Milnor 110 Lb. Washer Extractor Model 36026X8W.pdf

Published Manual Number/ECN: MQIHTM01U1/2014285A

• Publishing System: TPAS2

• Access date: 07/10/2014

• Document ECNs: Latest

48040F7B, F7N, H7N & 68036H5N

PELLERIN MILNOR CORPORATION POST OFFICE BOX 400, KENNER, LOUISIANA 70063-0400, U.S.A.

MQIHTM01U1/14285A

1 1. English 3 Maintenance Guide—Rubber Spring-resting, Tilt

Washer-extractor MQIHTM01EN/20120917

47 2. Deutsch 49 Wartung—Gummifederlagerung, kippbare

Waschschleudermaschine MQIHTM01DE/20120917

English 1

Published Manual Number: MQIHTM01EN

• Specified Date: 20120917

• As-of Date: 20120917

• Access Date: 20120917

• Depth: Detail

• Custom: n/a

• Applicability: IHT

• Language Code: ENG01, Purpose: publication, Format: 1colA

Maintenance Guide— Rubber Spring-resting, Tilt Washer-extractor

PELLERIN MILNOR CORPORATION POST OFFICE BOX 400, KENNER, LOUISIANA 70063 - 0400, U.S.A.

Applicable Milnor® products by model number:

48040H7N 68036H5N

Table of Contents

PELLERIN MILNOR CORPORATION

Table of Contents Sections Figures, Tables, and Supplements

Chapter 1. Machine Description, Identification, and Certification

1.1. About This Milnor® Machine—Rubber Spring-resting, Tilt Washer-extractor (Document BIUUUF01)

1.1.1. Functional Description

1.1.2. Machine Identification Figure 1: Machine Data Plate

1.2. General Content of the EC-Declaration of Conformity

(Document BIWUUL01)

Chapter 2. Safety

2.1. Safety— (Document BIUUUS27)

2.1.1. General Safety Requirements—Vital Information for

Management Personnel (Document BIUUUS04)

2.1.1.1. Laundry Facility

2.1.1.2. Personnel

2.1.1.3. Safety Devices

2.1.1.4. Hazard Information

2.1.1.5. Maintenance

2.1.2. Safety Alert Messages—Internal Electrical and

Mechanical Hazards (Document BIUUUS11)

2.1.3. Safety Alert Messages—Cylinder and Processing

Hazards (Document BIUUUS13)

2.1.4. Safety Alert Messages—Unsafe Conditions (Document

BIUUUS14)

2.1.4.1. Damage and Malfunction Hazards

2.1.4.1.1. Hazards Resulting from Inoperative Safety

Devices

2.1.4.1.2. Hazards Resulting from Damaged Mechanical

Devices

2.1.4.2. Careless Use Hazards

2.1.4.2.1. Careless Operation Hazards—Vital Information

for Operator Personnel (see also operator hazards throughout manual)

2.1.4.2.2. Careless Servicing Hazards—Vital Information

for Service Personnel (see also service hazards throughout manuals)

2.2. How To Use the Safety Stands on the Rubber

Spring-resting, Hydraulic-tilt Washer-extractor (Document

BIUUUS06)

Figure 2: Safety Stands for Rubber Spring-resting, Hydraulic-tilt Washer-extractor Models

Sections Figures, Tables, and Supplements

2.3. Prevent Damage From Chemical Supplies and Chemical

Systems (Document BIWUUI06)

2.3.1. How Chemical Supplies Can Cause Damage

2.3.1.1. Dangerous Chemical Supplies and Wash Formulas

2.3.1.2. Incorrect Configuration or Connection of Equipment Figure 3: Incorrect Configurations That

Let the Chemical Supply Go In the Machine by a Siphon

Figure 4: Incorrect Configurations That Let the Chemical Supply Go In the Machine by Gravity

2.3.2. Equipment and Procedures That Can Prevent Damage

2.3.2.1. Use the Chemical Manifold Supplied. Figure 5: Examples of Manifolds for

Chemical Tubes. Your equipment can look different.

2.3.2.2. Close the line.

2.3.2.3. Do not let a vacuum occur.

2.3.2.4. Flush the chemical tube with water.

2.3.2.5. Put the chemical tube fully below the machine inlet. Figure 6: A Configuration that Prevents

Flow in the Machine When the Pump is Off (if the chemical tube and tank have no pressure)

2.3.2.6. Prevent leaks.

Chapter 3. Routine Maintenance

3.1. Routine Maintenance—Rubber Spring-resting, Tilt

Washer-extractor (Document BIUUUM09)

3.1.1. How To Show the Maintenance On a Calendar Table 1: Where to Put Marks On a Calendar

3.1.2. Maintenance Summary Table 2: Guards and Related Components Table 3: Filters, Screens, and Sensitive

Components Table 4: Fluid Containers Table 5: Components that Become Worn Table 6: Bearings and Bushings. See Table

7 for Motors.

Table 7: Motor Grease Schedule. Use the data in Section 3.1.4.3 to complete this table.

Table 8: Mechanisms and Settings

3.1.3. How to Remove Contamination Table 9: Contamination Types, Cleaning

Agents, and Procedures

3.1.4. Lubricant Identification and Procedures Table 10: Lubricant Identification

3.1.4.1. Grease Gun Procedures

3.1.4.2. Procedures for Bearing Components Connected to a

Grease Plate

Sections Figures, Tables, and Supplements

3.1.4.3. Procedures for Motors Figure 7: Motor Grease Maintenance Conditions

Table 11: Motor Grease Intervals and Quantities. Use grease EM (Table 10)

3.1.5. Maintenance Components—Machines and Controls

Group (Document BIUUUM10)

Figure 8: Belt and Pulley Conditions To Look For. See Supplement 1.

Supplement 1: How to Examine Belts and Pulleys

Figure 9: Electric Box and Inverter. These are examples. Your machine can look different.

Figure 10: Chemical Inlet Manifolds for Chemical Pump Systems. See caution statement 24 . These are examples.

Your machine can look different.

Figure 11: Soap Chute and Optional 5-compartment Supply Injector.

These are examples. Your machine can look different.

Figure 12: Air Tube for the Water Level Sensor. These are examples. Your machine can look different.

Figure 13: Water Pressure Regulator for Chemical Flush. These are examples.

Your machine can look different.

Figure 14: Steam Inlet Strainer. These are examples. Your machine can look different.

Figure 15: Compressed Air Inlet Strainers.

These are examples. Your machine can look different.

Figure 16: Self-purging Air Line Filter to Remove Moisture and Other Contamination. These are examples.

Your machine can look different.

Supplement 2: How to Examine Compressed Air Mechanisms

Figure 17: Compressed Air Mechanisms.

These are examples. Your machine can look different.

Figure 18: Speed Sensor (photoeye) on Some Machines

Figure 19: Proximity Switches These are examples. Your machine can look different.

Supplement 3: How to Do a Test of Emergency Stop Mechanisms

Sections Figures, Tables, and Supplements

3.1.6. Maintenance Components—Large Extractors (Document

BIWUUM03)

Figure 20: Grease Ports for Grease-only Bearing Assembly

Figure 21: Grease ports for Door—Open Pocket Models. These are examples.

Your machine can look different.

Supplement 4: About the Shock Absorbers Figure 22: Suspension Components on

Each Side of Rubber Spring-resting Washer-extractor (see Supplement 4)

Figure 23: Tilt Components On Each Side of Rubber Spring-resting Washer-extractor—Hydraulic Tilt

Supplement 5: How to Do a Test of the Mechanical Brake

Figure 24: Example of Disk Brake. Your machine can look different.

3.1.7. Maintenance Components—Hydraulic Power Group

(Document BIPPBM05)

Figure 25: Hydraulic Power Components and System Oil Capacity

Supplement 6: How to Replace the Hydraulic Oil or Add Oil to the Full Mark

Supplement 7: How to Make Sure That the Hydraulic Oil is Serviceable

Supplement 8: How to Examine the Hydraulic System for Leaks

Chapter 1. Machine Description, Identification, and Certification

Chapter 1 Machine Description, Identification, and Certification

BIUUUF01 (Published) Book specs- Dates: 20120917 / 20120917 / 20120917 Lang: ENG01 Applic: IHT

1.1. About This Milnor® Machine—Rubber Spring-resting, Tilt

Washer-extractor This manual applies to the Milnor products whose model numbers are listed inside the front cover and which are in the families of machines defined below.

1.1.1. Functional Description

Washer-extractors wash linen using water and nonvolatile chemicals and remove excess water by centrifugal force.

Rubber Spring-resting Washer-extractor models are suspended washer-extractors with a housing in which the shell rests on rubber springs. These models are for use in on-premise laundry and industrial applications. Some of these models tilt to load and unload.

1.1.2. Machine Identification

Find the model number and other data for your machine on the machine data plate affixed to the machine. See the figure that follows.

Figure 1: Machine Data Plate

View of Data Plate (English text shown) Legend

1. Model number. See inside the front cover of this manual.

2. Data that uniquely identifies your machine

3. Cylinder maximum rotation speed in revolutions per minute, if applicable

4. Cylinder volume in the units of measure shown, if applicable

5. Piped utility requirements

6. Hydraulic oil pressure, if applicable

7. Electrical requirements

8. Part number for multi-unit machine, if applicable.

— End of BIUUUF01 —

BIWUUL01 (Published) Book specs- Dates: 20120917 / 20120917 / 20120917 Lang: ENG01 Applic: IHT

1.2. General Content of the EC-Declaration of Conformity

Manufacturer: Pellerin Milnor Corporation

Hereby we declare under our sole responsibility that the machinery Type (see the declaration for your machine) Serial no (see the declaration for your machine) Manufacturing date (see the declaration for your machine) is in conformity with the provisions of 2006/42/EC (17 May 2006) - Machinery 2004/108/EC (15 December 2004) - Electromechanical compatibility 2006/95/EC (12 December 2006) - Low voltage

Pellerin Milnor Corporation certifies that the machine(s) listed above, manufactured in Kenner, Louisiana, 70063, USA conform(s) as stipulated by schedule of verification of

ISO 10472-1:1997 - Safety requirements for industrial laundry machinery - Part 1: Common requirements

ISO 10472-2:1997 - Safety requirements for industrial laundry machinery - Part 2: Washing machines and washer-extractors

ISO 13857:2008 - Safety of machinery - Safety distances to prevent hazard zones being reached by upper and lower limbs

EN 61000-6-3:2007/A1:2011 - Emission standard for residential, commercial and light-industrial environments

EN 61000-6-4:2007/A1:2011 - Emission standard for industrial environments EN 60204-1:2006/A1:2009 - Safety of machinery - Electrical equipment of machines, Part

One, General requirements.

Safety compliance to the standard is described in detail in MILNOR manual (see the declaration for your machine).

This letter confirms that the machine(s) only meets the required aforementioned standards. It is the responsibility of the installer/owner of the machine(s) to ensure compliance with all requirements for on-site preparation, installation, and operation.

Our conformance to the above listed standards is certified with exceptions listed in MILNOR Conformance Report (see the declaration for your machine).

Place Kenner, Louisiana, 70063, USA Date of first issue of above mentioned machine type Signature Kenneth W. Gaulter Engineering Manager

Signature Russell H. Poy Vice President, Engineering

— End of BIWUUL01 —

Chapter 2 Safety

BIUUUS27 (Published) Book specs- Dates: 20120917 / 20120917 / 20120917 Lang: ENG01 Applic: IHT

2.1. Safety—

2.1.1. General Safety Requirements—Vital Information for

Management Personnel [Document BIUUUS04] Incorrect installation, neglected preventive maintenance, abuse, and/or improper repairs, or changes to the machine can cause unsafe operation and personal injuries, such as multiple fractures, amputations, or death. The owner or his selected representative (owner/user) is responsible for understanding and ensuring the proper operation and maintenance of the machine.

The owner/user must familiarize himself with the contents of all machine instruction manuals.

The owner/user should direct any questions about these instructions to a Milnor® dealer or the Milnor® Service department.

Most regulatory authorities (including OSHA in the USA and CE in Europe) hold the owner/user ultimately responsible for maintaining a safe working environment. Therefore, the owner/user must do or ensure the following:

• recognize all foreseeable safety hazards within his facility and take actions to protect his personnel, equipment, and facility;

• work equipment is suitable, properly adapted, can be used without risks to health or safety, and is adequately maintained;

• where specific hazards are likely to be involved, access to the equipment is restricted to those employees given the task of using it;

• only specifically designated workers carry out repairs, modifications, maintenance, or servicing;

• information, instruction, and training is provided;

• workers and/or their representatives are consulted.

Work equipment must comply with the requirements listed below. The owner/user must verify that installation and maintenance of equipment is performed in such a way as to support these requirements:

• control devices must be visible, identifiable, and marked; be located outside dangerous zones;

and not give rise to a hazard due to unintentional operation;

• control systems must be safe and breakdown/damage must not result in danger;

• work equipment is to be stabilized;

• protection against rupture or disintegration of work equipment;

• guarding, to prevent access to danger zones or to stop movements of dangerous parts before the danger zones are reached. Guards to be robust; not give rise to any additional hazards; not be easily removed or rendered inoperative; situated at a sufficient distance from the danger zone; not restrict view of operating cycle; allow fitting, replacing, or maintenance by restricting access to relevant area and without removal of guard/protection device;

• suitable lighting for working and maintenance areas;

• maintenance to be possible when work equipment is shut down. If not possible, then protection measures to be carried out outside danger zones;

• work equipment must be appropriate for preventing the risk of fire or overheating; discharges of gas, dust, liquid, vapor, other substances; explosion of the equipment or substances in it.

2.1.1.1. Laundry Facility—Provide a supporting floor that is strong and rigid enough to support–with a reasonable safety factor and without undue or objectionable deflection–the weight of the fully loaded machine and the forces transmitted by it during operation. Provide sufficient clearance for machine movement. Provide any safety guards, fences, restraints, devices, and verbal and/or posted restrictions necessary to prevent personnel, machines, or other moving machinery from accessing the machine or its path. Provide adequate ventilation to carry away heat and vapors.

Ensure service connections to installed machines meet local and national safety standards, especially regarding the electrical disconnect (see the National Electric Code). Prominently post safety information, including signs showing the source of electrical disconnect.

2.1.1.2. Personnel—Inform personnel about hazard avoidance and the importance of care and common sense. Provide personnel with the safety and operating instructions that apply to them.

Verify that personnel use proper safety and operating procedures. Verify that personnel understand and abide by the warnings on the machine and precautions in the instruction manuals.

2.1.1.3. Safety Devices—Ensure that no one eliminates or disables any safety device on the machine or in the facility. Do not allow machine to be used with any missing guard, cover, panel or door.

Service any failing or malfunctioning device before operating the machine.

2.1.1.4. Hazard Information—Important information on hazards is provided on the machine safety placards, in the Safety Guide, and throughout the other machine manuals. Placards must be kept clean so that the information is not obscured. They must be replaced immediately if lost or damaged. The Safety Guide and other machine manuals must be available at all times to the appropriate personnel. See the machine service manual for safety placard part numbers.

Contact the Milnor Parts department for replacement placards or manuals.

2.1.1.5. Maintenance—Ensure the machine is inspected and serviced in accordance with the norms of good practice and with the preventive maintenance schedule. Replace belts, pulleys, brake shoes/disks, clutch plates/tires, rollers, seals, alignment guides, etc. before they are severely worn. Immediately investigate any evidence of impending failure and make needed repairs (e.g., cylinder, shell, or frame cracks; drive components such as motors, gear boxes, bearings, etc., whining, grinding, smoking, or becoming abnormally hot; bending or cracking of cylinder, shell, frame, etc.; leaking seals, hoses, valves, etc.) Do not permit service or maintenance by unqualified personnel.

2.1.2. Safety Alert Messages—Internal Electrical and Mechanical Hazards [Document BIUUUS11] The following are instructions about hazards inside the machine and in electrical enclosures.

WARNING 1 : Electrocution and Electrical Burn Hazards—Contact with electric power can kill or seriously injure you. Electric power is present inside the cabinetry unless the main machine power disconnect is off.

• Do not unlock or open electric box doors.

• Do not remove guards, covers, or panels.

• Do not reach into the machine housing or frame.

• Keep yourself and others off of machine.

• Know the location of the main machine disconnect and use it in an emergency to remove all electric power from the machine.

WARNING 2 : Entangle and Crush Hazards—Contact with moving components normally isolated by guards, covers, and panels, can entangle and crush your limbs. These components move automatically.

• Do not remove guards, covers, or panels.

• Do not reach into the machine housing or frame.

• Keep yourself and others off of machine.

• Know the location of all emergency stop switches, pull cords, and/or kick plates and use them in an emergency to stop machine motion.

2.1.3. Safety Alert Messages—Cylinder and Processing Hazards

[Document BIUUUS13] The following are instructions about hazards related to the cylinder and laundering process.

WARNING 3 : Crush Hazards—Contact with the turning cylinder can crush your limbs.

The cylinder will repel any object you try to stop it with, possibly causing the object to strike or stab you. The turning cylinder is normally isolated by the locked cylinder door.

• Do not attempt to open the door or reach into the cylinder until the cylinder is stopped.

• Do not place any object in the turning cylinder.

• Do not operate the machine with a malfunctioning door interlock.

WARNING 4 : Confined Space Hazards—Confinement in the cylinder can kill or injure you. Hazards include but are not limited to panic, burns, poisoning, suffocation, heat prostration, biological contamination, electrocution, and crushing.

• Do not attempt unauthorized servicing, repairs, or modification.

WARNING 5 : Explosion and Fire Hazards—Flammable substances can explode or ignite in the cylinder, drain trough, or sewer. The machine is designed for washing with water, not any other solvent. Processing can cause solvent-containing goods to give off flammable vapors.

• Do not use flammable solvents in processing.

• Do not process goods containing flammable substances. Consult with your local fire department/public safety office and all insurance providers.

2.1.4. Safety Alert Messages—Unsafe Conditions [Document BIUUUS14]

2.1.4.1. Damage and Malfunction Hazards

2.1.4.1.1. Hazards Resulting from Inoperative Safety Devices

DANGER 6 : Entangle and Sever Hazards—Cylinder door interlock—Operating the machine with a malfunctioning door interlock can permit opening the door when the cylinder is turning and/or starting the cycle with the door open, exposing the turning cylinder.

• Do not operate the machine with any evidence of damage or malfunction.

WARNING 7 : Multiple Hazards—Operating the machine with an inoperative safety device can kill or injure personnel, damage or destroy the machine, damage property, and/or void the warranty.

• Do not tamper with or disable any safety device or operate the machine with a malfunctioning safety device. Request authorized service.

WARNING 8 : Electrocution and Electrical Burn Hazards—Electric box doors—Operating the machine with any electric box door unlocked can expose high voltage conductors inside the box.

• Do not unlock or open electric box doors.

WARNING 9 : Entangle and Crush Hazards—Guards, covers, and panels—Operating the machine with any guard, cover, or panel removed exposes moving components.

• Do not remove guards, covers, or panels.

2.1.4.1.2. Hazards Resulting from Damaged Mechanical Devices

WARNING 10 : Multiple Hazards—Operating a damaged machine can kill or injure personnel, further damage or destroy the machine, damage property, and/or void the warranty.

• Do not operate a damaged or malfunctioning machine. Request authorized service.

WARNING 11 : Explosion Hazards—Cylinder—A damaged cylinder can rip apart during extraction, puncturing the shell and discharging metal fragments at high speed.

• Do not operate the machine with any evidence of damage or malfunction.

2.1.4.2. Careless Use Hazards

2.1.4.2.1. Careless Operation Hazards—Vital Information for Operator Personnel (see also operator hazards throughout manual)

WARNING 12 : Multiple Hazards—Careless operator actions can kill or injure personnel, damage or destroy the machine, damage property, and/or void the warranty.

• Do not tamper with or disable any safety device or operate the machine with a malfunctioning safety device. Request authorized service.

• Do not operate a damaged or malfunctioning machine. Request authorized service.

• Do not attempt unauthorized servicing, repairs, or modification.

• Do not use the machine in any manner contrary to the factory instructions.

• Use the machine only for its customary and intended purpose.

• Understand the consequences of operating manually.

2.1.4.2.2. Careless Servicing Hazards—Vital Information for Service Personnel (see also service hazards throughout manuals)

WARNING 13 : Electrocution and Electrical Burn Hazards—Contact with electric power can kill or seriously injure you. Electric power is present inside the cabinetry unless the main machine power disconnect is off.

• Do not service the machine unless qualified and authorized. You must clearly understand the hazards and how to avoid them.

• Abide by the current OSHA lockout/tagout standard when lockout/tagout is called for in the service instructions. Outside the USA, abide by the OSHA standard in the absence of any other overriding standard.

WARNING 14 : Entangle and Crush Hazards—Contact with moving components normally isolated by guards, covers, and panels, can entangle and crush your limbs. These components move automatically.

• Do not service the machine unless qualified and authorized. You must clearly understand the hazards and how to avoid them.

• Abide by the current OSHA lockout/tagout standard when lockout/tagout is called for in the service instructions. Outside the USA, abide by the OSHA standard in the absence of any other overriding standard.

WARNING 15 : Confined Space Hazards—Confinement in the cylinder can kill or injure you. Hazards include but are not limited to panic, burns, poisoning, suffocation, heat prostration, biological contamination, electrocution, and crushing.

• Do not enter the cylinder until it has been thoroughly purged, flushed, drained, cooled, and immobilized.

— End of BIUUUS27 —

BIUUUS06 (Published) Book specs- Dates: 20120917 / 20120917 / 20120917 Lang: ENG01 Applic: IHT

2.2. How To Use the Safety Stands on the Rubber Spring-resting, Hydraulic-tilt Washer-extractor These machines are provided with two safety stands (painted red) for maintenance. After the shell is tilted up, the stands are placed around the tilt cylinder shafts. Use the safety stands to perform maintenance on the machine when it is tilted.

WARNING 16 : Crush Hazard—The safety stands provide protection against the un-powered drifting down of the shell during maintenance in the event of a leak in the hydraulic system.

• Never work under the raised shell or housing unless both safety stands are installed and power is locked out/tagged out. Do not work near the raised shell or housing with power on unless both safety stands are installed.

• Install these safety components using the procedure prescribed in this document.

• Maintain these safety components in good condition.

• Designate a convenient, secure area to stow these safety components when not in use.

Figure 2: Safety Stands for Rubber Spring-resting, Hydraulic-tilt Washer-extractor Models

Install the safety stands as follows:

1. At the controls, tilt the machine as in normal operation. Tilt up only as far as needed to insert the stands securely.

2. Referring to the figure, place the safety stands around the tilt cylinder shafts. Lock each stand in position with the bolt, nut and washers provided. Always use both stands.

3. Lock out/tag out power to the machine.

— End of BIUUUS06 —

BIWUUI06 (Published) Book specs- Dates: 20120917 / 20120917 / 20120917 Lang: ENG01 Applic: IHT

2.3. Prevent Damage From Chemical Supplies and Chemical

Systems

This document uses Simplified Technical English.

Learn more at http://www.asd-ste100.org.

All Milnor® washer-extractors and CBW® tunnel washers use stainless steel with the AISI 304 specification. This material gives good performance when chemical supplies are correctly applied.

If chemical supplies are incorrectly applied, this material can be damaged. The damage can be very bad and it can occur quickly.

Chemical supply companies usually:

• supply chemical pump systems that put the supplies in the machine,

• connect the chemical pump system to the machine,

• write wash formulas that control the chemical concentrations.

The company that does these procedures must make sure that these procedures do not cause damage. Pellerin Milnor Corporation accepts no responsibility for chemical damage to the machines it makes or to the goods in a machine.

2.3.1. How Chemical Supplies Can Cause Damage

2.3.1.1. Dangerous Chemical Supplies and Wash Formulas—Some examples that can cause damage are:

• a very high concentration of chlorine bleach,

• a mixture of acid sour and hypo chlorite,

• chemical supplies (examples: chlorine bleach, hydrofluosilicic acid) that stay on the stainless steel because they are not quickly flushed with water.

The book “Textile Laundering Technology” by Charles L. Riggs gives data about correct chemical supplies and formulas.

2.3.1.2. Incorrect Configuration or Connection of Equipment—Many chemical systems:

• do not prevent a vacuum in the chemical tube (for example, with a vacuum breaker) when the pump is off,

• do not prevent flow (for example, with a valve) where the chemical tube goes in the machine.

Damage will occur if a chemical supply can go in the machine when the chemical system is off.

Some configurations of components can let the chemical supplies go in the machine by a siphon (Figure 3). Some can let chemical supplies go in the machine by gravity (Figure 4).

Figure 3: Incorrect Configurations That Let the Chemical Supply Go In the Machine by a Siphon

Schematic Views

Legend

P. Pump T. Chemical tank S. The siphon occurs above here. Liquid in the gray parts of the chemical tube and tank can go in the machine.

Figure 4: Incorrect Configurations That Let the Chemical Supply Go In the Machine by Gravity

Schematic Views

T. Chemical tank D. Chemical tube. Liquid in the gray areas can go in the machine.

2.3.2. Equipment and Procedures That Can Prevent Damage

2.3.2.1. Use the Chemical Manifold Supplied.—There is a manifold on the machine to attach chemical tubes from a chemical pump system. Figure 3 shows examples. The manifold has a source of water to flush the chemical supplies with water.

Figure 5: Examples of Manifolds for Chemical Tubes. Your equipment can look different.

2.3.2.2. Close the line.—If the pump does not always close the line when it is off, use a shutoff valve to do this.

2.3.2.3. Do not let a vacuum occur.—Supply a vacuum breaker in the chemical line that is higher than the full level of the tank.

2.3.2.4. Flush the chemical tube with water.—If the liquid that stays in the tube between the pump and the machine can flow in the machine, flush the tube with water after the pump stops.

2.3.2.5. Put the chemical tube fully below the machine inlet.—It is also necessary that there is no pressure in the chemical tube or tank when the system is off. Figure 6 shows this configuration.

Figure 6: A Configuration that Prevents Flow in the Machine When the Pump is Off (if the chemical tube and tank have no pressure)

Schematic View Legend

I. Chemical inlet on the machine

L. Chemical tube

T. Chemical tank

2.3.2.6. Prevent leaks.—When you do maintenance on the chemical pump system:

• Use the correct components.

• Make sure that all connections are the correct fit.

• Make sure that all connections are tight.

— End of BIWUUI06 —

Chapter 3. Routine Maintenance

Chapter 3 Routine Maintenance

BIUUUM09 (Published) Book specs- Dates: 20120917 / 20120917 / 20120917 Lang: ENG01 Applic: IHT

3.1. Routine Maintenance—Rubber Spring-resting, Tilt

Washer-extractor

This document uses Simplified Technical English.

Learn more at http://www.asd-ste100.org.

Do the maintenance in Section 3.1.2 “Maintenance Summary” to make sure that the machine is safe, keeps the warranty, and operates correctly. This will also decrease repair work and unwanted shutdowns. Speak to your dealer or Milnor if repairs are necessary.

WARNING 19 : Risk of severe injury—Mechanisms can pull in and mutilate your body.

• You must be approved by your employer for this work.

• Use extreme care when you must examine components in operation. Remove power from the machine for all other work. Obey safety codes. In the USA, this is the OSHA lockout/tagout (LOTO) procedure. More local requirements can also apply.

• Replace guards and covers that you remove for maintenance.

3.1.1. How To Show the Maintenance On a Calendar

If you use software to keep the maintenance schedule for your plant, add the items in Section

3.1.2 to that schedule. If not, you can put marks on a calendar that work with the tables in Section

3.1.2. The marks are the numbers 2, 3, 4, 5, and 6. It is not necessary to show the number 1 (items you do each day) on the calendar. The number 2 = items you do each 40 to 60 hours, 3 = each 200 hours, 4 = each 600 hours, 5 = each 1200 hours, and 6 = each 2400 hours. These are the "Mark" numbers at the top of the narrow columns on the left of each table in Section 3.1.2.

Table 1 shows where to put the marks on a calendar. For example, if your machine operates between 41 and 60 hours each week, the first three marks are 2, 2, and 3. Put these marks on the first, second, and third weeks after the machine starts operation. If you do routine maintenance on a given day of the week, put the mark on that day of each week. Continue to put marks on the subsequent weeks. It can be necessary to do the 40 to 60 hour (2) maintenance more than one time each week. If the machine operates between 61 and 100 hours, put a 2 on two days of the week. If the machine operates 101 or more hours, put a 2 on three days of the week.

On each date with a 3, do the items with an x in the 3 or the 2 column of each table in Section

3.1.2. On each date with a 4, do the items with an x in the 4, 3, or 2 column. Continue this pattern.

Table 1: Where to Put Marks On a Calendar Week Number Hours /

Week 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Up to 40 2 2 2 2 3 2 2 2 2 3 2 2 2 2 4 2 2 2 2 3 2 2 2 2 3 2 2 2 2 5 41 - 60 2 2 3 2 2 2 3 2 2 4 2 2 3 2 2 2 3 2 2 5 2 2 3 2 2 2 3 2 2 4 61 - 80 2 2 3 2 3 2 4 2 2 3 2 2 3 2 5 2 3 2 2 3 2 4 2 2 3 2 2 3 2 6 81 - 100 2 3 2 3 2 4 2 3 2 3 2 5 2 3 2 3 2 4 2 3 2 3 2 6 repeat 101 - 120 2 3 2 3 4 2 3 2 3 5 2 3 2 3 4 2 3 2 3 6 repeat 121 - 140 2 3 2 3 4 3 2 3 5 2 3 2 3 4 3 2 3 6 repeat

Week Number, continued Hours / Week 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Up to 40 2 2 2 2 3 2 2 2 2 3 2 2 2 2 4 2 2 2 2 3 2 2 2 2 3 2 2 2 2 6 41 - 60 2 2 3 2 2 2 3 2 2 6 repeat

3.1.2. Maintenance Summary

The tables in this section give the routine maintenance items for your machine. Each table is for one type of procedure (example: apply grease to bearings and bushings). The top of the table gives the general procedure. The "More Data" column gives special instructions if necessary.

* If the machine operates more than 12 hours each day, do the "day" items two times each day.

Do the other items at the given hours or on the days that you show on a calendar (see Section 1).

Do all items in all tables for the maintenance intervals that apply (for example, day, 40 to 60 hours, and 200 hours).

Tip: The sections that follow the maintenance summary give more data about the maintenance items.

After you know this data, it is only necessary to look at the summary to do the maintenance.

Table 2: Guards and Related Components

Examine. If a component is damaged, missing, or not set, correct this immediately to prevent injury.

Mark

1 2 3 4 5 6 Do this each Component More Data x day* guards, covers x day* safety placards

Speak to your dealer or Milnor for replacement components.

x 200 hours fasteners Fasteners must be tight.

x day* safety stands, bars or pins

(painted red) Speak to your dealer or Milnor for replacement components.

x 200 hours anchor bolts and grout Grout must be good. Bolts must be tight.

x day* emergency stop mechanism See Supplement 3. Do a test of the control.

x 600 hours mechanical brake See Supplement 5. Do a test of the mechanical brake. If it does not operate correctly, repairs are necessary. Speak to your dealer or Milnor. This is not routine maintenance.

Table 3: Filters, Screens, and Sensitive Components

Remove contamination from these components to prevent damage and unsatisfactory performance.

Mark

1 2 3 4 5 6 Do this each Component

More Data. See also Section 3.1.3 “How to Remove Contamination” x 40 to 60 hours inverter fans, vents, filters See Figure 9. Keep good air flow.

x 600 hours motors Keep good air flow.

x 2400 hours entire machine Remove excessive dust and dirt.

x day* chemical inlet areas Some chemical supplies that stay on machine surfaces will cause corrosion damage. See Figure 10 and Section 2.3. “Prevent Damage From Chemical Supplies and Chemical Systems” x day* self-purging filter (and regulator) for compressed air

See Figure 16. Make sure the bowl drains automatically.

x 200 hours filter element for the filter (and reguator)

Replace the filter if you cannot remove contamination.

x 2400 hours strainer in water regulator for optional supply injector and pumped chemicals on some models.

See Figure 11 x 200 hours strainer(s) for air inlet See Figure 15 x 200 hours strainer for steam inlet.

(Steam is optional on some models.)

See Figure 14 x 200 hours speed sensor (photoeye) See Figure 18 x 2400 hours proximity switches See Figure 19 x 1200 hours oil filter for hydraulic tank See Figure 25. Replace the used with a new one. Speak to your dealer or Milnor.

Table 4: Fluid Containers

Examine. Add fluid if necessary and keep components clean to prevent damage.

Mark

1 2 3 4 5 6 Do this each Component

More Data. See also Section 3.1.4 “Lubricant Identification and Procedures” x day* See Figure 25 and Supplement 6. Examine the oil level and temperature. Add oil 68 (Table 10) if necessary. If the temperature is higher than 130° F (54° C) or the oil is contaminated, maintenance can be necessary Speak to your dealer or Milnor.

x 600 hours See Supplement 7. Examine the oil for contamination. Remove the used oil from the tank and add oil 68 (Table 10) if necessary.

x 2400 hours hydraulic tank

Remove used oil from the tank. Add oil 68 (Table 10).

x 200 hours Disk brake reservoir See Figure 24. Examine the oil level and quality. Add oil Dot3 (Table 10) if necessary.

If the oil is contaminated, it is necessary to bleed the brake system. Speak to your dealer or Milnor. This is not routine maintenance.

Table 5: Components that Become Worn

Examine. Tighten or replace if necessary, to prevent shutdowns and unsatisfactory performance.

Speak to your dealer for replacement parts

Mark 1 2 3 4 5 6

Do this each Component More Data x 200 hours drive belts and pulleys See Supplement 1 and Figure 8 x 200 hours tubes and hoses Examine hoses and hose connections for leaks.

x 1200 hours door bumpers See Figure 21 x 200 hours rubber springs See Figure 22 x 200 hours shock absorbers See Supplement 4 and Figure 22

Table 6: Bearings and Bushings. See Table 7 for Motors.

Apply grease to these components to prevent damage.

Mark

1 2 3 4 5 6 Do this each Component

More Data. See also Section 3.1.4 “Lubricant Identification and Procedures”

Grease plate 01 10025X for bearing housing. Use this data if your machine has this grease plate. See Figure 20 and Section 3.1.4.2.

x 200 hours seal Add 0.18 oz. (5.4 mL) of grease EPLF2 (Table 10) x 200 hours rear bearing Add 0.3 oz. (9 mL) of grease EPLF2 x 200 hours front bearing Add 0.6 oz. (18 mL) of grease EPLF2

Grease plate 01 10025Y for bearing housing. Use this data if your machine has this grease plate. See Figure 20 and Section 3.1.4.2.

x 200 hours seal Add 0.12 oz. (3.6 mL) of grease EPLF2 (Table 10) x 200 hours rear bearing Add 0.3 oz. (9 mL) of grease EPLF2 x 200 hours front bearing Add 0.3 oz. (9 mL) of grease EPLF2

Other Grease Ports x 200 hours hydraulic door bushings See Figure 21. Add 0.06 oz. (1.8 mL) of grease EPLF2 (Table 10) x 200 hours door latch plunger x 200 hours door open plunger

See Figure 21. Apply stick DE3 (Table 10) to surface.

x 200 hours lower pivot for hydraulic cylinders—one place, each side

See Figure 23. Add 0.06 oz. (1.8 mL) of grease EPLF2 (Table 10).

none upper pivot for hydraulic cylinders none front tilt pivot

See Figure 23. No grease maintenance necessary.

Table 7: Motor Grease Schedule. Use the data in Section 3.1.4.3 to complete this table.

Interval Quantity Dates When Grease is Added Motor Identification (example: main drive) Years Hours fl oz mL

Table 8: Mechanisms and Settings

Make sure mechanisms are serviceable and settings are correct to prevent unsatisfactory performance.

Mark 1 2 3 4 5 6

Do this each Component More Data x 2400 hours controller circuitry Examine wiring and connections in electrical boxes. Look for corrosion, loose connections.

See Section 3.1.3 x 200 hours water pressure regulator for optional supply injector

See Figure 11. Value: 28 PSI (193 kPa).

x 200 hours water pressure regulator for chemical flush

See Figure 13. Value: 28 PSI (193 kPa).

x 200 hours compressed air mechanisms See Supplement 2, Figure 17 x 200 hours bath level sensor that uses air pressure Examine the air tube and connections. See Figure 12 x 200 hours air pressure for bearing housing

See Figure 16 Value: 10 PSI (69 kPa) x 200 hours hydraulic line pressure See Figure 25. Approximate maximum pressure in operation = 700 PSI (48 bar).

3.1.3. How to Remove Contamination

Table 9: Contamination Types, Cleaning Agents, and Procedures

Material or Component

Usual Contamination

Example Cleaning Agent More Data machine housing dust, dirt — compressed air or shop vacuum

Air—no more than 30 psi (207 kpa). Do not push dust in mechanisms.

fins and vents on electrical components dust motors, inverters, braking resistors electric box interior dust all electric boxes shop vacuum, soft bristle brush, canned air for electrical components

Do not push dust in mechanisms.

electrical connections corrosion, varnish spade connector, molex connector, plug-in relay spray solvent for electrical components

Disconnect then connect it again. Use solvent if the bad connection continues.

dust none Use a clean, soft, dry cloth. electronic sensors dirt photoeye lens, reflector, laser, proximity switch, temperature probe warm water with soap, then water flush

Use clean, soft cloths.

stainless steel chemical spill shell, supply injector water Use a hose to flush the chemical supply from the surface fully. Do not get water on electrical components or mechanisms.

300 series stainless steel chemical corrosive attack shell interior, cylinder pickling and passivation

Speak to your dealer or Milnor.This is not routine maintenance.

painted metal, unpainted aluminum dust, dirt, grease frame members warm water with soap, then water to flush

Use clean cloths. Do not get water in electrical components.

rubber dirt, oil, grease drive belts, hoses warm water with soap, then water to flush

Use clean cloths. Flush fully. Oil or soap must not stay on drive belts. Make sure that drive belts are serviceable.

clear plastic, acrylic discoloration (yellowing) compressed air filter bowl, visual flow meter warm water with soap, then water to flush, then acrylic cleaner. Do not use ammonia.

Use only the necessary cleaning agents. Wash and rinse with clean, soft cloths. Follow instructions on acrylic cleaner.

glass discoloration (yellowing) door glass, site glass ammonia and water solution and water rinse then acetone

Use clean, soft cloths. Use only the necessary cleaning agents. If necessary, soak in cleaner.

soft air filter, lint filter, dust, lint on inverter electric box door, in air line filter bowl, in dryers shop vacuum Replace the used with a new filter when the vacuum cannot remove contamination.

rigid strainers, screens for water, steam mineral particles in water line, y-strainer water Use a rigid bristle brush. Flush with a flow of water.

rigid strainers, screens for oil metal shavings in hydraulic line carburetor cleaner or equivalent solvent

Soak. Use a rigid bristle brush.

steel drive components dirt, hardened lubricant bearings, roller chains, sprockets, gears carburetor cleaner or equivalent solvent

Soak. Use a cloth or soft bristle brush.

3.1.4. Lubricant Identification and Procedures

Table 10 identifies the lubricant for each lubricant code given in the maintenance summary. Get these or equivalent lubricants from from your local lubricant supplier.

When you add grease, always use the procedures given in Section 3.1.4.1. When you add grease to motors, also use the procedures given in Section 3.1.4.3.

CAUTION 20 : Risk of damage—Bad lubricant will decrease the life of components.

• Make sure that all equipment and fittings used to apply lubricants are clean.

• Use only the given lubricants or equivalent lubricants that have the same specifications.

Table 10: Lubricant Identification

Code Type Trademark Name Application Example EM grease Mobil Polyrex EM or as given on the motor nameplate motor bearings

EPLF2 grease Shell Alvania EP (LF) Type 2 drive shaft bearings and bushings, ball joints, chain drives

DOT3 oil NAPA SuperHeavy Duty Brake Fluid DOT 3 disk brakes

68 oil Shell Tellus 68 hydraulic system DE3 stick AGS Door-Ease DE-3 door latch plunger

3.1.4.1. Grease Gun Procedures

CAUTION 21 : Risk of damage—Hydraulic pressure can push out seals and push grease into unwanted areas (example: motor windings).

• Use a hand grease gun. A power grease gun gives too much pressure.

• Know the quantity of grease your grease gun gives each cycle (each stroke).

• Operate the grease gun slowly (10 to 12 seconds for one cycle).

• Add only the specified quantity. Stop if new grease come out of a drain port or other opening.

• Remove spilled grease from belts and pulleys.

The tables give grease quantities in fluid ounces (fl oz) and milliliters (mL). You can also use grease gun cycles (strokes). A cycle is each time that you pull the trigger. One cycle is usually approximately 0.06 fl oz (1.8 mL). Your grease gun can give more or less than this. Measure the output of your grease gun as follows:

1. Make sure that the grease gun operates correctly.

2. Operate the grease gun to put grease into a small container with fluid ounce or milliliter increments. Pull the trigger fully and slowly.

3. Add a sufficient quantity of grease to measure accurately. Count the number of cycles of the grease gun (the number of times that you pull the trigger).

4. Calculate the quantity for each cycle of the grease gun.

Example: 2 fl oz / 64 cycles = 0.031 fl oz for each cycle

Example: 59 mL / 64 cycles = 0.92 mL for each cycle

3.1.4.2. Procedures for Bearing Components Connected to a Grease Plate—Your machine has a grease plate on the machine housing or the shell. You add grease to components of the bearing housing at this location. The correct procedure is to add grease when the cylinder turns at wash speed, but obey these precautions:

• For all other grease maintenance, add grease with power removed from the machine.

• If the grease plate on your machine is not serviceable (if you must add grease at a different location), add grease with power removed from the machine.

• If you must remove a guard to get access to the grease plate, prevent access to the machine by other personnel.

If you obey these precautions, use the Manual mode to operate the machine at wash speed. Then add grease at the grease plate.

3.1.4.3. Procedures for Motors—If a motor on your machine does not have grease fittings, no grease maintenance is necessary. If a motor on your machine has grease fittings, it is necessary to add grease. But the interval is usually longer than for other maintenance. Table 11 gives motor grease intervals and quantities for motors with specified frame sizes and speeds. You get this data from the motor nameplate. Use Table 7 in Section 3.1.2 to record the data for the motors on your machine.

Figure 7: Motor Grease Maintenance Conditions

Grease Fitting and Grease Relief Grease Fitting and Grease Drain

Motor Nameplate Grease Fittings, No Reliefs or Drains

Legend

1. Grease fitting

2. Grease relief. Do not remove.

3. Grease drain plug. Remove first.

4. RPM (motor speed). This example is 1465

RPM at 50 Hz and 1765 RPM at 60 Hz.

5. NEMA (IEC) frame size. Example: 256T

CAUTION 22 : Risk of damage—You can push grease into the windings and burn out the motor if you fail to remove the grease drain plugs.

• If the motor has grease drain plugs, remove them before you add grease. If the motor has grease relief fittings, it is not necessary to remove them.

Apply grease as follows:

1. Operate the machine or use manual functions to operate the motor until it is warm.

2. Remove power from the machine.

3. If the motor has grease drain plugs, remove them. See caution statement 22 .

4. Add grease EM (Table 10) with the motor stopped. If the motor with the nameplate in Figure 7 operates at 60 Hz, the specified grease quantity for each grease fitting is 0.65 fl oz (18.4 mL).

5. If the motor has a grease drain plugs, operate the machine or use manual functions to operate the motor for two hours. Replace the drain plug.

Table 11: Motor Grease Intervals and Quantities. Use grease EM (Table 10)

On Motor Nameplate (see Figure 7) Interval Quantity

NEMA (IEC)

Frame Size

RPM Less Than or Equal To

Years Hours Fluid

Ounces mL

900 5.5 11000 1200 4.5 9000 1800 3 6000

Up to 210 (132)

3600 1.5 3000

0.34 9.5

900 4.5 9000 1200 3.5 7000 1800 2.5 5000

>210 to 280 (132 to 180)

3600 1 2000

0.65 18.4

900 3.5 7000 1200 3 6000 1800 2 4000

>280 to 360 (180 to 200)

3600 0.5 1000

0.87 24.6

900 2.5 5000 1200 2 4000 1800 1 2000

>360 to 5000 (200 to 300)

3600 0.5 1000

2.23 63.2

3.1.5. Maintenance Components—Machines and Controls Group

[Document BIUUUM10]

Figure 8: Belt and Pulley Conditions To Look For. See Supplement 1.

Types of Belt Damage How to Find a Worn Pulley

1. Broken cord—damage from a sharp object.

2. Cracks—belt is too large for the pulley.

3. Shiny side walls—oil or grease on belt.

4. The belt layers disconnect—Oil or grease.

5. Bands on side walls—dirt, particles.

6. Incorrect: The pulley is too worn.

7. Correct: The belt only touches the side walls. You can put a thin strip of paper into the space between the belt and the pulley.

8. Space

Supplement 1 How to Examine Belts and Pulleys

With power removed:

• Look for dirt, dust, oil, and grease. Remove contamination.

• Look for belt damage as shown in Figure 8.

• Look for worn pulleys as shown in Figure 8.

With the machine in operation—Do not touch the machine. Look and listen:

• A belt can have some vibration and not cause damage. It is necessary to correct this condition only if the vibration is large.

• A belt must have sufficient tension that there is no slippage on the pulley during operation.

If slippage occurs, you can usually tell from the noise.

About Component Replacement and Tension Adjustment—Correct adjustment is very important to the service life of components and operation of the machine. Your Milnor dealer can do this work. If you know how to do this work (for example, correctly align belts and pulleys), and you want to do it, speak to your dealer or Milnor for part numbers. Replace worn components before you make tension adjustments.

• Machines that use rods with full threads and nuts to hold the position of the motor base—Turn the nuts on the rods as necesary to adjust tension. Tighten the nuts.

• Machines that use a spring to hold tension on the motor base—Use the belt tension sleeve supplied with the machine. Put the sleeve on the rod that the spring is attached to or remove the sleeve to increase or decrease tension. Replace the spring if necessary.

Figure 9: Electric Box and Inverter. These are examples. Your machine can look different.

30022X_ Washer-extractor 48040F_ Washer-extractor 76039 CBW Tunnel Washer

Legend

1. Air filter

2. Fan on elecrtric box door. Tip: Put streamers in front of the fan to make sure the fan operates.

3. Inverter cooling vanes and vents. See caution statement 23 .

4. Braking resistor, if applicable

CAUTION 23 : Risk of damage—The inverter will burn out without sufficient airflow.

• Keep fans, filter, vents, and braking resistors clean.

Figure 10: Chemical Inlet Manifolds for Chemical Pump Systems. See caution statement 24 .

These are examples. Your machine can look different.

36026V7J 60044WP2 76039CBW

CAUTION 24 : Risk of corrosion damage to the machine and the goods—

• Connect chemical tubes only to chemical manifold inlets.

• Stop leaks. Remove leaked supplies from surfaces.

• Speak to your dealer or Milnor if you see corrosion damage.

Figure 11: Soap Chute and Optional 5-compartment Supply Injector. These are examples. Your machine can look different.

Soap Chute Supply Injector Flush Water Adjustment Components

Legend

1. Do not let chemical supplies stay on surfaces.

2. Water pressure regulator. See caution statement 25 .

3. Adjustment screw

4. Water pressure gauge.

5. Strainer inside

CAUTION 25 : Risk of injury and damage—Chemical supplies can splash on personnel and machine surfaces if water pressure is too high.

• Make sure the pressure is set as told in the maintenance summary.

Figure 12: Air Tube for the Water Level Sensor. These are examples. Your machine can look different.

30022T5E Washer-extractor 42044SP2 Washer-extractor 36030F8_ Washer-extractor

30022V6J…