Milnor CWES Tunnel.pdf

Published Manual Number/ECN: MQPCUM01U2/2017162A

• Publishing System: TPAS2

• Access date: 04/17/2017

• Document ECNs: Latest

76028CBW®, 76032CBW®,

76039CBW®, 92048CBW®

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

Chapter 3. Routine Maintenance

PELLERIN MILNOR CORPORATION

Chapter 3 Routine Maintenance

BIUUUM09 (Published) Book specs- Dates: 20160204 / 20160204 / 20160204 Lang: ENG01 Applic: PCU

3.1. Routine Maintenance—CBW® Tunnel Washer

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 25 : 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

Hours / Week

Week Number 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 Hours / Week

Week Number, continued 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 Do this each Component More Data 1 2 3 4 5 6 x day* guards, covers Speak to your dealer or Milnor for replacement components. x day* safety placards x 200 hours fasteners Fasteners must be tight.

x day* emergency stop mechanism See Supplement 5. Do a test of the control.

Table 3: Filters, Screens, and Sensitive Components

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

Mark Do this each Component

More Data. See also Section 3.1.3 “How to Remove Contamination” 1 2 3 4 5 6 x 40 to 60 hours inverter fans, vents, filters See Figure 12. 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 13 and Section 2.3. “Prevent Damage From Chemical Supplies and Chemical Systems” x 2400 hours strainer in water regulator for pumped chemicals.

See Figure 15 x 200 hours strainer(s) for air inlet See Figure 17 x 200 hours strainer for steam inlet.

(Steam is optional on some models.)

See Figure 16 x day* photoeyes See Figure 19 x 2400 hours proximity switches See Figure 20 x day* level float tube, if supplied See Figure 14. Lint can prevent float movement.

x 600 hours level float connecting hose, if applicable See Figure 14 x day* bowl on self-purging air filter for chain mist oiler

See Figure 24. Make sure water does not collect in the bowl.

x 600 hours inlet screen and filter in air filter bowl for chain mist oiler

See Figure 24 x day* weir boxes and weir plates Lint can collect and prevent full flow.

x day* steam trap See Figure 30. Open the valve momentarily to release contamination.

x 200 hours strainer in steam trap See Figure 30 x 2400 hours sumps with no drain valve See Figure 29 x day* wedge wire filter and lint basket in tank(s) See Figure 26 (conventional), Figure 27 (PulseFlow) x 40 to 60 hours level tank (conventional) Examine tank interior for contamination.

x 40 to 60 hours recirculation pump, inter-module pump(s) (PulseFlow)

See Figure 28

Table 4: Fluid Containers

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

Mark Do this each Component

More Data. See also Section 3.1.4 “Lubricant Identification and Procedures” 1 2 3 4 5 6

For the next three items, see Figure 23 first 100 hours speed reducer (gear reducer)

Remove used oil. Add oil 220 (Table 10). See Section 3.1.4.3 x 1200 hours Add oil 220 (Table 10) if necessary.

x 2400 hours Remove used oil. Add oil 220 (Table 10).

x day* reservoir for chain mist oiler

Add oil MCL (Table 10) if necessary. Figure x 2400 hours Remove used oil. Remove contamination from reservoir and suction tube. Add oil MCL (Table 10)

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 Do this each Component More Data 1 2 3 4 5 6 x 200 hours drive belts and pulleys See Supplement 2 and Figure 11 x 200 hours tubes and hoses Examine hoses and hose connections for leaks.

x 1200 hours drive couplings See Figure 21 x 200 hours support wheels, tracking wheels (guide wheels) See Figure 22 x 200 hours drive chains, chain tension mechanisms, sprockets

See Figure 25 x 200 hours water seals Look for leaks at the load chute and between modules or units. It is necessary to repair a large leak. Speak to your dealer or Milnor.This is not routine maintenance.

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

Apply grease to these components to prevent damage.

Mark Do this each Component

More Data. See also Section 3.1.4 “Lubricant Identification and Procedures” 1 2 3 4 5 6 x 600 hours support wheels Add 0.12 oz (3.5 mL) of grease EPLF2 (Table 10).

x 600 hours tracking wheels (guide wheels)

Add 0.12 oz (3.54 mL) of grease EPLF2 (Table 10).

x 600 hours drive coupling chain Put a light coat of grease CG (Table 10). See Figure 21

Table 7: Motor Grease Schedule. Use the data in Section 3.1.4.2 to complete this table.

Motor Identification (example: main drive)

Interval Quantity Dates When Grease is Added Years Hours fl oz mL

Table 8: Mechanisms and Settings

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

Mark Do this each Component More Data 1 2 3 4 5 6 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 chemical flush

See Figure 15. Value: 28 PSI (193 kPa).

x 2400 hours conductivity sensors, if supplied

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

x 200 hours ph sensors, if supplied.

x 2400 hours magnetic flow meters, if supplied Speak to your dealer or Milnor. This is not routine maintenance. Calibration fluid is available from Milnor; part number

09XSCD0002.

x 200 hours compressed air mechanisms See Supplement 4, Figure 18 x 40 to 60 hours chain mist oiler system See Figure 24. Examine chains for oil. Make sure that each nozzle gives a spray each time that the tunnel does a transfer. If not, remove contamination and make sure that the air pressure gauge shows the correct pressure for the number of chains. Values are given in pounds per square inch and (kilopascals):

1 chain = 20 (138) 2 chains = 35 (241), 4 chains = 40 (276), 6 chains = 45 (310), 8 chains = 50 (345), 10 or more chains = 60 (414).

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 shop vacuum, soft bristle brush, canned air for electrical components

Do not push dust in mechanisms.

electric box interior dust all electric boxes 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.

electronic sensors dust photoeye lens, reflector, laser, proximity switch, temperature probe none Use a clean, soft, dry cloth.

dirt 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.

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1. Clean, Blow Down, Remove Contamination

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 3.1.4.2.

CAUTION 26 : 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 CG grease Shell Alvania CG or equivalent

AGMA CG-1 or CG-2 drive couplings

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 220 oil Shell Morlina 220 small bearing housings, gear reducers, Hydrocushions™, isolators MCL oil Milnor chain lubricant (Milnor part number 20H000A).

mist oiler for tunnel drive chain

3.1.4.1. Grease Gun Procedures

CAUTION 27 : 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

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2. Grease and Lubricate all fittings

3.1.4.2. 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 10: 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 28 : 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 28 .

4. Add grease EM (Table 10) with the motor stopped. If the motor with the nameplate in Figure

10 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 10)

Interval Quantity

NEMA (IEC)

Frame Size

RPM Less Than or Equal To

Years Hours Fluid

Ounces mL

Up to 210 (132)

900 5.5 11000

0.34 9.5 1200 4.5 9000 1800 3 6000 3600 1.5 3000

>210 to 280 (132 to 180)

900 4.5 9000

0.65 18.4 1200 3.5 7000 1800 2.5 5000 3600 1 2000

>280 to 360 (180 to 200)

900 3.5 7000

0.87 24.6 1200 3 6000 1800 2 4000 3600 0.5 1000

>360 to 5000 (200 to 300)

900 2.5 5000

2.23 63.2 1200 2 4000 1800 1 2000 3600 0.5 1000

3.1.4.3. First Time Oil Procedure for Speed Reducers (Gear Reducers)—The oil in a speed reducer can deteriorate faster when this mechanism is new. Replace the oil in the speed reducer after the first 100 hours of operation. Do this maintenance one time, in addition to the periodic oil maintenance given in the table for fluid containers in the maintenance summary.

3.1.5. Maintenance Components—Machines and Controls Group

[Document BIUUUM10]

Figure 11: Belt and Pulley Conditions To Look For. See Supplement 2.

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 2

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 11.

• Look for worn pulleys as shown in Figure 11.

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.

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3. Check all Belts Chains and Pulleys for Wear

• 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.

Supplement 3

How to Examine Chains and Sprockets

With power removed:

• Look for contamination (examples: dirt, dust, dried grease). Remove contamination.

• Look for worn or damaged sprocket teeth. Examples are a hook shape, cracks, or corrosion.

If the sides of a sprocket are worn, this shows that the chain is incorrectly aligned.

• Look for loose chain. If the chain connects sprockets horizontally, the chain is loose if it hangs more than 0.25 inch for each foot (21 millimeters for each meter) of the span.

• If repairs are not necessary and lubricant was removed, apply new lubricant as specified in the maintenance summary.

With the machine in operation—Do not touch the machine. Look and listen. When movement starts or changes direction:

• the chain must not become tight very quickly and make a noise. If it does, the chain is too loose.

• the sprocket must not knock against the chain rollers. If it does, the rollers and/or sprocket are worn.

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 chain and sprockets), and you want to do it, speak to your dealer or Milnor for part numbers. Replace worn components before you make tension adjustments.

Figure 12: Electric Box and Inverter. These are examples. Your machine can look different.

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

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 29 .

4. Braking resistor, if applicable

CAUTION 29 : Risk of damage—The inverter will burn out without sufficient airflow.

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

Figure 13: Chemical Inlet Manifolds for Chemical Pump Systems. See caution statement 30 .

These are examples. Your machine can look different.

36026V7J 60044WP2 76039CBW

CAUTION 30 : 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.

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4. Clean all fans inlets and filters

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5. Check all chemical areas for leaks and corrosion

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Figure 14: Level Float Assembly. These are examples. Your machine can look different.

Typical Level Float Assembly 76039 CBW Module Level Float

1. Float tube and connecting hose. Remove lint that can prevent correct operation. See caution statement 31 .

2. Float and rod. The float must be free to move as the water level changes..

3. Clips. If it is necessary to move the clips to remove the float and rod, put marks on the rod so you can replace the clips accurately.

CAUTION 31 : Risk of malfunction—The level sensor must give correct data.

• Keep the connecting tube or hose free of blockages and leaks.

• Make sure that the connections are tight.

Figure 15: Water Pressure Regulator for Chemical Flush. These are examples. Your machine can look different.

64050E6N Washer-extractor 76039CBW Tunnel Washer Legend

1. Water pressure regulator

2. Water pressure gauge

3. See caution statement

33 . Remove plug to remove strainer.

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6. Check all level sensors appear to be working properly

Figure 16: Steam Inlet Strainer. These are examples. Your machine can look different.

42044SP2 Washer-extractor 76039CBW Tunnel Washer Legend

1. Steam strainer. Remove steam pressure before you remove the plug. See warning statement

2. Steam valve

WARNING 32 : Risk of severe injury—You can accidentally release pressurized steam.

• Close the external shutoff valve and release remaining pressure before you do maintenance.

Figure 17: Compressed Air Inlet Strainers. These are examples. Your machine can look different.

T-Strainer. Outside machine frame on some models.

T-Strainer. Inside machine frame on some models.

Y-strainer. Used on some models

1. See caution statement 33 . Remove plug to remove strainer.

2. Compressed air in.

CAUTION 33 : Risks of injury and damage—

• Close the external shutoff valve and release remaining pressure before you do maintenance.

Supplement 4 How to Examine Compressed Air Mechanisms

Your machine has one or more mechanisms that use compressed air for movement. Figure 18 shows some examples. To examine a compressed air mechanism, look at the mechanism and listen to it in operation. Do not touch the mechanism or put your hand in the machine.

Usually you can see movement directly or on a position indicator. Frequently, you can hear a valve open and close. When a signal from the controller to operate the mechanism occurs, the air pressure must increase sufficiently before movement occurs. When the signal stops, the system must release the compressed air. You can usually hear the sound of the exhaust air for a short time.

When a compressed air mechanism operates correctly, its time of movement is usually less than two seconds. The movement is smooth. It does not shake, change speed, or stop in the middle of travel. A mechanism that does not operate correctly will cause unsatisfactory performance. If the mechanism does not operate correctly and you cannot repair the problem, speak to your

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7. Clean all strainers once per quarter dealer or Milnor. Possible causes are as follows:

• a blockage or a leak in the air tube,

• a worn pilot air valve,

• worn components in the mechanism,

• air pressure supplied to the machine is not sufficient,

• a component used to remove contamination from the air line is clogged,

• a quick exhaust valve or muffler is clogged,

• on machines with an air line lubricator, a malfunction or incorrect adjustment prevents sufficient lubrication.

Figure 18: Compressed Air Mechanisms. These are examples. Your machine can look different.

Air Operated Water Valves - Milnor Air Cylinder Type

Air Operated Drain Valve - Milnor Air Cylinder Type

Air Operated Band Brake - Milnor Air Cylinder Type

Air Operated Water and

Steam Valves - Angle Type Air Operated Water Valve -

Ball Valve Type

1. Factory-set needle valves to cause two air cylinders to move together. Do not adjust.

2. Quick exhaust valves

3. Position indicator.

Yellow when valve is open.

4. Arrow position indicator

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

Photoeye protected by a site glass, each side of the CBW load chute

Photoeye and reflector on extractor discharge conveyor

→. Exposed surfaces that must be clean. Remove contamination with a soft cloth. If the surface is hard to touch, use a cloth on the end of a wood dowel or metal rod. If necessary, use a safe cleaning agent.

Figure 20: Proximity Switches These are examples. Your machine can look different.

1 Station Press Centrifugal Extractor Shuttle Conveyor

Typical Proximity Switch Legend

→. Area that must be clean. Remove contamination with a soft cloth. If the area is hard to touch, use a cloth on the end of a wood dowel or metal rod. If necessary, use a safe cleaning agent.

Supplement 5 How to Do a Test of Emergency Stop Mechanisms

This test applies to machines that have one or more stop mechanisms in addition to the Stop button ( 0). Do this test at the intervals given in the maintenance summary.

Definitions:

3-wire circuit—a series electrical circuit on a Milnor machine that must close before the machine can operate. If a switch in the circuit opens, machine movement stops and the operator alarm (a buzzer and a display message) comes on. When you push the start button ( 1), this closes the 3-wire circuit, which stops the operator alarm and lets the machine operate.

emergency stop mechanism—a manual control that opens the 3-wire circuit when a person or object operates the control. Examples - emergency stop button, kick plate, pull cord.

emergency stop button—a red push button on a yellow field that locks when a person pushes it (the electrical contacts stay open). It is necessary to turn the button clockwise to unlock it.

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8. Check all photo eyes and sensors

A machine can have zero or more emergency stop buttons.

kick plate—a metal plate on a shuttle conveyor that operates a switch when an object applies sufficient force to the plate. The kick plate is usually the first component of the shuttle to hit an object in the shuttle path. All Milnor shuttles that go left/right on a path have kick plates on the two sides of the machine.

WARNING 34 : You can be killed or severely injured if a shuttle strikes you even if you come in contact with the kick plate first.

• Never do a test of the kick plate when the shuttle operates.

pull cord—a wire on a conveyor that operates a switch when a person pulls the wire. All Milnor free-stand conveyors (a conveyor that is not a component of a larger machine) have pull cords on the two sides of the conveyor.

Do a test of all emergency stop mechanisms on the machine as follows:

1. Apply power to the machine ( M).

2. Push the start button ( 1). Do not cause the machine to operate. For example, do not start a formula or operate the machine manually. It is not necessary to do the test when the machine operates.

3. Operate an emergency stop mechanism (examples - button, kick plate, pull cord). If the mechanism operates correctly, the operator alarm comes on. Did this occur?

Yes—Release the emergency stop mechanism if necessary. For example, if this is an emergency stop button, turn the button clockwise to unlock it. Push the start button ( 1). Do the test on a different emergency stop mechanism. Continue until you do the test on all emergency stop mechanisms on the machine.

No—An electrical component is defective. Shut down the machine. Do not let the machine operate until you correct the problem.

3.1.6. Maintenance Components—Continuous Batch Washer Group

[Document BIPCUM06]

Figure 21: Drive Coupling Components. These are examples. Your machine can look different.

Flexible Coupling—76039CBW Drive Shaft Coupling—76039 CBW

Coupling Chain—92048 CBW Legend

1. Flexible coupling (orange plastic)—This component can become worn. Usually, you can replace the plastic component only.

2. Flexible coupling and metal components—Usually, the metal components do not not become worn.

3. Drive coupling—Examine the coupling for loose components.

4. Coupling chain—With power removed, remove the safety placard. Make sure that the chain is not loose. Apply grease.

5. View with safety placard removed. Replace the placard.

Figure 22: Grease Points. These are examples. Your machine can look different.

Grease plate—76039CBW Support wheel—76039CBW Drive motor—92048CBW

Tracking wheel—76039CBW Legend

1. Support wheel fittings

2. Tracking wheel fittings

3. Support wheel

4. Tracking wheel

5. Tube to grease plate

6. Motor grease fittings (all drive and pump motors)

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9. Inspect all couplings and chain couplings

Figure 23: Speed Reducer (gear reducer). These are examples. Your machine can look different.

Where to Add Oil—G3 or G4 CBW Where to Remove Oil—G3 or G4 CBW

Where to Add Oil—76032CBW Where to Remove Oil—76032CBW

1. Remove plug with vent hole and add oil.

2. Remove this plug when you add oil. Fill until the oil starts to come out here.

3. Remove one of the plugs to remove oil.

4. Remove the stopper and add oil.

5. Fill until the oil level is here. Remove the tube through the bottom of the bracket to remove oil.

Figure 24: Oil Mist System for Drive Chain

Oil Reservoir Air Filter and Regulator

Manual Controls for Maintenance

How to Align the Nozzle How to Examine the Spray Safely

1. Primary location to add oil

2. Alternative location to add oil

3. Filter

4. Screen

5. Hold this switch clockwise to put oil on the chains manually.

6. Key switch to let the cylinder controls operate manually.

7. Hold this switch in either direction to turn the cylinders manually in the direction shown.

8. Nozzle. The automatic oil spray must occur at each transfer.

9. Where to point the oil spray. One point for each nozzle.

10. Air pressure adjustment knob and gauge.

COttman

10. Confirm level in oil Mist System resevoir

Figure 25: Drive Chain. These are examples. Your machine can look different.

Chain and Sprockets Chain Tension Mechanism

1. Chain and sprockets. These components are serviceable when the chain has the correct tension (see Item 2) and the cylinders change direction smoothly.

2. The dimension when the chain has the correct tension.

3. Screws (not shown) to replace two springs.

Remove the tensioner from the machine before you change the springs.

Figure 26: Tanks That Collect Lint—Conventional CBW Tunnel Washers

Areas Where Lint Collects Legend

1. Lint filter—Use a rigid bristle brush to remove contamination from between grooves.

2. Lint basket—Remove the basket to remove collected lint.

3. Overflow and drain outlets—Keep free of blockages

Cross Section of a Tank Flow Splitter or Flow Lifter Press Water to Reuse Tank

COttman Text Box

11. Confirm Chain condition and tension

COttman

12. Clean all lint screens in tanks

Figure 27: PulseFlow® Tank—PulseFlow® CBW Tunnel Washers

Lint Filter Side Areas That Collect Lint

1. Lint filter—Use a rigid bristle brush to remove contamination from between grooves.

2. Lint basket—Remove the basket to remove collected lint.

Figure 28: Pumps that Move Water and Solids—PulseFlow® CBW Tunnel Washers. See warning statement 25 .

Re-circulation Pump Pump Between Modules Legend

A. From Module 1 B. To the load chute C. From upstream module D. To downstream module

1. With power removed, remove the safety guard.

Replace when completed.

2. Remove eight bolts.

3. Remove the housing. Use a rubber hammer.

Impeller Housing Removal. Do this on the installed pump.

Figure 29: Module Sump Drain and Weir Box. These are examples. Your machine can look different.

View From Below Sump View from Above Weir Box Legend

1. Module sump drain.

Remove the plug to let the drain sump empty.

Add water with a hose or a water valve to flush the sump.

2. Water hose—Put the hose on the module side of the weir plate.

Figure 30: Steam Trap

Steam Trap on Steam Header Legend

1. Condensation to the boiler

2. Valve to remove collected particles.

Materials will come out with steam pressure. Open this valve momentarily.

3. Steam strainer. Remove steam pressure before you remove item 4. See warning statement 32 in Section 3.1.5.

4. Remove this component to remove strainer.

— End of BIUUUM09 —

COttman

13. Drain Weir Boxes & Steam Trap Strainers