor (50' centers, or so) place one large diameter self-trainer on the return side in the middle of the conveyor. This roll can be shimmed up to increase the effectiveness of the roll.
19
These are some of the reasons that make training bi-directional conveyors so difficult. Therefore, all hardware must remain level and square and the use of bi-directional self-trainers is a must.
Index Page
C O N V E Y O R B E L T I N G A M E R I C A S
21 Laredo Drive
Scottdale, Georgia 30079 • USA
Phone: (404) 297-3170
Fax: (404) 296-5165 www.fennerdunlopamericas.com
IS O 9001: 2000 C ertified
10/03
APPENDIX D
Conveyor Belt Maintenance
Conveyor belt maintenance not only includes proper care of the belt itself but also includes care and maintenance of the frame and accessories.
The first step in the process is to design an inspection form to encompass all aspects of each conveyor. This brochure is designed to assist in the actual design of the inspection report and the steps needed to correct any problems that you see when making this inspection.
This inspection form will take into account various types of conveyors from package handling to bulk haulage, therefore some of the items covered in our inspection and repair report may not apply to your particular conveyor.
Index Page
Table of Contents
I. Belt Shut Down and Empty...................3
II. Belt Running Empty...............................4
III. Belt Running Loaded.............................4
IV. Corrective Action....................................4
V.
Inspection Form and Checklist.......7 & 8
Index Page
Index Page
I. Belt Shut Down and Empty
The first step is to inspect the conveyor belt when the system is shut down and empty. This allows the opportunity to check for any damage to the belt or splice. The conveyor should be locked out while making this inspection.
Rubber belt damage should be repaired using the hot vulcanized repair method or the cold repair method. Belt fabrics that are exposed to the weather or to product contamination should be properly cleaned, dried, then covered with new rubber. These repairs are critical to prevent moisture from penetrating the belt and breaking down the cover adhesions, and to prevent product contamination from abrading the carcass and also breaking down the adhesions.
Very few, if any repairs can be made to lightweight belts.
The splice can also be inspected and if damage in the splice is visible it is suggested that the splice be repaired or replaced.
This is also a good time to walk the conveyor and check the following components.
A) Tail Pulley free from build-up and trapped material
B) Tail Pulley damage
C) Skirting in the loading area
D) Impact Bed or Impact Idler damage
E) Slider Bed clean and smooth
F) Carrying Side Idler damage
G) Carrying Side Self Trainers - operational and not tied off
H) Secondary Loading Stations a) Skirting b) Impact Bed or Impact Idler damage
I) Tripper Frame damage
J) Tripper Discharge Pulley - clean
K) Tripper Bend Pulleys - clean
L) Head Pulley and/or Drive Pulley a) Clean b) Check for worn lagging c) Re-lag Drive Pulley if rubber is old, worn, smooth and hard
M) Head Pulley cleaner or scraper operational
N) Head Pulley Snub - clean
O) Return Idlers - clean & turning freely
P) Bend Pulleys - clean
Q) Take-Up - clean
R) Return Side Self Trainers - operational and not tied off
S) Damage to return side frame due to mistraining
T) Plow or Scraper in front of Tail Pulley - operational
The preceding list should be used as a guide when inspecting the conveyor while it is empty
3
Index Page and shut down.
Numerous items in the preceding list contained the words clean or operational. Pulleys or idlers that have build up on them will cause tracking problems. The same can be said for pulleys that have some of the rubber lagging worn off.
Scrapers, plows and self-trainers must be operational to perform their tasks. Belt damage, pulley damage and tracking problems will result if these accessory pieces of hardware are not maintained.
II. Belt Running Empty
The conveyor should be turned on and run empty. The purpose of this is to walk the conveyor, while running empty, to check for any tracking problems. Before any adjustments are made to correct a tracking problem, the system will need to be inspected under running conditions when loaded, because empty belts and loaded belts do not necessarily track the same way. For more information on tracking, refer to the Georgia Duck Tracking Brochure.
III. Belt Running Loaded
The next step in our inspection process is to run the belt in a loaded condition. We will add a few new steps in the inspection process and repeat a few of the previous steps.
The following is our check list for operating the conveyor while loaded:
A) Tail Pulley - Turning freely without bearing noise, product build up or carryback; belt tracking satisfactorily
B) Load area spillage
C) Carry Side Idlers - turning freely
D) Carry Side Self-Trainers - functioning
E) Secondary Loading Station spillage
F) Tripper Area a) Tracking b) Spillage
G) Head Pulley and or Drive Pulley a) Smoothly running b) Slippage when starting or running c) Belt Cleaners - functioning d) Belt Tracking
H) Head Pulley Snub - turning freely without bearing noise and clean
I) Return Idlers - clean and turning freely
J) Bend Pulleys - turning freely without bearing noise and clean
K) Take-up Pulley - turning freely without bearing noise, clean, moving freely in the frame
L) Return Side Self Trainers - functioning
M) General Belt Tracking
N) Plow or Scraper in front of Tail Pulley - functioning
IV. Corrective Action
The last step is to take the corrected action required on the conveyor in addition to:
A) Clean Up
B) Lubrication
C) Safety Concerns - such as installing or repairing conveyor crossovers, safety stop cables, holdbacks on incline conveyors, edge limit switches, motor guards, hand rails, etc.
We have mentioned the word cleanliness throughout this brochure. Maintaining a clean system can not be stressed enough.
4
Index Page
A conveyor system with carryback on the return side is the single biggest reason that conveyor belts are replaced, return idlers and pulleys are replaced and structure is worn through. Material build up on the belt and hardware causes tracking problems, that will lead to edge damage, that leads to new belt and new idlers.
We urge you to use scrapers on the head pulley and plows in front of the tail pulley as preven-
A power driven revolving brush will help remove product from the belt. This method is rarely used because the bristles tend to clog up with tion for damage in your maintenance planning.
Some sticky materials present a real challenge when it comes to preventing carryback. We would like to offer a few additional suggestions as to handling these products.
Cleated belts may be reversed to allow better release at the discharge point.
A dual scraper system on the head pulley is the most common way to eliminate product carryback.
A water spray on the belt cover along with wiper blades will effectively remove most products from sticking to the cover.
A series of out of round (cam shaped) return idlers will also assist in cleaning. These idlers are spiral wound from the edges towards the center of the idler and work on the premise of a turning beater bar arrangement.
A compressed air blast has been successfully used on material like coal and fine wet sand.
5 material and wear out quickly. A brush may be the only solution for cleated belts.
Product build up on return side pulleys is a major concern. If your belt is not effectively clean on the return run, then any bend pulleys or head snub pulley that come in contact with the carry side of the belt will accumulate product. We would like to offer a few hints on pulley and idler cleaning.
All return side pulleys that come in contact with the carry cover can be lagged with a soft rubber vulcanized to the pulley. The constant flexing action of the soft lagging will cause material to fall off and reduce material accumulation.
A lever weighted urethane scraper pressed against the pulley face, is an excellent way to remove build up. This system causes additional wear on the pulley face so it is suggested to use heavier walled return bend pulleys when using a scraper. If a scraper is applied to a head snub or bend pulleys at the take-up area then deflector plates will have to be installed to deflect he build up away from the belt.
Index Page
Return idlers can be rubber covered and will help prevent product from sticking to the return idlers.
Return idlers can be purchased that are nothing more than discs mounted on a shaft. These discs can be made of soft rubber, urethane, or ceramics. This type of return idler can be very effective to prevent build up. The major problem when using this style of return roller is that the manufacturers do not put enough discs on the shaft to effectively support the belt in the middle, and support the edges of the belt if any mis-tracking occurs.
Another effective measure is called a turnover system. By the use of a series of rollers the belt is flipped over at the head and tail on the return side. This allows the belt to run the return side with the carry (dirty side) side up and the pulley
(clean side) side down in contact with the return rollers. Any spillage from the product carryback will be limited to the two twist areas. For more information on turnover systems, refer to our brochure on Conveyor Design Tips.
The following inspection form and checklist should be used as a guide for your conveyor systems.
There may be additions or deletions depending on your particular conveyor designs.
6
CONVEYOR INSPECTION FORM AND CHECKLIST
Inspection Date _____________________ Conveyor Number_____________
I.
Belt Shut down and Empty
_____ Belt Condition
_____ Splice Condition
_____ Tail Pulley
_____ Skirting
_____ Impact Bed/Idlers
_____ Slider Bed
_____ Carry Side Idlers
_____ Carry Side Self Trainers
_____ Secondary Loading Station
_____ Tripper Frame
_____ Tripper Discharge Pulley
_____ Tripper Bends
_____ Head / Drive Pulley
_____ Head Pulley Cleaner
_____ Head / Drive Pulley Snub If Present
_____ Return Run Drive
_____ Return Idlers
_____ Bend Pulleys
_____ Take-Up Pulley
_____ Return Side Self Trainers
_____ Return Side Frame
_____ Tail Pulley Plow / Scraper
7
Corrective Action
Index Page
II.
Belt Running Empty
_____Tracking
III.
Belt Running Loaded
_____ Tail Pulley
_____ Spillage in Load Area
_____ Carry Side Self trainers
_____ Secondary Load Station Spillage
_____ Tripper Area
_____ Tracking
_____ Spillage
_____ Head Pulley
_____ Drive Pulley
_____ Head Pulley Cleaner
_____ Head / Drive Pulley Cleaner
_____ Head / Drive Pulley Snub
_____ Return Idlers
_____ Bend Pulleys
_____ Take-Up Pulley
_____ Return Side Self Trainers
_____ Belt Tracking
_____ Tail Pulley Plow / Scraper
IV. Corrective Action
_____ Clean Up
_____ Lubrication
_____ Safety
8
Corrective Action
Index Page
Index Page
C O N V E Y O R B E L T I N G A M E R I C A S
21 Laredo Drive
Scottdale, Georgia 30079 • USA
Phone: (404) 297-3170
Fax: (404) 296-5165 www.fennerdunlopamericas.com
IS O 9001: 2000 C ertified
10/03
APPENDIX E
Trouble Shooting
Spill
Effects of Off-Center Loading
Edge Wear
The enclosed conveyor belt trouble shooting chart can serve as a general guide for some of the more common conveyor belt problems.
If your belt problem does not seem to resolve itself with these corrective measures, or if your belt problem is not found on this list, then contact Georgia Duck and request a visit by one of our factory representatives.
* The idler junction is the gap between the functioning surfaces of the center roll and one of the side rolls of the idler (See Fig. 1). This gap poses a potential hazard for the belt by providing a narrow space in which the belt can settle experiencing highly detrimental flex and possible exposure to oil or grease from the idler bearings (Fig. 2).
When slipping of the belt into the idler junction is the cause of belt damage, it is called idler junction failure. The idler gap should be less than .4” or twice belt thickness-whichrever is less.
Fig. 1 Fig. 2
Index Page
Trouble Shooting
Problem/Cause For Solutions Refer to Answer #
A. Belt runs off at tail pulley.
B. Belt runs to one side for long distance or entire length of conveyor.
C. Particular section of belt runs to one side at all points on conveyor.
D. Belt runs off at head pulley.
E. Conveyor runs to one side at given point on structure.
F. Belt runs true when empty, crooked when loaded.
G. Belt slips.
H. Belt slips on starting.
I. Excessive belt stretch.
J. Grooving, gouging or stripping of top cover.
39 10 1 19 31
39 8 5 1
6 7 46
33 10 1 3
5 4 1 2 3 44
8 51 52
34 33 31 10 4 30
34 31 33 30 42 43
12 35 32 43
13 4 15 16 53
K. Excessive top cover wear, uniform around belt.
L. Severe pulley cover wear.
M. Longitudinal grooving or cracking of bottom cover.
N. Covers harden or crack.
O. Cover swells in spots or strreaks.
19 20 10 8 36
4 9 10 17 1 27
4 10 9 33 36
23 37
21
P. Belt breaks at or behind fasteners; fasteners pull out.
Q. Vulcanized splice separation.
R. Excessive edge wear, broken edges.
S. Transverse breaks at belt edge.
24 22 48 30 47 49
38 30 12 17 25
8 10 40 7 50 38
18 25 26
T. Short breaks in carcass parallel to belt edge, star breaks in carcass. 16 17
U. Ply separation.
V. Carcass fatigue at idler junction.*
W. Cover blisters or sand blisters.
X. Belt Cupping-Old Belt (was OK when new).
29 30 23
25 26 27 28 29 36
45 21
21 23
Index Page
Conveyor System Problems/Causes and
Their Solutions
1. Idlers or pulleys out-of square with center line of belt: readjust idlers in affected area.
2. Conveyor frame or structure crooked: straighten in affected area.
3. Idler stands not centered on belt: readjust idlers in affected area.
4. Sticking idlers: free idlers and improve maintenance and lubrication.
5. Build-up of material on idlers: remove accumulation; improve maintenance. Install scrapers or other cleaning devices.
6. Belt not joined squarely: remove affected splice and resplice.
7. Bowed belt: for new belt this condition should disappear during break-in; in rare instances belt must be straightened of replaced; check storage and handling of belt rolls.
8. Off-center loading or poor loading: adjust chute to place load on center of belt; discharge material in direction of belt travel at or near belt speed.
9. Slippage on drive pulley: increase tension through screw take-up or add counterweight; lag drive pulley; increase arc of contact.
10. Material spillage and build-up: improve loading and transfer conditions; install cleaning devices; improve maintenance.
11. Bolt heads protruding above lagging: tighten bolts; replace lagging; use vulcanized-on lagging.
12 Tension too high: increase speed, same tonnage, same speed; reduce friction with better maintenance and replacement of damaged idlers; decrease tension by increasing arc of contact or go to lagged pulley; reduce CWT to minimum amount.
13. Skirt boards improperly adjusted or of wrong material: adjust skirt board supports to minimum 1” between metal and belt with gap increasing in direction of belt travel; use skirt board rubber (not old belt).
14. Load jams in chute: redesign chute for proper angle and width.
15. Material hanging up in or under chute: improve loading to reduce spillage; install baffles; widen chute.
16. Impact of material on belt; reduce impact by improving chute design; install impact idlers, or impact bed.
17. Material trapped between belt and pulley: install plows or scrapers on return run ahead of tail pulley.
18. Belt edges folding up on structure: same corrections as for 1, 2, 3; install limit switches; provide more clearance.
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Index Page
19. Dirty, stuck, or misaligned return rolls: remove accumulations; install cleaning devices; use self-cleaning return rolls; improve maintenance and lubrication.
20. Cover quality too low: replace with belt of heavier cover gauge or higher quality rubber or other elastomer.
21. Spilled oil or grease: over-lubrication of idlers: improve housekeeping; reduce quantity of grease used; check grease seals
22. Wrong type of fastener, fasteners too tight or too loose: use proper fastener and splice technique; set up schedule for regular fastener inspection.
23. Heat or chemical damage: use belt designed for specific condition.
24. Fastener plates too long for pulley size: replace with smaller fasteners; increase pulley size.
25. Improper transition between troughed belt and terminal pulleys: adjust transition in accordance with Georgia Duck Belting Catalog.
26. Severe convex (hump) vertical curve: decrease idler spacing in curve; increase curve radius.
27. Excessive forward tilt of trough rolls: reduce forward tilt of idlers to no more than 2° from vertical.
28. Excess gap between idler rolls: replace idlers; replace with heavier belt.
29. Insufficient transverse stiffness: replace with the proper belt.
30. Pulleys too small: use larger diameter pulleys.
31. Counterweight too light: add counterweight or increase screw take-up tension to value determined from calculations.
32. Counterweight too heavy: lighten counterweight to value required by calculations.
33. Pulley lagging worn: replace pulley lagging.
34. Insufficient traction between belt and pulley: lag drive pulley; increase belt wrap; install belt cleaning devices.
35. System underbelted: recalculate belt tensions and select proper belt.
36. Excessive sag between idlers causing load to work and shuffle on belt as it passes over idlers: increase tension if unnecessarily low; reduce idler spacing.
37. Improper storage or handling: refer to Georgia Duck for proper storage or handling instructions.
38. Belt improperly spliced: resplice using proper method as recommended by Georgia Duck.
39. Belt running off-center around the tail pulley and through the loading area: install training idlers on the return run prior to tail pulley.
40. Belt hitting structure: install training idlers on carrying and return run.
41. Improper belt installation causing apparent excessive belt stretch: pull belt through counterweight with a tension equal to at least empty running tension; run belt in with mechanical fasteners.
42. Improper initial positioning of counterweight in its carriage causing apparent excessive belt stretch; check with Georgia Duck for recommended initial position.
43. Insufficient counterweight travel: consult Georgia Duck for recommended minimum distances.
44. Structure not level: level structure in affected area.
45. Cover cuts or very small cover punctures allow fines to work under cover and cut cover away from carcass: make spot repair with vulcanizer or self-curing repair material.
46. Worn edge: ”press” edge.
47. Interference from belt scrapers: adjust belt scrapers.
48. Tension too high for fasteners: use vulcanized splice.
49. Belt carcass too light: select stronger carcass.
50. Belt misalignment: see training recommendations.
51. Variations in nature and formation of load: use notched chute to keep load peak in exact center of belt.
52. Belt not making good contact with all idlers: adjust height so all idlers contact belt.
53. Sharp edges of material or tramp iron coming in contact with cover: use jingle bars, impact idlers, magnetic removal equipment.
Index Page
Index Page
C O N V E Y O R B E L T I N G A M E R I C A S
21 Laredo Drive
Scottdale, Georgia 30079 • USA
Phone: (404) 297-3170
Fax: (404) 296-5165 www.fennerdunlopamericas.com
IS O 9001: 2000 C ertified
10/03
APPENDIX F
1
2
APPENDIX G
Installation and Parts Replacement Manual for DODGE
Torque-Arm
™
TXT Double Reduction
Taper Bushed and Straight Bore Speed Reducers
TXT/HXT 1A
TXT/HXT 2A
TXT/HXT 3B
TXT/HXT 4B
TXT/HXT 5C
TXT/HXT 6A
TXT/HXT 7A
HXT 3B – 6B
HXT 4B – 6B
Includes Char-Lynn 6B Hydroil Reducers
HXT 5C – 6B
HXT 6A – 6B
These instructions must be read thoroughly before installation or operation.
INSTALLATION:
TXT 8A
TXT 9A
TXT 10A
HXT 7A – 6B
Below 15 RPM output speed, oil level must be adjusted to reach the highest oil level plug. If reducer position is to vary from those shown in Figure 1, either more or less oil may be required.
Consult Dodge.
1. Use lifting bracket where applicable to lift reducer.
2. Determine the running positions of the reducer. (See Fig. 1)
Note that the reducer is supplied with six plugs; four around the sides for horizontal installations and one on each face for vertical installations. These plugs must be arranged relative to the running positions as follows:
Horizontal Installations - Install the magnetic drain plug in the hole closest to the bottom of the reducer. Install the
plug in topmost hole. Of the two remaining plugs on the sides of the reducer, the lowest plug is the minimum oil level plug.
Vertical Installations - Install the plug in the hole provided in the upper face of the reducer housing.
If space is restricted on the upper face, install the vent in the highest hole on the side of the reducer per Figure 1 using the optional vertical vent kit. Install a plug in the hole in the bottom face of the reducer. Do not use this hole for the magnetic drain plug. Install the magnetic drain plug in the lowest hole on the sides of the reducer. Of the remaining holes on the sides of the reducer, use the plug in the upper housing half for the minimum oil level plug,
The running position of the reducer in a horizontal application is not limited to the four positions shown in Fig. 1. However, if running position is over 20° in position “B” & “D” or 5° in position
“A” & “C”, either way from sketches, the oil level plug cannot be used safely to check the oil level, unless during the checking, the torque arm is disconnected and the reducer is swung to within 20° for position “B” & “D” or 5° for position “A” & “C” of the positions shown in Fig. 1. Because of the many possible positions of the reducer, it may be necessary or desirable to make special adaptations using the lubrication furnished along with other standard pipe and oil level gauges as required.
holes
stand pipes
3. Mount reducer on driven shaft as follows:
WARNING: To ensure that drive is not unexpectedly started, turn off and lock out or tag power source before proceeding.
Remove all external loads from drive before removing or servicing drive or accessories. Failure to observe these precautions could result in bodily injury.
For Taper Bushed Reducer: Mount the reducer on the driven shaft per instruction sheet for the tapered bushing kit.
Figure 1 - Mounting Positions
4. Install sheave on input shaft as close to reducer as practical.
(See Fig. 2)
5. If not using a Dodge Torque-Arm motor mount, install motor and V-belt drive so belt will approximately be at right angles to the centerline between driven and input shaft. (See Fig. 3)
This will permit tightening the V-belt with the torque arm.
6. Install torque arm and adapter plates using the long reducer bolts. The adapter plates may be installed in any position around the input end of the reducer.
7. Install torque arm fulcrum on a and rigid support so that the torque arm will be approximately at right angles to the centerline through the driven shaft and the torque arm anchor screw. (See Fig. 4) Make sure that there is take-up in the turnbuckle for belt tension adjustment when using V-belt drive.
WARNING Because of the possible danger to persons(s) or property from accidents which may result from the improper use of products, it is important that correct procedures be followed. Products must be used in accordance with the engineering information specified in the catalog.
Proper installation, maintenance and operation procedures must be observed. The instructions in the instruction manuals must be followed.
Inspections should be made as necessary to assure safe operation under prevailing conditions. Proper guards and other suitable safety devices or procedures as may be desirable or as may be specified in safety codes should be provided, and are neither provided by Baldor Electric Company nor are the responsibility of Baldor Electric Company. This unit and its associated equipment must be installed, adjusted and maintained by qualified personnel who are familiar with the construction and operation of all equipment in the system and the potential hazards involved. When risk to persons or property may be involved, a holding device must be an integral part of the driven equipment beyond the speed reducer output shaft.
CAUTION: Unit is shipped without oil. Add proper amount of recommended lubricant before operating. Failure to observe this precaution could result in damage to or destruction of the equipment.
8. Fill gear reducer with the recommended volume of lubricant.
1
Figure 2 - Reducer and Sheave Installation
4. Mount the reducer on the driven shaft and align the shaft key with the reducer hub keyway. Maintain the recommended minimum distance “A” from the shaft bearing.
5. Insert the screws, with washers installed, in the unthreaded holes in the bushing flange and align with the threaded holes in the bushing backup plate. If necessary, rotate the bushing backup plate to align with the bushing screws. Tighten the screws lightly. If the reducer must be positioned closer than dimension “A”, place the screws with washers installed, in the unthreaded holes in the bushing before positioning reducer making sure to maintain at least 1/8” between the screw heads and the bearing.
6. Place the second tapered bushing in position on the shaft and align the bushing keyway with the shaft key. Align the unthreaded holes in the bushing with the threaded holes in the bushing backup plate. If necessary, rotate the bushing backup plate to align with the bushing holes. Insert bushing screws, with washers installed in the unthreaded holes in the bushing. Tighten screws lightly.
7. Alternately and evenly tighten the screws in the bushing nearest the equipment to the recommended torque given in
Table 1. Repeat procedure on outer bushing.
MINIMUM SHAFT LENGTH
A
Figure 3 - Angle of V-Drive
Figure 4 - Angle of Torque Arm
TXT TAPERED BUSHING INSTALLATION
WARNING: To ensure that drive is not unexpectedly started, turn off and lock out or tag power source before proceeding.
Remove all external loads from drive before removing or servicing drive or accessories. Failure to observe these precautions could result in bodily injury.
Taper Bore Bushings:
1. One bushing assembly is required to mount the reducer on the driven shaft. An assembly consists of two tapered bushings, bushing screws and washers, and necessary shaft keys or key.
The driven shaft must extend through the full length of the reducer. The minimum shaft length, as measured from the end of the shaft to the outer edge of the bushing flange
(see Figure 5), is given in Table 1. This dimension does not include dimension “A”. Dimension “A” should be added to the minimum shaft length to allow for the removal of the bushings at disassembly.
2. Place one bushing, flange end first, onto the driven shaft and position per dimension “A”, as shown in Table 1. This will allow the bolts to be threaded into the bushing and for future bushing and reducer removal. If the reducer must be positioned closer to the equipment than dimension “A”, place the screws, with washers installed, into the unthreaded holes of the bushing flange prior to placing the bushing on the shaft and position as required.
3. Insert the output key in the shaft and bushing. For ease of installation, rotate the driven shaft so that the shaft keyseat is at the top position.
2
Figure 5 - Minimum Recommended Dimensions
Table 1 - Minimum Mounting Dimensions and Bolt Torques
Minimum Required Shaft Length
Reducer Size Taper Bushing Straight Bushing
TXT1A
TXT2A
TXT3B
TXT4B
TXT5C
6-1/2
6-3/4
8-9/16
9-5/16
9-3/4
5-5/8
5-13/16
7-11/16
8-1/4
8-11/16
TXT6A
TXT7A
TXT8A
TXT9A
TXT10A
10-3/4
11-15/16
13-1/8
13-0
14-3/16
9-5/8
10-3/4
11-3/8
11-3/8
12-3/8
Bushing Screw Information and Minimum Clearance for Removal
Reducer Size Fastener Size Torque in In.-Lbs.
Dim. “A”
TXT1A 5/16-18 200 1-1/4
TXT2A
TXT3B
TXT4B
TXT5C
TXT6A
5/16-18
3/8-16
3/8-16
3/8-16
1/2-13
200
200
360
360
360
1-1/4
1-1/2
1-3/4
1-13/16
1-13/16
TXT7A
TXT8A
TXT9A
TXT10A
1/2-13
1/2-13
1/2-13
5/8-11
800
800
900
900
2-1/16
2-1/16
2-7/16
2-7/16
Straight Bore Bushings: LUBRICATION
1. One bushing assembly is required to mount the reducer on the driven shaft. An assembly consists of one keyed straight bushing, one plain straight bushing, required set screws, and necessary shaft key or keys. The driven shaft must extent through the reducer to operate properly. The minimum shaft length, as measured from the end of the shaft to the outer edge of the retaining collar, is given in Table 1.
2. Install the plain bushing into the reducer output hub on the side toward the equipment or bearing. Remove two short set screws from the retaining collar and install two of the longer set screws supplied with the bushing kit. Line up the bushing holes with the set screws. Thread the set screws in until they locate into the bushing holes. Make sure the set screws are threaded in only enough to locate the bushing in the reducer hub and does not extend thru the bushing.
3. Install the keyed bushing into the opposite end of the reducer hub as the plain bushing. Remove one short set screw from the retaining collar and install the remaining set screw from the bushing kit into the collar. Line up the bushing hole with the set screw. Thread the set screw in until it locates into the bushing hole. Make sure the set screw is threaded in only enough to locate the bushing in the reducer hub and does not extend through the bushing.
4. Mount the reducer on the driven shaft as close to the equipment or bearing as practical.
5. Line up the keyway in the bushing with the keyway in the driven shaft. Insert the key supplied with the bushing kit into the keyway. Gently tap the key into position until the key is flush with the edge of the reducer. Securely tighten all set screws.
IMPORTANT: Because Torque-Arm reducers are shipped without oil, it is extremely important to add the proper amount of lubricant prior to operating reducer. For most applications a high-grade petroleum-base rust and oxidation inhibited (R&O) gear oil is suitable. See Table 2 and Table 3 for proper oil volume and viscosity requirements.
Under severe conditions EP oil can be used provided the reducer is not equipped with an internal backstop. Internal backstops are designed to rely on friction to operate correctly. EP lubricants contain friction modifiers that will alter backstop performance and therefore must not to be used on reducers equipped with internal backstops.
Follow instructions on reducer warning tags.
Lubrication is very important for satisfactory operation. The proper oil level must be maintained at all times. Frequent inspection, at least monthly, with the unit not running and allowing sufficient time for the oil to cool and the entrapped air to settle out of the oil should be made by removing the level plug and verifying the level is being maintained. If oil level is low, add the proper lubricant until the oil volume is increased to the correct level.
After an initial operation of about two weeks, the oil should be changed. If desired, this oil may be filtered and reused. After the initial break in period, under average industrial operating conditions, the lubricant should be changed every 2500 hours of operation. At every oil change, drain reducer and flush with kerosene, clean magnetic drain plug and refill to proper level with new lubricant.
Standard Tapered Bushings Removal:
1. Remove bushing screws.
2. Place the screws in the threaded holes provided in the bushing flanges. Tighten the screws alternately and evenly until the bushings are free on the shaft. For ease of tightening screws make sure screw threads and threaded holes in the bushing flanges are clean. If the reducer was positioned closer than the recommended minimum distance
“A” as shown in Table 1, loosen the inboard bushing screws until they are clear of the bushing flange by 1/8”. Locate two
(2) wedges at 180 degrees between the bushing flange and the bushing backup plate. Drive the wedges alternately and evenly until the bushing is free on the shaft.
3. Remove the outside bushing, the reducer, key(s), and inboard bushing.
Under extreme operating conditions, such as rapid rise and fall of temperature, dust, dirt, chemical particles, chemical fumes, or oil sump temperatures above 200°F, the oil should be changed every
1 to 3 months, depending on severity of conditions.
CAUTION: Too much oil will cause overheating and too little will result in gear failure. Check oil level regularly. Failure to observe this precaution could result in equipment damage and/or bodily injury.
Heating is a natural characteristic of enclosed gearing. A maximum gear case temperature approaching 200°F is not uncommon for some units operating in normal ambient temperatures of 80°F. When operating at the rated capacity with proper lubrication, no damage will result from this temperature.
This maximum temperature was taken into consideration during the design of the reducer.
Table 2 - Oil Volumes
Reducer
Size
TXT1A
TXT2A
TXT3B
TXT4B
TXT5C
TXT6A
TXT7A
TXT8A
TXT9A
TXT10A
Ratio
9,15,25
9,15,25
9,15,25
9,15,25
9,15,25
9,15,25
9,15,25
15,25
15,26
15,24
1-7/8
3-1/4
4-1/4
6-1/2
8-1/2
13
23
② Position A
③ Qt ④ L
1/2
7/8
1-1/2
1/2
7/8
1-3/8
1-3/4
3-1/8
4
6-1/8
8
12-1/4
21-3/4
Approximate Volume of Oil to Fill Reducer to Oil Level Plug ⑥
② Position B ② Position C ② Position D ② Position E
③ Qt
1/2
④ L
1/2
③ Qt
5/8
④ L
5/8
③ Qt
3/4
④ L
3/4
③ Qt
1
④
1
L
1
1-1/2
2-1/4
4
5
8
11
13
14
1
1-3/8
2-1/8
3-3/4
4-3/4
7-1/2
10-3/8
12-1/4
13-1/4
5/8
3/4
1-1/4
3-1/4
4-1/4
7-1/4
10-1/2
12-1/2
15-3/4
5/8
3/4
1-1/8
3-1/8
4
6-7/8
9-7/8
11-7/8
14-7/8
1
2-1/4
1-3/4
4
5
9-1/4
8-1/2
14-1/4
18-3/4
1
2-1/8
1-5/8
3-3/4
4-3/4
8-3/4
8
13-1/2
17-3/4
1-5/8
2-5/8
3-3/8
7
8-5/8
15-3/8
19-1/8
25-3/8
41
1-1/2
2-1/2
3-1/8
6-5/8
8-1/8
14-1/2
18-1/8
24
38-3/4
4-1/4
8-5/8
9-1/8
16-3/8
19-1/8
25-3/8
41
② Position F
Qt L
1-1/4
1-3/4
3
1-1/8
1-5/8
2-7/8
4
8-1/8
8-5/8
15-1/2
18-1/8
24
38-3/4
① Oil quantity is approximate. Service with lubricant until oil runs out of oil level hole.
② Refer to Figure 1 for mounting positions.
③ US measure: 1 quart = 32 fluid ounces = .94646 liters.
④ Conversion from quarts rounded values.
⑤ Below 15 RPM output speed, oil level must be adjusted to reach the highest oil level plug. If reducer position is to vary from those shown in Figure 1, either more or less oil may
be required. Consult Dodge.
⑥ Consult Dodge for proper oil level for reducers equipped with backstops and which are mounted in either the C position or D position.
3
Output
RPM
301 – 400
201 – 300
151 – 200
126 – 150
101 – 125
81 – 100
41 – 80
11 – 40
1 – 10
TXT1A
320
320
320
320
320
320
320
320
320
TXT2A
320
320
320
320
320
320
320
320
320
Table 3 - Oil Recommendations
ISO Grades For Ambient Temperatures of 50°F to 125°F (Refer to Notes below)
TXT3B
220
220
TXT4B
220
220
Torque-Arm Reducer Size
TXT5C TXT6A
220
220
220
220
TXT7A
220
220
220
320
320
320
320
320
320
220
220
320
320
320
320
320
220
220
220
320
320
320
320
220
220
220
220
220
320
320
220
220
220
220
220
320
320
TXT8A
220
220
220
220
220
220
220
320
320
TXT9A
220
220
220
220
220
220
220
320
320
Output
RPM
301 – 400
201 – 300
151 – 200
126 – 150
101 – 125
TXT1A
220
220
220
220
220
TXT2A
220
220
220
220
220
ISO Grades For Ambient Temperatures of 15°F to 60°F (Refer to Notes below)
Torque-Arm Reducer Size
TXT3B TXT4B TXT5C TXT6A TXT7A
150
150
150
220
220
150
150
150
150
220
150
150
150
150
150
150
150
150
150
150
150
150
150
150
150
TXT8A
150
150
150
150
150
TXT9A
150
150
150
150
150
81 – 100
41 – 80
11 – 40
1 – 10
220
220
220
220
220
220
220
220
220
220
220
220
220
220
220
220
220
220
220
220
150
150
220
220
150
150
220
220
150
150
220
220
150
150
220
220
Notes:
1. Assumes auxiliary cooling where recommended in the catalog.
2. Pour point of lubricant selected should be at least 10°F lower than expected minimum ambient starting temperature.
3. Extreme pressure (EP) lubricants are not necessary for average operating conditions. TORQUE-ARM internal backstops are not suitable for use with EP lubricants.
4. Special lubricants may be required for food and drug industry applications where contact with the product being manufactured may occur. Consult a lubrication manufacturer’s representative for his recommendations .
5. For reducers operating in ambient temperatures between -22°F (-30°C) and 20°F (–6.6°C) use a synthetic hydrocarbon lubricant, 100 ISO grade or AGMA 3 grade (for example, Mobil SHC627) . Above 125°F (51°C), consult DODGE Gear Application Engineering (864) 284-5700 for lubrication recommendation .
6. Mobil SHC630 Series oil is recommended for high ambient temperatures.
150
150
220
220
TXT10A
150
150
150
150
150
TXT10A
220
220
220
220
220
220
220
320
320
4
10
8
6
5
4
3
2
100
80
60
50
40
30
20
1000
800
600
500
400
300
KINEMATIC
VISCOSITIES cSt/
40˚ C
2000 cSt/
100˚ C
70
60
50
40
30
20
200
5
4
10
9
8
7
6
OIL VISCOSITY EQUIVALENCY CHART
ISO
VG
AGMA
GRADES
SAE
GRADES
GEAR OILS
3
2
68
22
15
10
7
5
46
32
460
320
220
150
100
1500
1000
680
8A
8
7
6
5
4
3
2
1
250
140
90
85W
80W
75W
VISCOSITIES CAN BE
RELATED HORIZONTALLY
ONLY.
VISCOSITIES BASED ON
96 VI SINGLE GRADE
OILS.
ISO ARE SPECIFIED AT
40˚C.
AGMA ARE SPECIFIED AT
40˚C.
SAE 75W, 80W, AND 85W
SPECIFIED AT LOW
TEMPERATURE. EQUIVALENT
VISCOSITIES FOR 100˚F
AND 200˚ F ARE SHOWN.
SAE 90 TO 250 SPECIFIED
AT 100˚C.
40
35
32
SAYBOLT
VISCOSITIES
SUS/
100˚F
10,000
8000
SUS/
210˚F
300
6000
5000
4000
3000
200
2000
1500
1000
800
600
500
400
300
60
55
50
100
90
80
70
200
150
45
100
80
70
60
50
40
5
GUIDELINES FOR TXT REDUCER LONG-
TERM STORAGE
During periods of long storage, or when waiting for delivery or installation of other equipment, special care should be taken to protect a gear reducer to have it ready to be in the best condition when placed into service.
By taking special precautions, problems such as seal leakage and reducer failure due to lack of lubrication, improper lubrication quantity, or contamination can be avoided. The following precautions will protect gear reducers during periods of extended storage:
Motor Mounts
Preparation:
1. Drain oil from the unit. Add a vapor phase corrosion inhibiting oil (VCI-105 oil by Daubert Chemical Co.) in accordance with
Table 4.
2. Seal the unit airtight. Replace the vent plug with a standard pipe plug and wire the vent to the unit.
3. Cover all unpainted exterior parts with a waxy rust preventative compound that will keep oxygen away from the bare metal. (Non-Rust X-110 by Daubert Chemical Co. or equivalent)
4. The instruction manuals and lubrication tags are paper and must be kept dry. Either remove these documents and store them inside, or cover the unit with a durable waterproof cover which can keep moisture away.
5. Protect reducer from dust, moisture, and other contaminants by storing the unit in a dry area.
6. In damp environments, the reducer should be packed inside a moisture-proof container or an envelope of polyethylene containing a desiccant material. If the reducer is to be stored outdoors, cover the entire exterior with a rust preventative.
When placing the reducer into service:
1. Fill the unit to the proper oil level using a recommended lubricant. The VCI oil will not affect the new lubricant.
2. Clean the shaft extensions with petroleum solvents.
3. Assemble the vent plug into the proper hole.
Follow the installation instructions provided in this manual.
Table 4 - Quantities of VCI #105 Oil
Reducer Size Quantity (Ounces / Mililiter)
TXT1A 1 / 30
TXT2A
TXT3B
TXT4B
TXT5C
1 / 30
1 / 30
1 / 30
1 / 30
TXT6A
TXT7A
TXT8A
TXT9A
TXT10A
VCI #105 and #10 are interchangeable.
VCI #105 is more readily available.
2 / 59
2 / 59
3 / 89
4 / 118
6 / 177
Figure 6 - Motor Mounts
Warning: Belt guard removed for illustration purposes. Do not operate if belt guard is not in place.
Motor Mount Installation:
The TA motor mount is designed to be installed on the output end of the reducer as shown in Figure 6. If bottom mounting is desired, use the optional TAB style.
TA1M thru TA7M Motor Mount:
Remove the required housing bolts on the output end of the reducer. Place the motor mount brackets in position and install the longer housing bolts supplied with the motor mount assembly. Do not fully tighten the housing bolts at this time.
Install the bottom plate to the motor mount brackets and tighten with the hardware provided. Next, tighten the housing bolts to the torque values listed in Table 6.
Install the four adjusting studs to the bottom plate using the jam nuts provided and securely tighten. These nuts will not require any further adjustment. Add one additional jam nut to each stud and thread approximately to the middle of the stud. Install the top motor plate on top of the jam nuts. Assemble the remaining jam nuts on studs to secure top motor plate. Do not fully tighten these nuts yet.
Mount motor, drive and driven sheaves, and v-belts.
Note: Mount driven sheave as close to the reducer housing as practical.
Adjust v-belts to the proper tension by adjusting the jam nuts and securely tighten.
Check all bolts to insure that they are securely tightened.
TA8 thru TA10 Motor Mount:
Remove the required housing bolts on the output end of the reducer. Place the motor mount brackets in position and install the longer housing bolts supplied with the motor mount assembly. Do not fully tighten the housing bolts at this time.
6
Install the four adjusting studs to the top plate as shown using the jam nuts provided and securely tighten. Add one additional
jam nut to each stud and thread approximately to the middle of the stud. Install this assembly to the motor mount brackets and install the remaining jam nuts onto the studs to secure the top plate to the brackets. Tighten the housing bolts to the torque values listed in Table 6.
Removing Reducer from Shaft:
WARNING: To ensure that drive is not unexpectedly started, turn off and lock out or tag power source before proceeding.
Remove all external loads from drive before removing or servicing drive or accessories. Failure to observe these precautions could result in bodily injury.
Loosely install the front motor rail to the top plate. Measure the distance between the front and rear mounting holes on the motor and position the rear motor rail at this distance and loosely bolt to the top plate.
Taper Bushed Reducer:
Center the motor on the motor rails and securely bolt the motor to the motor rails.
Install the motor sheave and reducer sheave on their shafts.
Mount the reducer sheave as close to the housings as practical.
Install the v-belts and adjust the motor rails to permit proper alignment of the v-belts to the sheaves. Securely tighten the motor rails to the mounting plate.
Adjust the v-belts to the proper tension and securely tighten the adjusting nuts.
1. Disconnect and remove belt guard, v-drive, and motor mount as required. Disconnect torque arm rod from reducer adapter.
2. Remove bushing screws.
3. Place the screws in the threaded holes provided in the bushing flanges. Tighten the screws alternately and evenly until the bushings are free on the shaft. For ease of tightening screws, make sure screw threads and threaded holes in bushing flanges are clean. A tap can be used to clean out the threads. Use caution to use the proper size tap to prevent damage to the threads.
4. Remove the outside bushing, the reducer, and then the inboard bushing.
Check all bolts to see that they are securely tightened.
WARNING: To ensure that drive is not unexpectedly started, turn off and lock out or tag power source before proceeding.
Remove all external loads from drive before removing or servicing drive or accessories. Failure to observe these precautions could result in bodily injury.
REPLACEMENT OF PARTS
NOTE: Using tools normally found in a maintenance department, a Dodge Torque-Arm speed reducer can be disassembled and reassembled by careful attention to the instructions following.
Straight Bore Reducer:
1. Disconnect and remove belt guard, v-drive, and motor mount as required. Disconnect torque arm rod from reducer adapter.
2. Loosen and remove the set screws in both output hub collars.
3. Remove the collar from the output hub closest to the end of the shaft. This will expose three puller holes in the output hub to permit the use of a three prong puller. In removing the reducer from the shaft, use care not to damage the reducer output hub.
Cleanliness is very important to prevent the introduction of dirt into the bearings and other parts of the reducer. A tank of clean solvent, an arbor press, and equipment for heating bearings and gears (for shrinking these parts on shafts) should be available.
The oil seals are designed with a contact lip. Considerable care should be used during disassembly and reassembly to avoid damage to the surface on which the seals rub.
The keyseat in the input shaft, as well as any sharp edges on the output hub should be covered with tape or paper before disassembly or reassembly. Also, be careful to remove any burrs or nicks on surfaces of the input shaft or output hub before disassembly or reassembly.
Ordering Parts:
Disassembly:
1. Drain all oil from the reducer.
2. Remove all locking collars, retaining rings, and bushing backup plated as required. Position the reducer on its side and remove all housing bolts. Using the three pry slots around the periphery of the flange, gently separate the housing halves and open evenly to prevent damage to the parts inside. Remove the two dowel pins.
3. Lift input shaft, all gear assemblies, and bearing assemblies from housing.
4. Remove seals from housing.
5. Remove bearings from shafts and hubs. Be careful not to scratch or damage any assembly or seal area during bearing removal. The hub assembly can be disassembled for gear replacement but if scratching or grooving occurs on the hub, seal leakage will occur and the hub will need to be replaced.
When ordering parts for a Dodge Torque Arm reducer, specify reducer part number, part name, and quantity required.
TXT Reassembly:
It is strongly recommended that, when a pinion or gear is replaced, the mating pinion or gear is replaced also.
If the large gear on the output hub must be replaced, it is recommended that an output hub assembly consisting of a gear assembled on a hub be ordered to ensure undamaged surfaces on the output hub where the output seals rub. However, if it is desired to use the old output hub, press the gear and bearing off and examine the rubbing surface under the oil seal carefully for possible scratching or other damage resulting from the pressing operation. To prevent oil leakage at the shaft oil seals, the smooth surface of the output hub must not be damaged.
If any parts must be pressed from a shaft or from the output hub, this should be done before ordering parts to make sure that none of the bearings or other parts are damaged in removal. Do not press against rollers or cage of any bearing.
Because old shaft oil seals may be damaged in disassembly, it is advisable to order replacements for these parts.
7
1. Output Hub Assembly: Heat gear to 325°F to 350°F to shrink onto hub. Heat bearings to 270°F to 290°F to shrink onto hub. Any damage to the hub surfaces where the oil seals rub will cause leakage, making it necessary to replace the hub.
2. Countershaft Assembly: Heat gear to 325°F to 350°F and bearings to 270°F to 290°F to shrink onto shaft.
3. Input Shaft Assembly: Heat bearings 270°F to 290°F to shrink onto shaft. Press bearings on shaft.
4. Drive the two dowel pins into place in the right-hand housing half (backstop side).
5. Place R.H. housing half on blocks to allow for protruding end of output hub.
6. Install all bearing cups on TXT3B thru TXT10A in right-hand housing half, making sure they are properly seated. TXT1A and TXT2A reducers use ball bearings on all shafts and do not incorporate bearing cups.
7. Mesh output hub gear and small countershaft gear together and set in place in housing. Set input shaft assembly in
place in the housing. Make sure bearing rollers (cones) are properly seated in their cups.
8. Make sure both housing halves are clean. Apply a continuous 1/8” diameter bead of Dow Corning RTV732 sealant on the flange surface of the R.H. housing (make sure RTV is placed around all bolt holes). Set the left-hand housing half into position onto the dowel pins and gently tap with a soft hammer (rawhide, not lead hammer) until housing bolts can be used to draw housing halves together. Make sure reducer shafts do not bind while tightening housing bolts. Torque housing bolts per torque values listed in Table
6.
9. On TXT1A and TXT2A reducers, skip to step number 12.
10. Place the output bearing cup into the housing and tap into place. Install the output seal carrier and draw down with two bolts 180° apart to 50 inch pounds of torque. Loosen both bolts then retighten finger tight only. Measure the clearance between the housing and carrier flange at each bolt and average the two values. Add 0.010” to the average reading and make up shim pack. Install shim pack between the carrier flange and the reducer housing. Torque the bolts to the value shown in Table 6. Using a magnetic base and dial indicator, check the axial end play. Add or remove shims until the axial endplay reading of the output hub is per Table
5.
11. Repeat step 9 above for installing and adjusting the countershaft and input bearings. Adjust the axial endplay per Table 5.
12. Install input and output seals. Lightly coat the seal lips with Mobilith AW2 All-Purpose grease or equivalent. The possibility of damage and consequent oil leakage can be decreased by covering all sharp edges with tape prior to seal installation. Seals should be pressed or tapped with a soft hammer evenly into place in the reducer housing, applying pressure only on the outer edge of the seals. Extreme care should be used when installing seals to avoid damage due to contact with sharp edges on the input shaft or output hub. A slight oil leak at the seals may be evident during initial running, but should disappear unless seals have been damaged.
13. Install bushing backup plates and snap rings on Taper
Bushed reducers or hub collars on straight bore reducers and install backstop cover. Make sure all bolts are tightened to the correct torque values listed in Table 6.
Reducer Size
TXT1A
TXT2A
TXT3B
TXT4B
TXT5C
TXT6A
TXT7A
TXT8A
TXT9A
TXT10A
Table 5 - Bearing Adjustment Tolerances
Input
N / A
Bearing Endplay Values
Countershaft
N / A
Ouput
N / A
N / A N / A N / A
.002-.004 Loose .0005-.003 Loose .0005-.003 Loose
.002-.004 Loose .0005-.003 Loose .0005-.003 Loose
.002-.004 Loose .0005-.003 Loose .0005-.003 Loose
.002-.004 Loose .0005-.003 Loose .0005-.003 Loose
.002-.004 Loose .0005-.003 Loose .0005-.003 Loose
.002-.004 Loose .0005-.003 Loose .0005-.003 Loose
.002-.004 Loose .0005-.003 Loose .0005-.003 Loose
.002-.004 Loose .0005-.003 Loose .0005-.003 Loose
Reducer
Size
TXT1A
TXT2A
TXT3B
TXT4B
TXT5C
TXT6A
TXT7A
TXT8A
TXT9A
TXT10A
Table 6 - Recommended Bolt Torque Values
Recommended Torque Values (lbs.-ft.)
Housing
Bolts
30 - 27
30 - 27
50 - 45
50 - 45
75 - 68
75 - 68
150 - 135
150 - 135
150 - 135
150 - 135
Output Seal
Carrier
N/A
N/A
17 – 15
30 – 27
30 – 27
30 – 27
30 – 27
30 – 27
30 – 27
30 – 27
C/S Bearing
Cover
N/A
N/A
17 – 15
30 – 27
30 – 27
30 – 27
50 - 45
30 – 27
30 – 27
30 – 27
Backstop Cover Bolt Recommended Torque Values
Reducer Size Fastener Size Torque in Ft.-Lbs.
TXT1A 10 - 24 x 3/8 5 – 4
TXT2A
TXT3B
TXT4B
10 - 24 x 3/8
10 - 24 x 3/8
¼ - 20 x ½
5 – 4
5 – 4
8 – 7
TXT5C
TXT6A
TXT7A
TXT8A
TXT9A
TXT10A
¼ - 20 x ½
¼ - 20 x ½
¼ - 20 x ½
¼ - 20 x ½
¼ - 20 x ½
¼ - 20 x ½
8 – 7
8 – 7
8 – 7
8 – 7
8 – 7
8 – 7
Input Seal
Carrier
N/A
N/A
17 – 15
30 – 27
30 – 27
30 – 27
50 - 45
30 – 27
30 – 27
30 – 27
8
Reducer
Size
TXT1A
TXT2A
TXT3B
TXT4B
TXT5C
TXT6A
TXT7A
TXT8A
TXT9A
TXT10A
Reducer
Size
TXT1A
TXT2A
TXT3B
TXT4B
TXT5C
TXT6A
TXT7A
TXT8A
TXT9A
TXT10A
Replacement Part and Kit Numbers
Reducer
Size
TXT1A
Table 7 – Part Numbers for Replacement
Bearings, Double Reduction Reducers
Output Hub Bearing – LH and RH Sides
Part Number
424020
TXT2A
TXT3B
TXT4B
424022
402272/403127
402268/403163
TXT5C
TXT6A
TXT7A
TXT8A
TXT9A
TXT10A
402193/403016
402050/403140
402058/403111
402147/403105
402160/403110
402168/403116
Countershaft Bearing – LH Input Side
Part Number
424006
424000
402273/403094
402000/403000
402203/403027
402054/403159
402256/403053
402057/403143
402109/403078
402232/402231
Countershaft Bearing – RH Backstop Side
Part Number
424006
424000
402273/403094
402000/403000
402203/403027
402052/403142
402256/403053
402148/403106
402109/403078
402232/402231
Reducer
Size
TXT1A
TXT2A
TXT3B
TXT4B
TXT5C
TXT6A
TXT7A
TXT8A
TXT9A
TXT10A
Input Shaft Bearing – LH Input Side
Part Number
424112
424019
402204/403139
402280/403027
402144/403104
402196/403091
402150/403106
402098/403072
402114/403080
402114/403080
Reducer
Size
TXT1A
TXT2A
TXT3B
TXT4B
Input Shaft Bearing – RH Backstop Side
Part Number
424111
424090
402273/403094
402142/403102
TXT5C
TXT6A
TXT7A
TXT8A
TXT9A
402266/403073
402197/403091
402088/403047
402097/403072
402107/403076
TXT10A 402112/403080
Note: Bearing part numbers refer to Cup/Cone combinations, respectively, and apply to all ratios unless otherwise specified. For actual reducer ratios, refer to Table 9.
9
Reducer Size Ratio
Table 8 - Replacement Parts Kit Numbers
Output Hub Assembly
Seal Kit
Taper Hub Straight Hub
Countershaft
Assembly
Bearing Kit(s)
TXT1A
TXT2A
TXT3B
TXT4B
TXT5C
15:1
25:1
9:1
15:1
25:1
9:1
15:1
9:1
15:1
25:1
9:01
15:1
25:1
9:1
392119
392120
389720
389721
389722
390878
392111
389703
389710
389717
390151
392110
389702
389709
389716
389700
389701
389730
389707
389708
389731
389714
392100
392090
392091
392101
392092
392093
389729
389905 All
389906 All
392345 All
392347 All
392350 All
TXT6A
TXT7A
25:1
9:1
15:1
25:1
9:1
15:1
25:1
246340
247345
390935
390941
390988
390990
389715
392140
391171
391186
392141
391196
391197
335368 All
392353 All
TXT8A
15:1
25:1
248340 390944 390993
391184
391185
392355 All
15:1 390124
TXT9A 249340 390949 390159 392357 All
26:1
15:1
390139
390983
TXT10A 272460 390954 390160 392359 All
24:1 390998
Notes:
Seal Kit consists of Input Seal, Output Seals, Backstop Cover Gasket and RTV Sealant.
Output Hub Assembly consists of Output Hub, Output Gear and Gear Key.
Countershaft Assembly consists of Countershaft Pinion, Countershaft Gear and Gear Key.
Bearing Kit consists of LH and RH Output Bearing Cup/Cone, LH and RH Countershaft Bearing Cup/Cone (double reduction only) and LH and RH Input Bearing Cup/Cone.
10
Parts for TXT/HXT 1A & 2A Straight and Tapered Bushed Double Reduction Reducers
11
44
46
54
80
36
42
78
40
68
70
72
74
62
64
59
61
84
Ref.
12
1
2
3
①
22
①
①
25
①
16
18
20
34
38
130
41
48
50
52
60
Parts for TXT/HXT 1A & 2A Straight and Tapered Bushed Double Reduction Reducers
Description
Backstop Assembly
Housing-LH
Housing-RH
Housing-RH, Flange Mount Drilled
Housing-Hydroil LH
RTV Sealant, Tube
Air Vent
Housing Bolt
Housing Bolt-Adapter
Lock-Washer
Hex Nut
Dowel Pin
Magnetic Oil Plug
Oil Plug
Backstop Shaft Cover
Backstop Cover Screw
Seal Kit ②
Backstop Cover Gasket ④
Input Oil Seal ④
Output Hub Oil Seal ④
Input Pinion
9:1 Ratio ⑥
15:1 Ratio ⑥
25:1 Ratio ⑥
Hydroil Input Pinion
15:1 Ratio ⑥
25:1 Ratio ⑥
Input Pinion Key
Bearing Replacement Kit ②
Input Pinion Bearing-LH, Input Side ④
Input Pinion Bearing-RH, Backstop Side ④
Countershaft Pinion Bearing ④
Output Hub Bearings ④
Countershaft Pinion Assembly ②
9:1 Ratio ⑥
15:1 Ratio ⑥
25:1 Ratio ⑥
Countershaft Pinion ④
First Reduction Gear ④
9:1 Ratio ⑥
15:1 Ratio ⑥
25:1 Ratio ⑥
Countershaft to First Gear Key ④
Taper Bore Output Hub Assembly ②
Straight Bore Output Hub Assembly ③
Output Hub
Straight Bore ⑤
Taper Bore ④
Output Gear ④ ⑤
Output Gear Key ④ ⑤
Output Hub Snap Ring ④
Straight Bore Output Hub Key ⑤
Straight Bore Output Hub Collar
Straight Bore Output Hub Collar Screw
Taper Bore Bushing Backup Plate
Bushing Backup Plate Retaining Ring
Taper Bore Bushing Assembly ②
Bushing ④
1” Bore
1-1/16” Bore
1-1/8” Bore
1-3/16” Bore
1-1/4” Bore
1-5/16” Bore
1-3/8” Bore
1-7/16” Bore
1-11/16” Bore
1-1/2” Bore
1-5/8” Bore
1-3/4” Bore
1-15/16” Bore
1
1
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
4
1
1
1
1
1
1
1
1
1
1
1
1
1
Qty.
1
4
1
4
2
⑧
⑧
2
1
⑦
1
1
1
1
1
1
1
2
1
1
241481
241302
241200
241455
241449
443008
389905
424112
424111
424006
424020
392100
392090
392091
241216
241482
241170
241171
241309
390878
390151
TXT/HXT 1
242101
241358
241359
241387
241064
465044
900287
411418
411420
419011
407087
420145
430060
430031
242221
415022
392119
242220
241457
241210
241208
241265
241007
241217
421013
241296
241209
400062
241266
421111
241278
241280
241282
241286
241288
241290
241294
241292
N/A
N/A
N/A
N/A
N/A
242481
242186
242187
242188
242189
443014
389906
424019
424090
424000
424022
392101
392092
392093
242185
242482
242008
242005
242218
392111
392110
242208
242134
242181
443399
421017
242296
242209
400094
242137
421112
N/A
N/A
242146
242148
242150
242152
242154
242156
242164
242158
242162
242166
242168
TXT/HXT 2
252101
242353
242354
242393
242067
465044
900287
411418
411420
419011
407087
420145
430060
430031
243221
415022
392120
243220
242211
242210
12
Parts for TXT/HXT 1A & 2A Straight and Tapered Bushed Double Reduction Reducers
Ref.
86
88
90
Description
Bushing Screw ④
Lock Washer ④
Key, Taper Bore Bushing to Shaft ④
1” Bore
1-1/8” Bore
1-3/16” Bore
1-1/4” Bore
1-5/16” Bore
1-3/8” Bore
1-7/16” Bore
1-1/2” Bore
1-5/8” Bore
1-11/16”
1-3/4” Bore
1-15/16” Bore
①
94
96
98
100
102
104
106
110
Key, Bushing to Output Hub ④
1” Bore
1-1/8” Bore
1-1/8” to 1-1/2” Bore
Torque-Arm Assembly ②
Torque-Arm Rod End ④
RH Nut ④
Torque-Arm Turnbuckle ④
Torque-Arm Extension ④
LH Nut ④
Torque-Arm Fulcrum ④
Fulcrum Screw ④
Hex Nut ④
124
126
128
111
①
①
112
114
116
118
120
122
Adapter Assembly ②
RH Torque-Arm Adapter Bracket ④
LH Torque-Arm Adapter Bracket ④
Adapter Bushing ④
Adapter Bolt ④
Lock Washer ④
Hex Nut ④
Hydraulic Motor Adapter
Adapter Screw
Lockwasher
Input Pinion Seal, Hydroil
Motor to Adapter Screw
Motor to Adapter Lock Washer
Notes:
① Not shown on Drawing.
② Includes Parts Listed Immediately Below
③ Includes Parts Listed Immediately Below
④ Makes up Assembly Under Which it is Listed.
⑤ Makes up Assembly Under Which it is Listed.
⑥ See Table 9 for Actual Ratio.
⑦ 4 Required on TXT1A and 5 Required on TXT2A
⑧ 6 Required on TXT1A and 7 Required on TXT2A
6
1
1
6
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Qty.
6
6
TXT/HXT 1
411405
419010
259151
241242
241241
242243
411412
419011
407087
241454
417081
419046
241457
411408
419011
443272
443273
N/A
241097
241245
407093
241246
241247
407242
241249
411456
407091
443274
443271
241308
241307
241306
241310
241305
N/A
N/A
N/A
N/A
N/A
TXT/HXT 2
411390
419010
N/A
N/A
443284
243097
243245
407095
243246
243247
407244
243249
411484
407093
259152
242136
242135
243243
411437
419012
407089
242454
417081
419046
242457
411408
419011
N/A
443281
443281
443281
443264
443280
443282
443282
424172
242171
242170
443283
13
Parts for TXT3B thru TXT5C Straight and Tapered Bushed Double Reduction Reducers
14
Parts for TXT3B thru TXT5C Straight and Tapered Bushed Double Reduction Reducer
44
45
46
47
Ref.
12
1
2
①
①
16
18
20
22
①
32
33
34
38
39
①
25
28
30
36
42
78
40
130
41
48
50
60
62
64
68
70
72
74
76
80
81
82
52
54
55
56
57
58
59
Description
Backstop Assembly
Housing - TXT and Hydroil LH
Housing-RH
Housing-RH, Flange Mount Drilled
RTV Sealant, Tube
Air Vent
Housing Bolt
Housing Bolt-Adapter
Lock-Washer
Hex Nut
Dowel Pin
Magnetic Oil Plug
Oil Plug
Input Shaft Seal Carrier
Input Shaft Bearing Shim Pack
Input Seal Carrier Screw
Lock Washer
Backstop Cover
Backstop Shaft Cover
Backstop Cover Screw
Seal Kit ②
Backstop Cover Gasket ④
Input Pinion Shaft Seal ④
Output Hub Oil Seal ④
Input Pinion
9:1 Ratio ⑥
15:1 Ratio ⑥
25:1 Ratio ⑥
15:1 Ratio Hydroil Pinion ⑥
25:1 Ratio Hydroil Pinion ⑥
15:1 Ratio Hydroil 6-B Pinion ⑥
25:1 Ratio Hydroil 6-B Pinion ⑥
Input Pinion Shaft Key
Input Bearing Kit ②
Input Shaft Bearing Cone, Input Side ④
Input Shaft Bearing Cup, Input Side ④
Input Shaft Bearing Cone, Backstop Side ④
Input Shaft Bearing Cup, Backstop Side ④
Countershaft Pinion Assembly ②
9:1 Ratio ⑥
15:1 Ratio ⑥
25:1 Ratio ⑥
Countershaft Pinion ④
First Reduction Gear ④
9:1 Ratio ⑥
15:1 Ratio ⑥
25:1 Ratio ⑥
First Stage Gear Key ④
Countershaft Bearing Kit ②
Countershaft Bearing Cone, Input Side ④
Countershaft Bearing Cup, Input Side ④
Countershaft Bearing Cone, Backstop Side ④
Countershaft Bearing Cup, Backstop Side ④
Countershaft Bearing Cover, Input Side ④
Countershaft Bearing Shim Pack
Taper Bore Output Hub Assembly ②
Straight Bore Output Hub Assembly ③
Output Hub
Straight Bore ⑤
Taper Bore ④
Output Gear ④ ⑤
Output Gear Key ④ ⑤
Output Hub Collar, Straight Bore
Output Hub Collar Screw
Bushing Backup Plate, Taper Bore
Bushing Backup Plate Retaining Ring
Output Hub Seal Carrier, Input Side
Output Hub Bearing Kit ♦
Output Hub Bearing, Cone ④
Output Hub Bearing, Cup ④
Output Hub Bearing Shim Kit
Qty.
4
1
⑧
2
1
8
8
6
2
1
1
1
1
1
1
⑦
⑦
1
4
4
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
4
2
2
1
1
⑧
1
1
⑧
1
1
1
1
1
1
1
1
1
1
1
1
1
1
389703
389702
243557
243556
243570
243216
243572
400098
243308
421109
243547
389589
402272
403127
389706
389729
389700
389701
243555
243237
243238
243239
D8242
389588
402273
403094
402273
403094
243545
389705
243549
243550
243551
243553
243554
N/A
243498
443032
389587
402204
403139
402273
403094
TXT3B
HXT3B
243106
243228
243229
243384
465044
900287
411440
411442
419012
407089
420146
430060
430031
243543
389704
411390
419010
243560
416524
N/A
389720
243561
243558
243578
TXT4B
HXT4B
244106
244365
244366
244387
465044
900287
411442
411444
419012
407089
420146
430060
430031
244577
389711
411407
419011
244493
411035
N/A
389721
244593
244524
244673
389717
389716
245591
245590
245186
355064
245598
400154
245114
421107
245592
389596
402193
403016
389719
245482
245214
245212
D8243
389595
402203
403027
402203
403027
245594
389718
245599
245600
245601
245603
245604
N/A
245641
443096
389594
402144
403104
402266
403073
389731
389714
389715
245596
389710
389709
244589
244588
244188
354087
244658
400150
244099
421108
244591
389592
402268
403163
389713
389730
389707
389708
244590
244482
244214
244212
D8243
389591
402000
403000
402000
403000
244578
389712
244579
244580
244581
244583
244584
244586
244587
443082
389590
402280
403027
402142
403102
TXT5C
HXT5C
245154
245369
245370
245373
465044
904287
411464
411466
419013
407091
420147
430062
430033
245597
389732
411407
419011
245226
411394
419009
389722
245220
355011
245545
15
Parts for TXT3B thru TXT5C Straight and Tapered Bushed Double Reduction Reducer, continued
Ref.
Description Qty.
TXT3B
HXT3B
TXT4B
HXT4B
TXT5C
HXT5C
84
86
88
90
Taper Bore Bushing Assembly ②
Bushing ④
1-5/16” Bore
1-3/8” Bore
1-7/16” Bore
1-1/2” Bore
1-5/8” Bore
1-11/16” Bore
1-3/4” Bore
1-7/8” Bore
1-15/16” Bore
2” Bore
2-1/8” Bore
2-3/16” Bore
2-1/4” Bore
2-7/16” Bore
2-1/2” Bore
2-11/16” Bore
2-15/16” Bore
Taper Bushing Screw ④
Taper Bushing Lockwasher ④
Key, Bushing to Shaft ④
1-5/16” Bore
1-3/8” Bore
1-7/16” Bore
1-1/2” Bore
1-5/8” Bore
1-11/16” Bore
1-3/4” Bore
1-7/8” Bore
1-15/16” Bore
2” Bore
2-1/8” Bore
2-3/16” Bore
2-1/4” Bore
2-7/16” Bore
2-1/2” Bore
2-11/16” Bore
2-15/16” Bore
①
94
96
98
100
102
104
106
110
Key, Bushing to Output Hub ④
1-3/4” thru 1-15/16” Bore Bushing
1-7/16” thru 2-1/4” Bore Bushing
2-3/16” thru 2-15/16” Bore Bushing
Torque-Arm Rod Kit ②
Torque-Arm Rod End ④
RH Nut ④
Torque-Arm Turnbuckle ④
Torque-Arm Extension ④
LH Nut ④
Fulcrum ④
Fulcrum Screw ④
Hex Nut ④
112
114
116
118
120
122
Adapter Assembly ②
RH Adapter Plate ④
LH Adapter Plate ④
Adapter Bushing ④
Adapter Bolt ④
Lockwasher ④
Hex Nut ④
124
126
128
§
§
Hydroil Motor Adapter
15:1 Ratio Motor Adapter
25:1 Ratio Motor Adapter
Hydroil 6-B Motor Adapter, 15:1 and 25:1 Ratio
Adapter Screw
Lockwasher
Motor to Adapter Screw
Motor to Adapter Lock Washer
Notes:
Not shown on drawing.
② Includes parts listed immediately below
③ Includes parts listed immediately below
④ Makes up assembly under which it is listed.
⑤ Makes up assembly under which it is listed.
⑥ See Table 9 for actual ratio.
⑦ 4 required on TXT3B and TXT4B, 5 required on TXT5C
⑧ Two sets recommended.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
⑦
1
1
⑦
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
6
1
1
6
1
1
1
1
1
1
443262
N/A
N/A
243097
243245
407095
243246
243247
407244
243249
411484
407093
259153
243242
243241
243243
411437
419012
407089
443264
443264
443265
443265
443265
443266
443266
443267
443269
443268
N/A
443270
N/A
N/A
N/A
N/A
N/A
243282
243284
243260
243262
243264
243268
243266
243270
243272
243274
N/A
243276
N/A
N/A
N/A
N/A
N/A
411407
419011
243539
243541
243467
417081
419046
N/A
N/A
443257
243097
243245
407095
243246
243247
407246
243249
411484
407093
259154
244244
244243
245243
411460
419013
407091
N/A
N/A
443254
443254
443254
443254
443254
443255
443255
443255
443258
443259
443260
443261
N/A
N/A
N/A
N/A
N/A
244079
244081
244083
244085
244087
244089
244093
244095
244109
244111
244113
244115
N/A
N/A
N/A
411408
419011
244572
244572
244573
417108
419047
443251
443251
443251
N/A
443251
443251
443243
443244
443245
443250
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
245084
245086
245088
N/A
245090
245092
245094
245099
245110
245112
411435
419012
245606
245607
245643
415023
419047
N/A
443202
N/A
243097
243245
407095
243246
243247
407246
243249
411484
407093
259155
245242
245241
245243
411460
419013
407091
16
Parts for TXT6A thru TXT10A Straight and Tapered Bushed double Reduction Reducers
17
41
44
45
46
47
60
72
74
76
80
81
82
62
64
68
70
52
54
55
56
57
58
59
Ref.
12
1
2
33
34
35
38
39
①
28
30
32
20
22
①
25
①
①
16
18
36
42
78
40
130
48
50
Parts for TXT6A thru TXT10A Straight and Tapered Bushed double Reduction Reducers
Description
Backstop Assembly
Housing-TXT and Hydroil LH
Housing-RH
Housing-RH, Flange Mount Drilled
RTV Sealant, Tube
Air Vent
Housing Bolt
Housing Bolt-Adapter
Lock-Washer
Hex Nut
Dowel Pin
Magnetic Oil Plug
Oil Plug
Input Shaft Seal Carrier
Input Shaft Bearing Shim Pack
Carrier and Cover Screw
Lock Washer
Backstop Cover
Backstop Retaining Ring
Backstop Cover Screw
Backstop Cover Lock Washer
Seal Kit ②
Backstop Cover Gasket ③
Input Pinion Shaft Seal ③
Output Hub Oil Seal ③
Input Pinion
9:1 Ratio ⑥
15:1 Ratio ⑥
25:1 Ratio ⑥ ⑩
15:1 Ratio Hydroil Pinion ⑥
25:1 Ratio Hydroil Pinion ⑥
15:1 Ratio 6B Hydroil Pinion ⑥
25:1 Ratio 6B Hydroil Pinion ⑥
Input Pinion Shaft Key
Input Bearings
Input Shaft Bearing Cone, Input Side
Input Shaft Bearing Cup, Input Side
Input Shaft Bearing Cone, Backstop Side
Input Shaft Bearing Cup, Backstop Side
Countershaft Pinion Assembly ②
9:1 Ratio ⑥
15:1 Ratio ⑥
25:1 Ratio ⑥ ⑩
Countershaft Pinion ③
First Reduction Gear ③
9:1 Ratio ⑥
15:1 Ratio ⑥
25:1 Ratio ⑥ ⑩
First Stage Gear Key ③
Countershaft Bearings
Countershaft Bearing Cone, Input Side
Countershaft Bearing Cup, Input Side
Countershaft Bearing Cone, Backstop Side
Countershaft Bearing Cup, Backstop Side
Countershaft Bearing Cover, Input Side
Countershaft Bearing Shim Pack
Taper Bore Output Hub Assembly ②
Straight Bore Output Hub Assembly ④
Straight Bore Hub ⑤
Taper Bore Hub ③
Output Gear ③ ⑤
Output Gear Key ③ ⑤
Output Hub Collar, Straight Bore
Output Hub Collar Screw
Bushing Backup Plate, Taper Bore
Output Hub Retaining Ring
Output Hub Seal Carrier, Input Side
Output Hub Bearing Kit 1
Output Hub Bearing, Cone
Output Hub Bearing, Cup
Output Hub Bearing Shim Kit
Qty.
1
1
1
1
1
2
1
⑧
1
1
1
1
2
4
2
⑧
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
⑧
2
1
1
4
2
2
1
1
1
1
1
1
⑨
⑨
1
⑦
6
6
1
2
1
1
246340
246220
242210
246310
246481
246290
246291
246230
246286
N/A
246521
443113
TXT6A
HXT6A
246092
246358
246359
465044
904287
411466
411468
419013
407091
420147
430062
430033
246184
391164
411408
419011
246226
421029
411394
419009
402196
403091
402197
403091
392140
391171
391186
246294
246482
246492
246293
245218
402054
403159
402052
403142
246185
391165
390935
390988
246338
246269
246295
245217
246309
400154
246270
421055
246187
402050
403140
391187
247345
246220
242210
247310
247479
247370
247371
247463
247462
N/A
247521
443127
TXT7A
HXT7A
247260
247358
247359
465044
904287
411498
411499
419016
407095
420148
430064
430035
247320
390420
411433
419012
246226
421029
411394
419009
402150
403106
402088
403047
392141
391196
391197
247002
247478
247008
247005
247218
402256
403053
402256
403053
247194
390429
390941
390990
247338
272137
247215
245217
247309
400190
272138
421099
247315
402058
403111
390044
TXT8A
248340
248220
248211
258019
N/A
248370
248371
N/A
N/A
N/A
N/A
443133
249260
248358
248359
465044
904287
411499
411502
419016
407095
420148
430064
430035
258023
390038
411408
419011
248226
421034
411394
419009
402098
403072
402097
403072
N/A
391184
391185
248002
N/A
248213
248214
248218
402057
403143
402148
403106
248223
391182
390944
390993
248332
272036
248215
248217
248209
400190
272037
421098
258021
402147
403105
390048
TXT9A
N/A
390124
390139
249006
N/A
249008
249005
248218
402109
403078
402109
403078
249225
390168
390949
390159
250090
249140
021764
443413
249209
400194
272082
421097
249221
402160
403110
390171
249340
248220
248211
249210
N/A
272074
272106
N/A
N/A
N/A
N/A
443123
249260
249358
249359
465044
904287
411500
411502
419016
407095
420148
430064
430035
249211
390168
411408
419011
248226
421034
411394
419009
402114
403080
402107
403076
TXT10A
N/A
390983
390998
272249
N/A
250301
250005
248218
402232
402231
402232
402231
272251
390575
390954
390160
250008
272241
250007
250017
250009
400194
272242
421069
250011
402168
403116
390172
272460
248220
248211
250010
N/A
250300
250004
N/A
N/A
N/A
N/A
443123
250260
250358
250359
465044
904287
411502
411506
419016
407095
420148
430064
430035
249211
390168
411408
419011
248226
421034
411394
419009
402114
403080
402112
403080
18
Ref.
84
86
88
90
①
Parts for TXT6A thru TXT10A Straight and Tapered Bushed double Reduction Reducers
Description
Taper Bore Bushing Assembly ②
Bushing ③
2-3/16” Bore
2-1/4” Bore
2-7/16” Bore
2-1/2” Bore
2-11/16” Bore
2-13/16” Bore
2-7/8” Bore
2-15/16” Bore
3” Bore
3-3/16” Bore
3-7/16” Bore
3-15/16” Bore
4-3/16” Bore
4-7/16” Bore
4-15/16” Bore
5-7/16” Bore
Taper Bushing Screw ③
Taper Bushing Lockwasher ③
Key, Bushing to Shaft ③
2-3/16” Bore
2-1/4” Bore
2-7/16” Bore
2-1/2” Bore
2-11/16” Bore
2-13/16” Bore
2-7/8” Bore
2-15/16” Bore
3” Bore
3-3/16” Bore
3-7/16” Bore
3-15/16” Bore
4-3/16” Bore
4-7/16” Bore
4-15/16” Bore
5-7/16” Bore
Key, Bushing to Output Hub ③
2-3/16” thru 2-1/2” Bore Bushing
2-7/16” thru 3” Bore Bushing
2-3/16” thru 2-15/16” Bore Bushing
2-15/16” thru 3-7/16” Bore Bushing
3-7/16” thru 4-3/16” Bore Bushing
3-15/16” thru 4-7/16” Bore Bushing
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
6
6
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
TXT6A
246261
246262
246263
246264
246265
N/A
246266
246267
246283
N/A
246268
N/A
N/A
N/A
N/A
N/A
411435
419012
443211
443211
443214
443214
443238
N/A
443236
443237
443252
N/A
443213
N/A
N/A
N/A
N/A
N/A
N/A
443212
N/A
N/A
N/A
N/A
N/A
TXT7A
94
96
98
100
102
104
106
108
110
112
114
116
118
120
122
124
Torque-Arm Rod Kit ②
Torque-Arm Rod End ③
RH Nut ③
Torque-Arm Turnbuckle ③
Torque-Arm Extension ③
LH Nut ③
Fulcrum ③
Fulcrum Screw ③
Lockwasher ③
Hex Nut ③
Adapter Assembly ②
RH Adapter Plate ③
LH Adapter Plate ③
Adapter Bushing ③
Adapter Bolt ③
Lockwasher ③
Hex Nut ③
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
246097
245245
407097
245246
245247
407246
247248
411489
419014
407093
259156
246242
246241
245243
411460
419013
407091
247098
247239
407099
247246
247240
407248
247248
411489
419014
407093
259157
247242
247241
247244
411489
419014
407093
126
128
①
①
Hydroil Motor Adapter
Hydroil 6B Motor Adapter
Hydroil Adapter Screw
Lockwasher
Motor to Adapter Screw
Motor to Adapter Lock Washer
1
1
6
6
246465
246522
417108
906406
247464
247522
417141
907406
Notes:
① Not shown on drawing
② Includes parts listed immediately below
③ Makes up assembly under which it is listed
④ Includes parts listed immediately below marked
⑤ Makes up assembly under which it is listed
⑥ See Table 9 for actual ratio
⑦ Required only with optional backstop, 1 required on TXT6A and TXT7A, 2 required on TXT8A, TXT9A, & TXT10A.
⑧ 2 sets recommended
⑨ 18 Required on TXT6A, 20 Required on TXT7A, and 24 Required on TXT8A, TXT9A, & TXT10A
⑩ Nominal Ratio on TXT6A, TXT7A, and TXT8A is 25:1, Nominal Ratio on TXT9A is 26:1, and Nominal Ratio on TXT10A is 24:1
390129
271050
407104
271051
271052
407250
271054
411516
419020
407099
248110
272053
272053
271046
411510
419020
407099
N/A
N/A
N/A
N/A
N/A
N/A
443248
N/A
443248
443199
443199
443199
443199
443216
443235
443217
443218
N/A
N/A
N/A
N/A
N/A
N/A
272125
N/A
272147
272130
272131
272132
272133
272134
272135
272136
N/A
N/A
N/A
N/A
411456
419013
N/A
443198
N/A
N/A
N/A
N/A
TXT8A
443247
N/A
N/A
443171
443173
443174
443196
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
272048
N/A
N/A
272032
272033
272034
272035
N/A
N/A
411457
419013
N/A
N/A
N/A
443162
N/A
N/A
TXT9A
N/A
N/A
N/A
443249
272119
N/A
272066
443161
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A272056
272077
N/A
272079
272080
N/A
411484
419014
N/A
N/A
N/A
N/A
443121
N/A
390129
271050
407104
271051
271052
407250
271054
411516
419020
407099
249110
249241
249241
271046
411512
419020
407099
N/A
N/A
N/A
N/A
19
TXT10A
N/A
N/A
N/A
N/A
N/A
443191
390129
271050
407104
271051
271052
407250
271054
411516
419020
407099
250110
250041
250041
211046
411512
419020
407099
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
443192
N/A
443193
443194
443195
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
272214
N/A
272238
272239
272240
411484
419014
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
ACTUAL RATIOS
Table 9 – Actual Ratios
Nominal Ratios
Reducer Size
TXT1A
TXT2A
TXT3B
TXT4B
TXT5C
TXT6A
9:1
9.44
9.25
8.91
9.67
8.95
9.20
TXT7A
TXT8A
TXT9A
9.61
N/A
N/A
TXT10A N/A
* TXT9A is 26:1 Nominal Ratio and TXT10A is 24:1 Nominal Ratio
15:1
15.35
14.10
14.88
15.13
15.40
15.33
15.23
15.08
15.12
15.16
25:1*
25.64
23.46
24.71
24.38
25.56
25.13
24.59
24.62
25.66
24.30
World Headquarters
P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1) 479.646.4711, Fax (1) 479.648.5792, International Fax (1) 479.648.5895
Dodge Product Support
6040 Ponders Court, Greenville, SC 29615-4617 U.S.A., Ph: (1) 864.297.4800, Fax: (1) 864.281.2433
www.baldor.com
© Baldor Electric Company
MN1610 (Replaces 499304)
All Rights Reserved. Printed in USA.
3/10 FARR 25,000
*1610-0310*
APPENDIX H
INSTRUCTION MANUAL FOR
DODGE® TORQUE-ARM™ SPEED REDUCER BACKSTOPS
These instructions must be read thoroughly before installing or operating this product.
WARNING: To ensure that drive is not unexpectedly started, turn off and lock out or tag power source before proceeding.
Failure to observe these precautions could result in bodily injury.
WARNING: Do not use Dodge backstops in any reducers other than Dodge brand reducers.
CAUTION: Do not use EP oils or oils containing slippery additives such as graphite or molybdenum disulphide in the reducer when backstop is used. These additives will destroy sprag action.
INSTALLATION OF BACKSTOP
1. Remove backstop cover plate. This plate is directly opposite the extended end of the input shaft.
2. Face reducer looking at the side from which the cover plate was removed. Determine carefully the direction of rotation desired. The directions of rotation of input and output shafts are identical in double reduction reducers (Nos. TXT115 thru
TXT1225 and TDT1325 thru TDT1530) and opposite in single reduction reducers (Nos. TXT105 to TXT905). It is important that the direction be correctly determined because to reverse the direction after the backstop is installed, it is necessary to remove the backstop, turn it end for end and reinstall it.
3. Match arrow on backstop to direction of rotation desired for input shaft. Note that reversing backstop end for end changes direction of arrow. The input shaft will rotate in the same direction as the arrow on the backstop.
4. Proceed as follows:
Nos. TXT1A to TXT5C and Nos. TXT105 to TXT505A
Reducers —For ease of installation, a light coating of oil on the O.D. of backstop will help to rotate backstop for key installation. Slowly rotate input shaft in same direction as arrow on backstop. Without removing cardboard retainer from backstop, push backstop into reducer. When pushing backstop into reducer, it is very important not to hammer on backstop although it can be tapped gently if necessary.
Cardboard retainer will be pushed out automatically as backstop is pushed into reducer. If backstop has to be
WARNING: Because of the possible danger to person(s) or property from accidents which may result from the improper use of products, it is important that correct procedures be followed: Products must be used in accordance with the engineering information specified in the catalog. Proper installation, maintenance and operation procedures must be observed. The instructions in the instruction manuals must be followed. Inspections should be made as necessary to assure safe operation under prevailing conditions. Proper guards and other suitable safety devices or procedures as may be desirable or as may be specified in safety codes should be provided, and are neither provided by Baldor
Electric Company nor are the responsibility of Baldor
Electric Company. This unit and its associated equipment must be installed, adjusted and maintained by qualified personnel who are familiar with the construction and operation of all equipment in the system and the potential hazards involved. When risk to persons or property may be involved, a failsafe device must be an integral part of the driven equipment beyond the speed reducer output shaft.
removed for any reason, pull backstop from bore and insert cardboard retainer into I.D. of backstop to retain position of
Ensure backstop cover does not bind backstop.
Install Lockring in Outer
Groove of
Backstop
Assembly
Figure 1 - TXT3B
NOTE: A locking ring is required on TXT3B to position backstop in housing.
Nos. TXT6A, TXT7A and No. TXT605 Reducers —For ease of installation, a light coating of oil on the O.D. of backstop will help to rotate backstop for key installation. Some of the backstops have keys of different lengths. Place the longer key in the input shaft keyseat. For ease of installation, backstop complete with inner race must be pushed into reducer as a unit. When pushing backstop into reducer, it is very important not to hammer on backstop although it can be tapped gently if necessary. Place small snap ring in snap ring groove on input shaft, and place large snap ring in groove in housing outboard of backstop.
Nos. TXT8 to TXT12, TDT13 thru TDT15, TXT705 to
TXT905 Reducers — Place large snap ring in I.D. of housing or bacsktop carrier. For ease of installation, a light coating of oil on the O.D. of backstop will help to rotate backstop for key installation. Backstop complete with inner race must be pushed into reducer as a unit. When pushing backstop into Reducer, it is very important not to hammer on backstop although it can be tapped gently if necessary. Place the small snap ring in snap ring groove on input shaft, and place second large snap ring in housing outboard of backstop for sizes TXT8A, TXT9A and TXT10A.
1
HOUSING
INPUT
SHAFT
BACKSTOP
LARGE SNAP RING
SMALL SNAP RING
Figure 2 - TXT8A, 9A, 10A
1. Remove backstop cover plate.
2. Remove snap ring from end of shaft (snap ring is used only on Nos. TXT609 to TXT1225 and TDT1325 thru TDT1530 and
Nos. TXT605 to TXT905 reducers).
3. Insert tool, such as a screwdriver, in groove around O.D. of backstop and pry backstop from retainer housing. If backstop hs tapped holes in outer race, install two #10-24 machine screws in holes and use them to pry backstop from housing.
DIMENSIONAL CHECKS FOR REPLACEMENT
UNITS IN REDUCERS WITH TAPERED
ROLLER BEARINGS
Shaft Endplay: While the backstop is removed check the amount of endplay in the shaft if tapered roller bearings are used. It is possible that bearing wear or looseness might have increased the amount of endplay to an unacceptable level. Shaft endplay should not exceed .003”. Endplay is measured with a dial indicator at the end of the backstop shaft. The base of the indicator is attached to the reducer housing. From the other end of the shaft, an axial force must be applied in both directions. While rotating shaft, push and pull.
Housing
Carrier
Cover
Plate
CONCENTRICITY:
The amount of Total Indicated Run Out (T.I.R.) between the inner race (shaft) and the backstop bore in the housing is a critical measurement. It takes into consideration the effects of bearing endplay as well as machining eccentricities. The T.I.R. should not exceed .003” on TXT309B to TXT1225 and .004” T.I.R. on
TDT1325 to TDT1530. The base of the dial indicator can be mounted on the end of the shaft as shown, with the needle at the backstop bore in the housing. Rotate the shaft, sweeping the bore
360° which will give T.I.R.
Input
Shaft
Backstop
DIMENSIONS:
Verify input shaft diameter at the backstop journal. See chart for correct dimensions.
Large Snap Ring
Small Snap Ring
Figure 3 - TXT12, TDT 13-15, TXT805-905
Some of the backstops require two keys on the input pinion.
Dispose of extra key with units that require only one key. Line up keyways between backstop and input pinion. Install key(s).
5. Insert key between housing and backstop O.D. and replace gasket, cover plate and screws. When input shaft will be located higher than output shaft, put some non-EP grease in cover plate for the purpose of lubricating backstop. Use a high grade non-EP grease made especially for roller bearing service.
NOTE: Some backstops have keys that are rectangular in cross section. Keys should fit freely into respective keyways.
Forcing keys into place could result in premature failure of backstop.
NOTES:
1. TXT1 thru TXT6 — When replacing failed backstop, inspect shaft end for condition. Journal should be smooth and free of damage. See Fig. 1.
2. On older TXT12 thru TDT15, it is suggested that external backstop carrier be doweled to housing after concentricity is verified.
3. If reducer must be positioned with backstop above static level of oil, contact factory for lubrication recommendations before placing reducer in service.
TO REMOVE BACKSTOP
WARNING: To ensure that drive is not unexpectedly started, turn off and lock out or tag power source before proceeding.
Failure to observe these precautions could result in bodily injury.
WARNING: Removal of backstop may cause unexpected machine movement. Remove or block all external loads before servicing unit. Failure to observe these precautions could result in bodily injury.
Figure 4
Shaft
Diameter
Backstop
Journal
2
PART
NUMBER
241101
242101
CURRENT TXT
SERIES HOUSING
REDESIGN 2005
TXT109A
TXT115A
TXT125A
243101
243102
243106 TXT309B
TXT315B
TXT325B
244092
244101
244106 TXT409B
TXT415B
TXT425B
244148
TORQUE-ARM SPEED REDUCER BACKSTOP
TXT SERIES
BEARING
REDESIGN 1991
TXT SERIES
INTRO 1985
TDT SERIES TD SERIES
TDT 115
TDT 125
TDT 115
TDT 125
TXT 105
TXT 109
TXT 115
TXT 125
TDT 215
TDT 225
T 11
TDT 215
TDT 225
TDT 315
TDT 325
TDT 315
TDT 325
TXT 309
TXT 315
TXT 325
TXT 309A
TXT 315A
TXT 325A
TDT 415
TDT 425
TDT 415
TDT 425
TXT 409A
TXT 415A
TXT 425A
TXT 405
TXT 409
TXT 415
TXT 425
245101
245154 TXT509C
TXT515C
TXT525C
246092 TXT609A
TXT615A
TXT625A
246101
247092
247101
247260 TXT709A
TXT715A
TXT725A
248101
249260 TXT815A
TXT825A
TXT15A
TXT926A
250101
250260
252101
TXT1015A
TXT1024A
TXT209A
TXT215A
TXT225A
TXT 509B
TXT 515B
TXT 525B
TXT 505A
TXT 305A
TXT 509, 509A
TXT 515, 515A
TXT 525, 525A
TXT 605
TXT 609
TXT 615
TXT 625
TXT 505
TXT 705
TXT 709
TXT 715
TXT 725
TXT 815
TXT 825
TXT 915
TXT 926
TXT 805
TXT 1015
TXT 1024
TXT 1215
TXT 1225
TXT 205
TXT 209
TXT 215
TXT 225
TXT 305
TDT 515
TDT 525
TDT 615
TDT 625
T 16
T 15
Use Part Number 247260
TDT 715
TDT 725
T 17
TXT 815
TXT 825
TXT 915
TXT 926
TDT 1115
TDT 1125
TDT 515
TDT 525
TDT 615
TDT 625
TDT 615A
TDT 625A
TDT 715
TDT 725
TDT 715A
TDT 725A
Use Part Number 249260
TD 815
TD 825
TD 815A
TD 825A
TD 915
TD 1115
TD 1125
Use Part Number 249260
TD 1015
TDT 1024
T 18
TDT 1215
TDT 1225
TD 1015
TD 1024
TD 1215
TD 1225
T 12
T 13
254101
255101
256101
257101
272259
272293
TXT 905
T 14
TDT 1325; T 19
TDT 1425
TDT 1530
3
NUMBER
SERIES
No. 1
No. 2
No. 3
No. 11
SHAFT
DIMENSIONS
.6315/.6310
.7383/.7378
.9706/.9696
.8891/.8881
.7383/.7378
No. 4
No. 5
.9706/.9696
1.1355/1.1325
.8891/.8881
1.0521/1.0511
No. 16A
1.2965/1.2955
1.2150/1.2140
1.5005/1.5000
No. 6
No. 7A
No. 17A
1.2965/1.2955
1.5405/1.5400
1.5005/1.5000
No. 8
No. 9
No. 18
No. 13
No. 14
No. 15
No. 16
No. 17
1.7505/1.7500
1.7505/1.7500
.9706/.9696
1.1335/1.1325
1.5405/1.5400
1.7505/1.7500
1.7505/1.7500
1.9370/1.9360
2.7495/2.7490
P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1) 479.646.4711, Fax (1) 479.648.5792, International Fax (1) 479.648.5895
Dodge Product Support
6040 Ponders Court, Greenville, SC 29615-4617 U.S.A., Ph: (1) 864.297.4800, Fax: (1) 864.281.2433
www.baldor.com
© Baldor Electric Company
MN1606 (Replaces 499838)
All Rights Reserved. Printed in USA.
3/11 Printshop 5000
*1606-0311*
APPENDIX I
Instruction Manual for DODGE
®
Setscrew, Eccentric Collar, D-Lok, H-E Series & EZ-Kleen
Mounted Ball Bearings
These instructions must be read thoroughly before installation or operation.
4.
WARNING: To ensure that drive is not unexpectedly started, turn off and lock out or tag power source before proceeding. Failure to observe these precautions could result in bodily injury.
CAUTION: Under certain operating conditions.
It is possible for static electric charge to build up on EZ-KLEEN Polymer Housings. Do not operate these bearings in an environment where a sudden static discharge may cause either an operating hazard or personnel discomfort.
1.
INSTALLATION:
Clean shaft and bearing bore thoroughly. locations to permit easy removal of bearing.
2.
Slip bearing into position. Be sure that bearing is not on a worn section of the only with soft driver. DO NOT HAMMER
ON HOUSING.
3.
The bearing outer ring OD is spherical and swivels in the housing to accommodate misalignment. Snug holddown bolts and
5.
Tighten hold-down bolts to proper torque
(Table 1). Turn shaft by hand. Resistance to turning should be the same as before full tightening of hold-down bolts.
For setscrew mounted bearings: After final alignment of the shaft, tighten both setscrews hand tight, then the setscrews should be tightened alternately and in small
1. After 24 hours operation, the setscrews should be retightened to the torque in Table
1 to assure full locking of the inner race to the shaft. Care should be taken that the socket key or driver is in good condition with no rounded corners and the key is fully engaged in the setscrew and held square with the setscrew to prevent rounding out of the setscrew socket when applying maximum torque. Do not drill through the setscrew holes for spot drilling of the shaft.
(Some inner rings have tempered setscrew threads and can be damaged by a drill.)
If spot drilling is required, locate bearings on the shaft and center punch through the setscrew hole. Remove bearing and spot drill the shaft, then reassemble over the spot drilled position and assemble as position is in the center of free movement top to bottom as well as side to side.
Pass shaft through both bearings without forcing. This will prevent preloading of the bearings. Housing slippage depends on the mounting hold-down bolt tightening torque, number of bolts and friction characteristics between mounting surfaces. Auxiliary load carrying devices such as shear bars are advisable for side or end loading of pillow where normal to heavy loading or shock loading is encountered.
NOTE: On coated and non-metallic housings, hold-down bolts should be tightened carefully with flat washers to prevent damage to the coating. Coated housings have reduced friction characteristics, so auxiliary load carrying devices are even more important in those applications.
WARNING Because of the possible danger to persons(s) or property from accidents which may result from the improper use of products, it is important that correct procedures be followed: Products must be used in accordance with the engineering information specified in the catalog. Proper installation, maintenance and operation procedures must be observed. The instructions in the instruction manuals must be followed. Inspections should be made as necessary to assure safe operation under prevailing conditions. Proper guards and other suitable safety devices or procedures as may be desirable or as may be specified in safety codes should be provided, and are neither provided by Baldor Electric Company nor are the responsibility of Baldor Electric Company. This unit and its associated equipment must be installed, adjusted and maintained by qualified personnel who are familiar with the construction and operation of all equipment in the system and the potential hazards involved. When risk to persons or property may be involved, a holding device must be an integral part of the driven equipment beyond the speed reducer output shaft.
spot drilling.
NOTE: On all Setscrew Product the setscrews can be re-torqued many times without damage to the bearing system. To achieve maximum shaft holding power it is highly recommended that setscrews be replaced with new hardware after any disassembly operation.
6.
For eccentric collar mounted bearings, slide collar against cam end of inner race.
Use a punch in the hole provided in the collar, tap collar smartly in the direction of shaft rotation. Tighten setscrews to proper torque (Table 1). To remove bearings, loosen setscrew and tap collar in the direction opposite of shaft rotation.
7.
For D-LOK mounted bearings, be sure collar is square and tight against shoulder on inner ring. Tighten cap screw to recommended torque shown in Table 1.
8.
For expansion bearings (H-E Series), locate inner unit in housing to allow expansion in the desired direction before locking to the shaft.
1
Setscrew
Size
(in.)
#10
1/4
5/16
3/8
7/16
(mm)
M5
M6
M8
M10
M12
Key
Hex
Across
Flats
(in.)
3/32
1/8
5/32
3/16
7/32
(mm)
2.5
3
4
5
6
Setscrews
Standard Ball
Bearing Insert
Min Max
(in-lbs.) (in-lbs.)
28
66
3.2
6.2
26
46
Recommended Torque
126
228
342
(N-m)
14.2
33
80
156
275
428
(N-m)
3.7
7.7
17.8
31
57
Corrosion
Resistant
Stainless
Steel
(in-lbs.)
25
60
117
206
321
(N-m)
2.8
5.8
13.4
23
43
Cap
Screw
Size
(in.)
#8-32
#10-32
1/4-28
5/16-24
3/8-24
(mm)
M4
M5
M6
M8
Table 1 - Recommended Torque
D-LOK
Recom.
Torque
(in-lbs.)
58
90
180
400
750
(N-m)
5.85
10.75
20.5
45
EZ-Kleen
Recom.
Torque
(in-lbs.)
46
72
144
320
600
(N-m)
4.68
8.6
16.4
36
Metal Housings
Bolt
Size
(in.)
3/8-16
7/16-14
1/2-13
5/8-11
3/4–10
7/8–9
(mm)
M10
M12
M16
M20
M22
Recom.
Dry
Torque
(Grade 2)
(in-lbs.)
240
384
600
1200
1950
2890
(N-m)
29
50
124
238
322
Mounting Bolts
EZ-KLEEN Housed Bearings
2-Bolt PB, 2 &
4 Bolt
Flg. and Flg.
Brackets
Bolt
Size
(in.)
Torque
3/8-16
7/16-14
1/2-13
9/16-12
5/8-11
(in-lbs.)
225
350
500
650
1000
Tapped-Base PB
Bolt
Size
(in.)
3/8-16
7/16-14
1/2-13
Torque
(in-lbs.)
175
350
400
(mm)
M8
M10
M12
M14
M18
(N-m) Torque for
Austenitic (18-8)
15
25
50
75
125
Stainless
Max. torque values published.
Do not exceed.
Lubrication
High Speed Operation - In the higher speed ranges, too much grease will cause over-heating. The amount of grease that the bearing will take for a particular high speed application can only be determined by experience. If excess grease in the bearing causes overheating, it will be necessary to and is ready to run. When establishing a relubrication schedule, note that a small amount of grease at frequent intervals is preferable to a large amount at infrequent intervals.
Hours Run per Day
Lubrication Guide
Use a No. 2 Lithium complex base grease or equivalent*
Suggested Lubrication Period in Weeks
1 to 250
RPM
12
251 to 500
RPM
12
501 to 750
RPM
10
751 to 1000
RPM
7
1001 to 1500
RPM
5
1501 to 2000
RPM
4 8
16
24
12
10
7
5
5
3
4
2
2
1
2
1
*For EZ-Kleen series bearings, use an aluminum complex base grease.
2001 to 2500
RPM
3
1
1
2501 to 3000
RPM
2
1
1
Lubrication recommendations are intended for standard products applied in general operating contact product engineering at 864-284-5700.
*3016-0711*
P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1) 479.646.4711, Fax (1) 479.648.5792, International Fax (1) 479.648.5895
Dodge Product Support
6040 Ponders Court, Greenville, SC 29615-4617 U.S.A., Ph: (1) 864.297.4800, Fax: (1) 864.281.2433
www.baldor.com
© Baldor Electric Company All Rights Reserved. Printed in USA.
MN3016 (Replaces 499498) 07/11 PRINTSHOP 200
APPENDIX J
INSTRUCTION MANUAL
DODGE
®
TYPE E BEARINGS for 1
3 /
16
” to 3” and 35mm to 75mm Bore
Kind of Grease — Many ordinary cup greases will disintegrate at speeds far below those at which DODGE ® bearings will operate successfully if proper grease is used. DODGE ® bearings have been lubricated at the factory with No. 2 consistency lithium complex-base grease which is suitable for normal operating conditions. Relubricate with lithium complex-base grease or a grease which is compatible with original lubricant and suitable for roller bearing service. In unusual or doubtful cases the recommendation of a reputable grease manufacturer should be secured.
www.rockwellautomation.com www.ptplace.com www.dodge-pt.com www.reliance.com www.ptplace.ca
Corporate Headquarters
Rockwell Automation, 777 East Wisconsin Avenue, Suite 1400, Milwaukee, WI, 53202-5302 USA, Tel: (1) 414.212.5200, Fax: (1) 414.212.5201
Headquarters for Dodge and Reliance Electric Products
Americas: Rockwell Automation, 6040 Ponders Court, Greenville, SC 29615-4617 USA, Tel: (1) 864.297.4800, Fax: (1) 864.281.2433
Canada: Rockwell Automation Canada, 296 Walker Drive, Bramalea, Ontario, Canada L6T 4B3, Tel: (1) 905.792.1722
Europe: Rockwell Automation, Brühlstraße 22, D-74834 Elztal-Dallau, Germany, Tel: (49) 6261 9410, Fax: (49) 6261 1771
Asia Pacific: Rockwell Automation, 55 Newton Road, #11-01/02 Revenue House, Singapore 307987, Tel: (65) 351 6723, Fax: (65) 355 1733
Headquarters for Allen-Bradley Products, Rockwell Software Products and Global Manufacturing Solutions
Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.4444
2/04 16M-K
Copyright © 2004 Rockwell Automation. All rights reserved. Printed in USA.
DODGE is a trademark of Rockwell Automation.
IM499791
APPENDIX K
INSTRUCTION MANUAL FOR
DODGE
®
S-2000 SPHERICAL ROLLER BEARINGS
GENERAL INFORMATION
DODGE S-2000 Spherical Roller Bearing mounted units incorbearing while still allowing a full + or - 1 degree of misalignment.
The patented sealing system (Pat. #5,908,249) has proven conditions.
INSTALLATION INSTRUCTIONS
NON-EXPANSION BEARING
WARNING
TO ENSURE THAT DRIVE IS NOT UNEXPECTEDLY
STARTED, TURN OFF AND LOCK OUT OR TAG POWER
SOURCE BEFORE PROCEEDING. FAILURE TO
OBSERVE THESE PRECAUTIONS MAY RESULT IN
BODILY INJURY.
1. Clean shaft and bore of bearing. The shaft should be straight, free of burrs and nicks, and correct size (see shaft tolerance table). If used shafting is utilized, then the bearing should be mounted on unworn section of shafting.
2. Lubricate shaft and bearing bore with grease or oil to facilitate assembly. Slip bearing into position. When light press fit is required, press against the end of the inner ring of bearing. Do not strike or exert pressure on the housing or seals.
3. Bolt bearing to support, using shims where necessary to align bearing so inner ring does not rub on seal carrier.
Use full shims which extend across the entire housing base.
4. Determine final shaft postion and tighten setscrews in the locking collar(s) of non-expansion bearing to recommended torque while the other bearings remain free.
Rotate the shaft slowly under load, if possible, to properly center the rolling elements with respect to the raceways. Then tighten setscrews into the locking collar of the remaining bearings to the recommended torque.
5. Check rotation. If there is any strain, irregular rotational torque or vibration, it could be due to incorrect alignment, bent shaft or bent supports. Installation should be rechecked and correction made where necessary.
EXPANSION BEARING
Steps (1, 2, 3) Same as Non-Expansion Bearing.
4. Position expansion bearing in the housing. For normal expansion conditions, the bearing insert should be positioned in the center of the housing. To center bearing insert in housing, move bearing insert to extreme position and mark shaft. Then using bearing maximum total expansion table, move bearing insert in opposite direction one-half the total expansion to center bearing in the housing. If maximum expansion is required, move bearing insert to the extreme position in the housing to permit full movement in direction of expansion. After expansion bearing has been positioned in the housing, tighten the setscrews in the locking collar to the recommended torque.
5. Same as Non-Expansion Bearing.
FIELD CONVERSION (RE-OP) OF A NON-EXPANSION
BEARING INTO AN EXPANSION BEARING
All non-expansion bearing sizes can be re-oped to become expansion bearings. To re-op a non-expansion to an expansion bearing follow these steps:
1. Move the snap ring, opposite from the collar side of bearing, to the outermost snap ring groove.
2. Install bearing per Expansion Bearing instructions listed above.
NOTE: Bearing nameplate has a non-expansion Part
Number. When bearing is re-oped the bearing should be marked as expansion for future reference.
BEARING MAXIMUM TOTAL EXPANSION TABLE
SHAFT SIZE
1
4
7
/
16 in.
1
3
/
8
- 1
1
/
2
11
/
16
- 3
3
15
/
- 4
7
1 6
15
/
/
16
16
TOTAL
EXPANSION in.
3
/
16
1
/
4
5
/
16
3
/
8
WARNING: Because of the possible danger to persons(s) or property from accidents which may result from the improper use of products, it is important that correct procedures be followed: Products must be used in accordance with the engineering information specified in the catalog.
Proper installation, maintenance and operation procedures must be observed. The instructions in the instruction manuals must be followed.
Inspections should be made as necessary to assure safe operation under prevailing conditions. Proper guards and other suitable safety devices or procedures as may be desirable or as may be specified in safety codes should be provided, and are neither provided by Baldor Electric Company nor are the responsibility of Baldor Electric Company. This unit and its associated equipment must be installed, adjusted and maintained by qualified personnel who are familiar with the construction and operation of all equipment in the system and the potential hazards involved. When risk to persons or property may be involved, a holding device must be an integral part of the driven equipment beyond the speed reducer output shaft.
LUBRICATION INSTRUCTIONS
OPERATION IN PRESENCE OF DUST, WATER
OR CORROSION VAPORS
This bearing is factory lubricated with No. 2 consistency lithium complex base grease which is suitable for most applications. However, extra protection is necessary if bearing is subjected to excessive moisture, dust, or corrosive vapor. In these cases, bearing should contain as much grease as speed will permit (a full bearing with consequent slight leakage through the seal is the best protection against contaminant entry).
In extremely dirty environments, the bearing should be purged daily to flush out contaminants. For added protection, it is advisable to shroud the bearing from falling material.
HIGH SPEED OPERATION
At higher operation speeds, too much grease may cause overheating. In these cases, the amount of lubrication can only be determined by experience. If excess grease causes overheating, remove grease fittings and run for ten minutes.
This will allow excess grease to escape. Then wipe off excess grease and replace grease fittings.
In higher speed applications, a small amount of grease at frequent intervals is preferable to a large amount at infrequent intervals. However, the proper volume and interval of lubrication can best be determined by experience.
AVERAGE OPERATIONS
The following table is a general guide for normal operating conditions. However, some situations may require a change in lubricating periods as dictated by experience. If the bearing is exposed to unusual operating conditions, consult a reputable grease manufacturer.
Lubrication Guide
Read Preceding Paragraphs Before Establishing Lubrication Schedule
Suggested Lubrication Period in Weeks
Hours run per day
1 to
250 rpm
251 to 501 to
500 rpm
750 rpm
751 to 1001 to 1501 to 2001 to
1000 rpm
1500 rpm
2000 rpm
2500 rpm
2501 to
3000 rpm
8
16
24
12
12
10
12
7
5
10
5
3
7
4
2
5
2
1
4
2
1
3
2
1
2
1
1
OPERATING TEMPERATURE
Abnormal bearing temperatures may indicate insufficient lubrication. If the housing is too hot to touch for more than a few seconds, check the temperature by applying a thermometer at the top of the pillow block with the thermometer tip surrounded by putty.
Because the thermometer reading will be approximately
10°F lower than the actual bearing temperature, add ten degrees to the reading and compare to the temperature rating of your grease. If the bearing temperature reading is consistent and operating within the recommended limits of your grease, the bearing is operating satisfactorily.
The recommended maximum operating temperature for S-
2000 Spherical Roller Bearings is 200 °F.
STORAGE OR SPECIAL SHUT DOWN
If equipment will be idle for some time, before shutting down, add grease to the bearing until grease purges from the seals. This will ensure protection of the bearing, particularly when exposed to severe environmental conditions. After storage or idle period, add fresh grease to the bearing before starting.
SET SCREW TORQUE TABLE
Shaft Size
1
3
/
8
- 1
3
/
4
inches
11
15
/
16
- 2
7
/
16
inches
12
11
/
16
- 3
7
/
16
inches
13
15
/
16
- 4
15
/
16
inches
Socket
Set Screw
Size
5
/
16
inches
3
/
8
inches
1
/
2
inches
5
/
8
inches
Tightening
Torque
165 Inch Pounds
290 Inch Pounds
620 Inch Pounds
1325 Inch Pounds
RECOMMENDED SHAFT TOLERANCE TABLE
Normal
Low to Normal Equivalent
Load and Catalog
Shaft Size Speed*
Up to 1
1
/
2
inches
Over 1
1
/
2
to 2
1
/
2
inches
Over 2
1
/
2
to 4 inches
Over 4 to 5 inches
+.000 inches
+.000 inches
+.000 inches
+.000 inches
–.0005 inches
–.001 inches
–.001 inches
–.0015 inches
On severe applications and where dynamic balance and minimum runout are important, a snug to light press fit may be required to obtain optimum bearing performance. Consult factory.
*Normal equivalent load .08C to .18C.
3
COMPONENT PART NUMBERS (1 3/8" - 4 15/16")
ITEM 1 1A 2
Shaft Size Bearing Insert Assembly Bearing Insert Assembly * Collar
Size (R) Seal (L) Seal
1 3/8
1 7/16
1 1/2
1 11/16
1 3/4
1 15/16
2
2 3/16
2 7/16
2 11/16
2 15/16
3
3 7/16
3 15/16
4 7/16
4 15/16
QTY/PER
070000
070001
070002
070003
070004
070005
070006
070007
070008
070009
070010
070011
070012
070013
070014
070015
1
*Shaft sizes 4 7/16" - 4 15/16" have two collars a
** WSTU and TPHU TU take a 405016 grease fitting.
070016
070017
070018
070019
070020
070021
070022
070023
070024
070025
070026
070027
070028
070029
070030
070031
1
3
* Set
Screw
040050
040050
040050
040051
040051
070587
070587
070588
040054
400058
400058
400058
400058
400058
400094
400094
400094
400094
070589
070589
070589
400150
400150
400150
040056
060946
400154
400186
* 060947 * 400186
* 040059 * 400190
1 2
4
Snap
Ring
069276
069276
069276
069277
069277
069278
069278
069279
069280
069281
069281
069281
069282
069283
069284
069285
1
5
** Grease
Fitting
405015
405015
405015
405015
405015
405015
405015
405015
405015
405015
405015
405015
405015
405015
405015
405015
1 www.baldor.com www.ptplace.com www.dodge-pt.com www.reliance.com
Baldor Electric Company Headquarters
P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1) 479.648.5792, Fax (1) 479.648.5792, International Fax (1) 479.648.5895
DODGE/Reliance Division
6040 Ponders Court, Greenville, SC 29615-4617 U.S.A., Ph: (1) 864.297.4800, FAX: (1) 864.281.2433
IM499330 04/07-16M-K Copyright © 2007 Baldor Electric Company All Rights Reserved. Printed in USA.
This material is not intended to provide operational instructions. Appropriate instruction manuals and precautions should be studied prior to installation, operation or maintenance of equipment.
APPENDIX L
Mounted Roller Bearings
Installation Instructions
2000, 5000, 9000 Series
(See other side for Bearing Kit Replacement and Maintenance Instructions) (See separate sheet for 3000 install)
BEARING MOUNTING PROCEDURE
SET COLLAR-FIXED UNITS ONLY (2000, 5000)
1. Inspect shaft size (see shaft tolerance table). Clean shaft and mounting surface as needed
2. Position bearings on the shaft, applying all driving pressure to the face of the inner ring
3. Align the bearing housing to its mounting base by measuring from the face of the inner ring to the face of the threaded cover. Where shimming is required – use full shims across the housing base – not just at the bolt holes. All four measurements must be within .060” inches of one another
4. Bolt housing securely to mounting base
5. Tighten the set collar set screws on the bearing closest to the drive
(or most important to axial position of shaft) to the shaft. Proper tightening torque can be found in the SET SCREW TORQUE
TABLE.
The remaining bearings should not be secured to the
shaft at this time. Alternate torquing the screws to prevent unequal loading. If an Allen wrench is used as a torque wrench, place a length of pipe over the long end and pull until the wrench begins to twist.
6. Rotate the shaft under power to permit the remaining bearings to seek their natural running position on the shaft.
7. Shut off the power and torque down set screws in remaining bearings using procedure in Step 5
ADAPTER UNITS (9000)
1. Free tapered split sleeve in bore by backing off locknut and rapping the face of the locknut
2. Position bearing on shaft with fixed unit closest to drive (or most important to axial location of shaft)
3. Position and loosely bolt housing to mounting base.
4. Secure fixed bearing to shaft by tightening locknut until sleeve grips the shaft. Tighten locknut ½ to ¾ more and bend one of the lock washer tangs into one of the slots on the outside diameter of locknut
5. Align each bearing housing as accurately as possible to its mounting base or frame by measuring from the face of the inner ring to the face of the threaded cover. All four measurements must be within .060 inches of one another
6. Operate bearing under full load for several days to permit seating of bearing and sleeve on the shaft. Then shut down the system and retighten locknuts on all bearings
ADAPTER UNITS- EXPANSION UNITS ONLY (9000)
1. Center cartridge in outer housing. If maximum expansion capability is required, place cartridge in extreme position of housing to permit full movement of the cartridge in direction of expansion.
2. The remainder of the installation is the same as Fixed units, following steps
2, 3,4, 5 and 6
SET COLLAR-EXPANSION UNITS ONLY (2000, 5000)
1. Center cartridge in outer housing. If maximum expansion capability is required, place cartridge in extreme position of housing to permit full movement of the cartridge in direction of expansion
2. The remainder of the installation is the same as Fixed units, following steps 3,4, and 5
DUPLEX UNITS (ZD)
When mounting Duplex units, place end plate (bolted cover with pilot) into bore of housing. Press first outer ring until it seats against the pilot, then insert inner ring assembly and turn to free rollers. Press in second outer ring, turn inner ring assembly so rollers are free, and then seat second outer ring. Using shims as a feeler, determine exact amount required to fill space between housing face and bolted cover. See ADJUSTMENT TABLE and add shims to obtain proper bearing clearance. After unit is bolted together, free the bearing by pressing or striking inner ring on the side opposite the shim adjustment
GENERAL INSTALLATION COMMENTS
1. Shaft Journal areas must be free of burrs, cleaned of fretting corrosion and within the tolerance range shown in the SHAFT TOLERANCE TABLE.
2. Mounted units are prelubricated at the factory with multipurpose lithium soap grease. No additional grease is required at time of installation.
3. Position housings for a. Accessibility of grease fittings b. If thrust is present – place thrust force against shoulder of housing, not against threaded cover side
4. If spacer shims are used for alignment they must cover the entire housing base
5. Spot drill or mill flats on shaft for increased holding power of set screws or ease of removal
6. When a eccentric load condition exists, position set screws directly opposite from eccentric weight
7. Shaft shoulders are recommended for support vertical shafts and high thrust loads. The shoulder diameter should not exceed the outside diameter of the inner ring
8. When pillow blocks are mounted on an inclined plane or the work force is parallel with the base, either lateral bolts or welded stop blocks should be used to prevent shifting
9. Avoid direct hammer blows to the bearing and its components by using a soft drift or block
10. New seals should be used whenever a bearing is rebuilt
SET SCREW TORQUE TABLE
Shaft Size (Inches)
Normal Duty
2000 Series
3/4 – 1 1/4
1 7/16 - 2
2 3/16 – 2 1/4
2 3/8 – 3 1/2
3 11/16 - 4
…..
Heavy Duty
5000 Series
Set Screw Size
Tightening Torque
(Inch- Pounds)
…..
1 7/16 – 1 15/16
2 – 2 3/16
2 7/16 – 3 7/16
3 11/16 – 5 7/16
5 15/16 – 7
5/16
3/8
7/16
1/2
5/8
3/4
For more detailed instructions refer to latest REXNORD Catalog
185
325
460
680
1350
1600
Nominal
Shaft sizes
1-2
2-4
4-6
6-8
SHAFT TOLERANCE TABLE - INCHES
Commercial Shaft
Tolerance* (Cold
Finished Steel, Low
Carbon)
+.000 -.003
+.000 -.004
+.000 -.005
+.000 -.006
RECOMMENDED SHAFT TOLERANCES*
Set Collar Mounting
Severe Loading or
High Speed
Adapter
Mounting
Press Fit
Mounting
+.000 -.001
+.000 -.001
+.000 -.0015
+.000 -.0015
+.000 -.003
+.000 -.004
+.000 -.005
+.000 -.005
Consult
Rexnord
1. Housing
2. Inner Race
3. Threaded
Cover
4. Microlock
Assembly
5. Seal
6. Cartridge
7. Roller
8. Outer Ring
9. Set Collar
*Recommended shaft tolerances are generally satisfactory for loads up to 15% of C (see load ratings in catalog). High load applications will require a press fit to the shaft.
Bearing Replacement and
Mounted Roller Bearings
Single Collar
2000, 3000 Series
Double Collar
5000 Series
Maintenance Instructions
DISASSEMBLY
1. Remove set collars or other shaft locking device
3. Remove MICROLOCK screw and key. (Do not loose nylon washer)
4. Remove threaded cover by turning counter clockwise
5. Place housing threaded cover side down on arbor press with spacer blocks under housing
6. Place a soft metal bar or wood block on face of inner ring and press bottom outer ring and inner ring assembly from housing
7. To remove the back outer ring, large bore bearings 4 7/16” thru 7” have drive pin holes. The back outer ring of smaller size units may be removed with a bearing puller or hammer and drift.
REASSEMBLY
1. Place housing cover side up on arbor press with spacer blocks under housing.
2. Press in back outer ring and seat against housing shoulder.
3. Insert inner ring assembly and rotate to seat rollers against back outer ring.
4. Press in front outer ring.
5. Install threaded cover, turning clockwise until inner ring resists rotation or misalignment.
6. Back off threaded cover one quarter turn – align cover slot with the nearest counter bored hole in housing. See ADJUSTMENT TABLE.
7. Install microlock key with nylon washer under the head of the screw.
8. Using a soft drift or block, rap face of inner ring on side opposite threaded cover to seat front outer ring. Inner ring assembly should rotate freely.
9. Install seals. Z-Seal – Place centering spring in seal groove with fingers facing up. Place U-shaped element on fingers. Place centering ring on element with projection on face up. Install snap ring so that projection on centering ring is between ends of snap ring. K-Seal – Place seal into the seal groove with anti rotation boss sticking up. Install snap ring so that the raised boss is between the snap ring ends. M-Seal – Place seal into seal groove with spring facing out. No snap ring is required with M-Seal.
10. Install collars
11. Lubricate bearing with amount of grease shown in LUBRICATION
TABLE. Rotate inner ring assembly during lubrication to assure distribution of grease in bearing
(See other side for installation instructions)
LUBRICATION INSTRUCTIONS
GENERAL INFORMATION AND SELECTION
This information is to aid in the proper lubrication of Rexnord bearings for the majority of applications. Standard bearings come pre-lubricated from the factory with Exxon Ronex MP grease. Exxon Ronex MP is an N.L.G.I.
Grade 2. EP (extreme pressure) grease with a lithium complex thickener. It can be used for high loads, and in some cases at temperatures as low as
-40°F or as high as +350°F. For high speeds, other special service conditions, or for inquires on other acceptable greases, please consult your local Rexnord representative or the Rexnord Bearing Engineering
Department. When rebuilding Rexnord bearings for use in average operating conditions, the bearing should be lubricated with the amount of grease by weight as shown in the LUBRICATION TABLE.
RELUBRICATION
Bearings should be re-lubricated at regular intervals. The frequency and amount of lubricant will be determined by the type of service. General guidelines for re-lubrication frequency and amount are based upon average application conditions. See LUBRICATION TABLE
At High temperatures, greases tend to degrade more rapidly and thus require fresh grease more frequently. In general, small amounts of grease added frequently provide better lubrication. Most grease will eventually harden, causing re-lubrication to become less effective. When this occurs, the bearing should be disassembled, cleaned and lubricated per
LUBRICATION TABLE. When equipment will not be in operation for some time, grease should be added to provide corrosion protection. This is particularly important for equipment exposed to severe weather.
AUTOMATIC LUBRICATION SYSTEMS
A variety of automatic re-lubrication systems are available for use with roller bearings. Key considerations are:
1. NLGI grade of grease used, consistent with system layout
2. An amount/frequency combination necessary to replenish the grease
MIXING OF GREASES
Mixing of any 2 greases should be checked with the lubricant manufacturer. If the grease bases are different they should never be mixed
OIL LUBRICATION
Rexnord housing designs do not include oil sumps, thus they are not readily used with static oil lubrication. However, they can be adapted to recirculating oil systems provided an adequate drain size and proper seals are incorporated
LUBRICATION TABLE
SHAFT SIZE - INCHES
Adapter
9000 Series
GREASE WT. REQUIRED (OZ)
To Lubricate
Rebuilt Units
To Relubricate
Units
RECOMMENDED NUMBER OF MONTHS BEWEEN RELUBRICATION*
(BASED ON 40 HR. WK.)
RPM
3/4 -1
1 1/8 – 1 1/4
1 7/16 – 1 1/2
1 11/16 -1 3/4
1 15/16 -2
2 3/16 – 2 1/4
2 3/8 - 2 1/2
2 11/16 – 3
3 3/16 – 3 1/2
3 11/16 – 4
……
……
……
……
……
……
……
1 7/16
1 1/2 – 1 11/16
1 15/16
2 – 2 3/16
2 7/16
2 1/2 – 2 15/16
3 3/16 – 3 7/16
3 11/16 – 4
4 3/16 – 4 1/2
4 15/16 – 5
5 7/16
5 15/16 – 6
6 7/16 - 7
……
……
……
……
……
1 15/16 – 2
2 3/16
2 7/16 – 2 1/2
2 11/16 -3
3 3/16 – 3 7/16
3 11/16 – 4
4 3/16 – 4 7/16
4 15/16 – 5
5 3/16 – 5 7/16
5 15/16 – 6 7/16
0.4
0.5
0.6
0.8
0.9
1.1
1.5
2.8
3.7
6.9
8.4
14.3
22.1
25.3
33.0
0.1
0.1
0.1
0.2
0.2
0.2
0.3
0.5
0.6
1.1
1.5
2.5
4.0
4.5
6.0
12 8 5 2 1 1/2
*Relubrication amounts and frequencies shown in the table are based on standard clearance, moderate loads, etc., which yield housing temperatures of 150°F or less. Lubrication practices indicate that the relubrication frequency should be doubled for every 20°f above that level
ADJUSTMENT TABLE (AXIAL AND RADIAL CLEARANCES)
Size
Code
SHAFT SIZE (INCHES)
FACTORY ADJUSTMENT
(Average Speeds)
RECOMMENDED ADJUSTMENT HIGH
SPEEDS
CLEARANCE
ADJUSTMENT INCHES
PER 1/12 TURN
2-4
5-6
7-9
10-11
12-13
14-16
2000
SERIES
3/4 – 1 1/2
1 11/16 - 2
2 3/16 – 3
3 3/16 - 4
……
……
3000
SERIES
5000
SERIES
1 7/16 1 7/16
1 11/16 – 1 15/16 1 1/2 – 1 15/16
2 3/16 – 2 15/16
3 7/16 – 3 15/16
……
……
2 – 2 15/16
3 3/16 - 4
4 3/16 – 5
5 7/16 - 7
Rexnord Industries, LLC
Bearing Group
……
……
9000
SERIES
1 15/16 – 2 1/2
2 11/16 -3 7/16
3 11/16 – 4 7/16
4 15/16 – 6 7/16
STD AXIAL
CLEARANCE
.007-.012
.007-.012
.010-.017
.010-.017
.015-.025
.015-.025
STD RADIAL
CLEARANCE
.0022-.0037
.0020-.0034
.0026-.0044
.0025-.0043
.0032-.0054
.0032-.0054
SPEED
OVER
2000
1500
1250
1000
750
500
AXIAL
CLEARANCE
.012-.017
.012-.017
.017-.024
.017-.024
.025-.035
.025-.035
Phone: 317-273-5500 www.rexnord.com
RADIAL
CLEARANCE
.0037-.0053
.0034-.0049
.0044-.0062
.0043-.0060
.0054-.0076
.0054-.0076
AXIAL RADIAL
0.005
0.005
0.007
0.007
0.010
0.010
105-99501-07
ECN 5-43431
5-12-08
0.0016
0.0014
0.0018
0.0018
0.0022
0.0022
Mounted Roller Bearings
Twist Lock™ 3000 Series
Installation Instructions
( This sheet provides install information for the 3000 series, see 2000, 5000, 9000 sheet for more info)
Twist Lock™ 3000 Series Roller Bearing
This bearing is equipped with an eccentric locking set collar that should be tightened in the direction of shaft rotation
BEARING MOUNTING PROCEDURE
8. Position bearings on the shaft, applying the driving pressure to the face of the inner ring.
9. Align the bearing housing to its mounting base by measuring from the face of the inner ring to the face of the threaded cover. Where shimming is required – use full shims across the housing base – not just at the bolt holes. All four measurements must be within .060” inches of one another
10. Bolt housing securely to mounting base
11. Slide collar over the shaft until it nests over the cam of the inner ring. Do this on the bearing closest to the drive (or the most important to axial position of shaft). Rotate the collar in the direction of normal shaft rotation until snug. Utilizing a hammer and punch, rotate the collar until tight. Tighten set screws securely. Utilize torque values from the SET SCREW TABLE PER “SET SCREW SIZE”. If an Allen wrench is used as a torque wrench, place a length of pipe over the long end and pull until the wrench begins to twist.
12. The remaining bearings should not be secured to the shaft at this time
13. Rotate the shaft under power to permit the remaining bearings to seek their natural running position on the shaft.
14. Shut off the power and torque down set screws in remaining bearings using procedure in Step 4.
BEARING REMOVAL PROCEDURE
7. Use a hammer and punch to rotate the collar in the direction opposite the shaft rotation until it loosens. If the rotation direction is unknown, look for prior punch marks on the collar. Then rotate the collar in the opposite direction until it loosens.
8. Remove the collar from the shaft of the and inner ring. The bearing may now be removed from the shaft. To eliminate bearing damage, apply all driving force to the face of the inner ring.
Rexnord Industries, LLC
Bearing Group
Phone: 317-273-5500 www.rexnord.com
105-99501-16
ECN 5-43431
5-12-08
APPENDIX M
INSTALLATION AND
MAINTENANCE
INSTRUCTIONS FOR
ELECTRIC MOTORS
Frames 143/5T - 586/7T
READ CAREFULLY THIS MANUAL BEFORE
INSTALLING THE MOTOR.
RECEIVING CHECK
Check if any damage has occured during transportation.
Check nameplate data.
Remove shaft locking device (if any) before operating the
motor.
Turn the shaft with the hand to make sure if it is turning freely.
HANDLING AND TRANSPORTATION
1 - General
MOTORS MUST NOT BE LIFTED BY THE SHAFT,
BUT BY THE EYE BOLTS WHICH ARE PROPERLY
DESIGNED TO SUPPORT THE MOTOR WEIGHT.
Lifting devices, when supplied, are designed only to support the motor. If the motor has two lifting devices then a double chain must be used to lift it.
Lifting and lowering must be done gently without any shocks, otherwise the bearings can get damaged.
DURING TRANSPORTATION, MOTORS FITTED
WITH ROLLER OR ANGULAR CONTACT
BEARINGS ARE PROTECTED AGAINST BEARING
DAMAGES WITH A SHAFT LOCKING DEVICE.
THIS LOCKING DEVICE MUST BE USED ON ANY
FURTHER TRANSPORT OF THE MOTOR, EVEN
WHEN THIS MEANS TO UNCOPULE THE MOTOR
FROM THE DRIVEN MACHINE.
STORAGE
If motors are not immediately installed, they must be stored in dry places, free of dust, vibrations, gases, corrosive smokes, under constant temperature and in normal position free from other objects.
In case the motors are stored for more than two years, the bearings must be changed or the lubrication grease must be totally replaced after cleaning.
Single phase motors when kept in stock for 2 years or more must have their capacitors replaced (if any).
We recommend to turn the shaft (by hands) at least once a month, and to measure the insulation resistance before installing it, in cases of motors stored for more than 6 months or when subject to high humidity areas.
If motor is fitted with space heaters, these should be switched on.
Measure the insulation resistance before operating the motor and/or when there is any sign of humidity in the winding.
The resistance measured at 25°C (77
o
F) must be:
Ri > (20 x U) / (1000 + 2P) [Mohm] (measured with a
MEGGER at 500 V d.c.); where U = voltage (V); P = power
(kW).
If the insulation resistance is less than 2 megaohms, the winding must be dried according to the following:
Warm it up inside an oven at a minimum temperature of
80°C (176
o
F) increasing 5°C (41
o
F) every hour until 105°C
(221
o
F), remaining under this temperature for at least one hour.
Check if the stator insulation resistance remains constant within the accepted values. If not, stator must be reimpregnated.
INSTALLATION
1 - Safety
All personnel involved with electrical installations, either handling, lifting, operation or maintenance must be well informed and up-to-dated concerning the safety standard and principles that govern the work and carefully follow them.
We strongly recommend that these jobs are carried out by qualified personnel.
MAKE SURE THAT THE ELECTRIC MOTORS ARE
SWITCHED OFF BEFORE STARTING ANY
MAINTENANCE SERVICE.
Motors must be protected against accidental starts.
When performing any maintenance service, disconnect the motor from the power supply. Make sure all accessories have been switched off and disconnected.
Do not change the regulation of the protecting devices to avoid damaging.
LEAD CONNECTION IN SULATION INSIDE THE
TERMINAL BOX MUST BE DONE WITH AN
INSULATING MATERIAL COMPATIBLE WITH
MOTOR THERMAL CLASS WHICH IS SHOWN
ON THE MOTOR NAMEPLATE.
2 - Operating Conditions
Electric motors, in general, are designed for operation at an altitude of 1000m above sea level for an ambient temperature between 25°C (77°F) and 40°C (104°F). Any variation is stated on the nameplate.
COMPARE THE CURRENT, VOLTAGE,
FREQUENCY, SPEED, OUTPUT AND OTHER
VALUES DEMANDED BY THE APPLICATION WITH
THE DATA GIVEN ON THE NAMEPLATE.
Motors supplied for hazardous locations must be installed in areas that comply with that specified on the motor nameplate.
KEEP AIR INLET AND OUTLET FREE AND CLEAN.
THE AIR BLOWN OUT BY THE MOTOR SHALL
NOT ENTER AGAIN. THE DISTANCE BETWEEN
THE AIR INLET AND THE WALL MUST BE
AROUND ¼ OF THE INLET OPENING DIAMETER.
3 - Foundation
Motors provided with feet must be installed on though foundations to avoid excessive vibrations.
The purchaser is fully responsible for the foundation.
Metal parts must be painted to avoid corrosion.
The foundation must be uniform and sufficiently tough to support any short circuit strengths. It must be designed in such a way to stop any vibration originated from resonance.
4 - Drain Holes
Make sure the drains are placed in the lower part of the motor when the mounting configuration differs from that specified on the motor purchase order.
5 - Balancing
WEG MOTORS ARE DYNAMICALLY
BALANCED, WITH HALF KEY AT NO LOAD
AND UNCOUPLED.
Transmission elements such as pulleys, couplings, etc must be dynamically balanced with half key before installation. Use always appropriate tools for installation and removal.
6 - Alignment
ALIGN THE SHAFT ENDS AND USE FLEXIBLE
COUPLING, WHENEVER POSSIBLE.
Ensure that the motor mounting devices do not allow modifications on the alignment and further damages to the bearings.
When assembling a half-coupling, be sure to use suitable equipment and tools to protect the bearings.
Suitable assembly of half-coupling: check that clearance Y is less than 0.05mm and that the difference X1 to X2 is less than 0.05m as well.
Note: The“X” dimension must be at least 3mm.
7 - Belt Drive
When using pulley or belt coupling the following must be observed:
Belts must be tighten just enough to avoid slippage when running, according to the specifications stated on the belt supplier recommendation.
W ARNING:
Excessive tension on the pulleys will damage the bearings and lead to a probable shaft rupture.
8 - Connection
W terminal box for heating elements or direct winding heating.
W a charge which appears across the motor terminals, even when the motor has reached standstill.
A WRONG CONNECTION CAN BURN THE
MOTOR.
Voltage and connection are indicated on the nameplate.
The acceptable voltage variation is ± 10%, the acceptable frequency variation is ± 5% and the total acceptable variation is ± 10%.
9 - Starting Methods
The motor is rather started through direct starting. All Weg motors must be connected as shown on the motor nameplate, failure to follow the motor nameplate could lead to motor failure.
In case this is not possible, use compatible methods to the motor load and voltage.
3 lead single voltage and 9 lead dual voltage motors can be started as follows:
Full Voltage Direct On Line.
Auto-Transformer Starting.
Electronic Soft-Starting.
VFD Starting - subject to verification and application analysis.
6 lead single voltage motors and 12 lead dual voltage motors can be connected as follows:
Full Voltage Direct On Line.
WYE/DELTA Starting.
Auto-Transformer Starting.
Electronic Soft-Starting.
VFD Starting - subject to verification and application analysis.
The rotation direction is clockwise if the motor is viewed from DE side and if the phases are connected according to the sequence L1, L2, L3.
To change the rotation direction, interchange two of the connecting leads.
THE CONNECTION TO THE POWER SUPPLY
MUST BE DONE BY QUALIFIED PERSONNEL
AND WITH FULL ATTENTION TO ASSURE A SAFE
AND PERMANENT CONNECTION. AFTER
CONNECTING THE MOTOR, CHECK FOR ANY
STRANGE BODY INSIDE THE TERMINAL BOX.
THE CABLE INLETS NOT IN USE MUST BE
CLOSED.
Make sure to use the correct cable dimension, based on the rated current stamped on the motor nameplate.
BEFORE ENERGIZING THE TERMINALS, CHECK
IF THE EARTHING IS MADE ACCORDING TO THE
ACTUAL STANDARDS. THIS IS ESSENTIAL
AGAINST ACCIDENT RISKS.
When the motor is supplied with protective or monitor temperature device such as thermostats, thermistors, thermal protector, etc, connect their terminals to the corresponding devices on the control panel.
10- Start-Up
THE KEY MUST BE FASTENED OR REMOVED
BEFORE STARTING THE MOTOR.
a) The motor must start and operate smoothly. In case this does not occur, turn it off and check the connections and the mounting before starting it again.
b) If there is excessive vibration, check if the fastening screws are correctly fastened. Check also if the vibration comes from a neighbour machine. Periodical vibration checks must be done.
c) Run the motor under rated load for a short period of time and compare if the running current is equal to that stamped on the nameplate.
MAINTENANCE
WARNING:
SAFETY CHECK LIST.
1 - General Inspection
Check the motor periodically.
Keep the motor clean and assure free air flow.
Check the seals or V Ring and replace them, if required.
Check the connections as well as supporting screws.
Check the bearings and observe:
Any excessive noise, bearing temperature and grease condition.
When a changing, under normal conditions, is detected, check the motor and replace the required parts.
The frequency of the inspections depends on the motor type and on the application conditions.
LUBRICATION
FOLLOW THE REGREASING INTERVALS. THIS IS
FUNDAMENTAL FOR PROPER MOTOR
OPERATION.
1 - Machines without Grease Nipples
Motors up to frame 324/6T are normally fitted without grease nipples. In these cases the regreasing shall be done at the preventive maintenance job observing the following aspects:
Disassemble carefully the motors.
Take all the grease out.
Wash the bearing with querosene or diesel.
Regrease the bearing immediately.
2 - Machines Fitted with Grease Nipples
It is strongly recommended to grease the machine while running. This allows the grease renewal in the bearing housing.
When this is not possible due to turning parts by the grease device (pulleys, bushing, etc) that offer some risk to the physical integrity of the operator, proceed as follows:
Clean the area near to the grease nipple.
Put approximately half of the total grease and run the motor for 1 minute at full speed. Then turn off the motor and pump the rest of the grease.
The injection of all the grease with the motor in standstill can make the grease penetrate into the motor, through the inner seal of the bearing housing.
When regreasing, use only special bearing grease with the following properties:
WARNING:
The table above is specifically intended for relubrication with Polyrex
®
EM grease and bearing absolute operating temperature of:
70
o
C (158
o
F) for 254/6T to 324/6T frame motors;
85
o
C (185
o
F) for 364/5T to 586/7T frame motors.
For every 15
o
C (59
o
F) above these limits, relubrication interval must be reduced by half.
Shielded bearing (ZZ) are lubricated for berings life as long as they operate under normal ambient conditions and temperature of 70°C(158
o
F ).
WE RECOMMEND TO USE BALL BEARINGS FOR
MOTORS DIRECTLY COUPLED TO THE LOAD.
WARNING:
EXCESS OF GREASE CAN CAUSE BEARING
OVERHEATING RESULTING IN COMPLETE
DAMAGE.
Compatibility of P olyrex
®®®®®
EM grease
with other types of grease:
Containing polyurea thickener and mineral oil, the Polyrex
EM grease is compatible with other types of grease that contain:
Lithium base or complex of lithium or polyurea and highly refined mineral oil;
Inhibitor additive against corrosion, rust and anti-oxidant additive.
Notes:
Although Polyrex
®
EM is compatible with the types of grease given above, we do no recommend to mix it with any other greases.
If you intend to use a type of grease different than those recommended above, first contact WEG.
On applications (with high or low temperatures, speed variation, etc), the type of grease and relubrication interval are given on an additicional nameplate attached to the motor.
Vertical mounted motors must have the relubrication intervals reduced by half.
THE USE OF STANDARD MOTORS IN SPECIFIC
AREAS OR SPECIAL APPLICATIONS MUST BE
DONE BY CONSULT TO THE GREASE
MANUFACTURER OR WEG.
®
ASSEMBLY AND DISASSEMBLY
Disassembly and assembly must be done by qualified personnel using only suitable tools and appropriated methods.
The stator grips must be applied over the side face of the inner ring to be disassembled or over and adjacent part.
It is essential that the bearings disassembly and assembly be done under cleanning conditions to ensure good operation
and to avoid damages. New bearings shall only be taken out from their cases when assembling them.
Before installing a new bearing it is required to check the shaft fitting for any sharp edge or strike signals.
For bearing assembly, warm their inner parts with suitable equipment - inductive process - or use suitable tools.
SPARE PARTS
When ordering spare parts, please specify the full type designation and product code as stated on the motor nameplate.
Please also inform the motor serial number stated on the nameplate.
MOTORS FOR HAZARDOUS LOCATIONS
Besides the recommendations given previously, these ones must be also followed:
THE SPECIFICATION OF THE MOTOR
INSTALLATION PLACE IS FOR CUSTOMER’S
RESPONSIBILITY, WHO WILL ALSO DETERMINE
THE ENVIRONMENT CHARACTERISTICS.
Motors for hazardous locations are manufactured according to specific standards for such environments and they are certified by worldwide certifying entities.
1 - Installation
The complete installation must follow procedures given by the local legislation in effect.
THE INSTALLATION OF HAZARDOUS LOCATION
MOTORS MUST BE CARRIED OUT BY SKILLED
PEOPLE, AND THE THERMAL PROTECTION
MUST BE ALWAYS INSTALLED, EITHER INSIDE
OR OUTSIDE THE MOTOR, OPERATING AT THE
RATED CURRENT.
2 - Maintenance
Maintenance must be carried out by repair shops authorized by WEG.
Repair shops and people without WEG’s authorization who will perform any service or hazardous location motors will be fully responsible for such service as well as for any consequential damage.
ANY ELECTRICAL OR MECHANICAL
MODIFICATION MADE ON HAZARDOUS
LOCATION MOTORS WILL VOID THE
CERTIFICATION.
When performing maintenance, installation or relubrication, follow these instructions:
Check if all components are free of edges, knocks or dirt.
Make sure all parts are in perfect conditions.
Lubricate the surfaces of the endshield fittings with protective oil to make the assembly easier.
Use only rubber hammer to fit the parts.
Check for correct bolts tightening.
Use clearance calibrator for correct T-box fitting (smaller than 0.05mm).
DO NOT REUSE DAMAGED OR WORN PARTS.
REPLACE THEM BY NEW ONES SUPPLIED BY
THE FACTORY.
MOTORS DRIVEN BY VFD
Applications using VFD´s without filter can affect motor performance as follows:
Lower efficiency.
Higher vibration.
Higher noise level.
Higher rated current.
Higher temperature rise.
Reduced motor insulation.
Reduced bearing life.
1 - Standard Motors
Voltages lower than 440V do not require filter.
Voltages equal or higher than 440V or lower than 575V
require filter for motor power supply cables longer than 20
meters.
Voltages equal or higher than 575V require filter for any size
of power supply cables.
IF SUCH RECOMMENDATIONS ARE NOT
FOLLOWED ACCORDINGLY, MOTOR WARRANTY
WILL BE VOID.
2 - Inverter Duty Motors
Check power supply voltage of the forced cooling set.
Filters are not required.
WARRANTY TERMS
SERIES AND ENGINEERING PRODUCTS
WEG warrants its products against defects in workmanship and materials for 18 months from the invoice date issued by the factory, authorized distributor or agent limited to 24 months from manufacturing date independent of installation date as long as the following items are fulfilled accordingly:
- Proper transportation, handling and storage;
- Correct installation based on the specified ambient conditions and free of corrosive gases;
- Operation under motor capacity limits;
- Observation of the periodical maintenance services;
- Repair and/or replacement effected only by personnel duly authorized in writing by WEG;
- The failed product be available to the supplier and/or repair shop for a required period to detect the cause of the failure and corresponding repair;
- Immediate notice by the purchaser about failures occured and that these are accepted by WEG as manufacturing defects.
This warranty does not include disassembly services at the urchaser facilities, transportation costs with product, tickets, accomodation and meals for technical personnel when requested by the customer. The warranty service will be only carried out at
WEG Authorized Repair Shops or at WEG´s facilities.
Components whose useful life, under normal use, is shorter than the warranty period are not covered by these warranty terms.
The repair and/or replacement of parts or components, when effected by WEG and/or any WEG Authorized Repair Shop, will not give warranty extension.
This constitutes WEG´s only warranty in connection with this sale and the company will have no obligation or liability whatsoever to people, third parties, other equipment or installations, including without limitation, any claims for consequential damages or labor costs.
APPENDIX N
SERVICE RECOMMENDATIONS
FOR MASABA HUDRAULIC SYSTEMS (PUMPS & TANKS)
Daily Inspection:
With the conveyor down check hydraulic fluid level, Add an ISO-30 oil if required.
Inspect all hoses, inspect for any rubbing and or cracking-replace if needed.
Inspect entire machine for any hydraulic leaks-repair if needed.
Inspect cooler to make sure it is free of any type of debris, clean if required.
Check main system pressure is at 3,000 PSI- if pressure is not please contact
MASABA for further instructions.
6 Month Inspection/Maintenance:
Loosen love joy coupling and slide back to inspect rubber spider, Replace if worn.
Remove and replace hydraulic filter.
Inspect cylinders and motors for any leaks at the shafts-remove and repair if required.
12month maintenance:
Pressure wash any debris from power unit.
Drain hydraulic oil from tank, remove clean out cover and wipe out tank with clean non-lint bearing rags.
Install clean out cover, fill with oil.
APPENDIX P
ALLIED OIL & SUPPLY, INC.
2209 S. 24th Street
Omaha, NE 68108
402-344-4343
800-333-3717
FAX: 402-344-4360
MATERIAL SAFETY DATA SHEET
IDENTITY (As used on label and list): ALLIED AW HYDRAULIC OIL ISO 32, GROUP I
PRODUCT CODE: 900AN0032BU
NFPA Hazard Identification 0 – Least 1 – Slight 2– Moderate 3 – High 4 - Extreme
H e a l t h : 0 F i r e : 1 R e a c t i v i t y : 0
Section I - General Information
Allied Oil & Supply, Inc.
2209 S. 24 th
Street
Omaha, NE 68108
Information (402) 344-4343
Emergency/ Chemtrec (800) 424-9300 Reviewed: 12/29/03
COMPONENT NAME
Lubricating Oil Base Stock
Proprietary Additives
*Numbers are for oil mist.
Section II - Composition/Information on Ingredients
%
95-99
1-5
CAS
MIXTURE
MIXTURE
No IARC, NTP, OSHA and ACGIH listed carcinogens
OSHA PEL
5mg/m3*
ACGIH TLV
5mg/m3*
5mg/m3* 5mg/m3*
Section III - Hazards Identification
EYE CONTACT: Contact with eyes may cause eye irritation.
SKIN CONTACT: Prolonged or repeated contact may result in skin irritation or dermatitis.
INHALATION: Breathing oil mist in concentrations that exceed the TLV and PEL may result in respiratory discomfort and irritation.
INGESTION: Although this product is not expected to be acutely toxic, aspiration of liquid into the lungs during ingestion or vomiting may cause chemical pneumonitis.
CARCINOGENICITY: This product has not been classified as a carcinogen or probable carcinogen by OSHA,
NTP, or IARC.
SIGNS AND SYMPTOMS OF OVEREXPOSURE: May cause skin, eye, or respiratory irritation.
Page 1 of 4
MEDICAL CONDITIONS GENERALLY AGGRAVATED BY EXPOSURE: None recognized
OTHER HEALTH INFORMATION: None
Section IV - First Aid Procedures
EYE CONTACT: If splashed into eyes, flush with water for 15 minutes or until irritation subsides. Get medical attention if irritation persists.
SKIN CONTACT: Remove contaminated clothing. Wash skin thoroughly with soap and water. Get medical attention if irritation persists.
INHALATION: If overcome by vapor from hot product, immediately remove victim to fresh air. If breathing has stopped, administer artificial respiration. Call for medical attention. If overexposed to oil mist, remove from further exposure.
INGESTION: DO NOT induce vomiting, call medical attention immediately.
Section V - Fire and Explosion Hazard Data
Flash Point (deg F): > 425 Method Used: COC
Flammable or Explosive Limits (approximate % by volume in air) LEL: n/a UEL: n/a
EXTINGUISHING MEDIA: Use water spray, dry chemical, foam, or carbon dioxide. Use water to keep fireexposed containers cool. Water spray may be used to flush spills away from exposures.
SPECIAL FIRE FIGHTING PROCEDURES: Self-contained breathing apparatus may be required.
UNUSUAL FIRE AND EXPLOSION HAZARDS: None known
Section VI - Accidental Release Measures
STEPS TO BE TAKEN IN CASE MATERIAL IS RELEASED OR SPILLED: Add sand, earth, or other suitable absorbent to spill area. Keep product out of sewers and waterways by damming or impounding.
Section VII - Handling and Storage
PRECAUTIONS TO BE TAKEN IN HANDLING AND STORAGE: Store in a cool, dry place with adequate ventilation. Do not expose to extreme temperatures or flames.
OTHER PRECAUTIONS: None
Section VIII -
Exposure Controls/Personal Protection
RESPIRATORY PROTECTION: Use supplied-air respiratory protection in confined or enclosed space, if needed.
VENTILATION: Use local exhaust to capture vapor, mists or fumes, if necessary. Provide ventilation sufficient to prevent exceeding recommended exposure limit or buildup of explosive concentrations of vapor in air. Use explosion-proof equipment.
PROTECTIVE GLOVES: Use neoprene gloves, if needed, to avoid prolonged or repeated skin contact.
EYE PROTECTION: Wear goggles if there is likelihood of contact with eye(s).
Page 2 of 4
OTHER PROTECTIVE EQUIPMENT: Use neoprene apron or other clothing, if needed, to avoid prolonged or repeated skin contact.
WORK PRACTICES/ENGINEERING CONTROL: Keep containers closed when not in use.
PERSONAL HYGIENE: Wash skin thoroughly after contact, before breaks and meals, and at the end of the work period. Thoroughly clean contaminated clothing, including shoes, before re-use.
Boiling Point (deg F): n/a
Melting Point (deg F): ND
Section IX- Physical/Chemical Characteristics
Specific Gravity (H2O=1): .876
Vapor Density (Air=1): n/a
Evaporation Rate (n-butyl Acetate=1): n/a
APPEARANCE AND ODOR: Light amber liquid, mild petroleum odor.
Vapor Pressure (mm Hg): n/a
Solubility in Water : insoluble
Section X - Reactivity Data
STABILITY: Stable
INCOMPATIBILITY (MATERIALS TO AVOID): Strong oxidants such as liquid chlorine, concentrated oxygen, sodium hypochlorite or calcium hypochlorite.
HAZARDOUS DECOMPOSITION OR BYPRODUCTS: Carbon monoxide, aldehydes, and other petroleum decomposition products. Oxides of sulfur, phosphorus, calcium, zinc, and hydrogen sulfide may also be present.
HAZARDOUS POLYMERIZATION: Will not occur
CONDITIONS TO AVOID: None
Section XI - Toxicological Information
See Section IV
Section XII - Ecological Information
Section XIII - Disposal Considerations
WASTE DISPOSAL METHOD: Place in an appropriate disposal facility in compliance with local regulations.
Section XIV - Transport Information
NOT A REGULATED ITEM ACCORDING TO DOT.
Section XV-Regulatory Information
SARA SECTION 313: This product does not contain greater than 1.0% (greater than 0.1% for carcinogenic substances) of any chemical substance listed under SARA Section 313.
WHMIS classification for product: This product has been classified in accordance with the hazard criteria of the
CPR and the MSDS contains all the information required by the CPR.
Page 3 of 4
This material safety data sheet and the information it contains is offered to you in good faith as accurate. We have reviewed any information contained in the data sheet which we received from sources outside our company and we believe that information to be correct, but cannot guarantee its accuracy or completeness. Health and safety precautions in this data sheet may not be adequate for all individuals and/or situations. It is the user's obligation to evaluate and use this product safely and to comply with all applicable laws and regulations. No statement made in this data sheet shall be construed as permission or recommendation for the use of any product in a manner that might infringe existing patents. No warranty is made, either expressed or implied.
Page 4 of 4
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