CUMFLOW RP400XD ROTATING PAN MIXER PARTS

CUMFLOW RP400XD ROTATING PAN MIXER PARTS
CUMFLOW RP400XD
ROTATING PAN MIXER
PARTS
&
OPERATION MANUAL
WINGET LIMITED
PO BOX 41
EDGEFOLD INDUSTRIAL ESTATE
PLODDER LANE
BOLTON
LANCS
BL4 OLS
Tel: ++ 44 (0) 1204 854650
Fax:++ 44 (0) 1204 854663
crokersales@winget.co.uk
parts@winget.co.uk
www.winget.co.uk
INDEX
SECTION 1
GENERAL INFORMATION
1.1.
1.2.
1.3.
1.4
1.5
Company Details
Important Notice
Mixer Operational and Safety Requirements
Installation Drawing (Where applicable)
Test Certificates (Where applicable)
SECTION 2
INSTALLATION AND OPERATING INSTRUCTIONS
2.1.
2.2.
2.3.
Pre Installation Notes
Installation Instructions
Operating Instructions
SECTION 3
TECHNICAL SPECIFICATION AND MAINTENANCE
3.1.
3.2.
3.3.
3.4.
3.5.
Technical Specification
Shutdown Procedure and Maintenance
Maintenance of Mixer
Maintenance and Lubrication
Lubrication Layout
SECTION 4
MIXER SPARE PARTS
4.1.
4.2.
4.3.
4.4.
4.4.
4.5.
4.6.
4.7.
4.8.
4.9.
4.10.
4.11.
General Arrangement of Parts and Top & Bottom Structures
Pan Roller Assembly
Discharge Blade & Door Control Assembly
Discharge Door Pneumatic Cylinder
Pan Drive Assembly
Pan Assembly
Pan Door Assembly
Mixing Star Assembly
Fixed Blade Assembly
Layout of Guards
Pan Sealing Arrangement
Decals & Logo’s
SECTION 5
OPTIONAL ANCILLIARY EQUIPMENT SPARE PARTS
5.1
5.2
5.3
5.4
5.5
Arrangement of Loader Chassis Assembly
Arrangement of Loader Runway (Combined Motor, Brake & Gear Unit)
Arrangement of Winch Unit (Separate Motor, Brake & Gear Unit)
Arrangement of Loader Runway (Separate Motor, Brake & Gear Unit)
Worm Reduction Gearbox (Renold WU5)
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
Dewhurst Electromagnetic Brake
N.R. Range Electromagnetic Brake
Magnetic Brake Drum
Arrangement of Batchweigher
Arrangement of Whirler Motor Up
Arrangement of Whirler Motor Up 460Volt 3Ph 60Hz
Arrangement of Whirler
Arrangement of Whirler Split Shaft
Wire Rope Renewal Procedure
Wire Rope Safety Notes
Pneumatic Oiler (Not available on all models)
0-100 Litre Flow Meter
SECTION 6
ELECTRICAL SYSTEM
6.1
6.2
6.3
6.4
Electrical Instructions
Wiring Diagrams (Where Applicable)
Component Listing (Where Applicable)
Interlock Switch Mounting (Where Applicable)
SECTION 7
PNEUMATIC SYSTEM
7.1
7.2
Pneumatic Instructions – Shutdown Procedure
Pneumatic Circuit Layout
SECTION 8
MISCELLANEOUS
8.1
8.2
8.3
Noise
Special Pan Covers and Inlets
Miscellaneous Items
SECTION 9
ELECTRONIC LOADCELL & READOUT BOX
The contents of this handbook although correct at the time of publication, may be subject to
alteration by the manufacturers without notice and Winget Limited can accept no responsibility for
any errors or omissions contained within the following pages. Nor can we accept any liability
whatsoever arising from the use of this manual howsoever caused.
Winget Limited operate a policy of continuous product development. Therefore, some illustrations
or text within this publication may differ from your machine
Winget Limited can accept no responsibility for incorrectly supplied spare parts unless the part
number and a full description of the items required is given when the order is placed.
NOTE
Imperial fixings (bolts, setscrews, nuts, washers etc) have been progressively changed to Metric. If
in doubt as to whether you have a Metric or Imperial fixing please order the metric items listed, i.e.
bolt or set screw and associated or flat and spring washers to replace the existing items.
OPERATING
AND
MAINTENANCE MANUAL
SECTION 1
GENERAL INFORMATION
COMPANY DETAILS AND GENERAL INFORMATION
For any spares or service work, please contact:Winget Limited
P.O. Box 41
Edgefold Industrial Estate
Plodder Lane
Bolton
Lancs U.K.
BL4 OLS
Telephone No:
Facsimile No:
‘E Mail’
++ 44 (0)1204 854650
++ 44 (0)1204 854663
crokersales@winget.co.uk
parts@winget.co.uk
ORDERING SPARES
To help us to complete your order promptly and correctly we need:• Machine type and serial number
• Description and quantity of parts required
• The full address to which the parts are to be sent
Winget Limited can accept no responsibility for incorrectly supplied spare parts unless the
part number and a full description of the items required is given when the order is placed.
IMPORTANT NOTICE
The CUMFLOW RP400XD is a high performance mixer
The following precautions are necessary to obtain the best results and to avoid
damage to the MIXING STAR and PAN DRIVE
ENSURE TRANSIT BAR AND RING ARE REMOVED FROM DOOR
BEFORE STARTING MACHINE.
AGGREGATES
Strict control of graded aggregates must be maintained
Maximum size 19mm
Oversize lumps of aggregate or rogue materials must be prevented from
entering the Pan
MIXING STAR BLADES
They are to a special shape and material to prolong wear life. They should not
be modified in any way and only replaced with GENUINE ‘CROKER’ spares
Obtained from WINGET LIMITED.
A daily check is advisable to ensure that the Blades/Wearing parts are secure
and undamaged.
PAN RIM & BASE WEARING PLATES
They must be replaced before excessive wear causes distortion.
MAXIMUM BATCH LOADS
UNDER NO CIRCUMSTANCES should the Maximum Batch Loads quoted
be exceeded nor should the mixer be or re-started when there is a mix in the
Pan
MIXING PAN
Ensure that the Mixing Pan is rotating concentrically and that the pan base is
Rotating in horizontal place, otherwise damage may occur to the door
mechanics.
WARNING
THE MANUFACTURER ACCEPTS NO RESPOSIBILITY FOR ANY
DAMAGE OR FAILURE RESULTING FROM OPERATIONAL
MISUSE OR MALPRACTICE. ANY MODIFICATIONS TO THE
MACHINE WILL AFFECT ITS WORKING PARAMETERS AND
SAFETY FACTORS. REFER TO THE MANUFACTURERS BEFORE
FITTING ANY NON STANDARD EQUIPMENT OR PARTS.
THE MANUFACTURERS ACCEPT NO RESPONSIBILITY FOR ANY
MODIFICATIONS MADE AFTER THE MACHINE HAS LEFT THE
FACTORY, UNLESS PREVIOUSLY AGREED IN WRITING. THE
MANUFACTURERS WILL ACCEPT NO LIABILITY FOR DAMAGE
TO PROPERTY, PERSONNEL OR THE MACHINE IF FAILURE IS
BROUGHT ABOUT DUE TO SUCH MODIFICATIONS, OR THE
FITMENT OF SPURIOUS PARTS.
RP400XD
OPERATIONAL AND SAFETY
REQUIREMENTS
PRE-DELIVERY
1.1
Drive coupling alignments, pan and star meshing of pan rack and drive gear.
1.2
Operating clearances star blade to pan. Fixed blade to pan wall.
1.3
Discharge blade to pan base.
1.4
Rollers to register ring.
1.5
Correct oil level in gearboxes. All grease points charged. Gear teeth greased.
1.6
Air system tested.
1.7
Door operation and seating.
1.8
No load test. Correct rotations.
PRE INSTALLATION
2.1
Check consignment.
2.2
Offload equipment using certified lifting gear of suitable capacity, by a competent
person (see separate chart for nett weight).
INSTALLATION
3.1
Refer to contract arrangement and site instructions.
3.2
Mixer to be mounted on supports of adequate strength and rigidity to prevent undue
vibration when mixing and securely bolted.
3.3
Mixer frame to be level on structure, add packers as required.
3.4
Check that pan is correctly seated on Rollers and that pan rack and drive gear are in
correct mesh.
3.5
Check locating rollers to register ring.
3.6
Check operating clearances star blade to pan. Fixed blade to pan wall. Discharge
blade to pan base. See maintenance section Ops Manual.
ELECTRICAL SERVICES
4.1
Refer to wiring diagrams in Section 6. All wiring to be undertaken by competent
electrician.
4.2
Refer to pneumatic circuit diagram in Section 7. Connect compressor. Supply
compressed air 5.5 bars as required (80psi).
4.3
Refer to wiring diagram in Section 6 when connecting air control valves.
4.4
Remove transit bar and ring from door BEFORE starting mixer.
4.5
Ensure starters are mounted away from mixer on supports free of vibration.
4.6
Ensure starters are fitted with correct overloads – see technical specification power
units.
OPERATION
5.1
Correct oil level, gearboxes. Air line lubricator.
5.2
Mixing pan clear of loose nuts and bolts to prevent damage to fingers and blades.
5.3
Check correct rotation – mixing star – anti clockwise; mixing pan – anti clockwise.
All when viewed from the top.
5.4
Discharge door and blade correct operation.
5.5
Blade operating clearances adjust in line with maintenance instructions.
5.6
Never exceed manufacturer’s maximum capacity as detailed in specification.
SHUTDOWN
6.1
Prior to any work being carried out mixer to be isolated and physically locked off.
Recommended equipment double key exchange system.
6.2
Follow procedure detailed in company and users’ Health and Safety Policy at
all times.
6.2
Ensure all storage bins containing materials to be mixed are isolated.
6.3
Shut off water supply and drain off water tank or flowmeter
MAINTENANCE
7.1
Ensure that all maintenance is carried out in accordance with the Parts and
Operating manuals and proprietary manufacturer’s specific instruction.
7.2
Isolate electrical and other services to the mixer as section 6 above.
7.3
Service at recommended intervals.
7.4
Use Croker manufactured replacement parts supplied by WINGET LIMITED.
GENERAL
8.1
Under no circumstances should the Maximum Batch Loads be exceeded by
either weight and volume as stated in Technical Specification.
8.2
Mixer star blades to be checked daily for damage.
8.3
Pan rim and base wearing plates must be replaced before excessive wear causes
distortion.
8.4
Ensure mixing pan is rotating concentrically and pan base is rotating in
horizontal plane.
8.5
Mixer must not be stopped and started when there is mix in the pan.
8.6
Refer to Contract Drawing for scope of supply. Site instruction notes outlining
weights etc.
8.7
Refer to Method Statement when installation and commissioning is
responsibility of Winget Limited.
Nett Weights Max (kgs)
9.1
RP50XD
RP100XD
RP200XD
RP400XD
RP550XD
RP850XD
788
814
1400
2000
2150
2600
RP1250XD
RP1500XD
RP3000XD
FP1000
FP1500
FP2000
4840
4980
7112
4040
4065
4100
9.2
Refer to technical specification for nett weights of ancillary equipment.
9.3
Refer to contract drawing for nett weights of ancillary equipment.
Miscellaneous
10.1 Noise measured in accordance with Directive 79/113 EEC 85LPA.
RP400XD GENERAL ARRANGEMENT BASIC MACHINE
RP400XD GENERAL ARRANGEMENT WITH LOADER
RP400XD ARRANGEMENT OF BOTTOM DISCHARGE
LOADING HOPPER
RP400XD GENERAL ARRANGEMENT-PLANT
OPERATING
AND
MAINTENANCE MANUAL
SECTION 2
INSTALLATION AND OPERATING
INSTRUCTIONS
PRE-INSTALLATION
On arrival of the equipment it is advisable to check that all packages listed on
the consignment note have been received.
The equipment must be offloaded using certified lifting gear of suitable
capacity, by a competent person.
When unloading the mixer, care must be taken to ensure the discharge chute
remains clear of obstructions as the chute and door hang below the chassis.
An outline drawing and bolt hold plan is normally sent prior to the despatch of
the machine and will enable preparations to be made for the installation. With
the `picture` of what the machine will look like when it is assembled, the
ancillary equipment dismantled for transport can easily be identified.
INSTALLATION
Please refer to contract arrangement and site instructions as applicable.
It is recommended that a concrete foundation (to take foundation bolts – not
supplied) should be provided for each leg of the support structure and runway
when fitted. When the machine is supplied without a support structure it
should be mounted on supports of sufficient strength and rigidity to prevent
undue vibration when the machine is working. When making provision for a
loading hopper pit it is strongly recommended that the pit is concreted out so
that it can easily be kept clean and free from any build up which could prevent
the bottom limit switch from operating correctly.
Before completing the installation, check that the main mixer frame is level
with a spirit level. Packings should be inserted as required under the structure
legs or main frame. The packings under the mixing pan roller brackets are set
during manufacturing and must not be disturbed under any circumstances.
Check that the pan is seated and that the pan rack and drive gear are in mesh..
Also check that all the blade clearances are in line with the maintenance
instructions. It is essential that the machine is level and all rollers are in contact
with the pan roller track, if any of the rollers fail to revolve the trouble is
usually found to be uneven foundations.
On connecting to the power supply, the wiring diagram must be referred to.
A check that the wiring is correct is rotation of the following:• The mixing pan and mixing star rotate anti-clockwise when looking from
the top.
• The loader winch rotates anti-clockwise looking from the rope drum end
when the raise button is pressed.
• The whirler unit rotates clockwise when looking from the top.
It is advisable to mount the starters away from the machine on supports free
from vibration. Ensure that the starters are fitted with suitable overloads – see
technical specification – power units.
A simple Water Flow Meter is available as an option to the water tank, this has
a range of 0-100 litres and features an adjustable flow indicator with a reset
facility allowing very accurate measurement of water flow irrespective of the
pressure. The Flow Meter is normally fitted with a manual ‘on/off’ valve and is
protected by a washable in line strainer.
A supply of compressed air at 5.5 bars is required. The inlet for the connection
from the air line is tapped ½” B.S.P. A drop in pressure will cause incorrect
operation of the pneumatic system.
OPERATING THE MACHINE
Before starting production the following points should checked:(1)
That there is oil in (a)
(b)
(c)
(d)
the Star Drive Gearbox
the Pan Drive Gearbox
the Loader Winch Gearbox (when fitted)
the Air Line lubricator
(2)
The Mixing pan should be clear of loose nuts, bolts, spanners etc., as
these will damage the fingers and blades.
(3)
Check that the Discharge Door and Discharge Blade are operating
correctly.
(4)
Check that the blade clearances are correct and if necessary adjust, in line
with the maintenance instructions.
(5)
Check that the limit switches on the loader stop the Loading Hopper in
the required positions at the top and bottom of the runway and that the
magnetic brake is applied.
(6)
Check that the Water tank is set to the required amount and is filling up
to this level. (See later page for further information on Water Tank
operation, where fitted).
(7)
If a Flow Meter is fitted check that the pointer is reset to zero and the
strainer is clean and free from debris.
(8)
When Weigh Gear is fitted check that the setting arrangements and any
lubrication requirements have been carried out. .
IMPORTANT:
The CUMFLOW is a high performance Mixer.
The following precautions are necessary to obtain the best results and to avoid
damage to the Mixing Star and Drive.
AGGREGATES:
Strict control of graded aggregates must be maintained. Maximum Size 19mm.
Oversize lumps of aggregate or rogue material must be prevented from entering
the Pan.
MIXING STAR BLADES:
They are of a special shape and material to prolong wear life. They should not
be modified in any way and only replaced by genuine ‘WINGET CROKER’
spares.
A daily check is advisable to ensure that the Blades/Wearing Pieces are
securely bolted and undamaged.
PAN RIM & BASE WEARING PLATES:
They must be replaced before excessive wear causes distortion.
MAXIMUM BATCH LOADS:
Under no circumstances should the Maximum Batch Loads quoted be
exceeded nor should the Mixer be stopped and re-started when there is a mix in
the Pan.
After each mix the contents of the pan must be completely discharged before
attempting to close the discharge door. At the end of each period of operation
the mixing pan, mixing blades, discharge blade and fingers, discharge chute,
discharge door and seating must be washed down to prevent concrete setting on
them and so impairing the efficiency of the machine.
WARNING:
THE MAUFACTURER ACCEPTS NO RESPONSIBILITY FOR ANY
DAMAGE OR FAILURE RESULTING FROM OPERATIONAL MISUSE OR MALPRACTICE.
OPERATING INSTRUCTIONS FOR WEIGH GEAR
MECHANISM
HYDROSTATIC LOADCELL & GAUGE
The Hydrostatic Load Cell is connected by a flexible capillary tube (approx 9.7
metres long) to a 300mm (12”) diameter weigh gauge.
The whole system is assembled and filled with fluid under vacuum and under
no circumstances should any of the components be disconnected, in the event
of component damage the complete assembly should be returned to Winget
Limited for repair.
The system is factory calibrated and any variation between the calculated tare
and the actual tare recorded can be corrected by means of the tare adjustment
knob on the side of the gauge.
With no load acting on the loadcell the pointer will be below zero, this is to
accommodate the weight of the hopper. When the hopper is placed on to the
loadcell the pointer will register zero. Final zero adjustment can be made via
the zero adjustment knob on the side of the gauge housing.
ELECTRONIC LOADCELL & GAUGE
The electronic Loadcell & Gauge consists of an electrically operated loadcell
mounted on the weigher frame and connected to a remote mounted digital
readout control box. The connecting lead should be protected from damage
and the readout box mounted such that it is not affected by vibrations etc. The
mounting instructions detailed within Section 9 of this manual should be
followed to avoid excess vibrations damaging the control box. Section 9 also
contains detailed advice on setting up, obtaining zero and operation of the
loadcell and readout box and should be referred to before the equipment is
operated.
NOTE THE FOLLOWING WIRING CONNECTIONS
+ Excite RED
- Excite BLUE
+ Signal GREEN
- Signal YELLOW
OPERATING INSTRUCTIONS FOR 0-100 LITRE
WATER FLOWMETER
The simple manually operated 0-100 litre Water Flow Meter is available as an
option to the water tank and is normally mounted on the side of the mixer
feeding directly into the pan. The meter is normally fitted with 1” hose tail
connectors but different sizes of water inlet connections to suit various hose
diameters are also available. The meter is normally provided with a simple
‘on/off’ valve and inline filter/strainer mounted next to but down stream of the
flowmeter.
OPERATION
On a daily basis before use the strainer should be removed and checked for
debris and obstructions, cleaned and refitted. Ensure the on/off valve is in the
‘off ‘ position and turn on the main water supply. Set the adjustable pointer on
the dial face via the central knob to the required amount of water. Check the
indicator reads zero, if not operate the reset lever on the side of the meter which
will reset the indicator. Turn the on/off valve slowly to the ‘on’ position
watching the movement of the indicator around the dial, when the indicator
reaches the pointer sharply turn valve to the ‘off ‘ position. The indicator will
register the amount of water delivered. Operate the reset lever to bring the
indicator back to zero and repeat the operation for each batch of material
mixed.
When shutting down the mixer either at night or at the end of each shift it is
recommended that the main water supply to the flow meter and ‘on/off’ valve
is shut off.
If it is expected that the overnight temperatures will drop to or close to freezing
it is recommended that the Flow Meter, Valve, Filter and Pipework are drained
to prevent damage.
OPERATING THE MIXER
SAFETY NOTES
Never operate the mixer unless you have read and fully understand the contents
of the Operators Manual If you are in doubt as to any aspect of the equipments
operation contact the manufacturer for guidance
Never operate the mixer whilst wearing loose fitting clothing
Never reach inside the Pan whilst it is rotating
Never operate any equipment unless you have received adequate training
Cement, certain other minerals and organic compounds can cause skin irritation
leading to Dermatitis. Always use Personal Protective Equipment i.e. gloves etc
to protect the skin from direct contact. If in any doubt about the materials being
used consult your employers COSHH manual
Wear Eye protection to protect your eyes from dust and liquid splashes
Do not attempt to remove the pan single handedly, (RP50/100) obtain
assistance, use the Pan Trolley (if provided) or use suitable lifting equipment
Do not operate the mixer with any of the guards removed, safety devices or
interlocks disconnected. They are there to offer you some protection, ensure
they are correctly maintained
Carry out the daily maintenance before operating the mixer and report defects
to your supervisors
Oils, Greases and Lubricants are skin irritants and prolonged direct skin contact
can cause skin cancer. PPE or barrier creams should be used when carrying out
maintenance work, wash your hands on completion
Always dispose of waste oils and lubricants in a proper manner, it is illegal to
pour it down drains or bury it. Contact your local authority for a list of
authorised disposal sites
Always disconnect the power supply at the mains before carrying out any
maintenance work or cleaning the equipment down. Do not turn on the power
until everything has dried out
Do not allow waste from the wash down process to enter the public drainage
system unless it has been properly filtered.
Decals and Instruction Plates are attached to the equipment to warn against
hazards and assist in the safe operation of the equipment, if damaged or defaced
they should always be replaced.
It is likely that clutch and/or brake linings may contain asbestos and suitable
precautions should be taken to avoid breathing in the dust, protective clothing
should be worn. Hands should be washed immediately after handling
components and old discarded parts or linings should be disposed of in a
responsible manner in line with local or national regulations covering the
disposal of asbestos waste.
OPERATING
AND
MAINTENANCE MANUAL
SECTION 3
TECHNICAL SPECIFICATION
AND MAINTENANCE
TECHNICAL SPECIFICATION OF CUMFLOW RP400XD
CAPACITIES:
Maximum Batch Capacity
by Weight 610 kgs
by Volume 400 litres
Nominal Output (Based on 2.42kg/lt)
254 litres
Nominal Output (Based on 2.162kg/lt)
282 litres
Hourly Output @ 40/50/60 batches per/hr 11m3/13.75m316.5m3
BATCHLOADER CAPACITY
576 kg
AGGREGATES:
Maximum Aggregate Size
19 mm
MIXER FRAME:
Strongly constructed from welded Steel Channel
MIXING PAN:
Steel Base Pan mounted on three wide track rollers with central
discharge door. Pan Rim, Base and Discharge Door fitted with
renewable Wearing Plates.
MIXING STAR:
Fitted with 3 Spring loaded Star Blades, two at Pan floor level and
one for high level mixing.
FIXED BLADE:
Spring loaded pan side scraper assembly. Reversible when worn
DISCHARGE BLADE: Pneumatically operated in conjunction with the Discharge Door.
WHIRLER:
Intermittent blades mounted on vertical shaft.
POWER UNITS:
Mixing Star)
Mixing Pan)
Loader Motor (where fitted)
Whirler Motor (where fitted)
DRIVES
Mixing Pan
Mixing Star
Whirler
SPEEDS
Speed of Pan
Speed of Mixing Star
Speed of Loading Hopper
Speed of Whirler
5.5 kw
2.2 kw
4.0kw
7.5 kw
Gear unit with pinion and cast rack
Gear unit directly mounted
Vee Rope Drive
FREE AIR CONSUMPTION (PER BATCH 80 PSI)
WEIGHTS (UNLADEN) Without Loader
With Loader (approx)
12 rpm
56 rpm
21 metres/min
720 rpm
33.0 litres
2000 kg
2816 kg
ELECTRICS
Motor Voltage
Control Voltage
MACHINE SAFETY DIRECTIVE
All Gears are suitably guarded.
415V 3ph 50hz
Option 60 hz
110V
MAINTENANCE
IMPORTANT
ALWAYS ENSURE APPARATUS IS ISOLATED FROM MAINS SUPPLY
BEFORE COMMENCING MAINTENANCE.
SHUTDOWN PROCEDURE
Prior to any work being carried out the apparatus is to be isolated and physically locked off.
We recommend a double key exchange system.
Safe access to equipment with one access door and one control point.
Supply Locked
Off Key Free
Supply on
Key Trapped
Door Locked
Key Trapped
Door Open
Key Trapped
Equipment Stopped Supply
Locked Off Access Door
Open
Equipment Working Supply
On Access Door Locked
Supply Locked Off Key
Free
Follow the procedures detailed in your Health and Safety Policy at all times.
Ensure all storage bins containing materials to be mixed are isolated.
Shut down the water supply and drain off any water tanks or flowmeter fitted
MAINTENANCE OF MIXER
IMPORTANT NOTE:
Ensure that all maintenance is carried out in accordance with the Parts and Operating
Manual and Proprietary Manufacturer’s specific instruction.
PROCEDURE
1
ISOLATE ELECTRICAL, PNEUMATIC AND OTHER SERVICES TO THE
MIXER (see separate section).
2
Service at recommended intervals.
3
Use Croker manufactured replacement parts available from WINGET LIMITED.
4
Ensure all safety guards and interlocks are reinstated prior to operating the mixer.
5
Main items of wear (see Section 4).
A)
B)
C)
D)
Star Blades
Fixed Blade
Discharge Blade
Whirler Blades
Access to mixing pan internals is via the safety interlocks. Each of the above are
bolted components and are replaced by simple method and usually achieved in situ
without dismantling other components.
E)
Pan base and rim wearing plates are also bolted construction and can be
replaced in situ. However, pan covers will need to be dismantled to provide the
necessary access.
F)
Other items prone to less wear are star blade fingers, lower whirler shaft
assembly and mixing star. Each can be replaced again in situ but pan covers
would require dismantling to provide necessary access.
G)
Pan rollers can be adjusted to accommodate wear during operation. These can
be replaced when required in situ using jacking method to support pan and
provide the necessary access.
MAINTENANCE AND LUBRICATION
DAILY:
Using Total Multis EP2 Grease 2 (or equivalent) grease the following points:-
Discharge Blade Lifting Gear Brackets
Air Cylinder Lever Pivot Holder
Mixing Blade Finger Bearings
Fixed Blade Finger Bearsring
Discharge Blade Control Rod (Top)
Discharge Blade Control Rod (Bottom)
Discharge Blade Lifting Lever (Centre)
Discharge Blade Lifting Links
Loading Hopper Rollers
Pan Drive Plummer Bearings
Loader Rollers (Where fitted)
Whirler (Where Fitted)
2 Points
1 Point
3 Points
1 Point
1 Point
1 Point
1 Point
2 Points
2 Points
2 Points
4 Points
2 Points
Inspect and top-up if necessary:Air Line Lubricator
Use Total Azolla 27 (or equivalent)
or suitable Pneumatic Tool Oil.
WEEKLY: Inspect and top up if necessary:(1)
Star Drive Gearbox (Capacities Approximate)
RENOLD UNITS
FLENDER UNITS
SEVER UNITS
(2)
Cap 5.6 litres. Use Total Carter EP320
or Shell Omala 320 or equivalent.
Cap 13.0 litres. Use Total Carter EP220
or Shell Omala 220 or equivalent.
Cap 13.0 litres. Use Total Carter EP220
or Shell Omala 220 or equivalent.
Pan Drive Gear Box Capacities Approximate)
RENOLD UNITS
Cap 0.85 litres approx Renold Pan
Drives must be run on a Synthetic not a
Mineral oil. Use Total Carter EPHT320
or Total Carter SY320 or Mobil
Synthetic SHC632 or equivalent Synthetic
Oils. Different synthetic oils will not mix
with each other so the Gearbox must
always be drained and flushed prior to
topping up or refilling with oil.
(3)
FLENDER UNITS
Cap 1.1 litres approx. Flender Pan Drives
must be run on a Synthetic not a Mineral
Oil. Use Total Carter EPHT460 or Total
Carter SY460 or Tribol 800 iso460 or
B.P. Eersin SG-XP460 or equivalent
Synthetic oils. The different Synthetic
Oils will not mix with each other so the
Gearbox must always be drained and
flushed prior to topping up or refilling
with oil.
SEVER UNITS
Cap 2.0 litres approx. Sever Pan Drives
must be run on a Synthetic not a Mineral
Oil. Use Total Carter EPHT460 or Total
Carter SY460 or Tribol 800 ISO460 or
B.P. Eersyn SG-XP460 or Castrol
Alphasyn PG680 or equivalent
synthetic oils. The different synthetic
oils will not mix with each other so the
Gearbox must always be drained and
flushed prior to topping up or refilling
with oil.
Loader Winch Reduction Gearbox
(Renold WU5)
Loader Winch Gearbox (Flender)
Cap 4 litres. Use Total Carter EP320,
Total Carter EPHT320 or Total Carter
SY320 (or equivalent). Carter EPHT
and SY320 are Synthetic Oils which
will not mix with either Mineral Oils or
other makes of Synthetic Oils. If in
doubt drain and flush the gearbox
before topping up.
Cap 5.5 litres. Use Total Carter
EPHT460 or Total Carter SY460 or BP
Enersyn SG-XP460 or equivalent.
These are Synthetic Oils and will not
mix with either Mineral Oils or other
makes of Synthetic Oils. If in doubt
drain and flush the gearbox before
topping up.
Inspect and Adjust
(1)
Pan Gear and Pinion – Apply Open Gear Lubricant (or equivalent) as required.
(2)
Adjust Star Blades, Fixed Blades and Discharge Blade to the following settings, also
make sure that Blade fingers are free in their bearings and that the springs are clear of
obstructions.
Mixing Blade:
(3 mm) clear of pan base. Adjust by moving the blade down
its finger.
Discharge Blade:
Just touching pan base when finger bridge is resting on stop
sleeves. Adjust by moving bridge up or down fingers.
Fixed Blade:
(3 mm) clear of pan base and just touching pan rim.
Adjust by moving hinge brackets along its slots and
blade up or down its fingers. Re-set spring to 100 mm
overall length after setting blade.
(3)
After the first week’s running the Whirler Vee Belt Drive will need adjustment to take
up initial wear and stretch. At the correct tension it should be just possible to twist
each belt through 90o when gripped between finger and thumb midway between
pulleys.
(4)
Loading Hopper Wire Rope – clean off grit etc. and inspect for broken strands. Clean
and apply a suitable wire rope dressing.
500 HOUR MAINTENANCE FOR PAN AND STAR DRIVE GEAR UNITS
After 500 running tours, the Gearboxes should be drained and thoroughly flushed with a
light flushing oil and refilled with new oil of the correct grade listed below. It is advisable to
drain, flush and refill with new oil after every 12 months, or more often if operating
conditions are severe.
To fill the Gearboxes, remove the oil level plug and the filler breather plug and pour in oil
until it flows from the level hole. Replace the plugs making sure that the vent holes in the
filler breather plug are clear. Refer to the following notes.
RENOLD UNITS
Capacity of Star Gearbox: (approximate)
5.6 litres
Use Total Carter EP320 or Shell Omala 320 or equivalent
Capacity of Pan Gearbox: (approximate)
0.85 litres
The Renold Pan Drives must be run on a synthetic oil not a mineral. Use Total Carter
EPHT320 or Total Carter SY320 or Mobil SHC632 (Synthetic Oils). The different synthetic
oils will not mix with each other so the gearbox must be drained and flushed prior to
topping up or refilling with oil.
FLENDER UNITS
Capacity of Star Gearbox (approximate)
13.0 Litres
Use Total Carter EP220 or Shell Omala 220 or equivalent.
Capacity of Pan Gearbox (approximate)
1.1 Litres
The Flender Pan Drives must be run on a synthetic oil not a mineral. Use Total Carter
EPHT460 or Total Carter SY460 or Tribol 800-ISO460 or B.P. Enersyn SG-XP460
(Synthetic Oils). The different synthetic oils will not mix with each other so the gearbox
must be drained and flushed prior to topping up or refilling with oil.
SEVER UNITS
Capacity of Star Gearbox (approximate)
13.0 Litres
Use Total Carter EP220 or Shell Omala 220 or equivalent.
Capacity of Pan Gearbox (approximate)
2.0 Litres
The Sever Pan Drives must be run on a synthetic oil not a mineral. Use Total Carter
EPHT460 or Total Carter SY460 or Tribol 800 iso460 or B.P. Enersin SG-XP460 or
Castrol Alphasyn PG680 or equivalent synthetic oil. The different synthetic oils will not mix
with each other so the gearbox must be drained and flushed prior to topping up or refilling
with oil.
MONTHLY:
Inspect:
(1)
All blades for wear – replace when worn.
(2)
Pan rim, base and door wear plates – replace when worn
(3)
Pan Roller Bearings – replace if necessary
(4)
Pan Door Bearing – replace if necessary
(5)
Pneumatic system for leaks – repair or replace damaged parts.
(6)
Pneumatic Cylinders. Make sure that the door cylinder piston rod is at
the end of its travel when the discharge door is just home in its seating.
(7)
Check the S.H. bushing securing the Mixing Star and Pan Drive to their
respective gearbox shafts are tight. Torque setting 34 nm.
CAUTION:
BEFORE WORKING UNDER LOADING HOPPER, REST
HOPPER ON SAFETY BOLTS. DO NOT FORGET TO REMOVE
THESE BOLTS BEFORE RE-STARTING THE MACHINE
Loader Magnetic Brake (see below for N.R. Range brake units.) – adjust
if necessary, to the following instuctions (these instructions apply only if
a separate brake unit is fitted, refer to the manufacturer if a combined
motor and brake unit is fitted):Mounting:
Set the brake so that the horizontal centre-line of the shoe corresponds
with the centre-line of the brake wheel shaft and the shoe pivots are
equally spaced from the vertical centre-line.
Installing:
Slacken back equalising screw (Item 14) Slack nut (Item 5) and adjust
screw (Item 3) to give required braking torque.
WARNING:
The end of the adjusting screw (Item 3) must always be visible in the hole at the end
of the adjusting nut (Item 6).
Set nuts (Item 5) so that contact is made with the load spring block in the shoe lever
when solenoid plunger has moved through half its stoke. Once properly set, this
setting should not be altered. With solenoid plunger right down, set equalising screw
(Item 14) to give equal friction lining clearances.
Tighten locknuts (Item 5 & Item 14) and be sure that the load spring bracket is in
place.
Check adjustments frequently and lubricate brake shoe pivots. To adjust for wear,
screw in adjusting screw (Item 3) until the adjusting nuts are clear and only touch
lever (Item 1) when plunger is depressed through half its stroke.
When new Brake Linings are fitted, repeat all adjustments. Refer to notes on safe
handling and disposal of Asbestos waste and Brake Dust.
Orders and enquiries should always state full description of parts required together
with the make and model of brake and motor. The serial number on the brake should
always be quoted and when ordering replacement brake shoes give the dimensions
and number of rivet holes.
Check that the limit switch on the loader stops the hopper in the required position at
the top of the runway.
When operated the limit switch should stop the motor and apply the magnetic brake
unit.
If a Batch Weigher is not to be used in conjunction with the Loader, then the skip
track must be extended and a lower limit switch and hopper stops incorporated.
The loading hopper must operate the lower limit switch before the hopper stops are
reached and allowance made for the rope to slacken once the hopper is in the loading
position.
NR Range Loader Magnetic Brakes – adjust if necessary, to the
following instructions :-
MOUNTING
(1)
Release the spring pressure completely by unscrewing the torque screw H, in most
cases the brake can now be slipped over and off the brake drum. If the brake cannot
be slipped off the drum due to the proximity of equipment i.e. motors etc, the plain
arm can be removed by taking out the pivot pin K and withdrawing the arm from the
base. It may be necessary to remove the top rod.
(2)
Set the brake unit in position on the bed plate, insert the fixing bolts and screw down
finger tight.
(3)
If previously removed replace the plain arm, rod and pivot pin. With the brake base
resting evenly on the bed plate tighten up the torque screw H until the brake drum is
gripped tightly by the shoes.
(4)
Tighten down the fixing setscrews or bolts and set the brake arm shoe stop screws
Against the shoes to prevent them dropping in the released condition.
WIRING
A 3/4” screwed conduit entry is situated in each side of the base of the armature
housing to accommodate the wiring to the terminals, it is essential that the conduit or
lead in be flexible.
SETTING UP
(1)
Adjust and lock the torque screw H so that only 3mm (1/8”) of further adjustment is
available to compensate for any reduction in torque due to any wear of the brake
linings.
(2)
Remove cover A and with no current flowing set gap E, indicated on the brake label,
by adjusting the handwheel or alternatively the screw B. Replace the cover.
(3)
Adjust the setscrew D so that both shoes lift equally when the brake is energised.
(4)
When required the brake can be released manually by applying pressure to the release
device F, using a suitable lever
MAINTENANCE AND SERVICE
NOTE, until it is obvious that the friction surfaces have bedded down completely,
gap E should be should be carefully checked at frequent intervals. The length of this
period will depend on the frequency of the operation of the brake. After this period
normal maintenance only will be required. The only lubrication required is an
occasional light application to the armature spindle bearing through the holes
provided.
COIL REPLACEMENT
Isolate the electrical supply. Remove the armature cover A and disconnect the coil
leads. Slacken the top rod adjustments by rotating the handwheel or alternatively the
screw B anti-clockwise. Remove the e-clips on the armature spindle J and withdraw
the spindle, lift out the armature G. Remove the eight nuts at C and withdraw the coil.
Replace the coil and the nuts ensuring the positioning of the inner nuts prevents
distortion of the coil flange when the outer nuts are tightened. Refit the armature,
spindle and e-clips, reset the gap E as previously described and reconnect the leads.
Replace the cover.
BRAKE LINING REPLACEMENT
Isolate the electrical supply. Release the torque spring pressure by unscrewing the
torque screw N. Remove the shoe spindle and rotate the shoe around the drum by
approximately 90’ in an upward movement and withdraw. Fit new linings and
reassemble. Reset as previously described under setting.
WARNING
It is likely that the Brake Lining may contain asbestos and suitable precautions
should be taken to avoid breathing in the dust, protective clothing should be
worn. Hands should be washed immediately after handling components and old
discarded parts or linings should be disposed of in a responsible manner in line
with local or national regulations covering the disposal of asbestos waste.
ANNUALLY:
LOADER WORM REDUCTION GEAR UNIT RENOLD WU5
Drain and clean out the gear case and refill with Total Carter EP320, Total Carter
EPHT320 or Total Carter SY320 or equivalent. (EPHT and SY320 are Synthetic
Oils). Mineral and Synthetic oils and are incompatible and will not mix, neither will
different makes of Synthetic Oils. If in doubt thoroughly flush out the unit prior to
refilling. When running conditions are severe the oil should be changed more
frequently. (Capacities – 8.5 Imperial Pints: 4.0 Litres: 1.5 American Gallons).
LOADER WINCH GEAR BOX (FLENDER)
Drain and clean out the gear case and refill with Total Carter EPHT460 or Total
Carter SY460 or ICI Tribol 800-ISO460 or BP Enersyn SG-XP460 or equivalent.
These are Synthetic Oils, Mineral and Synthetic Oils are incompatible and will not
mix, neither will different makes of Synthetic Oils. If indoubt thoroughly flush out the
unit prior to refilling. When running conditions are severe this procedure should be
adopted more frequently. (Approximate Capacity – 11.6 Imperial Pints: 5.5 litres:
1.45 American Gallons)
NOTE
Electrical cables particularly those with copper conductors suffer from a
condition known as ‘relaxation’ which may cause wiring to work loose over a
period of time, it is recommended that the tightness of wiring connections and
terminals are checked following the first month in service.
LUBRICATION CHART
OPERATING
AND
MAINTENANCE MANUAL
SECTION 4
MIXER SPARE PARTS
RP400XD GENERAL ARRANGEMENT
RP400XD GENERAL ARRANGEMENT
1
2
3
4
5
6
7
8
9
10
11
11
12
12
13
14
15
16
17
18
19
20
21
22
23
23A
24
24A
25
26
27
29
35
36
42
46
46A
CR09100202
CR08100174
CR09100178
CR09100200
CR09100222
CR26100157
CR26100163
CR26100164
CR21100151
CR54100152
CR54100153
CR54100153SS
CR54100154
CR54100154SS
CR46100155
CR52100156
CR51100203
CR53100219
CR53100218
CR23100220
CR46100224
CR269280
CR269281
CR532016
CR299084
CR29100626
CR299085
CR29100625
CR159012
CR189004
CR329074
57S05D2
11S06H
8S06H
7S06
267S09
17S08
Discharge Blade Assembly
Arrangement of Mixing Star
Discharge Door Assembly
Fixed Blade Assembly
Pan Roller Assembly
Chassis
Top Structure
Top Structure Support
Pan Rack
Pan Rim
Pan Rim Wear Plate, Mild Steel
Pan Rim Wear Plate, Stainless Steel
Pan Base Wear Plate, Mild Steel
Pan Base Wear Plate, Stainless Steel
Bevel Pinion
Pan Drive Shaft
Discharge Chute
Packing
Packing
Pan Drive Shaft Coupling
Scraper Shovel Pinion
Guard (Door Cylinder)
Guard (Door Cylinder)
Weldable Stops Roller Spindles, Bearings Etc.
Pan Drive Gear Unit (FLENDER) 50Hz
Pan Drive Gear Unit USA/CAN Spec 60Hz
Mixing Star Gear Unit (FLENDER) 50Hz
Mixing Star Gear Unit USA/CAN Spec 60Hz
Bearing Pillow Block
SH Centre Bushing
Parallel Key
Screw Grub M8 x 10
Screw Set M16 x 50
Bolt M16 x 60
Nut M16
Washer Flat M16
Washer Spring M16
50
51
52
CR54100432
CR53100639
CR53100437
Discharge Blade Guard
Forklift Support Channel (Not Illustrated)
Extension Feet (Not Illustrated)
1
1
1
1
3
1
1
4
1
1
3
3
4
4
1
1
1
A/R
A/R
1
1
1
1
8
1
1
1
1
2
1
1
1
32
12
44
44
44
1
2
4
RP400XD PAN ROLLER ASSEMBLY
RP400XD PAN ROLLER ARRANGEMENT
1
2
3
4
5
6
7
8
9
10
11
12
CR52100216
CR21100217
88S17C
88S13C
228S11
267S12
44S16J
CR532016
105S07
8S06R
267S09
61S06
Pan Roller Spindle
Pan Roller
Bearing
Bearing
Hex Castle Nut
Flat Washer M24
Split Pin
Stop Roller Spindle, Not Illustrated
Washer Tapered, Not Illustrated
Bolt M16 X 120, Not Illustrated
Washer Flat M16, Not Illustrated
Nut Binx M16, Not Illustrated
4
4
4
4
4
4
4
8
8
8
8
8
RP400XD DISCHARGE BLADE ASSEMBLY
RP400XD DISCHARGE BLADE ASSEMBLY
1
2
2
3
3
3
3
4
5
6
7
8
9
10
10
11
12
13
14
15
16
17
18
19
20
30A
21
22
23
24
24A
24B
24C
24D
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
39A
40
CR26100170
CR52100171
CR52100171SS
CR540650
CR54100172
CR54100172H
CR54100172SS
CR52100173
CR26100175
CR53100176
CR26100177
CR26100189
CR52100201
CR53100194
CR53100194SS
CR53100192
CR26100191
CR53100190
CR541854
CR53100197
CR53100198
CR52100044
CR52100195
CR52100196
CR110298
CR110325
CR630075
CR520441
CR159013
CR030072
CR140004
CR140005
CR241648
CR241657
CR539103
CR159011
44S16J
267S12
11S02C
17S03
CR579003
52S05N
7S05
17S06
8S05K
105S05
11S06H
7S06
267S09
17S08
105S07
Finger Bracket
Discharge Blade Finger,Mild Steel
Discharge Blade Finger, Stainless Steel
Discharge Blade, obsolete use item 3 below
Discharge Blade, Mild Steel
Discharge Blade, Wear Resistant Steel
Discharge Blade, Stainless Steel
Bridge Hinge
Finger Bridge
Blade Lifting Link
Lifting Lever
Lever Bracket
Discharge Door Shaft
Wiper Seal Housing, Mild Steel
Wiper Seal Housing, Stainless Steel
Discharge Door Shaft Lever
Lever Pivot Holder
Cylinder Pivot Holder
Air Cylinder Bracket
Air Cylinder Lever
Stop Pipe
Pin
Hinge Pin
Locking Pin
Air Cylinder
Seal Kit Air Cylinder
Spacer
Clevis Pin
Bearing
Control Rod
L.H. Ball Joint
R.H. Ball Joint
Checknut - R.H. Thread 3/8" B.S.P.
Checknut - L.H. Thread 3/8" B.S.P.
Packer Plate Adaptor
Bearing
Split Pin
Washer Flat M24
Screw Set M6 x 25
Washer Spring M6
Wiper Seal
Screw C/Sunk M12 x 65
Nut M12
Washer Spring M12
Bolt M12 x 70
Washer Tapered M12
Screw Set M16 x 50
Nut M16
Washer Flat M16
Washer Spring M16
Washer Tapered M16
1
2
2
1
1
1
1
1
2
1
1
1
4
4
1
1
1
1
1
2
1
3
3
1
1
2
1
2
1
1
1
1
1
2
4
2
1
16
16
4
4
8
8
4
4
11
11
11
11
7
RP400XD DISCHARGE BLADE ASSEMBLY
41
42
43
43A
44
45
46
47
48
48A
49
49A
50
51
52
7S08
267S12
7S08
56S08
44S18P
CR329002
57S05D2
10S41
131S01
176S01
CR280008
176S01
7S07
267S10
56S07
Nut M24
Washer Flat M24
Nut M24
Nut Lock Thin M24
Split Pin
Key Parallel
Screw Grub M8 x 10
Washer Flat 1"
Grease Nipple 1/8" Straight
Cover Nipple Grease
Grease Nipple 1/4" 45' Angle
Cover Nipple Grease
Nut M20
Washer Flat M20
Nut Thin M20
2
2
1
1
5
2
3
2
3
3
1
1
4
4
2
RP400XD DISCHARGE DOOR AIR CYLINDER
RP400XD DISCHARGE DOOR AIR CYLINDER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
CR110298
CR110325
CR110336
CR110337
CR110338
CR110339
CR110340
CR110342
CR110349
CR110344
CR110343
CR110346
CR110341
CR110347
CR110348
CR110345
Air Cylinder Assembly Complete
Seal Kit for above
Bearing Assembly
Piston Rod Packing
Front End Cover Assembly
Cushion Seal
Cushion SealRetaining Ring
Rear End Cover Assembly
Rear Clevis Mounting
Tie Rod
Tie Rod Nut
Piston Seal
Piston & Piston Rod Assembly
Barrel
O' Ring
Wiper Seal
1
1
1
1
1
2
2
1
1
4
8
2
1
1
2
1
RP400XD PAN DRIVE ASSEMBLY
RP400XD PAN DRIVE ASSEMBLY
2
3
6
7
8
9
10
10A
10B
10C
11
11A
12
13
14
15
16
17
18
19
20
21
CR52100156
CR46100155
CR159012
CR532016
CR189004
CR23100220
*CR299084
*
*
CR29100626
CR329074
57S05D2
8S05H
267S07
105S05
61S05
8S06H
267S09
105S07
61S6
CR53100218
CR53100219
Pan Drve Shaft
Bevel Pinion
Bearing Plummer Block
Bearing Stop
SH Centre Bushing, Taper Lock
Flexible Coupling Assembly
*Pan Drive Gearbox Flender 2.2kw
*Pan Drive Gearbox Renold 2.2kw
*Pan Drive Gearbox Sever UK Spec
*Pan Drive Gearbox USA/CAN Spec 60Hz
Key Parallel
Screw Grub M8 x 10
Bolt M12 x 50
Washer Flat M12
Washer Tapered M12
Nut Binx M12
Bolt M16 x 50
Washer Flat M16
Washer Tapered M16
Nut Binx M16
Packing Large Hole (not illustrated)
Packing Small Hole (not illustrated)
*Quote Make & Model of motor/gearbox when ordering spares for this item
1
1
2
4
1
1
1
1
1
1
2
2
4
8
4
12
4
8
4
4
A/R
A/R
RP400XD MIXING PAN ASSEMBLY
RP400XD PAN ASSEMBLY
1
2
3
3
3
4
4
4
5
5
6
7
7A
8
9
10
11
12
13
14
15
CR21100151
CR54100152
CR54100153
CR54100153H
CR54100153SS
CR54100154
CR54100154H
CR54100154SS
CR54100154
CR54100154SS
52S03E
52S06N
52S06R
11S05F
52S06AG
7S03
61S05
7S06
17S04
267S07
17S08
Pan Rack
Pan Rim
Pan Rim Wear Plates, Mild Steel
Pan Rim Wear Plates, Wear Resistant Steel
Pan Rim Wear Plates, Stainless Steel
Pan Base Wear Plates, Mild Steel
Pan Base Wear Plates, Wear Resistant Steel
Pan Base Wear Plates, Stainless Steel
Door Seat, Mild Steel
Door Seat, Stainless Steel
Pan Rim Wear C/Sunk Screws M8 x 25
Pan Base Wear Plate C/Sunk Screws M16 x 65
Pan Base Wear Plate C/Sunk Screws M16 x 80
Pan Rim Hex Set Screws M12 x 40
Pan Door Seating C/Sunk Screws M16 x 85
Nut M8
Nut Binx M12
Nut M16
Washer Spring M8
Washer Flat M12
Washer Spring M16
1
1
3
3
3
4
4
4
1
1
24
8
8
12
8
24
12
24
24
12
24
RP400XD DISCHARGE DOOR ASSEMBLY
RP400XD DISCHARGE DOOR ARRANGEMENT
1
2
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
CR21100179
CR21100180
CR21100180SS
CR21100181
CR52100182
CR630387A
CR630387B
CR570017
CR210093
CR49100187
CR540451
CR150423
CR150347
11S05E
52S06AG
7S06
7S08
56S08
17S06
17S08
97S15
Door, Mild Steel
Door Seating, Mild Steel
Door Seating, Stainless Steel
Door Lever
Spindle
Thrust Washer
Distance Piece
Rubber Seal
Bottom Cover
Bottom Cover Washer
Nut Cover
Bearing
Bearing Thrust
Screw Set M12 x 35
C/sunk Screw M16 x 85
Nut M16
Nut M24
Nut Lock Thin M24
Spring Washer M12
Spring Washer M16
Clip Hose
1
1
1
1
1
1
1
1
1
1
1
1
1
4
8
8
1
1
4
8
1
RP400XD MIXING STAR ASSEMBLY
RP400XD MIXING STAR ARRANGEMENT
1
1
2
3
3
4
5
5A
5B
5B
5B
6
6A
6B
7
8
9
10
11
12
13
14
15
16
17
19
20
CR26100161
CR26100161SS
CR189008
CR26100162
CR26100162SS
CR330062
CR210007
CR210007P
CR210035
CR21100015
CR21100015SS
CR210123
CR21100169
CR21100262
CR26100166
CR63100167
CR189009
8S04N
11S06M
8S06Q
52S05L
61S04
61S05
7S06
267S07
17S08
CR280008
Mixing Star, Mild Steel
Mixing Star, Stainless Steel
Bush Oilite
Star Blade Finger inc Lever, Mild Steel
Star Blade Finger inc Lever, Stainless Steel
Spring
Star Blade (Less Wearing Plate)
Star Blade Polyurethane (Alternative)
Star Blade Cast, obsolete use item 5B below
Star Blade, Cast, replaces CR210035
Star Blade, Stainless Steel, alternative to cast CR21100015
Blade Wearing Plate (Obsolete use Item 6A Below)
Blade Wearing Plate
Blade Wearing Plate (Alternative to Item 6B)
Lever, part of item 3 not supplied separately
Collar
SH Star Shaft Centre Bushing
Bolt M10 x 90
Screw Set M16 x 70
Bolt M16 x 110
C/Sunk Screw M12 x 55
Nut Binx M10
Nut Binx M12
Nut M16
Washer Flat M12
Washer Spring M16
Grease Nipple 1/4" B.S.P. 45' Angle
1
1
6
3
3
3
3
3
3
3
3
3
3
1
3
6
3
6
3
6
9
6
6
3
RP400XD FIXED BLADE ASSEMBLY
RP400XD FIXED BLADE ASSEMBLY
1
2
3
4
4
5
6
6
7
7
8
9
10
11
12
13
14
15
16
16A
17
18
19
20
CR210102
CR660008
CR330063
CR53100199
CR53100199SS
CR63100159
CR530491
CR530491SS
CR530490
CR530490H
CR530490SS
8S04K
11S06M
8S05M
52S05H
61S04
7S05
7S06
17S06
CR289002
176S01
8S06J
267S09
17S08
7S06
Fixed Blade Spring Box
Star Finger Bush
Spring
Fixed Blade Finger and Lever, Mild Steel
Fixed Blade Finger and Lever, Stainless Steel
Collar
Fixed Blade Angle, Mild Steel
Fixed Blade Angle, Stainless Steel
Fixed Blade, Mild Steel
Fixed Blade, Wear Resistant Steel
Fixed Blade, Stainless Steel
Bolt M10 x 70
Screw Set M16 x 70
Bolt M12 x 80
C/Sink Screw M12 x 40
Nut Binx M10
Nut M12
Nut M16
Washer Spring M12
Grease Nipple 1/4" B.S.P. 90' Angle
Cover Nipple Grease
Bolt M16 x 65
Washer Flat M16
Washer Spring M16
Nut M16
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
4
1
4
1
1
2
4
2
2
RP400XD PANELS & GUARDS
RP400XD PANELS AND GUARDS
1
2
3
4
5
6
7
8
9
10
11
11A
12
13
14
15
16
17
CR54100204
CR54100205
CR54100206
CR54100207
CR54100208
CR54100209
CR54100210
CR54100211
CR26100212
CR242141
CR499017
267S05
CR53100214
CR54100203
11S04D
267S06
17S05
7S04
Pan Guard
Pan Guard
Pan Guard
Side Guard
Rear Guard
Top Guard
Splash Guard
Bottom Guard
Pan Guard Top Support
Screw Set M8 x 16
Washer Spring M8
Washer Flat M8
Support Angle
Discharge Chute (Not Illustrated)
Srew Set M10 x 30 (Not Illustrated)
Washer Flat M10 (Not Illustrated)
Washer Spring M10 (Not Illustrated)
Nut M10 (Not Illustrated)
1
1
1
2
1
1
1
1
1
40
40
40
2
1
4
8
4
4
RP400XD PAN SEALING EARLY VERSION
RP400XD PAN SEALING STRIP (EARLY TYPE)
1
2
3
4
5
6
CR479005
CR539124
CR529035
8S03C
61S03
267S05
Pan Sealing Rubber
Holding Plate
Spacer
Bolt M8 x 35
Nut Binx M8
Washer Flat M8
4
4
16
16
16
16
RP400XD DECALS AND LOGOS
1
CROKER CUMFLOW RP400XD
9
2
10
4
5
11
6
12
7
13
14
8
RP400XD DECALS AND LOGOS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
CR85100765
V2003037
101S05D
V2003039
V2003665
V2003598
V2004307
V2004223
V2004229
V2004744
504694600
513331600
CR85100771
CR85100772
Decal RP400XD
Plate Serial Number
Rivet Pop
Decal WINGET Medium
Decal Sling Point
Decal British Made
Decal Electrical Hazard
Decal CE Mark
Decal Operators Handbook
Decal Eye Protection
Decal Safety
Decal Danger
Decal Batch Loader Guarding
Decal Pan Guarding
3
1
4
3
4
3
5
1
3
3
3
8
2
2
INTENTIONALLY BLANK PAGE
INTENTIONALLY BLANK PAGE
INTENTIONALLY BLANK PAGE
OPERATING
AND
MAINTENANCE MANUAL
SECTION 5
OPTIONAL ANCILLARY EQUIPMENT
SPARE PARTS
RP400XD LOADER CHASSIS ASSEMBLY
RP400XD LOADER CHASSIS ASSEMBLY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
CR549002
CR269108
CR269109
CR539088
CR539089
CR539090
CR539091
CR26100312
CR26100313
CR53100314
CR53100288
CR532191
CR532244
CR532245
Bedplate Winch Unit
Runway, Loader R.H.
Runway, Loader L.H.
Support Angle, Winch Unit Bedplate
Channel Bedplate Support
Brace Diagonal
Brace Horizontal
Tie Beam, Long
Tie Beam, Short
Channel, Runway Support
Lower Tie Bracket
Plummer Block Bearing Support Angle
Cleat Bracing Support Bracket
Bracing Angle Support Bracket
1
1
1
2
1
1
3
1
1
2
2
1
2
2
16
17
18
18A
19
20
21
22
22A
22B
22C
23A
23B
24
8S05B
8S05C
52S05G
52S05K
7S05
17S06
267S07
8S06F
17S08
267S09
7S06
CR531003691
CR531003692
CR53100368
Bolt M12 x 30
Bolt M12 x 35
Bolt C/Sunk M12 x 35
Bolt C/Sunk M12 x 50
Nut M12
Washer Spring M12
Washer Flat M12
Bolt M16 x 50
Washer Spring M16
Washer Flat M16
Nut M16
Guide Rail L.H.
Guide Rail R.H.
Packing, Guide Rail
8
28
28
2
66
66
66
10
10
10
10
2
2
4
RP400XD LOADER C/W COMBINED MOTOR, BRAKE & GEAR UNIT
RP400XD LOADER C/W COMBINED MOTOR,
BRAKE & GEAR UNIT
1
2
3
4
5
5A
5B
5C
6
6A
6B
7
7A
7B
8
8A
9
10
11
11
12
13
14
14A
14B
15
15A
15B
15C
16
17
18
19
20
21
22
22A
22B
22C
22D
23
24
24A
24B
24C
25
26
27
CR239020
CR210191
CR520416
CR299102
8S07K
267S10
61S07
CR520143A
8S05L
61S05
CR520143C
8S05L
61S05
CR630209
57S05D2
CR210192
CR530896
CR21100121
CR210157
CR243033
CR530692
CR260769
8S05L
61S05
CR091036
7S05
8S05L
61S05
CR540756
CR089028
CR530968
CR530450
CR261502
CR220005
CR220100
CR229083
8S01D
17S02
7S01
CR150884
CR620006
11S02B
17S03
7S02
CR320020
333104020
CR600005
Chassis Assembly, See Separate Page
Rigid Couping c/w Taper Lock Bushes 1 x 60mm, 1 x 2"
Rope Drum
Rope Drum Shaft
Combined Motor Brake & Gear Unit Assembly
Bolt M20 x 70
Washer Flat M20
Nut Binx M20
Axle Top
Bolt Axle M12 x 75
Nut Binx M12
Axle Lower
Bolt Axle M12 x 75
Nut Binx M12
Axle Collar
Screw Grub
Rope Pulley
Taper Roller
Flanged Roller (Obsolete Use Item Below)
Flanged Roller
Anchor Bolt
Rope Retaining Block
Hopper Rope Guide
Bolt M12 x 75
Nut Binx M12
Hopper Rope Guide
Nut M12
Bolt M12 x 75
Nut Binx M12
Loading Hopper
Hopper Stop Wedge
Hopper Stop Pin (See Note)
Limit Switch Plate
Limit Switch Striker Plate
Limit Switch (Obsolete Use Item 22A Below)
Limit Switch Arm (Obsolete Use Item 22A Below)
Limit Switch
Limit Switch Securing Bolts (For CR229083) M5 x 40
Washer Spring M5
Nut M5
Bearing Plummer Block
Caution Plate
Screw Set M6 x 20
Washer Spring
Nut M6
Gib Head Key
Grease Nipple 1/4" B.S.P.
Chain (See Note)
* Items 18 & 27 can be purchased as assembly CR530062
1
1
2
1
1
4
4
4
1
2
2
1
2
2
2
2
2
2
2
6
1
2
2
2
2
2
2
4
1
2
2
1
1
1
4
4
4
1
2
8
8
8
2
4
2
RP400XD LOADER C/W COMBINED MOTOR,
BRAKE & GEAR UNIT
28
29
30
31
31A
32
33
34
35
36
37
38
39
40
40A
41
42
43
43
CR329053
CR329002
8S05D
8S06G
267S09
52S04G
52S05H
7S04
7S05
17S08
17S05
17S06
7S06
105S05
267S07
10S43
44S17K
CR531003691
CR531003692
Parallel Key
Parallel Key
Bolt M12 x 40
Bolt M16 x 55
Washer Flat M16
Screw Set C/Sunk M10 x 35
Screw Set C/Sunk M12 x 40
Nut M10
Nut M12
Washer Spring M16
Spring Washer M10
Spring Washer M12
Nut M16
Tapered Washer M12
Washer Flat M12
Washer Flat Axle Shaft
Pin Split
Guide Rail LH (Not illustrated)
Guide Rail RH (Not illustrated)
1
1
2
2
2
3
2
3
2
2
3
4
2
2
2
2
2
1
1
RP400XD WINCH UNIT, SEPARATE MOTOR, BRAKE & GEAR UNIT
RP400XD LOADER WINCH SEPARATE MOTOR, BRAKE & GEAR
UNIT
1
2
3
4
5
6
7
8
9
10
11
12
13
13A
14
15
16
17
18
19
20
21
22
23
24
25
*
*
*
8S05L
7S05
267S07
17S06
CR539021
CR530893
8S05B
11S05C
8S04E
7S04
17S05
52S04F
CR540522
CR549002
CR539020
8S06J
7S06
17S08
267S09
CR679000
CR320020
CR239004
CR540537
CR550114
CR210188
CR229014
CR220074
CR551423
CR551424
Bolt M12 x 75
Nut M12
Washer Flat M12
Spring Washer M12
Packing
Packing
Bolt M12 x 30
Bolt M12 x 25
Bolt M10 x 45
Nut M10
Spring Washer M10
Bolt Csk Skt Head M12 x 30
Hoisting Unit Bedplate, Obsolete see item 13A
Hoisting Unit Bedplate, Replaces item 13
Packing Reduction Unit
Bolt M16 x 65
Nut M16
Spring Washer M16
Washer Flat M16
Reduction Gear Renold WU5
Key Gib Head 9/16" x 5" Long
Reduction Gear Coupling RM30 c/w Taperlock Bus
Magnetic Brake Guard
Dewhurst 6" Diameter Magnetic Brake
Drum, Magnetic Brake Assembly, See Separate Page
4 KW Electric Motor D132M
Coil
}
Brake Lining Kit c/w screws} Used with Item 23
Brake Lining Screws
}
* Not illustrated
If the Brake Unit fitted to your machine is not a 'Dewhurst' unit please quote make,
model and serial number when ordering replacement parts or brake shoes or brake
assembly
4
14
6
14
4
4
6
2
4
4
4
2
1
4
4
4
4
4
1
1
1
1
1
1
1
1 set
12
RP400XD LOADER C/W SEPARATE MOTOR, BRAKE & GEAR UNIT
RP400XD LOADER C/W SEPARATE MOTOR,
BRAKE & GEAR UNIT
1
2
3
4
5
5A
5B
5C
6
6A
6B
7
7A
7B
8
8A
9
10
11
11
12
13
14
14A
14B
15
15A
15B
15C
16
17
18
19
20
21
22
22A
22B
22C
22D
23
24
24A
24B
24C
25
26
27
CR230112
CR210191
CR520416
CR520143A
8S05L
61S05
CR520143C
8S05L
61S05
CR630209
57S05D2
CR210192
CR530896
CR21100121
CR210157
CR243033
CR530692
CR260769
8S05L
61S05
CR091036
7S05
8S05L
61S05
CR540756
CR089028
CR530968
CR530450
CR261502
CR220005
CR220100
CR229083
8S01D
17S02
7S01
CR150884
CR620006
52S02D
17S03
7S02
CR320020
333104020
CR600005
Chassis Assembly, See Separate Page
Rigid Couping c/w Taper Lock Bushes RM30
Rope Drum
Rope Drum Shaft
Motor, Electric see Winch Unit on separate page
Reduction Unit Renold WU5, see Winch Unit on sep page
Brake Assembly, see Winch Unit on separate page
Brake Guard, see Winch Unit on separate page
Axle Top
Bolt Axle M12 x 75
Nut Binx M12
Axle Lower
Bolt Axle M12 x 75
Nut Binx M12
Axle Collar
Screw Grub
Rope Pulley
Taper Roller
Flanged Roller (Obsolete Use Item Below)
Flanged Roller
Anchor Bolt
Rope Retaining Block
Hopper Rope Guide
Bolt M12 x 75
Nut Binx M12
Hopper Rope Guide
Nut M12
Bolt M12 x 75
Nut Binx M12
Loading Hopper
Hopper Stop Wedge
Hopper Stop Pin (See Note)
Limit Switch Plate
Limit Switch Striker Plate
Limit Switch (Obsolete Use Item 22A Below)
Limit Switch Arm (Obsolete Use Item 22A Below)
Limit Switch
Limit Switch Securing Bolts (For CR229083) M5 x 40
Washer Spring M5
Nut M5
Bearing Plummer Block
Caution Plate
Screw Set C/Sunk M6 x 20
Washer Spring
Nut M6
Gib Head Key
Grease Nipple 1/4" B.S.P.
Chain (See Note)
* Items 18 & 27 can be purchased as assembly CR530062
1
1
2
1
1
2
2
1
2
2
2
2
2
2
2
6
1
2
2
2
2
2
2
4
1
2
2
1
1
1
4
4
4
1
2
8
8
8
2
4
2
RP400XD LOADER C/W SEPARATE MOTOR,
BRAKE & GEAR UNIT
28
29
30
31
31A
32
33
34
35
36
37
38
39
40
40A
41
42
43
44
CR329053
CR329002
8S05D
8S06G
267S09
52S04G
52S05H
7S04
7S05
17S08
17S05
17S06
7S06
105S05
267S07
10S43
44S17K
CR531003691
CR531003692
Key Parallel
Key Parallel
Bolt M12 x 40
Bolt M16 x 55
Washer Flat M16
Screw Set C/Sunk M10 x 35
Screw Set C/Sunk M12 x 40
Nut M10
Nut M12
Washer Spring M16
Spring Washer M10
Spring Washer M12
Nut M16
Tapered Washer M12
Washer Flat M12
Washer Flat Axle Shaft
Pin Split
Guide Rail LH (Not illustrated)
Guide Rail RH (Not illustrated)
1
1
2
2
2
3
2
3
2
2
3
4
2
2
2
2
2
1
1
RP400XD WORM REDUCTION GEARBOX RENOLD WU5
RP400XD WORM REDUCTION GEARBOX (RENOLD WU5)
*
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
CR679000
CR679001
CR679002
CR679003
CR679004
CR679005
CR679006
CR679007
CR679008
CR679009
CR679010
CR679011
CR679012
CR679013
CR679014
CR679015
CR679016
CR679017
CR679018
CR679019
CR679020
CR679021
CR679022
CR679023
CR679024
CR679025
CR679026
CR679027
Gearbox Complete (Renold WU5)
Gear Case
Worm Shaft End Cover
Worm Shaft End Cover Screw
Joint Flange Bolts
Joint Boss Bolts
Filler Plug and Washer
Worm Shaft Shims
Worm Shaft Oil Seals
Worm Shaft
Oil Level Plug and Washer
Worm Shaft Bearing
Wheel Shaft Blank End Cover
End Cover Screws
Wheel Shaft Shims
Oil Collector Boxes
Oil Collector Box Screws
Worm Wheel
Wheel Shaft Key
Wheel Shaft Distance Piece
Wheel Shaft End Cover
Wheel Shaft Bearing
Wheel Shaft Oil Seal
Wheel Shaft
Oil Drain Plugs
Fan
Fan Guard
Oil Seal Fan End
Identify gearbox Make & Model before ordering parts
1
1
2
12
4
4
1
as reqd.
1
1
2
2
1
12
as reqd.
2
4
1
1
2
1
2
1
1
2
1
1
1
SEPARATE BRAKE UNITS ONLY
WHEN ORDERING SPARES FOR BRAKE UNIT ALWAYS
QUOTE MAKE & MODEL. WHEN ORDERING
REPLACEMENT BRAKE SHOES QUOTE SIZE AND NUMBER
OF RIVET HOLES
RP400XD DEWHURST ELECTROMAGNETIC BRAKE ASSEMBLY
RP400XD DEWHURST ELECTROMAGNETIC BRAKE UNIT
SEPARATE BRAKE UNITS ONLY
1
2
3
CR550114
CR220074
CR551423
CR551424
Brake Unit Complete Dewhurst 6" Diameter
Electric Coil
Brake Linings & Rivets
Brake Shoes Retaining Screws
It is not possible to supply other major parts as separate items. If any other items are required
it will be necessary to replace the complete brake assembly.This is due to the number of
brake units fitted over the years from different manufacturers and the diffilculties encountered
identifying the different types. When ordering spares please quote the voltage, make, model
and if possible the serial number together with a full description of the part required. When
ordering replacement brake linings please give the physical dimensions together with the
number of rivet holes required.
1
1
1 SET
12
WHEN ORDERING SPARES FOR BRAKE UNIT ALWAYS
QUOTE MAKE & MODEL. WHEN ORDERING
REPLACEMENT BRAKE SHOES QUOTE SIZE AND NUMBER
OF RIVET HOLES
SEPARATE BRAKE UNITS ONLY
RP400XD N.R. RANGE ELECTROMAGNETIC BRAKE
RP400XD NR RANGE ELECTROMAGNETIC BRAKE UNIT
SEPARATE BRAKE UNITS ONLY
1
2
3
4
5
6
7
8
CR550115
CR550116
CR550117
CR550118
CR550119
CR550120
CR550121
CR551022
CR550123
Brake unit complete
Electric Coil
Brake Linings & Rivets
Brake Shoes
Torque Spring
Magnet Unit (Less Coil)
Magnet Carrier Arm (Less Shoe)
Plain Arm (Less Shoe)
Base
It is not possible to supply other major parts as separate items. If any other items are required
it will be necessary to replace the complete brake assembly.This is due to the number of
brake units fitted over the years from different manufacturers and the diffilculties encountered
identifying the different types. When ordering spares please quote the voltage, make, model
and if possible the serial number together with a full description of the part required. When
ordering replacement brake linings please give the physical dimensions together with the
number of rivet holes required.
1
1
1 SET
2
1
1
1
1
1
RP400XD MAGNETIC BRAKE DRUM
RP400XD MAGNETIC BRAKE DRUM
1
2
3
4
5
6
7
8
9
10
11
CR520154
41S05
2S04
CR210188
CR230010
CR320058
CR230011
41S04
2S03
CR230112
CR320011
Magnetic Brake Drum Pins
Spring Washer 3/8"
Nut 3/8" B.S.F.
Magnetic Brake Drum
Magnetic Brake Flexible Disc
Key Gib Head 10 X 8 X 60mm
Magnetic Brake Coupling Pin
Spring Washer 5/16"
Nut 5/16" B.S.F
Magnetic Brake Coupling
Key Gib Head 3/8"
3
3
3
1
1
1
3
3
3
1
1
RP400XD BATCHWEIGHER
RP400XD WEIGHBATCHER ASSEMBLY
1
2
3
4
5
6
7
8
9
10
11
12
12
13
14
15
16
17
18
19
20
21
CR091039
CR150921
8S05G
7S05
17S06
105S05
CR091039F
CR261504
52S05F
8S05B
CR091040J
CR220005
CR229083
CR532203
CR261508
CR091040
8S05F
8S05M
8S05J
CR261505
CR179002
CR179003
Weighbatcher Support Frame Assembly
Bearing Plummer Block, 1.25" Bore
Bolt M12 x 55
Nut M12
Washer Spring M12
Washer Tapered M12
Bearing Plate & Stop, Welded to item 1
Runway Supports LH & RH
Bolt Csk Hd M12 x 30
Bolt M12 x 30
Hopper Stops LH & RH, Welded to item 15
Limit Switch, Obsolete use item 12 Below
Limit Switch, CA12-G
Support Plate Limit Switch
Weighbridge, RP400 Standard 4' 2.25" Long
Runway Assembly c/w item 11
Bolt M12 x 50
Bolt M12 x 80
Bolt M12 x 65
Parallel Shaft Units
Hydraulic Loadcell & Gauge Assembly 0-1000Kg Range
Mountings, Anti Side Load
1
8
8
50
50
8
4
1PR
4
22
1PR
1
1
1
1
4
4
4
2
1
INTENTIONALLY BLANK PAGE
RP400XD WHIRLER ASSEMBLY
1
2
3
4
5
6
7
8
9
10
11
11
11
11
11
11
11A
11A
12
13
14
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
CR520520
CR261471
CR532110
CR532111
CR532109
CR569014
CR569016
CR150701
CR150538
52S05F
CR219006
CR219006SS
CR219006SSA
CR219006H
CR219006AH
CR219017
CR219007
CR219007SS
CR539005
11S05F
17S06
CR539044
CR220156
CR269165
CR349006
CR349011
CR349006
CR349002
CR169005
CR091013
CR329001
CR329000
11S05M
7S05
131S01
176S01
CR269147
Whirler Shaft
Bearing Housing
Bearing Cap
Bearing Cap
Spacer Top
Lipseal
Lipseal
Bearing
Bearing
S/Sunk Screw M12 x 30
Whirler Blade Square, Mild Steel
Whirler Blade Square, Stainless Steel
Whirler Blade Square, Stainless Steel, Angled
Whirler Blade Square, Tungsten Carbide Coated
Whirler Blade Square, Tungsten Carbide Coated, Angled
Whirler Blade, Two Blades, Tungsten Carbide Coated
Blade Round, Mild Steel
Blade Round, Stainless Steel
Retaining Washer
Screw Set M12 x 40
Washer Spring M12
Sleeve
Motor Electric
Bracket
Pulley 'V' Belt
Bush Fenner Taperlock
Pulley 'V' Belt
Bush Fenner Taperlock
Belt ''V'
Belt Guard
Key Parallel
Key Parallel
Screw Set M12 x 70
Nut M12
Nipple Grease Straight
Cover Nipple Grease
Support Whirler Motor
1
1
1
1
1
1
1
1
1
6
3
3
3
3
3
A/R
1
1
1
1
3
1
1
1
1
1
1
1
2
1
1
1
2
2
2
2
1
INTENTIONALLY BLANK PAGE
CROKER LOADER
WIRE ROPE RENEWAL PROCEDURE
1.
Place the Hopper on the hopper stops. Loosen nut from rope anchor bolt,
item 1, on one rope drum only, item 2.
2.
Remove end of old wire rope from anchor bolt.
3.
Fit end of new wire rope to anchor bolt and tighten nut.
4.
Lay other end of new wire rope end to end with old wire rope removed in
part 2. Bind both ends together with sticky tape (electrical or masking
tape).
5.
Carefully pull on the old wire rope to pull the new wire down to the
bottom of the hopper and around the rear axle rope pulley, item 3, and up
through the front axle rope guide, item 4.
6.
Remove front axle rope retainer blocks, items 5 and 6, and slide onto the
new rope.
7.
Continue to pull the wire and thread through the second rope guide, item
7, and down around the second rope pulley, item 8, and up to the second
rope drum, item 9.
8.
Remove old wire from second anchor bolt, item 10, on second rope
drum, item 9, and remove tape from ends of old and new wire.
9.
Fit second end of new wire to second anchor bolt, item 10, on second
rope drum, item 9.
10.
Tighten anchor bolt nuts on both rope drums.
11.
The new wire should now run over the front edges of both rope drums
and down to front edges of both the lower axle rope pulleys, items 3 and
8, and up the back of the rope pulleys to the rope guides, items 4 and 7,
with both rope retainer blocks, items 5 and 6, located on the section of
wire rope between the two rope guides at the back of the hopper.
12.
Start and stop the loader by hand, using the start and stop buttons, and
take out all the slack of the wire rope in the raise direction (see important
note on page 30), ensuring that the wire slots into both axle rope pulleys,
item 2 and 9, and that the wire has wound evenly onto both rope drums.
Make sure the hopper is level and sitting on weigher track stops before
positioning rope retainer blocks, items 5 and 6, approximately 2 inches
(50 mm) in board of rope guides, item 4 and 7, each side and make fast
retainer blocks onto wire.
13.
Check that both limit switches are working correctly and the magnetic
brake applies correctly.
14.
Make sure hopper clears both sides of rope drums at the top of its
operation.
NOTE: Hopper reaches end of travel between rope drums.
IMPORTANT NOTE
Ensure that the slack wire is taken up in the raise direction and not the lowering
direction. If the rope is wound incorrectly in the reverse direction on to the rope
drums the hopper will not stop at the upper limit switch. It will continue until it
makes contact with the top of the structure and will continue to heave until the
wire rope breaks, with the result , if both sides of the wire fail at the same time,
that the hopper will drop to the bottom end of the skip track.
RP400XD WIRE ROPE RENEWAL PROCEDURE
WIRE ROPES
SAFETY NOTES
ALWAYS
Store and handle the wire rope correctly, wear protective gloves and eye
protection.
Check the rope test certificate is still in date especially if the rope has been
in storage also check that the certificate is applicable to the rope.
Remove the rope from any reel or coil correctly and without kinking.
Only use correct end terminations and rope anchors.
Ensure that the rope is correctly located and seated on the rope drum.
Ensure that the rope is correct for the application and only use good quality
ropes from reputable suppliers.
Inspect the wire rope for damage, wear, corrosion or abuse at the start of
each shift.
Keep the wire rope clean and maintained in accordance with the
manufacturers instructions.
NEVER
Try to shorten any wire rope by knotting.
Bend a wire rope over small radii.
Subject wire ropes to shock loadings.
Allow wire ropes to run over sharp edges or abrasive surfaces etc.
Subject wire ropes to extremes of temperature.
Use wire ropes with obvious signs of mechanical, corrosive or heat damage.
Use wire ropes that are worn, frayed, split or corroded.
STORAGE
Store wire ropes in a clean well ventilated, dry location preferably
undercover and protected from extremes of temperatures.
If site conditions are such that undercover storage is not possible cover the
rope with a waterproof cover and support clear of the ground.
Rotate stored wire ropes, reels or coils regularly to prevent migration of the
rope lubricant, particular in warm environments.
Be aware that subjecting wire ropes to extremes of temperature as can affect
the in service performance, high storage temperatures can reduce the
effective strength of the rope.
SAFETY
Running wire ropes are hazardous and should be guarded or personnel
should be prevented access to them whilst in motion.
Wire ropes develop broken strands during their working life which present a
hazard to maintenance personnel, always wear suitable hand and eye
protection when handling ropes.
Take care when unfastening a coiled rope as the inherent springiness when
released may cause it to strike attendant personnel or other equipment
causing damage or injury.
Take care when removing worn, damaged or failed ropes from equipment as
they may be tightly coiled, grossly distorted and still retain their springiness.
IN SERVICE INSPECTION AND MAINTENANCE
Wire ropes used for lifting operations should be regularly inspected by a
competent person and inspection records kept upto date.
Inspections should not only concentrate on the rope but also extend to the
condition of sheaves, drums, guides etc.
Decisions on whether a wire rope is suitable for continued service should
only be made by a competent person.
IF IN DOUBT REPLACE THE ROPE.
INTENTIONALLY BLANK PAGE
INTENTIONALLY BLANK PAGE
OPERATING
AND
MAINTENANCE MANUAL
SECTION 6
ELECTRICAL SYSTEM
ELECTRICAL INFORMATION
1.
The mixing pan and mixing star motors should be interconnected in the control
to operate at the same time, as it is important that both are working before a mix
is added. Ensure that suitable overloads are fitted. The mixing pan and mixing
star rotate anti-clockwise when looking from the top.
NOTE:
2.
With motors 5.5 kw and above, use Star Delta Starters. Below
this, use Direct on Line Starters.
When a loader is attached a direct on line reversing starter is required complete
with suitable overloads. The loader winch rotates anti-clockwise looking from
the rope drum end and when the raise button is pressed.
The upper and lower limit switches are positioned to break the electrical supply
to the loader motor when the loading hopper is in the required position at the
top and bottom of the runway.
3.
The door control solenoid has to be energised when the mixer door is required
in the open position.
It is advisable to mount the starters away from the machine on supports free
from vibration.
4.
IMPORTANT NOTICE: All work on plant electrics including control panel
circuits to be under taken by a suitably qualified and competent electrical
person. All wiring in exposed positions should be suitably protected or
armoured cable and protected by a suitable earth leakage circuit breaker.
5.
The Mixing Star Dive and Pan Drive should be interconnected in order to start
in the following sequence:Mixing Star Motor
Pan Drive Motor
6.
When a Whirler is fitted the sequence should be:Whirler Motor
Mixing Star Motor
Pan Drive Motor
RP400XD MIXER CONTROL PANEL (SIMS) PAGE 1
RP400XD WIRING DIAGRAM MIXER CONTROL PANEL (SIMS) PAGE 2
RP400XD WINCH MOTOR BRAKE WIRING
FLENDER MOTORS ABOVE 4KW
BRAKE WIRED ACROSS MOTOR 6 PIN
TERMINAL BLOCK
THREE PHASE A.C. BRAKE CONNECTED
ACROSS MOTOR TERMINALS. DIRECT-ON
- LINE STARTING METHOD ONLY
RP400XD WINCH MOTOR BRAKE WIRING
FLENDER THREE PHASE BRAKE
SEPARATELY SWITCHED (9 PIN
TERMINAL BLOCK)
MOTOR CONNECTIONS
UP TO AND INCLUDING 4.0KW DIRECT ON LINE
STARTING
LINK W2 TO U2
LINK U2 TO V2
ABOVE 4.0KW DIRECT ON STARTING
LINK W2 TO U1
LINK U2 TO V1
LINK V2 TO W1
ABOVE 4.0KW STAR DELTA STARTING
NO LINKING
RP400XD FLENDER MOTOR WIRING DIAGRAM
MOTORS UPTO & INCLUDING 4.0Kw
SEE SEPARATE PAGE FOR MOTORS
5.5Kw AND ABOVE
UPTO & INC 4.0Kw
RP400XD FLENDER MOTOR WIRING DIAGRAM
MOTORS 5.5Kw AND ABOVE ONLY
SEE SEPARATE PAGE FOR MOTORS
4.0Kw & BELOW
5.5Kw & ABOVE
INTENTIONALLY BLANK PAGE
RP400XD INTERLOCK DOOR SWITCH
MISTURA DOOR INTERLOCK MECHANISM
1
2
2A
2B
3
CR719072
CR229093
CR229094
CR229124
CR229125
Interlock Door MLD100FB
Key MLK100A Code A
Key MLK100B Code B
Key MLK100C Code C
Cap Dust MLM100
When ordering replacement keys quote code of interlock mechanism
A/R
A/R
A/R
A/R
A/R
OPERATING
AND
MAINTENANCE MANUAL
SECTION 7
PNEUMATIC SYSTEM
SHUTDOWN PROCEDURE – PNEUMATICS
(This procedure to be read in conjunction with electrical procedure – see section six).
We Recommend
A lockable dump valve be fitted in the feed line to our mixing equipment (see
drawing below).
Prior to any maintenance, the mixing equipment must be isolated using the above
padlockable shut off valve. When put to the dump position, air will be allowed to
vent to atmosphere removing the potential stored energy hazard. With the system in
this condition, the mixer door will open and discharge blade will lower.
Important
Prior to entry into mixing pan, the air supply must be exhausted and isolated as above.
Check door is fully open and the discharge blade rests upon pan base before
commencing maintenance/cleaning. Also check that the pressure gauge reads zero.
Should blade or door remain up or partially closed, it is imperative that the cause is
investigated and dealt with prior to entering mixing pan. See maintenance section.
SHUT OFF VALVE
RP400XD PNEUMATIC SYSTEM SCHEMATIC
RP400XD PNEUMATIC CIRCUIT (PLASTIC PUSH IN FITTINGS)
1
1A
2
2A
2B
2C
2D
CR119347
191S03
CR110005
11S03C
267S05
17S04
7S03
Shut Off Valve
1/2"-1/2" BSP Male/Male Nipple Adaptor Tapered
Air Service Unit/Regulator/Lubricator
Screw Set Air Unit/Regulator Retaining
Washer Flat
Washer Spring
Nut
1
1
1
4
8
4
4
Available spares for Air Service Unit itemised below:
*
*
*
*
*
*
*
*
CR119373
CR119374
CR119375
CR119376
CR119377
CR119378
CR119379
CR119380
Bowl Regulator
Bowl Lubricator
Filter Repair Kit
Filter Element
Lubricator Repair Kit
Pressure Gauge
Bracket Mounting
Knob Regulator
1
1
1
1
1
1
2
1
3
4
5
6
6A
6B
6C
6D
6E
CR119261
CR119129
CR119119
CR119210
CR119346
11S03C
267S05
17S04
7S03
1/2" BSP Male x 12mm Fem Push In Straight Adaptor
3/8" BSP Male x 12mm Female Push In Elbow
12mm Diameter Plastic Air Hose
Electric/Pneumatic Solenoid Control Box
Electric/Pneumatic Solenoid Control Box 60 Hz
Screw Set Control Box Retaining
Washer Flat
Washer Spring
Nut
8
CR119129
3/8" BSP Male x 12mm Female Push In Elbow, Discharge Door
Cylinder, both ends
2
1
1
1
1
A/R
1
1
4
8
4
4
10
10A
CR110298
CR110325
Pneumatic Cylinder Discharge Door
Seal Kit For Item 10
12
13
V2003253
V2003111
Cable Tie Nylon Long (not illustrated)
Cable Tie Nylon short (not illustrated)
A/R
A/R
14
CR119215
M12 Female- M12 Male Push In Elbow, if required
A/R
15
16
CR119239
CR119144
Compressor 24 Litre Reciever No Illustrated
Adaptor 1/4" B.S.P.- 12mm Push In Fitting Not Illus
17
18
19
CR119153
CR119288
CR119289
Hose Clip Double (not illustrated)
Hose Clip (not illustrated)
Screw Self Tapping (not illustrated)
1
1
8
2
10
The following alternative items are used to reduce from 12mm diameter Air Hose to
8mm diameter Air Hose if required
CR119208
CR119133
M12 Male - M8 Female Straight Push In Reducer
8mm Diameter Plastic Air Hose
A/R
A/R
INTENTIONALLY BLANK PAGE
OPERATING
AND
MAINTENANCE MANUAL
SECTION 8
MISCELLANEOUS
MISCELLANEOUS
8..1 NOISE DETAILS
Measured in accordance with Directive 79/113EEC at four points around the machine
at 1 metre radius and at a height of 1 metre the noise did not exceed 85LPA
INTENTIONALLY BLANK PAGE
INTENTIONALLY BLANK PAGE
INTENTIONALLY BLANK PAGE
INTENTIONALLY BLANK PAGE
OPERATING
AND
MAINTENANCE MANUAL
SECTION 9
ELECTRONIC LOADCELL & INDICATOR/
READOUT BOX
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising