08/20/2012

CONDUMEX, INC.
2590 114TH STREET
SUITE 200
GRAND PRAIRIE, TX 75050
USA

Purchase Order #:
Sales Order #:
Line Item:

184559
0001532628
000030

Please note this documentation has been submitted for informational purposes only, and the order
has been released to production in accordance with the design as detailed per the enclosed
documentation.

Submitted Date: 08/20/2012

Print Quantity: 01

Document Name

Document
Number

Safety Check List

Installation Drawing
Machine Assembly Drawing
General Instructions
Recommended Bolting Torques
Flange and Gasket Proportions
Operation & Maintenance Instruction
R510 Impeller Assembly Drawing
Motor Maintenance Instructions
Sales Offices

IT-2144
1532628000030-A
1532628010-B
R281754-F
IT-850
DS-E-571
R281754-E
1532628010-C
IT-1488
IT-3839

Thank You.
For Questions please call: Manuel Nagano
SPX Process Equipment Mexico
Phone #: 55-5243-4218
Email: edgar.aguilar@spx.com

Document
Revision
G

D
P

MIXER MANUAL - INSTRUCTIONS

INSTALLATION
OPERATION
MAINTENANCE

Ship To:
Customer:
PO Number:
Model:
Order Number:
Line Number:

CONDUMEX, INC.
CONDUMEX, INC.
184559
Lightnin Mixer Model 4VTE100
0001532628
000030

http://www.lightninmixers.com

MIXER MANUAL - INSTRUCTIONS

LIGHTNIN SALES ORDER 0001532628
LIGHTNIN LINE ITEM 000030
Table of Contents
TITLE

DOCUMENT NO.

Safety Check List

Installation Drawing
Machine Assembly Drawing
General Instructions
Recommended Bolting Torques
Flange and Gasket Proportions
Operation & Maintenance Instruction
R510 Impeller Assembly Drawing
Motor Maintenance Instructions
Sales Offices

IT-2144
1532628000030-A
1532628010-B
R281754-F
IT-850
DS-E-571
R281754-E
1532628010-C
IT-1488
IT-3839

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.
CAUTION - Signals unsafe practices or hazards which could cause minor personal injury or property damage.
WARNING - Signals unsafe practices or hazards which could cause severe personal injury or death.
DANGER - 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.

EXAMPLES:

Revision
H

Date:

5/9/1986

Revised:

9/9/2011

INST. No. IT-2144

COPYRIGHT 2011 SPX CORPORATION

Page 1 OF 4

SAFETY CHECK LIST

IMPORTANT WARNINGS
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.
1.

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.

2.

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.

3.

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 .

4.

DO NOT operate shaft sealing devices at temperatures higher than those specified in the manual or on the
nameplates.

5.

DO NOT service the mixer until you have followed your "Control of Hazardous Energy Sources" (lockout, tagout
procedure) as required by OSHA.

6.

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.

7.

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.

8.

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.

9.

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.

10.

WARNING: Never attempt to move or adjust a mixer while it is running.

Revision
H

Date:

5/9/1986

Revised:

9/9/2011

INST. No. IT-2144

COPYRIGHT 2011 SPX CORPORATION

Page 2 OF 4

SAFETY CHECK LIST, cont'd.

IMPORTANT WARNINGS, cont'd.
11.

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.

12.

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.

13.

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.

14.

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.

15.

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.

16.

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.

17.

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.

Revision
H

Date:

5/9/1986

Revised:

9/9/2011

INST. No. IT-2144

COPYRIGHT 2011 SPX CORPORATION

Page 3 OF 4

CE COMPLIANCE
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
Noise: 2000/14/EC

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.

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.

NOISE LEVELS
SOUND PRESSURE LEVELS
Portable Series: ECL, EV - maximum 80 dBA @ 1 meter.
Heavy Series: S10, 70/80, 500/600 - maximum 85 dBA @ 1 meter.

PATENTS
THIS PRODUCT MAY BE COVERED BY ONE OR MORE OF THE FOLLOWING U.S. PATENTS:
5152606
5152934
5203630
5344235
5368390
5470152
5480228

5501523
5511881
5568975
5779359
5925293
5988604
6158722

6517233
6517246
6742923
6746147
6789314
6796707
6796770

6860474
6877750
6986507
7001063
7056095
7114844
7168641

7168848
7168849
7278799
7328809
7329065
7331704
7384551

7387431
7407322
7473025
7481573
7488137
7507028
7547135

7550120
7572112
7726946
7753215
7874719

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.

Revision
H

Date:

5/9/1986

Revised:

9/9/2011

INST. No. IT-2144

COPYRIGHT 2011 SPX CORPORATION

Page 4 OF 4

GENERAL INSTRUCTIONS FOR MODEL VTE

This LIGHTNIN9 Agitator is a piece of precision machinery of the highest quality. It is designed to operate
satisfactorily under all the conditions normally encountered.
With proper care, this LIGHTNIN Agitator will give years of trouble free service. If you should have any questions
regarding its operation, that are not answered in this manual, contact your authorized LIGHTNIN Mixer
Representative.
WARNING: Before attempting any maintenance or service on this machine, it is essential that appropriate safety
precautions be taken, including but not limited to locking out the power source and restraining both input and output
shafts of the unit from unexpected rotation. Even with the power source locked out, it is possible for a mixer shaft
(and thus all connected machinery) to be caused to rotate by the actions of the media being mixed, or other external
factors. Thus, it is necessary to ensure that the shafts are restrained from rotation or other movement while the
unit is being serviced. In addition to restraining the shaft from unexpected rotation, it is also essential that any locked
in torque loading (or other sources of stored energy) in the system be released or positively restrained before
attempting any service.
FAILURE TO BOTH LOCKOUT AND RESTRAIN THE MACHINE FROM UNEXPECTED MOVEMENT BEFORE
SERVICE OR MAINTENANCE ACTIONS CAN RESULT IN SERIOUS INJURY OR DEATH.
WARNING: EYE PROTECTION MUST BE WORN AT ALL TIMES WHILE SERVICING THIS AGITATOR.

SECTION 1 -- INITIAL INSPECTION, SHIPPING ARRANGEMENTS

1.1 As soon as the unit is uncrated, check for possible shipping damage. Report any damage immediately to the
carrier and our factory. DO NOT proceed with the servicing or installation of any unit with shipping damage
unless so directed by the factory.
1.2 The agitator is shipped as a complete unit, whenever possible, ready to install after unbolting from the shipping
skid. Any grease lubricated bearings in the unit have been serviced at the factory.
Various small components, such as impeller hardware, plugs, etc. are often packaged separately to avoid
damage during assembly or to insure that the unit remains sealed and properly preserved during shipment.
These components should be identified and assembled to the unit.
If shipping restrictions limit overall size, drives and/or motors may be shipped disassembled.
Factory installed V--belt drives are accurately aligned and adjusted, but should be rechecked in case
misalignment occured during shipping and handling. Refer to Section 2 of the Operating Instructions for
complete information and alignment of V--belts.
1.3 SHIPPING PROTECTION
All units are treated with corrosion inhibitors for protection during shipment and possible short term storage.
a . External Steel Surfaces -- All external steel surfaces not protected with permanent coatings are covered
with a rust preventative that is easily removed with kerosene or a similar solvent. All preservatives must
be removed before checking shaft alignments. Do not remove any wrappings or rotate the shafts until the
unit is ready for operation.
b . Protection Period -- Factory applied inhibitors will protect units from internal corrosion for periods up to (1)
year if stored indoors in clean, temperature controlled, dry surroundings. Review Section 4 of this manual
carefully if the unit is to be stored in conditions other than those described above prior to installation.
c . Storage -- This equipment is protected with corrosion inhibitors and preventatives before shipping and may
be stored indoors for a period of ONE YEAR after the time it leaves the factory. For longer storage periods,
or if the protective treatments have been disturbed in any way, see Section 4 of these instructions for
methods of reapplying the preservative treatments.
In the event that outdoor storage is necessary, the unit must be protected from the elements and extreme
temperature fluctuations. Constant temperature and dry ambient conditions will afford the best storage
results. Contact the factory if extended outdoor storage is required. Unprotected outdoor storage is NOT
PERMITTED.

REVISION

DATE 11--1--05
REVISED

LIGHTNIN

MIXERS AND AERATORS

LIGHTNIN
2005

INST. NO. R281754--F

PAGE 1 OF 7

SECTION 2 -- INSTALLATION
2.1 Refer to the Installation Drawing for:
a . Proper agitator location and off bottom distance.
b . Design loads, mounting details.
c . A minimum clearance of 3 is required around totally enclosed fan cooled motors to insure adequate motor
ventilation. The motor must be wired for the rotation as indicated by the rotation arrow.
2.2 The Impeller Instructions list the minimum opening required to pass the impeller into the tank. The impeller type
and diameter is listed on the installation drawing.
2.3 The unit must be installed by accomplishing each of the following actions in the order prescribed:
CAUTION: NEVER use the motor eyebolts to lift or support the assembled agitator. DO NOT hoist, handle
or rest the unit on any shaft extension.
a . Remove safety coverplates (320 & 322).
b . Support the mixer through openings in the fixed (120) bearing member and sling between the motor feet
and motor bracket (108) and mount the unit on the mouting flange (see Figure 1).
SLING

SLING
CAUTION: When taking up slack
on lifting cables, avoid sudden
impact loading on the lifting
devices.

Figure 1
c . Install safety coverplates (320 & 322).
d . Assemble the impeller to the mixer shaft. Refer to the impeller assembly drawing R281754--C. Make sure
the impeller hardware is tightened to the specific torques in the impeller instructions. A torque wrench must
be used to tighten all bolts to their specified torque values. Tighten all other hardware to the values shown
in IT--850. All bolts should be retightened 12 hours after assembly, and at each scheduled shut down
thereafter.
e . Motor Power Connections:
In order to insure proper functioning of the unit, it is essential that the motor maintenance instructions in
this manual and the nameplate be reviewed before connecting to power source.
2.4 It is the customers responsibility to touch up any paint damage incurred during installation and/or storage.

SECTION 3 -- ROLLER BEARING LUBRICATION

3.1 REGREASABLE BEARINGS
Open type bearings are initially lubricated at our factory. Housings are provided with grease fittings and
automatic relief fittings or relief plugs when required. Lithium based NLGI #2 consistency grease is used to
lubricate all open bearings.

REVISION

DATE 11--1--05
REVISED

LIGHTNIN

MIXERS AND AERATORS

LIGHTNIN
2005

INST. NO. R281754--F

PAGE 2 OF 7

Lithium base grease is a multi--purpose grease most ideally suited to covering the broad range of operating
conditions bearings are subjected to. It offers good resistance to water and remains stable through a wide
range of varying mechanical, oxidation and temperature conditions.
With the exception of polyurea greases, as noted below, only lithium greases must be used. Without taking
the bearing apart and throughly cleaning it, it is virtually impossible to remove all of the lithium grease which
was installed at the factory, and thus, undesirable cross contamination is unavoidable. Many greases are
not compatible with one another and cross contamination can, therefore, create serious problems. Since it
is not practical to present a complete compatability chart in this manual, it is best not to mix grease.
Greases made with polyurea complex thickeners are compatible with most greases, including lithium
thickened greases. Polyurea greases are generally higher in load capacity and may be used where an EP
grease is required.
3.2 REGREASING PROCEDURE
a . Installed bearings:
Before regreasing be sure to clean all grease fittings and purge ports thoroughly to prevent contamination
of the coupling during the regreasing operation. Make sure the recommended type of grease has been
loaded into the grease gun and that it is clean and free of contamination. Refer to the Assembly Drawing
for location of the grease and purge ports.
Use only one of the approved greases listed herein, NLGI Grade 2, when regreasing the couplings. The
required regreasing interval is dependant upon operating temperature of the coupling. At each
regreasing, the coupling should be checked for signs of leakage. Such leakage will greatly shorten the
required lubrication interval and thus the coupling seals must be maintained to prevent leakage.
Grease should be added to the coupling until fresh, clean grease is observed to flow from the purge port.
Do not stop pumping grease at the first sign of grease in the purge port. It is important that the new grease
replace as much of the old, worn grease as possible in order to insure that maximum coupling life is
attained. Be sure to wipe away any excess grease and replace and safety guards and covers which may
have been removed after completion of the regreasing operation.
b . Uninstalled bearings:
If a bearing is removed from the shaft assembly, it should be cleaned thoroughly with kerosene or a similar
solvent until all old grease and foreign matter is removed. Allow to air dry. DO NOT SPIN DRY BEARINGS.
Dip bearing in a light lubricating oil for protection if it is not to be regreased immediately.
Regrease the bearing by forcing grease between the rolling elements and the inner and outer races.
Thoroughly work the grease in from both sides of the bearing to insure that it is fully packed.
Before reinstalling the bearing, thoroughly clean the housing and coat it with fresh bearing grease. In
addition, pack the cavity below the bearing with fresh bearing grease of the same type. Replace all covers
and add lubricant through the fitting to purge the housing of air pockets and insure that the channels are
full.

REVISION

DATE 11--1--05
REVISED

LIGHTNIN

MIXERS AND AERATORS

LIGHTNIN
2005

INST. NO. R281754--F

PAGE 3 OF 7

3.3 APPROVED GREASES

Greases of various types may be used in LIGHTNIN units, depending on the specific operating conditions
to which the units are being subjected. Only greases selected from those identified in this manual as
Approved Greases may be used in LIGHTNIN units. All products listed in Tables 1 & 2 are compatible with
the original grease used at the factory.
a . Standard Lithium Greases
The greases listed in Table 1 are standard duty products and may be used for all couplings and bearings
in these units. Units shipped from the factory contain a standard lithium grease unless otherwise specified
by the purchaser, thus the factory fill is compatible with any grease listed in Table 1. In general, a standard
lithium grease is adequate for most applications.
b . Medium Duty Lithium EP Greases
For a small cost premium, the greases listed in Table 2 will provide generally longer bearing life and
improved system reliability. They may be used on any unit. Since these greases are lithium based, they
are also compatible with the products listed in Table 1 and with the original factory grease fill.
c . Heavy Duty EP Greases
For a slightly higher cost premium than the medium duty greases defined above, the heavy duty EP
greases listed in Table 3 can be used in all severe applications to yield longer bearing life and significantly
improved system reliability. They may be used in any unit.
It should be noted that these greases are not fully compatible with some lithium greases and thus any
bearing or coupling in which these products are to be used must be fully purged to eliminate as much of
the lithium product as possible before the unit is placed in service. On special request, units can be
delivered from the factory filled with a heavy duty EP grease.
TABLE 1
APPROVED STANDARD LITHIUM GREASES
MANUFACTURER

PRODUCT

MANUFACTURER

PRODUCT

REXLUBE

AMOCO
CHICAGO, IL

AMOLITH

BEL--RAY CO., INC.

FARMINGDALE, NY

TERMALENE

BP OIL CO.
CLEVELAND, OH

ENERGREASE LS

CASTROL INDUSTRIAL, INC.

CHICAGO, IL

CASTROL EP GREASE

CATO OIL & GREASE CO.

OKLAHOMA CITY, OK

MYSTIK JT

CITGO PETROLEUM CORP.

TULSA, OK

PREMIUM LITHIUM EP

CONOCO, INC.
HOUSTON, TX

SUPER--STA GREASE

CHEVRON U.S.A., INC.

SAN FRANCISCO, CA

DURA--LITH

COOKS INDUSTRIAL LUBRICANTS

LINDEN, NJ

UNIVERSAL GREASE

DRYDEN OIL CO., INC.

BALTIMORE, MD

LITHIUM EP

EXXON CO., U.S.A.

HOUSTON, TX

LIDOK EP

FISK BROTHERS REFINING CO.

LUBRIPLATE DIV. -- NEWARK, NJ

1200

GULF OIL CO.

HOUSTON, TX

GULFCROWN GREASE

HULS AMERICAN, INC.

PISCATAWAY, NJ

PQ 400 SERIES

MOBIL OIL CORP.

EDISON, NJ

MOBILITH AW

NIAGRA LUBRICANT CO.

BUFFALO, NY

EP LITHIUM

PENNWALT CORP., KEYSTONE LUBES

KING OF PRUSSIA, PA

81 EP

PENNZOIL PRODUCTS CO.

HOUSTON, TX

PENNLITH EP

PHILLIPS 66 CO.
BARTLESVILLE, OK

PHILUBE EP

SHELL OIL CO.

HOUSTON, TX

ALVANIA

SUN OIL CO.

PHILADELPHIA, PA

PRESTIGE

TEXACO LUBRICANTS CO.

HOUSTON, TX

REGAL

UNION OIL CO.

UNAX RX

WITCO CORP. -- LUBRIMATIC DIV.

OLATHE, KS

HI--TEMP LC

ZURN CO.
PHILADELPHIA, PA

ZURN GREASE EP

AMERICAN INDUSTRIAL RESEARCH

CORP. -- EAST RUTHERFORD, NJ

REVISION

DATE 11--1--05
REVISED

LIGHTNIN

MIXERS AND AERATORS

LIGHTNIN
2005

INST. NO. R281754--F

PAGE 4 OF 7

TABLE 2
APPROVED MEDIUM DUTY EP LITHIUM GREASES
MANUFACTURER

TIMKEN OK LOAD

PRODUCT

AMOCO
CHICAGO, IL

40

AMOLITH EP

MOBIL OIL CORP.

EDISON, NJ

40

MOBILUX EP

TEXACO LUBRICANTS CO.

HOUSTON, TX

40

MULTIFAK EP

CHEVRON U.S.A., INC.

SAN FRANCISCO, CA

40

DURA--LITH EP

FALK CORP.
MILWAUKEE, WI

50

LTG

GULF OIL CO.

HOUSTON, TX

40

GULFCROWN EP

TABLE 3
APPROVED HEAVY DUTY EP GREASES
MANUFACTURER

TIMKEN OK LOAD

PRODUCT

CHEVRON U.S.A., INC.

SAN FRANCISCO, CA

60

POLYUREA EP

SHELL OIL CO.

HOUSTON, TX

60

ALVANIA EP

PENNWALT CORP., KEYSTONE LUBES

KING OF PRUSSIA, PA

75

KEYSTONE EP

3.4 REGREASING INTERVALS

Open type bearings require fresh lubricant at regular intervals. The frequency of relubrication depends on:
a . Presence of excessive moisture.
b . Extent of atmospheric contamination.
c . Variations in ambient temperature.
d . Bearing operating temperatures.
TABLE 4
GREASED COMPONENT RELUBRICATION SCHEDULE
TYPE OF
GREASE

BEARING OPERATING TEMPERATURE

UNDER
160 F

160--185 F

186--200 F

STANDARD
NLGI #2

6 MOS.

5 MOS.

4 MOS.

NLGI #2 (EP)
EXTREME
PRESSURE

3 MOS.

2 MOS.

1 MO.

NLGI -- NATIONAL LUBRICATING GREASE INSTITUTE

For most applications, the regreasing intervals specified in Table 4 are adequate. Bearings operating at high
temperatures and/or bearings lubricated with extreme pressure (EP) grease require fresh grease at more
frequent intervals.

REVISION

DATE 11--1--05
REVISED

LIGHTNIN

MIXERS AND AERATORS

LIGHTNIN
2005

INST. NO. R281754--F

PAGE 5 OF 7

Periodic temperature checks should be made to establish lubrication intervals and to detect potential
problems that can result from overheating. Bearing operating temperatures can be determined with a surface
pyrometer or thermometer placed on the bearing housing wall adjacent to the bearing. Add 10 F to the actual
reading to compensate for heat transfer loss.

SECTION 4 -- STORAGE
LIGHTNIN Agitators, 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, high humidity, or both.
Properly treated and located in clean, dry surroundings, inactive equipment can be successfully stored without
damage due to corrosive attack. REVIEW and FOLLOW all instructions in this section.
FAILURE TO PROPERLY STORE AND PROTECT EQUIPMENT AS OUTLINED MAY VOID ANY WARRANTY,
EXPRESSED OR IMPLIED.
4.1 STORAGE CONSIDERATIONS
LIGHTNIN Agitators, 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, high
humidity, or both. Properly treated and located in clean, dry surroundings, inactive equipment can be
successfully stored for up to one year without damage from corrosive attack.
Electric motors or other prime movers are not prepared for indoor storage beyond the periods shown below
by LIGHTNIN. Outdoor storage of electric motors is not recommended by any motor manufacturer. For
storage periods beyond those shown below, refer to motor maintenance instructions furnished with this
manual for further details.
4.2 STORAGE OF NEW UNITS
LIGHTNIN Agitators are factory treated with high quality corrosion inhibitors and rust preventatives. With
reasonable care at the site, the products will effectively protect new, uninstalled units from corrosion due to
water and water vapor, for up to one year, depending on how the unit is stored. Outdoor, unprotected storage
is not permitted under any circumstances unless the unit has been specifically prepared for such storage
at the factory prior to shipment.
a . Uninstalled, Protected Storage
Installed, Inoperative Units
Installed, Operative Units
Depending on the conditions under which a new unit which has not been installed is stored, the initial
factory applied corrosion protection treatment will last up to one year. Actual preservation periods, as a
function of storage conditions are defined in Table 5.
TABLE 5
CORROSION PROTECTION PERIODS
PROTECTION PERIOD, MONTHS

STORAGE CONDITIONS

REVISION

INITIAL

PERIODIC INSPECTION

INDOORS IN A DRY AMBIENT

ATMOSPHERE WITH CONTROLLED
TEMPERATURES

12

12

INDOORS IN A DRY AMBIENT

ATMOSPHERE WITHOUT TEMPERATURE
CONTROL

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
12 INCHES ABOVE GROUND LEVEL TO REDUCE
MOISTURE PICKUP.

DATE 11--1--05
REVISED

LIGHTNIN

MIXERS AND AERATORS

LIGHTNIN
2005

INST. NO. R281754--F

PAGE 6 OF 7

b . Periodic Inspection
All protective coatings and wrappings must be maintained in good condition. Stored units should be
visually inspected periodically to insure that the factory wrappings and coatings are intact. If factory
wrappings and coatings are accidentally removed or damaged, reapply them over the exposed areas.
c . Refer to electric motor maintenance instructions furnished with this manual for further details on
represervation of the electric motor.
4.3 STORAGE OF DEACTIVATED UNITS
Under normal circumstances, units that have been in service, but will be idle less than 3 months, must be
run for at least 15 minutes every week, to redistribute grease, and receive regular maintenance. If this
procedure is followed carefully, such units do not require represervation.
a . Cover units stored outdoors with waterproof covering, allowing for free air circulation.
b . Periodic Inspection
All protective coatings and wrappings must be maintained in good condition. Stored units should be
visually inspected periodically to insure that the factory wrappings and coatings are intact. If factory
wrappings and coatings are accidentally removed or damaged, reapply them over the exposed areas.
c . Refer to electric motor maintenance instructions furnished with this manual for further details on
represervation of the electric motor.
4.4 START--UP PREPARATION
When a unit is removed from storage, perform the following steps before placing the unit in service:
a . Remove all wrappings and coverings.
b . Service the unit with lubricants as defined in Section 3.
c . Check shafts for free rotation.
d . Install all safety guards.

REVISION

DATE 11--1--05
REVISED

LIGHTNIN

MIXERS AND AERATORS

LIGHTNIN
2005

INST. NO. R281754--F

PAGE 7 OF 7

LIGHTNIN
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.
Recommended torques for tightening ANSI bolts and screws on LIGHTNIN Mixers and Aerators and their mounting structures are listed below 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. 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 the table. 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.

RECOMMENDED TIGHTENING TORQUES FOR COMMERCIAL

GRADE STEEL, GR5, 304 AND 316 STAINLESS STEEL (1) (2)
TIGHTENING TORQUES
(FT-LBS) (4)
GRADE 2, 3 OR
304/316 SS BOLTS
LUBRICATED

TIGHTENING TORQUES
(FT-LBS) (4)
GRADE 5
BOLTS
LUBRICATED

/4 20

4.6

7.2

/16 18

9.6

15

/8 16

17

26

27

42

/2 13

41

64

/16 12

60

92

83

128

/4 10

120 (3)

226

/8 9

142 (3)

365

1 8

212

547

301

675 (3)

425

952

557

1249

739

1657

754 (3)

1600 (3)

2 4 /2

1134

2406

1659

3519

2 /2 4

2269

4813

BOLT
THREAD
SIZE
1

/16 14

/8 11

1 /8 7
1 /4 7
1 /8 6
1 /2 6
1 /4 5
_

2 /4 4 /2
1

MARKING
GRADE

STEEL SAE GRADE

MARKING REFERENCE
GUIDE
(2)
SAE GRADES
0, 1 AND 2

NO MARK

SAE GRADE 3

SAE GRADE 5

ALL SOCKET
HEAD CAP SCREWS
SAE GRADE 5

(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 MANUFACTURERS 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
H

DATE 2-1-85
REVISED 12-08-11

LIGHTNIN
MIXERS AND AERATORS

LIGHTNIN
2008

INST. NO. IT-850

PAGE 1 OF 1

LIGHTNIN
SALES DATA BOOK

SEC. 14

PAGE 3.00

DATE 52097

FLANGE IS STEEL.
FACING & PARTS EXPOSED
TO TANK CONTENTS ARE
ALLOY SPECIFIED

FLANGE GASKET
NOT FURNISHED
BY LIGHTNIN

NOMINAL 3/16
RAISED FACE

1/16 RAISED FACE

ALLOY
CONSTRUCTION

STEEL
CONSTRUCTION

SEE NOTE 1

GASKET I.D.
B

FLANGE BOLT
HOLE SIZE &
QUANTITY

R.F.
A

RAISED FACE DIA.

GASKET O.D.

B.C.

BOLT CIRCLE DIA.

O.D.

FLANGE O.D.

NOTES:
1. GASKETS MUST BE SEATED BETWEEN THE RAISED FACES OF THE
MIXER AND TANK FLANGE TO EFFECTIVELY SEAL AGAINST PRESSURE,
VAPOR LEAKS AND/OR PRODUCT CONTAMINATION. DIMENSION C
IS THE MINIMUM GASKET CONTACT AREA FOR 150 LB. RAISED FACES.
2. THE STANDARD RING GASKET OUTSIDE DIAMETER EXTENDS TO THE
INNER EGDES OF THE FLANGE BOLTS, WHICH ACT AS CENTERING
DEVICES.
3. FULL FACE ANSI GASKETS ARE GASKETS WHICH EXTEND TO THE O.D.
OF THE FLANGE. FLANGE BOLT CLEARANCE HOLES MUST BE DRILLED
IN THIS FULL FACE TYPE GASKET. SEE TABLE FOR HOLE SIZE AND BOLT CIRCLE.
4. GASKETS CAN ALSO BE MADE EQUAL TO THE RAISED FACE (R.F.) DIAMETER
WITH THE SAME I.D. AS SHOWN IN THE TABLE (DIM. B)
5. GASKET MATERIAL AND THICKNESS ARE THE RESPONSIBILITY OF THE
USER. THEY MUST BE PRODUCT COMPATIBLE AND SUITABLE FOR ALL
SERVICE CONDITIONS.
6. GASKET STYLES OTHER THAN FLAT FACE RING GASKETS ARE AVAILABLE,
BUT ARE USUALLY MORE EXPENSIVE. GASKETS FOR FLANGES WITH
RATINGS IN EXCESS OF 150 LBS. ARE NOT SHOWN DUE TO VARIABLE DESIGN
CONDITIONS ENCOUNTERED. SPECIFICATIONS FOR OTHER THAN RING
GASKETS AND HIGHER PRESSURE DESIGNS CAN BE FOUND IN ASME
UNFIRED PRESSURE VESSEL CODES OR ANSI STANDARDS.
ISO 9001

2
ANSI 150 LB. FLANGE DATA
NOM. O.D.
SIZE

R.F.

B.C.

CERTIFIED

ANSI RING GASKET DATA

HOLE
QUAN.

HOLE
DIA.

A
(O.D.)

B
(I.D.)

WIDTH

C
MIN.

10.0

7.31

8.50

.88

7.750

5.562

1.094

11.0

8.50

9.50

.88

8.750

6.625

1.062

.94

13.5 10.62 11.75

.88

11.000

8.625

1.188

1.00

10

16.0 12.75 14.25

12

1.00

13.375 10.750

1.312

1.00

12

19.0 15.00 17.00

12

1.00

16.125 12.750

1.688

1.12

14

21.0 16.25 18.75

12

1.13

17.750 14.000

1.875

1.12

16

23.5 18.50 21.25

16

1.13

20.250 16.000

2.125

1.25

18

25.0 21.00 22.75

16

1.25

21.625 18.000

1.812

1.50

20

27.5 23.00 25.00

20

1.25

23.875 20.000

1.937

1.50

24

32.0 27.25 29.50

20

1.38

28.250 24.000

2.125

1.62

Certified By

.88

Date

C LIGHTNIN

1985
ALL EQUIPMENT DESIGN AND APPLICATION DATA SHOWN
HEREIN AND RELATED KNOW-HOW IS CONFIDENTIAL AND
THE PROPERTY OF THE LIGHTNIN GROUP OF COMPANIES.
NO USE OR DISCLOSURE THEREOF MAY BE MADE WITHOUT
OUR WRITTEN PERMISSION.

MIXERS AND AERATORS

OUTLINE DIMENSIONS IN INCHES

150 LB. ANSI STANDARD

FLANGE & GASKET
PROPORTIONS
DRAWING NO. DSE571B

OPERATING AND MAINTENANCE INSTRUCTIONS

FOR MODEL VTE
This LIGHTNIN9 Agitator is a piece of precision machinery of the highest quality. It is designed to operate
satisfactorily under all the conditions normally encountered.
With proper care, this LIGHTNIN Agitator will give years of trouble free service. If you should have any questions
regarding its operation, that are not answered in this manual, contact your authorized LIGHTNIN Mixer
Representative.
WARNING: Before attempting any maintenance or service on this machine, it is essential that appropriate safety
precautions be taken, including but not limited to locking out the power source and restraining both input and output
shafts of the unit from unexpected rotation. Even with the power source locked out, it is possible for a mixer shaft
(and thus all connected machinery) to be caused to rotate by the actions of the media being mixed, or other external
factors. Thus, it is necessary to ensure that the shafts are restrained from rotation or other movement while the
unit is being serviced. In addition to restraining the shaft from unexpected rotation, it is also essential that any locked
in torque loading (or other sources of stored energy) in the system be released or positively restrained before
attempting any service.
FAILURE TO BOTH LOCKOUT AND RESTRAIN THE MACHINE FROM UNEXPECTED MOVEMENT BEFORE
SERVICE OR MAINTENANCE ACTIONS CAN RESULT IN SERIOUS INJURY OR DEATH.
WARNING: EYE PROTECTION MUST BE WORN AT ALL TIMES WHILE SERVICING THIS MIXER.

SECTION 1 -- OPERATING THE MIXER

1.1 LIGHTNIN Agitators are designed to operate continuously under all standard conditions, in air, at low liquid
levels, and at normal levels. It is not good practice, however, to operate continuously when extreme vortexing
or surging occurs. Before operating the unit, check all bolts and other fasteners to make sure that they are
tight.
At the end of the mixing cycle, it is good practice to turn off the mixer before the tank has been drained to
a level which will result in excessive splashing.
Check all fasteners and mounting hardware for tightness 12 hours after assembly, and at each scheduled
shut down thereafter. Carefully examine the gear drive and associated components for any signs of leakage.
Stop the gear drive, allow all rotation to cease, and recheck the oil level. Reservice the gear drive as required.
If excessive leakage is observed, the cause must be established and corrected before continuing to operate
the unit.
Dirt on the motor case acts as an insulator and will prevent proper cooling. Always keep the motor clean. Refer
to Motor Maintenance Instructions furnished with this manual for further details.

SECTION 2 -- VEE BELT ALIGNMENT AND MAINTENANCE

2.1 If the drive was not completely assembled at the factory, proceed as follows:
a . Install the motor and/or belt guard (with cover removed) if not previously assembled.
b . Make sure the motor shaft is parallel with the agitator shaft.
NOTE: Use U--shaped shims under the motor feet to correct any motor shaft to agitator shaft parallelism
so as to provide proper support to the motor feet.
c . Install the sheaves. If the drive or driven sheave is furnished with a taper bushing, refer to the tag furnished
with the unit, and install the flanged side of the bushing facing in the direction indicated.
d . Line up the sheaves so that the corresponding belt grooves in each sheave are in alignment. Use a straight
edge to help obtain proper alignment.
e . Do not force belts over the sheaves, lower the motor by backing off the nuts on the adjustable motor support
arm (110).
2.2 Standard LIGHTNIN units are equipped with V--belts having one of the cross sections shown in Table 1. To
ensure that the V--belts are properly tensioned, determine the type V--belt supplied and refer to the
appropriate deflection force table. V--belt identifiers are located on the V--belt component.

REVISION

DATE 11--1--05
REVISED

LIGHTNIN

MIXERS AND AERATORS

LIGHTNIN
2005

INST. NO. R281754--E

PAGE 1 OF 7

TABLE 1 -- V--BELT CROSS SECTION

A
AX

B
BX

C
CX

3V
3VX

5V
5VX

8V
----

a . Seat the belts in the sheave grooves and take up the slack by raising the motor support with the adjustable
motor support arm (110) until a SLIGHT BOW appears on the slack side of the drive while the unit is running
under full load.
b . Stop the drive and apply the proper tension to the belts following the steps outlined. Refer to Figure 1.
c . Measure the belt span.
d . Using a spring scale or weight, apply a force to any ONE of the belts in the center of the span. The force
should be perpendicular to the span and toward the center of the drive. Measure the force required to
deflect any one of the belts 1/64 inch for every inch of span length. For example, the deflection for a 32
inch span would be 1/64 inch multiplied by 32, or 1/2 inch.
e . Tension new drives at the maximum deflection force recommended (see Table 2 or 3). Check the tension
at least two times during the first days operation as there will normally be a rapid decrease in belt tension
until the belts have run in.
BELT SPAN
DEFLECTION

FORCE

FIGURE 1
TABLE 2
SMALL
SHEAVE
DIA.
3.0 -- 3.6
3.8 -- 4.8
5.0 -- 7.0
3.4 -- 4.2
4.4 -- 5.6
5.8 -- 8.6
7.0 -- 9.4
9.6 -- 16.0

TABLE 3

DEFLECTION
BELT
BELT
CROSS FORCE -- LBS. CROSS
SECTION
SECTION
MIN.
MAX.
A

3
3--1/2
4

4--1/4
5
5--1/2

4
5--1/8
6--3/8

5--1/2
7--1/8
8--3/4

11--1/4 14--3/8
14--1/8 18--1/2

DEFLECTION
FORCE -- LBS.
MIN.

MAX.

AX

3--7/8
4--1/2
5

5--1/2
6--1/4
6--7/8

BX

5--3/4
6--1/2
7--3/8

8
9--1/8
10--1/8

CX

13--3/4
15--1/4

17--7/8
20--1/4

SMALL
SHEAVE
DIA.

DEFLECTION
BELT
BELT
CROSS FORCE -- LBS. CROSS
SECTION
SECTION
MIN.
MAX.

DEFLECTION
FORCE -- LBS.
MIN.

MAX.
5--1/2
7--7/8

2.65 -- 3.65
4.12 -- 6.90

3V

3--1/2
4--3/4

5
6--7/8

3VX

3--7/8
5--1/4

4.40 -- 6.70
7.1 -- 10.9
11.8 -- 16.0

5V

--10--1/2 15--3/4
13
19--1/2

5VX

10
15
12--7/8 18--3/4
15
22

12.5 -- 17.0
18.0 -- 22.4

8V

27
30

40--1/2
45

---

--

---

2.3 Check the tension periodically after the first days operation and keep tension in recommended area. The
correct operating tension for a V--belt drive is the lowest tension at which the belts will not slip under peak load
conditions.
2.4 Do not use belt dressing if belts are slipping, clean with warm, soapy water and readjust tension.
2.5 When it becomes necessary to replace belts, install a complete new matched set. New unstretched belts will
be shorter in length than the old belts and will, therefore, carry a greater portion of the load.

SECTION 3 -- REMOVING BEARINGS

3.1 Shaft bearings and components can be removed and replaced without lowering the liquid level in the chest
by tightly compressing the packing during the replacement procedure.
REVISION

DATE 11--1--05
REVISED

LIGHTNIN

MIXERS AND AERATORS

LIGHTNIN
2005

INST. NO. R281754--E

PAGE 2 OF 7

3.2 PREPARATION
a . Remove the following components from the agitator:
1 . Belt guard (184) and V--belts (183).
2 . Remove the driven sheave (182).
3.3 INBOARD BEARING REMOVAL (REFER TO FIGURE 3)
a . If both inboard and outboard bearings are to be replaced, the inboard bearing is to be removed from its
housing first to allow the shaft to be supported by the slinger collar (280).
b . To free the bearing from the tapered adapter sleeve:
1 . Remove three (3) jacking screws (281) from their storage position and install in the slinger collar (280)
so that they are 1/4 inch from the locknut (226).
2 . Mark a line along the inboard face of the slinger collar (280) for repositioning reference.
3 . Slide the collar (280) against the packing gland adjusting nuts (137).
4 . With a brass bar and mallet, tap the locknut until the tapered adapter sleeve (224) breaks free of the
bearing taper.
c . Re--position the slinger collar (280) at the scribed line and tighten the set screws (282).
d . Remove the 4 jacking screws (285) from storage position and insert through the outer set of clearance holes
in the slinger collar (280) flange.
e . Remove the plug screws (283) and gaskets (284) and thread the jacking screws (285) into the plug screw
holes.
f . To remove the bearing from the bearing housing:
1 . Unbolt the inboard oil seal retainer (133) and slide outboard on the shaft.
2 . Tighten the inner jacking screws (281) as far as they will go to partially push the bearing from the
housing.
3 . Back off the inner jacking screws (281).
4 . Remove the slinger collar set screws (282).
5 . Tighten the outer jacking screws (285) until they contact the bearing (123).
6 . Readjust the inner jacking screws (281) until they seat against the locknut (226).
7 . Tighten the outer jacking screws (285) evenly to simultaneously push the bearing out of the housing
and seat the slinger collar (280) in the housing bore.
CAUTION: The collar must seat in the housing bore before the bearing is completely free of the housing.

REVISION

DATE 11--1--05
REVISED

LIGHTNIN

MIXERS AND AERATORS

LIGHTNIN
2005

INST. NO. R281754--E

PAGE 3 OF 7

216
285
281
117

BEARING REMOVAL POSITION

OUTBOARD
INBOARD
OPERATING POSITION
115
224
133
123
STORAGE
POSITION
281 & 285

226
225
301

120

283
122

284

280
282

FIGURE 3 -- INBOARD BEARING ASSEMBLY DETAIL

3.4 OUTBOARD BEARING REMOVAL (REFER TO FIGURE 4)
a . To loosen the outboard bearing:
1 . Wrap the outboard shaft extension with tape and coat the tape with grease to protect the oil seal lips
during removal.
2 . Remove the outboard oil seal retainer (114).
3 . Remove the outboard retaining ring (119).
4 . Back off the locknut (126) 1/4 inch.
5 . Tap the loosened locknut to break the taper fit.
6 . Remove the locknut (126) and slide the tapered adapter sleeve off the shaft.
b . Unbolt the bearing housing (121) from the fixed bearing member (120) by removing the (8) housing bolts
(305).
c . The bearing housing (121) complete with bearings (123) can be removed from the shaft, washed clean and
the bearing replaced if necessary.
3.5 REPLACING BEARINGS
a . Model VTE with agitator shafts 2.5 inch diameter and smaller are furnished with ball bearings which require
standard tightening procedures for tapered adapter sleeve mounting.
b . Model VTE with agitator shafts 3 inch diameter and larger are furnished with spherical roller bearings which
are manufactured with an internal clearance greater than required in actual service. Precise measurement
and tightening is required to expand the inner race and obtain the proper operating internal clearance.
c . Prior to installing spherical roller bearings:
1 . Measure the unmounted radial clearance by standing the bearing upright on its outer race. Rotate the
inner race to uniformly seat the rollers in the raceways.
2 . Measure the clearance between the outer race and the uppermost set of rollers by inserting
progressively thicker feeler blades. Slide the feeler blades straight in over the length of the rollers, DO
NOT roll the blade across the rollers. Select the thickness that most closely approaches line to line
contact without excessive drag. Check opposite set of rollers.
3 . Repeat the measurements at two or three other locations with other sets of rollers. Record the
predominant blade thickness. This is the unmounted radial clearance that must be reduced to the
values in Table 1 during tightening.
REVISION

DATE 11--1--05
REVISED

LIGHTNIN

MIXERS AND AERATORS

LIGHTNIN
2005

INST. NO. R281754--E

PAGE 4 OF 7

d . Slide the inboard bearing components on the shaft in the following order:
1 . Locknut and washer (226), solid adapter sleeve (225) and oil seal (301).
2 . Inboard bearings (123), tapered adapter sleeve (224), retainer gasket (134) and oil seal retainer (133)
with oil seal (115).
e . Slide the outboard bearing locknut and washer (126) and solid adapter sleeve (125) onto shaft. (see
Figure 4)
f . If removed, install the Spirolox retaining ring (300) in the groove on the shaft (117) inboard of the bearing
adapter sleeve.
g . Press the oil seal (127) and outboard bearing into the outboard bearing housing (121). Use the oil seal
retainer (114) to firmly bottom the bearing against the housing shoulder, then remove.
h . Mount and secure the outboard bearing housing (121) to the bearing member (122).
i . Slide the tapered adapter sleeve (124) through the bearing and seat it against the split thrust collar (323).
j . Install the outer retaining ring (119).
k . Insert the solid adapter sleeve (125) through the oil seal (127) and thread the locknut (126) and the adapter
sleeve (124) hand tight.
l . Loosen the packing gland adjusting nuts (137) and readjust finger tight.
m . Rotate the shaft by hand and firmly tap the end of the shaft to help seat the adapter sleeve and squeeze
excess grease from between the rollers and bearing races.
123
121

LOCKNUT
WASHER
TANG

FEELER
BLADES

124

119
115
114
116

300
126
127
125

FIGURE 4 -- OUTBOARD BEARING DETAIL

n . For spherical roller bearings, tighten the locknut (126) with a hammer and drift. Periodically measure the
internal clearance during tightening. Continue tightening until the required reduction and final clearance
listed in Table 4 is obtained.

REVISION

DATE 11--1--05
REVISED

LIGHTNIN

MIXERS AND AERATORS

LIGHTNIN
2005

INST. NO. R281754--E

PAGE 5 OF 7

TABLE 4
SPHERICAL ROLLER BEARING RADIAL
INTERNAL CLEARANCE VALUES
SHAFT
DIA.

UNMOUNTED
MIN. / MAX.

REDUCTION REQD.
MIN. / MAX.

FINAL
CLEARANCE

3.0
3.5

.0032 / .0044

.0018 / .0025

.0014

4.0

.0039 / .0053

.0020 / .0028

.0020

4.5
5.0

.0047 / .0063

.0025 / .0035

.0022

5.5

.0051 / .0071

.0030 / .0040

.0022

6.0
6.5

.0055 / .0079

.0030 / .0045

.0024

.0063 / .0088

.0035 / .0050

.0028

.0079 / .0102

.0030 / .0045

.0049

INBOARD
7.0
7.5
OUTBOARD
7.0
7.5

o . For ball bearings, simply tighten the locknut securely.

p . Set the locknut washer tang in the closest slot. ALWAYS TIGHTEN. DO NOT LOOSEN if necessary to line
up with slot.
q . Install the inboard bearing (See Figure 5):
1 . Remove the (4) outer jacking screws (285) from the housing and slinger collar (280) and reinstall in
the tapped jacking screw holes in the collar flange.
2 . Tighten the jacking screws (285) until the collar is free of the housing.
3 . Remove both sets of jacking screws (281 and 285) and slide the slinger collar inboard as far as it will
go.
4 . Install the (4) outer jacking screws (285) in their storage position in the outboard bearing member (120).
5 . Install the oil seal (301). Use a piece of split pipe and tap in carefully. Use care to avoid damaging the
metal case on the seal.
6 . Install the bearing (123). Tap evenly to start the bearing into the housing bore.
7 . Push the tapered adapter sleeve (224) into the bearing bore.
8 . Install the gasket (216) and the oil seal retainer (133). Use the oil seal retainer to press the bearing into
the bore.
9 . Insert the solid adapter sleeve (225) through the oil seal (301) and thread the locknut (226) on the
adapter sleeve hand tight.

REVISION

DATE 11--1--05
REVISED

LIGHTNIN

MIXERS AND AERATORS

LIGHTNIN
2005

INST. NO. R281754--E

PAGE 6 OF 7

216
280

301

285
117

INBOARD
OUTBOARD

SCRIBED REF.
LINE

3/16

3/16 FLOAT
115
224
133
123
STORAGE
POSITION
281 & 285

226
225
280

120

283
122

284

282

FIGURE 5 -- INBOARD BEARING ASSEMBLY DETAIL

r . Set the inboard bearing:
It is important that the inboard bearing is located midway in the housing to allow positive float axially in
either direction.
1 . Force the entire bearing assembly inboard by applying and axial force against the top of the locknut
with a pry bar.
2 . Tighten the locknut (226) hand tight.
3 . Mark a reference line on the shaft locating the inboard face of the tapered adapter sleeve (224).
4 . Tap the bearing assembly outboard 3/16 of an inch beyond the reference line. Scribe a second
reference line for sleeve location.
s . Tighten the locknut (226):
1 . Tighten ball bearings by tightening the locknut securely.
2 . Tighten spherical roller bearings using the feeler blade measurement and internal clearance reduction
procedure outlined in 4.5.n and values in Table 4.
3 . While tightening floating bearings, use short, sharp blows with the drift and do not allow the sleeve to
move more than 1/16 of an inch from the scribed reference line.
4 . Bend the locknut washer tang into the closest slot. ALWAYS TIGHTEN. DO NOT LOOSEN if necessary
to line up with slot.
t . Install the oil seal retainer (133) and gasket (216).
u . Reposition the slinger collar (280) on the shaft in its original location and tighten the set screws (282).
v . Install the (3) jacking screws (281) in their storage position in the outboard bearing member (120).
w . Install the sheaves and V--belts. Align and adjust the V--belts as outlined in Section 2 of the Operating
Instructions.
x . Install the outboard supports or secure to the mounting support using the shims originally installed.
y . Lubricate the inboard and outboard bearing assemblies as outlined in the bearing lubrication section of the
General Instructions. Add lubricant until clean grease appears at the relief fitting.
z . Start the unit and adjust the packing gland (131) until there is a slight leakage of water beyond the outboard
ring of packing.
aa . Replace all safety covers and guards.
3.6 Refer to General Instructions for lubrication information.

REVISION

DATE 11--1--05
REVISED

LIGHTNIN

MIXERS AND AERATORS

LIGHTNIN
2005

INST. NO. R281754--E

PAGE 7 OF 7

MOTOR MAINTENANCE INSTRUCTIONS

FOR C--FACE AND FOOT MOUNTED
MOTORS FURNISHED BY LIGHTNIN9
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 Underwriters 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 resistance 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 current 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

DATE 3--1--78
REVISED 04--26--06

LIGHTNIN

MIXERS AND AERATORS

LIGHTNIN
1978

INST. NO. IT--1488

PAGE 1 OF 4

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 MOTOR 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 lubricant 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 periodic inspection. The following table offers suggested re--lubrication frequency based on general operating conditions.

REVISION

DATE 3--1--78
REVISED 04--26--06

LIGHTNIN

MIXERS AND AERATORS

LIGHTNIN
1978

INST. NO. IT--1488

PAGE 2 OF 4

Type of
Service

HP
Range

General Conditions

Re--Lubrication
Frequency

Standard

Eight hours per day, normal or light

loading, clean, 100 F Maximum Ambient

11/2 -- 71/2
10 -- 40
50 -- 150
200 -- 350

3 years
1 year
6 months
3 months

Severe

Twenty--four hours per day operation or

shock loading, vibration or in dirt or
dust @ 40 -- 50 C (100 -- 120 F)
Ambient

11/2 -- 71/2
10 -- 40
50 -- 150
200 -- 350

11/2 years
6 months
3 months
1 1/2 months

Very Severe

Heavy shock or vibration, dirt or dust,

high ambient temperature

11/2 -- 71/2
10 -- 40
50 -- 150
200 -- 350

6 months
3 months
2 months
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 leading 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.

REVISION

DATE 3--1--78
REVISED 04--26--06

LIGHTNIN

MIXERS AND AERATORS

LIGHTNIN
1978

INST. NO. IT--1488

PAGE 3 OF 4

SECTION 4 -- STORAGE
Electric motors and other prime movers are not prepared by LIGHTNIN for indoor storage beyond 12 months
in a dry ambient atmosphere with controlled temperatures or 6 months in a dry ambient atmosphere without
temperature control. OUTDOOR STORAGE OF ELECTRIC MOTORS IS NOT RECOMMENDED BY ANY
MOTOR MANUFACTURER. For information on storage periods beyond those shown, consult the motor
manufacturer.
4.1 STORAGE REQUIREMENTS FOR MOTORS -- These extended storage requirements must be followed
to allow the submission of a valid warranty claim.
a . The motors, if not mounted, are to be stored in the original containers in a clean, dry, protected warehouse.
b . The storage area is to be free from any vibration and from extremes in temperature.
c . Bearings
1 . Ball & Roller (anti--friction) -- The bearings are to be fully greased at the time of going into
extended storage. Motor shafts are to be rotated manually every month at least 10 to 15
revolutions, and every 6 months, additional grease added purging some of that in the cavity.
Grease in the bearings is to be purged at the time of removal from storage, making sure that
an ample supply of fresh grease is in each grease cavity.
2 . Sleeve (oil lube) -- The bearings are tested using an oil containing a rust inhibitor. If motor is
stored for more than one month, the oil reservoirs must be refilled to the indicated level with
the specified lubricant. The shaft should be rotated by hand every month at least 10 to 15
revolutions to assure that an oil film is on the shaft and bearing surfaces.
d . All drains to be fully operable while in storage, and/or the drain plugs removed. The motors
must be stored so that the drain is at the lowest point. All breathers and automatic T drains
must be operable to allow breathing at points other than through the bearing fits.
e . All units equipped with heaters are to have the heaters connected if storage conditions in any
way simulate or approach atmospheric conditions experienced in operation.
f . Windings to be megged at the time equipment is put into storage. At the time of removal from
storage, the resistance reading must not have dropped more than 50% from the initial reading. Any drop below this point necessitates electrical or mechanical drying. Where a large
quantity of motors is stored, an inspection or sampling should be made by removing the end
brackets and visually inspecting for the presence of water in the grease, or rust on the bearing. If present, replace the bearings and relubricate.
g . All external parts and motors subjected to corrosion should be protected by a corrosive resistant coating.
h . Where motors are not stored in the original containers, the mounting must be such that the
drains and breathers are fully operable. In this respect, the drains must be kept at the lowest
point in the motor and/or the drain plugs removed so that all condensation can automatically
drain out.
i . All other storage conditions apply, including rotation of motor shafts. Where such conditions
cannot be met, then the equipment must be treated the same as if it were mounted in its normal position, and all protective devices such as heaters, breathers and drains fully operable.

REVISION

DATE 3--1--78
REVISED 04--26--06

LIGHTNIN

MIXERS AND AERATORS

LIGHTNIN
1978

INST. NO. IT--1488

PAGE 4 OF 4

LIGHTNIN
_____________________________________________________________________

FOR AN UP TO DATE REPRESENTATIVE LIST

PLEASE GO TO: www.lightnin-mixers.com

-OR-

CALL: 1-888-649-2378
1-888-MIX-BEST

REVISION
P

DATE 12/28/05
REVISED 01/05/06

LIGHTNIN
MIXERS AND AERATORS

LIGHTNIN 2005

INST. NO. IT-3839

PAGE 1 OF 1

Notes

LIMITED WARRANTY
Unless otherwise noted on the face hereof, SPX goods, auxiliaries and parts thereof are warranted to the original purchaser against
defective workmanship and material for a period of twelve (12) months from date of installation or (18) months from date of
shipment from factory, whichever expires first. If the goods or services do not conform to the warranty stated above, then as Buyer s
sole remedy, SPX shall, at SPX s option, either repair or replace the defective goods or re-perform defective services. Third party
goods furnished by SPX will be repaired or replaced as Buyer s sole remedy, but only to the extent provided in and honored by the
original manufacturer s warranty. Unless otherwise agreed to in writing, SPX shall not be liable for breach of warranty or otherwise
in any manner whatsoever for: (i) normal wear and tear; (ii) corrosion, abrasion or erosion; (iii) any good or services which, following
delivery or performance by SPX, has been subjected to accident, abuse, misapplication, improper repair, alteration, improper
installation or maintenance, neglect, or excessive operating conditions; (iv) defects resulting from Buyer s specifications or designs
or those of Buyer s contractors or subcontractors other than SPX; or (v) defects resulting from the manufacture, distribution,
promotion or sale of Buyer s products.
THE WARRANTIES CONTAINED HEREIN ARE THE SOLE AND EXCLUSIVE WARRANTIES AVAILABLE TO BUYER AND SPX
HEREBY DISCLAIMS ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THE FOREGOING REPAIR,
REPLACEMENT AND REPERFORMANCE OBLIGATIONS STATE SPX S ENTIRE AND EXCLUSIVE LIABILITY AND BUYER S
EXCLUSIVE REMEDY FOR ANY CLAIM IN CONNECTION WITH THE SALE AND FURNISHING OF SERVICES, GOODS OR
PARTS, THEIR DESIGN, SUITABILITY FOR USE, INSTALLATION OR OPERATIONS.

REPAIR & SERVICE

GUIDE

LIGHTNIN Aftermarket Services

LIGHTNIN

The fastest route to uptime.

Aftermarket Services

Expertise: Service technicians are the backbone of our dedicated service

organization. They are uniquely qualied to keep your LIGHTNIN mixers running
right.
Lightnin Certied Technicians: All service technicians are certied via training courses to ensure that the work they do meets the highest standards for
consistency and reliability.
Genuine LIGHTNIN Parts: All LTN repairs follow original design specs and
use only factory-authorized replacement parts.
Full LIGHTNIN Factory Warranty: We're so condent we'll do the job right
that all LTN repair and service work is covered by a full factory warranty. What
we repair, we guarantee - 100%.

When repairs to your LIGHTNIN mixer is

needed, we guarantee the result for one full
year. This exclusive warranty covers all parts
and labor. Talk to your LIGHTNIN sales
representative for more information.

Repair Services: LIGHTNIN provides quick, reliable repair services - using

only certied technicians and factory-authorized replacement parts - on gearboxes, mechanical seals (seal cartridge and seal assembly), steady bearings,
machine assemblies, impellers, shafts and all portable units. This service can
be provided either at your site or at a LIGHTNIN Service Center location. All
work is backed by LIGHTNIN's full warranty on all parts and service.
Exchange Services: By eliminating repair time, LIGHTNIN Exchange Services offer the fastest way to get up and running when a breakdown occurs.
LTN keeps selected speed reducers, portable units and mixer subassemblies
in stock - and available for immediate exchange - at regional service centers.
Simply call and we will congure the appropriate assembly and ship it to you
within 24 hours. Then send the damaged assembly back to us within 30 days to ensure you receive a discounted price.
Equipment Upgrade Services: Preventive maintenance is your best defense
against costly unplanned downtime and repairs associated with old or obsolete
equipment. The full range of LTN upgrade services give you a convenient and
cost-efcient way to address problems before they happen by converting older
equipment to the latest, most reliable LIGHTNIN designs.
Additional LTN Services: In addition to minimizing downtime and repair
costs when equipment failure occurs, LTN offers a comprehensive range of
services for maximizing productivity through every stage of the equipment life
cycle.
t
Installation and Startup
t
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BOE
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t
"TTFU
.BOBHFNFOU

CALL:
The LIGHTNIN Experts
When your need is urgent and after
normal business hours call our 24-hour
SFTQPOTF
UFBN
IPUMJOF
BU
.*9
BEST (U.S. and Canada). Your request
will be promptly processed and directed
to your nearest LTN team member. For
more information visit our website:
www.spxft.com

Factory Service
Center Locations
Delavan, Wisconsin
.PEFTUP California
.VMCFSSZ Florida
Rochester, New York
Houston, Texas
Wytheville, Virginia

Authorized Service
Center Locations
Baton Rouge, Louisiana
Concord, Ontario, Canada
East Hanover, New Jersey
.BDPO
1PPMFS
"MQIBSFUUB Georgia

LIGHTNIN, An SPX Brand

135 Mt. Read Blvd., Rochester, NY 14611
Phone: (888) MIX-BEST or (888) 649-2378, Fax: (585) 436-5589
E-mail: LIGHTNIN@spx.com
For more information about our worldwide locations, approvals, certications, and local representatives, please visit www.lightninmixers.com.
SPX reserves the right to incorporate our latest design and material changes without notice or obligation.
Design features, materials of construction and dimensional data, as described in this bulletin, are provided for your information only and should
not be relied upon unless conrmed in writing. Certied drawings are available upon request.

Issued: 03/2010