FOOTE-JONES REDUCER SHAFT MOUNTED AND SCREW CONVEYOR DRIVES 8000 SERIES F O R M. Installation, lubrication, operation, maintenance Instruction.

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1 FOOTE-JONES REDUCER Installation, lubrication, operation, maintenance Instruction. Regal Beloit America, Inc. 2914Industrial Ave. Aberdeen, SD , F O R M 10171E Revised March 2018 Read and follow all instructions carefully. Disconnect and lock-out power before installation and maintenance. Working on or near energized equipment can result in severe injury or death. Do not operate equipment without guards in place. Exposed equipment can result in severe injury or death. Periodic inspections should be performed. Failure to perform proper maintenance can result in premature product failure and personal injury. SHAFT MOUNTED AND SCREW CONVEYOR DRIVES 8000 SERIES TABLE OF CONTENTS BACKSTOPS DAMAGE IN SHIPMENT DISASSEMBLY AND REASSEMBLY INSTALLATION LONG TERM STORAGE LUBRICATION MAINTENANCE CHECK POINTS... 8 MOTOR LOCATION... 3 MOUNTING POSITION OIL SEALS OPERATION... 8 REDUCER MOUNTING INSTRUCTIONS... 7 SCREW CONVEYOR ASSEMBLY SHEAVES AND BELTS... 4 STORAGE TORQUE ARM LOCATION WARNING / CAUTION NOTICE WARNING! THIS REDUCER IS SHIPPED DRY. OIL MUST BE ADDED BEFORE OPERATION. SEE TABLE 4 FOR LUBRICATION SPECIFICATION. WARNING! Rotary equipment is dangerous unless adequately guarded. The user is responsible for complying with all applicable safety regulations. Adequate safety instructions must be given by the user to personnel directly responsible for the installation, maintenance, and operation of the equipment. The gear unit must not be operated above its service rating. DAMAGE IN SHIPMENT Inspect the unit immediately upon receipt of shipment for any signs of rough handling or damage. Any evidence of this should be reported immediately to the carrier and a claim entered. This may show up as scuffed paint, broken or cracked casting, bend shafts, metal deformation or a shift in alignment of components. STORAGE All units are tested before shipment with a rust inhibiting type of oil which covers interior surfaces. Shaft extensions are coated with drying film rust preventive. This will provide protection of the units for normal periods during installation. Depending upon the severity of storage conditions, the protection could range from a few months for unprotected outside storage, to a year or so for temperature controlled indoor storage. LONG TERM STORAGE For positive long term storage protection, it is recommended that the following procedures be followed: REDUCER INTERIOR 1. For protection, fill the reducer completely with the same oil that will be used in operation. 2. Remove breather at top of reducer and insert pipe plug. 3. At the end of the storage period the oil should be drained out and filled to the proper level with the type of lubricant specified for operating the reducer. The breather should be remounted now. REDUCER EXTERIOR All exposed unpainted parts such as shafts should be coated thoroughly with a corrosion preventive compound, solvent cut back type, leaving a firm film. Use Nox Rust* No. 369 or equivalent. GENERAL 1. The input shaft of every reducer should be rotated once a month enough turns to produce one complete turn on the output shaft. This will prevent water etching or false brinelling of the bearings and seizure of the elastomeric seal lip material on the shaft. 2. Certain storage areas, such as an outside location close to salt water, can be quite severe. Under these circumstances, a periodic inspection of the equipment is recommended and retreatment applied if required. 3. For best protection, the equipment should be stored in a climate controlled building to minimize the effects of sun, moisture, wind, and airborne abrasive material. 4. If the equipment is stored outside, it should be protected with a tarpaulin. Optionally, units can be encapsulated in a polyethylene bag. This cover must be air tight and include a container of calcium chloride crystals to absorb moisture. To be effective, the crystals would need to be replaced at regular intervals. 5. An occasional break in the paint coating causing rust spots may occur during outdoor storage. These spots should be cleaned and touched up with paint before placing the equipment in service. 6. Before start up after storage, the unit should be checked carefully for any rust accumulation on gears or bearings, or on shafts in the seal areas. Oil seal leakage may result due to seal deterioration or cutting of the seal lip from rust accumulation on the shaft. Bearing cover and housing bolts should be checked to be sure they are tight. *Nox Rust is believed to be the trademark or trade name of Daubert Chemical Company and is not owned or controlled by Regal Beloit Corporation. 1

2 ASSOCIATED EQUIPMENT SHOULD ALSO BE PROTECTED MOTORS The bearings are usually pre-lubricated. Refer to motor manufacturer for storage protection and re-lube period. Use protective cover to keep out water. INSTALLATION BUSHING AND KEY ASSEMBLY Stock bushing sizes are shown in the product catalog table. These sizes will adapt Shaft Mount reducers to the most commonly used driven shaft sizes. A bushing set includes a taper bushing, two locknuts, one lockwasher, and a drive key. See figure 1. Figure 2 - Double Reduction Oil Level Above 30 RPM CAUTION! The exact angle at which the reducer is mounted is not critical. However, if the drive must be mounted in a position which varies more than 10 (0.17 radians) from illustrations A, B, C, or D, consult the factory for the proper oil level. The preferred positions are indicated by illustrations A and C in figures 2 and 3 for double reduction units and illustrations A and D for single reduction units. Figure 1 - Bushing Parts Breakdown MOUNTING POSITION After the motor and torque arm positions have been determined, the Shaft Mount Drive should be in one of the six positions A, B, C, D, E, or F. See the recommended mounting positions for the double reduction reducers in figures 2 and 3 and for single reduction reducers in figures 4 and 5. NOTE the change in oil level plug locations for output speed below 30 rpm shown in figure 3 for double reduction units and figure 5 for single reduction units. Numbered items are as follows: 1 - Bushing and Breather 2 - Oil Level Plug 3 - Magnetic Drain Plug Figure 3 - Double Reduction Oil Level Below 30 RPM 2

3 Figure 6 - Double Reduction Oil Level Above 30 RPM The location of the breather, oil level plug, and drain plug remain unchanged and should be determined from figures 2 4. If the angle of inclination exceeds 15 (0.26 radians), or there is angular variation in more than one plane refer to the factory for operation and lubrication instructions. Figure 4 - Single Reduction Oil Level Above 30 RPM The allowable 10 (0.17 radians) variation in mounting location does not apply to the mounting positions with the hollow shaft vertical (E and F). For vertical shaft operation with greater angular variation, factory oil level modifications are required. NOTE: Refer to the Factory for instructions. MOTOR LOCATION The belt tension for the shaft mount is adjusted with the turnbuckle in the torque arm or by movement of the motor platform on the optional piggyback motor mount. For units without a piggyback motor mount, the V-belt drive may be located in any convenient position regardless of the location of the torque arm. The most common location, however, is shown in figure 7 [90 (1.57 radians)] to a line between the input and output shafts. This location permits control of belt tension with a minimum adjustment of the torque arm turnbuckle. Figure 5 - Single Reduction Oil Level Below 30 The reducer may be mounted with the hollow shaft axis inclined as indicated in figure 6, not to exceed 15 (0.26 radians). Figure 7 3

4 TORQUE ARM LOCATION Since the entire reaction force acts through the torque arm, the mounting bracket must be firmly attached to a solid support. On single and double reduction reducers, the torque arm mounting bracket point is provided as shown in figure 8. Figure 9 CAUTION! Belts should not be too tight as this can place excessive loading on the connected elements. Refer to V-Belt manufacturer s data for proper tension. WARNING! Excessive belt tension can greatly reduce V-Belt life and result in serious damage to the motor and reducer. MINIMUM DIAMETER FOR DRIVEN SHEAVES Figure 8 The most efficient angle of the torque arm to the housing is at 90 (1.57 radians) to a line between the center of the hollow shaft and the torque arm holding bolt. The torque arm can descend up to 30 (0.52 rad) from the horizontal and ascend up to angle A defined in table 1 as illustrated in figure 8. TABLE 1 UNIT SIZE ANGLE A rad rad rad rad rad rad rad rad rad The length of the torque arm may be reduced by cutting material from the threaded end of the rod. CAUTION! IMPORTANT: In selecting the V-Belt drive, make certain that the driven sheave is at least as large as shown in table 2. This is necessary to prevent excessive loading on the bearings, shafts, and gearing. Use of smaller diameters may be possible with due consideration for sheave location, motor horsepower, and service factor. Consult the factory for review of smaller diameters. TABLE 2 UNIT SINGLE DOUBLE SIZE REDUCTION REDUCTION 7:1 15:1 & 25: SHEAVES AND BELTS In mounting these items, the center of the load should be located no farther out than one shaft diameter away from the bearing cover. Otherwise, excessive overhung loading could exist resulting in early failures to bearings, shafts and gearing. Refer to Table 2 for applicable minimum sheave diameters. The driver and driven sheaves should be properly aligned. A straight edge laid across the face of the sheaves will aid in installation. The straight edge should lay evenly across both sheaves with no gaping. See figure 9. GENERAL When sheaves are furnished with reducers, they are generally mounted at the factory. If sheaves are to be mounted in the field, extreme care should be used. It is quite easy to damage internal members by heavy blows used in sheave mounting. Select a sheave bore to give a tapping or light driving fit. If necessary, the sheave bore should be enlarged to provide this class of fit. If a press fit is required, we suggest the sheave be heated to expand the bore before installation. Heating above 250 F (121 C) is not recommended due to possible damage of the oil seal by heat conduction through the shaft. 4

5 WARNING! For safety, purchaser or user should provide protective guards over shaft extensions, and any sheaves and belts mounted thereon. Failure to do so may result in bodily injury and/or damage to equipment. BACKSTOP INSTALLATION AND MAINTENANCE DOUBLE REDUCTION AND 8415H25 BACKSTOP REMOVAL Removal of the backstop is basically the reverse of the assembly procedure. If the backstop cannot be easily removed from the housing, it may be necessary to remove the retaining ring and use the retaining ring grove with a suitable puller to extract the backstop from the housing bore. BACKSTOP INSTALLATION 1. Remove the four screws from the cover plate opposite the input shaft extension side of the reducer. 2. Insert key in backstop keyway. Leave about 0.25 (6.4 mm) of key in keyway with the greater length of the key extending outside the end face of the backstop. 3. Where applicable, install the retainer ring on the backstop before inserting into the housing. 4. Lubricate the end of the shaft before inserting backstop. DO NOT USE AN ANTI-SEIZE COMPOUND AS LUBRICANT. 5. Position backstop over input shaft so the arrow (etched in backstop) points in the same direction as motor rotation. See figure 10. Figure 11 Note: In sizes 8107 through 8407 and 8415H25, the gear oil also lubricates the backstop. WARNING! If a backstop fails, the input shaft should also be replaced as it probably was damaged during the failure process. WARNING! WHEN A BACKSTOP IS USED WITH THE REDUCER, DO NOT USE LUBRICANTS OF THE EP TYPE (EXTREME PRESSURE CHARACTERISTICS), OR THOSE CONTAINING SLIPPERY ADDITIVES. BACKSTOP MAINTENANCE DOUBLE REDUCTION 8415H15 Figure Turn the input shaft with one hand in the normal direction of the rotation while inserting the backstop in the housing. The key should be aligned with the keyway in the housing now and the backstop should move in easily. When installing the backstop, do not apply pressure to the side plates of the backstop. Drive only on the outer race. See figure 11. The backstop should be positioned with the retaining ring flush against the housing. 7. Test the direction of rotation to make certain the installation is correct. 8. Where applicable, install the grease plate and replace the gasket and cover plate. Tighten the screws to prevent leakage. For this unit size, an external backstop is used. The manufacturer does not recommend repair in the field, nor attempting to change direction of rotation in the field. In either case, the backstop should be returned to the factory. BACKSTOP OIL FILLING PROCEDURE 1. Remove plugs A and B as shown in figure 12 and add oil through A until oil flows from B. See backstop lubricant chart, table 3, for proper lubricant. CAUTION! If reducer is mounted at an angle in any plane, consult factory for proper backstop lubricant levels. 2. Install both plugs and tighten to prevent leakage. Plugs consists of a button head screw and leather washer. Be sure washer is in place. 5

6 TABLE 3 BACKSTOP LUBRICANT FOR REDUCERS WITH EXTERNAL BACKSTOPS Refer to Table 4 for reducers with internal backstops RECOMMENDED LUBRICANT GEAR REDUCERS AMBIENT TEMPERATURE RANGE - 10 F to +20 F +20 F to 125 F :1 Ratio Only 8507 & 8608 All Ratios Mobil Gargoyle Heavy Artic C Automatic Transmission Fluid Texaco Regal R & O No. 46 Sunoco Sunvis 921 Chevron Oil 46 Mobil DTE Heavy Medium Automatic Transmission Fluid Texaco Regal R & O No. 68 Shell Turbo Oil 68 Gulf Harmony 68 Amoco Industrial Oil 68 Exxon Teresstic Oil 68 Sunoco Sunvis 931 The following trade names, trademarks and/or registered trademarks are NOT owned or controlled by Regal Beloit Corporation and are believed to be owned by the following parties. Amoco: BP Products North America Inc.; Chevron and Texaco: Chevron Intellectual Property LLC; Exxon, Gargoyle, Mobil and Teresstic: Exxon Mobil Corporation; Gulf and Harmony: Gulf Oil Limited Partnership Gulf Acquisition LLC; Shell: Shell Trademark Management BV; Sunoco and Sunvis: Sunmarks, LLC becomes contaminated or oxidized (dark colored), the backstop should be flushed and oil changed. Drain oil from backstop, fill with Whitmore s Flushing Oil (# )** or equivalent, and run for several minutes. Then remove drain plugs in backstop and drain fluid. Add fresh oil (see Oil Filling Procedure). BACKSTOP DISASSEMBLY 1. To take off the backstop, drain oil from the backstop and remove backstop cap by unscrewing cap screws, holding it to the backstop body. Remove the retaining ring. The backstop and torque arm can be pulled off by prying between the torque arm and the housing, or by use of a gear puller. The manufacturer does not recommend repair in the field, nor attempting to change direction of rotation in the field. In either case, the backstop should be returned to the factory. 2. Clean off all sealant from the shaft surfaces as well as the key, keyways, and backstop bore. Flush out backstop with Whitmore s Flushing Oil (# )** or equivalent. Do not use carbon tetrachloride. Figure 12 BACKSTOP OIL LUBRICATION MAINTENANCE CAUTION! Reducers used in high humidity conditions, such as waste-water treatment plants, or subject to large temperature variations will incur internal moisture condensation. Pressure relief breathers are recommended for these type of applications. Oil analysis should also be performed frequently to check for water contamination. 1. Check oil level daily. (See Maintenance checkpoints.) 2. Add oil, if necessary, to the proper fluid level. BACKSTOP ASSEMBLY 1. IMPORTANT: Before replacing the backstop, coat thoroughly the shaft surface under the backstop, the shaft keyway, the backstop bore and its keyway, and the key with room temperature vulcanizing sealant (RTV) General Electric* RTV-102 or Permatex* No. 2. This is to prevent oil leakage from the reservoir back along the shaft. *The following trade names, trademarks and/or registered trademarks are not owned by Regal Beloit Corporation and are believed to be owned by the following parties: General Electric: General Electric Company; Permatex: Illinois Tool Works. ** Whitmore is believed to be a trade mark owned by Whitmore Mfg Co. 3. Flushing is recommended every six months for up to 12 hours per day operation, and every three months for 12 to 24 hours per day operation. For extremely dusty or dirty operating conditions, it may be necessary to change oil at more frequent intervals to keep oil clean. When oil 6

7 2. Balance of reassembly is reverse of disassembly. Check torque arm for free movement. It must not bind against the bearing cap or cap screws. 3. Fill backstop to indicated level with proper oil. See Backstop Lubricant chart table Place left lockwasher and left locknut on taper bushing. Turn left locknut until contact is made between the lockwasher and the end of the reducer hollow shaft. Tighten left locknut until all play is removed in the tapered portion of the bushing. REDUCER MOUNTING INSTRUCTIONS NOTE: Do NOT use an anti-seize compound on any of the assembled components. 1. Clean driven shaft to remove any contaminants. Dry thoroughly. 2. Screw on right locknut on the large end of the taper bushing. Turn nut until all threads on nut are engaged on bushing. 3. Slide bushing, lock nut end first, onto driven shaft. Locate bushing as close as possible to the driven shaft bearing support and above keyway in driven shaft. See figure 13. Figure Place key in bushing into driven shaft keyway. 5. Slide Shaft Mount Reducer over driven shaft and up onto the taper bushing. DO NOT HAMMER ON THE CASE OR INPUT SHAFT. A lead hammer or a soft punch may be used to tap against the end of the HOLLOW SHAFT. Press firmly on hollow shaft of reducer to make sure taper is fully engaged. See figure 14. LUBRICATION WARNING! THIS REDUCER IS SHIPPED DRY. OIL MUST BE ADDED BEFORE OPERATION. SEE TABLE 4 FOR LUBRICATION SPECIFICATIONS. The oil used should be a high quality product, having rust and oxidation inhibitors, anti-foaming agent, a high viscosity index (preferability above 90) and a low acid content. It should be neutral in reaction, free from girt or abrasives and non-corrosive to gears or bearings. CAUTION! IMPORTANT: WHEN A BACKSTOP IS FURNISHED WITH THE REDUCER, DO NOT USE LUBRI- CANTS OF THE EP TYPE, (EXTREME PRESSURE CHARACTERISTICS), OR THOSE CONTAINING SLIPPERY ADDITIVES. CAUTION! LOW TEMPERATURE OPERATION The pour point of the oil should, at minimum, be equal to the lowest ambient starting temperature. For best results, the pour point should be 5 to 10 degrees F (2.8 to 5.6 degrees C) below the lowest ambient starting temperature. For reducers operating in ambient temperature conditions below 15 F (-9.4 C) special lubrication is required. Refer to factory for recommendations, giving expected ambient temperature and operating cycle. CAUTION! HIGH TEMPERATURE OPERATION When ambient temperatures exceed 125 F (51.6 C) special lubrication, special oil seals, and/or increased cooling of the reducer may be required. Refer to factory for recommendations, giving expected ambient temperature and operating cycle. CAUTION! HIGH SPEED OPERATION When input speed exceeds 1800 rpm, special lubrication, and increased cooling of the reducer may be required. Refer to factory for recommendations, giving expected ambient temperature and operating cycle. CHANGE CYCLE The first oil change should be made after two weeks, or 100 hours of operation. After this, we recommend changing reducer oil every 2500 hours or six months, whichever occurs first. Consider seasonal temperature changes when changing oil. Operating conditions can vary this guide line. Abnormal temperatures and contamination can seriously affect the lubricant causing early sludging, oxidation, and acid formation. Under these conditions, a sample of the lubricant should be submitted to the petroleum supplier at periodic intervals. This will establish a change cycle which will provide for renewal of the oil before its degradation. Figure 14 7

8 TABLE 4 AGMA LUBRICANT NUMBERS FOR SHAFT MOUNT AND SCREW CONVEYOR REDUCER GEAR REDUCERS AGMA LUBRICANT NUMBER BY AMBIENT TEMPERATURES FOOD AND DRUG INDUSTRY Some operations in the Food and Drug Industry require special lubrication considerations in view of possible toxicity from contamination by the oil or grease used in the equipment. Some EP products contain Lead Naphthenate, Phosphorus, or Chlorine which are toxic and could be harmful. T Y P E SMR SCT Degrees F Degrees F NORMAL SERVICE HEAVY DUTY W/O BACKSTOP NORMAL SERVICE HEAVY DUTY W/O BACKSTOP CAUTION! In the Food (including animal food) and Drug Industry, consult the petroleum supplier for recommendation of lubricants which are acceptable to the Food and Drug Administrations and/or other authoritative bodies having jurisdiction. S I Z E EP 5 5 EP Where the lubricant contains Lead Naphthenate (an EP additive) the reducer oil sump temperature should not exceed 160 F (70 C). CAUTION! Always fill the speed reducer to the oil level indicator for proper lubrication. CAUTION! When a backstop is furnished with the reducer, do not use lubricants of the EP type, (Extreme Pressure Characteristics), or those containing slippery additives. CAUTION! Table 5 oil capacities are only an approximation and should not be used as the exact value for an oil fill. See figures 2-5 for location of the oil plug, oil drain, and breather for the six different mounting positions. OPERATION START UP Verify the rating of the reducer (indicated on the nameplate and certified print) to be sure that service rating, RPM or speed range, thermal rating, and any overhung or thrust loading are not exceeded in actual operation. If input speed exceeds 1800 rpm, refer to factory for operation and lubrication recommendations. 1. Make sure reducer is filled with correct lubricant to the proper level. Refer to the section of this bulletin on lubrication and/or the nameplate affixed to the reducer. 2. Check for free rotation of all elements. In many cases, the input shaft of the reducer can be turned by hand even with a connected load. 3. Check all bolts and cap screws to make sure they are tight. 4. Check belts for proper tension and alignment. WARNING! After energizing motive power, if any undue noise occurs, shut off power IMMEDIATELY. TABLE 5 APPROXIMATE OIL CAPACITY IN QUARTS (LITERS) SINGLE AND DOUBLE REDUCTION UNIT SIZE LONG AXIS LONG AXIS VERTICAL HORIZONTAL (047).75 (.71) (.71) 1.25 (1.18) (.95) ) (1.42) 2.5 (2.37) (2.37) 4.0 (3.79) (4.26) 5.0 (4.73) (6.15) 8.0 (7.57) (7.57) 12.5 (11.8) (8.52) 13.0 (12.3) 8507 Consult Factory Consult Factory 8608 Consult Factory Consult Factory 5. Observe temperature rise. This may take up to four hours to stabilize. In some instances the temperature in the oil sump may rise as much as 100 F (38 C) above the ambient. Actual operating temperature will vary slightly with the reducer size, ratio, type, and operating conditions. CAUTION! Under no circumstances should the oil bath temperature exceed 200 F (93 C). If this should occur, consult the factory. The housing and the shaft next to the high speed seal may show temperature significantly above 200 F (93 C). This will diminish as the seal and shaft sealing area wear in. Application of oil at this area during the break-in period will aid this process. Bearings can produce localized heating from cramping, either radial or axially. Check for insufficient end play. Many times the reducer temperature is judged by the touch of a hand and may be considered to be quite hot. The only positive method is to use a surface temperature measuring instrument or by using a thermometer directly in the oil bath. 8

9 6. About one month after start-up, check all bolts for tightness. Re-tighten as required. This refers to all components in the drive train. WARNING! Do not operate this unit beyond its service rating as any resulting failure could cause damage to property or life and limb. CAUTION! The system of connected rotating parts must be free from critical speed, torsional or other type of vibration, no matter how induced. The responsibility for this system analysis lies with the purchaser of the speed reducer. BREATHER Each unit is equipped with a breather. This should be cleaned at intervals to insure that it is working properly. 5. LUBRICANT CONDITION A change of color in the oil or thickening or unexplainable corrosion of internal parts is an indication that the lubricant has deteriorated and should be changed. 6. LOADING Periodic load checks are valuable in making sure that the reducer rating is not exceeded. 7. OIL BREATHER Must be kept clean. 8. VIBRATION A change in the vibration normally associated with the system can indicate worn parts. 9. DIRT ACCUMULATION Any undue accumulation of dirt on the reducer or in fan components where fans are used will affect proper cooling of the unit. 10. GREASE PURGE For units equipped with an optional grease purged sealing system, lubricate once per week with a high quality Lithium base grease NLGI number 2 consistency. MAINTENANCE CHECK POINTS For optimum protection and preventive maintenance, inspect the reducer daily. Points to cover are: 1. OIL LEAKAGE at oil seal, housing split, bearing cap shims, and pipe fittings. Tighten housing bolts, bearing cap bolts and pipe fittings and/or replace oil seal if leakage is sufficient to cause rapid drop in oil level. It may be necessary to add sealant between bearing cap shim packs and the housing, or at the housing split. 2. OIL LEVEL Any undue drop in oil level is a sign of oil leakage from some point on the reducer and should be corrected. The oil level should be checked when the reducer is not running. 3. TEMPERATURE Check the actual temperature of the oil bath, gear case, and shafts at various points. This should be done after the unit has been in operation at least two hours. The average oil bath temperature is 140 F (60 C) however, the range can vary from 100 F to 200 F (38 C to 93 C). Bearings can produce localized heating from cramping either radial or axial. Check for insufficient end play. Any undue rise in temperature above that normally encountered and not accountable for by a rise in the ambient should be investigated. Low oil level, abnormal loading, thickening of lubricant, and bearing seizure are possible sources. If a particular bearing is a heat source, the housing area adjacent to the bearing would warm up. 4. SOUND LEVEL A sudden change in the sound level is a possible indication of low oil level undue thinning out of lubricant, abnormal loading, or deterioration of internal parts. OIL SEALS All oil seals used in these units are dual lip type, and have a synthetic elastomer lip material. They are provided with a spring back of the inner lip which exerts constant pressure and keeps the lip in contact with the shaft. Some units are equipped with an optional grease purged sealing system for use in areas subjected to a considerable accumulation of external foreign matter. This consists of an exterior shroud covering the oil seal and a grease fitting. In any disassembly of the reducer or removal of bearing caps, it is recommended that all oil seals be replaced. CHANGING SEALS 1. If the unit is sheave driven, the driven sheave must be removed to gain access to the oil seal on the input shaft. To change oil seals on the output shaft, remove reducer from the driven shaft. See REDUCER REMOVAL for further information. 2. Remove grease shroud, if so equipped, from cover. Drill two holes in the seal face 180 (3.14 radians) apart. Insert large sheet metal screws and leave about 0.18 inches (4.76 mm) length of screw under the screw head exposed. Use a pry bar with the notch at one end under the screw heat to lift the seal out. See figure 15. Noise is usually difficult to isolate because sound can travel throughout an entire drive system. A noise can be pinpointed to a specific area by determining its approximate frequency and if it is at accurate regular intervals. 9

10 DISASSEMBLY AND REASSEMBLY REDUCER REMOVAL WARNING! Disconnect reducer from prime mover. Make sure no motion of driver or driven equipment can occur during this procedure. WARNING! Make certain that the power supply is disconnected before attempting to service or remove any components. Lock out the power supply and tag it to prevent unexpected application of power. Figure Take care not to damage the seal bore in the bearing cap or the shaft surface when removing the old seal. 4. Examine the new oil seal for cuts or imperfections in the lip. The lip should have a smooth and uninterrupted edge with no flashes from molding. The outside diameter of the seal should be free from scratches and burrs. Test the seal for grip on the shaft upon which it has to run; it should not be loose but should offer some drag to axial movement. If the seal is not satisfactory, discard it and try another one. 5. Clean the bearing cap seal bore and remove any burrs; coat the cap bore and the seal outside diameter with an adhesive sealant such as General Electric* RTV-102 or Permatex* No The shaft in the seal areas should be examined for score marks, scratching or grooving. First try polishing out the imperfections with a fine grade of emery cloth (No. 240). The polishing motion should not be axial or spiral in direction but circumferential. If the shaft surface can not be reconditioned sufficiently by polishing to remove all imperfections, it may be possible to shift the seal position sufficiently to escape this area. The inner lip with the spring in back of it is the important one to consider. The alternative is to metalize the shaft and re-grind to a surface finish of 10 to 20 RMS. If the surface imperfections are not too deep, a simple plunge grind to no more than (0.254 mm) undersize on the diameter may clean up the shaft. In fact, plunge grinding is preferable to polishing to remove any chance of spiral marks on the shaft which can cause oil leakage. A third option is to use a wear sleeve. Consult the manufacturer for installation instructions. Figure Remove left locknut and lockwasher from taper bushing mounted on driven shaft. See figure Tighten right locknut until contact is made with the reducer hollow output shaft. Continue turning this locknut until the reducer is pushed clear of the tapered portion of the bushing. 3. Remove the reducer off the driven shaft. Unit should be properly supported during this procedure. 7. Wrap (.127 mm) plastic shim stock around the shaft to cover up the keyway and any shoulders. Wipe oil or grease on the seal lip to ease assembly. Slip the seal on the shaft up to the bearing cap with the lip and spring facing in toward the reducer. Using the end of a piece of wood about 1 by 2 (25 by 50 mm), drive the seal in tapping first on one side then the other. See figure 16. The seal should be flush with the bearing cap outer face and square with the shaft. Remove the shim stock. If steel or brass shim stock is used, make sure all burrs on the edge are removed to avoid cutting the seal. For maximum protection, lay a strip of scotch tape along the exposed edge. 8. For those units having the optional grease purged sealing system, remount the shroud and add a high quality Lithium base grease of NLGI number 2 consistency. Figure 17 *The following trade names, trademarks and/or registered trademarks are not owned by Regal Beloit Corporation and are believed to be owned by the following parties: General Electric: General Electric Corp.; Permatex: Illinois Tool Works. 10

11 DISASSEMBLY 1. For ease of handling, place reducer on bench. Drain oil from reducer and remove air breather. 2. Removing the hex cap screws will permit the removal of the housing cover. Housing cover must be removed straight up to prevent damage to dowel pins. See figure After all cap screws are removed, two can be inserted in the tapped holes in the housing cover flange and used as jack screws to aid in cover removal. See figure 18. Figure 21 CLEANING All parts, including the housing, should be washed thoroughly with kerosene or a mineral solvent. Any accumulation of sludge deposits or corrosion should be removed. Do not use a wire brush on any seal, bearing, or gear tooth surfaces to avoid scratching. All old sealant should be scrapped from mating flange surfaces of the housing and bearing caps. Figure Bearings and gears are now fully accessible, ready for removal. See figure Remove exposed high speed bearings. All other bearings and/or gears are now easily removable as a unit (bearings, gear, and shaft). When removing a bearing cone from a shaft, a small press may be used, supporting the shaft assembly on the cone shoulder. Keep the bearings clean. Figure 22 REASSEMBLY 1. Reassembly is basically the reverse of the disassembly procedure. 2. Install new oil seals in the high speed and low speed open end bearings caps as discussed in CHANGING OIL SEALS. Figure Tapered roller bearing cups can be removed from the housing and cover bores using pry bars. See figure Bearing cones may be heated to ease assembly. This can be done with an infra-red lamp, a heated oil bath, or an oven. If an oil bath or oven is used, take care to support the bearing well off the bottom and away from the sides of the container to avoid direct contact with an area of localized heat from the heating element or the flame. WARNING! Do not exceed 250 F (121 C) to prevent drawing back the bearing hardness. 7. Figure 22 shows a typical disassembled unit with all components. 8. The oil seals are a press fit in the bores. They can be drawn out readily. Use a piece of wood preferably, to avoid damaging the seal bore surfaces in the bearing cap. 11

12 If heating facilities are not available, it will be necessary to use a press. In pushing the cone on the shaft make sure that no pressure is exerted on the cage or rollers, only on the cone shoulder and that the cone seats flush with the shaft shoulder. Before pressing on the shaft, check the shaft shoulder for burrs or dirt. Remove them if present, otherwise the bearing will not seat squarely. Apply anti-seize compound to the bearing seat before pressing. In supporting the shaft to press on a bearing, make certain that the point of support is on the shaft end and not on the cage and rollers. Check endplay by placing a dial indicator pointer on shaft end and wedge shaft to its extreme opposite positions. See figure 24. The total dial variation is the shaft endplay. If the endplay does not agree with the specification above, correct it by adding or removing shims as required. Add shims to increase endplay, remove shims to decrease endplay. Rotate shafts each time shims are added. 4. The shafts with bearings and gears installed along with the bearing caps and shim packs should be placed back in the housing in the reverse order of disassembly. Coat bearings with a thin film of oil before assembly into the housing. A sealant such as General Electric RTV-102 or Permatex No. 2 should be applied to the housing split and to the bearing cap flanges. 5. All bearing caps should be mounted with their original shim packs in position. In mounting the open end caps with oil seals, take care not to damage the seals. Wrap (0.127 mm) plastic shim stock around the shaft over the keyway and/or shaft shoulder to protect the seal lip. Do this gently to prevent dislocating the spring back of the lip. The housing bolts should be tightened before the bearing cap bolts. This should be done evenly to prevent warping the housing. See Figure 23, Table 6 for bolt torque values. Note that the maximum torque values are shown. Use 90% to 100% of these values. TABLE 6 RECOMMENDED BOLT TIGHTENING TORQUES BOLT GRADE FIVE SIZE (LB-FT) (N-M) Figure 23 Figure 24 After changing shims, recheck endplay. Plastic or metal shims are used in original assembly. Use no substitutes. 7. After completion of assembly, turn the input shaft by hand until the output shaft has made at least one complete revolution. There should be no undue drag at this point. If any gearing has been replaced, check to make sure that each set has backlash. 6. Bearing Adjustment. All reducers have tapered roller bearings and required a specific axial endplay for each size. Rotate the input shaft until the output shaft has made at least two full turns. This is to seat the rollers. Use the following endplays for each shaft bearing set-up. Single Reduction Input Shaft Bearings / /.076 mm Before start-up, fill reducer with oil and follow instructions listed under OPERATION. New bearings and oil seals may tend to run slightly warmer during break-in. If the reducer, for ease of repair, has been removed from its operating location recheck alignment of sheaves and tension on bolts. After one month of operation, it is advisable to recheck all bolts for tightness. Double Reduction Input Shaft / /.076 mm / /.102 mm Double Reduction Intermediate Shaft / /.076 mm Single and Double Reduction Output Shaft Preload /.002 Endplay..051 /.102 mm 12

13 SCREW CONVEYOR DRIVES The following parts are required to convert the shaft mount drive for screw conveyor service: Adaptor with mounting hardware Adaptor/Hollow shaft oil seal Adaptor Shim set Drive Shaft Drive Shaft Key Drive Shaft Retainer Adaptor Oil Seal Packing Gland Assembly - optional ASSEMBLY PROCEDURE 1. Remove oil seal from Low speed bearing cover. See CHANGING SEALS for instructions. 2. Remove low speed bearing cover on the side opposite the input shaft extension from unit. Remove and note the kind and number of shims from this bearing cap for use later when the adaptor is mounted. 3. Examine the new oil seal to be mounted in the adaptor for the hollow shaft for cuts or imperfections in the lip. The lip should have a smooth and uninterrupted edge with no flashes from molding. The outside diameter of the seal should be free from scratches and burrs. Test the seal for grip on the shaft upon which it has to run; it should not be loose but should offer some drag to axial movement. If the seal is not satisfactory, discard it and try another one. 4. Clean the adaptor rear seal bore and remove any burrs; coat the bore and the seal outside diameter with an adhesive sealant such as General Electric* RTV-102 or Permatex* No The shaft in the seal areas should be examined for score marks, scratching or grooving. First try polishing out the imperfections with a fine grade of emery cloth (No. 240). The polishing motion should not be axial or spiral in direction but circumferential. If the shaft surface can not be reconditioned sufficiently bypolishing to remove all imperfections, it may be possible to shift the seal position sufficiently to escape this area. The inner lip with the spring in back of it is the important one to consider. The alternative is to metalize the shaft and re-grind to a surface finish of 10 to 20 RMS. If the surface imperfections are not too deep, a simple plunge grind to no more than (0.254 mm) undersize on the diameter may clean up the shaft. In fact, plunge grinding is preferable to polishing to remove any chance of spiral marks on the shaft which can cause oil leakage. A third option is to use a wear sleeve. Consult the manufacturer for installation instructions. 6. Wipe oil or grease on the seal lip to ease assembly. Mount the seal inside the adaptor with the lip and spring facing in toward the reducer. The seal should be flush with the adaptor outer face closest to the reducer and square with the shaft. 7. Place the existing shim pack from the low speed cover on the adaptor and carefully mount the adaptor on the reducer. Do not damage the seal while sliding it across the hollow shaft. 8. The endplay of the low speed bearings must be checked at this time. Rotate the input shaft until the output shaft has made at least two full turns. This is to seat the rollers. Use the following endplays for the output shaft. Single and Double Reduction Output Shaft Preload /.002 Endplay..051 /.102 mm Check endplay by placing a dial indicator pointer on the hollow shaft end and wedge shaft to its extreme opposite positions. See figure 24. The total dial variation is the shaft endplay. If the endplay does not agree with the specification above, correct it by adding or removing shims as required. Add shims to increase endplay, remove shims to decrease endplay. Rotate shafts each time shims are added. After changing shims, recheck endplay. Plastic or metal shims are used in original assembly. Use no substitutes. 9. If the unit is equipped with the optional packing gland, install the bolts holding the packing gland in place and mount the packing gland on the adaptor. Load the packing material inside the rear spacer and place it in the front bore of the adaptor. Mount the front spacer between the packing gland and the rear spacer. 10. If the unit is not equipped with packing gland, install the adaptor oil seal inside the bore of the adaptor. 11. Examine the new oil seal to be mounted in the adaptor for the drive shaft for cuts or imperfections in the lip. The lip should have a smooth and uninterrupted edge with no flashes from molding. The outside diameter of the seal should be free from scratches and burrs. Test the seal for grip on the drive shaft; it should not be loose but should offer some drag to axial movement. If the seal is not satisfactory, discard it and try another one. 12. Clean the adaptor front seal bore and remove any burrs; coat the bore and the seal outside diameter with an adhesive sealant such as General Electric RTV-102 or Permatex No The drive shaft in the seal areas should be examined for score marks, scratching or grooving. First try polishing out the imperfections with a fine grade of emery cloth (No. 240). The polishing motion should not be axial or spiral in direction but circumferential. If the shaft surface can not be reconditioned sufficiently by polishing to remove all imperfections, it may be possible to shift the seal position sufficiently to escape this area. The inner lip with the spring in back of it is the important one to consider. The alternative is to metalize the shaft and regrind to a surface finish of 10 to 20 RMS. If the surface imperfections are not too deep, a simple plunge grind to no more than (0.254 mm) undersize on the diameter may clean up the shaft. In fact, plunge grinding is preferable to polishing to remove any chance of spiral marks on the shaft which can cause oil leakage. A third option is to use a wear sleeve. Consult the manufacturer for installation instructions. 14. Wipe oil or grease on the seal lip to ease assembly. Mount the seal inside the adaptor front oil seal bore with the lip and spring facing in toward the reducer. The seal should be flush with the adaptor outer face (trough end mounting surface) and square with the surface. 15. Insert the drive key into the drive shaft and install drive shaft through the adaptor into the gear drive. Take care not to damage the adaptor front oil seal and/or packing material. A brass bar may be used to tap the end of the drive shaft into the reducer hollow shaft until seated on the taper. 16. Install the shaft retainer. A tapped hole in the end of the drive shaft is provided for this purpose. *The following trade names, trademarks and/or registered trademarks are not owned by Regal Beloit Corporation and are believed to be owned by the following parties: General Electric: General Electric Corp.; Permatex: Illinois Tool Works. 13

14 DISASSEMBLY PROCEDURE Disassembly is basically the reverse of the assembly procedure. Disassembly, cleaning and reassembly of the remainder of the reducer is identically to the shaft mount instructions. Refer to the appropriate sections for further information on bearings, seals, etc. PARTS LIST SINGLE REDUCTION UNITS Item Description 1 Housing 2 Housing Cover 5 Low Speed Gear 6 Low Speed Shaft 10 Gasket, Rear Cover 11 Cover, Rear 12 Key, Low Speed Gear 14 Dowel Pin 15 High Speed Pinion & Shaft (5:1) 16 Oil Seal, Low Speed 17 Oil Seal, High Speed 19 Torque Arm Rod - R.H. 20 Torque Arm Rod - L.H. 21 Clevis Pin 23 Turnbuckle 24 Torque Arm Bracket 26 Low Speed Bearing 28 H.S. Shaft Extension Bearing 29 High Speed Blind Bearing 33 Retaining Ring 43 Breather 47 Hex Jam Nut 51 Locknut - Left 52 Lockwasher - Left 53 Locknut - Right 55 Shims - L.S. Bearing Cover 57 Shims - H.S. Bearing Cover 58 Cover - L.S. Bearing 59 Cover - Front Bore 60 Cover - High Speed Bearing 64 Tapered Bushing DOUBLE REDUCTION UNITS Item Description 18 Key, Backstop 19 Torque Arm Rod - R.H. 20 Torque Arm Rod - L.H. 21 Clevis Pin 23 Turnbuckle 24 Torque Arm Bracket 25 Backstop 26 Low Speed Bearing 28 H.S. Shaft Extension Bearing 29 High Speed Blind Bearing 30 Intermediate Pinion Bearing 33 Retaining Ring 43 Breather 47 Hex Jam Nut 51 Locknut - Left 52 Lockwasher - Left 53 Locknut - Right 55 Shims - L.S. Bearing Cover 56 Shims - Int. Bearing Cover 57 Shims - H.S. Bearing Cover 58 Cover - L. S. Bearing 59 Cover - Intermediate Bearing 60 Cover - High Speed Bearing 62 Retaining Ring, Backstop 63 Intermediate Gear Bearing 64 Tapered Bushing 67 Cover - Backstop 15:1 68 Oil Seal - Backstop (15:1) 70 Torque Arm - Backstop 75 Retaining Ring 77 Shaft Guard (Not used w/ b/s 15:1) 80 High Speed Bearing Spacer (25:1) PARTS LIST SCREW CONVEYOR DRIVE SINGLE AND DOUBLE REDUCTION Item Description 100 Adaptor 101 Packing Gland 102 Front Spacer 103 Rear Spacer 104 Packing 105 Adaptor Oil Seal 106 Drive Shaft 107 Drive Shaft Keeper Plate 108 Drive Shaft Key 1 Housing 2 Housing Cover 3 High Speed Gear 4 Low Speed Pinion Shaft 5 Low Speed Gear 6 Low Speed Shaft 11 Cover, Backstop 12 Key, Low Speed Gear 13 Key, High Speed Gear 14 Dowel Pin 15 High Speed Pinion & Shaft 16 Oil Seal, Low Speed 17 Oil Seal, High Speed 14

15 TORQUE ARM SUB-ASSEMBLY PARTS LIST DOUBLE REDUCTION SHAFT MOUNT DRIVE 15

16 SINGLE REDUCTION SHAFT MOUNT DRIVE SCREW CONVEYOR DRIVE 16

17 MECHANICAL WARNINGS AND CAUTIONS IMPORTANT INFORMATION PLEASE READ CAREFULLY The following and information is supplied to you for your protection and to provide you with many years of trouble free and safe operation of your Foote-Jones Gear product: Read ALL instructions prior to operating reducer. Injury to personnel or reducer failure may be caused by improper installation, maintenance or operation. Written authorization from Regal is required to operate or use reducers in man lift or people moving devices. Check to make certain application does not exceed the allowable load capacities published in the current catalog. Buyer shall be solely responsible for determining the adequacy of the product for any and all uses to which Buyer shall apply the product. The application by Buyer shall not be subject to any implied warranty of fitness for a particular purpose. For safety, Buyer or User should provide protective guards over all shaft extensions and any moving apparatus mounted thereon. The User is responsible for checking all applicable safety codes in his area and providing suitable guards. Failure to do so may result in bodily injury and/or damage to equipment. Hot oil and reducers can cause severe burns. Use extreme care when removing lubrication plugs and vents. Make certain that the power supply is disconnected before attempting to service or remove any components. Lock out the power supply and tag it to prevent unexpected application of power. Reducers are not to be considered fail safe or self-locking devices. If these features are required, a properly sized, independent holding device should be utilized. Reducers should not be used as a brake. Any brakes that are used in conjunction with a reducer must be sized or positioned in such a way so as to not subject the reducer to loads beyond the catalog rating. Lifting supports including eyebolts are to be used for vertically lifting the gearbox only and no other associated attachments or motors. Use of an oil with an EP additive on units with backstops may prevent proper operation of the backstop. Injury to personnel, damage to the reducer or other equipment may result. Overhung loads subject shaft bearings and shafts to stress which may cause premature bearing failure and/or shaft breakage from bending fatigue, if not sized properly. Test run unit to verify operation. If the unit tested is a prototype, that unit must be of current production. If the speed reducer cannot be located in a clear and dry area with access to adequate cooling air supply, then precautions must be taken to avoid the ingestion of contaminants such as water and the reduction in cooling ability due to exterior contaminants. Mounting bolts should be routinely checked to ensure that the unit is firmly anchored for proper operation. In the event of the resale of any of the goods, in whatever form, Resellers/Buyers will include the following language in a conspicuous place and in a conspicuous manner in a written agreement covering such sale: The manufacturer makes no warranties or representations, express or implied, by operation of law or otherwise, as to the merchantability or fitness for a particular purpose of the goods sold hereunder. Buyer acknowledges that it alone has determined that the goods purchased hereunder will suitably meet the requirements of their intended use. In no event will the manufacturer be liable for consequential, incidental or other damages. Even if the repair or replacement remedy shall be deemed to have failed of its essential purpose under Section of the Uniform Commercial Code, the manufacturer shall have no liability to Buyer for consequential damages. Resellers/Buyers agree to also include this entire document including the warnings and cautions above in a conspicuous place and in a conspicuous manner in writing to instruct users on the safe usage of the product. This information should be read together with all other printed information supplied by Regal. 17