DIMISA

DIMISA
September 12, 2005 M3 Engineering And Technology Corporation. P.O. No. 02209-G-001 Quotation DIMISA No. 1179-03
M3 ENGINEERING AND TECHNOLOGY CORPORATION
INSTALLATION, OPERATION AND MAINTENANCE MANUAL MULATOS GOLD PROJECT
MONTERREY, MXICO, SEPTEMBER 2005
DISEO DE MAQUINAS INDUSTRIALES, S.A. DE C.V.

Prol. Ruiz Cortines 444 Ote., Parque Industrial San Rafael Monterrey, Nuevo Len, Mxico
www.dimisa.com Tel +52 (81) 8131 0000 Fa x +5 2 (8 1 ) 8 3 6 4 6 1 0 0 conveyors@dimisa.com
DIMISA
CONTENTS
SECTION
1.2.3.4.5.6.7.INTRODUCTION. CONVEYOR INSTALLATION. CONVEYOR OPERATION. MAINTENANCE. TROUBLESHOOTING. SYNOPTIC SUMMARY OF CONVEYOR COMPONENTS. COMMERCIAL EQUIPMENT MANUFACTURERS RECOMMENDATIONS FOR THE INSTALLATION AND MAINTENANCE OF THEIR EQUIPMENT. 7.1 Pillow Blocks, SKF 7.1.1 7.2 7.3 SNL type.
Idlers by DIMISA, ANTI-DUST type. Reducers. 7.3.1 Reducers, FALK
7.4
Safety Devices, Conveyor Components Co. 7.4.1 7.4.2 7.4.3 7.4.4 Emergency stop switch, RS-2X type. Emergency stop switch, TA-2X type. Plugged Chute swith, CT-101 type. Speed switch TELEMECANIQUE, XSA type.
7.5 7.6
Belt conveyors, CONTITECH type. Belt Scrapers, MARTIN 7.6.1 7.6.2 Cleaner MARTIN, PRIMARY type. Cleaner MARTIN, SECONDARY type.
7.7 7.8
B-LOC, Keyless Locking Devices. Flexible Couplings FALK. 7.8.1 7.8.2 Coupling MCF 1090 type. Coupling T-10.
7.9 7.10
AC Induction Motors, GE Back Stop FALK

DIMISA
8. DIMISA REFERENCE DRAWINGS. 8.1 8.2 Belt Conveyor TB- 15-30-07 STD Project

DIMISA
I.
INTRODUCTION
Belt conveyors are relatively simple mechanical equipment regarding their installation, operation and maintenance. Consequently, this manual was prepared to serve as a practical guide to achieve these objectives. In the corresponding sections of this Manual, one can find the instructions for the correct conveyor installation, initial startup with minimal problems, and for the normal conveyor operation with practically no corrective maintenance required. For the components not manufactured by DIMISA, the manufacturers instructions are provided for their instalation, startup, operation, and maintenance.

DIMISA
II. INSTALLATION
2.1 SHIPMENT ACCEPTANCE AND INSPECTION Upon shipment delivery, it is important to inspect all the conveyor sections and their components such as motors, speed reducers, brakes, belting, etc., to assure of no damage during the conveyor transportation and unloading operations. The different conveyor sections, including the structural members, should be identified according to their part number or their piece number indicated in the drawings. A good practice is to closely group the conveyor sections and components according to their installation sequence. A bill of materials is shown in the DIMISA General Arrangement drawings for each of the belt conveyors. This bill of materials includes the identification numbers, or Tag, for the conveyor components and the supporting structures. The DIMISA Reference Drawings can be found in the last section of this Manual. The conveyor components found with damage must be repaired before proceeding with their installation, especially the structural components. 2.2 GENERAL CONSIDERATIONS FOR THE INSTALLATION OF SUPPORT STRUCTURES Before initializing the erection of structural components, verify that the area is completely clear, and that the foundations and anchor bolts are in place and finished to the elevations indicated in the drawings. The verification of the elevations and work points will permit estimating the required rework, in case they do not match with the drawings. In general, the belt conveyors can be of the following types: a) b) c) or d) 2.2.1 Horizontal conveyors, or parallel to grade level, supported by structural tables (stringers) and legs. Inclined conveyors supported by a truss structure or galleries. Inclined conveyors supported by structural tables (stringers) and legs, and truss structures galleries. Inclined conveyors are generally provided with intermediate structural supports (bents). CONVEYOR ORIENTATION The conveyor section, or its supporting structure, should be verified of their orientation and elevations as indicated on the drawings. 2.2.2 TRANSVERSAL LEVELING It is very important that the conveyor structure be plumb and transversally level to facilitate the alignment of the belt. 2.2.3 VERTICAL LEVELING The correct vertical alignment and elevation level of the conveyor structures is very important.

DIMISA
Unleveled structures or differences in their elevations can cause belt impacts and material build-up on the Idlers (during conveyor operation) making difficult the alignment of the belt 2.2.4 LONGITUDINAL ALIGNMENT The conveyor longitudinal alignment serves to verify the reference points. For long conveyors, topographical measurements are taken to establish and verify their coordinates as indicated on the drawings. 2.3 INSTALATION OF THE DIFFERENT CONVEYOR STRUCTURES 2.3.1 STRINGERS AND LEGS In general, the DIMISA conveyor stringers are of standard design lengths, thus allowing their installation interchangeability in practically any point along the conveyor trajectory. The conveyor stringers of special lengths are clearly identified in the drawings for their correct location and installation. For the stringers of special conveyor sections, the tag number of their support legs should be verified; these support legs are uniquely dimensioned to obtain the design belt trajectory. Each support leg has a welded base plate provided with a mounting hole so they can be secured to the floor by means of specified anchor bolts - once the vertical and transversal leveling, and the longitudinal alignment has been accomplished. The DIMISA design permits some adjustments to obtain the required conveyor leveling. 2.3.2 VERTICAL STRUCTURAL SUPPORTS (BENTS) The conveyor vertical supports -bents- are generally delivered in unassembled sections, are clearly identified by tag numbers for assembly according to the drawings, and should be bolted together before installation. These supports have welded base plates provided with mounting holes for securing them to the anchor bolts imbedded in the concrete foundation. The vertical and horizontal leveling of these supports should be verified by topographical measurements and compared with the reference drawings. 2.3.3 SUPPORT STRUCTURES TRUSS TYPE, AND WALKWAYS The stringers and truss structures supporting the conveyors are shipped in sections 12 to 15 meters long, and occasionally up to 18 meters if permitted by the freight carrier. The truss structures are generally provided with a lateral walkway and sometimes with two walkways. The walkway structures are shipped separate for field bolting installation. The support members for the walkway and handrails are first bolted to the truss structure, and then the walkway structure and the handrail system are installed. The joining of truss structure sections is generally by bolt connections, and when requested by the Client they can be field welded, once the leveling and alignment has been verified. Before the truss structures are elevated for installation on their support bents, it is recommended to install their carrying and return Idlers. The adjustment, leveling, and alignment of the Idlers should be done with the belt installed.

DIMISA
It is important to keep in mind that the conveyor structure is designed for supporting the weight of the materials they convey, the belting, and the conveyor components; consequently, it should not be used as support for elevating other structures or components during the conveyor erection works. Upon completion of the structure installation, it is recommended to touch-up the painted areas which were damaged during the shipping and erection works. 2.4 INSTALATION OF THE MECHANICAL COMPONENTS 2.4.1 BELT PULLEYS DIMISA Belt Pulleys are generally shop installed on their respective support frame or headbox, only requiring leveling and alignment after mounting the support frame or head-box over their supporting structure at the job site. It is very important to properly level and align the head and tail pulleys, according to the reference drawings, for they are the references for aligning all the Idlers and belt. 2.4.2 PILLOW BLOCKS Pillow blocks for shafts are generally shop installed during the pulley-shaft assembly. The pillow blocks are installed according to the manufacturer instructions, and mounting the fixed (nonexpansion) pillow block on the drive-unit side and the expansion pillow block on the opposite side. Horizontal jack screws are provided for the pillow block base to permit their alignment. 2.4.3 IDLER ASSEMBLIES Before the installation of conveyor stringers or trusses, it is possible that the support frames of the carrying and return-idler assemblies have already been installed on them. Since the procedures for the support-frames alignments and adjustments take the conveyor head pulley as reference, this should be level and properly aligned. The Idler rolls can be mounted on their respective support-frames, once the stringer or truss has been installed and leveled. To ensure proper belt alignment and tracking, it is important to verify the parallelism and leveling of the carrying- and the return-Idlers. For the installation of the Training-Carrying and Training-Return Idlers it is necessary to consider the following: - They should be installed according to the location and orientation as indicated on the Drawings. - Ensure that the Idler Rolls are centered with respect to their support-frame, and limit the support-frame movement with the swivel jack screws. - Compare and verify the level and parallelism of the Training-Carrying and Training-Return Idlers with respect to its previous Idler. - Once the Training Idlers are properly level, loosen the swivel adjusting screws to limit the movement between 3 to 5 degrees in each side, or that permitted by the belt. There are some Training-Idlers which are provided with fixed stops, shop pre-calibrated, for limiting Idler swivel action, not requiring any type of adjustments.

DIMISA
For the Training Idlers near the pulleys, the height and level of the center roll should be verified against the pulley. 2.4.4 LOAD SKIRTBOARDS AND PLENUMS FOR DUST SUPPRESSION All the load skirtboards and dust suppression plenums are clearly tagged and should be identified in their respective conveyor drawing. Skirtboards should be provided with wear liners before installing them on the conveyor. The rubber seals should be attached to the skirtboard and properly adjusted, once the skirtboard is mounted on the conveyor. The recommended seal-belt clearance shown on the drawings must be observed, and the rubber seal pressure on the belt should not be excessive. The plenums for dust-suppression systems are tag numbered in the drawings for identification and location. They can be installed over the skirtboard when this is mounted on the conveyor. A dust seal (by others) between skirtboard and plenum should be installed to prevent the escape of airborne dust. 2.4.5 BELT TAKE-UPS For each of the conveyors, the location and type of belt take-up is indicated on the drawings. Manually adjusted screw take-ups for short conveyors are generally shop installed at the tail pulley support frame. For the vertical gravity take-ups, the bend-pulleys frame, supports, guides, etc. should be installed during the erection of the conveyor supporting-structure. For the horizontal gravity take-ups, the carriage-mounted tail pulley, sheaves and steel cable, counterweight box with its supporting steel tower, and rails for the carriage, can be mounted during the conveyor pulleys installation. If the horizontal gravity take-up is equipped with a hydraulic unit instead of counterweight, the assembly procedure should be per drawings. A special section of this manual explains the operation of this type of take-up system equipped with a hydraulic unit. The tension weight and safety guards can be installed after the installation of the conveyor belt. Make sure the counterweight supporting mechanism is in the safety hold position during the belt installation. 2.4.6 CONVEYOR DRIVE UNIT
NOTE:
DANGER WARNING
Immediate Hazards that could result in severe personal injury or
NOTE:
Hazards or unsafe practices could result in product or property damages.

DIMISA
The conveyor drive unit(s) components consist of the electric motor, gear reducer, high and low-speed couplings and is provided by DIMISA in a machined common base plate. Although they have been shop-aligned at the plant, it is recommended to verify adjustments and alignments during the conveyor installation. It is fundamental practice to check that the location and orientation of the drive unit conforms to the reference drawings, and to verify the additional requirements for some cases of power transmission units using V-belts and sheaves.
WARNING
For inclined conveyors, it is important to confirm the location and requirements of backstops. Verify if they are integral with the speed reducer or for installation opposite the drive unit, and that it operates to prevent reverse belt travel.
DANGER
Verify the direction of motor rotation before connecting the high-speed coupling, in order to prevent personal injury or equipment damages. 2.4.7 BELT SCRAPERS Belt scrapers in the head discharge chute are shop-installed, and their adjustments must be made once the discharge chute has been positioned in place and the belt installed. The belt scraper at the tail-end should be installed after the belt is installed. 2.4.8 CONVEYOR BELT It is strongly suggested to observe the following recommendations: - Belting is generally shipped in reels and is very important not to drop them to the floor from the transport carrier platform, unload reels with fork lifts or similar equipment. - During the belting storage, it is also important to keep the belt reels in a vertical position, and to follow the manufacturer instructions. - Before belt installation verify that the belt width, type, and class, tension rating (PIW), covers thickness, and the number of plies, are the specified for this conveyor. - Verify the minimum length requirement for the hot-vulcanize belt splicing, it is important that the orientation of the splice corresponds to the belt travel direction. - The belt splicing operation should follow the proper belt cutting procedures, cure temperature, press pressure, and cure time. Make sure the belt edges are aligned, and that during the ply cutting procedure, the longitudinal chords of the next ply is not harmed.

DIMISA
2.4.9 SAFETY GUARDS
DIMISA generally provides safety guards for rotating and translation components such as: - Tail pulley Protection. - Horizontal and Vertical gravity take-up systems. - V-belt guards for drive units with sheaves and belts. - Coupling covers and guards. The DIMISA design of these safety guards, allows for their easy removal and re-installation by maintenance personnel.
DANGER
It is the Clients responsibility to ensure that before operating the Conveyor, the afety guards are properly installed in the equipment, and the adhered warning labels are kept unobstructed. Should the warning labels adhered to the equipment be damaged, replacements can readily be obtained from DIMISA. 2.4.10 SAFETY SWITCHES Manufacturers Manuals for the Safety and Control Switches can be found in the corresponding section of this manual. The Installation, Operation, and Maintenance Manual for the following switches are included: - Emergency Pull-Cord Stop Switch. - Belt Misalignment Switch. - Zero speed switch.

DIMISA
III. OPERATION OF BELT CONVEYORS

3.1 VERIFICATION The first thing that must be done before initiating any conveyor test run, is the verification of the correct mechanical and electrical installation. It is highly recommended that a DIMISA technician, together with the Client representative, reviews the mechanical systems installation. This includes: - Confirm that the belt pulleys are aligned and level. - Check that all carrying and return Idlers are aligned and level. - Check that the vulcanized belt splices, or mechanical belt splices, are aligned. - Check oil level in the gear reducer. - Check the amount of grease-lubrication in the couplings and pillow blocks. - Check the electric power wiring and the rotation of the electric motor, including the safety issues. - Check the proper operation of the Safety and Control switches. - Check that the belt, feed and discharge chutes, and skirtboards, are free of objects that could damage or obstruct their proper operation. - Verify that the Gravity Take-ups is unobstructed, and with the proper tension weight in the counterweigh box. - Verify that the Backstop, or Holdback, is installed and in proper working order (if required by the conveyor). - Confirm the rigidity of the conveyor supporting structure.
3.2
CONVEYOR TESTING WITH BELT EMPTY
DANGER
Before starting the conveyor, check that the belt is free of personnel and objects, sound the warning horn (if provided with this conveyor), and wait at least half-minute before start-up.
DANGER
To prevent serious accidents to personnel hands or body injury, install the safety guards and warning signs in the load and return sections of the conveyors with vertical concave or convex curves, and in the drive pulley, snub, take-up, bend, and tail pulley, (see attached drawing included in the corresponding section of this Manual). Connect the conveyor drive motor to the electric power source, and record the amperes taken by the motor. Having the conveyor in operation and the belt running, verify that the belt is centered over the Idlers. Record the head pulley RPM, and the belt speed.

DIMISA
Allow the conveyor to operate with the belt empty for at least 8 hours and record the hourly readings of the pillow block temperatures, gear reducers, and motor amperes. Verify that the return strand of the belt makes no contact with conveyor steel. 3.3 CONVEYOR TESTING WITH BELT LOADED.
DANGER
If further adjustments are required to the belt-empty conveyor operation, disconnect the motor from the electric power source before initiating any activity on the conveyor. At the beginning of this conveyor test, verify that the material load is centered along the belt, and that the skirtboard feed chutes show no material spillage. If necessary, adjust the clearance between the bottom edge of the rubber seal strips and the belt. Keep record of the drive motor amperages until the conveyor design capacity is reached. Verify that during conveyor start-up, the belt does not slip over the drive pulley (pulleys). If this happens, check the counterweight box for the tension weight and its free travel on the structural guides. Allow the equipment to operate during at least 4 hours at the conveyor normal operation capacity, during which time the following conditions must be observed: belt alignment over the Idlers, load centering over the belt, belt scrapers performance, material free flow in the feed and discharge chutes and skirtboard, and take-up operation. Make record of the following working temperatures: Gear reducer, pillow blocks, and motor. Once the conveyor has operated for 4 hours, unload the material over the belt and stop the equipment for inspection of all the components, and make adjustments to the belt scrapers and fasteners.
DANGER
Disconnect the drive motor(s) from the electric power source before making any conveyor adjustments or giving maintenance to conveyor components. Upon completion of the verifications and required corrections, start up the conveyor again and load the belt for normal operation conditions. Stop the conveyor after one hour of normal operation to verify the backstop (or Holdback) mechanism, and if the belt slips or material spillage is observed, verify the takeup system.
With the conveyor belt fully loaded, start-up the drive motor and measure amperage and temperature until normal operation capacity of conveyed material is handled. If no problems are observed during the stopping and start-up of the conveyor with material load, allow the equipment to operate at its nominal capacity during 24 hours and keep record of motor measurements, components temperatures, belt alignment, actual conveyor capacity, etc.

DIMISA
After the 24 hours, if possible, operate the conveyor during 1 to 2 hours at its design capacity, and keep record of the drive motor amperage, temperatures of the motor, gear reducer, and pillow blocks, belt misalignment, uniformity of material flow at the loading and discharge zones. If the conveyor operation is satisfactory after this test, the equipment is ready for normal duty. Keep these initial records of conveyor operation at nominal and design capacities, for later determining the conveyed material statistics such as kW/Ton, etc.

DIMISA
IV. MAINTENANCE
4.1 GENERAL The maintenance practices for belt conveyors are no different to those applied to other mechanical equipments. An effective preventive maintenance program will minimize corrective maintenance and capitalize on increased production. The belt conveyors are mechanical equipment of easy operation and maintenance. The verification of the following important elements will help maximize conveyor life and minimize operation costs. In addition to the recommendations from the manufacturers of gear reducers, pillow blocks, electric motors, etc., also verify that: - The material load is centered over the conveyor belt. - The belt is centered over the Idlers. - The skirtboard rubber seals are close to the belt to prevent the escape of material. - The belt and splices (vulcanized or mechanical) are in good condition. - The belt does not slide or slips over the drive pulley (pulleys). - The counterweight box contains the specified tension weight. - Idler rolls are free to rotate, and the swivel mechanism of the belt Training Idlers free to turn. - The belt scrapers are properly adjusted. - The pillow block bearings are adequately lubricated. It is important to avoid excessive grease lubrication to prevent overheating. - Check the oil level of the gear reducer and change oil at regular intervals according to the manufacturer recommendations. - Take oil samples from the gear reducer (at least once a year) for metallographic analysis. - The wear plate liners, at the chutes and material transfer points, should be within the adequate thickness limits, to prevent they drop over the belt. - Keep area clean. Clean up lubricants and other materials before starting conveyor. 4.2 LUBRICATION At the initial of conveyor operation, it is important to prepare a lubrication chart for: - Pillow blocks at the pulley shafts. - Gear reducers (oil level and change oil per manufacturer recommendations). - Holdbacks. - Pillow block bearings, motors, and rotating equipment. 4.3 IDLERS The conveyor is equipped with ANTI-DUST Idlers by DIMISA. These Idlers design highlight the prevention of dust entrance to the deep groove ball bearings, sealed-for-life. The check points to observe include: - Idler Rolls that do not rotate or do not make good contact with the belt. - Uneven wear of the roll shell. - The center pivotal frame of the Training Idlers, and their offset vertical guide rolls, are free to rotate with the belt travel.

DIMISA
4.4 BELT PULLEYS
Verify that the belt does not slip over the drive pulley (pulleys). If this happens, check the tension weight in the counterweight box, or the screw take-up adjustment. Check that the vulcanized rubber on the pulleys does not show excessive wear, or that material is not trapped between belt and pulleys. 4.5 OTHER COMPONENTS Check that the Skirtboard rubber seal strips do not show material escaping from the bottom edges, or excessive wear. Verify for no dust-emission or accumulated material in the inspection doors. Take necessary corrective actions to prevent material accumulation under the Idlers or decking. Check that all Safety Guards are properly installed, and inspection doors latched. 4.6 LUBRICATION CHARTS The lubrication charts for gear reducers, pillow blocks provide information related to their type of lubricant, quantities, and the regular intervals for oil change. These lubrication charts can be found in the following pages. 4.7 CLEANING RECOMMENDATIONS DIMISA Technical Bulletin DM #22 is included at the end of this section. This Bulletin makes reference to some recommendations for the selection and operation of belt scrapers for cleaning the conveyor belting.

M3 Engineering And Technology Corporation P.O. No. 02209-G-001
DIMISA
Quotation DIMISA No.1179-03
Bearing lubrication recommendations Pillow block bearings Type TB-15-30-07

SKF
Conveyor
Sizes (in) Drive 12 1/2 Tail 7 7/8 Bend 7 7/8 Take up 7 7/8 Contact 5 1/2 Drive 8.5
Quantity of grease (aprox) kg. Tail 2.7 Bend 2.7 Take up 2.7 Contact 2
Kind
SNL
M3 Engineering And Technology Corporation P.O. No. 02209-G-001
DIMISA
Quotation DIMISA No.1179-03
Lubrication recommendations for speed reducers by conveyor Speed reducer data Brand Type Size Ratio ISO grade Lubricating Oil Type Recommend ed Oil changes Range (F) Quantity (L) lubricating Brearing lubrication
Conveyor
TB-15-30-07
FALK
ZB
21X10
57.66
320
Synthetic 50 To 125
329
Exxon Co., Spartan Synthetic EP 320, Mobil Oil Corp., SHC 632, Mobilgear SHC 320
At start up. After every six mounths or 2500 hours, whichever occurs first
At every oil change.
TECHNICAL BULLETIN
INTERNAL PUBLICATION FROM DISEO DE MQUINAS BULLETIN 22 JUNE, 2004
CLEANING RECOMMENDATIONS FOR BULK MATERIAL HANDLING EQUIPMENT Bulk material handling installations frequently present operating conditions that are not the optimum in terms of cleaning and general organization. In the vast majority of the plants the escape of material, in the form of volatile dusts, dripping slurries or product spillage, and its constant accumulation over areas not well conditioned for it, constitute an operating condition that in many cases leads to low efficiency problems in the production process and even dangers for the well being of people and the integrity of machines and equipment. The clue for eliminating or limiting the impact of poor cleaning conditions in industrial areas consists at least of two factors: The use of appropriate designs in terms of the applicability and capacity of the systems destined to fight or capture the fugitive particles. The conformation of a preventive maintenance schedule or program that continuously focuses the attention of the related people over these problems. In belt conveyors and belt conveyor installations, the components that contribute to maintain the machines and the installations clean are roughly the following: a) Dust collectors. b) Dust suppressing systems. c) Loading skirtboards. d) Belt cleaners. Dust collectors. Many kinds of dust collectors exist, among which the ones most commonly used are of fabric or textile bags. These consist in an air circulation system that makes air pass through an inert fabric material (polyester in many cases), where the dust particles are captured and taken away from the main stream. Applications for which this kind of collector is more appropriate are those that present fine, dry and non-explosive dusts. Humid dusts tend to stick over the surface of the fabric material, situation that sometimes plugs the collector and prevents the flow of the air stream. Explosive or inflammable dusts often require that costly, special design antistatic bags and explosion-proof Fig. 1. Fabric dust collector with backwash. Some recommendations for the maintenance of these systems are: Daily: Take note of the pressure drop values at least the first thirty days of operation of the system. The adverse conditions that a many times can originate failures are frequently led by unusual changes in the pressure drop. Take into account that the pressure drop when the systems installation is recent will be less than after the first days of operation, due to the natural accumulation of captured dust in the filters. Thus, after a backwash of the filters a value similar to that of the first day of operation could be reasonably expected, and the subsequent values would correspond to the normal operation of the collector. Monthly: Inspect the filter media at least one time each month. Replace every damaged or consumed components. Also review with this periodicity the discharge zone of the collector. Every six months: Review and clean the dust accumulation inside the ducts of the dust collector. Check all the internal and external components to look for the presence of leaks of dirty or clean air. Confirm that damp zones or water deposits are not present inside the collector. Check the operation of the backwash blowers (in case of them being available), making sure that there are no obstructions in any nozzles, and review the correct operation of the automatic sequence. electrical systems are used.
TECHNICAL BULLETIN
Dust suppressors. These systems consist in localized water pressurization and aspersion devices. The fluid, plain water or surfactant-treated water, forms a curtain of droplets or particles in the place where dust is being generated, curtain that tends to contain the emissions and arrest the fugitive flow by contact. Very often chemical compounds denominated surfactants are added to the working fluid to reduce its surface tension and thus increase its damping effect, maximizing the capture of dust. This type of systems are more appropriate to be used in stock pile reclaims and storages, loading or discharging of belt conveyors, bucket elevators and similar others. The main requisite to fulfill is that the quality of the treated product is not affected by the addition of the working fluid and the surfactant compounds. If a rather pure material is desired, the method of dust suppression is not applicable. Some maintenance recommendations for dust suppression systems are the following: Daily: Take note of the operating pressures in each one of the critical points. Take any measures that you consider pertinent at this respect. Confirm the absence of working fluid leaks in the transport tubes and hoses. Clean any wind or ultrasonic sensors (if available). Monthly: Review that corrosion is not present in hydraulic tubing or pipe, as well as in any internal parts of the hydraulic system. Confirm the correct flow of the working fluid through the spray nozzles and that they are not obstructed by foreign material. Clean the inlet water filter and the circulating water filter. Annually: Make sure that the dose of the surfactant control system is correct. Review the general operation of the system and correct any issues. Loading skirtboards. The loading skirtboard is a cover made of natural rubber, synthetic rubber or urethane that is made to contain the dusts generated by the material drop in transfer zones between immediate belt conveyors. It consists mainly in an steel enclosure, lined with abrasion resistant plates to withstand the abrasion that Fig. 2. Primary and secondary skirtboard seals. Some maintenance recommendations are: Monthly: Check out the wear of the secondary seals. Replace them if they have a thickness of less than 1/16. Confirm the firm press of the clamps and that the primary seal is well fixed. Belt cleaners. There are at least three fundamental kinds of conveyor belt cleaning devices: the material flow produces in it, a thick polymer blade (called primary seal), located almost in contact with the belt, which function is containing the larger material particles, and one or more thinner blades (secondary seals), in charge of maintaining the fine powders inside the loading zone. If the fines concentration is low or the loading zone uses high-profile idlers, it might be convenient to employ only the primary seal. Applications with a lot of fines or intense dust generation may require secondary seals equipped with single, double or triple lip.
TECHINCAL BULLETIN. Please request it at our main offices giving us your name and address. THE BEST ALTERNATIVE IN BULK MATERIAL HANDLING SYSTEMS Prol. Ruiz Cortines 444 Ote., Cd. Guadalupe, N. L. Mxico, Tel. (81) 81310000, Fax (81) 81310010
TECHNICAL BULLETIN
LIMPIEZA EN EQUIPOS PARA EL MANEJO DE MATERIALES A GRANEL (CONT.) Primary, which eliminates the major part of the particles adhered to the belt. Secondary, which removes, by means of a more profound cleaning, the particles not eliminated by the primary. Plow type, employed to prevent that material spilled over the clean side of the belt can get trapped between it and the pulleys, producing damage. The primary and secondary cleaners eliminate the material adhered to the belt by means of applying friction over it with blades made of abrasion-resistant particles, of materials such as tungsten carbide, embedded in a polymer that confers them support and toughness. The polymer will mainly be urethane, which can be selected in agreement with the following general guidelines: Normal: Employ it with the majority of the applications, materials like bauxite, coke, coal, cold clinker, debris, sand, etc. High temperature: Use it in applications of materials at temperatures over 70 and up to 150 C. Intermittently, it can withstand temperatures of up to 175 C. High chemical resistance: It is the recommended material when reactive products, like limestone, copper and gold minerals, are conveyed. Antiadhesive: Employ it for highly viscous or sticky solids, as humid cement and some inert slurries. Some maintenance recommendations for primary and secondary conveyor belt cleaners are the following: Weekly: Verify that all the screws are tight. Review the wear of the blades and change them if it has gone through the wear limit line. Clean all the printed security warnings located near the cleaner. The rotary brush cleaners are primary cleaners that can be used at their own or in combination with any secondary device. Their principal features are the power they consume, the rotating speed and the material of the cleaning blades. Power and rotation speed play an important role in the cleaning of the belt. DM rotary cleaners are adequately sized regarding these variables to remove even the more difficult materials. The material of the cleaning blades will in general be natural rubber, although sometimes special compounds will be required, like nitrile, for oil and grease resistance, urethane for applications exposed to intense amounts of insolation or the EPR, for high temperatures..
Fig. 4. DM rotary cleaner. Some maintenance remarks regarding the DM rotary cleaners are as follows: Weekly: Clean out the material accumulated over the blades. Monthly: Verify that the blade wear is not excessive. Adjust the pressure of the cleaner until the degree of cleanliness desired is achieved without overloading the cleaners electric motor. At the same time planned to give maintenance to the rest motors and reducers of the project: Give maintenance to the reducer, motor, coupling and bearings of the belt cleaner in the same way
Fig. 3. Primary and secondary cleaners
TECHNICAL BULLETIN
that will be done with the rest of the systems. The plow cleaners are composed of a piece of polymeric material, arranged in a single or double blade disposition, which will deviate the solids deposited over the return side of the belt to tamper any possibilities that they get trapped by the pulleys. These cleaners are very simple and their wear tends to be less than with primary and secondary cleaners, because they hold less friction against the belt. Some recommendations for maintenance of this devices are: the preventive
Daily: Check that no material accumulates in the plowing zone. Correct any anomaly related to this. Monthly: Adjust the cleaner so it simply touches the belt. Verify that the wear is not excessive in the polymer. Replace it if necessary.
DIMISA
V. TROUBLESHOOTING
The following table provides a list of problems with remedies, to help preparing a preventive maintenance program for the different components in the conveyor.
PROBLEM
a)
POSSIBLE CAUSE
ONE OR MORE IDLERS AT JUST BEFORE THE PROBLEM ARE NOT ALIGNED, OR LEVEL. THE CONVEYOR STRUCTURE IS NOT PROPERLY ALIGNED, OR THE IDLERS UNDER THE SKIRTBOARD ARE NOT CENTERED.
REMEDY
a) b)
FORWARD THE IDLER END TOWARDS WHERE THE BELT TENDS TO ISALIGN. CORRECT THE ALIGNMENT OF CONVEYOR STRUCTURE, OR CENTER THE IDLERS UNDER THE SKIRTBOARD. REPLACE DAMAGED IDLERS. CHECK BELT SCRAPPERS, IMPROVE AREA CLEANINESS.
b) BELT MISALIGNS AT A PARTICULAR POINT.
c) DAMAGED IDLERS. d) MATERIAL ACUMMULATES ON THE IDLERS. a) BELT SPLICE IS NOT SQUARE.
c) d)
a) ONE SECTION OF THE BELT MISALIGNS ALL ALONG THE CONVEYOR. b) BELT WAS STORED. IMPROPERLY b)
CORRECT THE BELT SPILCES THAT ARE NOT SQUARED. RUN THE BELT FOR SOME TIME TO SEE IF TRACKING IMPROVES, IF NOT THEN SUBSTITUTE THAT BELT SECTION.
BELT TRAVELS TO ONE SIDE
MATERIAL LOAD NOT CENTERED
DIRECT FEED CHUTE SO MATERIAL LOAD STABILIZES AT BELT CENTER.
a) IF NEW, RUN BELT FOR SOME TIME TO SEE IF TRACKING IMPROVES BELT RUNS ERRATICALY AT ANY POINT. BELT RIGIDITY TOO STIFF. b) INSTALL TRAUGHING IDLERS. c) INSTALL A MORE FLEXIBLE BELT THAT WILL CONFORM TO THE TROUGHUNG IDLERS. a) HEAD PULLEY MISALIGNED. a) BELT MISALIGNS AT THE HEAD PULLEY. b) IDLERS POSITIONED NEXT TO THE HEAD PULLEY ARE MISALIGNED. b) ALIGN HEAD PULLEY. ALIGN IDLERS POSITIONED BEFORE THE HEAD PULLEY.

DIMISA
PROBLEM POSSIBLE CAUSE
REMEDY
a) BELT MISALIGNS AT THE TAIL PULLEY.
MATERIAL ACCUMULATES RETURN IDLERS.
ON
a) REMOVE FOREIGN MATERIAL AND CHECK THE BELT CLEANERS AT THE TAIL PULLEY. b) ALIGN THE RETURN IDLERS. c) DIRECT FEED CHUTE SO MATERIAL LOAD STABILIZES AT BELT CENTER.
b) MISALIGNED RETURN IDLERS. c) MATERIAL LOAD NOT CENTERED.
a)
BELT SLIPPING PULLEY.
ON
DRIVE
a) INCREASE THE TENSION WEIGHT IN THE COUNTERWEIGHT BOX. INCREASE THE BELT WRAP ANGLE ON THE DRIVE PULLEY. b) REPLACE THE DAMAGED IDLERS. c) CHECK OR REPLACE THE CLEANERS AND KEEP AREA CLEAN. d) REDUCE THE TROUGHING ANGLE OF IDLERS.
b) CARRYING IDLERS DAMAGED. EXCESSIVE WEAR ON THE BOTTOM COVER OF BELT. c) d) ACCUMULATED MATERIAL BETWEEN PULLEY AND BELT. TROUGHING VERY STEEP. IDLERS, ANGLE
a) REMOVE FOREIGN MATERIAL. REPLACE DAMAGED RETURN IDLERS. b) INCREASE BELT TENSION. a) FOREIGN MATERIAL ON RETURN IDLERS, OR DAMAGED. EXCESSIVE WEAR ON THE TOP COVER OF BELT. b) EXCESSIVE BELT SAG BETWEEN IDLERS. c) SKIRTBOARDS FITTED WITH STIFF SEAL STRIPS. d) d) IMPROPER MATERIAL LOADING. c) REPLACE SEAL STRIPS WITH FLEXIBLE, ADJUSTABLE, RUBBER SEAL STRIPS. DO NOT USE MATERIAL DISCARDED BELTING AS STRIPS. FROM SEAL
REDESIGN THE MATERIAL LOAD SYSTEM. THE MATERIAL SHOULD BE DELIVERED IN A UNIFORM FLOW TO THE CENTER OF THE BELT, IN THE DIRECTION OF BELT TRAVEL, AND CLOSE TO THE BELT AS POSSIBLE.

DIMISA
REMEDY
a)
REDUCE FRICTION LOADS BY REPLACING THE DAMAGED IDLERS AND REMOVING THE ACCUMULATED SPILLED MATERIAL. IMPROVE THE MAINTENANCE PROGRAM. REDUCE BELT TENSION WITH DRIVE PULLEY THAT IS LAGGED WITH VULCANIZED RUBBER, OR INCREASE THE BELT WRAP ANGLE. INCREASE THE BELT SPEED MAINTAINING THE SAME CONVEYOR CAPACITY. AJUST THE TENSION WEIGHT IN THE COUNTERWEIGHT BOX TO JUST AVOIDING BELT SLIPPAGE.
EXCESSIVE BELT STRETCHING
a) TOO MUCH BELT TENSION DUE TO POOR MAINTENANCE OF CARRYING AND RETURN IDLERS, OR SPILLED MATERIAL ACCUMULATED UNDER THE BELT. b) INADEQUATE BELT RATING FOR THE CONVEYOR DRIVE MOTOR SIZE.
b)
REPLACE WITH PROPER BELTING.
a) a) TOO MUCH BELT TENSION. STAPLES, IN MECHANICAL FASTENERS FOR BELT SPLICES, ARE DISLODGED THROUGH END OF BELT. b) WRONG TYPE OF STAPLES, OR INSUFFICIENT COMPRESSIVE CLAMPING. INADEQUATE START-UP. b)
REDUCE BELT TENSION. REPLACE STAPLES OF PROPER TYPE AND VERIFY THEY ARE SUFFICIENTLY COMPRESSED.
c)
c) INSTALL A GRAVITY TAKE-UP SYSTEM; IF EQUIPPED WITH ONE, THEN CHECK FOR OBSTRUCTIONS. ALSO INSTALL A HYDRAULIC COUPLING BETWEEN MOTOR AND GEAR REDUCER.
a) INSTALL IMPACT IDLERS. REDESIGN FEED CHUTE TO MINIMIZE MATERIAL IMPACTS ON THE BELT. a) b) c) IMPACTS ON THE BELT MATERIAL LOAD POINT. AT b) INSTALL BELT SCRAPERS AT THE HEAD AND TAIL PULLEYS; IF ALREADY SO EQUIPPED THEN CHECK THEIR ADJUSTMENTS. REPLACE WITH IDLERS ADEQUATE TROUGH ANGLE. OF
SMALL CUTS THAT ARE PARALLEL TO THE BELT.
TRAPPED MATERIAL BETWEEN BELT AND PULLEY. c) RODILLOS CON NGULO PRONUNCIADO Y BANDA DEMASIADO FLEXIBLE.
REDUCE THE TROUGHING ANGLE OF THE IDLERS, OR REPLACE BELT WITH ANOTHER THAT IS ADEQUATE FOR THIS APPLICATION.

DIMISA
REMEDY
a) INSTALL PULLEYS OF SIMILAR DIAMETERS, DIFFERENCES OF 3 MM WILL CAUSE A HIGH-PITCH SOUND. INCREASE THE BELT TENSION IN THE RETURN STRAND OF THE BELT. INSTALL A HYDRAULIC COUPLING BETWEEN THE MOTOR AND GEAR REDUCER.
a) EXCESSIVE NOISE, OR HIGHPITCH SOUND, AT DRIVE UNIT IN TANDEM. b) c)
INCORRECT PULLEYS.
DIAMETER
OF b)
LOW TENSION IN THE RETURN STRAND OF THE BELT. c) JOLTED START-UPS.
a) BOUNCING SOUNDS, DRIVE UNIT IN TANDEM. IN THE b)
ONE OR TWO PULLEYS NOT LOCKED TO SHAFT. DAMAGED DEFECTIVE. GEARS, OR
a) CHECK AND TIGHTEN SET- SCREWS IN PULLEY HUBS, OR REPLACE IF DAMAGED. b) REPLACE GEARS.

DIMISA
VI. SYNOPTIC SUMMARY OF COMPONENTS BY EQUIPMENT

The following pages show the synoptic summary for the mechanical components in each conveyor. Use this summary as a guide to quickly determine the type of components that may need special attention.

DIMISA
VII. MANUFACTURERS RECOMMENDATIONS OF THEIR COMMERCIAL EQUIPMENT

The following sections contain technical literature obtained from the manufacturers of the commercial equipment that were included in this Purchase Order. The components that have been considered are described in the following paragraphs.
7.1 Pillow Blocks, SKF 7.1.1 7.2 7.3 SNL type.
Idlers by DIMISA, ANTI-DUST type. Reducers. 7.3.1 Reducers, FALK
7.4
Safety Devices, Conveyor Components Co. 7.4.1 7.4.2 7.4.3 7.4.4 Emergency stop switch, RS-2X type. Emergency stop switch, TA-2X type. Plugged Chute swith, CT-101 type. Speed switch TELEMECANIQUE, XSA type.
7.5 7.6
Belt conveyors, CONTITECH type. Belt Scrapers, MARTIN 7.6.1 7.6.2 Cleaner MARTIN PRIMARY Cleaner MARTIN SECONDARY
7.7 7.8
B-LOC, Keyless Locking Devices. Flexible Couplings FALK. 7.8.1 7.8.2 Coupling MCF 1090 type. Coupling T-10
7.9 7.10
AC Induction Motors, GE Back Stop FALK.

DIMISA
SKF SNL BEARINGS
Contents:
Installation and maintenance instructions for SKF brand, SNL type bearings and bearing blocks. SKF English. 38
Published by: Language: Pages:

SNL plummer block housings, series 2, 3, 5 and 6
SNL plumer block housings, series 2, 3,5, and 6, up to size 32 are the most popular of the wide range of SKF housings. Because of their versatility it is seldom necessary to resort to tailored housings for specific applications. The housings are horizontally split and have two or four attachment bolt holes in the base as standard. Building block system The basis of the SNL plummer block housing system consists of a number of housings of the same design but in different sizes. By combining these housings with different standard seals a wide variety of housing variants, all belonging to the standard range, can be supplied (fig 1). SNL plummer blocks can accommodate shaft diameters ranging from 20 to 160 mm. Fig 1
Reinforced base The housing base is reinforced with ribs and extra material surrounding the holes for the attachment bolts in order to improve seating on the base plate (fig 2). The attachment bolts can be preloaded to give better location and cannot deform the housing base or housing bore.
Fig 2
Attachment SNL housings have two attachment bolt holes in the base as standard. Housings of size 511-609 and larger are also available with four cast attachment bolt holes as standard, designated FSNL. These larger housings are also available without attachment bolt holes (blank base, designated SSNLD), but only made of ductile cast iron. Also the smaller housings below size 511-609 can be used for four bolt mounting. Cast indications show where to drill the additional holes.
Good heat conduction The extra ribs the housing base (fig 3) provide additional surface area between the base and base plate to improve heat flow away from the bearing.
Fig 3
Relubrication facility SNL housings are supplied with a grease nipple. Two tapped holes for the nipple in the cap are standard. Cast indications mark other grease nipple locations for relubrication of the bearing or the seals (fig 4).
Fig 4
Caps and bases individually marked The housing base and cap are matched during manufacture and are not interchangeable. To prevent mixing, the same consecutive number is marked on the cap and base of each individual housing (fig 5).
Fig 5
Mounting aid To simplify mounting and make alignment more accurate, cast indications in the end faces of the housing base indicate the housing bore axis and the vertical axis (fig 6) Mounting instructions are also supplied with each housing.
Fig 6
Indications for holes to accommodate other components Cast indications mark the positions where holes can be drilled for dowel pins, sensors for condition monitoring and additional grease nipples (fig 7).
Fig 7
Lubrication SNL plummer block housings are so designed that the bearings in them can be lubricated with grease or oil, although grease lubrication is generally preferable. The lubricant should be selected with reference to the operating conditions. Relevant information will be found in the section "Lubrication" of the catalogue "Rolling bearings". If rolling bearings are to operate reliably they must be adequately lubricated to prevent direct metal-to-metal contact between the rolling elements, raceways and cages. The lubricant also inhibits wear and protects the bearing surfaces against corrosion. The choice of a suitable lubricant and method of lubrication for each individual bearing application is therefore important, as is correct maintenance A wide selection of greases and oils is available for the lubrication of rolling bearings and there are also solid lubricants, e.g. for extreme temperature conditions. The actual choice of a lubricant depends primarily on the operating conditions, i.e. the temperature range and speeds as well as the influence of the surroundings. The most favourable operating temperatures will be obtained when the minimum amount of lubricant needed for reliable bearing lubrication is provided. However, when the lubricant has additional functions, such as sealing or the removal of heat, additional amounts of lubricant may be required.
The lubricant in a bearing arrangement gradually loses its lubricating properties as a result of mechanical work, ageing and the build-up of contamination. It is therefore necessary for grease to be replenished or renewed and for oil to be filtered and changed at regular intervals. The information and recommendations in this section relate to bearings without integral seals or shields. SKF bearings and bearing units with integral seals and shields at both sides are supplied greased. Information about the greases used by SKF as standard for these products can be found in the relevant product sections together with a brief description of the performance data. The service life of the grease in sealed bearings most often exceeds bearing life so that, with some exceptions, no provision is made for the relubrication of these bearings.
Lubrication - Grease lubrication Grease lubrication is preferred for bearings in SNL plummer block housings. To enable efficient lubrication of the bearing they have two drilled and tapped holes in the housing cap. The hole in the middle is used to relubricate spherical roller bearings via the outer ring. The other hole is for relubricating self-aligning ball bearings and CARB bearings from the side (fig 4). The housings are supplied with a grease nipple AH 1/8-27 PTF and a metallic plug to close the second hole Fig 4
An adapter can also be supplied which makes it possible to use other grease nipples without having to rework the standard threaded hole. Cast dimples on the housing cap (fig 24) show where additional holes can be drilled to supply grease to the bearing or to special seals.
Fig 24
Grease quantities for initial lubrication and relubrication In the majority of applications, the amount of grease applied to the SNL housings when mounting (first fill) is adequate until the next routine inspection. Certain operating conditions may require frequent relubrication. Table 6 provides guideline values for the grease quantities to be applied for the first fill as well as for relubrication. The quantities for the first fill will take up 40 % of the free space in the housing.
Table 6: Grease quantities Housing Grease quantities First fill 1) g 25 40 50 60 65 75 100 150 180 230 280 330 430 25 40 50 60 65 75 100 150 5 5 10 10 10 10 15 15 20 20 25 25 40 5 5 10 10 10 10 15 15
Relubrication
SNL 205 SNL 206-305 SNL 207 SNL 208-307 SNL 209 SNL 210 SNL 211 SNL 212 SNL 213 SNL 215 SNL 216 SNL 217 SNL 218 SNL 505 SNL 506-605 SNL 507-606 SNL 508-607 SNL 509 SNL 510-608 SNL 511-609 SNL 512-610
SNL 513-611 SNL 515-612 SNL 516-613 SNL 517 SNL 518-615 SNL 519-616 SNL 520-617 SNL 522-619 SNL 524-620 SNL 526 SNL 528 SNL 530 SNL 532
180 230 280 330 430 480 630 850 1 000 1 100 1 400 1 700 2 000
20 20 25 25 40 50 55 70 80 95 110 130 150
1)
Fills approximately 40 % of the free space in the housing
Grease quantities Housing 1) Size SNL 3036 SNL 3038 SNL 3040 SNL 3044 SNL 3048 SNL 3052 SNL 3056 SNL 3060 SNL 3064 SNL 3068 SNL 3072 SNL 3076 SNL 3080 SNL 3084 SNL 3088 SNL 3092 SNL 3096 SNL 30/500 SNL 30/530 SNL 3134 SNL 3136 Grease quantities 2) First fill kg 1,2 1,5 2 2,7 3 3,9 4,9 5,2 7 8,7 10,9 10,9 11,7 11,8 14,4 18,8 18,5 20 21,5 1,1 1,4 0,1 0,11 0,13 0,15 0,17 0,21 0,22 0,27 0,29 0,35 0,36 0,38 0,44 0,47 0,51 0,55 0,58 0,6 0,72 0,12 0,14
Relubrication
SNL 3138 SNL 3140 SNL 3144 SNL 3148 SNL 3152 SNL 3156 SNL 3160 SNL 3164 SNL 3168 SNL 3172 SNL 3176 SNL 3180 SNL 3184 SNL 3188 SNL 3192 SNL 3196 SNL 3234 SNL 3236 SNL 3238 SNL 3240 SNL 3244 SNL 3248 SNL 3252 SNL 3256 SNL 3260 SNL 3264 SNL 3268 SNL 3272 SNL 3276 SNL 3280 SNL 3284 SNL 3288
1) 2)
1,8 2,3 2,7 3,4 4,3 4,4 6,2 7,7 9,4 9,7 9,6 12,2 14,9 16,2 17,4 17,2 1,9 1,9 2,2 2,5 3 3,8 5,6 5,6 6,9 8,6 8,4 10,7 12,3 14,6 15,3 15,1
0,17 0,19 0,22 0,26 0,32 0,34 0,4 0,48 0,55 0,58 0,6 0,65 0,78 0,81 0,91 0,98 0,17 0,18 0,2 0,23 0,29 0,35 0,42 0,44 0,52 0,6 0,69 0,75 0,82 0,92 1,03 1,11
For housings in the 40 series, please contact SKF application engineering Fills approximately 40 % of the free space in the housing
Points to remember For arrangements where the bearing is mounted on an adapter sleeve, grease should be supplied at the side opposite to the sleeve nut. For bearing arrangements at shaft ends, grease should always be supplied at the end cover side. Housings fitted with double-lip seals should be provided with a grease escape hole (fig 25) if they are to be relubricated frequently. SNL housings with a grease escape hole in the housing base can be supplied and are identified by the suffix V, e.g. SNL 511-609 V. If a grease escape hole has to be drilled, the recommended dimensions will be found in table 7. When relubricating periodically, the peripheral speed of the seal lips should be limited to 4 m/s. For housings with V-ring seals the efficiency of relubrication can be appreciably improved if an additional V-ring is arranged inside the housing at the same side as the grease is supplied. This forces grease to leave the arrangement at the side opposite to the supply side. For this purpose a V-ring and a splash plate, which covers a sector of more than 180 can be supplied as a set (fig 26). The set is designated by the prefix ASNA followed by the housing size identification and the suffix V, e.g. ASNA 511 V.
Fig 25
Table 7: Recommended dimensions for
grease escape hole
Housing Size SNL 205 SNL 206305 SNL 207 SNL 208307 SNL 209 SNL 210 SNL 211 SNL 212 SNL 213 SNL 215 SNL 216 SNL 217 SNL 218 SNL 505 SNL 506605 SNL 507606 SNL 508607 SNL 509 SNL 510608 SNL 511609 SNL 512610 SNL 513611
Dimensions Ja mm 8,5 10 10 9 10 11 10 9 13 12,5 14 17 20 8,5 10 10
N3
degrees
10 10 10 10 10 10 12 12 12 12 16 16 16 10 10 10
45 45 45 45 45 45 45 45 45 45 45 45 40 45 45 45
9 10 11
10 10 10
45 45 45
10 9 13
12 12 12
45 45 45
SNL 515612 SNL 516613 SNL 517 SNL 518615 SNL 519616 SNL 520617 SNL 522619 SNL 524620 SNL 526 SNL 528 SNL 530 SNL 532 Fig 26
12,5 14 17 20 20 21
12 16 16 16 16 16
45 45 45 40 50 50
21 24 22 23 25 25
20 20 20 20 20 20
50 55 55 50 55 60
Grease lubrication
Grease can be used to lubricate rolling bearings under normal operating conditions in the majority of applications. Grease has the advantage over oil that it is more easily retained in the bearing arrangement, particularly where shafts are inclined or vertical, and it also contributes to sealing the arrangement against contaminants, moisture or water. Excessive amounts of grease will cause the operating temperature within the bearing to rise rapidly, particularly when running at high speeds. As a general rule, when starting up only the bearing should be completely filled, while the free space in the housing should be
partly filled with grease. Before operating at full speed, the excess grease in the bearing must be allowed to settle or escape during a running-in period. At the end of the running-in period the operating temperature will drop considerably indicating that the grease has been distributed in the bearing arrangement. However, where bearings are to operate at very low speeds and good protection against contamination and corrosion is required, it is advisable to fill the housing completely with grease. Grease lubrication - Lubricating greases Lubricating greases consist of a mineral or synthetic oil combined with a thickener. The thickeners are usually metallic soaps. However, other thickeners, e.g. polyurea can be used for superior performance in certain areas, i.e. high temperature applications. Additives can also be included to enhance certain properties of the grease. The consistency of the grease depends largely on the type and concentration of the thickener used and on the operating temperature of the application When selecting a grease, the consistency, operating temperature range, viscosity of the base oil, rust inhibiting properties and the load carrying ability are the most important factors to be considered. Detailed information on these properties follows. Grease lubrication - Base oil viscosity The importance of the oil viscosity for the formation of an oil film to separate the bearing surfaces and thus for the life of the bearing is dealt with in the section "Lubricating conditions - the viscosity ratio "; the information applies equally to the base oil viscosity of greases. The base oil viscosity of the greases normally used for rolling bearings lies between 15 and 500 mm2/s at 40 C. Greases based on oils having higher viscosities than 1 000 mm2/s at 40 C bleed oil so slowly that the bearing will not be adequately lubricated. Therefore, if a calculated viscosity well above 1 000 mm2/s at 40 C is required because of low speeds, it is better to use a grease with a maximum viscosity of 1 000 mm2/s and good oil bleeding properties or to apply oil lubrication. The base oil viscosity also governs the maximum recommended speed at which a given grease can be used for bearing lubrication. The permissible rotational speed for grease is also influenced by the shear strength of the grease, which is determined by the thickener. To indicate the speed capability, grease manufacturers often quote a "speed factor". A = n dm
Where A=speed factor, mm/min n=rotational speed, r/min dm=mean diameter of the bearing
For applications operating at very high speeds, e.g. at A > 700 000 for ball bearings, the most suitable greases are those incorporating base oils of low viscosity. Grease lubrication Consistency Greases are divided into various consistency classes according to the National Lubricating Grease Institute (NLGI) scale. The consistency of grease used for bearing lubrication should not change drastically when operated within its specified temperature range after mechanical working. Greases that soften at elevated temperatures may leak from the bearing arrangement. Those that stiffen at low temperatures may restrict rotation of the bearing or have insufficient oil bleeding. Metallic soap thickened greases, with a consistency of 1, 2 or 3 are used for rolling bearings. The most common greases have a consistency of 2. Lower consistency greases are preferred for low temperature applications, or for improved pumpability. Consistency 3 greases are recommended for bearing arrangements with a vertical shaft, where a baffle plate is arranged beneath the bearing to prevent the grease from leaving the bearing. In applications subjected to vibration, the grease is heavily worked as it is continuously thrown back into the bearing by vibration. Higher consistency greases may help here, but stiffness alone does not necessarily provide adequate lubrication. Therefore mechanically stablGreases thickened with polyurea can soften or harden depending on the shear rate in the application. In applications with vertical shafts there is a danger that a polyurea grease will leak under certain conditionse greases should be used instead. Grease lubrication - SKF greases The SKF range of lubricating greases for rolling bearings comprises many types of grease and covers virtually all application requirements. These greases have been developed based on the latest information regarding rolling bearing lubrication and have been thoroughly tested both in the laboratory and in the field. Their quality is continuously monitored by SKF.
The most important technical specifications on SKF greases are given in table 1 Part 1: Technical specifications together with a quick selection guide table 1 - Part 2: Characteristics. The temperature ranges where the SKF greases can be used are schematically illustrated in diagram 3 according to the SKF traffic light concept.
Table 1: SKF greases - technical specifications and characteristics Part 1: Technical specifications Designation Description NLGI class Thickener/ base oil Base oil viscosity at 100 40 C C mm2/s 110 11 Temper ature limits LTL1) C -30 +120 HTPL2)
LGMT 2
All purpose industrial and automotive All purpose industrial and automotive Extreme pressure, high load
Lithium soap/ mineral oil Lithium soap/ mineral oil Lithium soap/ mineral oil
LGMT 3
120
12
-30
+120
LGEP 2
200
16
-20
+110
LGLT 2
Low load and temperature, high speed
Lithium soap/PAO
18
4,5
-50
+ 1 1 0
LGHP 2
High performance and high temperature Food compatible
2-3
Di-urea/ mineral oil Aluminium complex/ medical white oil
96
10,5
-40
+150
LGFP 2
130
7,3
-20
+110
LGGB 2
Biodegradable and low toxicity Wide temperature range
Lithium-calcium soap/ 110 ester oil Lithium soap/ mineral oil complex 185 peaks: 450 peaks: 400
13
-40
+120
LGWA 2
15
-30
+140 +220
LGHB 2
High viscosity and high temperature Extreme temperature
Calcium sulphonate complex/mineral oil PTFE/synthetic/ fluorinated polyether Lithium soap/ mineral oil
26,5
-20
+150 +200 +260
LGET 2
38
-40
LGEM 2
High viscosity with solid lubricants Extreme high viscosity with solid lubricants Extreme pressure, low temperature
500
32
-20
+120
LGEV 2
Lithium-calcium soap/ 1 000 mineral oil Lithium soap/ mineral oil 200
58
-10
+120
LGWM 1
16
-30
+110
1) 2)
LTL: low temperature limit HTPL: high temperature performance limit
Table 1: SKF greases - technical specifications and characteristics Part 2: Characteristics Designation High temperature, above +120 C LGMT 2 LGMT 3 LGEP 2 LGLT 2 LGHP 2 LGFP 2 LGGB 2 LGWA 2 LGHB 2 LGET 2 LGEM 2 LGEV 2 LGWM 1 + + o + + o
Low temperature
Very high speed
Very low speed or oscillations o o o +
Low torque, low friction
Severe vibrations
Heavy loads
Rust inhibiting properties + o + + + +
Water resistance
o o o + + o o o o
+ o + o o o o -
+ + + + o + + +
o o + o
+ + + + + + + + +
+ + +
o + +
Contact the SKF application engineering service o + + o o + + + + + + + + + + +
Symbols:
+ Recommended o Suitable - Not suitable
Where no symbol is indicated the relevant grease may be used - however, it is not recommended For further information please contact the SKF application engineering service
Diagram 3: The SKF traffic light concept - SKF greases Temperature, C SKF greases Designation LGMT 2 LGMT 3 LGEP 2 LGWM 1 LGFP 2 LGHB 2 LGEM 2 LGEV 2 LGLT 2 LGWA 2 LGGB 2 LGHP 2 For operating temperatures above 150 C, SKF LGET 2 is recommended
Further information on SKF greases can be found in the online catalogue "Maintenance and Lubrication Products". Grease lubrication Relubrication Rolling bearings have to be relubricated if the service life of the grease is shorter than the expected service life of the bearing. Relubrication should always be undertaken at a time when the condition of the existing lubricant is still satisfactory The time at which relubrication should be undertaken depends on many related factors. These include bearing type and size, speed, operating temperature, grease type, space around the bearing and the bearing environment. It is only possible to base recommendations on statistical rules; the SKF relubrication intervals are defined as the time period, at the end of which 99 % of the bearings are still reliably lubricated. This represents the L1 grease life. SKF recommends using experience based on data from actual applications and tests, together with the estimated relubrication intervals provided in the section "Relubrication intervals". Grease lubrication - Relubrication - Relubrication intervals The relubrication intervals tf for bearings with rotating inner ring on horizontal shafts under normal and clean conditions can be obtained from diagram 4 as a function of
the speed factor A multiplied by the relevant bearing factor bf where A = n dm n = rotational speed, r/min mean diameter dm = bearing = 0,5 (d + D), mm
bf = bearing factor depending on bearing type and load conditions (table the load ratio C/P
2)
The relubrication interval tf is an estimated value, valid for an operating temperature of 70 C, using good quality lithium thickener/mineral oil greases. When bearing operating conditions differ, adjust the relubrication intervals obtained from diagram 4, according to the information given under "Adjustments of relubrication intervals due to operating conditions and bearing types"
Diagram 4: Relubrication intervals at operating temperatures of 70 C tf, operating hours
A bf
The relubrication interval tf is an estimated value, valid for an operating temperature of 70 C, using good quality lithium thickener/mineral oil greases. When bearing operating conditions differ, adjust the relubrication intervals obtained from diagram 4, according to the information given under "Adjustments of relubrication intervals due to operating conditions and bearing types". If the speed factor A exceeds a value of 70 % of the recommended limit according to table 2 or if ambient temperatures are high, then the use of the calculations presented in the section "Speeds and vibration" is recommended to check the operating temperature and the proper lubrication method.
Table 2: Bearing factors and recommended limits for speed factor A Bearing type1) Bearing factor bf Recommended limits for speed factor A for load ratio C/P 15 C/P 8 mm/min 300 000 300 000 300 000
C/P 4
Deep groove ball bearings
500 000
400 000
Angular contact ball bearings
500 000
400 000
Self-aligning ball bearings Cylindrical roller bearings
500 000
400 000
- non-locating bearing 1,5 - locating bearing, without external axial loads or with light but alternating axial 2 loads - locating bearing, with constantly acting light axial load 4 - full complement2) 4
450 000
300 000
150 000
300 000
200 000
100 000
200 000 NA3)
120 000 NA3)
60 000 20 000 100 000 200 000
Needle roller bearings
350 000
200 000
Taper roller bearings Spherical roller bearings -when load ratio Fa/Fr e and dm 800 mm
350 000
300 000
series 213, 222, 238, 239 2 series 223, 230, 231, 232, 240, 2 248, 249 series 241 2 -when load ratio Fa/Fr e and dm > 800 mm
350 000 250 000 150 000
200 000 150 000 80 0004)
100 000 80 000 50 0004)
series 238, 239 2 series 230, 231, 232, 240, 248, 249 2 series 241 -when load ratio Fa/Fr > e all series CARB toroidal roller bearings - with cage - without cage, full complement2) 2 4 2
230 000 170 000 100 000
130 000 100 000 50 0004)
65 000 50 000 30 0004) 30 0004)
150 000
50 0004)
350 000 NA3)
200 000 NA3)
100 000 20 000 100 000 30 000 30 000
Thrust ball bearings
200 000 100 000 100 000
150 000 60 000 60 000
Cylindrical roller thrust bearings 10 Needle roller thrust bearings Spherical roller thrust bearings - rotating shaft washer
1)
10
200 000
170 000
150 000
The geometry factors and recommended practical speed factor "A" limits apply to bearings with standard internal geometry and standard cage execution. For alternative internal bearing design and special cage execution, please contact the SKF application engineering service The tf value obtained from diagram 4 needs to be divided by a factor of 10 Not applicable, for these C/P values a caged bearing is recommended instead 4) For higher speeds oil lubrication is recommended
2) 3)
When using high performance greases, a longer relubrication interval and grease life may be possible. Contact the SKF application engineering service for additional information. Estimation of the relubrication interval can be made with the program "Relubrication intervals". Adjustments of relubrication intervals due to operating conditions and bearing types Operating temperature To account for the accelerated ageing of grease with increasing temperature, it is recommended halving the intervals obtained from the diagram 4 for every 15 C increase in operating temperature above 70 C, remembering that the high temperature performance limit for the grease (diagram 1, HTPL) should not be exceeded. The relubrication interval tf may be extended at temperatures below 70 C if the temperature is not close to the lower temperature performance limit (diagram 1, LTPL). A total extension of the relubrication interval tf by more than a factor of two is not recommended. In case of full complement bearings and thMoreover, it is not advisable to
use relubrication intervals in excess of 30 000 hoursrust roller bearings, tf values obtained from diagram 4 should not be extended. For many applications, there is a practical grease lubrication limit, when the bearing ring with the highest temperature reaches an operating temperature of 100 C. Above this temperature special greases should be used. In addition, the temperature stability of the bearing and premature seal failure should be taken into consideration. For high temperature applications please consult the SKF application engineering service. Vertical shaft For bearings on vertical shafts, the intervals obtained from diagram 4 should be halved. The use of a good sealing or retaining shield is a prerequisite to prevent grease leaking from the bearing arrangement Vibration Moderate vibration will not have a negative effect on grease life, but high vibration and shock levels, such as those in vibrating screen applications, will cause the grease to churn. In these cases the relubrication interval should be reduced. If the grease becomes too soft, grease with a better mechanical stability, e.g. SKF grease LGHB 2 or grease with higher stiffness up to NLGI 3 should be used. Outer ring rotation In applications where the outer ring rotates, the speed factor A is calculated differently: in this case use the bearing outside diameter D instead of dm. The use of a good sealing mechanism is a prerequisite in order to avoid grease loss. Under conditions of high outer ring speeds (i.e. > 40 % of the reference speed listed in the product tables), greases with a reduced bleeding tendency should be selected. For spherical roller thrust bearings with a rotating housing washer oil lubrication is recommended Contamination In case of ingress of contamination, more frequent relubrication than indicated by the relubrication interval will reduce the negative effects of foreign particles on the grease while reducing the damaging effects caused by overrolling the particles. Fluid
contaminants (water, process fluids) also call for a reduced interval. In case of severe contamination, continuous relubrication should be considered. Very heavy loads For bearings operating at a speed factor A > 20 000 and subjected to a load ratio C/P < 4 the relubrication interval is further reduced. Under these very heavy load conditions, continuous grease relubrication or oil bath lubrication is recommended. Misalignment A constant misalignment within the permissible limits does not adversely affect the grease life in spherical roller bearings, self-aligning ball bearings or toroidal roller bearings Large bearings To establish a proper relubrication interval for line contact bearings, in particular large bearings (d > 300 mm) used in critical bearing arrangements in process industries, an interactive procedure is recommended. In these cases it is advisable to initially relubricate more frequently and adhere strictly to the recommended regreasing quantities, see section "Relubrication procedures Before regreasing, the appearance of the used grease and the degree of contamination due to particles and water should be checked. Also the seal should be checked completely, looking for wear, damage and leaks. When the condition of the grease and associated components is found to be satisfactory, the relubrication interval can be gradually increased. A similar procedure is recommended for spherical roller thrust bearings, prototype machines and upgrades of high-density power equipment or wherever application experience is limited Cylindrical roller bearings The relubrication intervals from diagram 4 are valid for cylindrical roller bearings fitted with
a moulded glass fibre reinforced polyamide 6,6 cage, designation suffix P a two-part machined brass cage guided by the rollers, designation suffix M.
For bearings with a pressed steel cage, designation suffix J, or with an inner or outer ring centred cage, designation suffixes MA, ML and MP, the value for the relubrication interval from diagram 4 should be halved. Moreover, grease with good oil bleeding properties
should be applied. For bearings with MA, MB, ML or MP cage generally oil lubrication should be preferred. Very short intervals If the determined value for the relubrication interval tf is too short for a particular application, it is recommended to
check the bearing operating temperature, check whether the grease is contaminated by solid particles or fluids, check the bearing application conditions such as load or misalignment
and last but not least, a more suitable grease should be considered. Selection of bearing type
Available space
In many cases, one of the principal dimensions of a bearing - the bore diameter - is predetermined by the machine's design and the shaft diameter For small-diameter shafts all types of ball bearings can be used, the most popular being deep groove ball bearings; needle roller bearings are also suitable (fig 1). For largediameter shafts, cylindrical, taper, spherical and toroidal roller bearings are available, as well as deep groove ball bearings (fig 2).
Fig 1
Fig 2
When radial space is limited, bearings with a small cross section, particularly those with a low cross-sectional height, should be chosen, i.e. bearings in the 8 or 9 Diameter Series (see under "Dimensions" in the "Bearing data - general" section). Needle roller and cage assemblies, drawn cup needle roller bearings and needle roller bearings without or even with inner ring (fig 3), are very appropriate as well as certain series of deep groove and angular contact ball bearings, cylindrical, taper, spherical and toroidal roller bearings.
Fig 3
When axial space is limited, certain series of cylindrical roller bearings and deep groove ball bearings can be used for radial or combined loads respectively (fig 4) as well as the various types of combined needle roller bearings (fig 5). For purely axial loads, needle roller and cage thrust assemblies (with or without washers) as well as thrust ball bearings and cylindrical roller thrust bearings can be used (fig 6).
Loads
Magnitude of load The magnitude of the load is one of the factors that usually determines the size of the bearing to be used. Generally, roller bearings are able to support heavier loads than similar sized ball bearings (fig 7) and bearings having a full complement of rolling elements can accommodate heavier loads than the corresponding caged bearings. Ball bearings are mostly used where loads are light or moderate. For heavy loads and where shaft diameters are large, roller bearings are usually the more appropriate choice.
Fig 7
Direction of load Radial load NU and N types cylindrical roller bearings, needle roller bearings and toroidal roller bearings can only support pure radial loads (fig 8). All other radial bearings can accommodate some axial loads in addition to radial loads; see "Combined loads".
Fig 8
Axial load Thrust ball bearings and four-point contact ball bearings (fig 9) are suitable for light or moderate loads that are purely axial. Single direction thrust ball bearings can only accommodate axial loads acting in one direction; for axial loads acting in both directions, double direction thrust ball bearings are needed
Fig 9
Angular contact thrust ball bearings can support moderate axial loads at high speeds; here the single direction bearings can also accommodate simultaneously acting radial loads, while double direction bearings are normally used only for purely axial loads (fig 10).
Fig 10
For moderate and heavy axial loads acting in one direction, needle roller thrust bearings, cylindrical and taper roller thrust bearings are suitable, as are spherical roller thrust bearings (fig 11). Spherical roller thrust bearings can also accommodate simultaneously acting radial loads. For heavy alternating axial loads, two cylindrical roller thrust bearings or two spherical roller thrust bearings can be mounted adjacent to each other.
Fig 11
Combined load A combined load comprises a radial and an axial load acting simultaneously. The ability of a bearing to carry an axial load is determined by the angle of contact a - the greater the angle, the more suitable the bearing for axial loads. An indication of this is given by the calculation factor Y, which becomes smaller as the contact a increases. The values of this factor for a bearing type or for individual bearings will be found in the introductory text of the product table sections, or in the actual product tables. The axial load carrying capacity of a deep groove ball bearing depends on its internal design and the internal clearance in the bearing, see the section "Single row deep groove ball bearings". For combined loads, single and double row angular contact ball bearings and single row taper roller bearings are most commonly used although deep groove ball bearings and spherical roller bearings are suitable (fig 12). In addition, self-aligning ball bearings and NJ and NUP type cylindrical roller bearings as well as NJ and NU type cylindrical roller bearings with HJ angle rings can be used for combined loads where the axial component is relatively small (fig 13).
Fig 12
Fig 13
Single row angular contact ball bearings and taper roller bearings, NJ and NU+HJ type cylindrical roller bearings and spherical roller thrust bearings can only accommodate axial loads acting in one direction. For axial loads of alternating direction these bearings must be combined with a second bearing. For this reason, single row angular contact ball bearings are available as "universal bearings" for paired mounting and single row taper roller bearings can be supplied as matched sets comprising two single row bearings, see
sections "Single row angular contact ball bearings" and "Paired single row taper roller bearings". When the axial component of combined loads is large, it may be supported independently from the radial load by a separate bearing. In addition to the thrust bearings, some radial bearings, e.g. deep groove ball bearings or four-point contact ball bearings (fig 14) are suitable for this task. To make sure that the bearing is only subjected to the axial load in such cases, the bearing outer ring must be mounted with radial clearance (fig).
Fig 14
Moment load When a load acts eccentrically on a bearing, a tilting moment will occur. Double row bearings, e.g. deep groove or angular contact ball bearings, can accommodate tilting moments, but paired single row angular contact ball bearings or taper roller bearings arranged face-to-face, or better still back-to-back, are more suitable (fig 15).
Fig 15
Misalignment Angular misalignments between the shaft and housing occur, for example, when the shaft bends (flexes) under the operating load, when the bearing seatings in the housing are not machined to the same height or when shafts are supported by bearings in separate housings that are too far apart. Rigid bearings, i.e. deep groove ball bearings and cylindrical roller bearings cannot accommodate any misalignment, or can only accommodate very minor misalignments, unless by force. Self-aligning bearings, i.e. self-aligning ball bearings, spherical roller bearings, toroidal roller bearings and spherical roller thrust bearings (fig 16), on the other hand, can accommodate misalignment produced under operating loads and can also compensate for initial errors of misalignment resulting from machining or mounting errors. Values for the permissible misalignments are given in the introductory text of the table section. If the expected misalignment exceeds the permissible values, please contact the SKF application engineering service.
Fig 16
Thrust ball bearings with sphered housing washers and seating rings, Y-bearing units and alignment needle roller bearings (fig 17) can compensate for initial misalignment arising from machining or mounting errors.
Fig 17
Oil lubrication Oil is generally used for rolling bearing lubrication when high speeds or operating temperatures preclude the use of grease, when frictional or applied heat has to be removed from the bearing position, or when adjacent components (gears etc.) are lubricated with oil. In order to increase bearing service life, all methods of bearing lubrication that use clean oil are preferred, i.e. well filtered circulating oil lubrication, oil jet method and the oil-spot method with filtered air and oil. When using the circulating oil and oil-spot methods, adequately dimensioned ducts must be provided so that the oil flowing from the bearing can leave the arrangement. Oil lubrication - Methods of oil lubrication Oil bath The simplest method of oil lubrication is the oil bath (fig 6). The oil, which is picked up by the rotating components of the bearing, is distributed within the bearing and then flows back to the oil bath. The oil level should be such that it almost reaches the centre of the lowest rolling element when the bearing is stationary. The use of oil levellers such as the SKF LAHD 500 is recommended to provide the correct oil level. When operating at high speed the oil level can drop significantly and the housing can become overfilled by the oil leveller, under these conditions, please consult the SKF application engineering service.
Fig 6
Oil pick-up ring For bearing applications where speeds and operating temperature are such that oil lubrication is necessary and high reliability is required the oil pick-up ring lubrication method is recommended (fig 7). The pick-up ring serves to bring about oil circulation. The ring hangs loosely on a sleeve on the shaft at one side of the bearing and dips into the oil in the lower half of the housing. As the shaft rotates, the ring follows and transports oil from the bottom to a collecting trough. The oil then flows through the bearing back into the reservoir at the bottom. SKF plummer block housings in the SONL series are designed for the oil pick-up ring lubrication method. For additional information please consult the SKF application engineering service.
Fig 7
Circulating oil Operation at high speeds will cause the operating temperature to increase and will accelerate ageing of the oil. To avoid frequent oil changes and to achieve a fully flooded condition, the circulating oil lubrication method is generally preferred (fig 8). Circulation is usually produced with the aid of a pump. After the oil has passed through the bearing, it generally settles in a tank where it is filtered and, if required, cooled before being returned to the bearing. Proper filtering leads to high values for the factor c and thus to long bearing service life, see section "SKF rating life".
Fig 8
Cooling the oil enables the operating temperature of the bearing to be kept at a low level. Oil jet For very high-speed operation a sufficient but not excessive amount of oil must be supplied to the bearing to provide adequate lubrication without increasing the operating temperature more than necessary. One particularly efficient method of achieving this is the oil jet method (fig 9) where a jet of oil under high pressure is directed at the side of the
bearing. The velocity of the oil jet must be high enough (at least 15 m/s) to penetrate the turbulence surrounding the rotating bearing. Oil-spot With the oil-spot method (fig 10) - also called the oil-air method - very small, accurately metered quantities of oil are directed at each individual bearing by compressed air. This minimum quantity enables bearings to operate at lower temperatures or at higher speeds than any other method of lubrication. The oil is supplied to the leads by a metering unit, such as the SKF TOS-EX2, at given intervals. The oil is transported by compressed air; it coats the inside of the leads and "creeps" along them. It is projected to the bearing via a nozzle. The compressed air serves to cool the bearing and also produces an excess pressure in the bearing arrangement that prevents contaminants from entering.
Fig 9
Fig 10
Oil mist Oil mist lubrication has not been recommended for some time due to possible negative environmental effects. A new generation of oil mist generators permits to produce oil mist with 5 ppm oil. New designs of special seals also limit the amount of stray mist to a minimum. In case synthetic non-toxic oil is used, the environmental effects are even further reduced. Oli mist lubrication today is used in very specific applications, like the petroleum industry. Oil lubrication - Lubricating oils Straight mineral oils are generally favoured for rolling bearing lubrication. Oils containing EP, antiwear and other additives for the improvement of certain lubricant properties are generally only used in special cases. The remarks covering EP additives in the section "Load carrying ability, EP and AW additives" also apply to those additives in oils. Synthetic versions of many of the popular lubricant classes are available. Synthetic oils are generally only considered for bearing lubrication in extreme cases, e.g. at very low or very
high operating temperatures. The term synthetic oil covers a wide range of different base stocks. The main ones are polyalphaolefins (PAO), esters and polyalkylene glycols (PAG). These synthetic oils have different properties to mineral oils, see table 3.
Table 3: Properties of oil types Properties Base oil type Mineral PAO 30 .. 0 low high 50 .. 40 moderate moderate
Ester 60 .. 40 high low to moderate
PAG appr. 30 high high
Pour point, C Viscosity index Pressure - viscosity coefficient
With respect to bearing fatigue life the actual lubricant film thickness plays a major role. The oil viscosity, the viscosity index and the pressure-viscosity coefficient influence the actual film thickness in the contact area for a fully flooded condition. For most mineral oil based lubricants, the pressure-viscosity coefficient is similar and generic values obtained from literature can be used without large error. However, the response of viscosity to increasing pressure is determined by the chemical structure of the base stocks used. As a result of this there is considerable variation in pressure-viscosity coefficients for the different types of synthetic base stocks. Due to the differences in the viscosity index and pressure-viscosity coefficient, it should be remembered that the lubricant film formation, when using synthetic oil, may differ from that of a mineral oil having the same viscosity. Accurate information should always be sought from the individual lubricant supplier In addition, additives play a role in the film formation. Due to differences in solubility, different types of additives are applied in synthetic oils when compared with the mineral oil based counterparts Oil lubrication - Lubricating oils - Selection of lubricating oil Selecting oil is primarily based on the viscosity required to provide adequate lubrication for the bearing at the bearing operating temperature. The viscosity of oil is temperature dependent, becoming lower as the temperature rises. The viscosity-temperature relationship of an oil is characterized by the viscosity index VI. For rolling bearing lubrication, oils having a high viscosity index (little change with temperature) of at least 95 are recommended In order for a sufficiently thick oil film to be formed in the contact area between rolling elements and raceways, the oil must retain a minimum viscosity at the operating temperature. The minimum kinematic viscosity 1 required at the operating temperature to provide adequate lubrication can be determined from diagram 5 provided a mineral oil is used. When the operating temperature is known from experience or can otherwise be determined, the corresponding viscosity at the internationally standardized reference
temperature of 40 C, i.e. the oil ISO VG viscosity class, can be obtained from diagram 6, which is compiled for a viscosity index of 95.
Diagram 5: Estimation of the minimum kinematic viscosity 1 at operating temperature Required viscosity at operating temperature
Diagram 6: Kinematic viscosity at reference temperature Viscosity at operating temperature
Certain bearing types, e.g. spherical roller bearings, toroidal roller bearings, taper roller bearings, and spherical roller thrust bearings, normally have a higher operating temperature than other bearing types, e.g. deep groove ball bearings and cylindrical roller bearings, under comparable operating conditions When selecting the oil the following aspects should be considered Viscosity calculations can be made with the program "Viscosity". Example A bearing having a bore diameter d = 340 mm and outside diameter D = 420 mm is required to operate at a speed n = 500 r/min. Therefore dm = 0,5 (d + D) = 380 mm. From diagram 5, the minimum kinematic viscosity 1 required to give adequate lubrication at the operating temperature is 10 mm/s. From diagram 6, assuming that the operating temperature of the bearing is 70 C, it is found that a lubricating oil of ISO VG 32 viscosity class, i.e. a kinematic viscosity of at least 32 mm2/s at the reference temperature of 40 C will be required
Oil lubrication - Oil change The frequency with which it is necessary to change the oil depends mainly on the operating conditions and the quantity of oil. With oil bath lubrication it is generally sufficient to change the oil once a year, provided the operating temperature does not exceed 50 C and there is little risk of contamination. Higher temperatures call for more frequent oil changes, e.g. for operating temperatures around 100 C, the oil should be changed every three months. Frequent oil changes are also needed if other operating conditions are arduous. With circulating oil lubrication, the period between two oil changes is also determined by how frequently the total oil quantity is circulated and whether or not the oil is cooled. It is generally only possible to determine a suitable interval by test runs and by regular inspection of the condition of the oil to see that it is not contaminated and is not excessively oxidised. The same applies for oil jet lubrication. With oil spot lubrication the oil only passes through the bearing once and is not recirculated
DIMISA
DIMISA ANTIDUST IDLERS
Contents:
Installation and maintenance recommendations for DIMISA brand, Antidust type idlers. Diseo de Mquinas Industriales, S. A. de C. V. English. 2.

TECHNICAL BULLETIN
INSTALLATION, CARE AND MAINTENANCE RECOMMENDATIONS FOR IDLERS GENERAL RECOMMENDATIONS: A belt conveyor must be designed and constructed in such a way that the belt travels constantly centered through the idlers and over the pulleys. To achieve this, the following general conditions must be present: a) All idlers have to be aligned and in the same transversal plane. b) All the pulleys must be in line, with their shafts parallel between them and at 90 respect the belts centerline. c) The material must be loaded very close to the centerline of the belt. d) The belt must be correctly aligned. REPAIR AND STORAGE: Idlers should be covered while in storage to protect them from the outdoor and other adverse conditions. Before installing them, check all the idlers to look for handling or relocation damage. Make sure that all the rollers still roll freely. INSTALLATION: Put the idlers in position, firmly sliding them in the same direction the belt moves and against the mounting bolts, adjusting them carefully. idlers located close to them, for this will cause improper overloads in bearigns and conveyor belt. The pulleys and the idlers located in their vicinity should be carefully aligned when installed and ought not to be moved to fulfill or correct belt alignment. If a section of the belt travels along the centerline of the conveyor through and other consistently travels incorrectly, there are high probabilities that the problem is due to a badly cut or improperly spliced belt. Other possibility is that the belt, stored inadequately, finally ended to bend itself. This condition, however, is rapidly corrected after hours of operation. If the belt is out of centerline always at the same point along the conveyor, the problem could be related to idler misalignment around the zone with trouble. A proper alignment is fulfilled by gently rotating some of the idlers located just before where the problem begins.
When belt is finally aligned, all the idlers must be secured in place. IDLER ALIGNMENT: After the belt and idler installation is complete, the conveyor can be started without load to check for alignment problems. This kind of test is known as a no-load test. A correctly aligned conveyor will have the centerline of its belt traveling around the geometric center of the through formed by the idlers. If any alignment-related problems are detected, it is not advisable to try to correct it moving the final (i.e. tail or head) pulleys or the
Another way of achieving alignment is tilting forward (no more than 2) the carrying idlers. This can be done putting a washer just below the base of the supporting plate of the idler. If the inclination used exceeds the 2 magnitude mentioned before, the alignment condition will not improve and the excessive tilt will produce more wear in belt and rollers. This method has the advantage (over rotating the entire idler around the center of the through) that it corrects the belt trajectory before and after the adjusted idler, being thus useful for the correction of belts with erratic motion. Both systems are unidirectional, that is, they will not work with reversible belts because their correcting effect will produce misalignment when a reversible belt changes its traveling direction.
TECHNICAL BULLETIN
Loading skirtboards should be adjusted to limit lateral material spillage and to maintain the burden centered over the belt while loading. The distance between skirtboards is commonly two thirds of the belts width, though it is desirable, when possible, to reduce this distance up to half the width of the belt, especially with free-flowing materials. The length of skirts should be enough to prevent lateral spillage. The material ought to be at rest over the belt before the skirtboards enclosure ends. Once belt alignment has been achieved in both carry and return sides, the conveyor installer should proceed to test the system at full load condition. LOADING THE CONVEYOR: The conveyors loading should be initiated with a light load, slowly increasing its level until the full design capacity is reached. The loading point is the most critical when putting material over the belt. There is where the belt receives the major part of its abrasion and practically all its impact load. The ideal condition is transferring the material from the loading hopper moving at a speed and with a direction as close as possible to the belts, with a minimum of impact and with the stream of material directed to the belts centerline. Off center loading is detrimental to both idlers and belting. It also affects the conveyors alignment, misaligning the belt, while a centered loading will tend to maintain the correct travel. SELF-ALIGNING IDLERS: A correctly aligned and loaded belt should travel centered alogn the conveyor without the aid of self-aligning idlers. This idlers are used to compensate ocassional non-centered loading and/or any other variable or eventual condition. Self-aligning idlers are installed along the conveyor at 100 feet intervals, but not less than 12 or 15 times the belt width over the pulleys. LUBRICATION: All idlers manufactured by DIMISA are factory lubricated and ready to use. Antidust idlers are provided lubricated with multilithium grease for either standard or extreme temperature ranges, depending on the case, and are sealed for life with an efficient labyrinth sealing system. Because the previous reason, Antidust idlers produced by Diseo de Mquinas do not require regreasing through all their lifetime.
DIMISA
FALK REDUCERS
Contents: Published by: Language: Pages:
Installation and maintenance instructions for FALK brand, ZB3 type speed reducers. FALK English. 11

Enclosed Gear Drives Installation & Maintenance Instructions
a good name in industry
21X10ZB3
Sizes 305 thru 585
(Page 1 of 11)
How to Use This Manual

This manual provides detailed instructions on installation and maintenance of parallel shaft Types A, AR, AXV and right angle Types AB, ABR, ABX, and ABRC gear drives. Use the table of contents below to locate required information. CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE FREE SERVICE OF YOUR FALK GEAR DRIVE.
Type A
Type ZB
Table of Contents
Installation Instructions . . . . . . . . . . . . . . Pages 1-3 Shaft Connections . . . . . . . . . . . . . . . . Pages 3-4 Tightening Torques . . . . . . . . . . . . . . . . . Page 5 Lubrication Recommendations . . . . . . . . . . Pages 5-8 Preventive Maintenance . . . . . . . . . . . . . . . Page 9 Stored and Inactive Gear Drives . . . . . . . . . . Page 11
Type AXVD
Type ABXU
Introduction
Credit for long service and dependable operation of a gear drive is often given to the engineers who designed it, or the craftsmen who constructed it, or the sales engineer who recommended the type and size. Ultimate credit belongs to the mechanic on the job who worked to make the foundation rigid and level, who accurately aligned the shafts and carefully installed the accessories, and who made sure that the drive received regular lubrication. The details of this important job are the subject of this manual. NAMEPLATE Operate Falk gear drives only at power, speed and ratio shown on the nameplate. Before changing any one of these, submit complete nameplate data and new application conditions to the Falk for correct oil level, parts, and application approval. DISASSEMBLY AND ASSEMBLY Disassembly & assembly instructions and parts guides are available from the Factory or Falk Representatives. When requesting information, please give complete data from the nameplate on the gear drive; Model, M.O.Number, Date, RPM, and Ratio. WARNING: Consult applicable local and national safety codes for proper guarding of rotating members. Lock out power source and remove all external loads from drive before servicing drive or accessories.
Type AR
Type ABR
Type ABRC
Installation Instructions
The following instructions apply to standard Falk Type A, AB, AXV, ABX, AR, ABR, & ABRC (Alignment Free) drives. If a drive is furnished with special features, refer to the supplementary instructions shipped with the drive. NOTE: Quadruple Reduction Type A Gear Drives: Removal of backstop and mounting bracket may be required for adequate clearance when installing foundation fasteners. Removal of fan assemblies may be required for adequate clearance when installing foundation fasteners. WELDING Do not weld on the gear drive or accessories without prior approval from The Falk Corporation. Welding on the drive may cause distortion of the housing or damage to the bearings and gear teeth. Welding without prior approval could void the warranty. EFFECTS OF SOLAR ENERGY If the gear drive operates in the sun at ambient temperatures over 100F(38C), then special measures should be taken to protect the drive from solar energy. This protection can consist of a canopy over the drive or reflective paint on the drive. If neither is possible, a heat exchanger or other cooling device may be required to prevent the sump temperature from exceeding the allowable maximum.
Warranty
The Falk Corporation (the Company) warrants that its products (i) conform to Companys published specifications, and (ii) are free from defects in material or workmanship. The duration of this warranty is three years from the date of shipment. Company does not warrant any purchased, non-Falk branded products or components (manufacturers warranty applies) or any defects in, damage to, or failure of products caused by: (i) dynamic vibrations imposed by the drive system in which such products are installed unless the nature of such vibrations has been defined and accepted in writing by Company as a condition of operation; (ii) failure to provide suitable installation environment; (iii) use for purposes other than those for which designed, or other abuse or misuse; (iv) unauthorized attachments, modifications or disassembly, or (v) mishandling during shipping.
The Falk Corporation, P Box 492, Zip 53201-0492 .O. 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com
April 2000 Supersedes 12-98
138-050
Installation & Maintenance Instructions Enclosed Gear Drives (Page 2 of 11)

MOUNTING POSITION Standard mounting positions for types A, AB, AXV, and ABX are with the base horizontal, and for types AR, ABR, and ABRC with the input and output shafts horizontal. If a gear drive is ordered for non-standard mounting positions, refer to the instructions provided with the drive for oil levels and bearing lubrication. If it is necessary to mount the gear drive in a different position from which it was ordered, refer to Falk for required changes to provide proper lubrication. FOUNDATION, GENERAL To facilitate oil drainage, elevate the gear drive foundation above the surrounding floor level. If desired, replace the drive oil drain plug with a valve, but provide a guard to protect the valve from accidental opening or breakage. When an outboard bearing is used, mount drive and outboard bearing on a continuous foundation or bedplate, and dowel both in place. FOUNDATION, STEEL When mounting gear drive on structural steel, it is recommended that an engineered design be utilized for a pedestal, adapter base or bed to provide sufficient rigidity, to prevent induced loads from distorting the housing and causing gear misalignment. In the absence of an engineered design, it is recommended that a base plate, with thickness equal to or greater than the thickness of the drive feet, be securely bolted to steel supports and extend under the entire Continuous Plate drive as illustrated. FOUNDATION, CONCRETE If a concrete foundation is used, allow the concrete to set firmly before bolting down the gear drive. For the best type of mounting, grout structural steel mounting pads into the mounting base, as illustrated, rather than grouting the drive directly into the concrete. Motors and other components mounted on motor plates or motor brackets may become misaligned during shipment. ALWAYS check alignment after installation. Refer to Page 4 for coupling alignment instructions. MOTOR BRACKETS Falk motor brackets provide an economical soft mounting for standard NEMA and IEC foot mounted AC induction electric motors. The weight, location, and starting torque of the motor will cause cantilevered motor brackets to deflect downward or to twist to varying degrees. The motor bracket/motor selections are engineered to be within acceptable deflection limits as determined by the Falk Corporation. Because the bracket is a soft motor support, deflection and vibration magnitude of the bracket may exceed levels normally considered acceptable for rigidly mounted machinery. For applications using other than standard selections, use of a motor plate is recommended. If a motor bracket is to be used,
it becomes the customers responsibility to support the rear of the motor bracket to limit deflection and vibration to within satisfactory levels as determined by the customer.
Gear Drive Alignment

FOOT MOUNTED DRIVES Align drive with driven equipment by placing broad, flat shims under all mounting pads. Start at the low speed shaft end and level across the length and then the width of the drive. Check with a feeler gauge to make certain that all pads are supported to prevent distortion of housing when drive is bolted down. After drive is aligned with driven equipment and bolted down, align prime mover to drive input shaft. Refer to Page 4 for coupling alignment. If equipment is received from Falk mounted on a bedplate, the components were accurately aligned at Falk with the bedplate mounted on a large, flat assembly plate. Shim under the bedplate foot pads until the gear drive is level and all feet are in the same plane. Check high speed shaft coupling alignment. If the coupling is misaligned, the bedplate is shimmed incorrectly. Re-shim bedplate and recheck high speed coupling alignment. If necessary, realign motor.
Leveling Reference Surfaces
Shims
SHAFT MOUNTED DRIVES Shaft mounted drive alignment occurs when the gear drive is attached to the driven shaft. The standard hollow low speed shaft is connected to the driven shaft with a shrink disc connection. Solid low speed shafts are typically connected with an MCF moment type coupling. Refer to the Shaft Connection section for coupling installation. There may be some visible movement of the drive while operating due to shaft and coupling runouts. Torque arm assemblies must be aligned such that the gear drive movement is not restricted during operation. Refer to torque arm instructions on Page 3. The Alignment Free drive flange motor adapter provides registration for the motor which eliminates the adjustments normally required for high speed coupling alignment.
Torque Arms
The torque arm connects a shaft mounted gearbox to the foundation. In static condition, it helps to support the weight of the gearbox/motor assembly. In the dynamic condition, it supports the weight and also transmits the torque reaction to
138-050
The Falk Corporation, P.O. Box 492, Zip 53201-0492 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131 Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com
Enclosed Gear Drives Installation & Maintenance Instructions (Page 3 of 11)

CORRECT METHOD Heat interference fitted hubs, pinions, sprockets or pulleys to a maximum of 275F (135C) and slide onto gear drive shaft. INCORRECT METHOD DO NOT drive coupling hub, pinion, sprocket or pulley onto the shaft. An endwise blow on the shaft/coupling may damage gears and bearings.
the foundation. The torque arm may be loaded in compression or tension. Maximum torque arm loads should be considered when designing the foundation for the torque arm anchor. TORQUE ARM ASSEMBLY The torque arm components are to be assembled according to the following illustration. A plain spherical bearing is fitted into the gearbox housing or bedplate. A pin engages the spherical bearing and connects it to the torque arm. Spacers center the bearing on the pin. The pin is retained by a snap ring. A similar connection is made between the torque arm and anchor bracket. In operation, the torque arm is to be perpendicular to the edge of the gear drive. Warning: Angular misalignment of the torque arm may restrict gear drive gear drive movement and cause excessive loading on the low speed shaft and driven equipment.
SPACER (4) TORQUE ARM (1) TORQUE ARM PIN (2) EXTERNAL RETAINING RING (2) TUBE FITTING (2)
CAUTION DO NOT HAMMER
PIPE PLUG SQUARE HEAD (2)
RADIAL SPHERICAL BEARING (2) ANCHOR BRACKET (1)
FLANGED MOTOR ADAPTERS Accurate axial positioning of the coupling hub on the motor shaft is required to ensure proper coupling gap. To establish the correct overhang on the motor shaft, measurements are required. Refer to Figure 1 below. First measure the distance from the motor mounting face of the motor to the end of the motor shaft (A). Then measure the distance from the motor mounting face of the motor adapter to the face of the gear drive hub (B). Refer to the coupling installation and maintenance instructions to determine the desired coupling gap. The coupling overhang is determined from the following equation: Overhang = A + Gap - B If the calculated overhang is a positive value, the motor shaft extends beyond the hub by that amount. NOTE: For couplings where the coupling gap does not occur at the end of the motor hub, an additional adjustment must be made. See dimension C in Figure 1 below.
FLANGE MOTOR ADAPTER MOTOR MOUNTING FACE
TORQUE ARM MOVEMENT Movement of the gear drive while operating is natural. The movement is due to shaft and coupling runouts. The standard torque arm is designed to accommodate this movement. It allows the gearbox to move slightly with the driven shaft. This prevents transmitting unnecessary additional loads to the driven shaft through the gearbox. DO NOT restrain free movement of the gear drive, to do so will adversely load the low speed shaft and driven shaft and may result in shaft or hub failure. Recheck torque arm movement during regular maintenance intervals.
C MOTOR
Shaft Connections
WARNING: Provide suitable guards in accordance with local and national standards. SHRINK DISC CONNECTIONS Shrink disc assemblies used on hollow low speed shafts and on some MCF coupling hubs require special installation procedures. Refer to the following Falk bulletins for detailed instructions: Shrink Discs 138-850 MCF couplings 458-862 COUPLING CONNECTIONS The performance and life of any coupling depends largely upon how well the coupling is installed and serviced. Refer to the coupling manufacturers manual for specific instructions.
Figure 1
A OVERHANG B COUPLING HUBS
FALK COUPLINGS (Except fluid type) Detailed installation manuals are available from Falk, your local Falk Representative or Distributorjust provide size and type designations stamped on the coupling. For lubricant requirements and a list of typical lubricants meeting Falk specifications, refer to appropriate coupling service manual. Flanged Type Rigid Couplings are typically used on drives with vertical output shafts. The low speed shaft extension ends of the solid vertical shaft drives are drilled and tapped to accommodate coupling keeper plates. Tightening torques for fasteners, including keeper plate fasteners are listed in Table 1, Page 5.
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FALK FLUID COUPLINGS Refer to the installation manual furnished with the Falk fluid coupling for installation and startup instructions. Type ABRC The Alignment Free flange motor adapter has two side inspection openings. On solid shaft gear drives, the opening opposite the low speed shaft extension has been marked to indicate the vertical midpoint of the adapter. On hollow shaft gear drives, the opening on the shrink disk side of the gear drive has been marked to indicate the vertical midpoint of the adapter. These marks are used to establish the proper fill angle for the fluid coupling. The fluid coupling outside diameter has been marked with two separate match marks. The recommended fill can be obtained by lining up the correct match mark on the fluid coupling with the mark in the inspection opening and filling the fluid coupling until fluid appears at the lip of the fill hole. To determine the correct mark on the fluid coupling begin by aligning the fill hole with the match mark in the inspection opening. For fill angles less than 90, rotate the fill plug upward till the match marks line up. For fill angles greater than 90, rotate the fill plug downward till the match marks line up. GAP AND ANGULAR ALIGNMENT If possible, after mounting coupling hubs, position the driving and driven equipment so that the distance between shaft ends is equal to the coupling gap. Align the shafts by placing a spacer block, equal in thickness to required gap, between hub faces, as shown at right, and also at 90 intervals around the hub. Check with feelers. OFFSET ALIGNMENT Align STEELFLEX ILLUSTRATED driving and driven shafts so that a straight edge will rest squarely on both couplings hubs as shown to the right and also at 90 intervals. Tighten foundation bolts of the connected equipment and recheck alignment and gap. SPROCKETS, PULLEYS OR STEELFLEX ILLUSTRATED SHEAVES Mount power take-offs as close to the gear drive housing as possible to avoid undue bearing load and shaft deflection. Align the output shaft of the gear drive square and parallel with the driven shaft by placing a straightedge across the face of the sprockets or sheaves as illustrated.Check horizontal shaft alignment by placing one leg WRONG RIGHT of a square against the face of the sheave or sprocket with the spirit level on the horizontal leg of the square.
GEAR DRIVE WALL
DO NOT over tighten belts or chains. Adjust chains to manufacturers specifications. Adjust belts as follows: The ideal tension is the lowest tension at which the belt will not slip under peak load conditions. Check the belt tension frequently during the first 24 to 48 hours of run-in operation. Over tightening belts shortens belt and bearing life. Keep belts free from foreign material which may cause slippage. Inspect the Vbelt periodically; tighten the belts if they are slipping. OUTBOARD BEARING Mount the outboard bearing and gear drive on a common foundation so that they will shift as an assembly if settling should occur. Bring the outboard bearing to the correct horizontal position with broad flat shims under the mounting pad. Align accurately so that the load is equally divided between the two drive bearings and the outboard bearing. Mount a stop bar against the pillow block foot on the load side when large horizontal load components are exerted on the pillow block. PINION MOUNTING Mount pinion as close to the drive as possible to avoid undue bearing load and shaft deflection. Refer to Falk for pinion alignment instructions.
Non Falk Couplings Refer to manufacturers installation and maintenance instructions.

BACKSTOPS To prevent damage to backstops due to incorrect motor shaft rotation at start up, couplings are NOT assembled when gear drives are furnished with backstops for all types except ABRC. For type ABRC drives, remove the backstop before electrically connecting the motor. AB, ABR, and ABRC backstops are held in place by a retaining ring on the intermediate shaft. After completing electrical connections, check motor and gear drive shaft rotations. If rotations are correct, complete alignment and assembly of coupling or re-install the backstop.
LEVEL
SQUARE AND PARALLEL
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Fastener Tightening Torques

Use the tightening torque values specified in Table 1 for fastening Falk gear drives, motors and accessories to their mounting surfaces with un-lubricated fasteners. DO NOT use these values for torque locking fasteners or for fastening components with aluminum feet or soft gaskets or vibration dampeners on the mounting surface. If the tightening torque exceeds the capacity of the torque wrench, use a torque multiplier. For inch fasteners, use Grade 5 for diameters though 1.500 inch and ASTM A 354 grade BC for larger diameter fasteners. Use ISO property class 8.8 for metric fasteners.
Water Cooling
WATER COOLED HEAT EXCHANGERS Install a shut-off or control valve in the water line to the heat exchanger to regulate the water flow through the exchanger. Also install a water flow gauge between the control valve and the exchanger to determine actual flow rate. Discharge water to an OPEN DRAIN to prevent back pressure. INTERNAL COOLING TUBES Refer to Manual 138-310 for installation, operation, and maintenance of internal cooling tubes.
Lubrication Systems
SPLASH LUBRICATED DRIVES Standard type A, AR, AB, ABR, and ABRC drives are splash lubricated. The lubricant is picked up by the revolving elements and distributed to the bearings and gear meshes. OIL PUMP LUBRICATED DRIVES Types AXV and ABX are equipped with an external oil pump to provide oil to the upper bearings and gear meshes. The system is composed of an electric motor driven gear pump, oil filter, flow indicator with switch, and an internal distribution network with relief valve (set at 30 psi). The pump system may be furnished with a 50 or 60Hz, 3 phase electrical motors based on the selection. Refer to the pump motor nameplate and Table 2 for electrical requirements. Wire the motor for correct rotation as indicated by the rotation arrow. The flow indicator has a single pole, double throw switch rated at 15A, 125V/7A, 250V maximum. Connect the flow indicator switch with the prime mover control circuitry to prevent drive operation without the lubrication system. Other types of gear drives may also be equipped with oil pumps for special lubrication considerations or external cooling.
TABLE 1 Tightening Torques: +/-5% DO NOT Lubricate Fasteners

Inch Fasteners Grade 5 Fastener Size .250-20 .3125-18 .375-16 .500-13 .625-11 .750-10 .875-9 1.000-8 1.125-7 1.250-7 1.375-6 1.500-6 1.750-5 2.000-4.5 2.250-4.5 2.500-4 2.750-4 3.000-4 Metal to Metal lb-ft 7 15 27 67 134 242 395 590 740 1060 1360 1840 3900 5900 8600 11800 14600 19400 Nm 10 21 37 91 184 330 530 800 1000 1420 1860 2480 5300 7900 11800 16000 19800 26400 Metal to Concrete lb-ft 6 12 22 54 108 194 315 475 590 840 1100 1460 2700 4100 6000 8300 10200 13600 Nm 8 16 30 73 146 265 425 640 800 1140 1480 1980 4240 6300 9400 12800 15800 21100
TABLE 2 Oil Pump Electrical Specifications

DRIVE SIZE HP Cycles, Hz RPM Voltage 405 & 425 1 50 1425 220/380/440 60 1725 208230/460 50 1425 220/380/440 445-485 2 505-535 3 60 50 60 1725 1425 1725 208208220/380/440 230/460 230/460
TABLE 1A Tightening Torques: +/-5% DO NOT Lubricate Fasteners

Metric Fasteners Property Class 8.8 Fastener Size M4 x .7 M5 x .8 M6 x 1.0 M8 x 1.25 M10 x 1.5 M12 x 1.75 M16 x 2 M20 x 2.5 M30 x 3.5 M36 x 4 M42 x 4.5 M48 x 5 M56 x 5.5 Metal to Metal lb-ft 2 4.5 7.5 18 36 62 56 305 1060 1680 3000 4500 7300 Nm 3 6 10 24 50 84 210 415 1 440 2 520 4 050 6 100 9 850 Metal to Concrete lb-ft 1.5 3.5 6 14 29 50 126 246 850 1500 2400 3600 5800 Nm 2 5 8 19 39 68 170 330 1 150 2 030 3 250 4 880 7 860
Caution: Refer to Falk for drives that use pumps to distribute lubricants with temperatures below 30F (-1C).
Lubrication Recommendations
Carefully follow lubrication instructions on the gear drive nameplate, warning tags, and installation manuals furnished with the gear drive. Lubricants listed in this manual are typical ONLY and should not be construed as exclusive recommendations. Industrial type petroleum based rust and oxidation inhibited (R & O) gear lubricants or industrial type sulfur-phosphorus extreme pressure (EP) gear lubricants are the recommended lubricants for ambient temperatures of 15F to 125F(-9C to +50C). For drives operating outside the above temperature range refer to Synthetic Lubricants paragraphs, Page 7. Synthetic lubricants can also be used in normal climates.
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VISCOSITY (IMPORTANT) The proper grade for R & O and EP lubricants is found in Table 3. For cold climate conditions refer to Table 6, Page 7 and the Synthetic Lubricant paragraphs. If a gear drive operates in a typical indoor environment where the ambient temperature is within 70F to 125F (21C to 52C), the oil viscosity should be increased one AGMA grade above that shown for the 50F to 125F(10C to 52C) range. That is, an AGMA Number 6 or 7 should be substituted for a 5 or 6 respectively, under these ambient conditions. OIL PUMPS When selecting a lubricant for a gear drive equipped with an oil pump, cold temperature oil viscosity is important. Lubricant viscosity at start-up generally should not exceed 1725 cSt (8,000 SSU). When exceeding this viscosity, pump cavitation is possible, reducing oil circulation and possibly damaging the pump. A sump heater may be required or it may be possible to use a lower viscosity oil to minimize pump cavitation, refer to Falk.
highly loaded gear drives or drives loaded in excess of original estimates, industrial type petroleum extreme pressure lubricants are preferred. The EP lubricants currently recommended are of the sulfur-phosphorus type.
TABLE 5 Extreme Pressure Lubricants

Maximum Operating Temperature 200F(93C)
Manufacturer Amoco Oil Co. BP Oil Co. Chevron U.S.A. Inc. Citgo Petroleum Corp. Conoco Inc. Exxon Co. U.S.A. E.F. Houghton & Co. Imperial Oil Ltd. Kendall Refining Co. Keystone Div. Pennwalt Corp. Lyondell Petrochemical (ARCO) Mobil Oil Corp. PetroCanada Products Phillips 66 Co. Shell Oil Co. Shell Canada Limited Sun Oil Co. Texaco Lubricants Valvoline Oil Co.
Minimum viscosity index of 90.
Lubricant Permagear/Amogear EP Energear EP Gear Compounds EP Citgo EP Compound Gear Oil Spartan EP MP Gear Oil Spartan EP Kendall NS-MP Keygear Pennant NL Mobilgear Ultima EP Philgear Omala Oil Omala Oil Sunep Meropa AGMA EP
TABLE 3 Viscosity Grade Recommendations for Petroleum Based R & O or EP Lubricants

Normal Climates Output RPM Output RPM Below 80 Output RPM 80 & Above 15 to 60F (-9 to +16C) ISO-VG 150 150 4 4 50 to 125F (10 to 52C) AGMA 6 5 320 220
AGMA ISO-VG
Petroleum Based Lubricants

R & O GEAR LUBRICANTS (Table 4) Industrial type petroleum based rust and oxidation inhibited (R & O ) gear lubricants are the most common and readily available general purpose gear lubricants. EXTREME PRESSURE (EP) LUBRICANTS (Table 5) For
TABLE 4
Petroleum Based R & O Gear Oils Maximum operating temperature of lubricants 200F (93C)
4 150 626-765 135-165 Lubricant Amer.Ind. Oil 150 ..... Machine Oil AW 150 Citgo Pacemaker 150 Dectol R&O Oil 150 Teresstic 150 HydroDrive HP 750 Teresso 150 Four Seasons AW 150 KLC40 Duro 150 DTE Oil Extra Heavy Pennzbell AW Oil 150 Premium R & O 150 Magnus Oil 150 Morlina 150 Tellus 150 Sunvis 9150 Regal Oil R&O 150 Unax RX 150 Turbine Oil 150 Valvoline AW ISO 150 5 220 918-1122 198-242 Lubricant Amer.Ind. Oil 220 Energol HLP-HD 220 Machine Oil AW 220 Citgo Pacemaker 220 Dectol R&O Oil 220 Teresstic 220 HydroDrive HP 1000 Teresso 220 ..... KLC-50 Duro 220 DTE Oil BB Pennzbell AW Oil 220 Premium R & O 220 Magnus Oil 220 Morlina 220 Tellus 220 Sunvis 9220 Regal Oil R&O 220 Unax RX 220 Turbine Oil 220 Valvoline AW ISO 220 6 320 1335-1632 288-352 Lubricant Amer. Ind. Oil 320 ..... Machine Oil AW 320 Citgo Pacemaker 320 Dectol R&O Oil 320 Teresstic 320 ..... Teresso 320 ...... ..... Duro 32 DTE Oil AA Pennzbell AW Oil 320 Premium R & O 320 Magnus Oil 320 Morlina 320 Tellus 320 ..... Regal Oil R&O 320 Unax AW 320 Turbine Oil 320 Valvoline AW ISO 320 7 460 1919-2346 414-506 Lubricant Amer. Ind. Oil 460 ..... ..... Citgo Pacemaker 460 Dectol R&O Oil 460 Teresstic 460 ..... ..... ..... ..... ..... DTE Oil HH Pennzbell AW Oil 460 ..... ..... Morlina 460 ..... ..... Regal Oil R&O 460 Turbine Oil 460 Turbine Oil 460 .....
AGMA Viscosity Grade ISO Viscosity Grade Viscosity SSU @ 100F Viscosity cSt @ 40C Manufacturer Amoco Oil Co. BP Oil Co. Chevron U.S.A., Inc. Citgo Petroleum Corp. Conoco Inc. Exxon Company, U.S.A. Houghton International, Inc. Imperial Oil Ltd. Kendall Refining Co. Keystone Lubricants Lyondell Petrochemical (ARCO) Mobil Oil Corp. Pennzoil Products company PetroCanada Products Phillips 66 Co. Shell Oil Co. Shell Canada Limited Sun Oil Co. Texaco Lubricants Unocal 76 (East) Unocal 76 (West) Valvoline Oil Co
Minimum viscosity index of 90.
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WARNING: EP LUBRICANTS IN FOOD PROCESSING INDUSTRY EP lubricants may contain toxic substances and should not be used in the food processing industry without the lubricant manufacturers approval. Lubricants which meet USDA H1 classification are suitable for food processing applications.
Synthetic Lubricants
Synthetic lubricants of the polyalphaolefin type are recommended for cold climate operation, high temperature applications, extended temperature range (all season) operation, and/or extended lubricant change intervals. The proper viscosity grade of synthetic lubricant is given in Table 6 Refer to Table 7 for Synthetic lubricants.
Normal Climates
TABLE 6 Viscosity Grade Recommendations for Synthetic Lubricants H

Cold Climates Output RPM Below 80 80 & Above 30 to +10F (34 to 12C) ISO-VG 32 32 AGMA 0S 0S 15 to +50F (26 to +10C) ISO-VG 68 68 AGMA 2S 2S 0 to +80F (18 to +27C) ISO-VG 150 150 AGMA 4S 4S +10 to +125F (12 to +52C) ISO-VG 320 220 AGMA 6S 5S +20 to +125F (7 to +52C) ISO-VG 320 320 AGMA 6S 6S
H Refer to Falk for viscosity recommendations when ambient temperatures are below 30F (34C) or above 125F (52C).
TABLE 7 Synthetic Lubricants Polyalphaolefin Type H

AGMA Viscosity Grade ISO Viscosity Grade 0S 32 2S 68 284347 4S 150 626765 Lubricant ... Chevron U.S.A., Inc. ... Syncon 32 ... ... ... Clarity Synthetic ... PM Oil 220 Syn. Gear ... Lube Tegra ... 220 ... ... ... Syncon ... ... EP 220 Drydene SHL Drydene SHL Drydene SHL Lubricant 150 Lubricant 220 Lubricant 320 Teresstic Teresstic Teresstic SHP 150 SHP 220 SHP 320 Spartan Spartan Spartan Synthetic Synthetic Synthetic EP 220 EP 320 EP 150 SHC 629 SHC 630 SHC 632 Mobilgear Mobilgear Mobilgear SHC 150 SHC 220 SHC 320 Pennzgear Pennzgear Pennzgear SHD 150 SHD 220 SHD 320 Super Maxol Super Maxol Super Maxol S 150 S 220 S 320 Super Gear Super Gear Super Gear Fluid 150EP Fluid 220EP Fluid 320EP ... Hyperia 220 Hyperia 320 Hyperia S320 ... Hyperia S220 ... ... 5S 220 198242 6S 320 288352
Viscosity SSU @ 100F 134164 Manufacturer
9181122 13351632
WARNING: SYNTHETIC LUBRICANTS IN FOOD PROCESSING INDUSTRY Synthetic lubricants may contain toxic substances and should not be used in the food processing industry without the lubricant manufacturers approval. Lubricants which meet USDA H1 classification are suitable for food processing applications.
Viscosity cSt @ 40C 28.835.2 61.274.8 135165
Bearing and Seal Greases

All drives and some backstops have grease lubricated seals. Some vertical shaft and specially mounted drives have grease lubricated bearings. Drives are shipped with NLG1 or #2 grease in the seal housing cavities unless otherwise specified. Refer to Table 8 for grease recommendations.
Conoco, Inc. Dryden Oil Co.
Exxon Co. U.S.A.
Syncon 68 Syncon EP 68 Drydene SHL Drydene SHL Lubricant 32 Lubricant 68 Teresstic Teresstic SHP 32 SHP 68 ... SHC 624 ... Pennzgear SHD 32 ... ... ... ... ... ... SHC 626 ... Pennzgear SHD 68 Super Maxol S 68 ... ... ... ...
TABLE 8 Greases for Bearings and Seals

(0 to 200F(-18 to +93C)
Manufacturer Amoco Oil Co. BP Oil Co. Chevron U.S.A., Inc. Citgo Petroleum Corp. Conoco Inc. Exxon Company, U.S.A. E.F. Houghton & Co. Imperial Oil Ltd. Kendall Refining Co. Keystone Div. Pennwalt Corp. Lyondell Petrochemical (ARCO) Mobil Oil Corp. Mobil Oil Corp PetroCanada Products Phillips 66 Co. Shell Oil Co. Shell Canada Limited Sun Oil Co. Texaco Lubricants Unocal 76 (East & West) Valvoline Oil Co.
H High performance synthetic alternate.
Lubricant Amolith Grease No. 2 Energrease LSEP2 Industrial Grease Medium Premium Lithium Grease No. 2 EP Conolith Grease No. 2 Unirex N2 Cosmolube 2 Unirex N2L MultiPurpose Lithium Grease L421 Zeniplex 2 Litholine H EP 2 Grease Mobilith 22 Mobilith SHC 460 H Multipurpose EP2 Philube Blue EP Alvania Grease 2 Alvania Grease 2 Ultra Prestige EP2 Premium RB Grease Unoba EP2 Multilube Lithium EP Grease
Mobil Oil Corp.
Pennziol Products Co. Petro-Canada Products Shell Oil Co.
Sun Co.
Texaco Lubricants Co. Whitmore Mfg. Co.
Sunoco Sunoco Challenge Challenge 220 320 Sunoco Sunoco Challenge ... ... ... Challenge EP 220 EP 220 Pinnacle 32 Pinnacle 68 Pinnacle 150 Pinnacle 220 Pinnacle 320 Pinnacle Pinnacle ... ... ... EP 150 EP 220 Decathlon Decathlon Decathlon ... ... 5EP 6EP 4EP
H Minimum viscosity index of 130. Consult lubricant supplier/manufacturer for
maximum operating temperature. Extreme Pressure EP lubricant (contains sulphur phosphorus ).
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GREASE LUBRICATED SEALS Most gear drives and backstops are furnished with grease purged seals which minimize the entry of contaminants into the drive or backstop. Gear drives and backstops are shipped with NLGI #2 grease in the seal housing cavities unless otherwise specified. If grease could contaminate the product, as in the food and drug industries, it should be removed. A grease that meets USDA H1 classification is suitable for food processing applications.
GREASE LUBRICATED BEARINGS Vertical shaft drives with hollow shafts or with drywells have grease lubricated lower low speed bearings. These bearings are lubricated at the Factory with an NLGI#2 grease. Refer to the preventive maintenance instructions for greasing instructions. BACKSTOPS For types AB, ABR, and ABX model C and later, backstops are furnished filled with oil. Remove plug from top of backstop and replace with vent wired to torque arm. Earlier models had backstops that are grease lubricated, do not use greases with molybdenum disulfide or other EP additives. Type A and AR drives may have a Falk pawl type backstop or a Falk PRT wedge ramp type backstop. Falk pawl backstops are prelubricated and sealed at assembly and require no future lubrication. These backstops also contain grease purgeable seals (see paragraph above for grease lubricated seals). Falk PRT backstops are shipped filled with oil. Remove plug from top of backstop and replace with vent wired to torque arm.
TYPICAL SEAL ASSEMBLIES

FOR GREASING SEAL THROTTLING BUSH SEAL SEAL DRAIN CAVITY FOR GREASING SEAL
SEAL DRAIN CAVITY PLUG (BUNA-N)
Oil Levels
Types A & B Prior to filling gear drive, remove the inspection cover and flood the oil troughs with oil. This will provide oil to the bearings. Fill the drive with oil to the level indicated on the oil dipstick. Approximate oil capacities are given on the drive nameplate and in Table 9. Types ABR, ABRC, and AR Fill the drive with oil to the level indicted on the oil dipstick. Approximate oil capacities are given on the nameplate and in Table 10. Drives with Oil Pumps Types ABX, AXV, and occasionally other types of gear drives will be equipped with oil pumps for cooling or special lubrication considerations. If a drive is equipped with an oil pump, fill the drive to the level marked on the dipstick. Run the lubrication system for several minutes to fill the system components. Verify that the pump is circulating oil properly, then recheck oil level. If necessary, add oil to compensate for filter and/or cooler. Before starting the gear drive, rotate the input shaft to check for obstructions. Then start the drive and allow it to run without load for several minutes. Shut down and recheck oil level. If everything is satisfactory, the drive is ready for operation.
LOW OIL LEVEL Sizes 385 & 405 thru 585 Inner Bush Seal and Outer Lip Type Seal
HIGH OIL LEVEL Sizes 385 & 405 thru 585 Two Lip Type Oil Seals
FOR GREASING SEAL BUSH SEAL SEAL DRAIN CAVITY SEAL COVER
BUSH SEAL SEAL DRAIN CAVITY
FOR GREASING SEAL SEAL COVER
SEAL GAGE PLUG BASE PLUG

BASE PLUG
LOW OIL LEVEL Sizes 305 thru 365 & 395 Inner Bush Seal and Outer Lip Type Seal
HIGH OIL LEVEL Sizes 305 thru 365 & 395 Inner Bush Seal and Outer Lip Type Seal
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change in ambient temperature, if required. Refer to Table 6 for synthetic lubricant viscosity recommendations. GREASE LUBRICATED SEALS Depending on the frequency and degree of contamination (at least every six months), purge contaminated grease from seals by slowly pumping fresh bearing grease , WITH A HAND GREASE GUN, through the seal until fresh grease flows out along the shaft. Wipe off purged grease. Refer to Table 8 for NLGI #2 greases. Some of these greases are of the EP type and may contain toxic substances not allowed in the food processing industry. A grease that meets the USDA H1 classification is suitable for food processing applications. CAUTION: Rapid greasing with a power grease gun can force grease inward past the seals and plug the oil drainback system causing seal leaks. GREASE LUBRICATED BEARINGS (TYPES AXV AND ABX) All hollow and most solid vertical low speed shaft drives have a grease lubricated lower low speed bearing. Grease bearings during oil changes or at intervals of every 6 months or 2500 hours of operation whichever is less. Table 11 contains low speed bearing grease capacities. HOLLOW SHAFT DRIVES Remove the pressure relief plug before greasing. Pump grease into bearing cage until fresh grease appears at the plug. Replace the pressure relief plug when finished. See Figure 2 below. Refer to Table 8 for NLGI #2 greases. Some of these greases are of the EP type and may contain toxic substances not allowed in the food processing industry. A grease that meets the USDA H1 classification is suitable for food processing applications.
Preventive Maintenance
AFTER FIRST WEEK Check alignment of total system and realign where necessary. Also tighten all external bolts and plugs where necessary. DO NOT readjust the internal gear or bearing settings in the drive, these were permanently set at Falk. AFTER FIRST MONTH Proceed as follows: 1. Operate drive until old sump oil reaches normal operating temperature. Shut down drive and drain immediately. 2. Immediately flush drive with an oil of the same type and viscosity grade as the original charge (warmed to approximately 100F (38C) in cold weather) by rapidly pouring or pumping a charge equal to 25 - 100% of the initial fill volume or until clean oil flows through the drain. 3. Close the drain and refill the drive to the correct level with new oil of the correct type and viscosity. PERIODICALLY 1. Check the oil level of the drive when it is stopped and at ambient temperature. Add oil if needed. If the oil level is ABOVE the high oil level mark on the dipstick, have the oil analyzed for water content. Moisture in the oil may indicate that a seal or the heat exchanger is leaking. If so, replace the defective part immediately and change the oil. DO NOT fill above the mark indicated as leakage or undue heating may result. 2. Check coupling alignment to make certain that foundation settling has not caused excessive misalignment. 3. If drive is equipped with a fan, periodically clean accumulated foreign matter from the fan, guard, and deflector. 4. If drive is equipped with a torque arm, check for free movement.
Lubricant Changes
OIL ANALYSIS REPORT Checking oil condition at regular intervals is recommended. In the absence of more specific limits, the guidelines listed below may be used to indicate when to change oil: 1. Water content is greater than 0.05% (500 ppm). 2. Iron content exceeds 150 ppm. 3. Silicon (dust/dirt) exceeds 25 ppm. 4. Viscosity changes more than 15%. PETROLEUM LUBRICANTS For normal operating conditions, change gear oils every 6 months or 2500 operating hours, whichever occurs first. Change oil more frequently when gear drives operate in extremely humid, chemical or dust laden atmospheres. In these cases, R & O and EP lubricants should be changed every 3 to 4 months or 1500 to 2000 hours. If the drive is operated in an area where the temperatures vary with seasons, change oil viscosity grade to suit temperature. Lubricant suppliers can test oil periodically and recommend economical change intervals. SYNTHETIC LUBRICANTS Synthetic lube change intervals can be extended to 8000 - 10,000 hours depending upon operating temperatures and lubricant contamination. Change oil more frequently when gear drives operate in extremely humid, chemical or dust laden atmospheres. In these cases, synthetic lubricants should be changed every 4 to 6 months or 4000 to 6000 hours. Laboratory analysis is recommended for optimum lubricant life and gear drive performance. Change lube with
Figure 2
BEARING GREASE FITTING
RELIEF PLUG
BACKSTOPS For types AB, ABR, and ABX refer to the supplemental backstop installation and maintenance instructions provided with the drive for recommended lubricants. It is recommended to lubricate backstops during regular drive lubrication intervals. If backstops are grease lubricated, do not use greases with molybdenum disulfide or other EP additives. Type A and AR drives may have a Falk pawl type backstop or a Falk PRT wedge ramp type backstop. Falk pawl backstops are prelubricated and sealed at assembly and require no future lubrication. These backstops also contain grease purgeable seals (see paragraph above for grease lubricated seals). Falk PRT backstops are a wedge ramp type and are oil lubricated. Follow lubrication recommendations as outlined in the supplemental backstop instructions furnished with the drive.
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TABLE 9 Types A & B Approximate Oil Capacities

DRIVE SIZE 305 325 345 365 385 395 405 425 445 465 485 505 525 545 565 585 Type A A1 Gallons 3 5 6 10 10 12 10 14 22 29 32 42 53 ... ... ... Liters 11 19 23 38 38 45 38 53 83 110 121 159 201 ... ... ... Gallons 4 6 8 13 10 16 15 20 22 30 38 50 59 115 130 215 A2 Liters 15 23 30 49 38 61 57 76 83 114 144 189 223 435 492 814 Gallons 4 6 9 13 10 17 15 21 29 39 57 78 95 135 160 250 A3 Liters 15 23 34 49 38 64 57 79 110 148 216 295 360 511 606 946 Gallons A4 Liters AB2 Gallons Liters Type AB AB3 Gallons Liters AB4 Gallons Liters DRIVE SIZE 305 325 345 365 385 395 425 405 445 465 485 505 525 545 565 585
10 14 20 28 38 56 77 93 ... ... ...
38 53 76 106 144 212 291 352 ... ... ...
11 11 14 22 30 31 39 48 ... ... ...
42 42 53 83 114 117 148 182 ... ... ...
11 15 20 29 39 52 70 87 111 142 220
42 57 76 110 148 197 265 329 420 538 833
11 15 22 30 39 58 80 100 138 170 275
42 57 83 114 148 220 303 379 522 644 1 041
TABLE 10 Types AR, AVX, ABR, and ABX Approximate Oil Capacities
Vertical Output DRIVE SIZE 405 425 445 465 485 505 535 555 10 15 25 30 40 50 70 100 ABX3 & AXV2 Gallons Liters 38 57 95 114 151 189 265 379 ABX4, AXV3, & AXV4 Gallons 10 15 25 30 45 60 80 120 Liters 38 57 95 114 170 227 303 454 14 19 35 40 50 65 95 130 ABR3 & AR2 Gallons Liters 53 72 132 151 189 246 360 492 Horizontal Output ABR4, AR3, & AR4 H Gallons 14/18 19/27 35/50 40/55 60/80 80/100 110/140 160/220 Liters 53/68 72/102 132/189 151/208 227/303 303/379 416/530 606/833 DRIVE SIZE 405 425 445 465 485 505 535 555
H Values to right of slash mark are for type AR4 drives when HS Shaft is above drive center line.
TABLE 11 Types AXV and ABX LS Shaft Lower Bearing Grease Capacity
Solid Shaft DRIVE SIZE oz 405 425 445 465 485 505 535 555 8 12 12 30 30 40 50 50 Down mL 237 355 355 890 890 1180 1480 1480 oz 12 18 18 40 40 50 50 60 Up mL 355 532 532 1180 1180 1480 1480 1770 oz 12 12 24 30 60 60 80 80 Hollow Shaft mL 355 355 710 890 1770 1770 2370 2370 DRIVE SIZE 405 425 445 465 485 505 535 555
138-050
Stored & Inactive Gear Drives

Each gear drive is protected with a rust preventative that will protect parts against rust for a period of 4 months in an outdoor shelter or 12 months in a dry building after shipment from Falk. If a gear drive is to be stored, or in inactive after installation beyond the above periods, drain oil from housing and spray all internal parts with a rust preventative oil that is soluble in lubricating oil or add Motorstor vapor phase rust inhibitor at the rate of one ounce per cubic foot (1.05 liters per cubic meter) of internal drive space (5% of sump capacity). Refer to Table 12 for Motorstor quantities. Rotate the shafts several times by hand. Before operating, drives which have been stored or inactive must be filled to the proper level with oil meeting the specifications given in this manual. Refer to Manual 128-014 for Start-up after Storage instructions. Periodically inspect stored or inactive gear drives and spray or add rust inhibitor every six months, or more often if necessary. Indoor dry storage is recommended. Gear drives ordered for extended storage can be treated at Falk with a special preservative and sealed to rust-proof parts for periods longer than those cited previously. The vented dipstick should be replaced with a plug (vented dipstick should be attached to gear drive for future use) so that the protective rust inhibiting atmosphere is sealed inside the drive. Install vented dipstick when preparing drive for operation.
TABLE 12 Motorstor/VCI10H
DRIVE SIZE 305 thru 425 445 thru 485 505 thru 535 545 thru 585 Ounces Per Drive 2 6 10 30
(Add to stored or inactive drives)

Motorstor Milliliters Per Drive 60 180 300 890
H Product of Daubert Chemical Company, Chicago, IL.
138-050
DIMISA
RS-2X CCC EMERGENCY STOP
Contents:
Installation and maintenance instructions for CCC brand, RS-2X type Emergency stop switch. Conveyor ComponentsCo. English. 2.

130 Seltzer Road, PO Box 167 Croswell, MI 48422 USA PHONE: (810) 679-4211 TOLL FREE (800) 233-3233 FAX: (810) 679-4510 Email: info@conveyorcomponents.com http://www.conveyorcomponents.com
CONVEYOR COMPONENTS COMPANY
MODEL RS: ROPE SAFETY CONTROL INSTALLATION INSTRUCTIONS TECHNICAL INFORMATION Raintight units (standard): Enclosure type 1, 3, 3R, 4 and 4X dust-tight and raintight construction with corrosion resistance. Gasket sealed for indoor/outdoor applications. Aluminum or optional cast iron housing with 3 conduit openings in base casting. Dual Rated Units: Enclosure type 1, 3, 3R, 4 and 4X dust-tight and raintight construction, also for use in Class II, Groups E, F & G and Class III Hazardous Locations. Aluminum or optional cast iron housing with 1 conduit opening in base casting. Explosion Proof units: Enclosure for use in Class I, Groups C & D; and Class II, Groups E, F & G, and Class III Hazardous Locations. Aluminum or optional cast iron housing with 1 conduit opening in base casting. Electrical Ratings:
SPDT switches: 20 Amps, 125/250/480 VAC 10 Amps, 125 VAC Inductive 1 hp, 125 VAC 2 hp, 250 VAC Amp, 24 VDC Amp, 125 VDC Amp, 250 VDC DPDT switches: 15 Amps, 125/250 VAC N/A 3/4 hp, 125 VAC 1 1/2 hp, 250 VAC N/A N/A N/A
Figure 1: Contacts
Micro-switch(es) may be wired for single throw operation, either normally open or normally closed as required. See figure 1. Figure 2: Electrical Terminals
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INSTALLATION INSTRUCTIONS 1. 2. 3. The base should be mounted on a flat surface using the three (3) mounting holes in the base casting (see figure 3). The holes in the base are manufactured for 3/8" bolts. Each unit can cover a maximum of 200 feet of conveyor 100 feet in each direction. Safety considerations dictate that not more than 100 feet of cable should be attached to each side. The eyebolts supporting the cable should be placed at intervals from 8 10. Care must be taken that the cable does not become too slack. However, if the cable is too tight, false actuation of the unit may occur. This unit is designed for pilot duty. The control circuit should be wired through the motor starter circuit of the conveyor or other equipment to be controlled. Do not wire the unit directly into a heavy duty motor circuit. See Switch information on front page. The control should be tested after installation by actuation of the cable. The protected equipment should stop and alarms should sound as required with a minimum effort on the cable. Cable tension can be adjusted as necessary by changing the location of the cable on the handle (see figure 4). Figure 3: Control Dimensions
4.
5.
Figure 4: Cable Positions
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DIMISA
TA-2X CCC EMERGENCY STOP
Contents:
Installation and maintenance instructions for CCC brand, TA-2X type Emergency stop switch. Conveyor Components Co. English. 4.


130 Seltzer Road, PO Box 167 Croswell, MI 48422 USA PHONE: (810) 679-4211 TOLL FREE (800) 233-3233 FAX: (810) 679-4510 Email: info@conveyorcomponents.com http:\\www.conveyorcomponents.com
MODEL TA CONVEYOR BELT ALIGNMENT CONTROL A. HOW IT WORKS The model TA Conveyor Belt Alignment Control protects conveyor belts from damage due to belt misalignment or runoff. These controls are used in pairs with one control placed on each side of the conveyor belt. Each control unit can be equipped with two micro-switches to produce signals indicating belt misalignment at two deviation points. The first signal point could be used to indicate small belt deviation by sounding an alarm. The second signal point could be used to guard against extreme belt runoff by shutting down the conveyor. Each control consists of aluminum housing with a red epoxy coated roller. The roller is adjustable up to 90 in both directions and is positioned approximately 1 from the conveyor belt. The micro-switch actuation points are adjustable from 0 to 45 by a simple change of the actuating cam(s). The model TA can be furnished with general purpose or explosion proof construction. Cast iron and epoxy coated housings are also available. B. RECOMMEDED NUMBER OF UNITS A minimum of four alignment controls is required for each conveyor belt, with one on each side of the belt near the head and tail pulleys. For conveyors greater that 1,500 feet (457 meters) long, an additional four alignment controls are required, evenly spaced, one on each side of the carrying and return belt. C. INSTALLATION INSTRUCTIONS Model TA control units are always used in pairs with one placed on each side of the conveyor belt, usually a pair at each of the head and tail ends of the conveyor. Additional pairs of TA units may be placed at other points along the conveyor. The micro-switch(es) can be wired to trigger a warning signal or be connected directly to the motor starter circuit to stop a conveyor. The control unit should be mounted on supports so that the roller is positioned perpendicular to the conveyor belt, and positioned to intercept the conveyor belt at its midpoint. The roller clamp may be loosened to pivot the roller into the proper position. The roller is 9-3/4 high, and the point of interception should be at the 47/8 point. Control units should not be mounted too close to the belt because false signals could result. In most applications, the controls could be mounted approximately 1 from the belt, eliminating false signals while still protecting the belt against wide deviations.
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Field wiring must meet or exceed the requirements of the National Electrical Code and any other agency or authority having jurisdiction over the installation. D. ROLLER POSTION AND MICRO-SWITCH ACTUATION SETUP Figure 1: Control Accuation Example The Model TA is shipped with the switch cam(s) centered with the roller arm. During the installation, the switch cam and the roller arm should be re-positioned to ensure switch actuation at the desired roller positions. 1. Roller Position Loosen the roller clamp and pivot the roller so that it is perpendicular to the belt at the midpoint of the roller. Then tighten the roller clamp. 2. Position the housing so the roller is 1 from the edge of the conveyor belt. Then fasten the mounting feet. 3. Switch Cam Adjustment Lock out all power to the switch unit and remove the cover. Use the 3/32 hex wrench provided to loosen the #10-32 set screw on the switch cam. 4. Pivot roller in the desired amount away from the belt for alarm or shutdown. Figure 2: Roller and Belt Position 5. Adjust cam in same direction as the roller will move until the micro-switch just trips. Then lock the setscrew. 6. Pivot the roller in the desired amount for second trip point if needed. 7. Adjust the second cam as in step 5.
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E. TECHNICAL INFORMATON 1. Individual Switch Contact Ratings: SPDT switches: 20 Amps, 125/250/480 VAC 10 Amps, 125 VAC Inductive 1 hp, 125 VAC 2 hp, 250 VAC Amp, 24 VDC Amp, 125 VDC Amp, 250 VDC DPDT switches: 15 Amps, 125/250 VAC N/A 3/4 hp, 125 VAC 1 1/2 hp, 250 VAC N/A N/A N/A
2. Conduit opening: One NPT standard opening is built-in. 3. Actuating Arm: Roller is red epoxy coated steel with stainless steel shaft. Roller arm travel is 90 in both directions from vertical. 4. External Hardware: stainless steel 5. Operating Temperature Range: -40F to 150F F. WIRING
Figure 3: SPDT 2-Switch Schematic
Figure 4: DPDT 2-Switch Schematic
Figure 5: Terminal Identification (SPDT)
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Figure 6: Terminal Identification (DPDT)
Figure 7: Wire Routing To properly wire to the micro-switches on the model TA, route incoming wires under the shaft and micro-switches to the rear right side of the switches. Avoid contact with the micro-switch levers and other moving parts inside enclosure.
G. DIMENSIONS Figure 8: Dimensions and Mounting, Model TA-2 Shown
Figure 9: Dimensions and Roller Travel
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DIMISA
CT-101 CCC PLUGGED CHUTE SWITCH
Contents:
Installation and maintenance instructions for CCC brand, CT-101 type Plugged Chute Switch. Conveyor Components Co. English. 2.

130 Seltzer Road, PO Box 167 Croswell, MI 48422 USA PHONE: (810) 679-4211 TOLL FREE (800) 233-3233 FAX: (810) 679-4510 Email: info@conveyorcomponents.com http://www.conveyorcomponents.com MODELS CT-100, CT-101 AND CT-102, CT-200 AND CT-201
Figure1: DIMENSIONS
CT-100/101 CONTROL UNIT
CT-200 COMPACT PROBE
CT-201 STANDARD PROBE
CT-200P COMPACT PROBE WITH OPTIONAL PADDLE WELDED TO BOTTOM
CONTROL UNIT SPECIFICATIONS: Input Supply Voltage: Power Consumption: Probe Voltage Output: Output Relay: 115 VAC @ 50/60 Hz 10 Watts 15 VDC DP/DT 10 Amp, 120 VAC Resistive; Optional 240 VAC available 5 Amp, 240 VAC Resistive 1 Amp, 28 VDC Resistive 1/4 hp, 120 VAC Motor 1/3 hp, 240 VAC Motor 0.1 to 10 Seconds. This adjustment will delay output relay action. CT-100: NEMA 12 CT-101: NEMA 4 CT-102: Panel mounting with no enclosure 18 V Bayonet base Normal (blue): Light on when relay is energized; probe is vertical. Alarm (red): Light on when relay is de-energized; probe is tilted. This jumper determines when the output relay actuates and deactuates. The following summarizes the operation with the jumper at each position. Position 1: Relay energizes when the probe is in the vertical position. Relay de-energizes when probe is in the tilted position. Position 2: Relay energizes when probe is in the tilted position. Relay de-energizes when probe is in vertical position.
Time Delay: Enclosure:
Indicator Lights:
Logic Selector:
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PROBE SPECIFICATIONS: Each probe contains one SP/ST, normally closed, mercury switch. Probes are available in optional stainless steel construction and with a paddle for use in applications where the materials are moving. CT-201: CT-200: Probe signal voltage: Probe ratings: Probe actuation angle: Standard heavy-duty probe model; 9 long Compact probe model; 6 long. 15 VDC 1.7 A @ 120VAC, 0.75 A @ 220VAC, 1.7 A @ 0-50VDC 15 from vertical Figure 2: CONTROL UNIT CIRCUIT
INSTALLATION INSTRUCTIONS: MOUNTING: The control unit should be mounted in an area free from vibration and the temperature should not exceed 125 F. Consideration should be given to mounting the unit where indicator lights will be visible to the necessary personnel, and wiring may be easily installed to the probe and other machinery. All wiring should be in compliance with applicable Local, Federal, and State codes. Probe connection cable is 16-2 type SO and is attached to the probe. Length is supplied as specified per order (probe cable may be spliced). If not specified, the probe is supplied with 3 feet of cable only.
TIME DELAY ADJUSTMENT CW = INCREASE CCW = DECREASE
LOGIC SELECTION SWITCH
WIRING:
PROBE INSTALLATION: The probe should be suspended using a fixed support, such as the CT-400 mounting bracket and CT-500 S-hook, at a position where it will easily intercept the bulk material at the desired indication point. There must be a free flow of material both to and away from the probe. In some installations, it is necessary to install a baffle or shield above the probe assembly to protect it from product surges. Figure3: TYPICAL INSTALLATIONS
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DIMISA
XS-A TELEMECANIQUE SPEED SWITCH
Contents:
Installation and maintenance instructions for TELEMECANIQUE brand, XS-A type Speed Switch. TELEMECANIQUE. English. 8

Product Data Bulletin

Underspeed Detection:
Bulletin No. 9006PD9501 June, 1995 Raleigh, NC, USA
A Means for Improved Productivity and Increased Operator Safety
INTRODUCTION
Motion detection is a valuable resource for improving productivity in many plants. As production speeds increase and more sophisticated assembly lines and conveyor systems are used, there is a greater need to monitor and control conveyor speed. This is particularly true since there are more motors, transmissions and belts that can fail, causing the system to halt. Motion detection can also be used to improve operator safety and equipment performance. Properly applied, motion detection devices can increase uptime and reduce maintenance time and expense. It is relatively easy to detect the presence or absence of an object on a conveyor, using anything from a photoelectric sensor to a limit switch. However, detecting the object does not necessarily indicate whether the conveyor is operating at the proper speed or delivering the product. The tendency is to assume that the belt or conveyor is operating properly. The drive system is usually external to the production control system, so a broken drive gear or belt can go undetected and result in serious damage as well as extensive downtime. This problem is not restricted to conveyor systems. Pumps and pistons and other devices that have linear or rotational motion can also jam. It is important to monitor any mechanism involved in the movement of product. Since most motors operate at a fixed speed, the factors that cause an underspeed condition on a conveyor also make the motors work harder to maintain proper speed. Without detection or correction, the motors may continue to overload until tripped by thermal overload relays in the motor starters. At that point, however, the overload relays and motors require time to cool down before restarting the conveyor three to five minutes for typical medium-sized motors. Motion detection devices reduce this downtime by signaling an underspeed condition before motor overloads trip, increasing productivity and reducing wear on motors and overloads.
UNDERSPEED APPLICATION
ZERO SPEED OR MOTION DETECTION
Another feature is the improvement of operator safety. When large equipment is in motion, it generally takes a long time to stop. Large motors may coast for many minutes after the motor is deenergized. In many cases, an operator who is pressed for time may approach this motor or its related mechanisms before they have come to a complete stop. This situation is a major cause of accidents. The solution to this problem is to control access to the hazardous area with a gate. The gate is latched during normal operation by a remote controlled safety interlock switch, such as a Telemecanique XCK J device. Motor speed is monitored by a motion detector, such as Telemecanique's XSA V. While the machine is moving, the access gate will remain closed and latched. Only when the motion detector senses that the motor or mechanism has slowed to a speed considered safe will the motion detector signal the safety interlock to release the latching mechanism and allow access to the hazardous area. The underspeed detector is used frequently to make the determination of safe access and is called a "zero speed" or "motion" detector.
1995 Square D All Rights Reserved
Underspeed Detection Basics of Motion Detection
Bulletin No. 9006PD9501 June, 1995
THE BASICS OF MOTION DETECTION
Motion, or underspeed, detection is based on the principle of counting targets in a predetermined amount of time. In its simplest terms, the procedure involves the following steps: 1. 2. 3. 4. Detecting the presence of one or several targets, Counting them during a known time interval, Comparing the total with a known value corresponding to the preset speed, Signaling the results.
This can also accomplished with a presence sensor and a device that generates pulses at set time intervals. When an object is detected, pulses are counted until the sensor detects the next object. The number of pulses is compared to a preset number. When the number of pulses counted exceeds the preset figure, a signal is transmitted to indicate underspeed operation. Fewer pulses indicate faster speed. Another principle, entirely analog, compares the voltage of a constant current charged capacitor with a preset threshold. The presence of a target starts the charging and the next target resets it to zero. When the speed decreases, the time between two targets increases, allowing the voltage across the capacitor to rise. Eventually, it rises above the preset threshold, triggering the underspeed signal. METHODS OF MOTION DETECTION There are three basic methods available for detecting motion: Using a presence sensor and timer. Using a dedicated motion detector with all the electronics in a single unit. Using a sensor coupled to a motion detection controller.
Each method has advantages and limitations based on the specific application parameters and needs.
Sensor and Timer
The simplest motion detection systems use presence sensors with timers, such as Telemecaniques XSC T (left) and XSD T inductive proximity sensors (Figure1). The timer is interposed between the sensor and the output so that any output signal from the sensor is delayed. The timer is coordinated with the speed at which the target should be moving. This allows a target to move out of the sensing zone before the time delay expires. In this case, no output signal is transmitted so there is no reaction. But if the target remains for too long a time in the sensing zone, the signal indicates an underspeed condition.
Figure 1
XSC T and XSD T Inductive Proximity Sensors
Underspeed Detection Methods of Motion Detection
This basic method of motion detection works fairly well in controlled applications and is relatively inexpensive to implement. This system is limited because it only detects underspeed conditions. It does not reliably detect stoppage in the line, because it does not send a signal if the stoppage occurs between two targets. There are many applications where these limitations are acceptable. Generally, preset detection times of up to 10 or 20 seconds are available in this type of system (while usually applied to linear motion detection, these times correspond to about 6 and 3 rpm, respectively, with only one target per rotation). This method requires a timed interlock to allow for start-up; otherwise, the device will continually signal an underspeed condition until the line reaches threshold speed. Another limitation with this system is a difficulty in proper detection of large objects following one another at close range and smaller objects sparsely spaced.
Self-Contained Motion Detector
Telemecaniques XSA V self-contained motion detector switch incorporates all the necessary electronics (sensor, timer and comparator) for rotational speed detection in a single housing (see Figure 2). It is specifically designed for rotational speed detection (see Figure 3). While other sensors signal the presence of a target, the dedicated motion detection device only provides signals related to target speed from its normally closed output. The output stays closed as long as the speed is above the preset value. It opens in an underspeed condition.
Figure 2
XSA V Self-Contained Motion Detector Switch
For rotational speed control on a grain feeder (Figure 3), one XSA V switch (left) monitors underspeed conditions to protect the motor, while a second device at the end of the transmission system detects conditions such as a broken conveyor.
Figure 3
Rotational Speed Control using XSA V Sensor

3
The speed ranges of the XSA V devices are greater than those attainable in the previous category of devices. Two types currently available have operating frequencies ranging from 6 to 150 pulses per minute and 120 to 3,000 pulses per minute, respectively, adjustable by potentiometers on the units. The pulses per minute correspond to the rotation speed of the shaft multiplied by the number of targets (see page 6). The low speed threshold range (6 to 150 pulses per minute) is used typically for "zero speed" detection. With several targets on a motor shaft, a speed of under 10 to 15 pulses (targets) per minute is considered acceptable in most cases. The high speed range (120 to 3,000 pulses per minute), is generally used in jamming and early transmission failure detection applications. The self-contained device is an inductive proximity sensor, which provides accurate, inexpensive detection of metal targets in applications where detecting an underspeed condition is critical. Current technology allows the device to be encased in a standard 30 or 18 mm tubular housing, which is easily mounted. It also has a built-in 9-second time delay to compensate for conveyor start-up. A 3-second time delay version is available for less inertial mechanisms. Because the motion detector is self-contained, it eliminates the need for additional logic interlocks. In PLC applications where the timing can be performed by the software and control devices are not powered down when the motor stops, the built-in power up delay is not required. Zero delay versions are available for applications of this sort or if delays longer than 9 seconds at start are required. This device, like any inductive sensor, is limited to applications involving metal targets. In addition, it only signals underspeed conditions and is limited to use with fairly large targets (30 x 30 mm or 18 x 18 mm standard). The maximum number of pulses per minute should also be considered. If the maximum speed is exceeded under normal conditions, the sensor does not have time to sense the target and falsely indicates an underspeed condition. The maximum speed values of the XSA V motion detector cover most industrial applications.
Sensor and Motion Detection Controller
When application parameters preclude the use of the first two motion detection solutions or dictate the need for maximum capability, a presence sensor can be coupled to Telemecaniques SX2 DV motion detection controller (Figure 4). The controller performs the electronic functions of comparison and switching of the output circuit to signal over- or underspeed conditions.
Figure 4
SX2 DV Motion Detection Controller
The SX2 DV unit provides a variety of advantages, including a wider range of operating frequencies from 2.2 pulses per minute up to 6,000 pulses per minute, and a built-in time delay variable from zero to 15 seconds. It is also possible to interlock with an external signal to allow for longer start-up times. The device has two potentiometers to adjust thresholds for over- or underspeed detection. The ability to use almost any sensor with this system provides the user with maximum flexibility. For example, where inductive sensors have limitations with temperature, shielded fiber optic extensions of photoelectric sensors are well-suited for high temperature applications. In an application that requires detecting nonmetallic objects, such as plastic bottles, a capacitive sensor can be used in conjunction with the motion detection controller. In low speed applications, a limit switch or magnetic proximity switch can be used. If the mounting space is limited or the targets are small (e.g., 2 mm), smaller sensors or fiber optic extensions can be used. In hazardous locations, a NAMUR inductive proximity sensor or other appropriate device can be used with an intrinsically-safe relay, providing transistor output to the motion detection controller. While two devices are needed in this method of motion detection, the advantages are versatility and accuracy of sensing. This solution is also the most costly of the three alternatives. Table 1 highlights the pertinent details of the three motion detection alternatives.
Table 1
Sensor with Time Delay Sensing Principle Min. # of Components Function Speed Range Underspeed Low (0.2 to 30 pulses per minute) Simplicity Cost Symmetrical configuration No start up delay Metal or reflective objects (targets only) Interlocking is cumbersome Range Inductive, Photoelectric 1
Motion Detection Methods

Self-Contained Inductive 1 Underspeed High (6 to 3,000 pulses per minute) Simplicity Start up delay, fixed Cost Output reflects speed only Metal targets Large size sensor (30 mm, 18 mm dia.) Limited to large targets (min. 18 x 18 mm) Hazardous environment Conveyor lines Feeders Fans & Blowers Pumps Grinders & Crushers Blenders & Mixers Cotton gins Saws Sensor and Motion Detection Controller Inductive, Photoelectric, Magnetic, Capacitive 2 Underspeed, Overspeed Very High (2.2 to 8,000 pulses per minute) Versatility Interlocks Start up delay, variable Hazardous environment Cost
Advantages
Limitations
Applications
Continuous detection of objects on conveyors Comments: More suited for detecting jamming of objects on a conveyor line Detects object only; will not reliably detect a stoppage on the line
All rotational and linear applications Comments: Virtually unlimited use in any environment Sensor is selected according to the application requirements
Underspeed Detection Application Tips
APPLICATION TIPS
Target Selection
It is relatively simple to select or design targets, especially for rotational applications. For transmission chains (including conveyors), the best approach generally is to position the detection device at the last conveyor roller in the drive system (the farthest roller put into motion by a single motor). A good target for speed detection is a cam or gear on the roller shaft (Figure 5, left). If this is not available, you must fabricate and mount a target. The design considerations include the number of targets needed as well as target size and material.
Figure 5
Using Roller Shafts and Gears as Targets
Number of Targets
To determine the number of targets required for accurate detection, use the formula: n=mxN Where: n = the speed threshold (number of pulses per minute), m = the number of targets needed, and N = the speed in rotations per minute.
In this situation, N is a known value, because it relates to the speed of the mechanism. Enter the number of pulses per minute n from the sensor specification. Then, solve for m, the number of targets needed. For example, if you want to detect a shaft speed of 3 rotations per minute and the minimum sensor speed threshold is 6 pulses per minute, then:
n 6 m = --- = -- = 2 N 3
In this example, a minimum of 2 targets will be needed to detect 3 rpm. In applications with very low shaft speeds, this formula helps determine if targets must be added to meet the minimum operating frequency of the sensor. Also, in these applications it is sometimes preferable to install more targets to reduce fault detection time. In this example, using 4 targets would change the pulses per minute to 12.
Underspeed Detection Application Tips
In typical conveyor applications with higher shaft speeds, the formula helps match the appropriate sensor and number of targets to the need. First determine the speed in rotations per minute (N), using a tachometer or other device. Next, select a detection method and device(s) with the appropriate range of operating frequencies in pulses per minute (n). Then, work with the formula to determine the optimum number of targets and resulting operating frequency. For example, if a conveyor has a shaft speed of 600 rpm, a self-contained motion detector with operating frequencies from 120 to 3,000 pulses per minute could be recommended, using from 1 to 5 targets (5 x 600 = 3,000). Since it is easier to incorporate an even number of targets than an odd number, the choice is to use either two or four targets. If two targets are used, the operating frequency is 1,200 pulses per minute; for four targets, it is 2,400 pulses per minute. An even number of balanced targets is best for accurate speed detection when the target is mounted on a shaft. This ensures symmetry (on/off time ratio remains constant). Mechanical symmetry is important, since it also reduces shaft wear.
Target Size
Generally, target size should be no smaller than the surface size of the sensor face. It is important to consider the sensing speed capability of the detection device selected. While the standard targets recommended for sensors can be used in motion detection applications, the target in motion should be considered to be smaller than it actually is because, while it is in motion, the target is in the sensing area for a short period of time. For maximum accuracy, use a larger target than the standard size listed for the sensor. To further improve accuracy, position the sensor as close to the target as possible. This keeps the target in the sensors detection zone for a longer time. It is possible to construct a standard target that covers a wide speed range and is suitable for use with most Telemecanique sensors. The target should be made from steel and rectangular in shape (200 mm x 90 mm x 2 mm). Mount the target symmetrically across the end of the rotating shaft (Figure 6). Next, position the sensing face of the detector on a radius of 80 mm from the horizontal axis of the shaft. The piece then acts as two diametrically opposed targets.
Figure 6
Standard Target Dimensions (mm)
Size is more critical at higher operation speeds, because the sensor must respond quickly. A good inductive device reacts in about 1 millisecond. The same is true for most photoelectrics, but some respond as fast as 5 microseconds. The additional cost of these faster devices must be weighed against the benefits they provide in sensing capability and flexibility, particularly in high-speed applications.
Underspeed Detection Conclusion
Target Material
Use caution when fabricating a target such as a gear tooth arrangement so that the target cams are far enough away from the sensor to distinguish the target from the background. It is best to place the sensor parallel to the axis to reduce background influences. Additionally, metallic targets can be placed on nonmetallic material to reduce background influences. Magnetic tape or other magnetic material can be used as a target, and a Telemecanique SG magnetic switch used for sensing. Where it is difficult to position a sensing device close to a target, a photoelectric sensor with fiber optic extensions can be coupled with the system and reflective tape used on the targets. Using fiber optic extensions is a good solution for motion detection in hazardous environments. Another method in these applications is to use one of Telemecaniques NAMUR inductive proximity sensors with an NY2 intrinsically safe relay and a solid state output to provide the speed required. If it is impossible to mount a target on a shaft, another solution is to print marks on it or attach colored paper to it, and use a Telemecanique XUR, XUM or XUV color mark detection sensor in conjunction with the motion detection controller.
CONCLUSION
You should consider the benefits of applying the motion detection principles described in this publication to existing as well as new systems. The demand for increased uptime, productivity and increased operator safety supports the use of control techniques that detect possible problems before they cause damage or stop production. Application parameters dictate which method of motion detection is best, as well as the selection of target size, material and location. Properly applied, a motion detection system is an important part of automated production and material handling systems. For further information, contact your local Square D/Telemecanique sales office.
DIMISA
CONTITECH CONVEYORS BELT
General brochure for CONTITECH brand, ST-3500 type Belt Conveyors. CONTITECH English. 5.

ContiFlex
Textile Conveyor Belts for a Wide Range of Conveying Tasks
ContiFlex Conveyor Belting

2-180 Number of Plies Fabric Type Rated Operating Tension (piw)
(Vulcanized Splice or Mechanical Fasteners)
2-220 2 P/N 220 .128 .058 24400
2-300 2 P/N 300 .160 .074 25000
3-330 3 P/N 330 .170 .077 36600
3-450 3 P/N 450 .201 .107 37500
4-500 4 P/N 500 .197 .097 41600
3-600 3 P/N 600 .220 .110 50000
4-600 4 P/N 600 .244 .125 50000
3-750 3 P/N 750 .272 .119 62500
5-750 5 P/N 750 .303 .159 62500
4-800 4 P/N 800 .313 .152 66600
2 P/N 180 .125 .056 20000
Nominal Carcass Gauge (in) Nominal Carcass Weight (piw) Belt Modulus (piw)
ContiFlex Minimum Pulley Diameters

2-180 Over 80% Tension 60% to 80% Tension 40% to 60% Tension Up to 40% Tension 16 14 12 10 2-250 16 14 12 10 2-330 18 16 14 12 3-375 18 16 14 12 3-500 22 18 16 14 4-500 24 20 18 16 3-600 24 20 18 16 4-600 30 24 20 16 3-750 30 24 20 18 5-750 30 24 20 18 4-800 30 24 20 18
ContiFlex Load Support

Material Weight Idlers 20 Light 0 to 40 lbs/ft
3 o
2-180 42 36 30 36 30 24 30 24 NR NR NR NR
2-250 48 42 36 42 36 36 36 30 NR 30 NR NR
2-330 60 54 48 54 48 42 48 42 36 36 30 24
3-375 72 60 54 60 54 48 54 48 42 48 42 36
3-500 72 66 60 66 60 54 60 54 48 54 48 42
4-500 84 72 60 72 60 54 60 54 48 54 48 42
3-600 84 72 60 72 60 54 60 54 48 54 48 42
4-600 96 84 72 84 72 60 72 60 54 60 54 48
3-750 84 72 66 72 60 54 66 60 54 54 48 42
5-750 96 84 72 84 72 60 72 60 54 60 54 48
4-800 96 84 72 84 72 66 72 60 54 66 60 54
35 45 20
Medium
41 to 80 lbs/ft3
35 45 20
Heavy
81 to 120 lbs/ft
35 45 20
Extra Heavy
Over 120 lbs/ft 3
35 45
Minimum Belt Width

2-180 20 Idlers
o
2-250 14 18 24
2-330 18 24 30
3-375 20 24 30
3-500 24 24 30
4-500 30 30 36
3-600 30 30 36
4-600 30 36 36
3-750 30 36 42
5-750 36 36 42
4-800 30 36 42
14 18 18
35 45
ContiFlex Conveyor Belting

3-900 Number of Plies Fabric Type Rated Operating Tension (piw)
(Vulcanized Splice or Mechanical Fasteners)
4-1000 4 P/N 1000 .313 .150 83300
5-1000 5 P/N 1000 .343 .170 83300
4-1200 4 P/N 1200 .358 .168 100000
6-1200 6 P/N 1200 .409 .202 100000
5-1250 5 P/N 1250 .392 .186 104100
3-1500 3 P/N 1500 .402 .196 100000
4-1500 4 P/N 1500 .429 .225 125000
4-1800 4 P/N 1800 .512 .245 120000
4-2000 4 P/N 2000 .555 .268 133300
3 P/N 900 .272 .124 75000
Nominal Carcass Gauge (in) Nominal Carcass Weight (piw) Belt Modulus (piw)
ContiFlex Minimum Pulley Diameters

3-900 Over 80% Tension 60% to 80% Tension 40% to 60% Tension Up to 40% Tension 30 24 20 18 4-1000 36 30 24 20 5-1000 36 30 24 20 4-1200 42 36 30 24 6-1200 42 36 30 24 5-1250 42 36 30 24 3-1500 48 42 36 30 4-1500 54 48 42 36 4-1800 54 48 42 36 4-2000 60 54 48 42
ContiFlex Load Support

Material Weight Idlers 20 Light 0 to 40 lbs/ft
3 o
3-900 84 72 66 72 66 60 66 60 54 60 54 48
4-1000 96 84 72 84 72 66 72 60 54 66 60 54
5-1000 108 96 84 96 84 78 96 84 72 84 72 66
4-1200 108 96 84 96 84 78 96 84 72 84 72 66
6-1200 120 108 96 108 102 96 108 96 84 102 84 78
5-1250 120 108 96 108 96 84 108 96 84 96 84 72
3-1500 114 108 96 102 96 84 96 84 72 84 72 55
4-1500 120 108 96 108 102 96 102 96 84 96 84 78
4-1800 126 114 102 114 108 102 108 102 96 102 96 84
4-2000 126 120 108 120 114 108 108 102 96 102 96 84
35 45 20
Medium
41 to 80 lbs/ft3
35 45 20
Heavy
81 to 120 lbs/ft
35 45 20
Extra Heavy
Over 120 lbs/ft
35 45
Minimum Belt Width

3-900 20 Idlers 35 45
o
4-1000 36 42 48
5-1000 42 42 48
4-1200 42 42 48
6-1200 48 48 54
5-1250 48 48 54
3-1500 42 48 54
4-1500 48 54 60
4-1800 54 54 60
4-2000 54 54 60
30 36 42
ContiFlex Cover Properties

General Purpose Cover Compounds
Cover Compound Tensile Strength
(Minimum)
Unit PSI % Shore A mm3 PIW

o
AR 2900 500 625 120 .0152

-40 to 200
AR Plus 3625 500 615 110 .0149

-40 to 200
AR Plus II 3771 550 625 100 .0149

-40 to 200
DuraStar 3843 550 655 90 .0157

-40 to 200
SAR 2900 450 625 70 .0150

-40 to 200
SAR II 3191 500 645 60 .0157

-40 to 200
Everlast 2900 500 685 30 .0156

-40 to 200
Elongation
(Minimum)
Durometer DIN Abrasion 1/32" Cover Weight Temperature Range
Oil Resistant Cover Compounds

(Minimum)
Unit PSI % Shore A mm

o 3
MOR 2300 450 655 160 .0161

-30 to 180
SOR 2900 400 675 100 .0200

-5 to 160
SOR-LT 2900 400 614 120 .1810

-30 to 160
lsand 2610 500 605 70 .0159

-50 to 160
Elongation
(Minimum)
Durometer DIN Abrasion (Maximum) 1/32" Cover Weight Temperature Range
PIW F
Heat Resistant Cover Compounds

(Minimum)

o 3
Vulcan 250 2900 550 605 120 .0152

-30 to 250
Vulcan 300 2900 550 605 110 .0154

-30 to 300
Vulcan 400 2300 450 655 150 .0147

-40 to 400
Vulcan 400 AR 2610 500 685 75 .0144

-40 to 200
Vulcan OR 3190 550 635 150 .0163

-5 to 250/350
Elongation
(Minimum)
PIW F
Fire Resistant Cover Compounds

(Minimum)

o 3
MSHA-AR 2900 500 655 135 .0165

-40 to 180
MSHA-AR II 3190 450 675 80 .0164

-40 to 180
CSA-AR 2900 500 635 135 .0168

-40 to 180
MSHA-MOR 2465 510 675 150 .0165

-35 to 160
MSHA-SOR 3263 370 715 80 .0165

-5 to 160
MSHA-SOR LT 2175 450 655 150 .0162

-40 to 200
Elongation
(Minimum)
PIW F
ContiFlex Cover Compounds

Abrasion and Severe Duty Service
AR AR is a premium general-purpose cover. Exceeds RMA requirements for Grade I covers. The best value for most abrasive materials handling applications. AR Plus is designed for high-impact stress applications where cutting, gouging, and tearing of the covers is a primary concern. Very good abrasion resistance. Designed for hard-rock ore, granite, quartz, and other sharp-edged, abrasive material. Far exceed RMA requirements for Grade I covers. AR Plus II offers enhanced physical properties for abusive appications where the combination of abrasion and cutting, tearing, and gouging of the covers is exteme. Excellent abrasion and abuse resistance. Far exceed RMA requirements for Grade I covers. DuraStar is the most gouge resistant belt in the world. Developed primarily for hard-rock ore, DuraStar is a premium compound for the most abusive applications. It is unmatched in resisting the damaging effects of large, sharp-edged, abrasive material. SAR offers superior performance in applications where severe abrasion is present. SAR is ideal for copper, gold, taconite, crushed stone, and other materials where superior abrasion resistance is required. It also offers excellent cut, gouge, and tear resistance. SAR II offers unparalled abrasion resistance in combination with oustanding cut, gouge, and tear resistance. Is suitable for the severest of abrasive applications such as hard-rock ore, primary crusher belts, granite, quartz, log handling, debarkers, and other abrasive materials The best resistance to sliding abrasion in the industry. Recommended for applications in which highly abrasive material is conveyed and premature belt wear is the primary reason for replacement. Also resists cutting, gouging, and tearing of the covers.
AR Plus
AR Plus II
DuraStar
SAR
SAR II
Everlast
High Temperature Service

Vulcan 250 Vulcan 300 Vulcan 400 Vulcan 400 SAR Vulcan OR Heat resistant to 250o F. Very good abrasion resistance. In addition to heat resistance, it also exceeds RMA requirements for Grade 1 covers.
o Heat resistant to 300 F. Superior abrasion resistance. Exceeds RMA requirements for Grade 1 covers o Heat resistant to 400 F. Very good abrasion resistance. Designed to withstand the degrading effects of material at elevated temperatures. Heat resistant to 400o F. Specially compounded for outstanding abrasion resistance. Designed to withstand the degrading effects of material at elevated temperatures while offering superior wear characteristics. Vulcan OR is specifically compounded to withstand the effects of a combination of elevated temperatures and oil. Ideal for hot asphalt, hot petroleum coke, and other materials that contain oil at elevated temperatures.
Oil Service
MOR (Medium Oil Resistance) SOR (Superior Oil Resistance) SOR-LT lsand MOR is ideally suited to handling waste products, sludge, sewage, wood products, and other moderately oily materials. SOR is recommended for use with materials having extreme concentrations oil. In addition to offering the best oil resistance in the industry, it displays excellent resistance to abrasion, cutting, tearing, and gouging. Superior oil resistance in combination with low temperature capability.
o lsand is designed to retain its flexibility while conveying oily material in temperatures to -50 F. Highly recommended for oil sand service in Northern Canada.
Flame-Resistant Service
MSHA-AR MSHA-AR offers high performance where flame resistant is required. It is fully resistant to the deleterious effects of ultraviolet and ozone and can be operated above and below ground. Very good abrasion and abuse resistance.
MSHA-AR II CSA-AR MSHA-MOR MSHA-SOR MSHA-SOR LT
MSHA-AR II is unparalleled in resistance to abrasion and abusive environments. Best abrasion resistance in the industry for a flame resistant belt. Ideally suited to abrasive materials and short, high-speed conveyors, above or below ground. CSA-AR is certified by the the Canadian Department of Energy, Mines and Resources for Type C applications. Flame resistant and resistant to materials with moderate amounts of oil. Ideal for handling extremely oily material where flame resistance is required. MSHA-SOR LT is resistant to very oily material in temperatures to -30 o F in applications that require flame resistance.
Special Purpose Covers

Ecostar Duracid ContiClean Low rolling resistance pulley cover, which is up to 30% more efficient than standard covers. Duracid is resistant to the damaging effects of sulfuric acid and exhibits excellent resistance to aging, weathering, and temperature. ContiClean is a family of non-stick belts that are designed to minimize the problems associated with conveying damp, sticky materials
DIMISA
MARTIN PRIMARY BELT CLEANER
Contents:
Installation and maintenance instructions for MARTIN brand, QC-2 type Belt cleaners. MARTIN English. 97

We Make Your Bulk Material Handling Cleaner, Safer, and More Productive
XHD DURT TRACKER Belt Cleaner

OPERATOR MANUAL For more information on this product click here or go to www.martin-eng.com
MARTIN ENGINEERING One Martin Place Neponset, IL 61234-9766 USA 800-544-2947 or 309-593-2384 Fax: 309-594-2432 ISO 9001 Quality Systems Certified
MARTIN XHD DURT TRACKER

Belt Cleaner
OPERATORS MANUAL
Important
Martin Engineering hereby disclaims any liability for injuries or damage resulting from use or application of this product contrary to instructions and specifications contained herein. Martin Engineerings liability shall be limited to repair or replacement of product shown to be defective. Observe all safety rules given herein along with owner and Government standards and regulations. Know and understand lockout/tagout procedures as defined by American National Standards Institute (ANSI) z244.1-1982, American National Standard for Personnel Protection - Lockout/Tagout of Energy Sources Minimum Safety Requirements and Occupational Safety and Health Administration (OSHA) Federal Register, Part IV, 29 CFR Part 1910, Control of Hazardous Energy Source (Lockout/Tagout); Final Rule. The following symbols may be used in this manual:
DANGER
Danger: Immediate hazards that will result in severe personal injury or death.
WARNING
Warning: Hazards or unsafe practices that could result in personal injury.
CAUTION
Caution: Hazards or unsafe practices that could result in product or property damages.
IMPORTANT
Important: Instructions that must be followed to ensure proper installation/operation of equipment.
NOTE
Note: General statements to assist the reader.
Table of contents
Section
List of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . List of tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generalbelt cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generaltensioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installations without chutework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt cleaner inspection access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt cleaner blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Materials required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
ii ii 1
1 1 1 1 1 2 2 2
Before installing belt cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing belt cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 4
Finding center point of pre-cleaner mainframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Finding center point of secondary cleaner mainframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Locating far side mount plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installing far side mount plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installing belt cleaner assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
After installing belt cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Weekly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Troubleshooting/installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Part numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Appendix A. Typical XHD DURT TRACKER Belt Cleaner Installations . . . . . . . . . . . . . . . A-1 Appendix B. XHD DURT TRACKER Belt Cleaner Labels . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Martin Engineering M3257-3/00
XHDDT Belt Cleaner
Table of contents
List of figures/tables
List of figures
Figure
1 2 3 4 5 6 7 8 9 10 11 12 13
Title
Page
Drawing arc to locate pre-cleaner mainframe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Marking pre-cleaner mainframe location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Secondary cleaner mainframe location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Marking mounting holes for far side mount plate . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installing far side mount plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Belt cleaner mainframe (shown with pre-cleaner blades). . . . . . . . . . . . . . . . . . . . 11 Installing belt cleaner mainframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Verifying proper mainframe location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Using end stop to locate pre-cleaner mainframe . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Installing locking collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Secondary cleaner changing belt line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Replacing XHD secondary blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 XHD DURT TRACKER Pre-Cleaner with Stainless Steel Track, P/N 32133-XXXXX or XHD DURT TRACKER Pre-Cleaner with Aluminum Track, P/N 32333-XXXXX or 33659-XXXXX (with 6.5-in. blades only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 XHD DURT TRACKER Secondary Cleaner, P/N 32638-XXXX (Aluminum Track) or P/N 32639-XXXX (Stainless Steel Track) . . . . . . . . . . . . 24
14
List of tables
Table
I II III IV V VI
Title
Page
Dimensions for locating XHDDT pre-cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Checking proper pre-cleaner mainframe location . . . . . . . . . . . . . . . . . . . . . . . . . 13 XHDDT pre-cleaner part numbers and quantities . . . . . . . . . . . . . . . . . . . . . . . . . 23 XHD DURT TRACKER blade specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 XHD DURT TRACKER Secondary Cleaner part numbers and quantities . . . . . 26 XHD DURT TRACKER Secondary Cleaner blade part numbers . . . . . . . . . . . . 26
ii
XHDDT Belt Cleaner
Introduction
GeneralBelt Cleaner
The Extra Heavy-Duty (XHD) DURT TRACKER Belt Cleaner is a rugged cleaner designed for use on severe applications. The XHD DURT TRACKER Belt Cleaning System consists of a Pre-Cleaner and a Secondary Cleaner. Either cleaner can be used alone, but Martin Engineering recommends using two cleaners for best results. (See appendix A for examples of typical XHD DURT TRACKER Belt Cleaner installations.) To introduce product back into the product flow, a Pre-Cleaner is installed on the face of the head pulley. On a dual cleaner system, the Secondary Cleaner is installed immediately following the Pre-Cleaner to remove stubborn material left on the conveyor belt.
General Tensioners
Martin Engineering recommends installing one of the following MARTIN tensioners with the XHD DURT TRACKER Belt Cleaner: MARTIN Air Tensioner. MARTIN XHD Spring Tensioner. Refer to MARTIN XHD Tensioners Operators Manual, P/N M3512 for installing tensioners.
Installations without chutework
These procedures were written for equipment that is being installed on enclosed pulley chutework. If the pulley is not enclosed, the equipment should be installed using the best available field resources and methods to ensure that the critical dimensions are followed for proper installation. MARTIN XHD Hanger Mounts can be used for installations without chutework. See Part Numbers for a list of mounts and part numbers.
Belt cleaner inspection access
If the belt cleaner is installed on enclosed pulley chutework, a CYA Inspection Door should be installed. CYA Inspection Doors are available from Martin Engineering or a representative. See Part Numbers for a list of MARTIN CYA Inspection Doors and part numbers.
Belt cleaner blades
XHD DURT TRACKER Blades are available in materials shown in table VI.
XHDDT Belt Cleaner
Introduction
Introduction
References
The following documents are referenced in this manual: American National Standards Institute (ANSI) z244.1-1982, American National Standard for Personnel Protection - Lockout/Tagout of Energy Sources - Minimum Safety Requirements, American National Standards Institute, Inc., 1430 Broadway, New York, NY 10018. Federal Register, Volume 54, Number 169, Part IV, 29 CFR Part 1910, Control of Hazardous Energy Source (Lockout/Tagout); Final Rule, Department of Labor, Occupational Safety and Health Administration (OSHA), 32nd Floor, Room 3244, 230 South Dearborn Street, Chicago, IL 60604. MARTIN CYA Inspection Door Operators Manual, P/N M3127. MARTIN XHD Tensioners Operators Manual, P/N M3512.
Safety
All safety rules defined in the above documents and all owner/employer safety rules must be strictly followed when working on the XHD DURT TRACKER Belt Cleaner.
Materials required
The following special equipment may be required to install and service the XHD DURT TRACKER Belt Cleaner: Hoist. Support roller.
XHDDT Belt Cleaner
Before installing belt cleaner IMPORTANT

The delivery service is responsible for damage occurring in transit. Martin Engineering CANNOT enter claims for damages. Contact your transportation agent for more information. 1. Inspect shipping container for damage. Report damage to delivery service immediately and fill out delivery services claim form. Keep any damaged goods subject to examination. 2. Remove XHD DURT TRACKER Belt Cleaner from shipping containers. Equipment in containers should include the following: XHD DURT TRACKER Belt Cleaner Assembly. Two Conveyor Products Warning Labels, P/N 23395. 3. If anything is missing or damaged, contact Martin Engineering or representative. !
WARNING
Before installing equipment, turn off and lock out/tag out energy source to conveyor and conveyor accessories. 4. Turn off and lock out/tag out energy source according to ANSI standards (see References). !
WARNING
If equipment will be installed in an enclosed area, gas level or dust content must be tested before using a cutting torch or welding. Using a cutting torch or welding in an area with gas or dust may cause an explosion. 5. If using a cutting torch or welding, test atmosphere for gas level or dust content. Cover conveyor belt with fire retardant cover.
NOTE
The chute wall that the tensioner will be located on is referred to as the operator side. The other side of the chute wall is referred to as the far side. 6. Determine which side of chute wall is easiest to access. Locate tensioner on most accessible chute wall.
NOTE
Please refer to MARTIN XHD Tensioners Operators Manual, P/N M3512 for installation of tensioners.
XHDDT Belt Cleaner
Before installation
Installation
Installing belt cleaner IMPORTANT

Read entire section before beginning work. To install the belt cleaner, follow the procedures in this section corresponding to the following steps: 1. 2. 3. 4. Find center point of belt cleaner mainframe (Pre-Cleaner or Secondary). Locate tensioner and far side mount plate on chute walls. Install far side mount plate. Install tensioner and belt cleaner assembly.
Finding center point of pre-cleaner mainframe
1. See figure 1 and table I. On operator side chute wall, mark vertical and horizontal center line of head pulley and draw an arc as shown.
Pulley radius + X
Pulley center point
Figure 1. Drawing arc to locate pre-cleaner mainframe (use with table I)
XHDDT Belt Cleaner
Table I. Dimensions for locating XHDDT pre-cleaner (use with figure 1)

Pulley diameter* in. (mm) 16 (400) 20 (500) 24 (600) 28 (700) 30 - 120 (750 - 3000) *Includes lagging & belt. 2. See figure 2. Draw a horizontal line parallel to pulleys horizontal center line as shown. Locate center point of pre-cleaner mainframe where this horizontal line intersects arc on chute wall. 3. Make sure mainframe and blades do not lie in path of material unloading from conveyor belt. Make sure blade tip is at or below horizontal center line.
Pulley radius + X 90 Center point of Pre-Cleaner mainframe 14 (355) min. 90
Dimension X in. (mm) 5.75 (146) 5.50 (140) 5.25 (133) 5.00 (127) 4.75 (120)
Figure 2. Marking pre-cleaner mainframe location

4. Repeat steps 1 through 3 for other side of chute. 5. If using a CYA Inspection Door, install it according to MARTIN CYA Inspection Door Operators Manual, P/N M3127. 6. Go to Locating tensioner and far side mount plate.
XHDDT Belt Cleaner
Installation
Installation
Finding center point of secondary cleaner mainframe
1. See figure 3. On operator side of chute wall, mark vertical and horizontal center line of head pulley to find pulley center point (A).
A A. Center point of pulley B. Blade-to-belt contact point C. Center point of secondary cleaner mainframe B
1 (25)
8.5 (216)
11.19 (284)
Figure 3. Secondary cleaner mainframe location

2. Measure 1 in. (25 mm) past point where conveyor belt leaves pulley and mark vertical line on chute wall. 3. Locate secondary cleaner where vertical line crosses bottom (return side) of conveyor belt: blade-to-belt contact point (B). (If belt is not adequately supported, a belt support must be installed. See step 4 under "After installing belt cleaner and tensioner.") 4. Starting from point (B), measure down as shown in figure 3 and mark center point of secondary cleaner mainframe (C) on chute wall. 5. Repeat steps 1 through 4 for other side of chute. 6. If using a CYA Inspection Door, install it according to MARTIN CYA Inspection Door Operators Manual, P/N M3127.
XHDDT Belt Cleaner
Locating far side mount plate
1. See figure 4. Use center point of belt cleaner mainframe as center point of far side (opposite side) mount plate. 2. Mark location of mounting holes on operator side and far side chute walls using far side mount plate as template.
Figure 4. Marking mounting holes for far side mount plate
XHDDT Belt Cleaner
Installation
Installation
IMPORTANT
Installing far side mount plate
For initial installation of mount plates, only finger tighten or tack weld to chute wall. After belt cleaner assembly has been installed and positioned, torque screw or permanently weld mount plates onto chute walls. 1. If bolting far side mount plate to chute wall, do the following: a. See figure 5. Drill or cut holes for mainframe and screws in far side chute wall. Remove burrs and sharp edges. b. Install mount plate onto chute wall with four hex head cap screws, flat washers, compression washers, and hex nuts.
9/16 (14) screw holes
4-1/2 (114) mainframe hole
Figure 5. Installing far side mount plate

2. If welding far side mount plate to chute wall, do the following: a. Remove shock bushing from mount plate. b. Drill or cut hole for mainframe in far side chute wall. Remove burrs and sharp edges. c. Position mount plate over hole in far side chute wall. d. Weld mount plate onto chute wall. e. Insert shock bushing into mount plate.
XHDDT Belt Cleaner
IMPORTANT
Before proceeding to step 3, follow the procedure under Installing belt cleaner assembly in this manual. 3. Install mount plate weldment (D) onto chute wall the same way you installed far side mount plate. (See Installing far side mount plate.). 4. Install belt cleaner mainframe assembly. 5. Slide nylon bushings and shock bushings over mainframe and into mount plates.
IMPORTANT
If installing pre-cleaner, lever arm weldment should point in direction of return belt travel. If installing secondary cleaner, lever arm weldment should be pointing in opposite direction of return belt travel.
NOTE
Refer to XHD Tensioners Operators Manual for proper positioning of the lever arm weldment. 6. Install belt cleaner mainframe assembly. MARTIN
NOTE
For easier maintenance, Martin Engineering recommends bolting rather than welding mount bracket to chute wall. 7. Bolt or weld mount bracket to chute wall as follows: a. If bolting mount bracket to chute wall, do the following: (1) Drill or cut four 9/16-in. holes in operator side chute wall. Remove burrs and sharp edges. (2) Install mount bracket on chute wall with four hex head cap screws, flat washers, compression washers, and hex nuts (M). b. If welding mount bracket to chute wall, do the following: (1) Position mount bracket on chute wall so that four mounting holes line up with four holes marked on chute wall. (2) Weld mount bracket onto chute wall. Skip weld around entire mount bracket surface contacting chute wall.
XHDDT Belt Cleaner
Installation
Installation
WARNING
Installing belt cleaner assembly
Belt cleaner is very heavy and requires a hoist or several people to lift. Attempting to lift belt cleaner without assistance could result in serious injury.
1. For easier handling, remove blades from mainframe as follows: a. Loosen hex head cap screws (A, figure 15) on end stop (B) on end of telescoping mainframe assembly (C) where lanyard (D) is visible. Remove end stop. b. Pull lanyard to slide blades (E) off end of mainframe assembly. 2. Remove two shock bushings from mount plates.
10
XHDDT Belt Cleaner
A B F D C
Figure 6. Belt cleaner mainframe (shown with pre-cleaner blades)

3. See figure 7. Insert end of belt cleaner mainframe through mounting hole in far side mount plate. Then insert other end into mounting holes in operator side mount plate weldment.
Figure 7. Installing belt cleaner mainframe

4. Slide two shock bushings over ends of mainframe and into mount plates. 5. Check for proper belt cleaner mainframe location as follows: a. Slide end stop onto mainframe.
11
XHDDT Belt Cleaner
Installation
Installation
b. Turn mainframe until top of end stop is parallel with conveyor belt as shown in figure 8.
End stop
Figure 8. Verifying proper mainframe location

c. Measure the distance between the top of the end stop and the conveyor belt on both sides. Adjust mainframe location to maintain the proper distance according to figure 8 and table II. d. Make sure mainframe is parallel to pulley. 6. Slide blades and end stop back onto mainframe assembly. Make sure lanyard is attached to far end of first blade and extends under all blades. Tighten hex head cap screws to secure end stop. !
CAUTION
Belt cleaner blades should be centered to clean area narrower than conveyor belt width. This allows movement of belt and prevents damage to edge of belt. 7. Loosen four square head set screws on bottom of mainframe assembly. Center the blades on belt by adjusting end weldments for telescoping mainframe (F, figure 6). Measure from center point of pulley to outside edge of first and last blade to make sure blades are centered.
12
XHDDT Belt Cleaner
8. Adjust end weldment to remove excess mainframe on far side. Tighten four square head set screws on mainframe weldment.
See table V for dimensions.
End Stop
Figure 9. Using end stop to locate pre-cleaner mainframe
Table II. Checking proper pre-cleaner mainframe location

Pulley diameter (A)* in. (mm) 16 (400) 20 (500) 24 (600) 28 (700) 30 - 120 (750 - 3000) Distance between end stop and belt (B) in. (mm) 1.00 (25) 0.75 (19) 0.50 (13) 0.25 (6) 0.00 Distance between mainframe center point and belt (C) in. (mm) 5.75 (146) 5.50 (140) 5.25 (133) 5.00 (127) 4.75 (120)
*Includes lagging and belt thickness.
13
XHDDT Belt Cleaner
Installation
Installation
9. See figure 10. Slide locking collar (A) over far side end weldment (B) and against shock bushing (C). Tighten two hex head set screws (D) against end weldment.
D B C
Figure 10. Installing locking collar

10. Tension blades against conveyor belt according to table III, IV, or V. See Installing XHD Spring Tensioner or Installing Air Tensioner.
14
XHDDT Belt Cleaner
After installing belt cleaner IMPORTANT

Read entire section before beginning work. 1. After you have installed belt cleaner, measure from pulley shaft to mainframe on both operator side and far side to make sure mainframe is parallel to pulley. 2. Measure from center point of end of mainframe to face of conveyor belt to make sure the proper critical dimension is held (see figure 2 or 3). 3. Measure from center point of pulley to outside edge of first and last blade to make sure blades are centered on belt. 4. Make sure secondary cleaner is not changing belt line (see figure 11). If it is, install belt support directly above blade-to-belt contact point.
Belt Line
Figure 11. Secondary cleaner changing belt line

5. Thoroughly wipe outside chute wall clean above belt cleaner on operator side. Place Conveyor Products Warning Label (P/N 23395) on chute wall visible to belt cleaner operator. !
WARNING
Failure to remove tools from installation area and conveyor belt before turning on energy source can cause serious injury to personnel and damage to belt. 6. Remove all tools and fire retardant cover from installation area and conveyor belt. !
DANGER
Do not touch or go near conveyor belt or conveyor accessories when conveyor belt is running. Body or clothing can get caught and pull body into conveyor belt, causing severe injury or death. 7. Turn on conveyor belt for 1 hour.
15
XHDDT Belt Cleaner
After installation
After installation
WARNING
Before adjusting belt cleaner, turn off and lock out/tag out energy source to conveyor belt and conveyor accessories. 8. After 1 hour of operation, turn off and lock out/tag out energy source according to ANSI standard (see References). 9. Make sure all fasteners are tight. Tighten if necessary. 10. Inspect belt cleaner for the following: Wear. (A small amount of break-in wear may be found. This will stop once blades wear to conveyor belt contour.) Material buildup. (No material between blades and return side of conveyor belt should be found.) 11. If wear, material buildup, or some other problem exists, see Troubleshooting/Installation Checklist.
16
XHDDT Belt Cleaner
Weekly maintenance IMPORTANT

Read entire section before beginning work. !
WARNING
Before servicing belt cleaner, turn off and lock out/tag out energy source to conveyor belt and conveyor accessories. 1. Turn off and lock out/tag out energy source according to ANSI standard (see References). 2. Make sure all fasteners are tight. Tighten if necessary. !
CAUTION
Do not allow blades to wear past wear line. If worn beyond wear line, blades may roll through and damage belt cleaner. 3. Check blades for wear. If blades are worn to wear line, replace blades as follows: a. Release tension from mainframe. b. If necessary, remove tensioner. c. Loosen two hex head cap screws on end stop and remove end stop. d. Pull lanyard to slide blades off end of mainframe weldment. If blades will not slide off, do the following: (1) Loosen elastic stop nuts to loosen track weldment(s). Repeat step 3.e. (2) If blades still will not slide off, remove elastic stop nuts and flat washers, track weldment(s), and blades.
NOTE
For easier blade replacement on longer cleaners, re-install long track weldments before sliding new blades onto cleaner. When all blades are in place, replace shorter track weldments. e. For pre-cleaners, slide new blades into track weldments. For secondary cleaners, do the following:
17
XHDDT Belt Cleaner
Weekly maintenance
Weekly maintenance
(1) See figure 12. Remove cotter pin (A), slotted hex nut (B), blade spacer, XHD washer (C), compression washer (D), and o-rings. Remove XHD secondary blade.
A. B. C. D.
Cotter pin Slotted hex nut XHD washer Compression washer
C B D A
Figure 12. Replacing XHD secondary blades

(2) Install new XHD secondary blade and items removed in step 3.f(1). (3) Slide blade assemblies into track weldments. f. Install lanyard, track weldment, elastic stop nuts, and end stop, as applicable. g. Tighten two hex head cap screws. h. Install tensioner and bracket, if removed, according to the MARTIN XHD Tensioners Operators Manual. i. Tension blades against conveyor belt. 4. Wipe all labels clean. If labels are not readable, contact Martin Engineering or a representative for replacements. !
WARNING
Failure to remove tools from installation area and conveyor belt before turning on energy source can cause serious injury to personnel and damage to belt. 5. Remove all tools from maintenance area. !
DANGER
Do not touch or go near conveyor belt or conveyor accessories when conveyor belt is running. Body or clothing can get caught and pull body into conveyor belt, causing severe injury or death. 6. Start conveyor belt.
18
XHDDT Belt Cleaner
Troubleshooting/installation checklist
Troubleshooting
Symptom
High blade wear rate.
If you are experiencing high blade wear or insufficient cleaning and carryback, see below. Corrective action Tension of cleaner on belt is set too high. Reduce tensioner setting.
Blade installed in material flow. Relocate belt cleaner.
Insufficient cleaning and carryback.
Tension of cleaner on belt is set too low or too high. Increase or decrease
tensioner setting.
Blades are worn. Check blades and replace if necessary. (See Weekly
Maintenance.) Uneven blade wear. If carryback is localized to center section of belt, reduce blade coverage by removing a blade from the mainframe, or replacing a 13-in. blade with a 6-in. blade. Blade installed in material flow. Relocate belt cleaner.
19
XHDDT Belt Cleaner
Installation checklist
If after taking the corrective actions suggested under Troubleshooting you are still experiencing problems, check for the following: Installation checklist
- Correct distance is maintained from center of Pre-cleaner mainframe to belt surface on both ends of mainframe according to table I. - Distance from center of Secondary cleaner mainframe to belt surface is 8-1/2 in. (216 mm) on both ends of mainframe. - Pre-cleaner blade tip is at or below horizontal center line of pulley, and does not lie in path of material flow. - Secondary cleaner blade tip is 1 in. (25 mm) past vertical center line of pulley. - Secondary cleaner is not changing belt line (figure 20). - Blades are centered on belt.
20
XHDDT Belt Cleaner
Part numbers
This section provides product names and corresponding part numbers for XHD DURT TRACKER Belt Cleaners and related equipment. Please reference part numbers when ordering parts:
XHD DURT TRACKER Belt Cleaner
XHD DURT TRACKER Pre-Cleaner Assembly: P/N 32133-XXXXX (stainless steel track). See figure 13. XHD DURT TRACKER Pre-Cleaner Assembly: P/N 32333-XXXXX (aluminum track). See figure 13. XHD DURT TRACKER Pre-Cleaner Assembly with 6.5-in. Blades: P/N 33659-XXXXX (aluminum track). See figure 13. With solid blade: P/N 32136-XXXXS. XHD DURT TRACKER Secondary Cleaner Assembly: P/N 32638-XXXX (stainless steel track) and 32639-XXXX (aluminum track). See figure 14. Shock Ring Mount L Bracket: P/N 33333 (for use with CYA Inspection Door). XHD Corner Flange Bracket: P/N 32818 (for use with CYA Inspection Door). Z Bracket Assembly: P/N 32481 (for use with CYA Inspection Door).
Mounts and brackets
CYA Inspection Doors
With standard door, up to 155 F (68 C): 9 x 12 in. (229 x 305 mm): P/N 27658-0912. 12 x 14 in. (305 x 356 mm): P/N 27658-1214. 12 x 18 in. (305 x 457 mm): P/N 27658-1218. 18 x 24 in. (457 x 610 mm): P/N 27658-1824. 24 x 24 in. (610 x 610 mm): P/N 27658-2424. With steel door: 9 x 12 in. (229 x 305 mm): P/N 34955-0912. 12 x 18 in. (305 x 457 mm): P/N 34955-1218. 18 x 24 in. (457 x 610 mm): P/N 34955-1824. 24 x 24 in. (610 x 610 mm): P/N 34955-2424.
Miscellaneous
Optional Control Kit with Non-Locking Regulator: P/N 32181. Optional Control Kit with Locking Regulator: P/N 32181-L. Winch: P/N 32263.
21
XHDDT Belt Cleaner
Part numbers
Part numbers
10 1 or 2 11 12
14**
13 3 8 or 9** 4 5
11 12
7
15**
13
Item
Description
Part no. 32136-13XXXX 32136-06XXXX 32174-01 14196 See tbl VI 11771 33190 32170-18** 32330-18** 32177-XXX* 18577 17328 32331-XXX* 32170-XXX** 32330-XXX** 23395
Qty See tbl III See tbl III 2 4 2 4 4 See tbl III See tbl III 1 See tbl III See tbl III 1 2 2 2
1 XHD pre-cleaner blade 13.10 2 XHD pre-cleaner blade 6.50 3 End stop extra heavy-duty 4 Screw hex head cap 1/2 -13NC x 2.00 5 End weldment for telescoping mainframe 6 Nut hex 1/2-13NC 7 Screw set 1/2-13NC x 1-1/2 (SS) 8 XHD track weldment SST 9 XHD aluminum track 10 Lanyard assembly 11 Nut stop 1/2-13NC 12 Washer flat 1/2 13 Mainframe weldment 14 XHD stainless steel track weldment 15 XHDDT aluminum track Conveyor Products Warning Label
Figure 13. XHD DURT TRACKER Pre-Cleaner with Stainless Steel Track, P/N 32133XXXXX* or XHD DURT TRACKER Pre-Cleaner with Aluminum Track, P/N 32333XXXXX* or 33659-XXXXX* (with 6.5-in. blades only)
*First XXX indicates belt width in inches; last XX indicates blade color and material (see table IV). **Items 8 and 14 are part of P/N 32133-XXXXX assembly; items 9 and 15 are part of P/N 32333-XXXXX or P/N 33659-XXXXX assembly. All other parts in assemblies except blades are identical. First XX indicates blade color/type (see table IV); third X indicates slit blades (1 for no slits); last X indicates solid blade (S). See appendix B.
22
XHDDT Belt Cleaner
Table III. XHDDT Pre-cleaner part numbers and quantities

Assembly Item 5 32133-XXXXX* part no. -18XX -24XX -30XX -36XX -42XX -48XX -54XX -60XX -66XX -72XX -78XX -84XX -96XX -102XX -108XX -120XX 32332-01 32332-02 32332-02 32332-03 32332-03 32332-04 32332-05 32332-05 32332-06 32332-05 32332-06 32332-06 32332-06 32332-07 32332-07 32332-07 Item 1 Item 2 Item 8, Items 11, qty qty** 9 qty 12 qty 1 1 2 2 3 3 3 4 4 5 5 6 7 7 8 8 0/2 1/3 0/4 1/5 0/6 1/7 1/7 1/9 1/9 0/10 1/11 0/12 0/14 1/15 0/16 1/17 0 0 0 0 2 2 2 2 2 2 2 2 2 2 2 2 4 4 6 6 8 10 10 12 12 12 14 14 16 18 18 20
*XXX indicates belt width in inches; last XX indicate blade color and material. **First number is for assembly 32333-XXXXX. Second number is for assembly 32659-XXXXX (which has only 6.5-in. blades).
Table IV. XHD DURT TRACKER blade specifications

Assy/blade Part no. suffix None BR GR Blade color Orange Brown Green Pre-cleaner blade types Standard Chemical resistant High temperature Durometer Temperature (shore A) F (C) 85 95 95 -20 to 160 (-20 to 71) -20 to 160 (-20 to 71) -20 to 250 (-29 to 121)* Max. belt speed fpm (m/s) 1200 (6) 1200 (6) 1200 (6)
*300 F (149 C) intermittent.
23
XHDDT Belt Cleaner
Part numbers
Part numbers
5 6 4 3
23 or 24** 9 10 11 12 13 14
2 25 1
15
16 17 21** 18 19 20
22**
Figure 14. XHD DURT TRACKER Secondary Cleaner, P/N 32638-XXXX (Aluminum Track) or P/N 32639-XXXX (Stainless Steel Track)* (Sheet 1 of 2)
*First XXX indicates belt width in inches; last X indicates blade material (see table VI). **Items 21 and 23 are part of P/N 32639-XXXX assembly; items 22 and 24 are part of P/N 32638-XXXX assembly. All other parts in assemblies are identical.
24
XHDDT Belt Cleaner
1 End weldment for telescoping mainframe 2 Screw hex head cap 1/2-13NC x 2.00 3 End stop extra heavy-duty 4 Screw socket head cap 3/8-16NC x 2.00 5 Key square 3/16 3.00 6 Shaft keyed 7 XHD urethane base 8 XHD secondary blade 9 Spacer blade 10 Nut slotted hex 3/4-10NC 11 Pin cotter 1/8 x 1.75 12 XHD washer 13 Washer compression 3/4 14 O-ring 15 XHD torsion arm weldment 16 Nut elastic stop 1/2-13NC 17 Washer flat 1/2 18 Mainframe weldment 19 Screw square head set SS 1/2-13NC x 1.50 20 Hex nut 1/2-13NC 21 XHD stainless steel track weldment** 22 XHD aluminum track** 23 XHDDT track weldment SST** 24 XHDDT aluminum track** 25 Lanyard assembly NS Label kit for XHDDT Label Conveyor Products Warning
See tbl V 14196 32174-01 11967 32624 32625 32637 See tbl VI 32622 32619 14210 32626 11754 M435 32634 18577 17328 32331-XXX* 33190 11771 See tbl V See tbl V 32170-18 32330-18 32177-XXX* 34018 23395
2 4 2 See tbl V See tbl V See tbl V See tbl V See tbl V See tbl V See tbl V See tbl V See tbl V See tbl V See tbl V See tbl V See tbl V See tbl V 1 4 4 2 2 See tbl V See tbl V 1 1 1
Figure 14. XHD DURT TRACKER Secondary Cleaner, P/N 32638-XXXX (Aluminum Track) or P/N 32639-XXXX (Stainless Steel Track)* (Sheet 2 of 2)
*First XXX indicates belt width in inches; last X indicates blade material (see table VI). **Item 21 and 23 are part of P/N 32639-XXXX assembly; items 22 and 24 are part of P/N 32638-XXXX assembly. All other parts in assemblies are identical. See appendix B.
25
XHDDT Belt Cleaner
Part numbers
Item
Description
Part no.
Qty
Part numbers
Table V. XHD DURT TRACKER Secondary Cleaner part numbers and quantities
Assembly 32638-XXXX Item 1 32639-XXXX* part no.
-18X -24X -30X -36X -42X -48X -54X -60X -72X -78X -84X -96X -102X -108X 32332-01 32332-02 32332-02 32332-03 32332-03 32332-04 32332-05 32332-05 32332-05 32332-06 32332-06 32332-06 32332-07 32332-07 32332-07 -120X 32170-120 32330-120
Item 21 part no.

32170-18 32170-24 32170-30 32170-36 32170-42 32170-48 32170-54 32170-60 32170-72 32170-78 32170-84 32170-96
Item 22 part no.

32330-18 32330-24 32330-30 32330-36 32330-42 32330-48 32330-54 32330-60 32330-72 32330-78 32330-84 32330-96
Items Items Items 4, 14 16, 17 5 - 13, 15 qty qty qty

2 4 6 8 10 10 12 14 16 18 20 22 24 26 28 4 4 6 6 8 10 10 12 12 14 14 16 18 18 20 1 2 3 4 5 5 6 7 8 9 10 11 12 13 14
Items 23, 24 qty

0 0 0 0 2 2 2 2 2 2 2 2 2 2 2
32170-102 32330-102 32170-108 32330-108 32170-42 32330-42
*First -XXX indicates belt width in inches; last X indicates blade material (see table VI).
Table VI. XHD DURT TRACKER Secondary Cleaner blade part numbers
Assembly 32638/32639** -XXXT -XXXC -XXXU -XXXS -XXXM -XXXH -XXXA Description XHD secondary assy w/tungsten-carbide blades XHD secondary assy w/chrome-plated tungsten-carbide blades XHD secondary assy w/urethane blades XHD secondary assy w/stainless steel blades XHD secondary assy w/mild steel blades XHD secondary assy w/heat-treated blades XHD secondary assy w/abrasion resistant blades Item 23 part no. 32633-T 32633-C 32633-U 32633-S 32633-M 32633-H 32633-A
**XXX indicates belt width in inches.
26
XHDDT Belt Cleaner
Appendix
Typical XHD DURT TRACKER Belt Cleaner Installations
A-1
XHDDT Belt Cleaner
Appendix A
Appendix A
XHD DURT TRACKER Pre-Cleaner With XHD Spring Tensioner

5.00 (127) 2.64 (67) 6.28 (159) 7.36 (187) 6.28 (159) Mount plate 2.64 (67) 7.36 (187) Corner Flange Bracket 14.19 (360) 8.50 (216) 5.00 (127) 12.50 (318)
Pulley Dia.* X Dim. in. (mm) in. (mm) 16 (400) 20 (500) 24 (600) 28 (700) 5.75 (146) 5.50 (140) 5.25 (133) 5.00 (127)
F 20.25 (514)
30 - 120 4.75 (120) (750 - 3000) *Includes lagging & belt.

C D 7.50 (191) 13.50 (343)
11.13 (283) E 14.12 (359) A. B. C. D. E. F. XHD Spring Tensioner, P/N 35392 Flange Corner Bracket, P/N 32818 XHD Pre-Cleaner Blade 13.10 (333) Lg., P/N 32136-13 XHD Pre-Cleaner Blade 6.50 (165) Lg., P/N 32136-06 XHD DURT TRACKER Pre-Cleaner Assembly, P/N 32333-XXX (Aluminum) 12 x 18-in. CYA Inspection Door, P/N 27658-1218 A-2
XHDDT Belt Cleaner
4.25 (108)
XHD DURT TRACKER Secondary Cleaner With Air Tensioner
4.00 (102)
6.00 (152)
A. Air Tensioner, P/N 32135 B. XHD DURT TRACKER Secondary Assembly, P/N 32638-XXXS (Aluminum) C. 12 x 18-in. CYA Inspection Door, P/N 27658-1218 D. XHD Stainless Steel Secondary Blade, P/N 32633-S E. Shock Ring Mount L Bracket, P/N 33333
11.25 (286) E
4.00 (102) 9.00 (229) 6.00 (152)
15.13 (384) Retracted 20.13 (511) Extended
A-3
XHDDT Belt Cleaner
Appendix A
Appendix B
Appendix B
XHD DURT TRACKER Belt Cleaner Labels
MUCHO CUIDADO
WARNING
Pinch point! Usted se puede pellizcar!

Label P/N 30528
Pinch Point Warning Label
ADVERTENCIA
!
WARNING
Lock out and/or tag out all energy sources to conveyor system and loading system before performing any work on conveyor or conveyor accessories. Failure to do so could result in severe injury or death. Cierre y/o rotule todas las fuentes de energa al sistema transportador y al sistema de carga antes de realizar cualquier trabajo en el transportador o sus accesorios. El no hacerlo puede resultar en heridas serias o muerte.
Label P/N 23395-01
Conveyor Products Warning Label
B-1
XHDDT Belt Cleaner
Get A No Risk 30-Day Trial!
Belt Tracking System Keeps Conveyors On-Line And Costs In Line!

MARTIN TRACKER Belt Tracking System continuously corrects belt wander, preventing spillage and damage. Its guaranteed to solve your tracking problem. For information on a No Risk Trial of the MARTIN TRACKER system, call toll free (in the USA) 888-256-7782 or 309-594-2384.
One Martin Place Neponset, IL 61345-9766 USA Phone: 309-594-2384 or 800-544-2947 FAX: 309-594-2432 http://www.martin-eng.com
Form No. M3257-3/00 MARTIN ENGINEERING 1996, 2000
DIMISA
MARTIN SECONDARY BELT CLEANER
Contents:
Installation and maintenance instructions for MARTIN brand, SECONDARY type Belt cleaners. MARTIN English. 41

We Make Your Bulk Material Handling Cleaner, Safer, and More Productive
MARTIN Chevron and RSV Belt Cleaners

OPERATOR MANUAL For more information on this product click here or go to www.martin-eng.com
MARTIN ENGINEERING One Martin Place Neponset, IL 61234-9766 USA 800-544-2947 or 309-593-2384 Fax: 309-594-2432 ISO 9001 Quality Systems Certified
#0&
a

'.6.'#0'45
Important
Martin Engineering hereby disclaims any liability for injuries or damage resulting from use or application of this product contrary to instructions and specifications contained herein. Martin Engineerings liability shall be limited to repair or replacement of product shown to be defective. Observe all safety rules given herein along with owner and Government standards and regulations. Know and understand lockout/tagout procedures as defined by American National Standards Institute (ANSI) z244.1-1982, American National Standard for Personnel Protection - Lockout/Tagout of Energy Sources Minimum Safety Requirements and Occupational Safety and Health Administration (OSHA) Federal Register, Part IV, 29 CFR Part 1910, Control of Hazardous Energy Source (Lockout/Tagout); Final Rule. The following symbols may be used in this manual:
DANGER
Danger: Immediate hazards that will result in severe personal injury or death.
WARNING
Warning: Hazards or unsafe practices that could result in personal injury.
CAUTION
Caution: Hazards or unsafe practices that could result in product or property damages.
IMPORTANT
Important: Instructions that must be followed to ensure proper installation/operation of equipment.
NOTE
Note: General statements to assist the reader.
Table of Contents
Section Page
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installations without chutework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt cleaner inspection access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Materials required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 1 1 1
Before Installing Belt Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing CHEVRON/RSV Belt Cleaners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 3
Finding center point of standard CHEVRON belt cleaner mainframe . . . . . . . . . . . . . . . . . . . . . 3 Finding center point of in-line CHEVRON belt cleaner mainframe . . . . . . . . . . . . . . . . . . . . . . . 4 Finding center point of RSV belt cleaner mainframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
After Installing CHEVRON Belt Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . After Installing RSV Belt Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting/Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix A. Typical Chevron Belt Cleaner Installations. . . . . . . . . . . . . . . . . . . . . . . . . . . Appendix B. Typical Chevron Belt Cleaner Installations. . . . . . . . . . . . . . . . . . . . . . . . . . .
7 9 11 12 13 A-1 B-1
MARTIN Chevron/RSV DURT TRACKER Belt Cleaners
Table of Contents
List of Figures/Tables
List of Figures
Figure
1 2 3 4 5 6 7 8 9 10 11
Title
Page
Standard Chevron Belt Cleaner Mainframe Location. . . . . . . . . . . . . . . . . . . . . . 3 In-Line Chevron Belt Cleaner Mainframe Location . . . . . . . . . . . . . . . . . . . . . . . 4 RSV DURT TRACKER Mainframe Location . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Removing RSV DURT TRACKER blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Chevron Belt Cleaner Changing Belt Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 RSV Belt Cleaner Changing Belt Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DURT TRACKER Mainframe with Chevron Blades, P/N 32266-XXXXXX . . 16 DURT TRACKER In-Line Chevron Mainframe Assembly, P/N 33705-XXX . 18 RSV DURT TRACKER Mainframe Assembly, P/N 33139-XXX . . . . . . . . . . . 20 RSV DURT TRACKER Mainframe Assembly with Snap-on Blade Holder Adapter, P/N 33139-XXSXXX . . . . . . . . . . . . . . . . . . . . 23 Conveyor Products Warning Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
List of Tables
Table
I II III IV V VI VII VIII
Title
Page
Belt Width and Blade/Hardware Quantity for Chevron Belt Cleaner. . . . . . . . . . 17 Belt Width and Blade/Hardware Quantity for In-Line Chevron Belt Cleaner . . . 19 Chevron Blade/Assembly Materials and Part Numbers . . . . . . . . . . . . . . . . . . . . 19 RSV DURT TRACKER Part Numbers and Quantities . . . . . . . . . . . . . . . . . . . 21 RSV DURT TRACKER Material and Part Numbers . . . . . . . . . . . . . . . . . . . . . 22 RSV DURT TRACKER Torsion Arm Base Colors . . . . . . . . . . . . . . . . . . . . . . 22 RSV DURT TRACKER with Snap-on Blade Holder Adapter . . . . . . . . . . . . . . 24 RSV DURT TRACKER Snap-on Blade Types and Part Numbers. . . . . . . . . . . 25
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MARTIN Chevron/RSV DURT TRACKER Belt Cleaners
General
The MARTIN Chevron Belt Cleaner was designed to control carryback and material buildup for chevron ribbed or cleated conveyor belts. The MARTIN Chevron Belt Cleaner consists of special torsion arms on a DURT TRACKER Track with 90-durometer urethane blades. Each blade has several independent fingers that flex with the chevron belt, and maintain an effective scraping contact. The MARTIN In-Line Chevron Belt Cleaner is available for applications where tight spacing limits room for installation of cleaning systems. It uses the same flexible cleaning blades mounted on sliding sleeves to provide a unitary cleaning edge.
Installations without chutework
These procedures were written for equipment that is being installed on enclosed pulley chutework. If the pulley is not enclosed, the equipment should be installed using the best available field resources and methods to ensure that the critical dimensions are followed for proper installation. The MARTIN Hanger Mount Assembly can be used for installations without chutework. See "Part Numbers" for a list of mounts and part numbers.
Belt cleaner inspection access
If the belt cleaner is installed on enclosed pulley chutework, a CYA Inspection Door should be installed. CYA Inspection Doors are available from Martin Engineering or a representative. See Part Numbers for a list of MARTIN CYA Inspection Doors and part numbers. The following documents are referenced in this manual: American National Standards Institute (ANSI) z244.1-1982, American National Standard for Personnel Protection - Lockout/Tagout of Energy Sources - Minimum Safety Requirements, American National Standards Institute, Inc., 1430 Broadway, New York, NY 10018. Federal Register, Volume 54, Number 169, Part IV, 29 CFR Part 1910, Control of Hazardous Energy Source (Lockout/Tagout); Final Rule, Department of Labor, Occupational Safety and Health Administration (OSHA), 32nd Floor, Room 3244, 230 South Dearborn Street, Chicago, Illinois 60604. MARTIN CYA Inspection Door Operators Manual, P/N M3127. Tensioners operators manuals (see Part Numbers in this manual for a complete list).
References
Safety Materials required
All safety rules defined in the above documents and all owner/employer safety rules must be strictly followed when working on the belt cleaner. Only standard hand tools are required to install and service this equipment.
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Introduction
Introduction
Before Installation
Before Installing Belt Cleaner IMPORTANT

The delivery service is responsible for damage occurring in transit. Martin Engineering CANNOT enter claims for damages. Contact your transportation agent for more information. 1. Inspect shipping container for damage. Report damage to delivery service immediately and fill out delivery services claim form. Keep any damaged goods subject to examination. 2. Remove belt cleaner from shipping container. Equipment in container should include the following: Chevron Belt Cleaner (mainframe and blades), or In-Line Chevron Belt Cleaner (mainframe and blades). Two Conveyor Products Warning Labels, P/N 23395. 3. If anything is missing, contact Martin Engineering or a representative. !
WARNING
Before installing equipment, turn off and lock out/tag out energy source to conveyor and conveyor accessories. 4. Turn off and lock out/tag out energy source according to ANSI standards (see References). !
WARNING
If equipment will be installed in an enclosed area, gas level or dust content must be tested before using a cutting torch or welding. Using a cutting torch or welding in an area with gas or dust may cause an explosion. 5. If using a cutting torch or welding, test atmosphere for gas level or dust content. Cover conveyor belt with fire retardant cover.
NOTE
The chute wall that the tensioner will be located on is referred to as the operator side. The other side of the chute is referred to as the far side. 6. Determine which side of chute is easiest to access. Locate the tensioner on the most accessible chute wall.
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Installing CHEVRON Belt Cleaner IMPORTANT

Read entire section before beginning work. To install the belt cleaner, follow the procedures corresponding to the following steps: 1. Find center point of belt cleaner mainframe (standard or in-line). 2. Install tensioner according to the applicable tensioners operators manual. (See Part Numbers in this manual for tensioner manual part numbers.)
Finding center point of standard CHEVRON belt cleaner mainframe
1. See figure 1. On operator side chute wall, draw horizontal and vertical center lines of pulley to find pulley center point (A). Make sure vertical center line is perpendicular to belt line. 2. Measure 1 in. (25 mm) past point where belt leaves pulley (B), and mark vertical line on chute wall perpendicular to belt line.
A. Center point of pulley B. Point where belt leaves pulley C. Center point of first belt cleaner mainframe D. Center point of second belt cleaner mainframe
1 (25) B
90
C 5-1/2 1/8 (140 3)
7-1/2 (190) 16-1/2 (419)
Figure 1. Standard Chevron Belt Cleaner Mainframe Location

3. Locate cleaner blades where this line crosses bottom (return side) of conveyor belt. If you cannot install cleaner at this point, install it as close to it as possible. (If belt is not adequately supported where blade contacts belt, a belt support must be installed. See step 4 under After Installing Belt Cleaner.)
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Installation
Installation
4. Measure vertically and horizontally as shown in figure 1 and mark mainframe center point (C). 5. Repeat steps 1 through 4 for far side chute wall.
NOTE
For maximum cleaning, Martin Engineering recommends installing Chevron Belt Cleaners in pairs (right and left) with torsion arm angles set in alternating directions. 6. To install second belt cleaner: a. On chute wall, measure 16-1/2 in. (419 mm) from center of first mainframe (C, figure 1) in direction of belt travel. b. Locate center of second cleaner mainframe (D) at this point. If you cannot install cleaner at this point, install it as close to it as possible. (If belt is not adequately supported where blade contacts belt, a belt support must be installed. See step 4 under After Installing Belt Cleaner.) 7. If using CYA Inspection Door, install according to MARTIN CYA Inspection Door Operators Manual, P/N M3127.
Finding center point of in-line CHEVRON belt cleaner mainframe
1. See figure 2. On operator side chute wall, draw horizontal and vertical center lines of pulley to find pulley center point (A). Make sure vertical center line is perpendicular to belt line. 2. Measure 1 in. (25 mm) past point where belt leaves pulley (B), and mark vertical line on chute wall perpendicular to belt line.
A. Center point of pulley B. Point where belt leaves pulley C. Center point of first belt cleaner mainframe D. Center point of second belt cleaner mainframe
1 (25) B
90
9 (230) C 5/8 (16)
10 min. (254)
Figure 2. In-Line Chevron Belt Cleaner Mainframe Location
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3. Locate cleaner blades where this line crosses bottom (return side) of conveyor belt. If you cannot install cleaner at this point, install it as close to it as possible. (If belt is not adequately supported where blade contacts belt, a belt support must be installed. See step 4 under "After Installing Belt Cleaner.") 4. Measure vertically and horizontally as shown in figure 2 and mark mainframe center point (C). 5. Repeat steps 1 through 4 for far side chute wall.
NOTE
For maximum cleaning, Martin Engineering recommends installing Chevron Belt Cleaners in pairs. 6. To install second in-line belt cleaner: a. On chute wall, measure at least 10 in. (254 mm) from center of first mainframe in direction of belt travel (see figure 2). b. Locate center of second cleaner mainframe (D) at this point. If you cannot install cleaner at this point, install it as close to it as possible. (If belt is not adequately supported where blade contacts belt, a belt support must be installed. See step 4 under After Installing Belt Cleaner). 7. If using CYA Inspection Door, install according to MARTIN CYA Inspection Door Operators Manual, P/N M3127.
Finding center point of RSV DURT TRACKER Secondary Cleaner mainframe
1. (See figure 3 for RSV DURT TRACKER Secondary Cleaner.) On operator side of chute wall, mark vertical and horizontal center line of head pulley to find pulley center point (A). Make sure center line is perpendicular to belt line.
1 (25)
90 Belt A. Center point of pulley B. Blade-to-belt contact point C. Center point of Secondary Cleaner mainframe
5-1/2 (140) 11.92 (303)
Figure 3. RSV DURT TRACKER Secondary Cleaner Mainframe Location
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Installation
Installation
2. Measure 1 in. (25 mm) past point where conveyor belt leaves pulley and mark vertical line on chute wall perpendicular to belt line. 3. Locate short arm blades where this line crosses bottom (return side) of conveyor belt: blade-to-belt contact point (B). (If belt is not adequately supported, a belt support must be installed. See step 4 under After Installing Belt Cleaner.) 4. Starting from point (B), measure vertically and horizontally as shown in figure 2, 3, or 4 and mark mainframe center point (C). 5. Repeat steps 1 through 4 for far side chute wall. 6. If using CYA Inspection Door, install according to MARTIN CYA Inspection Door Operators Manual, P/N M3127.e
Installing mainframe
1. Remove blades by loosening thumb screw (A, figure 4) on operator side of belt cleaner and removing end stop (B). Pull lanyard (C) to slide blades out of sleeve (D). A D
A. Thumb screw B. End stop C. Lanyard D. Sleeve
Figure 4. Removing RSV Blades
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IMPORTANT
Read entire section before beginning work. 1. After belt cleaner and tensioner are installed according to the applicable tensioner manual, measure from pulley shaft to mainframe, on both operator side and far side, to make sure mainframe is parallel to pulley. 2. Measure from center point of mainframe to face of conveyor belt to make sure proper dimension is held: 5-1/2 1/8 in. (140 3 mm) for standard cleaner (see figure 1). 9 (230) for in-line cleaner (see figure 2). 3. Measure from center point of pulley to outside edge of first and last blade to make sure blades are centered on belt. 4. Make sure cleaner is not changing belt line (see figure 5). If it is, install belt support directly above blade-to-belt contact point.
Belt Line
Figure 5. Belt Cleaner Changing Belt Line

5. Thoroughly wipe outside chute wall clean above tensioner (on both sides of chute if applicable). Place Conveyor Products Warning Label (P/N 23395) on chute wall visible to belt cleaner operator. !
WARNING
DANGER
Do not touch or go near conveyor belt or conveyor accessories when conveyor belt is running. Body or clothing can get caught and pull body into conveyor belt, causing severe injury or death. 7. Turn on conveyor belt for 1 hour.
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After Installation
After Installing CHEVRON Belt Cleaner
After Installation
WARNING
Before adjusting belt cleaner, turn off and lock out/tag out energy source to conveyor belt and conveyor accessories. 8. After 1 hour of operation, turn off and lock out/tag out energy source according to ANSI standards (see References). 9. Make sure all fasteners are tight. Tighten if necessary. 10. Inspect belt cleaner for the following: Wear. (A small amount of break-in wear may be found. This will stop once blades wear to conveyor belt contour.) Material buildup. (No material between blades and return side of conveyor belt should be found.) 11. If wear or material buildup exists, see Troubleshooting/Installation Checklist."
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IMPORTANT
Read entire section before beginning work. 1. Measure from pulley shaft to mainframe on both operator side and far side to make sure mainframe is parallel to pulley. 2. Measure from center point of mainframe to face of conveyor belt to make sure the proper critical dimension is held. (See figure 1, 2, 3, or 4.) 3. Measure from center point of pulley to outside edge of first and last blade to make sure blades are centered on belt. 4. Make sure Secondary Cleaner is not changing belt line (see figure 6). If it is, install belt support directly above blade-to-belt contact point.
Belt Line
Figure 6. Secondary Cleaner Changing Belt Line

5. Thoroughly wipe outside chute walls clean above belt cleaner on both sides of chute. Place a Conveyor Products Warning Label (P/N 23395) on each outside chute wall visible to belt cleaner operator. !
WARNING
DANGER
Do not touch or go near conveyor belt or conveyor accessories when conveyor belt is running. Body or clothing can get caught and pull body into conveyor belt, causing severe injury or death. 7. Turn on conveyor belt for 1 hour. !
WARNING
Before adjusting belt cleaner, turn off and lock out/tag out energy source to conveyor belt and conveyor accessories. 8. After 1 hour of operation, turn off and lock out/tag out energy source according to ANSI standards (see References). 9. Make sure all fasteners are tight. Tighten if necessary.
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After Installation
After Installing RSV Belt Cleaner
After Installation
10. Inspect belt cleaner for the following: Wear. (A small amount of break-in wear may be found. This will stop once blades wear to conveyor belt contour.) Material buildup. (No material between blades and return side of conveyor belt should be found.) 11. If wear, material buildup, or some other problem exists, see Troubleshooting/Installation Checklist.
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IMPORTANT
Read entire section before beginning work. !
WARNING
Before servicing belt cleaner, turn off and lock out/tag out energy source to conveyor belt and conveyor accessories. 1. Turn off and lock out/tag out energy source according to ANSI standards (see References). 2. Make sure all fasteners are tight. Tighten if necessary. 3. Check blades for excessive wear. If blades are worn to wear line, replace blades as follows: a. Release tension from mainframe.
NOTE
If blades will not slide off mainframe loosen or remove track weldments to make blade removal easier. b. Remove blades as instructed under Installing mainframe.
NOTE
If using split aluminum sleeve and track weldments have been removed, re-install before sliding new blades onto cleaner. c. Install new blades as instructed under Installing mainframe. d. Make sure blades are centered on belt. e. Apply tension to belt cleaner according to applicable tensioner manual. 4. Wipe all labels clean. If labels are not readable, contact Martin Engineering or a representative for replacements. !
WARNING
Failure to remove tools from installation area and conveyor belt before turning on energy source can cause serious injury to personnel and damage to belt. 5. Remove all tools from maintenance area. !
DANGER
Do not touch or go near conveyor belt or conveyor accessories when conveyor belt is running. Body or clothing can get caught and pull body into conveyor belt, causing severe injury or death. 6. Start conveyor belt.
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Maintenance
Weekly Maintenance
Troubleshooting
Troubleshooting/Installation Checklist
Troubleshooting
Symptom High blade wear rate.
If you are experiencing problems with belt cleaner, see below: Corrective Action Tension is set too high. Reduce tension. Tension is set too low or too high. Increase or decrease tension. Check blades for excessive wear and replace if necessary. Only one standard cleaner is installed. Install second cleaner.
Insufficient cleaning and carryback.
Material remaining on one side of belt cleats. (CHEVRON ONLY)
Installation checklist
If after taking corrective actions suggested under Troubleshooting you are still experiencing problems, check for the following: Installation Checklist
Distance from center of mainframe to belt surface is 5-1/2 in. (140 mm) on both ends for standard cleaner or 9 in. (230 mm) for in-line cleaner. Cleaner blade tip is 1 in. (25 mm) past vertical center line of pulley. Cleaner is not changing belt line (figure 3). Blades are centered on belt.
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Part Numbers
Notes
This section provides product names and corresponding part numbers for Chevron Belt Cleaners and related equipment. Please reference part numbers when ordering parts:
Chevron Belt Cleaners
DURT TRACKER Chevron Belt Cleaner Assembly (standard): P/N 36881-XXXXXX. See figure 4. DURT TRACKER In-Line Chevron Belt Cleaner Assembly: P/N 33705-XXX. See figure 5.
Recommended tensioners for standard Chevron Belt Cleaners
Belts 18 to 48 in. (400 to 1400 mm) wide: Twist Tensioner: P/N 31443. Adjustable "L" Bracket Twist Tensioner: P/N 31443-L. Flange Mount With AIR-ACTUATEDTM Tensioner: P/N 30691. Flange Mount Spring Tensioner: P/N 30691-SM. Adjustable "L" Bracket Air Tensioner: P/N 31291. Adjustable "L" Bracket Spring Tensioner: P/N 31291-SM. Shock (Ring) Mount Air Tensioner: P/N 32745. Belts 54 to 96 in. (1400 to 2400 mm) wide: Dual Twist Tensioner: P/N 31443-2R. Dual Adjustable "L" Bracket Twist Tensioner: P/N 31443-L2R. Dual Flange Mount With AIR-ACTUATEDTM Tensioner: P/N 30691-2R. Dual Flange Mount Spring Tensioner: P/N 30691-2S. Dual Adjustable "L" Bracket Air Tensioner: P/N 31291-2R. Dual Adjustable "L" Bracket Spring Tensioner: P/N 31291-2S. Dual Shock (Ring) Mount Air Tensioner: P/N 32745-2R.
Recommended tensioners for In-Line Chevron Belt Cleaners
Reversing Mount Tensioner Assembly for Top or Bottom: P/N 33599. Reversing Mount Air Bag Tensioner Assembly: P/N 33599-A. Reversing Mount Air Bag Tensioner Assembly With Plant Air Kit: P/N 33599-AK. Includes Reversing Mount Air Bag Tensioner Assembly, P/N 33599-A, with plant air kit parts.
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Part Numbers
Part Numbers
CYA Inspection Doors
With standard door, up to 155 F (68 C):
9 x 12 in. (229 x 305 mm): P/N 27658-0912. 12 x 14 in. (305 x 356 mm): P/N 27658-1214. 12 x 18 in. (305 x 457 mm): P/N 27658-1218. 18 x 24 in. (457 x 610 mm): P/N 27658-1824. 24 x 24 in. (610 x 610 mm): P/N 27658-2424.
With steel door:
9 x 12 in. (229 x 305 mm): P/N 34955-0912. 12 x 18 in. (305 x 457 mm): P/N 34955-1218. 18 x 24 in. (457 x 610 mm): P/N 34955-1824. 24 x 24 in. (610 x 610 mm): P/N 34955-2424.
Operators manuals
MARTIN CYA Inspection Door Operators Manual: P/N M3127. MARTIN Spring, Air, and Water Tensioners Operators Manual: P/N M3263. MARTIN Twist Tensioner Operators Manual: P/N M3296. MARTIN Reversing Mount Tensioner Operators Manual: P/N M3368.
Miscellaneous
Hanger Mount Assembly: P/N 27382. Use with standard Chevron Belt Cleaners to mount Twist Tensioner or Flange Mount Tensioner onto stringer instead of onto chute wall. Reversing Hanger Mount Assembly: P/N 33282. Use with In-Line Chevron Belt Cleaners to mount Reversing Mount Tensioner onto chute wall. (See below.)
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IMPORTANT
Mandrel Belt Cleaner Mount and Flange Mounting Bracket cannot be used with the In-Line Chevron Belt Cleaner. Mandrel Belt Cleaner Mount: P/N 34280-30 or 34280-48. Replaces far side belt cleaner mount and allows you to service belt cleaner from tensioner side. Flange Mounting Bracket: P/N 30537. Use to mount Flange or Hub Mount Tensioner onto chute wall with 12 x 18-in. (305 x 457-mm) CYA Inspection Door. (See below.)
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Part Numbers
Reversing "Z" Bracket: P/N 31158. For use with CYA Inspection Door. (See below.)
Part Numbers
1 4 2 3 5
7 12 8 11 10 13 9 14
6 16 17, 18, 19 20, 21, 22
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Left Torsion Arms
Right Torsion Arms
Item 1 2 3 4 5 6 7 8 9 10 11
Description Chevron Blade Chevron Torsion Arm Weldment DURT TRACKER Mainframe DURT TRACKER Sleeve Screw Set 1/2-13NC x 1.00 Stop End Nut Stop 5/8-11NC Washer Flat 5/8 Nut Jam 5/8-11NC Bolt Carriage 1/2-13NC x 1.00

Part No. See tbl. III 32268 30360-XX* 100339 22763-03 30386 24242 17154 21652 21239
Qty. See tbl. I See tbl. I 1 1 2 2 See tbl. I See tbl. I See tbl. I See tbl. I See tbl. I
CM DURT TRACKER Torsion Base 31032-01
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Figure 7. DURT TRACKER Mainframe With Chevron Blades, P/N 36881-XXXXXX** (Sheet 1 of 2)
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Item 12 13 14 15 16 17 18 19 20 21 22 NS L-Clip
Description
Part No. 32269 21569 24307 30574 See tbl. III 30354-01 30354-02 30354-03 30354-04 30354-05 30354-06 See tbl. I 23395 Assembly
Qty. See tbl. I See tbl. I See tbl. I 2 See tbl. I See tbl. I See tbl. I See tbl. I See tbl. I See tbl. I See tbl. I 1 2
Washer Ext./Int. Tooth Lock 1/2 Nut Stop 1/2-13NC Screw Thumb 3/8-16NC x .62 DT Chevron Torsion Arm
Pipe End Weldment (18.00 Lg) Pipe End Weldment (22.00 Lg) Pipe End Weldment (34.00 Lg) Mainframe Weldment (123.00 Lg) Mainframe Weldment (135.00 Lg) Mainframe Weldment (117.00 Lg) Lanyard Cable
See fig. 6 Label Conveyor Products Warning
*XX indicates belt width in inches. **XX indicates belt width. Third X indicates left (L) or right (R) torsion arm. Fourth X indicates blade material (urethane [U] or rubber [R]). Fifth and sixth X indicate base color (brown [BR] or green [GR]). Torsion Arm Assembly consists of base, arm weldment, blade, and hardware (assembled).
Figure 7. DURT TRACKER Mainframe With Chevron Blades, P/N 36881-XXXXXX** (Sheet 2 of 2)
Table I. Belt Width and Blade/Hardware Quantity for Chevron Belt Cleaner
Belt Width in. (mm) 18 (400-500) 24 (500-650) 30 (650-800) 36 (800-1000) 42 (1000-1200) 48 (1200-1400) 54 (1400-1600) 60 (1600-1800) 72 (1800-2000) 78 (1800-2000) 84 (2000-2200) 96 (2200-2400) Blade Coverage in. (mm) 12.5 (318) 18.5 (470) 24.5 (622) 30.5 (775) 36.5 (927) 42.5 (1080) 48.5 (1232) 54.5 (1384) 66.5 (1689) 72.5 (1842) 78.5 (1994) 90.5 (2299) Quantity Items 1, 2, 7, 10, 11, 12, 13, 14, 16 2 3 4 5 6 7 8 9 11 12 13 15 Quantity Items 8 and 9 4 6 8 10 12 14 16 18 22 24 26 30 1 1 Weldment Quantity Items 17 1 18 1 2 1 1 1 1 1 1 1 1 1 1 2 2 1 19 20 21 22 Lanyard Cable P/Ns 100349-47 100349-53 100349-59 100349-65 100349-71 100349-77 100349-83 100349-89 100349-101 100349-107 100349-113 100349-125
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Part Numbers
Part Numbers
2 3 4
5 7 6 8
Item 1 2 3 4 5 6 7 8 9
Description DURT TRACKER Mainframe Weldment Nut Elastic Stop 5/8-11 Washer Flat 5/8 Sleeve Spacer Screw Square Head Set 1/2-13 x 1.00 Sleeve End Sleeve Weldment Screw Hex Head Cap 5/8-11 x 2-1/2 Chevron Blade
Part No. 30709-XX* 24242 17154 23239-01 22763-03 23458 33704 22519 See tbl. III 23395
Qty. 1 See tbl. II See tbl. II See tbl. II 2 2 See tbl. II See tbl. II See tbl. II 2
See fig. 6 Label Conveyor Products Warning
*XX indicates belt width in inches. **First XX indicates belt width in inches. Third X indicates blade type (urethane [U] or rubber [R]).
Figure 8. DURT TRACKER In-Line Chevron Mainframe Assembly, P/N 33705-XXX**
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Table II. Belt Width and Blade/Hardware Quantity for In-Line Chevron Belt Cleaner
Belt Width in. (mm) 18 (400-500) 24 (500-650) 30 (650-800) 36 (800-1000) 42 (1000-1200) 48 (1200-1400) 54 (1400-1600) 60 (1600-1800) 72 (1800-2000) 84 (2000-2200) 96 (2200-2400) Blade Coverage in. (mm) 14 (356) 21 (533) 28 (711) 35 (889) 42 (1067) 42 (1067) 49 (1245) 56 (1422) 70 (1778) 77 (1956) 91 (2311) Quantity Items 2, 6, 7, 8 and 9 2 3 4 5 6 6 7 8 10 11 13 Quantity Item 3 4 6 8 10 12 12 14 16 20 22 26 Quantity Item 4 1 2 3 4 5 5 6 7 9 10 12
Table III. Chevron Blade/Assembly Materials and Part Numbers

Urethane DURT TRACKER Blade Blade Material Torsion Base Mainframe Type Part Number Color Standard Standard Standard Standard Standard Standard In-Line In-Line Urethane Urethane Urethane Rubber Rubber Rubber Urethane Rubber 32262 32262 32262 32757 32757 32757 32262 32757 Orange Brown Green Orange Brown Green Torsion Arm Assembly Part Numbers* 32270-XU 32270-XUBR 32270-XUGR 32270-XR 32270-XUBR 32270-XUGR Chevron Belt Cleaner Assembly Part Number** 36881-XXXU 36881-XXXUBR 36881-XXXUGR 36881-XXXR 36881-XXXUBR 36881-XXXUGR 33705-XXU 33705-XXR
*Torsion arm assembly consists of base, arm weldment, blade, and hardware (assembled). **XX indicates belt width. A third X indicates left (L) or right (R) torsion arm on standard Chevron belt cleaner. X indicates left (L) or right (R) torsion arm.
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Part Numbers
Part Numbers
1 2 3 4 5 6 11 10 12 13
16 17 18 25 19 20 21 22 23
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Item
15
24
Description 1 DT Pipe End Weldment (18.00) 2 DT Pipe End Weldment (22.00) 3 DT Pipe End Weldment (34.00) 4 Pipe End Weldment (Continuous 123.00) 5 Pipe End Weldment (Continuous 135.00) 6 Pipe End Weldment (Continuous 117.00) 7 Screw HHC 3/8 -16NC x 1-1/2 8 CM DURT TRACKER Torsion Base 9 Cable Lanyard 10 RSV Spacer Blade 11 Blade 12 Washer Flat 5/8 13 Nut Elastic Stop 5/8 -13NC 14 Washer Nylon 5/8 ID 15 Arm RSV Weldment 16 End Stop Plug 17 DURT TRACKER Mainframe 18 DURT TRACKER Split-Frame 19 Nut Jam 1/2 -13NC 20 Screw HHC 1/2 -13NC x 1-1/4 21 Bolt Carriage 1/2 -13NC x 3 22 Lockwasher Int/Ext Tooth 1/2 23 Nut Elastic Stop 1/2 -13NC 24 Nut Elastic Lock 1/2 -13NC 25 Washer Flat 1/2

Part No. 30354-01 30354-02 30354-03 30354-04 30354-05 30354-06 15673 See tbl VI ** 33145 See tbl V 17154 24242 33138 33141 30386 34424-XX* 34423-XX** 16889 13835 21239 21569 24307 18577 17328 23395
Qty ** ** ** ** ** ** 2 ** 1 ** ** ** ** ** ** 2 1 1 4 4 ** ** ** ** ** 1
See fig. 15 Conveyor Products Warning Label
Figure 9. RSV DURT TRACKER Secondary Cleaner Assembly, P/N 33139-XXXXX*

*XX indicates belt width in inches; third X indicates type of blade (see table V.); last XX indicates urethane base color. ** See table IV.
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20
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#46+0 0)+0''4+0) GFJJgEEfNF

21
Table IV. RSV DURT TRACKER Secondary Cleaner Part Numbers and Quantities
Belt Width in. (mm) 18 (400-500) 24 (500-650) 30 (650-800) 36 (800-1000) 42 (1000-1200) 48 (1200-1400) 54 (1400-1600) Qty Qty Qty Qty Qty Qty Qty Item 1 Item 2 Item 3 Item 4 Item 5 Item 6 Item 14 1 0 0 0 0 0 0 0 0 0 0 0 0 1 2 1 1 1 1 1 0 0 0 0 0 0 0 0 1 1 1 1 1 2 2 2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 1 0 0 4 6 8 10 12 14 16 18 20 22 24 26 30 Qty Items 8,10,11, 12,13,15, 21,22,23 2 3 4 5 6 7 8 9 10 11 12 13 15 Part No. Item 9 100349-47 100349-53 100349-59 100349-65 100349-71 100349-77 100349-83 100349-89 100349-95 100349-101 100349-107 100349-113 100349-125 Blade Coverage in. (mm) 12.5 (318) 18.5 (470) 24.5 (623) 30.5 (775) 36.5 (927) Length Item 18 in. (mm) 15 (381) 21 (533) 27 (686) 33 (838) 39 (991) Qty Item 24, 25 4 4 4 6 6 8 8 10 10 10 12 12 14
42.5 (1080) 45 (1143) 48.5 (1232) 51 (1295) 54.5 (1385) 57 (1448) 60.5 (1537) 63 (1600) 66.5 (1689) 69 (1753) 72.5 (1842) 75 (1905) 78.5 (1994) 81 (2057) 90.5 (2299) 93 (2362)
a *'8410f a '.6 .'#0'45
60 (1600-1800) 66 (1600-1800) 72 (1800-2000) 78 (1800-2000) 84 (2000-2200) 96 (2200-2400)
Part Numbers
Part Numbers
Table V. RSV DURT TRACKER Blade Material and Part Numbers

Assembly Part No.* 33139-XXTXX 33139-XXSXX Material Tungsten-Carbide Stainless Steel Blade Part No. Item 11 27924 16960
*XX indicates belt width in inches; last XX indicates torsion base color.
Table VI. RSV DURT TRACKER Torsion Arm Base Colors

Color Orange Brown Green Assembly Part No.* 33139-XXX 33139-XXXBR 33139-XXXGR Base Part No. 31032-01 31032-01BR 31032-01GR
*XX indicates belt width in inches; third X indicates type of blade (see table V.); last XX indicates torsion base color.
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22
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11 12 13 10 12 13 23 Long arm with urethane blade Short arm with steel blade
Item
15 11 10 16 17 18 19 24 20 21 22
14
Description 1 DT Pipe End Weldment (18.00) 2 DT Pipe End Weldment (22.00) 3 DT Pipe End Weldment (34.00) 4 Pipe End Weldment (Continuous 123.00) 5 Pipe End Weldment (Continuous 135.00) 6 Pipe End Weldment (Continuous 117.00) 7 Screw HHC 3/8 -16NC x 1-1/2 8 CM DURT TRACKER Torsion Base
Part No. 30354-01 30354-02 30354-03 30354-04 30354-05 30354-06 15673 See tbl VII ** See tbl VIII See tbl VIII 17154 24242 35402 30386
Qty ** ** ** ** ** ** 2 ** 1 ** ** ** ** ** 2 1 2 4 4 ** ** ** ** ** 1
9 Cable Lanyard 10 Adapter Blade Holder 11 Blade 12 Washer Flat 5/8 SS 13 Nut Stop/Jam 5/8 -11NC 14 Arm RSV Weldment 15 End Stop Plug 16 DURT 17 DURT TRACKER TRACKER Mainframe Split-Track
34424-XX* 34423-XX** 16889 13835 21239 21569 24307 18577 17328 23395
18 Nut Jam 1/2 -13NC 19 Screw HHC 1/2 -13NC x 1-1/4 20 Bolt Carriage 1/2 -13NC x 3 21 Lockwasher Int/Ext Tooth 1/2 22 Nut Elastic Lock 1/2 -13NC SS 23 Nut Elastic Lock 1/2-13NC 24 Washer Flat 1/2 See fig. 15 Conveyor Products Warning Label
Figure 10. RSV DURT Secondary Cleaner Assembly with Snap-on Blade Holder Adapter, P/N 33139-XXSXXX*
*XX indicates belt width in inches; S indicates Snap-on Blade, last two X indicates color urethane blade/Torsion Base (see table VIII). **See table VII.
TRACKER
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23
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Part Numbers
1 2 3 4 5 6
8 9
Part Numbers
Table VII. RSV DURT TRACKER Secondary Cleaner with Snap-on Blade Holder Adapter Part Numbers and QuantitiesTable VII. RSV DURT TRACKER with Snap-on Blade Holder Adapter
Qty Items Qty Qty Qty Qty Qty Qty 8,10,11, Item 1 Item 2 Item 3 Item 4 Item 5 Item 6 12,13,14, 20,21,22 Part No. Item 9 100349-47 100349-53 100349-59 100349-65 100349-71 100349-77 100349-83 100349-89 10 11 1 0 1 0 12 13 15 100349-95 100349-101 100349-107 100349-113 100349-125 12.5 (318) 18.5 (470) 24.5 (623) 30.5 (775) 36.5 (927) Blade Coverage in. (mm) 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 2 0 0 0 0 2 0 0 0 0 2 0 0 0 9 1 1 0 0 0 8 1 1 0 0 0 7 1 1 0 0 0 6 1 1 0 0 0 5 1 1 0 0 0 4 2 0 0 0 0 3 1 0 0 0 0 2 15 (381) 21 (533) 27 (686) 33 (838) 39 (991) 42.5 (1080) 45 (1143) 48.5 (1232) 51 (1295) 54.5 (1385) 57 (1448) 60.5 (1537) 63 (1600) 66.5 (1689) 69 (1753) 72.5 (1842) 75 (1905) 78.5 (1994) 81 (2057) 90.5 (2299) 93 (2362) Length Item 17 in. (mm) Qty Item 23, 24 4 4 4 6 6 8 8 10 10 10 12 12 14
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Belt Width in. (mm)
18 (400-500)
24 (500-650)
30 (650-800)
36 (800-1000)
42 (1000-1200)
24
48 (1200-1400)
54 (1400-1600)
60 (1600-1800)
66 (1600-1800)
72 (1800-2000)
78 (1800-2000)
84 (2000-2200)
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96 (2200-2400)
.Table Assembly Part No.* 33139-XXSU 33139-XXSUBR
VIII. Snap-on Type Blades and Part Numbers

Blade Type Part No. Item 8 31032-01 31032-01BR 31032-01GR ** ** ** ** Part No. Item 10 34711-GR1 34711-GR1 34711-GR1 34711-GR 34711-GR 34711-GR 34711-GR Part No. Item 11 32364-SS 32364-BR 32364-GR 30340 30337 30339-AR 30339-HT
Urethane - Orange Urethane - Brown
33139-XXSUGR Urethane - Green 33139-XXSSXX 33139-XXSTXX 33139-XXSAXX 33139-XXSHXX Stainless Steel Tungsten Carbide Abrasion Resistant Heat Treated
*First two X indicates belt width in inches, S indicates Snap-on Blade, next character indicates Blade Type, last two X indicates color Urethane Blade/ Torsion Base.
** Can be used in combination with any color Urethane Torsion Base.
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25
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Part Numbers
ADVERTENCIA
!
WARNING
Lock out and/or tag out all energy sources to conveyor system and loading system before performing any work on conveyor or conveyor accessories. Failure to do so could result in severe injury or death. Cierre y/o rotule todas las fuentes de energa al sistema transportador y al sistema de carga antes de realizar cualquier trabajo en el transportador o sus accesorios. El no hacerlo puede resultar en heridas serias o muerte.
Label P/N 23395
Figure 11. Conveyor Products Warning Label
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26
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Appendix A
Typical Chevron Belt Cleaner Installations
#46+0 0)+0''4+0) GFJJgEEfNF
A-1
a *'8410f '.6 .'#0'45
Appendix
Appendix
DURT TRACKER Chevron Belt Cleaner with Twist Tensioner Mounted on L-Bracket with CYA Door
6.0 (152)
4.5 (114)
6.0 (152) 1 (25) min.

90
4.5 (114) Far Side Mount (same bolt hole pattern for Twist Tensioner) 4.50 (114) 5.5 .12 (140 3)
A 4.50 (114) 7.88 (200) C 8.94 (227) A. B. C. D. E. B
7.5 (190) 16.5 (419) C
Chevron Blade, P/N 32262 (Urethane) or 32757 (Rubber) L-Bracket, P/N 33706 Twist Tensioner Assembly with Adjustable L-Bracket, P/N 31443-L 18 x 24-in. CYA Inspection Door, P/N 27658-1824 DURT TRACKER Chevron Belt Cleaner Assembly, P/N 32266-XXXXXX A C E
#46+0 0)+0''4+0) GFJJgEEfNF
A-2
a *'8410f '.6 .'#0'45
DURT TRACKER Chevron In-Line Belt Cleaner with Reversing Spring Tensioner Mounted on L-Bracket with CYA Door
A. Fabricated Z-Mount, P/N 31158 B. Chevron Blade, P/N 32262 (Urethane) or 32757 (Rubber) C. 9 x 12-in. CYA Inspection Door, P/N 27658-0912 D. DURT TRACKER Chevron In-Line Assembly, P/N 33705-XXX E. Reversing Mount Tensioner Assembly for Top or Bottom, P/N 33599
1 (25) min.
9.00 (230) .12 (3) 4.50 (114)
7.38 (187)
.63 (16)
3.00 (76) 6.00 (152)
C 6.00 (152) B D
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A-3
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Appendix
Appendix
DURT TRACKER Chevron Belt Cleaner with Spring Tensioner and Hanger Mount
10 (254) 16.5 (419) 8.25 (210) 3 (76) 2.62 (67) 1 (25) min.
4.5 (114) 6.5 (165) 6.0 (152)
4.5 (114)
6.0 (152)
B 7.5 (190)
4.5 (114) Far Side Mount (same bolt hole pattern for Twist Tensioner)
16.5 (419)
A. Hanger Mount Assembly, P/N 27382 B. Spring Tensioner, P/N 30691-SM C. DURT TRACKER Chevron Belt Cleaner Assembly, P/N 32266-XXXXXX D. Chevron Blade, P/N 32262 (Urethane) or 32757 (Rubber) D
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A-4
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Appendix B
Typical RSV DURT TRACKER Secondary Belt Cleaner Installations
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B-1
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Appendix
Appendix
RSV DURT TRACKER Secondary Cleaner With Twist Tensioner and Flange Bracket
1.00 (25) min 5.50 (140)
A. Twist Tensioner, P/N 31443 B. RSV DURT TRACKER Secondary Mainframe Assembly, P/N 33139-XXXXXX C. Flange Bracket, P/N 30537 D. 12 x 14-in. CYA Door, P/N 27658-1214
7.50 (191) 14.50 (368)
D 6.00 (152) 16.50 (419) 4.50 (114) .75 (19) 3.25 (83)
5.50 (140)
Cleaner mainframe position 5.50 (140) 3.25 (83)
4.50 (114)
13.62 (346) 6.00 (152)
3.25 (83)
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B-2
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Conveyor Stringer
6.0 (152) 1.0 (25) 4.5 (114) 6.0 (152) 5.5 .12 (140 3) 4.5 (114) Far Side Mount (same bolt hole pattern for Twist Tensioner) A B 10.0 (254) 6.5 (165) A. RSV DURT TRACKER Secondary Mainframe Assembly, P/N 33139-XXXXXX B. Twist Tensioner Assembly, P/N 31443 C. Hanger Mount Assembly, P/N 27382-2R .88 (22) 3.0 (76) C 5.5 to 12.5 adj. (140 to 318 adj.)
3.5 (89) 9.1 (232)
1.6 (41)
Conveyor Stringer 7.63 (194) A
3.25 (83)
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B-3
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Appendix
RSV DURT TRACKER Secondary With Twist Tensioner and Hanger Mount
1RWHV
One Martin Place Neponset, IL 61345-9766 USA Phone: 309-594-2384 or 800-544-2947 FAX: 309-594-2432 www.martin-eng.com
MARTIN ENGINEERING 1998, 2002
Form No. M3266-11/02
DIMISA
B-LOC KEYLESS LOCKING DEVICES
Contents:
Installation and maintenance instructions for MARTIN brand, QD type Keyless Locking Devices. MARTIN. English. 1.

INSTALLATION AND REMOVAL INSTRUCTIONS FOR B-LOC LOCKING ASSEMBLY SERIES B115
Thank you for purchasing a B-LOC Keyless Frictional Locking Device. B-LOC keyless connectors provide a high capacity, zero-backlash shaft/hub or coupling connection by means of a mechanical interference fit. Please follow these INSTALLATION AND REMOVAL INSTRUCTIONS carefully to ensure proper performance of this B-LOC unit.
NOTE:
In installations subjected to extreme corrosion, the slits in clamp collars Item 1 and Item 2, as well as in center collars, should be sealed with a suitable caulking compound or equivalent. Likewise, push-off threads should also be protected from corrosion. INSTALLATION OF B-LOC LOCKING ASSEMBLIES OVER SHAFT KEYWAYS
EWARNING E
When installing or removing B-LOC products, always adhere to the following safety standards: 1. Be sure that all power switches are locked out before installing or removing B-LOC products. 2. Eye protection is required when installing or removing B-LOC products - please wear safety glasses and protective clothing. INSTALLATION (Refer to Figures 1 and 2) B-LOC Locking Assemblies are supplied lightly oiled and ready for installation. When reinstalling a used unit, make sure that all slits are aligned and that front and rear clamp collars are not reversed (when assembled correctly there are no holes or threads behind taps in clamp collar Item 1, and no threads behind taps in center collar Item 3). The frictional torque capacity of these devices is based on a coefficient of friction of 0.12 for lightly oiled screw, taper, shaft and bore contact areas. Figure 1 Therefore, it is important not to use Molybdenum Disulfide (e.g., Molykote, Never-Seeze or similar lubricants) in any Locking Assembly installation. 1. Make sure that locking screw, taper, shaft and bore contact areas are clean and lightly oiled and that all collar slits are aligned. 2. Loosen all locking screws by a minimum of four (4) turns and transfer at least two (2) screws to push-off threads in clamp collar Item 1 to disengage this part from center collar Item 3. Similarly, transfer at least two (2) screws to push-off threads in center collar Item 3 to disengage this part from clamp collar Item 2 (see Figure 2). 3. Completed assembly can now be placed on shaft and inserted into hub bore by pushing against face of collar Item 1 while ensuring that collar Item 2 is not engaged at tapers during this phase. 4. After placement of Locking Assembly, relocate locking screws used for separation of collars. 5. Hand tighten connection and confirm that clamp collar Item 1 is parallel with face of part to be attached to shaft and/or with the front facing edge of center collar Item 3. 6. Use torque wrench and set it approximately 5% higher than specified tightening torque MA. Tighten locking screws in either a clockwise or counterclockwise sequence (it is not necessary to tighten in a diametrically opposite pattern), using only 1/4 (i.e., 90) turns for several passes until 1/4 turns can no longer be achieved. 7. Continue to apply overtorque for 1 to 2 more passes. This is required to compensate for a system-related relaxation of locking screws since tightening of a given screw will always relax adjacent screws. Without overtorquing, an infinite number of passes would be needed to reach specified tightening torque. 8. Reset torque wrench to specified torque (MA) and check all locking screws. No screw should turn at this point, otherwise repeat Step 7 for 1 or 2 more passes. It is not necessary to re-check tightening torque after equipment has been in operation. B-LOC Corporation 26 Gilbert Street Monroe, NY 10950
The Locking Assembly should be positioned so that slits in Locking Assembly collars that contact the shaft are located approximately opposite the keyway. In addition, a locking screw should be centered directly over the keyway. When tightening locking screws, it is important to follow the installation procedure outlined above, which specifies equal 1/4 turns of each locking screw. Failure to follow these instructions could result in excessive tightening of the screw over the keyway, possibly causing permanent deformation of the locking assembly collars. Even after 1/4 turns can no longer be achieved, it is important to continue to use equal turning angles for every screw until the specified tightening torque is reached. REMOVAL (Refer to Figure 2) Prior to initiating the following removal procedure, check to ensure that no torque or thrust loads are acting on the Locking Assembly, shaft or any mounted components IMPORTANT! Make sure ends of locking screws used for removal are ground flat and are slightly chamfered to prevent damage to screw and collar threads during push-off.
1. Check to ensure that axial movement of clamp collars - necessary for release of connection - is not restricted. Likewise, ensure that push-off threads are in good condition. 2. Remove all locking screws. Transfer required number of screws into all pushoff threads of clamp collar Item 1 (see Figure 2). Figure 2
3. Release collar Item 1 by progressively tightening all pushoff screws. Typically, the push-off screws appear to be completely tight after just one pass of tightening without any noticeable separation of clamp collars. Although it seems that the screws cannot be tightened further, several more rounds of torquing in either a clockwise or counterclockwise sequence will increase the push-off force in the system and ultimately release part of the front collar. Afterwards, only the screws which are still tight should be tightened further until complete dismounting is achieved. Remove clamp collar Item 1. 4. Transfer locking screws used for dismounting of clamp collar Item 1 into all push-off threads in center collar Item 3 (see Figure 2). Release clamp collar Item 2 by repeating procedures outlined in Step 3.
LOCKING SCREW SIZES AND SPECIFIED TIGHTENING TORQUE MA B115 LOCKING ASSEMBLY Tightening Torque MA (ft-lbs) 60 105 166 257 500 675 Screw Size M 10 M 12 M 14 M 16 M 20 M 22 Hex Key Size (mm) 8 10 12 14 17 17
Metric Series 70 100 170 220 280 360 x x x x x x 110 145 225 285 355 455 to to to to to to 90 160 200 260 340 600 x x x x x x 130 210 260 325 425 695
Inch Series 2-3/4 to 3-1/2 3-15/16 to 6 6-7/16 to 8
For technical assistance, please call 1-800-865-7756
DIMISA
FALK MCF-1090 FLEXIBLE COUPLINGS
Installation and maintenance instructions for FALK brand, MCF-1090 type coupling. FALK. Corp. English. 4.

Rigid Moment Couplings Installation & Maintenance Type MCF Sizes 1045 thru 1075 (Page 1 of 4)
This manual provides detailed instructions on installation, removal, maintenance, and part descriptions. Use the table of contents below to locate required information.
Introduction . . . . . . . . . . . . . . . . . . . . . Page 1 Installation . . . . . . . . . . . . . . . . . . Pages 1 thru 4 Removal . . . . . . . . . . . . . . . . . . . . . . . Page 4 Annual Maintenance . . . . . . . . . . . . . . . . . Page 4 Part Descriptions . . . . . . . . . . . . . . . . . . . Page 4 CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE FREE SERVICE.
Table of Contents
Introduction
This manual applies to Type MCF rigid moment couplings, Sizes 1045 thru 1075. The couplings are designed to shaft mount a gear drive to a shaft. The couplings will generally be mounted horizontally but they can be mounted vertically as well. MCF couplings are available with interference fit hubs (Type 2), hubs with shrink discs (Type 4), or a combination of Type 2 and Type 4 hubs. See Part Descriptions on Page 4. The performance and life of couplings depend largely upon how you install and service them. WARNING: Consult applicable local and national safety codes for proper guarding of rotating members. Observe all safety rules when installing or servicing couplings. WARNING: Lockout starting switch of prime mover and remove all external loads from drive before installing or servicing couplings. WARNING: Do not service the coupling without first completely reading installation, alignment, and maintenance instructions. The compressive fit between the shaft and hub provides both support for the drive assembly and transmits the torque. Failure to achieve correct fit between the shaft and hub, and between the two hubs can result in damage to the system components and has the potential to cause serious injury to personnel in the immediate vicinity. CAUTION: Visual movement of the drive and assembly is normal. The movement is due to shaft and coupling connection runout. DO NOT restrain this movement; to do so will adversely load the reducer low speed shaft and the connected shaft, and may result in shaft or hub failures.
Figure 1 TYPE 2 FEMALE HUB & TYPE 4 MALE HUB 5. If a keyway is present, the edges of the keyway should be broken with a file and free of burrs. 6. Mount hubs on shafts a. STRAIGHT BORED INTERFERENCE FIT HUB WITH KEY (TYPE 2 HUB). (1) Clean all parts. Heat hub to between 350F (177C) and 450F (232C) using an oven, torch, or an induction heater. WARNING: Do not use an oil bath to heat hub. When an oxy-acetylene or blow torch is used, use an excess acetylene mixture. Mark hub near the center of its length in several places on hub body with temperature sensitive crayons, one 350F (177C) and one 450F (232C) melt temperature. Direct flame toward hub bore using constant motion to avoid overheating an area. (2) Mount hub flush with face of shaft. Allow hub to cool before proceeding. Insert set screws, if required, and tighten. (3) Proceed to Step 6. b. below for installation of Type 4 hub with shrink disc, or to Step 7, Page 3, for balance of installation. b. HUB WITH SHRINK DISC (TYPE 4 HUB) IMPORTANT: Never tighten shrink disc locking screws before shaft is inside the hub to prevent plastic deformation of the hub. (1) Remove shipping spacers used to provide protection during transportation. (2) Make certain locking screw threads, screw head bearing area and tapers of the inner ring are lubricated. If not, lubricate them with a molybdenum disulfide grease such as Molykote Gn paste or similar. NOTE: It is very important for the shrink disc to be lubricated properly. If the correct lubricant is not used the coupling capacity can be reduced 50% or more.
Installation
1. Thoroughly clean, degrease, and dry coupling hub flange mounting faces, drive and driven shafts. Clean with a non-flammable solvent. See also Figure 3, Page 2. 2. Check both shafts for runout to ensure shafts are not bent. Refer to Figure 6, Page 3. 3. Shaft ends must be chamfered to provide a lead for hub mounting. 4. Shafts and bores must be free of burrs. Any rust or corrosion in the interference area must be removed before assembly.
The Falk Corporation, P .O. Box 492, Zip 53201-0492 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131 Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com
February 1995 (.pdf revision) NEW
458-862
Installation & Maintenance Rigid Moment Couplings (Page 2 of 4) Type MCF Sizes 1045 thru 1075
(5) Slide both hub and shrink disc into place on the shaft. Mount hub as shown in Figure 4, so that each hub face is flush with the end of its shaft.
(3) Position the shrink disc on the coupling hub. The hub outside diameter can be greased to aid assembly. Make sure the shrink disc is fully seated on the hub and is not jammed in the radius in the corner. See Figure 2.
Figure 4 Figure 2 (4) Degrease hub bore and shaft seat. See Figure 3. (6) Tighten three or four equally spaced shrink disc locking screws to establish a parallel condition of the collar faces, and a perpendicular position of the shrink disc collars relative to the shaft. This will properly seat the collars on the taper of the inner ring and avoid cocking of the collars. The following gap parallel tolerance values are recommended for the shrink disc sizes listed below, see Figure 5. Sizes 24 100 Sizes 110 260 Sizes 280 500 .015" max. deviation in gap .032" max. deviation in gap .062" max. deviation in gap
Figure 3
Figure 5
458-862
Rigid Moment Couplings Installation & Maintenance Type MCF Sizes 1045 thru 1075 (Page 3 of 4)
7. With suitable lifting equipment, move the drive/motor assembly into position approximately parallel and in line with the driven shaft using hub flanges as a guide. Align fastener holes, and install and hand tighten one flange fastener. Align hub registers and flange fastener holes. Install all flange bolts finger tight. 8. Use a precision torque wrench and equally tighten all opposing fasteners while allowing the drive assembly to move as required to draw the flanges together (flexible support). Continue tightening until flanges are mated and all flange fasteners are torqued to values specified in Table 2.
(7) Using a torque wrench, tighten all locking screws gradually one after another in a clockwise or counterclockwise sequence (not in diametrically opposite sequence). Depending on the size of shrink disc it can take as many as 10 to 15 complete passes before the specified tightening torque is reached, see Table 1. Make certain the locking screws are tightened properly, since this affects coupling capacity.
TABLE 1 Shrink Disc Locking Screw Tightening Torque Values

Screw Size (Metric) DIN 931 GR 10.9 M5 M6 M8 M10 M12 M16 M20 M24 M27 Distance Across Flats of Head (mm) 8 10 13 17 19 24 30 36 41 Tightening Torque (Nm) 5 12 30 59 100 250 490 840 1250 (lb-ft) 3.6 8.7 22 44 74 185 362 620 922
TABLE 2 Flange Fastener Tightening Torque

COUPLING SIZE 1045MCF 1055MCF 1060MCF 1065MCF 1075MCF Flange Fastener Size (in) Grade 8 1.1257UNC x 4.00 1.1257UNC x 4.00 1.2507UNC x 4.50 1.2507UNC x 5.00 1.5007UNC x 6.00 Flange Fastener Tightening Torque Tolerance 5% (Nm) 1320 1320 1850 1850 3180 (lb-ft) 970 970 1360 1360 2340
(8) Make certain that screws will no longer turn by applying specified torque only then is the installation complete. Make sure that both collars are still parallel, correct if not. (9) Check that the hub is correctly positioned on the shaft, then using dial indicators check hub runout as illustrated in Figure 6. Checking the hub runout ensures correctness of hub mounting and will reduce drive movement. Make sure runout values do not exceed limits listed in Table 3. If runout is excessive, reverse the hub assembly procedure, carefully reassemble, and recheck hub runout. Recheck all fasteners to be sure they are torqued to specified values in Table 1.
9. Fasten the torque arm to the bed frame and remove the lifting equipment. Falk recommends that a loose, unrestraining safety sling be attached to the bedplate and support structure, to support the drive in case of an emergency. 10. Using dial indicators per Figure 7, measure assembly runout on driving and driven shafts. Runout values should be within .005" TIR (total indicator reading) to minimize drive movement. See Table 3.
Figure 7
TABLE 3 Maximum Runouts (TIR) for Dial Indicators

Figure 6
ALL SIZES #1 .001 #2 .003 #3 .003
The Falk Corporation, P .O. Box 492, Zip 53201-0492 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone: 414-342-3131 Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com
458-862
Installation & Maintenance Rigid Moment Couplings (Page 4 of 4) Type MCF Sizes 1045 thru 1075
11. Run the drive for a short period of time, and then shut off and lockout motor. Recheck all fasteners for specified torque. 12. The coupling installation is now complete. WARNING: Install the warning nameplate supplied with the coupling on the coupling guard or on some other support structure near the coupling.
Removal
1. Do not disconnect torque arm or tie rod until the low speed coupling is completely disconnected. 2. With suitable equipment, remove the weight of the drive assembly from the coupling and driven shafts. It is necessary to make fine adjustments of position at each of the bedplate lugs. The lifting slings should have appropriate provisions for adjustment. 3. Lift the drive by the lifting lugs in the bedplate or wrap slings around the assembly when a bedplate is not used. Balance loads so drive is level and will not swing down when the coupling is disconnected. 4. Loosen flange fasteners in sequence until all fasteners have at least a .125" clearance under the fastener heads. Remove all but one fastener near the top of the flange. Separate the two flanges using four 1/213UNC fasteners (not supplied with coupling) inserted in the four jackscrew holes in the male register flange. Continue backing off the last flange fastener as the flanges are separated. When completely separated, adjust the weight of the drive assembly until the weight is off the last fastener. Carefully remove the last fastener.
5. Adjust the drive assembly position until all the weight of the assembly is balanced. Slowly move the drive assembly out and away from underneath the tie rod. When the drive assembly is not directly above the tie rod, and the tie rod is no longer bearing any of the weight, disconnect the tie rod. Slowly lower the assembly to the ground. 6. When removing the shrink disc, first clean all debris from between the hub flange and shrink disc clamping flange to ensure the flange can move axially when loosened. Then gradually loosen the locking screws in sequence using 90 turns to avoid tilting and jamming the collars. Do not completely unscrew the screws, otherwise the collars may spring off. Remove any rust from in front of the hub, and pull hub from shaft.
Annual Maintenance
Whenever the equipment is down for general maintenance or service, recheck the tightening torque of the shrink disc and flange fasteners. Tighten fasteners if necessary. For extreme or unusual operating conditions, check coupling more frequently.
Part Descriptions
Part descriptions are shown below. In addition, all coupling parts have identifying part numbers. When ordering parts, always SPECIFY SIZE and TYPE of hub, and part number.
MCF COUPLING SHOWN WITH TWO TYPE 2 HUBS
PART DESCRIPTIONS
1. Male Pilot Hub (Type 2) 2. Female Pilot Hub (Type 2) 3. Flange Fasteners 4. Male Pilot Hub (Type 4) 5. Female Pilot Hub (Type 4) 6. Shrink Disk
MCF COUPLINGS ARE ALSO AVAILABLE WITH COMBINATIONS OF TYPE 2 AND TYPE 4 HUBS
MCF COUPLING SHOWN WITH TWO TYPE 4 HUBS & SHRINK DISCS
458-862
DIMISA
FALK T-10 FLEXIBLE COUPLINGS
Contents:
Installation and maintenance instructions for FALK brand, T-10 type couplings. FALK Corp. English. 6.

Steelflex Couplings Type T10
Installation and Maintenance (Page 1of 6)
Sizes 10201140 & 20140
How To Use This Manual

This manual provides detailed instructions on maintenance, lubrication, installation, and parts identification. Use the table of contents below to locate required information.
TYPE T10 STEELFLEX COUPLING
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1 Lube Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1 Limited End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 1-2 Installation & Alignment Instructions. . . . . . . . . . . . Pages 2-4 Annual Maintenance, Relube & Disassembly . . . . . . . Page 4 Installation & Alignment Data . . . . . . . . . . . . . . . . . . Page 5 Parts Identification & Parts Interchangeability . . . . . . . Page 6 CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE FREE SERVICE.
INTRODUCTION
This manual applies to Sizes 1020T thru 1140T and 20T thru 140T10 Falk SteelfIex Tapered Grid Couplings. Unless otherwise stated, information for Sizes 1020T thru 1140T applies to Sizes 20T thru 140T respectively, e.g. 1020T = 20T, 1100T = 100T, etc. These couplings are designed to operate in either the horizontal or vertical position without modification. Beginning in year 1994 through 2003, these couplings were being supplied with one set of inch series fasteners and one set of Metric fasteners. Beginning in year 2004 only Metric fasteners are being supplied. Refer to Page 6 for part interchangeability. The performance and life of the couplings depend largely upon how you install and service them. CAUTION: Consult applicable local and national safety codes for proper guarding of rotating members. Observe all safety rules when installing or servicing couplings. WARNING: Lockout starting switch of prime mover and remove all external loads from drive before installing or servicing couplings.
superior lubricating characteristics and low centrifuge properties, Falk Long Term Grease (LTG) is highly recommended. Sizes 1020T to 1090T10 are furnished with a pre-measured amount of grease for each coupling. The grease can be ordered for larger size couplings. The use of general purpose grease requires re-lubrication of the coupling at least annually.
Long Term Grease (LTG)

The high centrifugal forces encountered in couplings separate the base oil and thickener of general purpose greases. Heavy thickener, which has no lubrication qualities, accumulates in the grid-groove area of Steelflex couplings resulting in premature hub or grid failure unless periodic lubrication cycles are maintained. Falk Long Term Grease (LTG) was developed specifically for couplings. It resists separation of the oil and thickener. The consistency of Falk LTG changes with operating conditions. As manufactured it is an NLGI #1/2 grade. Working of the lubricant under actual service conditions causes it to become semifluid while the grease near the seals will set to a heavier grade, helping to prevent leakage. LTG is highly resistant to separation, easily out performing all other lubricants tested. The resistance to separation allows the lubricant to be used for relatively long periods of time. Steelflex couplings initially lubricated with LTG will not require re-lubrication until the connected equipment is stopped for servicing. If a coupling leaks grease, is exposed to extreme temperatures, excessive moisture, or experiences frequent reversals, more frequent lubrication may be required. Although LTG grease is compatible with most other coupling greases, the mixing of greases may dilute the benefits of LTG.
LUBE FITTINGS
Cover halves have 1/8 NPT Iube holes. Use a standard grease gun and Iube fitting as instructed on Page 4.
LIMITED END FLOAT

When electric motors, generators, engines, compressors and other machines are fitted with sleeve or straight roller bearings, limited axial end float kits are recommended for protecting the bearings. Falk Steelflex couplings are easily modified to limit end float; refer to Manual 428-820 for instructions.
USDA Approval
LTG has the United States Department of Agriculture Food Safety & Inspection Service approval for applications where there is no possibility of contact with edible products. (H-2 ratings). CAUTION: Do not use LTG in bearings.
LUBRICATION
Adequate lubrication is essential for satisfactory operation. Page 2 provides a list of typical lubricants and specifications for general purpose and long term greases. Because of its
The Falk Corporation, P .O. Box 492, Zip 53201-0492 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com
May 2004 Supersedes 2-03
428-110
Installation and Maintenance (Page 2 of 6) Type T10
Steelflex Couplings
Sizes 10201140 & 20140
Specifications Falk LTG

The values shown are typical and slight variations are permissible. AMBIENT TEMPERATURE RANGE -20F (-29C) to 250F (121C). Min. Pump = 20 F (-7 C). MINIMUM BASE OIL VISCOSITY 3300SSU (715cST) @ 100F (38C). THICKENER Lithium & soap/polymer. CENTRIFUGE SEPARATION CHARACTERISTICS ASTM #D4425 (Centrifuge Test) K36 = 2/24 max., very high resistance to centrifuging. NLGI GRADE (ASTM D-217) 1/2 CONSISTENCY (ASTM D-217) 60 stroke worked penetration value in the range of 315 to 360 measured at 77F (25C) MINIMUM DROPPING POINT 350F (177C) minimum MINIMUM TIMKEN O.K. LOAD 40 lbs. ADDITIVES Rust and oxidation inhibitors that do not corrode steel or swell or deteriorate synthetic seals.
General Purpose Greases Meeting Falk Specifications

Lubricants listed below are typical products only and should not be construed as exclusive recommendations.
TABLE 1 General Purpose Greases H

Ambient Temperature Range 0F to 150F (-18C to 66C) -30F to 100F (-34C to 38C) Lubricant Amolith Grease #2 Energrease LS-EP1 Dura-Lith EP1 Premium Lithium Grease EP1 EP Conolith Grease #2 Unirex EP2 Cosmolube 1 Unirex EP2 Lithium Grease L421 81 EP-1 Litholine H EP 2 Grease Mobilith AW1 Multipurpose EP1 Philube Blue EP Alvania Grease 2 Alvania Grease 2 Ultra Prestige 2EP Multifak EP2 Unoba EP2 ... Manufacturer Lubricant Amoco Oil Co. Amolith Grease #2 BP Oil Co. Energrease LS-EP2 Chevron U.S.A. Inc. Dura-Lith EP2 Citgo Petroleum Corp. Premium Lithium Grease EP2 Conoco Inc. EP Conolith Grease #2 Exxon Company, USA Unirex EP2 E.F. Houghton & Co. Cosmolube 2 Imperial Oil Ltd. Unirex EP2 Kendall Refining Co. Lithium Grease L421 Keystone Div. (Pennwalt) 81 EP-2 Lyondell Petrochemical Litholine H EP 2 Grease (ARCO) Mobil Oil Corp. Mobilux EP111 Petro-Canada Products Multipurpose EP2 Phillips 66 Co. Philube Blue EP Shell Oil Co. Alvania Grease 2 Shell Canada Ltd. Alvania Grease 2 Sun Oil Co. Ultra Prestige 2EP Texaco Lubricants Starplex HD2 Unocal 76 (East & West) Unoba EP2 Valvoline Oil Co. Multilube Lithium EP Grease
Packaging
14 oz. (0,4 kg ) CARTRIDGES Individual or case lots of 10 or 30. 35 lb. (16 kg )PAIL, 120 lb. (54 kg ) KEG & 400 lb. (181 kg) DRUMS.
H Grease application or re-lubrication should be done at temperatures above 20F
General Purpose Grease

Annual Lubrication The following specifications and lubricants for general purpose grease apply to Falk Steelflex couplings that are lubricated annually and operate within ambient temperatures of 0F to 150F (-18C to 66C). For temperatures beyond this range (see Table 1), consult the Factory. If a coupling leaks grease, is exposed to extreme temperatures, excessive moisture or experiences frequent reversals, more frequent lubrication may be required.
Lubricants listed may not be suitable for use in the food processing industry; check
(-7C). If grease must be applied below 20F (-7C), consult The Falk Corporation. with lube manufacturer for approved lubricants.
INSTALLATION OF TYPE T10 STEELFLEX TAPERED GRID COUPLINGS Installation

Only standard mechanics tools, wrenches, a straight edge and feeler gauges are required to install Falk Steelflex couplings. Coupling Sizes 1020T thru 1090T are generally furnished for CLEARANCE FIT with setscrew over the keyway. Sizes 1100T and larger are furnished for an INTERFERENCE FIT without a setscrew. CLEARANCE FIT HUBS Clean all parts using a nonflammable solvent. Check hubs, shafts and keyways for burrs. Do not heat clearance fit hubs. Install keys, mount hubs with flange face flush with shaft ends or as otherwise specified and tighten setscrews. INTERFERENCE FIT HUBS Furnished without setscrews. Heat hubs to a maximum of 275F (135C) using an oven, torch, induction heater or an oil bath. To prevent seal damage, DO NOT heat hubs beyond a maximum temperature of 400F (205C). When an oxy-acetylene or blow torch is used, use an excess acetylene mixture. Mark hubs near the center of their length in several places on hub body with a temperature sensitive crayon, 275F (135C) melt temperature. Direct flame towards hub bore using constant motion to avoid overheating an area.
Specifications General Purpose Coupling Lubricants

The values shown are typical and slight variations are permissible. DROPPING POINT 300F (149C) or higher. CONSISTENCY NLGI No. 2 with 60 stroke worked penetration value in the range of 250 to 300. SEPARATION AND RESISTANCE Low oil separation rate and high resistance to separation from centrifuging. LIQUID CONSTITUENT Possess good lubricating properties equivalent to a high quality, well refined petroleum oil. INACTIVE Must not corrode steel or cause swelling or deterioration of synthetic seals. CLEAN Free from foreign inclusions.
428-110
Sizes 10201140 & 20140
WARNING: If an oil bath is used, the oil must have a flash point of 350F (177C) or higher. Do not rest hubs on the bottom of the container. Do not use an open flame in a combustible atmosphere or near combustible materials. Heat hubs as instructed above. Mount hubs as quickly as possible with hub face flush with shaft end. Allow hubs to cool before proceeding. Insert setscrews (if required) and tighten.
Use a spacer bar equal in thickness to the gap specified in Table 2, Page 5. Insert bar as shown below left, to same depth at 90 intervals and measure clearance between bar and hub face with feelers. The difference in minimum and maximum measurements must not exceed the ANGULAR installation limits specified in Table 2.
3 Offset Alignment
Maximize Performance And Life

The performance and life of couplings depend largely upon how you install and maintain them. Before installing couplings, make certain that foundations of equipment to be connected meet manufacturers requirements. Check for soft foot. The use of stainless steel shims is recommended. Measuring misalignment and positioning equipment within alignment tolerances is simplified with an alignment computer. These calculations can also be done graphically or mathematically. Alignment is shown using spacer bar and straight edge. This practice has proven to be adequate for many industrial applications. However, for superior final alignment, the use of dial indicators (see Manual 458-834 for instructions), lasers, alignment computers or graphical analysis is recommended.
MOUNT SEAL FIRST
Align so that a straight edge rests squarely (or within the limits specified in Table 2) on both hubs as shown above and also at 90 intervals. Check with feelers. The clearance must not exceed the PARALLEL OFFSET installation limits specified in Table 2. Tighten all foundation bolts and repeat Steps 2 and 3. Realign coupling if necessary.
4 Insert Grid
1 Mount Seals And Hubs

Lock out starting switch of prime mover. Clean all metal parts using a non-flammable solvent. Lightly coat seals with grease and place on shafts BEFORE mounting hubs. Heat interference fit hubs as previously instructed. Seal keyways to prevent leakage. Mount hubs on their respective shafts so the hub face is flush with the end of its shaft unless otherwise indicated. Tighten setscrews when furnished.
2 Gap and Angular Alignment
Pack gap and grooves with specified lubricant before inserting grid. When grids are furnished in two or more segments, install them so that all cut ends extend in the same direction (as detailed in the exploded view picture above); this will assure correct grid contact with non-rotating pin in cover halves. Spread the grid slightly to pass over the coupling teeth and seat with a soft mallet.
428-110
Steelflex Couplings
Sizes 10201140 & 20140
5 Pack With Grease And Assemble Covers
ANNUAL MAINTENANCE
For extreme or unusual operating conditions, check coupling more frequently. 1. Check alignment per steps on Page 3. If the maximum operating misalignment limits are exceeded, realign the coupling to the recommended installation limits. See Table 2 for installation and operating alignment limits. 2. Check tightening torques of all fasteners. 3. Inspect seal ring and gasket to determine if replacement is required. If leaking grease, replace. 4. When connected equipment is serviced, disassemble the coupling and inspect for wear. Replace worn parts. Clean grease from coupling and repack with new grease. Install coupling using new gasket as instructed in this manual.
Periodic Lubrication
MATCH MARK
MATCH MARK
Pack the spaces between and around the grid with as much lubricant as possible and wipe off excess flush with top of grid. Position seals on hubs to line up with grooves in cover. Position gaskets on flange of lower cover half and assemble covers so that the match marks are on the same side (see above). If shafts are not level (horizontal) or coupling is to be used vertically, assemble cover halves with the lug and match
MATCH MARK LUG UP
The required frequency of lubrication is directly related to the type of lubricant chosen, and the operating conditions. Steelflex couplings lubricated with common industrial lubricants, such as those shown in Table 1, should be relubed annually. The use of Falk Long Term Grease (LTG) will allow relube intervals to be extended to beyond five years. When relubing, remove both lube plugs and insert lube fitting. Fill with recommended lubricant until an excess appears at the opposite hole. CAUTION: Make certain all plugs have been inserted after lubricating.
Coupling Disassembly And Grid Removal
VERTICAL COUPLINGS
mark UP or on the high side. Push gaskets in until they stop against the seals and secure cover halves with fasteners, tighten to torque specified in Table 2. Make sure gaskets stay in position during tightening of fasteners. CAUTION: Make certain lube plugs are installed before operating.
Whenever it is necessary to disconnect the coupling, remove the cover halves and grid. A round rod or screwdriver that will conveniently fit into the open loop ends of the grid is required. Begin at the open end of the grid section and insert the rod or screwdriver into the loop ends. Use the teeth adjacent to each loop as a fulcrum and pry the grid out radially in even, gradual stages, proceeding alternately from side to side.
428-110
Sizes 10201140 & 20140
TYPE T COUPLING INSTALLATION & ALIGNMENT DATA

Maximum life and minimum maintenance for the coupling and connected machinery will result if couplings are accurately aligned. Coupling life expectancy between initial alignment and maximum operating limits is a function of load, speed and lubrication. Maximum operating values listed in Table 2 are based on cataloged allowable rpm. Values listed are based upon the use of the gaps listed, standard coupling components, standard assemblies and cataloged allowable speeds.
ANGULAR MISALIGNMENT Y
Values may be combined for an installation or operating condition. Example: 1060T max. operating misalignment is .016" parallel plus .018" angular. NOTE: For applications requiring greater misalignment, refer application details to Falk. Angular misalignment is dimension X minus Y as illustrated below. Parallel misalignment is distance P between the hub center lines as illustrated below. End float (with zero angular and parallel misalignment) is the axial movement of the hubs(s) within the cover(s) measured from O gap.
END FLOAT F P F
PARALLEL OFFSET MISALIGNMENT
P X GAP
TABLE 2 Misalignment & End Float

Installation Limits SIZE Parallel Offset-P Max Inch 1020T 1030T 1040T 1050T 1060T 1070T 1080T 1090T 1100T 1110T 1120T 1130T 1140T .006 .006 .006 .008 .008 .008 .008 .008 .010 .010 .011 .011 .011 Max mm 0,15 0,15 0,15 0,20 0,20 0,20 0,20 0,20 0,25 0,25 0,28 0,28 0,28 Angular (x-y) Max Inch .003 .003 .003 .004 .005 .005 .006 .007 .008 .009 .010 .012 .013 Max mm 0,08 0,08 0,08 0,10 0,13 0,13 0,15 0,18 0,20 0,23 0,25 0,30 0,33 Hub Gap 10% Inch .125 .125 .125 .125 .125 .125 .125 .125 .188 .188 .250 .250 .250 mm 3 3 3 3 3 3 3 3 5 5 6 6 6 Parallel Offset-P Max Inch .012 .012 .012 .016 .016 .016 .016 .016 .020 .020 .022 .022 .022 Max mm 0,30 0,30 0,30 0,41 0,41 0,41 0,41 0,41 0,51 0,51 0,56 0,56 0,56 Operating Limits Angular (x-y) Max Inch .010 .012 .013 .016 .018 .020 .024 .028 .033 .036 .040 .047 .053 Max mm 0,25 0,30 0,33 0,41 0,46 0,51 0,61 0,71 0,84 0,91 1,02 1,19 1,35 End Float Physical Limit (Min) 2 x F Inch .210 .198 .211 .212 .258 .259 .288 .286 .429 .429 .556 .551 .571 mm 5,33 5,03 5,36 5,38 6,55 6,58 7,32 7,26 10,90 10,90 14,12 14,00 14,50 Cover Fastener Tightening Torque Values Inch or Metric Series Fasteners (lb-in) 100 100 100 200 200 200 200 200 312 312 650 650 650 (Nm) 11,3 11,3 11,3 22,6 22,6 22,6 22,6 22,6 35 35 73 73 73 4500 4500 4500 4500 4350 4125 3600 3600 2440 2250 2025 1800 1650 Allow Speed (rpm) Lube Wt
lb .06 .09 .12 .15 .19 .25 .38 .56 .94 1.1 1.6 2.0 2.5
kg 0,03 0,04 0,05 0,07 0,09 0,11 0,17 0,25 0,43 0,51 0,74 0,91 1,14
TABLE 3 Coupling Cover Fastener Identification

SIZE Inch Series Fasteners Old Style New Style METRIC FASTENERS
1020-1070T10
SAE Grade 8
SAE Grade 8
Property Class 10.9
1080-1090T10
SAE Grade 8
SAE Grade 8
Property Class 10.9
1100-1140T10
SAE Grade 5
SAE Grade 5
Property Class 8.8
H Older style covers, Sizes 1020T10 thru 1070T10 must utilize socket head cap screws and locknuts held by the cover.
428-110
Steelflex Couplings
Sizes 10201140 & 20140
PARTS IDENTIFICATION
All coupling parts have identifying part numbers as shown below. Parts 3 and 4 (Hubs and Grids), are the same for both Type T10 and T20 couplings. All other coupling parts are unique to Type T10. When ordering parts, always SPECIFY SIZE and TYPE shown on the COVER.
CAUTION: Blue or non-painted grids may be used in all applications, but DO NOT substitute orange grids for blue or nonpainted. COVERS CAUTION: DO NOT mix cover halves of different designs. Sizes 1020T thru 1070T10 covers have been manufactured in several different two-rib designs and 80T thru 140T covers have been manufactured with two and three ribs. HARDWARE Older style covers, Sizes 1020T10 thru 1070T10, utilized socket head cap screws with captured locknuts. The new style covers use hex head cap screws (either inch or metric from year 1994 through 2003 and only Metric beginning in 2004). Specify the style cover when ordering replacement parts.
PARTS INTERCHANGEABILITY
Parts are interchangeable between Sizes 20T and 1020T, 30T and 1030T, etc. except as noted. GRIDS Size 1020T thru 1140T Steelflex couplings use blue or non-painted grids. Older models, 20T thru 140T, use orange grids.
PART NUMBER LOCATION
PART DESCRIPTION
1. Seal (T10) 2. Cover (T10) 3. Hub (Specify bore and keyway)
(2.) COVER (7.) 1030 T COUPLING SIZE PRODUCT CLASSIFICATION 10 TYPE B MODEL
4. Grid 5. Gasket (T10) 6. Metric Fasteners (T10). 7. Lube Plug
SIZE & (1.) SEAL PART NUMBER
(3.) HUB
(4.) GRID
SIZE
SIZE, PART NUMBER & BORE SIZE
(5.) GASKET PART NUMBER
ORDER INFORMATION
1. Identify part(s) required by name above. 2. Furnish the following information.
PART NUMBER (6.)
EXAMPLE: Coupling Size: 1030 Coupling Type: T10 Model: B Bore: 1.375 Keyway: .375 x .187 3. Contact your Falk Distributor or Falk for price and availability.
428-110
DIMISA
GE ELECTRIC MOTORS
Installation and maintenance instructions for GE three phase electric motors . GE. English. 44

DIMISA
FALK NRT BACK STOP
Contents:
Installation and maintenance instructions for FALK brand, NRT type Back stop. FALK Corp. English. 8.

Horizontal Shaft Backstops Installation & Maintenance Type NRT Sizes 1075 thru 1185 (Page 1 of 8)

The following instructions and recommendations apply to all standard Falk Type NRT backstops. Their performance and life depend largely upon how they are installed and serviced. Drawings are representative of this series of backstops and may not agree in exact detail with all backstop sizes. When requesting information specify the M.O. number, backstop size, model number, maximum running rpm, torque rating, torque arm angle degrees and date stamped on the backstop nameplate. This manual provides detailed instructions on installation, maintenance and parts identification. Use the following Table of Contents to locate required information.
Table of Contents
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Safety Codes & General Precautions . . . . . . . . . . . . . . . . . . 1 Application Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 1 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Dismantling, Repair & Parts Replacement . . . . . . . . . . . . . . . 8 Stored or Inactive Backstops . . . . . . . . . . . . . . . . . . . . . . . . 8 Part Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE FREE SERVICE.
DISMANTLING, REPAIR & PARTS REPLACEMENT See Page 8. The backstop and normal associated equipment (shaft, pulleys, etc.) involve moving parts, therefore consult local, state, OSHA and ANSI safety codes for proper guarding of revolving parts and possible pinch points. (A pinch point occurs at the contact point between the backstop torque arm and support, and between the torque arm and stirrup.) Carefully read and follow all supplementary instructions and tags attached to the backstop and then file for future reference. Operate the backstop within the torque rating, overrunning speed, temperature range and torque arm angle degrees listed on the nameplate. Follow lubrication instructions in this manual. When removing backstop from shaft, do not apply heat to the backstop. Apply axial force to the hub of the backstop only. Damage may occur to the backstop if it remains inoperative under full load for extended periods of time. If the shaft was accidentally rotated in the wrong direction of rotation at start-up, the backstop may have been damaged. Return the backstop to Falk for inspection.
Application Requirements
BACKSTOP APPLICATION The Falk NRT backstop is designed to prevent reverse rotation in applications such as inclined conveyors, bucket elevators, fans, rotary pumps and kilns. If local safety codes permit, the backstop may be used as a backup for a brake on these applications, but NOT in people conveying systems such as elevators, manlifts, ski tows or ski lifts. Also DO NOT use the backstop as a substitute for a brake. OPERATING TEMPERATURES Enclosure of the backstop may cause overheating. Provide adequate ventilation. Backstop operating temperatures, at maximum overrunning speed, may reach 200F (93C). Determine the effect of this temperature on the driven equipment and provide cooling if necessary. If a backstop operates in the sun at ambient temperatures over 100F (38C), then special measures should be taken to protect the backstop from solar energy. This protection can consist of a canopy over the backstop or reflective paint on the backstop. If neither is possible, a cooling device such as a fan may be required to prevent the sump temperature from exceeding the allowable maximum of 200F (93C). INDEXING Falk NRT backstops can be used for indexing service. Refer application data to Falk for selection. Indexing is defined as continuous cyclic or periodic application of the backstop as encountered in the conversion of reciprocating or oscillating motion into intermittent linear motion. JOGGING Defined as start/stop movement with jerking or jolting motion is permissible. NOTE: There must be at least one complete overrunning revolution between backstop operations or it is considered an indexing application. EXPLOSIVE ATMOSPHERES The purchaser is responsible for taking adequate precautions to prevent spark generation in explosive atmospheres. Consideration should be given to spark generation that may occur when the torque arm strikes the stirrup. CHEMICAL ATMOSPHERES The backstop may be damaged if exposed to certain types of chemicals or vapors; for example, potash dust, chlorine gas, carbon tetrachloride, etc. These materials may cause deterioration of the seals or aluminum roller cage rings.
Introduction
IMPORTANT: Mount the backstop ONLY at the torque arm angle degrees (5) stated on the nameplate and as described in Figure 4, Page 3. Lubrication lines and oil level will be incorrect for other angles; refer revised specifications to the Falk. WARRANTY The Falk Corporation (the Company) warrants that its products (i) conform to Companys published specifications, and (ii) are free from defects in material or workmanship. The duration of this warranty is three years from the date of shipment. Company does not warrant any purchased, non-Falk branded products or components (manufacturers warranty applies) or any defects in, damage to, or failure of products caused by: (i) dynamic vibrations imposed by the drive system in which such products are installed unless the nature of such vibrations has been defined and accepted in writing by Company as a condition of operation; (ii) failure to provide suitable installation environment; (iii) use for purposes other than those for which designed, or other abuse or misuse; (iv) unauthorized attachments, modifications or disassembly, or (v) mishandling during shipping.
Safety Codes & General Precautions

WARNING: Consult applicable local and national safety codes for proper guarding of rotating members. Lock out power source and remove all external loads from drive before servicing drive or accessories.
The Falk Corporation, P.O. Box 492, Zip 53201-0492 3001 W. Canal St., Zip 53208-4200, Milwaukee, WI USA Telephone : 414-342-3131 Fax: 414-937-4359 e-mail: falkinfo@falkcorp.com web: www.falkcorp.com
568-110
February 2005 Supersedes 1-04
Installation & Maintenance Horizontal Shaft Backstops (Page 2 of 8) Sizes 1075 thru 1185 Type NRT
AXIAL RETAINING COLLARS Axial retention of the backstop is required to prevent increased loads on the backstop bearings. Falk offers axial retaining collars as an optional extra charge accessory for all applications. The collars are manufactured to fit the backstop and the shaft and can be mounted on either side of the backstop. This allows the retaining collars to be mounted on the shaft inside of the backstop if the application requirements so dictate. If two(2) collars were furnished with the backstop, mount one collar on each side of the backstop (so backstop is sandwiched between the collars). LUBRICATION LINES, SIGHT GAUGE & BREATHER Do not assemble to backstop until backstop is mounted on the shaft.
Prevent accumulation of any foreign material or ice around torque arm and torque arm stirrup which could restrict free movement of the torque arm. LIFTING INSTRUCTIONS See Figure 5, Page 3. Cotter pins must be locked to prevent axial movement of torque arm pin. Sling torque arm as shown. Use clamps or similar device to prevent sling from slipping.
TABLE 1 Shaft Keyway Dimensions

BACKSTOP SIZE Nominal Shaft Diameter (OverIncludes) 1.9375 1.9375 - 2.2500 2.2500 - 2.7500 2.7500 - 3.2500 3.2500 - 3.5625 3.5625 - 3.7500 3.7500 - 3.9375 2.9375 2.9375 - 3.2500 3.2500 - 3.7500 3.7500 - 4.5000 4.5000 - 4.7500 4.7500 - 5.1875 3.4375 3.4375 - 3.7500 3.7500 - 4.5000 4.5000 - 5.0000 5.0000 - 5.5000 4.9375 4.9375 - 5.5000 5.5000 - 6.5000 6.5000 - 7.4375 5.9375 5.9375 - 6.5000 6.5000 - 7.5000 7.5000 - 8.0000 8.0000 - 8.4375 7.2500 7.2500 - 7.5000 7.5000 - 9.0000 8.5000 8.5000 - 9.0000 9.0000 -10.5000 9.0000 9.0000 -11.0000 11.0000 -12.0000 10.5000 10.5000 -11.0000 11.0000 -13.0000 13.0000 -13.2500 12.5000 12.5000 -13.0000 13.0000 -15.0000 15.0000 -15.5000 13.5000 13.5000 -15.0000 15.0000 -17.5000 15.5000 15.5000 -18.0000 18.0000 -20.0000 Shaft Keyway H Width x Depth .500 x .250 .500 x .250 .625 x .313 .750 x .375 .875 x .438 .875 x .438 1.000 x .500 .750 x .375 .750 x .375 .875 x .438 1.000 x .500 1.250 x .625 1.250 x .625 .875 x .875 x 1.000 x 1.250 x 1.250 x 1.250 x 1.250 x 1.500 x 1.750 x 1.500 x 1.500 x 1.750 x 2.000 x 2.000 x .438 .438 .500 .625 .625 .625 .625 .750 .750 .750 .750 .750 .750 .750 Key Key Length Min Key Material Furnished Engagement 7.250 7.250 6.000 7.000 5.500 7.250 7.000 7.000 7.000 5.500 7.000 7.000 7.000 9.000 9.000 9.000 7.000 7.000 7.000 7.000 8.000 9.000 8.000 8.000 9.000 9.000 10.500 11.000 11.000 11.000 11.000 11.000 12.000 13.000 12.000 13.000 12.000 12.000 13.000 12.000 15.500 15.500 12.000 13.000 16.000 16.000 13.000 17.000 17.000 14.000 7.25 7.25 6.00 5.50 4.00 5.00 5.00 6.50 6.50 5.00 5.00 3.50 7.00 8.00 8.00 8.50 6.00 6.50 6.50 6.50 6.50 5.50 7.50 7.50 9.00 8.00 10.50 11.00 11.00 10.50 10.00 10.00 9.50 13.00 11.50 11.00 11.00 11.00 13.00 9.00 12.00 12.00 12.00 9.00 15.50 15.50 13.00 13.50 13.50 13.50 2 2 2 1 1 1 1 2 2 2 1 1 1 2 2 1 1 1 2 2 1 1 2 2 1 1 1 1 1 1 2 2 1 2 2 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2
General Instructions
BACKSTOPSHAFT FITS The shaft must have a 125 micro inch (or finer) finish and clearance fits specified in Table 2 (Page 4). KEYS & KEYWAYS Keys to be used with Falk NRT backstops are furnished by Falk. They are either cold drawn 1045 steel or heat treated alloy steel (310-350 HB). DO NOT USE SLED RUNNER TYPE KEYWAY. IT MAY INDUCE UNDUE FORCES ON BACKSTOP.
1075
1085
1095
BACKSTOP MOUNTING POSITIONS The backstop rotational axis must be horizontal within 5 for all applications. The NRT backstop is capable of being mounted at any desired angle per Figures 2 and 4, Page 3; however, a horizontal mounting at 0 or 180 is preferred. The mounting angle must be specified at the time of purchase. This enables Falk to custom fit the lubrication lines and establish and mark the proper static oil level for the specified mounting angle. The lubrication lines, sight gauge and breather are removed for shipping purposes. Furnished lubrication lines and oil level will be incorrect for mounting angles not within 5 of the angle stamped on the nameplate refer revised specifications to Falk. TORQUE ARM STOPS (OR STIRRUP) The torque arm stops must be designed to resist the force developed by the actual torque applied to the backstop. The minimum recommended distance to the torque arm stop is .9N as illustrated in Figure 1, Page 3, and Table 3, Page 4. Use torque arm stops capable of withstanding the loads tabulated in Table 3, Page 4. Where shorter than recommended torque arms are required, the stirrup should be designed to withstand the increased reaction forces of the shorter torque arm. ActualRetentionForce = Actual Peak Backstopping Torque Actual Application Dimension N
1105
1115
1125
1.750 x .750 1.750 x .750 2.000 x .750 2.000 x .750 2.000 x .750 2.500 x .875 2.000 x .750 2.500 x .875 3.000 x 1.000 2.500 x 1.250 2.500 x 1.250 3.000 x 1.000 3.500 x 1.250 3.000 x 1.000 3.000 x 1.000 3.500 x 1.250 4.000 x 1.500 3.500 x 1.250 3.500 x 1.250 4.000 x 1.500 4.000 x 1.500 4.000 x 1.500 5.000 x 1.750
1135
1145
1155
1165
1175
The torque arm must be free to move within the stirrup. Provide clearance on three sides per Figure 3, Page 3. DO NOT restrict torque arm movement by welding or securing the torque arm to any supporting structure. Locate the torque arm support surface parallel (1/2) to the torque arm surface.
1185
H Keys are furnished by Falk to suit shaft and backstop keyways. Keys are either
cold drawn 1045 or heat treated alloy steel (310-350HB).

#1 Keys are cold drawn 1045 steel.
#2 Keys are heat treated alloy steel (310-350HB).
568-110
Horizontal Shaft Backstops Installation & Maintenance Type NRT Sizes 1075 thru 1185
90
N
(Page 3 of 8)
180
HORIZONTAL
Figure 1
.9 N ACTUAL APPLICATION DIMENSION N
270
Figure 4
THE BACKSTOP ROTATIONAL AXIS MUST BE HORIZONTAL WITHIN 5 N
SEE END VIEW BELOW
HORIZONTAL PREFERRED POSTION
STIRRUP 0.9N
COTTER PIN
BACKSTOP TORQUE ARM CAN BE MOUNTED AT ANY ANGLE
VERTICAL
NYLON SLING
TORQUE ARM PIN END COVER CAM OR HUB FACEPUSH ON THIS FACE WHEN INSTALLING BACKSTOP ON SHAFT
315 A BOOT OR HOOD IS RECOMMENDED FOR ALL MOUNTING POSITIONS 270 FLOOR SLOT
NYLON SLING
Figure 2
CLAMPS TO PREVENT SLING FROM SLIPPING OFF "I" BEAM 1" TO 1 " (25,4 mm to 38,1 mm) CLEARANCE
1" TO 1 " (25,4 mm TO 38,1 mm) CLEARANCE
TORQUE ARM
BALANCE POINT
1" TO 1 " (25,4 mm TO 38,1 mm) CLEARANCE
Figure 5
END VIEW
Figure 3
568-110
PUSH ON CAM FACE ONLY
TABLE 2 BackstopShaft Fits

Nominal Diameter (FromIncludes) 1.9375 2.9375 3.0000 7.9375 8.0000 11.9375 12.0000 14.9375 15.0000 20.0000 Nominal Shaft Tolerance +.0000, .0010 +.0000, .0010 +.0000, .0010 +.0000, .0010 +.0000, .0020 Nominal Bore BoreShaft H Diameter Tolerance MinMax Clearance +.0005, +.0015 +.0010, +.0025 +.0015, +.0035 +.0020, +.0045 +.0020, +.0045 .0005 .0025 .0010 .0035 .0015 .0045 .0020 .0055 .0020 .0065
INNER CAM MINIMUM SHAFT ENGAGEMENT
H A 125 micro inch (or finer) shaft finish and clearance fit specified
above are recommended.
TABLE 3 Backstop Reaction Force at Torque Arm Stirrup

BACKSTOP SIZE 1075 1085 1095 1105 1115 1125 1135 1145 1155 1165 1175 1185
Force (lb) =
Catalog Torque Rating PoundFeet 10,000 16,000 28,000 45,000 75,000 105,000 150,000 212,000 249,000 346,000 519,000 747,000
N (Inches) 36.0 48.0 54.0 66.0 72.0 78.0 82.0 88.0 94.0 100.0 120.0 120.0
.9N .5" 32.5 43.0 48.0 59.5 65.0 70.0 74.0 79.0 84.0 90.0 108.0 108.0
Torque Arm Reaction Forcelb 5550 6700 10500 13600 20800 27000 36500 48300 53300 69200 86500 124500
Figure 6
Reaction force is based on .9N torque arm length and 1.5 catalog rating:
5. In all cases where a Falk axial retaining collar is used (other than the applications referred to in Step 2 above), mount the collar to the backstop. First tighten the fasteners to the backstop and then the fasteners to the shaft. Torque to the (lb-in.) given in Table 5 below. For bore sizes requiring the use of two axial retention collars, mount collars (one on each side) on the shaft and tighten fasteners to the shaft.
1.50 x Catalog Torque Rating (lb - ft) x 12 (in per ft) .9N (in) 1.50 x Catalog Torque Rating x 1000 (mm per m) Force (N) = .9N (mm) For reduced length torque arms, substitute actual N dimension in formula.
TABLE 5 Axial Retaining Collar Fastener Tightening Torque lb-in

(All Fasteners are UNC)
Fastener Size .375"-16 .500"-13 .625"-11 .750"-10 1.000"- 8 1.250"- 7 Tightening Torque (lb-in) 440 1,025 2,050 3,475 7,875 13,750
Installation
MOUNT BACKSTOP CAUTION: Before installing backstop, check direction of shaft free rotation and required rotation of motor. The backstop overrunning (or free rotation) direction is indicated by a rotation arrow on each side of the backstop. 1. Clean the shaft and remove burrs. 2. Slide the axial retaining collar onto the shaft ONLY if the bore size or application requires a collar to be on the shaft inside of (or ahead of) the backstop. 3. Coat shaft and key with oil or anti-seize compound to ease installation of key, as well as backstop. Mount the heat treated key furnished with the backstop. 4. Refer to Figure 5, Page 3. Lift backstop and slide it onto shaft. Apply axial force only to the hub face of the backstop. The backstop must be positioned to meet certain minimum engagement requirements which vary with backstop and bore size. Minimum required engagement is determined by the GREATER distance of: A. Minimum required backstop key engagement as shown in Table 1, Page 2, or B. Minimum shaft/inner cam engagement as shown in Figure 6 and Table 4. If two axial retention collars are required, provide adequate shaft length to permit mounting the collars.
MOUNT TORQUE ARM 1. Lift torque arm as shown in Figure 5, Page 3, and attach it to the backstop with torque arm pins and cotter pins supplied with backstop. Lock cotter pins. 2. Place torque arm in torque arm support and then complete construction of the torque arm support as previously described under TORQUE ARM STOPS (OR STIRRUP) on Page 2. CAUTION: Check to see that backstop is not axially restrained through the torque arm and that accumulation of foreign material or ice cannot restrict movement of the torque arm. INSTALL LUBRICATION LINES, SIGHT GAUGE & BREATHER 1. As previously stated, Falk custom fits the lubrication lines and marks the static oil level to suit the mounting angle specified at the time of purchase. The lubrication lines, sight gauge and breather are removed for shipping purposes. The torque arm mounting angle is stamped on the backstop nameplate and the backstop must be mounted within 5 of this angle. See Figure 7, Page 5, for interpretation of mounting angle. Lubrication lines and oil level will be incorrect for other angles.
TABLE 4 Minimum Shaft Engagement

UNIT 1075 1085 1095 1105 1115 1125 1135 1145 1155 1165 1175 1185 SIZE Inches 6.2 6.2 8.1 8.1 9.0 9.6 11.4 11.4 11.5 13.8 14.3 14.7
568-110
90
BREATHER VENT ASSEMBLY
COVER
180
HORIZONTAL
0 BREATHER VENT ASSEMBLY PART NO. 775849
270
Figure 7
Use the above diagram to interpret the mounting angle specified on the backstop nameplate. View the backstop assembly from the shaft extension end as shown above. DO NOT exceed the mounting angle by 5 of the
specification on the backstop nameplate.
GREASE FITTINGS (2 OR 4) ROTATION ARROW 4 180 HORIZONTAL 2 OIL LEVEL TEE DRAIN LEFT 3 PURGE PLUGS (1 OR 2) RIGHT 0 OIL LEVEL TEE DRAIN PURGE PLUGS (1 OR 2) 3 VENT 90 1 ANGLES INCREASE C.C.W. ELBOW ROTATION ARROW 4 1
BREATHER VENT
3 THREAD FORMING SCREWS. TIGHTEN UNTIL SCREW HEAD BOTTOMS.
Figure 8
GREASE FITTINGS (2 OR 4) VENT ELBOW PURGE PLUGS (1 OR 2)
ROTATION ARROW
TEE
VENT ELBOW
GREASE FITTINGS (2 OR 4) HORIZONTAL
HORIZONTAL 3 2 OIL LEVEL 2 1
270
TEE
DRAIN
Figure 9
Figure 10
Figure 11
2. When the lubrication lines, sight gauge and breather are removed for shipping, the pipe tees and elbows (see Figures 9, 10, and 11) are left in the end cover at the proper angles for simple reassembly. The tees and elbows are plugged for shipment. 3. The sight gauge/piping subassembly must be mounted in a position that allows direct viewing of oil level markings. Figures 9, 10, and 11 are examples of left hand assembly configurations. Similar right hand configurations are possible. 4. Coat all pipe threads with Permatex #3 or equivalent. 5. Position backstop and torque arm at angle stamped on nameplate (5). Remove plug from the lowest pipe tee and attach sight gauge/piping subassembly. DO NOT tighten fittings. 6. With the sight gauge in the proper vertical position, locate and remove the plug nearest the unattached upper end of the sight gauge/piping subassembly. This plug may be in the backstop end cover (Figures 9 and 10) or it may be in the upper pipe tee (Figure 11). Install fitting but DO NOT tighten.
7. Position sight gauge oil level groove to the appropriate dimension shown in Figure 12 and Table 6, Page 6, and tighten all fittings. 8. Refer to the following section for recommended lubricant. Drain and flush Motorstor. Fill with lubricant by removing the pipe plug in the elbow installed at Falk in the uppermost hole. Also remove the uppermost pipe plug in the opposite end cover to act as a vent. Replace plugs after filling. 9. Install breather vent and associated piping parts in the same elbow referred to in Step 8 above. 10. Install breather vent cover per Figure 8. NOTE: The breather vent must be tightened before the cover is assembled. The cover cannot be used to tighten the vent. 11. Backstops ordered as spares (mounting angle not specified) will be furnished without lubrication lines but with a new breather vent. When installing one of these spares, remove the lubrication lines from the original backstop and install on the spare backstop along with the new breather vent.
568-110
LEVEL SQUARE
A OIL LEVEL B
HORIZONTAL
OIL LEVEL GROOVE HUB OR INNER CAM
of 15F to 40F (26C to 4C) use an SAE 10W40 motor oil with a pour point of at least 20F (29C). For ambient temperatures of 32F to 125F (0C to 52C) use an AGMA #4 oil. For temperatures below 15F (26C) use Mobil Aero HFA per paragraph 1 above. 3. Sizes 1155 thru 1185 inclusive For ambient temperatures of 15F to 40F (26C to 4C) use an SAE 10W40 motor oil with a pour point of at least 20F (29C). For ambient temperatures of 32F to 125F (0C to 52C) use an AGMA #5 oil. For temperatures below 15F use Mobil Aero HFA or Dexron. OIL LEVEL Drain and flush Motorstor. Fill the backstop with specified lubricant to the static level indicated by the scribed line on the vertical sight gauge. Check oil level in sight glass only when the unit is not operating. During operation the oil level in the sight glass will drop due to distribution of oil around the periphery of the housing. Approximate oil capacities are given in Table 7.
Figure 12 METHODS OF MEASURING LOCATION OF OIL
TABLE 6 Oil Level Dimensions H

UNIT SIZE 1075 1085 1095 1105 1115 1125 1135 1145 1155 1165 1175 1185
Dimension A or B.
TABLE 7 Approximate Oil Capacities H

BACKSTOP SIZE 1075 1085 1095 1105 1115 1125 1135 1145 1155 1165 1175 1185
level indicated on the sight gauge.
Ounce per side
Dimension A 4.0 5.3 5.8 7.6 8.6 9.7 10.8 12.1 14.1 15.1 18.6 20.0
Dimension B 0.8 1.2 1.2 1.7 2.2 2.3 3.0 2.9 3.5 4.4 5.4 5.0
Oil Capacity (Approx. Pints) 1/2 3 /4 1 1 /2 2 4 5 6 1 /2 8 10 16 20 26
Grease Purge Qty-Oz. 2 1/4 3 7 9 7 1/ 2 8 1/ 4 5 1/ 2 10 1/4 12 8 12 16 3/4
H Adjust piping so that the oil level indicator on sight gauge is within 1/4 of
H Use these quantities as a guide when ordering oil. Always fill to the static
Lubrication
RECOMMENDED LUBRICANTS Refer to Tables 8 thru 12 for transmission fluids, oils and greases meeting Falk specifications. NOTE: Lubricants listed are typical products ONLY and should not be construed as exclusive recommendations. Read and carry out all instructions on name and lubrication plates and heed all warning tags. Determine minimum and maximum ambient temperature in which the backstop is to operate and use the recommended lubricant for the particular size backstop which corresponds to the temperature conditions. CAUTION: DO NOT USE EXTREME PRESSURE LUBRICANTS OR GREASES. Typical extreme pressure additives are sulphur, chlorine, lead and phosphorus derivatives as well as graphite and molybdenum disulfide, which act under conditions of heat and pressure to produce a coating on the working surfaces. 1. Sizes 1075 thru 1095 inclusive For ambient temperatures of 15F to 125F (26C to 52C) use Dexron II automatic transmission fluid or AGMA #2 oil. For ambient temperatures above 125F (52C) use AGMA #3 oil. For ambient temperatures 15F to 40F (26C to 40C) use Mobil Aero HFA, Dexron, or equivalent. 2. Sizes 1105 thru 1145 inclusive For ambient temperatures
GREASE PURGED SEALS Backstops are furnished with grease purged tandem seals which, when greased, provide maximum protection under the most unfavorable conditions such as atmospheres laden with taconite or similarly severe abrasive dusts. The inner seal cavity is grease purged by Falk for all backstops. Refer to Figure 13, Page 7. To purge INNER purge chambers, remove only the INNER purge plugs on each side of the backstop. Pump the amount of NLGI #2 grease per Table 7 into the INNER grease fittings until contaminated grease is expelled from the purge plug openings. Wipe off purged grease and replace purge plugs. CAUTION: DO NOT use pressurized grease guns. The option of adding grease to the outer grease cavity is the purchasers; however, it is recommended that grease be added when operating in abrasive atmospheric conditions. Adding grease to the cavity is NOT RECOMMENDED if grease could contaminate the material being processed as in the food and drug industries. To purge OUTER purge chambers, pump NLGI #2 grease into OUTER grease fittings until contaminated grease is expelled around the shaft. Wipe off purged grease. If outer grease cavity is to be greased or purged, and the backstop is equipped with a shaft guard, remove guard cover to observe when grease is expelled from around the shaft.
568-110
PURGING GREASE
INNER GREASE FITTING OUTER GREASE FITTING OUTER GREASE CAVITY INNER GREASE CAVITY
TABLE 10 Dexron Automatic Transmission Fluids

API Gravity 28.2 Pour Point 50F (46C) Viscosity at 104F (4OC) SSU 187 Viscosity Index ASTM D-2270 161 Color Red Ambient Temp Range 40F to +125F (40C to +52C) Max Lube Operating Temp +200F (+93C) Manufacturer Amoco Oil Co. Atlantic Richfield Co. Cities Service Oil Co Conoco Inc. Exxon Co. U.S.A. Gulf Oil Co. U.S. Mobil Oil Corp. Phillips Petroleum Co. Shell Oil Co. Texaco Inc. Lubricant Dexron A-T-F Arco Dexron ATF II Automatic Trans. Fluid-Dexron Type Conoco Dexron II Fluid Exxon ATF Automatic Trans. Fluid-Dexron Mobil ATF 220 Automatic Trans. Fluid-Dexron Domax T-6 Texamatic Fluid 8570
TABLE 11 Multi-Viscosity Oils

Manufacturer Amoco Oil Co. Atlantic Richfield Co. Cities Service Oil Co. Conoco Inc. Exxon Co. U.S.A. Gulf Oil Co. U.S. Mobil Oil Corp. Phillips Petroleum Co. Shell Oil Co. Texaco Inc. Lubricant Amoco LDO 10W40 Arco Supreme 10W40 All Season Multi-Grade 10W40 Tracon Supreme 10W40 Uniflo 10W40 Gulf Pride Prem. 10W40 Mobil Super 10W40 Trop-Artic All-Season 10W40 Fire & Ice 10W40 Havoline Super Prem. 10W40
Figure 13
TABLE 8 Cold Climate Lubricant

Ambient Temperature Range -10F to -40F (-23C to -40C) Mobil Aero HFA
Ambient Temperature Range 15F to +4OF (26C to +4C).
SAE 10W-40 motor oil with a pour point of at least 20F (29C).
TABLE 9 Petroleum Based R & O Gear Oils (Maximum operating temperature of lubricants 200F (93C)
AGMA Viscosity Grade ISO Viscosity Grade Viscosity cSt @ 40C SSU @ 100F Manufacturer Amoco Oil Co. BP Oil Co. Chevron U.S.A., Inc. Citgo Petroleum Corp. Conoco Inc. Exxon Co., U.S.A. Houghton International Inc. Imperial Oil Ltd. Kendall Refining Co. Keystone Lubricants Lyondell Petrochemical (ARCO) Mobil Oil Corp. Petro-Canada Prod. Phillips 66 Co. Shell Oil Co. Shell Canada Ltd. Texaco Lubricants Unocal 76 (East) Unocal 76 (West) Valvoline Oil Co. 2 68 61.2-74.8 284-347 Lubricant Amer. Ind. Oil 68 Turbinol T-68 Hydraulic Oil AW 68 Citgo Pacemaker 68 Dectol R & O Oil 68 Teresstic 68 Hydro-Drive HP-300 Teresso 68 Kenoil R & O AW 68 KLC-20 Duro 68 DTE Oil Heavy Harmony 68 Magnus Oil 68 Turbo T68 Tellus 68 Regal Oil R & O 68 Unax RX 68 Turbine Oil 68 Valvoline AW ISO 68 3 100 90-110 417-510 Lubricant Amer. Ind. Oil 100 Turbinol T-100 Machine Oil AW 100 Citgo Pacemaker 100 Dectol R & O Oil 100 Teresstic 100 Hydro-Drive HP-500 Teresso 100 Kenoil R & O AW 100 KLC-30 Duro 100 DTE Oil Heavy Harmony 100 Magnus Oil 100 Morlina 100 Tellus 100 Regal Oil R & O 100 Unax RX 100 Turbine Oil 100 Valvoline AW ISO 100 4 150 135-165 626-804 Lubricant Amer. Ind. Oil 150 .... Machine Oil AW 150 Citgo Pacemaker 150 Dectol R & O Oil 150 Teresstic 150 Hydro-Drive HP-750 Teresso 150 Four Seasons AW 150 KLC-40 Duro 150 DTE Oil Extra Heavy Harmony 150 or 150D Magnus Oil 150 Morlina 150 Tellus 150 Regal Oil R & O 150 Unax RX 150 Turbine Oil 150 Valvoline AW ISO 150 5 220 198-242 918-1140 Lubricant Amer. Ind. Oil 220 Energol HLP-HD 220 Machine Oil AW 220 Citgo Pacemaker 220 Dectol R & O Oil 220 Teresstic 220 Hydro-Drive HP-1000 Teresso 220 .... KLC-50 Duro 220 DTE Oil BB Harmony 220 Magnus Oil 220 Morlina 220 Tellus 220 Regal Oil R & O 220 Unax RX 220 Turbine Oil 220 Valvoline AW ISO 220
568-110
TABLE 12 Greases for Grease Purged Seals

(0 to 200F (18 to +93C)
Manufacturer Amoco Oil Co. Exxon Company, U.S.A. E.F. Houghton & Co. Imperial Oil Ltd. Kendoll Refining Co. Shell Oil Co. Shell Canada Limited Texaco Lubricants Lubricant Amoco Rykon Premium Grease No. 2 Unirex N2 Cosmolube 2 Unirex N2L Multi-Purpose Lithium Grease L421 Alvania Grease 2 Alvania Grease 2 Marfak #2
whichever occurs first. Refer to Figure 8, Page 5. NOTE: the filter element can not be cleaned, it must be replaced. Attach date tag to filter to show when filter should be replaced. (Breather Vent Assembly is Falk part # 775849.) TORQUE ARM ALIGNMENT Check alignment of the torque arm whenever the lubricant is changed. Maintain clearances between torque arm and support as specified in the TORQUE ARM STOPS (OR STIRRUP) paragraph, Page 2.
Dismantling, Repair & Parts Replacement

WARNING: DO NOT attempt to service or remove backstop before removing load. An important part of the Falk NRT backstop manufacturing process is the full load and overrunning testing with specially instrumented equipment. Consequently, return NRT backstops to Falk for repair and full load testing. Except for replacement of oil seals (Service Manual 568-130), NRT backstops should not be dismantled or repaired in the field. If seals are to be replaced, it is important that the cam and roller assemblies not be removed from the outer race. Removal will void applicable warranties. When writing to Falk Service Department concerning required service, state nature of problem and give complete data from backstop nameplate; M.O. number, size, date, etc.
H The option of adding grease is the purchasers. Adding grease to the seal
cavities is NOT RECOMMENDED if grease could contaminate the material being processed as in the food and drug industries use food grade greases.
Preventive Maintenance
AFTER FIRST WEEK OF OPERATION Drain lubricant and flush with fresh lubricant by operating 5 to 10 minutes. Drain again and fill with fresh, clean lubricant. LUBRICANT CHANGES For normal operating conditions (8 to 10 hours per day) with low dust or abrasive environment and ambient temperatures less than 150F (66C), change lubricant every six months or 2500 hours, whichever occurs first. For 24 hours per day operating conditions, change lubricants every three months of operation. For operation in a dusty or abrasive environment, it may be necessary to change lubricant and flush every 300 hours. Have a lubricant supplier test oil samples from the backstop periodically and recommend economical change periods based on the rate of lubricant contamination and degradation. PURGING GREASE SEALS Periodically (at least at every lubricant change) depending upon the frequency and degree of contamination, purge contaminated grease from grease purged seals. See instructions on Page 6 for purging grease. FILTERED BREATHER For normal operating conditions (8 to 10 hours per day) with low dust or abrasive environment and ambient temperatures less than 150F (66C), replace filter every 12 months or 5000 hours, whichever occurs first. For continuous operation and/or operation in dusty or abrasive environments, replace filter every 6 months or 2500 hours, PART DESCRIPTIONS
1. 2. 3. 4. 5. 6. End Cover Gasket Bearing Outer Seal Inner Seal Rollers 7. Roller Cage End Rings (2) 8. Inner Cam 9. Outer Race 10. Labyrinth Shroud (Not available on all sizes)
Stored or Inactive Backstops

Backstops are shipped WITHOUT LUBRICANT but do contain one ounce of Motorstor vapor phase rust inhibitor which will protect internal parts against rust for a period of up to six months. If the backstop is to be stored or inactive for more than six months, add the recommended amount of lubricant from Table 7, Page 6, and add one ounce of Motorstor every additional six month period. Indoor dry storage is recommended. If outdoor storage is necessary, cover the backstop with tarpaulin or suitable covering. Product of the Daubert Chemical Co., Chicago, IL. BEFORE PLACING BACKSTOP IN OPERATION Drain lubricant mixture and replace breather and oil sight gauge, if removed. Flush backstop and refill with clean, fresh lubricant per instructions above.
13.Roller Cage Fasteners 14.Rotation Direction Plate 15.End Cover Fasteners 16.Torque Arm 17.Torque Arm Pin
16 10 14 11
11.Optional Axial Retaining Collar 12.Stop Lug

13
12 1 2 4 5 3 6 7 8 9
17 1 2 3 5 4
15
15
568-110
DIMISA
VIII. DIMISA REFERENCE DRAWINGS

The following sections contain the reference drawings prepared by DIMISAS Engineering Department, for the fabrication of the Belt Conveyors in this Purchase Order and any other future references related to them. The contents of these sections are for the following:
8.1 8.2 Belt Conveyor TB-15-30-07 STD Project


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M3 ENGINEERING AND TECHNOLOGY CORPORATION

INSTALLATION, OPERATION AND MAINTENANCE MANUAL MULATOS GOLD PROJECT

MONTERREY, MXICO, SEPTEMBER 2005

DISEO DE MAQUINAS INDUSTRIALES, S.A. DE C.V.

www.dimisa.com Tel +52 (81) 8131 0000 Fa x +5 2 (8 1 ) 8 3 6 4 6 1 0 0 conveyors@dimisa.com

Idlers by DIMISA, ANTI-DUST type. Reducers. 7.3.1 Reducers, FALK

AC Induction Motors, GE Back Stop FALK

DISEO DE MAQUINAS INDUSTRIALES, S.A. DE C.V.

www.dimisa.com Tel +52 (81) 8131 0000 Fa x +5 2 (8 1 ) 8 3 6 4 6 1 0 0 conveyors@dimisa.com

DISEO DE MAQUINAS INDUSTRIALES, S.A. DE C.V.

www.dimisa.com Tel +52 (81) 8131 0000 Fa x +5 2 (8 1 ) 8 3 6 4 6 1 0 0 conveyors@dimisa.com

DISEO DE MAQUINAS INDUSTRIALES, S.A. DE C.V.

www.dimisa.com Tel +52 (81) 8131 0000 Fa x +5 2 (8 1 ) 8 3 6 4 6 1 0 0 conveyors@dimisa.com

DISEO DE MAQUINAS INDUSTRIALES, S.A. DE C.V.

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DISEO DE MAQUINAS INDUSTRIALES, S.A. DE C.V.

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Immediate Hazards that could result in severe personal injury or

Hazards or unsafe practices could result in product or property damages.

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III. OPERATION OF BELT CONVEYORS

CONVEYOR TESTING WITH BELT EMPTY

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M3 Engineering And Technology Corporation P.O. No. 02209-G-001

Quotation DIMISA No.1179-03

Bearing lubrication recommendations Pillow block bearings Type TB-15-30-07

M3 Engineering And Technology Corporation P.O. No. 02209-G-001

Quotation DIMISA No.1179-03

At every oil change.

Fig. 3. Primary and secondary cleaners

b) BELT MISALIGNS AT A PARTICULAR POINT.

BELT TRAVELS TO ONE SIDE

MATERIAL LOAD NOT CENTERED

DIRECT FEED CHUTE SO MATERIAL LOAD STABILIZES AT BELT CENTER.

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a) BELT MISALIGNS AT THE TAIL PULLEY.

MATERIAL ACCUMULATES RETURN IDLERS.

b) MISALIGNED RETURN IDLERS. c) MATERIAL LOAD NOT CENTERED.

BELT SLIPPING PULLEY.

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EXCESSIVE BELT STRETCHING

REPLACE WITH PROPER BELTING.

SMALL CUTS THAT ARE PARALLEL TO THE BELT.

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