LIGHTNIN XDQ Series User manual

MIXER MANUAL
INSTRUCTIONS
INSTALLATION
OPERATION
MAINTENANCE
Book No. BK1978

INSTRUCTION MANUAL
LIGHTNIN SALES ORDER L880659
LIGHTNIN LINE ITEM 000010
TABLE OF CONTENTS
Safety Check List
Vert. On Center Installation Dwg.
Angular Off-Set Installation Dwg.
Dimension Drawing
Direct Drive Assembly Drawing
Gear Drive Assembly Drawing
General Instructions
General Instructions
Safety Cover Instructions
A310 (1 piece) Impeller Assembly
A310 - Bolted Impeller Drawing
A100 Impeller Assembly
R100 - One Piece Impeller Drawing
R100 - Bolted Impeller Drawing
Recommended Bolting Torques
Wiring Diagram
Spare Parts Lists 1
Spare Parts Lists 2
Spare Parts Lists 3
Spare Parts Lists 4
Spare Parts Lists 5
Sales Offices
IT-2144
IT-1985
IT-1986
DST82
L-16716
L-16717
IT-1997
IT-1994
IT-1989
L-16701
L-16673
L-17875
L-16844
L-16845
IT-850
IT-2081
IT-2044
IT-2045
IT-2046
IT-2047
IT-2048
IT-3839
DOCUMENT NO.TITLE

REVISION 2007 DATE 5–9–86
REVISED 05–14–07 PAGE 1 OF 2
INST. NO. IT–2144
G©LIGHTNIN
LIGHTNIN
MIXERS AND AERATORS
®
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. FAIL-
URE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS INJURY. Ensure the use of
qualified, quality trained and safety conscious personnel.
2. 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.
3. DO NOT operate shaft sealing devices at temperatures or pressures higher than those specified in the manual
or on the nameplates.
4. DO NOT service the mixer until you have followed your ”Control of Hazardous Energy Sources” (lockout,
tagout procedure) as required by OSHA 29 CFR Part 1910.
5. DO NOT touch rotating mixer parts or any part of mixer that has the potential of having a hot surface
including motor, gear drive housing, seal, shafting and flange.
6. 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 drive motor.
7. 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.
9. 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 mixer mounting
surface is the responsibility of the customer.
C. Ensure all detachable components are securely coupled to the mixer.
D. Thoroughly REVIEW and ADHERE TO the mixer operating instructions supplied by LIGHTNIN.
E. Ensure the mixer output shaft rotates freely by hand.
F. Ensure all personnel and equipment are clear of rotating parts.
G. Ensure all external connections (electrical, hydraulic, pneumatic, etc.) have been completed in accordance
with all applicable codes and regulations.
DO NOT enter the mixing vessel UNLESS:
10. A. The mixer power supply is locked out (follow Item number 4).
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.
8. 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.
Use only the lifting device, if provided, on your unit to install the mixer. Use shouldered eyebolts and tighten
securely to handle component parts. We strongly recommend that the hoist rings be of safety swivel type with
360°rotational capability. Lift per instructions in the instruction manual.
1.

REVISION 2007 DATE 5–9–86
REVISED 05–14–07 PAGE 2 OF 2
INST. NO. IT–2144
G©LIGHTNIN
LIGHTNIN
MIXERS AND AERATORS
®
CE COMPLIANCE
If mixer nameplate has a CE marking on it, then the equipment furnished conforms to the
following directives:
98/37/EC Machinery Directive
89/336/EEC Electro–Magnetic Compatibility
73/23/EEC Low Voltage
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.
CAUTION: CE Compliance does not imply that the mixer satisfies PED (Pressure
Equipment 97/23/EC) or ATEX (Potential
Explosive Atmospheres 94/9/EC) unless marking is clearly shown on mixer.
‘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
THIS PRODUCT MAY BE COVERED BY ONE OR MORE OF THE FOLLOWING U. S. PATENTS:
5006283 5046245 5118199 5152934 5152606 5203630
5344235 5364184 5368390 5378062 5427450 5454986
5470152 5478149 5480228 5501523 5511881 5560709
5568975 5568985 5655780 5720286 5746536 5758965
5779359 5842377 5925293 5951162 5972661 5988604
6089748 6109449 6142458 6158722 6250797 6299776
6334705 6386753 6457853 6634784 6715913 6742923
6746147 6789314 6796707 6796770 6808306 6843612
6860474 6877750 6935771 6986507 6997444 7001063
7056095 7168641 7168848 7168849

LIGHTNIN MAINTENANCE AND SERVICE MANUAL
DRAWING IT–1985
ISSUED – 3/15/83
REVISED – 2/26/01
CERTIFIED DIMENSION DRAWING FOR
LIGHTNIN XDQ AND XJQ SERIES MIXERS
Vertical On–Center Mounting
ALL DIMENSIONS IN INCHES
CERTIFICATION: This drawing, when used in conjunction with the attached specification sheet for
LIGHTNIN Order _________________________ represents certified dimensions. ©LIGHTNIN
2001
ADJUSTABLE
1
APPR.
WGT.
MODEL WITH C F
51XDQ–30 21–1/2
NOTES:
REFER TO ORDER SPECIFICATION SHEET FOR:
A. MODEL NUMBER AND MOTOR HORSEPOWER.
B. SHAFT DIAMETER AND FULL LENGTH.
2
3MIXER WEIGHT CAN VARY WITH MOTOR CHARACTERISTICS,
SHAFTAND IMPELLER SELECTION.
4DIMENSION ”A” IS MAXIMUM. CAN VARY SLIGHTLY DEPENDING
ON MOTOR ENCLOSURE.
5CONDUIT BOX NOT INCLUDED WITH EXPLOSION PROOF MOTOR.
A
4
DETAIL ”A”
C. SHAFT CONNECTION – STANDARD CHUCK OR ALTERNATE
D. QUANTITYAND SIZE OF IMPELLERS.
E. IF LOWER IMPELLER IS EQUIPPED WITH STABILIZER.
COUPLING CONSTRUCTION.
6EQUISPACED TANK BAFFLES NOT FURNISHED BY ”LIGHTNIN”.
SEE SPECIFICATION SHEET FOR BAFFLE DIMENSIONAL DATA.
IMPELLER
DIA. MINIMUM
OPENING (IN.)
MINIMUM DIAMETER OPENING REQUIRED TO PASS
IMPELLER WHEN DETACHED FROM SHAFT
2.5 2
IMPELLER
DIA. MINIMUM OPENING (IN.)
10.0 7–3/4
3.4 2–5/8 11.2 8–3/4
3.8 3 11.8 9–1/4
4.5 3–1/2 12.8 10
5.2 4 13.6 10–5/8
5.9 4–5/8 15.1 11–3/4
6.3 4–7/8 15.6 12–1/4
6.8 5–1/4 17.0 13–1/4
7.6 6 19.0 15
CHUCK WITH CPLG.
B
TANK MAY BE
ROUND, SQUARE
OR RECTANGULAR
6
1
BAFFLE
LENGTH
BAFFLE
WIDTH
TANK SIZE
8–1/4
MAX.
2
A
1
9 MAX.
B
1
A
7–1/2
MAX.
1–3/4
C
XDQ or XJQ
174 thru 350 XDQ or XJQ
30 thru 117
2
5
SEE DETAIL ”A”
E
F – CPLG. BOLT DIA.
B
ALTERNATE COUPLING
CONSTRUCTION
(SEE NOTE 1c)
IMPELLER
ROTATION
MIXER SUPPORT CHANNELSIZE
TANKS UP TOAND INCLUDING 8 FEET – 4” X 7.25#
TANKS OVER 8 FEET – 6” X 8.2#
(NOT FURNISHED BY ”LIGHTNIN”):
(4) 11/16 MTG. HOLES
IN TOP FLANGE
OF CHANNELS
HH
H
H
LBS. EHK
56XDQ–43 6–1/2 0 3/83–1/8 3–7/8 4 10
60XDQ–87 21–3/4
70XDQ–117 22–1/2
135XDQ–174 24–1/4
140XDQ–230 26 6–3/4 0 1/23–1/8 4–3/4 5–1/2 13
155XDQ–350
63XJQ–30 23–1/4 6–3/8 1–3/8 3/82–3/4 3–7/8 4 10
66XJQ–43
70XJQ–65 24–5/8
83XJQ–87 7 1–5/8 1/22–3/8 4–3/4 4–1/2 11
89XJQ–117 25–3/8
155XJQ–174 28–3/4
200XJQ–230 30–1/2 6–3/4 1–7/8 1/23 4–3/4 5–1/2 13
225XJQ–350
”K”
SQUARE
1–5/16
FOR AIR MOTOR UNITS,
REFER TO DS–T–85.
2

LIGHTNINMAINTENANCE AND SERVICE M ANUAL
CERTIFIED DIMENSION DRAW ING FOR
LIGHTNINXDQ AND XJQ SERIES M IXERS
AngularO ff--C e n terM ounting
ALL DIMENSIONS ININCHES
CERTIFIC ATION:Thisdraw ing,w hen used in conjunction w iththe attached specification sheetfor
LIGHTNINOrder_________________________ representscertified dim ensions.
©LIGHTNIN
2001
ADJUSTABLE
1
APPR.
WGT.
MODEL WITH C F
51XDQ --3 0
21--1 /2
NO TES:
REFER TO O RDER SPECIFICATIO N SHEET FOR:
A. M ODEL NUM BER AND M O TOR HO RSEPO W ER.
B. SHAFT DIAM ETER AND FULL LENG TH.
2
3MIXER W EIGHT CAN VARY W ITH MOTOR CHARACTERISTICS,
SHAFT AND IM PELLER SELECTION.
4DIMENSION ”A”IS M AXIMUM.CAN VARYSLIG HTLY DEPENDING
ON M OTOR ENCLOSURE.
5CONDUITBOXNOTINCLUDED W ITH EXPLO SION PROOF M OTOR.
A
4
DETAIL”A”
C. SHAFT CONNECTION --STANDARD CHUCK OR ALTERNATE
D. QUANTITY AND SIZE O F IM PELLER S.
E. IFLOWERIM PELLER ISEQUIPPED W ITH STABILIZER .
COUPLING CONSTRUCTION.
CHUCK
WITH
CPLG.
B
D
1
TA N K S IZE
8--1 /4
M AX.
2
A
1
9 M AX.
B
1
A
7--1 /2
M AX.
1--3 /4
C
XDQ orXJQ
174 thru 350
XDQ orXJQ
30 thru 117
2
5
SEE DETAIL”A”
E
F--CPLG .BO LT D IA.
B
ALTERNATE COUPLING
CONSTRUCTION
(SEE NOTE 1c)
IM PE LLE R
ROTATION
MIXER SUPPO RT CHANNEL SIZE
TANKS UP TO AND INCLUDING 8 FEET --4”X 7.25#
TAN KS O VER 8 FEET --6”X 8.2#
(NOT FURNISHED BY ”LIGHTNIN”):
(4)11/16 M TG .H O LE S
IN TOP FLANGE
OF CHANNELS
LBS.
E H J L M
56XDQ --4 3
6--1 /20 3/83--1 /82--1 /43--7 /845--3 /812--1 /410
60XDQ --8 7 2 1 --3 /4
70XDQ --117 22--1 /2
135XDQ --174 24--1 /4
140XDQ --230
26
6--3 /40 1/23--1 /834--3 /45--1 /27--5 /816--3 /413--1 /2
155XDQ --350
63XJQ --3 0
23--1 /46--3 /81--3 /83/82--3 /42--1 /43--7 /845--3 /812--1 /410
66XJQ --4 3
70XJQ --6 5
24--5 /8
83XJQ --8 7 7 1 --5 /81/22--3 /82--1 /44--3 /44--1 /25--7 /813--1 /411
89XJQ --117 25--3 /8
155XJQ --174 28--3 /4
200XJQ --230
30--1 /2
6--3 /41--7 /81/2334--3 /45--1 /27--5 /816--3 /413--1 /2
225XJQ --350
1--5 /16
DRAW ING IT--1986
ISSUED --3/15/83
REVISED --2/26/01
SHEET 1 of2
H
H
J
J
REFER TO SHEET 2 O F 2
FO R M IXER PO SITIONING
DIMENSIONS
SHO RT O FFSET
LO N G
O FFSET
C
LTA N K
C
LSHAFT
10O
6REFER TO SHEET 2 O F 2 FO R M INIMUM DIAM ETER O PENING
REQUIRED TO PASS IM PE LLER /S W HEN DETACHED FROM SHAFT.
6
D
ANG LE RISER
BASE DETAIL
HH
M
J
L
J
(4)11/16 D IA.
FO R AIR MOTOR UNITS,
REFER TO DS--T --85.
MOUNTING HOLES

LIGHTNINMAINTENANCE AND SERVICE M ANUAL
DRAW ING IT--1986
ISSUED --3/15/83
REVISED --4/2/03
CERTIFIC ATION:This m ounting data,w hen used in conjunction w iththe dim ension draw ing and orderspecification sheetforthe
LIGHTNINOrderN um berlisted on S heet1 of2 representscertified dim ensions.
©LIGHTNIN
2001
SHEET 2 of2
NOTE:
1CONSULT FACTORY FOR TANK DIAM ETERS OR DEPTHS NO T LISTED.
IM P E LLE R
DIA.
MINIMUM
OPENING (IN.)
MINIMUM DIAM ETER OPENING REQUIRED TO PASS
IMPELLER W HEN DETACHED FROM SHAFT
2.52
IM P E LLE R
DIA.
MINIMUM
OPENING (IN.)
10.07--3 /4
3.42--5 /811.28--3 /4
3.8311.89--1 /4
4.53--1 /2 12.810
5.2 4 13.610--5 /8
5.94--5 /8 15.111--3 /4
6.34--7 /8 15.612--1 /4
6.85--1 /4 17.013--1 /4
7.6 6 19.015
XDQ & XJQ SERIES M IXER PO SITIONING
DATA
BASED ON 10
OANGULAR OFF--SET
MOUNTING
ALL DIMENSIONS ININCHES (mm)
TA N K
DIA.
LO N G O FF-
SET SHORT
O FF-SET
M AXIMUM
TA N K
DEPTH
inches inches inches inches
24 36 6--3 /43--7 /8
27 41 7--5 /84--3 /8
30 45 8--5 /16 4--3 /4
36 54 9--7 /85--3 /4
42 63 11--1 /26--5 /8
48 72 13 7--1 /2
54 81 14--1 /28--1 /2
60 90 16--1 /89--5 /16
66 100 17--7 /810--5 /16
72 108 19--1 /411--1 /8
78 117 20--3 /412
84 126 22--3 /813
90 135 24 13--3 /4
96 144 25--1 /214--3 /4
102 154 27--1 /415--3 /4
mm mm mm mm
915 170 100
685 1040 195 110
760 1145 210 120
915 1370 250 145
1065 1600 290 170
1220 1830 330 190
1370 2055 370 215
1525 2285 410 235
1675 2540 455 260
1830 2745 490 280
1980 2970 525 305
2135 3200 570 330
2285 3430 610 350
2440 3660 650 375
610
2590 3910 690 400
108 162 28--5 /816--9 /16
114 171 30--3 /16 17--7 /16
120 180 31--3 /418--5 /16
2745 4115 730 420
2895 4345 765 445
3050 4575 810 465
XDQ & XJQ SERIES M IXER PO SITIONING
DATA
BASED O N 7OANGULAR OFF--S E T
MOUNTING
TA N K
DIA.
LO N G O FF-
SET
SHORT
OFF-SET
M AXIMUM
TA N K
DEPTH
inches inches inches inches
24 48 6--3 /85--1 /8
27 54 7--1 /85--3 /4
30 60 7--13/16 6--5 /16
36 72 9--1 /47--1 /2
42 84 10--3 /48--3 /4
48 96 12--1 /49--15/16
54 108 13--11 /16 11 --1 /8
60 120 15--1 /812--5 /16
66 132 16--5 /813--1 /2
72 144 18--1 /16 14--3 /4
78 156 19--1 /215--15/16
84 168 21 17--1 /8
90 180 22--7 /16 18--3 /8
96 192 23--7 /819--9 /16
102 204 25--3 /820--3 /4
mm mm mm mm
1220 165 130
685 1370 180 145
760 1525 200 160
915 1830 235 190
1065 2135 275 225
1220 2440 315 255
1370 2745 350 285
1525 3050 385 315
1675 3355 425 345
1830 3660 460 375
1980 3965 495 405
2135 4270 535 435
2285 4575 570 470
2440 4880 610 500
610
2590 5185 645 530
108 216 26--13/16 21--15/16
114 228 28--5 /16 23--3 /16
120 240 29--3 /424--3 /8
2745 5490 680 560
2895 5795 720 590
3050 6100 755 620

SALES DATA BOOK SEC. 2 PAGE 51.0 DATE 9–30–99
DRAWING NO. L–16716B
©LIGHTNIN
1999
ISO 9001
CERTIFIED
XDQ DIRECT DRIVE
OPEN TANK MIXERS
ASSEMBLY DRAWING
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
R
ITEM PART NAME
1 HEX HEAD CAP SCREW
2 HEX HEAD CAP SCREW
3 LOCKWASHER
4 SHAFT SCREW
8 CHUCK SCREW
11 LIMIT PIN
18 CHUCK WASHER
20 BRASS WASHER
21 SNAP RING
23 RETAINING RING
24 OIL SEAL
25 FLEXIBLE MOUNTING
27 BALL BEARING
34 CHUCK GRIP
36 HOUSING
38 DRIVE SHAFT
41 MOTOR
ITEM PART NAME
42 MIXER SHAFT
43 HEX KEY WRENCH (NOT SHOWN)
44 IMPELLER
45 SET SCREW
46 MOTOR SHAFT KEY
47 LOCKWASHER
48 HEX HEAD CAP SCREW
49 HEX NUT
50 PLAINWASHER
59 WASHER (XDQ30 THRU 117 ONLY)
67 HEX HEAD CAP SCREW
68 LOCKWASHER
100 ANGLE RISER ASSEMBLY
102 ANGLE RISER (L.H.)
103 ANGLE RISER (R.H.)
105 SAFETY COVER
WHEN ORDERING PARTS, SPECIFY;
MACHINE SERIAL NO., ITEM NO.AND
DRAWING NO.
1
38
46
59
4
3
MOTOR HANDLE
MOTOR AND DRIVE SHAFT ASSEMBLY
MODELS XDQ 30 THRU 117 ONLY
38
67
68
42
DETAIL ”A”
ALTERNATE COUPLING CONSTRUCTION
(ITEMS 8, 11, 18, 21 & 34 NOT FURNISHED)
45
42 44
27
24
8/43
18
34
38
4
36
1
41
46
23
1HARDWARE ITEMS 47, 48, 49 & 50 FURNISHED
ONLY FOR UNITS WITH ANGLE RISERS.
11
SEE DETAIL ”A”
4850
25
47
49
2SAFETY COVER FURNISHED (NOT SHOWN).
SEE IT–1989 FOR DETAILS.
102/103
100 – ANGLE RISER ASS’Y
FURNISHED ONLY FOR UNITS WITH
ANGULAR OFFSET MOUNTING
2/20
21
2

SALES DATA BOOK SEC. 2 PAGE 69.0 DATE 5–1–00
DRAWING NO. L–16717D
©LIGHTNIN
2000
ISO 9001
CERTIFIED
XJQ GEAR DRIVE
OPEN TANK MIXER
ASSEMBLY DRAWING
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
R
31
46
59
4
3
MOTOR HANDLE
MOTOR SHAFT AND PINION ASSEMBLY
MODELS XJQ 30 THRU 117 ONLY
38
67
68
69
42
DETAIL ”A”
ALTERNATE COUPLING CONSTRUCTION
(ITEMS 8, 11, 18, 21 & 34 NOT FURNISHED)
45
42 44
26
23
18
8/43
21
11 34
38
4
1
41
46
2/20
ITEM PART NAME
1 HEX HEAD CAP SCREW
2 HEX HEAD CAP SCREW
3 LOCKWASHER – PINION SCREW
4 PINION SCREW
8 CHUCK SCREW
11 LIMIT PIN
18 CHUCK WASHER
21 SNAP RING
22 RETAINING RING
23 RETAINING RING (2)
24 OIL SEAL
25 FLEXIBLE MOUNT
26 OIL SEAL
27 BALL BEARING
28 INNER RING
29 OUTER RING AND ROLLER ASSY
30 GEAR/PINION SET
31 PINION
ITEM PART NAME
39 GRIP SPRING SET
41 MOTOR
42 MIXER SHAFT
43 HEX KEY WRENCH (NOT SHOWN)
44 IMPELLER
45 SET SCREW
46 MOTOR SHAFT KEY
47 LOCKWASHER
48 HEX HEAD CAP SCREW
49 HEX NUT
50 PLAIN WASHER
59 WASHER (XJQ 30 THRU 117 ONLY)
60 O–RING
61 GRIP SPRING LOCKNUT
67 HEX HEAD CAP SCREW
68 LOCKWASHER
69 HEX NUT (XJQ 30 THRU 117 ONLY)
70 OIL SEAL WHEN ORDERING PARTS, SPECIFY
MACHINE SERIAL NO., ITEM NO. &
DRAWING NO.
31
37
36
70
71
61
32
39
22
27
24 23
23
32 INTERNAL GEAR
34 CHUCK GRIP
36 HOUSING
37 SPACER
38 DRIVE SHAFT
71 SLINGER
100 ANGLE RISER ASSEMBLY
102 ANGLE RISER (L.H.)
103 ANGLE RISER (R.H.)
105 SAFETY COVER
20 BRASS WASHER
(XJQ 174 THRU 350 ONLY)
1HARDWARE ITEMS 47, 48, 49 & 50 FURNISHED
ONLY FOR UNITS WITH ANGLE RISERS.
2SOLD IN SETS ONLY.
1
3SAFETY COVER FURNISHED (NOT SHOWN).
SEE IT–1989 FOR DETAILS.
3
2
2
22
48
50
47
49
25
102/103
100 – ANGLE RISER ASS’Y
FURNISHED ONLY FOR UNITS WITH
ANGULAR OFFET MOUNTING
60
NOTES:
28
29
26
28
29

LIGHTNIN
MIXERS AND AERATORS
®
REVISION 2001 DATE 3–16–83
REVISED 2–26–01
INST. NO. IT–1997
CPAGE 1 OF 9
LIGHTNIN
MIXERS AND AERATORS
®
©© LIGHTNINLIGHTNIN
GENERAL INSTRUCTIONS
LIGHTNINXJQ 30 THRU 350 SERIES
OPEN TANK FIXED MOUNT MIXERS
SECTION 1 – INITIAL INSPECTION, SHIPPING ARRANGEMENTS AND STORAGE
1.1 As soon as you have uncrated your mixer, check it for shipping damage and report any damage immediately
to the carrier and to our factory.
1.2 Mixer and impellers are packed together. The mixer shaft is packed in a separate container.
1.3 Do not remove wrappings or protective coatings if the mixer is to be stored before it is placed in operation. Store
the mixer in a clean, dry location, with circulating air, free from wide or rapid variations in temperature. When
gear drive models have been stored for more than a year, the condition of the gear lubricant should be checked
before the mixer is installed (see lubrication instructions).
SECTION 2 – MIXER AND SHAFT INSTALLATION
2.1 Refer to the installation drawing for proper mixer mounting and location.
2.2 All mixers are furnished with safety covers. Do not remove during operation.
a . Stop unit and disconnect power supply before removing safety cover.
b . Re–install safety cover after servicing the unit.
SAFETY COVER
4 VENT HOLES
4 HEX HEAD
FASTENERS
2.3 Impeller rotation must be according to the arrow on the mixer nameplate.
a . Single phase totally enclosed motors are wired at our factory for correct rotation.
b . All three phase and explosion proof motors must be field wired for proper rotation. If rotation does not
agree with nameplate, reverse any two line leads.
c . Dual voltage motors must be wired for the desired voltage. Refer to the connection diagrams provided
on the motor nameplate or inside the conduit box cover.
2.4 LIGHTNIN Mixers are equipped with ball bearing chemical plant motors specifically designed for mixer service
in totally enclosed or explosion proof construction.
a . Constant speed mixers are furnished with LIGHTNIN DURA–MIXenergy efficient motors unless
otherwise specified.
b . For variable speed mixers with electronic or air driven motors, refer to supplementary instructions for
motor control data and connection requirements.

LIGHTNIN
MIXERS AND AERATORS
®
REVISION 2001 DATE 3–16–83
REVISED 2–26–01
INST. NO. IT–1997
CPAGE 2 OF 9
LIGHTNIN
MIXERS AND AERATORS
®
©© LIGHTNINLIGHTNIN
2.5 Single Phase Motors for XDC30 thru 87 (or motors nameplated 1/4 thru 1 horsepower):
a . Totally enclosed motors are furnished with eight foot cords fitted with UL approved three prong
grounded plugs suitable for the correct voltage.
b . Explosion proof motors are furnished with a pipe tap connection and suitable leads. A conduit box with
internal switch is available for explosion proof service.
c . All DURA–MIXsingle phase motors are equipped with an internal over–temperature device with
manual reset. If the thermal trips, wait fifteen (15) minutes and depress the reset button on the motor
body. A click indicates reset.
2.6 Three Phase Motors:
a . All totally enclosed motors are equipped with a conduit box and suitable leads.
b . All explosion proof motors are furnished with a pipe tap connection and suitable leads.
IMPORTANT: ALL THREE PHASE MOTORS (except explosion proof on XDC 30 thru 65 or other XP
motors nameplated 3/4 horsepower and below) are equipped with over–temperature thermostats
which are designed to interrupt current in the holding coil of magnetic starters only. The motor
thermostats will reset themselves, but the control panel ”start” button must be depressed to start the
motor.
EXPLOSION PROOF MOTORS on XDC 30 thru 65 or XP motors nameplated 3/4 horsepower and
below are equipped with automatic over–temperature circuits which can trip and reset themselves
after the motor cools. TO AVOID INJURY DUE TO UNEXPECTED START UP, DISCONNECT FROM
POWER UNTIL THE MOTOR COOLS.
2.7 Procedure for units equipped with chuck:
a . To install the mixer shaft, back off the chuck screw (refer to Figure 1) as far as the limit pin will allow.
DO NOT FORCE.
b . Insert the mixer shaft into the chuck bore as far as it will go, and draw up the chuck screw with the
wrench provided, rotating the shaft slightly back and forth to make sure the chuck grip seats against
the flat of the shaft.
c . Tighten the chuck screw with the wrench provided. The wrench has been properly sized to tighten the
screw. DO NOT IMPACT THE WRENCH OR USE AN EXTENSION.
NOTE: A safety feature is provided by a slight taper in the flat on the mixer shaft. The shaft cannot drop
out unless the grip is intentionally released.
CHUCK GRIP
CHUCK SCREW
LIMIT PIN
CHUCK
FIGURE 1 – CHUCK DETAILS
2.8 Procedure for units equipped with couplings:
a . Connect the mixer shaft (42) to the drive shaft (38) by bolting the coupling halves together.
CAUTION: Care should be exercised in order to prevent damage to the coupling rabbets, and to insure
proper seating of the coupling halves.
2.9 Position the impeller(s) on the mixer shaft. Refer to the specification sheet for recommended dual impeller
spacing. The larger wedge shaped portion of the hub body must face up towards the mixer. The bottom of
the hub is stamped ”DOWN”. Refer to Figure 2 for general orientation reference. Tighten impeller set screws
securely. For unusually severe conditions, the shaft should be spotted for the set screws.

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MIXERS AND AERATORS
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REVISION 2001 DATE 3–16–83
REVISED 2–26–01
INST. NO. IT–1997
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ROTATION
LEADING
EDGE
LARGE WEDGE SHAPED
PORTION OF HUB MUST
FACE UP.
CONVEX SURFACE
”DOWN” STAMPED ON
LOWER FACE
FIGURE 2 – IMPELLER ORIENTATION
SECTION 3 – MIXER OPERATION
3.1 LIGHTNIN mixers are designed to operate continuously at normal or low liquid levels, and in air.
IMPORTANT: Variable speed drives sometimes have critical ranges where the unit should not be operated
during drawoff or in air. These ranges will be indicated on a warning decal at the speed control. It is not good
practice to operate any mixer continuously when extreme vortexing or surging occurs.
3.2 At the end of two weeks service, check the housing cap screws, chuck screw and mounting bolts for tightness.
3.3 Dirt on the motor case acts as an insulator to prevent proper cooling. Always keep the motor clean.
3.4 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.
3.5 A built–in shock load feature is included in the gear drive. The grip springs (39) provide a keyless friction drive
between the gear and the drive shaft, and the springs will slip before the mixer is damaged. Therefore, if the
mixer shaft does not rotate when the motor is turned on, remove the motor (41) from the housing (36) and
tighten the grip spring locknut (61) securely. The table below lists the recommended tightening torque for this
locknut. If a torque wrench is not available, be sure the locknut is tightened sufficiently to prevent grip spring
slippage.
GRIP SPRING SPACER (37)
OIL SEAL (70)
DRIVE SHAFT (38)
INTERNAL GEAR (30)
SLINGER (71)
GRIP SPRING LOCKNUT (61)
GRIP SPRING SET (39)
PINION (31)
RETAINING RING (22)
FIGURE 3 – GRIP SPRING ASSEMBLY
RECOMMENDED TIGHTENING TORQUE FOR GRIP SPRING LOCKNUT
MODEL
TIGHTENING TORQUE
IN FOOT–POUNDS
XJQ 30
20
XJQ 87 & 117
50
XJQ 43
20
XJQ 65
50
XJQ 174
125
XJQ 230 & 350
125

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INST. NO. IT–1997
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SECTION 4 – FLEX MOUNT REPLACEMENT
4.1 The flex mounts can be removed with a long bolt and two pieces of tubing as shown in Figure 4.
HEX HEAD CAP SCREW
PLAIN WASHER
TUBING
FLEX MOUNT (25)
HOUSING (36)
TUBING
PLAIN WASHER
HEX NUT
(MINIMUM 5 INCHES
LONG)
(7/8 INCH MAXIMUM
OUTSIDE DIAMETER)
(2 INCH MINIMUM
INSIDE DIAMETER)
OR PLATE
FIGURE 4 – FLEX MOUNT REMOVAL
4.2 Tighten the nut until the mount is free of the housing.
4.3 To install new mounts, use a long bolt and a piece of tubing as shown in Figure 5.
HEX HEAD CAP SCREW
PLAIN WASHER
TUBING
FLEX MOUNT (25)
HOUSING (36)
PLAIN WASHER
HEX NUT
(MINIMUM 4–1/2 INCHES
LONG)
(1–3/8 INCH MINIMUM
INSIDE DIAMETER)
FIGURE 5 – FLEX MOUNT INSTALLATION
4.4 Lubricate the mount with a natural rubber lubricant or liquid hand soap.
4.5 Tighten the nut until the mount is tight with the housing base.
4.6 Replace ALL mounts if one is replaced.
4.7 Tighten mounting hardware to 85 ft–lbs. Use double nuts to lock in position.
SECTION 5 – MIXER LUBRICATION
5.1 STANDARD GEAR LUBRICANT – The factory supplied NLGI EP0 grease is a high quality lubricant with a
lithium base, suitable for operation in ambient temperatures ranging between +50°F and +200°F. Under
normal operating conditions, this lubricant need not be changed until the unit has been dismantled
for some reason.
5.2 Under adverse operating conditions, periodic changes of lubricant may be necessary. Adverse conditions are
defined as operating in very humid, dust laden or chemical atmospheres, or where wide variations in ambient
temperature occurs. Such adverse conditions can lead to deterioration of lubricant compounds and additives,
and it is recommended that the condition of the grease be checked within six months after start up. Reputable
lubricant suppliers can analyze the grease and recommend economical, safe change schedules.
5.3 Gear Lubricant Recommendations:
Use only a lubricant suitable for the temperature and operating conditions.
AMBIENT
TEMP.
RANGE
50°F to 200°F
NLGI #
EP 0
BASE
LITHIUM
MIN. OIL
VISCOSITY
SUS
750 @ 100°F
76 @ 210°F 200°F
MAX.
OPERATING
TEMP.

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REVISION 2001 DATE 3–16–83
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INST. NO. IT–1997
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LIGHTNIN EP0 grease (part number 123620PSP) is available in 2 pound containers.
Approved Alternate Lithium EP 0 Greases
MANUFACTURER PRODUCT
Agip GR MU/EP 0
Amoco Amolith EP 0
BP A0, CA or CS0
Castrol Helveum 0, Impervia CL
Chevron Duralith EP 0
Citgo Premium Lithium EP0
Elf EPEXA0
Exxon Lidok EP0
Lubriplate 630 AAA
Mobil Mobilux EP 0
Pennzoil Pennlith EP710
Shell Alvania EP 0
Sunoco Prestige 740 EP
Texaco Multifak EP 0
NOTE:
This cross reference list should be used as a guide
only. Before using these products, discuss with
a local supplier.
For operation in ambient temperatures below +50°F, we recommend use of a synthetic grease (Mobil SHC
007 or equal) compounded only with synthesized hydrocarbon fluids. This grease is suitable for a wide range
of ambient temperatures between –30°F and +200°F, and should be considered where seasonal lubricant
changes are necessary
5.4 Changing Gear Lubricant:
a . Make sure the mixer housing is vertical to prevent spillage.
b . Remove the motor to housing cap screws and lift off the motor by its handle.
c . Remove all old grease from the gear chamber and wipe clean.
d . Pack the chamber with fresh grease (see table below). Paddle the grease to fill voids and remove air
pockets, rotating the shaft and shaking the housing while paddling.
GEAR CHAMBER CAPACITY
MODEL GREASE – LBS.
XJQ 30 & 43 1.25 
XJQ 65 thru 117 2.25 
XJQ 174 thru 350 3.0 
 PACK CHAMBER FLUSH WITH TOP OF THE INTERNAL GEAR.
 PACK CHAMBER TO WITHIN 3/4” BELOW TOP OF INTERNAL GEAR.
e . Check the O–ring in the flange of the motor and replace if it is deformed, cut or deteriorated.
f . Carefully align the motor rabbet and guide into the housing bore. Guide the pinion into mesh with the
gear, and make sure the O–ring is properly seated in the groove.
g . Check for free movement of all components by rotating the drive shaft.
h . If satisfactory, replace the motor to housing hardware and tighten securely.
SECTION 6 – DISASSEMBLY
6.1 Removing the Mixer Shaft:
a . Remove the limit pin (11) by driving it into the counterbored hole.
b . Remove the chuck screw (8).
c . Remove snap ring (21), chuck grip (34) and chuck washer (18) from the chuck screw.

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6.2 Removing the Motor from the Housing:
a . Set the mixer in a vertical position to prevent spilling the gear lubricant.
b . Remove the four housing cap screws and washers (1, 2 & 20).
c . Raise the motor (41) by its handle (35) or eyebolts to separate the motor from the housing (36).
d . Remove the O–ring (60).
6.3 Removing the Pinion from the Motor:
a . Hold the pinion (31) from turning and remove the pinion cap screw (4) in one of the following ways:
1 .XJQ 30 thru 117 – Use a Phillips screwdriver.
2 .XJQ 174 thru 350 – Use a 5/16 inch hex key wrench.
3 .XJQ 174 thru 350 (with a nylon slinger) – The slinger (71) must be removed by breaking it. Place
a wooden block under the slinger and strike the opposite side with a chisel.
b . Remove the pinion with a bearing puller.
6.4 Removing Drive Shaft, Bearings and Oil Seals from the Housing:
a . Remove the lubricant from the gear chamber.
b . Remove the grip spring locknut (61) from the upper end of the drive shaft (38). Use one of the following
methods to hold the drive shaft from turning:
1 . Procedure for units equipped with chuck:
a .XJQ 30 thru 117 – Insert a hex key wrench (43) in the chuck screw.
b .XJQ 174 thru 350 – Remove the chuck assembly per paragraph 6.5. Insert a 1 foot length of 1
inch diameter bar into the chuck grip bore.
2 . For models with rigid couplings:
a .Bolts can be inserted into the coupling half and a bar interlocked between the bolts to keep the
drive shaft from rotating.
c . Thread a nut on the end of the drive shaft (38) to protect the threads when pressing out the shaft.
d . Mount the housing in an arbor press, motor end upward, and press the drive shaft clear of the internal
gear bore.
e . Remove the internal gear (30), the two grip spring sets (39) and the grip spring spacer (37).
f . Remove the drive shaft, with the bearing inner ring (29) in place, through the lower opening in the
housing.
g . If it is necessary to remove the bearing inner ring, start it from its seat with a thin screwdriver or wedge,
then remove it from the drive shaft with a bearing puller.
h . XJQ 174 thru 350 ONLY – Pry the oil seal (70) from the housing bore as shown in Figure 6.
1 .Insert a 7/8 bolt into the ball bearing (27) bore.
2 .Use the bolt head as a fulcrum and pry out the oil seal (70) with pliers.
PLIERS
7/8 BOLT
22
70
27
24
FIGURE 6 – OIL SEAL REMOVAL
i . Use Wades Truarc No. 4 pliers to remove the internal retaining ring (22).
j . Remove the ball bearing (27) and upper oil seal (24) through the upper opening of the housing.
k . Remove the internal retaining rings (23).
l . Mount the housing, motor end upward, in an arbor press and press out the oil seal (26) and the outer
ring and roller assembly (29).

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6.5 Disassembling the Chuck:
a . Remove the limit pin (11) by driving it into the counterbored hole.
b . Remove the chuck screw (8).
c . Remove snap ring (21), chuck grip (34) and chuck washer (18) from the chuck screw.
SECTION 7 – ASSEMBLY
7.1 Preparing for Assembly:
a . Clean all parts thoroughly.
b . Inspect for the following defects:
1 .Cracks or damage of the housing.
2 .Dents, gouges or scoring of the drive shaft, housing bore, and particularly the mating faces of the
motor and the housing.
c . Repair or replace defective parts. It is good practice to replace an oil seal which has been removed
from the housing. Apply a small quantity of bearing grease to the housing bore and around the oil seal
lip to provide lubrication and to make the seal more effective.
d . Replace the O–ring if it is cut, deformed or deteriorated.
e . Replace the ball bearing and roller bearing (including the bearing inner ring) if they show indications
of wear.
7.2 Assembling the Drive Shaft in the Housing:
a . Mount the housing (36) in an arbor press, motor end up.
b . Press the upper oil seal (24), sealing lip upward, approximately 1/8 inch below the shoulder of the bore.
c . Press the ball bearing (27) on its outer race against the shoulder of the housing bore.
d . Install retaining ring (22).
e . XJQ 174 thru 350 ONLY:
1 .Apply a heavy coating of ball bearing grease to the top of the ball bearing (27).
2 .Apply a coating of Loctite ”Bearing Mount” grade to the outside of the new oil seal (70).
3 .Press the oil seal (70), sealing lip up, into the housing until it seats against the retaining ring (22).
f . Turn the housing motor end down in the press, and install the inner of the two lower retaining rings (23).
g . Pack the outer ring and roller assembly (29) with a suitable bearing grease and press it into the housing
bore until it registers against the retaining ring.
h . Press the oil seal (26), with its sealing lip towards the motor end of the housing, against the outer ring
and roller assembly.
i . Install outer retaining ring (23).
j . If the bearing inner ring (28) has been removed from the drive shaft (38), press it in place.
k . Apply a thin film of light oil on the tapered surfaces only of each grip spring set.
CAUTION: For proper operation of the grip springs, oil must not get between the grip spring driving
surfaces and the drive shaft or gear bore.
l . Install the inner ring of the lower grip spring set (39) so that the thicker edge seats against the shaft
shoulder.
m . Place the housing on its side and grease the lips of the oil seals.
n . Hold the internal gear (30) in place in the gear chamber and pass the drive shaft through its bearings
as far as it will go into the hub of the gear.
o . With the gear on the end of the shaft, turn the housing motor end down and press the shoulder of the
drive shaft against the inner race of the ball bearing (27).
p . Turn the housing motor end up. Center the internal gear in the drive shaft and install the external ring
of the lower grip spring set (39), grip spring spacer (37) and upper grip spring set (39). Both grip spring
sets should be installed with the thicker edge of the external ring upward (see Figure 7).

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REVISED 2–26–01
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GRIP SPRING SPACER (37)
OIL SEAL (70)
DRIVE SHAFT (38)
INTERNAL GEAR (30)
SLINGER (71)
GRIP SPRING LOCKNUT (61)
GRIP SPRING SET (39)
PINION (31)
RETAINING RING (22)
FIGURE 7 – GRIP SPRING ASSEMBLY
q . Apply a thin coat of light oil on the threads of the drive shaft and the bottom surface of the grip spring
locknut.
r . Thread the grip spring locknut (61) onto the end of the drive shaft (finger tight). Rotate the internal gear
(30) by hand, and at the same time tighten down on the locknut until the internal gear can no longer
be rotated. Tighten the locknut securely. (The table below lists the recommended tightening torque
for this locknut. If a torque wrench is not available, be sure locknut is tightened sufficiently to prevent
grip spring slippage.) Use one of the following methods to prevent the drive shaft from turning while
performing this operation.
XJQ SERIES MODEL 30 & 43 65 thru 117 174 thru 350
TIGHTENING TORQUE (FT.–LBS) 20 50 125
RECOMMENDED TIGHTENING TORQUE FOR GRIP SPRING LOCKNUT
1 .Procedure for units equipped with chuck:
a .XJQ 30 thru 117 – Reassemble the chuck assembly. Insert a hex key wrench into the chuck
screw.
b .XJQ 174 thru 350 – With the chuck assembly removed from the drive shaft, insert a 1 foot length
of 1 inch diameter bar in the chuck grip bore.
2 .For models with coupling:
a .Bolts can be inserted into the coupling half and a bar interlocked between the bolts to keep the
drive shaft from rotating.
7.3 Assembling the Pinion on the Motor Shaft:
a . XJQ 174 thru 350 ONLY:
1 .Install the slinger on the motor shaft, allowing a gap of 1/32 inch gap between the motor oil seal and
the top of the slinger.
2 .Check shaft end play and rotate to make sure slinger rotates freely.
3 .Coat the set screw threads with Loctite and tighten the set screw securely.
b . Apply a thin film of grease to the motor shaft or pinion shaft.
c . Make sure that the motor shaft key (46) is in place in the motor shaft keyway.
d . Assemble the pinion on the motor shaft by driving it into place with light strokes of a mallet.
e . Make sure that the pinion and motor shafts butt securely, then install and tighten the pinion screw (4).
7.4 Assembling the Chuck:
a . Assemble chuck washer (18), chuck grip (34) and snap ring (21) on the chuck screw (8).
b . Thread the chuck screw into the chuck end of the drive shaft, far enough to insert the limit pin (11), so
that the end of the pin is 3/16 of an inch underflush.
7.5 Assembling the Motor to the Housing:
a . Fill the gear chamber of the housing (36) level with a suitable lubricant (see Section 5). Make sure that
the grease is solidly packed without air pockets by paddling the grease, rotating the drive shaft by
hand, tapping or shaking the housing.

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b . Clean the mating surfaces of the motor (41) and the housing (36).
c . Place the O–ring (60) on the motor (41).
d . Align the motor rabbet with the opening of the housing, and lower the motor into place using care so
as not to damage the O–ring.
e . Align the motor and housing so that the switch, conduit box or junction box of the motor are opposite
the large opening on the front of the housing.
f . Align the screw holes and install the housing cap screws and washers (1, 2 & 20).
g . Rotate the drive shaft several revolutions by hand to make sure that all parts are running freely.
h . Reassemble the mixer shaft to the unit as described in the installation instructions.

REVISION 2001 DATE 3–16–83
REVISED 2–26–01 PAGE 1 OF 5
INST. NO. IT–1994
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LIGHTNIN
MIXERS AND AERATORS
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GENERAL INSTRUCTIONS FOR
LIGHTNINXDQ 30 THRU 350 SERIES
OPEN TANK FIXED MOUNT MIXERS
SECTION 1 – INITIAL INSPECTION, SHIPPING ARRANGEMENTS AND STORAGE
1.1 As soon as you have uncrated your mixer, check it for shipping damage and report any damage immediately
to the carrier and to our factory.
1.2 Mixer and impellers are packed together. The mixer shaft is packed in a separate container.
1.3 Do not remove wrappings or protective coatings if the mixer is to be stored before it is placed in operation. Store
the mixer in a clean, dry location, with circulating air, free from wide or rapid variations in temperature.
SECTION 2 – MOUNTING
2.1 Support the mixer by the motor handle or eye bolts and mount it on the support base. Refer to the installation
or dimension drawing.
2.2 All mixers are furnished with safety covers. Do not remove during operation. Stop unit and disconnect power
supply before removing safety cover. Reinstall safety cover after servicing the unit.
4 VENT HOLES
4 HEX HEAD
FASTENERSFIGURE 1 – SAFETY COVER
2.3 Impeller rotation must be according to the arrow on the mixer nameplate.
a . Single phase totally enclosed motors are wired at our factory for correct rotation.
b . All three phase and explosion proof motors must be field wired for proper rotation. If rotation does not agree
with nameplate, reverse any two line leads.
c . Dual voltage motors must be wired for the desired voltage. Refer to the connection diagrams provided on
the motor nameplate or inside the conduit box cover.
SECTION 3 – MOTOR CONNECTIONS
3.1 LIGHTNINMixers are equipped with ball bearing chemical plant motors specifically designed for mixer
service in totally enclosed or explosion proof construction.
a . Constant speed mixers are furnished with LIGHTNIN DURA–MIXenergy efficient motors unless
otherwise specified.
b . For variable speed mixers with electronic or air driven motors, refer to supplementary instructions for motor
control data and connection requirements.
3.2 Single Phase Motors for XDQ/XJQ 30 thru 87 (or motors nameplated 1/4 thru 1 horsepower):
a . Totally enclosed motors are furnished with eight foot cords fitted with UL approved three prong grounded
plugs suitable for the correct voltage.
b . Explosion proof motors are furnished with a pipe tap connection and suitable leads. A conduit box with
internal switch is available for explosion proof service.
c . All DURA–MIXsingle phase motors are equipped with an internal over–temperature device with manual
reset. If the thermal trips, wait fifteen (15) minutes and depress the reset button on the motor body. A click
indicates reset.