MBL Operation Manual EK-200 [PDF]

Zitiervorschau

MUAR BAN LEE

(Co.No. 664866 - T)

TECHNOLOGY SDN. BHD Specialists In Oil Seed Crushing Machinery

Palm Kernel

Oil Expeller

EK-100-K / EK-150-K / EK-200-K

Operation Manual & Part List

ISO 9001:2008 Certified

Ver 01.2010

Headquarters (Factory 1)

JR52, Lot 1818,Jalan Raja, Kaw. Perindustrian Bukit Pasir, 84300 Muar, Johor, Malaysia. Branch Production (Factory 2)

No21, Jalan Rami 4, Kaw. Perindustrian Bukit Pasir, 84300 Muar, Johor, Malaysia.

Tel : +606 985 9998 Email : [email protected]

Tel : +606 985 8889 Website : WWW.MBL.COM

MUAR BAN LEE ENGINEERING SDN. BHD. Customer

:

Date : 23 JAN 2017

INDUSTRIAL A.V.M

1.0 Product General Information Model

: EK-200-K

Description

: PALM KERNEL OIL EXPELLER

1st Pressing Machine

:

2

Unit/s

Serial No.

: SN

9908/14

To SN

9909/14

2nd Pressing Machine

:

--

Unit/s

Serial No.

: SN

--

To SN

--

Machine r.p.m

Capacity

Recommended AMP

1st Pressing

:

17.8 r.p.m

20-22

MT/24HRS

65 ~ 75 AMP

2nd Pressing

:

--

--

MT/24HRS

--

Gearbox Brand

: SUMITOMO

Make

:

SUMITOMO JAPAN

Size

: YHD080P3-LR-56

Ratio

:

56:1

Type

: TRIPLE REDUCTION HELICAL GEAR

Rated Torque

: 74'000

Service Factor

Required Torque for Bolt & Nut

: 1’400 ( Need to inspect every 14 days)

Drive

1st Pressing

: 2.5

2nd Pressing

: --

Coupling

Brand

: ELECTRIM

Type

: GEAR COUPLING 18T

Power

: 55kW (75hp)

Dimension

: Dia. 380mm

R.P.M

: 6 Pole

:

Pulley

Pulley & Belt

Belt Motor

Remark

Gearbox

1st Pressing

:

224 mm

224 mm

2120 mm

2nd Pressing

:

-- mm

-- mm

-- mm

5 SPC --

MUAR BAN LEE TECHNOLOGY SDN. BHD. OIL EXPELLER

INDEX 1.0 2.0 3.0

Technical Specifications and Details General Information and Pre-operating Instructions Operation Instructions 3.1 Before Operating Oil Expeller 3.2 For Newly Start 1st Stage Pressing Expeller 3.3 For Newly Start 2nd Stage Pressing Expeller 3.4 Stopping the Oil Expeller 3.5 Final Adjustment 16 Hours after the Start-up

4.0

General Maintenance Instructions 4.1 Main Cage 4.1.1 Removal Main Cage 4.1.2 Refitting Main Cage 4.2

Feed Cage 4.2.1 Removal of Feed Cage 4.2.2 Refitting of Feed Cage

4.3

Removal and Refitting Worm and Distance Pieces 4.3.1 General Description 4.3.2 Removal and Replacement of Worm and Distance Pieces

4.4 4.5 4.6

Removal of Main Shaft Reclaiming Worm and Distance Pieces Method of Reclaiming Work 4.6.1 Preparation 4.6.2 Rebuilding 4.6.3 Grinding and Finishing

4.7

Drawings

Operation Manual / Page 1 of 16

MUAR BAN LEE TECHNOLOGY SDN. BHD. OIL EXPELLER

IMPORTANT ! · ·

Kernel Quality = Moisture Content in Kernel must less than 7%, and Dirt must less than 6%. (Malaysia Edible Oil Manufacturer’s Association Standard.) Please check through all conveying system, elevating system, silo, hopper, oil expeller and other equipments/facilities is free from carrying any foreign metal objects at all times. The metal objects will be caused serious damage to the crushing equipments/facilities. Especially to oil expeller; worms, taper head, wear plate and cages.

NO METAL OBJECTS IS ALLOWED !!!

·

Please check through all the necessary lubricating components before the 1st newly start up, every day before start production and follow maintenance schedule.

Check the following for lubrication: -

GEARBOX

OIL LEVEL

COVER

1/2 GLASS TO

3/4 GLASS OIL

OIL SIGHT GLASS

OIL OUTLET

Operation Manual / Page 2 of 16

MUAR BAN LEE TECHNOLOGY SDN. BHD. OIL EXPELLER

OIL EXPELLER OIL LEVEL GREA SE N IPPL E

60%

+

V G 3 2 0 ( O IL )

40% GREA SE

FIL L L U B RIC A N T O IL IN TO O IL RESERV O IR

OIL + GREASE

LUBRICATING GREASE Lubricating greases are thickened mineral oils or synthetic fluids. The consistency of grease depends largely on the type and quantity of the thickening agent used. * Castrol LM General Purpose Bearing Grease. LUBRICATING OIL For the lubrication of ball and roller bearing, only solvent refined mineral oils should be considered. Oils containing additives to improve certain properties (lubricant film strength, oxidation resistance etc.) are normally only required for exceptional operating conditions. Synthetic oils as bearing lubricants are mainly only used as base oils for greases or in extreme cases where there may be very high operating temperature. * Synthetic Oil VG320

Operation Manual / Page 3 of 16

MUAR BAN LEE TECHNOLOGY SDN. BHD. OIL EXPELLER

TECHNICAL SPECIFICATIONS AND DETAILS Palm Kernel Oil Expeller The palm kernel oil expeller has been specifically design for both pre-pressing and final pressing of hard seeds such as palm kernel.

M . Ban Lee

1.1

F

E

D

C

B

A

G

M . Ban Lee

Model: EK Series

F

E

D

C

B

A

G

Model: EKM Series

* figure 1 & 2 Item

Description

A

Oil Press

B

Hopper Type of Coupling

C

Coupling

EK Series 1. Pin & Bush

D

Gearbox

E

Pulley & Belt

F

Electric Motor

G

Machine Footing

2. Gear

EKM Series 3. Split

1. Gear

2. Positive Engagement

Operation Manual / Page 4 of 16

MUAR BAN LEE TECHNOLOGY SDN. BHD. OIL EXPELLER

1.2

Oil Press Single screw press, it is consisting a set of high quality worms and collars. The pressing pressure can be adjusted the extruding gap accordingly to the actual pressing requirement. (refer Newly Start Up.)

1.3

Pressing Speed 1st Pressing r.p.m 2nd Pressing r.p.m

: (Motor rpm x pulley 1) (/ Pulley 2) (/ Gearbox Ratio) @ +/- 17 : (Motor rpm x pulley 1) (/ Pulley 2) (/ Gearbox Ratio) @ +/- 12

1.4

Main Shaft The main shaft is fabricated from high tensile steel ASSAP 705 and the key ways run along the shaft for the worm and distance piece.

1.5

Cages and Bars The pressure barrel can be split along the horizontal centerline and can be removed by loosening the mounting bolts and nuts; which clamp the reinforcement ribs. The bars welded to the cage are wither from case hardened lining bars or mild steel flat bars.

Operation Manual / Page 5 of 16

MUAR BAN LEE TECHNOLOGY SDN. BHD. OIL EXPELLER

2.

GENERAL INFORMATION & INSTRUCTIONS

2.1

The arrangement and foundation dimensioned drawing are specifically designed to suite each individual mill layout.

Foundation (for reference only)

A

M . Ban Lee

M . Ban Lee

A

ALL EXPELLER FOOTING WELDING ON I-BEAM * ( I Beam 6" x 6" ) * ( WELDING ROD 6013 / MILD STEEL)

+ 254

Concrete

±0

I Beam 6"x6" 20 lbs SEC TIO N A - A ( N .T.S )

2.2

When installing new press machines, all presses should be leveled accordingly before being grouted in position. Sufficient wedges must be installed under the common base of the press to ensure that it is not distorted or strained before final grouting and tightening of the hold-down bolts.

2.3

Ensure clear access is provided for the removal of the press barrel and main shaft.

2.4

If a number of units of kernel press are installed, ensure that the started control cabinet for each press is clearly numbered and conspicuously displayed in order not to arouse confusion in the event of an emergency shutdown.

2.5

Check the overload settings of the starters, which should normally be at 110% of the full load. Check the fuses in the main control cabinet.

Operation Manual / Page 6 of 16

MUAR BAN LEE TECHNOLOGY SDN. BHD. OIL EXPELLER

Ensure that the plant operator has an unrestricted view of the control cabinet and in particular, the kernel press main motor ammeter. When the full load amperage of the kernel press has been determined (refer the plate on the Press motor), it is very often useful to indicate this value on the operator as a quick visual indication.

3.

OPERATING INSTRUCTIONS

3.1

Before Operating Oil Expeller

3.1.1

Ensure that extruding section of the oil expeller is empty by observation through the feeling hopper. Especially free from metal objects.

3.1.2

Ensure all mounting and hold-down bolts and nuts are securely tightened.

1 2 3 4 5 6 7 8 9 1011121314

M . Ban Lee

2.6

** 14 NOS OF NUT (SQUARE BAR)

HAMMER (12 LBS)

** 4 NOS OF NUT

** BOLTS & NUTS

** 4 NOS OF NUT

3

1

4

2

** BOLTS & NUTS

3.1.3

Proper adjustment of the belt tension

3.2

For Newly Start Up The 1st Stage Pressing Expeller

3.2.1

Check the clearance between the taper head and the wear plate at the rear of the block. Initially, a 16mm clearance should be allowed.

Operation Manual / Page 7 of 16

MUAR BAN LEE TECHNOLOGY SDN. BHD. OIL EXPELLER

11

10

16 mm

3.2.2

Check the direction of rotation of the extruder. The correct direction should be in Clock-Wise direction when observed from the output end.

3.2.3

Once completed both prior steps, fed the press with kernels through the hopper. NEVER use dry kernel for the start – up operations. Always rinse the kernel with some water for initial start. Continuously, recollect the discharged cake and manually fed them back to the expeller through the hopper for about 20 – 25 minutes.

PALM KERNEL

WATER

HOPPER

3.2.4

After a few hours of operation at low loading, the expeller beltings might need some readjustment. (Refer procedure for stopping the expeller)

3.2.5

Allow the oil expeller to operate at low loading for at least 50 hours.

Operation Manual / Page 8 of 16

MUAR BAN LEE TECHNOLOGY SDN. BHD. OIL EXPELLER

3.2.6

After completed the step 3.2.5, readjust the taper head to allow 12 to 13mm clearances for optimum pressing; or otherwise make adjustment accordingly judging from the observation of the cake condition.

3.3

For Newly Start Up The 2nd Stage Pressing Expeller

3.3.1

Check the clearance between the taper head and the wear plate at the rear of the block. Initially, a 12 – 13mm clearance should be allowed.

11

10

12~13 mm

3.3.2

Follow Step 3.3.2 – 3.2.5 as above.

3.3.3

Upon completion, readjust the taper head to allow 9 – 10mm clearances; or otherwise make adjustment accordingly judging from the observation of the cake condition.

3.4

Stopping the Oil Expeller

3.4.1

Shut the incoming kernel / cake chute of the overhead silo. Rinse the kernel (1st Pressing) / Cake (2nd Pressing) in the feeding hopper with SOME WATER in order to soften the output cake. (see next figure)

PALM KERNEL or CAKE WATER HOPPER

3.4.2

Once the output cake shown to be softened or by experience that the oil expeller is no longer under loading, means the oil expeller can be stopped now.

Operation Manual / Page 9 of 16

MUAR BAN LEE TECHNOLOGY SDN. BHD. OIL EXPELLER

PALM KERNEL or CAKE

PALM KERNEL or CAKE

WATER

WATER

BEFORE STOP!

SEE THE DISCHARGING!!

3.4.3

Failure to adhere to the step 3.4.1 and 3.4.2 will result in blockage during the next start-up. (Blockage = High Ampere = Electrical Trip)

3.4.4

Always ensure a continuous loading or feeding of the kernel to the expeller. Any free running or disrupted loading in between will result in the breakage of the compactness of the cake in expeller. There might be the possibility of the cake could not be discharges hence harden at the cone section; ultimately pose difficulties in the next start – up.

SUPPLY OF PALM KERNEL or CAKE

SUPPLY OF PALM KERNEL or CAKE

3.5

Final Adjustment 16 Hours After the Start-up

3.5.1

Re-adjust the belting tension

3.5.2

Re-tighten all the bolts and nuts

3.5.3

Re-tighten the left hand lock nut that would determine the clearance of the taper head.

NOTE: Failure to observe and practice all these recommendations above would pose unforeseen disruption in the operation.

Operation Manual / Page 10 of 16

MUAR BAN LEE TECHNOLOGY SDN. BHD. OIL EXPELLER

4.

GENERAL MAINTENANCE INSTRUCTIONS

4.1

Caution! Before implementing any maintenance procedure, ensure that the press machine is safely electrically isolated. OFF

Removal of Main Cage 4.1.1.1 Remove the top and side covers of the kernel press. 4.1.1.2 Place suitable protection cover across the press base to restrict any parts from dropping into the oil conveyor below. This is to prevent any accidental dropping of parts into the running oil conveyor beneath. 4.1.1.3 Below the cage, place one or two timbers (strong enough to withstand the weight of the cage) onto which the mounting square bar bolt and reinforcement rib could be lowered.

TIMBER

TIMBER

4.1.1.4 Loosen all the mounting bolts. (don’t remove the nuts from bolts)

M . Ban Lee

4.1.1

Operation Manual / Page 11 of 16

MUAR BAN LEE TECHNOLOGY SDN. BHD. OIL EXPELLER

* Don’t remove nuts from the bolts.

4.1.1.5 The reinforcement rib is of two sections, split it into two halves. The top half can be removed leaving the lower half in position. However, the lower half can be removed, depending on the working condition. 4.1.1.6 The barrel or the body cage can be split horizontally. Removal of the top half can be done by lifting the two hooks welded at the side plate. If the mating between the two halves is too tight, apply a sharp wedge at the split point. 4.1.2

Re-fitting the Main Cage 4.1.2.1 Ensure all mating surfaces of the cages are properly cleaned. 4.1.2.2 Once the surface of the cages is mated, tightening of the 1½ inches mounting bolt should be done systematically and with zigzag orientation. This is to ensure both cages and scrapper make even contact.

4.2

Feed Cage

4.2.1

Removal of Feed Cage 4.2.1.1 Remove the top inlet chute from the feeding inlet. 4.2.1.2 Loosen all 4 mounting bolts; which hold the two halves feed cages together. 4.2.1.3 Loosen 2 bolts that mount the top cage to the block.

4.2.2

Re-fitting the Feed Cage 4.2.2.1 The mating surfaces of the cage should be properly cleaned. 4.2.2.2 Align the scraper to avoid the cage being in contact with the feed worm 4.2.2.3 Place the top feed cage in position; mating evenly with the lower feed cage. 4.2.2.4 Tighten the mounting bolts that clamp the two halves together.

4.3

Removal and Renewal of Worm and Distance Piece The worm assembly parts are either hard-faced or casehardened, depending on the user requirements. The worm and distance pieces are of sliding fit, which installation can be done by just slotting them into the main shaft. Operation Manual / Page 12 of 16

MUAR BAN LEE TECHNOLOGY SDN. BHD. OIL EXPELLER

Please note that all the worm and distance pieces are changeable parts, depending on the rate of wear of each part. 4.3.1

Remove the main cage. (refer 4.1)

4.3.2

Remove the feed cage. (refer 4.2 )

4.3.3

Remove the adjusting nut by turning anti – clockwise direction.

4.3.4

Remove the left –hand lock nut by turning in clockwise direction.

4.3.5

Remove the adjustable sleeve.

4.3.6

The worm and distance piece can now be removed from the shaft. It is noted that after running for some time, it might be difficult to remove the worms from the shaft. Hence it is necessary by use a drift to remove the worm initially and a crowbar might also be used behind the worm flight. If the worms are in particularly tight, it is a common practice to quickly heat the worm with a blowlamp or an oxy-acetylene flame. When heating, care should be taken not to reach a dull-red heat. This heating is just to serve as to expand the worm bore slightly and also burns out some of the solid that stuck in between the worms and shaft. For better thermal expansion, the heat source should be directed concentrated along the keyway; which have the minimum thickness.

4.3.7

When replacing new set of worms, care should be taken in installing in the correct order with the specified orientation. And, always ensure that the joint faces are perfectly clear.

4.3.8

The worms and distance pieces can be reclaimed provided that they are not too badly worn.

4.4

Removal of Worm Shaft

4.4.1

Remove the main cage; both the upper and bottom half (refer 4.1).

4.4.2

Remove the feed cage; both the upper and bottom half (refer 4.2).

4.4.3

Remove all worms and distance pieces.

4.4.4

Loosen all the 6 nos of allen-nut screw and remove the bearing housing cover.

4.4.5

Loosen the jam screw at the coupling. (below is several difference type of couplings.) JAM SCREW

GEARBOX

MAIN SHAFT

Pin & Bush Type

Operation Manual / Page 13 of 16

MUAR BAN LEE TECHNOLOGY SDN. BHD. OIL EXPELLER JAM SCREW

GEARBOX

MAIN SHAFT

Gear Type

JAM SCREW

GEARBOX

MAIN SHAFT

Split Type

JAM SCREW

GEARBOX

PINION SHAFT

Positive Engagement Type

4.4.6

The Shaft can be removed now.

4.4.7

The refitting of the worm shaft is the reverse of the previously described procedure.

4.5

Reclaiming of Worms and Distance Pieces From the economic point of view, it is desirable that the worm can be refurbished after wear had taken place, and such reclamation can be repeatedly carried out so long that the following guidance is observed. If the reclamation of worms is to be undertaken, it is essential that the rebuilding be done before the pieces become too badly worn. In the case of the hard-faced worms, as soon as the hard facing is worn away from the leading edge of the flight, the worm should be taken out from service in order not to further expose the base metal of the worm. Distance pieces become scoured at the point where the adjoining worm flight finishes. However, it is difficult to state a definite point at which the case-hardened worn should be taken out of service for reclamation. It is actually a matter of judgement, mainly based on the rate of fallOperation Manual / Page 14 of 16

MUAR BAN LEE TECHNOLOGY SDN. BHD. OIL EXPELLER

off of the press performance. The location where the wear takes place normally occurs at the radius of the leading edge of the worm flight. When the worm edge is worn out, it is advisable that the worm should be taken out of service.

If the worm is severely worn before reclamation, even an excessive amount of the weld metal deposited for building up the profile will cause distortion of the worm and this render it unserviceable. When rebuilding worms which have been badly worn or rebuilt a number of times, care must be taken to ensure that the original pitch is maintained and the weld metal is deposited on the same side of the flight form which it has worn-off. After a number of rebuilds, it can somehow be difficult to judge correctly of where the original flight has been and hence it is important that the original dimensions are maintained. For your information, the method of rebuilding the case hardened and hardfaced worms are different in the sense of depositing the new metal onto the worn area. 4.6

Methods of Reclaiming Work

4.6.1

Preparation Before rebuilding, the worn parts must be thoroughly cleaned and degreased. Boiling in a caustic solution is regarded as the most effective way. But, a thorough wash in kerosene followed by a wash using a weak detergent solution is usually satisfactory. The most critical area of wear and any pitted area must be ground out manually until a clean area is achieved, this should be done prior to the final degreasing.

4.6.2

Rebuilding 4.6.2.1 The case hardened worm is built by the electrical welding technique. Usually 10 S.W.G. (3.2mm dia.) welding rods are used for hard material. Users are advised to using complex carbide hard facing electrode with 65 / 70 HRC which is suitable for welded components operating under extremely aggressive condition and can withstand an operation temperature over 1100F (593C); yet still retain its hardness. The original worms and distance pieces reclaimed by WELDTECH E668 and E663 from USA.

Operation Manual / Page 15 of 16

MUAR BAN LEE TECHNOLOGY SDN. BHD. OIL EXPELLER

4.6.2.2 In order to deposit a sufficiently thick layer of metal onto the softer base material, it usually requires two layers of welding metal to avoid ‘assimilation’ of the weld and parent metal; which ultimately will result in soft finishes. 4.6.2.2 For high volume production of rebuilding the worms, it is recommended that a ‘Manipulator’ be used to hold the work piece during the welding process for the sake of convenience. This ‘Manipulator’ is also used with a gas mantle for rebuilding satellite worms. 4.6.2.4 Upon completion of the welding process, let the worm to cool off in the open air. Conversely, the cooling time mush not be accelerated by quenching; which will result in server distortion. 4.6.3

Grinding and Finishing (Case hardened & Hard Faced.) 4.7.1.1 Upon completely cooled, the bore of the item must be check to ensure no distortion in roundness. Similarly, check the squareness of the faces, by using a special mandrel that is identical in diameter to the expeller shaft, and has a key and key way cut into it to reproduce the exact worn shaft dimension. 4.6.3.2 If the worm is noted to be unsatisfactory when fitted into the mandrel, the rectification must be carried out where possible. Ideally a small internal grinder will be used to remove the interfering section. 4.6.3.3 If the end faces do no sit square with the mandrel, then these must be rectified again and machined back to its original length. Use a small surface grinder for this rectification process. When the end faces are deemed square, check the dimension of the overall worm length.

Operation Manual / Page 16 of 16

MODEL: EK - 200 - K

PARTS CATALOGUE

MUAR BAN LEE

information may result in unnecessary delay in supply the correct parts.

order will ensure you to obtain the right part. Failure to provide correct

Correct MODEL, IDENTIFICATION, PART NUMBER given when placing

when requesting the spare-parts for MODEL: EK - 200 - K Oil expeller.

This part catalogue is to provide a quick reference guide for you

GENERAL INFORMATION

ISO Certified

MUAR BAN LEE

A

LUBRICANT = 70% GREASE = 30%

Tel: +606 985 9998 Url: www.MBL.com

Fax: +606 985 8889 Email: [email protected]

JR52, Lot 1818, Jalan Raja, Kaw. Perindustrian Bukit Pasir, 84300, Muar, Johor Darul Takzim, Malaysia.

MUAR BAN LEE

B

A

Oil Outlet

Model: : JUNE 2014 Date

Check By : Project & Marketing

Drawn By : IT & Design

Rev : 0

: NOT TO SCALE

3rd Angle

EK - 200 - K

Title: Part List

Cake Outlet

Scale

Dwg. No. : EK / 200 / K / G.Info 01

B

Kernel Input

ISO Certified

MUAR BAN LEE

Tel: +606 985 9998 Url: www.MBL.com

Fax: +606 985 8889 Email: [email protected]

JR52, Lot 1818, Jalan Raja, Kaw. Perindustrian Bukit Pasir, 84300, Muar, Johor Darul Takzim, Malaysia.

MUAR BAN LEE

SEMI - DISSEMBLE ILLUSTRATION

Model: : JUNE 2014 Date

Check By : Project & Marketing

Drawn By : IT & Design

Rev : 0

: NOT TO SCALE

3rd Angle

EK - 200 - K

Title: Part List Scale

Dwg. No. : EK / 200 / K / G.Info 02

1 1 1 1 1 1 1 1 1 SET 1 SET

TAPER COLLAR

HIGH PRESSURE WORM

TAPER COLLAR

HIGH PRESSURE WORM

STRAIGHT COLLAR

HIGH PRESSURE WORM

STRAIGHT COLLAR

LEFT HAND LOCK NUT

FEED CAGE SCRAPER

BODY CAGE SCRAPER

1-3

1-4

1-5

1-6

1-7

1-8

1-9

1-10

37.

38.

ISO Certified

MUAR BAN LEE

1

INTERMEDIATE WORM

1-2

1-9

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Fax: +606 985 8889 Email: [email protected]

JR52, Lot 1818,, Jalan Raja, Kaw. Perindustrian Bukit Pasir, 84300, Muar, Johor ohor Darul Takzim, Malaysia.

MUAR BAN LEE

1

FEED WORM

1-1

1-10

QTY.

PART NAME

P/N.

Check By : Project & Marketing

3rd Angle

(1st Pressing)

EK - 200 - K

Model: : JUNE 2014 Date

Drawn By : IT & Design

Rev : 0

Title: Part List : NOT TO SCALE

38

1-3

Scale

Dwg. No. : EK / 200 / K / A

1-8

1-7

1-6

1-5

1-4

1-2

1-1

P/N. 38 body cage scraper please specified for 1st or 2nd Pressing.

Notes:

Page:

37

A

4 SETS

4 PCS

1 SET

4 SETS

1

BOLT & NUT

BOLT

BODY CAGE

BOLT & NUT

HOPPER

1a.

1b.

2.

2a.

3.

ISO Certified

MUAR BAN LEE

2

2a

Tel: +606 985 9998 Url: www.MBL.com

Fax: +606 985 8889 Email: [email protected]

JR52, Lot 1818, Jalan Raja, Kaw. Perindustrian Bukit Pasir, 84300, Muar, Johor Darul Takzim, Malaysia.

MUAR BAN LEE

P/N. 2, Body Cage please specified for 1st. or 2nd. Pressing.

Notes :

1 SET

FEED CAGE

1.

QTY.

PART NAME

P/N.

Check By : Project & Marketing

3rd Angle

1a

EK - 200 - K

Model:

: JUNE 2014 Date

Drawn By : IT & Design

Rev : 0

: NOT TO SCALE

Title: Part List Scale

Dwg. No. : EK / 200 / K / B

3

Page:

1b

1

B

KEY FOR TAPER HEAD

ADJUSTING NUT

MAIN SHAFT KEY

DRIVE KEY

6

7

8,9

10

ISO Certified

MUAR BAN LEE

TAPER HEAD - 1st Pressing

5-1

6

5-1

58

G14

G13a

G13

G12

G11

P/N.

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Fax: +606 985 8889 Email: [email protected]

JR52, Lot 1818, Jalan Raja, Kaw. Perindustrian Bukit Pasir, 84300, Muar, Johor Darul Takzim, Malaysia.

1

1

1

1

1

1

QTY.

MUAR BAN LEE

58

MAIN SHAFT

4.

7

PART NAME

P/N.

8

G14

9

Model: : JUNE 2014 Date

Check By : Project & Marketing

G11

3rd Angle

10

EK - 200 - K

Rev : 0

Drawn By : IT & Design

G12

Title: Part List : NOT TO SCALE

G13a

G13

4

1

1

9

1

1

1

QTY.

Scale

Dwg. No. : EK / 200 / K / C

JAM NUT

“O” RING

BOLT

COVER

18T COUPLING FOR MAIN SHAFT

18T COUPLING FOR GEARBOX

PART NAME

Page:

C

ISO Certified

MUAR BAN LEE

27 27a 27b 28 29 30 31

23a 24 24a 25 25a 25b 26

1 1 4 4 4 4 8

1 1 1 3 1 4 1 1

1 4 1 1 SET

1 4 1 2 1 4 1 1 1

QTY.

15a

15

31

18

19

15a

28

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Fax: +606 985 8889 Email: [email protected]

JR52, Lot 1818, Jalan Raja, Kaw. Perindustrian Bukit Pasir, 84300, Muar, Johor Darul Takzim, Malaysia.

MUAR BAN LEE

BLOCK NO.1 BOLT, WASHER & NUT BLOCK NO. 2 BOLT, WASHER & NUT BLOCK NO. 3 BOLT, WASHER & NUT WEAR PLATE OIL SEAL SPHERICAL ROLLER BEARING 22324 COVER BOLT THRUST COLLAR STOPPER COLLAR SPHERICAL ROLLER THRUST BEARING 29428 BEARING BUSH 29428 THRUST PLATE 29428 BOLT GREASE RESERVOIR BOLT GREASE RESERVOIR COVER SPHERICAL ROLLER BEARING 22322 COVER OIL SEAL BOLT STAY PIPE (L) STAY PIPE (S) STAY BOLT NUT

15 15a 16 16a 17 17a 18 19 20

21 21a 22 22a 23

PART NAME

P/N.

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RIB PLATE

SPACER

BOLT & NUT

32

33

34

ISO Certified

MUAR BAN LEE

PART NAME

P/N.

34

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JR52, Lot 1818, Jalan Raja, Kaw. Perindustrian Bukit Pasir, 84300, Muar, Joh Johor D Darul Takzim, Malaysia. 0, M ul Takzi Mal si

MUAR UAR BAN LEE

34

4

20

12

QTY.

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BOLT & NUT

STAY PIPE

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MUAR BAN LEE

4

SQUARE BAR

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39

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JR52, Lot 1818, Jalan Raja, Kaw. Perindustrian Bukit Pasir, 84300, Muar, Johor Darul Takzim, Malaysia.

MUAR BAN LEE

QTY.

PART NAME

P/N.

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SIDE COVER (Long) (Left)

SIDE COVER (Long) (Right)

SIDE COVER (Short)

TOP COVER

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MUAR BAN LEE

1

RIB PLATE COVER

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18, Jalan Raja, Kaw. Perindustrian Bukit Pasir, JR52, Lot 1818, 84300, Muar, Johor Darul Takzim, Malaysia.

MUAR R BAN LEE

40

1

FRONT COVER

40

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P/N.

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BELTS

GEARBOX PULLEY

PULLEY BUSH (GEARBOX)

MOTOR PULLEY

PULLEY BUSH (MOTOR)

GEARBOX

MOTOR

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50

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52

ISO Certified

MUAR BAN LEE

PULLEY AND BELT COVER

45

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1

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1

1

5

1

QTY.

51

48

47

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JR52 JR52, Lot 1818 1818, Jalan Raja Raja, Kaw. Perindustrian Bukit Pasir Pasir, 84300, Muar, Johor Darul Takzim, Malaysia.

MUAR BAN LEE

PART NAME

P/N.

50

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ADJUSTING BOLT (LEFT)

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MACHINE FOOTING

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BOLT, WASHER & NUT

55

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MUAR BAN LEE

56

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JR52, Lot 1818, Jalan Raja, Kaw. Perindustrian Bukit Pasir, 84300, Muar, Johor Darul Takzim, Malaysia.

MUAR BAN LEE

Note: P/N 55 Please specified the brand of gearbox

57

MOTOR FOOTING

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(GEARBOX)

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No.

IM10-014

PARAMAX INSTRUCTION MANUAL

TYPE • • YHD080P3-LR/RL-55.066 SHI MANUF. No.

TS9ZA006-001 TS9ZA006-002 TS01A038-001 TS01A039-001 TS01A039-002

Sumitomo Heavy Industries, Ltd.• • ENGINEERING DEPT. OKAYAMA GB PLANT POWER TRANSMISSION & CONTROLS GROUP

DATE

2010/3/2

APPR.

CONTENTS 1

PREFACE......................................................................................................................................... 2

2

CONSTRUCTION ............................................................................................................................. 2

3

INSTALLATION ................................................................................................................................ 2

4

OPERATION..................................................................................................................................... 2

5

LUBRICATION.................................................................................................................................. 3 5-1

Lubrication method .................................................................................................................... 3

5-2

Selection of lubricant oils ........................................................................................................... 3

5-3

Oil quantity................................................................................................................................. 3

6

MAINTENANCE................................................................................................................................ 3 6-1

Oil check and change ................................................................................................................ 3

6-2

Oil filling and draining ................................................................................................................ 3

6-3

Oil seal inspection and change .................................................................................................. 3

6-4

Extended storage of the unit ...................................................................................................... 3

7

MAINTENANCE OF PARTS............................................................................................................. 4 7-1

Renewal parts............................................................................................................................ 4

7-2

Dismantling and Assembly ........................................................................................................ 4

8

ESSENTIALS OF LONG-TERM STORAGE..................................................................................... 4

9

Warranty ........................................................................................................................................... 5

10

Table 1.Recommended lubricants................................................................................................. 6

12

Table 2. Oil Quantity List ............................................................................................................... 6

13

Table 3. Corrosion Preventive Oil Quantity List............................................................................. 6

14

Table 4. Oil Seal List ..................................................................................................................... 6

15

Table 5. Bearing List ..................................................................................................................... 6

16

SAFETY AND OTHER PRECAUTIONS ....................................................................................... 7

1

1 PREFACE This Instruction Manual should be thoroughly reviewed before commencement of installation and operation of the units.

2 CONSTRUCTION (1)

External gears are used for this reduction gear unit.

(2)

Gears are made of hardened steel to insure a long life. Helical gears are used to provide sufficient strength and operation.

(3)

Shafts are made of a properly hear treated alloy steel.

(4)

Bearings are used for the reduction gear unit.

(5)

Extreme care is taken to prevent oil leaks by liquid packings at gear box mating surfaces and cover mounting surfaces, and oil seals at input and output shafts.

(6)

The reduction gear unit is equipped with an oil filler, a drain plug, air breather , oil gauge.

3 INSTALLATION (1)

The reduction gear unit must be securely installed in position on the flat and rigid foundation to prevent heavy stresses on the unit. Accelerated wear, vibration or noise can be caused by incorrect installation.

(2)

When couplings are used, never use rigid coupling. Use flexible couplings.

(3)

When shrunk fitted gears, pulleys or couplings to shafts, use care to prevent damage.

(4)

The alignment of the reduction gear unit with a driving motor and other machines must be made as accurately as possible. Allowable parallel and off-set misalignment is within 50 um.

(5)

Never install the reduction gear unit such a manner, as to cause defamation of the housing. Such installation method will have adverse effect on the bearings.

(6)

Bolts used for the installation of the drive unit must be the equivalent of JIS Class 10.9 strength.

4 OPERATION Accomplish the following procedures for the operation of the unit after installation.

(1)

Make sure that proper lubricants are used. Recommended lubricant oils are shown in Table 1.

(2)

Lubricant oil is drained from the unit before shipment. Fill the unit with oil, using care to prevent foreign matter from entering the unit. Check the oil level in unit with an oil level gauge.

(3)

A “run-in” operation is carried out for all the reduction gear units before shipment. However, they should be rechecked before placing them in operation to ensure that they work smoothly. On initial operation do not apply a full load on the unit. Increase the load gradually.

(4)

Extreme care should be exercised especially when extended storage of the unit is expected. Gears and bearings are splash lubricated. A unit kept idle for a long time may need oiling before operation. On initial operation accomplish the above procedure, (3) , after inching the unit several times with no load.

(5)

During operation keep a record of temperatures and noise of the major portions. This will be of some reference to future maintenance and operation.

(6)

If any of the followings occur, stop and check the unit.

1)

Oil temperature rises above 90• •

2)

Excessive noise or vibration occurs suddenly.

2

(7)

Oil should be drained before transportation from the units.

5 LUBRICATION 5-1

Lubrication method Gear and Bearinng : Oil bath

5-2

Recommended lubricants Recommended lubricants are listed in Table1.

5-3

Oil quantity Use an oil gauge to check the unit for the proper amount of oil. Outline oil quantity is shown in Table 2.

6 MAINTENANCE 6-1

Oil check and change

(1)

Oil quantity should be checked periodically by means of an oil sight gauge. For accurate measurement, stop the unit. When the unit has not been used for a long period, check the unit after no load operation for about 2 to 3 minutes as mentioned on above 4-(4).

(2)

The first oil change should be made after 500hours of operation or 6months, whichever comes first. The second oil replacement should be conducted after 2,500hours of operation or 6months, whichever comes first.

(3)

The oil should be replaced with new oil every 5,000hours or every 1year, whichever comes first, if the oil temperature falls below 70• •. If the oil temperature rises above 70• •, the oil should be changed every 2,500hours or every 6months, whichever comes first.

(4)

Where operating conditions are severe, such as rapid rise and fall of temperature, or the presence of corrosive gases in the atmosphere which will result in the rapid deterioration of the oil, reference should be made to lubricant manufactures.

(5)

Oil flushing helps cleaning. The use of a solvent should be avoided to clean the internal parts of the unit.

6-2

Oil filling and draining

(1)

Drain the oil from a drain plug, by removing the oil drain plug.

(2)

While taking all possible care to prevent the entry of rain water and other foreign matter through the oil filler, the prescribed quantity of oil should be poured into the unit while observing the oil level gauge. Quantity below the prescribed level will result in inadequate lubrication, while excessive supply will cause excessive temperature rise and accelerate oil deterioration.

6-3

Oil seal inspection and change Worn oil seals may result in oil leaks. Inspect and replace oil seals at regular interval.

6-4 (1)

Extended storage of the unit If the unit is not to be operated for over a month, replace the oil upon suspension of operation,

3

and run the unit with no load on it at least once a week.

(2)

If the unit is not operated for over three months or it is difficult to accomplish instructions in above article (1), drain oil, fill the unit with the proper amount of corrosion preventive oil (JIS NP20 or equivalent) in accordance with Table3, and seal it. When staring the unit again, replace the anti-corrosion oil with the proper amount of recommended lubricating oils. NOTE, be sure to seal the air vent plug to keep the unit tightly closed dusting storage.

7 MAINTENANCE OF PARTS • • • • •Overhaul • • • the machine 3• •5 year after initial operation, depending on the operating condition. Replace the following parts to extend the service life.

7-1

Renewal parts • • •Bearing, • oil seal, collar, shim, packing, visible gauge, air breather • • •Shafts • and gears when damage is found. • • •Other • parts (incl. special applications) as necessary.

7-2

Dismantling and Assembly The PARAMAX DRIVE should be returned to our plant for dismantling and assembly, in principle. Advise us of the machine No. of the speed reducer to overhaul, serial No., type, number of speed reducers, and period.

8 ESSENTIALS OF LONG-TERM STORAGE 1.

Using interior of general factory of warehouse, store the machine under comparatively favorable conditions.

2.

Store in an environment where moisture, dust, violent temperature variations and corrosive gases like sulfurous acid gas are absent.

3.

Make sure of the rusting situation inside the equipment and then spray and also supply Shell VSI Circulating Oil 32 of the Shell Oil Company and seal it hermetically and repeat the procedure identified above every half a year.

4.

Do not use any mixture with other rust-proof oil.

5.

Drain the rust-proof oil when operation is to be commenced; start operation after supplying the recommended lubricant.

6.

Do not operate the equipment with dust-proof oil in.

While Daphne Ever Coat No.1 is coated on the shaft thrusting unit and the mounting face, make sure of the rust situation by sight.

7.

The oil quantity of Shell VSI Circulating Oil is in a Table3.

4

9 Warranty The warranty for PARAMAX DRAIVE is as follows:

Warranty Period

Warranty Condition

Exception for Warranty

The warranty period for the Products shall be 18 months after the shipment of the Products from the seller’s works or 12 months from the Products coming into operation, whichever comes first. In case that any problems, troubles or damages on the Products arise due to the defects in the Products during the above “Warranty Period”, although the Products are appropriately and properly installed in, connected or combined to the equipment or machines, or maintained in accordance with the maintenance manual and are properly operated under the conditions as described in the catalogue or otherwise as agreed upon in writing between the Seller and the Buyer or its customers, the Seller will provide, at its sole discretion, appropriate repair or replacement on the Products free of charge, except as stipulated in the “Exception for Warranty” as described below. However, in the event that the Products is installed in, connected or combined to or integrated into the equipment or machines, the Seller shall not reimburse the costs for removal or re-installation of the Products or other incidental costs related thereto and any lost opportunity, loss of profit or any other incidental or consequential losses or damages incurred by the Buyer or its customers. 1. Notwithstanding the above warranty, the warranty as set forth herein shall not be applied to the problems, troubles or damages on the Products which are caused by: installations, connections, combinations or integration of the Products in or to the other equipment or machines, which are rendered by any person or entity other than the Seller, 2. the insufficient maintenance or improper operation by the Buyer or its customers, such that the Product is not appropriately maintained in accordance with the maintenance manual provided or designated by the Seller, 3. the improper uses or operations of the Products by the Buyer or its customers which are not informed to the Seller, including, without limitation, the Buyer’s or its customers’ operation of the Products not in conformity with the specifications, or use of the lubrication oil in the Products which is not recommended by the Seller, 4. any troubles, problems or damages on any equipment or machines in or to which the Products are installed, connected or combined or installed, or any specifications particular to the Buyer or its customers, or 5. any changes, modifications, improvements or alterations on the Products or those functions which are rendered on the Products by any person or entity other than the Seller, 6. any parts in the Products which are supplied or designated by the Buyer or its customers, 7. earthquake, fire, flood, sea-breeze, gas, thunder, acts of God or any other reasons beyond the control of the Seller, 8. waste, exhaustion, normal tear or ware, or deterioration on the parts of the Products, such as bearing, oil-seal. 9. any other troubles, problems or damages on the Products which are not attributable to the Seller.

5

10 Table 1. Recommended lubricants MEROPA

SPARTAN

MOBILGEAR

OMALA

WM220

EP220

630

220

MEROPA

SPARTAN

MOBILGEAR

OMALA

WM320

EP320

632

320

MEROPA

SPARTAN

MOBILGEAR

OMALA

WM460

EP460

634

460

ISO VG220*

ISO VG320*

ISO VG460* 2 o *ISO VG number is the value of the kinematic viscosity in mm /s(cSt)at 40 C.

11 Table 2. Oil Quantity List 9per one unit) TYPE

Oil Quantity[L]

YHD080P3-LR/RL-55.066

65

12 Table 3. Corrosion Preventive Oil Quantity List(per one unit) Oil Quantity

TYPE YHD080P3-LR/RL-55.066

APPROX.

Filling

Spray

2,000cc

200cc

13 Table 4. Oil Seal List(per one unit) HIGH SPEED SHAFT

D-80 X 100 X 12

X2

LOW SPEED SHAFT

D-170 X 200 X 16

X2

14 Table 5. Bearing List(per one unit) HIGH SPEED SHAFT

#32311X1 #33213X1

INTERMEDIATE SHAFT

#22314X2

INTERMEDIATE SHAFT

#23222X2

LOW SPEED SHAFT

#23034X2

6

15 SAFETY AND OTHER PRECAUTIONS

• •

•

The gear unit should be handled,installed and maintained by trained technicians. Carefully read manual and all accompanying documents before use(installation, operation, maintenance, inspection, etc.) Thoroughly understand the machine, information abut safety, and all precautions for correct operation. Maintain this manual for future reference. Pay particular attention to the “DANGER” and “CAUTION” warnings regarding safety and proper use.

• • DANGER • CAUTION Matters described

• •Improper handling may result in damage, serious personal injury and/or death. • • Improper handling may result in damage and/or personal injury.

• CAUTION

in

may lead to serious danger depending on the situation.

Be to observe important matters herein.• •

• • DANGER ••••••••••• zTransport, installation, plumbing, operation, maintenance, and inspections should be handled by properly trained technicians; otherwise, injury or the machine may result. zWhen the unit is to be used in a system for transport of human beings, a secondary safety device should be installed to minimize chances of accidents resulting in injury, death, or damage to the system. zWhen the unit is to be used for an elevator, install a safety device on the elevator side to prevent it from falling, otherwise, serious injury, death, or the elevator may result.

•••••••••••••••• zNever stand directly under a unit suspended by a crane or other lifting mechanism; otherwise personal injury or death may result.

••••••••••••• zNever approach or touch any rotating parts(shaft, etc.)during operation, loose clothing caught in these rotating parts may result in severe injury and/or death.

• •••••••••••••••••••••••••••••••••• zNever approach or touch any rotating parts(shaft, etc.)when maintaining or inspecting the reducer during operation. Loose clothing cought in these rotating parts may result severe injury and/or death. zBe sure to stop both the driving and driven machines before checking any tooth surfaces, otherwise, you may be caught in the gear engaging section. resulting in severe injury and/or death. zDo not operate any units without all(safety)covers in place. Failure to do so may cause injury and/or death.

• ••••• • • • • • •

z • •• • • • •• • • • •• • • • • • •• • • • • • •• • •• • • • •• • •• • • •• • • • • • •• • • • •• • •• • • •• • • • •••••••••••••••••••••••••••••• • • • • • • • • • • •

z • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

7

•

CAUTION

••••••••••• z The unit should be operated only within its design and performance specifications; otherwise, injury or damage to a system may occur. z Keep hands and foreign objects from the internal moving parts of the unit ; otherwise, injury or damage to a system may occur. z Damaged units should be taken off-line and not put back in operation until properly repaired. z Any modifications or alterations of any kind, to the unit, will void the warranty and all subsequent claims. z Do not remove the rating plate.

• ••••••••••••••••••••••••• z unpack the after verifying that it is positioned right side up ; otherwise, injury may result. z Verify that the unit received is in fact the one ordered. When a different product is installed, injury or damage to the system may result.

•••••••••••• z Exercise ample care not to drop the unit during transport. When a hanging bolt or hole is provided, be sure to use it. after mounting the unit on a system, however, do not hoist the entire system using the hanging bolt or hole. Before hoisting, check the weight with the rating plate, crate, outline drawing, catalog, etc. Never hoist the unit that exceeds the rating of the crane or other mechanism being used to lift it ; otherwise, injury or damage to the unit and/or lifting device may occur.

• ••••••••••••• z Do not place objects that will hinder ventilation around the unit ; otherwise, cooling effect is reduced, and may lead to a possible fire hazard due to excessive heat build-up. z Do not step on or hang from the unit ; otherwise, injury may result. z Do not touch the key way at the shaft end or on the inside of the unit ; injury may result. z When the unit is used in food processing applications vulnerable to oil contamination, install an oil pan or other such device to cope with oil leakage due to failure or limited service life. Otherwise, oil leakage may damage products.

• •••••••••••••••••••••••••••••• z When coupling unit with a load, confirm that the alignment error is within the specified limits shown in the maintenance manual, drawings, catalog, etc.;otherwise, damage to the system may result, due to misalignment. z Correctly tighten respective bolts to the specified torque shown in the drawing, catalog, etc. ; otherwise ; scattering fragments may damage the system. z When a belt is used for coupling the unit with another machine, check that the belt tension and the parallelism of the pulley are within the specified limits. When the unit is directly coupled with another machine, check that the direct coupling accuracy is within the specified limits ; otherwise, the system may be damaged, due to misalignment. z Install appropriate guard devices around rotating parts ; otherwise, injury may result. z Remove the key temporarily attached to the output shaft of the unit when the shaft is free-rotating (i.e. not loaded) ;otherwise, injury may result. z Confirm the direction of rotation before coupling the unit with its driven machine. Difference in the direction of rotation may cause injury or damage to the system.

• •••••••••• z The reducer will get very hot during operation. Do not touch or come in contact in any way with the reducer ; otherwise, you may suffer bums. z If the reducer is operating in an abnormal way, stop the unit immediately ; otherwise, injury may result. z Do not operate the reducer in a manner the exceeds its rating criteria ; otherwise, injury or damage to the system may result. z Do not remove any covers or open the reducer during operation;otherwise, splashing lubricant may cause burns. z Do not loosen the oil filler plug during operation ; otherwise, splashing lubricant may cause bums. z For a system in which a lubricant motor pump is provided separately, switch on the pump motor prior to switching on the reducer motor. This will enable praper lubrication of the bearings prior to start-up. Failure to do so may damage the unit. z When reversing the direction of rotation, first bring the unit to a complete stop, then commence reverse rotation ; otherwise, the system may be damaged. z Identify and provide appropriate corective action in a timely fashion for any abnormal operation characteristics according as the maintenance manual. Do not operate the unit until corrective action has been taken.

• ••••••••••••••••••••••••••••••••• z Change lubricant according to the maintenance manual, and use only those recommended lubricants ; otherwise, the system may be damaged. z Do not change the oil during operation or soon after operation has ceased ; otherwise, the hot oil may cause burns.

• ••••••••••••••••••••••••••• z Repair, disassembly, and reassembly should be handled by properly trained technicians ; the system may be damaged.

• ••••••••• z Dispose the reducer and lubricant as general industrial waste.

8