Installationand

MaintenanceManualand Parts List

IMPORTANT!

DO NOT DESTROY

Speed Reducers4A, 4AC, 5A, 5AC

Effective August, 1998(Supercedes September, 1997)

Bulletin No# 431

HYTROL CONVEYOR CO., INC.© COPYRIGHT 1998–HYTROL CONVEYOR CO., INC.

Jonesboro, ArkansasSt. Louis, MissouriManteca, California

2

INTRODUCTIONThis manual provides information concerningusage, lubrication, and maintenance of theHYTROL Speed Reducers.

It is important that this information is followed somaximum efficiency and life of the Speed Reduceris obtained.

Most HYTROL conveyor drives are supplied withthe HYTROL Speed Reducer.

Models 4A and 5A Speed Reducers are used withV-Belt drives, whereas the 4AC and 5AC Reducersare supplied with the “C” Face Drive.

● General Information

To determine the ratio and/or the assembly date ofa HYTROL Reducer, refer to the numbers stampedon the end of the output shaft.

Figure 2A shows the location of these numbers.AVAILABLE RATIOS ARE ALSO CHARTED INTHIS FIGURE.

● Determining Gear Ratio

● Table of ContentsINTRODUCTION

General Information . . . . . . . . . . . . . . . .2Determining Gear Ratio . . . . . . . . . . . . .2Determining Right or Left Hand Reducer . . .3

MAINTENANCELubrication . . . . . . . . . . . . . . . . . . . . . . .4Removal & Installation . . . . . . . . . . . . . .5“C” Face Motors . . . . . . . . . . . . . . . . . . .5

REPLACEMENT PARTSHow To Order Replacement Parts . . . . . .64A and 4AC Parts Drawing & List . . . . . .65A and 5AC Parts Drawing & List . . . . . .7

FIGURE 2A

AVAILABLE RATIOS

MODEL 4A & 4AC

Gear Ratio Gear Ratio

MODEL 5A & 5AC

10:1

20:1

30:1

40:1

50:1

60:1

10:1

20:1

30:1

40:1

N/A

60:1

3 45

OUTPUTSHAFT

ASSEMBLYDATE5/94

YEAR

MONTHRATIO30:1

3

To determine a right hand or left hand HYTROLReducer, look into the output shaft with the inputshaft on the high side. If the input is on the right

side, it is a right hand reducer. If it is on the left, it isa left hand reducer. (See Figure 3A).

● Determining Right or Left Hand Reducer

FIGURE 3A

MODELS 4A & 4AC SPEED REDUCERS

MODELS 5A & 5AC SPEED REDUCERS

INPUT SHAFT

OUTPUTSHAFT

“C” FACEADAPTOR

RIGHT HANDASSEMBLY

LEFT HANDASSEMBLY

INPUT SHAFT

OUTPUTSHAFT

“C” FACEADAPTOR

RIGHT HANDASSEMBLY

LEFT HANDASSEMBLY

4

● Lubrication

MAINTENANCEThe HYTROL Speed Reducer, if properly used, shouldrequire little maintenance except for scheduled lubrica-

tion. Instructions for changing oil and recommendedlubricants are as follows.

Initial Oil Change– Drain the oil in a new SpeedReducer after approximately 500 hours of operation andrefill with recommended oil from lubrication chart (Figure4B).

Regular Oil Change– After initial change, in normal con-ditions, the oil should be changed every 2500 hours ofoperation, or every 6 months, whichever is first.

To Refill– Determine position of Reducer from Figure 4A

and refill with amount of oil shown in capacity chart(Figure 4C).

Grease Fittings– The Hytrol 5A and 5AC Reducershave grease fittings to lubricate the input shaft bearing ifthey are not positioned to be adequately lubricated by oilsplash. (See Figure 4A, Positions A, E, and F).Periodically lubricate these bearings with a good gradeof NLGI-No. 2 Lithium Base EP Grease, applying only avery small amount each time.

FIGURE 4A - MOUNTING POSITIONS

FIGURE 4B–LUBRICANT FIGURE 4C–REFILL CAPACITY

AMBIENTTEMPERATURE

REDUCERMODEL

-30º F to +10º F 4A & 4AC 1-1/4 QT. 1-1/2 QT. 1-1/4 QT.

1-1/4 QT. 1-3/4 QT. 1-1/4 QT.5A & 5AC

+10º F to +125º F

SHELL ATFDEXTRON 32

SHELL EPOMALA #680

AGMA CLASS #8EP

RECOMMENDEDOIL OR

EQUIVALENT A B C D E F

MOUNTING POSITION

POSITION A POSITION C POSITION E

POSITION B POSITION D POSITION F

OUTPUT SHAFT INPUT SHAFT

DRAIN

OIL LEVEL

VENT PLUG GREASE FITTING5A/5AC ONLY

INPUT SHAFTDRAIN

OIL LEVEL

VENT PLUG

OUTPUT SHAFT

INPUT SHAFT

VENT PLUG

OUTPUT SHAFT GREASE FITTING5A/5AC ONLY

INPUT SHAFT

DRAIN

VENT PLUG

OUTPUT SHAFTINPUT SHAFT DRAIN

OIL LEVEL

VENT PLUG

OUTPUT SHAFT

INPUT SHAFT

DRAIN

OIL LEVELAPPROX. 1/2”BELOW HOLE

VENT PLUG

OUTPUT SHAFT

GREASE FITTING5A/5AC ONLY

OIL LEVELBELOW HOLEAPPROX. 1/2” ON 4A/4ACAPPROX. 3/4” ON 5A/5AC

DRAIN

OIL LEVEL

HYTROLKIT NO.052.145052.146

MOTORHORSEPOWER

1/2 - 11-1/3 - 2

“A”

5/8” DIA.7/8” DIA.

5

● Removal & Installation

● “C” Face Motors

When the reducer is used in conjunction with sheavesand sprockets, care should be taken to insure thatshafts are parallel and sheaves and/or sprockets are inalignment. This will prevent damage to bearings, chainand sprockets, sheaves and V-Belts.

1. . .

Sheaves and sprockets should be properly keyed andtightened to the shafts to prevent wear to the shaft andbores. Extreme belt or chain tension should be avoided.

When assembling sheaves or sprockets on reducershafts, they should be installed as close to the reducerhousing as possible. Sheaves or sprockets should notbe driven onto the shaft: This could result in damage tobearings and/or reducer housing.

2 . . .

3 . . .

If the speed reducer is removed from the conveyor for main-tenance purposes, the following precautions should be takenupon reinstalling the reducer.

1. . .

2. . .

FIGURE 5A

Place sleeve onto coupling gear on motor and easemotor into place (look through hole in “C-Face” adaptorto see that sleeve seats onto coupling gear of reducer).Align motor mounting holes to “C-Face” adaptor andinstall mounting bolts.With coupling properly installed, there should beapproximately 1/32” end play in the coupling sleeve. Ifadditional clearance is required, remove motor andreadjust coupling flange.

3 . . .

4 . . .

5 . . .

Models 4AC and 5AC speed reducers are supplied with a“C-Face” adaptor and are coupled directly to the motor bycoupling gears and sleeve.

To replace the coupling, refer to figure 5A and follow theinstructions listed below.

Install 3/4” bore coupling gear to reducer shaft using3/16” x 1” long shaft key. Tighten set screws throughhole in “C-Face” adaptor.Install coupling gear to motor (refer to chart for correctbore size). Locate 2-1/32” from face of motor using3/16” x 1” long shaft key. Tighten set screws.

STEP 1COUPLING GEAR(MOUNT NEAR END OFSHAFT) SEE INSET FORDIMENSION

SHAFT KEY

COUPLER SLEEVE

“C” FACE ADAPTORHOUSING

STEP 2COUPLING GEAR(MOUNT NEAR END OF SHAFT)SEE INSET FOR DIMENSIONS

SET SCREW

SET SCREWINSERT IN COUPLING GEARTHROUGH HOLE IN SIDE OFADAPTOR HOUSING

SPEED REDUCERSHAFT (INPUT)

“C” FACE MOTOR

2-1/32”

“A”

REDUCERMOTOR

2-1/4”

6

● How to Order Replacement Parts

● Model 4A and 4AC Parts Drawing & List

Included in this manual are parts drawings with completereplacement parts lists. When ordering replacementparts, please refer to the ordering procedure below:

Contact Dealer from whom conveyor was purchased ornearest HYTROL Distributor.

1. . .

Provide Distributor with Part Description and Numberfrom Parts List.

Advise if you are in a breakdown situation, so fastestpossible service is provided.

2. . .

3. . .

23

20

20

10

719

3

17

13

16

196

1610

1

20

17

821

11

12

84

1517

5

19

9

9

2

1413

19

16

24

17

25

Ref. No. Part No. Description1 R-00145 4A Reducer Housing2 R-00035 Worm Gear (Specify Ratio)3 R-00150 Worm Shaft “V-Belt” (Input) (Specify Ratio)4 — Worm Gear Shaft (Output)— R-00040 Standard Reducer— R-00139 Timing Belt Drive Reducer Only5 R-00047 Front Cover6 R-00148 Side Cover7 R-00149 Side Cover (Input)8 012.102 Tapered Roller Bearing — 1 in. I.D.9 012.103 Bearing Cup

10 011.102 Radial Bearing11 051.114 Worm Gear Spacer12 R-00154 Spalsh Shield13 015.101 Oil Seal (3/4 in. Shaft)14 015.102 Oil Seal (1 in. Shaft)15 — Front Cover Gasket— 052.118 .004 in. Thick— 052.1181 .008 in. Thick— 052.1182 .016 in. Thick

Ref. No. Part No. Description— 052.1183 .031 in. Thick16 — Side Cover Gasket— 052.119 .004 in. Thick— 052.1191 .008 in. Thick— 052.1192 .016 in. Thick17 054.102 Gasket Seal Paste (Not Shown)18 095.100 Gear Reducer Oil (Not Shown)19 049.539 Flange Lockbolt — 5/16-18 x 3/4 in. Long20 092.0372 Hex Socket Plug—3/8 in. NPT21 090.201 Woodruff Key—#80722 054.1055 Vent Plug—3/8 in. NPT (Not Shown)23* R-00151 Worm Shaft “C-Face” (Input) (Specify Ratio)24* R-00146 C-Face Motor Adaptor25* — Coupling Kit — Motor To Reducer— 052.145 5/8 in. — 3/4 in. (1/2 thru 1 HP)— 052.146 7/8 in. — 3/4 in. (1-1/2 thru 2 HP)26 R-00152 4A Reducer — Complete (Specify Ratio)27 R-00153 4 AC Reducer-Comp., Less Coupling (Specify Ratio)

* FOR 4AC REDUCER ONLY

7

● Model 5A and 5AC Parts Drawing & List

26

23

22

22

11

720

3

18

14

17

206

1711

10

22

18

8

21

12

13

84

1618

5

20

91

9

2

15

10

14

20

17

27

18

28

Ref. No. Part No. Description1 R-00161 5A Reducer Housing2 R-00025 Worm Gear (Specify Ratio)3 R-00165 Worm Shaft “V-Belt” (Input) (Specify Ratio)4 R-00167 Worm Gear Shaft (Output)— R-00167 Standard Reducer— R-00169 Timing Belt Drive Reducer Only5 R-00162 Front Cover6 R-00148 Side Cover7 R-00149 Side Cover (Input)8 012.104 Tapered Roller Bearing — 1-1/4 in. I.D.9 012.105 Bearing Cup—1 1/4 in. Brg.

10 012.106 Tapered Roller Bearing—27/32 in. I.D.11 012.107 Bearing Cup—27/32 in. Brg.12 051.115 Worm Gear Spacer13 R-00154 Splash Shield14 015.101 Oil Seal (3/4 in. Shaft)15 015.102 Oil Seal (1 in. Shaft)16 — Front Cover Gasket— 052.115 .004 in. Thick— 052.1153 .008 in. Thick— 052.116 .016 in. Thick— 052.1163 .031 in. Thick17 — Side Cover Gasket— 052.119 .004 in. Thick— 052.1191 .008 in. Thick

Ref. No. Part No. Description— 052.1192 .016 in. Thick18 054.102 Gasket Seal Paste (Not Shown)19 095.100 Gear Reducer Oil (Not Shown)20 049.539 Flange Lockbolt — 5/16-18 x 3/4 in. Long21 090.2012 Woodruff Key—#81022 092.0372 Hex Socket Plug—3/8 in. NPT23 092.036 Threaded Plug—1/8 in. NPT24 092.103 Spec. Short Grease Fitting—1/8” NPTF (N/Shown)25 054.1055 Vent Plug—3/8 in. NPT26* R-00166 Worm Shaft “C-Face” (Input) (Specify Ratio)27* R-00146 C-Face Motor Adapter28* — Coupling Kit—Motor to Reducer— 052.145 5/8 in. — 3/4 in. (1/2 thru 1 HP)— 052.146 7/8 in. — 3/4 in. (1-1/2 thru 2 HP)29 R-00163 5A Reducer — Complete (Specify Ratio)30 R-00164 5 AC Reducer-Comp., Less Coupling (Specify Ratio)

* FOR 5AC REDUCER ONLY

HYTROL CONVEYOR COMPANY, INC.2020 Hytrol Drive

Jonesboro, Arkansas 72401

Phone: (870) 935-3700www.hytrol.com www.ezlogic.com

EFFECTIVE JULY, 1998

Printed in the USA 7/98