INSTALLATION, OPERATION, LUBRICATION, & MAINTENANCE MANUAL FOR THE 300-G JUMBO PUGMILL Contents: I. Lifting instructions II. Installation III. Prior to start-up IV. After 40 hours operation V. Maintenance VI. Words of caution Attachments: SEW Eurodrive Technical Documents Gearbox Model M3PSF60 Carlson Powerflo Clutch - Service Instructions Falk Single Engagement Gear Coupling Maintenance Instructions Clutch Solenoid - Engineering & Technical Data APS Pug Knife Installation Diagram I. Lifting instructions The 300G Jumbo Pugmill weighs approximately 13,000 pounds (excluding motor). The sling points for this machine are shown in the diagram below (reference Drawing 300G-101). Note that the water shroud (and, if applicable, the safety fence around the pug tub) should be removed prior to lifting. Figure 1: Lifting diagram for 300G Pugmill. The water shroud should be removed prior to lifting. RevJANUARY082001 1
II. Installation The pugmill should be installed following the recommendations on the certified installation print. These recommendations include structural steel or foundation requirements, foundation bolts, grouting, and leveling. A. Leveling The pugmill should be leveled using shims to within 0.015 per foot. This must be checked on the top of the gearbox (remove small cover on top for machined surface) and on each coupling half as shown in Figures 2, 3, and 4. Note that the difference between the two hub measurements must be 0.015 or less, not each individual measurement 0.015 or less. For example, it is acceptable if the gearbox side hub is sloping uphill 0.007 per foot and the pugshaft side hub is sloping downhill 0.008 per foot. In a similar manner, it is okay if the gearbox side hub is sloping downhill 0.002 per foot and the pugshaft hub is also sloping downhill 0.017 per foot. The surfaces where the level is checked should be cleaned of all paint and dirt. Once the machine is level make sure all foundation clamps or bolts are tight before grouting or welding the shims in place. Figure 2: Machinist level on the gearbox coupling half. RevJANUARY082001 2
Figure 3: Machinist level on the pug shaft hub. The difference between the level on the gearbox coupling half and the pug shaft hub should be less than 0.015. Figure 4: Machinist level on the top of the gearbox. RevJANUARY082001 3
B. For machines mounted on a concrete foundation The Pugmill must be leveled using 1 Grade 8 tie-down clamps and flat metal shims. The approximate 1 space between the bottom of the machine sills and the concrete pad should be filled with a non-metallic non-shrinking grout made from a base of either Portland cement or epoxy. This grout should have a compressive strength of no less than 5,000 psi (350kg/cm2) after fully cured, and a 4,000 psi (280 kg/cm2) 24-hour strength. The grout must completely fill the space under the machine sills and should extend from the foundation pad to the upper edges of the sill lower flange at a slope of 45 degrees. This will properly bed the machine and the shims so misalignment does not occur over time due to creep or erosion. All foundation clamps should be checked to ensure they are tight after the grout has properly cured. C. For machines mounted on steel framework The Pugmill must be leveled using tie-down bolts and shims between the sills and the support beams. Do not weld the machine sills to the support structure; this will make any future leveling adjustment difficult. Holes may be drilled or burned through the Pugmill sills and supporting steel framework for the tie-down bolts (minimum 1 Grade 8). Flat steel shims should be placed under the sills at all bolt-down locations and tack welded in place to prevent them from loosening or moving. All foundation bolts should be checked to ensure they are tight after the shims have been secured. D. Motor installation The driving motor should be set only after the Pugmill has been set in place. Refer to the certified installation drawing for details. If the motor is to be mounted to either side of the Pugmill, all reasonable effort should be made to keep the motor shaft height even with the gearbox input shaft height. This will minimize the motor bearing overhung load. E. Material feed to the pugmill The material fed into the Pugmill should be added at the end farthest from the discharge. This provides the most complete mixing of the material as it travels the length of the tub to the discharge end. Also, never feed material into the Pugmill unless it is running. It is important not to allow material to fall onto the clutch and sheave. This may affect both the operation and life of the clutch and sheave. Depending on the location and operation of overhead conveyors or other equipment, some type of cover may be required over the clutch and sheave to prevent this from happening. F. Crane We strongly recommend an overhead crane system over the gear housing area. G. Electrical The electrical connections required include drive motor (horsepower and voltage are specific to each installation), clutch solenoid, and (if applicable) safety proximity switch(es) for tub safety grating or safety fence. Refer to installation drawing for specific RevJANUARY082001 4
voltages on these components. All safety switches should be interlocked with the clutch solenoid so that the clutch is disengaged if any safety switch is opened. The feed conveyor should also be interlocked so that no material is fed if the clutch is disengaged. H. Compressed air for pneumatic clutch The Carlson Powerflo PM clutch is designed to operate at 100 psi. The maximum allowable air pressure is 120 psi. It is important to note the volume of air required by the clutch diaphragm per engagement; an accumulation tank may be needed to ensure adequate air volume is available at the required pressure. The use of a low pressure switch to disengage the clutch if the air pressure drops below 100 psi is recommended to prevent damage to the clutch lining. Table 1:Clutch air supply requirements Clutch Model Operating Air Pressure Air Volume Per Engagement 14PM 100 psi - 110 psi (6.895 bar 7.584 bar) 18 cubic inches I. Air line lubricator These are required for the solenoid air valves. SAE 10W non-detergent type oil should be used. Adjust the lubricator so that one drop of oil will enter the clutch at each clutch engagement. J. Belt installation and proper tensioning Belt tension must be sufficient to overcome slipping under maximum peak load (either at start or under standard operation). To increase total tension, increase the center distance. Before tensioning any drive it is imperative that the sheaves be properly installed and aligned. Never apply belt dressing, as this will damage the belt and cause early failure. Reduce the center distance so the belts may be placed over the sheaves and into the grooves, without forcing them over the sides of the grooves. Arrange the belts so the top and bottom have about the same sag. Increase the center distance until the belts are snug. Operate the drive a few minutes to seat the belts in the sheave grooves. Under the highest loading condition there should be a slight bowing of the slack side, which indicates proper tension. If the slack side remains taut during peak load, the belts are too tight. If the belts bow excessively or slip, the drive must be stopped and belts tightened. Check the tension of a new drive frequently during the first days of operation by observing the slack side span. After a few days operation the belts will seat themselves in the grooves and it may be necessary to readjust the drive tension. RevJANUARY082001 5
III. Prior to start-up A. Check all grease fittings on the Pugmill All grease fittings are lubricated at the factory but should be checked again. B. Check the oil level in the gear housing The oil level can be checked at the sight-glass and should be at the designated level (this is marked but is usually the shaft centerline). C. Clear the Pugmill tub Tools, materials, and any other foreign material can cause damage to the Pugmill. It is good practice to also check any upstream equipment such as conveyors or feeders for such objects. D. Check the rotation of the driving motors The rotation of the motors must be such that the pug-shaft rotates in a clockwise direction if standing at the front of the Pugmill (end opposite the gearbox). Observe directional arrows on the drive. E. Remove any dust plugs from the air solenoid and air exhaust valves IV. After 40 hours of operation A. Open inspection covers on gear cases and inspect gear teeth. B. Check foundation bolts to make sure they are still pulled tight. C. Inspect the tension and alignment of the V-belts and sheaves. D. Observe the flow of material through the tub. The optimum material level is roughly 3 inches (7.6 mm) above the top of the pug-shaft on the high material side. Observe the level of material in the pugmill during operation and adjust the pitch of the pug knives if necessary. It is usually unnecessary to readjust all the knives. The knives are set with +1/8 (0.32 mm) pitch at the factory. The rear knife pitch should be set so the knife nearly touches the rear bulkhead. This action will then wipe the rear bulkhead as clean as possible. The adjustable dam at the discharge can also be raised or lowered to change the material level in the tub. RevJANUARY082001 6
V. Maintenance A. Lubrication Instructions Table 2: Lubrication schedule LOCATION FREQUENCY AMOUNT REMARKS TYPE SEW Eurodrive Gearbox First oil change after 500 hours. Drain when oil is warm. Subsequent oil changes must be at 2,000 hours intervals, minimum. 22 Gal (83 L) Oil level should be checked when unit is at rest. Do not overfill. AGMA 8EP/ ISO VG 680 (Chevron ISO VG 680) SEW Eurodrive Gearbox Input and Output Shaft Seals Every 160 hours Small amount until grease appears. Lithium soap based, EP NLGI #2 grease (Chevron Dura-Lith EP2) Falk Gear Coupling Re-lubrication is required every 6 months. If the coupling leaks grease, is exposed to extreme temperatures, excessive moisture, or experiences frequent reversals, more frequent lubrication may be required. Fill as needed. NLGI #0 grease with minimum Timken OK load of 30 lbs. for ambient temperatures between - 30 and 20 F (-34 to 94 C). Front pug-shaft bearing Every 40 hours Until grease appears. Lithium soap based, EP NLGI #2 grease (Chevron Dura-Lith EP2) Rear dirt seals Every 4 hours Small amount until grease appears. Running these seals dry may prematurely wear the shaft. Lithium soap based, EP NLGI #2 grease (Chevron Dura-Lith EP2) Air solenoid lubricator Check daily Fill as needed. One drop of oil per clutch engagement. SAE 10W Non-detergent oil RevJANUARY082001 7
Figure 5 shows greasing points for the 300G Pugmill (Reference Drawing 300G-102 Rev 1). Figure 5: Location of greasing points Table 3 shows a list of products that meet these specifications. Chevron products are used at the factory unless noted. Table 3: Acceptable gear oils and greases MANUFACTURER AGMA 8 EP ISO VG 680 Gear Oil (Mineral) AGMA 5 EP ISO VG 220 Gear Oil EP NLGI #2, Lithium Soap Based Grease EP NLGI #0 Lithium Soap Based Grease CHEVRON ISO VG 680 EP ISO 220 Dura-Lith EP2 Dura-Lith EP0 EXXON Spartan EP 680 Spartan EP 220 Unirex EP2 Lidok EP0 MOBIL Mobilgear 636 Mobilgear 630 Mobilux EP2 Mobilux EP0 SHELL Omala Oil 680 Omala Oil 220 Alvania EP2 Alvania EP R0 TEXACO Meropa 680 Meropa 220 Multifak EP2 Multifak EP0 RevJANUARY082001 8
B. Clutch Maintenance Over time, the clutch unit must be adjusted for friction lining wear. The capscrews around the outside diameter of the clutch use tube spacers to set the gap between the two outer pressure plates. As the lining wears, the clearance between each friction lining and pressure plate increases. When the total of the two clearances (one lining and pressure plate on either side of the diaphragm) is greater than 0.125 (3.175 mm), one of the thin spacers should be removed from behind each capscrew. This reduces the travel of the diaphragm and prolongs its life. The total clearance cannot exceed 0.250 (6.35 mm) or damage to the return bolts or diaphragm can result. After the adjustment spacers have been removed, the diaphragm and friction linings must be centered to obtain equal clearance between the linings and pressure plates. Refer to the clutch IOL&M for additional information. C. Pug Knives Make sure the machine is properly locked out before attempting to make any adjustments to the pug knives. Setting the pitch of the knives controls the rate at which material is discharged and the degree of mixing. Decrease the pitch (rotate the knife tips toward the discharge end) of two or three rows of the knives to raise the level of material in the tub, or increase the pitch to lower it. The material level may run lower or higher at different sections of the pugmill, even with all the knives at the same pitch. Pug Knife Pitch Setting Procedure 1) Clear the tub of material and turn the shaft until one row of pug shank bolts is exposed on top of the shaft. Begin with the first pug knife in the row. 2) Loosen the shank bolt three turns counterclockwise. 3) Tap on the knife/shank assembly with a soft mallet until it can be turned. The knife material is brittle; do not use a metal hammer and do not apply excessive force when tapping. 4) Place the short leg of a 24 framing square against the wall of the pug tub and the long leg against the side of the knife towards the discharge end. 5) Turn the knife until the trailing edge is touching the square and the leading edge of the knife point is 0.125 plus the desired pitch from the square. For reverse pitch, place the square on the opposite side of the knife and add 0.125 to the desired reverse pitch setting. 6) Apply 225 ft-lbs. torque to the shank bolt. Make sure the minimum 0.125 gap is maintained between the pug-shaft and pug knife blades after the shank bolt is tight. 7) Rotate the pug-shaft by hand when finished to make sure no knives are rubbing the pug tub. 8) Run the pug mill for one hour and reapply 225 ft-lbs. torque to the shank bolts of all knives that were adjusted. See the attached diagram. RevJANUARY082001 9
VI. Words of caution A. Guarding The pug tub should always guarded to prevent accidental contact with the rotating knives. The guards should never be raised or removed without properly locking out the electrical controls. Unless special arrangements have been made, the customer is responsible for installing and maintaining guards or fences around the motor and belt drive. Once again, these should never be removed or opened without properly locking out the electrical controls. The Pugmill is equipped with a coupling guard. This guard must be removed to service the coupling, but only after the machine electrical controls have been properly locked out and tagged out. B. Foreign objects in the pug tub Tramp iron, bolts, etc. can cause damage to the machine and all reasonable measures should be taken to prevent them from entering the pug tub. Magnets on the feed conveyor should be considered. Also, after any breakage inside a machine all material should be cleaned out to find the cause of the wreck. The offending item or a cracked knife or other part will almost invariably cause another breakage if left in the machine. C. Lubricants The specifications provided on oils and greases should be strictly followed. Any departure from these specifications will diminish performance and void the warranty on the machine. RevJANUARY082001 10