BESSER DYNAPAC 3 AT A TIME (466361F9710US). OPERATION / MAINTENANCE MANUAL

SECTION 10

TROUBLESHOOTING

10.2.9 CORE BAR CRACK

10.2.10 CRACKING AT PALLET SIDE

a. Check vibrator brake settings.

Check for loose core assembly.

b. Check vibrators shaft speeds.

Check for bent core assembly.

c. Check for loose cores.

Check pallet receiver frame for level.

d. Check vibrator sheave alignment.

Check pallet receiver rubbers. Pallet may be mov-

ing during finish time (it may require pallet snub-

e. Check pallet guides. Rear guides may have a

bers).

groove worn so pallets stick during stripping opera-

tion (this may not apply to V4).

Check pallet guides.

Check feed and finish time (it may need more).

Check core bars for material build-up.

g. Check for material build-up on core bars or core

Check for thick and thin pallets.

assemblies.

h. Check vibrator brakes (may be slipping).

h. Check mix (it can be too dry).

Check for material between pallet and pallet receiv-

er rubbers.

Pallet receiver and stripper head alignments.

10-9

466361F9710US F1 29OC99

SECTION 10

TROUBLESHOOTING

10.2.15 COARSENESS ON BOTTOM OF BLOCK

10.2.16 HAIRLINE CRACKING AND PULLING

LEAVING A BAD EDGE

AT TOP OF BLOCK ON COMPLETION

OF STRIPPING

a. Check pallet receiver rubbers.

Check spring opening to assure height pins stay

together during strip.

b. Check if pallet moves during vibration.

b. Check to make sure stripper shoe protrudes

c. Check vibrator weights, may have to change to

through bottom of mold at completion of strip.

larger or smaller vibrator weights.

c. Check adjustment for stripping.

d. Check mold for loose parts.

d. Check division plates for wear.

e. Check stripper head alignment.

e. Check for loose stripper shoes.

Check for material segregation.

Check moisture content of mix. It may be too wet.

g. Check for build up on pallets or mold.

h. Check for core spillage on pallet.

Check moisture content of mix. It may be to dry.

Check vibrator shaft rotation.

k. Make sure pallet is against bottom of mold.

10-12

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

SECTION 11

MAINTENANCE

11.1

PREVENTIVE MAINTENANCE

Correct maintenance is largely a matter of good judgment on the part of the operator in charge. The DYNA-

PAC, like any other machine, will do the work required just as long as it is properly cared for. A good preven-

tive maintenance program based on the recommendations below will extend the machine’s life at a high level

of performance.

Check the following procedures daily and every time a product or mold change is done.

COMPONENT

REF.¹

CHECK FOR

TOLERANCE²

ACTION

HOURS³

Upper and lower height stops

5.22

Loose clamp / wear

see torque chart

repair

400

Lower height stops wire

5.22

Loose / broken

repair / replace

400

Spring link assembly Spring opening

5.33

Gap as mold touches throat

1/16" [1.5mm]

adjust

400

Pallet receiver rubbers

4.14

All rubbers same height

max:015" [.38mm]

replace

400

Mold

5.9

Centered (after vibration)

± .030" [.76mm]

adjust

400

Mold locks and liner

5.2

Wear

0 to .125" [3mm]

replace

1000

.020" ± .030"

Mold lock liner

5.2

Clearance

adjust

1000

[.51mm ± .76mm]

every

.030" ± .010"

Apron plate

5.17

Clearance to mold

adjust

mold

[.76mm ± .25mm]

change

every

.125" ± .010"

Apron plate

5.17

Height above mold

adjust

mold

[3mm ± .25mm]

change

Pallet receiver frame -

.020" ± .005"

every

5.16

Clearance

adjust

guide liners

[.51mm ± .13mm]

week

Stripper head frame -

.020" ± .005"

every

5.28

Clearance

adjust

guide liners

[.51mm ± .13mm]

week

Table 11.1

PREVENTIVE MAINTENANCE TABLE

¹ The "REF." column refers you to the figure in this manual where the component is illustrated and

where adjustment instructions is given.

² If TOLERANCE is not respected, proceed to ACTION.

³ Hours of operation.

11-1

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

11.2

SERVICE AND REPAIRS

11.2.1

DRIVE MOTOR (not illustrated)

COMPONENT

CHECK FOR

ACTION

HOURS

Mounting bolts

Recommended torque

torque

installation

Bearings

.002 [.05mm] radial move

repair / replace

4000

Lubrication

lubricate

2000

Sheave

Wear - Match with gauge #112541

replace

400

Surface contamination, wear, cuts, cracks

Belts

replace

400

Match with gauge #112541

Table 11.2

11.2.2 BESCODYNE CLUTCH/BRAKE UNIT (FIGURE 11.1)

Figure 11.1

COMPONENT

CHECK FOR

ACTION

HOURS

Input sheave #112339F2280

Match with gauge #112541

torque

installation

Output sheave #112339F6080

Match with gauge #112541

repair / replace

4000

Oil - 10 quarts

check level

weekly

Lubrication

Oil - Use Mobil Automatic Transmission Fluid

change

3 weeks

ATF-210 (Type “F”) or equivalent

Disc

Centered (after vibration)

replace

400

Surface contamination, wear, cuts, cracks

Belts

replace

400

Match with gauge #112541

Table 11.3

11-2

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

11.2.2 BESCODYNE CLUTCH/BRAKE UNIT

(continued)

1. Check the disc wear surfaces for scoring, galling or

evidence of uneven wear.

11.2.2.1 CHECKING THE OIL LEVEL

2. Check the clutch and brake plates for scoring or

Every week or until experience dictates otherwise,

galling. Make sure they are flat. If a perceptible

check the oil level. Always check the oil level with the

ridge is worn in any of the drive plates, replace all of

drive at room temperature and while it is not running.

the drive plates and friction discs as a complete set.

The drive has an oil sight gauge located at the output

3. Carefully check the piston and bore surfaces for

end of the drive. The oil level is to be at the center of

nicks, scratches, scoring or other damage which

the gauge.

would affect operation or cause leakage.

4. Pay particular attention to Wear Sleeve (#250),

11.2.2.2 CHANGING THE OIL

Mating Ring (#4) and shafts in the area of rotary

seals. Check for nicks or scratches which would

IMPORTANT : Open the disconnects to the drive

cause leakage. Replace any damaged parts.

motors before attempting to change the oil.

5. It is not necessary to remove the ball bearings to

Every three months, completely drain the oil from the

check their operation. Slowly rotate the free race of

drive using the drain plugs provided. If the oil sight

each bearing by hand checking to see if it turns

gauge is dirty, it should be removed and cleaned.

freely without rough or flat spots.

Reinstall the drain plugs and refill the drive to the cen-

ter of the sight gauge with fresh oil.

11.2.2.5 REPAIR AND REPLACEMENT

Note: Do not overfill the drive unit. Excess oil will cause

A fine stone or crocus cloth may be used to remove

the unit to overheat.

minor surface defects from parts as long as the operat-

ing or sealing action of the part is not affected. The use

of coarser abrasive or other machining methods should

11.2.2.3 TYPE OF OIL

not be attempted. Otherwise, damaged parts should be

replaced.

Use only Mobil Automatic Transmission Fluid ATF-21 0

(type

“F’) or Mobil Multi-purpose Automatic

Replacement is recommended also for the following, as

Transmission Fluid for most drives. Other fluids may be

applicable:

specified for special applications. Always use the type

of fluid specified on the Name Plate.

1. Replace all O-Rings, Liners, Gaskets and Oil Seals

removed during the course of disassembly.

11.2.2.4 CLEANING AND INSPECTION

2. Replace Clutch or Brake Discs and Drive Plates as

complete sets only.

Clean metal parts in a suitable solvent and dry in a

stream of low pressure compressed air. The Clutch and

Brake Drive Plates can be cleaned in solvent, but DO

11.2.2.6 BELTS (ref. table 11.3)

NOT clean the Clutch and Brake Friction Discs in sol-

vent. Use only a clean, dry and lint-free rag to clean

Check wear and tension on input and output belts as

these Friction Discs. (Solvent will damage the resilient

described in table 11.3 (see figure 11.4 and 11.5).

paper-based friction material used on the Friction

Discs). Keep the Drive Plates and Friction Discs in the

Note: Refer to Bescodyne catalogue #502-03/20-001

same order as they were removed. After cleaning,

for more complete instructions on this unit.

inspect parts for cracks, distortion, scoring, nicks, burrs

or other damage would affect serviceability. Pay partic-

ular attention to the following:

11-3

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

11.2.2.7

PROCEDURE FOR CHECKING BRAKE

AND CLUTCH STACKS FOR WEAR.

An easy procedure has been established to visually

If the rear surface of the clutch thrust plate (D) has

check the brake and clutch stacks for wear to deter-

moved up to or past the “stack wear” groove (A), the

mine whether or not they need to be replaced.

clutch stack needs to be replaced (see figure 11.2).

Two “stack wear” grooves (A) have been machined in

4. Exhaust the air pressure from the clutch port.

the input shaft (B) lugs to facilitate this visual check

(see figure 11.2)

B. BRAKE STACK WEAR

5. Apply air pressure to the brake port.

CAUTION: Disconnect and lock-out all

6. Using a flashlight, observe the clutch stack through

electrical power to the drive motor. This

the inspection port (A) (see figure 11.3).

step must be taken to avoid any possi-

bility of personal injury or damage to the

If the rear surface of the Thrust place (E) has moved

drive unit.

up to or past the “stack wear” groove #1, the brake

stack is worn and needs to be replaced.

1. Remove the inspection pipe plug from the top of the

input housing.

Note: Both the brake stack and the clutch stack can

individually be checked for wear. If either stack is

A. CLUTCH STACK WEAR

worn and needs to be replaced, both stacks

should be replaced as a complete set. Refer to

2. Apply air pressure to the clutch port.

service manual and repair parts for clutch/brake

drives (502-03/20-001) Besser catalog No.

3. Using a flashlight, observe the clutch stack (C)

437629F001, section 7 - DISASSEMBLY and

through the inspection port (see figure 11.2).

section 9 REASSEMBLY for brake and clutch

stack replacement.

Clutch stack (C)

Stack wear

Rear surface of pressure plate

groove (A)

“Stack wear” groove #1

“Stack wear” groove #2

Stack wear

groove (A)

Inspection port

Clutch thrust

plate (D)

Clutch stack

Input shaft (B)

Inspection port -B

Clutch thrust plate - E

Figure 11.2

STACK WEAR GROOVES.

Figure 11.3

BRAKE AND CLUTCH STACKS FOR WEAR.

11-4

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

11.2.2.8 BESCODYNE UNITS SERVICE TIPS

KNOW THE AIR PRESSURES

CHANGING OIL

Don’t guess, be positive. Use 70 psi (4.8 bar) for

Besser recommends changing the oil in

Clutch. Use 50 to 55 psi (3.4 to 3.8 bar) for Brake.

Bescodynes drives every three months. Use a

Multi-Purpose ATF 210 Automatic Transmission

BRAKES

Fluid.

Brakes are spring-boosted, so less air pressure is

required.

Note: Do Not Overfill. Refer to Besser Service Bulletin

No. 93-4, for additional information.

GAUGES AND REGULATORS

Use glycerine-filled gauges; they are accurate and

Note: DO NOT FLUSH with any solvents; we recom-

last longer.

mend to simply change the oil.

DYNAPAC USES TWO DIFFERENT UNITS

EXCESSIVE HEAT

5S and 10S units use entirely different friction lin-

Excessive heat can be a real enemy! Keep fans

ing. Radically higher pressures will cause prema-

intact and fan shroud in place.

ture wear. Integrally piloted valve will not shift at

pressures below 40 psi (2.8 bar) and must be con-

verted to externally piloted. For a conversion, con-

sult a Besser representative or refer to Besser

Service Bulletin No. 91 -1.

EXCEEDING 80 psi (5.5 bar)

Exceeding this pressure on the clutch for any

length of time can result in early failure of thrust

bearings.

AIR LINE LUBRICATION

Use an air line lubricator only when a lubricator has

been used previously. A small trace of oil in the air

valve and piston of the Bescodyne can extend life.

Use the same ATF oil in the lubricator as used in

the Bescodyne. When adjusting the lubricator, fol-

low the adjustment procedures as outlined by the

manufacturer.

CLEANER AIR

Always invest in good quality air filters, regulators

and lubricators. The result of using air filters, regu-

lators and rubricators is clean air that is free of

moisture and contaminants.

V-BELTS

While it is necessary to maintain enough belt ten-

sion to drive the block machine, overtightening of

V-belts on the output end of the Bescodyne drive

could cause fatigue breakage of the spliced output

shaft. When the 4 or 5 groove output sheave

becomes worn, it is tempting to over-tighten the

belt to prevent slipping. When slippage occurs,

replace the output sheave.

11-5

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

11.2.3 REPLACING PINION SHAFT

11.2.4 TURNING BULL GEAR.

Before replacing pinion shaft, make sure machine is in

The bull gear must be turned in order to extend its life

safe position. Stripper head frame and pallet receiver

span. Turn bull bear when .020” (.5mm) clearance

frame must be down. Also, make sure there is no ten-

develops between pinion and bull gear teeth.

sion on the pinion gear.

Before turning bull gear, make sure machine is in its

1. Remove pinion shaft assembly from machine and

safe position. Stripper head frame and pallet receiver

transfer parts to be rebuilt to new shaft.

frame must be down.

2. Reinstall rebuilt assembly and adjust so teeth have

1. Unbolt bull gear from hub (bolt A in figure 11.9).

equal pressure across width and a clearance of

.012” to .019” (.3mm to .5mm).

2. and turn pinion shaft to turn bull gear 90⁰.

3. Finally, rebolt to hub.

Figure 11.8

PINION SHAFT

Figure 11.9

BULL GEAR

11-7

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

11.2.5 PINION SHAFT (FIGURE 11.6 AND 11.7)

COMPONENT

CHECK FOR

ACTION

HOURS

Sheave P/N 112339F6280

Wear - Match with gauge #112541

replace

400

Bearings

.005” [.127mm] radial move

replace

2000

0.012” to 0.019”

Pinion

Alignment, wear and clearance

between teeth

Taper lock-tight

Lubrication

Automatic

Table 11.4

11.2.6 CAM SHAFT (NOT ILLUSTRATED)

COMPONENT

CHECK FOR

ACTION

HOURS

Bull gear

Alignment, wear and tightness

adjust

installation

Bearings

Clearance, seals

repair / replace

2000

Lubrication

Automatic

Cam assemblies

Table 11.5

11.2.7 FEED, STRIPPER HEAD AND PALLET RECEIVER SHAFTS & LINKS

COMPONENT

CHECK FOR

ACTION

HOURS

Bearings

Wear. .030” [.76mm] clearance

replace

1000

Rollers

Wear. .010” [.25mm] clearance

replace

1000

Wear. .030” [.76mm] between feeler gauge

Bushings

replace

1000

pin and bushing

Pins

Wear. .010” [.25mm]

replace

1000

Links

Link ends tightness (see torque chart)

replace

400

Link bearings

Wear. .030” [.76mm] clearance

replace

1000

Link pins

Wear. .010” [.25mm] clearance

replace

1000

Table 11.6

11-8

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

11.2.8

FEEDBOX

COMPONENT

CHECK FOR

ACTION

HOURS

Agitator motor

Lubrication (see manufac.’s manual)

lubricate

4000

Agitator sheave

Worn (match with gauge #112541)

repair / replace

400

Agitator belts

Wear and tension (match with gauge #112541)

check level

400

Agitator bearings

Wear

replace

400

Agitator nylons

Worn. .030” [.76mm] clearance

replace

400

Agitator rollers

Worn. .010” [.25mm] clearance

replace

400

Agitator bars

Worn more than 1/2” [13mm] in dia.

replace

400

Back bar and guide

Bent or worn more than .030” [.76mm]

clean & replace

Daily

Liners

Bent or worn more than .060” [1.5mm]

replace

Daily

Loose back bar

Bent or worn more than .100” [2.5mm]

replace

Daily

Hopper

Bent or worn more than .100” [2.5mm]

replace

Daily

Gate

Bent or worn more than .100” [2.5mm]

replace

Daily

Baffle

Bent or worn more than .100” [2.5mm]

replace

Daily

Apron plate

Worn more than .125” [3mm]

replace

Daily

Wear shoes

Worn more than .125” [3mm]

replace

Daily

Rollers

Worn more than .010” [.25mm]

replace

100

Bushings

Worn more than .030” [.76mm]

replace

100

Pins

Worn more than .010” [.25mm]

replace

100

Back top plate

Worn more than .100” [2.5mm]

replace

100

Feedbox track

Worn more than .060” [1.5mm]

replace

400

Table 11.7

11.2.9 PALLET & BLOCK DELIVERY

COMPONENT

CHECK FOR

ACTION

HOURS

Pallet conveyor chain

3% elongation and sloppy rollers

Adjust

1000

Pallet conveyor shafts

Pallet conveyor bearings

.020” [0.5mm] radial movement

replace

1000

Pallet conveyor sprockets

No longer smooth when engages chain

replace

1000

Pallet conveyor trunion shaft bearings

.020” [0.5mm] radial movement

replace

1000

Pallet conveyor chain track

1/8” [3mm] wear or can no longer adjust

replace

1000

Pallet lugs

Won’t consistently push pallets

replace

1000

Table 11.8

11-9

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

11.2.10 PALLET & BLOCK MOVING BARS

COMPONENT

CHECK FOR

ACTION

HOURS

Linkage bearings

.010” [0.25mm] radial movement

replace

1000

Slides

Can no longer adjust

replace

1000

Guide rollers

won’t turn or .010” [0.25mm] radial movement

replace

1000

Pallet cradle

Bent or broken

replace

1000

Block fingers

Worn more than 1/16” [1.6mm]

replace

1000

Table 11.9

11.2.11 PALLET & BLOCK SUPPORT SHAFT

COMPONENT

CHECK FOR

ACTION

HOURS

Linkage bearings

.030” [0.76mm] radial movement

replace

1000

Bearings

.030” [0.76mm] radial movement

replace

1000

Cam rollers

won’t turn or .005” [0.13mm] radial movement

replace

1000

Table 11.10

11.2.12 PALLET & BLOCK DRIVE

COMPONENT

CHECK FOR

ACTION

HOURS

Shaft bearings

005” [0.13mm] radial movement

replace

1000

Link bearings

005” [0.13mm] radial movement

replace

1000

Cam

Surface rough or penned

replace

1000

Gearbox

(see manufac.’s manual)

replace

1000

Drive belt and sheaves

(see manufac.’s manual)

replace

1000

Motor

(see manufac.’s manual)

replace

4000

Motor brake

(see manufac.’s manual)

replace

1000

Table 11.11

Figure 11.10

Figure 11.11

11-10

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

11.3

TRABON PUMP MAINTENANCE

11.3.2 TRABON PISTON STROKE ADJUSTMENT

The adjustments covered in this section are:

AL-5M Pump stroke adjustment for Besser block

machines:

1. PUMP IN-FEED PRESSURE.

On AL-5M pumps, we recommended in the past a set-

2. THE SOLENOID FLOW ADJUSTMENT controls the

ting of .020 which would be 20 thousandths cubic inch-

speed the air piston shifts.

es of grease per stroke or.328 cubic centimeters. .020

is the middle of 3 calibration marks.

3. THE PUMP PISTON STROKE determines how

much grease is pumped each stroke.

On the right side of the pump, remove the calibrated sil-

ver cap. Put the open end of the cap up against the lock-

4. LUBRICATION RATE ADJUSTMENT Adjusted

nut. The stroke is how far the screw sticks out and match-

through the Graphic Control Station. Refer to section

es the calibrations on the cap. To adjust the stroke,

9.5: “TIMER ADJUSTMENT” - F3 -Timers 5 and 6.

loosen the lock nut on the adjustment screw. Turn the

screw inward or clockwise to reduce the stroke. Turn the

5. FILLING THE GREASE PUMP.

screw outward or counterclockwise to increase the

stroke. The lock nut has to be retightened and the cap

For more complete instructions on the TRABON

placed up against it again to recheck the settings after

PUMP, refer to “Trabon Pump Owner’s Service Manual

you change them. After final adjustment, tighten lock

#437629F913”.

nut, then tighten silver cap onto the adjustment screw.

Warning: Be very careful while adjusting or trou-

L-25M Pump stroke adjustment:

bleshooting the lube system that the machine is not

On AL-25M pumps used on block machines, set the

turning, and the main drive motor is off.

pump stroke on the mark between the 30 line and the

.075 line. This will be a setting of approximately.052

cubic inches which is equal to .853 cubic centimeters.

11.3.1 TRABON IN-FEED PRESSURE

The method of adjustment is described and shown in

the Pump owner’s manual on page 4-2 and 4-3.

ADJUSTMENT

The Trabon pneumatic pump has a air-to-lube ratio of

30 to 1. The Trabon in-feed air pressure on many

Besser Vibrapacs is supplied from the Bescodyne main

drive brake air regulator. In this case when the brake

regulator adjustment is changed, it also affects the

Trabon pump. The Trabon pump pressure ideally

should be 60-80 psi [4.1-5.5 bar], which can develop at

least 1800 psi [124 bar] pumping pressure.

Note: It may be advantageous to connect your Trabon

pump to the Bescodyne main drive clutch rather

than to the brake. The clutch air pressure adjust-

ment is higher than the brake. Starting in 1991,

Besser block machines have a separate air regu-

lator supplied to the Trabon pumps. The plastic

air solenoids on double acting pumps may not

operate with less than 70 PSI [4.8 bar].

Figure 11.12THE TRABON LUBE PUMP

11-12

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

AL-25M Pump stroke adjustment for Besser slump

11.3.5 FILLING THE GREASE PUMP

mixers:

Set the stroke adjustment for .030 cubic inches, .492

Grease To Use:

cubic centimeters for AL-5M and AL-25M pumps.

We recommend Lithium based E.P.-1 grease, such as

Shell Alvania E.P. No. 1, or Mobilux E.P. No. 1. In cold-

er climates and/or in colder months, Shell Alvania E.P.

11.3.3 TRABON SOLENOID FLOW CONTROL

No. 0, Mobilux E.P. No. 0, or grease with equivalent

ADJUSTMENT FOR ALS PUMPS

specifications may be used.

The solenoid flow adjustment controls the speed at

Filling the Pump:

which the Trabon air piston shifts. The solenoid flow

The Trabon Pump, on the average, should be filled with

controls should be adjusted to get a gentle but positive

grease after 35 hours of operation. It is best if the pump

shift of the piston without slamming.

never runs out of grease because excessive air can be

introduced into the system. Before filling the pump, turn

Single acting ALS pumps have one flow adjustment

the filter handle a few times to clean it. Attach a filling

which controls the in-feed air into the SA port.

pump hose to the fill stud quick disconnect located just

Depending on the air plumbing, you may have to use

ahead of the filter.

an offset screwdriver to adjust the flow control.

Warning: If a high pressure supply pump is used to fill

Turn the solenoid adjusting screw clockwise all the way

the Trabon grease reservoirs, wear safety glasses.

in. Back the adjusting screw out 1/16 to 1/4 turn. Press

Pressure could build up high enough to fracture the

the manual shifting override button on the air solenoid.

reservoir and send particles flying.

You should be able to hear the air piston shifting and

Note: If air does get into the automatic greasing sys-

the exhaust air exiting the DA port. Adjust the solenoid

tem, refer to the proper sections:

as slow as possible while still getting a positive shift of

the piston. If you place your hand on the air cylinder of

1. To bleed air from the Reservoir, refer to Section 1 in

the Trabon pump, you should also be able to feel it

Pump owner’s manual.

shifting.

2. To bleed air from the Pump, refer to Section 6 in

Pump owner’s manual,

3. To bleed air from the Feeder Blocks and Grease

11.3.4 TRABON SOLENOID FLOW CONTROL

Lines, refer to Section 9 in Pump owner’s manual.

ADJUSTMENT FOR ALJ PUMPS

Operate the filler pump at a steady speed to allow air-

free filling of the reservoir. Filling the pump too fast may

On the double-acting pumps when the solenoid flow

form air pockets. Also to avoid inducing air into the

controls are adjusted, the exhaust air flow is also

pump, make sure there is enough grease in the supply

adjusted. When the Trabon air piston shifts forward, air

source to fill the reservoir without disconnecting and

flows in the SA port and out the DA port. So, to adjust

reconnecting the filler hose. While filling the pump,

the speed of the piston shift forward, turn the front or

watch the grease level rise. Stop adding grease when

right hand flow control which adjusts the air coming out

the level reaches the air bleed hole.

of the DA port. Loosen the lock nuts and turn both

screws all the way clockwise to shut off the flow. Start

Note: Never fill over the air bleed hole; this will cause a

by backing both screws out 1/2 turn and testing the

vapor lock in the system. The air bleed hole is

pump shift with the plastic manual override button. The

found about 2/3, the way up the plastic reservoir

reverse speed is controlled by air for the most part, but

on the right. When filling is complete, turn the

the return spring will also be helping. The reverse

supply source off and disconnect supply line

speed is controlled by the exhaust air coming out of the

from the fill stud. Install the plastic dust cap over

SA port which is the back or left hand flow control. Set

the fill stud to keep dirt out of the lube system.

both flow control adjustments to obtain a positive shift

without a hard, slamming action. When adjustments

are completed, tighten the lock nuts so the adjustment

screws cannot move out of adjustment.

11-13

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

11.4

BEARING MAINTENANCE

11.4.1 REMEMBER THESE DO’S AND DON’TS

When handling bearings:

DO:

DON’T:

Remove all outside dirt from housing before expos-

1 . Don’t work in dirty surroundings.

ing bearing.

2. Don’t use dirty, brittle or chipped tools

Treat a used bearing as carefully as you would a

new one.

3. Don’t use wooden pallets or work on wooden

bench tops.

Work with clean tools in clean surroundings.

4. Don’t handle with dirty, moist hands.

Handle with clean, dry hands, or preferably with

clean canvas gloves.

5. Don’t use gasoline containing tetraethyl lead, as

they may be injurious to health.

Use clean solvents and flushing oils.

6. Don’t spin unclean bearings.

Lay bearings out on clean paper.

7. Don’t spin bearings with compressed air.

Protect disassembled bearings from rust and dirt.

8. Don’t use cotton waste or dirty cloths to wipe bear-

Use clean lint-free cloths or rags to wipe bearings.

ings.

Keep bearings wrapped in oil proof paper when not

9. Don’t expose bearings to rust or dirt.

in use.

10. Don’t nick or scratch bearing surface faces.

10. Clean inside of housing before replacing bearing.

11-14

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

11.4.2 LUBRICATION TIPS

Lubrication is essential for the proper operation of bear-

bearing user, metal chips, grit, abrasive, dust, etc., are

ings. Grease and oil are both used over a considerable

all DIRT. Avoid them.

range of speeds and operating temperatures. The

choice of the type of lubricant should be made only

after careful consideration of the several factors

11.4.4 PREVENTIVE MAINTENANCE

involved.

Have a perfectly clean work bench on which to place

Keep lubricants clean. Dirt causes most bearing fail-

bearings before and after cleaning. Place the bearing in

ures, and one easy way for it to get to bearings is to

a degreaser or in a container of appropriate solvent

be put there in the grease. Keep covers tight on all

such as standard solvent, kerosene, methyl-chloroform,

grease cans. Use only clean dishes and clean spat-

or similar solvents. “Swirl” the bearing around in the

ulas with grease. Keep grease stored away from all

cleaning solvent allowing it to wash through the bear-

dust, dirt, and metal chips,

ing, carrying away any grit particles and dissolving all

oil or grease. Finally, slowly revolve the inner ring so

Standardize your greasing procedures. Make sure

the cleaning solvent reaches all parts of the bearing.

all maintenance personnel understand proper greas-

Do not allow the bearing to rest on the bottom of the

ing methods. Do not let inexperienced personnel

container. Cleaning of a bearing interior around the

take over greasing; it is too important. Establish pre-

balls or rollers is often done with a normal paint brush.

cise instructions regarding cleaning of greasing

This is a satisfactory practice although care should be

equipment, grease fittings, grease cups (before refill-

taken to use a good quality brush which does not lose

ing them). Oil cups and grease fittings can be

its bristles, and that none of the bristles become lodged

marked with colored paints to systemize your relubri-

between the balls or rollers and separators or rings. A

cation.

piece of bristle can be as harmful as a steel chip.

Relubricate on schedule. Do not wait for trouble to

ONCE IN, DIRT IS HARD TO GET OUT - A clean bear-

signal the need for additional lubrication.

ing placed on a dusty bench always becomes contami-

Relubrication schedules should be posted on

nated. Dirt, once entrenched in the separator, is

machines.

exceedingly difficult to remove. Make cleanliness your

first rule for working with bearings,

Use only high grade grease in bearings. Low grade

grease is a false economy. Its use usually results in

Bearings with closures on both sides should not be

shortened bearing life. Also, try to use the grease

cleaned by dipping, spraying and the like, which would

recommended by the machine manufacturer.

wash out the grease. The outer surfaces of such bear-

ings may be carefully wiped with a lint-free cloth and

Over-greasing is bad, It causes churning of the lubri-

light oil or solvent, after which they can be lightly coat-

cant and subsequent over-heating. If bearing runs

ed with a protective lubricant, and wrapped to protect

hot after relubrication, open the drain plug and let

against dirt and corrosion.

some of the grease run out while the bearing is

operating. Never fill end-bells more than one third

Throughout the cleaning process, and especially where

full when re-greasing.

a bearing has been solvent cleaned, remember that

corrosion can be caused by perspiration from hands.

Never start a new machine until the bearings have

been lubricated according to directions.

So if a bearing has been solvent cleaned, wipe it care-

fully before applying a protective oil coat.

11.4.3 WATCH OUT FOR DIRT

USE AIR WITH CAUTION - Never use unfiltered air.

Make sure all traces of water and dirt in the air line are

The most important precaution to be observed in han-

trapped out. Dirty air can blow dust into the bearing

dling or using bearings is to keep them clean. Dirt is the

ruining careful cleaning work. Never allow the air blast

greatest enemy of bearings. It causes wear, destroys

to spin a bearing. If you must use air, hold bearing and

their accuracy, and shortens their life. To the

hose carefully.

11-15

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

11.4.5 RELUBRICATE AFTER CLEANING

Always re-lubricate bearings immediately after they

failure, it should be removed with care to avoid damage

have been cleaned. Immerse in light clean oil and

to the shaft, housing or other machine parts and to

rotate the inner ring very slowly until all the solvent has

avoid obliterating the cause of failure.

been removed. Oil has a tendency to slip away from

metal surfaces already wet with solvents, leaving the

As mentioned before, at least one of the bearing rings

bearing surfaces unprotected and in danger of rust and

is press fitted sometimes to a very tight fit. At this point,

corrosion.

we are concerned largely with the proper handling of

press fitted parts.

11.4.6 REWRAP AFTER CLEANING

The first basic principle is that no press fit should be

broken unless it is essential to the job being done,

Immediately after re-lubricating the bearing, wrap well

Many roller bearings are separable and when it is cer-

in clean polyethylene or oiled paper. Replace in its box,

tain the bearing itself has not been damaged, it is best

making sure that inside of box is also clean. Reseal the

to leave the press fitted member in place. In addition to

box. A good shop practice is to write on the sealing

the time and trouble involved, removal may cause dam-

tape the date of cleaning, the type of lubricant, and the

age to the bearing seat. However, if any failure is evi-

name of the person cleaning the bearing.

dent, the entire bearing should be replaced. The sec-

ond basic principle is that, in removing a ring, the dri-

ving force be directed through the inner or outer ring

11.4.7 BEARING REMOVAL

which is being removed, and not be transmitted through

the balls, rollers, separators, closures and the like.

Bearings may have to be removed as part of an over-

haul program to service another part, or to replace the

bearing. In any case, even if the bearing is an obvious

Shaft Shoulder

Bearing Inner Ring

Shaft Shoulder

Press Ram

Split ring

Figure 11.13Bearings

11-16

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

The familiar arbor press is a very good machine for

to build a simple puller adapted to the job, especially if

removing (or installing) bearings. if action is rapid,

it is repetitive.

smooth and positive. In addition, it can supply a

greater force than most other means. Further, it is a

The use of a hammer and drift directly in the ring is

useful shop accessory for many other types of work.

very bad practice. An auxiliary fixture as shown here

Unfortunately, space restrictions prevent its use in

should be used.

many jobs.

Large roller bearing inner rings are particularly difficult

The arbor press requires various fixtures as an aid to

to remove by any of the methods given here. Usually,

removing or installing bearings. Although some of these

these rings are separable and it is necessary to destroy

aids are not inexpensive to make, their use is justified

them by heating or splitting. No specific instructions can

by the saving in time and by the freedom from damage

be given here except that ail attempts should be made

to the equipment under repair. This is especially true if

to prevent damage to the shaft.

the job is a repetitive one.

The best fixture for pressing off inner rings from a shaft

11.4.8 IDENTIFICATION DAMAGE AND FAIL-

is a split ring with the outer area relieved. For most

URE ON BEARINGS

roller bearings, flat bars or U-shaped washers as

shown here are quite satisfactory. They are not recom-

INSPECTION:

mended for ball bearings since the outer ring or the clo-

When a machine or other piece of equipment is down

sure may project beyond the inner ring face a small

for repair, the objective of the maintenance personnel is

amount, A possible solution to this problem is to insert

to repair it and get it going as soon as possible.

a small piece of shim stock about 0.01“ [0.25mm] thick

However, some knowledge of bearing failure and dam-

between the fixture and the inner ring face. Also, an

age identification is required to determine:

interference condition can be checked by oscillating the

outer ring while applying a little pressure.

Whether the bearing is suitable for further service.

The arbor press can also be used to remove outer rings

If there is some underlying cause for failure so that

from housings in those cases where the housing can

corrective measures can be applied before

be handled in the arbor press and where a portion of

installing a new bearing. Here are some inspection

the outer ring is exposed. In the event the entire outer

tips and techniques to be used before or during

ring is exposed, a section of tubing capped by a flat bar

machine dismantling Before removing or replacing

can be used as illustrated. In other cases, where there

a “noisy” bearing, try to determine if the bearing is

is axial space restriction, a fiat bar can sometimes be

the cause. To start with, a common complaint is

inserted to bear against the face.

that the bearing is “noisy”. This is a natural reaction

of machine users to unusual noise emanating from

Next to the arbor press, the puller is the best removal

a machine. Generally, a noisy bearing produces a

tool and is often necessary because of size and space

continuous whine. A pulsating noise is usually the

restrictions in the arbor press. Pullers are made in dif-

result of a malfunction of some other part. It must

ferent configurations and sizes and with accessories to

be remembered too that all ball and roller bearings

make them adaptable to various jobs. Larger sizes are

have some noise level. Bearings in good condition

available with a hydraulic piston and hand pump.

tend to produce a pleasant sound compared to a

harsh sound from one that is not functioning prop-

As with the arbor press, the pressure must be applied

erly. Another point to remember is that a noisy

directly through the press fitted member. In addition,

machine is not always a sign of imminent bearing

where screw adjustments to the arms are made, care

failure, but may indicate the need for lubrication.

should be taken to pull the press fitted part off straight

and true. It is advisable to use a piece of soft metal in

On dismantling a machine, it is often possible to

the shaft center to prevent scoring due to the pressure

make pertinent examination of the bearing without

of the puller screws.

removing it from the shaft or housing

The least desirable method is removal of inner and

outer rings by driving with a hammer. Where machine

shop facilities are available, it may be worth the effort

11-17

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

This is especially true with separable roller bearings,

If a part adjacent to the bearing has failed, it is good

including single row tapered bearings. In such cases,

practice to replace the bearing even though it is not

major damage or failure can readily be noted. Ball

obviously damaged. It is also good practice to replace a

bearings, being non separable, present considerably

bearing which has seen considerable service. The

more difficulty, especially those with seats or shields.

good judgment of the maintenance person is required

here to determine a balance between the cost and diffi-

In all cases, if failure or damage is not obvious, look for

culty of replacement vs. the possibility of a subsequent

these signs :

breakdown.

A loose fit of the rotating ring. This is probably a sig-

nal that the ring has rotated and that wear has taken

11.4.9 TYPES OF BEARING DAMAGE

place. Where the ring is not loose by normal feel but

there are rust-like loose particles around the fit area,

Here are photographs and a description of the more

check carefully for wear.

common types of bearing damage. Many of these type

of damage, especially in ball bearings, cannot readily

Indents, flaking or heavy rust on the operating sur-

be seen without dismantling the bearing. Hence, this

faces. In many cases, these conditions result from

identification is of benefit in cases of chronic failure,

metal particles thrown off by failure of an adjacent

where a specific cause is sought. These types of failure

gear, or the like.

are grouped as those caused by:

Undue looseness in a radial bearing. In most cases,

- Installation

radial shake, which can be felt by hand, is an indica-

- Operating conditions

tion that undue wear has taken place. Another sign

- Normal fatigue

of wear is a gritty feel of the lubricant adjacent to the

bearing. In connection with the noise problem dis-

cussed earlier, keep in mind that excessive bearing

11.4.10 INSTALLATION DAMAGE

wear can be a cause of noise by allowing the rotat-

ing member to move due to unbalance or other

BALL RING BRINELL:This type of brinelling on the

forces.

shoulders is caused by excessive thrust which pushes

the balls up on the pathway and creates a triangular

Missing balls or rollers. If one or more balls or rollers

shaped dent or “Brinell” spot at the junction of pathway

fall out of a separator, sufficient wear to the separa-

and shoulder.

tor may have occurred to indicate the need for bear-

ing replacement.

Rough rotation or “sticking” of the bearing when

rotated by hand. This test requires considerable

judgment and experience. In the case of “open”

bearings, the bearing should be cleaned and lightly

oiled before testing. A good practice is to clean it

again using a strong solvent like varnish remover,

then oil and retest. If the roughness or sticking per-

sists, discard the bearing. Ball bearings with clo-

sures cannot, of course, be washed and oiled.

These can be given the hand rotation test, repeated-

ly rotating and oscillating while applying a little axial

pressure in one direction and then the other.

We do not recommend rotating bearings by power to

check the noise characteristics. Besides the obvious

danger of damage, this test requires great experience

to determine if the bearing is faulty. As pointed out

before, all bearings have some sound level,

11-18

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

11.5

SMARTPAC MAINTENANCE AND

CARE

Store in clean dry area.

Lubricate bearings before storing.

Keep quick disconnects clean and capped.

For extended storage, spray rust preventive in tube

hole & seals.

Handle units with care; do not hit or pry the

weights.

Mount to good mold side bars and make sure bear-

ing housings are seated directly to bar and vibrator

bolts are properly torqued. DO NOT force by hitting

the bearing housing with a hammer.

Lift unit by the shaft, not by bearing housing as this

can damage the seals.

Clean quick disconnects before engaging.

Replace “O” ring in quick disconnects at least every

month or when they become worn or damaged.

10.

Never operate system pressure above 80 psi (5.5 bar).

11. Use only new clean fluid when filling the system.

Contamination will cause erratic operation.

12- Do not disassemble unit.

13. To prevent crimping of shaft, Besser recommends

the sheaves be tightened to 18 lbs ft. (27 N.M.) of

torque. Tightening over 18 lbs ft.(27 N.M.) will

cause rotary union to bind, reducing its life.

14. Never put undue pressure on rotary union fittings or

connection hose.

15. Lubricate vibrator bearing every 8 hours with 1 oz

[30 ml]. of clean high temperature synthetic grease

#114135.

16. Always have guards in place when operating vibra-

tor motors.

17. Keep system in top condition by replacing any worn

belts, sheaves, etc...

11-19

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

11.6 SLC CONTROLLER MAINTENANCE

11.6.1 PREVENTIVE MAINTENANCE

The SLC controller will give you reliable service. If a

problem should occur, the first step in the troubleshoot-

The printed circuit boards of the controller must be pro-

ing procedure is to identify the problem and its source.

tected from dirt, oil, moisture and other airborne conta-

Do this by observing your machine or process and by

minants. In order to protect these boards, the controller

monitoring the diagnostic LED indicators on the CPU,

must be installed in an enclosure suited to the environ-

Power Supply and I/O modules. By doing this, the

ment. The interior of the enclosure should be kept

source of a problem can generally be narrowed down

clean and the enclosure door should be kept closed

to the processor, wiring, or the input/output devices.

whenever possible.

To assist you in identifying the source of the controller’s

Regularly inspect your terminal connections for tight-

operation problem, we have included some trou-

ness. Loose connections may cause improper function-

bleshooting considerations including status indication,

ing of the controller or damage the components of the

trouble description, probable causes and recommend-

system.

ed action.

CAUTION: To ensure personal safety

and to guard against damaging equip-

11.6.3 DIAGNOSTIC CHECKS

ment, inspect connections with incom-

ing power OFF.

A.Battery

The SLC Controller has power supplied by a

The National Fire Protection Association (NFPA)

lithium battery. The battery is located in the

gives recommendations for electrical equipment

power supply inside the control panel. Replace

maintenance. Refer to article 70B of the NFPA for

the battery if the low battery signal activates.

general requirements regarding safety related work

See figure 11.14 (page 11-22).

practices.

B.Fuses

A burned-out fuse may cause the power supply

11.6.2 TROUBLESHOOTING

indicator light to illuminate in controller. Check

When troubleshooting, pay careful attention to these

the two fuses, located behind the lithium bat-

general warnings:

tery. The battery is located in the SLC-500 con-

trol panel. Replace burned-out fuses with new

CAUTION: Have all personnel remain

fuses. See figure 11.14 (page 11-22).

clear of the controller and equipment

when power is applied. The problem

C.Circuit breakers

may be intermittent and sudden.

A tripped circuit breaker may result for no

apparent reason. Check the circuit breakers,

Unexpected machine motion could result in injury.

located in the SLC control panel, and reset any

Have someone ready to operate an Emergency Stop

tripped circuit breakers. See figure 11.14 (page

switch in case it becomes necessary to shut off

11-22).

power to the controller equipment. Also, see NFPA

70E Part II for additional guidelines for safety related

D. Memory loss

work practices.

When the power to the panel goes off due to a

power surge, drop or a dead battery, a memory

Never reach into a machine to actuate a switch since

loss may result. The CPU fault light will illumi-

unexpected machine motion can occur and cause

nate to indicate problem. To restore the memo-

injury. Use a wooden stick. A metal rod could dam-

ry, turn the panel power OFF. Insert EPROM

age the machine and/or conduct current to the per-

into the inside of the processor. Restore the

son holding it.

power. The SLC-500 will automatically read the

EPROM into its RAM and go into RUN mode.

Remove all electrical power at the main power dis-

The CPU light will illuminate to indicate a suc-

connect switches before checking electrical connec-

cessful transfer. Turn the power OFF. Remove

tions or inputs/outputs causing machine motion.

the EPROM from the unit.

11-20

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

11.6.4 TROUBLESHOOTING TABLE GUIDE

Refer to the following log to determine the status of the LED indicators:

Indicates that LED is OFF

Indicates that LED is ILLUMINATED

Indicates that LED is FLASHING

TROUBLESHOOTING CONSIDERATION

STATUS

DESCRIPTION

PROBABLE

RECOMMENDED

INDICATORS

CAUSES

ACTION

POWER¹

Inadequate

No line power

Verify proper line voltage and connections on the

System Power

power supply.

PC RUN

Verify proper 115/230 Volt power supply jumper

CPU FAULT

placement.

FORCED I/O

Refer to Page 5-6 of the SLC manual for

placing the jumper.

BATTERY LOW

Power supply fuse

Check for proper power supply connections.

Replace fuse.

On modular SLC con-

figuration systems,

If fuse blows again, replace power supply.

you will find the

POWER LED indica-

Refer to page 8-7 of the SLC manual for fuse

tor on the rack mount-

location and replacement procedures.

ed power supply of

each rack.

Power supply

Remove line power to power supply. Remove

overloaded

several output modules from the chassis. Wait

five minutes. Reapply power.

If condition reoccurs, re-calculate module config-

uration power required and verify proper power

supply selection. See page 1-7 of the SLC

manual.

Note: This problem can occur intermittently if power

supply is slightly overloaded when output

loading and temperature varies.

Defective power

1. Recheck other probable causes.

supply

2. Monitor line power to chassis power supply for

possible transient or shorting.

3. Replace power supply

11-22

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

Refer to the following log to determine the status of the LED indicators:

Indicates that LED is OFF

Indicates that LED is ILLUMINATED

Indicates that LED is FLASHING

TROUBLESHOOTING CONSIDERATION

STATUS

DESCRIPTION

PROBABLE

RECOMMENDED

INDICATORS

CAUSES

ACTION

POWER¹

Processor not in

Either improper

Verify selected processor mode.

RUN mode

mode selected or

PC RUN

user program logic

If th eprocessor is in the Program/Test modes, attempt

Run mode entry:

CPU FAULT

- If keyswitch is in the REM position and there is no key,

use the programmer.

FORCED I/O

- If the keyswitch is in REM or PROG position, and you

have the key, toggle to the RUN position.

BATTERY LOW

If in the suspend mode, check user program logic

On modular SLC con-

for suspend instructions.

figuration systems,

you will find the

Refer to Advanced programming software manu-

POWER LED indica-

al - Publication 1747-6.4.

tor on the rack mount-

ed power supply of

Line power out of

Check proper 120/240 Volt power supply jumper

each rack.

operating range

selection and incoming power connections.

Monitor for proper line voltage at power supply

connections.

Improper seating

Remove power and inspect the power supply

of power supply

chassis connections and the CPU chassis connec-

and/or CPU in the

tions.

rack

Re-install the devices and re-apply power.

IMPORTANT - The CPU will only operate in

SLOT 0 chassis #1.

Defective CPU,

Attempt RUN mode selection using a program-

power supply or

ming device in existing chassis.

chassis

Place CPU in another chassis not in the existing

system. Apply power, reconfigure and attempt

RUN mode selection. If unsuccessful, replace

CPU.

Try existing power supply in test chassis. If

unsuccessful, replace power supply. If RUN

mode is allowed, replace the existing chassis.

11-23

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

Refer to the following log to determine the status of the LED indicators:

Indicates that LED is OFF

Indicates that LED is ILLUMINATED

Indicates that LED is FLASHING

TROUBLESHOOTING CONSIDERATION

STATUS

DESCRIPTION

PROBABLE

RECOMMENDED

INDICATORS

CAUSES

ACTION

POWER¹

System inoperable

User program

1. Monitor logic in RUN mode and verify desired I/O

no major CPU

logic error

status.

PC RUN

fault detected

2. Check for minor CPU faults.

CPU FAULT

Refer to Advanced programming software manual -

FORCED I/O

publication #1747-6.4.

BATTERY LOW

Defective I/O

1. Test inputs and outputs according to start-up pro-

Devices or I/O

cedures on page 9-27 of the SLC manual.

wiring

POWER¹

CPU fault

CPU memory

1. Cycle power.

error

PC RUN

Fault memory

1. Remove power and then remove the memory

CPU FAULT

module

module from the CPU.

FORCED I/O

2. Re-install the CPU and cycle power.

BATTERY LOW

Note: If steady CPU FLT LED changes to flashing,

replace the existing memory module with a

replacement module. Refer to chapter 5 of the

SLC manual for removing and installing mem-

ory modules.

Faulty CPU/power

1. Place the CPU in another chassis not in the exist-

supply

ing system and cycle power. If steady CPU

FAULT LED reappears, replace the CPU.

2. If CPU FAULT LED clears, monitor line power to

power supply in existing system.

3. Replace existing system power supply if line

power checks OK.

On modular SLC con-

figuration systems,

you will find the

Processor

If upgrading the CPU to a different firmware level,

POWER LED indica-

firmware installed

verify firmware chip orientation matches the

tor on the rack mount-

incorrectly

upgrade kit directions.

ed power supply of

each rack.

11-24

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

Refer to the following log to determine the status of the LED indicators:

Indicates that LED is OFF

Indicates that LED is ILLUMINATED

Indicates that LED is FLASHING

TROUBLESHOOTING CONSIDERATION

STATUS

DESCRIPTION

PROBABLE

RECOMMENDED

INDICATORS

CAUSES

ACTION

POWER¹

CPU major error

Initial CPU factory

Refer to chapter 7 of the SLC manual and follow

power-up

the start-up procedures.

PC RUN

condition.

Clear processor memory to get rid of the flashing

CPU FAULT

FLT LED.

FORCED I/O

Hardware/soft

Use programmer to monitor and clear the fault

ware major fault

(or if keyswitch in REM):

BATTERY LOW

detected.

a. Monitor status file word S:6 for major error

On modular SLC con-

Note: erratic

code.

figuration systems,

repetitive power

you will find the

cycling can cause

b. Refer to the Advanced programming software

POWER LED indica-

a CPU major

manual - Publication 1747-6.4 for error codes

tor on the rack mount-

hardware fault.

and additional troubleshooting information.

ed power supply of

each rack.

c. Remove hardware / software condition

causing fault.

d. Clear status file S:1/13 major error bits, if set.

e. Clear status file S:5 minor error bits, if set.

Clear status file S:6 major error code

(optional)

g. Attempt a CPU RUN mode entry. If unsuc-

cessful, repeat recommended action steps

above.

Use the keyswitch to clear the fault. Toggle the

keyswitch to PROG and back to RUN. (see page

9-11 of the SLC manual). If FAULT occurs again,

use programmer to get error code and determine

the source of the problem.

11-25

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

Refer to the following log to determine the status of the LED indicators:

Indicates that LED is OFF

Indicates that LED is ILLUMINATED

Indicates that LED is FLASHING

TROUBLESHOOTING CONSIDERATION

STATUS

DESCRIPTION

PROBABLE

RECOMMENDED

INDICATORS

CAUSES

ACTION

POWER¹

System does not

User forced I/O

1. Monitor program file online and identify forced

operate per

disabling

I/O.

PC RUN

ladder logic.

operation

2. Disable appropriate forces and test system condi-

CPU FAULT

tions again.

FORCED I/O

Refer to either the Hand-Held terminal program-

ming manual - Publication 1747 - 809 or the

BATTERY LOW

Advanced programming software manual -

Publication 1747-801.

POWER¹

System does not

Forces user

1. Monitor program file on-line and identify pro-

operate per

programmed are

grammed forces.

PC RUN

programmed

not enabled.

forces.

2. Enable appropriate forces and test system condi-

CPU FAULT

tions again. Once forces are enabled FORCED

I/O LED should be steady.

FORCED I/O

Refer to the Advanced programming software

BATTERY LOW

manual - Publication 1747-6.4.

POWER¹

CPU major error

Loss of RAM

1. Verify battery is connected. See pages 5-1 and

with low or NO

memory during

8-5 of the SLC manual.

PC RUN

battery back-up

power down

period

2. Replace the battery if you want RAM battery

CPU FAULT

backup. See page 8-5 of the SLC manual.

FORCED I/O

3. Refer to CPU major error recommended action

steps.

BATTERY LOW

Refer to the Advanced programming software

manual - Publication 1747-6.4.

On modular SLC configuration systems, you will find the POWER LED indicator on the rack mounted power supply of each rack.

Regardless of any other LED status indicator conditions, always replace the battery when the BATTERY LOW LED indicator is illuminated if

RAM battery back-up is desired.

11-26

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

11.7.1.3

VENTILATION

CAUTION: Before doing any kind of

maintenance or service operation, shut

To prevent pressure build-up, a breather plug is fitted

all power off and lock out machine.

on top of the housing. Take care and check regularly

Always follow the lockout procedure list-

that this breather does not become clogged.

ed in the Safety section of this manual !

11.7.1.4

OIL CHANGE

11.7.1 REDUCER MAINTENANCE

A. The first oil change has to be made after 800

The reducer must be lubricated and greased at some

hours of operation. You can reuse the removed

predetermined intervals.

oil after filtering (use a 40µm filter).

When changing oil, choose your oil according to the oil

B. Subsequently, the next oil changes have to be

grade table (see table 11.14). The new oil must also

made every 8000 hours of operation or every

have the required viscosity according to temperature

two years max.

conditions (see table 11.15).

11.7.1.5

OUTPUT SHAFT DISTANCE

11.7.1.1

OIL FILLING

You must adjust the output shaft distance, called “dis-

Fill reducer with 0.8 gallons of oil. Check the oil level

tance X” (see figure 11.20), of the reducer before start-

plug position to fill the exact amount of oil.

ing it. Adjust the output shaft to have a distance "X" of

4.133" [105mm].

11.7.1.2

OIL DRAINING

Drain oil while unit is still warm. To facilitate oil draining,

remove filler plug.

Figure 11.20DISTANCE “X”

Aral

Castrol

Chevron

Elf

Esso

Exxon

Fina

Gulf*

Mobil

Shell

Sunoco

Texaco

Total

Winter-shall

Degol

Energol

Alpha

Spartan

Reduct-

Spartan

Mobil

Sunep

Carter

Giran

Goya

Omala

Meropa

Ersolan

GR-XP

elf

lubric.

Gear

1060

220

SP 220

220

HD 220

630

ISO 220

220

*Gulf Ultima 220 for Canada

Table 11.14 OIL GRADE (EP GEAR OIL)

AMBIENT TEMPERATURE

+15⁰F

+60⁰F

-10⁰C

+15⁰C

+32⁰F

+105⁰F

0⁰C

40⁰C

ISO VG 100 (AGMA 3EP)

ISO VG 220 (AGMA 5EP)

Table 11.15 OIL VISCOSITY

11-29

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

worn-out parts. For more detailed information on the

CAUTION: Before doing any kind of

variator, please refer to the manufacturer’s manual.

maintenance or service operation, cut

all power off and lock out machine.

11.7.3.1

OIL LEVEL

Always follow the lockout procedure list-

ed in the Safety section of this manual !

Oil level must be carefully watched as frequently as

possible. Keeping the oil at the required level is very

11.7.2 CLUTCH/BRAKE UNIT MAINTENANCE

important. The appropriate oil level is:

The Power Flo model CAB-CC is a pneumatic brake

Upper Red Mark : when not in operation

such that when air pressure is applied to the clutch port

Lower Red Mark : during operation

or to the brake port, the double acting piston will move

to engage the clutch and release the brake or move to

Make a daily inspection of the oil level.

engage the brake and release the clutch, respectively.

This model is made with a female nema C-face mount-

11.7.3.2

OIL CHANGE

ing on the clutch side and a male nema C-face on the

brake side.

Suggested interval for oil change for NA type Beier

variators is 500 hours after initial operation and every

The clutch/brake requires filtered and lubricated air

2,500 hours thereafter. This is the recommendation for

pressure. Also, the following items have a limited life

normal operation. Of course, oil should be changed

and may eventually need replacing:

more frequently whenever deterioration is detected,

Friction discs

since deterioration occurs in different operation hours

O-rings

subject to brand of oil, conditions of loading and sur-

Bearings

roundings.

Note that the maximum case temperature of the

11.7.3.3

OIL SELECTION

clutch/brake unit should be 180⁰F (82⁰C).

The most important factor for the lubricant for the varia-

For more information on your clutch/brake unit and to

tor is its viscosity. When there are seasonal ambient

know how to assemble and disassemble the unit to

temperature changes, change oil periodically to meet

replace these parts, please refer to the manufacturer’s

the viscosity requirement due to the respective ambient

manual. To obtain a repair kit, spanner or fitting for the

temperature. Recommended oils to be used with Beier

unit, contact the manufacturer as indicated on the man-

variators are listed in table 11.16.

ual.

Note: For the maintenance, it is recommended that the

11.7.3 VARIATOR MAINTENANCE

maintenance records be attached to the drive.

Keep record of (1) Date of last oil change,

The SM- Beier variator unit of the block moving mecha-

(2) Brand of oil supplied, (3) Name of personnel

nism must be regularly lubricated and checked for

who did it, etc.

Recommended oils for use in NA Type variators - USE NO SUBSTITUTES

WARNING : DO NOT USE OILS CONTAINING E.P. ADDITIVES - OR AUTOMOBILE OILS

Ambient Temperature F⁰ (C⁰)

14⁰ to 32⁰

32⁰ to 95⁰

95⁰ to 122⁰

Manufacturer

(-10⁰ to 0⁰)

(0⁰ to 35⁰)

(35⁰ to 50⁰)

Gulf Oil Corp.

Harmony 46AW

Harmony 68AW

Harmony

Harmony 150AW

Harmony 220

Exxon Co.

Nuto H46

Nuto H68

100AW

Terrestic 150

Terrestic 220

Mobil Oil Corp.

Mobil DTE 25

Mobil DTE 26

Terrestic 100

Mobil DTE

Mobil DTE Hvy

Extra Heavy

Shell Oil Co.

Tellus 46

Tellus 68

Tellus 100

n.a

n.a.

Texaco Inc.

Rando 46

Rando 68

Regal R&O 100

Regal R&O 150

Regal R&O 220

Table 11.16 OIL GRADE AND VISCOSITY - NA TYPES

11-30

466361F9710US F1 29OC99

SECTION 11

MAINTENANCE

11.7.3.4

CHECK POINTS

C) Warning signals for replacement

During overhaul, examine the following compo-

During daily oil level inspection, give care to the follow-

nents carefully and replace them when the com-

ing abnormalities that may be the first signs of some

ponents show symptoms mentioned below in

faults/failures occuring in the drive.

table 11.17.

Excessive temperature rise

Feel or measure temperature on the casing.

Allowable temperature rise measured on the sur-

face of the casing is 86⁰F to 105⁰F over the ambi-

Component

Symptoms

ent temperature. Excessive temperature rise can

be attributed to various hidden causes. Please

Breakage

refer to section 11.7.3.6 (Variator troubleshooting)

Discolor due to seizure

for details.

Wear (reaching 20 microns)

Cone Discs

Flaw

Pitting/Spalling

Abnormal sound

Galling

Abnormal sound is the sign of damage or failure

of components and it varies with the kind of com-

Wear of rim

ponent damage. Please refer to section 11.7.3.6

Pitting/Spalling/

(Variator troubleshooting) for details.

Galling

Discolor due to seizure

Flange Discs

Oil leakage

Note: Slight pitting, spalling, flaw

Oil leakage arises from various causes such as

or burr can be corrected by an

worn oil seal, loose housing fit, excessive oil,

oil grind lapping stone.

faulty gasket, etc. Since oil leakage causes other

Wear

troubles, it must be quickly taken care of.

Fatigue

Bearings

Discolor

Other abnormal performance

Broken Retainer

In addition to the above signs, several other

abnormal performances may be found during

Discolor due to seizure

operation though they may occur infrequently.

Fatigue of Key and Keyseat

Spine shafts

Fatigue on spline (if wear

They are increase of power consumption, vibra-

Input Shaft with Spline

exceeds 0.1mm in depth on

tion, fluctuating output speed, inability or difficulty

spline, replace)

of change speed, etc. Please refer to section

11.7.3.6 (Variator troubleshooting) for details.

Wear

Oil seal

Loss of elasticity

11.7.3.5

MAINTENANCE OVERHAUL

Pitting

Spalling

A) Overhauling period

Gears

Discolor due to seizure

After two years of continuous operation, an entire

Flaw

maintenance overhaul is recommended. This

include disassembly of the variator and inspection

Frequent speed change

of the wear on components. Please refer to the

causes wear in the hubs on

manufacturer’s manual for details.

the casing and cover which

Casing & Cover

supports swing shaft

Creep due to wear exceed-

B) Recommended replacement parts

ing 0.1mm requires replace-

The main components, which yield to wear during

menty

operation, are cone discs, flange discs, spline

shafts, gears, bearings and oil seals. Please

Table 11.17 OIL QUANTITY

refer to the manufacturer’s manual for details.

11-31

466361F9710US F1 29OC99

BESSER DYNAPAC 3 AT A TIME (466361F9710US). OPERATION / MAINTENANCE MANUAL - page 5