Dupps 12/12-4 Pressor®

Installation, Operations and Maintenance Manual

for

TYSON Fresh Meats-Holcomb Holcomb, Kansas
USA

Publication No: Publication Date:

804127-6 8/21/2023

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Copyright © 2023 – The Dupps Company. All rights reserved.
The Dupps Company
548 North Cherry Street
P.O Box 189
Germantown, OH 45327-0189

This publication contains proprietary information, which is copyright protected. Without the prior written permission of The Dupps Company, do not reproduce, store in a retrieval system, or transmit any part of this publication, in any form or by any means.

Dupps®, Drainor®, Equacookor®, ICIS®, Pressor®, Productization®, Quadpass®, Sedimentor®,

Supercookor®, Superpressor®, and The Dupps Oval are registered trademarks of The Dupps Company.

DiscorTM, GrindorTM, HogorTM, HydrolyzorTM, PrecrushorTM, PrehogorTM, PreheatorTM, PredrainorTM, and ThermsavorTM are trademarks of The Dupps Company.

Mobil®, Mobilith®, Mobilgear®, and Mobilux®, are registered trademarks of Mobil Oil Corporation. Loctite® is a registered trademark of Loctite Corporation.
Rains-Flo® is a registered trademark of Rains-Flo Manufacturing, Inc.

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Adrián Gutiérrez

Parts and Service Contact Information

“Won’t Let You Down”

To Contact The DUPPS Company for a Parts Sales or Field Service related order, or technical assistance, please contact one of the following:

DUPPS Headquarters

Germantown, Ohio U.S.A. 548 North Cherry Street

Germantown, Ohio 45327-0189

DUPPS – Ankeny

1429 SE Cortina Drive

Ankeny, Iowa 50021

Phone: FAX: Email:

(1) 515-964-1110
(1) 515-964-0863 info@dupps.com

Phone: Mobile: Email:

(55) 11 4827 2764
(55) 11 99974 3144 LFerreira@dupps.com


Phone: FAX: Email: Website:

(1) 937-855-6555
(1) 937-855-6554 info@dupps.com www.Dupps.com

24/7 Emergency Parts Sales & Field Service

Phone: FAX:

(1) 937-855-6555 (1) 937-855-6554

DUPPS – Europe Mavitec B.V.

Phone: (31) 72-574 5988 FAX: (31) 72-574 5548

Email:

DUPPS – Japan
Akane Engineering Co. Ltd.

Phone: (81) 338 362025 FAX: (81) 338 362029

Email:

DUPPS – Australia
Keith Engineering, PTY LTD

Phone: (61) 985 21000 Email:

Galileistraat 20, 1704 SE Heerhugowaard, Holland

The Netherlands

DUPPS – Mexico

Germantown, Ohio 45327-0189 Phone: (52) 1 442-145-9049

Email: agutierrez@dupps.com

DUPPS do Brasil

(including Central and South America)

Leandro Ferreira, General Manager Rua Rinaldo Kasinski
621 – Parque João Ramalho – Mauá SP-09380-128 Brasil

info@mavitec.com

Web: https://www.mavitec.com

P.O. Box 189

Moa Bldg. 6-5-11 Sotokanda

Chiyoda-ku, Tokyo 101-0021 Japan

Koji Okada san

kokada@akane-eng.co.jp

20 Kellet Close

Erskine Park, NSW 2759 Australia

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Mr. Derek Henderson

derek@keitheng.com.au

Web: http://www.keitheng.com.au

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Table of Contents

Parts and Service Contact Information………………………………………………………………….. iii

Table of Contents ……………………………………………………………………………………………….. v Configuration Sheet ……………………………………………………………………………. 1 Introduction ……………………………………………………………………………………….. 3 Chapter 1 Safety Guidelines…………………………………………………………….. 5

Warning Signs and Labels…………………………………………………………………………………….5 Safety Alert Symbol…………………………………………………………………………………………………… 5 Operating Safety …………………………………………………………………………………………………6 Maintenance Safety……………………………………………………………………………………………..6 Hydrogen Sulfide Gas Emissions…………………………………………………………………………..7

Chapter 2 Specifications and Installation…………………………………………….9 Major Components………………………………………………………………………………………………9 Feed Hopper and Cage Assembly……………………………………………………………………………….. 9 Main Shaft and Barrel Cage ……………………………………………………………………………………….. 9 Hydraulic Choke……………………………………………………………………………………………………….. 9 Figure 2-1 : Dupps 12/12-4 Pressor (splash shields removed)…………………………………………………… 10 Gearbox ………………………………………………………………………………………………………………… 10 Options…………………………………………………………………………………………………………….11 Integral Jib …………………………………………………………………………………………………………….. 11 Liquid Pump …………………………………………………………………………………………………………… 11 Feed Screw and Magnetic Chute ………………………………………………………………………………. 11 Specifications ……………………………………………………………………………………………………11 Figure 2-2 : Specifications — 12/12-4 Pressor ………………………………………………………………………… 11 Figure 2-3 : Dimensional Data — 12/12-4 Pressor …………………………………………………………………… 12 Fastener Torque Specifications…………………………………………………………………………………. 12 Figure 2-4 : Fastener Torque Specifications — 12/12-4 Pressor………………………………………………… 12 Installation ……………………………………………………………………………………………………….. 12 Support …………………………………………………………………………………………………………………. 13 Figure 2-5 : Typical Discharge Chute and Conveyor ………………………………………………………………… 13 Clearance………………………………………………………………………………………………………………. 13 Cleaning Precautions ………………………………………………………………………………………………. 13 Installation Procedure…………………………………………………………………………………………13 Hydraulic Console Installation …………………………………………………………………………………… 14 Figure 2-6 : Hydraulic Diagram ……………………………………………………………………………………………… 14 Connecting the Hydraulic Lines…………………………………………………………………………………. 15 Filling the Hydraulic Oil Reservoir………………………………………………………………………………. 15 Water and Compressed Air Connections…………………………………………………………………….. 15 Figure 2-7 : Feed Chute Installation ……………………………………………………………………………………….. 16 Electrical Installation…………………………………………………………………………………………..16 Figure 2-8 : Figure 2-8: Electrical Diagram — Single Pressor ……………………………………………………. 18 Figure 2-9 : Figure 2-9: Electrical Diagram for Two Pressors — Sheet 1 of 2………………………………. 19 Figure 2-10 : Figure 2-9 (cont’d): Electrical Diagram for Two Pressors — Sheet 2 of 2…………………. 20

Chapter 3 Operating Instructions …………………………………………………….. 21 Controls and Adjustments …………………………………………………………………………………..21 Motor Load Control …………………………………………………………………………………………………. 21 Hydraulic System ……………………………………………………………………………………………………. 21 Operating Procedures ………………………………………………………………………………………..22

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Start Up Procedure …………………………………………………………………………………………………. 22

Shut Down Procedure ……………………………………………………………………………………………… 23 Operational Troubleshooting……………………………………………………………………………….24 Figure 3-1 : Operational Troubleshooting Chart……………………………………………………………………….. 24

Chapter 4 Lubrication and Maintenance …………………………………………… 25 Personal Safety…………………………………………………………………………………………………25 Lubrication………………………………………………………………………………………………………..25

Recommended Lubricants ……………………………………………………………………………………….. 25 Figure 4-1 : Recommended Lubricants …………………………………………………………………………………… 26 Lubrication Schedule & Procedures …………………………………………………………………………… 26 Figure 4-2 : Lubrication Schedule and Procedures…………………………………………………………………… 26 Hydraulic Oil Changing and Cleanliness……………………………………………………………………… 26 Choke Hydraulic System Maintenance………………………………………………………………….27 Hazards Associated with Hydraulic Oil Leaks………………………………………………………………. 27 Inspection and Maintenance……………………………………………………………………………………… 27 Keep the Hydraulic Fluid Clean …………………………………………………………………………………. 28 Troubleshooting the Hydraulic Choke …………………………………………………………………..28 Figure 4-3 : Hydraulic Choke Troubleshooting…………………………………………………………………………. 28 Pressure Adjustments ……………………………………………………………………………………………… 29 Pump Output Pressure…………………………………………………………………………………………….. 29 Choke Operating Pressure……………………………………………………………………………………….. 29 Adding a Second Control Station …………………………………………………………………………29

Chapter 5 Disassembly and Repair …………………………………………………. 31 Personal Safety…………………………………………………………………………………………………31 Hydraulic Choke………………………………………………………………………………………………..31

Replacing the Choke Head ………………………………………………………………………………………. 31 Figure 5-1 : Section through the Hydraulic Choke ……………………………………………………………………. 32 Remove the Choke Assembly …………………………………………………………………………………… 32 Check the Choke Mounting Screws and Holes………………………………………………………………………… 33 Installing the Choke Head …………………………………………………………………………………..33 Replacing Thread Inserts in the Pressor Frame …………………………………………………………… 33 Overhauling the Choke Cylinder…………………………………………………………………………..33 Disassemble the Choke Cylinder ………………………………………………………………………………. 34 Assembling the Choke Cylinder ………………………………………………………………………………… 34 Main Barrel Cage ………………………………………………………………………………………………35 Removing the Main Barrel Cage ………………………………………………………………………….35 Figure 5-2 : Screws in Choke End of Main Barrel Cage ……………………………………………………………. 35 Assembling the Main Barrel Cage ……………………………………………………………………………… 36 Figure 5-3 : Main Barrel Cage ……………………………………………………………………………………………….. 37 Inspect Parts Before Re-Use…………………………………………………………………………………….. 37 Figure 5-4 : Barrel Bar Inspection ………………………………………………………………………………………….. 38 Figure 5-5 : Checking Cage Ribs with Straight Edge………………………………………………………………… 38 Cage Assembly Procedure……………………………………………………………………………………….. 38 Figure 5-6 : Setting the Knife Bar Keyway Gap ……………………………………………………………………….. 39 Figure 5-7 : Clamping the Knife Bars and Key …………………………………………………………………………. 39 Figure 5-8 : Seating Ring and Spacer Installation…………………………………………………………………….. 40 Figure 5-9 : Barrel Bar Installation …………………………………………………………………………………………. 41 Installing the Main Barrel Cage Assembly …………………………………………………………………… 41 Figure 5-10 : Figure 5-10: Main Cage Assembly Cross Section…………………………………………………. 42 Feed Hopper and Cage………………………………………………………………………………………42 Disassembling the Feed Hopper Cage……………………………………………………………………….. 43 Assembling the Feed Hopper Cage……………………………………………………………………………. 43

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Main Shaft and Flights………………………………………………………………………………………..44 Removing the Main Shaft Assembly …………………………………………………………………………… 44 Pressor Thrust Collar Assembly ………………………………………………………………………………… 45

Figure 5-11 : Thrust Collar Assembly Cross Section ………………………………………………………………… 46 Choke End Removal ……………………………………………………………………………………………….. 46 Side Removal…………………………………………………………………………………………………………. 46

Figure 5-12 : Main Shaft Removal …………………………………………………………………………………………. 47 Disassembling the Main Shaft and Flights…………………………………………………………………… 47 Figure 5-13 : Main Shaft Assembly ………………………………………………………………………………………… 48 Parts List for Main Shaft Assembly ………………………………………………………………………………………… 48 Figure 5-14 : Main Shaft Assembly ………………………………………………………………………………………… 48 Assembling the Main Shaft and Flights ………………………………………………………………………. 48 Installing the Main Shaft …………………………………………………………………………………………… 49 Inspection and Repair of Feed Quill and Flights……………………………………………………..49 Field Repair of Pressor Flights ………………………………………………………………………………….. 49 Welding Procedure…………………………………………………………………………………………….50

Recommended Weld Materials ……………………………………………………………………………50 Filler Materials (for filling deep voids) …………………………………………………………………………. 50 Final Cover Pass (light buildup)…………………………………………………………………………………. 50

Chapter 6 Parts Lists …………………………………………………………………….. 51

Illustrated Parts Lists………………………………………………………………………………………….52 Figure 6-1 : Main Cage Assembly ………………………………………………………………………………………….. 53 Figure 6-2 : Shaft 12/12-4 Pressor …………………………………………………………………………………………. 54 Figure 6-3 : Feed Hopper & Cage Assy. 12/12-4 Pressor …………………………………………………………. 55 Figure 6-4 : Hopper Cage, 12/12-4 Pressor …………………………………………………………………………….. 56 Figure 6-5 : Hydraulic Choke Assembly ………………………………………………………………………………….. 57 Figure 6-6 : Quick Disconnect Hose Assemblies ……………………………………………………………………… 59 Figure 6-7 : Thrust Collar Assembly ……………………………………………………………………………………….. 60 Figure 6-8 : Tallow Screw Assembly (w/o pump)……………………………………………………………………… 61 Figure 6-9 : Gearbox ……………………………………………………………………………………………………………. 62

Spare Parts List…………………………………………………………………………………………………64 Figure 6-10 : Spare Parts List — 12/12-4 Pressor ……………………………………………………………………. 65

Chapter 7 Appendix A – Vendor Information ……………………………………… 67

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PRESSOR® Configuration Sheet

TYSON FRESH MEATS INC. ACCOUNTS PAYABLE AR07694 P. O. BOX 7142
SPRINGDALE AR 72766-7142 USA

Drive Motor:

Gearbox: Main Shaft: Options:

12/12-4 C34_353118 208935 804127-06 804127

103879

200

1750

149786

460

60

65.2:1

12″

12”

2 x – –

Tallow Screen Jib Beam Hoist
Other-

180468 (w/o pump) 108898
–
–

Spacers and Shims—Thickness: Main Cage

Spacers:

Shims: Hopper Cage

Spacers: Shims:

Notes: –

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Introduction

This manual contains specifications, operating instructions, maintenance and service procedures, and illustrated parts listings for Dupps Pressor®. Carefully read the instructions and safety precautions given in this manual. Do not service this equipment until you have read this manual thoroughly.

IMPORTANT:

This manual should be regarded as part of the equipment. It should remain with the equipment. If the equipment is relocated or sold, or its ownership transferred, please notify the Dupps Company at the address below, so we can contact the current owner in case of product updates or revisions to this manual.

The service procedures in this manual describe regular maintenance, trouble shooting, disassembly, and assembly of selected components. Contact your authorized Dupps service representative or the component manufacturer before performing service procedures that are not described in this manual.

At the time of writing, this manual was completely up to date. However, due to continual design improvement, some descriptions and/or illustrations in this manual could vary slightly from the equipment delivered to you. If you have questions regarding safety, operation, or service of this machine, please contact:

The Dupps Company
548 North Cherry Street
P O Box 189
Germantown, Ohio 45327-0189 Telephone: (937) 855-6555 Fax: (937) 855 6554
E-mail: info@dupps.com

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Chapter 1

Safety Guidelines

Safety is your responsibility and ours. You are cautioned to read and understand these safety guidelines before operating, or performing maintenance on, the equipment described in this manual.

To protect your employees, follow the training suggestions, maintenance schedules and procedures, and the operating safeguards described in this manual. The operation, safety, and performance of the equipment may be materially impaired if:

• The equipment has not been installed properly; or

• The equipment has not been operated in conformity with the instructions

  in this manual; or

• Repairs, alterations, or replacements not provided for in this manual have been made without approval of the Dupps Company.

  These safety guidelines have been prepared to help equipment operators and maintenance personnel practice good safety procedures. These guidelines should be used as a supplement to other safety precautions and warnings provided in the following:

1. 1)  All other manuals pertaining to the equipment, auxiliary equipment, and controls. These include manuals or other publications supplied by the manufacturers of the component parts of the equipment.

2. 2)  Federal and state safety laws and regulations. See the latest edition of the Occupational Safety and Health Act (OSHA) available from the Department of Labor, Washington, DC.

3. 3)  Local safety rules and codes; and facility safety procedures.

4. 4)  Good common sense.

Warning Signs and Labels

Make certain that all warning signs and labels are kept clean and visible. All lost or damaged warning signs and labels must be replaced immediately. Replacement warning signs and labels are available from The Dupps Company.

Safety Alert Symbol

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

The safety alert symbol is used in this manual. It is also used on safety warning signs and labels that may be attached to the equipment. This symbol will always be used in combination with a signal word, DANGER, WARNING, CAUTION, or NOTICE, which indicates the level of severity of the potential hazard as follows:

DANGER: indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

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WARNING: indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION: indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE: used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

Operating Safety

This equipment should be operated only by qualified persons, instructed in safety and all equipment functions. Every person operating this equipment and every person working in the area of this equipment must be trained to understand and use your facility’s Energy Control (Lockout/Tag out) Procedures. Refresher training should be done periodically.

Do not operate the equipment with safety guards, shields, covers, and other protective devices disconnected, removed, or out of place. If a guard, shield, or cover, or other protection (i.e., electrical interlock or alarm) is removed for maintenance or repairs, install it properly before connecting the power supply to the equipment.

Brackets or other similar structures on the vessel are not to be used as steps or platforms for access or any other purpose whatsoever. Use only OSHA approved steps or safety platforms that meet all local, state, and federal safety requirements. If none exist use separate approved lifts or ladders.

Maintenance Safety

Assign only trained, qualified service or maintenance personnel to perform maintenance and repair work on this equipment.

Never perform any maintenance or procedure on any equipment or machine wile that equipment or machine is in operation. Always follow your facility’s Energy Control (Lockout/Tagout) Procedures before any maintenance, or repair work on this or any other equipment.

Do not perform maintenance on this equipment until you read and understand all the safety instructions. Follow your facility’s Energy Control (Lockout/Tag out) Procedures when you perform maintenance and repair work on this equipment. When you perform maintenance or repair work inside a cooker or other vessel, follow your facility’s procedures for working in Confined Spaces.

Brackets or other similar structures on the vessel are not to be used as steps or platforms for access or any other purpose whatsoever. Use only OSHA approved steps or safety platforms that meet all local, state, and federal safety requirements. If none exist use separate approved lifts or ladders.

Performing maintenance according to recommended schedules for the equipment as set forth in this manual is a further safeguard for enhanced operator and equipment safety.

After performing maintenance, install all guards, shields, covers, and other safety devices. Install all fasteners provided for attaching these devices to prevent accidental or unauthorized removal. Make sure all guards, shields, covers, and other protective devices (i.e., electrical interlock or alarm) have

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been installed before removing lockout protection. Be sure all safety devices are in place when the equipment is operating.

Hydrogen Sulfide Gas Emissions

WARNING:

The rendering facility should be monitored throughout for hydrogen sulfide gas emissions. All personnel in and around the rendering facility should wear individual monitors. Failure to follow this instruction can result in serious personal injury or death.

Hydrogen Sulfide gas (H2S) is lethal and can cause serious injury or death in high concentrations. Hydrogen sulfide gas (H2S) is produced in nature during the bacterial breakdown of organic matter and as a by-product of hydrolyzation. In a rendering facility high concentrations can occur at various locations, particularly at raw material storage areas and from any leaks from a hydrolyzor or batch cooker. At lower concentration levels, hydrogen sulfide has a smell of rotten eggs; at higher concentrations it will numb the sense of smell and will be unnoticed.

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Chapter 2

Specifications and Installation

The Dupps Pressor® separates liquid from solid material by the application of high pressure. Initially developed to remove liquid fat from unpressed crax in the rendering process, the Pressor is an important element in the Dupps continuous rendering system. It is also used extensively in batch rendering plants. Dupps Pressors are used to press liquids from a variety of other materials as well.

Major Components

The Dupps Pressor is an uncomplicated but rugged machine with seven major components. (See Figure 2-1) These are:

1. 1)  Feed hopper and cage assembly

2. 2)  Main shaft and main cage assembly

3. 3)  Hydraulic choke assembly

4. 4)  Liquid screw and optional liquid pump

5. 5)  Gearbox

6. 6)  Integral hoist (optional)

7. 7)  Hydraulic console

Feed Hopper and Cage Assembly

The feed material enters the Pressor through the feed hopper. The hopper cage encloses the feed quill section of the Pressor shaft. The feed quill pushes material into the barrel cage section. Free liquid drains off the material through the hopper cage.

Main Shaft and Barrel Cage

The main shaft is a heavy duty screw conveyor which rotates in the slotted barrel cage. The root diameter of the main shaft is tapered so it is larger near the discharge end of the Pressor than at the feed end. The rotation of the main shaft conveys the material through the barrel cage toward the choke opening.

Hydraulic Choke

The hydraulic choke is located at the discharge end of the Pressor. The choke is a hydraulically operated, sliding sleeve assembly which varies the size of the orifice through which the pressed material must pass. The flights on the rotating shaft move the feed material down the length of the screw toward the choke opening. The combination of the increasing root diameter of the shaft and the small choke orifice reduce the volume of the material, thus subjecting it to extreme pressure. This pressure is proportional to the hydraulic pressure on the choke, and—for a given choke pressure—the feed rate. Thus, the residual liquid in the pressed cake is a function of both the choke setting (hydraulic pressure) and the feed rate. The pressure forces the liquid from the material. The extracted liquid drains through the slots in the barrel cage to the liquid screw in the base of the Pressor.

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The hydraulic console contains the pump and hydraulic fluid to operate the choke. One hydraulic unit can operate the chokes of two Pressors. The choke IN and OUT controls are on the operator’s panel. Adjustments for choke hydraulic pressure are located on the hydraulic console.

WARNING:

To clearly show certain details in the illustration, this equipment is shown with some covers, guards, or other safety equipment removed or in the open position. Be sure all covers and guards are properly installed before operating the equipment. Failure to follow this instruction can result in serious personal injury or death.

Figure 2-1 : Dupps 12/12-4 Pressor (splash shields removed)

Gearbox

The main shaft is driven by a totally enclosed, double reduction gear drive with a self contained lubrication system. The main shaft is coupled to the drive by a keyed, tapered tang and socket. A positively lubricated, heavy duty roller bearing takes the thrust load of the main shaft. The drive motor is flange mounted and coupled directly to the gearbox which is an integral part of the Pressor structure. A V belt drive is optionally available. The intermediate shaft of the gear reducer drives the liquid screw by means of a chain and sprocket.

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Options Integral Jib

The integral jib facilitates the removal of the barrel cage, main shaft, and choke assembly.

Liquid Pump

An optional liquid pump is available to remove the liquid from the Pressor for further refining. The pressed cake discharges through an opening in the bottom of the choke assembly.

Feed Screw and Magnetic Chute

In most rendering applications, an optional feed screw discharges the feed material into the feed hopper through a chute. A permanent plate magnet in the chute removes tramp iron from the material before it enters the feed hopper. The chute and magnet are illustrated in the Installation section of this chapter.

NOTE: Tramp metal in the feed can cause considerable damage to the Pressor and must therefore be removed from the system. An aluminum scoop is furnished with the Pressor for cleaning the plate magnet. A step is provided on the side of the Pressor for access to the magnet.

Specifications

This section lists specifications, weights, and dimensions for standard Dupps 12/12-4 Pressors. Note that these specifications are for typical standard Pressors. Some Pressors may be configured for specific applications. For this reason, these specifications may or may not apply to the Pressor supplied to you.

Pressor Specifications are listed in Figure 2-2. The overall dimensions of the Pressor are shown in Figure 2-3

12/12-4 Pressor

Shaft Assembly Main Cage Assembly Choke Assembly

Gearbox

Figure 2-2 : Specifications — 12/12-4 Pressor

Pressor Weight Dimensions Weight
Weight

Weight
Motor
Motor Frame Size Motor Speed Electrical Freq. Speed Ratio Output Speed
Oil Capacity

22,725 lbs. See Figure 2-3 1,746 lbs 3,605 lbs 1,019 lbs
200 Hp
445 TSC 1458rpm
50 Hz
51.55:1
28.3
30 US Gallons

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Figure 2-3 : Dimensional Data — 12/12-4 Pressor

Fastener Torque Specifications

Figure 2-4 lists torque specifications for threaded fasteners. The values listed are for lubricated threads in good condition.

Note: The cage bolts that attach the two halves of the main barrel cage have only their calculated maximum torque values listed in Figure 2-4. In actual practice, these bolts are tightened with a 1-1/2” drive impact wrench using 80 psi air pressure; and removed using 100 psi air pressure.

Main Barrel Cage Main Barrel Cage Choke

Cage bolts at choke end
Cage bolts
Choke housing to Pressor frame

2-1/2” –8 TPI 2”-8 TPI 1-1/8” –7 TPI

5,000 lb-ft max. (calculated) 3,000 lb-ft max. (calculated) 600 lb-ft max.

Figure 2-4 : Fastener Torque Specifications — 12/12-4 Pressor

Installation

The Dupps Pressor is shipped in one piece which is ready to be unloaded and put into operation. The Parts Lists chapter contains a list of accessory items shipped with the Pressor. Unless shipped overseas, it is not crated and needs only be lifted by the lugs provided and moved into position. The Pressor weight is listed in the “Specifications” section of this chapter.

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Support

The preferred support method is a level concrete pad with a recommended height of 24 inches (see Figure 2-3). Mounting the Pressor on a pad provides access to the liquid discharge (under the gearbox) and clearance for a 12” discharge conveyor and chute under the choke (see Figure 2-5). The Pressor should not be lagged down.

Figure 2-5 : Typical Discharge Chute and Conveyor

Clearance

See the “Specifications” section of this chapter for machine dimensions, clearance requirements, and recommended placement of the hydraulic control console. Place the console near the discharge end of the Pressor, if possible, so the operator can see the discharge while standing in front of the console.

Cleaning Precautions

If an abrasive cleaning procedure, such as sandblasting, is to be performed on or around this equipment, take steps to protect the equipment from the abrasive cleaning agents. These abrasive materials remain suspended in the air for long periods after cleaning. When these materials settle out of the air, they can get into bearings, seals, and other critical machine components, causing serious damage. If planning such a procedure, contact the factory for specific recommendations.

Installation Procedure

After setting the Pressor in place in the desired location, use a spirit level placed on the gearbox cover to accurately level the Pressor.

Make the necessary connections to the feed hopper. This will vary with the installation and the device used for feeding the Pressor.

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Connect the discharge conveying systems for press liquid and pressed cake. If the Pressor has an optional integral liquid pump, use long sweep ells (two of which are supplied with the Pressor) in the pump discharge lines. Pump discharge lines must pitch down away from the Pressor—after initial vertical rise—to prevent solids from blocking the line.

Hydraulic Console Installation

The choke is regulated by a double acting hydraulic cylinder at the discharge end of the Pressor. The cylinder is an integral part of the choke assembly. It is controlled by the Pressor hydraulic console through two hydraulic lines.

Figure 2-6 : Hydraulic Diagram

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Connecting the Hydraulic Lines

NOTICE:

Keep the hydraulic system components free of dirt. Failure to follow this instruction can result in internal damage to the hydraulic system.

Fittings are furnished for connecting the hydraulic console to the choke cylinder with 1/2” pipe. To make these connections use clean, pickled, Schedule 80 pipe (not supplied with the Pressor). In addition, two hose assemblies with quick-disconnect couplings are provided to make the connections at the choke cylinder ports. One line goes from the valve port marked A to the A (Retract) side of the choke cylinder (See the hydraulic diagram in Figure 2-6). The other line goes from the valve port marked B to the B (Extend) side of the choke cylinder. Take care to keep the hydraulic piping, choke assembly, and hydraulic parts of the console free of dirt. A very small particle of dirt in the hydraulic system will cause the choke sequence valve to malfunction. See NOTICE.

Filling the Hydraulic Oil Reservoir

Before starting the system, fill the hydraulic reservoir with high quality, pre- filtered hydraulic fluid. See the “Lubrication and Maintenance” chapter (or the metal plate on the hydraulic console) for recommended hydraulic oil). Fill the reservoir through the filler/breather on top of the reservoir. Fill to the top of the sight gauge on the side of the reservoir.

Water and Compressed Air Connections

A 3/8” cold water line must be provided for the atomizing nozzle in the Pressor feed chute. (See Figure 2-7) Compressed air must be piped to the solenoid control valve of the air cylinder on the feed screw.

15

Figure 2-7 : Feed Chute Installation

A compressed air supply, with a 1” connector, should be located near the Pressor. The air supply must be capable of delivering 90 psi at 100 cfm, to accommodate an air operated impact wrench for removing the main cage bolts. Compressed air must be piped to the solenoid valve for the air cylinder that operates the slide gate on the feed conveyor.

Electrical Installation

Electrical controls for the Pressor motor, feed screw motor, hydraulic choke, and hydraulic pump motor may be supplied as options. Make all electrical connections indicated on the appropriate wiring diagram in Figure 2-8 (single Pressor) or Figure 2-9 (two Pressors). Make the following connections and checks:

NOTICE 1:

Make sure the Pressor shaft runs counter-clockwise when viewed from the choke end. Failure to follow this instruction will result in damage to the Pressor.

The main Pressor drive motor is flange mounted directly to the gearbox. The motor must be wired so the Pressor shaft rotates counter-clockwise when viewed from the choke end. NEVER run the shaft clockwise. See NOTICE 1.

The dual set point amp meter, supplied with the Pressor, indicates the load on the main Pressor motor. A current transformer steps down the Pressor motor current for the amp meter. Install the current transformer on one of the

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motor leads at the main Pressor motor starter. The wiring for the transformer is shown on the wiring diagram in Figure 2-8 and Figure 2-9 (Terminals 9 and 10).

NOTICE 2:

Make sure hydraulic pump motor rotation matches the direction indicated on the pump housing. Failure to follow this instruction will result in damage to the hydraulic pump.

The hydraulic pump motor is located on the hydraulic console. When electrical power is applied to the motor, its direction of rotation must be checked. The correct pump motor rotation is indicated on the pump housing. If the rotation is wrong, reverse the direction by exchanging two of the electrical connections at the motor. See NOTICE 2.

Each directional control valve on the hydraulic console has a solenoid that requires a 120V control circuit. The valves must be wired so that energizing the solenoid causes the choke to extend.

If the Pressor is equipped with an optional feed conveyor, make sure the feed conveyor drive is connected so its rotation will cause material to discharge into the Pressor feed chute.

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Figure 2-8 : Figure 2-8: Electrical Diagram — Single Pressor

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Figure 2-9 : Figure 2-9: Electrical Diagram for Two Pressors — Sheet 1 of 2

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Figure 2-10 : Figure 2-9 (cont’d): Electrical Diagram for Two Pressors — Sheet 2 of 2

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Chapter 3 Operating Instructions Controls and Adjustments

The push buttons on the control panel are pull to start, push to stop type. Each push button has a built in indicator light to show when its circuit is on. A two position selector switch labeled CHOKE IN and OUT is provided for manual choke control. When the selector is positioned at CHOKE IN the green CHOKE IN light comes on to indicate that the choke is in operating position.

Motor Load Control

A dual set point amp meter on the control panel monitors the load on the Pressor motor. The black needle on the face of the amp meter indicates the percentage of full load of the Pressor motor. The two adjustable red needles indicate the low (choke) and high (feed conveyor) set points. If the motor load becomes too high, the amp meter reduces the load by controlling the choke and feed conveyor.

Adjust the amp meter set points before starting the Pressor. For maximum throughput, adjust the amp meter set points as follows:

Low set point—95% of full load.

High set point—approximately 105% of full load.

Local conditions and experience can result in slightly different set points.

The amp meter operates as follows:

1. 1)  When the load on the Pressor motor goes above the first (lower) set point, the choke automatically moves to the OUT position.

2. 2)  If the Pressor motor load goes above the second (higher) set point the feed conveyor stops and the valve that supplies water to the feed chute (see Figure 2 7) opens to spray water into the Pressor feed hopper.

3. 3)  When the Pressor motor load falls below the higher set point, the feed conveyor starts again and the water flow stops.

4. 4)  When the motor load falls below the lower set point, the choke returns to the IN position

The amp meter is provided specifically to protect the Pressor motor from overloading, and to keep the Pressor from “freezing up” or jamming. Bypassing this device will result in reduced output, increased liquid content, or damage to the Pressor.

Hydraulic System

Refer to Figure 2 6. The hydraulic system pump on the Pressor console supplies the hydraulic fluid to operate the choke. The hydraulic pump must be running in order to operate the choke. A filter in the pump suction line protects the hydraulic system from foreign matter.

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The hydraulic fluid flows through a check valve, pressure control valve, a 4 way solenoid valve, and then to the choke cylinder. The solenoid valve controls the in and out movement of the choke. The CHOKE IN/OUT selector switch controls the 4 way valve.

When the hydraulic pump is running and the selector switch is in the IN position, hydraulic pressure in cylinder B moves the choke in. When the selector switch is in the OUT position, hydraulic pressure in cylinder A moves the choke out. The side of the cylinder that is not pressurized drains to the reservoir. If the motor load goes above the lower limit on the motor load control amp meter, then the amp meter control moves the choke to the out position regardless of the position of the selector switch.

The pressure gauge mounted on the choke cylinder shows the choke operating pressure. The pressure gauge on the hydraulic console shows pump discharge pressure. The pump discharge pressure should always be 150 psi greater than the choke operating pressure. Instructions for adjusting the pump discharge pressure are included in The “Choke Hydraulic System” section of the “Lubrication and Maintenance” chapter.

NOTICE:

Do not turn the choke switch to the IN position unless there is material discharging from the Pressor. Failure to follow this instruction will result in damage to the Pressor.

Adjust the choke pressure or move the choke IN only when the Pressor is running and discharging material. Running the Pressor empty with the choke IN will force the choke head against the nose cone. The resulting metal-to- metal contact between the moving parts will cause immediate and serious damage. See NOTICE.

Operating Procedures

The following instructions assume that the Pressor has been test run and found ready for normal operation.

WARNING:

Make sure the aluminum splash shields are properly installed before starting the Pressor. Failure to follow this instruction can result in serious personal injury or death.

When the Pressor is operating, hot liquid under pressure is expelled through the slots in the main barrel cage. Hot liquid could present a burn hazard to personnel in the area around the Pressor. The aluminum splash shields are designed to contain the hot liquid and channel it to the liquid screw in the base of the machine. Before starting the Pressor, make sure the aluminum splash shields are properly installed. See WARNING.

Start Up Procedure

1) Start the pressed cake and liquid discharge handling equipment.

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NOTICE:

Do not turn the choke switch to the IN position unless there is material discharging from the Pressor. Failure to follow this instruction will result in damage to the Pressor.

2. 2)  Turn the choke switch to the OUT position and start the hydraulic pump. Do not run the empty Pressor with the choke in the IN position. Doing so will result in metal-to-metal contact between the choke head and the nose collar and damage to the Pressor. See NOTICE.

3. 3)  Start the Pressor.

4. 4)  Start the Pressor feed conveyor. Open the feed conveyor slide gate and begin feeding material to the Pressor.

5. 5)  Continue feeding with the choke switch in the OUT position until either the discharged cake is hot, or some liquid is being pressed through the main cage, or both.

6. 6)  Move the choke switch to the IN position. Adjust the choke pressure to 385 psi to 450 psi, 475 psi max, by turning the knob on the pressure control valve.

7. 7)  Adjust the choke pressure and the Pressor feed conveyor speed to obtain the highest cake output consistent with lowest liquid content.

8. 8)  Due to varying local conditions, some experimentation with the choke and feed screw settings may be necessary to obtain optimum results. When operating correctly, the Pressor discharges a cake 3/4” to 1” thick in a constant flow. A thin cake discharged in spurts indicates that the Pressor is being “starved” and the feed rate should be increased. A good cake is usually soft or pliable when discharged, becoming hard and brittle after cooling for a few minutes.

Shut Down Procedure

1. 1)  Before all the unpressed material has gone through the Pressor, save several shovel loads of pressed cake to be used later to clean out the Pressor.

2. 2)  After the feed conveyor is empty and the last unpressed material has passed into the feed hopper, move the choke selector switch to the OUT position and stop the feed conveyor. Turn off the hydraulic pump.

3. 3)  Put the pressed cake, saved in step 1, into the feed hopper.

4. 4)  Turn off the Pressor motor when all cake discharge has stopped.

5. 5)  If the Pressor is equipped with the optional liquid pump, clear the pump and the discharge line as follows:

6. 6)  Close the 2” valve in the header.

7. 7)  Open the appropriate 3/4” steam valve on the header to clear the discharge line and pump.

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Operational Troubleshooting

The troubleshooting chart in Figure 3-1 lists most of the problems that are likely to occur when operating a Pressor, with their causes and remedies. For operating problems not listed in the chart, contact the Dupps Company.

Pressor won’t feed.

Thin cake or low output.

High fat content in cake.

Too much steam at discharge. Excess solids from main barrel slots.

Liquid fat discharging with cake.

Choke reversing frequently.
Feed stopping frequently.

Pressor motor stops under load.

Overcooked feed material.

Choke discharge pops and sputters.

Overfeeding.
Feed not properly drained (Batch system).
Feed not properly drained (Continuous system).

Undercooked feed (Batch system). Undercooked feed (Continuous system).
Worn or broken knife bars.

Choke pressure too high.
Main shaft flights worn. Underfeeding.
Choke pressure too high. Undercooked feed (Batch system). Undercooked feed (Continuous system).

Overfeeding.
Choke pressure too low.
Feed overcooked.
Worn choke head, flights, or knife bars.
Undercooked feed.
High moisture in feed.
High moisture in feed.
Worn barrel bars.
Underfeeding.
Feed overcooked.
Improper barrel bar spacing. Motor overloaded.

Motor overloaded.
Overfeeding.
Excessive choke pressure. Choke or feed screw controls not functioning.

High bone content in feed. Long cooking time or end point temperature too high.
Feed too wet.

Underfeeding.

Slow down feed screw.
Hold feed in percolator longer to drain free run fat.

a). Reduce Supercookor discharge rate.

b). Open choke to relieve pressure on cake; close when Pressor again accepts feed.
Increase cooking time or end point temperature. Reduce Supercookor discharge rate; or increase end point temperature.

Replace broken knife bars in feed hopper or main barrel cages
Reduce choke pressure.
Rebuild main shaft or replace worn flights. Increase feed screw speed.

Decrease choke pressure.
Increase cooking time or end point temperature. Reduce Supercookor discharge rate; or increase end point temperature.
Decrease feed screw speed.
Increase choke pressure.
Reduce cooking time or end point temperature. Rebuild, or replace worn parts.

Increase cooking time or end point temperature. Decrease (or stop adding) water at feed chute. Increase cooking time or end point temperature. Reline main barrel cage with new bars. Increase feed rate.

Reduce cooking time and end point temperature. Increase bar spacing.
Decrease choke pressure.

Decrease choke pressure and/or feed rate. Reduce feed rate.
Reduce choke pressure.
Check control setpoints and circuit connections.

Add or increase water in feed chute. a). Revise cooking procedure.
b). Add water to feed chute
a). Reduce or stop water at feed chute. b). Increase cooking time or end point temperature.

Increase feed or decrease choke pressure.

Figure 3-1 : Operational Troubleshooting Chart

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Chapter 4

Lubrication and Maintenance

This chapter provides specific recommendations for periodic maintenance. It also gives detailed information about recommended lubricants, lubrication schedules, and procedures.

An hour meter is furnished with each Pressor to aid in determining maintenance and lubrication intervals. The meter is similar to an electric clock, but it records only when the Pressor feed conveyor is running.

Personal Safety

WARNING:

Follow your facility’s Energy Control (Lockout/Tagout) Procedures before performing maintenance, or repair work on this equipment. Turn off and lock out the electrical power to the Pressor, hydraulic console, and other connected equipment. Failure to follow this instruction can result in serious personal injury or death.

Before performing service on the Pressor, turn off and lock out the electrical power supply to the Pressor and to the hydraulic console to prevent starting during service operations. In addition, turn off and lock out power to any feed and discharge equipment connected to the Pressor. See WARNING.

Wear suitable safety equipment when performing service on the Pressor (eye protection, protective head gear, etc.). Use a suitable lifting device to lift heavy components.

Lubrication
Recommended Lubricants

Figure 4-1 lists recommended lubricants to use for each press component. Most of the lubricants named here are products of the Mobil Oil Corporation. The use of equivalent lubricants is acceptable. However, due to the large number of lubricant manufacturers and continuing product development, the Dupps Company cannot evaluate and certify specific brands of lubricants. The lubricant supplier should certify equivalency to the reference products listed in this manual.

Mobil lubricants with prefix SHC (example: SHC 634) have a synthetic hydrocarbon base. Note that synthetic lubricants from different manufacturers could have different chemical makeup, making them incompatible with each other. Do not mix synthetic based lubricants from different manufacturers in the same unit or component.

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Gearbox

Liquid Screw Drive
Motor Coupling
Feed Screw Gearbox Discharge End Bearing (in choke body) Hydraulic Console

Mobilgear® 600 XP 680 oil (factory installed), or equivalent Mobil® SHC 634 oil (approved alternate), or equivalent Mobilith® SHC 460 grease, or equivalent
Mobilux EP 111 grease, or equivalent

Mobil SHC 634 oil, or equivalent Mobilith® SHC 460 grease, or equivalent Mobil DTE 26 oil, or equivalent

Mobil, Mobilith, Mobilux, and Mobilgear are trademarks of the Mobil Oil Co.

Figure 4-1 : Recommended Lubricants

Lubrication Schedule & Procedures

Figure 4-2 gives the lubrication schedule and procedures. Figure 4-1 lists the specification for the various lubricants required for the Pressor.

COMPONENT

PROCEDURE

Hydraulic Console

Daily

6 Months or 2500 hr.

1 Week

First 200 hr.; then every 6 Months or 2500 operating hr.

1 Week 8 Hours

250 hours

Check the condition of the oil. If it is contaminated, clean the reservoir and replace the oil. Use the procedure for oil changing at 6 month intervals.

Drain the reservoir. Clean the inside of the reservoir with a clean, lint-free cloth. Fill reservoir with clean, pre-filtered oil to the full mark on the sight gauge.

Check the oil level with the dipstick located on the rear of the gearbox. If oil level is low, fill with the specified oil to the level indicated on the dipstick.
Drain the gearbox. Flush the inside of the box with kerosene to remove dirt and sludge. Fill the gearbox with new oil to the level indicated on the dipstick. Lubricate the grease fittings. Check the oil level in the box, and add oil if necessary.

Lubricate through the grease fitting.

Grease the fittings on (1) flange bearing on end of liquid screw discharge box, and (2) liquid screw shaft support bearing under the gearbox.

Check the oil level in the reservoir. Oil level is indicated by a sight gauge on the side of the reservoir. If it is low, fill with clean, pre-filtered oil to the full mark on the sight gauge. Add oil only through the filler/breather provided on top of the reservoir.

Check the indicator on top of the oil filter. If it indicates a dirty filter install a new filter. Discard the old filter. The filter is a spin-on cartridge; an oil filter wrench may be required to remove the old filter.

Pressor Gearbox

Feed Screw Gearbox

Discharge End Bearing (in choke body)

Liquid Screw Drive

Figure 4-2 : Lubrication Schedule and Procedures

INTERVAL

Hydraulic Oil Changing and Cleanliness

Clean hydraulic oil is essential to long life and reliability of the hydraulic system. Contaminated oil causes poor performance and early failure of

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system components. For this reason, every effort should be made to eliminate contamination and prevent the entry of dirt into the system.

Observe the following recommendations for maintaining the hydraulic system:

1. 1)  Use pre-filtered oil, if possible. Oil from barrels can be quite dirty and have water contamination.

2. 2)  Always use the filler/breather on top of the reservoir to fill or add oil to the reservoir.

3. 3)  Change the filter element regularly according to the lubrication schedule in this chapter.

4. 4)  In addition to scheduled filter changes, change the filter element as soon as possible when the indicator shows that the filter element is dirty. If the element becomes completely clogged, the filter bypass valve will open and none of the oil will pass through the filter.

5. 5)  When changing the hydraulic oil, drain the reservoir and remove dirt that has settled in the reservoir by wiping down the inside of the reservoir with lint free cloths.

Choke Hydraulic System Maintenance

This section includes information about the hydraulic console, including pressure adjustments, trouble shooting, and adding a second Pressor to a single Pressor unit. See the “Lubrication” section of this chapter for recommended hydraulic oil, and recommendations for changing the oil and filters.

Hazards Associated with Hydraulic Oil Leaks

WARNING:

Do not go near leaks in the hydraulic system when the system is under pressure. Do not use your finger or skin to check for or locate leaks. Always relieve system pressure before loosening fittings. Failure to follow these instructions can result in serious personal injury or death.

A pinhole leak in a high-pressure hydraulic system can allow oil to escape either in a concentrated stream or in an atomized mist. The concentrated stream can easily puncture skin and enter the bloodstream. Atomized oil, if in the presence of an ignition source such as an open flame or smoking materials, is easily ignited and burns with high heat release. See WARNING.

To reduce the possibility of personal injury from pinhole leaks, follow the maintenance guidelines given under the heading: “Inspection and Maintenance.”

Inspection and Maintenance

Visually inspect the hydraulic console, fluid lines, fittings, and hose assemblies once a week. Remove excessive dirt buildup; dirt can hide leaks or signs of damage. Correct leaking port conditions by tightening loose fittings or replacing damaged parts. Tighten, repair, or replace clamps, guards, or shields as necessary.

Replace any hose assembly having any of the following conditions:

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1. 1)  Leaks at the fitting or in the hose. Leaking fluid is a fire hazard.

2. 2)  Damaged, cut, or abraded cover (any reinforcement exposed).

3. 3)  Kinked, crushed, flattened, or twisted hose.

4. 4)  Hard, stiff, heat cracked, or charred hose.

5. 5)  Blistered, soft, degraded, or loose cover.

6. 6)  Cracked, damaged, or corroded fittings.

7. 7)  Fitting slippage on hose.

Keep the Hydraulic Fluid Clean

NOTICE:

If the hydraulic oil becomes contaminated, drain and thoroughly clean the reservoir and strainer. Refill with clean oil. Failure to follow this instruction will result in damage to the hydraulic system components.

A very small particle of dirt in the hydraulic system will cause the choke control valve to malfunction. Keep the hydraulic piping, choke assembly, and hydraulic parts of the console free of dirt. If the hydraulic oil becomes contaminated, drain and thoroughly clean the reservoir and replace the oil filter. Refill the reservoir with clean oil. See NOTICE.

Troubleshooting the Hydraulic Choke

Figure 4-3 lists difficulties which can occur in the hydraulic choke section of the Pressor. The Figure also gives the cause and remedy for each. For operating problems not covered in the table, contact the factory.

Oil leaks in choke area.

Choke moves slowly or not at all.

Defective cylinder gasket. Leaking O rings.
Loose hydraulic connections. Insufficient oil in reservoir Dirty pump inlet strainer. Clogged pressure control valve.

Pump shaft not turning.

Replace gasket.
Replace O rings.
Tighten fittings.
Add oil to full mark on sight gauge. Replace strainer.

Clean pressure control valve. Check condition of motor coupling. Replace coupling if needed.

Faulty solenoid in directional control valve.
Leaking main piston cup packing.

Replace solenoid. Replace packing.

Figure 4-3 : Hydraulic Choke Troubleshooting

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Pressure Adjustments

To identify the pump, reducing valve and other components of the hydraulic console, refer to the illustrations in the Illustrated Parts Lists chapter.

Pump Output Pressure

Pump output pressure can be adjusted, if necessary, by turning the adjusting screw on the hydraulic pump. With the pump running:

1. 1)  Loosen the jam nut on the pressure adjusting screw.

2. 2)  Open the gauge isolator so the gauge will read pump pressure.

3. 3)  Turn the pressure adjusting screw in (clockwise) to increase pressure. Turn the screw out (counterclockwise) to decrease pressure.

4. 4)  Adjust the pump output pressure to 500 psi.

5. 5)  Tighten the jam nut on the output pressure adjusting screw.

6. 6)  Close the gauge isolator.

Choke Operating Pressure

The operating pressure at the choke cylinder should be in the range 385 to 450 psi. It should never exceed 475 psi. It may be adjusted by turning the adjustment screw in the pressure regulating valve. The valve is located between the manifold and the directional control valve. If the hydraulic console operates two Pressors, it has a separate pressure regulating valve and directional control valve for each Pressor.

Before adjusting the choke operating pressure, make sure the pump output pressure is properly adjusted. Adjust the choke operating pressure as follows. With the pump running:

1. 1)  Advance the choke (pressure to port B).

2. 2)  Observe the choke pressure on the gauge mounted on the choke cylinder port B.

3. 3)  Loosen the jam nut on the adjustment screw on the pressure reducing valve.

4. 4)  Turn the adjustment screw in (clockwise) to increase pressure. Turn the screw out (counterclockwise) to decrease pressure.

5. 5)  Adjust the choke pressure to 450 psi.

6. 6)  Tighten the jam nut on the choke pressure adjustment screw.

7. 7)  Start the system and adjust within the recommended 385 to 450 psi range to yield the desired cake output.

Adding a Second Control Station

The manifold on the hydraulic console will accommodate two control valves for two Pressors. If only one valve is on the console and a second valve is desired, first make sure the power to the hydraulic console is turned off and locked out. Then, remove the cover plate and mount the additional pressure reducing valve and directional control valve on the manifold. Make the other piping and hose connections to the second Pressor (refer to the “Installation” chapter of this manual.

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Chapter 5

Disassembly and Repair

This chapter contains step-by-step instructions for disassembly and re- assembly of the following Pressor assemblies:

• Choke and hydraulic cylinder;

• Main cage, including barrel bars and spacers; and

• Main shaft and flighting.

  Repair and overhaul of the Pressor gearbox and thrust bearing units are not within the capabilities of most in plant maintenance departments. As such, they are beyond the scope of this manual. Contact the manufacturer for assistance in the event the gearbox or thrust bearing require repair.

  Personal Safety

  WARNING:

  Follow your facility’s Energy Control (Lockout/Tagout) Procedures before performing maintenance, or repair work on this equipment. Turn off and lock out the electrical power to the Pressor, hydraulic console, and other connected equipment. Failure to follow this instruction can result in serious personal injury or death.

  Before performing service on the Pressor, turn off and lock out the electrical power supply to the Pressor and to the hydraulic console to prevent starting during service operations. In addition, turn off and lock out power to any feed and discharge equipment connected to the Pressor. See WARNING.

  Wear suitable safety equipment when performing service on the Pressor (eye protection, protective head gear, etc.). Use a suitable lifting device to lift heavy components.

  Hydraulic Choke

  This section describes disassembly and re-assembly of the hydraulic choke. Refer to Figure 5-1. Note that the choke head, a high-wear part, can be removed and replaced without disassembling the choke.

  Replacing the Choke Head

  This procedure permits removal of the choke head without disassembling the choke. The combination choke and thrust collar remains locked in place by the main barrel cage. Removal of the collar requires separation of the cage halves.

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Figure 5-1 : Section through the Hydraulic Choke

Remove the Choke Assembly

Use the following procedure to remove the choke head. Figure 5-1 shows a cross section through the choke assembly.

NOTICE:

After removing the hydraulic lines from the choke, be sure to place suitable caps on the lines and plug the openings in the choke assembly. Failure to follow this instruction can result in damage to critical hydraulic components.

1. 1)  Remove the hydraulic lines from the choke cylinder at the quick disconnect couplings. Drain the hydraulic fluid from the cylinder by removing the drain plug from the bottom of the cylinder. Be sure to place suitable caps on the lines and plug all openings in the choke assembly to prevent contamination of the hydraulic system. See NOTICE.

2. 2)  Remove the two screws that fasten the two halves of the flinger ring attached to the main shaft next to the choke support bearing. Separate the flinger ring and remove it.

3. 3)  Using the integral hoist or equivalent, attach a suitable sling to the choke assembly. While supporting the choke with the hoist, remove the screws that attach the choke housing to the Pressor frame.

4. 4)  Continue supporting the choke with the hoist. Pull the choke assembly from the shaft. When the choke head clears the end of the shaft, set the choke assembly on the floor.

5. 5)  Remove the plugs from the two access holes in the choke housing. The choke head retaining screws are accessible through the holes after the plugs are removed.

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6) Remove the choke head retaining screws. Remove the choke head from the choke body.

Check the Choke Mounting Screws and Holes

After removing the choke assembly from the Pressor frame, check the condition of the mounting screws and the threaded holes in the Pressor. The long screws thread into the main cage. The short screws thread into inserts that are welded into the frame, as shown in Figure 5-1. If the threads are stripped, the thread inserts can be replaced. Replacing the inserts requires removal of the main cage because the inserts are installed from inside the frame. See “Replacing Thread Inserts in the Pressor Frame” elsewhere in this section of the manual.

Installing the Choke Head

1. 1)  Install the choke head in the body and secure it with the retaining screws. Install the retaining screw access plugs.

2. 2)  Install the choke assembly on the Pressor by carefully guiding the choke head into the thrust collar. Install and tighten the screws that attach the choke assembly to the Pressor frame.

3. 3)  Install the flinger ring on the main shaft as shown in Figure 5-1.

4. 4)  Connect the hydraulic lines to the choke housing and choke cylinder.

Replacing Thread Inserts in the Pressor Frame

The thread inserts for the choke mounting screws in the Pressor frame can be replaced with new inserts. The Dupps Field Service department is equipped to remove and replace the inserts efficiently without damage to the frame or the inserts.

To gain access to the insert(s) to be replaced, the choke and main cage assemblies must be removed. The inserts are installed from the cage side of the frame end plate and welded in place (Figure 5-1). The welding is also on the cage side of the end plate. The welds can be removed by drilling with a 2” diameter drill approximately 3/8” deep, or by hand grinding. When welding in a new insert, install an old screw into the insert to protect the insert threads from weld splatter.

Overhauling the Choke Cylinder

If the choke cylinder is leaking, disassemble it and replace the piston cups, packing, and O-rings. Use the following disassembly and assembly procedures and Figure 5-1 to the overhaul the choke.

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Disassemble the Choke Cylinder

NOTICE:

After removing the hydraulic lines from the choke, be sure to place suitable caps on the lines and plug all openings in the choke assembly. Failure to follow this instruction can result in damage to critical hydraulic components.

1. 1)  Remove the hydraulic lines from the choke cylinder at the quick disconnect couplings. Drain the hydraulic fluid from the cylinder by removing the drain plug from the bottom of the cylinder.

2. 2)  Remove the two screws that fasten the two halves of the flinger ring attached to the main shaft next to the choke support bearing. Separate the flinger ring and remove it.

3. 3)  Using the integral hoist or equivalent, attach a suitable sling to the choke assembly. While supporting the choke with the hoist, remove the screws that attach the choke housing to the Pressor frame. Move the choke assembly to a bench or clear area on the floor for further disassembly.

4. 4)  Remove the bolts that attach the hydraulic cylinder to the choke housing. Remove the cylinder.

5. 5)  Loosen the set screw in the rod nut on the piston end of the piston rod and remove the nut.

6. 6)  Remove the plates, piston cups, and piston head from the rod.

7. 7)  Pull the choke body and piston rod from the choke housing. Remove the O rings from the grooves in the seal insert.

8. 8)  Loosen the set screw in the rod nut on the choke end of the piston rod and remove the nut.

9. 9)  Remove the choke body from the piston rod.

Assembling the Choke Cylinder

Use the procedure that follows to assemble the choke piston. Figure 5-1 shows a section through the choke assembly. Use new piston cups and O rings.

1. 1)  Insert the short end of the piston rod into the choke body. Install and tighten the nut. Tighten the set screw in the nut.

2. 2)  Check the condition of the bore and O ring grooves in the piston rod seal insert. If damaged or worn, remove the seal insert and replace it with a new one. If replacing the insert, be sure to install a new O ring in the insert’s external groove. The internal O rings should be replaced in any case.

3. 3)  Apply petrolatum to the O rings and install the O rings into the grooves in the seal insert.

4. 4)  Slide the choke housing over the piston rod, taking care not to damage the O rings.

5. 5)  Assemble the plates, cups, and piston head. The plates must fit inside the cups. Install the outboard nut and tighten the set screw in the nut.

NOTE: The plates are not identical. Install the heavier (thicker) spacer plate first (on the choke side of the piston head). Install the thinner follower plate last (on the hydraulic cylinder side of the choke head). See Figure 5-1.

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6. 6)  Install a new gasket on the choke flange before installing the cylinder.

7. 7)  Slip the cylinder over the piston taking care not to crimp or tear the piston cups. Make sure the hydraulic line fitting is on top and the drain hole is on the bottom. Install and tighten the bolts attaching the cylinder to the choke housing.

8. 8)  Position the choke assembly so the shaft support bearing is aligned with the shaft and the choke head is aligned with the thrust collar. Carefully guide the choke head into the thrust collar, and the shaft support bearing onto the shaft. Install and tighten the screws that attach the choke assembly to the Pressor frame.

9. 9)  Install the plug in the drain hole in the bottom of the cylinder.

10. 10)  Install the flinger ring on the main shaft as shown in Figure 5-1. Lubricate

    the discharge end bearing (see Chapter 4).

11) Connect the hydraulic lines to the choke housing and choke cylinder.

Main Barrel Cage

The Pressor tool kit contains the necessary tools (sockets, wrenches, etc.) to disassemble the Pressor main cage. Although it is not required, a suitable air operated impact wrench (rated at 2600 lb-ft) is recommended for removing and installing the main cage bolts. Use the integral hoist, or an equivalent, to lift and handle the two cage halves.

Removing the Main Barrel Cage

Use the following procedure to remove and disassemble the main barrel cage.

1) Remove the four 8 inch long hex head cap screws that hold the choke end of the cage to the thrust collar. These are four of the twelve screws that attach the choke housing to the end of the Pressor frame (see Figure 5-2).

Figure 5-2 : Screws in Choke End of Main Barrel Cage

2. 2)  Refer to Figure 5-3. Remove the main cage bolts and nuts.

3. 3)  Turn the two cage jack screws in alternately and evenly to separate the cage halves and disengage them from the groove in the thrust collar. Be careful not to damage the cage keys.

4. 4)  Using the hoist, place the cage halves on a workbench or clean floor.

35

5. 5)  To remove the barrel bars from the cages, first remove the knife bars, pressure bars, and cage keys.

6. 6)  Remove the barrel bars, spacers, and shims. Keep all the spacers from each cage section together. Finally, remove the seating rings.

NOTICE:

Keep spacers from each section of barrel bars together. Do not intermix spacers from one section to another. Failure to follow this instruction can result in decreased press performance.

Note: Spacers of different thickness are used in each section of the barrel cage. Do not intermix spacers from one section with those from another section. Keep spacers for each section of barrel bars together and separate from spacers for the other sections. Use the same spacers—or new spacers of the same thickness—when assembling the cage. See NOTICE.

Assembling the Main Barrel Cage

NOTICE:

Do not interchange either half of the main cage with a cage half from another assembly. Cages may only be used as a matched pair. Failure to follow this instruction can result in damaged cage parts.

The two halves of the main barrel cage are manufactured as a matched pair. Cage halves cannot be used interchangeably with other similar cage halves from other Pressors or spare assemblies. Always re-assemble the cage using only the original mating halves. See NOTICE.

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Figure 5-3 : Main Barrel Cage

Ref Part Description

1. 1  Main Cage, Bare

2. 2  2 1/2” Cage Bolt

3. 3  2 1/2” Washer

4. 4  2” Cage Bolt

5. 5  Jack Screw

6. 6  2 1/2” Socket Nut

7. 7  2” Cage Nut

Ref Part Description 8 Cage Key
9 HP AKF Knife Bar

10 LP AKF Knife Bar 11 BKF Knife Bar
12 CKF Knife Bar
13 CKF Pressure Bar 14 KF Pressure Bar

Ref Part Description 15 HKF Pressure Bar
16 Wedge Bar
17 Spacer

18 Barrel Bar 19 Shim
20 2” Seat Ring 21 1” Seat Ring

Inspect Parts Before Re-Use

1. 1)  Check the amount of wear on the barrel bars. If the barrel bars are worn more than 1/8 inch, as shown in Figure 5-4, install new bars.

2. 2)  Check the knife bars for damage and excess wear. Replace worn or broken knife bars with new knife bars.

3. 3)  Place the cage half on a workbench with its open side up. Check the ribs with a straight edge. Lay the straight edge in the cage as shown in Figure 5-5. Check to see if all ribs are touching the straight edge. The cage should be rebuilt if there is a gap of 1/16” or more between the straight edge and one or more ribs.

37

Figure 5-4 : Barrel Bar Inspection

P PR-109

Figure 5-5 : Checking Cage Ribs with Straight Edge

Cage Assembly Procedure

1. 1)  Install the long knife bar at the choke end of the cage half. Position the bar with the notch at the discharge (choke) end of the cage. Install but do not tighten the knife bar retaining screws.

2. 2)  Install the short knife bar in the same manner as the long bar, except with the notch at the opposite end of the cage.

3. 3)  Place the cage key in the gap between the back edge of the knife bar and the cage casting. Then, insert.025” barrel bar spacers between the key and the cage casting. These spacers should be located near the ends of the knife bars and near the center of the long key (see Figure 5-6.)

NOTE: The key installation behind the knife bars is temporary. The key and spacers are being used to set the gap between the knife bars and the cage casting. The .025” spacers are used because the gap must be a little wider than the key. The key will be removed after the gap is set. Later it will be installed, without spacers, behind the pressure bars.

38

Figure 5-6 : Setting the Knife Bar Keyway Gap

4) Check the fit-up. The key should be firmly seated in the groove, and flush with the cage on the ends. Place one or more clamps over the assembly, as required, to eliminate any bow or twist in the key. (See Figure 5-7.)

Figure 5-7 : Clamping the Knife Bars and Key

5) Tighten the knife bar retaining screws.

39

6. 6)  Remove clamp(s). Then, using a soft-faced mallet or wood block to protect the key, drive the key lengthwise in the groove a few inches. With the end of the key protruding from the cage, tap the key up out of the groove. Remove the spacers and check for a loose fit between the key and the keyway. Set the key aside until all the barrel bars are installed.

7. 7)  Place a 1” wide seating ring on each end rib of the cage. Place a 2” wide seating ring on each of the intermediate ribs. (See Figure 5-8.)

8. 8)  In the cage section at the choke end, install a wedge bar next to the knife bar. The wedge bar must have its thick edge against the seating ring, and its thin edge towards the inside of the cage.

9. 9)  Install the barrel bars and spacers in each of the four cage sections. Do not reuse worn shims, seating rings, or spacers. Assemble all the wedge bars, barrel bars, and spacers in one section at a time beginning at the choke end and working toward the feed end.

NOTE: The barrel bar spacer thickness in each section depends upon the specific pressing application. Figure 5-8 shows the standard spacer thickness for the rendering applications listed. For other applications, consult the factory. The Pressor’s Configuration Sheet lists the actual spacer thickness supplied from the factory when new.

Figure 5-8 : Seating Ring and Spacer Installation

10. 10)  Be sure that the bars’ beveled edges are oriented toward the direction of rotation of the main shaft as shown in Figure 5-9.

11. 11)  After the wedge barrel bar in each section is installed, install the pressure bars. Tighten the pressure bar screws and determine the shim thickness required to fill the space remaining between the wedge bar and the pressure bar. Loosen the pressure bars and install the proper shims. Refer to the cross section view of the main cage assembly (Figure 5-10) for proper stack-up and orientation of all the parts.

40

12. 12)  Before tightening the pressure bar retaining screws, place the cage key in the slot between the back edges of the pressure bars and the cage casting.

13. 13)  Tighten the pressure bar retaining screws securely.

14. 14)  Repeat Steps 1 through 13 to assemble the other cage half.

Figure 5-9 : Barrel Bar Installation

Installing the Main Barrel Cage Assembly

Use the hoist to lift each assembled cage half into position on the Pressor. Be sure the groove in the cage engages the flange on the combination choke and thrust collar. Install the cage bolts and nuts. Pull the cage halves together evenly, by alternately tightening the top and bottom bolts a few turns at a time until the cages are pulled tightly together.

41

Figure 5-10 : Figure 5-10: Main Cage Assembly Cross Section

Feed Hopper and Cage

The feed hopper and cage assembly is made of three major parts: the feed hopper, the hopper cage, and the hopper discharge end. The feed hopper is bolted to the hopper mounting bars which are welded to the Pressor frame. The hopper discharge end is bolted to the hopper and to the hold down bracket. Figure 5-11 shows the hopper and cage assembly.

42

Feed Hopper and Cage — 12/12-4 Pressor

Disassembling the Feed Hopper Cage

Use the following procedure to remove and disassemble the hopper cage:

1. 1)  Attach a sling to the jib hoist. Run the sling around the hopper discharge end and under the hopper cage to support and lower the cage from above.

2. 2)  While supporting the cage assembly with the hoist, remove the cage bolts. Guide the cage from below, and carefully lower and remove it from the machine.

3. 3)  Remove the socket head screws that attach the hopper cage knife bars and wedge bars.

4. 4)  Remove the hopper cage knife bars, wedge bars, pressure bars, barrel bars, barrel bar spacers, shims, and seating rings.

Assembling the Feed Hopper Cage

Before assembly, inspect the components of the feed hopper and cage assembly listed below:

43

1. 1)  Check the barrel bars for excess wear. If bars are worn more than 1/8 inch, as shown in Figure 5-4, install new bars.

2. 2)  Check the knife bars for damage or excess wear. Replace knife bars as required.

3. 3)  Check the feed hopper discharge end for nicks, gouges, or excess wear. The discharge end of the feed hopper can be removed by removing the screws that attach it to the feed hopper.

Assemble the feed hopper and cage using the following procedure and Figure 5-11.

1. 1)  Place the cage on a workbench with its open side up.

2. 2)  Place a 1-1/4” wide seating ring on each rib of the cage.

3. 3)  Install one pressure bar and one knife bar on one side of the cage. Install and tighten the socket screws.

4. 4)  Install a wedge bar against the pressure bar and knife bar that were installed in the previous step. The narrow edge of the wedge bar should be facing the inside of the cage (see Figure 5-11).

5. 5)  Install the barrel bars and spacers in the cage. (Be sure that the bars’ beveled edges are directed toward the direction of rotation of the main shaft, as shown in Figure 5-9)

NOTE: The barrel bar spacer thickness depends upon the specific pressing application. A spacer thickness of .095″ is recommended for rendering applications. For other applications consult the factory.

6. 6)  After the last barrel bar is installed, install the remaining wedge bars. Then install the pressure bar and knife bar with the socket screws.

7. 7)  Determine the shim thickness required to fill the space between the wedge bar and the pressure bar. Loosen the pressure bar and install the proper shim. Tighten the pressure bar screws. Repeat this step for the knife bar shim.

NOTE: Do not reuse worn shims, seating rings or spacers.

8) Position the cage under the feed hopper. Make sure the discharge end ring fits into its seat in the main barrel cage. Carefully raise the cage assembly into position and align the bolt holes with those in the feed hopper. Install and tighten the hopper cage bolts, nuts, and lockwashers.

Main Shaft and Flights

This section describes removal and disassembly of the main Pressor shaft. Disassembly of the main shaft is a difficult procedure requiring special tools. We recommend returning the main shaft to the factory for disassembly and replacement of worn parts.

Removing the Main Shaft Assembly

Use the following procedure to remove the main shaft assembly:

1. 1)  Remove the choke assembly following the procedure in the “Hydraulic

   Choke” section of this chapter.

2. 2)  Remove the main barrel cage using the procedure in the “Main Barrel Cage” section of this chapter.

44

3. 3)  Remove the feed hopper cage using the procedure in the “Feed Hopper and Cage” section of this chapter.

4. 4)  Remove the hold-down plate from the feed hopper discharge end (see Figure 5-11.

5. 5)  Remove the screws that attach the feed hopper discharge end to the feed hopper. Remove the discharge end.

6. 6)  Rotate the main shaft to the position where the drive key (in the tapered tang and socket) is on top.

7. 7)  See the thrust collar illustration in Figure 5-12. Remove the six pull up collar cap screws attaching the pull up collar to the thrust collar. Begin evenly tightening the four jacking screws to dislodge the shaft from the thrust collar. When the shaft is free, remove the pull up collar from the shaft by removing the four screws that fasten the two halves of the collar together.

8. 8)  Follow the “Choke End Removal” or “Side Removal” procedure to remove the shaft from the Pressor.

Pressor Thrust Collar Assembly

Refer to Figure 5-12.

1. 1)  Drain the oil from the Thrust Collar Housing by removing the Pipe plug

   from the bottom of the housing.

2. 2)  With the Pressor shaft removed, remove the seal from the end of the Thrust Collar Housing.

3. 3)  Remove the (12) 5/8” HHCS holding the housing to the gearbox.

4. 4)  Slide the housing over the thrust collar extension until the housing is free and can be lifted out of the pressor. Remove the gasket from the face of the housing and discard. A new gasket will be needed for re assembly. To prevent the bearing carrier from being pulled out with the thrust collar, replace (2) of the 5/8” HHCS that were removed.

5. 5)  Rotate the gearbox until the tapped hole in the outer diameter of the trust collar is at the top. Install a 3/4-10 lifting eye into the tapped hole.

6. 6)  The thrust collar weighs about 900 pounds. Use an appropriately sized lifting device to support the thrust collar.

7. 7)  The thrust collar fits fits tightly onto the pressor gearbox slow speed shaft. To remove the thrust collar from the slow speed shaft, some type of puller is needed. One way to remove the thrust collar is by using a hydraulic jack. Place the hydraulic jack in the center of the thrust collar. Make a thrust plate with holes to match the bolt pattern at the end of the thrust collar. Using long screws, or all thread with heavy nuts, attach the thrust plate with the hydraulic cylinder located centered in the thrust collar.using the hydraulic jack remove the thrust collar from the slow speed shaft .

8. 8)  The thrust bearing is made up of on roller assembly and two thrust plates, one on each side of the roller assembly. The thrust bearing may have remained with the thrust collar. Inspect the thrust plates and roller assembly for wear and or damage. Replace if required.

9. 9)  Do not remove the bearing carrier unless disassembly of the gearbox is required. The bearing carrier contains the output shaft bearing which should stay in place unless additional maintenance is required.

45

10. 10)  The thrust collar key is held in place by (2) 1⁄2-13 SHCS. Remove the screws and key. Inspect for damage and wear. Replace if required.

11. 11)  To reassemble the thrust collar assembly, reverse the steps above. Insure all parts are clean and free of dirt before assembly. Failure to do so could cause early failure of the thrust and or output shat bearings.

12. 12)  The thrust bearing is designed so the outer diameter on the inner thrust plate will be snug in the bearing carrier. The inner diameter of the outer thrust plate should be snug to the thrust collar. During reassembly insure the thrust plates are located properly.

Figure 5-11 : Thrust Collar Assembly Cross Section

Choke End Removal

Use the jib hoist and a suitable sling to carefully work the main shaft out through the hole in the combination choke and thrust collar in the end of the Pressor frame. See Figure 5-13. When the drive end of the shaft clears the feed hopper, slip the feed hopper discharge end off over the feed quill.

Side Removal

Remove the combination choke and thrust collar from the choke end of the Pressor frame. Using a brass drift and a hammer on the feed side of the collar, work around the shaft, tapping on the rim of the collar to drive the collar out the choke side of the frame.

46

Use the jib hoist and a suitable sling to work the main shaft out of the Pressor. Carefully pull the shaft toward the choke end of the machine until the tapered tang clears the thrust collar. Then, swing the drive end of the shaft to the side of the machine (the side opposite the motor) and extract it drive end first. See Figure 5-13. The feed hopper discharge end can be removed after the shaft is clear of the Pressor.

Figure 5-12 : Main Shaft Removal

Disassembling the Main Shaft and Flights

If the main shaft is to be disassembled, use of a flight puller is recommended.

NOTE: Disassembly of the main shaft is a difficult procedure requiring special tools. We recommend returning the main shaft to the factory for disassembly and replacement of worn parts.

Use the following procedure and Figure 5-14 to disassemble the main shaft and flights after removing the shaft from the machine.

1. 1)  Inspect the cake breakers on the flight locknut. Replace damaged or excessively worn breakers.

2. 2)  Carefully grind the welds attaching the locknut step key to the shaft. Remove the locknut step key.

3. 3)  Remove the flight locknut from the shaft using the flight locknut wrench supplied in the Pressor tool kit. The flight locknut has left hand threads.

4. 4)  Using a flight puller, remove the flights from the shaft (see Figure 5-14):

NOTE: The exact configuration of the flights on the Pressor shaft depends upon the pressing application. Figure 5-14 shows a typical flight arrangement for rendering applications.

5. 5)  5) Remove the keys from the keyseat in the shaft.

6. 6)  6) Clean the bare shaft and the inside diameter of all reusable parts.

47

Figure 5-13 : Main Shaft Assembly

Parts List for Main Shaft Assembly

REF PART NAME REF

1. 1  Bare Shaft 6

2. 2  Feed Quill Key 7

3. 3  Feed Quill 8

4. 4  Long Flight Key 9

5. 5  Flight, B1 10

Figure 5-14 : Main Shaft Assembly

PART NAME

Flight, C1 O-Ring Flight, D1 Flight, E1 Flight, F1

REF PART NAME

11. 11  Flight, G1

12. 12  Nose Collar

13. 13  Flight Locknut w/sleeve

14. 14  Step Key

Assembling the Main Shaft and Flights

Check the feed quill and flights for excessive wear or damage that would affect their usability. Replace worn feed quill and flights with factory new or rebuilt parts. Assemble the main shaft and flights using the following procedure and Figure 5-14.

1. 1)  Clean all flight keys and keyways and install the flight keys.

2. 2)  Install the flights on the shaft as shown in Figure 5-14. (The exact flight configuration may be different than that shown.)

3. 3)  Install the flight locknut. Tighten the nut using the flight locknut wrench to insure firm contact of all parts. (A 1-1/2” drive air operated impact wrench is recommended for this purpose.)

4. 4)  Install the locknut step key into the keyseat in the locknut. Weld the key to the shaft.

48

Installing the Main Shaft

Using the jib hoist and a suitable sling, install the main shaft assembly in the reverse order of removal described previously in this section of the manual. Remember to slide the feed hopper discharge end on the shaft before installing the shaft into the Pressor. Make sure the tapered section of the main shaft is properly seated in its mating taper in the thrust collar.

Inspection and Repair of Feed Quill and Flights

Check the feed quill and flights for excessive wear or other damage that would affect their usability. Refer to Figure 5-14. Replace worn feed quill and flights with factory new or rebuilt parts.

On standard feed quill and flights, the Dualloy hard surface material is applied onto the steel core by a proprietary casting method. The surface is field repairable under certain conditions (see “Field Repair of Pressor Flights” in this section).

Field Repair of Pressor Flights

It is possible for qualified personnel to rebuild the leading edges of the standard cast Dualloy Pressor flights by overlaying them with weld material while the main shaft is still in the Pressor. This may help to lengthen the time period between complete main shaft rebuilds. Before proceeding, however, be advised of the following disadvantages and pitfalls:

1. 1)  Arc welded deposits of hard facing welding rod are not as hard as those applied with gas and, therefore, wear more rapidly.

2. 2)  Improperly attached ground clamp will result in arcing through the thrust bearing, causing premature bearing failure.

3. 3)  Excess weld deposit on the leading edge of the flight will interfere with the knife bar.

4. 4)  Excess weld deposit on the top of the flight will gouge the barrel bars.

5. 5)  The shrinkage of flights due to heat of welding (a) makes the flights difficult to remove and (b) causes gaps at the seams between flights, which allow product to migrate between the flights and shaft.

6. 6)  Temperature extremes caused by arc welding frequently result in cracks in the flight body which can cause separation or breakage of the hardface material in normal operation of the machine.

7. 7)  No warranty work or credit will be given on any flight on which welding has been done.

49

Welding Procedure

Break down the main cage while the Pressor is hot (250o-300o F). It is very important that the entire shaft be at operating temperature before beginning to weld.

Using either MIG welder or Wire welder, begin applying thin layers of weld material (see “Recommended Weld Materials” in this section) on the leading edge of the flight.

After the desired amount of weld material has been deposited on the flights, either cover the entire shaft with an insulated blanket for at least two hours or return the shaft to service immediately.

Recommended Weld Materials Filler Materials (for filling deep voids)

• TechniweldTM 308 stainless (MIG or wire)

• Techniweld ER 80-S-D2 (MIG or wire)

• 8018 (stick)

• 7018 (stick)

  Final Cover Pass (light buildup)

  AWS A5.14-89 ER NI.1 Nickel 61

• Ideal welding parameters are as follows:

• Wire size: .045”

• Weld speed: 26W

• Volts: 26 – 28

50

Chapter 6

Parts Lists

This chapter contains illustrations and tabulated parts lists for the Dupps 10 4 Pressor. The three sections in this chapter contain the following:

• Illustrated Parts Lists. The lists in this section identify all the parts in the Pressor.

• Spare Parts List. Selected parts in this section are identified as recommended spares.

  Below is a list of the figures found in this chapter and the Pressor assemblies they pertain to.

Figure 6-1 Figure 6-2 Figure 6-3 Figure 6-4 Figure 6-5 Figure 6-6 Figure 6-7 Figure 6-8 Figure 6-9 Figure 6-10 Figure 6-11

Main Cage Assembly Main Shaft & Flights Hopper & Cage Assembly Hopper Cage

Hydraulic Choke
Quick Disconnect Hose Assembly
Thrust Collar Assembly
Liquid Screw Assembly (Pressor w/ Fines System) Gearbox
Accessories Supplied with the Pressor
Spare Parts List

51

Illustrated Parts Lists

In each Figure, the REF numbers are keyed to the illustration. The QTY column lists the quantity of the part used in the assembly. The PN column lists the Dupps part number for each part. The PART NAME column gives the part description.

In some cases, a complete assembly containing all or most of the parts in a listing has its own part number. In these cases, the assembly part number is given at the top of the list.

If a single reference item has two or more part numbers listed, this indicates different configurations, or options, of the Pressor.

52

Figure 6-1 : Main Cage Assembly

REF QTY

209325 Main Cage Assembly (45, 35, 25,20) 145070 12/12-4 Main Cage
108017 Square Head Set Screw 1-8 X 6” 182770 Pressor Cage w/Bolt Lock

100622 Cage Bolt 2-8 x 12” 175763 Pressor Cage Bolt 100623 Socket Cage Nut 2 1/2-8 109055 Cage Bolt Nut 2-8 145073 LP “AKF” Knife Bar 145980 HP “AKF” Knife Bar 145075 “BKF” Knife Bar

128223 “KF” Pressure Bar

145078 “HKF” Pressure Bar

REF QTY

1 1-6 2 2-1 2-2 3

1

4 12 12 12 4

10 11 12 13 14 16 17 18 19 20 21 22 23

2 32 14 4 264 2
1 box 1 box 1 box 1 box 2
4 16

145077 “CKF” Pressure Bar
100586 3/4-16 x 5” HHCS
145071 Internal Seat Ring .062” X 2” 145072 End Seat Ring .062” x 1”
110077 Barrel Bar 1-1/4 X .500
128226 Cage Key
104718 .045” x 1” x 1 1/4” Spacer (200/box) 101440 .035” x 1” x 1 1/4” Spacer (200/box) 101437 .025” x 1” x 1 1/4” Spacer (200/box) 101435 .020” x 1” x 1 1/4” Spacer (200/box) 104232 .125” x 1 1/4” x 12” Shim
105852 .250” x 1 1/4” x 12” Shim
128218 Wedge Bar

5 12 6-1 2 6-2 2

7 2 84 92

Part List: Main Cage Assembly

53

Figure 6-2 : Shaft 12/12-4 Pressor

REF QTY

1. 1  1 145094

2. 2  1 141564

3. 3  1 145091

4. 4  1 159612

5. 5  1 141570

6. 6  1 141571

REF QTY

7 1 8 1 9 1

10 1 11 1 12 1 13 1

145096 Shaft Assembly

142642 141573 141574 141575 145092 169239 119909

“D1” Flight
“E1” Flight
“F1” Flight
“G1” Flight
Nose Collar
Flight Locknut w/Sleeve Flight Locknut Step Key

Bare Shaft Feed Quill Key Feed Quill Flight Key “B1” Flight “C1” Flight

Part List: Shaft 12/12-4 Pressor

54

Figure 6-3 : Feed Hopper & Cage Assy. 12/12-4 Pressor

REF QTY

1. 1  1

2. 2  1

3. 3  1

4. 4  1

7. 7  6

8. 8  6

9. 9  3

REF 173560 Hopper and Cage Assembly 11

145057 FIN MACH 12 FULL FD HPR 108723 CHUTE 12 HPR – 10 PRSR 108317 SET HPR MTG BAR 2/SET 192361 HOLD DOWN FD HPR W/O DRN 100608 1-1/4-7 HEAVY HEX NUT 120441 1-1/4 LOCKWASHER

102239 1-8×2HHCS,GR5

12 10 13 10 16 6 17 1 18 1 19 1 20 4

102437 LOCKWASHER MED 3/4
120413 3/4 -10 × 2 HHCS, GR8
100611 HHCS 1-1/4 X 5 A325
172096 2 FH DISCH CG W/O DRAIN 151107 HPR CG-12F PRS .095 COMP 145063 2 PC FLOAT RING 12F PRS 140570 PRS FD HPR MTG BAR GUSSET

10 6
Parts List: Feed Hopper & Cage Assy. 12/12-4 Pressor

104289 LOCKWASHER MED 1

55

Figure 6-4 : Hopper Cage, 12/12-4 Pressor

REF QTY

1. 1  1

2. 2  1

3. 3  1

4. 4  1

5. 5  1

6. 6  60

Parts List: Hopper Cage, 12/12-4 Pressor

REF

7 8 9 10 11 12

QTY

4
5
2
2
1 box 4

151107

Hopper Cage Assembly

128219 Wedge Bar
109267 .062” x 1 1/4” Seat Ring
104229 Shim.062x1x12
145153 Shim.032x1x12
108332 .095” x 1/2” x 1” Spacer (200/box) 100573 5/8-18 x 1 1/4” SHCS

12” Hopper Cage
“AKF” Knife Bar
“BKF” Knife Bar
Left Hand Pressure Bar Right Hand Pressure Bar

145059
145066
145067
145147
145146
101308 Barrel Bar

56

7

Figure 6-5 : Hydraulic Choke Assembly

57

REF QTY

165748 Hydraulic Choke Assembly

145026 Choke Assembly
143393 Hydraulic Cylinder
104226 Piston Rod Nut with Screw 101284 Follower Plate
101260 Fabric Cup
101285 Piston Head
101286 Spacer Plate
140918 Piston Rod
140905 Choke Gasket
145027 Choke Housing
175957 Piston Rod Sleeve
188286 O-Ring 343 Viton 70D 169317 Hallite 533 Wear Ring 141149 O-Ring 337 Viton 90D 128359 Loctite 243
145028 Choke Body
102729 3/4” Square Head Pipe Plug 144609 1 1/2” Socket Head Pipe Plug 100611 1-1/4-7 × 5 HHCS
102441 1-1/4” Lockwasher
100608 1 1/4-7 Hex Nut
146871 Choke Head
102261 5/8-11 ×1 1/4” SHCS
173686 Bearing Housing with Sleeve

REF QTY 1-19-1 1 1-19-2 1 1-19-3 2 1-19-4 2 1-19-5 1

1-28 1 1-29 1 1-30 1 1-31 1 1-32 1 1-33 1 1-34 1 1-35 1 1-36 1 1-37 3 1-38 3 1-40 1

2 1 3 8 4 4 5 1

5-1 1 6 8 7 4 8 8

173688 Bearing Housing
173687 Bronze Sleeve
174307 1” Nord–Lockwasher
145033 HHCS 1 X 3 GR5 (drilled)
150803 3/4-10 x 3 1/4” Drilled Brass HHCS 102743 1/8” NPT 90° Street Elbow

162186 1/8” x 10 1/2” Pipe Nipple 102592 1/8” NPT Full Coupling 102507 1/8” NPT Grease Fitting 108243 1/2N – 8 PN Hydraulic Nipple 102583 1/2” NPT Pipe Cap

102570 3/4” x 1/2” Steel Pipe Bushing 162185 1/8” x 7 1/4” Pipe Nipple 102604 1/8” NPT 90° Elbow
120149 3/4-10 x 1 3/4” HHCS

183128 Choke Travel Restricting Spacer 102727 1/2 NPT Square Head Pipe Plug 101266 Flinger Ring
143435 1 1/8-7 x 7” HHCS

145030 1 1/4-7 x 9” HHCS
145031 Combination Choke and Thrust Collar 145045 Thrust Collar Insert
104293 1 1/8” Lockwasher
102441 1 1/4” Lockwasher
183829 Choke Mounting Thread Insert

1 1- 1 1- 2 1- 3 1- 4 1- 5 1- 6 1- 7 1- 8 1- 9

1 1 2 1 2 1 1 1 1 1

5. 1-9-5  1

6. 1-9-6  1

7. 1-9-7  1

8. 1-9-8  2

1-9-10 .013

1-10
1-11
1-12
1-13
1-14
1-15
1-17
1-18
1-19 1
Parts List: Hydraulic Choke Assembly

1 1 2 12 12 12 1 4

58

Figure 6-6 : Quick Disconnect Hose Assemblies

REF QTY

1 1 101385 2 2 108240 3 2 108242 4 1 108243 5 1 108253

1/2 × 1/2 90o Street Elbow
1/2 × 60 Hose Assembly
1/2” Quick Disconnect Coupling 1/2” Pipe Nipple w/ 7/8 Hex 1/2” Male Run Tee

REF QTY

6 1 7 1 8 1 9 1

100264 1500 lb Pressure Gauge 104196 Snubber
102562 1/2 × 1/4 Steel Pipe Bushing 102570 3/4 × 1/2 Steel Pipe Bushing

Parts List: Quick Disconnect Hose Assemblies

59

Figure 6-7 : Thrust Collar Assembly

REF QTY

1 12 2 12

REF QTY

160181 ThrustCollarAssembly(Kit#108862) 104207 5/8 -11 × 2-1/2 HHCS
104283 5/8” Lockwasher
159412 Thrust Bearing Split Seal (Kit# 150657) 101335 Bearing Housing

102175 5/16-18 x 3/4” HHCS 102431 5/16” Lockwasher 159611 Gasket(Kit#108864) 150161 Split Shaft Seal
151623 Split Seal Retaining Ring

101334 Thrust Collar

4 1
2 176377 Dowel Pin

3 3-1 3-2 3-3 3-4 3-5 3-6

1

1 16 16 1 1 1

5. 5  2

6. 6  6

7. 7  4

8. 8  1

9. 9  2

10. 10  1

11. 11  1

102723 1/4” Square Head Pipe Plug 118905 3/4-10 x 2 1/2” HHCS
110282 3/4-10 x 2” Square Head Set Screw 101333 Pull-up Collar

100568 1/2-13 X 1 3/4” SHCS 101254 Thrust Bearing 101318 Thrust Collar Key

Parts List: Thrust Collar Assembly

60

Figure 6-8 : Tallow Screw Assembly (w/o pump)

REF QTY

REF QTY

7. 7  4

8. 8  4

9. 9  4

10. 10  1

11. 11  1

12. 12  1

1 2 3 4 5 6

1 1 1 16 16 4

180468

Tallow Screw Assembly

113374 5/8-11 Hex Nut 104283 5/8” Lockwasher 102417 5/8” Flat Washer 146865 Tallow Screw 101704 O-Ring

128829 Bearing Standoff

Discharge Box
Flange Babbitt Bearing
Flanged Spherical Roller Bearing 1/2-13 x 1 1/2” HHCS
1/2” Lockwasher

112047
102000
101255
120327
104302
104207 5/8-11 x 2 1/2” HHCS

Parts List: Tallow Screw Assembly (w/o pump) o

61

Figure 6-9 : Gearbox

62

REF QTY

REF QTY

36 1 37 1 38 1 39 1 40 1 41 1 42 1 43 1 44 4 45 1 46 11 47 1 48 1 49 1 50 1 52 1 53 1 54 25 56 1 57 3 58 1 59 3 60 26 61 1 62 1

62-1 1 62-2 1 62-3 1 62-4 1

63 1 64 2 65 2 66 2 67 4 68 3

REF QTY

d 1 e 1 f 1 g 1

1. 1  1

2. 2  1

3. 3  2

4. 4  2

5. 5  2

6. 6  1

7. 7  1

8. 8  1

10. 10  4

11. 11  2

12. 12  1

13. 13  8

14. 14  8

15. 15  3

16. 16  20

17. 17  2

18. 18  1

19. 19  1

20. 20  2

21. 21  2

22. 22  2

23. 23  2

24. 24  1

25. 25  1

26. 26  1

27. 27  1

28. 28  1

29. 29  1

30. 30  1

31. 31  8

32. 32  1

33. 33  1

34. 34  1

35. 35  2

149786 Gear Assembly

101246 Snap Ring
101233 High Speed Bearing Carrier, Blind 101697 O-Ring
104713 Cylindrical Roller Bearing
105168 Snap Ring
101227 High Speed Pinion
101234 High Speed Bearing Carrier, Through 108804 Oil Wiper Support Bar
102293 1/4-20 Hex Nut
111759 1/4-20 x 2 1/4” HHCS
107299 Shaft Seal
104302 1/2” Lock Washer
120327 1/2-13 x 1 1/2” HHCS
108847 5/8-11 x 2 3/4” HHCS with drilled head 120149 3/4 -10 × 1-3/4 HHCS
104724 Cylindrical Roller Bearing
101231 Intermediate Pinion
101251 Shaft Seal
105736 Snap Ring
101702 O-Ring
101219 Intermediate Bearing Carrier, Through 105739 Snap Ring
101225 Intermediate Gear Bushing
101236 Intermediate Gear Key
101218 Intermediate Gear
101214 Long Oil Wiper
101215 Short Oil Wiper
113416 Key
101235 Intermediate Bearing Carrier, Blind 104207 5/8 -11 x 2 1/2″ HHCS
101248 Slow Speed Bearing Carrier, Through 110400 Key
101249 Snap Ring
101253 Spherical Roller Bearing

101238 Slow Speed Shaft
101268 Slow Speed Gear Key
101230 Slow Speed Gear
101223 Slow Speed Gear Bushing
107387 Slow Speed Bearing Carrier, Blind 101706 O-Ring
101342 Driven Sprocket
114355 Key
108538 3/4-10 × 2-3/4” HHCS with drilled head 103475 Filler / Breather
104283 5/8” Lock Washer
101346 Drive Sprocket
108814 Chain
102089 Connector Link
104474 Chain Tensioner
101273 Chain Guard
103067 Idler Sprocket
102437 3/4” Lock Washer
104472 Tensioner Shaft
101252 1” Socket Pipe Plug, Magnetic
102584 3/4” NPT Pipe Cap
118913 Chain Shackle
102181 3/8 -16 × 1 HHCS
112043 Intermediate Pinion Extension
159299 Drive Coupling (Kit# 101274)
101275 Coupling Grid
101276 Coupling Cover
115513 Coupling Hub with 2 3/8” Bore
115514 Coupling Hub with 2 1/4” Bore
103879 200 HP Motor
102178 5/16-18 x 2” HHCS
104335 5/16” Flat Washer
102297 5/16” Lock Hex Nut
104319 3/8” Lock Washer
117805 1/4 Self Drill Self Tap Screw x 3/4

101367 Sliding Bar Wrench Assembly 101694 O-Ring
101369 Socket Retaining Pin
129732 Cage Bolt Wrench

Parts List: Gearbox (see Figure 6-9)

REF QTY

11 21 a1 b1 c1

101392 Aluminum Scoop
108883 Tool Kit, Complete (includes a thru g) 101364 1-1/8” Socket, 3/4” Drive
101361 4” Extension
101366 3-1/16” Socket, 1-1/2” Drive

Accessories for 12/12-4 Pressor

63

Spare Parts List

This section gives part numbers for recommended spare parts. Recommended spare parts should be stocked at your facility, in the quantities shown, to reduce downtime for maintenance, service, or repairs.

QTY
209325 Main Cage Assembly (45, 35, 25, 20)

Figure 6-1

6-1 2 145073 6-2 2 145980 7 2 145075 8 4 128223 9 2 145078 10 2 145077 12 14 145071 13 4 145072 14 264 110077 16 2 128226 17 1 box 104718 18 1 box 101440 19 1 box 101437 20 1 box 101435 21 2 104232 22 4 105852 23 16 128218

LP “AKF” Knife Bar
HP “AKF” Knife Bar
“BKF” Knife Bar
“KF “ Pressure Bar
“HKF” Pressure Bar
“CKF” Pressure Bar
.062” x 2” Internal Seat Ring .062” x 1” End Seat Ring Barrel Bar

Cage Key
.045” x 1” x 1 1/4” Spacer (200/box) .035” x 1” x 1 1/4” Spacer (200/box) .025” x 1” x 1 1/4” Spacer (200/box) .020” x 1” x 1 1/4” Spacer (200/box) .125” x 1 1/4” x 12” Shim
.125” x 1 1/4” x 12” Shim
Wedge Bar

145096 Pressor Shaft Assembly – complete

Figure 6-2

Figure 6-4

Figure 6-5

3 1 145091 5 1 141570 6 1 141571 7 1 142642 8 1 141573 9 1 141574

10 1 141575 11 1 145092

Feed Quill “B1” Flight “C1” Flight “D1” Flight “E1” Flight “F1” Flight “G1” Flight Nose Collar

151107 Hopper Cage Assembly – complete

2 1 145066 3 1 145067 4 1 145147 5 1 145146 6 60 145061 7 4 128219 8 5 109267 9 2 104229

10 2 104230 11 1 box 108332

“AKF” Knife Bar
“BKF” Knife Bar
Left Hand Pressure Bar
Right Hand Pressure Bar
Barrel Bar
Wedge Bar
.062” x 1 1/4” Seat Ring
.063” x 1” x 12” Shim
.031” x 1” x 12” Shim
.095” x 1/2” x 1” Spacer (200/box)

165748 Hydraulic Choke Assembly – complete

1-2 2 104226 1-4 2 101260 1-7 1 140918 1-8 1 140905

1-9-5 1 175957 1-9-6 1 188286

Rod Nut with Screw Fabric Cup
Piston Rod
Choke Gasket Piston Rod Sleeve O-Ring

(continued on next page)

64

Figure 6-5

Figure 6-6

Figure 6-7

Figure 6-8

Figure 6-9

QTY

7. 1-9-7  1

8. 1-9-8  2

1-9-10 .013

17. 1-17  1

18. 1-18  4

19. 1-19  1

1-19-2 1 1-19-5 1

5 1 8 8

6 1

4. 3-4  1

5. 3-5  1

10. 10  1

11. 11  1

3. 3  2

4. 4  2

6 1

17. 17  2

18. 18  1

19. 19  1

21 2 35 2 41 1 61 1 63 1

169317 Hallite Wear Ring 141149 O-Ring
128359 Loctite 243
146871 Choke Head
102261 5/8-11 x 1 1/4” SHCS

173686. 173686  Bearing Housing with Sleeve

173687. 173687  Bronze Sleeve

150803 3/4 -10 × 3 1/4” Brass HHCS with lube hole 145031 Combination Choke and Thrust Collar 183829 Choke Mounting Thread Insert

Quick Disconnect Hose Assemblies

100264 Pressure Gauge

160181 Thrust Collar Assembly (Kit# 108862) 159611 Gasket
150161 Split Shaft Seal
101254 Thrust Bearing

180468 Tallow Screw Assembly 101704 O-Ring

149786 Gearbox Assembly – complete

101697 O-Ring
104713 Cylindrical Roller Bearing 101227 High Speed Pinion
104724 Cylindrical Roller Bearing 101231 Intermediate Pinion
101251 Shaft Seal
101702 O-Ring
101253 Spherical Roller Bearing 101706 O-Ring
112043 Intermediate Pinion Extension 103879 200 HP Electric Motor

Figure 6-10 : Spare Parts List — 12/12-4 Pressor

65

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66

Chapter 7

Appendix A – Vendor Information

This appendix contains service information provided by the manufacturers of certain commercial components used on the Dupps Pressor. Contact the vendor or your Dupps service representative before performing service procedures that are not included in these instructions.

We have attempted to ensure that the information included here was current at the time this manual was compiled. The vendors can, however, update or change this information without notification. Contact the Vendor or the Dupps Company if there is any doubt about the accuracy or timeliness of the information included here.

Dodge Falk

Leeson/Lincoln

Coupling Coupling

Electric Motor

MN4027 428-110 SIM 300-088.02 Bulletin 2400

Instruction Manual Installation and Maintenance Standard Induction Motors Lubrication and Installation Troubleshooting

67

(This page intentionally left blank)

68

DODGE® PARA-FLEX® Couplings

Includes ATEX Approved Couplings

These instructions must be read thoroughly before installation or operation. The instruction manual was correct at the time of printing. Please see www.dodge-pt.com for updated instruction manual.

WARNING: To ensure that drive is not unexpectedly started, turn off and lock out or tag power source before proceeding. Failure to observe these precautions could result in bodily injury.

WARNING: All products over 25 kg (55 lbs) are noted on the shipping package. Proper lifting practices are required for those products.

the flanges in four places 90° apart. The gap between the flange and straight edge should not exceed 1/32” (0.79mm). To achieve maximum coupling performance, align the coupling as accurately as possible during initial installation.

4. Remove any anti-rust lubricants or oil from the grooved side of the clamp rings. Loosen but do not remove clamp ring screws until only one or two threads are engaged and proceed to the section on flexible element installation.

Three-Piece Flange Styles

1. Disassemble the clamp rings from the flanges. Place the external clamp rings on the shafts with the grooved side facing the shaft end.

2. For the TAPER-LOCK flange, install the bushing in the flange per instructions included with bushing.

3. Check the axial float of the shafts. Position the shafts at the mid- point of the float. Where Limited End Float is required or Sleeve Bearings are used, consult DODGE for application assistance.

4. Referring to Figure 2 and Table 1, observe the “B” dimension for the coupling size being installed. Mount and position the flanges on the shafts so that dimension “B” is achieved when the shafts are in their final position.

   For the TAPER-LOCK flange, secure the flange assembly to the shaft by positioning the assembly onto the shaft allowing for small axial movement which will occur during tightening procedure. Alternately torque setscrews to recommended torque setting. For the clearance fit straight bore (FBX) flange, tighten the set screws to values listed in Table 2. Align flanges using precision equipment such as dial indicators or laser equipment.

   If precision equipment is not available, scales, straight edges, and calipers can be used as less accurate means of alignment. If using a scale or calipers, refer to Figure 3 and check the angular misalignment by measuring dimension “B” at four places 90° apart. Adjust the equipment until the four measurements do not vary more than value “C” in Table 1. If using a straight edge, check the parallel offset by laying the straight edge across the outside diameter of the flanges in four places 90° apart. The gap between the flange and straight edge should not exceed 1/32” (0.79mm). To achieve maximum coupling performance, align the coupling as accurately as possible during initial installation.

5. Remove any anti-rust lubricants or oil from the element side of the clamp rings. Assemble clamp rings on the flanges engaging only one or two threads and proceed to the section on flexible element installation.

FLANGE INSTALLATION Two-Piece Flange Styles

B

Flange
PX40 STANDARD TAPER-LOCK

B

Flexible Element

B

Flexible Element

Internal Clamp Ring

External Clamp Ring

Flange

Flexible Element

Internal Clamp Ring

Flange

BB

PX140 thru 320 TAPER-LOCK

PX50-120QD FLANGE ASSEMBLY

PX140-200QD FLANGE ASSEMBLY

Figure 1 – Two-Piece Flange Styles

1. For the TAPER-LOCK® and QD flanges, install bushing in the flange per instructions included with bushing or find the instruction manuals at www.dodge-pt.com.

2. Check the axial float of the shafts. Position the shafts at the mid- point of the float. Where Limited End Float is required or Sleeve Bearings are used, consult DODGE for application assistance.

3. Referring to Figure 1 and Table 1, observe the “B” dimension for the coupling size being installed. Mount and position the flanges on the shafts so that dimension “B” is achieved when the shafts are in their final position.

   For the TAPER-LOCK and QD flanges, secure the flange assembly to the shaft by positioning the assembly onto the shaft allowing for small axial movement which will occur during tightening procedure. Alternately torque hardware to recommended torque setting. For the clearance fit straight bore (FBX) flange, tighten the set screws to values listed in Table 2. Align flanges using precision equipment such as dial indicators or laser equipment.

   If precision equipment is not available, scales, straight edges, and calipers can be used as less accurate means of alignment. If using a scale or calipers, refer to Figure 3 and check the angular misalignment by measuring dimension “B” at four places 90° apart. Adjust the equipment until the four measurements do not vary more than value “C” in Table 1. If using a straight edge, check the parallel offset by laying the straight edge across the outside diameter of

WARNING: Because of the possible danger to person(s) or property from accidents which may result from the improper use of products, it is important that correct procedures be followed. Products must be used in accordance with the engineering information specified in the catalog. Proper installation, maintenance and operation procedures must be observed. The instructions in the instruction manuals must be followed. Inspections should be made as necessary to assure safe operation under prevailing conditions. Proper guards and other suitable safety devices or procedures, as may be desirable, or as may be specified in safety codes should be provided, and are neither provided by Baldor Electric Company, nor are the responsibility of Baldor Electric Company. This unit and its associated equipment must be installed, adjusted and maintained by qualified personnel who are familiar with the construction and operation of all equipment in the system and the potential hazards involved. When risks to persons or property may be involved, a holding device must be an integral part of the driven equipment beyond the speed reducer output shaft.

BBBB

External

Internal

Figure 2 – Three-Piece Flange Styles

Flange Flex

PX50-120 TL

PXFBS

PXBBS

PXTBS

1

Figure 3

Figure 4

Coupling Size Flange Style Two-Piece

PX40 130

PX50 130

PX60 290

PX70 290

PX80 290

PX90 480

Table 1 – Mounting Dimensions

Clamp Ring Screw Wrench Torque (lb-in)

Distance Between Flanges B (in)

49/64

31/32

1-9/32

1-1/2

1-1/2

1-17/32

1-23/32

1-9/16

1-3/4

2-1/16

2-11/16

3-5/16

3-29/32

4-7/32

4-1/2

Distance Between Flanges “B” (mm)

Total Difference See Figure 8 (below) C (in)

1/64

1/64

1/64

1/64

1/64

1/32

1/32

1/32

1/32

1/32

1/16

1/16

1/16

1/16

1/16

Total Difference “C” (mm)

0.4

0.4

0.4

0.4

0.4

0.8

0.8

0.8

0.8

0.8

1.6

1.6

PX100

PX110

PX120

PX140

PX160

PX200

PX240

PX280

PX320

Coupling Size

PXM 40

PXM 50

PXM 60

PXM 70

PXM 80

PXM 90

PXM 100

PXM 110

PXM 120

PXM 140

PXM 160

PXM 200

Inch Set Screw Size

Torque (lb-in)

Torque (Nm)

Metric Set Screw Size

Torqe (in-lbs)

Installation Torque (Nm)

480

480

1080

1080

2160

2160

3600

4320

4320

Flange Style Three-Piece

130

130

290

290

290

480

480

480

1080

1080

1150

2400

4020

6600

6600

Clamp Ring Screw Torque (Nm)

Thread Size

M6

M6

M8

M8

M8

M10

M10

M10

M12

M12

M16

M16

#1 #2

1.8 1.8

0.2 0.2

M5 M6

35 64

4 7.2

Flange Style Two-Piece

Flange Style Three-Piece

15

15

36

36

36

72

72

72

15

15

36

36

36

72

72

72

19.4

24.6

32.5

38.1

38.1

38.9

43.7

39.7

44.5

52.4

68.3

84.1

#0

1

0.1

M4

19

2.2

#3 #4

55

0.6 0.6

M8 M10

150 290

125 125

125 125

311 130

311 271

Table 2 – Set Screw Torque

#5 #6 #8 #10

1/4

5/16

3/8

7/16 1/2 9/16 5/8

3/4 7/8

10 10 20 36 87 165 290 430 620 1325 2400 5200 7200

1.1 1.1 2.3

M12 M16 M20

480 1190 2100

4.1 9.8 18.6 32.8 48.6 70.1 149.7 271.2 587.5 813.5

17 33 54 134 237

NOTE: Many sizes of PARA-FLEX elements are supplied with a cardboard gauge to facilitate accurate flange spacing before installing the rubber tire element. This gauge comes in the box with the element. Gauges not supplied for PX40 and PX140 through PX320. Gauges should not be used for alignment purposes.

FLEXIBLE ELEMENT INSTALLATION

1. Clean flange mounting area as well as surface that will come in contact with the element with a solvent, such as Xylene (Xylol), to remove grease, oil, wax, and dirt from surfaces. Do not clean the element with the solvent. A diluted soapy water solution may be applied to aid with element installation.

2. Wrap flexible element around flanges as shown in Figure 5. Make sure beads of element are fully worked down upon the seats. To ensure proper seating, tap around the tire’s outside diameter with a small mallet until split is closed. Make sure element is evenly centered on the flanges.

3. Hold split of flexible element closed as shown in Figure 6. Tighten (finger tight) one or two screws 180° from split. Using both hands, knead the tire pulling it toward the split. Hold split closed and tighten (finger tight) the next two screws farthest from the split. Repeat the procedure on all remaining clamp ring screws. Use a torque wrench to tighten each clamp ring screw in succession to the torque specified in Table 1. Using a torque wrench, recheck all

clamp ring screw torque values before coupling operation.

4. Optional Procedure: Hold split of flexible element closed as shown in Figure 6. Tighten (finger tight) one or two screws 180° from split. Using both hands, knead the tire pulling it toward the split. Hold split closed and tighten (finger tight) the next two screws in a star or cross pattern as shown in Figure 7. Repeat the procedure on all remaining clamp ring screws. Use a torque wrench to tighten each screw to the torque specified in Table 1. Using a torque wrench, re- check all clamp ring screw torque values before coupling operation.

5. Install coupling guards per OSHA or applicable requirements. Guarding should be designed so that coupling tyre will be contained wihtin the guard in the event that the coupling tyre is thrown from

the coupling assembly.

Figure 5

3 15

87

62 4

2

Figure 6

Figure 7

FLEXIBLE ELEMENT REPLACEMENT

Loosen all clamp ring screws. Grasp one end of flexible element at the split and peel off the flanges. Clean clamping parts with a solvent, such as Xylene (Xylol), to remove grease, oil, wax, and dirt from surfaces. Do not clean element with solvent. Check to see that only one or two threads of each clamp ring screw are engaged. Re-align flanges and install new flexible element according to the sections on flange installation and flexible element installation. When replacing clamp ring screws and washers, use only SAE Grade 8 or ISO Class 10.9 screws and hardened washers.

WARNING: The metal components of the coupling that clamp the flexible element will operate properly only if the screws are tightened properly. Tightening one screw to full torque before proceeding to the next screw may cause excessive clamp ring or flange deflection. To prevent clamp ring and flange deflection, the screws must be evenly and gradually tightened to full torque.

FLOATING SHAFT COUPLING INSTALLATION

ATEX Approved PARA-FLEX Couplings

These instructions do not cover all details or variations in equipment nor provide every possible contingency or hazard to be met in connection with installation, operation, and maintenance. Should further information be desired, or should particular problems arise which are not covered in this manual, the matter should be referred to your local BaldorDodge representative.

DODGE Elastomeric couplings are manufactured under the guidelines of the ATEX directive 94/9/EC.

DODGE Elastomeric couplings are suitable for ATEX category 2 and M2, Group II and I for gas and dust environments and are also suitable for ATEX category 3 for all gas or dust environments with ignition temperatures higher than T5 = 100° C.

A sticker indicating ATEX certification will be attached to the product or on the box containing the product and will be similar to the following:

OR

Figure 9 – ATEX Certification

WARNING: These couplings are designed to operate with surface temperatures below 100°C when properly installed and selected. Excessive temperatures greater than 80°C is a result of an abnormal operating condition caused by:

1. Improper installation – refer to installation manual for proper procedures

2. Excessive misalignment – re-align coupling / shafts

3. Failure of the coupling element – replace elastomeric

4. Excessive speed – re-evaluate application and selection

5. Excessive vibration – determine source, re-evaluate

   application

If applied in a Division 1 or Zone 1 environment, the excessive temperature may cause ignition of hazardous materials.

In hazardous environments, DODGE elastomeric couplings should not be considered as fail safe or “break-away” power transmission devices. Overloads imposed to these devices could cause irreparable damage, shall be considered an explosive hazard, could create projectiles, and/ or could cause torque transmission interruptions. The coupling shall be sized and used to the stated torque capabilities of the unit as published in the DODGE PT Components Engineering Catalog. Any assistance needed in selection shall be referred to a BaldorDodge representative.

Additional Instruction for Safe Installation and Use

1. All rotating parts should be guarded to prevent contact with foreign objects which could result in sparks, ignition, or damage to the coupling.

2. Couplings should be periodically inspected for normal wear, dust/dirt buildup or any similar scenario that would impede heat dissipation.

3. Increasing levels of vibration and noise could indicate the need for inspection, repair or replacement of the coupling or element.

4. Electrical sparks are a source of ignition. To reduce the risk, proper electrical bonding and grounding is recommended.

5. Overloading may result in breakage or damage to the coupling or other equipment. As a result the coupling could become an explosion hazard. Damaged coupling components or elements must not be operated in hazardous environment.

6. If thrust loading or axial movement is anticipated, The DODGE PARA-FLEX coupling is the desired unit for use as it has design capability of accepting this movement up to 5/16”. Couplings are not intended to be used as thrust bearing members.

7. Coupling guards should have a minimum of 2” clearance over PARA-FLEX tire style couplings. (3” clearance for PARA-FLEX style couplings greater than 16” outer diameter.)

8. The date code should be read as:

   Indicates Month (one dot per month)

BPS Flange

B

FLG. to FLG. Distance F/S FLG. to FLG. Distance

BCS Flange

BBPS x BBPS BBPS x TBPS TBPS x TBPS

B

Flexible Element

External Clamp Ring

Floating Shaft Bearing Assembly

Piloted Internal Clamp Ring Assembly

Figure 8 – Floating Shaft Coupling

1. Disassemble the clamp rings from the flanges. Place the external clamp rings on the shafts with the grooved side facing the shaft end.

2. Check the axial float of the shafts. Position the shafts at the mid- point of the float. Where Limited End Float is required or Sleeve Bearings are used, consult DODGE for application assistance.

3. Referring to Figure 8 and Table 1, observe the “B” dimension for the coupling size being installed. Mount and position the flanges on the shafts so that dimension “B” is achieved when the shafts are in their final position. Where flanges contain set screws, tighten to values listed in Table 2.

4. Remove any anti-rust lubricants or oil from the grooved side of the clamp rings. Assemble internal and external clamp rings to floating shaft flanges and snug up clamp ring screws. Slip internal piloted clamp rings onto the turned down portion of floating shaft. Hub projection on clamp ring should be toward floating shaft as shown in Figure 8.

5. Position and support floating shaft assembly between driving and driven flanges. Make sure clamp ring pilot is seated in flange counterbore. Assemble external clamp rings to flange with screws. Tighten screws sufficiently to prevent movement between the parts.

6. Align flanges using precision equipment such as dial indicators or laser equipment. If precision equipment is not available, scales, straight edges, and calipers can be used as less accurate means of alignment. If using a scale or calipers, refer to Figure 3 and check the angular misalignment by measuring dimension “B” at four places 90° apart. Adjust the equipment until the four measurements do not vary more than value “C” in Table 1. Repeat the procedure at both ends of the coupling. To achieve maximum coupling performance, align the coupling as accurately as possible during initial installation.

7. Loosen clamp ring screws and proceed to Section II for element installation.

3

14
Year

Indicates

EC Declaration of Conformity

The undersigned, representing the following supplier and the authorised representative established within the Community

Baldor Electric Company 5711 R. S. Boreham, Jr. Street Fort Smith, Arkansas 72901 USA

herewith declare that the Products

Product identification (brand and catalogue number/part number):

Baldor Electric Germany GmbH Dieselstrasse 22a
85551 Kirchheim
Germany

Couplings
Dodge Paraflex, Dodge D-Flex, Dodge Power Plus, Equipment Group I, Category M2 c/Equipment Group II Category 2 GD T5 Tamb – 30°C to +50°C

are in conformity with the provisions of the following EC Directive(s) when installed in accordance with the installation instructions contained in the product documentation:
94/9/EC ATEX

and that the standards and/or technical specifications referenced below have been applied:

EN 1127-1:1998 EN 13463-1:2001

Notified Body:
Sira Certification Service – 0518 Rake Lane, Eccleston
Chester, CH4 0JN
England
Certificate: SIRA 04ATEX9358 Supplier:
Signature

Explosive Atmospheres – Explosion Prevention And Protection – Part 1: Basic Concepts And Methodology
Non – Electrical Equipment For Potentially Explosive Atmospheres -Method And Requirements

Name: Position: Date:

L. Evans Massey
Manager Standards and Certification 20-July-09

Authorised Representative in the Community:

Signature

Name: Position: Date:

Michael Klein
Product Group Director Europe 20-July-09

Document Control Number: DOC-BEZ-DA-M22-A-EN.DOC

1 / 1

P.O. Box 2400, Fort Smith, AR 72902-2400 U.S.A., Ph: (1) 479.646.4711, Fax (1) 479.648.5792, International Fax (1) 479.648.5895

Dodge Product Support

6040 Ponders Court, Greenville, SC 29615-4617 U.S.A., Ph: (1) 864.297.4800, Fax: (1) 864.281.2433

www.baldor.com

© Baldor Electric Company *4027-0814* All Rights Reserved. Printed in USA. MN4027 (Replaces 499710) 8/14 Litho 20,000

Falk® Steelflex® Couplings • Installation & Maintenance Type T10 • Sizes 1020–1140 & 20–140 (Page 1 of 6)

are furnished with a pre-measured amount of grease for each coupling. The grease can be ordered for larger size couplings.

The use of general purpose grease requires re-lubrication of the coupling at least annually.

TYPE T10 STEELFLEX COUPLING

How To Use This Manual

This manual provides detailed instructions on maintenance, lubrication, installation, and parts identification. Use the table of contents below to locate required information.

Table of Contents

Introduction ………………………………………………………. Page 1 Lube Fittings…………………………. ………………………….. Page 1 Limited End Float ………………………………………………. Page 1 Lubrication …………………………………………………… Pages 1-2 Installation & Alignment Instructions ………………… Pages 2-4 Annual Maintenance, Relube & Disassembly ………… Page 4 Installation & Alignment Data ………………………………. Page 5 Parts Identification & Parts Interchangeability ……….. Page 6

CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE FREE SERVICE.

INTRODUCTION

This manual applies to Sizes 1020T thru 1140T and 20T thru 140T10 Falk SteelfIex Tapered Grid Couplings. Unless otherwise stated, information for Sizes 1020T thru 1140T applies to Sizes 20T thru 140T respectively, e.g. 1020T = 20T, 1100T = 100T, etc. These couplings are designed to operate in either the horizontal or vertical position without modification. Beginning in year 1994 through 2003, these couplings were being suppliedwithone setofinchseries fasteners and one set of Metric fasteners. Beginning in year 2004 only Metric fasteners are being supplied. Refer to Page 6 for part interchangeability.

The performance and life of the couplings depend largely upon how you install and service them.

CAUTION: Consult applicable local and national safety codes for proper guarding of rotating members. Observe all safety rules when installing or servicing couplings.

WARNING: Lockout starting switch of prime mover and remove all external loads from drive before installing or servicing couplings.

LUBE FITTINGS

Cover halves have1/8 NPT Iube holes. Use a standard grease gun and Iube fitting as instructed on Page 4.

LIMITED END FLOAT

When electric motors, generators, engines, compressors and other machines are fitted with sleeve or straight roller bearings, limited axial end float kits are recommended for protecting the bearings. Falk Steelflex couplings are easily modified to limit end float; refer to Manual 428-820 for instructions.

LUBRICATION

Adequate lubrication is essential for satisfactory
operation. Page 2 provides a list of typical lubricants
and specifications for general purpose and long term greases. Because of its superior lubricating characteristics and low centrifuge properties, Falk Long Term Grease (LTG) is highly recommended. Sizes 1020T to 1090T10

Rexnord
5555 S. Moorland Rd., New Berlin, WI 53151-7953
Telephone: 262-796-4060 Fax: 262-796-4064 www.rexnord.com

Long Term Grease (LTG)

The high centrifugal forces encountered in couplings separate the base oil and thickener of general purpose greases. Heavy thickener, which has no lubrication qualities, accumulates in the grid-groove area of Steelflex couplings resulting in premature hub or grid failure unless periodic lubrication cycles are maintained.

Falk Long Term Grease (LTG) was developed specifically for couplings. It resists separation of the oil and thickener. The consistency of Falk LTG changes with operating conditions. As manufactured it is an NLGI #1/2 grade. Working of the lubricant under actual service conditions causes it to become semifluidwhile thegreasenear the seals will set to a heavier grade, helping to prevent leakage.

LTG is highly resistant to separation, easily out performing all other lubricants tested. The resistance to separation allows the lubricant to be used for relatively long periods of time.

Steelflex couplings initially lubricated with LTG will not require re-lubrication until the connected equipment
is stopped for servicing. If a coupling leaks grease, is exposed to extreme temperatures, excessive moisture, or experiences frequent reversals, more frequent lubrication may be required.

Although LTG grease is compatible with most other coupling greases, the mixing of greases may dilute the benefits of LTG.

USDA Approval

LTG has the United States Department of Agriculture Food Safety & Inspection Service approval for applications where there is no possibility of contact with edible products. (H-2 ratings).

CAUTION: Do not use LTG in bearings.

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May 2004 Supersedes 2-03

Falk Steelflex Couplings • Installation & Maintenance

(Page 2 of 6) Type T10 • Sizes 1020–1140 & 20–140

Specifications — Falk LTG

The values shown are typical and slight variations are permissible.

AMBIENT TEMPERATURE RANGE — -20°F (-29°C) to 250°F (121°C). Min. Pump = 20° F (-7° C).

MINIMUM BASE OIL VISCOSITY — 3300SSU (715cST) @ 100°F (38°C).

THICKENER — Lithium & soap/polymer.

CENTRIFUGE SEPARATION CHARACTERISTICS — ASTM #D4425 (Centrifuge Test) — K36 = 2/24 max., very high resistance to centrifuging.

NLGI GRADE (ASTM D-217) —1/2

CONSISTENCY (ASTM D-217) — 60 stroke worked penetration value in the range of 315 to 360 measured at 77°F (25°C)

MINIMUM DROPPING POINT — 350°F (177°C) minimum MINIMUM TIMKEN O.K. LOAD — 40 lbs.

ADDITIVES — Rust and oxidation inhibitors that do not corrode steel or swell or deteriorate synthetic seals.

Packaging

14 oz. (0,4 kg ) CARTRIDGES — Individual or case lots of 10 or 30.

35 lb. (16 kg )PAIL, 120 lb. (54 kg ) KEG & 400 lb. (181 kg) DRUMS.

General Purpose Grease

Annual Lubrication — The following specifications and lubricants for general purpose grease apply to Falk Steelflex couplings that are lubricated annually and operate within ambient temperatures of 0°F to 150°F (-18°C to 66°C). For temperatures beyond this range (see Table 1), consult the Factory.

If a coupling leaks grease, is exposed to extreme temperatures, excessive moisture or experiences frequent reversals, more frequent lubrication may be required.

Specifications — General Purpose Coupling

Lubricants

The values shown are typical and slight variations are permissible.

DROPPING POINT — 300°F (149°C) or higher.

CONSISTENCY — NLGI No. 2 with 60 stroke worked penetration value in the range of 250 to 300.

SEPARATION AND RESISTANCE — Low oil separation rate and high resistance to separation from centrifuging.

LIQUID CONSTITUENT — Possess good lubricating properties equivalent to a high quality, well refined petroleum oil.

INACTIVE — Must not corrode steel or cause swelling or deterioration of synthetic seals.

CLEAN — Free from foreign inclusions.

428-110

May 2004 Supersedes 2-03

General Purpose Greases Meeting Rexnord

Specifications

Lubricants listed below are typical products only and should not be construed as exclusive recommendations.

TABLE 1 — General Purpose Greases

Ambient Temperature Range

Manufacturer

Amoco Oil Co.
BP Oil Co.
Chevron U.S.A., Inc. Citgo Petroleum Corp Conoco Inc.

Exxon Company, U.S.A..

E.F. Houghton & Co.

Imperial Oil Ltd.

Kendall Refining Co.

Keystone Div. (Pennwalt) Lyondell Petrochemical (ARCO)
Mobil Oil Corp..

Petro-Canada Products Phillips 66 Co.
Shell Oil Co.
Shell Canada Ltd.

Sun Oil Co.
Texaco Lubricants Unocal 76 (East & West) Valvoline Oil Co.

0°F to 150°F (-18°C to 66°C)

Lubricant 

Amolith Grease #2 Energrease LS-EP2 Dura-Lith EP2
Premium Lithium Grease EP2 EP Conolith Grease #2 Unirex EP2

Cosmolube 2
Unirex EP2
Lithium Grease L421 81 EP-2

Litholine H EP 2 Grease Mobilux EP111

Multipurpose EP2
Philube Blue EP
Alvania Grease 2
Alvania Grease 2
Ultra Prestige 2EP
Starplex HD2
Unoba EP2
Multilube Lithium EP Grease

-30°F to 100°F (-34°C to 38°C)

Lubricant 

Amolith Grease #2 Energrease LS-EP1 Dura-Lith EP1
Premium Lithium Grease EP1 EP Conolith Grease #2 Unirex EP2

Cosmolube 1
Unirex EP2
Lithium Grease L421 81 EP-1

Litholine Complex EP1 Mobilith AW1

Multipurpose EP1 Philube Blue EP Alvania Grease 2 Alvania Grease 2 Ultra Prestige 2EP Multifak EP2 Unoba EP2

…

★ Grease application or re-lubrication should be done at temperatures above 20°F (-7°C). If grease must be applied below 20°F (-7°C), consult

the Factory.

† Lubricants listed may not be suitable for use in the food processing industry; check with lube manufacturer for approved lubricants.

INSTALLATION OF TYPE T10 STEELFLEX GRID COUPLINGS

Installation

Only standard mechanics tools, wrenches, a straight edge and feeler gauges are required to install Falk Steelflex couplings. Coupling Sizes 1020T thru 1090T are generally furnished for CLEARANCE FIT with setscrew over the keyway. Sizes 1100T and larger are furnished for an INTERFERENCE FIT without a setscrew.

CLEARANCE FIT HUBS — Clean all parts using a non- flammable solvent. Check hubs, shafts and keyways for burrs. Do not heat clearance fit hubs. Install keys, mount hubs with flange face flush with shaft ends or as otherwise specified and tighten setscrews.

INTERFERENCE FIT HUBS — Furnished without setscrews.

Heat hubs to a maximum of 275°F (135°C) using an oven, torch, induction heater or an oil bath. To prevent seal damage, DO NOT heat hubs beyond a maximum temperature of 400°F (205°C).

When an oxy-acetylene or blow torch is used, use an excess acetylene mixture. Mark hubs near the center
of their length in several places on hub body with
a temperature sensitive crayon, 275°F (135°C) melt temperature. Direct flame towards hub bore using constant motion to avoid overheating an area.

Rexnord 5555 S. Moorland Rd., New Berlin, WI 53151-7953 Telephone: 262-796-4060 Fax: 262-796-4064 www.rexnord.com

Falk Steelflex Couplings • Installation & Maintenance

Type T10 • Sizes 1020–1140 & 20–140 (Page 3 of 8)

Use a spacer bar equal in thickness to the gap specified in Table 2, Page 5. Insert bar as shown below left, to same depth at 90° intervals and measure clearance between bar and hub face with feelers. The difference in minimum and maximum measurements must not exceed the ANGULAR installation limits specified in Table 2.

3 — Offset Alignment

WARNING: If an oil bath is used, the oil must have a flash point of 350°F (177°C) or higher. Do not rest hubs on the bottom of the container. Do not use an open flame in a combustible atmosphere or near combustible materials.

Heat hubs as instructed above. Mount hubs as quickly as possible with hub face flush with shaft end. Allow hubs to cool before proceeding. Insert setscrews (if required) and tighten.

Maximize Performance And Life

The performance and life of couplings depend largely upon how you install and maintain them. Before installing couplings, make certain that foundations of equipment to be connected meet manufacturers’ requirements. Check for soft foot. The use of stainless steel shims is recommended. Measuring misalignment and positioning equipment
within alignment tolerances is simplified with an alignment computer. These calculations can also be done graphically or mathematically.

Alignment is shown using spacer bar and straight edge. This practice has proven to be adequate for many industrial applications. However, for superior final alignment, the use of dial indicators (see Manual 458-834 for instructions), lasers, alignment computers or graphical analysis is recommended.

1— Mount Seals And Hubs

MOUNT SEAL FIRST

Lock out starting switch of prime mover. Clean all metal parts using a non-flammable solvent. Lightly coat seals with grease and place on shafts BEFORE mounting hubs. Heat interference fit hubs as previously instructed. Seal keyways to prevent leakage. Mount hubs on their respective shafts so the hub face is flush with the end of its shaft unless otherwise indicated. Tighten setscrews when furnished.

2 — Gap and Angular Alignment

Align so that a straight edge rests squarely (or within the limits specified in Table 2) on both hubs as shown above and also at 90° intervals. Check with feelers. The clearance must not exceed the PARALLEL OFFSET installation limits specified in Table 2. Tighten all foundation bolts and repeat Steps 2 and 3. Realign coupling if necessary.

4 — Insert Grid

Rexnord
5555 S. Moorland Rd., New Berlin, WI 53151-7953
Telephone: 262-796-4060 Fax: 262-796-4064 www.rexnord.com

Pack gap and grooves with specified lubricant before inserting grid. When grids are furnished in two or more segments, install

them so that all cut ends extend in the same direction (as detailed in the exploded view picture above); this will assure correct grid contact with non-rotating pin in cover halves. Spread the grid slightly to pass over the coupling teeth and seat with a soft mallet.

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May 2004 Supersedes 2-03

FalkTM Steelflex® Couplings • Installation & Maintenance

(Page 4 of 6) Type T10 • Sizes 1020–1140 & 20–140

5 — Pack With Grease And Assemble Covers

ANNUAL MAINTENANCE

For extreme or unusual operating conditions, check coupling more frequently.

1. Check alignment per steps on Page 3. If the maximum op-erating misalignment limits are exceeded, realign the cou-pling to the recommended installation limits. See Table 2 for installation and operating alignment limits.

2. Check tightening torques of all fasteners.

3. Inspect seal ring and gasket to determine if replacement is required. If leaking grease, replace.

4. When connected equipment is serviced, disassemble the coupling and inspect for wear. Replace worn parts. Clean grease from coupling and repack with new grease. Install coupling using new gasket as instructed in this manual.

Periodic Lubrication

MATCH MARK

MATCH MARK

Pack the spaces between and around the grid with as much lubricant as possible and wipe off excess flush with top of grid. Position seals on hubs to line up with grooves in cover. Position gaskets on flange of lower cover half and assemble covers so that the match marks are on the same side (see above). If shafts are not level (horizontal) or coupling is to be used vertically, assemble cover halves with the lug and match mark UP or on the high side. Push gaskets in until they stop against the seals and secure cover halves with fasteners, tighten to torque specified
in Table 2. Make sure gaskets stay in position during tightening of fasteners.

MATCH MARKLUG UP

The required frequency of lubrication is directly related to the type of lubricant chosen, and the operating conditions. Steelflex couplings lubricated with common industrial lubricants, such as those shown in Table 1, should be relubed annually. The use of Falk Long Term Grease (LTG) will allow relube intervals to be extended to beyond five years. When relubing, remove both lube plugs and insert lube fitting. Fill with recommended lubricant until an excess appears at the opposite hole.

CAUTION: Make certain all plugs have been inserted after lubricating.

Coupling Disassembly And Grid Removal

Whenever it is necessary to disconnect the coupling, remove the cover halves and grid. A round rod or screwdriver that will conveniently fit into the open loop ends of the grid is required. Begin at the open end of the grid section and insert the rod or screwdriver into the loop ends. Use the teeth adjacent to each loop as a fulcrum and pry the grid out radially in even, gradual stages, proceeding alternately from side to side.

Rexnord 5555 S. Moorland Rd., New Berlin, WI 53151-7953 Telephone: 262-796-4060 Fax: 262-796-4064 www.rexnord.com

VERTICAL COUPLINGS

CAUTION: Make certain lube plugs are installed before operating.

CAUTION:

428-110

May 2004 Supersedes 2-03

TYPE T COUPLING INSTALLATION &

ALIGNMENT DATA

Maximum life and minimum maintenance for the coupling and connected machinery will result if couplings are accurately aligned. Coupling life expectancy between initial alignment and maximum operating limits is a function of load, speed and lubrication. Maximum operating values listed in Table 2 are based on cataloged allowable rpm.

Values listed are based upon the use of the gaps listed, standard coupling components, standard assemblies and cataloged allowable speeds.

Falk Steelflex Couplings • Installation & Maintenance

Type T10 • Sizes 1020–1140 & 20–140 (Page 5 of 8) Values may be combined for an installation or operating

condition.

Example: 1060T max. operating misalignment is .016″ parallel plus .018″ angular.

NOTE: For applications requiring greater misalignment, refer application details to the Factory.

Angular misalignment is dimension X minus Y as illustrated below. Parallel misalignment is distance P between the hub center lines as illustrated below.

End float (with zero angular and parallel misalignment) is the axial movement of the hubs(s) within the cover(s) measured from “0” gap.

ANGULAR MISALIGNMENT Y

X

PARALLEL OFFSET MISALIGNMENT P

P

END FLOAT FF

GAP

TABLE 2 — Misalignment & End Float

TABLE 3 — Coupling Cover Fastener Identification

★ Older style covers, Sizes 1020T10 thru 1070T10 must utilize socket head cap screws and locknuts held by the cover. 

Rexnord
5555 S. Moorland Rd., New Berlin, WI 53151-7953
Telephone: 262-796-4060 Fax: 262-796-4064 www.rexnord.com

428-110

May 2004 Supersedes 2-03

Falk Steelflex Couplings • Installation & Maintenance

(Page 6 of 6) Type T10 • Sizes 1020–1140 & 20–140

PARTS IDENTIFICATION

All coupling parts have identifying part numbers as shown

below. Parts 3 and 4 (Hubs and Grids), are the same for both

Type T10 and T20 couplings. All other coupling parts are unique to

Type T10. When ordering parts, always SPECIFY SIZE and TYPE shown on the COVER.

PARTS INTERCHANGEABILITY

Parts are interchangeable between Sizes 20T and 1020T, 30T and 1030T, etc. except as noted.

GRIDS — Size 1020T thru 1140T Steelflex couplings use blue or non-painted grids. Older models, 20T thru 140T, use orange grids.

CAUTION: Blue or non-painted grids may be used in all applications, but DO NOT substitute orange grids for blue or nonpainted.

CAUTION: COVERS — DO NOT mix cover halves of different designs. Sizes 1020T thru 1070T10 covers have been manufactured in several different two-rib designs and 80T thru 140T covers have been manufactured with two and three ribs.

HARDWARE — Older style covers, Sizes 1020T10 thru 1070T10, utilized socket head cap screws with captured locknuts. The new style covers use hex head cap screws (either inch or metric from year 1994 through 2003 and only Metric beginning in 2004). Specify the style cover when ordering replacement parts.

PART NUMBER LOCATION

(2.) COVER (7.)

(4.) GRID

(5.) GASKET

(6.)

1030 T 10

B

PART DESCRIPTION

1. Seal (T10)
2. Cover (T10)
3. Hub (Specify bore and keyway) 4. Grid
5. Gasket (T10)
6. Metric Fasteners (T10).
7. Lube Plug

ORDER INFORMATION

1. Identify part(s) required by name above.

2. Furnish the following information.

   EXAMPLE:
   Coupling Size: 1030 Coupling Type: T10 Model: B Bore: 1.375
   Keyway: .375 x .187

3. Contact your Rexnord DistributororRexnord for price and availability.

(3.) HUB

SIZE

PART NUMBER

COUPLING SIZE

TYPE

MODEL

SIZE & PART NUMBER

(1.) SEAL

SIZE, PART NUMBER & BORE

SIZE

PRODUCT CLASSIFICATION

PART NUMBER

428-110

May 2004 Supersedes 2-03

Rexnord 5555 S. Moorland Rd., New Berlin, WI 53151-7953 Telephone: 262-796-4060 Fax: 262-796-4064 www.rexnord.com

300-088.02

Installation

After unpacking, check for damage. Be sure that shaft rotates freely. Before making electrical power connections, check for proper grounding of motor and application. All electrical contacts and connections must be properly insulated and enclosed. Couplings, belts, chains or other mounted devices must be in proper alignment, balance and secure to insure safe motor operation.

Electrical Wiring

Prior to connecting to the power line, check nameplate for proper voltage and rotation connection. This motor should be installed in compliance with the National Electrical Code and any other applicable codes. Voltage at motor not to exceed + or -10% of nameplate. Authorized person should make all electrical connections.

Mounting

This motor should be securely mounted to the application. Sufficient ventilation area should be provided to insure proper operation.

RECOMMENDED COPPER WIRE & TRANSFORMER SIZE

Caution:
1. Disconnect power to the motor before performing service or maintenance. 2. Discharge all capacitors before servicing motor.
3. Always keep hands and clothing away from moving parts.
4. Be sure required safety guards are in place before starting equipment.

Motor Trouble-Shooting Chart

Motor Trouble-Shooting Chart 10/13/00 (continued)

Bulletin 2400

10/00