ＧＥＡＲ ＢＯＸ

ＩＮＳＴＲＵＣＴＩＯＮ ＭＡＮＵＡＬ

Messrs. SM Cyclo de Chile Ltda.

GEAR BOX

Orden Interna Sumitomo CHD1A064

Orden Interna Weir Minerals 189316

技 術 部

2012.09.13
ENGINEERING DEP

WORK No. １２−ＮＡＥＡ０１

Date: Sep. 2012

TOTAL PAGE 9
 技 術 部

2012.06.01
ENGINEERING DEP
Ⅰ．ＭＥＳＳＲＳ SM Cyclo de Chile Ltda.

Ⅱ．ＮＯ. ＯＦ ＯＲＤＥＲ --

Ⅲ．ＭＡＮＵＦＡＣＴＵＲＥＲ ｓ
12-NAEA01
ＳＥＲＩＡＬ ＮＵＭＢＥＲ

Ⅳ．ＤＡＴＥ ＯＦ ＭＡＮＵＦＡＣＴＵＲＥ Sep. 2012

Ⅴ．ＳＰＥＣＩＦＩＣＡＴＩＯＮ

１） ＴＹＰＥ DHB115

２） ＩＮＰＵＴ ＰＯＷＥＲ 2700 HP

３） ＩＮＰＵＴ ＳＨＡＦＴ ＳＰＥＥＤ 1500 r／min

４） ＯＵＴＰＵＴ ＳＨＡＦＴ ＳＰＥＥＤ 261 r／min

５） ＧＥＡＲ ＲＡＴＩＯ 1 ／ 5.747

６） ＴＯＲＱＵＥ ＯＦ
--
ＯＵＴＰＵＴ ＳＨＡＦＴ

７） ＵＳＥ ＣＯＮＤＩＴＩＯＮＳ --

８） ＬＵＢＲＩＣＡＴＩＯＮ ＭＥＴＨＯＤ FORCED LUBRICATION

９） ＬＵＢＲＩＣＡＴＩＯＮ ＯＩＬ JIS K2219 GEAR OIL Gr.2 , ISO VG 220

１０） ＬＵＢＲＩＣＡＴＩＯＮ ＧＲＥＡＳＥ --

１１） ＬＵＢＲＩＣＡＴＩＯＮ ＯＩＬ Q'TY APPROX. 430 L

１２） ＯＩＬ ＳＥＡＬ

ＩＮＰＵＴ ＳＨＡＦＴ TB-17020016 x 1

ＯＵＴＰＵＴ ＳＨＡＦＴ
TB-27033025 x 1
１３） ＢＥＡＲＩＮＧ
22330 C3 x 1 , 22326 C3 x 1
ＩＮＰＵＴ ＳＨＡＦＴ

ＩＮＴＥＲＭＥＤＩＡＴＥ ＳＨＡＦＴ 22344 x 1 , 23240 x 1 , 29428 x 2

ＯＵＴＰＵＴ ＳＨＡＦＴ 23052 x 1 , 32336DF+KR x 1

１４） ＭＡＳＳ APPROX. 8900 kg ( LUBRICATION UNIT: 500 kg )

SHELL VSI CIRCULATING OIL 32

１５） ＲＵＳＴ ＰＲＥＶＥＮＴＩＶＥ ＯＩＬ
APPROX. 15 L

１６） ＯＴＨＥＲＳ --

−1−
1. Method of Use.

The method of use and maintenance of this machine is easy and

simple. If however, the method of use of this machine should be
erroneous, there would be a danger of damaging the machine within a
short period of time. Accordingly, if is strongly recommended to pay
special attention to the following matters in order to attain perfect
maintenance of the machine.

1-1 Installation and coupling.

This speed reduction gear is assembled in such a way that it may

have the best possible tooth contact and lubricating condition as it
is installed in the standard position. The foundation on
which the machine is to be installed should be properly strengthened
to eliminate the loosening and vibrations of the machine during its
operation. When installing the machine, distortions may sometimes
occur due to its own weight of this machine in accordance with the
condition of the foundation. Consequently, the foundation bolts should
be fastened, when correcting the leveling of the machine by using liners
and wedges, and then, the leveling of the machine is confirmed after
its fastening.
For centering of coupling, measure the deviation on the outside
diameter of datum face for centering as well as the deviation on the end
face using dial gauge, and ensure that the tolerances of both the
deviation of face and of axis are within 5/100 mm.

1-2 Operation

On finishing installation, grease upping must be performed by feeding

Grease at necessary points. If circumstance permits it is desirous to perform
test run of prime mover being disconnected from mating machine. Upon
ascertaining that there is no anomaly, connect the prime mover to the
machine.

1) First conduct no-load operation of reduction gear alone.

the no-load operation should be continued for more than three
hours. The more the time for test run is spent, the more the
operation later will become smooth and durability of machine will
be increased. The test run should be performed to make certain
that the operation can be had without being attended with anomalous
power consumption, noise of gear bearing temperature.
2) Next connect the reduction gear with machine to enter upon
operation which should be performed in stages. At this phase,
pay attention that load must be applied little by little. Under
any circumstance avoid applying full load from the beginning.

-2-
 3) Checks to be made during or after operation should be made on the
following points.
① Whether or not the bearing is overheated.
② Whether or not anomalous sound is being emanating.
③ Whether or not the extent of vibration is great.
④ Whether or not the set bolts and foundation bolts and loose.
⑤ Whether or not the oil level is proper.
After checking aforementioned items, full load operation may be
Entered upon.

4) Operation of oil pump

Start the pump motor three to five minutes before starting operation of the
drive motor for the speed reducer.

2. Check and Maintenance

2-1 Standard for Check

1) General
During operation, always attend to sound, heating, oil leakage, and
vibration. Even while the machine is working trouble –free, regular
check should preferable be performed once a year. In performing
regular, check wash the machine with clean oil without dismantling
gears and bearings, so far as dismantling is not particularly
necessary, and check for any anomalous wear or flaws.

2) Reduction gear body

(1) Gear wheel

Machine Checking Checking Checking Checking
Checked Item points Time Frequency
Anomalous noise Contact part of During operation Ordinary
gear wheel and
Surrounding case
Gear
Oil feeding Oil gauge During operation Ordinary
wheel
condition and suspension
Tooth contact Tooth face During Every 6
and Wear suspension Months

(2) Bearing
Checking Checking Checking Checking
Item Point Time Frequency
Bearing Temperature, Pedestal, During Daily
Anomalous noise Surrounding case operation

-3-
 a. Bearing temperature should be less than 80℃
Should the bearing temperature becomes above 90℃, lubricating
oil tend to deteriorate due to oxidation at high temperature
and causes break of oil film in consequence of which seizure
may result, and hence the temperature should always be checked.
b. When change of temperature is intense it is an indication of
some anomaly. When temperature exceeds 80°, stop operation
and check lubrication, and also check whether there is foreign
matters caught in the machine.

(3) Oil seal

Checking Checking Checking Checking
Item Point Time Frequency
Oil seal Oil leakage Sealing part During Daily
operation

When oil leaks from oil seal part following causes are
Considered, that is, life of oil seal is expired, damage to
lip due to bad fitting or insertion, damage to shaft sliding
face.

3) Maintenance during suspension of operation

In case where machine is cut off from service for long period of
time, cautions must be exercised to prevent ingress of dust and
generation of rust.
a. More than once monthly, perform operation of machine for about
One hour.
b. More than once monthly, check the gear wheel and bearing part,
etc. for generation of corrosion through inspection holes of
each case and from side cover.

4) Lubricating oil

Checking Checking Checking Checking

Item Points Time Frequency
Extent of Oil During suspension As
Lubricating Deterioration undermentioned
oil and purity
Checking of Oil gauge During operation Ordinary
oil level and suspension

Perform sampling of lubricant from time to time to have it inspected for its
property. Inspection are done by oil maker, so, forward sample of about 1 liter to
the maker and receive inspection report and prescription.
Since oil containing solid, water content or bubbles as well oil of acidity is
harmful to machine, oil should be always kept clean. After the passage of 500
hours after the commencement of the operation of the machine installed, it is
advisable to replace the oil with the fresh one without fail. Inspection of oil by

-4-
 user should be conducted once per 2,500 hrs running as a rule, or in case where
working hour is short perform inspection once in 6 months period. Besides, all
problems relating to oil should be handled in accordance with maker’s direction.
Caution: Same brand of lubricating oil should be used in continuation.
When it has to be changed with other brand by some reason replacement of
lubricant should be made after completely extracting old oil.
Under no circumstance should mixture of more than two brands be used.

3. Disassembly and Assembly

Perform disassembly and reassembly by referring to the annexed

drawings.

3-1 Disassembly

1) When disassembly is conducted, get to work after have a proper

understanding of each construction.

2) Parts disassembled should be marked with mating marks for the

convenience of reassembly.

3) Parts disassembled should not be stained, and their finished faces

should be protected from getting flaws. For this purpose they
should not be placed directly on the ground or concrete. Small
parts should preferably kept in box so that they may not miss.

4) Parts disassembled should be cleaned enough, and should be coated

not collect on them during assembly work.

5) Avoid directly hitching wires on machining part, but apply clothes

to hitching wire.

Disassembly order：
① Remove couplings on prime mover side and on driven machine side.
② Remove exterior and interior pipes which hinder the work.
③ Remove bolts on the case fitting surface.
④ Draw out respective bearing and gear wheel.
(Do not take off gear wheel or bearing from shaft unless it is necessary.)

3-2 Reassembly

Prior to starting assembly, inside of casing, gears, shaft, bearings

and all other parts should be well washed with cleaning oil.
When bearing is re-used, retainer and other parts should be checked
if they are free from bruise.
Assembly is accomplished by taking reverse order of steps to the
disassembly. Parts locked should be locked again. If locking parts
are found defective replace them.
Fitting faces of both case and side cover should be coated with

-5-
 liquid packing (three bond) to prevent oil leakage.
End cover should be fitted with oil seal and seal retainer in
advance. (Note： Ensure that oil seal edge and contact surface
with the edge is free from damage. Even small flaw may cause oil leakage.)
Then coat liquid packing on the end cover and fit it.
Lastly mount air breather, oil gauge and drain plug, etc.
With these mounted re-assembly is completed.

4. Long term storage point of the unit

Follow the following points, when being kept after shipment without
operating one month or more.

1) Keep it in a general factory indoor or a general warehouse without the influences

of a rainstorm, humidity, dirt, an intense temperature change, sulfurous acid gas,
etc.
2) Check an internal antirust state, spray & pour in "SHELL VSI CIRCULATING
OIL 32" (gaseous phase rust preventive oil) by SHOWA SHELL SEKIYU, and
seal after that. Avoid the mixed use with other rust preventive oil. Then, the
above should work for every half a year.
3) Operate after draining rust preventive oil and changing to recommendation
lubricating oil, when starting operation. Don't operate by rust preventive oil.
4) Equivalent of the NP-1 by JIS K 2246 is applied to shaft part at the time of
shipment. If an antirust state is checked by viewing and there is a problem,
apply an equivalent of the NP-1 by JIS K 2246.
5) The amount of oil supply of "shell VSI circulating oil 32" refer to the amount of
rust preventive oil. (1-page principal items table)

-6-
5. SAFETY AND OTHER PRECAUTIONS
• The gear unit should be handled, installed and maintained by trained technicians.
• Carefully read manual and all accompanying documents before use(installation, operation,
maintenance, inspection, etc.)
Thoroughly understand the machine, information abut safety, and all precautions for correct
operation. Maintain this manual for future reference.
• Pay particular attention to the “DANGER” and “CAUTION” warnings regarding safety and proper use.
：Improper handling may result in damage, serious personal injury and/or
! DANGER death.

：Improper handling may result in damage and/or personal injury.

! CAUTION
Matters described in ! CAUTION may lead to serious danger depending on the situation.
Be to observe important matters herein.

! DANGER
General
z Transport, installation, plumbing, operation, maintenance, and inspections should be handled
by properly trained technicians; otherwise, injury or the machine may result.
z When the unit is to be used in a system for transport of human beings, a secondary safety device
should be installed to minimize chances of accidents resulting in injury, death, or damage to
the system.
z When the unit is to be used for an elevator, install a safety device on the elevator side to
prevent it from falling, otherwise, serious injury, death, or the elevator may result.
Installation
z Never stand directly under a unit suspended by a crane or other lifting mechanism; otherwise
personal injury or death may result.

Operation
z Never approach or touch any rotating parts(shaft, etc.)during operation, loose clothing caught
in these rotating parts may result in severe injury and/or death.

Daily inspection and maintenance

z Never approach or touch any rotating parts(shaft, etc.)when maintaining or inspecting the
reducer during operation.
Loose clothing coaught in these rotating parts may result severe injury and/or death.
z Be sure to stop both the driving and driven machines before checking any tooth surfaces,
otherwise, you may be caught in the gear engaging section. resulting in severe injury and/or
death.
z Do not operate any units without all(safety)covers in place. Failure to do so may cause injury
and/or death.

《Note》
z A copy this manual should be sent to the actual user of the gear unit.
z This manual should be maintained by the user.

-7-
 ! CAUTION
General
z The unit should be operated only within its design and performance specifications; otherwise, injury or damage
to a system may occur.
z Keep hands and foreign objects from the internal moving parts of the unit ; otherwise, injury or damage to a
system may occur.
z Damaged units should be taken off-line and not put back in operation until properly repaired.
z Any modifications or alterations of any kind, to the unit, will void the warranty and all subsequent claims.
z Do not remove the rating plate.
Inspection upon delivery
z unpack the after verifying that it is positioned right side up ; otherwise, injury may result.
z Verify that the unit received is in fact the one ordered. When a different product is installed, injury or damage
to the system may result.
Transport
z Exercise ample care not to drop the unit during transport. When a hanging bolt or hole is provided, be sure
to use it. after mounting the unit on a system, however, do not hoist the entire system using the hanging bolt
or hole. Before hoisting, check the weight with the rating plate, crate, outline drawing, catalog, etc. Never
hoist the unit that exceeds the rating of the crane or other mechanism being used to lift it ; otherwise, injury
or damage to the unit and/or lifting device may occur.
Installation
z Do not place objects that will hinder ventilation around the unit ; otherwise, cooling effect is reduced, and
may lead to a possible fire hazard due to excessive heat build-up.
z Do not step on or hang from the unit ; otherwise, injury may result.
z Do not touch the key way at the shaft end or on the inside of the unit ; injury may result.
z When the unit is used in food processing applications vulnerable to oil contamination, install an oil pan or
other such device to cope with oil leakage due to failure or limited service life. Otherwise, oil leakage may
damage products.
Coupling with other machines
z When coupling unit with a load, confirm that the alignment error is within the specified limits shown in the
maintenance manual, drawings, catalog, etc.;otherwise, damage to the system may result, due to misalignment.
z Correctly tighten respective bolts to the specified torque shown in the drawing, catalog, etc. ; otherwise ;
scattering fragments may damage the system.
z When a belt is used for coupling the unit with another machine, check that the belt tension and the parallelism
of the pulley are within the specified limits. When the unit is directly coupled with another machine, check
that the direct coupling accuracy is within the specified limits ; otherwise, the system may be damaged, due
to misalignment.
z Install appropriate guard devices around rotating parts ; otherwise, injury may result.
z Remove the key temporarily attached to the output shaft of the unit when the shaft is free-rotating (i.e. not
loaded) ;otherwise, injury may result.
z Confirm the direction of rotation before coupling the unit with its driven machine. Difference in the direction
of rotation may cause injury or damage to the system.
Operation
z The reducer will get very hot during operation. Do not touch or come in contact in any way with the reducer ;
otherwise, you may suffer bums.
z If the reducer is operating in an abnormal way, stop the unit immediately ; otherwise, injury may result.
z Do not operate the reducer in a manner the exceeds its rating criteria ; otherwise, injury or damage to the
system may result.
z Do not remove any covers or open the reducer during operation;otherwise, splashing lubricant may cause burns.
z Do not loosen the oil filler plug during operation ; otherwise, splashing lubricant may cause bums.
z For a system in which a lubricant motor pump is provided separately, switch on the pump motor prior to switching
on the reducer motor. This will enable praper lubrication of the bearings prior to start-up. Failure to do so
may damage the unit.
z When reversing the direction of rotation, first bring the unit to a complete stop, then commence reverse rotation ;
otherwise, the system may be damaged.
z Identify and provide appropriate corective action in a timely fashion for any abnormal operation characteristics
according as the maintenance manual. Do not operate the unit until corrective action has been taken.
Daily inspection and maintenance
z Change lubricant according to the maintenance manual, and use only those recommended lubricants ; otherwise,
the system may be damaged.
z Do not change the oil during operation or soon after operation has ceased ; otherwise, the hot oil may cause
burns.
Disassembly and reassembly
z Repair, disassembly, and reassembly should be handled by properly trained technicians ; the system may be damaged.
Disposal
z Dispose the reducer and lubricant as general industrial waste.

-8-
 技 術 部

2012.05.21
ENGINEERING DEP
 技 術 部

2012.06.25
ENGINEERING DEP
 技 術 部

2012.06.25
ENGINEERING DEP
 技 術 部

2012.06.25
ENGINEERING DEP
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 Lovejoy / Sier-Bath
“FSL” Slide Type Coupling

Size FSL 2 thru FSL 7

Introduction
galling lubricant. Insure that seals and pipe plugs are in
place in the gear sleeve. Lubricate around sleeve gear
Carefully follow the instructions in this manual for teeth and seal surface and place over respective shaft
optimum performance and trouble free service. before mounting hubs. Protect shaft on which sleeve
will rest during hub installation.
This manual applies to standard “FSL” Slide type
couplings. The “FSL” Slide type couplings are 2) Determine the mounting arrangement of the proper
recommended for horizontal applications only. For mating hubs as illustrated in figure 1. Heat hubs in
vertical applications please consult with Lovejoy either an oil bath or oven until bores are larger than
application Engineering. shaft diameter. Mount so that the end of each hub is
The “FSL” Slide type coupling is used for applications flush with the end of the shaft as illustrated in figure 1.
Allow hubs to cool before proceeding.
requiring axial movement between the shaft ends
greater than standard. This function must be WARNING: If an oil bath is used, the oil must have a
performed under NO LOAD, STATIC conditions. flash point of 350°F or higher. Do not rest hubs on
the bottom of the container. Do not use an open
Installation & Alignment Instructions flame in a combustible atmosphere or near
combustible materials.
All parts must be clean and free of any foreign
materials before attempting assembly, use a non-
flammable solvent. All Parts should be examined for
3) Although the shafts may be perfectly aligned at
installation they should be realigned after mounting of
any damage during shipping and handling.
coupling. Position equipment in the approximate
Measurements should be taken to verify correctness of
alignment with the approximate “G” dimension found on
parts to meet application requirements, such as, hub
Chart 1. Align coupling using the instrument method as
and shaft fits, shaft separation, etc. Check hubs, shafts
described below.
and keyways for burrs.
4) Angular Alignment – Using an inside micrometer,
1) Install keys in respective shafts. Keys should fit
take readings at four points 90°° apart. Adjust
shaft keyseat with a tight fit on the sides and slight
machines until all four readings are identical. The
clearance over the key. Coat the shafts with an anti-
difference in maximum and minimum measurements
Caution: Consult applicable local and national safety codes must not exceed the installation angular limits
for proper guarding of rotating coupling. Observe all specified in chart 1.
safety rules when installing or servicing coupling.
5) Parallel Offset Alignment – The dial indicator
Warning: Lockout starting switch of prime mover and method is recommended for this procedure. Attach the
remove all external loads form drive before installing or dial indicator base to one hub and set the dial indicator
servicing coupling.
needle in contact with the outside diameter of opposite
hub. Rotate hub on which the indicator is mounted
TABLE OF CONTENTS 360°, taking indicator readings at four points 90°°
apart. Adjust machines until all four readings are
1 Introduction identical. The difference in maximum and minimum
1 Installation & Alignment Instructions
measurements must not exceed the installation-offset
limits specified in chart 1. Relocate the indicator dial
2 Maintenance base to the opposite hub and repeat the procedure.
Tighten all foundation bolts and repeat step 4 and 5.
2 Part Identification

Lovejoy / Sier-Bath 1 Slide Type FSL Coupling instructions

Realign coupling if necessary. Any parts showing signs of wear or damage should be
replaced. These parts are available for purchase by
Warning: Before installing couplings, make certain
that foundations of equipment to be connected meet referencing the coupling UPC number, size, type and
manufacturer’s requirement. Check for “soft foot”. bolting style. Hub and sleeve should be replaced as
The use of stainless steel shims is recommended. half coupling whenever possible.

6) Coat hub teeth and body as well as inside of sleeve Check alignment per steps 4 and 5. If maximum
with coupling grease. Slide the sleeve onto its operating misalignment values are exceeded, realign
respective hub, making sure that the gear teeth mesh the coupling to the recommended installation values
properly. Apply light dots of oil to one side of the found in chart 1.
gasket. Install gasket between the sleeve flanges,
align the boltholes and press the side with oil against
flange. Place Plate into counter bore of sleeve. Move Lubrication
sleeves together, with lube plugs 90° apart. Install Adequate lubrication is essential for satisfactory
bolts and locknuts, tightening alternately and evenly to
operation. Lovejoy Coupling Grease is specially
recommended torque in chart 1. Remove the two lube
formulated for coupling applications to increase
plugs in each sleeve and fill coupling with the coupling life while drastically reducing maintenance
recommended amount of coupling grease indicated in
cycle time. And it'’ in complete compliance with AGMA
Chart 1. Replace lube plugs and tighten securely.
9001 lubrication recommendations.

Unlike bearing or general-purpose grease, coupling

grease must withstand the centrifugal forces generated
Maintenance by a spinning coupling. Lovejoy Coupling Grease is
Following an initial break-in period of about 3 million designed to resist centrifugal separation, which allows
revolutions (80 hr. @ 600 rpm) it is recommended that the lubricant to be used for relatively long periods of
the coupling be completely flushed and re-lubricated. time.
Thereafter, a regular relubrication schedule should be
Other benefits of this product includes; highest
maintained. If coupling leaks grease, is exposed to
pressure and wear protection available, built-in rust
extreme temperatures, excessive moisture or frequent
and corrosion inhibitors, increased coupling life,
reversals, frequent lubrication may be required. For
reduced maintenance costs, reduced downtime and
average industrial operating conditions, relubrication
superior lubrication.
every 12 months should suffice with periodic visual
inspections to insure that neither the quality nor the One of the secrets to the success of Lovejoy Coupling
supply (due to leakage) of the lubricate has Grease is the variable consistency throughout the
deteriorated to an unacceptable level. working cycle of the application. The consistency of
our grease changes with the operating conditions.
During relubrication cycle or at least yearly, whichever
Working of the lubricant under actual service
comes first, the coupling should be disassembled and
conditions causes the grease to become semi-fluid,
thoroughly cleaned of all grease. Remove and visually
functionally splash lubricating the wear surfaces of the
inspect all parts; gear teeth for signs of abnormal
coupling. As the grease cools, it returns to the original
stress and wear, the seals and gaskets for any cracks
consistency, thereby preventing leakage.
or breaks.

Lovejoy / Sier-Bath 2 Slide Type FSL Coupling instructions

 FIGURE 1

CHART 1
Size F2 F2.5 F3 F3.5 F4 F4.5 F5 F5.5 F6 F7
"G" hub Separation 0.125 0.19 0.19 0.25 0.25 0.312 0.312 0.312 0.312 0.375
"AP" MAX Separation 0.78 0.94 1.03 1.06 1.31 1.69 1.97 2.06 1.47 1.91
Installation Offset MAX 0.002 0.003 0.003 0.004 0.005 0.005 0.006 0.007 0.008 0.008
Limits Angular MAX 0.009 0.011 0.013 0.015 0.018 0.02 0.022 0.024 0.026 0.031
Operating Offset MAX 0.009 0.012 0.014 0.017 0.02 0.02 0.026 0.027 0.032 0.033
Limits Angular MAX 0.036 0.045 0.052 0.061 0.072 0.081 0.087 0.096 0.105 0.122
Max Speed 5000 4400 4000 3500 3000 2700 2500 2200 2100 2000
Lube capacity Weight 5.8 oz 10.5 oz 1 lb 1.25 lb 2 lb 3.5 lb 4.5 lb 6.5 lb 7.25 lb 9.25 lb
Volume 3/8 pt 3/4 pt 1-1/8 pt 1-1/2 pt 1-7/8 pt 2 qt 2.5 qt 3.5 qt 1 gal 1-1/4 gal
Tightening Torque 940 1750 1750 2650 2650 2650 3650 3650 3650 4850
in-lb.

Lovejoy / Sier-Bath 3 Slide Type FSL Coupling instructions

 Lovejoy Grid Coupling
Grid Coupling Installation Instructions
Pre-Assembly Inspection
Hubs, covers and grids come in a variety of sizes and types. First,
determine the size and type of components being used. Remove all
components from their boxes and packaging. Check maximum RPM
values in Table 2 against operating speed.

Inspect all coupling components and remove any protective coatings or

lubricants from bores, mating surfaces and fasteners. Clean all parts using
a non-flammable solvent. Make sure that shaft, hubs and keyways are
clean and smooth.

Assembly Instructions HORIZONTAL VERTICAL

1. Lightly smear seals with grease. When using vertical covers place
a greased seal on each of the covers and install covers and the
gasket on shafts before mounting hubs. When using horizontal
covers, lightly smear seals with grease and place seals on shafts
before mounting hubs (and covers, if necessary) on the shafts.
2. When installing coupling hubs onto each shaft, use keys where
required. Keys should fit snugly. Seal the keyways to prevent
grease leakage.
3. Coupling hub sizes 1020 - 1090 are clearance fit with the shaft
and are supplied with set screws. Do not heat the clearance fit
hubs. Position the hubs on the shafts to approximately achieve
HORIZONTAL VERTICAL
the "G” dimension shown in Table 2. It is usually best to have an
equal length of shaft extending into each hub. Tighten the set
screws.
Coupling hub sizes 1100 and larger are an interference fit with
the shaft and are not supplied with set screws. It is necessary to
heat hubs, using a torch, oven, induction heater or an oil bath, to a
maximum temperature of 275° F. To avoid overheating the hubs,
direct flame towards the bore using a constant motion. If an oil
bath is used it must have flash point of at least 350° F. DO NOT
rest hubs on the bottom of container or apply heat directly to the
teeth. HORIZONTAL VERTICAL
Heat hubs as specified above. Mount hubs immediately with the
hub teeth flush with the shaft end unless otherwise specified.
Allow the hubs to cool before proceeding to the next step.
4. Set gap using a spacer bar equal in thickness to the nominal gap
specified in Table 2. With the spacer bar inserted to the same
depth, measure clearance between the bar and hub face at 90°
intervals using feelers. Determine the maximum and minimum
dimensions without rotating the coupling, the difference of these
two measurements must be less that the Angular value in Table 2.
5. Check the parallel alignment by placing a straight edge across the
two coupling hubs, and measuring the maximum offset at various HORIZONTAL VERTICAL
points around the periphery of the coupling without rotating the
coupling. If the maximum offset exceed the Parallel value in Table
2, realign the shafts.
6. Tighten all foundation bolts using the tightening torque values
specified in Table 1. Repeat steps 5 and 6 and if necessary
re-align the coupling.
7. Before inserting the grid segments, thoroughly pack the grooves
with specified lubricant. When grids are supplied in two or more
segments assemble so that the cut ends of a segment joint extend
in the same direction. Spread the grid slightly so that it will pass
over the coupling teeth, and tap all the rungs into the respective HORIZONTAL VERTICAL
slots with a soft mallet.
 Lovejoy Grid Coupling
Grid Coupling Installation Instructions
Assembly Instructions - Continued Tightening Torque for Set Screws Table 1
8. Pack the spaces around the grid with lubricant and wipe off the For Inch Screws For Metric Screws
excess, flush with the top of grid. When using vertical covers slide Set Screw Tightening Set Screw Tightening
the covers over the hubs to match with each other, positioning the Coupling Size Length Torque Size Length Torque
gasket between the two cover halves. Install the fasteners through Size Inch in-lbs Nm mm in-lbs Nm
the cover halves and torque to the specifications in Table 3.
1020 8-32 3
⁄16 13.5-15 1.5-1.7 M5 5 24-26 2.8-3
When using horizontal covers position seals on hubs so that they line 1030 8-32 3
⁄16 13.5-15 1.5-1.7 M5 5 24-26 2.8-3
up with grooves in cover. Position gaskets on lower cover half and 1040 10-24 1
⁄4 32-36 3.6-4 M6 6 42-44 4.75-5
assemble covers so that match marks are on the same side. If using 1050 10-24 1
⁄4 32-36 3.6-4 M6 6 42-44 4.75-5
the coupling in any position other than horizontal, assemble cover 1060 10-24 1
⁄4 32-36 3.6-4 M6 6 42-44 4.75-5
halves with the lug and match mark up, or on the high side. Tighten 1070 1
⁄4-20 5
⁄16 78-87 9-10 M8 8 84-88 9.5-10
the fasteners to the torque specified in Table 3. 1080 1
⁄4-20 5
⁄16 78-87 9-10 M8 8 84-88 9.5-90
1090 5
⁄16-18 3
⁄8 150-165 17-18 M10 10 165-176 19-20
Make certain all plugs are inserted and secured before operating the
equipment.
Misalignment and End Float Table 2
Max. Total
Note: Install coupling guards per OSHA and ASME 815.1 requirements.
Coupling Vertical Horiz. G Misalignment End Grease
Size Speed Speed Dim. Parallel Angular Float Weight
RPM RPM ± 10% Inch Inch Inch oz. kg
Annual Maintenance 1020 6000 4500 0.13 0.012 0.010 0.210 1.00 0.03
1030 6000 4500 0.13 0.012 0.012 0.198 1.40 0.04
1040 6000 4500 0.13 0.012 0.013 0.211 1.90 0.05
1. To prevent the possibility of unexpected motion, ensure that the
1050 6000 4500 0.13 0.016 0.016 0.212 2.40 0.07
power source is isolated before attempting to service the system 1060 6000 4350 0.13 0.016 0.018 0.258 3.00 0.09
components. 1070 6000 4125 0.13 0.016 0.020 0.259 4.00 0.11
1080 5500 3600 0.13 0.016 0.024 0.288 6.10 0.17
2. Adequate lubrication is essential to prolong the life of the coupling 1090 4750 3600 0.13 0.016 0.028 0.286 9.00 . 0.25
and obtain trouble free service. It is recommended that the couplings 1100 4000 2440 0.19 0.020 0.033 0.429 15.00 0.43
be relubed annually when using the common industrial lubricants 1110 3250 2250 0.19 0.020 0.036 0.429 17.60 0.51
shown in our catalog. If using Lovejoy Coupling Grease, lube 1120 3000 2025 0.25 0.022 0.040 0.556 25.60 0.74
intervals can be extended. However, a coupling exposed to extreme 1130 2700 1800 0.25 0.022 0.047 0.551 30.00 0.9
temperatures, excessive moisture, frequent reversals or grease 1140 2400 1650 0.25 0.022 0.053 0.571 40.00 1.14
leakage may require more frequent lubrication.

Remove covers and check lubricant condition, alignment and general Tightening Torque For Cover Fasteners Table 3
condition of grid members and teeth every year. Couplings used in Horizontal Cover Fastener Vertical Cover Fastener
high ambient temperatures (greater than 158º F), at high speeds Coupling Tightening Tightening
and/or frequent reversing applications may require more frequent Size Size Torque Values Size Torque Values
inspection and relubing. Inch Metric in-lb Nm Inch Metric in-lb Nm
1020 1
⁄4-20 M6 100 11 1
⁄4-20 M6 71 8
3. If lubricant is required, remove both lube plugs and insert the 1030 1
⁄4-20 M6 100 11 1
⁄4-20 M6 71 8
appropriate lubrication fitting in one of the tapped holes. Fill with the 1040 1
⁄4-20 M6 100 11 1
⁄4-20 M6 71 8
recommended lubricant until excess appears at the opposite lube 1050 5
⁄16-18 M8 195 22 5
⁄16-18 M8 159 18
hole. Replace both lube plugs. 1060 5
⁄16-18 M8 195 22 5
⁄16-18 M8 159 18
1070 5
⁄16-18 M8 195 22 5
⁄16-18 M8 159 18
4. For best results, clean coupling of all lubricant and replenish every 1080 5
⁄16-18 M8 195 22 5
⁄16-18 M8 159 18
two years. 1090 5
⁄16-18 M8 195 22 5
⁄16-18 M8 159 18
1100 3
⁄8-16 M10 336 28 3
⁄8-16 M10 336 38
1110 3
⁄8-16 M10 336 38 3
⁄8-16 M10 336 38
Grid Removal 1120 1
⁄2-13 M12 549 62 3
⁄8-16 M10 336 62
When it is necessary to remove the grid, remove the cover. Use a round 1130 1
⁄2-13 M12 549 62 1
⁄2-13 M12 549 62
rod or screwdriver that fits into the open loop ends of the grid. Using the
1140 1
⁄2-13 M12 549 62 1
⁄2-13 M12 549 62
teeth on the hub as a support, pry the grid out radially in even, gradual
Notes: 1. Horizontal covers 1020-1090 are supplied with socket head cap
stages, proceeding alternately from side to side.
screws, horizontal covers 1100-1140 are supplied with hex head cap
screws.
2. Vertical covers are supplied with hex head cap screws.

Lovejoy, Inc. 2655 Wisconsin Ave.

Downers Grove, IL 60515 2/02
630-852-0500 Fax: 630-852-2120 697904-05585
www.lovejoy-inc.com Where the World Turns for Couplings.
Features
• Peak equivalent, true RMS or true
Model PC425 Loop Powered Sensor (LPSTM)
peak output Side exit, 4-20 mA vibration with temperature
• Temperature signal output
• Optional dynamic signal output
output
• Corrosion resistant Output, 4-20 mA
• Hermetic seal Full scale, 20 mA (±5%) ............................................................. see Table 1 on back
• ESD protection Frequency response:
• Overload protection ±10% ....................................................................................... 10 Hz - 1.0 kHz
• Reverse wiring protection ±3 dB ....................................................................................... 4 Hz - 2 kHz
Repeatability .............................................................................. 5%
Benefits Transverse sensitivity, max ....................................................... see Table 1 on back
• Choice of output: RMS, equivalent
peak, and true peak; permits you to Output, temperature
choose the sensor that best fits your Temperature output sensitivity, ±5°K ........................................ 10 mV/K
industrial requirements Temperature measurement range ............................................ 223 to 358 K (-50 to 85° C)
• Provides continuous trending of
overall machine vibration Output, dynamic
• Can help guide maintenance PC425xxx-yy-DA PC425xxx-yy-DV
Sensitivity (±10%) ....................................................................... 100 mV/g 100 mV/ ips
Full scale .................................................................................... 20g, peak 1.5 ips @ 1kHz
The 4-20 mA output of the PC425 Series
Frequency response:
is proportional to vibration. An output of 4
±3 dB ....................................................................................... 2.5 Hz - 10 kHz 2.5 Hz - 2.5 kHz
mA indicates a level of 0 ips or no vibration Amplitude nonlinearity, maximum ............................................ 1%
present for velocity output models and 0 Resonant frequency, mounted, nominal ................................... 21 kHz
g for acceleration output models. A full- Transverse sensitivity, max ....................................................... 5%
scale reading of 20 mA indicates that the
maximum range (RMS, Equivalent Peak or Electrical
True Peak) of the chosen unit, acceleration Power requirements (two wire loop power):
or velocity, is present. Voltage (between pins A & B) .................................................... 10 VDC min, 30 VDC max
Loop resistance1 at 24 VDC, maximum ..................................... 700Ω
Optionally, any of the base sensor models
Turn on time, 4-20 mA loop ....................................................... 30 seconds
can have dynamic signal output. Adding -DA
Grounding................................................................................... case isolated, internally shielded
to a model specifies a dynamic acceleration Power requirements (temperature sensor):4
signal output (100 mV/g). Adding -DV to a Voltage source............................................................................ 12 to 18 V
model specifies a dynamic velocity signal Current ....................................................................................... 0.4 to 5 mA
output (100 mV/ips).
The temperature output of the PC425 Series Environmental
is in terms of degrees kelvin (K), where 0 K Temperature range .................................................................... –40 to 85°C
= -273° C. The voltage output at 0° C = 2.73 Vibration limit ........................................................................... 250 g peak
Shock limit ................................................................................ 2,500 g peak
Volts (273 K). The voltage output at 80° C =
Sealing ...................................................... ................................ hermetic
3.53 Volts (353 K).
Physical
Sensing element design ............................................................ PZT ceramic / shear
Weight ....................................................................................... 320 grams
Case material............................................................................. 316L stainless steel
Mounting .................................................................................... 1/4 - 28 captive bolt
Output connector ....................................................................... MIL-C-5015 style, 6-pin
Mating connector ....................................................................... R19SLI5
Recommended cabling .............................................................. J9T4 / J9T4A /J95

See back for notes.

Sensor connector 6-pin top view

98895 Rev.B1 01/10

Due to continued research and product development, Wilcoxon Research reserves the right to amend this specification without notice.
 Connector pin Function J9T4 / J9T4A J95
Shell ground
A loop positive (+) white red
B loop negative (-) black black
C dynamic signal (optional) n/c white
D temperature signal green green
E temperature common red yellow
F not used n/c n/c

Notes: 1 maximum loop resistance (RL) can be calculated by:

VDC power - 10 V
RL (max. resistance) =
20 mA

2
Lower resistance is allowed, greater than 10Ω recommended
3
Minimum RL wattage determined by: (0.0004 x RL)
4
The temperature sensor must have a current flow to operate. This current can be provided through constant-current diodes
5
When ordering a 4 conductor cable assembly, use the following format : R19SL1-x-J9T4A-xxx-PC; only available with non-dynamic output
units

Table 1: PC425xxx-yy-Dz model number selection

xxx (4-20 mA output type) -yy (full scale) -Dz (dynamic output)A
AR = acceleration, RMS -05 = 5 g (49 m/sec2) -DA = dynamic acceleration 100 mV/g
AP = acceleration, equivalent peak B -10 = 10 g (98 m/sec2) (10.2 mV/ m/sec2)
ATP = acceleration, true peak C -20 = 20 g (196 m/sec2) -DV = dynamic velocity 100 mV/ips
(3.94 mV/ mm/sec)
VR = velocity, RMS -05 = 0.5 i.p.s. (12.8 mm/sec) -DA = dynamic acceleration 100 mV/g
VP = velocity, equivalent peak B -10 = 1.0 i.p.s. (25.4 mm/sec) (10.2 mV/ m/sec2)
VTP = velocity, true peak C -20 = 2.0 i.p.s. (50.8 mm/sec) -DV = dynamic velocity 100 mV/ips
-30 = 3.0 i.p.s. (76.2 mm/sec) (3.94 mV/ mm/sec)
-50 = 5.0 i.p.s. (127 mm/sec)
A
Dynamic output is an option on all models. If dynamic output option is not desired, do not add -DA or -DV to the model number.
B
Equivalent peak output is developed based on the true RMS value of vibration. For a pure sine wave, the equivalent peak output is
1.414 times the RMS value.
C
True peak output is based on the actual measured peak value using the time waveform and is not based on the RMS calculation.

PC425xxx-yy wiring PC425xxx-yy-Dz wiring

A loop positive (+)
+ DC power
supply
RL
B loop negative (-) 12 VDC to
- 36 VDC
PC425 Series

C
N/C
PC425 Series

Signal measuring
side exit
sensor

circuitry
side exit

D temperature signal
sensor

PLC/DCS 4-20mA input card

E temperature common

F
N/C
CCD
+ DC power
12 VDC to
- 18 VDC

+
Temperature DC voltage
-
Wilcoxon Research Inc
20511Seneca Meadows Parkway
Germantown, MD 20876USA

Tel: 301 330 8811

Fax: 301 330 8873
Email: [email protected]
All wire and cable used for installation of the PC425 Series sensor should be shielded.
Generally accepted instrumentation wiring practice considers the best way to ground www.meggitt.com
the shield is to connect it at the measurement end of the cable. The shield should not
be wired to ground at the sensor end of the cable. The Wilcoxon R19SLI type connector
leaves the shield unconnected at the sensor end of the cable.
Features
Model PC421 IS Series
• Intrinsic safety rated Intrinsically safe,side exit, 4-20mA,
• Peak equivalent or true RMS Loop-powered sensors (LPS)™
• Corrosion resistant
• Hermetic seal
• ESD protection
Output, 4-20 mA
Full scale, 20 mA (±5%)........................................................ see Table 1 on back
• Overload protection Frequency response:
• Reverse wiring protection ±10% ................................................................................. 10 Hz - 1.0 kHz
±3 dB ................................................................................. 4 Hz - 2 kHz
Repeatability ....................................................................... ±2%
Transverse sensitivity, max.................................................. 5%
Benefits
• Choice of output: RMS, equivalent Electrical
peak, and true peak; permits you to Power requirements (two wire loop power):
choose the sensor that best fits your Voltage (between pins A & B)...................................................12 VDC min, 30 VDC max
industrial requirements Loop resistance1 at 24 VDC, maximum.....................................600Ω
• Provides continuous trending of Turn on time, 4-20 mA loop......................................................30 seconds
overall machine vibration Grounding.................................................................................case isolated, internally
• Can help guide maintenance shielded
Environmental
Temperature range..................................................................–40 to 85°C
The 4-20 mA output of the PC421 Series Vibration limit .........................................................................250 g peak
is proportional to vibration. An output of 4 Shock limit . .............................................................................2,500 g peak
mA indicates a level of 0 ips or no vibration Sealing ..................................................... ................................hermetic
present for velocity output models and 0
g for acceleration output models. A full- Physical
scale reading of 20 mA indicates that the Sensing element design...........................................................PZT ceramic / shear
maximum range (RMS, or peak) of vibration Weight .....................................................................................320 grams
is present. Case material...........................................................................316L stainless steel
Mounting..................................................................................1/4 - 28 captive bolt
Outut connector .......................................................................2 pin, MIL-C-5015 style
PC421xxx-yy-Dz.......................................................................3 pin, MIL-C-5015 style
Mating connector . ...................................................................R6 type
Recommended
cabling ............................................................J9T2A
Connector pin Function
Shell ground
A loop positive (+)
B loop negative (-)

Notes: 1 maximum loop resistance (RL) can be calculated by:

DC supply RL RL (minimum wattage

voltage (max resistance)2 capability)3
VDC power - 10 V
RL (max. resistance) = 20VDC 400. 1/4 watt
20 mA 24VDC 600. 1/2 watt
26VDC 700. 1/2 watt

2
Lower resistance is allowed, greater than 10Ω recommended
3
Minimum RL wattage determined by: (0.0004 x RL) Wilcoxon Research Inc
4
The following are recommended barrier strips: MTL7087, 21 Firstfield Rd
MTL7187, or MTL787S for Class I, Division 1 locations. Gaithersburg, MD 20878
USA

Tel: 301 330 8811

Fax: 301 330 8873
Email: [email protected]

www.meggitt.com
*CSA approval: class I, division 1, groups A, B, C, D
LCIE approval: EEx ia IIC T3
When installed in accordance with WR drawing 12799

98901 Rev.A.3 04/05

Table 1: PC421xxx-yy-IS model number selection
xxx (4-20 mA output type) -yy (full scale)
AR = acceleration, RMS -05 = 5 g (49 m/sec2)
AP = acceleration, peak -10 = 10 g (98 m/sec2)
-20 = 20 g (196 m/sec2)

VR = velocity, RMS -05 = 0.5 i.p.s. (12.8 mm/sec)
VP = velocity, equivalent peak B -10 = 1.0 i.p.s. (25.4 mm/sec)
-20 = 2.0 i.p.s. (50.8 mm/sec)
-30 = 3.0 i.p.s. (76.2 mm/sec)
-50 = 5.0 i.p.s. (127 mm/sec)

PLC or DCS
+24 Volt supply Pin A
4 1 system
4-20mA return
Pin B +24 volt supply
5 2 4-20 mA return
shield
3
Intermediate 6 Not
Shield MTL 7000
terminal connected
R6Q1 or R6W type block MTL 7700
connector (optional)
(isolated)

PC421 Series

Earth
ground

All wire and cable used for installation of the PC421 Series sensor should be shielded. Generally accepted instrumentation wiring practice
considers the best way to ground the shield is to connect it at the measurement end of the cable. The shield should not be wired to ground at
the sensor end of the cable. Wilcoxon R6W and R6QI type connectors leave the shield unconnected at the sensor end of the cable.
製造番号:12NAEA01
図面番号:B8-0875-E220