Amarillo 1800 Manual

© AGC 2004
OPERATING
AND
MAINTENANCE
INSTRUCTIONS
FOR
MODEL 1800 – 2600
Amarillo Gear Company
P.O. Box 1789
Amarillo, Texas 79105-1789
Phone: [phone] Revision: C
Date: March 18, 2005
Fax: [phone]
www.amarillogear.com Page: 1 of 5 FORM: 189

Form 189C
1
OPERATING AND MAINTENACE INSTRUCTIONS
AMARILLO RIGHT ANGLE GEAR DRIVES
(MODEL 1800 – MODEL 2600)
INSTALLATION
Unless otherwise specified, all units are shipped with the proper type and amount of
lubricant. However, check to see if the oil is at the proper level. Add lube oil if necessary.
Inspect and clean the top of the pump discharge base and the bottom of the gear drive. Make
sure burrs or foreign material which might cause misalignment are removed.
Using mineral spirits or a suitable solvent, remove the rust preventive compound from the shaft
extension and clean thoroughly. Install the coupling half of the flange. Hammering or
mechanically forcing the coupling onto the shaft is not permissible, as it can damage the bearings or
disturb the setting of the gears. Interference fits are permissible, if the coupling can be heated for
installation and fitted without hammering or mechanically forcing it onto the shaft. Check run-out
of the aligning surfaces on both coupling halves before installing the connecting members.
Align the driver with the gear drive to obtain parallel and angular alignment. Misalignment should
be as close to zero as possible for smoothest operation and maximum life. Misalignment should be
no greater than that specified by the coupling or driveshaft manufacturer. Offset of universal type
drive shafts should also be within the limits specified by the manufacturer. When aligning universal
drive shafts, make sure the knuckles are in phase, the flange faces are parallel in the horizontal
and vertical planes and the slip joint is free. Use only the specified tools and procedures when
aligning the driver and the gear drive. Recheck alignment and re-torque driveshaft fasteners at
regular intervals after start of operation. Correct the alignment if drifting or settling has occurred.
Excessive noise and vibration in a new gear drive is almost always an indication of poor
installation, as all drives have been tested at the factory prior to shipping. Failure to correct an
installation problem can result in damage to the pump and gear drive. The factory warranty does not
apply unless the gear drive is properly installed. Proper installation includes alignment of power
unit, right angle drive and pump. It is also necessary to provide an adequate foundation for the
pump / engine and a positive method of preventing the power unit from shifting to assure alignment
will be maintained.
On engine drive systems, it is common for one or more resonant speeds to exist between zero rpm
and the operating speed. Continued operation at a resonant speed will result in torsional vibration
which can be damaging to all components of the system. The most common indication of torsional
vibration is as unusual rumbling or clattering noise from the gear drive at a sharply defined speed.
The noise will disappear when the speed is increased or decreased. This noise is not indicative of a
defect but results when the vibratory torque exceeds the driving torque and causes the gear teeth to
separate and clash together very rapidly. Transition through a resonant speed range to operating
speed is not normally damaging but continued operation close to a resonant speed should be
avoided. To avoid operation at a resonant speed it may be necessary to change the elastic
characteristics of the rotating components, install a flexible coupling, or change the speed of the
engine with respect to the pump (change gear ratio). Contact Amarillo Gear for more information
on resonant speeds and torsional vibration.

Form 189C
2
LUBRICATION
This section covers the main lubrication system of the gear drive. For gear drives equipped with
optional pre-lube system and other lube system accessories, refer to the appendix for additional
instructions.
The main lubrication system is equipped with a positive displacement pump and pressure relief
valve. The relief valve pressure is set at the factory and should not be adjusted in the field to
regulate the system oil pressure. The system is designed to maintain lube oil pressure at 40-50 psig
when the unit is at operating temperature. If coolant is used, its pressure should be less than the oil
pressure, whenever possible.
Use only rust and oxidation inhibited (R&O) gear oil in accordance with the latest American Gear
Manufacturers Association (AGMA) lubrication standards. For general operating conditions, the
recommended AGMA lubricant number is given in TABLE 1. In general, the mineral oils listed are
adequate for ambient temperatures between 20°F (-7°C) and 120°F (49°C). Recommended mineral
oils are shown in TABLE 2 (Recommended Mineral Oils). If the gear drive will be started when the
ambient temperature is below 20°F (-7°C), use a lube oil heater or one of the recommended
synthetic lubricants shown in TABLE 3 (Recommended Synthetic Lubricants). If the ambient
temperature is above 120°F (49°C), use one of the recommended synthetic lubricants shown in
TABLE 3. Gear oils containing extreme pressure (EP) additives are not recommended.
CAUTION: Never use EP additives if a sprag type non-reverse is used.
TABLE 1 - OIL CAPACITY / RECOMMENDED AGMA LUBRICANT NUMBER
Operating Oil Temperature
Model Oil
Capacity Factory Oil Fill
Less than
160°F
(71°C)
Greater than 160°F
(71°C) & Less than
180°F (82°C)
Greater than
180°F (82°C) (3
month change
interval)
Greater than 180°F
(82°C) (6 month
change interval)
1800 26 Gallons
(98 Liters) 5 4 5 5 5S
2200 38 Gallons
(144 Liters) 5 4 5 5 5S
2600 61 Gallons
(231 Liters) 5 4 5 5 5S
CHANGE INTERVAL
Change oil every 2500 hours of operation or every six months, whichever comes first. The change
interval should be decreased if the gear drive is subjected to conditions that tend to decrease oil
quality, such as water contamination or high operating temperatures. Drives that are operated
intermittently or in climates with hot days and cool nights will accumulate moisture more rapidly
than drives operating at constant temperature. Frequency of oil change will depend on the rate of
water condensation and the rate of oil oxidization. Operating temperatures above 180°F (82°C) will
cause mineral oils to oxidize more rapidly and require more frequent oil changes. For high
operating temperatures, change mineral oils every 1000 operating hours or every 3 months,
whichever comes first. To extend the change interval to 2500 hours or six months, use one of the
recommended synthetic oils shown in TABLE 3 (Recommended Synthetic Lubricants).

Form 189C
3
OIL CHANGE PROCEDURE
With the oil at or near operating temperature, completely drain oil by removing the drain plugs in
the base flange of the gear drive and the heat exchanger. Clean oil level sight gauges if necessary.
Refill oil at the filler plug located directly below the name plate with the correct lubricant as shown
in TABLE 1. Verify oil level is at the midpoint of the upper oil level sight gauge or higher. The
approximate oil capacity of the gear drive is given in TABLE 1. For a gear drive without a pre-lube
system, run the engine for 3-4 minute at idle to fill the heat exchanger (See CAUTION below). For
a gear drive with a pre-lube system, run the pre-lube pump for one to two minutes. After filling the
heat exchanger, recheck the oil level and add if necessary.
CAUTION: If the pin and ratchet non-reverse clutch is used, make sure the vertical speed
does not fall below the limit specified below in: “PIN & RATFCHET NON-
REVERSE CLUTCH INSTRUCTIONS”.
OIL FILTER
The filter element should be replaced every time the oil is changed. For gear drives equipped with a
CUNO Model 1B1 filter, use a CUNO U30Q8 filter element. Verify the oil filter model number on
the oil filter name plate. If duplex filters are used, see APPENDIX for additional instructions.
COOLING
The heat exchanger has been sized to maintain the oil temperature between 160°F - 180° F when
operated under normal operating conditions and water temperature. It usually requires 1-3 hours for
the oil temperature to stabilize after start-up. It is suggested to use 15 gpm as the initial coolant flow
rate. The coolant flow rate should be adjusted to maintain the oil temperature within the previously
discussed temperature range. The coolant pressure should be less than the lube oil pressure
whenever possible. The maximum allowable coolant pressure is 150 psig.
PIN & RATCHET NON – REVERSE CLUTCH INSTRUCTIONS
Pins and pin holes in the non-reverse clutch must be clean and free of oil so that the pins will fall
freely. Drives used in fire pump applications must be provided with an anti-reverse mechanism.
The non-reverse mechanism is not to be disabled for these applications. The gear drive may be
damaged by accidental shock engagement of the non-reverse clutch. This can be caused by the
engine backfiring with the clutch engaged, or by the pump starting to back-spin before a pin engages
the ratchet. Check the gear drive carefully after any shock engagement of the non-reverse clutch.
The non-reverse clutch is not guaranteed against damage from accidental shock engagements.
The non-reverse pins will pick up off the ratchets at approximately 200 rpm output shaft speed.
Below this speed, the pins will fall freely against the ratchets which will cause a loud rattling noise
and is considered normal. Prolonged operation below 200 rpm will cause excessive wear on the
ramps of the non-reverse plate and should be avoided. During the break-in period, small metal
particles may wear off the ramps. This is considered normal wear and is not a cause for alarm. If
the gear drive operates with excessive vibration, the vibration forces can cause the non-reverse pins
to fall against the non-reverse ratchet plate even when the pump speed is above 200 rpm. Should
this occur, the unit should shut down immediately and the cause of the vibration found and corrected
before further operation.

Form 189C
4
TABLE 2 – Recommended Mineral Oils
AGMA LUBRICANT NUMBER 4 5
Atlantic Richfield Co. (ARCO) Duro 150 Duro 220
British Petroleum Energol GR150 Energol GR220
Chevron Oil Co. AW Machine Oil 150 AW Machine Oil 220
Cities Services Oil Co. Pacemaker 150 Pacemaker 220
Conoco Dectol 150 R&O Dectol 220 R&O
Exxon Co. Teresstic 150 Terrestic 220
Farmland Industries 0047 0048
Gulf Oil Corporation Harmony 150D Harmony 220
Mobil Oil Co. DTE Oil Extra Heavy DTE Oil BB
Pennzoil Pennzbell TO 150 Pennzbell TO 220
Phillips Petroleum Co. Magnus 150 Magnus 220
Shell Oil Co. Morlina 150 Morlina 220
Sun Oil Co. Sunvis 7150 Sunvis 9220
Texaco Regal 150 R&O Regal 220 R&O
TABLE 3 - Recommended Synthetic Lubricants
AGMA LUBRICANT NUMBER 5S
ISO Grade 220
Chevron Oil Co. Clarity 220 Synthetic
Conoco Syncon 220 R&O Oil
Mobil Oil Co. SHC 630
Note: This list of oil brand names, shown in Table 2 and Table 3 is for the purpose of identifying types
and is not construed as exclusive.