Prometal UNIVERSAL 1000, Maintenance Manual

Page 1: ...Maintenance manual Universal 1000 P R O M E T A L 1 Maintenance manual UNIVERSAL 1000 Concrete block making machine ...

Page 2: ...es and other chemical substances 11 Lubrication preliminary remarks storage and servicing 11 Industrial safety 12 Checking cleaning of bearings 13 Screwed and electrical connections 13 EMergency OFF 14 Maintenance 15 Cleaning 15 Lubrication 15 Servicing 15 Vibration unit 15 Mould support 16 Filler box table and hopper 16 Filler box drive 17 Tamper head brake 17 Mould and tamper head mounting 18 Hy...

Page 3: ...val 33 Chain conveyor 33 Drive shaft 33 Lubricating 33 Weekly every 50 hours 33 Drive chain 33 Transport chain 33 Rocker limit switch 33 Lubrication plan and points 36 Tamper head maintenance 41 Setting the tamper head 42 Mould maintenance 46 Mould change 46 Important hints for mould changing 48 Mould changing 49 Mould and tamper head mounting on machine frame 64 Vibrator table maintenance 65 Vibr...

Page 4: ... O M E T A L 4 Machine center part 77 Filler box and agitator maintenance 78 Hopper maintenance 80 Table plate lifter 81 Table plate clamping 81 Table plate adjusting 81 Lifter unit for the table plate 82 Pneumatic mould clamping Option 82 ...

Page 5: ...ndicate ways of safe and easy operating which will allow efficient use of machine Warning It is important to follow strictly maintenance manual to avoid possible danger for operators health It is necessary to follow work safety instructions strictly Caution It is important to follow strictly maintenance manual to avoid possible damage for the machine It is necessary to follow work safety instructi...

Page 6: ...l since we cannot accept any liability for damage and malfunctions resulting from non observance This manual is to be read and put to appropriate use by all persons whose job it is to work with the machine system e g In case You encounter any problems or if You have any question do not hesitate and contact our technical support All rights reserved including those of translation into other language...

Page 7: ...s hydraulic oil and grease Mechanical maintenance maintenance lubrication inspection and adjustment work Hydraulic maintenance maintenance inspection and adjustment work If you adhere to these inspections and maintenance it will considerably extend the life time of the machine system Therefore it must be in Your own interest to follow this manual carefully and maintain machine system at regular in...

Page 8: ... for use with a shackle and pin type lifting aid Chains of suitable length and lifting capacity must be used Lifting points are designed to position the crane age point as close to the centre of gravity of the machine as possible but due to design restrictions it is not possible to ensure that the frame will remain horizontal while lifting Care is therefore needed to avoid personal injury or equip...

Page 9: ...including rings due to the accident risks involved Personal protective equipment is to be used where necessary or stipulated Heed all safety and hazard warning instruction given on the machine system Make sure all safety and hazard warnings on the machine system and legible Always avoid any course of action which could jeopardies safety Before switching on starting up the machine system make sure ...

Page 10: ... electrical system or parts must be performed by electrician or qualified personnel under the guidance and supervision of an electrician in line with the appropriate regulations Machine and system components that are under inspection repair or maintenance must be de energized where prescribed For parts that are isolated check for no voltage first Hydraulics Warning Oil drippings and leakages may a...

Page 11: ...Poor or frequent lubrication will shorten the service life of the anti friction bearings and result in failure Lubrications itself and other associated operations are to be performed with the machines system stopped Lubricants such as oil and grease are to be kept in clean closed containers cans drums tins to prevent the ingress of dust and moisture and to reduce oxidation effect of the air level ...

Page 12: ...essure limiting pressure reduction valve These valves are installed in the system in such a manner that they are outside the hazard zone However increased care is to be taken when performing such task When cleaning hoppers main hydraulic system is to be turned off Wear safety helmet on entering machine pit Caution Even if the pump is switched off pipes can be pressurized if the cylinders are perpe...

Page 13: ... loading After cleaning every component with suitable cleaning agent bearings must be thoroughly dried and then immediately protected against corrosion by oiling or greasing them This part is especially important for the machine that remains shut down for a lengthy period of time Screwed and electrical connections After 20 30 hours screws and bolts have to be checked whether they are tight or not ...

Page 14: ...tches the complete control voltage is disconnected Hint Reconnecting of control voltage is possible only by switching on the key switch after unlocking the emergency switch Key Switch The key switch Control Voltage On is located on the control panel or on the end wall of the control cabinet With this the control voltage is switched on With switch Control Voltage Off is switched off ...

Page 15: ...mber of lubrication points on the machine has been kept to the minimum Types of lubricants to be used are given in our lubricant table The points concerned are listed in a separate lubrication chart outlining the lubrication intervals Servicing By its very nature a heavy duty vibration machine is subject to considerable loading and there is bound to be component wear Design measures and the use of...

Page 16: ... particularly on mould replacement Secure loose parts and renew damaged ones Renew damaged or worn bushings Filler box table and hopper Check tightness of bronze wear strips on end faces of filler box tables Secure loose strips renew if damaged or severely worn Check scraper plates of filler box tables and replace if necessary Check functioning of hopper outlets Renew worn bolts and bronze bushing...

Page 17: ...ber bushings Make sure that filler box walls are not too worn if they are rework or replace filler box Check rollers for bearing damage Tamper head brake Renew damaged rubber buffers between tamper head frame and tamper head carrier Make sure that there is no residual concrete left in the tamper head carrier Renew damaged worn bushings If top vibrators are fitted check their attachment to the tamp...

Page 18: ...the event of leakage at the plunger rods of the hydraulic cylinders Tighten loose pipe clamps as otherwise switching impact in the hydraulic system could overload the pipe unions and cause them to brake off Always keep oil cooler away from dust It is appropriate to clean it at frequent intervals with compressed air so as to maintain the cooling capacity The best temperature range for hydraulic oil...

Page 19: ...Maintenance manual Universal 1000 P R O M E T A L 19 ...

Page 20: ...de clamping Supporting screws Check and clean Filler box agitator cart Inside Clean from remaining concrete Filler box agitator cart Wheel wheel path Check and clean Agitator Check condition and clean Filler box Stripper frame strings Check and clean Table plate Check condition and clean Concrete hopper Concrete hopper hopper flaps Check condition and clean Hydraulic unit Inspection glasses Check ...

Page 21: ...pers Lubricating checking and cleaning Vibrator table Wear ledges and impact bars Checking distance and parallelism Vibrator table Rubber buffers Checking the condition Rocker arms Bearings hydraulic cylinder Lubricating checking the tight fit of screws Filler box agitator cart Stripper brush Checking the tight fit of screws Agitator cart Crank arm drive hydraulic cylinder Checking the tight fit o...

Page 22: ...tenance Maintenance activity Motors Electrical connections Checking the tight fit Tamper head brake Brake linings Checking the thickness Tamper head cross stripper brush Bearings sprocket wheel columns Checking lubricating cleaning Tamper head cross stripper brush Chain tension Checking adjust if necessary Charging frame Lifting spindles Checking for wear Charging frame Guide columns locking Check...

Page 23: ...g the filter mat cleaning or changing Yearly maintenance every 2000 hours Part Point of maintenance Maintenance activity Tamper head Tamper head vibrator Changing completely Vibrator table Vibrator bearing Changing completely Hydraulic unit Pressure filter Changing filter inside Hydraulic unit Hydraulic oil Changing Powersupply unit Bufferbattery Changing Recommendation yearly exchange every 2000 ...

Page 24: ...t incorporating accumulators must be carried out after release of the fluid pressure Hydraulic pump Hydraulic pump rating is max 170 bar Pressure limiting valves are set in order to ensure that pump is never overcharged not even in continuous run at maximum load This setting is done in factory and must not be changed The downstream hydraulic slide valves operate the individual movements of the mac...

Page 25: ...Maintenance manual Universal 1000 P R O M E T A L 25 Hydraulic system ...

Page 26: ...Maintenance manual Universal 1000 P R O M E T A L 26 ...

Page 27: ...Maintenance manual Universal 1000 P R O M E T A L 27 Basic principles for the installation of hose assemblies ...

Page 28: ...l reservoir Oil quantity for tank is aproximately 400 liters Establishing faults in hydraulic system Work on hydraulic equipment must be carried out only by persons with special knowledge and experience in hydraulic system Any contamination will reduce the service life of a hydraulic system Check all lines hoses and screwed connections regularly for leaks and obvious damage Repair damage immediate...

Page 29: ...perience has shown that 80 of faults damage in hydraulic oil systems are due to selection of the wrong oil and poor oil condition Pumps valves and motors are maintenance free Maintenance work is therefore concentrated on oil checks and filter element replacement Maintenance intervals depend on the system concerned and are governed by operating conditions and applications Pressurized fluid Always u...

Page 30: ... To clean the oil side the cooler unit must be separated from the oil circulation In and Out The oil side should be cleaned half yearly every 1000h Light dirt in the oil passages can be flushed away with perchlorate The required flushing time depends on dirt condition and should be between 10 and 30 minutes afterwards the cleaning agent must be completely removed with compressed air Decreasing coo...

Page 31: ...el 2 Transport chain 3 Rocker limit switch 4 Gear motor 5 Sprocket wheel 6 Drive shaft 7 Adjusting screw with lock nut 8 Skid rails The right tension of the transport chains is very important for a troublefree transport of the production pallets A regulary inspection is therefore required ...

Page 32: ...L 32 In case there is too much slack follow this procedure open the lock nut on the adjusting screw turn the adjusting screw slightly to the right see if the tension is sufficient secure this setting with the lock nut Maintain chain conveyor regulary ...

Page 33: ...nsporting chain Sprocket wheels skid rails Chain tension Checking Cleaning Re adjusting Weekly every 50 hours Weekly every 50 hours If necessary Rocker limit switch Function Switch position Setting Checking Checking Re adjusting Weekly every 50 hours Monthly every 200 hours If necessary Check condition of the transport chains weekly every 50 hours if case of any wear or damages exchange immediatel...

Page 34: ...Maintenance manual Universal 1000 P R O M E T A L 34 The switch cam on the rocker must be at the minimum 8mm 0 32 below the limit switch ...

Page 35: ...mm 0 32 below the limit switch If right adjusted the switch roll must be 35mm 1 37 above the transport chain Pallet transport maintenance Pallet transport fixture must be maintained regulary Check weekly every 50 hours that the latches are moving easily Clean weekly every 50 hours the wheels and the wheel path Check weekly every 50 hours the tension of the drive chain Chain should give in not more...

Page 36: ...lity lubricants recommended by PROMETAL Before You start lubricating nipple heads must be cleaned thoroughly Pos Piece Greasing points Piece Grease nipple Working hours 20 40 100 200 1 8 Filler box roller bearings 8 X 2 Mould points look from the inside 13 Mould and tamper head 13 X 3 1 Agitator 1 X ...

Page 37: ...Maintenance manual Universal 1000 P R O M E T A L 37 4 4 Hopper bearings 2 in total and hydraulic cylinder 4 X 5 8 Machine frame 8 X 6 Swivel head X ...

Page 38: ...Maintenance manual Universal 1000 P R O M E T A L 38 7 2 Tamper head vibrator 4 400 hours 8 2 Mould vibrators 4 400 hours 9 4 Conveyor 4 X 10 2 Table plate lifter 4 X ...

Page 39: ...hanging clean also oil reservoir For lubrication of the vibrator bearings use roller bearing grease CALYPSOL H 443 HD 88 Multi purpose greases are not appropriate and should not be used In order to avoid any confusion with unfit greases use above mentioned grease also for all other greasing points of the machine Alternative greases MANUFACTURER GREASE TYPE Mobil Oil AG BP Engergrease LS EP2 FINA F...

Page 40: ... parts 3 Examine parts for damage and replace if necessary 4 Fill antifriction bearings with grease Lubricants can be obtained through PROMETAL Multi purpose greases are not appropriate and should not be used In order to avoid any confusion with unfit greases use above mentioned grease also for all other greasing points of the machine Tamper head vibrators All bearings are correctly lubricated on ...

Page 41: ... main plate or tamper head itself the stopcocks must be closed and the retaining bolts for securing the tamper head must be in position Also control voltage must be switched off Machine that are equipped with tamper head vibration the tamper head and tamper head plate respectively are connected with the guide bridge by means of rubber buffers Tamper head bridge carrier ...

Page 42: ...efore You start any inspection maintenance or repair work insert first the tamper head safety bolts insert four distance pieces into outer mould cavities their height must be exactly corresponding with the height of the intended products activate master switch on the control panel for the function tamper head down remove tamper head safety bolts first unscrew and move to end down position tamper h...

Page 43: ...ry 200 hours for thickness of brake linings They should not be less than 2 3mm 0 080 0 120 Check if the linings are equaly worn Unequal linings wear is sign that one of the hydraulic cylinders aren t working properly Check the reason Also check weekly every 50 hours that the brake linings are not oily If there is for any reason a leakage in the hydraulic brake system repair immediately Check weekl...

Page 44: ...eck the hydraulic fittings and seals for possible leakage Retaining screws for tmper head plate There are 4 four retaining screws to secure the tamper head plate They must be set with a distance of 4 mm 0 160 between the screw head and the tamper head plate 1 Open the self locking nut on top of the tamper head traverse 2 Turn the lock nut several turns down 3 Press the screw head up against tamper...

Page 45: ...0 P R O M E T A L 45 Rubber buffers on tamper head mould and vibrator table Rubber buffers must be exchanged regulary Tamper head rubber buffers Mould rubber buffers 4 rubber buffers in total Vibrator table 12 rubber buffers in total ...

Page 46: ...lity of the product The time for changing these rubber buffers is directly related to the production exchange based on a 1 shift operation yearly exchange based on a 2 shift operation half year exchange based on a 3 shift operation 3 months Always completely exchange rubber buffers Use only original spare parts Mould maintenance Mould system consisting of mould guide mould clamping Mould change NO...

Page 47: ...etup repair or maintenance work first insert safety bolt For mould change please follow next procedure Mould and tamper head dismantling check that filler box is in start position move up mould for about 25 cm under floor Turn in position OFF main switch on electric board before continue with next mould change steps remove protective meshes from both sides of machine that you can reach screws that...

Page 48: ...illing position Moulds lying on the production floor are braking the oscillations of the vibrators Result A bad compaction of the stones If after a certain period the metal buffers wear out they have to be renewed in time or to be lined with sheet metal the floor clearance of the moulds after filling should be 2 3 mm this distance allowing an irreproachable vibration of the mould above the product...

Page 49: ...Maintenance manual Universal 1000 P R O M E T A L 49 Mould changing First insert mould changing track After this is done insert mould changing cart into this track ...

Page 50: ...Maintenance manual Universal 1000 P R O M E T A L 50 Put cylinders into cart Now insert cart under mould and tamper head ...

Page 51: ...Maintenance manual Universal 1000 P R O M E T A L 51 This is followed with unscrewing all screws ...

Page 52: ...Maintenance manual Universal 1000 P R O M E T A L 52 Now lower down tamper head and mould ...

Page 53: ...Maintenance manual Universal 1000 P R O M E T A L 53 Pull out cart with mould on itself ...

Page 54: ...Maintenance manual Universal 1000 P R O M E T A L 54 After You safely remove used mould insert new one Put cart into track and move it inside ...

Page 55: ...aintenance manual Universal 1000 P R O M E T A L 55 Put mould bolts back but don t screw them Using new bolts and screws on every mould change is highly recommended Tight up tamper head screws and bolts ...

Page 56: ...Maintenance manual Universal 1000 P R O M E T A L 56 Lift tamper head up and down and use pre vibration with extreme caution this is done to adjust mould and tamper head ...

Page 57: ...Maintenance manual Universal 1000 P R O M E T A L 57 Lift up or lower down mould depending machine frame using rack winch this is used to adjust mould and floor plate on the same height level ...

Page 58: ...Maintenance manual Universal 1000 P R O M E T A L 58 After adjustment is done ...

Page 59: ...Maintenance manual Universal 1000 P R O M E T A L 59 Release floor plate screws and adjust distance of mould and floor plate ...

Page 60: ...Maintenance manual Universal 1000 P R O M E T A L 60 After adjustment is done tight all screws up Lift tamper head up and move filler box over mould ...

Page 61: ...Maintenance manual Universal 1000 P R O M E T A L 61 This is done for brush adjusting Adjust height of tamper head and brush so it can clean tamper head during work ...

Page 62: ...ment There are 3 sensors for mould and 4 sensors for tamper head Mould sensors Disload of tamper head is point where tamper head leaves mould and continue lifting up without mould Distance it determins height of Your desired production For example 200mm concrete block ...

Page 63: ...Maintenance manual Universal 1000 P R O M E T A L 63 Tamper head sensors Concrete block height sensor is located on both sides Tamper head stopper ...

Page 64: ...mould tight mould to machine frame rubber buffers must be aligned well between mould and mould clamping device without distortion check that tamper head shoes are well centered in mould body tight well screws that fixes tamper head to tamper head bridge check the electric cables and connectors for vibrators and if they are not damaged plug them in These instructions are valid for all mould types ...

Page 65: ...Maintenance manual Universal 1000 P R O M E T A L 65 Vibrator table maintenance ...

Page 66: ...90 the wear ledges must be changed otherwise the heads of the fixation screws will be worn so much that they can not be removed anymore Remove possible paint from the bearing surface when changing them Check weekly every 50hours distance and parallelism between wear ledges and the impact bars But at least at every mold change The right height distance between wear ledges and impact bars must be ma...

Page 67: ... for the wegde type hight adjuster Place a ruler across the wear ledges and measure the distance between wear ledges and impact bars measure distance equally outer side of the vibrator table Adjust the exact dimension by turning adjusting screw to the right or left Repeat this process on every adjusting screw Secure this setting with lock nut on adjusting screw Tighten fixation screws with 710 Nm ...

Page 68: ...ures have to be protected against incidental activation The switching off procedure of the operating instruction has to be considered During the exchange of large and heavy components suitable chain hoists and similar aids should be held ready and used The components are to be fastened carefully to the chain hoist and to be secured Attention Only suitable and technically perfect chain hoists shoul...

Page 69: ...d the same value on the reference percentage scale The weights positioned at the two sides of the vibrator can only be adjusted on two different values for particular machines and for special uses Once the eccentric weight has been taken to the desired value tighten the screw fastener or nut using the dynamometric wrench and repeat the same operation on the opposite weight Once the operation on th...

Page 70: ...er supply from the vibrator Reposition the covers ensuring that the seals OR are correctly positioned and tighten the screw fastener Vibration force adjustement Attention This operation must be carried out exclusively by specialised staff with the power supply disconnected To adjust vibration intensity it is necessary to remove the weight covers It is usually necessary to adjust the weights in the...

Page 71: ...e weights positioned at the two ends of the shaft must be positioned in a way to read the same value on the reference percentage scale The weights positioned at the two sides of the vibrator can only be adjusted on two different values for particular machines and for special uses Once the eccentric weight has been taken to the desired value tighten the screw fastener or nut using the dynamometric ...

Page 72: ...e installing vibrators Bolt connection is to be secured with by chemical means of screw locking e g with Locktite 601 or similar All bolts connections are to be carried out with a torque according to the manufacturer specification for screws and nuts Also for the fixing attachment use only bolts with grade of 8 8 and nuts of grade 6 Vibrators designation Housing size Hexagon bolts for threaded hol...

Page 73: ...e motor can not be switched on It also has to be secured that nobody is in the danger area of the imbalances when the covers are opened Caution The vibrators of newly supplied machines are pre set by the makers for an average centrifugal force as per table As far as no other values are available from experience introduction should begin with this adjustment If necessary the centrifugal force it ma...

Page 74: ...cable e g at the connector or at the distribution panel Do not swap leads in the terminal box of the vibrator 5 Mount the cover again Adjustment of the unbalance The unbalances of the vibrators are normally set to the maximum generation of centrifugal force for which the vibrator was designed for 1 Remove both covers 2 Loosen the clamping screw of the adjusting unbalance on one side and adjust acc...

Page 75: ... to be kept dirt free in order to secure good heat dissipation The cleaning with high pressure steam or high pressure water is not permitted because water can penetrate into the interior and destroy the electrical winding The fixing bolts of the vibrator foot and those of the unbalance covers should be examined for the right tightening torque and should be re tightened if necessary Defective fixin...

Page 76: ...mply with the regulations of the screw manufacturer Secured bolt connections e g with Loctite should not be pulled tight but should be exchanged and secured again if these have loosened 2 Connecting cables should be examined on resonant vibrations and also on abraded spots if necessary rewire vibration free or renew the cable Lubrication plan and points Please check lubrication plans and points ch...

Page 77: ... A L 77 Machine center part There are several points which have to be maitained regulary Check condition and clean guiding columns weekly every 50 hours Wear scratches on the guiding columns always shows a serious sign of insufficient cleanliness ...

Page 78: ...tor must be maintained regulary Clean filler box and agitator daily based on 1 shift operation Check and clean the wheels and the wheel path on filler box and agitator cart Check weekly every 50hours condition of cleaning brush on the filler box Check weekly every 50hours fixation screws on the cleaning brush ...

Page 79: ...h maintenance Brush frame for the coarse mix as well as for the face mix must be maintained regulary Clean and check brush frame daily based on a 1 shift operation Check and clean the springs on brush frame daily based on 1 shift operation Use diesel oil for cleaning ...

Page 80: ...Clean if needed and lubricate according to plan use only high quality grease Clean hopper by knocking off residual concrete After this open hopper outlets to enable the loose concrete to drop into filler boxes with which the concrete is moved into mould and removed from the machine together with the pallet Check all fixation screws ...

Page 81: ...plate clamping Check weekly every 50 hours the tight fit of the fixation screws from the table plate clamping Table plate adjusting On every side are two 2 adjusting screws for the alignment of the table plate They are secured with a lock nut You can adjust the table plate as follows open first the lock nuts open all lock nuts on both sides in front and back Turn the adjusting screws in the desire...

Page 82: ...te located clean and check regulary the push rods on the lifter units check the mechanical components for wear Pneumatic mould clamping Option Check air suspensors regularly In case there are holes and air is leaking exchange immediately Also check rubber clamps on the inner side regularly In case of wear exchange immediately During maintenance depressurize pneumatic system first ...

Page 83: ...0 P R O M E T A L 83 Pallet stabilizer Check pallet stabilizer for signs of wear regularly If Rubber clamp is damaged exchange immediately Lubricate all points every 50 hours Pallet stabilizer is pre adjusted by manufacturer and ready ...