R05323 m-100-x009-0293

MIXER MANUAL - INSTRUCTIONS
INSTALLATION
OPERATION
MAINTENANCE
Ship To: MINERA CHINALCO PERU S.A
Customer: MINERA CHINALCO PERU S.A
PO Number: R05323-M-100
Model: 17Q10
Order Number: 0001161978
Line Number: 000231
Tagging:
UNIT 260-AG-001 MILK OF LIME STORAGE TANK
AGITATORS MOTOR 260-AG-001-M1
http://www.lightninmixers.com
Toromocho EPCM Project
Equipment Tags:
Purchase Order No. Doc Type Sequential No. Aker Solutions Rev No.
Status Code Reviewer Eng. Date
Status Code:
1. Reviewed and accepted as final certified. Manufacture may proceed.
2. Reviewed and accepted as noted. Submit certified dwgs. Manufacture may proceed.
3. Reviewed and returned. Correct and resubmit. Manufacture should not proceed.
4. Review not required. For information only. Manufacture may proceed.
Reviewed for general dimensions only. This review does not relieve the vendor of full
responsibility for the adequacy correctness, accuracy and completeness of calculations,
details and dimensions by reviewing these documents.
Aker Solutions does not accept liability for their completeness or accuracy.

MIXER MANUAL - INSTRUCTIONS
LIGHTNIN SALES ORDER 0001161978
LIGHTNIN LINE ITEM 000231
Safety Check List
Inspection and Test Plan
Installation Drawing
A510 Impeller Assembly Drawing
GENERAL NAME PLATE DRAWING
General Instructions
Troubleshooting Guide
Shaft Instructions
Impeller Welded A510 / A510E
Field Patch Kit Supplement
Gear Drive Assembly Drawing
Gear Drive Instructions
Coupling Instructions
Motor Maintenance Instructions
Equipment Data Sheets
MOTOR DATA SHEET
Motor - Installation, Operation & Maint.
Lubrication Schedule
Bolt Torque Schedule
Welding Procedure
Weld Repair Procedures
Spare Parts
Sales Offices
IT-2144
1161978ITP
1161978000231-A
1161978231-B
1161978231-NP
IT-3749
IT-3989
IT-3752
IT-4056
IT-5343
1161978231-Y
IT-3751
IT-693
IT-1488
1161978231-EDS
1161978231-MD
50033244R2
1161978231-LUBE
1161978-BTS
1161978-W
1161978-WR
1161978231-SP
IT-3839
DOCUMENT NO.TITLE
Table of Contents

CAUTION -
WARNING -
DANGER -
Revision Date: 5/9/1986
H Revised: 9/9/2011
Signals unsafe practices or hazards which could cause severe personal injury or death.
Signals immediate hazards which will probably cause severe personal injury or death.
This mixer should be equipped with safety or instructional labels similar to those shown below. If any of the labels are
missing, damaged or otherwise illegible, DO NOT install, service or operate the mixer. Contact your LIGHTNIN ®
representative immediately for instructions.
INST. No. IT-2144
COPYRIGHT © 2011 SPX CORPORATION Page 1 OF 4
EXAMPLES:
Signals unsafe practices or hazards which could cause minor personal injury or property damage.
IMPORTANT: READ THIS SECTION THOROUGHLY
SAFETY INSTRUCTIONS / CHECKLIST
IF YOU DO NOT UNDERSTAND ANY PORTION OF THESE INSTRUCTIONS DO NOT ATTEMPT TO INSTALL OR
OPERATE THIS MIXER! CONTACT YOUR LIGHTNIN ® REPRESENTATIVE FOR ANY QUESTIONS YOU MAY
HAVE CONCERNING SAFETY OR THESE INSTRUCTIONS.
Your LIGHTNIN ® mixer is equipped with safety labels which contain specific instructions pertaining to the safe
handling and operation of the mixer. For your protection, you must understand that failure to follow the safety
instructions imprinted on the safety labels or failure to follow the safety instructions printed in this instruction manual
may result in serious personal injury or death. In addition, failure to adhere to safety instructions may cause damage to
property or equipment.
In this publication, and on the mixer safety labels, the words DANGER, WARNING and CAUTION may be used to
signify special instructions to be observed by the installer or user. These instructions warn of potential hazards
concerning service, installation or operation if the instructions are performed incorrectly, carelessly or are ignored.
Safety instructions alone cannot eliminate the hazards they signal. Strict compliance with these special instructions,
along with safe work habits and simple "common sense" are major accident prevention measures.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Date: 5/9/1986
Revised: 9/9/2011
SAFETY CHECK LIST
WARNING: When moving, installing or lifting this mixer, always use equipment which is rated to carry the full load
of the mixer. Use only the lifting device, if provided, on your unit to install the mixer. Failure to follow these
instructions could cause severe injury, death or damage to property. Consult the appropriate section of this manual
for lifting and installation instructions.
WARNING: DO NOT connect the motor to the power source until all components are assembled, the mixer is
installed, and all hardware is tightened to the proper torque which is specified in the operation and maintenance
manuals supplied by LIGHTNIN ®.
DO NOT operate shaft sealing devices at temperatures higher than those specified in the manual or on the
nameplates.
DO NOT service the mixer until you have followed your "Control of Hazardous Energy Sources" (lockout, tagout
procedure) as required by OSHA.
IMPORTANT WARNINGS
WARNING: DO NOT attempt to connect a power source to this mixer unless you are licensed or certified to do so.
Failure to follow this instruction could cause severe injury, death or damage to property.
All LIGHTNIN ® Mixers and Aerators are provided with properly designed lifting devices and safety covers to avoid potential
injury and/or equipment damage. The following SAFETY CHECK LIST should be THOROUGHLY REVIEWED AND ADHERED
TO before installing, operating or performing maintenance on the mixer. FAILURE TO FOLLOW THESE INSTRUCTIONS
COULD RESULT IN SERIOUS INJURY. Ensure the use of qualified, quality trained and safety conscious personnel.
Revision
H
WARNING: Never attempt to move or adjust a mixer while it is running.
WARNING: Never touch a mixer, which has an electric motor, or any part of an electrical service line cord or
conduit, while your hands or feet are wet or if you are standing on a wet or damp surface. Failure to follow this
instruction may result in severe electrical shock or death.
DANGER: Never touch any rotating part of a mixer with bare hands, gloved hands or any other part of your body,
or with any hand held object. Rotating parts include, but are not limited to, the mixer shaft, impeller(s), set screws,
hardware, couplings, mechanical seals and motor fans.
COPYRIGHT © 2011 SPX CORPORATION
INST. No. IT-2144
Page 2 OF 4
WARNING: DO NOT touch any part of mixer that has the potential of having a hot surface including the motor,
gear drive housing, seal, shafting and flange. When a mixer is running, the motor temperature rises. This is a
normal occurrence, but the motor temperature may be high enough to cause burns to the hands or any other part of
the body. DO NOT touch a mixer motor until it cools for at least one hour. Failure to follow these instructions may
result in severe personal injury.
WARNING: DO NOT operate mixer for service other than its intended use, that being fluid mixing with the mixer
attached to a rigid structure and connected to a power source appropriate to operate the mixer drive motor.

11.
12.
13.
14.
15.
16.
17.
Date: 5/9/1986
Revised: 9/9/2011H COPYRIGHT © 2011 SPX CORPORATION Page 3 OF 4
WARNING: Eye protection must be worn at all times while servicing this mixer. Failure to follow this instructions
may result in severe injury or death.
WARNING: Never attempt to clean or service the mixer, or any part of it, while the mixer is running, or while it is
connected to a power source. Always turn the mixer off and disconnect the power before cleaning or servicing.
CAUTION: When repairing the mixer, or replacing parts, use factory authorized parts and procedures. Failure to
do so may result in damage to the mixer or injury to the user.
DO NOT enter the mixing vessel UNLESS:
A. The mixer power supply is locked out (follow item number 5).
B. The mixer shaft is firmly attached to the mixer drive or the shaft is supported securely from below.
C. You have followed applicable confined space regulations.
Revision INST. No. IT-2144
DO NOT operate mixer until you have checked the following items:
A. Make sure the mixer is properly grounded.
B. Ensure all protective guards and covers are installed.
Guarding of the mixer shaft below the mixer mounting surface is the responsibility of the customer.
C. Ensure all detachable components are securely coupled to the mixer.
D. Thoroughly REVIEW and ADHERE TO the mixer operating instructions supplied by LIGHTNIN ®.
E. Ensure the mixer output shaft rotates freely by hand.
F. Ensure all personnel and equipment are clear of rotating parts.
G. Ensure all external connections(electrical, hydraulic, pneumatic, etc.) have been completed in accordance
with all applicable codes and regulations.
DO NOT make any field changes or modifications (horsepower, seal material components, output speed, shaft
lengths, impellers, etc.) without reviewing the changes with your LIGHTNIN ® Sales Representative or the
LIGHTNIN ® Customer Service Department.
DO NOT install an aftermarket Variable Frequency Drive without first consulting your LIGHTNIN ® Sales
Representative or the LIGHTNIN ® Customer Service Department to determine the compatibility of the existing
motor with the Variable Frequency Drive.
SAFETY CHECK LIST, cont'd.
IMPORTANT WARNINGS, cont'd.

5152606 5501523 6517233 6860474 7168848 7387431 7550120
5152934 5511881 6517246 6877750 7168849 7407322 7572112
5203630 5568975 6742923 6986507 7278799 7473025 7726946
5344235 5779359 6746147 7001063 7328809 7481573 7753215
5368390 5925293 6789314 7056095 7329065 7488137 7874719
5470152 5988604 6796707 7114844 7331704 7507028
5480228 6158722 6796770 7168641 7384551 7547135
Revision Date: 5/9/1986
H Revised: 9/9/2011
CAUTION: When applicable specific markings required by Pressure Equipment Directive 97/23/EC (PED) and/or
Equipment for Use in Potential Explosive Atmospheres Directive 94/9/EC (ATEX) will be indicated on supporting
nameplates. If there is any doubt relating to the intended use of this equipment please contact LIGHTNIN® before
installation and operation.
PATENTS
ENVIRONMENTAL NOTICE
Dispose of equipment responsibly at the end of its service, in accordance with
local laws and directives. Correct disposal is the responsibility of the end
user. If in doubt, consult with local environmental agencies for advice on the
best method of disposal.
CE COMPLIANCE
COPYRIGHT © 2011 SPX CORPORATION Page 4 OF 4
If the mixer nameplate has a CE marking on it, then the equipment furnished conforms to the following directives:
Machinery Directive: 2006/42/EC
Electro-Magnetic Compatibility: 2004/108/EC
Low Voltage Directive: 2006/95/EC
Any CE marking and/or associated documentation applies to the mixer only. This has been supplied on the basis
that the mixer is a unique system. When the mixer is installed, it becomes an integral part of a larger system which
is not within the scope of supply and CE marking is the responsibility of others.
INST. No. IT-2144
Heavy Series: S10, 70/80, 500/600 - maximum 85 dBA @ 1 meter.
THIS PRODUCT MAY BE COVERED BY ONE OR MORE OF THE FOLLOWING U.S. PATENTS:
NOISE LEVELS
SOUND PRESSURE LEVELS
Portable Series: ECL, EV - maximum 80 dBA @ 1 meter.
Noise: 2000/14/EC

SPX FLOW TECHNOLOGY - LIGHTNIN DIVISION QUALITY PLAN
(INSPECTION & TEST PLAN)
CUSTOMER: Aker Metals Inc. as agent for Minera Chinalco Peru SA
Customer Purchase Order: R05323-M-100
SPX Process Equipment Order No.: 1161978//1334495
Mixer Model No.: 14Q1, X6P50, X6Q200, X6Q100, 14Q2, 14Q3, 14Q1, 75Q15, 15Q5, X6P200,
15Q3, 14Q1.5, 14Q2, 15Q5, 15Q2, 15Q7.5, 15Q5, 16Q5, 75Q30, 14Q2,17Q10,
783Q150, 98QS75, 14Q2//14Q2, 16Q10, X6Q150, 17Q20, 14Q2, 15Q5,15Q3,
14Q1, 14Q1, 14Q1, 14Q3, 14Q3, X6Q150, 15Q5, X6Q150, 16Q7.5, 16Q7.5,
15Q7.5, 15Q7.5, 15Q5, 15Q5, 14Q1, 14Q1.5
Tag No.: 284AG051/67/70, 260AG025, 288AG200, 286AG110/120, 284AG062/3/4,
282AG005, 260AG046, 245AG008, 245AG007, 285AG095/100, 285AG094,
284AG071, 284AG061ACD, 283AG041, 281AG003, 260AG004, 260AG001,
245AG006, 220AG010/11, 284AG075//284AG076, 285AG105/15, 285AG109/
INSPECTION POINTS
See Legend
Action
Points
Activity Description Remarks LIGHTNIN CUSTOMER
1.0 MATERIAL INSPECTION
1.1 Wetted Parts.
Materials purchased to applicable ASTM Specifications.
Materials purchased from qualified suppliers. Material Test
Reports (MTRs) to be supplied for 316 SS material. Positive
Material Identification (PMI) reports for castings per
LIGHTNIN procedure QCT-024. Certificate of Materials
(C of C) to be supplied for carbon steel components.
RV RV
1.2
Balance of Unit
(Non-Wetted Parts).
Materials purchased from approved suppliers.
Certificate of Materials to be supplied.
RV RV
2.0 GEAR BOX (REDUCER) SPIN TEST
2.1
Reducer No Load Spin Test at SPX
Process Equipment in Rochester.
Per SPX Process Equipment Standard Reducer Test
Procedures IWI-9019 (70/700 unit tag #s), IWI-9020
(S10 unit tag #s) & QCT-010 (Portable units w/tag #s
284AG051/54/67; 282AG005; 291AG740;
292AG752/53/54). Certificate of Test to be supplied.
RV RV
3.0 MECHANICAL SEAL TEST
3.1
Run Test of Seal (for 70/80 &
700/800 Series).
Per SPX Process Equipment Standard Test Procedure
QCT-011.
N/A N/A
4.0 WETTED PARTS (LOWER SHAFT & IMPELLER(s))
4.1
Welding Procedure Specification,
Welding Procedure Qualification,
Welding Operator Qualification.
Per SPX Process Equipment Standard Weld Procedures. RV RV
4.2 Visual & Dimensional Inspection.
Assemble Lower Shaft Assembly to verify component fit.
Verify dimensional compliance w/approved installation
drawings. Assembly Worksheets to be provided.
RV RV
4.3
PT examination of finished wetted
alloy welds.
Per LIGHTNIN standard procedure QCT-001. PT
reports to be supplied.
RV RV
5.0 DRIVE ASSEMBLY
5.1 Visual & Dimensional Inspection.
Assemble complete to verify component fit up. Verify
Dimensional Compliance w/approved Installation
Drawings.
LW CW
5.2
Equipment tagging and
nameplate verification.
Equipment and motor nameplate data per General
Arrangement drawing.
LW CW
6.0 PAINTINGS & COATINGS
6.1 Painting.
Special paint. Verifiy paint thickness (DFT).
Certificate of Paint provided.
LW CW
7.0 PACKAGING & DELIVERY
7.1 Marking/Tags Per Lightnin standard procedure. LW CW
7.2 Packaging Inspection Per Lightnin standard procedure. LW CW
7.3 Release to Ship Per Lightnin standard procedure. LW CW
LEGEND: RV = Review / verify activity, documentation DATE: 4-Oct-11
CW = Customer Witness. Rev: Issued
LW = Lightnin QA Witness BR
OI = Operator Performed/Inspection.
H = Hold Point
N/A=Not Applicable 1161978/1334495-ITP
FORM QCF-028 (Original Form)
NOTE: THIS FORM IS REVISED FOR THIS SPECIFIC CUSTOMER, & SPEC. Per the Above DATE. rev 3/25/08
12, 285AG116,291AG700, 291AG704, 291AG707, 291AG711/14,
291AG717/20, 291AG724/28/32, 291AG738, 291AG737, 291AG740,
292AG750/85, 292AG752P1/753P2/754P3, 292AG755, 292AG757/758,
758, 292AG760, 292AG768, 293AG403, 293AG405,
293AG410/13, 293AG419

REVISION DATE 01-31-96 INST. NO. IT-3749
O REVISED 12-09-11 COPYRIGHT © 2008 SPX CORPORATION PAGE 1 OF 11
GENERAL INSTRUCTIONS
FOR
LIGHTNIN®
SERIES 10 – MODELS 14, 15, 16, 17
SECTION 1 - INITIAL INSPECTION, SHIPPING ARRANGEMENTS
1.1 Check shipping crates and your LIGHTNIN equipment for possible shipping damage. Report any damage immediately to
the carrier and our factory.
1.2 All Series 10 mixers are shipped completely assembled except for the lower shaft, impeller assembly, and mechanical seal,
if supplied. The in-tank shaft and impeller blades will be crated separately or secured to the main shipping skid.
1.3 All mixers are treated with corrosion inhibitors for protection during shipment and possible storage.
a. All steel surfaces not protected with permanent coatings are covered with a rust preventative that is easily removed with
kerosene or similar solvents.
b. All internal surfaces are protected against corrosion due to water or water vapor in case the mixer will not be put into
service right away.
1.4 The dipstick/oil fill plug is packaged separately and should be identified. A plastic plug is installed in the opening to ensure
that the mixer remains sealed and properly preserved during shipment. DO NOT remove this plug until the mixer is put into
service.
1.5 Factory applied inhibitors will protect mixers from internal corrosion for periods up to (1) year if stored indoors in clean, dry
surroundings. OUTDOOR STORAGE IS NOT RECOMMENDED. Review the section on storage carefully if the mixer is to
be stored or inactive for an extended period.
SECTION 2 - INSTALLATION
2.1 Recommended lifting procedures are covered in Section 3 of these instructions. Important mounting and operating
information is shown on the installation drawings.
a. Mixer weight and design loads imposed by the mixer for mounting structure design.
b. Location and mounting dimensions.
c. Baffle information (when required).
2.2 Install the dipstick/oil fill plug.
2.3 Lower the shaft and impeller hub assembly into the vessel and support in an upright position.
2.4 Angle Mount Mixers: Lower shaft must be installed vertically with the mixer in a level horizontal position.
To avoid insufficient gear drive lubrication, install the mixer as shown on the Installation Drawing.
2.5 Place the mixer on the mounting structure or tank nozzle. Refer to Section 3 for proper lifting procedures.
2.6 Refer to the shaft installation instructions before inserting impeller shaft into gear drive for important assembly procedures
and tightening torques.
2.7 IMPELLER ASSEMBLY
a. When installing the impeller/s on a shaft, refer to the impeller drawing and instructions. Make sure the impellers are
installed for the shaft rotation indicated and that impeller hardware is tightened to the specific torques listed in the
impeller instructions.
b. For angle mount mixers supplied with a LIGHTNIN mechanical seal, it may be necessary to install the impeller/s from
inside the tank.
2.8 Tighten all in-tank hardware to the specific torques listed in either Section 7 or special torques that will be listed on
individual instruction sheets where applicable.
2.9 It is the customer’s responsibility to touch up any paint damage incurred during installation and/or shipping.

SECTION 3 - RECOMMENDED LIFTING PROCEDURES
CAUTION: FAILURE TO LIFT THE MIXER AS DESCRIBED IN THESE INSTRUCTIONS MAY CAUSE PERSONAL INJURY
OR PROPERTY DAMAGE.
3.1 GENERAL LIFTING INSTRUCTIONS
a. WE DO NOT RECOMMEND that you include the lower shaft and impeller assembly as part of the mixer being lifted.
b. When taking up slack on the lifting sling or strap, avoid sudden impact loading of the lifting devices.
c. The mixer must be supported until it is securely bolted to the mounting structure.
d. If removed, re-install the coupling shield and the safety guard prior to start-up.
3.2 LIFTING PROCEDURE
a. Refer to Figure 1 for proper lifting scheme.
b. Place a ”choker” sling or strap around the motor pedestal (230). Ensure the strap is BELOW the strap retention flange.
c. DO NOT lift by wrapping a sling or strap around the motor. The motor connection is not designed to support the weight of
the entire mixer.
SECTION 4 - START-UP
4.1 Dipstick / Breather
a. For mixers without angle risers, the gear drive dipstick/oil fill plug is removed prior to shipment and replaced with a solid
plug to provide an airtight housing.
b. For mixers with angle risers, the breather is removed prior to shipment and replaced with a solid plug to provide an
airtight housing.
4.2 FILL THE GEAR DRIVE WITH OIL TO THE PROPER LEVEL. Refer to Section 5 for recommended oil and viscosity recommendations.
4.3 Refer to the motor maintenance instructions before connecting the motor to the power source.
a. Rotate the motor shaft to check for free rotation.
b. It is recommended that stator windings be checked for insulation resistance. If resistance is less than one megaohm,
windings should be dried thoroughly.
c. Check the motor nameplate for proper line voltage and correct connections according to the wiring diagram.
d. Before making permanent motor lead connections, check impeller shaft rotation. Jog the motor to determine if rotation is
correct, then make permanent connections. Make sure the mixer is properly grounded in accordance with applicable UL
codes.
4.4 If your mixer is equipped with a mechanical seal, refer to the seal instructions for pressure, temperature and lubricant
specifications.

4.5 Before filling and/or pressurizing vessel:
a. Run mixer in air and check for any unusual noises.
b. Check output RPM.
c. Check all bolts for tightness. After two weeks of operation, recheck hardware for tightness.
4.6 After filling and/or pressurizing vessel:
a. Jog the motor or rotate the input shaft by hand to ensure impellers are free of obstructions.
b. Never start up the mixer with the impeller/s imbedded in solids or set-up liquids.
c. Take load reading.
4.7 Install and secure the coupling shield (247) and safety guard (240) before operating the mixer.
SECTION 5 - GEAR DRIVE LUBRICATION
WARNING: EYE PROTECTION MUST BE WORN AT ALL TIMES WHILE SERVICING THIS MIXER.
5.1 Fill the gear drive with oil to the proper level using only one of the products listed in Table 1 as appropriate for the expected
ambient temperature range. If the oils listed in Table 1 are not available, the EP oils listed in Table 2 may be used as a
substitute. Use only one type of oil in any single mixer. Do not mix oil types, grades or brands in any mixer. If it becomes
necessary to add oil to a mixer prior to the normal drain interval, be sure to use only the same type, brand and grade oil
used at the original fill. Do not use any product not listed in Table 1 without prior factory approval (refer to Paragraph 5.8 for
additional details).
In selecting an oil from Table 1, use the grade that most closely suits the average ambient temperature range that may be
expected before the next oil change. If the expected ambient temperature overlaps two temperature ranges defined in
Table 1, use the lower viscosity grade.
5.2 Lubrication instruction revisions
Both AGMA Standards and Lubricant Manufacturer’s offerings change, over time. The lubricant information in this general
instruction may be different than in older versions. In most cases LIGHTNIN urges the customer to be consistent with
AGMA lubrication standards, but we recognize that they may have had successful field experience based on the older
instructions. Immediate conversion is not required, however a gradual transition to the current lubrication standards is
recommended.
MANUFACTURER BRAND PRODUCT
Ambient Temperature °C (°F )
-25° to -5° C
(-15° to +25°F)
(AGMA 2 S, ISO
68)
-10° to +40° C
(+15° to +100° F)
(AGMA 3 S, ISO 100)
+30° to +55° C
(+90° to +130° F)
(AGMA 4 S, ISO 150)
EXXONMOBIL MOBIL
Mobil SHC 600 / 600*
(1)
Mobil SHC 626 Mobil SHC 627 Mobil SHC 629
EXXONMOBIL EXXON MobilGear SHC No Product No Product MobilGear SHC 150
CHEVRON CHEVRON Tegra No Product No Product Tegra 150
CHEVRON TEXACO Pinnacle EP No Product No Product Pinnacle EP 150
SHELL SHELL Omala HD No Product No Product Omala HD 150
Table 1 – Approved Synthetic Oils
(1) Mobil does not rate this product as “EP” due to the lack of “EP” additives. The load carrying capability of these oils is equal to
or greater than the limits of “EP” oils.

Temperature Range °C (°F )
-10° to +5° C
(+10° to
+40° F)
+5° to +20° C
(+40° to
+70° F)
+20° to +40° C
(+70° to
+100° F)
+40° to +55° C
(+100° to
+130° F)
MANUFACTURER BRAND PRODUCT
AGMA Viscosity Grade
2 EP – 3 EP 3 EP – 4 EP 4 EP – 5 EP 5 EP – 6 EP
EXXONMOBIL MOBIL MobilGear 600 XP 68 - 100 100 - 150 150 - 220 220 - 320
EXXONMOBIL EXXON Spartan EP 100 100 - 150 150 – 220 220 - 320
CHEVRON CHEVRON Gear Compound EP 100 100 - 150 150 – 220 220 - 320
CHEVRON TEXACO Meropa 100 100 - 150 150 – 220 220 - 320
SHELL SHELL Omala 100 100 - 150 150 – 220 220 - 320
Table 2 – Approved Petroleum Based EP Oils
5.3 Filling mixer with oil:
a. Mixers mounted vertical on tank centerline can be filled by removing the dipstick/oil fill plug. Add the amount of oil
stamped on the mixer nameplate. Replace the dipstick/oil fill plug and recheck oil level. The dipstick full mark should
always be used as the most accurate guide to the actual oil level in a specific mixer. Always stop the mixer to check the
oil level.
b. Mixers with angular offset mounting are furnished with a stand pipe type arrangement for oil measurement. The stand
pipe/oil drain assembly must be adjusted to maintain the elevation of the stand pipe in respect to the top face of the
gear drive (see Figure 2), using the values in the table. Once this has been accomplished, fill the stand pipe to the top
and replace the oil plug. The oil level should be maintained within 1/8” of the top of the stand pipe.
CAUTION: DUE TO LUBRICATION CONSIDERATIONS, MAXIMUM ALLOWABLE INPUT SPEED IS 2000 RPM.
Series 10 Mixers are supplied with one of the following dipsticks:
a. 220021PSP (blade #219646) for use with input speeds of 1800, 1500, 1200, 1000, 900, or 750 RPM.
b. 220022PSP (blade #219649) for use with input speeds at or below 600 RPM.

Mixer size
Input RPM
1800, 1500, 1200,
1000, 900, 750
600 and Below
14 & 15 8 (9) 9 (10)
16 17 (18) 18 (20)
17 21 (23) 23 (25)
Oil Capacity – Liters (Quarts)
If the mixer is to be operated at or below 600 RPM for an extended period of time, and dipstick 220021PSP has been
furnished, fill the gear drive housing with oil to a point 11mm (7/16 inch) OVER the full mark on the dipstick. When normal
operation resumes (input speed above 600 RPM), the excess oil must be removed or oil spillage will occur.
If the mixer is to be operated above 600 RPM for an extended period of time, and dipstick 220022PSP has been furnished,
drain the gear drive housing of oil to a point 11mm (7/16 inch) BELOW the full mark on the dipstick. When normal
operation resumes (input speed below 600 RPM), oil must be added or gear drive damage will occur.
CAUTION: DIPSTICK 220022PSP WAS NOT DESIGNED TO REGISTER THE LOWER OIL LEVEL MENTIONED ABOVE.
TO ENSURE PROPER LOW OIL LEVEL READING, DIPSTICK 220021PSP MUST BE USED.
5.4 The oil change frequency required for the gear drive is dependant upon the type of oil being used and the overall operating
conditions. In general, higher operating or local ambient temperatures or adverse operating conditions will require more
frequent oil changes. Table 3 provides specific guidance regarding the oil change interval for these gear drives. These oil
change intervals must be adhered to.
Duty Classification
Oil Selected
from Table
Oil Change Interval
(Whichever occurs first)
Operating Hours Calendar Months
Intermittent 2
1
2500
5000
6
12
Continuous
(24 Hours Per Day)
2
1
4380
8760
6
12
Table 3 – Recommended Normal Oil Change Intervals
5.5 The lubricant change interval may be extended if a comprehensive oil analysis program is established. Such a program
must include both spectrographic and ferrographic analyses as well as viscosity, total acid number, total based number,
and water content. If such an analysis program is in place, the oil should only be changed when degradation or
contamination is indicated by the analysis results. In no case should the oil change interval exceed 36 months.
DO NOT MIX oil types, grades or brands in the same mixer. If, at any oil change interval, it is necessary to change
lubricant, it is necessary to flush the mixer as follows:
a. Drain existing lubricant from gear drive as fully as possible.
b. Refill mixer as described above with new lubricant.
c. Operate gears drive long enough to reach normal operating temperature, usually at least two hours.
d. Drain and discard the lubricant from the gear drive.
e. Refill mixer with new lubricant and return to service.

5.6 More frequent oil change intervals, of one half to two thirds of the periods listed in Table 3, may be necessary if unfavorable
operating conditions that tend to degrade the oil or cause excessive condensation exist. Unfavorable conditions are
defined as:
a. Intermittent operation with rapid changes in oil temperature.
b. Wide fluctuations in ambient temperatures over short time spans.
c. Harmful vapors, chemical fumes, dusty atmospheres or prolonged humid atmospheres.
d. If adverse operating conditions are present, reputable lubricant suppliers can test oil and recommend economical oil
change schedules.
5.7 No periodic grease relubrication is required except for the motor bearings. All gear drive bearings are lubricated by oil
splash. Refer to the motor maintenance instructions for motor bearing lubricant specifications and recommended
frequency of relubrication.
5.8 ALTERNATE OILS
a. Care must be taken to choose an appropriate alternate lubricant.
b. The selection of an alternate oil should be done only after thorough evaluation by a qualified individual. Lubrication is a
complex subject with numerous variables.
NOTE: The gear drive contains elastomers, gear case sealer and other materials that may not be suitable for use
with an alternate oil. It is the customer’s responsibility to ensure that the oil is compatible.
c. All lubricants DO NOT perform equally, even though they may be the same AGMA viscosity grade. Each lubricant has
different performance levels based on the specific additives and formulations. It is the Customer’s
responsibility to understand the performance capability of the alternate lubricant they will be
using.
d. LIGHTNIN DOES NOT APPROVE OR INVESTIGATE ALTERNATE OILS. We recognize, however, that
alternate oils may perform adequately and provide other benefits to the customer. Customers may want an alternate oil
due to cost, availability or commonality of use with other equipment. In light of this, LIGHTNIN provides general
guidance for the customer or a third party to evaluate alternate oils.
e. LIGHTNIN offers general guidelines for evaluating alternate oils, however, successful field experience is critical to the
selection.
f. Most lubricant manufacturers can provide, upon request, product specification data sheets for each of their products.
These data sheets generally provide all or most of the data required.
g. If a lubrication related failure occurs, the Customer’s lubricant evaluation and field experience would be considered in
the failure analysis.
h. The Warranty may be voided if the customer has not conducted a proper lubricant evaluation,
before using the alternate lubricant.
i. For suggestions of a third party to perform an oil evaluation, the Society of Tribologists and Lubrication Engineers may
be contacted at www.stle.org.

TABLE 4
MINIMUM PHYSICAL AND PERFORMANCE REQUIREMENTS FOR
EXTREME PRESSURE AND SYNTHETIC GEAR LUBRICANTS
PROPERTY TEST PROCEDURE ACCEPTANCE CRITERIA
Flash Point ( °F ) ASTM D 92 400 (Minimum)
Viscosity ASTM D 445 Per AGMA 9005-E02 Table 4
Viscosity Index ASTM D 2270 EP: 90 (Minimum), SYN: 120 (Minimum)
Oxidation Stability
ASTM D 2893 (Increase in
Kinematic Visc. of a sample at 250°F )
6% Maximum
Rust Protection
ASTM D 665 B
(24 hrs in synthetic sea water)
No Rust
Corrosion Protection
ASTM D 130 (Copper strip
corrosion after 3 hrs. @ 212°F
1b strip
Foam Suppression
ASTM D 892
(Must be within the limits shown)
Maximum Volume of Foam (ml) after:
Sequence: I II III
Temp. °F: 75 200 75
After 5 Min. Blow: 75 75 75
After 10 Min. Rest: 10 10 10
Demulsibility
ASTM D 2711 MOD
(Must be within the limits shown)
AGMA Grades EP Syn.
. 2-7 8-13
Max. % H20 in oil 2.0 2.0 1.0
after 5 hr. test
Max. Cuff after
centrifuging (ml) 1.0 4.0 2.0
Min. Total free water
collected during entire
test (start w/ 90 ml of
water) (ml) 80.0 50.0 60.0
Cleanliness None Must be free from grit and abrasives.
Pour Point ASTM D 97
Timken OK Load ( lbs. ) ASTM D 2782 60 (Minimum)
FZG Test (No. of stages
passed)
DIN 51 354 ( A/8.3/90°C parameters) 12 (Minimum)
Filterability None
Must be filterable to 25 microns without the loss
of additives.

SECTION 6 - STORAGE PROCEDURES
LIGHTNIN Mixers and Aerators, like all precision equipment, must be protected against corrosion during prolonged periods of
inactivity. The primary cause of corrosion is condensation due to fluctuating temperatures and/or high humidity. Properly treated
and located in clean, dry surroundings, inactive equipment can be successfully stored without damage from corrosion attack.
REVIEW AND FOLLOW THE PROCEDURES THAT FOLLOW. FAILURE TO PROPERLY STORE AND PROTECT THE
EQUIPMENT AS OUTLINED MAY VOID ANY WARRANTY, EXPRESSED OR IMPLIED.
Electric motors or other prime movers are not prepared for indoor storage beyond the periods listed by LIGHTNIN. OUTDOOR
STORAGE OF MOTORS IS NOT RECOMMENDED BY ANY MOTOR MANUFACTURER. For storage periods beyond those
mentioned, refer to motor maintenance instructions furnished with this manual for further details.
The seal cartridge of mechanical seal mixers is not filled with lubricant. Fill the seal cartridge with lubricant as outlined in the seal
maintenance instructions of this manual.
6.1 STORAGE OF NEW MIXERS
LIGHTNIN mixers are factory treated with high quality corrosion inhibitors and rust preventatives. The products used will
effectively protect mixers from corrosion due to water and water vapor for the following initial periods depending on how the
mixers are stored.
a. LENGTH OF CORROSION PROTECTION
1. 12 months, when stored in a dry, ambient atmosphere with controlled temperatures. Corrosion protection to be
reapplied at 12 month intervals.
2. 6 months, when stored indoors in a dry, ambient atmosphere without temperature control. Corrosion protection to be
reapplied at 6 month intervals.
3. 6 months, when stored outdoors as crated, with suitable protection from the elements. Coverings must be
waterproof, but have provisions for free circulation of air to avoid buildups of condensation. Equipment must be
elevated at least 300mm (12 inches) above ground level to reduce moisture pickup. CORROSION PROTECTION
TO BE REAPPLIED AT 4 MONTH INTERVALS AFTER INITIAL STORAGE.
b. STORAGE OF INSTALLED MIXERS
1. Mixers that have been installed, but not filled with oil and will be inactive for an extended period should be prepared
per 6.2
2. Mixers that have been installed, filled with oil and run, but will be inactive for an extended period should be prepared
for storage per 6.3.
c. STORAGE OF CRATED MIXERS
For mixers that will be stored for periods longer than 6 months as crated indoors without temperature control or
outdoors, remove the dipstick/oil fill plug (located on top of the gear drive) per Section 4.1. Add 0.06 liter (2 ounces) of
”NOX RUST” and replace the plug.
d. INSPECTION
Inspect factory installed wrappings and coatings. If factory wrappings and coatings are accidentally removed or
damaged, reapply them over the exposed areas. Corrosion inhibitors deteriorate rapidly when exposed to air and water
vapors.
6.2 CORROSION PROTECTION RENEWAL
Careful adherence to the renewal procedures will afford adequate protection for the same period covered by a factory
prepared mixer when stored under conditions as defined in 6.1. These procedures should be repeated at the same
intervals as noted in 6.1.
a. The interior of the gear drive must be treated with a vapor phase inhibitor.
”NOX RUST” VCI No. 10 preservative oil, a product of Daubert Chemical Co., Chicago, IL. (This is the factory applied
product).
b. Prepare the mixer as follows:
1. Remove cover and protective wrappings.
2. Remove oil fill plug and add 0.06 liter (2 ounces) of ”NOX RUST” to sump oil.
3. Add fresh grease to the motor bearings. Remove relief plugs and add lubricant until fresh grease appears at the
relief. Replace plugs.
4. Rotate motor shaft by hand to distribute grease and turn over oil in gear sump.

5. Spray ”NOX RUST” preservative oil to exposed cavities.
6. Seal off breathing passages with VPI paper and wrap with waterproof tape.
6.3 STORAGE OF INACTIVE MIXERS
Mixers that have been in service, but will be idle less than 3 months, should be run at least 15 minutes every week and
receive regular maintenance. Mixers inactive more than 3 months should be prepared as follows:
a. Check the condition of the oil. (Lubricant suppliers can furnish oil checking service).
b. If the oil condition is good, add 0.06 liter (2 ounces) of ”NOX RUST” rust preventative oil to the regular oil.
c. If the oil has deteriorated, or is due to be changed under normal schedules, drain the gear drive completely.
1. Spray a mist of ”NOX RUST” in the gear drive, directing the spray to all corners for maximum coverage.
2. Add 0.06 liter (2 ounces) of ”NOX RUST”.
d. Remove the dipstick/oil fill plug and store in a safe place. Seal the opening with a solid plug.
e. Cover mixers stored indoors with a waterproof covering, allowing for free air circulation.
f. Inspect the drive every 4 months and:
1. Regrease all motor bearings. Rotate motor shaft.
2. Add additional ”NOX RUST” as outlined above.
3. Rotate shafts to distribute fresh oil and grease.
6.4 START-UP PREPARATION
a. Remove all wrappings and coverings.
b. Rotate shafts to check for free movement.
c. Install the dipstick/oil fill plug.
d. Check oil fill level, with the mixer stopped, and fill if necessary.
SECTION 7 - BOLT TIGHTENING TORQUE RECOMMENDATIONS
Inadequately or improperly tightened hardware can loosen due to vibration or the load reactions imposed by fluid forces. This
can result in reduced equipment service life or damage and failure.
7.1 Recommended torques for tightening metric bolts and screws on LIGHTNIN Mixers and Aerators and their mounting
structures are listed in Table 5 for your general reference. These average torque values should be considered only as
guides and not as absolute values.
The amount of torque required to maintain a tight connection can vary considerably for bolts of the same size under
different operating conditions. Variations such as basic joint design, compression factors, type and strength of base and
hardware material, surface finish of mating parts and lubrication are only some of the factors that influence the tightness of
bolted connections for given bolt torques.
UNLESS SPECIFICALLY LISTED ELSEWHERE IN THE DETAILED INSTRUCTIONS, TIGHTEN THE MIXER AND
MOUNTING HARDWARE TO THE RECOMMENDED VALUES SHOWN IN TABLE 5. A torque wrench must be used to
ensure compliance with these torque requirements.
Certain assembly connections may require special torques that are not listed in Table 5. These torques can be found in the
detailed assembly and disassembly sections of your manual. REVIEW YOUR MANUAL CAREFULLY TO DETERMINE
WHERE SPECIAL TORQUES ARE REQUIRED.
For severe duty service, torques higher than listed, to tighten a bolt to maximum capacity, can often be used. However, due
to the many variables previously mentioned, the only absolute method to determine optimum torque is to deliberately yield
a bolt under actual conditions. If a bolt does yield or shear, 75% of the torque applied in yielding the bolt can be used to
obtain a tight connection that is satisfactory.
ALL BOLTS SHOULD BE RETIGHTENED 12 HOURS AFTER ASSEMBLY, AND AT EACH SCHEDULED SHUT DOWN
THEREAFTER.

TABLE 5
RECOMMENDED TIGHTENING TORQUES FOR COMMERCIAL
GRADE STEEL, GR5, 304 AND 316 STAINLESS STEEL (1) (2)
BOLT
THREAD
SIZE
TIGHTENINGTORQUES
(FT-LBS) (3)
GRADE 5.6 OR
304/316 SS BOLTS
LUBRICATED
TIGHTENINGTORQUES
(FT-LBS) (3)
GRADE 8.8
BOLTS
LUBRICATED
ISO MARKING REFERENCE GUIDE
(2)
M5 1.7 4.1 HEX HEAD CAP SSREWS
M6 3.0 7.0
M7 5.0 12
M8 7.0 17
M10 14 34
M12 25 59
M14 39 93 HEX NUT
M16 62 146
M18 85 200
M20 120 284
M22 163 386
M24 207 491
M27 303 718 SOCKET HEAD CAP SSREWS
M30 412 975
M33 561 1327
M36 720 1704
M39 932 2205
M42 1153 2727
(1) ALL BOLTS SHOULD BE COATED WITH OIL, GREASE OR AN ANTI-SEIZE COMPOUND WHENEVER POSSIBLE. THE THREADS AND
BEARING FACE OF BOLT HEADS AND/OR NUTS SHOULD BE LUBRICATED.
(2) TORQUE VALUES SHOWN SUPERSEDE PREVIOUS TABLES THAT MAY HAVE ALLOWED LOWER VALUES. IT IS RECOMMENDED THAT
ONLY FASTENERS BE USED THAT ARE PROPERLY MARKED, INCLUDING MANUFACTURER’S TRADE MARKING. ONLY FASTENERS
MARKED AS SHOWN ARE GUARANTEED TO MEET SPECIFICATION AND PERFORMANCE REQUIREMENTS.
(3) CONVERSION FACTORS:
FRICTION LOCKING DEVICES MULTIPLY LUBRICATED VALUE BY 1.15. THESE TORQUES PERTAIN TO BOLTS OR NUTS WITH FRICTION
LOCKING DEVICES SUCH AS NYLON PELLETS OR PATCHES, FIBER INSERTS OR UPSET THREADS.
DRY VALUES MULTIPLY LUBRICATED VALUE BY 1.33.
METRIC VALUES IN N-m 1FT-LB = 1.3558 N-m
7.2 Recommended torques for tightening ANSI standard bolts and screws are listed in Table 6 for your general reference.
These average torque values should be considered only as guides and not as absolute values.
The amount of torque required to maintain a tight connection can vary considerably for bolts of the same size under
different operating conditions. Variations such as basic joint design, compression factors, type and strength of base and
hardware material, surface finish of mating parts and lubrication are only some of the factors that influence the tightness of
bolted connections for given bolt torques.
UNLESS SPECIFICALLY LISTED ELSEWHERE IN THE DETAILED INSTRUCTIONS, TIGHTEN THE MIXER AND
MOUNTING HARDWARE TO THE RECOMMENDED VALUES SHOWN IN TABLE 6. A torque wrench must be used to
ensure compliance with these torque requirements.

Certain assembly connections may require special torques that are not listed in Table 6. These torques can be found in the
detailed assembly and disassembly sections of your manual. REVIEW YOUR MANUAL CAREFULLY TO DETERMINE
WHERE SPECIAL TORQUES ARE REQUIRED.
For severe duty service, torques higher than listed, to tighten a bolt to maximum capacity, can often be used. However, due
to the many variables previously mentioned, the only absolute method to determine optimum torque is to deliberately yield
a bolt under actual conditions. If a bolt does yield or shear, 75% of the torque applied in yielding the bolt can be used to
obtain a tight connection that is satisfactory.
ALL BOLTS SHOULD BE RETIGHTENED 12 HOURS AFTER ASSEMBLY, AND AT EACH SCHEDULED SHUT DOWN
THEREAFTER.
TABLE 6
RECOMMENDED TIGHTENING TORQUES FOR COMMERCIAL
GRADE STEEL, GR5, 304 AND 316 STAINLESS STEEL (1) (2)
BOLT
THREAD
SIZE
TIGHTENINGTORQUES
(FT-LBS) (4)
GRADE 2, 3 OR
304/316 SS BOLTS
LUBRICATED
TIGHTENINGTORQUES
(FT-LBS) (4)
GRADE 5
BOLTS
LUBRICATED
MARKING
GRADE
STEEL SAE GRADE
MARKING REFERENCE
GUIDE
(2)
1
/4
_
20 4.6 7.2
NO MARK
SAE GRADES
0, 1 AND 2
5
/16
_
18 9.6 15
3
/8
_
16 17 26
7
/16
_
14 27 42
SAE GRADE 3
1
/2
_
13 41 64
9
/16
_
12 60 92
5
/8
_
11 83 128
SAE GRADE 5
3
/4
_
10 120 (3) 226
7
/8
_
9 142 (3) 365
1
_
8 212 547
ALL SOCKET
HEAD CAP SCREWS
SAE GRADE 5
1
1
/8
_
7 301 675 (3)
1
1
/4
_
7 425 952
1
3
/8
_
6 557 1249
1
1
/2
_
6 739 1657
1
3
/4
_
5 754 (3) 1600 (3)
2
_
4
1
/2 1134 2406
2
1
/4
_
4
1
/2 1659 3519
2
1
/2
_
4 2269 4813
(1) ALL BOLTS SHOULD BE COATED WITH OIL, GREASE OR AN ANTI-SEIZE COMPOUND WHENEVER POSSIBLE. THE THREADS AND
BEARING FACE OF BOLT HEADS AND/OR NUTS SHOULD BE LUBRICATED.
(2) TORQUE VALUES SHOWN SUPERSEDE PREVIOUS TABLES THAT MAY HAVE ALLOWED LOWER VALUES. IT IS RECOMMENDED THAT
ONLY FASTENERS BE USED THAT ARE PROPERLY MARKED, INCLUDING MANUFACTURER’S TRADE MARKING. ONLY FASTENERS
MARKED AS SHOWN ARE GUARANTEED TO MEET SPECIFICATION AND PERFORMANCE REQUIREMENTS.
(3) ALLOWABLE BOLT STRESS VALUES CHANGE AT THESE LOCATIONS AND IS REFLECTED IN THE SUGGESTED TORQUE VALUES.
(4) CONVERSION FACTORS:
FRICTION LOCKING DEVICES MULTIPLY LUBRICATED VALUE BY 1.15. THESE TORQUES PERTAIN TO BOLTS OR NUTS WITH FRICTION
LOCKING DEVICES SUCH AS NYLON PELLETS OR PATCHES, FIBER INSERTS OR UPSET THREADS.
DRY VALUES MULTIPLY LUBRICATED VALUE BY 1.33.
METRIC VALUES IN N-M 1FT-LB = 1.3558 N-M

REVISION
1996
DATE 8–1–96
REVISED PAGE 1 OF 3
INST. NO. IT–3989© LIGHTNINLIGHTNIN
MIXERS AND AERATORS
®
GUIDE TO TROUBLESHOOTING
LIGHTNINR SERIES 10 MIXERS
REDUCER:
OBSERVATION POSSIBLE CAUSE ACTION
Noisy Operation 1. Worn or damaged parts Check bearings and gears for
excessive wear. Replace worn
parts. Attempt to find cause
of wear. Check for abrasives
in oil, improper oil, inadequate
or improper grease, overload,
incorrect rotation, excessive
shock, etc.
2. Overloading Overloading can cause
excessive separation of gear
teeth and loud operation. Check
process fluid, agitator speed,
impeller diameter against unit
assembly drawing.
3. Worn or improperly Couplings can generate noise
installed or maintained which seems to eminate from
couplings gear case. Check for proper
lubrication, alignment or worn
parts.
Abnormal Heating 1. Incorrect oil Review Lubrication Instructions.
Replace with proper oil.
2. Unusual ambient conditions Units installed in a hot area of a
plant where air flow is restricted
can overheat. Remove obstruc–
tion and if necessary, force
circulate air.
3. Improper oil level Add or remove oil.
Leaking 1. Worn oil seals Replace defective seals.
2. Oil level too high Too high an oil level can cause oil
to leak through the inner oil seal
under the split removable
coupling. On an open tank unit, oil
could consequently leak into the
tank. On a seal unit, oil could leak
out on top of the seal assembly
or leak down the outside of the
seal hub and out between the
gear drive housing and the seal
flange. Also, oil could leak past
the high speed oil seal on the
pinion shaft and enter the motor
pedestal cavity. Remove oil.
3. Plugged breather Clean or replace breather.

REVISION
1996
DATE 8–1–96
REVISED PAGE 2 OF 3
MIXERS AND AERATORS
®
AERATOR OR MIXER:
OBSERVATION POSSIBLE CAUSE ACTION
Noisy Bearing 1. Wrong type of bearing See Lubrication Instructions.
lubricant.
2. Insufficient grease in Add proper quantity. See
bearing housing Lubrication Instructions.
3. Foreign matter in bearing Clean bearing housing. Replace
housing seals as required.
4. Bearing failure Replace bearings.
5. Interference of movable Check for interference and
machine parts provide necessary clearance.
6. Loose hardware or machine Retighten to recommended
component torque and reassemble as
necessary.
Overheated bearing 1. Wrong type of bearing See Lubrication Instructions
lubricant
2. Insufficient grease in Add proper quantity. See
bearing housing Lubrication Instructions.
3. Excessive grease in Remove and add proper
bearing housing quantity. See Lubrication
Instructions.
Vibration 1. Foreign matter in bearing Clean bearing housing. Replace
housing seals as required.
2. Bearing failure Replace bearings.
3. Improper linear or angular Correct alignment. See Shaft and
alignment of shaft couplings Coupling Instructions.
4. Loose hardware or machine Retighten to recommended
component torque and reassemble as
necessary.

REVISION
1996
DATE 8–1–96
REVISED PAGE 3 OF 3
MIXERS AND AERATORS
®
MOTOR:
If trouble develops in operation of motor, be sure that:
a. The bearings are in normal condition and have been properly lubricated with a high grade ball bearing lubricant,
free of dirt or grit. (If dirt enters bearing, flush and relubricate).
b. There is no mechanical misadjustment to prevent free rotation of moving parts of motor and drive.
c. All bolts and nuts are properly tightened.
d. Motor instructions have been carefully carried out.
e. That rated voltage is available in all phases at the motor terminals.
f. That the line voltage, frequency and phase correspond to the values stamped on the nameplate.
g. That all connections and contacts are properly made in all circuits between motor and line, and between motor
and control.
h. That overload and low voltage devices in control equipment, fuses or other protective devices are in proper
working order.
i. That no excessive overload exists on the motor. Compare line amperes at full load with nameplate stamping.

REVISION
1996
DATE 4--15--96
REVISED 05--19--05 PAGE 1 OF 3
INST. NO. IT--3752
C
© LIGHTNIN
LIGHTNINMIXERS AND AERATORS
®
SHAFT INSTALLATION FOR LIGHTNIN
SERIES 10 WITH OPEN TANK
SECTION 1 -- INSTALLATION
WARNING: ANGLE MOUNT SERIES 10 MIXERS:
Mixer assembly must be in a level position before performing any shaft maintenance.
Impeller assembly / blades may require removal from the shaft during installation or removal and to prevent
the impeller from contacting the tank wall.
1.1 Disconnect motor leads or otherwise lock--out power supply.
1.2 Remove safety guard (240) and coupling shield (247).
1.3 Remove the split low speed coupling assembly (220) and components.
1.4 Lower a sling or chain fall through the center of the gear drive housing.
1.5 With the impeller shaft (117) supported in an upright position within the vessel, install an eyebolt (see Table)
in the shaft tapped hole. Use only a heavy--duty shouldered eyebolt. If the eyebolt shoulder will not seat
against the shaft, use a spacer or jam nut to insure a tight connection.
We strongly recommend that either the eyebolt or hoist ring be of the safety swivel type with a 360° rotational
capability.
EYEBOLT TABLE
Unit
Size
Eyebolt
Size
Working
Load Capacity
in lbs.
3/8--16 140014/15
Shaft
Dia.
2
(in.)
Eyebolt
Size
Working
Load Capacity
in N
M12 3925
Shaft
Dia.
50
(mm)
1/2--13 260016 2--1/2 65
5/8--11 400017 3 M16 785075
* Units supplied in the Asia Pacific region may be using an M10 eyebolt.
M10 (*) 2600
1.6 Raise the shaft to a height sufficient to allow installation and positioning of the split low speed coupling (220).
While the shaft is suspended, install the split coupling (220) and key (224) to the shaft and secure it with the
socket head cap screws (221) and hex nuts (222). Tighten the hardware with the shaft recessed a maximum
of 1/8 inch below the top of the split coupling.
1.7 Lower the shaft and coupling down and seat the coupling into the rabbet on the low speed gear hub (204). Be
sure to line up the holes in the split coupling with the tapped holes in the gear hub. Apply a coating of LOCTITE
242 or equivalent to cap screws (223) and loosely install.
1.8 Remove the hoist and eyebolt. Install the thrust plate (225) and cap screws (227) finger tight. Install cap screw
(226) securely.
1.9 Remove socket head cap screws (221), coat the threads with LOCTITE 242 or equivalent, and re--install
loosely.
1.10 Tighten the hardware to the proper torques in the following sequence:
a . Shaft cap screw (226). This draws the shaft up to the thrust plate (225).
b . Socket head cap screws (221) and hex nuts (222). Restrain the hex nut, then TIGHTEN THE CAP
SCREWS TO THE TORQUE LISTED IN THE TABLE BELOW, keeping the gap between the coupling
halves approximately equal from side to side.

REVISION
1996
DATE 4--15--96
INST. NO. IT--3752
C
© LIGHTNIN
®
TIGHTENING TORQUES
UNIT
SIZE
THREAD
SIZE
TORQUE
14 & 15 M16 122
16 M20 257
17 M20 257
ITEM 221 CAP SCREW
N m
c . Cap screws (223) and then (227) cap screws. Use the torque values listed in the General Instructions.
1 3
24
TORQUE SEQUENCE 226 227
225
220 222
223
221
204
224
Figure 1
1.11 Rotate input shaft by hand to check for free motion of the shafts.
1.12 Install the coupling shield (247) and secure the safety guard (240) before operating mixer.
SECTION 2 -- SHAFT REMOVAL
2.1 Jog the motor or rotate the shaft to make sure the impeller(s) or shaft are not imbedded in tank contents or
otherwise seized.
2.2 Disconnect motor leads or otherwise lock--out power supply.
2.3 Angle Mount Series 10 Mixers:
a . Mixer must be in a level position BEFORE starting any shaft maintenance.
b . Check the position of the impeller(s). It may be necessary to remove the impeller blades to properly level
the mixer.
2.4 Remove the safety guard (240) and the coupling shield (247).
2.5 Remove in order, cap screws (227, 226 & 223) and remove the thrust plate (225).
2.6 Install a shouldered eyebolt (see Eyebolt Table) in the shaft tapped hole and lift up the shaft and split coupling
(220) with a hoist.

REVISION
1996
DATE 4--15--96
INST. NO. IT--3752
C
© LIGHTNIN
®
2.7 Remove the socket head cap screws (221) and nuts (222) and remove the split low speed coupling (220) and
key (224).
2.8 The shaft (117) can now be lowered down into the tank and supported in an upright position.
2.9 For re--installation of the shaft and low speed split coupling, refer to Section 1.
2.10 Rotate input shaft by hand to check for free rotation of the input and output shafts.
2.11 Install the coupling shield (247) and secure the safety guard (240) before operating mixer.

LIGHTNIN
MIXERS AND AERATORS
®REVISION
H 2001
DATE
REVISED 12–09–11 PAGE 1 OF 2
INST. No. IT–40562–25–97
© LIGHTNIN
INSTALLATION OF A510 AND A510E AXIAL FLOW
IMPELLER ONE PIECE HUB WELDED TO
IMPELLER SHAFT BOLTED ON BLADES
SECTION 1 – GENERAL
1.1 Refer to the appropriate table for the minimum diameter opening that the impeller will pass through. Opening
shown is based on disassembled impellers with the hub on the shaft.
1.2 A510 type impellers are shipped disassembled for ease of shipment and handling at the job site. Refer to
Section 2 for impeller assembly guides.
SECTION 2 – IMPELLER ASSEMBLY
2.1 Mate the three blades (convex side up) on the hub ears. If fins (168) are furnished, mount them before installing
hex nuts (167).
WARNING: Before securing the hardware, apply pressure to the blade so that its edge is firmly seated against
the raised shoulder on each hub ear. After tightening hardware, check to make sure that the blade has not
shifted away from the hub ear shoulder. PROPER BLADE POSITIONING IS IMPORTANT TO IMPELLER
FUNCTION.
2.2 IT IS ESSENTIAL that the hardware securing the blades to the hub is tightened to the specific torques in Table
1. It is important that tight connections are maintained as impellers are usually subjected to a wide range of
adverse loading conditions imposed by fluid force reactions.
2.3 It is good practice to RETIGHTEN all bolted connections after the equipment has been in operation. It is
recommended that all hardware be checked for tightness 12 hours after assembly, and at each scheduled
shut down thereafter.
TABLE 1 – IMPELLER TIGHTENING TORQUES
TORQUE (FT–LBS)
BOLT THREAD SIZE GRADE 2, 3 OR 304 / 316 SS
BOLTS
GRADE 5 BOLTS
3/8–16 17 26
1/2–13 41 64
5/8–11 83 128
3/4–10 120 226
7/8–9 (1) 142 365
1–8 212 547
1–1/8–7 301 675
1–1/4–7 425 952
Torque must be applied to the hex nuts. Restrain the bolt heads and tighten the hex nuts.
Torque values are based on hardware, threads and bearing surfaces lubricated with a light oil.
LIGHTNIN standard steel material is SAE Grade 5.
(1) Allowable bolt stress values change at these locations and this is reflected in the torque values.

LIGHTNIN
MIXERS AND AERATORS
®REVISION
H 2001
DATE
INST. No. IT–40562–25–97
© LIGHTNIN
ONE PIECE HUB WELDED TO IMPELLER SHAFT
NOTES:
1 WHEN ORDERING PARTS,
SPECIFY DRAWING NUMBER,
PART NAME, ITEM NUMBER,
AND MACHINE SERIAL NUMBER
MINIMUM DIAMETER OPENING
160 BLADE
ITEM PART NAME
2
165 HEX HD. CAP SCREW
167 HEX NUT
168 STABILIZER FIN
IMPELLER DIA. = D
ROTATION
0.045D
0.08D
167
160
CONVEX SURFACE OF BLADE
MUST FACE MOTOR AND HUB EAR
TOP OF HUB
STAMPED
CL
165
CAST LOCATING LUGS FOR
BLADE SEATING. (2) PER EAR
BOTTOM EDGE
OF BLADE
OF IMPELLER
THE NUMBER OF
BOLTS SHOWN IS
NOT NECESSARILY
THE NUMBER OF
BOLTS FURNISHED
”FACE TO MOTOR”
0.158D
0.4D
STABILIZER FINS (168)
FURNISHED ONLY WHEN
SPECIFIED
IMPELLER SHAFT
WITH HUB
REQUIRED TO PASS DISASSEMBLED
IMPELLER IS THE LARGER OF THE
IMPELLER SHAFT WITH HUB:
2” SHAFT – 9” DIA.
2–1/2” SHAFT – 13” DIA.
3” SHAFT – 15” DIA.
3–1/2” THRU 4–1/2” SHAFT – 17” DIA.
5” & 5–1/2” SHAFT – 20” DIA.
BLADE (160) OFF HUB:
0.165D
FOLLOWING:
A.
B.
BOLTED ON BLADES
FIGURE 1 – A510 AND A510E AXIAL FLOW IMPELLER

REVISION DATE: 10/19/2006 LIGHTNIN 2006 IT-5343
A MIXERS AND AERATORS LIGHTNIN PAGE 1 OF 1
FIELD PATCH KIT SUPPLEMENT
Your unit is furnished with a field patch kit designed to cover exposed hardware in otherwise covered areas
of in-tank components. The common areas to which the field patch kit is applied are shown below.
The method of installing the patch kit is generally dictated by the type of original covering and size of the
patch. Therefore, there are no standard methods of installation. Your patch kit will include the necessary
instructions for your particular situation.
Regardless of the type of patch being applied, the following general rules apply:
The metal and/or rubber in the patch area must be properly prepared by buffing and grinding. The
surface of the rubber adjacent to the area to be patched should be buffed back a minimum of 4
inches (or as near to 4 inches as practical depending on area to be patched).
Before applying cement, the entire work area must be clean and dry. All buffing dust, moisture, acid
fumes, etc. shall be removed not only from the direct area, but also the adjacent area where it
might be carried or blown into the work area.
Cements must be applied in the proper sequence on metal and/or buffed rubber and allowed to dry
between coats.
The mating covered surface shall have a minimum 30 degree skive and must be of the correct size
for complete overlay.
The patch must be carefully rolled and stitched down to remove any and all air.
Refer to the instructions furnished with your patch kit for specific details
on installation of the patch and shelf life of patch kit.

REVISION
2001
DATE 2–15–96
INST. NO. IT–3751
E
© LIGHTNINLIGHTNIN
MIXERS AND AERATORS
®
GEAR DRIVE MAINTENANCE INSTRUCTIONS FOR
LIGHTNINR SERIES 10 MODEL 17
SECTION 1 – GENERAL
1.1 Series 10 gear drives are precision manufactured and assembled to provide long trouble–free service when
properly maintained. If it becomes necessary to disassemble the unit, careful precise re–assembly is
necessary.
a . Equipment that may be required to service a unit, in addition to standard mechanics tools, are hoist, slings,
arbor press, wheel pullers, torque wrench, feeler gauges, dial indicator and micrometers.
b . When disassembling a unit, clean external surfaces adjacent to covers to prevent dirt from entering the
housing.
c . During disassembly, keep old shim–pack sets with their respective cages and retainers for reference when
reassembling.
d . It is recommended that oil seals, O–rings and gaskets be replaced when units are disassembled.
e . Refer to the Mixer Assembly drawing included in this manual for parts identification.
f . Refer to the General Instructions for bolt tightening torques.
g . HIGH SPEED COUPLINGS as standard are either elastomer flexible element type (standard duty) or TYPE
H or T10 tapered grid (variable speed/variable torque applications).
h . Determine the type high speed coupling furnished and refer to the appropriate Coupling Instructions for
required alignment and assembly procedures. Coupling identifiers are located on the coupling
components.
1.2 Prior to servicing the gear drive, do the following:
a . Disconnect the motor leads or otherwise lock–out power supply.
b . Drain oil from gear drive by removing the 1/2” NPT oil drain plug.
c . Remove safety guard (240) and coupling shield (247).
d . Remove the low speed coupling (220) and impeller shaft (117) per the Shaft Installation and Removal
Instructions included in this manual.
SECTION 2 – PARTS REMOVAL
2.1 SEAL REPLACEMENT
a . We recommend that oil seals and O–rings be replaced when the unit is dismantled. Carefully check for
nicks, gouges and deformities if they are not being replaced.
b . Coat O–rings and the rubber lip of all oil seals with a light grease before installing.
c . Be sure to install all oil seals in the correct orientation (with the closed side of the metal case facing upward).
Refer to mixer assembly drawing.
d . Install oil seals with the appropriate seal driver, being careful not to damage the metal case. If new oil seals
are being used, coat seal cases with Permatex #1 or equivalent and press into bores with the proper seal
driver. Apply a coating of grease to the oil seal lip and cavity.
e . If a bearing has been removed and its condition is suspect, clean the bearing with a solvent and allow to
dry. DO NOT SPIN dry bearings. Dip the bearings in a light oil for protection before spinning to check
bearing condition.
2.2 MOTOR REMOVAL
a . If a TAPER GRID HIGH SPEED COUPLING is furnished:
1 . Remove the split cover and grids.
2 . Remove the cap screws connecting the motor pedestal (230) to the gear drive housing (200) and
remove the motor (101), motor coupling half (233) and motor pedestal as an assembly.
b . If an ELASTOMER TYPE HIGH SPEED COUPLING is furnished, proceed per Section 2.2a–2.

REVISION
2001
DATE 2–15–96
INST. NO. IT–3751
E
© LIGHTNINLIGHTNIN
MIXERS AND AERATORS
®
2.3 LOW SPEED GEAR REMOVAL
a . Remove the drive cover (201) and oil seal (202). Scrape off all gasket material from the cover and the gear
drive housing.
b . Remove all of the hex head cap screws (209) holding the gear (210) to the gear hub (204).
c . Upon removal of the cap screws (209), you will find that two of the holes in the gear are tapped with M16
threads. Install two jacking screws or bolts, 75mm (3 inch) long with at least 40mm (1–1/2 inch) of thread
into the tapped holes. Tighten these screws until the gear is free of the gear hub, then pick up the gear
by the jacking screws and lift it out of the gear housing. (see Figure 1)
d . Inspect the gear for damage and replace if necessary. We strongly recommend that the gear (210) and low
speed pinion (236) be replaced as a set.
206
208
207 203 JACKING SCREW
210
200204212
1/2 NPT OIL DRAIN
211
213
216
215
217
218
Figure 1205
242
234
235
2.4 LOW SPEED GEAR HUB AND BEARING REMOVAL
a . Remove the low speed bearing retainer (206), shim set (207) and O–ring (242).
b . Place a 25mm (1 inch) thick steel rectangular bar across the top of the bearing pedestal of the gear drive
housing as shown in Figure 2. Using a large gear puller, pull the low speed gear hub (204) and the low
speed bearings (205) off of the bearing pedestal of the gear drive housing. Refer to Figure 2.
c . Inspect the bearings and replace if necessary. If the bearings are replaced, a new shim set (207) will be
required. Using a drift, drive the outer races from the bearing pedestal. The inner race and rollers of the
lower low speed bearing can be removed from the bearing pedestal of the gear drive housing by using a
puller on the bearing cage. Only do so if you have determined that the bearing must be replaced, since
the puller will damage the bearing.
203
200
204
205
PULLER
BAR
Figure 2

REVISION
2001
DATE 2–15–96
INST. NO. IT–3751
E
© LIGHTNINLIGHTNIN
MIXERS AND AERATORS
®
2.5 HIGH SPEED PINION REMOVAL
IMPORTANT: To remove the high speed pinion shaft (211) it is necessary to first loosen the low speed pinion
shaft (236).
a . Remove bearing retainer (239) and the shim set (241), being careful not to damage the shim set.
b . Install a piece of threaded stock into the 5/8–11 tapped hole in the end of the low speed pinion shaft (236).
Then install a 30mm (11/4 inch) high spacer, thrust plate and hex nut as shown in Figure 3.
c . Tighten the hex nut, raising the low speed pinion shaft until the upper intermediate bearing is free of its
housing.
d . Move the low speed pinion shaft (236) away from the high speed pinion and shaft (211).
e . Remove the high speed pinion shaft coupling half (234) and the flexible element (235) (WOODS
SURE–FLEX COUPLINGS ONLY) from the high speed pinion shaft (211).
f . Remove the high speed bearing retainer (215) and the shim set (216), being careful not to damage the shim
set.
g . The high speed pinion shaft (211) and bearings (213 & 213) can now be lifted out of the gear housing.
Inspect the pinion shaft and replace if necessary.
h . Inspect the high speed bearings (212 & 213) and replace if necessary. If the bearings or the pinion shaft
are replaced, a new shim set (216) will be required. If the bearings must be replaced, the outer race of the
lower bearing can be removed from its bore with a small puller.
Figure 3
5/8–11 THREADED STOCK
THRUST PLATE
HEX NUT
30mm (1–1/4 INCH) HIGH SPACER
229
237
213A
236
2.6 LOW SPEED PINION AND GEAR REMOVAL
a . Return low speed pinion shaft (236) to its original position.
b . Replace the upper spacer, thrust plate and hex nut, and install a second spacer between the high speed
gear (237) and the underside of the gear drive housing (see Figure 4). This will press the gear off the shaft.
c . Tighten the hex nut, raising the low speed pinion shaft (236) until it is clear of the high speed gear (237)
and remove the shaft.
d . Remove the spacer (214).
e . Inspect the intermediate bearings (213A & 229) and replace if necessary. If the bearings or the pinion shaft
are replaced, a new shim set (241) will be required. If the bearings must be replaced, the outer race of the
lower bearing can be removed from its bore with a small puller.

REVISION
2001
DATE 2–15–96
INST. NO. IT–3751
E
© LIGHTNINLIGHTNIN
MIXERS AND AERATORS
®
5/8–11 THREADED STOCK
THRUST PLATE
HEX NUT
30mm (1–1/4 INCH) HIGH SPACER
229
237
213A
Figure 4
236
SPACER
SECTION 3 – GEAR DRIVE ASSEMBLY
3.1 INTERMEDIATE BEARING INSTALLATION
a . Coat the bearing bores in the gear drive housing (200) and the low speed pinion shaft (236) with oil prior
to installing the intermediate bearings (229 & 213A).
b . Press the outer race of the intermediate bearing (213A) into the gear drive housing. Refer to the assembly
drawing for the correct bearing orientation. Make sure the races are seated against the shoulder by
checking for a gap with feeler gauges.
c . Preheat the inner races of the intermediate bearings (229 & 213A), and the high speed gear (237) in an
oil bath or oven with a maximum temperature of 135° C (275° F).
d . Remove the upper intermediate bearing (229) from the oil bath or oven, and press it onto the low speed
pinion shaft. Check for proper seating with feeler gauges. Refer to assembly drawing for correct orientation
of the bearing races.
e . Place two spacers (approx. 13mm (1/2 inch) high) next to the lower intermediate bearing bore as shown
in Figure 5.
f . Place the low speed pinion shaft (236), with upper bearing inner race and key (238) installed, into the gear
drive housing, positioned so that it is above the top of the housing.
g . Remove high speed gear (237) from the oil bath or oven and place it on the spacers as shown in
Figure 5.
237
236
238
SPACER
Figure 5

REVISION
2001
DATE 2–15–96
INST. NO. IT–3751
E
© LIGHTNINLIGHTNIN
MIXERS AND AERATORS
®
h . Press the low speed pinion shaft (236) into the high speed gear (237). Check for proper seating with feeler
gauges. Remove the spacers.
i . Remove the inner race of the lower intermediate bearing (213A) from the oil bath or oven, and place it into
position in the outer race already installed.
j . Place the spacer (214) on the lower intermediate bearing inner race and press the pinion shaft and gear
assembly in place. Check for proper seating with feeler gauges.
k . Install the outer race of the upper intermediate bearing (229) and slide it into the bearing bore.
3.2 HIGH SPEED BEARING, PINION SHAFT AND GEAR INSTALLATION
a . Coat the bearing bores in the gear drive housing (200) and the pinion shaft (211) with oil prior to installing
the high speed bearings (212 & 213).
b . Press the outer race of the lower high speed bearing (212) into the bore of the gear drive housing (200)
and press the inner race of the lower high speed bearing onto the end of the pinion shaft (211). Check for
proper seating with feeler gauges. Refer to assembly drawing for correct orientation of the bearing races.
c . Set the pinion shaft and high speed bearings (212 & 213) in the gear drive housing.
d . Install the upper high speed bearing outer race on the pinion shaft (211) and slide it into the bearing bore.
3.3 LOW SPEED BEARING INSTALLATION
a . Coat the bearing bores in the gear hub (204) and the bearing pedestal of the gear drive housing (200) with
oil prior to installing new bearings.
b . Press the outer races of both low speed bearings (205) into the gear hub (204). Refer to assembly drawing
for the correct bearing orientation. Make sure the races are seated against the shoulders by checking for
a gap with feeler gauges.
c . Preheat the inner races of the low speed bearings in an oil bath or oven with a maximum temperature of
135° C (275° F).
d . Remove one of the inner races from the oil bath or oven, and slide it down the bearing pedestal, seating
it against the bottom of the gear drive housing.
e . Place the gear hub over the bearing pedestal and rest it on the lower bearing.
f . Slide the second inner race and rollers onto the bearing pedestal, seating it into the upper outer race in the
gear hub.
3.4 SETTING THE AXIAL PRELOAD IN THE LOW SPEED ROLLER BEARINGS
NOTE: Hex head cap screws (208) are furnished with Nylok inserts and should only be installed once. To
establish proper preload, use hardware that does not contain a locking patch or pellet, then use new
hardware for final assembly. USE ONLY THE QUANTITY OF BOLTS LISTED IN 3.4.a TO INITIALLY SET
THE PRELOAD.
a . To set the bearings, install the low speed bearing retainer (206) without the shims (207). Install four M8 x
40mm long bolts (without locking patch or pellet) in a symmetrical pattern.
b . Tighten the bolts in a symmetrical pattern to 18 ft–lbs. It is critical that these bolts be tightened only to the
torque indicated, and no greater.
NOTE: This is the torque for setting the preload ONLY.
c . Rotate the gear hub (204) at least five revolutions in one direction, and tighten the bolts again to 18 ft–lbs.
d . Repeat preceding step until the bolt load does not change after the gear hub is rotated.
e . With a feeler gauge, measure the gap between the low speed bearing retainer (206) and the top of the
drywell. Do this in four places in close proximity to the bolts in the bearing retainer. These gap
measurements should be close in value, but some difference is expected. If more than .005” difference
is present, repeat Steps 3.4.a through 3.4.d. If the measurements are close to one another, take the
average of the four measurements, and this is the total number of shims (207) that must be added between
the low speed bearing retainer (206) and the drywell.
f . The bolts apply a load capable of deflecting the bearings the desired amount of .003”. The gap measured
is the desired shim pack thickness.
g . Remove the bearing retainer (206) and add the required shims (207).

REVISION
2001
DATE 2–15–96
INST. NO. IT–3751
E
© LIGHTNINLIGHTNIN
MIXERS AND AERATORS
®
h . Install O–ring (242) and low speed bearing retainer (206). Insert new hex head cap screws (208) with
unused Nylok inserts, and tighten to 20 ft–lbs.
200204205
206
Figure 6
MEASURED
GAP
DRY WELL
AREA
TORQUE (4) CAP SCREWS
TO 18 FT–LBS.
i . Apply Loctite #515 gasket eliminator to the outer diameter of the oil seal (203) and install the oil seal. Refer
to Machine Assembly drawing for the correct orientation. Align the seal to within .007” TIR using a dial
indicator.
j . With the use of two jacking screws or bolts, as described in Section 2.3–c, set the low speed gear (210) in
place on the gear hub (204). You may have to rotate the pinion shaft to mesh the gear and pinion together.
Be sure to line up the holes in the gear with the holes in the gear hub. Remove the jacking screws.
k . Install the hex head cap screws (209) and secure the gear to the gear hub by drawing the gear down on
the gear hub evenly with the cap screws (209).
3.5 SETTING THE AXIAL FLOAT IN THE INTERMEDIATE ROLLER BEARINGS
a . To seat the bearings, install the bearing retainer (239) without the shim set (241) and tighten the cap screws.
Remove the bearing retainer and hardware.
b . Install the bearing retainer (239) with a full new shim set (241) and tighten the cap screws. Remove the
plug from the center of the bearing retainer and install a hex head cap screw (5/8–11 x 1–1/2” lg. minimum)
into the tapped hole in the end of the pinion shaft (211).
NOTE: The hex head cap screw must be installed so that it bottoms out in the tapped hole. Rotate the
pinion shaft (211) to align the bearing rollers.
c . Measure the axial float per the following procedure (refer to Figure 7):
1 . Set up a dial indicator on the end of the cap screw.
2 . Grasp the cap screw and move the pinion shaft up and down while measuring the axial float with the
dial indicator.
d . Remove shims and repeat steps “b” and “c” until an axial FLOAT of 0.013mm to 0.05mm (.0005 to .0020
inches) is attained.
e . Rotate low speed shaft by hand and check for smooth operation.

REVISION
2001
DATE 2–15–96
INST. NO. IT–3751
E
© LIGHTNINLIGHTNIN
MIXERS AND AERATORS
®
239
DIAL INDICATOR
236
241
Figure 7
229
213
212
211
204
210
237
238
214
213A
3.6 SETTING THE AXIAL FLOAT IN THE HIGH SPEED ROLLER BEARINGS
a . To seat the bearings, install the high speed bearing retainer (215) without the shim set (216), and tighten
the hardware. Remove the bearing retainer and hardware.
b . Install the high speed bearing retainer with a full new shim set (216) and tighten the hardware. Rotate the
pinion shaft (211) to align the bearing rollers.
c . Measure the axial float per the following procedure (refer to Figure 8):
1 . Install the coupling hub (234) on the pinion shaft (211) and tighten set screw.
2 . Set up a dial indicator on the end of the pinion shaft.
3 . Grasp the coupling hub (234) and move the pinion shaft up and down while measuring the axial float
with the dial indicator.
d . Remove shims and repeat steps “b” and “c” until an axial FLOAT of 0.013mm to 0.05mm (.0005 to .0020
inches) is attained.
e . Rotate high speed shaft by hand and check for smooth operation.
f . Loosen the set screw on the coupling hub (234) and move the hub down the shaft as far as possible for easy
installation of motor and flexible coupling element.
206
208 207 203
200204205212
1/2 NPT OIL DRAIN
211
213
216
215
217
218
210
201
DIPSTICK / OIL
DIAL INDICATOR
Figure 8
202
242
234
FILL PLUG

REVISION
2001
DATE 2–15–96
INST. NO. IT–3751
E
© LIGHTNINLIGHTNIN
MIXERS AND AERATORS
®
3.7 FINAL ASSEMBLY
a . Apply Loctite #515 gasket eliminator to the outer diameter of oil seal (202) and drive a new outer oil seal
into the bore of the drive cover (201).
b . Apply a bead of non–hardening RTV silicone caulk around the top of the gear drive housing (200).
c . Install the drive cover and seal assembly and fasten with the required hardware. Be sure to engage the pin
holes in the cover with the alignment pins in the gear drive housing.
d . If a TAPER GRID HIGH SPEED COUPLING is furnished:
1 . Install the motor (101), motor pedestal (230) and motor coupling hub (233).
2 . Install flexible elements, secure hubs, covers and lubricate coupling.
e . If an ELASTOMER TYPE HIGH SPEED COUPLING is furnished:
Install the motor (101), motor pedestal (230), motor coupling hub (233) and the coupling flexible element
(235) as an assembly. ELASTOMER TYPE couplings do not require lubrication.
f . Refer to the appropriate Coupling Instructions for required assembly procedures.
g . Re–fill the unit with oil with the mixer stopped. Refer to the General Instructions for oil specifications and
capacity. Check oil level with the dipstick.
h . Install the impeller shaft (117) and the low speed coupling (230) per the Shaft Installation and Removal
Instructions.
i . Install the coupling shield (247) and safety guard (240) before re–connecting power.

REVISION
1971
DATE 7-15-71
REVISED 2-10-03 PAGE 1 OF 6
INST. NO. IT-693
F
© LIGHTNINLIGHTNIN
MIXERS AND AERATORS
®
INSTALLATION INSTRUCTIONS FOR
ELASTOMER SLEEVE COUPLINGS
NOTE: The mixer is furnished with either an Elastomeric or T10/H high speed, and/or a T20/V low speed tapered grid
coupling. Determine the coupling size and manufacturer so that correct coupling alignment procedure can be employed.
Coupling identifiers are located on the coupling components.
IMPORTANT: ALWAYS RECHECK HIGH SPEED COUPLING ALIGNMENT PRIOR TO INITIAL START IN CASE
MISALIGNMENT OCCURS DUE TO SHIPPING, HANDLING AND INSTALLATION.
ELASTOMER SLEEVE (SPLIT)
SHAFT FLANGE
2 SET SCREWS
PER FLANGE
PARALLEL ANGULAR
OUTSIDE CALIPERS
INTRODUCTION:
Elastomeric couplings consist of three basic elements - two shaft flanges and one elastomer split sleeve. Each
shaft flange is identified with basic size and shaft bore. Elastomer sleeves are identified with basic size and a
material code letter stamped on or molded in.
Rubber sleeves are black and are coded with size/style designations 4JES thru 8JES and 9E. Polyester sleeves
are peach color and designated as 6HS thru 11HS.
INSTALLATION AND MAINTENANCE:
Only simple tools are required; an allen wrench, straightedge and outside calipers. To install or replace elastomer
sleeves, loosen both set screws in one of the shaft flanges and slide the flange back. Remove the two piece sleeve
or spread apart one-piece split sleeves and replace with the same type new sleeve. Install the new sleeve over
the shafts and slide the sleeve into the stationary shaft flange until it seats firmly against the flange inner wall. For
couplings equipped with a type E sleeve (two piece with a retaining ring), the retaining ring has to be pried out of
the sleeve groove for sleeve removal and back into position after installing new sleeve and checking alignments.
Slide the loose shaft flange into position, engaging the sleeve teeth until the sleeve fits snugly against the flange
inner wall. The teeth on the elastomer sleeve should be fully engaged and slightly underflush within each shaft
flange. DO NOT force the flanges together so as to compress the sleeve in any way.
NOTE: Shaft gap is determined by the width of the elastomer element when engaged in both hub halves.
PARALLEL ALIGNMENT:
Place a straightedge across the 2 coupling flange rims and measure the maximum offset at 90° intervals around
the coupling. If the maximum offset exceeds the allowable values in the table, add or subtract equal thicknesses
of motor foot shims until parallel alignment is as close as possible.
ANGULAR ALIGNMENT:
Check angular alignment with outside calipers (or micrometers) as shown above. Check at 90° intervals around
the coupling. DO NOT ROTATE the coupling during this measurement. The difference between the maximum and
minimum measurement should not exceed the allowable value in the table. Re-check parallel alignment once
angular alignment has been achieved.
NOTE: To insure maximum sleeve life, keep misalignment values as near zero as possible.

REVISION
1971
DATE 7-15-71
INST. NO. IT-693
F
© LIGHTNINLIGHTNIN
MIXERS AND AERATORS
®
MAXIMUM ALLOWABLE MISALIGNMENT
(DIMENSIONS IN INCHES)
BASIC
SLEEVE
SIZE
FLANGE SET
SCREW TORQUE
(FT-LBS)
RUBBER SLEEVES
(TYPE JES & E)
PARALLEL ANGULAR
POLYESTER SLEEVES
(TYPE H.S.)
PARALLEL ANGULAR
.005 .014 -- --4 3
.008 .018 -- --5 7
.008 .023 .005 .0056 13
.010 .026 .006 .0077
.010 .031 .008 .0088
.013* .036* .008 .0099 23
-- -- .010 .01110
-- -- .011 .01211
* THESE ARE TYPE E SLEEVES (TWO-PIECE WITH RING)
TABLE 1 - ELASTOMERIC INSTALLATION DATA
IMPORTANT: Before starting up, be sure the coupling guard is replaced and properly secured. Elastomer sleeves can
be thrown from the assembly when subjected to a severe shock load.
Due to vastly different torque ratings, NEVER substitute a polyester (peach) sleeve with a rubber (black) sleeve or vice
versa. Do not use polyester sleeves on variable speed applications until the application has been reviewed by
LIGHTNIN Engineering personnel.

REVISION
1971
DATE 7-15-71
INST. NO. IT-693
F
© LIGHTNINLIGHTNIN
MIXERS AND AERATORS
®
INSTALLATION AND MAINTENANCE INSTRUCTIONS
FOR GRID TYPE FLEXIBLE COUPLINGS
IMPORTANT: ALWAYS RECHECK HIGH SPEED COUPLING ALIGNMENT PRIOR TO INITIAL START IN CASE
MISALIGNMENT OCCURS DUE TO SHIPPING, HANDLING AND INSTALLATION.
WHEN ORDERING PARTS, SPECIFY COUPLING SIZE AND TYPE AS SHOWN
TYPE T10/H AND T20/V TAPERED GRID COUPLING PARTS
TYPE T10/H
TYPE T20/V
1. SEAL
2. COVER
3. HUB (SPECIFY BORE AND KEYWAY)
4. GRID
5. GASKET
6. NUTS, BOLTS (AND LOCK
WASHERS WHEN REQUIRED)
7. LUBE PLUG
1
7
2
3
4
5
2
5
3476
1
MATCH MARK
MUST BE UP
FOR VERTICAL
APPLICATIONS
6
INTRODUCTION:
These instructions apply to Type T10/H and Type T20/V Tapered Grid Couplings. These couplings are designed
to operate in either the horizontal or vertical position without modification. However, for vertical applications, the
match mark shown above must be up. The performance and life of the couplings depend largely upon how you
install and service them. Carefully follow the instructions that follow for optimum performance and trouble free
service.
PARTS IDENTIFICATION:
All coupling parts have identifying part numbers as shown above. Parts 3 and 4 (Hubs and Grids) are the same
for both T10/H and T20/V couplings; all other coupling parts are NOT INTERCHANGEABLE. Therefore, when
ordering parts, always SPECIFY SIZE and TYPE.
INSTALLATION:
Only standard mechanic’s tools, wrenches, a straight edge and feeler gauges, are required to install Taper Grid
couplings. Couplings are furnished for PUSH or LIGHT TAP FIT with set screws. For best results, clean all parts
thoroughly and align coupling for minimum angular and parallel misalignment. Set the coupling gap as
recommended; permanently fasten unit foundation bolts and then recheck alignment. Refer to Page 5 for detailed
instructions.
LIMITED END FLOAT:
When electric motors are fitted with sleeve bearings, limited axial and float couplings should normally be employed
to protect motor bearings. Tapered Grid couplings are easily modified to limit end float. Consult the factory if this
feature is required.

REVISION
1971
DATE 7-15-71
INST. NO. IT-693
F
© LIGHTNINLIGHTNIN
MIXERS AND AERATORS
®
LUBRICATION:
Flexible couplings are shipped from the factory lubricated as follows:
High Speed Couplings - Type T10 or H - Shell EP2
Low Speed Couplings - Type T20 - Falk Long Term Grease
Type H - Texaco Marfax 2 or Mobilux EP2 Grease
Adequate lubrication is essential for proper operation of the coupling. It is recommended that the coupling be
checked once a year and lubricant added if required. Unusual conditions may have an effect on the lubricant. For
applications involving exposure to excessive moisture, extreme heat or cold, severe and rapid reversing or heavy
shock loads, it is recommended the coupling be checked at more frequent intervals. The following specifications
apply to lubricants for Grid couplings which are lubricated annually and operate within ambient temperatures of 0°
to 150° F. For temperatures beyond this range, consult the factory.
Dropping Point - 300° F or higher
Consistency - NLGI No. 2 with worked penetration value in the range of 250 to 300.
Separation and Resistance - Low oil separation rate and high resistance to separation from centrifuging.
Liquid Constituent - To posses good lubrication properties...equivalent to a high quality, well refined petroleum
oil.
Inactive - Should not corrode steel or cause swelling or deterioration of neoprene.
Clean - Free from foreign inclusions.
A list of lubricants meeting the above specifications is available from the factory.
LUBE FITTINGS:
A standard grease gun with a 1/8 NPT fitting, or any standard lube fitting including the Alemite No. 1610B, Lincoln
No. 5000 or Universal No. 800, may be used on the 1/8 NPT fitting in the cover.

REVISION
1971
DATE 7-15-71
INST. NO. IT-693
F
© LIGHTNINLIGHTNIN
MIXERS AND AERATORS
®
INSTALLATION OF TYPE T10/H AND T20/V TAPERED GRID COUPLINGS
1 MOUNT COVERS, SEALS
AND HUBS
2 CHECK GAP AND
ANGULAR ALIGNMENT
For best results, use a spacer bar equal
in thickness to the gap specified in Table
2. Check alignment by placing the
spacer between the hubs as shown, and
at 90° intervals around the hub.
3 CHECK OFFSET
MISALIGNMENT
Align shafts so that a straight edge will
rest squarely on both hubs as shown,
and at a position 90° away. Fasten
foundation bolts and recheck both angu-
lar and offset alignment before doweling
connected machinery in place.
Place Type T20/V cover and seal, or
Type T10/H seal only on shaft BEFORE
mounting hub (the Type T10/H cover is
mounted later). Mount hubs on their
respective shafts so the hub face is
flush with the end of its shaft.
NOTE: Recommended minimum
engagement is one shaft diameter.
4 INSERT GRID 5 POSITION COVERS
Pack the spaces between and around the grid with as much lubricant as possible and
wipe off excess flush with top of grid. Covers will be easier to install if lube plugs are not
in place during this operation to allow trapped air to escape.
Type T10/H Cover: Assemble cover halves with the lug and
match mark UP, or on the high side of the coupling so that the
cover will be correctly positioned. The adjacent cover outer rib is
match marked to indicate location of the lug. Slide seals into posi-
tion on the hubs. Cover halves assemble in only one position. The
correct position is with the lube holes (one in each cover half) at
180°. If bolt holes do not line up, reverse one cover half. Insert
gaskets at cover splits and secure with cap screws and elastic
stop nuts furnished. Lubricate per Step 6.
Type T20/V Cover: Place seals on cover halves and slide into hubs. Position cover
halves with lube holes (one in each half cover) at 180°. Draw gasket and cover halves
together, and secure with cap screws, nuts and lockwashers furnished. Lubricate per
Step 6.
After coupling hubs are aligned, insert
the Type T20/V gasket through the gap
and hang it on either hub. Pack gap and
grooves with lubricant before inserting
grid. When grids are furnished in two
segments, install them so that all cut
ends extend in the same direction. This
will assure correct grid contact with lug
in the T10/H cover and permit cover
installation. Since grid runs are truly
radial, it is necessary to spread the grid
slightly to pass it over the coupling
teeth. To minimize spreading, start grid
at either end and then tap it into place.
DO NOT attempt to force grid to the bot-
tom of the groove, it will seat easily after
all rungs are positioned.
6 LUBRICATE - With the lube relief plug removed, fill the coupling through fitting
with recommended grease until an excess appears at the relief. INSTALL LUBE PLUG
when lubrication is completed.
7 COUPLING DISASSEMBLY AND GRID REMOVAL - Whenever it is
necessary to disconnect the coupling, draw back the cover halves and remove the grid. A
round rod or screwdriver that will conveniently fit into the open loop ends of the grid is
required. Begin at the open end of the grid section and insert the rod or screwdriver into
the loop ends. Use the teeth adjacent to each loop as a fulcrum and pry the grid out
radially in even, gradual stages. Proceed alternately from side to side, lifting the grid about
halfway out until the end of the grid is reached. By following the same procedure once
again, the grid will clear the teeth.
T10/H T20/V
LUG UP
VERTICAL
COUPLINGS

REVISION
1971
DATE 7-15-71
INST. NO. IT-693
F
© LIGHTNINLIGHTNIN
MIXERS AND AERATORS
®
TABLE 2 - TAPER GRID INSTALLATION DATA
GAP
AT CENTERLINE
G
G NOMINAL
ANGULAR
MISALIGNMENT
Y
X MINUS Y**
OFFSET
MISALIGNMENT
P
P MAXIMUM
X
SERVICE LIFE OF COUPLING DEPENDS ON GOOD ALIGNMENT
SIZE
MAXIMUM
SPEED
(RPM)
COVER
BOLT
TORQUE
T10/H T20/V
GAP AT CENTERLINE
MIN. NOMINAL MAX.
X - Y**
MAX.
P
MAX.
(IN-LBS)
LUBE
WGT.
(LBS.)
4500 6000 .062 .125 .1881020T .005 .005 100 .06
4500 6000 .062 .125 .1881030T .005 .005 100 .06
4500 6000 .062 .125 .1881040T .005 .005 100 .12
4500 6000 .062 .125 .1881050T .005 .005 200 .12
4350 6000 .062 .125 .1881060T .010 .010 200 .19
4125 5500 .062 .125 .1881070T .010 .010 200 .19
3600 4750 .062 .125 .2501080T .010 .010 200 .38
3600 4000 .062 .125 .2501090T .012 .012 200 .56
2440 3250 .062 .188 .3751100T .012 .012 260 .94
2250 3000 .062 .188 .3751110T .012 .012 260 1.1
2025 2700 .062 .250 .5001120T .012 .012 650 1.6
1800 2400 .062 .250 .5001130T .012 .012 650 2.0
1650 2200 .062 .250 .5001140T .015 .015 650 2.5
1500 2000 .062 .250 .5001150T .015 .015 650 4.2
1350 1750 .062 .250 .5001160T .015 .015 650* 6.2
1225 1600 .062 .250 .5001170T .015 .015 1300 7.7
* 160T20/V TORQUE = 1300 IN-LBS
** X MINUS Y IS THE DIFFERENCE IN MINIMUM AND MAXIMUM CLEARANCE BETWEEN THE HUBS
AT 180° AT THE OUTER EXTREMITY OF THE HUBS.
ALL DIMENSIONS ARE IN INCHES

REVISION
1978
DATE 3--1--78
INST. NO. IT--1488
D
LIGHTNIN
MIXERS AND AERATORS
LIGHTNIN
MOTOR MAINTENANCE INSTRUCTIONS
FOR C--FACE AND FOOT MOUNTED
MOTORS FURNISHED BY LIGHTNIN
SECTION 1 -- INITIAL INSPECTION, SHIPPING ARRANGEMENTS
1.1 Care is taken at the factory to assure that the motor arrives at its destination in first class condition. If there
is evidence of rough handling or damage in shipment, file a claim at once with the carrier and notify our
factory.
Examine the outside of the motor carefully for damage, with particular attention to the conduit box, fans
and covers. Check nameplate for correct speed, horsepower, voltage, hertz and phase for
conformance with power supply. Turn the shaft by hand to be sure it rotates freely. If the motor has been
mishandled sufficiently to break external parts, the end shield should also be removed to check for
internal damage unless the motor is explosion--proof. See warning below on explosion--proof motors.
1.2 ! WARNING
• EXPLOSION--PROOF MOTORS -- These motors are constructed to comply with the U.L. Label
Service Procedure manual. When repairing and reassembling a motor that has an Underwriter’s Label,
it is imperative that the unit be reinspected and;
a . All original fits and tolerances must be maintained
b . All plugs and hardware to be securely fastened
c . Any part replacements, including hardware, be accurate duplicates of the originals
REPAIR WORK ON EXPLOSION--PROOF MOTORS CAN ONLY BE DONE BY THE ORIGINAL
MANUFACTURER OR U.L. CERTIFIED SERVICE SHOPS. VIOLATIONS OF ANY OF THE ABOVE
ITEMS WILL INVALIDATE THE SIGNIFICANCE OF THE U.L. LABEL.
SECTION 2 -- START--UP
2.1 After unpacking and inspection to see that all parts are in good condition, turn the shaft by hand to be
sure there are no obstructions to free rotation. Equipment which has been in storage should be tested
prior to being put into service.
a . It is best to check the insulation resistance of the stator winding with a megohmeter. If resis-
tance is lower than one megaohm, the windings should be dried thoroughly before operating.
Do not exceed a temperature of 80° C (185° F) in drying.
b . Motors are shipped from the factory with the bearings properly packed with grease and ready
to operate. Where the unit has been subjected to extended storage (6 months or more), the
bearings should be relubricated prior to starting.
2.2 WIRING -- Examine the nameplate data to see that it agrees with the power circuit to which the motor
is to be connected. The motor is guaranteed to operate successfully with frequency not more than 5%
and voltage not more than 10% above or below the nameplate data, or combined variation of voltage
and frequency of not more than 10% above or below nameplate data. Efficiency, power factor and cur-
rent may vary from nameplate data.
2.3 Temporarily connect the motor leads to a power source that matches the line voltage and wiring diagram
specified on the motor nameplate.
2.4 Check impeller shaft rotation by jogging the motor until it is determined that rotation is correct.

REVISION
1978
DATE 3--1--78
INST. NO. IT--1488
D
LIGHTNIN
MIXERS AND AERATORS
LIGHTNIN
2.5 ! CAUTION
Repeated trial starts can overheat the motor (particularly for across-the-line starting). If repeated trial
starts are made, allow sufficient time between trials to permit heat to dissipate from the windings or rotor
to prevent overheating. Starting currents are several times running currents, and heating varies as the
square of the current.
When checks are satisfactory, make permanent connections.
2.6 ! WARNING
The frames and other metal exteriors of motors should be grounded to limit their potential to ground in
the event of accidental connection or contact between live electrical parts and the metal exteriors.
Explosion-proof motors should be grounded through the conduit box.
2.7 ! WARNING
Before starting motor, remove all unused shaft keys and loose rotating parts to prevent them from flying
off.
2.8 Start motor and operate at minimum load prior to filling the tank or basin. Look for any unusual condition.
The motor should run smoothly with little noise. If the motor should fail to start and produces a decided
hum, it may be that the load is too great for the motor or that it has been connected improperly. Shut
down immediately and investigate for trouble.
If motor is totally enclosed fan--cooled or non--ventilated, it is recommended that condensation drain
plugs be removed. These are located in the lower portions of the end shields or frame. Explosion--proof
motors do not have any plugs to remove.
SECTION 3 -- MOTOR MAINTENANCE AND STORAGE
3.1 To insure continued reliable operation of electric motors, the following basic rule applies: KEEP THE MO-
TOR CLEAN, DRY AND PROPERLY LUBRICATED. Motors should be inspected at regular intervals
with frequency depending upon the type of motor and the service.
Windings should be cleaned by blowing or vacuuming dust from them. Ventilating openings must be kept clear. If
dust and dirt is to be removed with a vacuum cleaner, nozzles should be of the non--metallic type. Deposits of dirt
and grease may be removed by using a commercially available low volatile solvent. DO NOT USE GASOLINE OR
OTHER FLAMMABLE SOLVENTS.
3.2 Terminal connections and assembly hardware may loosen from vibration during service and should be
tightened.
3.3 Insulation resistance should be checked at operative temperature and humidity conditions to determine
possible deterioration of insulation due to excessive moisture or extremes in operating environment. If
wide variations are detected, motors should be reconditioned.
3.4 LUBRICATION - Prior to shipment, motor bearings are greased with the proper amount and grade of lubri-
cant by the motor vendor. Motors equipped with sealed bearings require no additional lubrication. Motors
equipped with open or shielded bearings require lubrication periodically. It is recommended that the
bearing lubricant be inspected at the end of two or three months to determine the necessity to add
grease. Frequency of re--lubrication will vary with particular application and can be determined with peri-
odic inspection. The following table offers suggested re--lubrication frequency based on general operat-
ing conditions.

REVISION
1978
DATE 3--1--78
INST. NO. IT--1488
D
LIGHTNIN
MIXERS AND AERATORS
LIGHTNIN
Type of HP Re--Lubrication
Service General Conditions Range Frequency
Standard Eight hours per day, normal or light 11/2 -- 71/2 3 years
loading, clean, 100° F Maximum Ambient 10 -- 40 1 year
50 -- 150 6 months
200 -- 350 3 months
Severe Twenty--four hours per day operation or 11/2 -- 71/2 11/2 years
shock loading, vibration or in dirt or 10 -- 40 6 months
dust @ 40 -- 50° C (100 -- 120° F) 50 -- 150 3 months
Ambient 200 -- 350 1 1/2 months
Very Severe Heavy shock or vibration, dirt or dust, 11/2 -- 71/2 6 months
high ambient temperature 10 -- 40 3 months
50 -- 150 2 months
200 -- 350 1 month
All motors over 1800 RPM should be checked for re--lubrication at three month intervals.
! CAUTION: The greatest cause of bearing failure is over--greasing rather than under--greasing.
3.5 TYPE OF LUBRICANT
a . Check the motor nameplate to determine whether a specific grease has been recommended
by the motor manufacturer. Use that grease, if possible.
b . Lacking a specific grease recommendation, refer to the following.
For best results, grease should be compounded from a lithium soap base and a good grade
of petroleum oil. It should be of No. 2 consistency and stabilized against oxidation. Most lead-
ing oil companies have special bearing greases that are satisfactory.
3.6 LUBRICATION PROCEDURE
a . Motors equipped with grease fittings or plugs:
1 . Motor should be warm and disconnected from power source.
2 . Clean the exterior of the motor.
3 . Remove all pipe plugs and relief plugs.
(For some TEFC motors, it may be necessary to remove caps on fan cover and hexagonal rod
through fan cover to gain access to grease plugs and relief plugs)
4 . Using a low pressure, hand operated grease gun, pump in clean grease until it appears at the
relief hole or along motor shaft.
5 . Run the motor with the plugs removed for approximately two (2) hours.
6 . Stop the motor and wipe away excess grease at relief or along shaft and replace plugs.
b . Motors not having pipe plugs or grease fittings in bearing housings can be re--lubricated by
removing end shields from motor, cleaning grease cavities and refilling cavities to capacity
with new grease.
! CAUTION: Bearings and grease must be kept free of dirt.
c . Oil lubricated motors -- (sleeve bearing equipped) Oil should be added annually after 3 years
of normal or 1 year of heavy duty service. Electric motor or SAE 20 oil should be used.
For more specific maintenance and lubrication instructions, contact your local motor
manufacturer representative.

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