MILLENNIUM 3 DN-33 Fleshing Machine

Transcription

MILLENNIUM 3
DN-33 Fleshing Machine
Operation Manual
Version
3.0
1
DN-33
2
MILLENNIUM 3
DN-33 Fleshing Machine
3
DN-33
TABLE OF CONTENTS
PAGE
1.
OVERVIEW
6
2.
INTRODUCTION
7
3.
INITIAL INSPECTION
8
3.1
Identification plate
8
3.2
Accessories
9
4.
TRANSPORTATION
10
5.
INSTALLATION
11
6.
5.1
Installing the machine base
11
5.2
Area around the machine
12
5.3
Leveling
12
5.4
Installing the water tank
13
5.5
Electric installation
14
TECHNICAL SPECIFICATIONS
6.1
Final inspection
16
17
7.
SAFETY
18
8.
IDENTIFICATION OF CONTROL COMPONENTS
19
9.
MECHANICAL ADJUSTMENTS
21
9.1
Transport drive rollers - height and spring
21
pressure adjustment
10.
9.2
Hose and table alignment
22
9.3
Hose and table compensation
23
9.4
Removing access covers
24
9.5
Hydraulic adjustment
25
9.6
Transport drive speed
27
CONTROL PANEL
10.1
11.
4
Control panel components
OPERATING SEQUENCE
27
29
31
11.1
Starting the equipment
31
11.2
Checking the safety and emergency system
32
11.3
Safety test procedure
33
11.4
Open/close sequence
34
11.5
Checking the hydraulic system
35
11.6
Thickness adjustment
36
11.7
Fleshing process
37
11.8
Drive pedals
38
11.9
Table compensation pedal
39
11.10
Sharpening the blades
40
11.11
Turning off the equipment
42
12.
PERIODIC LUBRICATION
43
13.
IMPORTANT RECOMMENDATIONS
45
13.1
14.
Cleaning the equipment
MAINTENANCE
14.1
Transport drive rollers - height and spring
45
46
47
pressure adjustment
14.2
47
14.3
Open/close cylinders
49
14.4
Transport drive roller bearings
51
14.5
Transmission
53
14.6
Return filter
54
14.7
Transport drive reducer
54
14.8
Hydraulic unit
55
14.9
Drive
57
14.10
Blade sharpener
58
14.11
Blade roller replacement
59
14.12
Blocking of the safety system
63
14.13
Electric equipment
65
15.
TROUBLESHOOTING
66
16.
WARRANTY
67
17.
SPARE PARTS
69
18.
ELECTRIC SCHEMES
186
19.
HYDRAULIC SCHEME
197
20.
TECHNICAL SUPPORT
198
5
DN-33
1.
OVERVIEW
Congratulations!
Your company has just received a top of line piece of equipment.
The MILLENNIUM 3 DN-33 Fleshing Machine was designed based on the
most up-to-date technical standards, employing state of the art technology to
ensure the best possible results for your company.
The characteristics of the MILLENNIUM 3 DN-33 Fleshing Machine make it
extremely efficient. It features 3300-mm working width, a 36-blade, large-diameter
cylinder, low-speed engine, and an exclusive fluid-filled hose system (patent) that
makes the cylinder adjust itself to the irregular thickness of hides.
Simple and precise adjustment mechanisms offer great performance and
high productivity. In addition, the equipment comes with an efficient safety system
for protection of the operator.
Electricity consumption is low, with an electric power capacity of 52 kW.
Our greatest satisfaction is to supply our clients with equipment that will
ensure the best possible results.
Please contact us if you have any questions about operating the DN-33.
Contact information
Phone +55-51- 568 1900
[email protected]
BREMM PECK Máquinas Industriais Ltda.
Av. Mauá, 2479
Bairro Santos Dumont
São Leopoldo - RS - Brazil
CEP 93.110-320
Phone: +55-51-568.1900
Fax: +55-51-568.3665
[email protected]
E-mail:
www.bremmpeck.com.br
6
2.
INTRODUCTION
This is the technical manual for the
MILLENNIUM 3 DN-33 Fleshing Machine
This manual is part of the equipment and should be kept close to it so that it
is available if consultation is necessary.
This document contains all the instructions concerning your machine, from
initial inspection to operating guidelines and maintenance advice.
It is very important that you read this manual carefully before handling or
operating the equipment. This will allow the operator to correctly understand all
working/control mechanisms. This way, operation, adjustment, and maintenance
will be appropriately carried out, and the equipment will reach its best
performance.
Only one copy of this manual is supplied with your equipment. If more
copies are required, contact us and provide the model and part number (for that,
see the identification plate on your machine).
It is very important that the equipment be operated by
trained personnel -- this is a rotating machine that has moving
parts which may seriously harm the operator!
Since we always improving our products, we reserve the right to change the
specifications of this equipment without prior notice.
This manual was developed according to Brazilian Technical Standard
NBR 14245.
Version 3.0 – March / 2004
7
DN-33
3.
INITIAL INSPECTION
The DN-33 fleshing machine that you have just received was submitted to all
the tests that are recommended for this type of equipment.
Prior to shipping, all components were verified, so as to guarantee that your
equipment is being supplied in perfect working conditions.
Nevertheless, you should perform a visual inspection on receiving your
machine, to make sure that it has not been injured during transportation. If you
observe any signs of damage on the body or components, do not proceed with the
installation guidelines presented below. First, check the cause of the damage,
correct the problem and make sure that the equipment is in adequate operating
conditions.
3.1
Identification plate
If you have questions, contact either BREMM PECK or the transportation
company who delivered the equipment.
Check the identification plate. You will need this information for all
inquiries concerning your equipment.
REAR VIEW
8
3.2
Accessories
The tools supplied with the DN-33 are the following:
9 Leveling support plates - (6 items)
9 Wrenches to adjust transport drive roller springs and table compensation – (2
items)
9 Fixed wrenches to adjust the height of the transport drive roller – (2 items)
9 Auxiliary devices for blade cylinder replacement – (2 items)
9
DN-33
4.
TRANSPORTATION
Your machine is being supplied with two steel bars underneath it so as to
help with transportation. The steel cables used for unloading, transporting and
moving the equipment to the installation site should be pulled around these bars.
Once the machine has reached the installation site, the steel bars should be
removed and returned to BREMM PECK.
TRANSPORTATION OF EQUIPMENT – 13,000 KG
REMOVE TRANSPORTATION BARS AFTER
CORRECTLY POSITIONING THE EQUIPMENT.
The machine base should be prepared in advance. It must be leveled and
adjusted taking into consideration the weight of the equipment (13,000 kg), as well
the room required for introduction of the leather, movements of the operator, and
final discharge. This will depend on the type of feeder used by your company.
10
5.
INSTALLATION
5.1
Installing the machine base
The foundation on which the machine base will stand should be prepared
following the appropriate technical standards and taking into consideration the
weight of the equipment.
DRIVE SIDE
FRONT SIDE (OPERATION)
REAR SIDE
WATER SUPPLY
POWER SUPPLY
CONNECT
GROUND ROD
DETAIL (SUPPORT)
GROUND!
We recommend the installation of ground rods connected to the
equipment structure using GREEN/YELLOW wire (10 mm2 section).
11
DN-33
5.2
Area around the machine
0,80 m
In the layout project, keep in mind that you will need room for equipment
access and operation (minimum of 800 mm). In addition, the need for maintenance
and the conditions required for its performance should also be considered, such as
the use of a forklift, a hauler, or a tackle. Therefore, we recommend that the access
routes to the rear and front sides of the equipment be kept free.
0,80 m
5.3
Leveling
The DN-33 has six leveling points. Since the equipment is large and has
heavy mechanisms located apart from one another, it is important that these six
points be perfectly leveled and positioned, so as to guarantee a perfect
alignment. This will enable a smooth, vibration-free operation.
LEVELING POINTS
THREE AT THE FRONT SIDE
THREE AT THE REAR SIDE
LEVELING BOLTS
12
5.4
Installing the water tank
The DN-33 needs water for the fleshing process and for cooling the hydraulic
system.
Connect the water hose using a bracket.
L
To assure the best performance of your equipment, we recommend the
installation of a valve at the water supply.
Keep in mind that you will need room for waste resulting from the fleshing
process at the rear side of the equipment.
13
DN-33
5.5
L
Electric installation
We recommend that the electric supply installation be provided with a
switch located apart from the equipment, aiming at increasing safety.
Remove the upper cover at the rear of the DN-33 to access the power
supply components.
ELECTRIC PANEL
REAR VIEW
Make sure that the equipment is connected to the electricity outlet.
When connecting the electric
supply cables to the terminals,
verify that the moving direction
of the blade roller is correct.
14
The cables should be connected following the equipment technical and
power specifications (see following).
Verify that the feeding voltage is the same as that required by the equipment.
R
380V
N
Power voltage
220 V, 50 ou 60 Hz
380 V, 50 ou 60 Hz
440 V, 50 ou 60 Hz
Section of feeding
cables
95 mm2
50 mm2
50 mm2
T
S
Section of neutral and ground cables
10 mm2
Ground wire
installation
Ground wire
Fixator
Caution!
This equipment requires grounding!
15
DN-33
6.
TECHNICAL SPECIFICATIONS
DN33 MILLENNIUM 3 FLESHING MACHINE
TECHNICAL CHARACTERISTICS
Working width
3300 mm
Blade roller power
50 cv
Hydraulic pump power
20 cv
Total installed power
70 cv
Working speed
0 a 65 m / min.
Depth x Width x Height
1900 mm x 6200 mm x 1900 mm
Weight
13.000 kg
Mean water consumption
20 L / min.
Hydraulic system working pressure
See p. 25
Volume of hydraulic oil in the reservoir/Type
220 L / ISO 68
Production capacity
** 200 to 250 hides/hour
Mean energy consumption
** 35 to 46 KWh
Triphasic electric installation with ground
220 V, 50 or 60 Hz
380 V, 50 or 60 Hz
440 V, 50 or 60 Hz
Fleshing of cattle, horse and buffalo
hides
(Voltage and Frequency)
Field of application
Specifications subject to change without notice.
** Data may vary according to type of operation, size and weight of hides, type of feeder, ability of the
operators, etc.
OPERATING CHARACTERISTICS
16
•
Transport drive roller operation through cardans and hydromotor with hydraulic
speed adjustment.
•
Safety systems with safety bars and photoelectric sensors that run a test at start
of operation.
•
Open/close system, with wide opening and rapid, precise movements.
•
Transportation cylinders with self-adjustment or simple adjustments.
•
Large-diameter blade roller – 36 low-speed blades.
•
Fluid-filled hose system that compensates for the irregularities usually observed
in hides.
•
Thickness adjustment with a 0.1 mm precision rate.
•
Thickness compensation system at the hose table by means of springs and
hydraulic cylinders.
6.1
Final inspection
Before starting your equipment, a final inspection of its components and
mechanisms should be carried out.
Check the following:
9 Leveling
9 Water supply
9 Power supply
9 Drive pedals
9 Operating system
9 Hydraulic system
Once the machine is installed, BREMM PECK will carry out a final
inspection and start the equipment.
At this final inspection, operating and maintenance instructions concerning
the first hours after the DN-33 starts operating will be given to you by BREMM
PECK.
17
DN-33
7.
SAFETY
Before using your equipment, carefully read these safety instructions.
L
This sign indicates information that will be necessary during the
operating process.
This sign indicates an operating instruction.
It always suggests that the technical manual should be consulted.
This sign indicates situations that could be dangerous for either the
machine or the operator.
Information preceded by this sign should be carefully observed so as to
guarantee the operator’s safety.
Prior to starting the operation of the equipment, operators should be
well trained and should be wearing appropriate personal protective
equipment.
Never operate the equipment if protection covers are not adequately
placed!
If any of the safety devices is damaged, do not start the machine
without verifying the cause of damage and solving the problem!
Never operate this equipment while wearing clothes that may get
caught in the cylinders!
Keep in mind that this is a rotating machine with rollers and blades.
Therefore, it may cause severe injury to the operator!
18
8.
IDENTIFICATION OF CONTROL COMPONENTS
FRONT
8
8
6
10
6
4
12
5
11
7
7
9
1
2
2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
3
Structure
Drive pedals
Compensation pedal
Support roller
Transport drive roller
Safety and emergency bars
Compensation and table adjustments
Transport drive roller adjustments
Hydraulic unit
Indicator
Drive Assembly
Control panel
19
DN-33
REAR
13
14
15
16
COMPONENTS
13.
14.
15.
16.
20
Electric components
Operating unit
On/Off - Sharpener
Blade roller sharpener
9.
MECHANICAL ADJUSTMENTS
9.1 Transport drive rollers - height and spring pressure
adjustment
Transport drive rollers are mounted on one only balance bearing, so as to
guarantee a uniform force distribution.
Height and pressure adjustment is carried out on the top of both sides, under
the plastic cover.
Dish spring pressure is determined by the large round nuts and pins.
Turning the nuts clockwise increases the pressure.
Once pressure is adjusted, the height of the transport drive rollers in relation
to the support roller should be observed, so as to ensure that they are not
compressing the coating.
Cylinder height adjustment is carried out using the hex head nuts.
Spring pressure and cylinder height should be uniform at both sides of the
equipment.
TRANSPORT
DRIVE ROLLER
HEIGHT
ADJUSTMENT
SPRING
PRESSURE
ADJUSTMENT
Spring pressure and cylinder height should be adjusted in order to
prevent excessive compression, since this may damage the hides and/or
the support roller coating.
L
Close the equipment for adjustment. Once all adjustments are
completed, the locknuts should be locked again.
21
DN-33
9.2
The parallel position of the hose table in relation to the blade roller is
adjusted in the factory and does not require further corrections or changes.
Similarly, the hose is aligned during the factory mounting process and does not
require corrections.
However, in cases where a different adjustment is necessary, hose alignment
may be altered using the thrust bolts located at the front side of the table,
underneath the protection plate.
HOSE TABLE
ADJUSTMENT BOLTS (UNDERNEATH THE
PROTECTION PLATE)
ADJUSTMENT BOLTS
L
Make sure that there are no salient parts that could come in contact
with the blades during operation; this will result in premature wear or
damage to the hose.
For safety reasons, this adjustment should be carried out with the machine
closed, with the blade roller turned off and stopped, and with the transport drive
roller also turned off.
22
The adequate clearance between the hose table and the blade roller can be
determined with the help of a clearance gauge, in order to ensure that clearance
will be uniform along the whole extension of the hose.
9.3
Hose and table compensation
TABLE-SUSTAINING HYDRAULIC CYLINDERS
The table-sustaining hydraulic cylinders allow for thickness compensation
when working with hides with different weight or size.
The stroke of the hydraulic cylinders can be regulated to leave a preestablished clearance between the hose and the blade roller (compensation).
REMOVE THIS COVER TO
ACCESS THE TABLE
COMPENSATION
ADJUSTMENT
23
DN-33
9.4
Removing access covers
In order to adjust these mechanisms,
remove the access cover shown in the picture by
loosening the fastening nuts.
FASTENING NUTS
ACCESS COVER
Stroke adjustment is carried out via the
limiting nuts, located immediately above the
rollers. Turning the nuts clockwise decreases
the roller stroke.
Once the stroke is adjusted, the nuts
should be fastened again.
LIMITING NUTS
The table is supported by two dish
spring assemblies. These dish springs are
located on the hydraulic cylinder shafts.
Spring pressure may be adjusted via
the regulating nuts, if necessary.
REGULATING NUTS
Turning the nuts
increases spring pressure.
anticlockwise
Adjustment is carried out using the
pins supplied with the tools and
accessories.
24
9.5
Hydraulic adjustment
Open the control panel cover to
access
the
hydraulic
control
components.
The hydraulic pressure is
adequately adjusted before the
equipment is shipped.
MANOMETER
INSULATING VALVE
The general pressure of the system
is set to 135 bar, and can be read on the
manometer by activating the insulating
valve located below it.
Pressure will only reach its peak
value in three situations: during machine
opening, while the machine is closed
and the transport drive roller is at full
speed, or while the machine is closed
and the transport drive roller is turned
off.
These are the best conditions for assessing the actual equipment general
pressure.
25
DN-33
L
To assess equipment pressure, close the machine and turn off the
transport drive roller.
General pressure is regulated by the pressure regulating valve, located next
to the hydraulic block.
GENERAL PRESSURE
REGULATING VALVE
TABLE PRESSURE
OPEN/CLOSE PRESSURE
TRANSPORT
Open/close pressure is set to 75 bar on the pressure reducing valve, located
below the flow regulating valve and the open/close directional valve. For this
reading, a manometer must be coupled to the outlet of the pressure reducing valve.
26
The pressure of the thickness compensation hydraulic cylinders is set to 45
bar at the pressure reducing valve, located below the directional valve. To make
this reading, a manometer must be coupled to the outlet of the pressure reducing
valve.
9.6
Transport drive speed
Transport drive speed ranges
from 0 to 65 m/min (hydraulic
adjustment) at the flow regulating
valve, depending on the operation
that is being performed.
TRANSPORT DRIVE SPEED
REGULATING VALVE
Turning the knob of the valve
clockwise decreases the transport
drive speed.
10. CONTROL PANEL
TRANSPORT
DRIVE ROLLER
ON/OFF
COMMUTATOR
The
transport
drive roller may also be
turned off via the control
panel commutator. This
facilitates
eventual
maintenance
or
adjustment procedures.
COMMUTATOR
GENERAL CONTROL
27
DN-33
CONTROL PANEL
^
All DN-33 operating controls are located on the control panel.
Once all necessary mechanical adjustments have been made, the next step is
to activate the control buttons.
The control panel has an acrylic cover that ensures fast access to the
emergency button. To access other controls, open this cover.
The acrylic cover should be kept over the panel during machine
operation, so as to allow prompt access to the emergency button.
28
10.1
Control panel components
INDICATOR - BLADE
ROLLER ON
INDICATOR HYDRAULIC PUMP ON
TURNS ON
HYDRAULIC
PUMP
INCREASES FLESHING
THICKNESS
TURNS ON
BLADE ROLLER
INDICATOR THICKNESS
CONTROL
STROKE END
INDICATOR MAXIMUM RECOIL
GENERAL CONTROL
INDICATOR
STROKE END
INDICATOR MAXIMUM
ADVANCEMENT
GENERAL
CONTROL
COMMUTATOR
WHEN ACTIVATED,
INDICATES THAT
BLADES ARE WORN
EMERGENCY
TRANSPORT
DRIVE ROLLER
ON/OFF
COMMUTATOR
TURNS OFF BLADE
ROLLER
TURNS OFF
HYDRAULIC PUMP
DECREASES FLESHING
THICKNESS
29
DN-33
When the acrylic cover is placed over the control panel (standard position),
the only accessible button is the emergency button.
This cover should be placed over the panel and kept in this position after the
performance of all adjustments that are necessary for operation.

EMERGENCY
The upper part of the control panel features an indicator that has important
warning functions.
BLADE SHARPENING
TIMER
WHEN LIT, INDICATES
NEED FOR SHARPENING
TABLE COMPENSATION
FLASHES WHEN
COMPENSATION IS
ACTIVATED
SAFETY TEST
REMAINS LIT UNTIL
COMPLETION OF THE
SAFETY TEST
INDICATOR
10.2
Aspects that should be taken into consideration while
operating the equipment
Observe the correct posture and
the use of adequate personal
protective equipment so as to
assure the safety of operators.
1
{ Ò
Protect your eyes
Protect your hands
30
11.
L
OPERATING SEQUENCE
The equipment requires two (2) operators working simultaneously.
11.1
1
Starting the equipment
3
2
In order to start the machine and begin operations, follow the instructions
below:
1. Set the general control commutator to position 1; a green indicator will light
above the commutator, indicating adequate electricity supply, and a red
indicator will light above the right-side protection plate, indicating that the
closing process is blocked and that a safety test should be carried out.
2. Start the hydraulic pump by pressing the corresponding button.
3. Start the blade roller by pressing the corresponding button.
4. Run a safety test, as described on pages 32-33.
5. Close the machine as described on page 34 and perform the open/close
system filling procedure, as described on page 35.
6. Activate water supply for the hydraulic system cooling. The machine will be
ready to start operating.
In cases of emergency, activate the emergency button located on the
control panel acrylic cover. If the equipment happens to be closed, it
will open, and the blade roller will be turned off; then the red
indicator will light, showing that the closing system is blocked. In
order to restart the working cycle, it is necessary to turn on the blade
roller again and to perform a safety test.
31
DN-33
11.2
Checking the safety and emergency system
The equipment has a very efficient safety and emergency system.
The system is composed by two electropneumatic pedals for opening/closing
the machine, two electropneumatic safety bars that open the machine (located at
the upper protection plate), and a photoelectric sensor that prevents closing of the
machine when a foreign body is detected in the support roller closing line – all
these parts are monitored through tests that are performed each the machine starts
operation.
INDICATOR
SAFETY AND EMERGENCY BARS
PHOTOELECTRIC
SENSOR
DRIVE PEDALS
PHOTOELECTRIC
SENSOR
32
11.3
L
Safety test procedure
The machine will not close until this test is carried out!
INDICATOR LIT, SHOWING THE NEED
TO PERFORM THE SAFETY TEST
For this test, the control commutator has to be on.
It is necessary to simultaneously
activate the two safety bars.
Then, intercept the photoelectric sensor
beam projection.
The blocking indicator will
turn off, and the machine will be
ready for operation.
The safety and emergency system should be checked every time the
machine is started.
This will ensure the safety of the operators as well as the interruption of
operation whenever necessary!
33
DN-33
11.4
Open/close sequence
DRIVE PEDALS
The DN-33 closing process occurs as described below:
To close the machine, the two drive pedals should be activated.
Once a pedal is activated, the photoelectric sensor beam should not be
intercepted (if this happens, the machine will not close even after activation of the
second pedal).
If this is the case, release the two
pedals again and restart the closing
process.
Once the closing process has
started, the photoelectric sensor loses its
function.
SENSOR
Prior to completion of the closing
process, the machine can be opened, if
necessary, by releasing one of the pedals.
Once the machine is closed, it
may be opened again by activating any
of the safety bars or pedals.
L
34
CLOSING PROCESS
At any moment, activation of the safety bars will stop the closing
process and/or open the machine.
11.5
Checking the hydraulic system
Check the closing system every time you use your equipment so as to guarantee the
synchronicity of the open/close hydraulic cylinder.
To carry out this test, do the following:
• Close the machine
MACHINE CLOSED
BALL VALVE
OPEN

• Open the ball valve and close it
again. This will fill the open/close system.
CLOSE
The figure on the right shows the ball valve
being opened by moving the lever upwards.
This is a preventive test that guarantees the best performance for your equipment.
L
After opening the machine, open the ball valve and close it again so as
to remove excessive pressure from the filling system.
Never activate the open/close system while the ball valve is open!
35
DN-33
11.6
L
Thickness adjustment
To carry out this procedure, keep the equipment closed!
To adjust the distance between the
hose and the blade roller (fleshing thickness)
close the equipment using the “+” and “-“
buttons located on the control panel.
The “+” button indicates more
thickness, that is, a greater distance between
the hose and the blade roller. On the other
hand, “-“ indicates less thickness.
Each
“+”/“-“
pulse
alters
the
hose/roller distance in 0.1 mm.
The adjustment should be carried out
taking into consideration the irregularities of
different leathers and also the wear of the
blades.
36
MACHINE
CLOSED
11.7
Fleshing process
TRANSPORT
DRIVE ROLLER
LEATHER
BLADE ROLLER
At the first stage of the fleshing
process, the machine will remain
open, and the leather will be
introduced into the support roller
(downwards).
SUPPORT
ROLLER
HOSE
After this stage, the pedals are
activated.
The machine closes at this point.
The leather exits the machine (second
fleshing stage).
OUTPUT
Finally, the machine opens again and is
ready for another fleshing cycle.
37
DN-33
11.8
Drive pedals
MACHINE OPEN
TRANSPORT
BLADE
DRIVE PEDALS
SUPPORT
The pedals activate the equipment closing/opening functions.
If only one pedal is activated, the machine will not close – for that, both
pedals have to be activated simultaneously.
Once the leather has been introduced into the machine (first half of the
hide), each operator activates a drive pedal in order to close the machine.
Then, the transport drive system is activated and drives the hide outwards.
One of the operators opens the machine using a pedal or safety bar. Then they turn
the hide around and introduce the second half of the hide, repeating the fleshing
cycle.
The photoelectric sensor is installed above the support roller. If the light
beam is intercepted by a foreign body, the closing movement will not occur.
Example: if one of the operators has already introduced half a hide into the
machine and activates the pedal, and the other
operator interrupts the sensor beam while
introducing another half hide, the machine will
not close, in spite of the activated pedal. In other
words, if the beam is intercepted after activation of
one of the pedals, the machine saves this
information and blocks the closing process. In this
case, both pedals should be released, and the
closing cycle should be restarted.
Similarly, if the machine is opened via
activation of one pedal and this pedal remains
pressed, activation of the second pedal will not
cause the machine to close.
To close the machine, it is always necessary
to perform the whole cycle of pedal activation,
avoiding obstruction of the photoelectric sensor
beam.
38
SENSOR BEAM
11.9
Table compensation pedal
During the fleshing process, it may become necessary to use the table
compensation feature (e.g. if there is a thicker or heavier hide in a lot). Activating
this pedal increases the opening of the table slightly, increasing the distance
between the hose and the blade roller (and therefore the fleshing thickness).
This pedal may be activated before or during the fleshing cycle.
If the machine has already closed and the operator observes defective or excessive
fleshing, the compensation pedal may be used.
The table compensation pedal activates the hydraulic cylinders of the table,
changing their position.
The range of thickness for compensation is determined by the stroke length
of the table compensation cylinders, as described on page 23.
TABLE COMPENSATION PEDAL
Once this pedal is activated, the yellow indicator starts flashing.
To make the table return to its
original position, press the compensation
pedal again.
The table will return to its normal
position, and the indicator will turn off.
39
DN-33
11.10
Sharpening the blades
The blade sharpening process is part of the DN-33 operating cycle. Blade
sharpening should be carried out on a regular basis, every 30 minutes or less while
in operation.
When the blade roller is turned on,
the sharpening timer is automatically
activated.
From this moment on, the blue
indicator will light every 30 minutes to
indicate the need for blade sharpening.
Whenever the indicator lights, the
sharpening procedures described below
should be carried out.
Open the blade roller rear protection.
This protection plate, located at the rear side of
the machine, should be lifted and kept open
with the help of the hook.
^
1
Q
Protect your eyes
Q
{
Ò
Protect your hands
40
Remember that this is a rotating machine, and
that the blades may cause severe injuries to the
operator!
Do not perform this operations wearing clothes
or equipment that may get caught in the
cylinder!
Activate the commutator in order
to turn on the sharpening cart.
The commutator is located in the
rear, on the left. When activated, the
commutator sets the timer to indicate
the need for sharpening every 30
minutes.
The ideal timing for the cart to
run a sharpening cycle is every 30
minutes or whenever cutting capacity
decreases (deficient hide fleshing/
cleaning).
The abrasive stone or brick used in the sharpening process should be
positioned against the blades with the help of the steering assembly, for smooth
sharpening.
Turning the steering assembly
clockwise brings the abrasive brick closer
to the blades.
If one only sharpening cycle is
necessary (which is usually the case), the
commutator may be turned off again,
because the cart will not stop before
reaching the stroke end.
ABRASIVE BRICK
Once the sharpening process is complete, the protection plate should be
returned to its original position,
covering the blade roller.
L
L
After each sharpening cycle, brush the blades in order to remove debris
that may damage the hides.
Sharpening should be smooth. Take care not to place the abrasive stone
too close to the blades.
41
DN-33
11.11
Turning off the equipment
3
1
2
With the machine open, do the following:
1.
2.
3.
4.
Turn off the blade roller at the corresponding button;
Turn off the hydraulic pump at the corresponding button;
Change the general control commutator to position 0;
Close the hydraulic system cooling water supply.
MACHINE
OPEN
42
12.
PERIODIC LUBRICATION
It is important to adequately lubricate the machine mechanisms so as to
guarantee the best performance and durability of your equipment.
2
FRONT
ANNUAL
REPLACEMENT
TRANSPORT
REDUCER
SUPPORT ROLLER
HYDRAULIC
SYSTEM
4
3
3
WEEKLY LUBRICATION
DESCRIPTION
1
2
3
4
4
1
REPLACEMENT EVERY
5,000 HOURS
LUBRICANT
Hydraulic system
Table mount
Open/close mount
ISO 68 hydraulic oil
ISO 460/SAE 140 gear oil
EP 2 bearing grease
EP 2 bearing grease
QUANTITY
(liters)
220.0
2.0
Important recommendations:
9 Adequate running-in allows for quality improvement on the surface of teeth and therefore
extends the working life of reducers.
9 When changing the oil after the running-in process, empty the reducer completely, so that
9
loose particles are expelled together with the lubricant.
When the lubricant is changed, the reducer should be carefully washed with a quick-acting
solvent.
Never mix synthetic products with mineral products.
Check the oil level on a regular basis and add oil whenever necessary.
Do not apply grease on reducers lubricated with oil and vice-versa.
Synthetic grease is used for permanent lubrication only.
9
9
9
9
9 Try to give an adequate destination to the lubricants used; preferably, recycle them.
9 For detailed information on lubrication of mechanisms check:
14 – Maintenance – page 46
43
DN-33
WEEKLY LUBRICATION
9
REAR
ANNUAL LUBRICATION OR
EACH TIME THE BLADES ARE
REPLACED
DAILY LUBRICATION
5
11
6
9
6
5
7
8
10
DAILY LUBRICATION
ANNUAL LUBRICATION
DESCRIPTION
5
6
7
8
9
10
Blade roller
Steering shaft bearings
Thickness box drive reducer
Sharpener drive reducer
Transport drive roller greasers
Sharpener and bar chain
LUBRICANT
KLÜBER ISOFLEX NBU-15 *
KLÜBER ISOFLEX NBU-15 *
EP 2 bearing grease
ISO 68 lubricant for sliding
guides
* Use
KLUBER ISOFLEX NBU 15*
grease only
44
QUANTITY
(liters)
0.2
0.25
-
13.
IMPORTANT RECOMMENDATIONS
The DN-33 was basically
designed to work with the
following types of hides:
• Cattle
• Horse
• Buffalo
These
hides
considered large-sized.
are
The DN-33 can efficiently handle irregularities in leather thickness, provided
it is adequately regulated and adjusted.
L
When the leather is still fresh (coming directly from the slaughtering
establishment) it can be fleshed right away. On the other hand, if using
salted hides, rewet the leather before the fleshing process, in order to
re-hydrate the hide and make it malleable.
If you have questions about operating the equipment carefully read the
instructions in this manual, especially those related to operation and
adjustments.
13.1
Cleaning the equipment
When cleaning the equipment on the outside, use only water and soap. Do not
use abrasives, because they may damage the painting as well as the components.
Daily cleaning routine
At the end of a working day, clean the equipment using running water at
room temperature or at 60° C maximum.
If you have questions, please contact our Customer Service Department:
Phone +55-51- 568-1900
[email protected]
45
DN-33
14.
MAINTENANCE
The DN-33 is a robust machine, designed for high performance and great
durability. In normal working conditions, the DN-33 requires very little
maintenance.
However, in order to guarantee its maximum working life, some important
preventive maintenance recommendations should be observed.
MAINTENANCE COMPONENTS – FRONT SIDE
HEIGHT AND SPRING
PRESSURE ADJUSTMENT TRANSPORT DRIVE ROLLERS
SUPPORT ROLLER
TRANSPORT DRIVE ROLLER
BLADE ROLLER
ELECTRIC COMPONENTS
CONTROL
PANEL
BEARINGS
HYDRAULIC UNIT
TABLE COMPENSATION
HOSE TABLE
MAINTENANCE COMPONENTS – REAR SIDE
ELECTRIC
COMPONENTS
TRANSMISSION
DRIVE UNIT
BLADE SHARPENER
46
Turn off the machine before any maintenance procedure.
14.1
Transport drive rollers - height and spring pressure
adjustment
Check the following:
9 Nuts are fastened.
9 Keep mechanism protection in place during operation.
PROTECTION
14.2
If you need to adjust this mechanism, keep in mind:
9 The DN-33 should never operate without the upper table protection
plate.
HOSE TABLE
47
DN-33
If you need to adjust the bolts located at the table front, carefully read
the instructions on page 22.
ADJUSTMENT BOLTS
(UNDERNEATH THE
PROTECTION PLATE)
If the hose requires replacement, both the mount plates located at the front
side of the table and the hose will have to be removed. After cleaning the area, the
new hose should be mounted and the plates should be fastened again. When
working on this mounting process, make sure that the new hose is firmly fastened
and that the mount plates are adequately aligned parallel to the upper part of the
table.
HOSE FASTENING PLATES
ADJUSTMENT AND
FASTENING
L
48
ADJUSTMENT AND
FASTENING
All precautions should be taken not to leave any salient sections that
could get in contact with the blades during operation; this will result in
premature wear or damage to the hose.
14.3
Lift the control panel
cover to access the rightside mechanisms
Remove the side
cover to access the
left-side mechanisms
49
DN-33
The connections of the open/close hydraulic system and of the table
compensation cylinders are located on both sides of the machine.
These connections should be protected against blows and checked on a
regular basis. If there are signs of oil leakage, the problem should be corrected in
order to guarantee the adequate operation of the machine.
Photoelectric sensors are also located on the sides of DN-33. These sensors
are delicate, and should be protected against bad weather conditions and blows.
50
14.4
Transport drive roller bearings
The transport drive bearing lubrication points are connected to the
lubrication panel, located on the rear part of the machine, on both sides.
GREASERS ON
LUBRICATION
PANEL
All lubrication points are connected to the respective greasers, which should
be filled with bearing grease.
Lubrication should be carried out every week.
51
DN-33
Do not operate the DN-33 without the
protection covers!
The open/close mounts and cylinders, the
hydraulic unit, and the drive and transmission units are
located on the right side of the machine.
In order to access these components, it is
necessary to lift the control panel cover.
Check the greasers; they should
be lubricated with bearing grease
every week.
GREASERS
52
14.5
Transmission
Lift the control panel cover to access the internal transmission component
mechanisms (cardans) and the transmission chain connecting the cylinders.
GREASE
Check the lubrication points and the greasers; they should be lubricated
every week.
GREASERS
GREASE
53
DN-33
14.6
Return filter
The return filter of the hydraulic
system should be replace once a year.
RETURN FILTER
14.7
The transport drive reducer is
provided with an oil level indicator.
Check the oil level every week and
add oil if necessary.
OIL LEVEL INDICATOR
A first oil change should be carried
out after the first 20-30 days of operation in
order to clean the gear adjustment system.
In order to do so, drain the oil through
the cap located at the bottom of the reducer.
After that, the oil should be
changed once a year.
Capacity: 2 liters of SAE 140 or ISO
460 transmission oil.
54
14.8
Hydraulic unit
In the hydraulic unit, the
following aspects should be observed:
INSULATING VALVE
MANOMETER
• The hydraulic system operates
with a 220-liter oil reservoir.
• The oil type used is ISO 68.
• Once a year, the filters should
be cleaned. In order to do so,
remove the cover of the
reservoir (pos. 6, page 90),
remove the hydraulic oil and
clean the bottom of the tank.
FILLER NOZZLE
SUCTION-TYPE FILTER
(LOCATED NEXT TO THE
HYDRAULIC PUMP,
SUBMERGED)
Caution!
Do not leave the nozzle
open so as to prevent
debris from getting into the
tank and contaminating
the system!
OIL LEVEL
INDICATOR
GENERAL PRESSURE
REGULATING VALVE
Check the hydraulic pressure:
The general hydraulic pressure, set
to 135 bar, can be read on the manometer
by activating the insulating valve located
above it.
The pressure is regulated at the
pressure regulating valve, located next to
the hydraulic block.
55
DN-33
Open/close pressure is set to 75 bar on the pressure reducing valve, located
below the flow regulating valve and the open/close directional valve. To make this
reading, couple a manometer to the outlet of the pressure reducing valve.
TABLE COMPENSATION
DIRECTIONAL VALVE
OPEN/CLOSE DIRECTIONAL
VALVE
TRANSPORT DRIVE
DIRECTIONAL VALVE
The pressure of the thickness compensation hydraulic cylinders is set to 45
bar at the pressure reducing valve, located below the directional valve. To make
this reading, couple a manometer to the outlet of the pressure reducing valve.
For any pressure verification, close the machine and turn off the transport
drive roller .
The system does not cause the oil level to lower.
A lower oil level is a sign of leakage, which may compromise
operation.
This kind of problem should be checked and corrected.
56
14.9
Drive
The steering assembly drive system is located on the rear part of the
machine.
In normal working conditions, these components do not require
maintenance. However, once a year the items described below should be checked.
Adjustments should be carried out if necessary.
PRESSURE AGENTS
BELT
TENSION
The moto-reducer of the sharpening assembly also presents lubrication points.
GREASER
CHAIN
GREASER
Lubricate the chain every
day and the greasers every
week.
57
DN-33
14.10
Blade sharpener
The blade sharpener has bar lubrication points.
The assembly has automatic oil droppers that lubricate the bar during the
sharpening process.
Lubricate the sharpener
chain every day.
Lubrication can also be carried
out according to the instructions
given below.
Before starting the sharpening
process, lubricate the bar using an
oilcan.
To replace the sharpening stone,
the corresponding fastening bolts
should be loosened. Then, the stone
should be replaced and firmly fixed
again, so as to guarantee the perfect
operation of the sharpener.
Caution!
During the sharpening process, the blade roller will be moving. Do not
touch it with your hands !
58
14.11
Blade roller replacement
27 mm
The working life of the blade roller is determined according to the wear
observed on the blades.
Original blades are 27 mm thick; they grow thinner after several sharpening
procedures.
Wear is compensated by the blade roller advancement system via the ( - )
button, on the control panel.
The minimum height limit for the blades is of approximately 7mm; at this
point, the maximum advancement stroke end will be activated (located in the rear,
on the left, underneath the sharpening bar, identified as BLADES WORN).
When this stroke end is activated, the corresponding indicator will light on
the control panel, and it will not be possible to further decrease the fleshing
thickness.
This indicates that it is time to replace the blade roller.
GENERAL
CONTROL
COMMUTATOR
BLADES
WORN
To replace the blade roller, follow the steps below:
1. Turn on the general commutator.
59
DN-33
Inside the control board, within the electric components, find the
MAXIMUM RECOIL commutator.
ELECTRIC
COMPONENTS
MAXIMUM RECOIL
COMMUTATOR
2. Activate the MAXIMUM RECOIL commutator inside the control board and
press the ( + ) button on the control panel. The recoil movement of the blade
roller will start (as if increasing the fleshing thickness) until the maximum
recoil stroke end is touched (located next to the maximum advancement stroke
end).
3. Turn off the MAXIMUM RECOIL commutator and the general commutator.
60
4. Release the bearings and remove the blade roller protection cover.
5. Remove the internal bar protection plate.
6. Remove the bolts of the blade
roller cardan coupling flange and
the fastening bolts of the side
bearing covers.
7. Fasten the auxiliary devices for blade roller replacement supplied with the tools
using the same fastening bolts used for the covers.
61
DN-33
8. With the help of an adequate belt, remove the blade roller using a tackle, a
forklift or a hauler (truck capacity must be compatible with the weight of the
roller).
9. Install the new blade roller with extreme caution and avoiding shocks. Check
the position of the vibration dampers.
10. Remove the auxiliary devices and fasten the bearing covers.
11. Fasten the cardan to the coupling flange.
12. Return the internal bar protection plate and the blade roller protection cover to
their original position.
13. Turn on the general commutator.
14. With the blade roller on, proceed with the adjustment of the blades so that they
are parallel to the bar (contact between the abrasive brick and the blades must
be uniform).
15. The blade roller should be turned off, and the machine should be closed as
soon as the roller stops rotating. With the help of a clearance gauge and using
the ( - ) button on the control panel, adjust the distance between the blade roller
and the hose, so that the desired fleshing thickness is obtained.
62
14.12
Blocking of the safety system
The safety system employs a photoelectric sensor and safety bars, as
described on pages 32-33; these mechanisms are tested every time the machine is
turned on, before it starts operating.
If one of these devices is damaged and stops
working, the machine will not be able to operate,
because the safety system will be blocked (emergency
status).
PHOTOELECTRIC
SENSOR
To operate the machine while in emergency
status, the aspects mentioned below should be
observed until replacement of the damaged item.
The photoelectric sensor
commutator is located on the
electric component panel. In
normal working conditions, this
commutator should remain on.
PHOTOELECTRIC SENSOR
COMMUTATOR
To operate the machine
while in emergency status, the
points listed below should be
observed until replacement of
the damaged item.
ON
Identify the origin of the
problem
(either
the
photoelectric sensor or a safety
bar).
SAFETY BLOCKING
63
DN-33
If the defect is on one of the bars, just activate the SAFETY BLOCKING
button on the electric panel. This will simulate a safety test and will release the
machine.
)
Remember that you are operating the equipment in emergency
conditions -- the safety bar is not working.
In case the defect is on the photoelectric sensor, just turn off the sensor via
the commutator located on the electric panel and run a safety bar test as usual to
release the machine.
)
Remember that you are operating the equipment in emergency
conditions -- the operators will be working without protection of the photoelectric
sensor.
OFF
PHOTOELECTRIC SENSOR
COMMUTATOR
Immediately replace the sensor and return the commutator to its original
position (Position 1 – ON).
Remember that this is an emergency situation.
The machine is working without protection devices!
64
14.13
Electric equipment
The electric system works
with fuses on the power supply
input.
If the fuses are damaged, determine
the cause and solve the problem. Do
not replace the fuse without doing
so.
Open the covers to access
the fuses.
OPEN
Fuse replacements must
match the original fuses exactly.
65
DN-33
15.
TROUBLESHOOTING
PROBLEM
SOLUTION
9 check whether the red indicator is on, suggesting the need to perform a
The machine does not
close.
safety test;
9 check whether the photoelectric sensors are clean and aligned;
9 check whether one of the pedals is activated or pressed;
9 check whether the cause of the problem is electrical or hydraulic.
The machine is not
closing completely on
one of the sides.
9 close the machine and carry out the open/close system filling procedure.
The machine has closed
and does not open
anymore, even after
activation of the pedals,
safety bars and the
control
panel
emergency button.
9 the presence of false air has been detected in the open/close system.
The machine closes but
the
transport
drive
roller does not move.
9 check whether the transport drive blocking commutator (on the control
The machine presents
little drive capacity, or
the leathers are not
being driven in a
uniform way.
9 check the height of the transport drive rollers in relation to the support
Fleshing is deficient.
With the machine open, open and close the filling valve.
Activate the air valve and the closing directional valve manually, and
simultaneously open the filling valve in order to remove the air from the
system. Close the filling valve and release the air valve and the closing
directional valve.
panel) is activated;
9 check whether the cause of the problem is electric or hydraulic.
roller, verifying that they are not too high or misaligned;
9 check the occurrence of power failure in the transport drive roller dish
springs.
9
9
9
9
check if the table compensation system is activated;
sharpen the blades;
decrease the fleshing thickness using the “- “ button on the control panel;
check and increase (if necessary) the pressure of the table-sustaining dish
springs.
Fleshing is deficient,
and it is not possible to
decrease the fleshing
thickness.
9 check if the blade replacement indicator is lit. In emergency cases, when it
Thickness
compensation at the
table is not according to
the current need.
9 increase or decrease the stroke of compensation hydraulic rollers, as
The machine is cutting
the paws or humps of
leathers.
brush the blades with a steel brush in order to remove sharpening debris;
check whether the hides are adequately positioned (centered and aligned);
in the case of paws, check whether the hides are adequately cut.
is really necessary to work despite the minimum limit of blade height
determined by the manufacturer, the minimum stroke end (located on the
rear side of the machine, underneath the bar) can be repositioned so as to
allow further advancement until blade roller replacement is possible.
9
9
9
After sharpening, the 9
leathers present blade
marks or meat debris.
66
described on page 23, section 9.3.
the sharpening stone was placed too close to the blades, resulting in
irregularities. Sharpen the blades in a very uniform manner.
15.
WARRANTY
WARRANTY CERTIFICATE
BREMM PECK LTDA provides the user of this equipment with
warranty against any defects in parts or factory defects, as long as they
are proven to have occurred in normal working conditions.
This warranty does not cover:
¾
¾
¾
¾
Equipment supplied by third parties, such as bearings, gaskets, etc.
Electric equipment
Electronic equipment
Hydraulic equipment
The coating of roller and blades is not covered by this warranty.
The replacement of defective parts and the performance of repairs
under warranty should be carried out by BREMM PECK personnel only.
The warranty is valid for 12 months as of the date of purchase
(as recorded in the invoice).
WARRANTY CANCELLATION:
The warranty will not be applicable in one of the following cases and
conditions:

After warranty expiration.

Inadequate use of the equipment (not in accordance with the manual).

Connection to an inadequate electric power source.

Incidental damage (lightning, floods, earthquakes, fires, etc.).

Damage caused by accidents.

Equipment showing signs of violation or adjustment/repair by people
other than BREMM PECK personnel.

Alterations in default configurations.
67
DN-33
68
17.
SPARE PARTS
Spare parts for maintenance are described in the following pages.
Use only original BREMM PECK parts. This will ensure the perfect
functioning and the durability of your equipment, as well as the honoring of your
warranty certificate.
When ordering spare parts, provide the information found on the
identification plate.
Our Customer Service Department will be pleased to help you.
Contact information
Phone: +55-51-568-1900
[email protected]
BREMM PECK Máquinas Industriais Ltda.
Av. Mauá, 2479
Bairro Santos Dumont
São Leopoldo - RS - Brazil
CEP 93110-320
Fone: +55-51-568-1900
Fax: +55-51-568-3665
E-mail: [email protected]
DN-33 MILLENNIUM 3
Spare Parts
69