Arasmith Lily Pad & Salvager

Chipper & CUBER Maintenance and

Operations Manual
 TABLE OF CONTENTS

Introduction…………………………………………………………..3
Warranty……………………………………………..………………..4
Parts List…………………………………................................5
New Machine Quality Check.........................……….….6
Cold Startup and New Machine Installation..............7
Power Requirements……………………………………………..8
Electrical Safety Plugs-Access Doors……………………….9-10
Installation, Startup, and Maintenance…………………..11
Preventive Maintenance………………………………………..12
Knife Changing and Part Identification……….………..…13
Knife Grinding………………………………………………………..14
Knife Maintenance………………………………………………...15-16
Anvil Adjustment…………………………………………………...17
Spout Replacement………………………………………………..18
Anvil Support Plate Replacement…………………………...19
Chip Deflector Repair……………………………………..….…..20
Drum Removal…………………………………………………..…..21-22
Notes..................………………………………………………......23
Lubrication…………………………………………………….……….24
Motor Lubrication…………………………………………….……25
Log Orientation……………………………………………………..26
Troubleshooting…………………………………………………….27
Summary……………………………………………………………….28
Suggested Bolt Torque Rates…………………………………29-30
MSDS…………………………………………………………………….31-35
SKF Bearing Installation……………………………………..….36-59
TB WOODS V-Belt Drives……………………………………….60-84
Safety plug information................…………………………85-86
Motor Component Specifications…………………………..87-92
Toshiba Specification Guide......................................93-99
Toshiba Current Relay...............................................100-122
 INTRODUCTION

The purpose of this manual is to familiarize operation and

maintenance personnel with the ARASMITH LILY PAD AND
SALVAGER CHIPPER. Please read it thoroughly before
attempting to operate the chipper. This manual contains
information on proper operation, how to maintain the machine
and it's components in the best possible working condition, and
how to diagnose and correct malfunctions. Also included is a
spare parts list to aid you in replacing items necessary for
proper operation of the chipper, a set of drawings, and
descriptive literature on components not manufactured by
ARASMITH INDUSTRIES INTERNATIONAL, LLC.

3
 Arasmith Industries International, LLC

TWO YEAR WARRANTY

Arasmith Industries International, LLC, hereinafter referred to as “seller”, hereby warrants that, at delivery, all new
equipment will meet the specifications set forth in the quotation given herewith.

Seller hereby warrants against defects in material or workmanship for a period of two (2) year from the date of
shipment. Seller will repair or replace, at its own factory or another place designated by Seller, any part found by
Seller to be defective in material or workmanship within two (2) year from the date of shipment.

Note: This warranty applies to the part or equipment being used by a single shifter per 8 hour work day and will
expire at the conclusion of two (2) year from the date of shipment or 4,160 work hours, whichever occurs first.

This warranty is null and void and shall not apply should Seller determine that said part or equipment has been
operated outside the normal intended use for said part or equipment.

Should a part or equipment be found, within the terms set forth herein, by Seller to be defective in
workmanship despite having been used in the ordinary and anticipated normal intended use, seller will accept
return of the part or equipment for repair or replacement should the Seller deem it necessary; however, Buyer
will bear the cost of returning the part or equipment to Seller for repair and/or replacement AND Buyer will
bear the cost of having the repaired and/or replacement part or equipment returned to them. Buyer shall ship
the part or equipment to a location designated by Seller for said repair and/or replacement.

Seller shall not be liable for any incidental or consequential damages incurred during return or any incidental or
consequential damages for breach of the above warranties resulting from negligence in manufacture or otherwise.
The Seller’ s liability and the Buyer’s exclusive remedy is expressly limited to repair or replacement of the part or
equipment deemed defective pursuant to the terms of this Warranty and shall be repaired and/or replaced
pursuant to the terms and conditions set forth herein. All equipment purchased, other than equipment
manufactured by Seller, shall carry the manufacturer’s warranty and guarantees only and this warranty shall not
apply to said equipment. Due to variations in material condition, maintenance and chip requirement, Seller does
not guarantee chip quality.

Buyer agrees to indemnify and hold Seller harmless from any and all claims or liabilities from accidents involving
these machines caused by failure of Buyer, it’s users and/or employees, or agents to follow warnings, instructions
or recommendations given by or available from Seller or by failure of Buyer, it’s users and/or employees, or agents
to comply with all applicable industry standards, Federal, State and/or local laws and regulations including but not
limited to the Occupational Safety and Health Act of 1970.

THE WARRANTIES CONTAINED HEREIN ARE THE ONLY WARRANTIES MADE BY THE SELLER OR ANYONE ELSE WITH RESPECT TO THE EQUIPMENT
BEING SOLD HEREUNDER AND SUPERSEDE ANY OTHER WARRANTIES, EXPRESSED OR IMPLIED , INCLUDING BUT NOT LIMITED TO: WARRANTY
OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. NO ORAL WARRANTIES OR GUARANTEES OF ANY KIND HAVE
BEEN MADE TO BUYER.

This warranty is or may be modified by specific terms set forth or contained in the quotation given herewith.

4
 BOISE CASCADE
CUSTOMER

CUSTOM PARTS LIST OAKDALE,LA

LOCATION

50-50-H-1318-DS-879 50"X50" CHIPPER 12.30.22

SERIAL# MODEL DATE:
MIN
PART DESCRIPTION PART # #/SET REQUIRED
STOCK
CHIPPER KNIFES TK19RX500 100 2 SETS
KNIFE CLAMPS KC-4R 100 1 SET
KNIFE CLAMP BOLTS KB-4 100 1 SET
ANVIL BARS A-5 25 1 SET
ANVIL SUPPORT PLATE ASP-50 1
MOTOR DR SHEAVE 10-8V125 1
CHIPPER SHEAVE 10-8V53 1
BELT BANDED 8V2240 10
MOTOR BUSHING J 3 7/8 1
CHIPPER BUSHINGS P6 1
TOSHIBA 507UZ 300HP 1200 RPM 507UZ 1
MALE SAFTEY PLUG N/A
FEMALE SAFTEY PLUG N/A
ARASMITH BEARING REBUILD KIT ARA-407.BRG.RK 1
BEARING HOUSINGS EX/NE ARA-407.HS.EX.NE.CMPL 1
ANVIL BOLT (BOLTS FOR ANVIL BARS) A-5BLT 50

5
 New Machine Quality Check

1. Check welds for cracks and loose parts.

2. Drum rolls freely with no metallic sounds or catching.
3. Anvil to knife clearance 1/16”.
4. Check all anvils for tightness.
5. Knifes are sharp and in correct position and tight.
6. Belts are secure and tight.
7. All grease lines are in place and secure.
8. Bearings are greased to factory specification.
9. Remove drain plug from line on top bearing.
10. Make sure grease is showing on bottom bearing seal.
11. Motor is pre greased to factory specification.
12. Motor is tight and secure.
13. Chip slinger inside drum has 5/8 clearance from knife holders.
14. All doors and safety disconnect plugs are secure and in place.
15. In feed and out feed are clear of debris.
16. All guards must be in place and secure.
17. Safety decals are in the proper places.
18. Quality paint with 2 spare cans of touch up paint of machine color.
19. MVR 1000 is mounted securely to the side of the machine
.
20. All electricalconduits are in place with no damage.
21. E-series grease pump is mounted securely to chipper with lines intact.
22. All fasteners accounted for.
22. Unsecured items are consolidated and shrink wrapped.
23. Chipper is free of cosmetic defect after shipping.
24. Chipper is in good working condition.
Q.A. Technician___________________________ Date________________________.

6
 Cold Startup and New Machine Installation

Important: When performing any maintenance, disconnect and

lockout all sources of power to the chipper.

Warning: Never start the machine until all tools are removed from
the area and personnel are at a safe distance.

o 1. No losses and damage during shipment.

o 2. All exterior bolted assembles are secure.
o 3. Check machine electrical system for exposed or broken wires.
o 4. All hydraulic lines are properly installed and fastened.
o 5. Greaser is filled with shell Alvania #2 or Amaco RyconEP #2 to proper operating level.
o 6. Grease drain line on top bearing is open.
o 7. Check anvil base to Knife clearance, bolt torque (refer to operation manual).
o 8. Verify knife bolts and clamps are secure.
o 9. Check belts for proper adjustment.
o 10. Clear all debris from moving parts.
o 11. Rotate Drum by hand 2 full rotations, listen for noise or catching.
o 12. All safety shutoff switches are in place.
o 13. All guards and doors are in place.
o 14. Jog machine on/off check spin direction, listen for noise or catching.
o 15. Start machine: warm-up/system check 15 minute.
o 16. Smooth startup, no noise.
o 17. All gages and meters are on.
o 18. Cycle Bearing Greaser system.
o 19. Low psi shutoff on pneumatic greaser(If applicable)
o 20. Check machine plumbing for leaking fluids.
o 21. Check MRV1000 for correct operation of temp and vibration.
o 22. Check out feed for material exit and free from obstruction.
Q.A. Technician___________________________ Date_______________________

7
 ARASMITH LILY PAD CHIPPER POWER
REQUIREMENTS

ELECTRICAL
Chipper: 1 ea. 200 HP, 1200 RPM, 444TS/445TS Frame, 460/3/60

8
 Electrical Safety Plugs - Access Doors

PLEASE NOTE: ELECTRICAL SAFETY PLUGS DO NOT TAKE THE PLACE OF

GOOD SAFETY PRACTICES. WHEN PERFORMING ANY MAINTENANCE,
DISCONNECT AND LOCKOUT ALL SOURCES OF POWER TO THE MACHINE!
WAIT FOR THE ROTOR TO COME TO A COMPLETE STOP BEFORE
PERFORMING ANY MAINTENANCE!
Electrical safety plugs are installed on the drive guard and main access
doors. Safety plugs must be disconnected to gain access to the belt-
drive and/or hog components.
Unless provided by Arasmith Industries International, LLC, it is the
responsibility of the customer/end-user/equipment owner to properly
wire all safety plugs into the equipment. This includes the drive
motor and all related conveyor disconnects. Proper wiring ensures the equipment
cannot operate.
If the machine is equipped with a hydraulic in-feed guard, the drive motor
disconnects should have a normally open set of contacts. This ensures the
hydraulic pump used to raise the in-feed guard will not operate unless the
safety disconnects are properly engaged.

9
 ACCESS DOOR ELECTRICAL SAFETY PLUGS

Electrical safety plugs are provided on the drive guard(s) and main
access doors.
These safety plugs must be unplugged when gaining access to the
belt drive or chipper drum. Unless ARASMITH has supplied a motor
control system, it is the responsibility of the customer or end user to
properly wire these plugs into the drive motor(s) disconnect(s) and all
related conveyor disconnects so that if any of the plugs are pulled,
NOTHING CAN OPERATE. These plugs do not take the place of a good
safety practice of MANUALLY DISCONNECTING AND LOCKING OUT
ALL POWER SOURCES BY THE OPERATOR OR MAINTENANCE
PERSONNEL BEFORE ANY MAINTENANCE IS PERFORMED.

10
 INSTALLATION, START-UP AND OPERATION
IMPORTANT: WHEN PERFORMING ANY MAINTENANCE, DISCONNECT AND
LOCKOUT ALL SOURCES OF POWER TO THE CHIPPER.
WARNING: NEVER START THE MACHINE UNTIL ALL TOOLS ARE REMOVED
FROM THE AREA AND PERSONNEL ARE AT A SAFE DISTANCE.

At time of delivery, the Chipper should be examined for losses and damage during
shipment and the delivering carrier notified immediately of such. Contact ARASMITH
for replacement of parts. Due to the low vibration level of a ARASMITH Chipper, a
simple I-beam or concrete pad can be used for support. However, accessibility by
maintenance personnel must be an essential part of the installation. Also, because of
its simple design and versatility, a variety of equipment may be used as a means of
conveying material to and from the machine. The discharge conveyor should be of
sufficient capacity to keep the machine clear of chips, and ledges that hinder
discharging avoided.
All that is required to start-up the ARASMITH Chipper is to make the necessary
electrical connections. All other maintenance and adjustments were made prior to
shipment. As with the start-up of any new machine it is wise to observe the Chipper
run without a load before processing any material. First rotate the drum by hand for a
few revolutions, listening for any metal contact, etc. If nothing unusual is observed,
jog the starter so the motor turns the drum slowly, continuing to listen carefully. If
nothing is heard, bring the drum up to speed. At this point pay particular attention to
vibration! The Chipper should be running smooth. If everything checks out, feed a few
pieces of wood into the in-feed opening. They should be consumed in a relatively
short time. During this initial session, check the drive for signs of looseness, watch
conveyors to see if they are of sufficient capacity, and listen to the machine.
Afterwards, shut the chipper down and make a thorough inspection of the machine.
Knives should be checked to see if they are sharp and tight, bearings inspected for
excessive heat (grease expelled from the seals is normal), bolts checked for tightness,
etc.
After the final inspection, the chipper is ready for normal operation and if properly
cared for will give years of satisfactory service. In the back of the manual you will find
cold start and installation check sheet.
NOTE: WHEN PERFORMING ANY KIND OF MAINTENANCE, DISCONNECT AND
LOCKOUT ALL SOURCES OF POWER TO THECHIPPER! NEVER START THE MACHINE
UNTIL ALL TOOLS ARE REMOVED AND PERSONNEL ARE AT A SAFE DISTANCE!

11
 PREVENTIVE MAINTENANCE

Below are recommendations for performing preventive maintenance operations

DAILY
Examine knives for wear.
Check knife bolts for looseness.
Check lubrication systems for sufficient lubricant.

WEEKLY
Examine anvil segments for wear. Check
anvil bolts for looseness.
Examine infeed wear plates and strips for wear.
Inspect electrical safety disconnects for proper operation.

MONTHLY
Examine drum surface for wear. Examine
spout plate for wear.
Examine chip slinger assembly for wear and cracked welds. Check drive belts
for wear and looseness during initial
Break in, check belt tension more frequently.

NOTE: See specific sections following this page for correct maintenance
procedures.
See manufacturer's literature at the back of this manual for additional
maintenance instructions and recommendations.

12
 KNIFE CHANGING

The process of changing knives is quick and easy. Access to the holders is gained
through the door at the side of the chipper and by using a 5/8" allen wrench, the knife
bolts and clamps can be removed and the knives taken out. Once removed, the knives
can then be resharpened. Before placing resharpened knives into the drum, the holders,
clamps and the knives should be wiped clean to keep foreign material from between

damage to the holder, or poor quality chips could result). Once in the holder, the position
of the knife before it is tightened into place is very important. If too far forward (figure B,
next page), the knife would protrude too far above the drum surface and could be
damaged if it were to hit the anvil. The correct position (figure A, next page) is all the way
down in the holder. After correctly positioning the knife, it may once more be tightened
down. We recommend a torque range of 120-140 ft-Ibs for the knife bolt.

NOTE: WHEN PERFORMING ANY KIND OF MAINTENANCE, DISCONNECT AND LOCKOUT

ALL SOURCES OF POWER TO THE CHIPPER! NEVER START THE MACHINE UNTIL ALL
TOOLS ARE REMOVED AND PERSONNEL ARE AT A SAFE DISTANCE!

***We recommend using an electric impact wrench (120VAC, 7.0 AMPS, 3/4" drive) and a 5/8"
impact hex bit socket 3/4" drive.

13
 KNIFE GRINDING
Below are shown the recommended angles for grinding ARASMITH winged style chipper
knives. The ARASMITH Rotary Knife Grinder is preset to grind the knives at these angles.
These angles have proven to give the best results in most cases. Knives may be resharpened
until they become 2 1/16" long, at which time they should be disposed. For the best knife life,
avoid burning the knife steel. Also, as the cutting edge dulls, the rate of knife wear increases.
For further information refer to your ARASMITH Knife Grinder Manual.

NOTE: OBSERVE ALL SAFETY PRECAUTIONS, WEAR SAFETY GLASSES, GLOVES AND ALL OTHER APPROPRIATE
SAFETY APPAREL. AND USE THE PROPER EQUIPMENT WHILE HEATING THE BABBIT AND BABBITING THE
KNIVES

14
 Regularly Scheduled Knife Maintenance

Regularly maintaining your knives will save your knife steel. See the diagrams shown below for
examples of knives in various stages.

The first example is a new or correctly ground knife.

1

The second example is representative of a

normally worn knife. To sharpen this knife properly,
2 grind back to the dotted line.

The third example is a badly worn knife. Wear has

occurred behind the cutting edge. In this case,
grinding to a sharp edge is not sufficient. The complete
worn area must be removed or rubbing will occur in
3 the chipping process. Grind the knife back to the
dotted line to properly sharpen the knife. Chipped or
damaged knives should be treated in the same
manner.

Diagram 5 - Knives in various stages of use.

15
REGULARLY SCHEDULED KNIFE MAINTENANCE SAVES KNIFE STEEL
Operating a chipper with dull knives will cause excessive wear to the knife cutting edges, wasting
usable knife steel and at the same time wearing away the clearance angle. This will reduce the rate at
which material is consumed and create thin or irregular cut chips.

Illustrated above is a badly worn knife. If ground back to the dotted line (A), a sharp edge would exist.
However, the knife would still have worn areas and the cutting edge would be somewhat blunt and
above the desired location. This condition would create a rubbing action that would cause premature
dulling, wood to bounce around in the spout, and possibly cause the chipper to smoke. The knife must
be ground back to dotted line (B) to remove all worn areas and chip at maximum efficiency.

16
 ANVIL ADJUSTMENT

WARNING- DO NOT ENTER THE CHIPPER SPOUT AT ANY TIME! The process of adjusting the
anvil segments can be performed from outside the chipper. It is an easy procedure but
requires two men to do the job most efficiently (one man at the front of the machine to replace,
adjust, and tighten the anvils and the other man to turn the chipper drum). First, loosen the
anvil bolts and remove the anvil segments. Then replace any worn or damaged segments or
turn them to expose a new edge (be sure all anvil segments and the anvil support plate are
clean and without burrs. Anvil clearances are not critical, adjust anvils as close as possible
without hitting the knives. Maximum clearance ·is·1 716"·. Anvils may be set by using a gauge.
Starting at one end, reinstall an anvil and place the gauge alone side the segment with the
shim in front of the anvil against the drum. Tap the anvil forward until it just makes contact
with the gauge. Remove the gauge and tighten the bolts holding the anvil, using care not to
move the anvil in the process. In most cases more than one knife passes in front
of an anvil segment. Be sure to check the clearance between each knife and its anvil bar before
proceeding onto the next anvil. Continue the process until all but the last anvil on the opposite
end has been set. Adjust this segment without using the gauge by setting its rear surface flush
with the rear surface of the anvil next to it. When finished, rotate the drum a full revolution to
double check and see that no knives are hitting.

ANVIL
ASSEMBLY

NOTE: WHEN PERFORMING ANY KIND OF MAINTENANCE, DISCONNECT AND LOCKOUT ALL
SOURCES OF POWER TO THE CHIPPER! NEVER START THE MACHINE UNTIL ALL TOOLS ARE

17
 SPOUT REPLACEMENT
Should the spout or anvil support plate become damaged and expose the anvils in such
a way as to create a shelf that inhibits material from feeding, or should it be
determined that wear in the spout is responsible for a reduction in chip quality, the
spout should be replaced. This may be done by first unbolting the spout, and then
bolting in a new section. The bottom of the spout should be 1/16" to 1/8" from the
knives. There should also be 1/8" clearance between the bottom of the spout and the
anvil segments.

18
 ANVIL SUPPORT PLATE REPLACEMENT
If the anvil support should become damaged and require replacement, the
procedure is as follows:

19
 CHIP DEFLECTOR REPAIR

The purpose of the chip deflector is to remove the chips from within the drum.
There is one or two of them in each machine depending on the size. Unless
damaged, there is no scheduled maintenance other than periodically inspecting
weld seams for cracks. There is a certain amount of vibration (the longer the
deflector, the greater the vibration) which could cause the welds to fatigue and
crack. If cracks are found, re-weld heavily over them. Also, a brace from the tip of
the -deflector to the side of the machine will reduce vibration considerably.
If a deflector should become damaged and replacement is required, cut out a new
one using the old one as a template. When positioning it in the drum, maintain a
5/8” clearance between it and the drum I.D. A nut 5/8” high at each end will
support it the proper height above the drum until the deflector has been tack
welded into place. If in places the clearance is less, trim where needed. Maintain
a 1” clearance at the head. On the side of the drum with the outboard bearing,
four blocks are welded at the end of the drum I.D. Their purpose is to keep the
deflector plate from clogging in the corner. When replacing the chip deflector on
that side, be sure to notch out clearance for these blocks. When finished, rotate
the drum a full revolution to make sure nothing is hitting.

ADD BRACES IF NOT

ALL READY INSTALLED

BALANCE BLOCK

1"

CLEANER BLOCKS

5/8" 50o- 55o

10o

20
 DRUM REMOVAL

The normal procedure for removing the drum from the chipper is as follows:
1. Lockout all power to chipper, remove the drive belts, chipper sheave and
bushing.
2. Remove the anvil segments.
3. Install shim blocks under the drum, between the drum and frame to keep
the drum
from dropping as little as possible when the bearings are broken down.
4. If either of the bearings installed on the chipper are adapter type, break
them down and loosen the adapters-so that they will slide on-the-shaft-
Adapter bearing housings should remain bolted to the frame while being
broken down (for more information on bearings, see the manufacturer's
literature at the back of this manual).
5. Remove the bearing on the removable bolt on side plate.
6. Remove the side plate.
7. Remove or unbolt the other bearing depending on chipper construction.
8. Slide the drum/shaft assembly out of the frame. Lifting eyes will be placed
in the available threaded holes to assist drum removal. Avoid using chains
directly on the shaft or letting the shaft hit nearby structures, as this would
gall or nick the shaft.

At this point the drum/shaft/hub assembly and bearings are out of the machine and are
easily accessible for maintenance and further disassembly. Because in some of the larger
sizes of chippers the bearing next to the drive is only accessed by removing the chipper
drum/shaft assembly, we recommend replacing this bearing at a drum change out.
Thoroughly clean the shaft before reinstalling the bearings and bushings. When changing
out a drum it usually is not necessary to loosen the hub bushing. Simply unbolt the drum
from the hub flange (10 bolts). When installing the bearings and any bushings on a shaft,
they may be initially positioned in the same location as they were originally. However, the
drum and/or shaft may have to be shifted for proper final alignment of the drum to the spout
after the drum has been installed in the frame. To reinstall, follow the above order in reverse.

21
22
NOTES

23
 LUBRICATION

The bearings located on each side of the machine are used to provide the
greatest degree of rigidity possible. A grease fitting and bleed plug are provided
for the bearings. At the time of installation, these bearings are usually lubricated
with a #2 lithium or polyuria base grease, which is suitable for normal operating
conditions. See below for a detailed description of the actual grease used. Re-
lubricate with a grease which is compatible with the original lubricant and
suitable for roller bearing service. For more detailed information concerning the
bearings and their lubrication, please refer to the manufactures publications at
the end of this manual.

ARASMITH 4-7/16”, 5-15/16”, & 7-15/16” BEARING LUBRICATION INSTRUCTIONS

Arasmith bearings are lubricated at the factory. We recommend re-lubricating

these bearings with a grease which is compatible with the original lubricant and
suitable for roller bearing service. When adding grease to a bearing, the plug
fitting should be removed and grease added until fresh grease is expelled
through the plug hole. Allow the machine to run for approximately 15 minutes
with the fittings removed to allow excess grease to be expelled before replacing
the plug. We recommend greasing these bearings after a maximum of 40 hours
of operation. For further lubrication information, contact a lubrication engineer or
your bearing representative.
ORIGINAL LUBRICANT: SKF-LGEP 2/18 HIGH LOAD

Suggested Compatible Lubricants:

AMBIENT TEMPERATURE 30° F AND HIGHER-CHEVRON BLACK PEARL EP, NLGI #2
AMBIENT TEMPERATURE 30° F AND LOWER- CHEVRON BLACK PEARL EP, NLGI #0

24
 MOTOR LUBRICATION

Refer to the motor manufacturer’s literature at the back of this

manual regarding lubrication for the motor bearings. A grease line
with remote fitting is usually provided for greasing the bearing on
the drive end of the motor shaft when ARASMITH provides the
motor.

25
 LOG ORIENTATION

ANVIL SIDE

Material may be conveyed into the chipper from any direction as

long as it is dropped in front of the drum centerline and the fiber is
oriented parallel with the centerline as much as possible. Log ends
should lay parallel with the drum to produce the best chip quality
possible. Thin lumber trim ends do not require an orientation.

26
 TROUBLESHOOTING

PROBLEM CAUSE REMEDY

Knives damaged Metal in chipper A metal detector should be installed
Knife bolts not tight enough Tighten
Worn clamp or knife holder Replace
Wood between knife/holder components Clean parts when changing knives

A lot of fines produced Short knife Replace, check babbit and overall knife length
Dull or damaged knives Replace install sharp knives
Direct feeding of log ends Feed logs parallel to shaft for best chips

Chip gullet plugged Short knife Reposition knife

Obstruction in gullet Remove obstruction

Large # of slivers Worn anvil or anvil out of adjustment Replace or readjust anvils
Log end fiber perpendicular to shaft Feed logs parallel to shaft for best chips

Material Not Readily Damaged or very dull knives Install sharp knives
Consumed Short knife Replace, check babbit and overall knife length
Worn spout plate Replace spout plate

Drum stalls Not enough horsepower Install larger motor

Loose belts Readjust belt tension
Chip build-up in drum Improve chip discharging and removal

Bent or broken shaft Metal in chipper Replace shaft

Drum wobbles Bent or broken shaft Replace shaft

Loose hub bushing Retighten bushing bolts
Bearing failure Replace or rebuild bearing

Drum shifts Loose hub bushings Retighten bushing bolts

Loose bearing adapter(s) Retighten adapter nut
Metal in chipper Install stops at each end of the drum

Broken chip deflector Chip build-up in drum Improve chip discharging and removal
Drum shifted Weld stops to minimize shifting
Weld failure Reweld heavily

Smoke generated Short or damaged knife(s) Replace knife

Spout worn Replace spout plate
Wood build-up in chipper Check all discharge areas for a build-up of wood

27
 SUMMARY

The most important fact for the operator of an ARASMITH "LILY PAD" CHIPPER
to keep in mind is that the chipper is a precision machine and must be properly
maintained for it to continue
to produce a high quality end product.

* ALWAYS LOCK OUT ALL SOURCES OF POWER TO THE CHIPPER

WHEN DOING ANY MAINTENANCE. WAIT FOR THE DRUM
TO COME TO A COMPLETE STOP BEFORE PERFORMING
ANY WORK ON THE MACHINE.

* OBSERVE INDUSTRY AND OSHA SAFETY PRECAUTIONS

AND WEAR APPROPRIATE SAFETY APPAREL.

* CLEAN AND EXAMINE THE CHIPPER WHEN TIME IS

AVAILABLE.

* USE HIGH QUALITY REPLACEMENT PARTS.

* MAINTAIN DRUM, KNIVES, ANVILS, BEARINGS, ECT. IN

PROPER WORKING ORDER.

* INSTALL A HOPPER OVER THE SPOUT OPENING TO

CONTAIN WOOD IN THE MACHINE.

* KEEP PERSONNEL AT A SAFE DISTANCE FROM THE

CHIPPER WHILE IT IS IN OPERATION.

28
 TORQUE RATES
ASTM A354-BD SAE GRADE 8

Bolt Size TPI Proof Load (lbs) 1 Clamp Load (lbs) 2 Tightening Torque (ft lbs)
Lubricated Plain
1
⁄4 20 3,800 2,850 6 12
5
⁄16 18 6,300 4,725 12 25
3
⁄8 16 9,300 6,975 22 44
7
⁄16 14 12,750 9,563 35 70
1
⁄2 13 17,050 12,788 53 107
9
⁄16 12 21,850 16,388 77 154
5
⁄8 11 27,100 20,325 106 212
3
⁄4 10 40,100 30,075 188 376
7
⁄8 9 55,450 41,588 303 606
1 8 72,700 54,525 454 909
11⁄8 7 91,550 68,663 644 1,287
11⁄4 7 120,000 90,000 938 1,875
13⁄8 6 138,600 103,950 1,191 2,382
11⁄2 6 168,600 126,450 1,581 3,161
13⁄4 5 228,000 171,000 2,494 4,988
2 41⁄2 300,000 225,000 3,750 7,500
21⁄4 41⁄2 390,000 292,500 5,484 10,969
21⁄2 4 480,000 360,000 7,500 15,000
23⁄4 4 517,650 388,238 8,897 17,794
3 4 626,850 470,138 11,753 23,507
31⁄4 4 745,500 559,125 15,143 30,286
31⁄2 4 874,650 655,988 19,133 38,266
33⁄4 4 101,4300 760,725 23,773 47,545
4 4 1,163,400 872,550 29,085 58,100
* SAE J429 grade 8 bolts do not exceed 1-1/2″ diameter.

29
 TORQUE RATES
ASTM A193 B7 Bolts and Studs
Minimum Minimum Est. Tightening Torque
Nominal Clamp
Threads Tensile Yield Shear K = 0.12 K = 0.15 K = 0.20
Dia. Load
Per Inch Strength Strength Strength
(in.) (lbs.) (lbs.) (lbs.) (lbs) (ft-lbs) (ft-lbs) (ft-lbs)
1/4 20 3978 3341 2016 2506 6 8 10
1/4 28 4547 3819 2441 2864 7 9 12
5/16 18 6554 5505 3401 4129 13 16 22
5/16 24 7258 6097 3931 4573 14 18 24
3/8 16 9686 8136 5083 6102 23 29 38
3/8 24 10979 9222 6063 6916 26 32 43
7/16 14 13289 11162 6997 8372 37 46 61
7/16 20 14840 12465 8173 9349 41 51 68
1/2 13 17737 14899 9425 11175 56 70 93
1/2 20 19994 16795 11146 12596 63 79 105
9/16 12 22743 19104 12150 14328 81 101 134
9/16 18 25373 21313 14159 15985 90 112 150
5/8 11 28250 23730 15131 17798 111 139 185
5/8 18 31995 26876 17999 20157 126 157 210
3/4 10 41808 35118 22643 26339 198 247 329
3/4 16 46620 39161 26344 29371 220 275 367
7/8 9 57717 48482 31438 36362 318 398 530
7/8 14 63684 53495 36035 40121 351 439 585
1 8 75718 63603 41316 47702 477 596 795
1 14 84986 71388 48473 53541 535 669 892
1 1/8 7 95409 80144 51969 60108 676 845 1127
1 1/8 8 98807 82998 54570 62248 700 875 1167
1 1/4 7 121139 101757 66722 76318 954 1192 1590
1 1/4 8 124963 104969 69664 78727 984 1230 1640
1 1/2 8 186480 156644 105376 117483 1762 2203 2937
1 1/2 6 175657 147551 97013 110664 1660 2075 2767
1 5/8 8 221841 186346 125992 139760 2271 2839 3785
1 3/4 8 260269 218626 148450 163970 2869 3587 4782
1 7/8 8 301766 253483 172748 190112 3565 4456 5941
2 8 346330 290917 198887 218188 4364 5455 7273
2 1/4 8 444663 373517 256688 280138 6303 7879 10505
2 1/2 8 555267 466425 321851 349819 8745 10932 14576
The torque values can only be achieved if nut (or tapped hole) has a proof load greater than or equal to the bolt's minimum ultimate tensile strength.
Clamp load calculated as 75% of the yield strength for the B7 specified in ASTM A193.
Torque values calculated from formula T=KDF, where
Coatings such as Teflon or Xylan offer extremely low coefficients of friction. Often we will experience K values around 0.12 or even lower.
K = 0.15 for "lubricated" conditions and K = 0.20 for "dry" conditions
D = Nominal Diameter
F = Clamp Load
Tensile and Yield strengths in accordance with ASTM A193
Minimum ultimate tensile strength: 125,000 PSI (up through 2-1/2") and 115,000 PSI (over 2-1/2 through 4)
Minimum yield strength: 105,000 PSI (up through 2-1/2") and 95,000 PSI (over 2-1/2 through 4)
Estimated Shear Strength based off of 60% of minimum tensile strength using the thread root area. It is not part of the ASTM A193 specification.

30
 SAFETY DATA SHEET

Section 1 – Product and Company Information

Material Name: Tool Steel, Alloy, Stainless, and High Speed Steel
Including but not limited to the following grades:
Tool Steel: W1, A2, D2, H13, O1, S7
Alloy: 4140/4142, C1018, A36
Stainless: 410, 420, 440C
High Speed: M2, M3, M4, M43, M34, T15

Manufacturer Information: Precision Marshall Steel Company

99 Berry Road
Washington, PA 15301

Phone: 724-222-2100

Recommended Use: Solid steel, various uses and forms

Section 2 – Hazards Identification

Classification: Solid

Signal Word: Non Hazardous

Hazard Statement: Solid metallic products are generally classified as “articles” and do not
constitute a hazardous material in solid form under the definitions of OSHA Hazard
Communication Standard 29 CFR 1910.1200.
Any articles manufactured from these solid products would be generally classified as non-
hazardous. Subsequent operations such as cutting, grinding, milling, welding or processing in
any other manner may produce potentially hazardous dust or fumes which may be inhaled,
swallowed or come in contact with skin or eyes. Inhaling dusts, fumes or mists generated during
manufacturing processes may be hazardous to your health. This material may have a light
coating of oil for rust prevention.

Precautionary Statements:
Wear personal protective equipment when required.
Gloves should be worn when handling.
Face/eye protection should be worn when processing.
Do not breathe dust/fumes when processing.
In case of inadequate ventilation wear respiratory protection.

31
 Section 3 – Composition/Information

COMPONENT CAS NO. TOOLSTEEL ALLOY STAINLESS HIGH SPEED

Iron Fe 7439-89-6 BASE BASE BASE BASE

Chromium Cr 7740-47-3 0.0 - 13.0 0.8 - 1.20 1.5 - 18.0 0.0 – 4.50
Molybdenum Mo 7439-98-7 0.0 - 1.50 0.0 - 0.35 0.0 - .750 0.0 – 5.50
Vanadium V 7440-62-2 0.0 - 1.20 0.0 - 0.30 - 0.0 – 2.20
Nickel Ni 7440-02-0 0.0 - 0.40 0.0 - 0.50 0.0 - 0.25 0.0 – 0.40
Manganese Mn 7439-96-5 0.0 - 2.50 0.7 - 1.30 0.0 - 1.00 0.0 – 0.40
Carbon C 7440-44-0 0.0 - 1.60 0.15 - 0.42 0.0 - 1.20 0.0 – 0.88
Silicon Si 7740-21-3 0.0 - 1.20 0.15 - 0.45 0.0 - 1.00 0.0 – 0.45
Copper Cu 7440-50-8 0.0 - 0.30 0.0 - 0.30 0.0 - 0.20 0.0 – 0.25
Tungsten W 7440-33-7 0.0 - 0.30 0.0 - 0.00 - 0.0 – 6.75
Phosphorous P 7723-14-0 0.0 - 0.40 0.0 - 0.35 0.0 - .040 0.0 – 0.025
Sulfur S 7704-34-9 0.0 - 0.05 0.0 - 0.40 0.0 - 0.03 0.0 – 0.025

Note: all values expressed as weight percent and are approximate

The above listing is a summary of elements used in tool steel, alloy, stainless and high-speed
steels. Different grades contain various combinations of these elements. Other trace elements
may also be present in minute amounts. These small quantities are referred to as “trace” or
“residual” elements; they originate in the raw materials used. The elements listed above are
considered to be components rather than trace.

Section 4 – First Aid Measures

Steel in its present state is not likely to present any acute or chronic health effects. However,
during processing such as cutting, grinding, milling, or welding, fumes or dust may be emitted that
may cause irritations, difficulty in breathing or allergic skin reactions.

Eye Contact: Flush immediately with running water to remove particles. Keep eye wide open
while rinsing. Get medical attention if irritation persists.

Skin Contact: If irritation develops, brush off excess dust. Wash area with soap and water to
remove particles.

Inhalation: Move to fresh air. If condition continues, consult a physician

Ingestion: Do not induce vomiting. Consult a physician if large quantities have been ingested.

Section 5 – Fire Fighting Measures

Flash Point: Nonflammable

No Explosion Hazard

32
 Section 6 – Accidental Release Measures

No specialized clean up procedures needed

Section 7 – Handling and Storage

Handling: Avoid sharp edges or heated material. Avoid dust particles when machining.

Storage: No special storage requirements

Section 8 – Exposure Controls/Personal Protection

When machining – good ventilation is recommended to keep airborne concentration of dust and
fumes at acceptable levels.

Eye/Face Protection: Wear safety glasses when cutting or grinding. Face shields when welding
or burning.

Respiratory Protection: Wear NIOSH approved dust/mist/fume respirator when welding or

burning.

Hand Protection: Wear gloves when handling sharp edges

Other Protective Equipment: Use appropriate protective clothing as required such as fire
retardant clothes or aprons when welding or burning

Section 9 – Physical and Chemical Properties

Physical state Solid Flash Point NA

Flammable limit NA Evaporation Rate NA
Odor Odorless Flammability Nonflammable
Odor threshold NA Explosive limits NA
Vapor pressure NA Vapor density NA
Vapor density NA Relative density 7.86
Melting point 1530 C / 2786 F Partition coefficient No data
Solubility Not Soluble Auto-ignition temp. No data
Boiling Point NA Decomposition temp. No data

33
 Section 10 – Stability and Reactivity

Stability: Stable under normal storage conditions

Hazardous Reaction Potential: Will not occur

Conditions to avoid: None

Hazardous decomposition products: NA

Incompatible Products: Strong acids

Section 11 – Toxicological Information

Lethal Dose/ Concentration: None established

Mutagenicity: NA
Teratogenticity: NA
Reproductive effects: NA
Carcinogenic: Not found to be carcinogenic by NTP, IARC, or OSHA in its present state.
(Note: fumes/dusts/mists from processing this material may be carcinogenic if inhaled over long
periods of time)

Section 12 – Ecological Information

No adverse ecological effects

Section 13 – Disposal Considerations

Waste Disposal: Recycle scrap materials through scrap dealer. Dispose of non-cyclable
material in accordance with local, state, and federal regulations.

34
 Section 14 – Transport Information

Not regulated – no special transport instructions

Section 15 – Regulatory Information

This product is not hazardous under the criteria of the Federal OSHA Hazard Communication
Standard 29 CFR 1910.1200 however dusts and fumes from this product may be hazardous and
require protection to comply with applicable federal, state and local laws and regulations.

Section 16 – Other information

Prepared by Precision Marshall Steel Company. Revised February 2015 to align with HazCom
2012 (Globally Harmonized System of Classification) OSHA Appendix D of 29 CFR 1910.1200

Information included in the Safety Data Sheet is based on data provided from sources believed to
be accurate. No warranty or guaranty of any kind is expressed or implied regarding the accuracy
or correctness of this data.

The actual use of this product is beyond our control, and it is each employer's responsibility to
assure the safety and health of their employees. Precision-Marshall Steel Company will not
assume liability arising out of the use of this product by others

35
36
 Drive-up is achieved with a force of suf­
ficient magnitude applied directly to the face
of the inner ring. This force is generated with
one of the following devices:
1. Threaded lock nut
2. Bolted end plate
3. Hydraulic nut
4. Mounting sleeve
Cold Mounting
The mounting of any tapered bore bearing is
affected by driving the bearing on its seat a
suitable amount. Since the amount of drive­
up is critical to determining the amount of
interference, cold mounting is typically the
most common method used for mounting
tapered bore bearings. Accurately controlling
the axial position of the inner ring is very
difficult with hot mounting.
Oil-injection (hydraulic) mounting
This is a refined method for cold mounting a
tapered bore bearing. It is based on the
injection of oil between the interfering sur­
faces, thus greatly reducing the required axi­
al mounting force. The pressure is generally
supplied with a manually-operated recipro­
cating pump. The required pressure seldom
exceeds 10,000 psi, and is usually much
less. The oil used for oil-injection mounting
should be neither too thin nor too viscous. It
is difficult to build up pressures with exces­
sively thin oils, while thick oils do not readily
drain from between the fitting surfaces and
require a little more axial force for position­
ing the bearing. This method cannot be used
unless provided for in the design of the
mounting. (Contact SKF for retrofitting
details.)
SIC.F'
Mounting tapered bore Step 4
double row self-aligning Screw off the nut from the adapter sleeve
assembly and remove the locking washer.
ball bearings
Most tapered bore self-aligning ball bear­
ings are mounted with the use of adapter
sleeves. Therefore, this instruction will be
limited to adapter sleeves only.
Precautions
For hollow shafts, please consult SKF Appli­ Step 5
cations Engineering. The bearings should Wipe preservative from the adapter 0. D.
be left in their original packages until and bore. Remove oil from the shaft to pre­
immediately before mounting so they do vent transfer of oil to the bore of the adapter
not become dirty. The dimensional and sleeve.
form accuracy of all components, which will
be in contact with the bearing, should be
checked.
Step 1
Remove any burrs or rust on the shaft with
an emery cloth or a fine file.
Step 6
Position the adapter sleeve on the shaft,
threads outboard as indicated, to the
approximate location with respect to
required bearing centerline. For easier posi­
tioning of the sleeve, a screwdriver can be
placed in the slit to open the sleeve. Apply­
Step 2 ing a light oil to the sleeve outside diameter
Wipe the shaft with a clean cloth. surface results in easier bearing mounting
and removal.
Step 3
Measure the shaft diameter. Step 7
Wipe the preservative from the bore of the
Shaft tolerance limits for adapter bearing. It may not be necessary to remove
mounting seatings the preservative from the internal compo­
Nominal diameter Tolerance limits
nents of the bearing unless the bearing will
inch inch be lubricated by a circulating oil 9r oil mist
over including system.
1/2 1 0.000 I -0.002
1 2 0.000 I -0.003
2 4 0.000 I -0.004
4 6 0.000 I -o.oos
6 0.000 I -0.006
37
Step 8
Place the bearing on the adapter sleeve,
leading with the large bore of the inner ring
to match the taper of the adapter. Apply the
locknut with its chamfer facing the bearing
(DO NOT apply locking washer at this time
because the drive-up procedure may dam­
age the locking washer). Applying a light
coating of oil to the chamfered face of the
lock nut will make mounting easier.
Step 11
Identify the specific locknut part number on
the adapter sleeve to determine if it is an
inch or metric assembly and reference
either Table 1 or Table 2 on page 17.
Locate the specific bearing series column
and bearing bore diameter row in the appli­
cable table. Select the corresponding tight­
ening angle.
Step 13
Find the locking washer tang that is nearest
a locknut slot. If the slot is slightly past the
tang don't loosen the nut, but instead tight­
en it to meet the closest locking washer
tang. Do not bend the locking tab to the
bottom of the locknut slot.

Step 9
Using a spanner wrench, hand-tighten the
locknut so that the sleeve grips the shaft and
the adapter sleeve can neither be moved
axially, nor rotated on the shaft. With the
bearing hand tight on the adapter, locate the
bearing to the proper axial position on the
shaft. A method for checking if the bearing
and sleeve are properly clamped is to place a
screwdriver in the adapter sleeve split on the
large end of the sleeve. Applying pressure to
the screwdriver to attempt to turn the sleeve
around the shaft is a good check to deter­
mine if the sleeve is clamped down properly.
If the sleeve no longer turns on the shaft,
then the zero point has been reached. Do
not drive the bearing up any further.
Step 14
Check that the shaft and outer ring can be
rotated easily by hand.
Step 12
Remove the locknut and install the locking
washer on the adapter sleeve. The inner
prong of the locking washer should face the
bearing and be located in the slot of the oo
adapter sleeve. Reapply the locknut until
tight. (DO NOT drive the bearing further up
the taper, as this will reduce the radial inter­
nal clearance further).

Step 10
Place a reference mark on the locknut face
and shaft, preferably in the 12 o'clock position, T he angles of degree correlate to the hours on a
to use when measuring the tightening angle. clock. Use this guide to help visualize the turning
angles shown on Tables 1 and 2.

5K.f"

38
 Table 1

Angular drive-up for self-aligning ball bearings (metric nut)

Bearing Metric Axial drive-up Turning angle
bore nut bearing series bearing series
diameter designation 12 K 13 K 22 K 23 K 12 K 13 K 22 K 23 K
d
(mm) (mm) (mm) (mm) (mm) (deg) (deg) (deg) (deg)

25 KM(FE)5 0.22 0.23 0.22 0.23 55 55 55 55

30 KM(FE)6 0.22 0.23 0.22 0.23 55 55 55 55
35 KM(FE) 7 0.30 0.30 0.30 0.30 70 70 70 70
40 KM(FE)8 0.30 0.30 0.30 0.30 70 70 70 70
45 KM(FE)9 0.31 0.34 0.31 0.33 75 80 75 80
50 KM(FE)lO 0.31 0.34 0.31 0.33 75 80 75 80
55 KM(FE)11 0.40 0.41 0.39 0.40 70 75 70 75
60 KM(FE)12 0.40 0.41 0.39 0.40 70 75 70 75
65 KM(FE)13 0.40 0.41 0.39 0.40 70 75 70 75
70 KM(FE) 14
75 KM(FE)15 0.45 0.47 0.43 0.46 80 85 75 85
80 KM(FE)16 0.45 0.47 0.43 0.60 80 85 75 85
85 KM(FE)17 0.58 0.60 0.54 0.59 105 110 95 110
90 KM(FE)18 0.58 0.60 0.54 0.59 105 110 95 i10
95 KM{FE)19 0.58 0.60 0.54 105 110 95 105
100 KM(FE)20 0.58 0.60 0.54 0.59 105 110 95 110
105 KM{FE)21
110 KM(FE)22 0.67 0.70 0.66 0.69 120 125 120 125
120 KM24 0.67 120

Table 2

Angular drive-up for self-aligning ball bearings (inch nut)

Bearing Inch nut Threads per Axial drive-up Turning angle
bore designation inch bearing series bearing series
diameter 12 K 13 K 22 K 23 K 12 K 13 K 22 K 23 K

(mm) (inch) (inch) (inch) (inch) (deg) (deg) (deg) (deg)

25 NOS 32 0.009 0.009 0.009 0.009 100 100 100 100

30 N06 18 0.009 0.009 0.009 0.009 55 55 55 55
35 N07 18 0.012 0.012 0.012 0.012 75 75 75 75
40 NOS 18 0.012 0.012 0.012 0.012 75 75 75 75
45 N09 18 0.012 0.013 0.012 0.013 80 85 80 85
50 N10 18 0.012 0.013 0.012 0.013 80 85 80 85
55 Nll 18 0.016 0.016 O.D15 0.016 100 85 80 85
60 N12 18 0.016 0.016 O.D15 0.016 100 105 100 105
65 N13 18 0.016 0.016 O.D15 0.016 100 105 100 105
70 N14
75 AN15 12 0.018 0.019 0.017 0.018 75 85 75 85
80 AN16 12 0.D18 0.019 0.017 0.024 75 85 75 85
85 AN17 12 0.023 0.024 0.021 0.023 100 100 90 100
90 AN18 12 0.023 0.024 0.021 0.023 100 100 90 100
95 AN19 12 0.023 0.024 0.021 0.023 100 100 90
100 AN20 12 0.023 0.024 0.021 0.023 100 100 90 100
105 AN21
110 AN22 12 0.026 0.028 0.026 0.027 115 115 110 115
120 AN24 12 0.026 115

SKF
39
Mounting tapered bore
spherical roller bearings
Tapered bore spherical roller bearings can
be mounted using one of three methods:
radial clearance reduction, angular drive-up,
or axial I SKF hydraulic drive-up. All three
methods require the inner ring to be driven
up a tapered seat in order to achieve the
proper interference fit. T he specific method
selected by the end user will be dependent
upon the size of the bearing, the number of
bearings to be mounted, and the space con­
straints in the area surrounding the bearing.
Radial clearance reduction
method for mounting tapered
bore (1:12) spherical roller
bearings on adapter sleeves
Precautions
For hollow shafts, please consult SKF Appli­
cations Engineering. The bearings should be
left in their original packages until immedi­
ately before mounting so they do not
become dirty. The dimensional and form
accuracy of all components, which will be in
contact with the bearing, should be checked.
Step 1
Remove any burrs or rust on the shaft with
an emery cloth or a fine file.
Step 2
Wipe the shaft with a clean cloth.
Step 3 Step 6
Measure the shaft diameter. Position the adapter sleeve on the shaft,
threads outboard as indicated, to the
Shaft tolerance limits for adapter approximate location with respect to
mounting seatings required bearing centerline. For easier posi­
tioning of the sleeve, a screwdriver can be
Nominal diameter Tolerance limits
placed in the slit to open the sleeve. Apply­
inch inch
over including ing a light oil to the sleeve outside diameter
surface results in easier bearing mounting
1/2 1 0.000 / -0.002 and removal.
1 2 0.000 I -0.003
2 4 0.000 I -0.004
4 6 0.000 / -0.005
6 0.000 I -0.006
Step 4
Screw off the nut from the adapter sleeve
assembly and remove the locking washer.
Step 7
Wipe the preservative from the bore of the
bearing. It may not be necessary to remove
the preservative from the internal compo­
nents of the bearing unless the bearing will
be lubricated by a circulating oil or oil mist
system.
Step 5
Wipe preservative from the adapter 0. D.
and bore. Remove oil from the shaft to pre­
vent transfer of oil to the bore of the adapter
sleeve.
Step 8
Measure the unmounted radial internal
clearance in the bearing. The values for
unmounted internal clearance for tapered
bore spherical roller bearings are provided
in Table 3 on page 20.
Oscillate the inner ring in a circumferen­
tial direction to properly seat the rollers.
Measure the radial internal clearance in the
bearing by inserting progressively larger
feeler blades the full length of the roller
between the most unloaded roller and the
outer ring sphere. NOTE: Do not roll com­
pletely over a pinched feeler blade, slide
through the clearance. It is permissible to
rotate a roller up onto the feeler blade but
be sure it slides out of the contact area with
a slight resistance. Record the measurement
on the largest size blade that will slide
through. This is the unmounted radial inter­
nal clearance.
51C.F
40
 Repeat this procedure in two or three
other locations by resting the bearing on a
different spot on its 0.0. and measuring
over different rollers in one row. Repeat the
above procedure for the other row of rollers
or measure each row alternately in the pro­
cedure described above.
Step 9
Place the bearing on the adapter sleeve,
leading with the large bore of the inner ring
to match the taper of the adapter. Apply the
locknut with its chamfer facing the bearing
(DO NOT apply the locking washer at this
time because the drive-up procedure may
damage the locking washer). Applying a light
coating of oil to the chamfered face of the
lock nut will make mounting easier.
SKF
Step 10
Using a spanner wrench, hand-tighten the
locknut so that the sleeve grips the shaft
and the adapter sleeve can neither be
moved axially nor rotated on the shaft. With
the bearing hand tight on the adapter, locate
the bearing to the proper axial position on
the shaft.
Step 11
Select the proper radial internal clearance
reduction range from Table 3 on page 20.
Using a hammer and a spanner wrench or
just a hydraulic nut, begin tightening the nut
in order to drive the inner ring up the
tapered seat until the appropriate clearance
reduction is achieved. NOTE: LARGE SIZE
BEARINGS WILL REQUIRE A HEAVY DUTY
IMPACT SPANNER WRENCH AND SLEDGE
HAMMER TO OBTAIN THE REQUIRED
REDUCTION IN RADIAL INTERNAL CLEAR­
ANCE. AN SKF HYDRAULIC NUT MAKES
MOUNTING OF LARGE SIZE BEARINGS
EASIER. Do not attempt to tighten the lock­
nut with hammer and drift. The locknut will
be damaged and chips can enter the bearing.
41
Step 12
Remove the locknut and install the locking
washer on the adapter sleeve. The inner
prong of the locking washer should face the
bearing and be located in the slot of the
adapter sleeve. Reapply the locknut until
tight. (DO NOT drive the bearing further up
the taper, as this will reduce the radial inter­
nal clearance further).
Step 13
Find the locking washer tang that is nearest
a locknut slot. If the slot is slightly past the
tang don't loosen the nut, but instead tight­
en it to meet the closest locking washer
tang. Do not bend the locking tab to the
bottom of the locknut slot.
Step 14
Check that the shaft and outer ring can be
rotated easily by hand.
 Table 3

Unmounted radial internal clearance Recommended clearance

of SKF tapered bore spherical roller reduction values of SKF tapered
bearings (in inches) bore bearings (in inches)

Bore diameter Normal (3 (4 Reduction in radial internal clearance

range
(mm) (in.) (in.) ( in.) (in.)
mm max min max mm max mm max11

24 30 0.0012 0.0016 0.0016 0.0022 0.0022 0.0030 0.0006 0.0008

31 40 0.0014 0.0020 0.002 0.0026 0.0026 0.0033 0.0008 0.0010
41 so 0.0018 0.0024 0.0024 0.0031 0.0031 0.0039 0.0010 0.0012
51 65 0.0022 0.0030 0.003 0.0037 0.0037 0.0047 0.0012 0.0015
66 80 0.0028 0.0037 0,0037 0.0047 0.0047 0.0059 0.0015 0.0020
81 100 0.0031 0.0043 0.0043 0.0055 0.0055 0.0071 0.0018 0.0025
101 120 0.0039 0.0053 0.0053 0.0067 0.0067 0.0087 0.0020 0.0028
121 140 0.0047 0.0063 0.0063 0.0079 0.0079 0.0102 0.0025 0.0035
141 160 0.0051 0.0071 0.0071 0.0091 0.0091 0.0118 0.0030 0.0040
161 180 0.0055 0.0079 0.0079 0.0102 0.0102 0.0134 0.0030 0.0045
181 200 0.0063 0.0087 0.0087 0.0114 0.0114 0.0146 0.0035 0.0050
201 225 0.0071 0.0098 0.0098 0.0126 0.0126 0.0161 0.0040 0.0055
226 250 0.0079 0.0106 0.0106 0.0138 0.0138 0.0177 0.0045 0.0060
251 280 0.0087 0.0118 0.0118 0.0154 0.0154 0.0193 0.0045 0.0065
281 315 0.0094 0.0130 0.013 0.0169 0.0169 0.0213 0.0050 0.0075
316 355 0.0106 0.0142 0.0142 0.0185 0.0185 0.0232 0.0060 0.0085
356 400 0.0118 0.0157 0.0157 0.0205 0.0205 0.0256 0.0065 0.0090
401 450 0.0130 0.0173 0.0173 0.0224 0.0224 0.0283 0.0080 0.0105
451 500 0.0146 0.0193 0.0193 0.0248 0.0248 0.0311 0.0085 0.0110
501 560 0.0161 0.0213 0.0213 0.0268 0.0268 0.0343 0.0095 0.0125
561 630 0.0181 0.0236 0.0236 0.0299 0.0299 0.0386 0.0100 0.0135
631 710 0.0201 0.0264 0.0264 0.0335 0.0335 0.0429 0.0120 0.0155
711 800 0.0224 0.0295 0.0295 0.0378 0.0378 0.0480 0.0135 0.0175
801 900 0.0252 0.0331 0.0331 0.0421 0.0421 0.0539 0.0145 0.0195
901 1000 0.0280 0.0366 0.0366 0.0469 0.0469 0.0598 0.0160 0.0215
1001 1120 0.0303 0.0406 0.0406 0.0512 0.0512 0.0657 0.0175 0.0235
1121 1250 0.0327 0.0441 0.0441 0.0559 0.0559 0.0720 0.0190 0.0255
1251 1400 0.0358 0.0484 0.0484 0.0614 0.0614 0.0787 0.0215 0.0285
1401 1600 0.0394 0.0532 0.0532 0.0677 0.0677 0.0866 0.0235 0.0315
1601 1800 0.0437 0.0591 0.0591 0.0756 0.0756 0.0945 0.0265 0.0350

1. CAUTION: Do not use the maximum reduction of radial internal clearance when the initial unmounted radial internal clearance is in the lower half of the tolerance
range or where large temperature differentials between the bearing rings can occur in operation.
NOTE: If a different taper angle or shaft system is encountered, the following guidelines can be used.
The axial drive-up "'S" is approximately:
• 16 times the reduction on 1:12 solid tapered steel shafts
• 18 times the reduction on 1:12 taper for sleeve mounting
• 39 times the reduction on 1:30 solid tapered steel shafts
• 42 times the reduction on 1:30 taper for sleeve mounting

5KF"

42
Radial clearance reduction method
for mounting tapered bore (1:12)
spherical roller bearings onto a
solid tapered shaft
Precautions
For hollow shafts, please consult SKF Appli­
cations Engineering. The bearings should be
left in their original packages until immedi­
ately before mounting so they do not
become dirty. The dimensional and form
accuracy of all components, which will be in
contact with the bearing, should be checked.
Step1
Remove any burrs or rust on the shaft with
an emery cloth or a fine file.
Step 2
Wipe the shaft with a clean cloth.
Step 3
Measure the shaft taper for geometry and
contact using taper gauges.
SIC.F
Step 4
Wipe the preservative from the bore of the
bearing. It may not be necessary to remove
the preservative from the internal compo­
nents of the bearing unless the bearing will
be lubricated by a circulating oil or oil mist
system.
Step 5
Measure the unmounted radial internal
clearance in the bearing. The values for
unmounted internal clearance for tapered
bore spherical roller bearings are provided
in Table 3 on page 20.
Oscillate the inner ring in a circumferen­
tial direction to properly seat the rollers.
Measure the radial internal clearance in the
bearing by inserting progressively larger
feeler blades the full length of the roller
between the most unloaded roller and the
outer ring sphere. NOTE: Do not roll com­
pletely over a pinched feeler blade, slide
through the clearance. It is permissible to
rotate a roller up onto the feeler blade but
be sure it slides out of the contact area with
a slight resistance. Record the measure­
ment on the largest size blade that will slide
through. This is the unmounted radial
internal clearance.
Repeat this procedure in two or three
other locations by resting the bearing on a
different spot on its 0.0. and measuring
over different rollers in one row. Repeat the
above procedure for the other row of rollers
or measure each row alternately in the
procedure described above.
43
Step 6
P lace the bearing on the tapered shaft,
leading with the large bore of the inner ring
to match the taper of the shaft. Apply the
locknut with its chamfer facing the bearing
(DO NOT apply the locking washer at this
time because the drive-up procedure may
damage the locking washer). Applying a
light coating of oil to the chamfered face of
the lock nut will make mounting easier.
Step 7
Select the proper radial internal clearance
reduction range from Table 3 on page 20.
Using a hammer and a spanner wrench or
just a hydraulic nut, begin tightening the
nut in order to drive the inner ring up the
tapered shaft until the appropriate clear­
ance reduction is achieved. NOTE: LARGE
SIZE BEARINGS WILL REQUIRE A HEAVY
DUTY IMPACT SPANNER WRENCH AND
SLEDGE HAMMER TO OBTAIN THE
REQUIRED REDUCTION IN RADIAL INTER­
NAL CLEARANCE. AN SKF HYDRAULIC NUT
MAKES MOUNTING OF LARGE SIZE BEAR­
INGS EASIER. Do not attempt to tighten the
locknut with a hammer and drift. The lock­
nut will be damaged and chips can enter
the bearing.
Step 8
Remove the locknut and install the locking
washer on the shaft. The inner prong of the
locking washer should face the bearing and
be located in the keyway. Reapply the lock­
nut until tight. (DO NOT drive the bearing
further up the taper, as this will reduce the
radial internal clearance further).
Step 9
Find the locking washer tang that is nearest
a locknut slot. If the slot is slightly past the
tang don't loosen the nut, but instead tight­
en it to meet the closest locking washer
tang. Do not bend the locking tab to the
bottom of the locknut slot.
Step 10
Check that the shaft and outer ring can be
rotated easily by hand.
Angular drive-up method for Step 3
mounting tapered bore (1:12) Measure the shaft diameter.
spherical roller bearings on an
adapter sleeve Shaft tolerance limits for adapter
mounting seatings
The angular drive-up method simplifies the
mounting process by equating axial drive up Nominal diameter Tolerance limits
to the rotation of a locknut. By knowing the inch inch
threads per inch of a locknut, the number of over including
rotations to achieve a specific axial move­
1/2 1 0.000 I -0.002
ment can be determined. In order to make 1 2 0.000 I -0.003
this mounting method work properly, the 2 4 0.000 I -0.004
starting point is important since that is the 4 6 0.000 / -0.005
reference point to determine when to start 6 0.000 I -0.006
counting the rotation of the locknut.
Precautions Step 4
The bearings should be left in their original Screw off the nut from the adapter sleeve
packages until immediately before mount­ assembly and remove the locking washer.
ing so they do not become dirty. The dimen­
sional and form accuracy of all components,
which will be in contact with the bearing,
should be checked.
Step 1
Remove any burrs or rust on the shaft with
an emery cloth or a fine file.
Step 5
Wipe preservative from the adapter 0. D.
and bore. Remove oil from the shaft to pre­
vent transfer of oil to the bore of the adapter
sleeve.
Step 2
Wipe the shaft with a clean cloth.
Step 6
Position the adapter sleeve on the shaft,
threads outboard as indicated, to the
approximate location with respect to
required bearing centerline. For easier posi­
tioning of the sleeve, a screwdriver can be
placed in the slit to open the sleeve. Apply­
ing a light oil to the sleeve outside diameter
surface results in easier bearing mounting
and removal.
SIC.F
44
Step 7
Wipe the preservative from the bore of the
bearing. It may not be necessary to remove
the preservatives from the internal compo­
nents of the bearing unless the bearing will
be lubricated by a circulating oil or oil mist
system.
Step 8
Place the bearing on the adapter sleeve,
leading with the large bore of the inner ring
to match the taper of the adapter. Apply the
locknut with its chamfer facing the bearing
(DO NOT apply the locking washer at this
time because the drive-up procedure may
damage the locking washer). Applying a light
coating of oil to the chamfered face of the
lock nut will make mounting easier.
®
� (t----._
\JJL)_)
Step 9
Using a spanner wrench, hand-tighten the
locknut so that the sleeve grips the shaft
and the adapter sleeve can neither be
moved axially, nor rotated on the shaft. With
the bearing hand tight on the adapter, locate
the bearing to the proper axial position on
the shaft. A method for checking if the bear­
ing and sleeve are properly clamped is to
place a screwdriver in the adapter sleeve
split on the large end of the sleeve. Applying
pressure to the screwdriver to attempt to
turn the sleeve around the shaft is a good
check to determine if the sleeve is clamped
down properly. If the sleeve no longer turns
on the shaft, then the zero point has been
reached. Do not drive the bearing up any
further.
5K.F
Step 10
Place a reference mark on the locknut face
and shaft, preferably in the 12 o'clock posi­
tion, to use when measuring the tightening
angle.
Step 11
Locate the specific bearing part number in
Table 4 on page 24. Note the specific lock
nut part number on the adapter sleeve to
determine if it is an inch or metric assembly.
Once the appropriate locknut part number
has been obtained, select the corresponding
tightening angle from Table 4.
Step 12
Using a hammer and a spanner wrench,
begin tightening the locknut the corre­
sponding tightening angle. NOTE: LARGE
SIZE BEARINGS WILL REQUIRE A HEAVY
DUTY IMPACT SPANNER WRENCH AND
SLEDGE HAMMER TO OBTAIN THE
REQUIRED REDUCTION IN RADIAL INTER­
NAL CLEARANCE. Do not attempt to tighten
the locknut with hammer and drift. The
locknut will be damaged and chips can enter
the bearing.
45
Step 13
Remove the locknut and install the locking
washer on the adapter sleeve. The inner
prong of the locking washer should face the
bearing and be located in the slot of the
adapter sleeve. Reapply the locknut until
tight. (DO NOT drive the bearing further up
the taper, as this will reduce the radial inter­
nal clearance further).
I©
Step 14
Find the locking washer tang that is nearest
a locknut slot. If the slot is slightly past the
tang don't loosen the nut, but instead tight­
en it to meet the closest locking washer
tang. Do not bend the locking tab to the
bottom of the locknut slot.
(f�
Step 15
Check that the shaft and outer ring can be
rotated easily by hand.
 Table 4 oo

Angular drive-up for spherical roller bearings

(metric and inch nuts)

Bearing Bearing bore Axial Metric nut Turning Inch nut Turning 75°
designation diameter drive-up designation angle designation angle
d a a 90°
(mm) (mm) (degrees) (degrees)
105 °
222xx series
22206 K 30 0.30 KM(FE)6 110 N 06 115
22207 K 35 0.35 KM(FE)7 115 N 07 120
22208 K 40 0.35 KM(FE)8 125 N 08 135
22209 K 45 0.40 KM(FE)9 130 N 09 140 180°
22210 K so 0.40 KM(FE)10 140 N 10 150
22211 K 55 0.45 KM(FE)11 110 N 11 155 The angles af degree correlate to the hours on a
22212 K 60 0.45 KM(FE) 12 115 N 12 165 clock. Use this guide to help visualize the turning
22213 K 65 0.45 KM(FE)13 120 N 13 170 angles shown on Table 4.
22214 K 70 0.60 KM(FE) 14 130 N 14 175
22215 K 75 0.60 KM(FE) 15 135 AN 15 120 SKF hydraulic (axial) drive-up
22216 K 80 0.60 KM(FE)16 140 AN 16 130 method for tapered bore (1:12)
22217 K 85 0.70 KM(FE) 17 145 AN 17 135 spherical roller bearings on an
22218 K 90 0.70 KM(FE)18 150 AN 18 145 adapter sleeve
22219 K 95 0.70 KM(FE)19 155 AN 19 145
The axial drive-up method relies on the
22220 K 100 0.70 KM(FE) 20 160 AN 20 150
bearing being driven up a tapered seat a
22222 K 110 0.75 KM(FE) 22 175 AN 22 160
specific amount to ensure the inner ring is
22224 K 120 0.75 KM 24 185 AN 24 170
expanded enough to provide proper clamp-
223xx series
ing force on the shaft or sleeve. In order for
22308 K 40 0.35 KM(FE)8 125 N 08 135
this method to work properly, the starting
22309 K 45 0.40 KM(FE)9 135 N 09 140
point is important since that is the reference
22310 K so 0.40 KM(FE)10 145 N 10 150
point to determine when the bearing has
22311 K 55 0.45 KM(FE)11 115 N 11 155
been driven up enough. A new method of
22312 K 60 0.45 KM(FE)12 120 N 12 165
accurately achieving this starting point has
22313 K 65 0.45 KM(FE)13 125 N 13 170
been developed by SKF and is now available.
22314 K 70 0.60 KM(FE) 14 135 N 14 175
The method incorporates the use of a
22315 K 75 0.60 KM(FE)15 135 AN 15 120
hydraulic nut fitted with a dial indicator, and
22316 K 80 0.60 KM(FE)16 145 AN 16 130
a specially calibrated pressure gauge,
22317 K 85 0.70 KM(FE)17 150 AN 17 135
mounted on the selected pump.
22318 K 90 0.70 KM(FE)18 155 AN 18 145
A special hydraulic pressure table provid-
22319 K 95 0.70 KM(FE)19 165 AN 19 145
ing the required psi pressures must be used
22320 K 100 0.70 KM(FE)20 170 AN 20 150
for each bearing type (see Table 5 on page
22322 K 110 0.75 KM(FE) 22 185 AN 22 160
26). This enables accurate positioning of the
22324 K 120 0.75 KM 24 195 AN 24 170
bearing at the starting point, where the axial
drive-up is measured. This method provides:
Drive up and angular rotation values are the same for both CC and E design SKF spherical roller bearings. 1. Reduced time to mount bearings.
For sizes greater than those shown above we recommend the use of the SKF Hydraulic drive-up method. 2. A reliable, safe and accurate method of
For threads per inch see Table 2 (page 17).
clearance adjustment.
3. Ideal way to mount sealed spherical
roller bearings.

Precautions
For hollow shafts, please consult SKF Appli-
cations Engineering. The bearings should be
left in their original packages until immedi-
ately before mounting so they do not
become dirty. The dimensional and form
accuracy of all components, which will be in
contact with the bearing, should be checked.

SKF
46
Step 1
Remove any burrs or rust on the shaft with
an emery cloth or a fine file.
Step 6
Position the adapter sleeve on the shaft,
threads outboard as indicated, to the
approximate location with respect to
required bearing centerline. For easier
positioning of the sleeve, a screwdriver can
be placed in the slit to open the sleeve.
Step 9
Drive the bearing up the adapter sleeve the
required distance 55 shown under column
heading 1*** of Table 5. The axial drive-up
is best monitored by a dial indicator.

Step 2
Wipe the shaft with a clean cloth.

Step 7
Applying a light oil to the sleeve outside
diameter surface results in easier bearing
mounting and removal. Wipe the preserva­
tive from the bore of the bearing. It may not
be necessary to remove the preservative
Step 3 from the internal components of the bear­
Measure the shaft diameter. ing unless the bearing will be lubricated by
a circulating oil or oil mist system.
Shaft tolerance limits for adapter
mounting seatings
Step 10
Remove the hydraulic nut and install the
locking washer on the adapter sleeve. The
inner prong of the locking washer should
face the bearing and be located in the slot
of the adapter sleeve. Reapply the locknut
until tight. (DO NOT drive the bearing further
up the taper, as this will reduce the radial
internal clearance further).

Nominal diameter Tolerance limits

inch inch
over including

1/2 1 0.000 I -0.002

Step 11
1 2 0.000 I -0.003
2 4 0.000 I -0.004 Find the locking washer tang that is nearest
4 6 0.000 I -o.oos Step 8 a locknut slot. If the slot is slightly past the
6 0.000 I -0.006 Place the bearing on the adapter sleeve, tang don't loosen the nut, but instead tighten
leading with the large bore of the inner ring it to meet the closest locking washer tang.
to match the taper of the adapter. Apply the Do not bend the locking tab to the bottom of
Step 4 hydraulic nut (DO NOT apply the locking the locknut slot.
Remove the locknut and locking washer washer at this time). Ensure that the
from the adapter sleeve assembly. bearing bore size is equal to the hydraulic
nut. Otherwise, the pressure in the table
must be adjusted. Drive the bearing up to
the starting position by applying the
hydraulic pressure listed in Starting Position
1 * in Table 5 for the specific bearing size
being mounted. Monitor the pressure by the
gauge on the selected pump. As an alterna­
tive, SKF mounting gauge TMJG 1000 can Step 12
Step 5 be screwed directly into the hydraulic nut. Check that the shaft and outer ring can be
Wipe preservative from the adapter 0. 0. rotated easily by hand.
and bore. Remove oil from the shaft to Note: For bearings with a bore diameter great­
prevent transfer of oil to the bore of the er than 200mm, hydraulic assist is recom­
adapter sleeve. mended in addition to using the hydraulic nut.

5KF
47
 Table 5

Pressure and axial drive-up for spherical roller bearings

Starting position Final position

SKF bearing Hydraulic Radial clearance Axial drive-up

designation pressure reduction from zero from starting
position position 55

1* (psi) 2** (psi) (in.) 1*** (in.) 2**** (in,)

213xx series
21310 EK 286 0.0009 0.0146 Zero Starting Final
position position position
.J .J
21311 EK 215 365 0.0010 0.0154 0.0181
21312 EK 351 600 0.0011 0.0177 0.0205
21313 EK 365 625 0.0012 0.0185 0.0213
21314 EK 386 658 0.0012 0.0205 0.0232
21315 EK 318 542 0.0013 0.0201 0.0229
21316 EK 319 545 0.0014 0.0209 0.0236 s
21317 EK 254 434 0.0015 0.0205 0.0236
21318 EK 270 460 0.0016 0.0225 0.0252
21319 EK 278 476 0.0017 0.0232 0.0260
21320 EK 216 368 0.0018 0.0229 0.0256

222xx series
22210 EK 102 191 0.0009 0.0126 0.0154
22211 EK 104 194 0.0010 0.0142 0.0169
22212 EK 139 248 0.0011 0.0154 0.0181
22213 EK 168 313 0.0011 0.0162 0.0189
22214 EK 135 244 0.0013 0.0173 0.0201
22215 EK 126 225 0.0013 0.0177 0.0209
22216 EK 146 262 0.0014 0.0189 0.0217
22217 EK 168 300 0.0015 0.0197 0.0229
22218 EK 174 318 0.0016 0.0213 0.0240 b
22219 EK 199 354 0.0017 0.0221 0.0248
22220 EK 212 376 0.0018 0.0229 0.0256
22222 EK 251 452 0.0019 0.0248 0.0276
22224 EK 267 471 0.0021 0.0268 0.0299
22226 EK 284 502 0.0023 0.0284 0.0311
22228 CCK/W33 338 595 0.0025 0.0311 0.0339
22230 CCK/W33 361 634 0.0027 0.0335 0.0362
22232 CCK/W33 373 731 0.0028 0.0355 0.0382 C
22234 CCK/W33 402 751 0.0030 0.0374 0.0402
22236 CCK/W33 361 676 0.0032 0.0390 0.0422
22238 CCK/W33 371 706 0.0033 0.0410 0.0437
22240 CCK/W33 389 722 0.0035 0.0433 0.0461
22244 CCK/W33 426 838 0.0039 0.0477 0.0504
22248 CCK/W33 480 938 0.0043 0.0524 0.0552
22252 CCK/W33 470 914 0.0046 0.0559 0.0587
22256 CCK/W33 428 818 0.0050 0.0595 0.0626
22260 CCK/W33 419 802 0.0053 0.0634 0.0662
22264 CCK/W33 442 841 0.0057 0.0674 0.0705

* Values given valid for HMV (C) E series hydraulic nuts equal to bearing size and with one sliding surface (see Figures band c). Surfaces lightly oiled with light oil.
Values given valid for HMV (C) E series hydraulic nuts equal to one size smaller than bearing size and two sliding surfaces (see Figure e).
Surfaces lightly oiled with light oil.
Values given are valid for one sliding surface (see Figures b and c). Surfaces lightly oiled with light oil.
**** Values given are valid for two sliding surfaces (see Figure e). Surfaces lightly oiled with light oil. The difference in drive-up between one surface and two surfaces is
the result of smoothing.
NOTE: To convert values to mm and MPa mm = in x 25.4 MPA = psi x 0.0069

SKF"

48
 Table 5 Table 5

Pressure and axial drive-up for spherical roller bearings Pressure and axial drive-up for spherical roller bearings

Starting position Final position Starting position Final position

SKF bearing Hydraulic Radial clearance Axial drive-up SKF bearing Hydraulic Radial clearance Axial drive-up
designation pressure reduction from zero from starting designation pressure reduction from zero from starting
position position 55 position position 55

1* (psi) 2** (psi) (in.) 1*** {in.) 2**** (in.) 1* (psi) 2** (psi) (in.) 1*** (in.) 2**** (in.)
223xx series 230xx series
22310 EK 270 0.0008 0.0134 0.0162 23022 CCK/W33 157 283 0.0019 0.0240 0.0268
22311 EK 287 532 0.0010 0.0150 0.0181 23024 CCK/W33 149 262 0.0021 0.0260 0.0288
22312 EK 345 616 0.0011 0.0162 0.0189 23026 CCK/W33 184 325 0.0023 0.0276 0.0303
22313 EK 306 570 0.0011 0.0165 0.0193 23028 CCK/W33 175 309 0.0025 0.0295 0.0327
22314 EK 374 674 0.0013 0.0185 0.0217 23030 CCK/W33 180 316 0.0027 0.0319 0.0347
22315 EK 338 608 0.0013 0.0189 0.0217 23032 CCK/W33 180 351 0.0028 0.0335 0.0362
22316 EK 348 624 0.0014 O.D197 0.0225 23034 CCK/W33 194 363 0.0030 0.0351 0.0378
22317 EK 428 764 0.0015 0.0213 0.0240 23036 CCK/W33 219 409 0.0032 0.0374 0.0406
22318 EK 432 787 0.0016 0.0225 0.0256 23038 CCK/W33 215 409 0.0033 0.0394 0.0422
22319 EK 441 784 0.0017 0.0232 0.0260 23040 CCK/W33 236 438 0.0035 0.0418 0.0445
22320 EK 595 1057 0.0018 0.0252 0.0280 23044 CCK/W33 242 476 0.0039 0.0453 0.0485
22322 EK 653 1176 0.0019 0.0272 0.0299 23048 CCK/W33 216 422 0.0043 0.0489 0.0516
22324 CCK/W33 634 1118 0.0021 0.0288 0.0319 23052 CCK/W33 249 484 0.0046 0.0532 0.0559
22326 CCK/W33 686 1209 0.0023 0.0307 0.0335 23056 CCK/W33 225 431 0.0050 0.0630 0.0595
22328 CCK/W33 729 1282 0.0025 0.0331 0.0359 23060 CCK/W33 255 487 0.0053 0.0607 0.0634
22330 CCK/W33 766 1344 0.0027 0.0355 0.0382 23064 CCK/W33 232 442 0.0057 0.0642 0.0670
22332 CCK/W33 747 1465 0.0028 0.0374 0.0402 23068 CCK/W33 267 492 0.0060 0.0682 0.0713
22334 CKK/W33 760 1417 0.0030 0.0390 0.0418 23072 CCK/W33 238 448 0.0064 0.0717 0.0745
22336 CCK/W33 747 1396 0.0032 0.0414 0.0441 23076 CCK/W33 229 419 0.0067 0.0753 0.0780
22338 CCK/W33 738 1405 0.0033 0.0433 0.0461 23080 ...K/W33 254 476 0.0071 0.0796 0.0823
22340 CCK/W33 745 1382 0.0035 0.0457 0.0485 23084 CAK/W33 236 439 0.0074 0.0827 0.0855
22344 CCK/W33 811 1595 0.0039 0.0508 0.0536 23088 CAK/W33 248 450 0.0078 0.0867 0.0894
22348 CCK/W33 808 1581 0.0043 0.0548 0.0575 23092 CAK/W33 249 452 0.0081 0.0906 0.0934
22352 CCK/W33 815 1581 0.0046 0.0591 0.0619 23096 CAK/W33 218 400 0.0085 0.0934 0.0961
22356 CCK/W33 827 1581 0.0050 0.0634 0.0662
231xx series
23120 CCK/W33 206 364 0.0018 0.0225 0.0252
23122 CCK/W33 210 378 0.0019 0.0240 0.0268
23124 CCK/W33 257 454 0.0021 0.0264 0.0295
23126 CCK/W33 239 421 0.0023 0.0280 0.0307
23128 CCK/W33 248 435 0.0025 0.0299 0.0327
23130 CCK/W33 322 564 0.0027 0.0327 0.0355
23132 CCK/W33 328 641 0.0028 0.0343 0.0374
23134 CCK/W33 310 579 0.0030 0.0359 0.0386
23136 CCK/W33 335 626 0.0032 0.0382 0.0410
23138 CCK/W33 363 690 0.0033 0.0402 0.0429
23140 CCK/W33 377 700 0.0035 0.0426 0.0453
23144 CCK/W33 393 773 0.0039 0.0465 0.0492
23148 CCK/W33 378 741 0.0043 0.0500 0.0532
23152 CCK/W33 418 811 0.0046 0.0544 0.0571
23156 CCK/W33 377 721 0.0050 0.0579 0.0607
23160 CCK/W33 409 780 0.0053 0.0619 0.0646
23164 CCK/W33 448 853 0.0057 0.0662 0.0689
23168 CCK/W33 489 900 0.0060 0.0705 0.0733
23172 CACK/W33 473 890 0.0064 0.0745 0.0772
23176 CAK/W33 416 760 0.0067 0.0772 0.0800

* Values given valid for HMV (C) E series hydraulic nuts equal to bearing size and with one sliding surface (see Figures band c). Surfaces lightly oiled with light oil.
Values given valid for HMV (C) E series hydraulic nuts equal to one size smaller than bearing size and two sliding surfaces (see Figure e).
Surfaces lightly oiled with light oil.
Values given are valid for one sliding surface (see Figures band c). Surfaces lightly oiled with light oil.
Values given are valid for two sliding surfaces (see Figure e). Surfaces lightly oiled with light oil. The difference in drive-up between one surface and two surfaces is
the result of smoothing.
NOTE: To convert values to mm and MPa mm = in x 25.4 MPA = psi x 0.0069

51C.F
49
 Table 5 Table 5

Pressure and axial drive-up for spherical roller bearings Pressure and axial drive-up for spherical roller bearings

Starting position Rnal position Starting position Final position

SKF bearing Hydraulic Radial clearance Axial drive-up SKF bearing Hydraulic Radial clearance Axial drive-up
designation pressure reduction from zero from starting designation pressure reduction from zero from starting
position position $5 position position Ss

1• (psi) 2**(psi) (in.) 1*** (in.) 2**** {in.) 1•(psi) 2**(psi) (in.) 1 *** (in.) 2**** (in.)

232xx series 240xx series

23218 CCK/W33 245 447 0.0016 0.0213 0.0244 24024 CCK30/W33 157 302 0.0021 0.0646 0.0717
23220 CCK/W33 278 494 0.0018 0.0229 0.0256 24026 CCK30/W33 203 387 0.0023 0.0693 0.0764
23222 CCK/W33 341 615 0.0019 0.0248 0.0276 24028 CCK30/W33 186 357 0.0025 0.0741 0.0812
23224 CCK/W33 367 647 0.0021 0.0272 0.0299 24030 CCK30/W33 194 370 0.0027 0.0796 0.0867
23226 CCK/W33 371 655 0.0023 0.0288 0.0315 24032 CCK30/W33 191 409 0.0028 0.0835 0.0906
23228 CCK/W33 439 774 0.0025 0.0311 0.0339 24034 CCK30/W33 219 444 0.0030 0.0879 0.0950
23230 CCK/W33 451 792 0.0027 0.0335 0.0362 24036 CCK30/W33 257 521 0.0032 0.0946 0.1020
23232 CCK/W33 477 935 0.0028 0.0355 0.0382 24038 CCK30/W33 225 467 0.0033 0.0977 0.1050
23234 CCK/W33 497 929 0.0030 0.0370 0.0398 24040 CCK30/W33 251 508 0.0035 0.1040 0.1110
23236 CCK/W33 461 863 0.0032 0.0390 0.0418 24044 CCK30/W33 252 541 0.0039 0.1130 0.1210
23238 CCK/W33 471 898 0.0033 0.0410 0.0437 24048 CCK30/W33 219 464 0.0043 0.1220 0.1290
23240 CCK/W33 503 934 0.0035 0.0433 0.0461 24052 CCK30/W33 274 581 0.0046 0.1330 0.1400
23244 CCK/W33 550 1080 0.0039 0.0477 0.0504 24056 CCK30/W33 239 499 0.0050 0.1410 0.1480
23248 ...K/W33 626 1224 0.0043 0.0520 0.0552 24060 ...K30/W33 273 567 0.0053 0.1510 0.1580
23252 ...K/W33 667 1296 0.0046 0.0563 0.0595 24064 CCK30/W33 261 538 0.0057 0.1610 0.1680
23256 ... K/W33 599 1147 0.0050 0.0599 0.0626 24068 CCK30/W33 296 592 0.0060 0.1710 0.1780
23260 . .K/W33 629 1201 0.0053 0.0642 0.0670 24072 CCK30/W33 270 551 0.0064 0.1790 0.1860
23264 ... K/W33 677 1289 0.0057 0.0686 0.0713 24076 CCK30/W33 258 513 0.0067 0.1880 0.1950
23268 ... K/W33 721 1328 0.0060 0.0725 0.0756
23272 ...K/W33 677 1275 0.0064 0.0760 0.0788 241xx series
23276 ...K/W33 686 1253 0.0067 0.0800 0.0831 24122 CCK30/W33 225 442 0.0019 0.06D7 0.0674
24124 CCK30/W33 280 538 0.0021 0.0666 0.0737
239xx series 24126 CCK30/W33 271 521 0.0023 0.0705 0.0776
23936 CCK/W33 122 0.0032 0.0366 24128 CCK30/W33 273 522 0.0025 0.0756 0.0827
23938 CCK/W33 104 0.0033 0.0382 24130 CCK30/W33 342 654 0.0027 0.0820 0.0890
23940 CCK/W33 129 0.0035 0.0406 24132 CCK30/W33 370 786 0.0028 0.0871 0.0942
23944 CCK/W33 109 0.0039 0.0437 24134 CCK30/W33 315 638 0.0030 0.0898 0.0965
23948 CCK/W33 93 0.0043 0.0473 24136 CCK30/W33 357 726 0.0032 0.0961 0.1030
23952 CCK/W33 132 0.0046 0.0516 24138 CCK30/W33 384 798 0.0033 0.1010 0.1080
23956 CCK/W33 119 0.0050 0.0552 24140 CCK30/W33 410 827 0.0035 0.1070 0.1140
23960 CCK/W33 154 0.0053 0.0595 24144 CCK30/W33 409 873 0.0039 0.1170 0.1240
23964 CCK/W33 139 0.0057 0.0626 24148 CCK30/W33 412 876 0.0043 0.1260 0.1340
23968 CCK/W33 129 0.0060 0.0662 24152 CCK30/W33 450 950 0.0046 0.1370 0.1440
23972 CCK/W33 116 0.0064 0.0697 24156 CCK30/W33 402 837 0.0050 0.1450 0.1520
23976 CCK/W33 152 0.0067 0.0741 24160 CCK30/W33 448 929 0.0053 0.1560 0.1630
24164 CCK30/W33 492 1018 0.0057 0.1670 0.1740
24168 ECAK30/W33 522 1047 0.0060 0.1770 0.1840
24172 ECCK30J/W33 476 974 0.0064 0.1850 0.1920
24176 ECAK30/W33 439 871 0.0067 0.1930 0.2010

* Values given valid for HMV (C) E series hydraulic nuts equal to bearing size and with one sliding surface (see Figures band c). Surfaces lightly oiled with light oil.
Values given valid for HMV (C) E series hydraulic nuts equal to one size smaller than bearing size and two sliding surfaces (see Figure e).
Surfaces lightly oiled with light oil.
Values given are valid for one sliding surface (see Figures band c). Surfaces lightly oiled with light oil.
Values given are valid for two sliding surfaces (see Figure e). Surfaces lightly oiled with light oil. The difference in drive-up between one surface and two surfaces is
the result of smoothing.
NOTE: To convert values to mm and MPa mm = in x 25.4 MPA = psi x 0.0069

SKF
50
Mounting of
CARS ® toroidal
roller bearings
CARB can accommodate axial displacement
within the bearing. This means that the
inner ring as well as the roller assembly can
be axially displaced in relation to the outer
ring. (ARB can be secured with lock nuts
KMF .. E or KML. If standard KM, AN, or N
style lock nuts and locking washers are used
instead, a spacer may be needed between
the bearing inner ring and the washer to
prevent washer contact with the cage, if axi­
al displacement or misalignment are
extreme, see Figure 9. The spacer dimen­
sions shown in Figure 10 will help ensure
safe operation with axial offset ±10% of
bearing width, and 0.5° misalignment.
Note that both the inner and outer ring
must be locked in the axial direction as
shown in Figures 9 and 10.
Figure 9
Axial location and axial displacement
Figure 10
Initial axial displacements and
spacer dimensions
SKF
Spacer dimensions Radial clearance reduction
For mounting with standard KM, AN and N method for mounting tapered
lock nuts and locking washers, as shown in bore (1:12) CARB on adapter
Figure 10, spacers with the following sleeves
dimensions are needed:
d< 35 mm 81 = 2 mm Precautions
35 mm< d< 120 mm 81 = 3 mm For hollow shafts, please consult SKF Appli­
d > 120 mm 81 = 4 mm cations Engineering. The bearings should be
Dimensions d and d2 as shown in Figure left in their original packages until immedi­
10 must be obtained from the SKF General ately before mounting so they do not
Catalog, CARB section. become dirty. The dimensional and form
accuracy of all components, which will be in
contact with the bearing, should be checked.
Axial mounting position
Initial axial displacement of one ring in rela­ Step 1
tion to the other can be used to increase the Remove any burrs or rust on the shaft with
available axial clearance for shaft movement an emery cloth or a fine file.
in one direction, see Figure 10.
It is also possible to accurately adjust the
radial clearance or the radial position of the
bearing by displacing one of the rings. Axial
and radial clearance are interdependent, i.e.
an axial displacement of one ring from the
center position reduces the radial clearance. Step 2
This principle is shown in Figure 11 as Wipe the shaft with a clean cloth.
applied to CARB C 2220.
Figure 11
The clearance window for CARB®
�•11rm
AdJust&bleinttrnalctn.rance
Step 3
Measure the shaft diameter.
-1 -6 -s -4 -) -2 ·1 0 1 2 J 4 5 6 1
A� d�p!�Cllmenl mn,
Shaft tolerance limits for adapter
mounting seatings
For example, if the axial displacement is Nominal diameter Tolerance limits
2.5 mm, the radial clearance is reduced inch inch
from 100 to 90 µm and the radial position over including
of the bearing changes from -50 to -45 µm,
1/2 1 0.000 I -0.002
(Figure 11 ). For more information please 1 2 0.000 I -0.003
contact SKF. 2 4 0.000 / -0.004
4 6 0.000 / -0.005
6 0.000 / -0.006
Mounting of CARB toroidal roller
bearings with cylindrical bore Step 4
The same precautions and mounting proce­ Screw off the locknut from the adapter
dures apply as other bearings with cylindri­ sleeve assembly and remove the locking
cal bores. See page 13 for the different washer.
methods of mounting cylindrical bore (ARB.
51
Step 5
Wipe preservative from the adapter 0. D.
and bore. Remove oil from the shaft to pre­
vent transfer of oil to the bore of the adapter
sleeve.
outer ring sphere. NOTE: Do not roll com­
pletely over a pinched feeler blade, slide
through the clearance. It is permissible to
rotate a roller up onto the feeler blade but
be sure it slides out of the contact area with
a slight resistance. Record the measurement
on the largest size blade that will slide
through. This is the unmounted radial inter­
nal clearance.
Repeat this procedure in two or three
other locations by resting the bearing on a
different spot on its 0.0. and measuring
over different rollers.
Step 10
Using a spanner wrench, hand-tighten the
locknut so that the sleeve grips the shaft
and the adapter sleeve can neither be
moved axially, nor rotated on the shaft. With
the bearing hand tight on the adapter, locate
the bearing to the proper axial position on
the shaft.

Step 6
Position the adapter sleeve on the shaft,
threads outboard as indicated, to the
approximate location with respect to
required bearing centerline. For easier posi­
tioning of the sleeve, a screwdriver can be
placed in the slit to open the sleeve. Apply­
ing a light oil to the sleeve outside diameter
surface results in easier bearing mounting
and removal.
Step 7
Wipe the preservative from the bore of the
bearing. It may not be necessary to remove
the preservative from the internal compo­
nents of the bearing unless the bearing will
be lubricated by a circulating oil or oil mist
system.
Step 8
Measure the unmounted radial internal
clearance in the bearing. The values for
unmounted internal clearance for (ARB
are provided in Table 6.
Oscillate the inner ring in a circumferen­
tial direction to properly seat the rollers.
Measure the radial internal clearance in the
bearing by inserting progressively larger
feeler blades the full length of the roller
between the most unloaded roller and the
Step 11
Select the proper radial internal clearance
reduction range from Table 6 on page 31.
Using a hammer and a spanner wrench or
just a hydraulic nut, begin tightening the
locknut in order to drive the inner ring up the
tapered seat until the appropriate clearance
reduction is achieved. NOTE: LARGE SIZE
BEARINGS WILL REQUIRE A HEAVY DUTY
IMPACT SPANNER WRENCH AND SLEDGE
HAMMER TO OBTAIN THE REQUIRED
REDUCTION IN RADIAL INTERNAL CLEAR­
The feeler gauge should be ANCE. AN SKF HYDRAULIC NUT MAKES
moved to and fro MOUNTING OF LARGE SIZE BEARINGS EAS­
IER. Do not attempt to tighten the locknut
with hammer and drift. The locknut will be
Step 9 damaged and chips can enter the bearing.
Place the bearing on the adapter sleeve,
leading with the large bore of the inner ring
to match the taper of the adapter. Apply the
locknut with its chamfer facing the bearing
(DO NOT apply the locking washer at this
time because the drive-up procedure may
damage the locking washer). Applying a light
coating of oil to the chamfered face of the
lock nut will make mounting easier. With
the bearing hand tight on the adapter
sleeve, locate the bearing to the proper
axial position on the shaft.

5K.F
52
 Table 6

Radial internal clearance (RIC) of CARB ® toroidal roller bearings with tapered bore
Bore diameter Unmounted radial internal clearance Reduction in RIC Axial drive-up (5)1
range C2 Normal C3 (4 1:12 taper
d min max min max min max min max min max min max
mm inch inch inch inch inch

18 24 0.0007 0.0012 0.0012 0.0017 0.0017 0.0022 0.0022 0.0027 0.0004 0.0006 0.0083 0.0114
25 30 0.0009 0.0015 0.0015 0.0020 0.0020 0.0026 0.0026 0.0032 0.0005 0.0007 0.0098 0.0134
31 40 0.0011 0.0018 0.0018 0.0024 0.0024 0.0031 0.0031 0.0039 0.0006 0.0009 0.0118 0.0165
41 50 0.0013. 0.0021 0.0021 0.0029 0.0029 0.0037 0.0037 0.0046 0.0008 0.0012 0.0146 0.0201
51 65 0.0017 0.0025 0.0025 0.0035 0.0035 0.0044 0;0044 0.0058 0.0010 0.0015 0.0173 0.0252
66 80 0.0020 0.0031 0.0031 0.0043 0.0043 0.0054 0.0054 0.0069 0.0013 0.0019 0.0213 0.0299
81 100 0.0025 0.0038 0.0038 0.0052 0.0052 0.0068 0.0068 0.0086 0.0016 0.0024 0.0256 0.0366
101 120 0.0030 0.0045 0.0045 0.0061 0.0061 0.0079 0.0079 0.0100 0.0020 0.0028 0.0311 0.0433
121 140 0.0035 0.0053 0.0053 0.0071 0.0071 0.0091 0.0091 0.0116 0.0024 0.0033 0.0366 0.0500
141 160 0.0041 0.0061 0.0061 0.0083 0.0083 0.0106 0.0106 0.0133 0.0028 0.0038 0.0421 0.0567

161 180 0.0046 0.0068 0.0068 0.0094 0.0094 0.0119 0.0119 0.0150 0.0031 0.0043 0.0476 0.0634
181 200 0.0051 0.0076 0.0076 0.0102 0.0102 0.0130 0.0130 0.0164 0.0035 0.0047 0.0535 0.0701
201 225 0.0057 0.0084 0.0084 0.0113 0.0113 0.0143 0.0143 0.0181 0.0039 0.0053 0.0591 0.0783
226 250 0.0063 0.0093 0.0093 0.0124 0.0124 0.0158 0.0158 0.0201 0.0044 0.0059 0.0657 0.0866
251 280 0.0069 0.0102 0.0102 0.0135 0.0135 0.0175 0.0175 0.0219 0.0049 0.0067 0.0728 0.0969
281 315 0.0078 0.0111 0.0111 0.0148 0.0148 0.0189 0.0189 0.0243 0.0055 0.0075 0.0811 0.1083
316 355 0.0088 0.0125 0.0125 0.0165 0.0165 0.0213 0.0213 0.0267 0.0062 0.0085 0.0909 0.1217
356 400 0.0099 0.0138 0.0138 0.0185 0.0185 0.0235 0.0235 0.0296 0.0070 0.0094 0.1020 0.1366
401 450 0.0111 0.0151 0.0151 0.0207 0.0207 0.0257 0.0257 0.0329 0.0079 0.0106 0.1146 0.1535
451 500 0.0120 0.0171 0.0171 0.0226 0.0226 0.0289 0.0289 0.0359 0.0089 0.0118 0.1283 0.1701
501 560 0.0132 0.0187 0.0187 0.0249 0.0249 0.0316 0.0316 0.0396 0.0098 0.0132 0.1421 0.1902
561 630 0.0150 0.0209 0.0209 0.0276 0.0276 0.0349 0.0349 0.0437 0.0110 0.0150 0.1591 0.2134
631 710 0.0166 0.0232 0.0232 0.0304 0.0304 0.0388 0.0388 0.0484 0.0124 0.0167 0.1783 0.2402
711 800 0.0189 0.0265 0.0265 0.0339 0.0339 0.0433 0.0433 0.0543 0.0140 0.0189 0.2008 0.2701
801 900 0.0208 0.0289 0.0289 0.0376 0.0376 0.0478 0.0478 0.0600 0.0157 0.0213 0.2256 0.3035
901 1000 0.0228 0.0320 0.0320 0.0409 0.0409 0.0528 0.0528 0.0657 0.0177 0.0236 0.2535 0.3370
1.001 1120 0.0254 0.0352 0.0352 0.0459 0.0459 0.0589 0.0589 0.0738 0.0197 0.0264 0.2811 0.3768
1.121 1250 0.0278 0.0384 0.0384 0.0502 0.0502 0.0644 0.0644 0.0809 0.0220 0.0295 0.3150 0.4213
1. Valid only for solid tapered shafts.
CAUTION: Do not use the maximum reduction of radial internal clearance when the initial unmounted radial internal clearance is in the lower half of the tolerance
range or where large temperature differentials between the bearing rings can occur in operation.

Step 12 Step 13 Step 14

Remove the locknut and install the locking
washer on the adapter sleeve. The inner prong
of the locking washer should face the bearing
and be located in the slot of the adapter sleeve.
Reapply the locknut until tight. (DO NOT drive
the bearing further up the taper. as this will
reduce the radial internal clearance further).
Find the locking washer tang that is nearest Check that the shaft and outer ring can be
a locknut slot. If the slot is slightly past the rotated easily by hand.
tang don't loosen the nut, but instead tight­
en it to meet the closest locking washer
tang. Do not bend the locking tab to the bot­
tom of the locknut slot.

511C.F
53
Radial clearance reduction
method for mounting tapered
bore (1:12) CARB ® toroidal
bearings onto a tapered shaft
Precautions
For hollow shafts, please consult SKF Appli­
cations Engineering. The bearings should be
left in their original packages until immedi­
ately before mounting so they do not
become dirty. The dimensional and form
accuracy of all components, which will be in
contact with the bearing, should be checked.
Stepl
Remove any burrs or rust on the shaft with
an emery cloth or a fine file.
Step 2
Wipe the shaft with a clean cloth.
Step 3
Measure the shaft taper for geometry and
contact using taper gauges.
Step 4
Wipe the preservative from the bore of the
bearing. It may not be necessary to remove
the preservative from the internal compo­
nents of the bearing unless the bearing will
be lubricated by a circulating oil or oil mist
system.
Step 5
Measure the unmounted radial internal
clearance in the bearing. The values for
unmounted internal clearance for tapered
bore CARB are provided in Table 6 on page
31. Oscillate the inner ring in a circumferen­
tial direction to properly seat the rollers.
Measure the radial internal clearance in the
bearing by inserting progressively larger
feeler blades the full length of the roller
between the most unloaded roller and the
outer ring sphere. NOTE: Do not roll com­
pletely over a pinched feeler blade, slide
through the clearance. It is permissible to
rotate a roller up onto the feeler blade but
be sure it slides out of the contact area with
a slight resistance. Record the measurement
on the largest size blade that will slide
through. This is the unmounted radial inter­
nal clearance.
Repeat this procedure in two or three
other locations by resting the bearing on a
different spot on its 0.0. and measuring
over different rollers.
54
The feeler gauge should be
moved to and fro
Step 6
Place the bearing on the tapered shaft,
leading with the large bore of the inner ring
to match the taper of the shaft. Apply the
locknut with its chamfer facing the bearing
(DO NOT apply the locking washer at this
time because the drive-up procedure may
damage the locking washer). Applying a light
coating of oil to the chamfered face of the
lock nut will make mounting easier.
Step 7
Select the proper radial internal clearance
reduction range from Table 6 on page 31.
Using a hammer and a spanner wrench or
just a hydraulic nut, begin tightening the nut
in order to drive the inner ring up the
tapered shaft until the appropriate clearance
reduction is achieved. NOTE: LARGE SIZE
BEARINGS WILL REQUIRE A HEAVY DUTY
IMPACT SPANNER WRENCH AND SLEDGE
HAMMER TO OBTAIN THE REQUIRED
REDUCTION IN RADIAL INTERNAL CLEAR­
ANCE. AN SKF HYDRAULIC NUT MAKES
MOUNTING OF LARGE SIZE BEARINGS EAS­
IER. Do not attempt to tighten the locknut
with a hammer and drift. The locknut will be
damaged and chips can enter the bearing.
5K.F"
Step 8
Remove the locknut and install the locking
washer on the shaft. The inner prong of the
locking washer should face the bearing and
be located in the keyway. Reapply the lock­
nut until tight. (DO NOT drive the bearing
further up the taper as this will reduce the
radial internal clearance further).
Step 9
Find the locking washer tang that is nearest
a locknut slot. If the slot is slightly past the
tang don't loosen the nut. but instead tight­
en it to meet the closest locking washer
tang. Do not bend the locking tab to the
bottom of the locknut slot.
Step 10
Check that the shaft and outer ring can be
rotated easily by hand.
51C.F"
Angular drive-up method for Step 4
mounting tapered bore (1:12) Screw off the nut from the adapter sleeve
CARB toroidal bearings on an assembly and remove the locking washer.
adapter sleeve.
The angular drive-up method simplifies the
mounting process by equating axial drive up
to the rotation of a locknut. By knowing the
threads per inch of a locknut, the number of
rotations to achieve a specific axial move­
ment can be determined. In order to make
this mounting method work properly, the
starting point is important since that is the Step 5
reference point to determine when to start Wipe preservative from the adapter 0. D. and
counting the rotation of the locknut. bore. Remove oil from the shaft to prevent
transfer of oil to the bore of the adapter sleeve.
Precautions
The bearings should be left in their original
packages until immediately before mount­
ing so they do not become dirty. The dimen­
sional and form accuracy of all components,
which will be in contact with the bearing,
should be checked.
Step 6
Step 1 Position the adapter sleeve on the shaft,
Remove any burrs or rust on the shaft with threads outboard as indicated, to the approx­
an emery cloth or a fine file. imate location with respect to required bear­
ing centerline. For easier positioning of the
sleeve, a screwdriver can be placed in the slit
to open the sleeve. Applying a light oil to the
sleeve outside diameter surface results in
easier bearing mounting and removal.
Step 2
Wipe the shaft with a clean cloth.
Step 7
Wipe the preservative from the bore of the
bearing. It may not be necessary to remove
the preservative from the internal components
of the bearing unless the bearing will be lubri­
Step 3 cated by a circulating oil or oil mist system.
Measure the shaft diameter.
Shaft tolerance limits for adapter
mounting seatings
Nominal diameter Tolerance limits
inch inch
over including
1/2 1 0.000 I -0.002
1 2 0.000 I -0.003
2 4 0.000 I -0 004
4 6 0.000 I -0.005
6 0.000 I -0.006
55
Step 8
Place the bearing on the adapter sleeve,
leading with the large bore of the inner ring
to match the taper of the adapter. Apply the
locknut with its chamfer facing the bearing
(DO NOT apply the locking washer at this
time because the drive-up procedure may
damage the locking washer). Applying a light
coating of oil to the chamfered face of the
lock nut will make mounting easier.
Step 9
Using a spanner wrench, hand-tighten the
locknut so that the sleeve grips the shaft and
the adapter sleeve can neither be moved
axially, nor rotated on the shaft. With the
bearing hand tight on the adapter, locate the
bearing to the proper axial position on the
shaft. A method for checking if the bearing
and sleeve are properly clamped is to place a
screwdriver in the adapter sleeve split on the
large end of the sleeve. Applying pressure to
the screwdriver to attempt to turn the sleeve
around the shaft is a good check to deter­
mine if the sleeve is clamped down properly.
If the sleeve no longer turns on the shaft,
then the zero point has been reached. Do not
drive the bearing up any further.
Step 10
Place a reference mark on the locknut face
and shaft, preferably in the 12 o'clock position,
to use when measuring the tightening angle.
Step 11
Locate the specific bearing part number in
Table 7. Note the specific lock nut part
number on the adapter sleeve to determine
if it is an inch or metric assembly. Once the
appropriate locknut part number has been
obtained, select the corresponding tighten­
ing angle from Table 7 on page 35.
Step 12
Using a hammer and a spanner wrench,
begin tightening the locknut the correspond­
ing tightening angle. NOTE: LARGE SIZE
BEARINGS WILL REQUIRE A HEAVY DUTY
IMPACT SPANNER WRENCH AND SLEDGE
HAMMER TO OBTAIN THE REQUIRED
REDUCTION IN RADIAL INTERNAL CLEAR­
ANCE. Do not attempt to tighten the locknut
with hammer and drift. The locknut will be
damaged and chips can enter the bearing.
56
Step 13
Remove the locknut and install the locking
washer on the adapter sleeve. The inner
prong of the locking washer should face the
bearing and be located in the slot of the
adapter sleeve. Reapply the locknut until
tight. (DO NOT drive the bearing further up
the taper, as this will reduce the radial inter­
nal clearance further).
Step 14
Find the locking washer tang that is nearest
a locknut slot. If the slot is slightly past the
tang don't loosen the nut, but instead tight­
en it to meet the closest locking washer
tang. Do not bend the locking tab to the
bottom of the locknut slot.
Step 15
Check that the shaft and outer ring can be
rotated easily by hand.
SKf"'
 Table 7 SKF hydraulic (axial) drive-up
method for tapered bore (1:12)
Angular drive-up for CARB® toroidal roller bearings (metric and inch nuts) CARS toroidal bearings on an
adapter sleeve.
Be.aring Bearing bore Axial Metric nut Turning Inch nut Turning The axial drive-up method relies on the
designation diameter drive-up designation angle designation angle
d a a
bearing being driven up a tapered seat a
specific amount in order to ensure the inner
(mm) (mm) (degrees) (degrees)
ring is expanded enough to properly clamp
22xx series the shaft or sleeve. In order for this method
C 2205 K 25 0.25 KM(FE) 5 100 N 05 190 to work properly, the starting point is
C 2206 K 30 0.25 KM(FE) 6 105 N 06 115 important since that is the reference point
C 2207 K 35 0.30 KM(FE) 7 115 N 07 120 to determine when the bearing has been
C 2208 K 40 0.30 KM(FE) 8 125 N 08 135
driven up enough. A new method of accu­
C 2209 K 45 0.37 KM(FE) 9 130 N 09 140
C 2210 K 50 0.37 KM(FE) 10 140 N 10 150 rately achieving this starting point has been
C 2211 K 55 0.44 KM(FE) 11 110 N 11 155 developed by SKF and is now available. The
C 2212 K 60 0.44 KM(FE) 12 115 N 12 165 method incorporates the use of an SKF
C 2213 K 65 0.44 KM(FE) 13 120 N 13 170 hydraulic nut, HMV(C) .. E fitted with a dial
C 2214 K 70 0.54 KM(FE) 14 125 N 14 175 indicator and a specially calibrated pressure
C 2215 K 75 0.54 KM(FE) 15 130 AN 15 120 gauge, mounted on a selected pump. The
C 2216 K 80 0.54 KM(FE) 16 140 AN 16 130
C 2217 K 85 0.65 KM(FE) 17 145
equipment is shown in Figure 12 below.
AN 17 135
C 2218 K 90 0.65 KM(FE) 18 150 AN 18 145 The required pressure for each CARB bear­
C 2219 K 95 0.65 KM(FE)19 150 AN 19 150 ing is given in Table 8, page 37. This enables
C 2220 K 100 0.65 KM(FE) 20 155 AN 20 160 accurate positioning of the bearing at the
C 2222 K 110 0.79 KM(FE) 22 170 AN 22 160 starting point, from where the axial drive-up
C 2224 K 120 0.79 KM 24 180 AN 24 170 (s) is measured. Table 8 also provides the
23xx series required psi pressures required for each.
C 2314 K 70 0.54 KM(FE) 14 130 N 14 185 1. Reduced time to mount bearings.
C 2315 K 75 0.54 KM(FE) 15 135 AN 15 130
2. A reliable, safe and accurate method of
C 2316 K 80 0.54 KM(FE) 17 140 AN 16 135
C 2317 K 85 0.65 KM(FE) 18 145 AN 17 140 clearance adjustment.
C 2318 K 90 0.65 KM(FE)19 155 AN 18 145
C 2319 K 95 0.65 KM(FE) 20 155 AN 19 150 Precautions
C 2320 K 100 0.65 KM(FE) 21 160 AN 20 155 For hollow shafts, please consult SKF Appli­
cations Engineering. The bearings should be
For sizes greater than those shown above we recommend the use of the SKF Hydraulic drive-up method.
left in their original packages until immedi­
For threads per inch see Table 2 (page 17).
ately before mounting so they do not
become dirty. The dimensional and form
accuracy of all components, which will be in
contact with the bearing, should be checked.

Step1
Remove any burrs or rust on the shaft with
an emery cloth or a fine file.

Figure 12
Step 2
Wipe the shaft with a clean cloth.

SIC.F
57
Step 3 Step 7 Step 10
Measure the shaft diameter. Applying a light oil to the sleeve outside Remove the hydraulic nut and install the
diameter surface results in easier bearing locking washer on the adapter sleeve. The
Shaft tolerance limits for adapter mounting and removal. Wipe the preserva­ inner prong of the locking washer should
mounting seatings tive from the bore of the bearing. It may not face the bearing and be located in the slot of
be necessary to remove the preservative the adapter sleeve. Reapply the locknut until
Nominal diameter Tolerance limits
inch inch from the internal components of the bear­ tight. (DO NOT drive the bearing further up
over including ing unless the bearing will be lubricated by a the taper, as this will reduce the radial inter­
circulating oil or oil mist system. nal clearance further).
1/2 1 b.ooo 1-0.002
1 2 0.000 / -0.003
2 4 0.000 I -0.004
4 6 0.000 / -0.005
6 0.000 I -0.006

Step 4
Remove the locknut and locking washer
from the adapter sleeve assembly.
Step 5
Wipe preservative from the adapter 0. D. and
bore. Remove oil from the shaft to prevent
transfer of oil to the bore of the adapter sleeve.
Step 6
Position the adapter sleeve on the shaft,
threads outboard as indicated, to the
approximate location with respect to
required bearing centerline. For easier
positioning of the sleeve, a screwdriver
can be placed in the slit to open the sleeve.
Step 11
Step 8 Find the locking washer tang that is nearest
Place the bearing on the adapter sleeve a locknut slot. If the slot is slightly past the
leading with the large bore of the inner ring tang don't loosen the nut, but instead tight­
to match the taper of the adapter. Apply the en it to meet the closest locking washer
hydraulic nut (DO NOT apply the locking tang. Do not bend the locking tab to the
washer at this time). Ensure that the bear­ bottom of the locknut slot.
ing size is equal to the hydraulic nut. Other­
wise, the pressure in the table must be
adjusted. Drive the bearing up to the start­
ing position by applying the hydraulic pres­
sure listed in Starting Position 1* in Table 8
for the specific bearing size being mounted.
Monitor the pressure by the gauge on the
selected pump. As an alternative, SKF
mounting gauge TMJG 1000 can be
screwed directly into the hydraulic nut. Step 12
Check that the shaft and outer ring can be
rotated easily by hand.
Step 9
Drive the bearing up the adapter sleeve the
required distance S5 shown under column
heading 1*** of Table 8. The axial drive-up
is best monitored by a dial indicator.

i i
L___�.�

SKF
58
 TableS

Pressure and axial drive-up for CARB toroidal roller bearings with tapered bore

Starting position Final position Starting position Final position

SKF bearing Hydraulic Radial clearance Axial drive-up SKF bearing Hydraulic Radial clearance Axial drive-up
designation pressure reduction from zero from starting designation pressure reduction from zero from starting
position position 55 position position 55

1* (psi) 2** (psi) (in.) 1 *** (in.) 2**** (in.) 1* (psi) 2** (psi) (in.) 1*** {in.) 2*'***(in.}

C 22xx series C 31xx series

C2210K 97 185 0.0009 0.0126 0.0154 C3130K 349 613 0.0027 0.0331 0.0359
C2211K 83 154 0.0010 0.0138 0.0165 (3132K 300 589 0.0028 0.0343 0.0370
C2212K 158 283 0.0011 0.0154 0.0181 (3136K 247 464 0.0032 0.0370 0.0398
C2213K 119 222 0.0011 0.0158 0.0185 C3140K 393 731 0.0035 0.0426 0.0457
C2214K 110 199 0.0013 0.0169 0.0197 C3144K 400 787 0.0039 0.0465 0.0496
C2215K 102 183 0.0013 0.0173 0.0250 C3148K 291 571 0.0043 0.0489 0.0516
C2216K 149 268 0.0014 0.0189 0.0217 C3152K 400 777 0.0046 0.0540 0.0567
C2217K 162 290 0.0015 O.G197 0.0225 (3156K 381 731 0.0050 0.0579 0.0607
C2218K 197 358 0.0016 0.0217 0.0244 C3160K 407 777 0.0053 0.0619 0.0646
C2220K 162 287 0.0018 0.0221 0.0252 C3164K 303 576 0.0057 0.0634 0.0662
C2222K 216 390 0.0019 0.0244 0.0272 C3168K 386 712 0.0060 0.0686 0.0713
C2226K 209 368 0.0023 0.0276 0.0303
C2228K 342 603 0.0025 0.0311 0.0339 C 32xx series
C2230K 260 454 0.0027 0.0323 0.0351 C3224K 357 629 0.0021 0.0268 0.0299
C2234K 374 697 0.0030 0.0370 0.0398 C3232K 389 761 0.0028 0.0343 0.0370
C2238K 257 489 0.0033 0.0390 0.0422 C3236K 535 1001 0.0032 0.0398 0.0429
C2244K 283 557 0.0039 0.0453 0.0481
C 40xx series
C 23xx series C4028K30 180 345 0.0025 0.0741 0.0812
C2314K 291 525 0.0013 0.0177 0.0209 C 4032K 152 325 0.0028 0.0820 0.0890
C2315K 326 587 0.0013 0.0189 0.0217
C 2316K 306 550 0.0014 0.0193 0.0221
C2317K 348 622 0.0015 0.0205 0.0232
C2318K 418 760 0.0016 0.0225 0.0252
C2319K 323 574 0.0017 0.0225 0.0252 Zero Starting Final
C2320K 371 658 0.0018 0.0232 0.0260 position position position

C 30xx series \___. J �

(3036K 207 389 0.0032 0.0374 0.0402
C3038K 232 442 0.0033 0.0398 0.0426
(3040K 235 435 0.0035 0.0418 0.0445
C3044K 229 450 0.0039 0.0453 0.0481
C3048K 194 380 0.0043 0.0485 0.0512
(3052K 257 499 0.0046 0.0532 0.0559
C 3056K 245 470 0.0050 0.0571 0.0599
C3060K 261 499 0.0053 0.0611 0.0638

n
(3064K 261 497 0.0057 0.0650 0.0678
C3068K 296 545 0.0060 0.0689 0.0721
C3092K 290 526 0.0081 0.0918 0.0946

cB As, .

b C
�

d
-

* Values given valid for HMV (C) E series hydraulic nuts equal to bearing size and with one sliding surface (see Figures band c). Surfaces lightly oiled with light oil.
Values given valid for HMV (C) E series hydraulic nuts equal to one size smaller than bearing size and two sliding surfaces (see Figuree).
Surfaces lightly oiled with light oil.
Values given are valid 'for one sliding surface (see Figures band c). Surfaces lightly oiled with light oil.
Values given are valid for two sliding surfaces (see Figuree). Surfaces lightly oiled with light oil. The difference in drive-up between one surface and two surfaces is the
result of smoothing.
NOTE: To convert values to mm and MPa mm ; in x 25.4 MPA; psi x 0.0069

SKF
59
 Form 1688
Installation & Maintenance of
P-1688-TBX V-Belt Drives

60
 Quality Products and the
Support to Back Them Up – Wood’s
V-Belt sheaves of close grain, high-tensile cast iron are machined
to provide safe, vibration-free operation at speeds up to 6500 FPM.
Made to order sheaves of ductile iron material can be provided for
speeds up to 10,000 FPM. V-Belt drives are only the beginning of
what Wood’s can do.

Wood’s offers a complete line of high capacity synchronous drives. The

Synchonous-Plus system offers a higher horsepower capacity drive at the cost of
the competitions standard rated product. Wood’s also offers the aramid
fiber QT Powerchain drive in 8M and 14M pitch. The QT drive is capable
of high horsepower capacity in a smaller package. Both QT and Synchonous-Plus
sprockets offer metric/inch drilling for applications which require a totally
metric drive system.

Wood’s has many different ways of offering variable speed for customer
applications. The most basic way is through the use of one of our many
belted variable speed systems. Wood’s also offers many different options
in the line of electronic inverters and electronic speed controls. One of the
most unique ways of varying speed, however, is our HSV/HSVA hydrostatic
systems. The HSV system is ideal for harsh, dirty, or explosive proof
environments.

Wood’s Elastomeric coupling line offers something for every

application. Wood’s Jaw couplings offer a full compliment of spider
materials and bore options. Our Sure-Flex line offers 4-way flexing
action, and many different flange and sleeve options to meet your
needs. The Dura-Flex coupling is designed and patented with
improvements over other similar type coupling that provide for the
maximum possible service life.

Wood’s line of steel couplings offers both gear and disc coupling
options. Wood’s Form-Flex disc couplings offer zero-backlash and
eliminate the need for lubrication. Our gear couplings are available in
all the standard, spacer, and special options common to the industry.
In both disc and gear lines we welcome the challenge of the “special”
coupling.

61
 Contents

1 Inspection
and Maintenance
Inspect While Running................................... 1
Inspect Sheaves Often.................................. 1
Use Belt and Sheave Gages......................... 2
Check Belt Fit................................................ 2
Keep Belts Clean........................................... 3
Use Belt Guards............................................ 3
Check for Hot Bearings................................. 3
Maintain Proper Belt Tension......................... 3

2 Belt Selection
Selecting Correct Belts.................................. 4
ORS Construction.......................................... 5
Explosive Atmospheres................................. 5 The V-Belt Drive is
Proper Belt Storage....................................... 6 industry’s most popular
means of power transmis-
3 Safety Tips sion. It is easy to select, simple
Guard Drives.................................................. 7 to install, and will provide years of
Safe Speed Limits.......................................... 7 reliable performance.

Even when misapplied, improperly in-

4 Drive Installation
Sheave and Bushing Installation................... 8
Sheaves and Bushing Removal..................... 9
Check Alignment ........................................ 10
Install Belts.................................................. 11
Take-Up Allowances.................................... 11
5 Tensioning the Drive
General Method........................................... 12
Force Deflection Method.............................. 13
Belt Elongation Method............................... 16
stalled or completely ignored, the V-Belt Drive will usu-
ally deliver some kind of performance. However, with
proper installation and maintenance, many years of
operating efficiency can be added to the life span of
the V-Belt Drive.
It is hoped that the information contained herein will
help you receive the greatest possible value from your
V-Belts and sheaves, and will help you receive a full
measure of performance from industry’s dominant
drive.

6 Trouble Shooting
V-Belts
How to Spot Trouble..................................... 18
How to Diagnose Failure.............................. 19

62
 V-Drive Inspection and
Maintenance Procedures
side of the drive to be sure that all of the belts are run-
ning tight. If one or more belts are running loose, the
drive needs to be retensioned, or the belts replaced
with a matched set.

The above conditions could also be caused by uneven

wear of the grooves in the sheave. These should be
checked with sheave grooves gages.

Inspect
sheaves
often

Keep all sheave grooves smooth and uniform. Burrs

and rough spots along the sheave rim can damage
belts. Dust,oil and other foreign matter can lead to pit-
ting and rust and should be avoided as much as pos-
sible. If sheave sidewalls are permitted to “dish out,” as
shown in the picture on page 2, the bottom “shoulder”
ruins belts quickly by chewing off their bottom corners.
Also, the belt’s wedging action is reduced and it loses
its gripping power.

A shiny groove bottom indicates that either the sheave,

the belt or both are badly worn and the belt is bottom-
ing in the groove.

Badly worn grooves cause one or more belts to ride

lower than the rest of the belts, and the effect is the
same as with mismatched belts. This is called ”differen-
tial driving.” The belts riding high in the grooves travel
faster than the belts riding low. In a drive under proper
tension, a sure sign of differential driving is when one
or several belts on the tight side are slack.

Check alignment of drive. Sheaves that are not aligned

properly cause excessive belt and sheave wear. When
the shafts are not parallel, belts on one side are drawn
tighter and pull more than their share of the load. These
overloaded belts wear out faster, reducing the service
life of the entire set. If the misalignment is between
the sheaves themselves, belts will enter and leave
the groove at an angle, causing excessive cover and
sheave wear and premature failure. See page 10 for
complete information on drive alignment.

63
 Sheave grooves must be

like this not this

Groove gage

Belts and
sheave gages
Belts and sheave groove gage sets are available
from your Wood’s distributor.
You can use them to determine the proper belt
section by trying the old belt in the various gages
until a proper fit is obtained. The cross section of
the Classical or Narrow belt can be read from the
gage.
To check sheave grooves for wear, simply select the
proper gage and template for the sheave diameter;
then insert the gage in the groove until the rim of the
gage butts against the outside diameter of the sheave
flange. Worn grooves will show up as illustrated below.
If more than 1/32 inch of wear can be seen, poor V-belt
life may be expected.
Check belt fit

Classical V-belts should ride in standard sheave

grooves so that the top surface of the belt is just above
the highest point of the sheave. In A-B combination
Dished out grooves, an A section belt will ride slightly low in the
groove, while a B belt will be in the normal position. In
special deep groove sheaves, belts will ride below the
top of the sheave.

Narrow belts are purposely designed so that the top

of the belt will ride above the O.D. of the sheave. The
tensile cords are located in the belt so that they ride
almost at the O.D. of the sheave. This simplifies sheave
identification and drive calculations.

No matter which V-belt section the sheave is grooved

for, the belts should never be allowed to bottom in the

64
groove. This will cause the belt to lose it wedging ac-
tion, to slip and/or burn. Sheaves worn to the point
where they allow a belt to bottom should be replaced
immediately.
If the belts are slipping on your drive, retension the
drive. Never use belt dressing to correct slipping belts.
Maintain
proper belt tension

Keep belts Maintaining correct tension is the most important rule

clean
Dirt and grease reduce belt life. Belts should be wiped
with a dry cloth occasionally to remove any build-up of
foreign material. If the belts have been splattered with
grease and/or oil, clean them with methyl chloroform or
soap and water. Inflammable cleaners such as gaso-
line are to be avoided as a matter of safety.
Although all Wood’s V-belts are of oil resistant con-
struction, an occasional cleaning will help to prolong
their life.
of V-belt care. It will give the belts 50% to 100% longer
life.
Belts that are too loose will slip, causing excessive
belt and sheave wear. V-belts that sag too much are
snapped tight suddenly when the motor start or when
peak loads occur. That snapping action can actually
break the belts, because the added stress is more than
the belt was designed to take. This can be clearly dem-
onstrated with a piece of string, as illustrated.

Under no circumstances is the use of belt dressing rec-

ommended on a V-belt. The remedial effect is only tem-
porary. It is much better to keep the belts and grooves
of the drive clean.

Use belt guards

Belt guards protect personnel and the drive itself. They

should definitely be used in abrasive atmospheres to
protect the drive from sand, metal chips and other for-
eign matter. But they should be ventilated to avoid ex- Loosely-held string snaps easily,
cessive heat. Taut string can stand a strong pull
Check them periodically for damage and for loose or
missing mounting bolts. These could cause the belts to
come in contact with the guard and cause failure.

Guards alone will generally protect belts from abra-

sion. But where abrasive materials are common — in
rock processing machinery, grinders, foundries, etc.
— drives should be inspected frequently for excessive
belt and groove wear

Check for
hot bearings

When the drive has been stopped for inspection, check

the bearings to make sure they are not running hot.
If they are, it could be due to improper lubrication or
improper drive tension. Hot bearings can be caused
by belts that are either too tight or too loose. Check the
tension carefully using the instructions furnished.

65
Belt Selection

Selecting the Classical Narrow

correct belts Belts Belts

66
To assure maximum V-belt life, follow the minimum rec- For maximum performance from belts in oily atmo-
ommended pitch and sheave diameters for belts estab- spheres, they should be guarded as much as practical
lished by Mechanical Power Transmission Association against excessive amounts of oil and should be peri-
and Rubber Manufacturers Association standards. odically cleaned with methyl chloroform. Oil and grease
on belts and sheaves will tend to lubricate the drive and
reduce the traction of the belt, even though they may
not actually harm the belts themselves. However, since
Classical Minimum *
Belt Section Pitch Diameter the friction factor is reduced, belts must be operated at
A 3.0” abnormal tensions, and their life is shortened.
AX 2.2”
Belt failure caused by oil is obvious and easy to de-
B 5.4” tect. The most apparent sign is the build-up of a black,
BX 4.0” soft substance that can be wiped off when the belt is
C 9.0” rubbed. Another sign is a softening and swelling of
CX 6.8” the belt to the point where it no longer fits the sheave
D 13.0” groove properly.
* Not applicable to Light Duty Belts Like oil resistance, resistance to ozone is a matter of
degree. Narrow, Classical and Light Duty belts are re-
Narrow Minimum
Belt Section Sheave Diameter
sistant to normal amounts of ozone in the atmosphere.
However, high concentrations such as found around
3V 2.65”
arc welding equipment can cause rubber to harden and
3VX 2.2”
crack. It is because of ozone that belts should never be
5V 7.1”
stored in direct sunlight.
5VX 4.4”
8V 12.5” Belts intended for operation in potentially dangerous
atmospheres are constructed with a relatively low elec-
trical resistance characteristic and referred to as “static
All belts
conducting”. All Narrow, Classical and Light Duty belts
“ORS”
meet the following requirements.
At one time it was necessary to order special belts for
In the standard method of measuring a belt’s electrical
various types of environments. All Wood’s belts are of
resistivity, two 5/8” diameter flat contacts are placed 81/2”
“ORS” construction, meaning they are heat resistant,
apart on centers, moistened with water and pressed
oil resistant and static conducting.
against the belt with a force of 121/2 lbs. The resistance
By heat resistant, we mean these belts will operate well “conductivity” between the contacts is measured with
in ambient temperatures up to 140°F. They may be op- an ohmmeter operating at a potential of 500 volts and
erated at higher temperatures, but there would be a having an accuracy range from 0 to 10 megohms. Ex-
reduction in service life. In general, short belts develop perience has demonstrated that the dissipation provid-
higher internal temperatures than long belts. They are ed by belts having a resistance of 6 megohms or less
usually subjected to more flexures per minute and are “when new and measured as above” is satisfactory for
frequently found on totally-enclosed drives where there operation in hazardous atmospheres.
is little or no air circulation.
Explosive
Oil resistance is a matter of degree. It varies with the atmospheres
amount of contact with oil, whether it is continuous or
Belts on drives in hazardous atmospheres should be
intermittent immersion, exposure to an atmospheric
kept reasonably free of encrusted accumulations of
mist or an occasional spattering. A great many chemi-
non-conducting materials. In addition, all elements
cals, particularly petroleum derivatives, can cause de-
of the drive must be interconnected and grounded to
terioration. All Narrow, Classical and Light Duty belts
earth as illustrated on the following page.
will withstand nominal exposure to oil and grease, but
they are not 100% oilproof.

67
Although we know of no explosion caused by static
generated by a V-belt drive, we cannot accept respon-
sibility beyond that of furnishing belts within the above
described limits.
Store belts
properly
V-belts should be stored in a cool, dry place out of di-
rect sunlight. They should be kept away from ozone-
producing equipment such as arc welders and high
voltage apparatus. Temperature should be below 85°F,
relative humidity below 70%. If belts are stored in piles,
the piles should be kept small to avoid excessive weight
Proper V-drive installation in explosive atmospheres
68
which could distort the bottom belts. When belts are
stored in boxes, the box size should be limited. Ideally,
belts should be hung on saddle type pegs. With proper
storage, belt quality will not change significantly within
eight years.
Assuming good storage practices, a decrease in ser-
vice life of approximately 10% per year of storage be-
yond eight years can be expected. From a norm of eight
years storage life at 85°, it is estimated that the storage
limit should be reduced by half for each 15° increase
in temperature. A significant increase in humidity may
cause a fungus to form on belts, but any effect on the
performance on the belt would be very slight.
 Safety Tips

No matter where rotating machines are located or by Safe speed is cast into the arm of Wood’s sheaves.
what means they are driven, there is always a chance
of personal injury unless they are installed and oper-
ated under safe conditions. It is with this thought up-
permost in our minds that is manual is written.

Guard
all drives
properly

All regulating agencies such as OSHA, State Depart-

ments of Labor and Industry, insurance firms and other
safety authorities either recommend or insist on drive
guards. We, also, strongly recommend that every V-belt
drive be completely guarded. Do not be lulled into a Burst testing. Results of centrifugal force are clearly
sense of security by a temporary or makeshift guard. shown in these broken “D”-groove sheaves. The pat-
Of course, provision can and should be made for prop- tern of breakage is typical. The rim breaks away from
er ventilation and inspection by the use of grills, inspec- the arms, arms break from hub and the hub shatters
tion doors and removable panels. But the guard should through its bolt holes. With the force in several hundred
have no gap where workers can reach inside and be- thousand pounds, it all happens in a split second.
come caught in the drive. Besides being a safety as-
set, a good guard helps make maintenance easier by
protecting the drive from weather and foreign objects.

Check
Safe
speed limits

Safe speed limits for sheaves manufactured by TB

Wood’s Incorporated have been established by a rig-
orous burst testing program. The limit for cast iron
sheaves has been established at 6500 fpm; the maxi-
mum speed in rpm corresponding to 6500 fpm is either
cast or stamped on each sheave.

Before installing the drive, this safe speed limit should

be checked against the speed of the shaft on which
it is being installed. Operating sheaves above recom-
mended speeds could result in serious damage to
equipment and/or serious personal injury.

69
 Drive Installation

Sure-Grip® Sheave
and Bushing
Installation
Instructions

Wood’s Sure-Grip bushings are the most widely used, features provide greater adaptability. Sure-Grip bush-
tapered, QD-type and have exceptional holding power ings can be used interchangeably in many of Wood’s
that eliminates wobble. Standard and reverse mounting products as well as those of other manufacturers.

To Install:

IMPORTANT:
DO NOT USE LUBRICANTS IN THIS INSTALLATION

Before beginning, make sure the correct size and

quantity of parts are available for the installation. The
bushing has been manufactured to accept a setscrew
over the key and its use is optional. It is packaged with FIG. 1 Standard Mounting
the hardware on sizes SH to M and loosely installed in
the bushing on sizes N to S.

1. Inspect the tapered bore of the sheave and the ta-

pered surface of the bushing. Any paint, dirt, oil or
grease MUST be removed.

2. S
 elect the type of mounting (See Fig. 1 or 2) that
best suits your application.

3. S
 TANDARD MOUNTING: Install shaft key. (Note: If
key was furnished with bushing, you must use that
key.) Install bushing on clean shaft, flange end first.
If bushing will not freely slide on the shaft, insert a
screwdriver or similar object into the flange sawcut
to act as a wedge to open the bushing’s bore. Cau-
tion: Excessive wedging will split the bushing.
If using the setscrew, tighten it just enough to pre-
vent the bushing from sliding on the shaft. Caution:
Do not over tighten setscrew! Slide sheave into
position on bushing aligning the drilled holes in the
sheave with the tapped holes in the bushing flange.
(Note: Install M thru S bushings so that the two
tapped holes in the sheave are located as far away
as possible from the bushing’s sawcut.) Loosen\ly
thread the capscrews with lockwashers into the as-
sembly. DO NOT USE LUBRICANT ON THE CAP-
SCREWS!
70
FIG. 1 Reverse Mounting
4 REVERSE MOUNTING: With large end of the taper
out, slide sheave onto shaft as far as possible. Install
shaft key. (See shaft key note in #3 above.) Install bush-
ing onto shaft so tapered end will mate with sheave.
(See wedging note in #3 above.) If using the setscrew,
tighten it enough to prevent the bushing from sliding on
the shaft. Caution: Do not tighten setscrew! Pull the
sheave up on the bushing, aligning the drilled holes in
the bushing flange with the tapped holes in the sheave.
Loosely thread the capscrews with lockwashers into
the assembly. DO NOT USE LUBRICANT ON THE
CAPSCREWS!
5. Using a torque wrench, tighten all capscrews evenly
and progressively in rotation to the torque value in Ta-
ble. There must be a gap between the bushing flange
and sheave hub when installation is complete. DO NOT
OVER TORQUE! DO NOT ATTEMPT TO CLOSE GAP
BETWEEN BUSHING FLANGE AND SHEAVE HUB!
 To Remove:

1.  elieve drive tension by shortening the center

R moval holes and progressively tighten each one
distance between driver and driven sheaves.
2. Lift off belts.
3. Loosen and remove cap screws. If the bushings
have keyway setscrews, loosen them.
4. As shown below, insert cap screws (three in JA
through J bushings, two in QT and M thru W
bushings and four in S bushing) in tapped re-
until mating part is loose on bushing. (Excep-
tion: If mating part is installed with cap screws
heads next to motor, with insufficient room to in-
sert screws in tapped holes, loosen cap screws
and use wedge between bushing flange and
mating part.)
5. Remove mating part from bushing, and if nec-
essary, bushing from shaft.

Sure-Grip Bushing
Screw Tightening Information

Ft.-Lbs.
Tapered Size & Thread
To Apply With
Bushing of Cap Screw
Torque Wrench
QT 1
/4 — 20 9
JA No. 10 — 24 5
SH-SDS-SD 1
/4 — 20 9
SK 5
/16 — 18 15
SF 3
/8 — 16 30

E 1
/2 — 13 60
F 9
/16 — 12 110
J 5
/8 — 11 135
M 3
/4 — 10 225
N 7
/8 — 9 300

P 1—8 450
W 11/8 — 7 600
S 11/4 — 7 750

CAUTION: The tightening force on the screws is multiplied many times by the
wedging action of the tapered surface. If extreme tightening force is applied,
or if a lubricant is used, bursting pressures will be created in the hub of the
mating part.

71
 Check alignment
Although alignment is not as critical in V-belt drives as
in others, proper alignment is essential to long belt and
sheave life.
First, make sure that drive shafts are parallel. The
most common causes of misalignment are non-parallel
shafts and improperly located sheaves.
Shaft alignment can be checked by measuring the dis-
tance between the shafts at three or more locations. If
the distances are equal, then the shafts will be parallel.
To check the location of the sheaves on the shafts, a
straightedge or a piece of string can be used. If the
sheaves are properly lined up, the string will touch them
at the points indicated by the arrows in the accompany-
ing sketch. Rotating each sheave a half revolution will
72
Where shafts are not parallel, belts on one side are
drawn tighter and pull more than their share of the load.
As a result, these belts wear out faster, requiring the
entire set to be replaced before it has given maximum
service. If misalignment is in the sheave, belts will enter
and leave the grooves at an angle, causing excessive
belt cover and sheave wear.
determine whether the sheave is wobbly or the drive
shaft is bent. Correct any misalignment.
With sheaves aligned, tighten cap screws evenly and
progressively. Apply the recommended torque to cap
screws as listed in table on page 9. NOTE: There
should be 1/8” to 1/4” gap between the mating part hub
and the bushing flange. If the gap is closed, the shaft is
seriously undersize.
 Install belts

Shorten the center distance between the driven and
the driver sheave so the belts can be put on without
the use of force.
While the belts are still loose on the drive, rotate the
drive until all the slack is on one side. Then increase
the center distance until the belts are snug. The drive is
now ready for tensioning.
NOTE: Never “roll” or “pry” the belts into the sheave
grooves. This can damage the belt cords and lead to
belt turnover, short life or actual breakage. Moreover, it
is both difficult and unsafe to install belts this way.
Keep takeup rails, motor base or other means of center
distance adjustment free of dirt, rust and grit. Lubricate
adjusting screws and slide rails from time to time.

No! Yes!

When belts are forced into the sheave with a screw- It is well worth the time to move the driver unit forward
driver or other wedge, the outer fabric is often ruptured so V-belts can be slipped easily into the sheave groove
and cords broken. without damage.

Center Distance Allowance for Installation and Take-Up (Inches)

Narrow Belts
For Installation (Subtract) For Take-Up (Add)
Belt
3VX 5VX 8VX
Length 3V 5V 8V All
& & &
Banded Banded Banded Cross Sections
3V 5V 8V
250 thru 475 0.5 1.2 - - - - 1.0
500 thru 710 0.8 1.4 1.0 2.1 - - 1.2
750 thru 1060 0.8 1.4 1.0 2.1 1.5 3.4 1.5
1120 thru 1250 0.8 1.4 1.0 2.1 1.5 3.4 1.8
1320 thru 1700 0.8 1.4 1.0 2.1 1.5 3.4 2.2
1800 thru 2000 - - 1.0 2.1 1.8 3.6 2.5
2120 thru 2360 - - 1.2 2.4 1.8 3.6 3.0
2500 thru 2650 - - 1.2 2.4 1.8 3.6 3.2
2800 thru 3000 - - 1.2 2.4 1.8 3.6 3.5
3150 thru 3550 - - 1.2 2.4 2.0 4.0 4.0
3750 - - - - 2.0 4.0 4.5
4000 thru 5000 - - - - 2.0 4.0 5.5
Classical Belts
For Installation (Subtract) For Take-Up (Add)
Belt
Length AX BX BX CX CX DX DX
All
Designation & & & BP & & CP & & DP
Cross Sections
AP BP Banded CP Banded DP Banded
21 thru 35 0.8 1.0 1.5 - - - - 1.0
36 thru 55 0.8 1.0 1.5 1.5 2.0 - - 1.5
56 thru 85 0.8 1.2 1.6 1.5 2.0 - - 2.0
86 thru 112 1.0 1.2 1.6 1.5 2.0 - - 2.5
116 thru 144 1.0 1.3 1.8 1.5 2.1 2.0 2.9 3.0
148 thru 180 - 1.3 1.8 2.0 2.2 2.0 3.0 3.5
191 thru 210 - 1.5 1.9 2.0 2.3 2.0 3.2 4.0
225 thru 240 - 1.5 2.0 2.0 2.5 2.5 3.2 4.5
255 thru 300 - 1.5 2.2 2.0 2.5 2.5 3.5 5.0
315 thru 390 - - - 2.0 2.7 2.5 3.6 6.0
420 and Over - - - 2.5 2.9 3.0 4.1 1.5% of belt length

73
 Tensioning V-Belt Drives
Without exception, the most important factor in the suc-
cessful operation of a V-belt drive is proper belt-tension-
ing. To achieve the long, trouble free service associ-
ated with V-belt drives, belt tension must be sufficient
to overcome slipping under maximum peak load. This
could be either at start or during the work cycle. The
amount of peak load will vary depending upon the char-
acter of the driven machine or drive system. To increase
total tension, merely increase the center distance. Be-
fore attempting to tension any drive it is imperative that
the sheaves be properly installed and aligned. If a V-belt
slips it is too loose. Add to the tension by increasing the
center distance. Never apply belt dressing as this will
damage the belt and cause early failure.
General method
The general method for tensioning V-belts should satisfy
most drive requirements.
Step 1: R
 educe the center distance so that the belts
may be placed over the sheaves and in the
grooves without forcing them over the sides of
Figure 1
74
the grooves. Arrange the belts so that both the
top and bottom spans have about the same
sag. Apply tension to the belts by increasing
the center distance until the belts are snug.
See figure 1.
Step 2: O
 perate the drive a few minutes to seat the
belts in the sheave grooves. Observe the op-
eration of the drive under its highest load con-
dition (usually starting). A slight bowing of the
slack side of the drive indicates proper tension.
If the slack side remains taut during the peak
load, the drive is too tight. Excessive bowing
or slippage indicates insufficient tension. If
the belts squeal as the motor comes on or at
some subsequent peak load, they are not tight
enough to deliver the torque demanded by the
drive machine. The drive should be stopped
and the belts tightened.
Step 3: C
 heck the tension on a new drive frequently
during the first day by observing the slack side
span. After a few days of operation the belts
will seat themselves in the sheave grooves and
it may become necessary to readjust so that
the drive again shows a slight bow in the slack
 Force deflection
method

This method should be used only for tensioning drives
on which the grade of belt, rated belt capacity, service
factor, design horsepower, etc. are known.
Step 1: Install belts per Step 1 of General Method.
Measure span length (t) in inches as shown in
figure 2, or calculate using formula.
Step 2: From figure 2 the deflection height (h) is always
1
/64” per inch of span length (t). For example, a
32” span length would require a deflection of
32
/64” or 1/2”.
Step 3: Determine
 the minimum, maximum, and initial
recommended pounds force using table 1 or
calculate based on the required Static Strand
Tension (Ts). Note: The initial recommended
force is used only for installing new belts which
have not seated themselves into the sheave
grooves and where initial belt stretch has not
taken place.
a. If the deflection force is below the mini-
mum, the belts are too loose and the ten-
sion should be increased by increasing the
center distance.
b. If the deflection force is higher than the
maximum, the belts are too tight and the
tension should be decreased.
When new V-belts are installed on a drive the INITIAL
tension will drop rapidly during the first few hours. Check
tension frequently during the first 24 hours of operation.
Subsequent retensioning should fall between the mini-
mum and maximum force.
To determine the deflection distance from normal posi-
tion, use a straightedge or stretch a cord from sheave
to sheave to use as a reference line. On multiple-belt
drives an adjacent undeflected belt can be used as a
reference.

Step 4: U
 sing a spring scale, apply a perpendicular
force to any ONE of the belts at the mid point
of the span as shown in figure 2. Compare this
deflection force with the values found in Step 3.

Figure 2

75
 Table 1 Minimum deflection force values shown in Table 1 are
Recommended Minimum Force Per Belt based on assumed average static tensions for drives
having multiple belts or more than one V-band, thus
Belt
Small Sheave Drive Ratio eliminating calculations. (For drives using only one belt
Selection Speed
Dia. 1.0 1.5 2.0
4.0 & or one V-band, deflection force must be determined by
Range over
use of engineering formulas.)
1200-3600 2.65 2.0 2.4 2.6 3.0
1200-3600 3.65 2.8 3.6 3.8 4.2 Find the minimum recommended deflection force for the
3V 1200-3600 4.75 3.8 4.2 4.4 4.8
1200-3600 5.60 4.2 4.6 4.8 5.4 belt section and type based upon the small sheave di-
1200-3600 6.90 4.6 5.0 5.2 5.6 ameter, speed and drive ratio. For intermediate sheave
900-1800 7.1 8.5 9.5 10.0 11.0 diameters and/or drive ratio combinations the minimum
900-1800 9.0 10.0 11.0 12.0 13.0 deflection force may be interpolated.
5V
900-1800 14.0 12.0 13.0 14.0 15.0
700-1200 21.2 14.0 15.0 16.0 17.0
For Narrow Band, Classical Band and Classical Cog
900-1800 12.5 18.0 21.0 23.0 25.0
900-1800 14.0 21.0 23.0 24.0 28.0 Band belts multiply the minimum deflection force from
8V 700-1500 17.0 24.0 26.0 28.0 30.0 Table 1 by the number of belts in the band. Where larger
700-1200 21.2 28.0 30.0 32.0 34.0 values make use of the Force Deflection Method im-
400-1000 24.8 31.0 32.0 34.0 36.0
practical, use the Elongation Method to tension V-bands.
1200-3600 2.20 2.2 2.5 2.7 3.0
1200-3600 2.50 2.6 2.9 3.1 3.6
1200-3600 3.00 3.1 3.5 3.7 4.2
3VX
1200-3600 4.12 3.9 4.3 4.5 5.1
1200-3600 5.30 4.6 4.9 5.1 5.7
Table 2
1200-3600 6.9 5.0 5.4 5.6 6.2 K Factors and Arc of Contact
1200-3600 4.4 6.5 7.6 8.0 9.0
1200-3600 5.2 8.0 9.0 9.5 10.0 Arc Factor Arc Factor
D—d D—d
1200-3600 6.3 9.5 10.0 11.0 12.0 Contact Contact
5VX C Ac K C Ac K
1200-3600 7.1 10.0 11.0 12.0 13.0 Degree Degree
900-1800 9.0 12.0 13.0 14.0 15.0 0.000 180 1.000 24.750 0.750 136 0.879 30.411
900-1800 14.0 14.0 15.0 16.0 17.0 0.025 179 0.997 24.883 0.775 134 0.874 30.388
1800-3600 3.0 2.0 2.3 2.4 2.6 0.050 177 0.994 25.019 0.800 133 0.869 30.975
1800-3600 4.0 2.6 2.8 3.0 3.3 0.075 176 0.990 25.158 0.825 131 0.864 31.270
AP 0.100 174 0.987 25.300 0.850 130 0.858 31.576
1800-3600 5.0 3.0 3.3 3.4 3.7
1800-3600 7.0 3.5 3.7 3.8 4.3 0.125 173 0.983 25.444 0.875 128 0.852 31.892
1200-1800 4.6 3.7 4.3 4.5 5.0 0.150 171 0.980 25.591 0.900 127 0.847 32.219
1200-1800 5.0 4.1 4.6 4.8 5.6 0.175 170 0.977 25.742 0.925 125 0.841 32.558
BP 0.200 169 0.973 25.896 0.950 123 0.835 32.909
1200-1800 6.0 4.8 5.3 5.5 6.3
1200-1800 8.0 5.7 6.2 6.4 7.2 0.225 167 0.969 26.053 0.975 122 0.829 33.273
900-1800 7.0 6.5 7.0 8.0 9.0 0.250 166 0.966 26.213 1.000 120 0.823 33.652
900-1800 9.0 8.0 9.0 10.0 11.0 0.275 164 0.962 26.377 1.025 118 0.816 34.045
CP 0.300 163 0.958 26.545 1.050 117 0.810 34.454
900-1800 12.0 10.0 11.0 12.0 13.0
700-1500 16.0 12.0 13.0 13.0 14.0 0.325 161 0.954 26.717 1.075 115 0.803 34.879
0.350 160 0.951 26.892 1.100 113 0.796 35.323
900-1500 12.0 13.0 15.0 16.0 17.0
900-1500 15.0 16.0 18.0 19.0 21.0 0.375 158 0.947 27.072 1.125 112 0.789 35.786
DP 0.400 157 0.943 27.257 1.150 110 0.782 36.270
700-1200 18.0 19.0 21.0 22.0 24.0
700-1200 22.0 22.0 23.0 24.0 26.0 0.425 155 0.939 27.445 1.175 108 0.774 36.777
0.450 154 0.935 27.639 1.200 106 0.767 37.307
1800-3600 3.0 2.5 2.8 3.0 3.3
0.475 153 0.930 27.837 1.225 104 0.759 37.864
1800-3600 4.0 3.3 3.6 3.8 4.2
AX 0.500 151 0.926 28.040 1.250 103 0.751 38.448
1800-3600 5.0 3.7 4.1 4.3 4.6
1800-3600 7.0 4.3 4.6 4.8 5.3 0.525 150 0.922 28.249 1.275 101 0.742 39.064
0.550 148 0.917 28.463 1.300 99 0.734 39.713
1200-1800 4.6 5.2 5.8 6.0 6.9
0.575 147 0.913 28.684 1.325 97 0.725 40.398
1200-1800 5.0 5.4 6.0 6.3 7.1
BX 0.600 145 0.908 28.910 1.350 95 0.716 41.123
1200-1800 6.0 6.0 6.4 6.7 7.7
1200-1800 8.0 6.6 7.1 7.5 8.2 0.625 144 0.904 29.142 1.375 93 0.706 41.892
0.650 142 0.899 29.381 1.400 91 0.697 42.709
900-1800 7.0 10.0 11.0 12.0 13.0
0.675 141 0.894 29.627 1.425 89 0.687 43.580
900-1800 9.0 11.0 12.0 13.0 14.0
CX 0.700 139 0.889 29.881
900-1800 12.0 12.0 13.0 13.0 14.0
0.725 137 0.884 30.142
700-1500 16.0 13.0 14.0 14.0 15.0
900-1500 12.0 16.0 18.0 19.0 20.0
900-1500 15.0 19.0 21.0 22.0 24.0
DX
700-1200 18.0 22.0 24.0 25.0 27.0
700-1200 22.0 25.0 27.0 28.0 30.0

MAXIMUM Deflection Force = Minimum times 1.5

INITIAL Deflection Force = Minimum time; 2.0
TB Wood’s • 888-449-9439
76
 Force deflection
engineering
formulas

For a more precise method, or where a V-drive combina-

tion is not within specified limits, table 1, use the follow- Explanation of Symbols
ing engineering formulas to determine force deflection Ac = Arc of contact - smaller sheave, degrees
values.
C = Center Distance, inches
Step 1: D
 etermine Span Length (t) and Deflection D = Large sheave pitch diameter, inches
Height (h). Reference figure 2.
d = Smaller sheave pitch diameter, inches
Step 2: Calculate the Static Strand Tension (Ts). DHP = Design horsepower based upon the
recommended application service factor
K X DHP MS2
Ts = +
N X S 2 h = Deflection height, inches (Refer. figure 2)
K = Value from table 2 depending on D—d
Step 3: C
 alculate the recommended Deflection
C
Forces (P) for drives using multiple belts or
or K = 16.5 2.5-Ac
more than one V-band.
Ac
Ts + Y L = Belt length, inches
PMinimum =
16
M = Centrifugal constant table 3
1.5(Ts) + Y N = Number of belts or V-band ribs
PMaximum =
16
P = Deflection force, pounds
PInitial = 1.33 times Pmaximum S = Belt speed, FPM/1000
t = Span length, inches (Refer. figure 2)
Y = Belt constant table 3

Note: F
 or drives using only one belt or one V-band, and at least one shaft free to rotate, use the following to de-
termine the recommended Deflection Forces (P).

= Ts = Y L )
( = 1.5(Ts) + Y L )
(
t t
PMinimum PMaximum PInitial = 1.33 times PMaximum
16 16

Table 3
Belt Constants M & Y

Narrow Narrow Cog Classical Classical Cog

Factors
3V 4V 8V 3VX 5VX AP BP CP DP EP AX BX CX DX

M
.46 1.23 3.28 .39 1.08 .66 1.08 1.98 3.74 5.85 .61 1.00 1.78 3.97
Single Belts
M
.51 1.32 3.80 – – – 1.40 2.33 4.29 6.26 – 1.28 2.10 4.56
V-band

Y 4.0 12.00 22.00 7.0 20.0 6.0 9.0 16.0 30.00 45.00 7.0 10.00 28.00 82.00

77
 Belt elongation method

This method is recommended for V-band drives where larger deflecting forces make the use of previously de-
scribed methods impractical.

Elongation is related to the tension causing it; thus, tape measured V-band lengths, both slack and tight, can be
used to obtain proper V-band tension.

Step 1: D
 ecrease the center distance until the V-band(s) can be easily slipped into the sheave grooves. Forcing
the belts on can damage the load-carrying cords and cause premature belt failure.

Step 2: W
 ith the V-band(s) still on the drive at NO tension, measure the outside circumference (slack O.C.) of
the bands. Note: If retensioning a used drive, decrease the center distance until there is no tension on
the band(s), then measure the outside circumference (slack O.C.) of the band(s).

Step 3: Determine the required Static Tension (Ts) per individual rib strand using the following formula.

K X DHP MS2
Ts = +

N X S 2

Step 4: Find a range of recommended tensions.

Lower Tension = Ts
Upper Tension = 1.5 times Ts

Step 5: Calculate minimum and maximum elongated band lengths for use in tensioning the drive.
a. From table 4, find length multipliers corresponding to the lower and upper Ts values in Step 4
above.
b. Multiply the slack O.C. found in Step 2 by the length multipliers to find the minimum and maximum
elongated band lengths.

Step 6: Increase the drive center distance until a tape measurement of the band(s) O.C. is between the two
values calculated for elongated band length in Step 5b.

Step 7: R
 etension as required. New V-bands may lose tension rapidly during the run-in period and will probably
require retensioning. V-bands that have been on a drive for some time may also require retensioning
due to tension decay from normal use and wear.

78
 Table 4 Belt length multipliers
for tensioning banded belts

NARROW BAND CLASSICAL BAND CLASSICAL COG BAND

Ts CROSS SECTION
Per
Strand 5V 8V BP CP BX CX DX
(lbs.) 3V 5V1700 5V1800 8V1700 8V1800 BP144 Over CP144 Over DP All All All
& under & over & under & over & under BP144 & under CP144 Sizes Sizes Sizes

10 1.00186 1.00056 1.00001 1.00013 1.00010 1.00113 1.00141 1.00029 1.00052 1.00013 1.00082 1.00027 1.00013
12 1.00220 1.00068 1.00097 1.00016 1.00012 1.00135 1.00168 1.00035 1.00062 1.00016 1.00098 1.00032 1.00016
14 1.00254 1.00079 1.00113 1.00019 1.00014 1.00157 1.00194 1.00041 1.00072 1.00019 1.00114 1.00038 1.00019
16 1.00288 1.00090 1.00129 1.00021 1.00016 1.00178 1.00220 1.00046 1.00082 1.00021 1.00129 1.00043 1.00021
18 1.00320 1.00101 1.00144 1.00024 1.00018 1.00199 1.00246 1.00052 1.00092 1.00024 1.00145 1.00048 1.00024
20 1.00352 1.00112 1.00159 1.00027 1.00020 1.00220 1.00271 1.00058 1.00102 1.00027 1.00160 1.00054 1.00027
24 1.00414 1.00133 1.00190 1.00032 1.00024 1.00261 1.00320 1.00069 1.00122 1.00033 1.00191 1.00065 1.00032
28 1.00472 1.00155 1.00219 1.00037 1.00029 1.00301 1.00368 1.00081 1.00141 1.00038 1.00220 1.00075 1.00038
32 1.00520 1.00176 1.00249 1.00043 1.00033 1.00339 1.00414 1.00092 1.00161 1.00044 1.00250 1.00086 1.00043
36 1.00556 1.00197 1.00277 1.00048 1.00037 1.00377 1.00458 1.00104 1.00180 1.00050 1.00278 1.00097 1.00059
40 1.00588 1.00217 1.00305 1.00054 1.00042 1.00413 1.00500 1.00115 1.00199 1.00056 1.00306 1.00107 1.00054
45 1.00625 1.00243 1.00340 1.0060 1.00047 1.00458 1.00529 1.00129 1.00222 1.00063 1.00341 1.00121 1.00061
50 1.00659 1.00268 1.00374 1.00067 1.00053 1.00500 1.00553 1.00144 1.00246 1.00071 1.00374 1.00134 1.00068
55 1.00691 1.00293 1.00406 1.00074 1.00058 1.00528 1.00574 1.00158 1.00268 1.00078 1.00407 1.00147 1.00075
60 1.00722 1.00317 1.00438 1.00081 1.00064 1.00553 1.00591 1.00172 1.00291 1.00086 1.00439 1.00161 1.00081
65 1.00754 1.00341 1.00470 1.00088 1.00070 1.00576 1.00606 1.00186 1.00313 1.00094 1.00470 1.00174 1.00088
70 1.00787 1.00365 1.00500 1.00095 1.00076 1.00596 1.00620 1.00200 1.00335 1.00102 1.00500 1.00187 1.00095
75 1.00822 1.00389 1.00523 1.00101 1.00082 1.00614 1.00632 1.00214 1.00357 1.00110 1.00522 1.00200 1.00102
80 1.00861 1.00412 1.00545 1.00108 1.00088 1.00631 1.00644 1.00228 1.00378 1.00118 1.00543 1.0213 1.00109
85 1.00903 1.00434 1.00566 1.00115 1.00094 1.00646 1.00656 1.00242 1.00399 1.00127 1.00563 1.00227 1.00116
90 1.00949 1.00456 1.00586 1.00122 1.00100 1.00659 1.00668 1.00256 1.00420 1.00135 1.00581 1.00240 1.00123
95 1.01000 1.00478 1.00606 1.00129 1.00106 1.00672 1.00682 1.00270 1.00441 1.00144 1.00599 1.00253 1.00130
100 1.01056 1.00500 1.00625 1.00136 1.00113 1.00684 1.00697 1.00284 1.00461 1.00152 1.00616 1.00266 1.00137
120 1.01333 1.00561 1.00696 1.00164 1.00139 1.00727 1.00780 1.00339 1.00528 1.00188 1.00679 1.00319 1.00166
140 1.01692 1.00617 1.00765 1.00192 1.00166 1.00771 1.00912 1.00393 1.00579 1.00226 1.00736 1.00371 1.00195
160 1.02081 1.00672 1.00836 1.00220 1.00194 1.00827 1.01104 1.00447 1.00627 1.00265 1.00793 1.00423 1.00224
180 1.02385 1.00728 1.00913 1.00249 1.00223 1.00902 1.01357 1.00500 1.00675 1.00306 1.00854 1.00474 1.00253
200 1.02655 1.00707 1.01000 1.00277 1.00254 1.01000 1.01718 1.00534 1.00724 1.00349 1.00922 1.00525 1.00283
240 1.03118 1.00921 1.01213 1.00335 1.00319 1.01279 1.02268 1.00607 1.00832 1.00440 1.01090 1.00625 1.00343
280 1.03579 1.01088 1.01524 1.00395 1.00389 1.01663 1.02737 1.00692 1.00963 1.00542 1.01313 1.00724 1.00405
320 1.04070 1.01292 1.01834 1.00454 1.00461 1.02088 1.03275 1.00797 1.01124 1.00656 1.01590 1.00824 1.00468
360 1.04671 1.01562 1.02162 1.00515 1.00543 1.02423 1.03853 1.00926 1.01317 1.00771 1.01925 1.00924 1.00532
400 1.05308 1.01826 1.02526 1.00575 1.00631 1.02708 1.04393 1.01081 1.01580 1.00886 1.02229 1.01026 1.00598
450 1.02179 1.03056 1.00652 1.00744 1.03072 1.05000 1.01311 1.01877 1.01028 1.02625 1.01156 1.00683
500 1.02558 1.03643 1.00732 1.00859 1.03425 1.01610 1.02186 1.01164 1.03000 1.01292 1.00768
550 1.02927 1.04200 1.00813 1.00976 1.03781 1.01888 1.02500 1.01293 1.03354 1.01435 1.00856
600 1.03286 1.04642 1.00896 1.01094 1.04158 1.02169 1.02813 1.01413 1.03685 1.01557 1.00946
650 1.03632 1.05000 1.00982 1.01213 1.04567 1.02449 1.03123 1.01524 1.04000 1.01729 1.01037
700 1.03967 1.01071 1.01331 1.05000 1.02718 1.03426 1.01625 1.04333 1.01919 1.01130
750 1.04310 1.01163 1.01449 1.03000 1.03719 1.01718 1.04667 1.02126 1.01224
800 0.04655 1.01257 1.01571 1.03282 1.04000 1.01802 1.05000 1.02372 1.01320
850 0.05000 1.01354 1.01689 1.03563 1.04268 1.01833 1.02607 1.01418
900 1.01454 1.01887 1.03838 1.04524 1.01936 1.02840 1.01518
950 1.01561 1.01927 1.04101 1.04768 1.02044 1.03068 1.01619
1000 1.01667 1.02049 1.04345 1.05000 1.02156 1.03209 1.01717

79
 Trouble Shooting V-Belts
How to spot V-belt trouble

Trouble Cause To correct

Belt slip Not enough tension. Replace belts; apply proper tension
(sidewalls glazed)

Drive Squeals Shock load Apply proper tension.

Not enough arc of contact. Increase center distance.
Heavy starting load. Increase tension.

Belt turned over. Broken cord caused by prying on Replace set of belts correctly.
sheave.
Overloaded drive. Redesign drive.
Impulse loads. Apply proper tension
Misalignment of sheave and shaft. Realign drive.
Worn sheave grooves. Replace sheaves
Flat idler sheave. Align idler: Re-position on slack
of the drive close to drive sheave.
Excessive belt vibration. Check drive design. Check
equipment fo solid mounting
Consider use of band belts

New belts installed with old belts. Replace belts in matched set only.
Mismatched belts. Sheaves grooves worn unevely: Replace sheaves.
improper groove angle. Give
appearance of mismatched
belts.
Sheave shafts not parallel. Give Align drive.
appearance of mismatched
belts.

Belt Breaks Shock loads. Apply proper tension; Recheck

Heavy starting loads.
Belt pried over sheaves
Foreign objects in drive
drive.
Apply proper tension; Recheck
drive. Use compensator
starting.
Replace set of belts correctly.
Provide drive shroud.

Belt wears rapidly Sheave grooves worn. Replace sheaves.

Sheave diameter too small. Redesign drive.
Mismatched belts. Replace with matched belts.
Drive overloaded. Redesign drive.
Belts slips. Increase tension.
Sheaves misaligned. Align sheaves.
Oil or hear condition. Eliminate oil. Ventilate drive.

80
 How to diagnose
V-belt failure

V-Belt Troubleshooting Checklist

BELT CONDITION

CAUSE
Oil-softened rubber.

PREVENTION
Splash guards will protect drives against oil. Al-
though Classical belts are oil resisting exces-
sive oil can cause some deterioration.

Oil Deterioration

CAUSE
Cover fabric ruptured when belt was pried over
sheave during installation.

PREVENTION
Proper installation of belts by moving motor so
belts do not have to be pried into the grooves.

Cover Fabric Rupture

CAUSE
Belts too loose. Belt didn’t move, friction
against sheave burned rubber. When belt
finally grabbed, it snapped.

PREVENTION
Maintain proper tension on the drive.

Slip Burn

81
 How to diagnose
V-belt failure

V-Belt Troubleshooting Checklist

BELT CONDITION

CAUSE
Severe back-bend idlers. Improper storage.
Excessive ambient operating temperature.

PREVENTION
Check storage conditions. If back-bend idler
cannot be avoided, install idler of larger diam-
eter. Avoid ambient temperature over 140°.

Base Cracking

CAUSE
Split along pitch line indicating belt ran over
too small a sheave.

PREVENTION
Redesign drive using sheaves of proper size.

Ply Separation

CAUSE
Ruptured cord in the plies.

PREVENTION
Check for rocks or tools falling into sheave
grooves. Check tension. Belts loose enough to
twist in groove can rupture cords.

Ruptured

CAUSE
Misalignment. Grit or dirt. Normal wear.

PREVENTION
Align sheaves. Replace belts as required.

Worn Belt Sides

82
 How to diagnose
V-belt failure

V-Belt Troubleshooting Checklist

BELT CONDITION

CAUSE
Cover wear indicates slip. Clean break reveals
sudden snap.

PREVENTION
Maintain proper tension on the drive.

Sub break

CAUSE
Breakdown of adhesion or broken cords.

PREVENTION
Do not pry belts on drives. Check sheaves for
recommended diameters.

Distorted Belt

CAUSE
Foreign material and rust in sheaves wore
away sidewalls, letting belt drop to bottom of
groove.

PREVENTION
Dust guards help protect against abrasion. Ten-
sion must be maintained in dusty atmospheres.

Abrasion

83
 Sure-Grip® Sheave Features

Wood’s sheaves are constructed of fine grain, high tensile cast iron, and have been carefully engineered to as-
sure maximum performance over a long life span. Behind each sheave is one of the most extensive engineer-
ing design and testing programs in the industry.

DESIGN INTEGRITY MACHINING

TB Wood’s Incorporated has been a leading supplier TB Wood’s Incorporated has numerous machining
of cast iron pulleys, v-belt sheaves, synchronous belt facilities throughout North America. Each is equipped
sprockets and Sure-Grip mounting bushings since the with modern CNC equipment and capable of doing
inception of these products. We are committed to the high precision machining. Statistical process controls
continual improvement of our standard products and are in place in each location, and each has been ISO-
special or MTO products through design, materials 9001 certified.
and quality enhancements. For example, new product
designs are typically computer generated and then SPECIFICATIONS
verified using finite element analysis before CAD TB Wood’s products are manufactured to conform to
drawings are made. This enables Wood’s to quickly or exceed recognized industry standard specifications.
and accurately quote on any special needs, and to The following is a listing of some of these specs.
relay the tool paths for new designs quickly from engi-
neering to the shop floor. ANSI/RMA IP-20 Classical V-Belt Sheaves
FOUNDRY PROCESSES ANSI/RMA IP-22 Narrow V-Belt Sheaves
TB Wood’s Incorporated has a modern state-of-the- ANSI/RMA IP-24 Synchronous Sprockets
art foundry in Chambersburg, PA where cast iron and MPTA QD-1 QD Bushing Guideline
ductile iron castings are produced. This captive found-
ry operation not only gives Wood’s the control needed MPTA SPB Pulley Balance
to obtain standard high quality castings as they are re- MPTA SAS V-Belt Sheave Arm Stress
quired , but also enables them to produce any special MPTA SF Pulley Surface Finish
requirements in a minimal amount of time.

84
85
86
 ROTATION
p C s +0.002
� -0 000
IZI AB
M
,....--,......_ �
+ R
+0.000
Dew 5
T -O.D1
u +0.000
�I
MiN.l �
0 �_j
V I 0
+o.oo
0
- .06

BxH
HOLES E E SEE NOTE 5

A M CONDUIT I' 2F ' I' I

BAI
' 'N-W' I 1.NOTES:
DIMENSION V REPRESENTS LENGTH
OF STRAIGHT PART OF SHAFT
B 2. MAIN CONDUIT BOX MAY BE ROTATED
IN 90" INCREMENTS
UNC GND BOLT
3. KEY DIMENSIONS EQUAL S x S x 6.91
2"-13 (MOTOR SUPPLIED WITH KEY)
SEE NOTE 7 4. MOTOR WEIGHT SHOWN IS MAXIMUM
HORSEPOWER IN FRAME
UNITS: INCHES 5. THIS DIMENSION EQUALS 2F FOR N447T
MOUNTING
M[NPI]
MOTOR DIMENSIONS

87
CONDUIT BOX
J 0
FRAME
A p
6. STANDARD PRODUCT USE Bl-DIRECTIONAL
SIZE B C D G K M T AB AC AE AF XL XN FAN. OPPOSITE ROTATION AVAILABLE
N447T/N449T 22.0 34.7 59.3 11.00 1.4 4.6 13.8 20.9 25.0 27.0 3.0 4.00 24.0 19.7 11.00 9.2 15.2 10.2 ONLY BY CONNECTION CHANGE
7. FRAME GROUND BOLT STANDARD ON
N447TS/ N449TS 22.0 34.7 55.6 11.00 1.4 4.6 13.8 20.9 25.0 27.0 3.0 4.00 24.0 19.7 11.00 9.2 15.2 10.2 841 PRODUCT
MAXIMUM
WEIGHT
SHAFT EXTENSION KEY SEAT BEARINGS
s
FRAME MOUNTING
SIZE E 2F H BA N-W V u R ES LS ROLLER LS BALL 6P LS BALL 4P OS 4N8P LS BALL 2P OS 2P
N447T/N449T 9.00 20.00/25.00 0.82 7.50 8.50 8.25 3.375 2.880 0.875 6.88 NU322C3 6322C3 6318C3 6318C3 - -
N44 7TS /N449TS 9.00 20.00/ 25.00 0.82 7.50 4.75 4.50 2.375 2.021 0.625 3.00 -
6318C3 6318C3 6318C3 6313C3 6313C3
3800 lbs.

TAG NO's.:
CUSTOMER: MOTOR MODEL NO.: --------------
P.O. NO.: HP : VOLTAGE: RPM(SYN.): Hz:-- [X] STANDARD (NO AUX. BOXES)
FRAME SIZE: PRODUCT TYPE: TEFC EQP Ill 840
D RTD AUX. BOX
0 SPACE HEATER AUX. BOX
COMMENTS : ------------------------------

0 BEARING RTD's
PER: DATE:-----

TOSHI B A RESERVES THE RIGHT TO M AKE CHANGES O F TECHNI CAL I M PROVEM ENT AN D THE DATA M AY CHANGE WITHO UT NOTI CE [X] PRELIMINARY
DO NOT U SE FOR CON STR U CTION, IN STALLA TION, OR APPLI CATION P URPOSES UNLES S THE DRAWING I S M ARKED AS CERTI FIED 0 CERTIFIED
TOTALLY-ENCLOSED FAN-COOLED XT SERIES
HORIZONTAL FOOT-MOUNTED
TOSHIBA 3 PHASE INDUCTION MOTOR VISIT OUR WEBSITE AT:
TOSHIBA INTERNATIONAL CORPORATION www.toshiba.com/ind
F1 ASSEMBLY
MDS L0031-18 R05
 Issued Date 4/23/2015 Transmit #
Issued By dschoeck Issued Rev

TYPICAL MOTOR PERFORMANCE DATA

Model: B2006FLF4BSHDL

HP kW Pole FL RPM Frame Voltage Hz Phase FL Amps

200 150 6 1190 N449T 460 60 3 246
NEMA NEMA Ambient
Enclosure IP Ins. Class S.F. Duty kVA Code
Nom. Eff. Design (°C)
TEFC 54 F 1.15 CONT 96.2 B F 40 C

Load HP kW Amperes Efficiency (%) Power Factor (%)

Full Load 200 149.1 245.2 96.2 83.1
¾ Load 150.00 111.9 191.8 95.5 80.3
½ Load 100.00 74.6 143.9 93.8 72.7
¼ Load 50.00 37.3 105.8 88.1 50.2
No Load 89.0 3.7
Locked Rotor 1398.00 24.4

Torque Rotor wk²

Full Load Locked Rotor Pull Up Break Down Inertia
(lb-ft) (% FLT) (% FLT) (% FLT) (lb-ft²)
883 150 130 240 130.94

Safe Stall Time(s) Sound

Bearings* Approx. Motor Weight
Pressure
Cold Hot
dB(A) @ 1M DE NDE (lbs)
25 15.5 - 6318C3 NU322C3

*Bearings are the only recommended spare part(s).

Motor Options:
Product Family:EQPIII 840
Mounting:Footed,Shaft:T Shaft

Customer
Customer PO
Sales Order
Project #
Tag:

All characteristics are average expected values.

TOSHIBA INTERNATIONAL CORPORATION · HOUSTON, TEXAS U.S.A.
Engineering bmammen Doc. Written By D. Suarez Doc.# / Rev MPCF-1119 / 0
Engr. Date 7/8/2014 Doc. Approved By M. Campbell Doc. Issued 6/8/2011

88
 Issued Date 4/23/2015 Transmit #
Issued By dschoeck Issued Rev

SPEED TORQUE/CURRENT CURVE

Model: B2006FLF4BSHDL

HP kW Pole FL RPM Frame Voltage Hz Phase FL Amps

200 150 6 1190 N449T 460 60 3 246
NEMA NEMA Ambient
Enclosure IP Ins. Class S.F. Duty kVA Code
Nom. Eff. Design (°C)
TEFC 54 F 1.15 CONT 96.2 B F 40 C
Rotor wk² Torque
Locked Rotor
Inertia Full Load Locked Rotor Pull Up Break Down
Amps
(lb-ft²) lb-ft
(lb-ft) (%) (%) (%)
1398.00 130.94 883 150 130 240

Customer wk² Load Inertia (lb-ft²) -

Customer PO Load Type -
Sales Order Voltage (%) 100
Project # Accel. Time -
Tag:

All characteristics are average expected values.

TOSHIBA INTERNATIONAL CORPORATION · HOUSTON, TEXAS U.S.A.
Engineering bmammen Doc. Written By D. Suarez Doc.# / Rev MPCF-1121 / 0
Engr. Date 7/8/2014 Doc. Approved By M. Campbell Doc. Issued 6/8/2011

89
90
SOLID STATE STARTERS
TS, TD & TX Series

Toshiba introduces a new advanced low voltage,

Digital Solid State Starter, the TX Series. The TD
& TX Series are available from 48A through
1600A. The TS (analog) Series is available from
6A through 32A.

The TD & TX Series are programmable through a

Operator Interface. The TD keypad includes a 4
digit LED readout and status indicators. The TX
keypad includes a LCD display (2 lines x 20 char.).
The TD & TX models include electronic overload
protection using Real-Time Thermal Modeling
which continuously calculates motor temperature
even when the motor is not running, and has
Retentive Thermal Memory. Thermal memory is
Metering/Communications
maintained in brown-out or black-out conditions.
TD Series
The overload will not reset until there is sufficient
z Phase Currents (A, B & C)
motor thermal capacity available for a successful
z Remaining Thermal Capacity of Motor
start.
z Elapsed Time (ETM)
z Run Counter
Standard Features z Detailed Fault Codes & Fault History
z Smooth, Stepless Soft Start - Voltage Ramp (Last 3 Faults)
/Current Limit z Lockout Time Remaining
z Soft Stop - Decel/Pump Control z Real Time Clock
z Current Ratings: 6 - 1600A z Modbus RTU RS485 Communications
z Voltage Ratings: 208 - 600Vac
z Continuous Rating - 125% Adjustments
z Overload Capacity - 500% for 60 seconds TS Series (6 - 32A)
z Overload Capacity - 600% for 30 seconds z Voltage Ramp Start (0 - 60 sec.)
z 120Vac Control Voltage z Initial Voltage (0 - 80%)
z Phase Rotation Insensitive z Current Limit Start (200 - 500%)
z Soft Stop - Deceleration (0 - 30 sec.)
Protective Features z Stop Voltage (0 - 100%)
TS Series (6 - 32A) TD & TX Series (48 - 1600A)
z Overload (Thermal Bimetallic Overload Relay) z Voltage Ramp Start (1 - 120 sec.)
on all enclosed starters (i.e. NEMA Type 1 z Initial Voltage (0 - 100%)
enclosure). Chassis units do not come z Current Limit Start (200 - 600%)
standard with an overload relay. z Decel Ramp Time - Deceleration (1 - 60 sec.)
z Overtemperature z Stop Voltage (0 - 100%)
TD & TX Series (48 - 1600A) z Initial Decel Voltage Level (0 - 100%)
z Phase Loss (Single Phase)/Imbalance (5 - 30%) z Voltage Jog (0 - 100% Voltage, 1 - 20 sec.)
z Electronic Overload (Individually selectable hot z Current Jog (100 - 500%)
& cold curves, Class 5 - 30) z Kick Start (10 - 100% Voltage, 0.1 - 2 sec.)
z Shorted SCR z Starts per Hour (1 - 10 Starts/hr, 1 - 60 min.
z Shorted Load between start attempts)
z Short Circuit z Coast Down Lockout Timer (1 - 60 min.)
z Overtemperature z Overload Reset (Manual or Automatic)
z Undercurrent (10 - 90% of motor FLA) z Dual Ramp Settings - Four programmable ramp
z Overcurrent (50 - 300% of motor FLA) options
z Repetitive Starting z Programmable Output Relays

91
Toshiba International Corp.
 BILL OF MATERIAL
36.00 1-17.41-j Item Description
3.00 (TYP.)- I 30.00 j-16.00-f-o.,9 CB CIRCUIT BREAKER
Iul CPT CONTROL POWER TRANSFORMER
FU,1,2 CONTROL FUSES
I _t.Q;p. ·- I
ij �=�=,1 DRIP/ GND GROUND PAD
SHIELD
* GS GROUND SENSOR
HNDL CB OPERATOR HANDLE
HNDL
11 c:::c:c:!I sss SOLID STATE STARTER
I i'
T1 T1,2 CONTROL TERMINAL STRIP
� r 1/W SSS VIEWING WINDOW
PILOT 1M BYPASS CONTACTOR
©*
DEVICES
I

61.25 60.00
1/W KEYPAD

� * OPTIONAL DEVICE

92
sss

•
LnJ

FRONT VIEW FRONT VIEW RIGHT SIDE VIEW

0.438 DIA. (TYP.) J (W/0 DOOR)

NOTES
MAXIMUM HORSEPOWER
sss 1M 1. ENCLOSURE: lYPE NEMA 3R/12
208V 240V 380V 415V 480V 575V
2. FINISH: ASA61 GRAY
TD009 EH-210C 60 75 125 125 150 200 3. APPROX. WEIGHT: 500 lbs.
TD010 EH-260C 75 100 150 150 200 250 4. ALL DIMENSIONS ARE IN INCHES AND ARE
TD011 EH-300C 100 125 200 200 250 300 FOR REFERENCE ONLY.

REVISION: SCALE:
: TosH1aA ou'TLINE DIAGRAM-WALL MOUNT 1.0=12.0
TOSHIBA INTERNATIONAL CDRPDRATIDN
2
MADE IN HOUSTON, TEXAS U.SA SOLID STATE STARTER W/ AIR BYPASS
1
THIS MATERIAL IS THE EXCLUSIVE PROPERTY OF
o 08/15/01 FIRST ISSUE CA AL AL TOSHIBA INTERNATIONAL CORPORATION ANO SHALL CUSTOMER: PROJECT NUMBER: DRAWING NUMBER:
USED
REV DATE DESCRIPTION BY CHK APPR �:� ���rriD, ��� "&rr�� STD STD L 1 086Y03
 TOSHIBA
Specification Guide

TD Series
Digital Solid State Reduced Voltage
Soft Starter
200 – 600V, 48 – 1250A
Overview: This Specification Guide is to assist Plant and Consulting Engineers in specifying and
describing Toshiba TD Series Digital Reduced Voltage Solid State Starter. This equipment
is offered as a superior method of providing control and protection for AC motors. It also
solves performance, control and reliability problems typical of electro-mechanical reduced
voltage motor starter methods, such as Wye-Delta, Part Winding, AutoTransformer, and
Primary Resistors. Advantages of Digital Reduced Voltage Solid State Starters include solid
state construction, advanced motor protection, stepless acceleration, reduced inrush
current, minimal maintenance and high duty cycle capability. Applications include, but are
not exclusively dedicated to, pumps, fans, blowers, grinders, compressors, lumber and rock
processing, conveyors, and mixers.

CONTENTS
1.0 Introduction .......................................................................................................... 2
2.0 Codes & Standards .............................................................................................. 2
3.0 Product Features .................................................................................................. 2
A. Motor and Load Protection .............................................................................. 2
B. Acceleration Control ........................................................................................ 3
C. Deceleration Control ........................................................................................ 4
D. Starter Protection ............................................................................................. 4
E. Input / Output features ..................................................................................... 4
F. Operator Interface ............................................................................................ 5
G. Metering ........................................................................................................... 5
H. Serial Communications .................................................................................... 5
I. Fault History..................................................................................................... 5
4.0 Design Specifications .......................................................................................... 6
A. Power Ratings.................................................................................................. 6
B. SCR Devices.................................................................................................... 6
C. Ambient Conditions .......................................................................................... 6
5.0 Mechanical Construction ..................................................................................... 6
A. Enclosure ......................................................................................................... 6
B. Terminations .................................................................................................... 7
6.0 Quality Requirements .......................................................................................... 7
7.0 Documentation ..................................................................................................... 7
8.0 Spare Parts ........................................................................................................... 7
9.0 Start Up/ Service................................................................................................... 7

93
Introduction
This specification describes the performance, functional specifications and fabrication details for a digital reduced
voltage, stepless, solid state motor starter that shall provide a selectable voltage ramp, current limit or current ramp
(all standard) method of soft starting 3-phase AC induction motors.
A) The motor starter shall be self-contained and house the solid-state controller, motor overload protection
(Class 5 through Class 30 selectable) and a disconnect means as required on the drawings, in one
enclosure.
2) Codes and Standards
A) Unit(s) must be manufactured to the codes listed below:
1) National Electrical Code
B) Unit(s) must be approved and/or certified by, and carry the label(s) of one or more of the following
organizations:
1) Underwriters Laboratories (UL)
2) Canada Standards Association (CSA) or cUL is acceptable
C) Units shall be Combination Starters with circuit breakers, shall be UL listed for use in combination with the
specific associated circuit breaker, and shall have passed a 3 cycle withstand test per UL standards.
3) Product Features
Solid state reduced voltage motor starters shall be Toshiba TD Series (sized as indicated), or pre-approved equal,
modified to meet the requirements of this specification. The starter shall be complete with the following standard
features and adjustments.
A) Motor and Load Protection shall be integral to the starter assembly. All current referenced protection
features shall be automatically calculated from the motor nameplate FLA as entered by the user. All time
based protection features shall be based on a Real Time Clock with retentive memory so that they remain
active should the power fail and be restored. Starter shall provide the following functions:
1) I2t Thermal Overload shall be provided by the on-board microprocessor control based on inverse time-
current trip curves as defined by NEMA trip curve Classes. The trip curves Classes shall be
programmable from between Class 5 and Class 30 and the starter shall be UL listed to provide each
individual class. As the most important protection feature of a starter, the overload protection shall be
based on a Dynamic Thermal Register retained in memory and provide the following features:
(a) Retentive Thermal Memory shall be used to ensure that the overload protection does not lose
track of motor temperature after the power is lost or shut down. Upon reapplication of power, the
microprocessor shall be updated as to the motor temperature and adjusted for real time cooling
while the power was off.
(b) Dynamic Reset Capacity shall retain a snapshot of the thermal capacity necessary to restart the
motor. The starter shall determine how much thermal capacity is required, learning this information
from the previous successful start-up. After an overload trip has occurred the protection shall
prevent resetting until enough cooling time has passed and sufficient motor thermal capacity is
available.
(c) True Thermal Modeling for cool down time shall be a feature of the reset calculations. Since a
motor will cool faster when the temperature differential is higher, the starter shall require sufficient
time for the motor to cool based on the trip level percentage. Linear cool down time calculations
can subject the motor to damage from premature restart and will not be acceptable.
(d) Separate Trip Curves shall be provided for Starting and Running, allowing a higher level curve to
avoid nuisance tripping during Acceleration, but dropping to a lower level for maximum motor
protection while Running. For maximum flexibility, each trip curve shall be programmable within the
Class ranges described above.

94
 (e) Manual or Automatic Reset of the Overload Protection shall be selectable in programming to
provide for automatic reset in unattended remote applications. The factory default shall be Manual
Reset.
2) Phase-Loss Protection shall be standard and shut down the starter if current through any leg drops to
20% of unit programmed FLA or less, regardless of line voltage integrity. This protection shall be
implemented by hardware and non-adjustable, but capable of over ride by service personnel for test
procedures.
(a) Phase Imbalance Protection shall also be provided, with adjustable sensitivity in programming.
The sensitivity shall be adjustable for imbalances between any two phases of between 5% and
30%. A time delay of up to 20 seconds shall avoid nuisance tripping from short duration transients.
This protection shall be capable of being disabled when not needed.
3) Short Circuit Detection with dual mode protection for starting and running operation shall be standard.
This circuit MUST be provided to protect the starter from load failures. This protection shall be
implemented by hardware and non-adjustable, but capable of over ride by service personnel for test
procedures.
(a) In the starting mode the starter shall employ a ¼ second pre-check routine to determine if the load
circuit has a fault condition and disable the ramping prior to reaching the Initial Voltage setting. This
is to avoid additional equipment damage after a fault has occurred while the starter is off.
(b) In the running mode this feature will shut down the starter if current through any leg exceeds 10
times unit FLA for 12.5 milliseconds.
4) Shear Pin Protection shall be provided separate from the above. This Over Current trip shall be
adjustable at lower levels for the purpose of protecting mechanical components from undue shock
when rapid unexpected load changes occur.
(a) Adjustment level shall be from 100% to 300% of the programmed motor FLA
(b) A time delay of up to 20 seconds shall prevent nuisance tripping from short duration transients.
5) Load Loss Protection shall shut down the starter on an adjustable Under Current condition. This shall
be programmable as follows:
(a) Adjustment level shall be from 10% to 90% of the programmed motor FLA
(b) A time delay of up to 20 seconds shall prevent nuisance tripping from short duration transients.
6) Coast Down Lockout shall be provided to prevent restarting of the motor during backspin after
shutting off. The coast down lockout time shall be programmable between 0 and 60 minutes following a
Stop command.
7) Starts-per-Hour Lockout shall be provided to prevent damage to the motor from rapid cycling of start
commands for any reason. The maximum starts-per-hour shall be programmable between 1 and 10
starts.
(a) Time Between Starts Lockout shall also be programmable to work with the above. A minimum
time of between 0 and 60 minutes between start attempts shall prevent restarting too rapidly for the
motor and load conditions as determined by the user.
B) Acceleration Control shall be fully adjustable in programming to match any application. As a minimum,
starter shall come complete with the following settings:
1) Ramp Type: To ensure maximum flexibility in matching the load conditions in the field, the starter shall
provide all of the following methods of closed loop acceleration ramp control:
Voltage Ramp, Voltage Ramp with Current Limit,
Current Limit Only (Current Step) or Current Ramp (Torque Ramp).
2) Starting Torque: Initial torque output shall be programmable as either Current or Voltage output, and
adjustable between 0-100% of maximum Locked Rotor Torque (600% current) available from the
motor.

95
 3) Maximum Current Limit: To ensure reliability of starting under any circumstances that the motor can
function in, Current Limit shall be adjustable between 200 and 600% of the unit rating. This will allow
locked rotor current to be delivered to the motor if necessary. Lighter duty starters with lower current
limit settings will not be acceptable.
4) Ramp Time: The time between Initial Torque and Full Output shall be adjustable between 1 and 120
seconds.
5) Dual Ramps: To accommodate changing load conditions, the starter shall provide (2) two separately
adjustable ramp profiles, selectable via a dry contact closure. Each ramp will provide all of the above
features.
6) Kick Start: To provide for starting of difficult loads, the starter shall include a Kick Start feature that will
apply a high output for a short time on initial start command. The Kick Start voltage level shall be
adjustable from 10 – 100% voltage, for 0.1-2 seconds maximum.
7) Jog: For checking rotation at start-up or during other testing procedures, the starter shall provide a
programmable Jog feature, initiated by a dry contact closure. The Jog output shall match the selected
Ramp method, but shall have independent output level adjustment. Jogging shall be limited to a
maximum of 20 seconds.
C) Deceleration Control (Ramp Down) shall be built in and selectable with the following adjustments, all of
which shall be completely independent of any Acceleration Ramp settings:
1) Step Down Voltage: adjustable from 100% to 0 of line voltage, allowing the motor torque to drop off
immediately to a level that affects output without waiting for a linear ramp.
2) Deceleration Ramp Time: adjustable from 0 – 30 seconds to allow gentle controlled deceleration in
excess of the natural coast-to-stop time of the load.
3) Stop Voltage Level, adjustable from 100 – 0% of line voltage to automatically turn off the starter when
the output torque has reached a desired level.
4) Selectable Operation During Overload, to allow the user to decide if the motor shall turn off or
continue to Decel when an overload condition is detected.
D) Starter Protection shall be provided to maintain reliability of both the equipment and the circuit
components, with the following features:
1) Shorted SCR Detection shall be standard. This function must automatically prevent a “start” sequence
when at least one SCR is shorted. A means of having qualified service personnel defeat the lockout of
this circuit MUST be provided for “Must Run” situations.
2) Shunt Trip Circuit shall be standard. This feature shall instantly energize a dry relay contact that can
be wired to a “Shunt Trip” coil of the circuit breaker in order to protect the motor from damage. This
protection shall only operate if there is current flowing through any phase of the starter when in the “Off”
condition, as in the case when there are multiple shorted SCRs or if a bypass contactor is stuck in the
closed position. This feature shall be independent of the above Shorted SCR protection so that it
cannot be defeated.
3) Starter Overtemp Trip shall be built-in and protect the SCRs from excessive heat build-up in the
enclosure or heat sinks.
E) Input / Output features shall be as follows:
1) Inputs shall be provided for the control and option selection of the starter as follows. All input and
control devices shall be rated for 120VAC control or shall require dry contact closures without the need
for external power supplies or interposing relays.
(a) On-Off Control shall be 120VAC to avoid potential problems with voltage drop in long control wire
runs. The starter shall provide for 2 wire or 3 wire control schemes. Seal-In relay contact for the 3-
wire control scheme shall be internal, dedicated to that use and not counted as an output contact.
Terminals shall be provided for field installation of interlock devices if specified elsewhere.
(b) Dual Ramp and Jog Select inputs shall require only dry contact closures. Because they are not
crucial for safe operation, they may use low voltage circuits powered by a built-in source.

96
 2) Outputs shall be provided for the following functions in addition to the seal-in relay used in 3 wire
control schemes as mentioned above. The outputs shall be three (3) Form “C” contact relay outputs,
rated for 240VAC, 5AMPS, 1200VA max., with each relay being programmable for any one of the
following functions:
(a) Run Indicator Relay programmable to change state on either of the following conditions:
Run / Stop, Start / End of Decel
(b) At Speed Relay programmable to change state on either of the following conditions:
At Speed / Stop, At Speed / End of Decel
(c) Fault Indicator Relay programmable for each of the following fault conditions:
Shorted SCR, Phase Loss, Shunt Trip, Over Load Trip, Over Temp Trip, Short Circuit, Current
Imbalance, Shear Pin / Over Current, Load Loss / Under Current, or Any Trip
(d) Lockout Indicator Relay including the following conditions:
Coast Down / Back Spin, Minimum Time Between Starts
F) Operator Interface Panel with simple to use adjustment and status indication on a dead-front shroud of the
starter shall be provided. This panel shall be capable of being remotely mounted up to 10 feet (3 meters)
from the starter chassis, such as on the front door of the enclosure.
1) Adjustments shall be made by keypad with tactile feedback keys for high noise environments. No
binary coded dipswitches shall be used for programming. Pass code protection shall be available to
prevent unauthorized changes to the programming.
2) Alphanumeric Display shall be 7 segment, high brightness LED for long life and visibility in low
contrast environments without the need for backlighting. Display shall have a minimum of 4 digits so
operators do not need to calculate current values over 999A.
3) Indicators using long life LED devices shall provide additional quick annunciation of Run and Fault
operation, including the following 8 specific conditions:
Power On; At Speed; Overload; Over-Temperature; Shorted SCR; Phase Loss; Short Circuit; and
Shunt Trip
G) Metering functions shall be provided through the Alpha-Numeric Display for indicating the following;
1) Output Current for each individual phase. Indicating range to be 0.0 – 9999 amps
2) Remaining Thermal Capacity to indicate heating effect and cooling rate of the motor. Range shall be
0 – 100% of the remaining capacity and count up towards 100% while cooling.
3) Elapsed Time shall indicate the number of hours that the starter has been in a Run condition. Range
shall be 0,0 to 1,000,000.0 hours, non-resetable.
4) Run Cycles, showing a running count of the number of Run Commands given to the starter. Range
shall be 0 – 10,000,000 cycles, non-resetable.
H) Serial Communications shall be built-in as a standard feature without the need for separate modules.
1) Communications protocol shall be Modbus RTU via RS485 signal.
2) Units shall be capable of being connected to an intelligent communication device and in a network of up
to 247 devices with unique addresses.
I) Fault Codes and a Fault History shall be displayed automatically upon any new fault and retained in non-
volatile memory for viewing by service personnel later.
1) History shall include the last (3) three fault conditions experienced by the starter.
2) Time and Date stamps of these faults shall be available

97
4) Design Specifications
A) Power Ratings
1) Input: 200 – 600V ±10%, 3 phase 50 / 60Hz (selectable) ± 5Hz. Unit(s) will operate with any
incoming phase sequence.
2) Output: Reduced voltage three phase AC derived from phase-angle fired inverse-parallel thyristors,
ramped to full voltage.
3) Control Method: To ensure reliable gate firing even in adverse power conditions, firing circuits shall
use individual phase transformer coupling method for maximum isolation and rapid rise of firing pulse.
4) Current Rating(s): 48, 78, 120, 180, 220, 288, 414, 475, 550, 718, 1006, 1150, 1250 Amps (choose
size for specific application).
5) Output Capacity: Heavy Duty, rated as follows. Light duty rated starters are not acceptable. As a
standard of duty rating, the output overload capacity shall be 500% of unit rating for 60 seconds. The
continuous duty rating shall be a minimum of 115% of nominal motor FLA to accommodate motors with
1.15 service factors without over sizing.
6) Control Power: 120VAC, 60Hz, 50VA minimum but adequate to operate all associated devices in
each starter.
B) SCR Devices
1) PIV Ratings: 1600V Minimum.
2) Protection: RC snubber network circuits on each phase assembly. To avoid possible
component damage, MOV protective devices shall not be used inside the cabinet with the starter.
3) Efficiency: 99.7% through SCRs, 99.97% when bypass is used.
C) Ambient Conditions
1) Temperature: As a standard of unit design quality, starter shall be documented to show that the
open chassis design has been tested for 0 – 50° C (-32 to 122° F) operation. Enclosed ventilated units
designed for standard airflow at 0 – 40° C.
2) Altitude: 3300 ft (1000 m) maximum without derating.
3) Humidity: 0 – 95% RH, non-condensing.
4) Thermal: Heat sink temperature switches designed to trip at 85° C.
5) Mechanical Construction
A) Enclosure shall contain the digital solid state controller and disconnect means (optional) as required.
1) NEMA 1 enclosed units shall be ventilated, with fan forced cooling where necessary. Cooling fans shall
be impedance protected and ball bearing construction for continuous use.
2) NEMA 3R/4/12 enclosed units rated 120 amps and above shall be supplied with a full horsepower
rated, bypass contactor rated for the motor full load running amps. Bypass Contactor to be rated for
Across-the-Line starting.
3) Wall mount enclosures shall include mounting feet as necessary to keep exposed heat sinks away
from the wall for sufficient airflow (units rated below 120A only).
4) Free standing enclosures shall include leg stands to allow easy bottom conduit entry unless shown
otherwise on the drawings.
B) Terminations shall be made on factory supplied mechanical lugs of sufficient size to accommodate the
required wire for the line and load. Lugs are to be clearly marked as Line (L1, L2, L3) and Load (T1, T2, T3)
and with appropriate tightening torque specifications.

98
6) Quality Requirements
A) All incoming material shall be inspected and/or tested for conformance to quality assurance.
B) Power semiconductors shall be fully tested for proper electrical characteristics (dv/dt, di/dt, etc.).
C) All subassemblies shall be inspected and/or tested for conformance to vendors engineering and quality
assurance specifications.
D) Printed circuit boards shall be burned in for a minimum of 48 hours at 60°C.
E) The complete unit shall be functionally tested before shipment to assure proper operation per specification.
7) Documentation
Units shall be shipped with a complete set of documentation to include the following items:
A) Complete schematics and wiring diagrams
B) Enclosure outline drawings
C) System instruction manuals
D) Contactor and disconnect system data, if applicable
E) All drawings shall be done in AutoCAD and shall be available on magnetic medium (i.e. 3.5 inch disks).
8) Spare Parts
A recommended spare parts list, and associated pricing, will be supplied with each different solid state reduced
voltage starter. The manufacturer will provide representation and local support to the job site.
9) Start Up, Adjustment and Training
A) Start Up Procedures. All starters will come factory pre-set for general applications so that only minor
adjustments are necessary in the field to match specific conditions. Start up procedures shall be intuitive
and simple enough so as not to require factory assistance or training. Basic start up shall include entering
of motor data and overload selection. Additional features will only be activated when necessary.
B) Adjustments. To facilitate ease of initial setup, all necessary adjustments shall be capable of being made
without the need for pass codes. Pass code use shall be optional at user discretion. No settings and
adjustments shall require a battery back up for retention.
C) Training. All necessary training for operator personnel shall be simple enough to be performed by local
factory representatives if required.

99
TOSHIBA
CURRENT RELAY
MODEL RC803A

1 120 .
200/240 V

/60Hz LOT.NO

100
The RC803A CURRENT RELAY is designed to
control processes and equipment by monitor-
ing the current of an induction motor or other
similar loads .

CONVEYORS
Protect against jams and excessive loads .
Indicates broken or loose belt.

PUMPS
Protect against dry running, clogging and worn
bearings .

FANS
Monitor fans for worn or broken belts.
Indicates closed dampers or blocked filters .

trip adjustble underct and Overcunt .

points .

*Adjustable start-up delay.

*Fail safe construction-relay operates as

soon as the input current exceeds the preset
level or power supply is de-energized .

*Individual SP-DT (1 NO-NC) output contact

for overcurrent and undercurrent trip points .

Separate LED indication for overcurrent and

undercurrent trip points.

Small and compact size .

101
 unctions

[1] Start up delay time setting

[2] Overcurrent response delay time
setting
[3] Overcurrent setting
[5] [4] Undercurrent response delay time
setting
[5] Undercurrent setting

AC250V 3A(p .f=0 . 4)

e ~ 100/_
120 - 200/240 V
50/60Hz L0T.N0

TOSHIBA CORPORATION

Ill

Overcurrent
trip point

c
Reset
U [2l hysteresis

O
J

Reset '
Start up point
delay [3l Normal
starting current
current
(0 .3-0 .45A)

Time
Undercurrent
trip point

102
 Items Specifications

Type of current sensing Overcurrent/Undercurrent

_Rated current 5A Max . Cont inuous

Adjustable range 0.5-5A

Accuracy 10%

Reset hysteresis 10%

Temperature error (±30°C) ± 5%

Supply voltage 100 ~ 120V AC

200 ~ 240V AC

Frequency (± 10%) 50/60Hz

Start up delay, adjustable 0 (inst.)-30 sec.

Response delay, adjustable 0 (inst.)- 3 sec.

Ambient temperature -10-+50°C

Power consumption 3.5VA

Current transformer burden 0.1VA

Output contact arrangement Overcurrent; SPDT (1 NO-NC)

Undercurrent ; SPDT (1 NO-NC)

Output contact rating" Continuous Breaking

Volt . Current Current

120V AC 5A 5A (Inductive, pf = 0.4)

240V AC 5A 3A (Inductive, pf=0 .4)

24V DC 5A 0.3A (L/R =15 ms)

120V DC 5A 0.15A (L/R = 15 ms)
240V DC 5A 0.1 A (L/R = 15 ms)

Dielectric withstand voltage

2000V AC-1 min .
between terminals and ground

Weight 0.75kg (1 .7 lbs.)

'Meets or exceeds NEMA B300 .

103
 POWER
SOURCE CURRENT
O.C ." U.C .' INPUT

GRD

5 6 7 8 9 10 12 13

Power supply Output Output Current input

'Output contact arrangement after power supply applied.

O .C . . . .Overcurrent
U.C. . -Undercurrent

Dimensions

70(2-3/4) 17(43/64)
50 (1-31/32) 77(3-1/32)

0 El r[©71
O ~ ~I

O O O
rol
O
CURRENT RELAY all 00 C)

[©71',

of

7 (q/22)
10(25/64)
Unit mm (in)

104
TOSHIBA

I NSTRUCTI O N M A N U A L

CURRENT RELAY

RC803A-HP1

TOSHIEA CORPORATION

105
 TOSHIBA
6F9E0090

CONTENTS

1. G e n e r a l Descrigtion __-----_-__----____--------------------- 2

2. C h e c k B e f o r e U s i n g -__-----__-_---_-_______________________- 2

2.1 E x t e r n a l Amearance -_-_-_---_-__-__-_---------------- 2

2.2 Specifications _--_---_-__-__--_-__------------------- 3

3. DescriDtion o f ODeration__-______-_______-__--------------- 5

4. Applications __-______-_________---------------------------- 6

4.1 Overcurrent Detection on Hotors ----------------------- 6

4.2 Undercurrent Detection on Motors ---------------------- 0

b.3 Limiting Starting Current of Rotors ------------------- 9 .

4.4 Transformers -__----__-__-___-___---------------------- 10
-

4.5 H e a t e r s , Laape a n d O t h e r C i r c u i t s - - - - - - - - - - - - - - - - - - - - - 10

5. Mounting ---____----___-_-_-_____________________----------- 10

6. A d j u s t a e n t s - - - - - - - - - - --__-_----______---___________________ 12

6.1 Current Setting ____-----_-_____-______________________ 12

6.2 S e t t i n g t h e D e t e c t i o n D e l a y Tiae - - - - - - - - - - - - - - - - - - - - - - 12

6.3 S e t t i n g t h e R e s p o n s e D e l a y Tiae - - - - - - - - - - - - - - - - - - - - - - - 13

7. Ogerat ional l e s t ____--_____--___________________________--- 13

8. C o v e r Reaoval _ - _ - m - m m - - - - _ _ _ _ - _ _ - _ _ - _ _ - - _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 17

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 =rosHl=A
6F9E0090

Please thoroughly read this instruction manual before using the

RC803A Current SensinD Relay.

1. General DescriDtion
This current relay is designed to detect current in AC circuits
with a wide range of aDDiications, e.t., detection of abnoraai
current of VariOUS electrical eauiment due to overloads or broken
c i r c u i t s (e.g., heater circuits), detection of starting current to
autoaaticaiiy advance the secondary resistance on induction wound
rotor motor controllers.
During starting, excessive current such as inrush current, lay
exceed rated current flow in motor or transforaer circuits. this
current relay has an adjustable delay circuit to prevent it fro&
operating during start-up.
F u r t h e r , t h i s c u r r e n t relay i s f a i l s a f e . T h e r e l a y ooerates

- at the saae tile control Dower is applied. and the relay is de-
energized when the inout signal exceeds the Dreset level or control
Dower is removed.

2. Check Before Using

Before using this relay. check the following Doints. If any
defects are found, contact the dealer free which you purchased this
relay.
2 . 1 E x t e r n a l Aopearance
Check the relay for any missing Darts and for damage, dirt,
rust, and loosened screi6 caused during transportation.

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 TOSHIBA
6F9EO090

2.2 Specifications
_____________-_-________________________------------------------------

ITEH SPECIFICATIDHS
Rated Current 5A (continuous)

Range of current 0.5 - 5A (For current above this range, use a

sensing CT (current transforrer) and connect the
relay to its secondary side).

Inout c i r c u i t > 6OOV)

voltage 3 To detect current in high voltage circuits,
use a CT, and connect the relay to its
secondary side.

Type of Current Overcurrent, Undercurrent

ReSDOnSe delay 0.1 - 3s

time-adjustable
range

Detection delay 0.1 - 30s

tile-adjustable
range

Operating volt. a5 - 132VAC. 170 - 250VAC, 50/6Diiz

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 TOSHIEA
6F9E0090

ITEH SPECIFICATIORS
A m b i e n t temp. - 1 0 - *SO%
range

Temp. e r r o r +10X a t t30Y

Dielectric with- Between terminals and ground

stand voltage 2DOOVAC f o r 1 #in.

Imgulse w i t h - Between terminals and ground

stand voltage 1 X 40)~s a t 45OOV ( s t a n d a r d w a v e f o r m )

Insulation B e t w e e n t e r m i n a l s a n d g r o u n d 1DOH Ohm o r

resistance more w h e n m e a s u r e d w i t h a SDOVDC a e g g e r .
-

Vibration
-Oscillation A m p l i t u d e 2.5~ - 20Hz (26)
-1aoulse 156

Overcurrent 4 0 t i m e s o f m a x . c o n t i n u o u s c u r r e n t (SAI,
intensity f o r 1 s e c . , agglied t w i c e , i n a c c o r d a n c e w i t h
JEC 174.

Output contact Over Current: SPDT

rating Under Current; SPDT
(250VAC aax. I

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 TOSHIBA
6F9E0090

Inductive load
t-K&-
I

Break Continuous
120 5A SA
WEHA AC
AC (p.f.-0.4)
Rating
240 3A SA
Designation
_--_________________-----------------.
B300
24 0.3A !iA
DC 120 O.l!iA (L/R=15ms) 5A
240 O.lA 5A

ITEH SPECIFICATIONS
Hysteresis AgDrox. 10X of ooerating value.

-
Power consumption oDperating Power 3.5VA
olnput Circuit D.lVA (when 5A is applied)

Height .75kg ( 1 . 7 lb)

3 . DescriDtion o f Ooeration
When the detected current exceeds the detection circuit
o p e r a t i n g l e v e l , t h e d e t e c t i o n d e l a y t i m e r i s a c t u a t e d . I f over-
current is continuously detected for more then the detection delay
time set value, the overcurrent response delay timer is actuated.
Then, if overcurrent is detected when the resDonse delay timer has
elapsed, the overcurrent relay is actuated.
If current drops below the undercurrent detection set ValUe,
the resgonse delay timer is actuated, and after the set tile has
exoired, the undercurrent detection relay is actuated. In the case
of undercurrent detection, the detection delay timer is not actuated.

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 TOSHIBA
6F9E0090

Detection delay
.I .pL1

mrellt

level (0.3-O.b5A)
0
\ Undercurrent detect img

FiD. 1 Characteristics

1. APDl ication
4.1 Overcurrent Detection on Hotors
An aDDlication example Is shown in Fig. 2. In this clrcult.
an excessive load is detected by detecting the overcurrent of a
motor and the lain circuit is ooend to Protect

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TOSHIBA
6F9Eoo90

the uotor from being damaged. If the detected current is above

!iA. and in case of a high voltage circuit, use an external CT and
connect the secondary side of CT to the relay as shown in the
following figure:

AC3-Phase Power SuDDly

Ll
Y 23 1
I A I

# ‘I
=
I1
Current relay

Note: T h e RCB03’s OUtDUt

contacts are shown
with Dower source
aDDl ied.

TiD. 2 ADDlication ExaaDle using An External CT

112
 T O S H I B A
6F9E0090

further, when this relay is used in a uotor circuit, the

detection delay timer should be set lonfler than the startinv
time (about 120%) so that this relay is not actuated by inrush
current. If current flowinp in the uain circuit becomes abnormal
after the tiee Deriod of the detection delay timer has elapsed.
the relay is actuated when the set tiue of the response delay
tiler i s o v e r .

4.2 Undercurrent Detection on Hotors

To utilize the undercurrent detection function, the relay
i s u s e d i n a notor c i r c u i t w i t h a f i x e d l o a d , t o d e t e c t l i v h t
or no load conditions. For examDIe. in the case of a DUUD UOtOr,
this relay is used to detect undercurrent when the VOlUue Of
water SUDDlied in a water Dipe is low, or in case of a thread
-
winding rachine, when the tension of the thread droes.

113
TOSHIBA
6F9EOO90

ACJ-Phase Power SUDDIY

Current relay

Note: The RC803’s outDut

contacts are shown
with Dower source
aDDl ied.

Fig. 3 Application Example

4 . 3 Limiting S t a r t i n o c u r r e n t o f Rotors
Many eotors of uediua and large capacity use a aethod to
s t a r t b y l i m i t i n g s t a r t i n g c u r r e n t . 8y d e t e c t i n o t h e lain
circuit current, this relay can automatically advance the
starting resistance on the secondary side of the motor (in this
case, the knob of the detection delay timar and that of the
resoonse delay timer should be kept at the minimum settings).

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 ToSHIEA
6F9EOO90

4 . 4 Transformers
To use this current relay for detecting overcurrent on
transformers. it is necessary to set the detection delay tiler
with the inrush current of transforeer taken into consideration.

4 . 5 H e a t e r s , LauDs a n d o t h e r C i r c u i t s
This relay can be used to detect the disconnection of
circuits by sensing the existence of current flow. In other
words, if disconnection occurs, current does not flow and an
undercurrent condition is detected by the relay. For exaeDle.
this relay can be used to detect the disconnection of heater
circuits on constant temperature ovens or heatar circuits for
insulators on transmission and distribution facilities In
extremely cold regions.

5. Hount ing
See Fig. 4 for uounting dieensions. Be careful not to use this
relay in the following conditions:

(1) teeperatures outside -10 - +SO”C.

(2) subject to high teeDeratUre, steal or dripping water,
(3)
(4) LOCatiOnS s u b j e c t t o v i b r a t i o n (total a m p l i t u d e 2.5~ o r eore,
20 tiles/m. or aore) and shock (above 156 in 3 directions).

4
8
z

- lo-
115
 TOSHISA
6F9E0090

7
50 3-$7 Hole

Hountino holes

Fig. 4 Dimensions

B
!3
t.

-
116 ll-
 TOSHIBA GF9EOO90

6 . AdjustDents

6.1 Current setting

(1) When detected current is in a range of 0.5 - 5A:

After confirming that the current value under noraal load
condition is in a range of 0.5 - SA, set the current
adjusting knob to the desired detecting value.
(2) When detected current is above 5A:
Using an external CT (current transformer), properly suited
for the detected Current value, connect the secondary side of
t h e C T t o t h e input terminal o f t h e r e l a y . C a l c u l a t e t h e
secondary current CorresDonding to the detected current
value, based on the CT ratio. Then set the current adjusting
Knob to this calculated value.
-

6.2 Setting the detection delay tiae

Setting time varies depending upon each individual aDDlication.
Adjust the detection delay tile according to the following:

(1) Hotor l o a d
TO avoid detection during start-up, set the delay tire to
aDDroxisately 120% of starting tile.
(2) Transformer load
If the inrush current (inrush time varies deDending uDon
caDacity) i s l a r g e , s e t t h e d e l a y tile to approximately
1 2 0 % o f t h i s i n r u s h tile. Genenrally, If t h e caDacity i s
Wall, inrush time is short and therefore, even when the
adjusting knob is set at the minims position. there should
not be any nuisance tripping.

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 TOSHIEA
6F9Eoo9o

6.3 Setting the ResDonse delay time

Adjust the set tile according to the ourgose of detection (I.e.
overcurrent or undercurrent). The set tire for the resoonse
delay varies ger aDDllcation. Host applications cay not need
any delay tile. It is aainly used to prevent nuisance trioging
(ride through) by ignoring aoeentary load gliches.

7 . Ooerational l e s t

(1) Check both the control and detection circuits to confirm there
is no eis-wiring.
(2) Check if the current dedtction tiae delay, and resgonse
tiae delay settings are correct.
(3) If the wiring ard settings are correct, energize the control
-
circuit and check if it is the erooer voltage.

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TOSHIBA
6F9E0090

(4) When the Dower source is aDDlied. the relay is excited and the
OutDut contact’s states are reversed. The relationshiD between
the input signal end the outDut contacts are shown in Table 2.
Check this relationship during the test.

Table 2
(5) If no Droblea is found when the Dower source is aDDlied. turn
the rain circuit switch ON and Derforg the following checks:

(a) In the case of a motor load

I f t h e s e t start-up tiae d e l a y i s t o o s h o r t , t h e r e l a y say
be actuated. In such a case, reset the detection delay tiae
adjusting knob accordingly. A f t e r t h e s t a r t - u p tiae d e l a y
has exDired. apply current above the set detection value
t o confirm t h a t t h e r e l a y f u n c t i o n s ( a f t e r t h e resoonse
d e l a y tile), In addition, check that the detection
i n d i c a t i n g lamp l i g h t s a t t h e sale t i m e t h e r e l a y ODerates.

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 TOSHIBA
6F9E0090

(b) When undercurrent or disconnection is detected

At the sale time the lain circuit switch is turned OH, the
starting current and rated current flows, and the relay is
picked UP. If current drODS below the undercurrent set point,
the undercurrent State is detected and the relay drops out.
(Refer to Fig. 5)
Caution: If input signal to this current relay is zero (When StoDDed).
it is not possible to judge if it is undercurrent or in a
disconnected state. In this case, it is recommended to
have a circuit connecting a normally oDen auxiliary con-
tact of the Dain circuit switch in series with the alara or
IauD c i r c u i t . t h i s w i l l D r e v e n t t h e r e l a y f r o r signalling a
fault condition during a normal shutdown.

-12015-
TOSHIBA
6F9E0090

(6) If the relay does not operate in the above test, check if
the current setting is correct or if the ingut signal is
above the set detection value. If the ingut signal is
correct, check the operation of the relay by gradually
reducing the setting of the current adjusting knob. If the
relay still does not ooerate. it is defective. In this case,
please contact the dealer froa which you purchased the relay
or Toshiba.

Power Source -

Detected current

Overcurrent
detect ion -
I-/ T3
Undercurrant
detect ion I

Tl: Detection delay tire

T2: Overcurrent detecting resgonse delay tiler
T3: Undercurrent detecting resgonse delay tlaer

Fig. !i Relay Operation

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 TOSHIBA
6F9E0090

8. Cover Reroval
To adjust the current and time settings the cover must be raaoved.
Reaove the cover by amlYing a force in the direction of the arrow
as shown below. To replace the cover, place the projection of the
cover in the slip out oreventive hole and then insert the bosses
of the cover into the 2 holes at the uooer left and right.

Cover Ak

iz

-
122 17.-