Instruction manual

ManualsBrandsMagnum ManualsLawn and Garden246185

TABLE OF CONTENTS

TERMS AND CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

IDENTIFYING YOUR NEW MASABA MAGNUM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

CONVEYOR DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SETTING UP YOUR MAGNUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SITE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

UNLOADING YOUR MAGNUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

OPERATING YOUR MAGNUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

POWER CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

CONVEYOR PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

POSITIONING YOUR MAGNUM FOR RADIAL TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

LOWERING THE MAGNUM LIFTING JACKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

POSITIONING THE SWING AXLE FOR RADIAL TRAVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

INSTALLING OPTIONAL SAFETY STOPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

RADIAL POWER TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

POSITIONING YOUR MAGNUM FOR ROAD TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . 23

MAGNUM OPERATION MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

PROGRAMMABLE LOGIC CONTROLLER (PLC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

PLC INPUT DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

MANUAL & AUTO SYSTEM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

PLC OPERATIONAL PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

ADJUSTING CONVEYOR HEIGHT (MANUAL MODE) . . . . . . . . . . . . . . . . . . . . . . . . . 36

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

BELT TRACKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

OPTIONAL GREASE BANK SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

TROUBLESHOOTING BELT CONVEYORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

VENDOR SPECIFIC MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

TROUBLESHOOTING MAGNUM CONVEYORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

INSTALLING/TENSIONING V-DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

CHECK CONDITION OF SHEAVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

CHECK SHEAVE ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

V-BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

BELT SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

GENERAL RULES OF TENSIONING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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

Summary of content (150 pages)

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TABLE OF CONTENTS TERMS AND CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 IDENTIFYING YOUR NEW MASABA MAGNUM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CONVEYOR DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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 .
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MASABA, INC. (d/b/a MASABA Mining Equipment) TERMS AND CONDITIONS 1. 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.
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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.
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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.
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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 MOVING PARTS. LONG HAIR SHOULD BE SECURED UNDER A CAP OR HAT.
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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 PREVENT INJURIES FROM WHIPPING OR FLAILING HOSES. GENERAL Successful operation of a machine depends upon good maintenance.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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• 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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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13. Re-pin the swing axle to the undercarriage. 14. Repeat steps 6-13 on the opposite side of the MAGNUM.
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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.
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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.
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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”.
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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.
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3. You should now see the home screen. 4. Touch anywhere on the home screen to access the Main Menu screen.
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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 Conical, Inline Windrow, and Inline Conical.
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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 MAGNUM 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.
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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.
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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.
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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.
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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.
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• 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.
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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 direction of belt travel. CORRECTION Advance, in the direction of belt travel, the end of the idler toward which the belt has shifted.
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2. PARTICULAR SECTION OF BELT RUNS TO ONE SIDE AT ALL POINTS OF CONVEYOR. 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.
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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.
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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.
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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.
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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.
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APPENDIX A Conveyor Belt Storage and Installation
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Index Page Conveyor Belt Storage and Installation Receiving the Roll Storage Upon delivery, check the factory packaging for damage, punctures, etc. Make any appropriate claim against the carrier at that time. 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.
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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.
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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.
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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. NOTE: A ½” square drive electric impact wrench with Flexco 5552 Quick Change Chuck will speed hole boring operation. 6. Align bolts with templet teeth and place the other belt end over bolts. Remove templet. 2. Support belt ends with wood plank. Nail Flexco Templet in position with belt ends tight against lugs. 3.
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APPENDIX C Belt Tracking
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Index Page Table of Contents I. Conveyor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Supporting Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pulleys, Rollers, Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Crowns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Index Page “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.
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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.
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Index Page Take-up tension must be high enough to allow elastic recovery of elongation due to starting forces, load changes, etc. The take-up device in a conveyor belt system has three major functions: 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.
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Index Page II. Non Structural Components Camber Cleanliness 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.” 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.
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Index Page 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. 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.
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Index Page 1 FOOT 1 FOOT 1 FOOT 1 FOOT 1 FOOT 1 FOOT BELT END BELT CENTER LINE CUT LINE T-SQUARE OR FRAMING SQUARE MARKING OF CUT LINE AND OTHER RIGHT ANGLE GUIDE LINES 7 BELT END
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Index Page An alternative method of squaring belt ends is called the “double intersecting arc” method. Double Check Squareness 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. A 5’ CUT LINE On bulk haulage belting, a nail can be used as the pivot point and an arc is struck with a steel tape.
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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. 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.
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Index Page Pulley Crown on Lightweight and Monofilament Belt 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.
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Index Page 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.
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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: be necessary to compromise and not cock the roll quite as much as we would like.
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11 10 13 6’ 8 12 CARRYING RUN 9 7 TRACKING 6 4 HYPOTHETICAL CONVEYOR FIGURE #1 4’ 5 2 14 8’ RETURN RUN 3 13 BELT TRAVEL 15 8’ 1 16 Index Page
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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.
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Index Page 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.
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11 10 TAKE-UP 8 RETURN 12 BELT TRAVEL 9 7 6 16 HYPOTHETICAL CONVEYOR FIGURE #2 DRIVE PULLEY 4 TRACKING 5 3 13 2 14 15 1 16 Index Page
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Index Page Short Center-Wide Belt Conveyors details of conveyors must be discussed with a Georgia Duck distributor or Georgia Duck representative. 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.
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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. 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.
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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. 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.
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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.
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APPENDIX D Conveyor Belt Maintenance
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Index Page 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.
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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.......
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Index Page D) Impact Bed or Impact Idler damage E) Slider Bed clean and smooth 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.
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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. a) Tracking b) Spillage G) Head Pulley and or Drive Pulley a) Smoothly running Scrapers, plows and self-trainers must be operational to perform their tasks.
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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. A power driven revolving brush will help remove product from the belt.
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Index Page 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.
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Index Page CONVEYOR INSPECTION FORM AND CHECKLIST Inspection Date _____________________ I.
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Index Page II. Belt Running Empty Corrective Action _____Tracking III.
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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.
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APPENDIX E Trouble Shooting Edge Wear Spill Effects of Off-Center Loading
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Index Page 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).
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Index Page Trouble Shooting Problem/Cause For Solutions Refer to Answer # A. Belt runs off at tail pulley. 39 10 1 19 B. Belt runs to one side for long distance or entire length of conveyor. 39 8 5 1 C. Particular section of belt runs to one side at all points on conveyor. 6 7 46 33 10 1 3 E. Conveyor runs to one side at given point on structure. 5 4 1 2 F. Belt runs true when empty, crooked when loaded. 8 51 52 G. Belt slips. 34 33 31 10 H. Belt slips on starting.
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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.
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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.
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Index Page 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.
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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.
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APPENDIX F 1
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2
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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 HXT 3B – 6B HXT 4B – 6B TXT/HXT 5C TXT/HXT 6A TXT/HXT 7A Includes Char-Lynn 6B Hydroil Reducers HXT 5C – 6B HXT 6A – 6B TXT 8A TXT 9A TXT 10A HXT 7A – 6B These instructions must be read thoroughly before installation or operation. INSTALLATION: 1. 2.
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4. 5. 6. Figure 2 - Reducer and Sheave Installation 7. 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. 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.
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LUBRICATION Straight Bore Bushings: 1. 2. 3. 4. 5. 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.
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Table 3 - Oil Recommendations ISO Grades For Ambient Temperatures of 50°F to 125°F (Refer to Notes below) Output RPM Torque-Arm Reducer Size TXT1A TXT2A TXT3B TXT4B TXT5C TXT6A TXT7A TXT8A TXT9A TXT10A 301 – 400 320 320 220 220 220 220 220 220 220 220 201 – 300 320 320 220 220 220 220 220 220 220 220 151 – 200 320 320 220 220 220 220 220 220 220 220 126 – 150 320 320 320 220 220 220 220 220 220 220 101 – 125 320 320 320 320 220 220 220 220 220
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OIL VISCOSITY EQUIVALENCY CHART KINEMATIC VISCOSITIES cSt/ 40˚ C 2000 1000 cSt/ 100˚ C ISO VG AGMA GRADES SAE GRADES GEAR OILS 8000 60 1500 50 1000 8A 40 680 8 460 7 320 6 250 30 200 100 80 10 9 8 60 7 50 6 140 20 4 220 5 150 4 100 3 8 68 46 2 2 90 800 80 600 70 500 80W 22 10 7 5 3 60 55 50 1 32 4 3 85W 1000 300 6 5 90 400 15 10 2000 1500 75W 5 200 100 40 30 300 3000 400 20 SUS/ 210˚F 6000 5000 4000 600 300 SUS/ 100˚F 10,000 70 80
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GUIDELINES FOR TXT REDUCER LONGTERM STORAGE Motor Mounts 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.
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Removing Reducer from Shaft: 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. WARNING: To ensure that drive is not unexpectedly started, turn off and lock out or tag power source before proceeding.
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8. 9. 10. 11. 12. 13. place in the housing. Make sure bearing rollers (cones) are properly seated in their cups. 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.
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Replacement Part and Kit Numbers Table 7 – Part Numbers for Replacement Bearings, Double Reduction Reducers Reducer Size Input Shaft Bearing – LH Input Side Part Number 424112 Reducer Size Output Hub Bearing – LH and RH Sides Part Number TXT1A TXT2A 424019 TXT1A 424020 TXT3B 402204/403139 TXT2A 424022 TXT4B 402280/403027 TXT3B 402272/403127 TXT5C 402144/403104 TXT4B 402268/403163 TXT6A 402196/403091 TXT5C 402193/403016 TXT7A 402150/403106 TXT6A 402050/403140 TXT8A 402098/403072
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Table 8 - Replacement Parts Kit Numbers Reducer Size Ratio TXT1A 15:1 Seal Kit Output Hub Assembly Taper Hub Straight Hub 390878 390151 9:1 TXT3B TXT4B 392111 392110 392093 9:1 389729 389720 389703 389702 389701 9:1 389730 15:1 389721 389710 389709 15:1 389717 389716 390935 390988 TXT9A TXT10A 391171 391186 392141 25:1 15:1 26:1 15:1 24:1 392350 All 392140 246340 9:1 15:1 392347 All 389715 247345 390941 390990 25:1 TXT8A 389714 25:1 15:1 392345 All 389731 38972
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Parts for TXT/HXT 1A & 2A Straight and Tapered Bushed Double Reduction Reducers 11
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Parts for TXT/HXT 1A & 2A Straight and Tapered Bushed Double Reduction Reducers Ref. Qty.
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Parts for TXT/HXT 1A & 2A Straight and Tapered Bushed Double Reduction Reducers Ref. Qty.
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Parts for TXT3B thru TXT5C Straight and Tapered Bushed Double Reduction Reducers 14
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Parts for TXT3B thru TXT5C Straight and Tapered Bushed Double Reduction Reducer Qty.
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Parts for TXT3B thru TXT5C Straight and Tapered Bushed Double Reduction Reducer, continued Qty.
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Parts for TXT6A thru TXT10A Straight and Tapered Bushed double Reduction Reducers 17
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Parts for TXT6A thru TXT10A Straight and Tapered Bushed double Reduction Reducers Ref. Qty.
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Parts for TXT6A thru TXT10A Straight and Tapered Bushed double Reduction Reducers Ref. Qty.
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ACTUAL RATIOS Table 9 – Actual Ratios Reducer Size Nominal Ratios 9:1 15:1 25:1* TXT1A 9.44 15.35 25.64 TXT2A 9.25 14.10 23.46 TXT3B 8.91 14.88 24.71 TXT4B 9.67 15.13 24.38 TXT5C 8.95 15.40 25.56 TXT6A 9.20 15.33 25.13 TXT7A 9.61 15.23 24.59 TXT8A N/A 15.08 24.62 TXT9A N/A 15.12 25.66 TXT10A N/A 15.16 24.30 * TXT9A is 26:1 Nominal Ratio and TXT10A is 24:1 Nominal Ratio World Headquarters P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1) 479.646.
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APPENDIX H INSTRUCTION MANUAL FOR DODGE® TORQUE-ARM™ SPEED REDUCER BACKSTOPS These instructions must be read thoroughly before installing or operating this product. removed for any reason, pull backstop from bore and insert cardboard retainer into I.D. of backstop to retain position of 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.
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1. 2. HOUSING 3. DIMENSIONAL CHECKS FOR REPLACEMENT UNITS IN REDUCERS WITH TAPERED ROLLER BEARINGS BACKSTOP INPUT SHAFT 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.
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TORQUE-ARM SPEED REDUCER BACKSTOP PART NUMBER CURRENT TXT SERIES HOUSING REDESIGN 2005 TXT SERIES BEARING REDESIGN 1991 TXT SERIES INTRO 1985 241101 242101 TXT109A TXT115A TXT125A TXT 105 TXT 109 TXT 115 TXT 125 243101 243102 243106 TDT SERIES TD SERIES NUMBER SERIES SHAFT DIMENSIONS TDT 115 TDT 125 TDT 115 TDT 125 No. 1 .6315/.6310 TDT 215 TDT 225 T 11 TDT 215 TDT 225 No. 2 No. 3 No. 11 .7383/.7378 TDT 315 TDT 325 TDT 315 TDT 325 TXT 309 TXT 315 TXT 325 TXT309B TXT315B TXT325B .
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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) *1606-0311* All Rights Reserved. Printed in USA.
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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. 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.
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Table 1 - Recommended Torque Setscrews D-LOK Mounting Bolts Metal Housings Recommended Torque Setscrew Size Key Hex Across Flats Standard Ball Bearing Insert Min Max Corrosion Resistant Stainless Steel Cap Screw Size Recom. Torque EZ-Kleen Recom. Torque Bolt Size EZ-KLEEN Housed Bearings Recom. Dry Torque (Grade 2) 2-Bolt PB, 2 & 4 Bolt Flg. and Flg. Brackets Tapped-Base PB Bolt Size Torque  Bolt Size Torque  (in.) (in.) (in-lbs.) (in-lbs.) (in-lbs.) (in.) (in-lbs.) (in-lbs.
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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 ® bearings have successfully if proper grease is used. DODGE been lubricated at the factory with No. 2 consistency lithium complex-base grease which is suitable for normal operating conditions.
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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.
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APPENDIX K ® INSTRUCTION MANUAL FOR DODGE S-2000 SPHERICAL ROLLER BEARINGS GENERAL INFORMATION EXPANSION BEARING DODGE S-2000 Spherical Roller Bearing mounted units incorporate a unique way of sealing th e internal components of the bearing while still allowing a full + or - 1 degree of misalignment. The patented sealing system (Pat. #5,908,249) has proven effective, due to its constant o c ntact pressure, in protecting the internal bearing components under maximum allowable misaligned conditions.
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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).
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3
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COMPONENT PART NUMBERS (1 3/8" - 4 15/16") ITEM Shaft Size Size 1 Bearing Insert Assembly (R) Seal 1A Bearing Insert Assembly (L) Seal 2 * Collar 3 * Set Screw 4 Snap Ring 5 ** Grease Fitting 1 3/8 1 7/16 1 1/2 1 11/16 070000 070001 070002 070003 070016 070017 070018 070019 040050 040050 040050 040051 400058 400058 400058 400058 069276 069276 069276 069277 405015 405015 405015 405015 1 3/4 1 15/16 070004 070005 070020 070021 040051 070587 400058 400094 069277 069278 405015 405015 2 2 3/
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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) ADAPTER UNITS (9000) 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.
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Bearing Replacement and Maintenance Instructions Mounted Roller Bearings (See other side for installation instructions) LUBRICATION INSTRUCTIONS DISASSEMBLY Remove set collars or other shaft locking device Remove seals Remove MICROLOCK screw and key. (Do not loose nylon washer) Remove threaded cover by turning counter clockwise Place housing threaded cover side down on arbor press with spacer blocks under housing 6.
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Twist Lock™ 3000 Series Installation Instructions Mounted Roller Bearings ( 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.
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APPENDIX M INSTALLATION AND MAINTENANCE INSTRUCTIONS FOR ELECTRIC MOTORS Frames 143/5T - 586/7T
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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.
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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).
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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.
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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.
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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.
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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 ARNING ARNING: V oltage may be connected at standstill inside the terminal box for heating elements or direct winding heating.
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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.
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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.
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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.
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9700 6000 4700 4700 18 21 27 27 27 27 27 21 27 34 45 45 45 60 324/6T 364/5T 404/5TS 444/5TS 504/5TS 586/7TS 324/5T 364/5T 404/5T 444/5T 447/5T 504/5T 586/7T 9800 3600 3600 3600 3600 3600 9800 11500 1200 rpm 1000 rpm 900 rpm 9700 9700 9700 9700 9700 20000 20000 20000 11600 11600 11600 11600 11600 20000 20000 20000 14200 14200 14200 14200 14200 20000 20000 20000 16400 16400 16400 16400 16400 20000 20000 20000 17300 17300 17300 17300 17
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WARNING: The table above is specifically intended for relubrication with Polyrex ® EM grease and bearing absolute operating temperature of: 70 oC (158 oF) for 254/6T to 324/6T frame motors; 85 oC (185 oF) for 364/5T to 586/7T frame motors. For every 15 o C (59 oF) 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 oF ).
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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.
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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.
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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.
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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.
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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 ca
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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.
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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 Health: 0 Fi r e : 1 1 – Slight 2– Moderate 3 – High 4 - Extreme Reactivity: 0 Section I - General Information Allied Oil & Supply, Inc. 2209 S.
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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.
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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. Section IX- Physical/Chemical Characteristics Boiling Point (deg F): n/a Specific Gravity (H2O=1): .
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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.