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Truck Unloader User`s Manual

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1. Index Page Table of Contents le Goriveyor Components so k x S fw kita inte tea A m ak l S a tay e aM CUR S ERE 3 Supporting Structure an war a ve e Maen ety mates 3 Pulleys Rollers Idlers 45 sex ate AE Re dx va ibus bed vA o AS ait xvid 3 CLOWNS a sc mta ti e e baie e a posses a ee che 3 Jake poco cvs Pe e at Re te he RR an TU SAO e e auos Ra dee a cere A eb D Gb nba 4 Il Non Str ct ral Components asea ade DR ares o qty xo NR ee dA 5 Cleanliness pinne aa 5 Neutral Belt Stresses us dea xen a iod dare ERE RE p dat 5 d Bst i tct qu de e far 5 SOW BOW A eiua iacere lea cpu redu ri aoa PUN NUR NO 6 Belt DP MT P at en A e wae cas 226 Gs 6 Square Belt EDS Reems ea hed we dc was 6 Ill General Training Procedures 9 IV Training Package or Unit Handling 0 12 V Training Bulk Haulage
2. 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 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 thick ness whichrever is less VE Fig 1 Fig 2 Trouble Shooting Problem Gause For Solutions Refer to Answer A Belt runs off at tail pulley 39 10 1 19 31 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 po
3. 18 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 compo nents 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 Index Page l Conveyor Components Supporting Structure The supporting structure is designed to hold con veyor 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 buck led it Are the anchors firm Conveyor sections are bolted to the supporting structure They should be square and horizon tal 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 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 adjust
4. 4 IV Corrective 4 V Inspection Form and Checklist 71 88 Index Page l 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 pre vent moisture from penetrating the belt and breaking down the cover adhesions and to pre vent product contamination from abrading the car cass and also breaking down the adhesions Very few if any repairs can be made to light weight 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 an 4 I
5. Notes Y Although Polyrex EMis compatible with the types of grease given above we do no recommend to mix it with any other greases v If you intend to use a type of grease different than those recommended above first contact WEG Y 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 v Vertical mounted motors must have the relubrication intervals reduced by half un THE USE OF STANDARD MOTORS IN SPECIFIC X f Z 1 i AREAS OR SPECIAL APPLICATIONS MUST BE DONE BY CONSULT TO THE GREASE MANUFACTURER OR WEG gt 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
6. 389794 389795 389796 389797 389798 389799 389800 4 Drive Collar 400094 400094 400094 400094 400094 400150 400150 400150 400150 t Consists of one each of the shims listed immediately below marked with a dagger Usually one 015 shim and one 004 or 006 shim when required T Parts marked with a dagger make up the adjustment shim pack One required Four required except for piloted flange bearing which requires two Not shown on drawing 65 setscrews angle gt of Uses 405016 lubrication fitting Shaft Tolerances Up to 11 2 0000 0005 19 16 to 3 0000 0010 35mm to 75mm Type E Bearings 24 20 an Eta NOTE The two digit numbers are for reference only Order parts by the six digit numbers in the Parts List Each six digit number is a complete identifi cation of the part or assembly mwan E 4 LA 34 35mm 75mm Type E Bearing Parts for 35MM to 75MM Type E Pillow Block Bearings Item 24 32 12 14 18 te oce om 20 34 Shaft Housing Cone Cup Collar Snap Shim 0 004 0 006 0 015 Seal Set Lube Size Ring Pack Shim Shim Shim Screw Fitting 35 MM 061320 389740 390751 046120 401004 391102 427071 427081 427091 061356 400713 405601 40 MM 061321 389741 390755 046121 401008 391103 427072 427082 427092 061357 400713 405601 45 MM 1061322
7. 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 tele scopes 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 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 Extre
8. 10 11 12 13 14 15 16 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 autho rization 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 war ranty 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 o
9. 25 1 Ratio Hydroil Input Pinion 15 1 Ratio 25 1 Ratio amp Input Pinion Key Bearing Replacement Kit amp Input Pinion Bearing LH Input Side Input Pinion Bearing RH Backstop Side Countershaft Pinion Bearing amp Output Hub Bearings OONO mauau 241481 242481 241302 242186 241200 242187 241455 242188 241449 242189 443008 443014 389905 389906 424112 424019 424111 424090 424006 424000 424020 424022 Countershaft Pinion Assembly 2 9 1 Ratio 15 1 Ratio 25 1 Ratio Countershaft Pinion First Reduction Gear 9 1 Ratio 15 1 Ratio 25 1 Ratio Countershaft to First Gear Key Taper Bore Output Hub Assembly Straight Bore Output Hub Assembly 9 Output Hub Straight Bore amp Taper Bore Output Gear d Output Gear Key Output Hub Snap Ring Q Straight Bore Output Hub Key Straight Bore Output Hub Collar Straight Bore Output Hub Collar Screw Taper Bore Bushing Backup Plate Bushing Backup Plate Retaining Ring 392100 392101 392090 392092 392091 392093 241216 242185 241482 242482 241170 242008 241171 242005 241309 242218 390878 392111 390151 392110 241208 242208 241265 242134 241007 242181 241217 443399 421013 421017 241296 242296 241209 242209 400062 400094 241266 242137 421111 421112 Taper Bore Bushing Assembly Bushing 1 Bore 241278 N A 1 1 16 Bore 241280 N A 1 1 8 Bore 241282 242146 1 3 16 Bore 241286 242148 1 1
10. A MEMBER OF THE ABB GROUP 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 MN1606 Replaces 499838 3 11 Printshop 5000 1606 0311 APPENDIX Instruction Manual for DODGE Setscrew Eccentric Collar D Lok H E Series amp 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 Undercertainoperatingconditions 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 INSTALLATION 1 Clean shaft and bearing bore thoroughly Measure and confirm shaft size and tolerance File flats on shaft at setscrew locations to permit easy removal of bearing 2 Slip bearing into position Be sure that bearing is not on a worn section of the shaft For tighter fits tap inner ring face only with soft driver DO NOT HAMMER ON HOUSING 3 The bearing
11. 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 e 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 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 SECU
12. Moderate 3 High 4 Extreme Health 0 Fire 1 Reactivity 0 Section I General Information Allied Oil amp Supply Inc 2209 S 24 Street Omaha NE 68108 Information 402 344 4343 Emergency Chemtrec 800 424 9300 Reviewed 12 29 03 Section II Composition Information on Ingredients COMPONENT NAME Yo CAS OSHA PEL ACGIH TLV Lubricating Oil Base Stock 95 99 MIXTURE 5mg m3 5mg m3 Proprietary Additives 1 5 MIXTURE 5mg m3 5mg m3 Numbers are for oil mist No IARC NTP OSHA and ACGIH listed carcinogens 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 irrita
13. 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 Exces sive 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 ona 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 Reefing the Belt No weight to be placed on top Index Page Installation Once the roll of be
14. 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 p THE SPECIFICATION OF THE MOTOR f 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 A MOTORS MUST BE CARRIED OUT BY SKILLED PEOPLE AND THE THERMAL PROTECTION C 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 AN MODIFICATION MADE ON HAZARDOUS A LOCATION MOTORS WILL VOID THE CERTIFICATION When performing maintenance installation or relubrication follow these instructions v Check if all components are free of edges knocks or d
15. sick via kaye bala ae nee EA RIS Fenner Dunlop Trouble Shooting APPENDIXF Dodge Torque Arm Shaft Mount Speed Reducer Lubrication APPENDIX G Dodge Installation and Parts Replacement Manual for Speed Reducers APPENDIX H Dodge Instruction Manual for Torque Arm Speed Reducer Backstops APPENDIX 522 5 Dodge Instruction Manual for Mounted Ball Bearings APPENDIX J rai rh eR 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 WEG Electric Motor Installation and Maintenance APPENDDXAN Lin UC RAN do eR I RR ti MASABA Hydraulic System Service APPENDIX MASABA Hydraulic System Schematic If Equipped APPENDIX P pow w iih a e Re Allied Oil and Supply Material Safety MASABA INC d b a MASABA Mining Equipment TERMS AND CONDITIONS OFFER amp 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 docu
16. 0000c 0000c 0000c 0000c 0000c 0000c 0000c O0Z 1 00511 81 19 782 0000 0000 0000 0000 00002 0000 0000 00002 00003 00181 00751 EL 19 92 eq SINOU semau UONBOUqN Sy uda uda udi wda udi udi udi occas SUE 006 009 022 OSZ 006 0001 OOCL OOSL 0081 0006 0096 jornouy NOXX3 OSS3 ISVIYO WI XITYATOd GAGNSWINOOSY SIVAYSLNI NOILVOIHS TT3H WARNING The table above is specifically intended for relubrication with Polyrex EM grease and bearing absolute operating temperature of Y 70 C 158 F for 254 6T to 324 6T frame motors v 85 C 185 F for 364 5T to 586 7T frame motors For every 15 C 59 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 F WE RECOMMEND TO USE BALL BEARINGS FOR ETA MOTORS DIRECTLY COUPLED TO THE LOAD am WARNING EXCESS OF GREASE CAUSE BEARING OVERHEATING RESULTING IN COMPLETE DAMAGE Compatibility of 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 Y Lithium base or complex of lithium or polyurea and highly refined mineral oil v Inhibitor additive against corrosion rust and anti oxidant additive
17. 6B Hydroil Pinion 25 1 Ratio 6B Hydroil Pinion 41 Input Pinion Shaft Key Input Bearings 44 Input Shaft Bearing Cone Input Side 45 Input Shaft Bearing Cup Input Side 46 Input Shaft Bearing Cone Backstop Side 47 Input Shaft Bearing Cup Backstop Side Countershaft Pinion Assembly 9 1 Ratio 15 1 Ratio 25 1 Ratio 48 Countershaft Pinion 50 First Reduction Gear amp 52 246481 247479 N A N A N A 246290 247370 248370 272074 250300 246291 247371 248371 272106 250004 246230 247463 N A N A N A 246286 247462 N A N A N A N A N A N A N A N A 246521 247521 N A N A N A 443113 443127 443133 443123 443123 402196 402150 402098 402114 402114 403091 403106 403072 403080 403080 402197 402088 402097 402107 402112 403091 403047 403072 403076 403080 392140 392141 N A N A N A 391171 391196 391184 390124 390983 391186 391197 391185 390139 390998 246294 247002 248002 249006 272249 9 1 Ratio 15 1 Ratio 25 1 Ratio W First Stage Gear Key 246482 247478 N A N A N A 246492 247008 248213 249008 250301 246293 247005 248214 249005 250005 245218 247218 248218 248218 248218 Countershaft Bearings 54 Countershaft Bearing Cone Input Side 55 Countershaft Bearing Cup Input Side 56 Countershaft Bearing Cone Backstop Side 57 Countershaft Bearing Cup Backstop Side Countershaft Bearing Cover Input Side Countershaft Bearing Shim Pack 58 59 Taper Bore Output Hub Assembly Straight Bore Output Hub Assemb
18. A N A N A N A 443272 443273 N A 241097 241245 407093 241246 241247 407242 241249 411456 407091 259151 241242 241241 242243 411412 419011 407087 241454 417081 419046 241457 411408 419011 TXT HXT 2 411390 419010 N A 443281 443281 443281 443264 443280 443282 443282 424172 242171 242170 443283 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 Parts for TXT3B thru TXT5C Straight and Tapered Bushed Double Reduction Reducers 62 64 16 2 20 22 82 jes 89 32 33 76 c 80 81 54 55 42 41 52 55 50 114 STRAIGHT BORE NOTE THE TWO DIGIT NUMBERS ARE FOR REFERENCE ONLY ORDER PARTS BY THE SIX DIGIT NUMBER IN THE PARTS LIST EACH SIX DIGIT NUMBER IS A COMPLETE IDENTIFICATION OF THE PART OR ASSEMBLY BACKSTOP ASSEMBLY m s m 58 130 126 128 106 110 62 64 16 2 20 22 82 80 81 32 33 78 76 72 86 88 80 81 b0 EZ 59 32 33 58 56 577 74 48 25 54 55 yo 38 39 41 50 34 44 45 my 28 36 32 33 46 47 30 iii 112 118 120 122 116 HYDROIL INPUT 104 14 TAPER 18 102 ASSEMBLY TORQUE ARM Parts for TXT3B thru TXT5C Straigh
19. Bore 3 15 16 Bore 4 3 16 Bore 4 7 16 Bore 4 15 16 Bore 5 7 16 Bore Taper Bushing Screw Taper Bushing Lockwasher Key Bushing to Shaft amp 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 amp 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 Torque Arm Rod Kit Torque Arm Rod End amp RH Nut amp Torque Arm Turnbuckle Torque Arm Extension LH Nut Fulcrum 8 Fulcrum Screw Lockwasher Hex Nut Adapter Assembly RH Adapter Plate LH Adapter Plate amp Adapter Bushing Adapter Bolt Lockwasher Hex Nut Hydroil Motor Adapter Hydroil 6B Motor Adapter Hydroil Adapter Screw Lockwasher Motor to Adapter Screw Motor to Adapter Lock Washer 246261 N A N A N A N A 246262 N A N A N A N A 246263 272125 N A N A N A 246264 N A N A N A N A 246265 272147 N A N A N A N A 272130 N A N A N A 246266 272131 N A N A N A 246267 272132 272048 N A N A 246283 272133 N A N A N A N A 272134 N A N A N A 246268 272135 272032 N A272056 N A N A 272136 272033 272077 272214 N A N A 272034 N A N A N A N A 272035 272079 272238 N A N A N A 272080 27
20. 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 PAN THE CONNECTION TO THE POWER SUPPLY K MUST BE DONE BY QUALIFIED PERSONNEL J 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 y 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 FASTENED OR REMOVED b 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 ifthe vibration comes from a neighbour machine Periodical vibration checks must be done Run the motor under rated load for a short period of time and compare if the running current is
21. The Truck Unloader must have adequate clearance all around to allow for maintenance and the removal of material spillage The conveyor work site must have solid compacted ground with no more than one degree slope to ensure proper operation This will prevent the Truck Unloader from rolling down hill UNLOADING YOUR MASABA EQUIPMENT It is recommended that you unload your Truck Unloader at the site it will be used Your Truck Unloader was delivered nearly fully assembled and can be disconnected from the delivery truck at the designated site To disconnect your Truck Unloader from the delivery truck 1 2 Set the air brakes or block the wheels the Truck Unloader Lower the landing legs Depending on the option you chose these could be hydraulic or man ually 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 oper ate 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 a 4 Disconnect the air brakes from the tractor Disconnect the king pin from the tractor 5 Drive tractor away from the Truck Unloader OPERATING YOUR LOW P
22. Torque Arm Reducer Size 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 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 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 m OIL VISCOSITY EQUIVALENCY CHART KINEMATIC SAYBOLT VISCOSITIES VISCOSITIES SAE cSt cSt AGMA GRADES SUS SUS 40 C 100 C GRADES GEAR OILS 100 F 210 F 10 000 8000 300 70 60 6000 5000 4000 3000 2000 1500 1000 800 600 500 400 300 200 150 VISCOSITIES CAN BE RELATED HORIZONTALLY ONLY 15 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 5 SPECIFIED AT LO
23. 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 nec essary 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 pos sible 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 align ing 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 Index Page Roll 10 would now be functioning as the head pulley snubber Any adjustment off the perpendicular of roll 10 would hav
24. and Empty Corrective Action Belt Condition Splice Condition Pulley Skirting Impact Bed ldlers Slider Bed Side Idlers 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 Index Page Il Belt Running Empty Corrective Action Tracking Ill Belt Running Loaded 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 Index Page ZFENNETR gt D UNLOP CONVEYOR BELTING AMERICAS 21 Laredo Drive Scottdale Georgia 30079 USA Phone 404 297 3170 ISO 9001 2000 Certified Fax 404 296 5165 www fennerdunlopamericas com 10 03 APPENDIX E FENNER DUNLOP CONVEYOR BELTING Trouble Shooting
25. and hard which can result in slippage It is good practice to replace rubber lagging when a new belt is installed par ticularly 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 con tact 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 contri bution 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 adver
26. equal to that stamped on the nameplate MAINTENANCE P 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 SSASSS LUBRICATION FOLLOW THE REGREASING INTERVALS THIS 15 FUNDAMENTAL FOR PROPER MOTOR cos gt 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 Y Disassemble carefully the motors v Take all the grease out Wash the bearing with querosene or diesel Y 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 Y Clean the area n
27. for Installation 1 Square belt ends using centerline method Cut 2 Support belt ends with wood plank Nail 3 Spray templet holes with Flexco Silicone belt ends using Flexco 840 Series Belt Cutter Flexco Templet in position with belt ends tight Lubricant Punch or bore bolt holes Remove against lugs templet NOTE A 4 square drive electric impact 4 For 2 1 2 3 1 1 2FP 2FP and RP2 assemble 5 Fold one belt end back and insert bolts in one wrench with Flexco 5552 Quick Change bottom plate Insert 2 bolts and attach clip row of holes Chuck will speed hole boring operation 6 Align bolts with templet teeth and place the other 7 Place top plates over bolts using bolt horn 8 Start nuts on bolts by hand belt end over bolts Remove templet 9 Cut Flexco Lok Tape 3 1 2 times the belt width 10 Pull tape tight and hold in position by 11 Tighten all fasteners from edges to center and feed tape under top plates under the bottom tightening a fastener at each end Then tighten all Tighten all nuts uniformly NOTE A Flexco plates then back under top plates other plates Power Wrench used with an impact tool will speed this step considerably FLEXCO 12 Hammer plates in belt with wood block 13 Break off excess bolt ends using two bolt Retighten nuts breakers Peen or grind bolts to finish APPENDIX C ZFENINET oD CONVEYOR BELTING
28. installations including without limitation any claims for consequential damages or labor costs APPENDIX N SERVICE RECOMMENDATIONS FOR MASABA HUDRAULIC SYSTEMS PUMPS 8 TANKS Daily Inspection X With the conveyor down check hydraulic fluid level Add 150 30 oil if required M Inspect all hoses inspect for any rubbing or cracking replace if needed M Inspect entire machine for any hydraulic leaks repair if needed X Inspect cooler to make sure it is free of any type of debris clean if required X Check main system pressure is at 3 000 PSI if pressure is not please contact MASABA for further instructions 6 Month Inspection Maintenance X Loosen love joy coupling and slide back to inspect rubber spider Replace if worn X Remove and replace hydraulic filter M Inspect cylinders and motors for any leaks at the shafts remove and repair if required 12month maintenance X Pressure wash any debris from power unit M Drain hydraulic oil from tank remove clean out cover and wipe out tank with clean non lint bearing rags X Install clean out cover fill with oil MASABA MINING EQUIPMENT APPENDIX P ALLIED OIL 8 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 l Slight 2
29. make shim pack Install shim pack between the TXT10A 150 135 30 27 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 Backstop Cover Bolt Recommended Torque Values 2 the axial endplay reading of the output hub is per Table Torque in Ft Lbs 11 Repeat step 9 above for installing and adjusting the TXTIA 10 24x 3 8 countershaft and input bearings Adjust the axial endplay per Table 5 TXT2A 10 24 x 3 8 12 Install input and output seals Lightly coat the seal lips TXT3B 10 24 x 3 8 with Mobilith AW2 All Purpose grease or equivalent The possibility of damage and consequent oil leakage can be TXT4B 14 20 x decreased by covering all sharp edges with tape prior to seal TXISC Y 20x X installation Seals should be pressed or tapped with a soft mec dria hammer evenly into place in the reducer housing applying TXT6A 14 20x 1 pressure only on the outer edge of the seals Extreme care should be used when installing seals to avoid damage due TXT7A 14 20 x Ye to contact with sharp edges on the input shaft or output TXT8A 4 20 hub A slight oil leak at the seals may be evident during initial running but should disappear unless seals have been TXT9A 4 20 damaged 13 Install bushing backup plates and snap rings on Taper 4 20 Bushed reducers or hub collars on straight bore reducers in
30. 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
31. 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 above that level ADJUSTMENT TABLE AXIAL AND RADIAL CLEARANCES FACTORY ADJUSTMENT RECOMMENDED ADJUSTMENT HIGH Average Speeds SPEEDS PER 1 12 TURN 2000 3000 5000 9000 STD AXIAL STD RADIAL SPEED AXIAL RADIAL AXIAL RADIAL SERIES SERIES SERIES SERIES CLEARANCE CLEARANCE OVER CLEARANCE CLEARANCE 3 4 1 1 2 17 16 17 16 007 012 0022 0037 2000 012 017 0037 0053 0 005 0 0016 111 16 2 111 16 1 15 16 11 2 1 15 16 007 012 0020 0034 1500 012 017 0034 0049 0 005 0 0014 23 16 3 2 3 16 2 15 16 2 2 15 16 115 16 2 1 2 010 017 0026 0044 1250 017 024 0044 0062 0 007 0 0018 33 6 4 3 7 6 3 15 16 3 3 16 4 2 11 16 3 7 16 010 017 0025 0043 1000 017 024 0043 0060 0 007 0 0018 4316 5 311 16 4 7 16 015 025 0032 0054 750 025 035 0054 0076 0 010 0 0022 5 7 16 7 4 15 16 6 7 16 015 025 0032 0054 500 025 035 0054 0076 0 010 0 0022 REXNORD Rexnord Industries LLC Phone 317 273 5500 AN Bearing Group www rexnord com 5 12 08 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 Place a soft metal bar or wood block on face of in
32. 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 DIMENSIONS Verify input shaft diameter at the backstop journal See chart for correct dimensions 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 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 Diameter Backstop Journal Figure 4 TORQUE ARM SPEED REDUCER BACKSTOP NUMBER SHAFT CURRENT TXT TXT SERIES PART TXT SERIES SERIES HOUSING BEARING TDT SERIES TD SERIES NUMBER REDESIGN 2005 REDESIGN 1991 INTRO 1985 SERIES DIMENSIONS 241101 TDT 115 TDT 115 No 1 6315 6310 TDT 125 TDT 125 242101 TXT109A TXT 105 TDT 215 TDT 215 No 2 383 7378 TXT115A TXT 109 TDT 225 TDT 225 No 3 TXT125A TXT 115 T 11 No 11 TXT 125 TDT 315 TDT 315 TDT 325 TDT 325 243102 TXT 309 TXT 315 TXT 325 243106 TXT309B TXT 309A TXT315B TXT 315A TXT325B TXT 32
33. 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 The remaining bearings should not be secured to the shaft at this time Rotate the shaft under power to permit the remaining bearings to seek their natural running position on the shaft Shut off the power and torque down set screws in remaining bearings using procedure in Step 4 BEARING REMOVAL PROCEDURE 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 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 Phone 317 273 5500 10598501116 REXNORD Bearing Group www rexnord com APPENDIX M MOTORS AND DRIVES EO NSTALLATI ON AND MAI NT ENANCE NSTRUCTI ONS FOR ELECTRI C MOTORS Frames 143 5T 586 7T READ CAREFULLY THIS MANUAL BEFORE Am INSTALLING THE MOTOR 1 RECEIVING CHECK Y Check if
34. 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 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 Loosely install the front motor rail to the top plate Measure the distance betw
35. 0 N A 244113 245092 N A 244115 245094 N A N A 245099 N A N A 245110 N A N A 245112 411407 411408 411435 419011 419011 419012 Notes Not shown on drawing Includes parts listed immediately below Includes parts listed immediately below Makes up assembly under which it is listed 6 Makes up assembly under which it is listed 6 See Table 9 for actual ratio 4 required on TXT3B and TXT4B 5 required TXT5C Two sets recommended 16 Parts for TXT6A thru TXT10A Straight and Tapered Bushed double Reduction Reducers 1 2 62 20 22 16 80 81 82 32 33 68 78 60 0 64 76 59 32 35 58 D 54 55 50 52 28 56 57 44 45 is 38 39 35 34 80 4 45 32 33 36 sa 46 47 114 112 25 118 120 122 116 STRAIGHT BORE NOTE THE TWO DIGIT NUMBERS ARE FOR REFERENCE ONLY ORDER PARTS BY THE SIX DIGIT NUMBER IN THE PARTS LIST EACH SIX DIGIT NUMBER IS A COMPLETE IDENTIFICATION OF THE PART OR ASSEMBLY 12 BACKSTOP ASSEMBLY 17 1 2 62 20 22 16 80 81 82 32 55 74 78 86 88 gr 84 A ERE 124 126 128 HYDROIL INPUT 72 50 56 57 48 58 39 35 34 36 46 47 112 118 120 122 116 TAPER BORE TORQUE ARM ASSEMBLY Parts for TXT6A thru TXT10A Straight and Tapered Bushed double Reduction Reducers Description Qty TXT6A TXT7A TXT8A TXT9A TXT10A HXT
36. 02 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 2 46 to 3 and 35mm to 75mm Bore INSTALLATION INSTRUCTIONS 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 bodily injury 1 Clean shaft bore of bearing Lubricate with light oil or antiseize compound 2 Slip bearing in position 3 Bolt bearing to support using shims where necessary to align bearing 4 Tighten setscrews to the torque values shown on Table 1 5 The effort required to turn the shaft should be the same before and after bolting bearing to the support LUBRICATION INSTRUCTIONS Storage or Special Shutdown If exposed to wet or dusty conditions or to corrosive vapors extra protection is necessary Add grease until it shows at the seals rotate the bearing to distribute grease cover the bearing After storage or idle period add a little fresh grease before running High Speed Operation In the higher speed ranges too much grease will cause overheating The amount of grease tha
37. 1 4 Bore N A 443260 443251 2 7 16 Bore N A 443261 443243 2 1 2 Bore N A N A 443244 2 11 16 Bore N A N A 443245 2 15 16 Bore N A N A 443250 Key Bushing to Output Hub 1 3 4 thru 1 15 16 Bore Bushing 443262 1 7 16 thru 2 1 4 Bore Bushing N A 2 3 16 thru 2 15 16 Bore Bushing N A Torque Arm Rod Kit 243097 243097 243097 Torque Arm Rod End 243245 243245 243245 RH Nut 407095 407095 407095 Torque Arm Turnbuckle 243246 243246 243246 Torque Arm Extension 243247 243247 243247 LH Nut 407244 407246 407246 Fulcrum 243249 243249 243249 Fulcrum Screw amp 411484 411484 411484 Hex Nut 407093 407093 407093 Adapter Assembly 259153 259154 259155 RH Adapter Plate 243242 244244 245242 LH Adapter Plate 243241 244243 245241 Adapter Bushing amp 243243 245243 245243 Adapter Bolt 411437 411460 411460 Lockwasher 419012 419013 419013 Hex Nut 407089 407091 407091 Hydroil Motor Adapter 15 1 Ratio Motor Adapter 243539 244572 245606 25 1 Ratio Motor Adapter 243541 244572 245607 Hydroil 6 B Motor Adapter 15 1 and 25 1 Ratio 243467 244573 245643 Adapter Screw 417081 417108 415023 Lockwasher 419046 419047 419047 Motor to Adapter Screw Motor to Adapter Lock Washer 243282 N A N A 243284 N A N A 243260 244079 N A 243262 244081 N A 243264 244083 N A 243268 244085 N A 243266 244087 N A 243270 244089 245084 243272 244093 245086 243274 244095 245088 N A 244109 N A 243276 244111 24509
38. 11 40 220 220 220 TDT1425 120 88 138 m U S Measure 1 qt 32 fluid oz TXT SCXT HXT A 3 5 209 215 225 m 1 e 1 e 1 7 1 2 24 2 3 7 8 1968 13 2 2 37 14 a 9 Pa 28 a 4 37 EZ 74 9 5 an 5 8 9 709 715 725 62 97 15 1626 Te 9 7 9 19 174 1 10 8 805 6 22 915 926 13 905 143 4 1215 1225 59 se so 369 100 100 rori225 e2 ee so 10 110 120 192 61 150 150 170 281 281 Lubricant Grade Equivalents NOTE Mobil SHC 630 Series oil is recom mended for high ambient temperatures NOTES 1 Assumes auxiliary cooling where ommended in the catalog 2 Pour point of lubricant selected should be at least 10 F lower than expected minimum ambient starting tempera ture 3 Extreme pressure EP lubricants not recommended for average oper ating conditions 4 4 Special lubricants may be required for food and drug industry applica tions where contact with the product being manufactured may occur Con sult a lubrication manufacturer s rep resentative for his recommendations 5 Do not use oils containing EP addi tives such as graphite or molybde num disulphide in the reducer when backstop is used These additives will destroy sprag action h 6 For reducers operating in amb
39. 20 301 400 RPM 1 320 320 151 200 126 150 320 220 101 125 320 320 220 220 220 220 220 220 220 220 220 220 320 320 320 220 8 9 12 13 14 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 220 320 320 320 320 320 320 320 320 220 220 220 1 220 220 41 80 320 320 320 320 220 220 220 220 220 220 220 220 220 11 40 320 320 320 320 320 320 320 320 320 320 220 220 220 220 Table 2 Lubrication Recommendations ISO Grades For Ambient Temperatures of 15 F through 60 F Output TXT SCXT HXT Reducers 1 10 220 220 220 220 220 220 220 220 220 Reducer Size RPM 1 2131415 6 7 10 12 13 14 15 301 400 220 220 150 150 150 150 150 150 150 150 150 150 150 150 201 300 220 220 150 150 150 150 150 150 150 150 150 150 150 151 200 220 220 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 81 100 220 220 150 150 150 150 150 150 150 150 150 41 80 220 220 2
40. 2239 N A N A N A N A 272240 411435 411456 411457 411484 411484 419012 419013 419013 419014 419014 443211 N A N A N A N A 443211 N A N A N A N A 443214 443248 N A N A N A 443214 N A N A N A N A 443238 443248 N A N A N A N A 443199 N A N A N A 443236 443199 N A N A N A 443237 443199 N A N A N A 443252 443199 443247 N A N A N A 443216 N A N A N A 443213 443235 N A N A N A N A 443217 443171 443249 N A N A 443218 443173 272119 443192 N A N A 443174 N A N A N A N A 443196 272066 443193 N A N A N A 443161 443194 N A N A N A N A 443195 rer a a a aaa gt a a a a a a Co a CC n 443212 N A N A N A N A N A N A N A N A N A N A 443191 246097 247098 390129 390129 390129 245245 247239 271050 271050 271050 407097 407099 407104 407104 407104 245246 247246 271051 271051 271051 245247 247240 271052 271052 271052 407246 407248 407250 407250 407250 247248 247248 271054 271054 271054 411489 411489 411516 411516 411516 419014 419014 419020 419020 419020 407093 407093 407099 407099 407099 259156 259157 248110 249110 250110 246242 247242 272053 249241 250041 246241 247241 272053 249241 250041 245243 247244 271046 271046 211046 411460 411489 411510 411512 411512 419013 419014 419020 419020 419020 407091 407093 407099 407099 407099 246465 247464 246522 247522 417108 417141 906406 907406 OO mama fa a a a a aa po aa a a a aa a Pa a a a on Notes Not shown on drawing Includes parts listed immediately below a
41. 245590 243570 244188 245186 243216 354087 355064 243572 244658 245598 400098 400150 400154 243308 244099 245114 421109 421108 421107 243547 244591 245592 389589 389592 389596 402272 402268 402193 403127 403163 403016 389706 389713 389719 Output Hub Seal Carrier Input Side Output Hub Bearing Kit IX Output Hub Bearing Cone Output Hub Bearing Cup Output Hub Bearing Shim Kit a 1 4 4 1 1 1 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 1 1 1 2 4 2 2 1 1 2 2 15 Parts for TXT3B thru TXT5C Straight and Tapered Bushed Double Reduction Reducer continued TXT3B TXT4B TXT5C Taper Bore Bushing Assembly Bushing 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 Taper Bushing Lockwasher Key Bushing to Shaft Q 1 5 16 Bore 443264 N A N A 1 3 8 Bore 443264 N A N A 1 7 16 Bore 443265 443254 N A 1 1 2 Bore 443265 443254 N A 1 5 8 Bore 443265 443254 N A 1 11 16 Bore 443266 443254 N A 1 3 4 Bore 443266 443254 N A 1 7 8 Bore 443267 443255 443251 1 15 16 Bore 443269 443255 443251 2 Bore 443268 443255 443251 2 1 8 Bore N A 443258 N A 2 3 16 Bore 443270 443259 443251 2
42. 3 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 Accord ingly we would urge that carrying idlers not be used for tracking unless absolutely necessary and simply be squared relative to the belt center line The discharge pulley 16 is located in a high ten sion portion of the belt circuit Further there is usu ally 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 Empty Full As each adjustment is made on the individual components of the conveyor system it is neces sary 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 adjust ment you have made If the belt has over reacted do not proceed to another adjustment until you first modify the original adjustment and
43. 389742 403006 046122 401012 391104 427073 427083 427093 061358 400708 405601 50 MM _ 061322 389743 403006 046122 401012 391104 427073 427083 427093 061358 400708 405601 55 MM 1061323 389744 390762 046123 401016 391105 427074 427084 427094 061359 400709 405601 60 MM 061324 389745 390766 046124 401020 391106 427075 427085 427095 061360 400709 405601 65 MM_ 061324 389746 390766 046124 401020 391106 427075 427085 427095 061360 400709 405601 70 MM 061325 389747 390771 046125 401024 391107 427076 427086 427096 061361 400710 405601 75 MM 061325 389748 390771 046125 401024 391107 427076 427086 427096 061361 400710 405601 Quantity 1 1 2 2 Per 2 1 2 4 1 L 65 Set Screw Angle Consists of one each of 0 004 0 006 and 0 015 shims These parts make up shim pack Not shown on drawing 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 Rockw
44. 4 Bore 241288 242150 1 5 16 Bore 241290 242152 1 3 8 Bore 241294 242154 1 7 16 Bore 241292 242156 1 11 16 Bore N A 242164 1 1 2 Bore N A 242158 1 5 8 Bore N A 242162 1 3 4 Bore N A 242166 1 15 16 Bore N A 242168 12 Parts for TXT HXT 1A amp 2A Straight and Tapered Bushed Double Reduction Reducers Bushing Screw Lock Washer 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 94 1 1 8 Bore 1 1 8 to 1 1 2 Bore Torque Arm Assembly Torque Arm Rod End RH Nut Torque Arm Turnbuckle Torque Arm Extension LH Nut Torque Arm Fulcrum Fulcrum Screw Hex Nut Adapter Assembly RH Torque Arm Adapter Bracket LH Torque Arm Adapter Bracket Adapter Bushing Adapter Bolt Lock Washer Hex Nut Hydraulic Motor Adapter Adapter Screw Lockwasher Input Pinion Seal Hydroil Motor to Adapter Screw Motor to Adapter Lock Washer Notes amp Not shown on Drawing Includes Parts Listed Immediately Below Includes Parts Listed Immediately Below Makes up Assembly Under Which it is Listed Makes up Assembly Under Which it is Listed 6 See Table 9 for Actual Ratio 4 Required on TXT1A and 5 Required TXT2A 6 Required on TXT1A and 7 Required on TXT2A ty 13 TXT HXT 1 411405 419010 443274 443271 241308 241307 241306 241310 241305 N A N
45. 5A 244092 TDT 415 TDT 415 TDT 425 TDT 425 244101 244106 TXT409B TXT 409A TXT415B TXT 415A TXT425B TXT 425A 244148 TXT 405 TXT 409 TXT 415 TXT 425 245101 TDT 515 TDT 515 TDT 525 TDT 525 245154 TXT509C TXT 509B TXT 509 509A TXT515C TXT 515B TXT 515 515A TXT525C TXT 525B TXT 525 525A 246092 TXT609A TXT 605 TDT 615 TDT 615 No 16A TXT615A TXT 609 TDT 625 TDT 625 TXT625A TXT 615 T 16 TDT 615A TXT 625 TDT 625A 247092 Use Part Number 247260 247260 TXT709A TXT 705 TDT 715 TDT 715 No 17A 1 5005 1 5000 TXT715A TXT 709 TDT 725 TDT 725 TXT725A TXT 715 T 17 TDT 715A TXT 725 TDT 725A 248101 Use Part Number 249260 249260 TXT815A TXT 815 TXT 815 TD 815 No 8 1 7505 1 7500 TXT825A TXT 825 TXT 825 TD 825 No 9 TXT15A TXT 915 TXT 915 TD 815A TXT926A TXT 926 TXT 926 TD 825A No 18 TDT 1115 TD 915 TDT 1125 TD 1115 TD 1125 250101 Use Part Number 249260 250260 TXT1015A TXT 805 TD 1015 TD 1015 1 7505 1 7500 TXT1024A TXT 1015 TDT 1024 TD 1024 TXT 1024 T 18 TD 1215 TXT 1215 TDT 1215 TD 1225 TXT 1225 TDT 1225 TXT209A TXT 305A TXT 205 No 13 9706 9696 TXT215A TXT 209 TXT225A TXT 215 TXT 225 TXT 305 T 14 TXT905 TDT1325 T19 1 7505 1 7500 TDT 1425 TDT 1530 1 7505 1 7500 3 243101 9706 9696 8891 8881 383 7378 2 on 9706 9696 1 1355 1 1325 8891 8881 1 0521 1 0511 1 2965 1 2955 1 2150 1 2140 1 5005 1 5000 1 9370 1 9360 2 7495 2 7490 BALDOR
46. 6 070005 070021 070587 400094 069278 405015 070006 070022 070587 400094 069278 405015 2 6 070007 070023 070588 400094 069279 405015 27 16 070008 070024 040054 400094 069280 405015 211 16 070009 070025 070589 400150 069281 405015 2 2 6 070010 070026 070589 400150 069281 405015 070011 070027 070589 400150 069281 405015 Shaft sizes 4 7 16 4 15 16 have two collars WSTU and TPHU TU take a 405016 grease fitting BALDOR a i ae www baldor com www ptplace com www dodge pt com www reliance com BALDOR RELIANCE B 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 1 499330 04 07 16 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 Installation Instructions REXNORD Mounted Roller Bearings 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 Inspect shaft size see sha
47. 6A HXT7A 12 Backstop Assembly 246092 247260 249260 249260 250260 Housing TXT and Hydroil LH 246358 247358 248358 249358 250358 Housing RH 246359 247359 248359 249359 250359 Housing RH Flange Mount Drilled 465044 465044 465044 465044 RTV Sealant Tube 904287 904287 904287 904287 465044 Air Vent 411466 411498 411499 411500 904287 Housing Bolt 411468 411499 411502 411502 411502 Housing Bolt Adapter 419013 419016 419016 419016 411506 Lock Washer 407091 407095 407095 407095 419016 Hex Nut 420147 420148 420148 420148 407095 Dowel Pin 430062 430064 430064 430064 420148 Magnetic Oil Plug 430033 430035 430035 430035 430064 Oil Plug 246184 247320 258023 249211 430035 Input Shaft Seal Carrier 391164 390420 390038 390168 249211 Input Shaft Bearing Shim Pack 411408 411433 411408 411408 390168 Carrier and Cover Screw 419011 419012 419011 419011 411408 Lock Washer 246226 246226 248226 248226 419011 Backstop Cover 421029 421029 421034 421034 248226 Backstop Retaining Ring 411394 411394 411394 411394 421034 Backstop Cover Screw 419009 419009 419009 419009 411394 Backstop Cover Lock Washer 419009 Seal Kit 246340 247345 248340 249340 272460 Backstop Cover Gasket 246220 246220 248220 248220 248220 Input Pinion Shaft Seal amp 242210 242210 248211 248211 248211 Output Hub Oil Seal amp 246310 247310 258019 249210 250010 Input Pinion 9 1 Ratio amp 15 1 Ratio 6 25 1 Ratio W 15 1 Ratio Hydroil Pinion 25 1 Ratio Hydroil Pinion 15 1 Ratio
48. 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 shaft 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 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 8 D or 5 in position A amp 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 amp D or 5 for position A amp 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 filling holes furnished along with other standard pipe fittings stand pipes and oil level gauges as required 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 R
49. IED 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 main tenance 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 writ ing 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 pro
50. NTENANCE 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 N LEAD CONNECTION IN SULATION INSIDE THE TERMINAL BOX MUST BE DONE WITH AN Pi ET INSULATING MATERIAL COMPATIBLE WITH C gt MOTOR THERMAL CLASS WHICH IS SHOWN ON THE MOTOR NAMEPLATE M P 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 OTHER 1 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 a KEEP AIR INLET AND OUTLET FREE AND CLEAN THE AIR BLOWN OUT BY THE MOTOR SHALL 7 1 x NOT ENTER AGAIN THE DISTANCE BETWEEN THE AIR INLET AND THE WALL MUST BE AROUND OF THE INLET OPENING DIAMETER 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
51. OOSENING 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 disas sembled and reassembled during normal maintenance periods Caution must be used when operating your equipment in high winds If possible lower your con veyor 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 dam age 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 haz ard Failure to follow these
52. RECAUTIONS 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 recom mended torque while the other bearings remain free Rotate the shaft slowly under load if possible to prop erly 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 condition
53. RED 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 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 L
54. ROFILE TRUCK UNLOADER POWER CONNECTION DANGER PROPER LOCKOUT TAGOUT PROCEDURES SHOULD BE FOLLOWED BEFORE ATTEMPTING TO CONNECT YOUR TRUCK UNLOADER TO ANY POWER SOURCE FAILURE TO FOLLOW YOUR COMPANY DESIGNED LOCKOUT TAGOUT PROCEDURE CAN RESULT IN SERIOUS INJURY OR DEATH Before operating your Truck Unloader 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 UNFOLDING YOUR LOW PROFILE TRUCK UNLOADER RAMP WINGS Your Truck Unloader arrived with the drive over ramp wings in travel position They must be unpinned and unfolded before use Use the following steps to unfold your drive over ramp wings 1 Unpin and remove the road travel bars at both ends of the folding ramp wings Place the retention bars on the studs indicated at the bottom of the photo below for storage 2 Operate the hydraulic levers labeled LEFT RAMP and RIGHT RAMP in the Down position RIGHT DOWN DOWN 3 Once both ramp wings are fully on the ground unbolt the retention bar that holds the ramp extensions in place 4 Place a chain around both lifting eyes on the ramp extensions Carefully
55. T LENGTH right if desired Figure 3 Angle of V Drive fe Lf H Right angle or may vary 30 in tension d 20 in compression Torque Arm and 42 A Ewa Take up Torque Arm may Figure 5 Minimum Recommended Dimensions be located to the right if desired Table 1 Minimum Mounting Dimensions and Bolt Torques Minimum Required Shaft Length Taper Bushing Straight Bushing Figure 4 Angle of Torque Arm 6 1 2 TXT TAPERED BUSHING INSTALLATION TXT2A 6 3 4 5 13 16 WARNING To ensure that drive is not unexpectedly started 916 turn off and lock out or tag power source before proceeding TXT4B 9 5 16 8 1 4 Remove all external loads from drive before removing or 1705 z TXT5C 9 3 4 8 11 16 servicing drive or accessories Failure to observe these precautions could result in bodily injury TXT6A 10 3 4 Taper Bore Bushings TXT7A 11 15 16 10 3 4 TXT8A 13 1 8 11 3 8 1 One bushing assembly is required to mount the reducer TXT9A 11 3 8 on the driven shaft An assembly consists of two tapered bushings bushing screws and washers and necessary shaft TXT10A 14 3 16 12 3 8 keys or key The driven shaft must extend through the full length of the Bushing Screw Information and Minimum Clearance for Removal reducer The minimum shaft length as measured from the a 9 end of the shaft to the outer edge of the bushing flange Torque in In Lbs dn mou 5 is L
56. TABLE OF CONTENTS TERMS AND CONDITIONS ex wate yok di a kan gon ee doi ate ava eee 1 SAFETY RULES kota di hed hid 3 SETTING UP YOUR LOW PROFILE TRUCK UNLOADER 7 SITE PREPARATION a ai MR no URS RO GU RP RR Alba ROAR OA RR RR Eng 7 UNLOADING YOUR MASABA EQUIPMENT 7 OPERATING YOUR LOW PROFILE TRUCK 8 POWER CONNECTION rte GR ER INN a bik A RUS ke no Ma ae 8 UNFOLDING YOUR LOW PROFILE TRUCK UNLOADER RAMP 5 8 CONVEYOR PREPARATION eee bea a Sad ER ees 11 CONVEYORSOPBRATIOIN ise aoe ANY babe ED 12 IDENTIFYING THE OPERATIONAL 12 RAISING AND LOWERING THE DISCHARGE CONVEYOR 16 CONTROLLING THE VOLUME OF MATERIAL 17 APPENDIX A ia esas rei E NS Fenner Dunlop Belt Storage and Installation APEENDEXAB ES Ma Sent ey 5 Flexco Bolt Solid Plate Belt Splice APPENDIX lese EN EEG ee E ae ee KI p Fenner Dunlop Belt Tracking be RA GE RAMA ok a babe Fenner Dunlop Belt Maintenance APPENDIX E
57. 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 o o A o m place in the housing Make sure bearing rollers cones are properly seated in their cups 8 Make sure both housing halves are clean Apply Recommended Torque Values Ibs ft 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 TXT1A and TXT2A reducers skip to step number 12 TXTSC 30 27 10 Place the output bearing cup into the housing and tap into TXT6A 30 27 place Install the output seal carrier and draw down with two bolts 180 apart to 50 inch pounds of torque Loosen both TXT7A 50 45 bolts then retighten finger tight only Measure the clearance TXT8A 30 27 between the housing and carrier flange at each bolt and average the two values Add 0 010 to the average reading 150 135 30 27 and
58. W TEMPERATURE EQUIVALENT VISCOSITIES FOR 100 F AND 200 F ARE SHOWN Exe SAE 90 TO 250 SPECIFIED AT 100 C 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 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 Sealthe 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 insi
59. a a 1 2 4 TXT1A 5 16 18 1 1 4 include dimension A Dimension A should be added to the minimum shaft length to allow for the removal of the 2 5 16 18 1 14 bushings at disassembly TXT3B 3 8 16 1 1 2 2 Place one bushing flange end first onto the driven shaft TXT4B 3 8 16 1 3 4 and position per dimension A as shown in Table 1 This will allow the bolts to be threaded into the bushing and for TXTSC 3 8 16 1 13 16 future bushing and reducer removal If the reducer must TXTGA 1 2 13 1 13 16 be positioned closer to the equipment than dimension A place the screws with washers installed into the unthreaded TXT7A 1 2 13 2 1 16 holes of the bushing flange prior to placing the bushing on TXT8A 1 2 13 2 146 the shaft and position as required 3 Insert the output key in the shaft and bushing For ease of TXT9A 1 2 13 90 2 7 16 installation rotate the driven shaft so that the shaft keyseat TXT10A 5 8 11 9 2 7H6 is at the top position Straight Bore Bushings 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 reduc
60. 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 perpen dicular 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 equiva lent A variance suggests that something has been overlooked in examination of the structure pulleys idlers etc 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 train ing sequence previously outlined namely 1 Return run working from head toward tail low tension side Top run working from tail toward head high tension side 3 First empty then full with belt running Return Run 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
61. alcium 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 1 096 greater than 0 196 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 ev
62. all plug in topmost hole Of the remaining plugs on the sides of the reducer the lowest one is the minimum oil level plug The running position of the reducer in a horizontal application is not limited to the four positions shown However if running position is over 20 either way from sketches the oil level plug cannot be safely used to check the oil level unless during the checking the torque arm is disconnected and the reducer is swung to within 20 of the positions shown Because of the many possible positions of the reducer it may be necessary or desirable to make special adaptions using the lubrication fitting holes furnished along with other standard pipe fittings stand pipes and oil level gauges as required Vertical Installations install the filler ventilation plug in the hole provided in the top face of the reducer housing Use the hole in the bottom face for the magnetic drain plug Of the remain ing holes on the sides of the reducer use a plug in the upper housing haif for the minimum oil level plug HORIZONTAL APPLICATIONS 4 D C POSITION D POSITION P PLUG D B POSITION D DRAIN L LEVEL A POSITION B BREATHER E POSITION F POSITION NOTE Below 15 RPM output speed oil level must be adjusted to reach the highest oil level plug P Table 1 Lubrication Recommendations ISO Grades For Ambient Temperatures of 50 F through 125 F 3 TXT SCXT HXT Reducers 2 320 2
63. aluate 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
64. 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 TXTIA to TXT5C and Nos TXT105 to TXT505A Reducers For ease of installation a light coating of oil on the O D of backstop will hel
65. any damage has occured during transportation v Check nameplate data Y Remove shaft locking device if any before operating the motor Y Turn the shaft with the hand to make sure if it is turning freely HANDLING AND TRANSPORTATION 1 General pan 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 a THIS LOCKING DEVICE MUST BE USED ON ANY FURTHER TRANSPORT OF THE MOTOR EVEN 1 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 keptin stock for 2 years or more must have their capacitors replaced if any We recomme
66. ase PB Bearing Insert Resistant Recom Flg and Flg Bolt Torque Size Torque Flats Stainless Torque Brackets in in lbs Steel Bolt Torque Size 0 in los in lbs in in lbs in in lbs 3 8 16 7 16 14 1 2 13 Torque for Austenitic 18 8 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 remove grease fitting to permit excess grease to escape The bearing has been greased at the factory 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 Lubrication Guide Use a No 2 Lithium complex base grease or equivalent Hours Run Suggested Lubrication Period in Weeks For EZ Kleen series bearings use an aluminum complex base grease Lubrication recommendations are intended for standard products applied in general operating conditions For modified products high temperature applications and other anomalous applications contact product engineering at 864 284 5700 BALDOR 3016 0711 A MEMBER OF THE ABB GROUP P O Box 2400 Fort Smith AR 729
67. 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 2 WEG MOTORS ARE DYNAMICALLY N 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 AN 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 least3mm 7 Belt Drive When using pulley or belt coupling the following must be observed v Belts must be tighten just enough to avoid slippage when running according to the specifications stated on the belt supplier recommendation WARNING Excessive tension on the pulley
68. between the head and take up areas after the take up 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 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 self trainers 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 In areas along the carry side where the frame is not level and true the following additional training me
69. cation Schedule Shaft Size SetScrewSize Tightening Torque H Suggested Lubrication Period in Weeks EA 556218 165in lbs ipn OA Run 1to 251to 501to 751 to 1001 to 1501 to 2001 to 2501 to 13 4 21 2 3 16 290 in Ibs 250 500 750 1000 1500 2000 2500 3000 2 3 15213 620 in ibs Day RPM RPM RPM RPM RPM RPM 35 40MM M8 17 8 NM 8 12 12 10 7 5 4 3 2 45 65MM M10 35 NM 16 12 7 5 4 2 2 2 1 70 75MM M12 57 NM 24 10 5 3 2 1 1 1 1 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 Rockwell Automation nor are the responsibility of Rockwell Automation 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 a
70. cing in curve increase curve radius Excessive forward tilt of trough rolls reduce forward tilt of idlers to no more than 2 from vertical Excess gap between idler rolls replace idlers replace with heavier belt Insufficient transverse stiffness replace with the proper belt Pulleys too small use larger diameter pulleys Counterweight too light add counterweight or increase screw take up tension to value determined from calculations Counterweight too heavy lighten counterweight to value required by calculations Pulley lagging worn replace pulley lagging Insufficient traction between belt and pulley lag drive pulley increase belt wrap install belt cleaning devices System underbelted recalculate belt tensions and select proper belt 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 Improper storage or handling refer to Georgia Duck for proper storage or handling instructions Belt improperly spliced resplice using proper method as recommended by Georgia Duck Belt running off center around the tail pulley and through the loading area install training idlers on the return run prior to tail pulley Belt hitting structure install training idlers on carrying and return run 41 42 43 44 45 46 47 48 49 50 51 52 53 Index Page Improper belt installation causi
71. d 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 SEVERABILITY WAIVER The invalidity or unenforceability of any provision of this Contract shall not affect the validity or enforceability of any other pro vision 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 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 ENTIRE AGREEMENT The terms set forth here
72. d 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 whatso ever 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 po
73. de 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 VCI 105 and 10 are interchangeable VCI 105 is more readily available TXT5C TXT6A TXT7A TXT8A Motor Mounts Bo l 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
74. 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 Itis a cosmetic defect and is not indicative of a cambered belt Belt Tension Belt tension must be great enough to prevent slip page 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 deteriora tion 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 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 con sumption up can actually result in a stalled sys tem and can cause severe tracking problems Square Ends Accurate squaring of the belt ends prior to splicing is essential to belt tracking and helps d
75. duct 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 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 disclaim ers 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
76. e 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 sprag After rotation is verified discard cardboard retainer Ensure backstop cover does not bind backstop aH Install Lockring in Outer Groove of Backstop Assembly i 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 pus
77. e enough free span transition for the belt to elon gate and conform Pretension to get pulley crown conformation is very important too much preten sion can cause pulley deflection and bearing prob lems Georgia Duck has specific carcass construc tions to meet very short center wide belt applica tions in the 1 1 ratio of length to width and even less Please consult factory if you have needs in this area 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 con veyor 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 ten sion 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 Take up The take up device in a conveyor belt system has three major functions 1 To establish and preferably to maintain a pre determined 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 leng
78. e little tracking effect because there is no unsupported belt span between 11 and 10 Further such a deviation from the perpendicu lar would have a substantial cambering effect Under the circumstances therefore it should be set per pendicular to the belt center line Our comments relative to roll 9 through 5 inclu sive would be substantially the same as before Reaction of roll 4 however would reverse Pre viously 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 cen ter 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 s
79. e 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 The reader should also keep in mind another potential problem when trying to train a bi direc tional 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 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 directiona
80. ear to the grease nipple v Putapproximately half ofthe total grease and run the motor for 1 minute atfull speed Thenturn offthe 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 00621 OOVEL 00511 00511 00 01 0082 0065 00 0066 09 142 985 0000c 00751 00 61 00761 00221 0086 009Z 0009 00 Sv 19 06 00002 00461 0041 0041 0021 0086 009Z 0009 00Zr Sr J1S Ztt 0000c 00 51 00 61 OOLE L 00221 0086 0092 0009 0047 SV LS bbr 0000 008 1 00561 00561 008 1 00911 0056 009Z 0009 19 0 0000 00002 00002 00461 00621 00791 00271 00911 0046 LG LS V9E 0000c 0000c 0000c 0000c 0000c 0000c 0000c 0000c 0000c 00611 0086 Ic LS t c sDuueeg 1e oJ eoupur Ao sunou ur semau uoneouqnjeg 0000c 0000c 0000c 00 61 00621 00791 00271 00911 0046 0097 009 LG 512 986 0000 00002 00002 00 61 00621 00791 00271 00911 0046 005 009 LG 514 20 lt 00007 00007 00007 00 61 00621 00791 00271 00911 0046 005 009 LG SLS bbb 0000c 0000c 0000c 00461 00621 00791 00271 00911 0046 005 009 LG SLS v0b 0000c 0000c 0000c 00 61 00621 00791 00271 00911 0046 005 0096 22 16 96 00007 00007 00007 00007 00007 00007 00007 00007 00007 00611 0086 Ic 19 tc 0000c 0000c
81. ed 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 maladjust ment or defect in the system which will throw the Index Page belt off to such a degree as to threaten belt dam age 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 indicat ed 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 per pendicular to the system center line and severe belt tracking problems still persist it is advisable to shut the system down and establish
82. ee 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 con struction be balanced or neutral in terms of the internal stresses imparted to the belt during manu facture 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 here by defined as camber To measure belt camber it is recommended that the belt be unrolled on a flat surface like the ware house 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 pe
83. eed Reducers Lubrication of TORQUE ARM Reducers CAUTION Unit is shipped without oil Add proper amount of rust and oxidation inhibited R amp O gear oil before operating Failure to observe these precau tions could result in damage to or destruction of the equipment Lubrication is extremely important for satisfactory operation The proper oil level as shown in Table 3 must be maintained at all times Frequent inspections with the unit not running and allowing sufficient time for the oil to cool and the entrapped air to settle out of the oi should be made by removing the level plug to see that the level is being maintained If low add the proper type and viscosity of lubricant through one of the upper openings until it comes out of the oil level hole Replace the oil level plug securely Refer to Tables 1 and 2 for viscosity recommendations After an initial operation of about two weeks the oil should be changed If desired this oil may be filtered and reused Very often small metal particles will show up in the oil due to the wearing in process After the initial break in period the lubricant should be drained magnetic drain plug cleaned gear case flushed and refilled every 2500 hours of operation under average industrial conditions CAUTION Too much oil will cause overheating and too little will result in gear failure Check oil level regularly More frequent oil changes are recommended when operating continu
84. een 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 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 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 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 sho
85. elf 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 Index Page eit 3Hn9l3 HOA3ANOO IVOLL3H LOdAH ONDPIOVul AATINd dA FAVIL TAAVEL 1348 16 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 normal ly 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 Index Page details of conveyors must be discussed with a Georgia Duck distributor or Georgia Duck repre sentative Tracking Priority Finally we would like to suggest that when track ing a conveyor belt number one priority should be given to adjustin
86. ell Automation Canada 296 Walker Drive Bramalea Ontario Canada L6T 4B3 Tel 1 905 792 1722 Europe Rockwell Automation BriihlstraGe 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 e ANE RELIANCE Beermen 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 APPENDIX K INSTRUCTION MANUAL FOR DODGE 5 2000 SPHERICAL ROLLER BEARINGS GENERAL INFORMATION DODGE S 2000 Spherical Roller Bearing mounted units incor porate a unique way of sealing ta 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 ef ective due to its constant ontact pressure in protecting the internal bearing components undenaximum allowable misaligned 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 P
87. elt 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 some times produce cases which do not appear clear cut 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 proce dure 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 v
88. embly 9 1 Ratio 15 1 Ratio 6 25 1 Ratio Countershaft Pinion First Reduction Gear 9 1 Ratio 15 1 Ratio 25 1 Ratio First Stage Gear Key Countershaft Bearing Kit 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 O 243549 244579 245599 243550 244580 245600 243551 244581 245601 243553 244583 245603 243554 244584 245604 N A 244586 N A 243498 244587 245641 443032 443082 443096 389587 389590 389594 402204 402280 402144 403139 403027 403104 402273 402142 402266 403094 403102 403073 389729 389730 389731 389700 389707 389714 389701 389708 389715 243555 244590 245596 243237 244482 245482 243238 244214 245214 243239 244212 245212 D8242 D8243 D8243 389588 389591 389595 402273 402000 402203 403094 403000 403027 402273 402000 402203 403094 403000 403027 243545 244578 245594 389705 389712 389718 389703 389710 389717 389702 389709 389716 Taper Bore Output Hub Assembly 2 Straight Bore Output Hub Assembly 8 Output Hub Straight Bore amp Taper Bore Output Gear Output Gear Key Output Hub Collar Straight Bore Output Hub Collar Screw Bushing Backup Plate Taper Bore Bushing Backup Plate Retaining Ring 243557 244589 245591 243556 244588
89. emove 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 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 flat 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 sufficient take up in the turnbuckle for belt tension adjustment when using V belt drive 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 D OIGE integral part of the driven equipment beyond the speed reducer output Keep 4 Mount the reducer on the driven s
90. er 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 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 ea
91. ery 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 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 bett 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 dimin ish Yarns on both sides of the belt seek that posi tion which results in the least stress to themselves consistent with the physical structure across which they are stressed and consistent with their individ ual position w
92. f 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 above Milled or filed flats are preferable to 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 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 For expansion bearings H E Series locate inner unit in housing to allow expansion in the desired direction before locking to the shaft DODGE Table 1 Recommended Torque Setscrews D LOK Mounting Bolts Recommended Torque Metal Housings EZ KLEEN Housed Bearings 2 Bolt PB 2 amp Standard Ball Corrosion Recom EZ Kleen 4Bok Tapped B
93. 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 gov ernmental 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 para graph 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 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 prod ucts or parts furnished under this Contract is believed to be reliable but Seller makes no warranty express or implie
94. ft tolerance table Clean shaft and 1 Free tapered split sleeve in bore by backing off locknut and rapping the face mounting surface as needed of the locknut Position bearings on the shaft applying all driving pressure to the 2 Position bearing on shaft with fixed unit closest to drive or most important to face of the inner ring axial location of shaft Align the bearing housing to its mounting base by measuring from 3 Position and loosely bolt housing to mounting base the face of the inner ring to the face of the threaded cover Where 4 Secure fixed bearing to shaft by tightening locknut until sleeve grips the shimming is required use full shims across the housing base not shaft Tighten locknut 1 to 34 more and bend one of the lock washer tangs just at the bolt holes All four measurements must be within 060 into one of the slots on the outside diameter of locknut inches of one another Align each bearing housing as accurately as possible to its mounting base or Bolt housing securely to mounting base frame by measuring from the face of the inner ring to the face of the Tighten the set collar set screws on the bearing closest to the drive threaded cover All four measurements must be within 060 inches of one or most important to axial position of shaft to the shaft Proper another tightening torque can be found in the SET SCREW TORQUE Operate bearing under full load for several days to permit seating of bearing TABLE The remaining bea
95. g return idlers followed by adjust ment 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 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 load ing stations have to be centered so that product is introduced to the center of the belt Any belt train ing idlers that are on the system must be in proper working order and be installed in the proper direc tion The lagging on the drive pulley should be inspected and replaced if the lagging is damaged or if the surface is smooth
96. g so that Mixing of any 2 greases should be checked with the lubricant 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 manufacturer If the grease bases are different they should never be mixed Install collars OIL LUBRICATION Lubricate bearing with amount of grease shown in LUBRICATION Rexnord housing designs do not include oil sumps thus they are not TABLE Rotate inner ring assembly during lubrication to assure readily used with static oil lubrication However they can be adapted to distribution of grease in bearing recirculating oil systems provided an adequate drain size and proper seals are incorporated LUBRICATION TABLE SHAFT SIZE INCHES GREASE WT REQUIRED OZ Single Collar Double Collar Adapter To Lubricate To Relubricate RPM 2000 3000 Series 5000 Series 9000 Series Rebuilt Units Units 100 500 1000 1750 3000 3 4 1 0 4 0 1 118 114 0 5 12 5 2 1 17 16 1 1 2 0 6 111 16 1 3 4 11 2 1 11 16 0 8 1 15 16 2 1 15 16 0 9 23 16 2 1 4 2 23 16 115 16 2 1 4 23 8 21 2 27 16 23 16 1 5 211 16 3 21 2 215 16 27 16 21 2 2 8 33 16 31 2 33 16 37 16 211 16 3 3 7 311 16 4 311 16 4 33 16 37 16 6 9 43 16 41 2 311 16 4 8 4 415 16 5 43 16 47 16 14 3 57 16 415 16 5 2241 515 16 6 53 16 57 16 25 3 6 7 16 7 5 15 16 6 7 16 33 0 Relubrication amounts and frequencies shown in the table are based on standard clearance
97. gnment 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 guid ed to maintain the pulley axis on a line perpendicu lar 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 con ditions 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 Index Page Il 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 fr
98. haft and align the shaft key Close hr 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 Driven in the bushing backup plate If necessary rotate the bushing Shaft Input backup plate to align with the bushing screws Tighten the lt Shaft screws lightly If the reducer must be positioned closer than B dimension A place the screws with washers installed Keep in the unthreaded holes in the bushing before positioning Close 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 Figure 2 Reducer and Sheave Installation and align the bushing keyway with the shaft key Align the unthreaded holes in the bushing with the threaded holes in Right angle the bushing backup plate If necessary rotate the bushing or may vary backup plate to align with the bushing holes Insert bushing 30 in tension screws with washers installed in the unthreaded holes in the 20 in compression bushing Tighten screws lightly 7 Alternately and evenly tighten the screws in the bushing V Belt nearest the equipment to the recommended torque given in a Table 1 Repeat procedure on outer bushing Drive V Belt Drive may be located to the MINIMUM SHAF
99. hed 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 HOUSING Sy BacksToP K INPUT SHAFT A LARGE SNAP RING L SMALL SNAP RING Figure 2 TXT8A 9A 10A Housing Carrier 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 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 resul
100. hrough 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 Suggesied Lubrication Period in Weeks 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 thermom eter at the top of
101. ient temperatures between 22 F 30 C and 20 F 6 6 C use a synthetic hycrocarbon lubricant 100 ISO grade or AGMA 35 grade for example Mobil SHC627 Above 125 F 51 6 C consult DODGE Gear Application Engineering at 803 288 9050 for lubrication recommendation 1 i APPEN DIX 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 5C TXT 8A TXT HXT 2A TXT HXT 6A TXT 9A TXT HXT 3B TXT HXT 7A TXT 10A TXT HXT 4B Includes Char Lynn 6B Hydroil Reducers HXT 3B 6B HXT 5C 6B HXT 7A 6B HXT 4B 6B HXT 6A 6B These instructions must be read thoroughly before installation or operation INSTALLATION Use lifting bracket where applicable to lift reducer Determine the running positions of the reducer See Fig 1 NA 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 filter ventilation 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 filter ventilation plug in the hole provided in the upper face of
102. im t t t t 427090 427091 427092 427093 427094 427095 427096 18 Snap Ring 2 2 2 2 401002 401004 401008 401012 401016 401020 401024 19 Shield 0 0 1 0 061368 061369 061370 061371 061372 061373 061374 T lan 20 em Single Lip 2 2 2 2 061355 061356 061357 061358 061359 061360 061361 1 1 2 Bolt Gray Iron 1 0 0 0 060400 060401 060402 060403 060404 060405 060406 Pillow Block Hsg 4 Bolt Gray Iron 4 1 0 0 0411 0412 2 Pillow Block Hsg 0 06 06 2 Cast Steel 1 0 0 0 060052 060053 060054 060055 060056 060057 060058 Pillow Hsg 1 Top Angle 0 0 0 1 012265 012266 012267 012668 Housing A Flange Housing 0 1 0 o 069100 059101 059102 059103 059104 059105 059106 28 Housing de 0 0 1 0 059168 059170 059171 059172 059173 059174 059175 WideSlt 0 0 0 1 012350 012351 012352 012353 012354 012355 Take Up Housing Fitting on 1 1 1 1 405015 405015 405015 405015 405015 405015 405015 Refer Part Number for Various Shaft Sizes ence Name of Part 13 16 11 4 13 17 16 41 2 15 5 11 16 13 4 17 8 115 16 32 389782 389783 389784 389785 389786 389787 389788 389789 389790 389791 34 Drive Collar 400054 400054 400058 400058 400058 400058 40058 400094 400094 400094 ence Name of Part 2 23 16 2 4 27 16 21 2 211 16 23 4 215 46 3 32 Cone 389792 389793
103. in 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 SURVIVAL The provisions of Sections 3 4 5 and 7 through 16 shall survive the termination and performance of this Contract 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 Itis 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
104. ing the tail pulley will have very little if any Index Page 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 camber ing 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 whatso ever 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 1
105. instructions may put an individual at risk of serious injury or death DANGER 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 equip ment It is the responsibility of the operator to replace any worn torn hard to read or missing decals Equipment starts automatically can cause severe injury KEEP AWAY sea weeny Moving equipment can cause severe Injury KEEP AWAY Exposed moving parts can cause severe injury LOCK OUT POWER before removing guard weeny A DANGER Moving parts will cause severe Injury KEEP AWAY A DANGER Cilmbing sitting walking or riding on conveyor at any time will cause severe injury or death KEEP OFF rm amann Walking or standing on CONVeyOr covers gratings can cause severe injury STAY OFF SETTING UP YOUR LOW PROFILE TRUCK UNLOADER SITE PREPARATION Location of the Truck Unloader is generally determined by the location of discharge of mate rial to be conveyed Improper site conditions can adversely affect the operation and mainte nance of your Truck Unloader The area around the Truck Uloader should be kept clear and level to make the unloading of the trucks and discharge of material as convenient as possible
106. ints on conveyor 6 7 46 D Belt runs off at head pulley 33 10 1 3 E Conveyor runs to one side at given point on structure 5 4 1 2 3 44 F Belt runs true when empty crooked when loaded 8 51 52 G Belt slips 34 33 31 10 4 30 H Belt slips on starting 34 31 33 30 42 43 1 Excessive belt stretch 12 35 32 43 J Grooving gouging or stripping of top cover 13 4 15 16 53 K Excessive top cover wear uniform around belt 19 20 10 8 36 L Severe pulley cover wear 4 9 10 17 1 27 M Longitudinal grooving or cracking of bottom cover 4 10 9 33 36 N Covers harden or crack 23 37 0 Cover swells in spots or strreaks 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 T Short breaks in carcass parallel to belt edge star breaks in carcass U Ply separation V Carcass fatigue at idler junction W Cover blisters or sand blisters X Belt Cupping Old Belt was OK when new 10 11 12 13 14 15 16 17 18 Index Page Conveyor System Problems Causes and Their Solutions Idlers or pulleys out of square with center line of belt readjust idlers in affected area Conveyor frame or structure crooked straighten in affected area Idler stands not centered on belt readjust idlers in affected area Sticki
107. irt Y Make sure all parts in perfect conditions Y Lubricate the surfaces ofthe endshield fittings with protective oil to make the assembly easier Y Use only rubber hammer to fit the parts v Check for correct bolts tightening Use clearance calibrator for correct T box fitting smaller than 0 05mm 2 DO NOT REUSE DAMAGED OR WORN PARTS THEM BY NEW 5 SUPPLIED BY N THE FACTORY MOTORS DRIVEN BY VFD Applications using VFD s without filter can affect motor performance as follows Lower efficiency Y Higher vibration Y Higher noise level Y Higher rated current Y Higher temperature rise Reduced motor insulation Reduced bearing life 1 Standard Motors v Voltages lower than 440V do not require filter Y Voltages equal or higher than 440V or lower than 575V require filter for motor power supply cables longer than 20 meters v Voltages equal or higher than 575V require filter for any size of power supply cables IF SUCH RECOMMENDATIONS ARE NOT AX N FOLLOWED ACCORDINGLY MOTOR WARRANTY WILL BE VOID 2 Inverter Duty Motors Y Check power supply voltage of the forced cooling set v 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
108. istribute 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 carpen ter 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 Index Page BELT 1 FOOT 1 FOOT 1 FOOT 1 FOOT END BELT CENTER LINE CUT LINE PX BELT END I 1 MARKING OF LINE AND OTHER RIGHT ANGLE GUIDE LINES An alternative method of squaring belt ends is called the double intersecting arc method First establish the center line as indicated previ ou
109. ithin the matrix of the belt carcass Accordingly the belt will shift on the crowned pul ley until these stressing forces are balanced and minimized centering the belt Experiment has shown that a crown is most effec tive 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 Index Page In most non unit handling conveyors this opti mum 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 pul leys 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 effect
110. ive the crown will be Snub pulleys can reduce effectiveness by 5096 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 diame ter 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 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 sim ply aligning the roll or rolls which are cock
111. ken into consideration during the design of the reducer Table 2 Oil Volumes Approximate Volume of Oil to Fill Reducer to Oil Level Plug Reducer Position A Position Position C Position D Position E Position F ae sw o s ec ou ec s e sm TXTIA TXT2A TXT3B TXT4B TXT5C TXT6A TXT9A TXT10A Oil quantity is approximate Service with lubricant until oil runs out of oil level hole Refer to Figure 1 for mounting positions US measure 1 quart 32 fluid ounces 94646 liters Conversion from quarts rounded values 1 2 1 2 1 2 1 2 5 8 Fea eve eve e rae rom om om win eve s n wae om om a reve 5 8 5 8 3 4 1 1 8 1 5 8 2 7 8 8 1 8 8 5 8 15 1 2 18 1 8 38 3 4 6 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 Consult Dodge for proper oil level for reducers equipped with backstops and which are mounted in either the C position or D position 3 Table 3 Oil Recommendations ISO Grades For Ambient Temperatures of 50 F to 125 F Refer to Notes below Output Torque Arm Reducer Size ISO Grades For Ambient Temperatures of 15 F to 60 F Refer to Notes below Output
112. l self trainers is a must Index Page ZFENNETR gt D UNLOP CONVEYOR BELTING AMERICAS 21 Laredo Drive Scottdale Georgia 30079 USA Phone 404 297 3170 ISO 9001 2000 Certified Fax 404 296 5165 www fennerdunlopamericas com 10 03 APPENDIX D FENNER gt DUNLOP CONVEYOR BELTING Conveyor Belt Maintenance ou 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 l Belt Shut Down and Empty 3 Belt Running Empty 4 Belt Running Loaded
113. leys at the take up area then deflector plates will have to be installed to deflect he build up away from the belt 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 prob lem 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 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 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 Index Page CONVEYOR INSPECTION FORM AND CHECKLIST Inspection Date Conveyor Number l Belt Shut down
114. lift and move the extensions off of the folding ramp wings 5 Once the ramp extensions are off the folding wings Operate the hydraulic LEFT RAMP and RIGHT RAMP levers in the Up direction to slightly raise the ramp wings 6 With the ramp wings slightly elevated position the ramp extensions so that they line up with the ramp wings 7 Operate the hydraulic LEFT RAMP and RIGHT RAMP levers in the Down position until the ramp wings and ramp extensions interlock DANGER THE AREA AROUND THE FOLDING RAMP WINGS MUST BE KEPT CLEAR OF PERSONNEL DURING THE OPERATION OF THE HYDRAULIC CONTROLS OR REMOTE CONTROLS IF EQUIPPED FAILURE TO DO SO CAN RESULT IN SERI OUS INJURY OR DEATH IT IS IMPORTANT THAT ANYONE OPERATING THE OPTIONAL REMOTE CONTROL HAVE LINE OF SIGHT VISION TO AREA UNDER NEATH RAMP WINGS CONVEYOR PREPARATION Prior to running your conveyor for the first time perform the following tasks e Confirm that all shipping brackets and straps have been removed and that there are no obstructions to impede the operation of the conveyor belt e Always track belts prior to running material belts may need to be adjusted once material starts running See Appendix C 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 e Check all conveyor flashing
115. lowing 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 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 ta
116. lting has been transported to the point of installation it should be mounted on a suitable shaft for unrolling and threading onto the conveyor Conveyor belt ing 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 Left Temporary flat roll at bend point Below Threading through return strand Note Temporary flat roll at bend point as roll is pulled onto troughing idlers 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 condi tions is to lay the roll on a turntable with a vertical spindle Index Page ZFENNETR gt D UNLOP CONVEYOR BELTING AMERICAS 21 Laredo Drive Scottdale Georgia 30079 USA Phone 404 297 3170 ISO 9001 2000 Certified Fax 404 296 5165 www fennerdunlopamericas com 10 03 APPENDIX B Installing Flexco Bolt Solid Plate Instructions
117. ly 60 Straight Bore Hub amp Taper Bore Hub 9 62 Output Gear 64 Output Gear Key 8 amp 68 Output Hub Collar Straight Bore 70 Output Hub Collar Screw 2 7 Bushing Backup Plate Taper Bore 74 Output Hub Retaining Ring 76 Output Hub Seal Carrier Input Side Output Hub Bearing Kit 1 80 Output Hub Bearing Cone 81 Output Hub Bearing Cup 82 Output Hub Bearing Shim Kit 402054 402256 402057 402109 402232 403159 403053 403143 403078 402231 402052 402256 402148 402109 402232 403142 403053 403106 403078 402231 246185 247194 248223 249225 272251 391165 390429 391182 390168 390575 390935 390941 390944 390949 390954 390988 390990 390993 390159 390160 246338 247338 248332 250090 250008 246269 272137 272036 249140 272241 246295 247215 248215 021764 250007 245217 245217 248217 443413 250017 246309 247309 248209 249209 250009 400154 400190 400190 400194 400194 246270 272138 272037 272082 272242 421055 421099 421098 421097 421069 246187 247315 258021 249221 250011 402050 402058 402147 402160 402168 403140 403111 403105 403110 403116 391187 390044 390048 390171 390172 18 Parts for TXT6A thru TXT10A Straight and Tapered Bushed double Reduction Reducers mt ponm na na mmm n 84 Taper Bore Bushing Assembly Bushing 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
118. me 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 com pounds 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 expo sure 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 pre ferred 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 materials acids and chemicals are also stored or used
119. ment 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 ta
120. ments 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 All pulleys snub rollers carrying idlers and return idlers must be square with the frame perpendicu lar 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 cen ter line Crowns Crowned pulleys for lightweight conveyor belt can be trapezoidal or radial shaped Georgia Duck has products to accommodate both styles howev er 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 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 Remember for crowns to be effective there must b
121. mp Makes up assembly under which it is listed Includes parts listed immediately below marked Makes up assembly under which it is listed 6 See Table 9 for actual ratio Required only with optional backstop 1 required on TXT6A and TXT7A 2 required on TXT8A TXT9A amp TXT10A 2 sets recommended 18 Required on TXT6A 20 Required on TXT7A and 24 Required on TXT8A TXT9A amp TXT10A 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 19 ACTUAL RATIOS Table 9 Actual Ratios Nominal Ratios Reducer Size 771 TXT9A is 26 1 Nominal Ratio and TXT10A is 24 1 Nominal Ratio BALDOR 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 1 10 0 3 1 www baldor com Baldor Electric Company MN1610 Replaces 499304 All Rights Reserved Printed in USA 3 10 FARR 25 000 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
122. mpleteness 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 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 It is important to note at this point that virtually any adjustment you make to these rolls will be slight 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 G the snubber pulley Roll 7 will not be very effective for tracking pur poses because of the short unsupported belt span but can be a problem camber wise if it is not per pendicular to the belt center line This pulley should be square and left there The take up pulley 8 does have potential for tracking as well as for camber due to
123. nable amount of tracking force on the belt because of the unsupported belt span preceding it but it can also exert a consider able 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 cen tering 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 bett 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 proximi ty of roll 11 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 adjust
124. nd run empty The purpose of this is to walk the con veyor 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 condi tions 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 Ill 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 Index Page 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 l 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 Traine
125. nd 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 24 20 ES 34 07 2 mis BUN i 13 6 to 3 Type E Bearing vw L LA Parts for 13 16 to 3 Type E Bearing NOTE The two digit numbers are for reference only Order parts by the six digit numbers in the Parts List Each six digit number is a complete identifi cation of the part or assembly Piloted Bearing Only Required for One Assembly Part Number for Various Shaft Sizes Piloted Refer Pillow Flange Flange Take Up 11 2 15 8 13 4 17 8 21 4 27 16 21 16 23 4 ence Name of Part Block Bearing Bearing Bearing 1 3 16 11 4 13 8 17 16 111 16 115 16 2 23 16 21 2 215 16 3 12 Cup 2 2 2 2 390748 390751 390755 403006 390762 390766 390771 14 Drive Collar 2 2 1 2 060944 040050 040051 040052 040053 040054 040055 Adjustment 1 1 1 1 16 391101 1102 1 1 1 Shim Pack sett Seti Seti Seti 01 391102 391103 391104 391105 391106 391107 Toos Thick Shim t t t t 427070 427071 427072 427073 427074 427075 427076 006 Thick Shim t t t 427080 427081 427082 427083 427084 427085 427086 015 Thick Sh
126. nd 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 Insulation Resistance Check 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 F must be Ri gt 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 v Warm it up inside an oven at a minimum temperature of 80 C 176 F increasing 5 C 41 F every hour until 105 C 221 F remaining under this temperature for at least one hour Check ifthe 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 5 ANY Ce MAI
127. ndex Page 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 l 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 Head Pulley cleaner or scraper operational lt Head Pulley Snub clean Return ldlers clean 8 turning freely P Bend Pulleys clean Take Up clean 2 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 and shut down Numerous items in the preceding list contained the woras 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 dam age pulley damage and tracking problems will result if these accessory pieces of hardware are not maintained li Belt Running Empty The conveyor should be turned on a
128. nditions 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 partot e driven equipment beyond the speed reducer output shaft 4 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 increments to the torque specified in Table 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 o
129. ner ring and press bottom outer ring and inner ring assembly from housing 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 CLEARANCE SHAFT SIZE INCHES ADJUSTMENT INCHES Twist Lock 3000 Series REXNORD Hever PRAGA 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 Position bearings on the shaft applying the driving pressure to the face of the inner ring 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 Bolt housing securely to mounting base 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
130. nformation 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 REASSEMBLY RELUBRICATION Bearings should be re lubricated at regular intervals The frequency and Place housing cover side up on arbor press with spacer blocks under amount of lubricant will be determined by the type of service General housing guidelines for re lubrication frequency and amount are based upon average Press in back outer ring and seat against housing shoulder application conditions See LUBRICATION TABLE Insert inner ring assembly and rotate to seat rollers against back outer ring At High temperatures greases tend to degrade more rapidly and thus Press in front outer ring require fresh grease more frequently In general small amounts of grease Install threaded cover turning clockwise u
131. ng apparent excessive belt stretch pull belt through counterweight with a tension equal to at least empty running tension run belt in with mechanical fasteners Improper initial positioning of counterweight in its carriage causing apparent excessive belt stretch check with Georgia Duck for recommended initial position Insufficient counterweight travel consult Georgia Duck for recommended minimum distances Structure not level level structure in affected area 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 Worn edge press edge Interference from belt scrapers adjust belt scrapers Tension too high for fasteners use vulcanized splice Belt carcass too light select stronger carcass Belt misalignment see training recommendations Variations in nature and formation of load use notched chute to keep load peak in exact center of belt Belt not making good contact with all idlers adjust height so all idlers contact belt Sharp edges of material or tramp iron coming in contact with cover use jingle bars impact idlers magnetic removal equipment Index Page ZFENNETR gt D UNLOP CONVEYOR BELTING AMERICAS 21 Laredo Drive Scottdale Georgia 30079 USA Phone 404 297 3170 ISO 9001 2000 Certified Fax 404 296 5165 www fennerdunlopamericas com 10 03 APPENDIX F TORQUE ARM Shaft Mount Sp
132. ng idlers free idlers and improve maintenance and lubrication Build up of material on idlers remove accumulation improve maintenance Install scrapers or other cleaning devices Belt not joined squarely remove affected splice and resplice 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 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 Slippage on drive pulley increase tension through screw take up or add counterweight lag drive pulley increase arc of contact Material spillage and build up improve loading and transfer conditions install cleaning devices improve maintenance Bolt heads protruding above lagging tighten bolts replace lagging use vulcanized on lagging 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 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 Load jams in chute redesign chute for proper angle and width Material hanging up in or under ch
133. ntil inner ring resists rotation or added frequently provide better lubrication Most grease will eventually misalignment harden causing re lubrication to become less effective When this occurs Back off threaded cover one quarter turn align cover slot with the the bearing should be disassembled cleaned and lubricated per nearest counter bored hole in housing See ADJUSTMENT TABLE LUBRICATION TABLE When equipment will not be in operation for some Install microlock key with nylon washer under the head of the screw time grease should be added to provide corrosion protection This is Using a soft drift or block rap face of inner ring on side opposite particularly important for equipment exposed to severe weather threaded cover to seat front outer ring Inner ring assembly should AUTOMATIC LUBRICATION SYSTEMS rotate freely MN m A variety of automatic re lubrication systems are available for use with Install seals Z Seal Place centering spring in seal groove with fingers roller bearings Key considerations are facing up Place U shaped element on fingers Place centering ring on 1 NLGI grade of grease used consistent with system layout element with projection on face up Install snap ring so that projection on 2 An amount frequency combination necessary to replenish the grease centering ring is between ends of snap ring K Seal Place seal into the MIXING OF GREASES seal groove with anti rotation boss sticking up Install snap rin
134. nveyor if for any reason the MAGNUM would stop operation this function would stop the Truck Unloader to keep it from dumping material onto the MAGNUM In manual mode this func tion would be the responsibility of the operator Ramps mode This switch has two 2 positions Manual and Timed The manual position allows the operator to lower or raise the ramps with the hydraulic hand levers located left of the panel In the timed position the ramps will lower or raise in accordance with the program set by the operator 6 Ramps determination This switch has three 3 positions Left Both and Right These different positions allow the operator to choose how to lower or raise the ramps 7 Ramps direction This switch has two 2 positions up and down It allows the operator to move the ramps in the desired direction 8 Conveyor This switch has two 2 positions up and down It allows the operator to raise or lower the slip tube to change the height of material discharge RAISING AND LOWERING THE DISCHARGE CONVEYOR The discharge conveyor on your Truck Unloader can be raised or lowered by use either of two 2 onboard systems 1 The electrical panel has a switch shown above that operates the conveyor up or down Turn the Master switch to the on position pull the Hydraulic Unit button switch to start and oper ate the Conveyor switch in the desired direction 2 If you purchased the optional gas powered mot
135. 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 8 2A Straight and Tapered Bushed Double Reduction Reducers STRAIGHT BORE 41 62 20 22 59 80 78 90 84 7 74 72 54 44 52 ad 42 11 60 64 TAPER BORE 48 25 50 46 34 38 36 112 122 120 BACKSTOP ASSEMBLY Parts for TXT HXT 1A amp 2A Straight and Tapered Bushed Double Reduction Reducers Backstop Assembly 242101 252101 Housing LH 241358 242353 Housing RH 241359 242354 Housing RH Flange Mount Drilled 241387 242393 Housing Hydroil LH 241064 242067 RTV Sealant Tube 465044 465044 Air Vent 900287 900287 Housing Bolt 411418 411418 Housing Bolt Adapter 411420 411420 Lock Washer 419011 419011 Hex Nut 407087 407087 Dowel Pin 420145 420145 Magnetic Oil Plug 430060 430060 Oil Plug 430031 430031 Backstop Shaft Cover 242221 243221 Backstop Cover Screw 415022 415022 Seal Kit 392119 392120 Backstop Cover Gasket 242220 243220 Input Oil Seal 241457 242211 Output Hub Oil Seal amp 241210 242210 Input Pinion 9 1 Ratio amp 15 1 Ratio
136. or start the motor and locate the hydraulic hand lever labeled conveyor Operate this lever in the desired direction As the slip tube raises or lowers watch for adjustment holes in the undercarriage Stop the slip tube when the holes appear at the desired discharge height Insert the supplied retention pins into the undercarriage holes to secure the slip tube Failure to insert slip tube retention pins properly can result in conveyor damage and possi ble injury IMPORTANT When inserting the slip tube retention pins it is important that the tab on the pin faces awa from the raised slip tube as indicated below Do not use the pin tab to get more height tube damage may result CONTROLLING THE VOLUME OF MATERIAL DISCHARGE Your Low Profile Truck Unloader is equipped with a gating mechanism that can be used to con trol the volume of material discharge To change the volume of discharge turn the crank handle shown below to either raise or lower the gate shown on the right until desired volume is achieved APPENDIX A PENNE Ft gt D UNLOP CONVEYOR BELTING Conveyor Belt Storage and Installation Index Page Conveyor Belt Storage and Installation
137. 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 unsup ported 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 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 impart ing the camber to the belt in this section If it is necessary to adjust roll 2 to an off perpen dicular 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 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 co
138. ously or at high temperatures or under conditions of extreme dirt or dust Use only recom mended lubricants listed on this page or equivalent Special attention should be given to checking of lubri cants when any of the following conditions exist 1 High operating temperatures resulting from heavy intermittent loads causing the temperature of the gear case to rise rapidly and then cool 2 Unusual ambient conditions which may tend to cause condensation on the inside of the gear case thereby contaminating the oil 3 Operating temperatures that would cause oil to approach 200 F continually 4 Subjection of reducer to unusual vapors or moist atmosphere 5 Subjection of reducer to extremely dusty or dirty environment Under these extreme operating conditions the oil should be changed every 1 to 3 months depending on severity of conditions Operating Temperatures Heating is a naturai characteristic of enclosed gearing and a maximum gear case temperature approaching 200 F is not uncommon for some units operating in normal ambient temperatures 80 F When operating at rated capacity no damage will result from this tempera ture as this was taken into consideration in the design of the gear case and in the selection of the lubricants Horizontal Installations Install the magnetic drain plug in the hole closest to the bottom of the reducer Throw away the tape that covers the filler ventilation plug in shipment and inst
139. outer ring OD is spherical and swivels in the housing to accommodate misalignment Snug holddown bolts and use shaft to swivel each bearing until its final 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 blocks and radial loads for flange units 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 co
140. p 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 failsaf
141. posure 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 Section IX Physical Chemical Characteristics Boiling Point deg F n a Specific Gravity 2 1 876 Vapor Pressure mm Hg n a Melting Point deg F ND Vapor Density Air 1 n a Solubility in Water insoluble Evaporation Rate n butyl Acetate 1 n a APPEARANCE AND ODOR Light amber liquid mild petroleum odor Section X Reactivity Data STABILITY Stable INCOMPATIBILITY MATERIALS TO AVOID Strong oxidants such as liquid chlorine concentrated oxygen sodium hypochlorite or c
142. r 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 spe cial 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 repre sentatives 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
143. rfectly 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 Maximum Deviation Inches a E Camber 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 Skew Bow The fill yarns weft yarns in the belt carcass will usually lie along the perpendicular to the belt cen ter line Any deviation from this perpendicular line by the fill yarn is hereby
144. rings should not be secured to the and sleeve on the shaft Then shut down the system and retighten locknuts shaft at this time Alternate torquing the screws to prevent on all bearings 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 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 The remainder of the installation is the same as Fixed units following steps 2 3 4 5 and 6 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 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
145. rmit full movement of the cartridge in direction of expansion The remainder of the installation is the same as Fixed units following steps 3 4 and 5 noon SET SCREW TORQUE TABLE Shaft Size Inches i N Normal Duty Heavy Duty Set Screw Size n 2000 5000 SAL ken 3 4 1 1 4 5 16 185 T 1746 2 17 16 1 15 16 3 8 325 1 Housing 23 16 21 4 2 23 16 7 16 460 2 Inner 23 8 3 1 2 27 16 3 7 16 1 2 680 4 31116 4 31116 57716 5 8 1350 3 2 5 15 16 7 3 4 1600 A 4 Microlock SHAFT TOLERANCE TABLE INCHES Assembly Nominal Commercial Shaft RECOMMENDED SHAFT TOLERANCES 5 Shaft 52 Set Gellar Mounting Adapter Press Fit ie 6 Cartridge sizes Loading or Mounting Mounting 7 Roller High Speed 8 Outer Ring 1 2 000 003 000 001 000 003 9 Set Collar 2 4 000 004 000 001 000 004 Consult 4 6 000 005 000 0015 000 005 Rexnord 6 8 000 006 000 0015 000 005 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 REXN RD Mounted Roller Bearings Bearing Replacement and Maintenance Instructions See other side for installation instructions DISASSEMBLY LUBRICATION INSTRUCTIONS GENERAL INFORMATION AND SELECTION This i
146. rod ucts 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 Index Page 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 wil n 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 prod uct 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 rub ber vulcanized to the pulley The constant flex ing 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 sug gested to use heavier walled return bend pul leys when using a scraper If a scraper is applied to a head snub or bend pul
147. rs 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 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 track ing 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 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 carry back A water spray on the belt cover along with wiper blades will effectively remove most p
148. s will damage the bearings and lead to a probable shaft rupture 8 Connection WARNING oltage be connected at standstill inside the terminal box for heating elements or direct winding heating WARNING The capacitor on single phase motors can retain a charge which appears across the motor terminals even when the motor has reached standstill A A WRONG CONNECTION CAN BURN THE YN MOTOR Voltage and connection are indicated on the nameplate The acceptable voltage variation is 1096 the acceptable frequency variation is 596 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 v 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 Y 6lead 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
149. s the bearing insert should be posi tioned in the center of the housing To center bearing insert in housing move bearing insert to extreme posi tion and mark shaft Then using bearing maximum total expansion table move bearing insert in opposite direc tion 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 TOTAL SHAFT SIZE EXPANSION in in 13 8 11 2 3 16 111 16 37 16 1 4 315 16 5 16 47 16 415 16 3 8 WARNING Because of the possible danger to persons s or property from accidents which may result from the improper u
150. se 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 Self training idlers do not work when placed too close to a terminal pulley snub bend or take up These pul leys 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 take up is 80 behind the head place one self trainer
151. se 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 LUBRICATION 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 amp 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 al
152. se 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 t
153. sly 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 ALTERNATIVE ARC METHOD OF SQUARING ENDS JOINING OF THE POINTS WHERE THE ARCS INTERSECT GIVES THE RIGHT ANGLE CUT LINE Index Page Double Check Squareness 3 A 5 N AY p M M pi S ou S gt CUT LINE me ee ee ZON 7 M M M M M M M C 5 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 It is always a good idea to double check the accu racy of the squared and cut end Measure 5 feet along each edge from the end of
154. ssembly it is advisable to order replacements for these parts 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 Taper Bushed Reducer 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 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 o
155. ssesses the rights of a secured party under the Uniform Commercial Code Upon Seller s request Buyer shall execute all necessary financ ing statements and other documents evidencing this security interest with the appropriate sate and local authorities Seller is entitled to and is hereby granted rea sonable access to Buyer s locations as necessary to exercise its remedies as a secured party 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 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 NOTICES Any notices consents or other communications required or permitted under this Contract must be in writing an
156. stall backstop cover Make sure all bolts are tightened to the correct torque values listed in Table 6 Table 5 Bearing Adjustment Tolerances Bearing Endplay Values Reducer Size TXT3B 002 004 Loose 0005 003 Loose 0005 003 Loose Replacement Part and Kit Numbers Bearings Double Reduction Reducers Size Part Number Size Part Number Size Part Number Size Part Number TXT5C 402203 403027 TXT6A 402054 403159 TXT7A 402256 403053 TXT8A 402057 403143 TXT9A 402109 403078 Note Bearing part numbers refer to Cup Cone combinations respectively TXT10A 402232 402231 and apply to all ratios unless otherwise specified For actual reducer ratios refer to Table 9 Size Part Number Table 8 Replacement Parts Kit Numbers e pe e 92000 TXTIA 392119 390878 390151 389905 All 3900 2 053 O 392120 392111 392110 392000 389906 All 2 1 3909 389720 389703 389702 3870 392345 All 1 389721 389710 389709 L E 392347 All 2 389722 389717 389716 39740 392350 All 389715 246340 390935 390988 335368 All 391186 247345 390941 390990 392353 All 391184 caw EC EM wee All 391185 390124 249340 390949 390159 392357 All 390139 390983 272460 390954 390160 392359 All 390998 Notes Seal Kit consists of Input Seal Output Seals Backstop Cover Gasket and RTV Sealant Output Hub Assembly consists
157. t and Tapered Bushed Double Reduction Reducer m TXT3B TXT4B TXT5C 12 Backstop Assembly 243106 244106 245154 Housing TXT and Hydroil LH 243228 244365 245369 Housing RH 243229 244366 245370 Housing RH Flange Mount Drilled 243384 244387 245373 RTV Sealant Tube 465044 465044 465044 Air Vent 900287 900287 904287 Housing Bolt 411440 411442 411464 Housing Bolt Adapter 411442 411444 411466 Lock Washer 419012 419012 419013 Hex Nut 407089 407089 407091 Dowel Pin 420146 420146 420147 Magnetic Oil Plug 430060 430060 430062 Oil Plug 430031 430031 430033 Input Shaft Seal Carrier 243543 244577 245597 Input Shaft Bearing Shim Pack 389704 389711 389732 Input Seal Carrier Screw 411390 411407 411407 Lock Washer 419010 419011 419011 Backstop Cover 243560 244493 245226 Backstop Shaft Cover 416524 411035 411394 Backstop Cover Screw N A N A 419009 Seal Kit 389720 389721 389722 Backstop Cover Gasket 243561 244593 245220 Input Pinion Shaft Seal 243558 244524 355011 Output Hub Oil Seal 243578 244673 245545 Input Pinion 9 1 Ratio 15 1 Ratio 25 1 Ratio 15 1 Ratio Hydroil Pinion 25 1 Ratio Hydroil Pinion 15 1 Ratio Hydroil 6 B Pinion 25 1 Ratio Hydroil 6 B Pinion n Input Pinion Shaft Key Input Bearing Kit amp 44 Input Shaft Bearing Cone Input Side 45 Input Shaft Bearing Cup Input Side 46 Input Shaft Bearing Cone Backstop Side 47 Input Shaft Bearing Cup Backstop Side Countershaft Pinion Ass
158. t 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 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 CHECKSFORREPLACEMENT 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 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
159. t the bearing will take for a particular high speed application can only be determined by experience see Operating Temperature below If excess grease in the bearing caused overheating it will be necessary to remove grease fitting also drain plug when furnished to permit excess grease to escape The bearing has been greased at the factory and is ready to run When estab lishing a relubrication schedule note that a small amount of grease at frequent intervals is preferable to a large amount at infrequent intervals Operation in Presence of Dust Water or Corrosive Vapors Under these conditions the bearing should contain as much grease as speed will permit since a full bearing with consequent slight leakage is the best protection against entrance of foreign material In the higher speed ranges too much grease will cause overheating see High Speed Operation In the lower speed ranges it is advisable to add extra grease to a new bearing be fore putting into operation Bearings should be greased as often as necessary daily if required to maintain a slight leakage at the seals Average Operation This bearing has been greased at the factory and is ready to run The following table is a general guide for relubrication However certain conditions may require a change of lubricating periods as dictated by experience See High Speed Operation and Operating in Presence of Dust Water or Corrosive Vapors Opera
160. th 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 ten sion 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 estab lish and are adjusted by trial methods until slip page is avoided They are unable to compensate for any length changes in the belt between adjust ments and thus permit wide variation in belt ten sion 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 ten sion is applied to the pulley the pulley remains at right angles to the direction of belt travel Also the Index Page 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 ali
161. the belt then utilizing a tape measure check the two diagonals They should be equal and further should intersect on the belt center line Index Page Ill 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 run ning 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 b
162. 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 Socket Set Screw Tightening Shaft Size Size Torque 13 8 13 4 inches 5 16 inches 165 Inch Pounds 1115 16 27 16 inches 3 8 inches 290 Inch Pounds 1211 16 37 16 inches 1 2 inches 620 Inch Pounds 1315 16 415 16 inches 5 8 inches 1325 Inch Pounds RECOMMENDED SHAFT TOLERANCE TABLE Low to Normal Equivalent 1to 251 501 751 to 1001 to 1501 to 2001 to 2501 to 250 500 750 1000 1500 2000 2500 3000 rpm rpm rpm rpm rpm rpm rpm rpm Normal Load and Catalog Shaft Size Speed Up to 11 2 inches 000 inches 0005 inches O
163. 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 HORIZONTAL APPLICATIONS B B B D 5 D 5 Position Position Position Position D B Breather D Drain L Level P Plug VERTICAL MOUNT L D D Position E Position F Figure 1 Mounting Positions 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
164. the unsup ported belt span between itself and rolls 7 and 9 If however we adjust roll 8 so it is off perpendicu lar 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 per pendicular to the belt center line Unfortunately this Index Page L JA9NDIJ HOA3ANOO TVWOLLJHLOdAH ONIMOVuL 8 8 NNd 1 TAAVYEL 1148 NNA 9NIAHHVO 13 may not always be possible since roll 8 is a take up 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 B 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 Roll 9 can exert a reaso
165. thod can be used Each individual idler stand can be tilted in the line of travel by placing a wash er under the rear legs of the idler stand This for ward 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 exces sive 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 Maximum Direction of travel Washer Top idler stand Feeder Belts Short centered feeder belts should be double checked for squareness with a steel tape The two terminal pulleys need to be parallel level and square 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 Index Page 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 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 driv
166. ting Temperature Abnormal bearing temperature may indicate faulty lubrication Norma temperature may range from cool to warm to the touch up to a point too hot to touch for more than a few seconds depending on bearing size and speed and surrounding conditions Unusually high temperature accompa nied by excessive leakage of grease indicates too much grease High temperature with no grease showing at the seals particularly if the bearing seems noisy usually indicates too little grease Normal temperature anda slight showing of grease at the seals indicate proper lubrication 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 9 bearings have been lubricated at the factory with No 2 consistency lithium com plex base grease which is suitable for normal operating condi tions 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 Special Operating Conditions Refer acid chemical extreme or other special operating conditions to DODGE Reliance Electric industrial Company Greenville S C TABLE 1 Lubrication Guide Set Screw Torque Table Read Preceding Paragraphs Before Establishing Lubri
167. tion 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 Ifovercome 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 gt 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 fire exposed 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 Ex
168. to make sure it is in the proper position and fully tightened to reduce spillage Check V Belts on belt drive for proper tensioning Check Belt Cleaner for proper tensioning CONVEYOR OPERATION There are two ways to operate your Low Profile Truck Unloader 1 You can operate your Truck Unloader through the use of the Main Electrical Panel and the various switches included on it 2 If you purchased your Truck Unloader with the optional gas powered motor you can operate it using that motor and the appropriately labeled hand valves The number of hand valves may vary depending on the configuration you ordered If you ordered hydraulic landing legs your valve bank will include two 2 extra hand valves IDENTIFYING THE OPERATIONAL ELECTRICAL PANEL There are several switches that control the operation of your Low Profile Truck Uloader They are identified as follows 1 Main Power This switch is has two 2 positions on and off Turn it to the on position to power all other switches on the panel 2 Conveyor Pull this button switch to start the conveyor belt in motion Push this button switch to stop conveyor belt motion 3 Hydraulic Unit Pull this button switch to start the hydraulic pump Push this button switch to stop the hydraulic unit 4 Magnum Interlock This switch has three 3 positions Manual Off and Automatic In automatic mode when your Truck Unloader is conveying material to a MAGNUM Co
169. ue 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 IMPL
170. uld 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 When ordering parts for a Dodge Torque Arm reducer specify reducer part number part name and quantity required 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 disa
171. units are prelubricated at the factory with multipurpose lithium soap grease No additional grease is required at time of installation 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 If spacer shims are used for alignment they must cover the entire housing base Spot drill or mill flats on shaft for increased holding power of set screws or ease of removal When a eccentric load condition exists position set screws directly opposite from eccentric weight 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 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 begins to twist Rotate the shaft under power to permit the remaining bearings to Seek their natural running position on the shaft Shut off the power and torque down set screws in remaining bearings using procedure in Step 5 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 pe
172. 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 connec tion 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 Com ponent 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
173. ute improve loading to reduce spillage install baffles widen chute Impact of material on belt reduce impact by improving chute design install impact idlers or impact bed Material trapped between belt and pulley install plows or scrapers on return run ahead of tail pulley Belt edges folding up on structure same corrections as for 1 2 3 install limit switches provide more clearance 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Index Page Dirty stuck or misaligned return rolls remove accumulations install cleaning devices use self cleaning return rolls improve maintenance and lubrication Cover quality too low replace with belt of heavier cover gauge or higher quality rubber or other elastomer Spilled oil or grease over lubrication of idlers improve housekeeping reduce quantity of grease used check grease seals Wrong type of fastener fasteners too tight or too loose use proper fastener and splice technique set up schedule for regular fastener inspection Heat or chemical damage use belt designed for specific condition Fastener plates too long for pulley size replace with smaller fasteners increase pulley size Improper transition between troughed belt and terminal pulleys adjust transition in accordance with Georgia Duck Belting Catalog Severe convex hump vertical curve decrease idler spa
174. utput hub 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 TXT Reassembly 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 Countershaft Assembly Heat gear to 325 F to 350 F and bearings to 270 F to 290 F to shrink onto shaft Input Shaft Assembly Heat bearings 270 F to 290 F to shrink onto shaft Press bearings on shaft Drive the two dowel pins into place in the right hand housing half backstop side Place R H housing half on blocks to allow for protruding end of output hub Install all bearing cups on
175. ver 11 2 to 21 2 inches 000 inches 001 inches Over 21 2 to 4 inches 000 inches 001 inches Over 4 to 5 inches 4 000 inches 0015 inches 12 10 7 5 5 3 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 2 BOLT PILLOW 2 BOLT PILLOW 4 BOLT PILLOW 4 BOLT PILLOW BLOCK S2000 R BLOCK S2000 L BLOCK S2000 R BLOCK S2000 L 3 amp 4 BOLT ROUND 38 4 BOLT ROUND 4 BOLT SQUARE 4 BOLT SQUARE FLANGE S2000 R FLANGE S2000 L FLANGE 2000 R FLANGE S2000 L PILOTED FLANGE PILOTED FLANGE WIDE SLOT TAKE UP TPHU TAKE UP 2000 R 2000 L 2000 R 2000 R COMPONENT PART NUMBERS 1 3 8 4 15 16 tA 2 3 4 5 Shaft Size Bearing Insert Assembly Bearing Insert Assembly Collar Snap Grease cu E sew ig rng 070000 070016 040050 400058 069276 405015 070001 070017 040050 400058 069276 405015 070002 070018 040050 400058 069276 405015 111 16 070003 070019 040051 400058 069277 405015 1 15 1
176. xes 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 pro vided however Seller shall not be responsible for any delays in delivery WARRANTY Limited Warranty Exclusion of Third Party Components Subject to the terms conditions and limitations contained herein Seller warrants only to the orig inal Buyer that a Seller s new equipment products and Seller s new component products will not fail to operate in accordance with their respective specifica tions d

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