MASTER ENGINEERING/ TECHNICAL. XL Reducers And Gearmotors INSTALLATION

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1 INSTALLATION Proper installation of MASTER speed reducers will ensure reliable service and maximum life. Key items to minimize possible failures include: Gear Case Mounting To insure uniform pressure mount gear case on flat surface. Use uniform torque when mounting bolts are tightened. Shaft Overhung Loads Excessive overhung loads due to over tightening of belts or chains can result in broken shafts and reduced bearing life or failure. Couplings Improper coupling alignment can result in excessive stresses on gear unit shaft and bearings. Shock Loads Excessive shock loads can also result in damaging stresses on shafting and bearings. LUBRICATION - RIGHT ANGLE This gearcase has been lubricated at the factory for only one mounting position. Before starting, check the mounting position diagrams in Instruction Manual E--3614, pages 6 through 9 to make sure that the oil level plug and oil level are in the correct location for which the unit is to be operated. This is extremely important, as insufficient lubricant will damage gears and bearings in a very short time. If any change is necessary, the vent plug must he relocated above the new oil level. When the unit is to be mounted in a position other than those shown in the diagrams, consult the factory. Units mounted with output shafts in the vertical position require street ells to raise the oil level to the top edge of the bronze worm gear. On some sizes this street ell is shipped separately to avoid breakage in transit. The location for the street ell is indicated by an instruction tag wired to a throwaway plug (a throwaway plug can be recognized by the cross-drilled hole in the head of the plug). Before putting unit into operation turn the unit up so that oil will not drain out when the throwaway plug is removed. Remove and discard the throwaway plug and install the street ell in a vertical position as indicated on the mounting position diagrams in Instruction Manual E--3614, pages 6 through 9. The unit is factory-filled with the proper amount of lubricant to bring the oil level to the top of the street ell. On some mounting positions zerk fittings are provided for grease lubricating bearings located above the operating oil level. Lubricate with a good grade of roller bearing grease when changing gear lubricant at the recommended change interval. Texaco Marfak No.3 is a suitable grease. Do not overlubricate grease-packed bearings. Single reduction worm gear units for output shaft down mounting have one pipe-tapped hole in the center of the closed bearing housing. Combination units for output shaft down mounting have two pipe-tapped holes in line, one in the center of the output shaft and one in the center of the second stage pinion shaft. Units are shipped from the factory with throwaway plugs in these tapped holes (a throwaway plug can be recognized by the cross-drilled hole in the head of the plug). Before putting units into operation remove and discard the throwaway plugs and install the zerk fittings. Flanged units for the flange/output shaft up mounting have two pipe-tapped holes in the side of the flanged bearing housing. One of these holes is for a zerk fitting. Its location can be recognized by the throwaway plug. Remove and discard the throwaway plug and install the zerk fitting. CAUTION PROPER OPERATION OF THIS UNIT REQUIRES VENTlNG. REPLACE THE THROW AWAY PLUG WITH VENT PROVIDED. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN DAMAGE TO OR DESTRUCTION OF THE EQUIPMENT. Vent plug locations can be recognized by a throwaway plug. The vent plug is wired to the throwaway plug to avoid mistaking it for a zerk location. The vent plug is designed to prevent dirt and water from entering the gearcase and also to release air pressure caused by heat generated in the case. Without proper air venting the increase in pressure may force lubricant through the oil seals and result in oil leakage and damage to the unit. Do not restrict the operation of the vent with paint or other obstructions. NOTE: Standard vents are spring loaded which open at approximately.50 P.S.I. If sight gauges are installed on a gear unit, the vent must be a type which is open continuously. OPERATING TEMPERATURES Heating is a natural characteristic of right angle gear units with a worm gearset. A maximum gearcase sump temperature approaching 200 F. is not uncommon for units operating in normal ambient temperatures. When operated at the rated capacity, no damage will result from this temperature, as this was taken into consideration in the design of the gearcase and the selection of the lubricant. The proper lubricant must be selected for the operating ambient temperature range, with seasonal changes in lubricant viscosity grade whenever necessary. Output speeds above 300 RPM may require a lighter viscosity grade of lubricant. Select the lubricant from the proper column on page G Lubricants other than those listed should not be used without specific factory approval as performance or gear life may be adversely affected. G6--66

2 LUBRICATION RIGHT ANGLE (CONT.) Lubrication is extremely important for satisfactory operation. The proper oil level must be maintained in the gearcase at all times. The correct level is indicated by the red head pipe plug. Frequent inspections with the unit not running (preferably when warm), should be made by removing the plug to see that the level is being maintained. If low, (without replacing oil level plug), add lubricant through one of the proper holes until it comes out of the oil level hole. Replace the oil level plug securely. grit and metal particles from the run-in period. Lubricant should he drained, the gearcase flushed with mineral spirits and refilled after the first 250 hours of operation; then every 1300 hours or six months thereafter, whichever occurs first. (Normal operation is running 16 hours per day in 80 F. ambient). More frequent oil changes may be necessary when running continuously at high temperatures. Use only recommended lubricants as listed in the table below. NOTE: If Mobil SHC-629 or SHC-634 are used for normal operation (viscosity group ), the time for changing the lubricant may be extended. Drain, flush, and refill after the first 1500 hours of operation: then every 5000 hours thereafter. (SHC is a registered trademark of the Mobil Corporation). APPROVED LUBRICANTS VS. AMBIENT CONDITIONS: The satisfactory performance of gears and bearings in gearmotors and reducers depends on clean lubricant, free from dust, grit, sludge, and moisture. Depending on operating conditions, the lubricant will eventually become contaminated and should be replaced periodically. When first put into operation, the lubricant in new gearcases becomes contaminated with AMBIENT LUBRICANT VISCOSITY GROUP VS. OUTSHAFT SHIPPED TEMPERATURE UP TO 300 RPM OVER 300 RPM -65 F. TO 0 F F. TO +20 F F TO +55 F F. TO +110 F F. TO +165 F VISCOSITY GROUP AMOCO OIL COMPANY AMOCO PERMAGEAR AMOCO EP460 WORM GEAR OIL ATANTIC RICHFIELD ARCO MINEARAL GEAR OIL S.A.E CARR OIL COMPANY LUB 733 EP140 DARMES INDUSTRIAL CORP. GEAR BOX OIL DX-9140 DUBOIS CHEMICAL CO. E.G.O. EP90 EP140 EXXON CYLESSTIC TK460 FISKE BROTHERS LUBRIPLATE APG GULF OIL COMPANY TRANSGEAR LUBE EP90 EP140 E.F. HOUGHTON CO. MP GEAR OIL KEYSTONE LUBE CO. WG-A MOBILE OIL CORP. SHC-600 SERIES SHC-600 SERIES AVREX MOBILFLUID CYLINDER OIL EXTRA HELCA SHC-629* SHC-629* SHC-634 PHILLIPS PETROLEUM PHILUBE SHELL OIL CO. AEROSHELL FLUID 4 5-L TEXACO VANGUARD 460 ULTRACHEM. INC. CHEMLUBE 140* ISO OR A.G.M.A VISCOSITY GRADE ISO 15 ISO 46 AGMA 1 *Viscosity of these oils is actually less than the listed ISO or A.G.M.A. grade. ISO 320 AGMA 5 600W ISO 460 AGMA 7 SHC-634* SUPER CYLINDER ISO 680 AGMA 8 G6--67

3 LUBRICATION-RIGHT ANGLE (CONT.) RECOMMENDED LUBRICANTS It is impossible to select one gear lubricant of petroleum origin which is usable over a wider range of temperatures such as minus (-)65 F. to plus (+)165 F., as is required for some installations. When such conditions are encountered it is necessary to change the lubricant depending on the ambient (surrounding air) temperature at the time of operation. Use lubricants of the proper viscosity group as outlined in the previous table. Note 1. Lubricants shipped in the gearcase from the factory are viscosity group oils for standard ambient conditions and continuous duty. Note 2. If a USDA-HI food grade lubricant is desired, Chevron FM lubricating oil 460X may be used in ambient temperatures of +15 F to +110 F. Chevron FM lubricating oil is available as a factory fill, but if it becomes necessary to install this oil in the field by draining a gearcase which contains our standard non-food grade lubricant the gearcase must be flushed thoroughly before installing the new oil. Do not operate gear unit in ambient temperatures below -65 F. nor above +165 F. For temperatures below -10 F. special oil seals are required and bearings in the gearcase must be packed with Aeroshell 7 grease instead of Marfak No. 3. All group lubricants, except Mobil SHC-634 must be changed after 300 hours of high temperature operation. Mobil SHC-634 must he changed after 1500 hours of high temperature operation. When changing oil from one viscosity group to another, flush the gearcase with mineral spirits before installing the new oil. FOR INTERMITTENT DUTY IN A WIDE TEMPERATURE RANGE (Defined as not over 30% duty nor more than 30-minute operation continuously). AMBIENT TEMPERATURE VISCOSITY GROUP -65 F. TO +10 F F. TO +50 F F. TO +110 F F. TO +165 F LOW TEMPERATURE APPLICATIONS XL Right Angle Reducers and Gearmotors XL reducers and gearmotors operating in low ambient temperature applications ranging from +10 F down to --45 F, will require special considerations. The reducers require nitrile seals, hytrel coupling spiders, and low temp lubrication along with XT construction. The gearmotors require nitrile seals, low temp lubrication, XT construction and motors with low temp grease. G6--68

4 LUBRICANT CAPABILITIES The following table lists the typical lubricant supplied in the MASTER XL reducers and the approximate amount of lubricant supplied in the standard floor mounted reducers. FACTORY GEAR VOLUME VOLUME LUBE SIZE QUARTS GALLONS W12A RELIANCE W16A GEAR OIL 140 W21A AGMA 7 W28A ISO 460 W40A* H419* *UNITS USE MOBIL C12A SHC629 C16A AGMA 4 C21A ISO 150 C28A C40A* NOTE: MOUNTINGS OTHER THAN STANDARD FLOOR MOUNTED REDUCERS CAN REQUIRE AS MUCH AS TWO TO THREE TIMES THE AMOUNT OF LUBRICANT SHOWN FOR THE STANDARD ASSEMBLY. MAINTENANCE Periodic changing of lubricant is important for maximum reducer performance. Lubricant should be drained and refilled after the first 250 hours of operation; then every 1500 hours or six months thereafter, whichever occurs first.** Inadditiontolubricationandinstallation, regularinspection to ensure tightness of bolts and screws, correct alignment of shaft and couplings, no major oil leaks, no excessive heating and no unusual vibration or noises will guarantee maximum performance and life of your MASTER XL reducer. * For temperatures below + 10 F special oil seals are required. ** All group 63 lubes except Mobil SHC634 must be changed after 300 hrs. of high temperature operation. OVERHUNG LOAD To determine overhung load, divide the torque required by the pitch radius of the sprocket, sheave, etc. and multiply, by the appropriate factor as follows: Chain Drive V-Belt Synchronous Belt Drive 1.10 Flat Belt 2.50 Spur or Helical l Gear The calculated overhung load must not exceed the Output Shaft rating. For loads acting at more than one shaft diameter from bearing housing, use following conversion factors: Distance in Shaft Diameters From Brg. Hsg. Multiply OHL Capacity By This Factor 1D 1.0 2D.65 3D.45 4D.35 5D.30 REDUCER SERVICE FACTORS Prime Mover Electric Motor Electric Motor With Frequent Starts and Stops Multi-cylinder Internal Combustion Engine Single Cylinder Internal Combustion Engine Driven Machine Load Classification Duration of Service Medium Heavy Per Day Uniform Shock Shock G6--69

5 SERVICE FACTOR CLASSIFICATIONS Hrs. Per Day Hrs. Per Day Hrs. Per Day Application Application Application AGITATORS CONVEYOR HEAVY DUTY GENERATORS Pure Liquids I NOT UNIFORMLY FED (Cont d) (Not Welding) I II Liquids and Solids II Il Screw II II Liquids Variable Density II II Shaker III III HAMMER MILLS III III BLOWERS CRANES & HOISTS LAUNDRY WASHERS Centrifugal I II Main Hoists Reversing II II Lobe II II Heavy Duty III III Vane I II Medium Duty II II LAUNDRY TUMBLERS II II Reversing II II BREWING & DISTILLING Skip Hoists II II LINE SHAFTS Bottling Machinery I II Travel Motion II II Driving Processing Brew Kettles Continuous Trolley Motion II II Equipment II II Duty II Other Line Shafts I II Cookers Continuous Duty II Mash Tubs Continuous Duty II CRUSHERS LUMBER INDUSTRY Scale Hopper Ore III III Barkers Hydraulic Frequent Starts II II Stone III III Mechanical II II Burner Conveyor II II DREDGES Chain Saw and Drag Saw III III CAN FILLING MACHINES I II Cable Reels II Chain Transfer III III Conveyors II II Craneway Transfer III III CANE KNIVES II II Cutter Head Drives III Ill De.Barking Drum III III Jig Drives III III Edger Feed II II CAR DUMPERS III Maneuvering Winches II Gang Feed II II Pumps II II Green Chain II II CAR PULLERS II Screen Drive III III Line Rolls III III Stackers II II Log Deck III III CLARIFIERS I II Utility Winches II Log.Haul lncline III III Log-Haul Well Type III III CLASSIFIERS II II ELEVATORS Log Turning Device III III Bucket Uniform Load I II Main Log Conveyor III III CLAY WORKING MACHINERY Bucket Heavy Load II II Off Bearing Rolls II II Brick Press III III Bucket Continuous I II Planer Feed Chains II II Briquette Machine III III Centrifugal Discharge I II Planer Floor Chains II II Clay Working Machinery II II Escalators I I Planer Tilting Hoist II II Pug Mill II II Freight II II Re-Saw Merry-Go-Round Gravity Discharge I II Conveyor II II COMPRESSORS Man Lifts Roll Cases III III Centrifugal I II Passenger Slab Conveyor III III Lobe II II Service Hand Lift III Small Waste Conveyor * Reciprocating belt I II Multi.Cylinder II II FANS Small Waste Conveyor Single Cylinder III III Centrifugal I II chain II II Cooling Towers Sorting Table II II CONVEYORS UNIFORMLY Induced Draft II II Tipple Hoist Conveyor II II LOAD OR FED Forced Draft Tipple Hoist Drive II II Apron I II Induced Draft II II Transfer Conveyor II II Assembly I II *Large (Mine. etc.) II II Transfer Rolls II II Belt I II Large Industrial I II Tray Drive II II Bucket I II Light (Small Diameter) I II Trimmer Feed II II Chain I II Waste Conveyor II II Flight I II FEEDERS Oven I II Apron II II MACHINE TOOLS Screw I II Belt II II Bending Roll II Disc I II Notching Press Belt Driven I II CONVEYOR HEAVY DUTY Reciprocating III III Plate Planer III III NOT UNIFORMLY FED Screw II II Punch Press Gear Driven III III Apron II II Tapping Machines III Assembly II II FOOD INDUSTRY Other Machine Tools III Belt II II Beet Slicer II II Main Drives II II Bucket II II Cereal Cooker I II Auxiliary Drives I II Chain II II Dough Mixer II II Flight II II Meat Grinders II II Live Roll Oven II II Reciprocating III III (1) This list is not all-inclusive and each individual gearmotor application should be checked to determine if any unusual operation conditions will be encountered * Classes listed are minimum and normal conditions are assumed in view of varying load conditions. It is suggested that these applications be carefully reviewed before final selection is made. Check safety codes and consult Application Engineering. G6--70

6 SERVICE FACTOR CLASSIFICATIONS Hrs. Per Day Hrs. Per Day Hrs. Per Day Application Application Application METAL MILLS PAPER MILLS Cont d. SEWAGE DISPOSAL Draw-Bench-Carriage III III Cutters Ptaters III EQUIPMENT Cont d. Draw-Bench-Main Drive II III Cylinders II Collectors Circuline or Forming Machines III III *Dryers II Straighfline I II Pinch Dryer & Scrubber Felt Stretcher II Dewatering Screens II II Rolls Reversing Fell Whipper III Grit Collectors I II *Slitters II II Jordans III Scum Breakers II II Table Conveyors Log Haul III Slow or Rapid Mixers II II Non-Reversing II II *Presses II Sludge Collectors I II *Reversing Pulp Machines II Thickeners II II Wire Drawing & Reel II Vacuum Filters II II Flattening Machine II II *Stock Chests II Wire Winding Machine II *Suction Roll II SCREENS Washers and Thickeners II Air Washing I II MILLS ROTARY TYPE Winders II Rotary Stone or Gravel II II *Ball II II Traveling Water Intake I II *Cement Kilns II PRINTING PRESSES I II Dryers & Coolers II II SLAB PUSHERS II II Kilns II II PULLERS *Pebble II II Barge Haul II III STEERING GEAR II II Rod III III Tumbling Barrels III III PUMPS STOKERS I II Centrifugal I II MIXERS *Proportioning II II TEXTILE INDUSTRY Concrete Continuous II II Reciprocating Batchers II II Concrete Intermittent I II Single Acting Calenders II II Constant Density I II 3 or more Cylinders II II *Card Machines II II Variable Density II II Double Acting Cloth Finishing Machines 2 or more Cylinders II II (washers pads enters OIL INDUSTRY Single Acting dryers calenders. etc. ) II II Chillers II II or 2 Cylinders Dry Cans II II Oil Well Pumping *Double Acting Dyeing Machinery II II Paraffin Filter Press II II Single Cylinder Knitting Machines Rotary Kilns II II Rotary Gear Type I II (Looms. etc.) Lobe Vane I Il Looms II II PAPER MILLS Mangles Il II Agitators (Mixes) Il II RUBBER INDUSTRY Nappers Il II Barker Auxiliaries Hydraulic III Mixer III III Range Drives Barker Mechanical III *Rubber Calender II II Soapers II II Barking Drum II II *Rubber Mill (2 or more) II II Spinners Il II *Beater & Pulpers II *Sheeter II II Tenter Frames Il II Bleacher I II Tire Building Machines II II Winders (other than *Calenders II Tire & Tube Press Openers I I Batchers) II II Calenders Super III Tubers and Strainers II II Yard Preparatory Machines Converting Machines Excec. (Cards Spinners Cutters, Platers II SEWAGE DISPOSAL Slashers. etc.) II II Conveyors II EQUIPMENT *Coach II Bar Screens II WINDLASS Il II Chemical Feeders I II (1) This list is not all-inclusive and each individual gearmotor application should be checked to determine if any unusual operation conditions will be encountered * Classes listed are minimum and normal conditions are assumed in view of varying load conditions. It is suggested that these applications be carefully reviewed before final selection is made. Check safety codes and consult Application Engineering. G6--71

7 SHIPPING WEIGHTS RIGHT ANGLE GEARMOTORS HP 1 / 56WG12A / 56WG12A / WG16A / 145WG16A WG21A WG21A WG28A / 213WG28A CG12A CG16A CG16A CG21A CG21A CG28A CG28A WG21A 78 56WG21A WG21A WG21A WG28A WG28A CG40A WG40A WG21A CG21A CG21A CG28A CG28A CG40A CG21A CG28A CG28A CG28A CG28A CG40A 755 WEIGHT ADDITIONS TO BE ADDED TO ABOVE LISTINGS CG28A CG28A CG28A CG40A CG40A CG28A 330 GEARCASE W12 W16 W21 W28 WG40 CG12 CG16 CG21 CG2B CG40 Multi-Mount J Mount FIange BRAKES BRAKE 3,6 ft./ib. 10 ft./ib. 15 ft./ib. WEIGHT G6--72