Winget CUMFLOW RP100XD MK2 Parts & Operation Manual Download Page 3

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INDEX

SECTION 1

GENERAL INFORMATION

1.1.

Company Details

1.2.

Important Notice

1.3.

Mixer Operational and Safety Requirements

1.4

Installation Drawing

SECTION 2

INSTALLATION AND OPERATING INSTRUCTIONS

2.1.

Pre Installation Notes

2.2.

Installation Instructions

2.3.

Operating Instructions

SECTION 3

TECHNICAL SPECIFICATION AND MAINTENANCE

3.1.

Technical Specification

3.2.

Shutdown Procedure and Maintenance

3.3.

Lubrication

3.4.

Gear Unit Maintenance

SECTION 4

MIXER SPARE PARTS

4.1.

Mixing Pan & Drive

4.2.

Mixing Star & Drive

4.3.

Mixing Star Assembly

4.4.

Mixing Star Lifting Arrangements

4.5.

Layout of Guards

4.6.

Micro Switch Cam & Proximity Switch

4.7.

Electrical Switch Gear

4.8.

Decals & Logos

SECTION 5

ANCILLIARY EQUIPMENT SPARE PARTS

5.1

Pan Trolley Four Wheels

5.2

MoD Additional Parts

Summary of Contents for CUMFLOW RP100XD MK2

Page 1: ...XER 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 service winget co uk www winget co uk ...

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Page 3: ...TION 3 TECHNICAL SPECIFICATION AND MAINTENANCE 3 1 Technical Specification 3 2 Shutdown Procedure and Maintenance 3 3 Lubrication 3 4 Gear Unit Maintenance SECTION 4 MIXER SPARE PARTS 4 1 Mixing Pan Drive 4 2 Mixing Star Drive 4 3 Mixing Star Assembly 4 4 Mixing Star Lifting Arrangements 4 5 Layout of Guards 4 6 Micro Switch Cam Proximity Switch 4 7 Electrical Switch Gear 4 8 Decals Logos SECTION ...

Page 4: ...ffer from your machine Winget Limited can accept no responsibility for incorrectly supplied parts unless the machine serial number 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 m...

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Page 6: ...OPERATING AND MAINTENANCE MANUAL SECTION 1 GENERAL INFORMATION RP100XD MK2 ...

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Page 8: ...nget co uk parts winget co uk service 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 parts unless the machine serial number part number and a full description ...

Page 9: ...ot 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 MAXIMUM BATCH LOADS UNDER NO CIRCUMSTANCES should the Maximum Batch Loads quoted be exceeded nor should the mixer be stopped or re started when there is a mix in Pan MIXING PAN Ensure that the Mixing Pan is r...

Page 10: ...ERS 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 ...

Page 11: ... 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 and that pan rack and drive gear are in correct mesh ELECTRICAL SERVICES 4 1 Refer to wiring diagram in Ops Manual All wiring to be undertaken by competant electrician it is recommen...

Page 12: ...ocedures detailed in your companies Heath and Safety Policy at all times 6 3 Ensure all storage bins containing materials to be mixed are isolated 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 re...

Page 13: ...outlining weights etc 8 7 Refer to Method Statement when installation and commissioning is responsibility of Croker Nett Weights Max kgs 9 1 RP50XD 788 RP1250XD 4840 RP100XD 900 RP1500XD 4980 RP200XD 1400 RP3000XD 7112 RP400XD 2000 FP1000 4040 RP550XD 2150 FP1500 4065 RP850XD 2600 FP2000 4100 9 2 Refer to technical specification for nett weights of ancillary equipment 9 3 Refer to contract drawing...

Page 14: ...INSTALLATION DRAWING ...

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Page 16: ...OPERATING AND MAINTENANCE MANUAL SECTION 2 INSTALLATION AND OPERATING INSTRUCTIONS ...

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Page 18: ...using certified lifting gear of suitable capacity by a competent person 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 ...

Page 19: ...an rack and drive gear are in mesh Also check that all the blade clearances are in line with the maintenance instructions On connecting to the power supply the wiring diagram must be referred to Note it is recommended that the mains electrical supply is taken via an earth leakage circuit breaker The wiring is correctly connected to the motors when the pan and star drive rotate as follows The mixin...

Page 20: ...on When the mixing pan is removed the mixer cannot be operated as the proximity switches need to sense the pan in position to complete the electrical circuit 7 On completion of the mixing cycle the raising of the mixing star operates a limit switch which automatically stops all moving parts 8 The pan can then be removed by hand or with the special lifting trolley available as an option IMPORTANT A...

Page 21: ...able 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 canc...

Page 22: ...that the wheels are equally spaced to each side of the mainframe chassis 6 Fully raise the Mixing Star by means of the handwheel and allow the pan to come to a complete stop Manually rotate the pan until two of the Pan Lifting Lugs are at right angles to the mainframe chassis This will allow the Trolley when correctly positioned below the pan to cleanly lift the pan clear of the rack 7 Push the Tr...

Page 23: ...an be easily and quickly positioned over the rack and lowered into place 9 On no account must attempts be made to engage the trolley with the mixer mainframe chassis unless the Star Drive is raised and the rack stationary 10 Do not swing on the Trolley Handles doing so may cause the Trolley to become unstable and it may tip backwards especially if the pan is empty causing injury to either yourself...

Page 24: ... on the control panel 4 Ensure the red emergency stop plunger on the front of the control panel is not depressed 5 Press the green start button 6 With both hands on the hand wheel rotate the hand wheel anti clockwise and lower the mixing star slowly and gently down into the mixing pan The motors driving the pan and star should start automatically as the star enters the pan Note do not allow the mi...

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Page 26: ...OPERATING AND MAINTENANCE MANUAL SECTION 3 TECHNICAL SPECIFICATION AND MAINTENANCE ...

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Page 28: ...tally enclosed geared electric motor to suit 3 phase 50 cycles 380 420 volts a c supply Mixing star drive 2 2kw totally enclosed geared electric motor to suit 3 phase 50 cycles 380 420 volts a c supply POWER UNITS 240V Mixing pan drive 1 1kw totally enclosed geared electric motor to suit 1 phase 50 cycles 240 volts a c supply Mixing star drive 2 2kw totally enclosed geared electric motor to suit 1...

Page 29: ...WEIGHTS UNLADEN 900kg approx Weight of additional pan 89kg approx PAN LIFTING TROLLEY RHS steel frame mounted on four industrial castors with tubular section handle ...

Page 30: ...ilable 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 Star Blades B Fixed Blade 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 C Other items prone to l...

Page 31: ...80 litres cap NOTE Total Carter SP220 is a synthetic oil and should not be mixed with mineral oils such as Mobil Mobilgear 630 unless the gearbox is thoroughly flushed out after draining INSPECT AND ADJUST MONTHLY 1 Pan Gear and Pinion grease 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 Finge...

Page 32: ...g as well as the cover lattice of the fan bonnet should be kept clean in order not to endanger the cooling of the motor with dust and dirt Although the bearings of the motor have life time lubrication the oil in the gearbox of a new unit should be drained after the first 500 hours of operation and the case thoroughly flushed with a light flushing oil before refilling with fresh oil to the correct ...

Page 33: ...LUBRICATION CHART ...

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Page 35: ...OPERATING AND MAINTENANCE MANUAL SECTION 4 MIXER SPARE PARTS ...

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Page 37: ...RP100XD MK2 MIXING PAN DRIVE ...

Page 38: ...20023 ALTERNATIVE 1 2 X 7 16 X6 CUT TO SIZE 1 15 CR460022 BEVEL PINION 1 16 CR150925 BEVEL PINION SHAFT BEARING 1 16A 176S01 COVER NIPPLE GREASE 1 16B 7S06 NUT M16 2 16C 11S06P SCREW SET M16 X 80 2 17 8S05J BOLT BEARING M12 X 65 2 17A 61S05 NUT BINX M12 2 17B 267S07 WASHER FLAT M12 2 17C 105S05 WASHER TAPER M12 2 18 CR52100896 BEVEL PINION SHAFT 1 19 CR329015 COUPLING DRIVEN HALF FEATHER KEY 1 20 ...

Page 39: ...RP100XD MK2 STAR DRIVE ASSEMBLY ASSEMBLED LENGTH OF COUPLING ITEM 3 ON SHAFTS IS 73MM ...

Page 40: ...1S06M SCREW SET M16 X 70 4 7D 7S06 NUT M16 6 7E 11S06K SCREW SET M16 X 60 2 8 CR460024 GEAR BEVEL 2 8A 57S05D2 GRUB SCREW M8 6 8B 555116600 PLATE GEAR RETAINING 2 8C 11S04D SCREW SET M10 X 30 2 8D 17S05 WASHER SPRING M10 2 8E 267S06 WASHER FLAT M10 2 9 CR329046 KEY FEATHER BEVEL GEAR HORIZONTAL 1 2X5 16X2 1 9A CR329093 KEY FEATHER BEVEL GEAR VERTICAL 1 2X5 16X3 4 1 10 CR210139 SUPPORT CONICAL STAR...

Page 41: ...24B 105S05 WASHER TAPER M12 4 24C 61S05 NUT BINX M12 4 25 11S04G SCREW SET GEAR MOTOR UNIT M10 X 45 4 25A 17S05 WASHER SPRING M10 4 25B 267S06 WASHER FLAT M10 4 26 CR26100867 STAR ARM CHASSIS FRAME 1 RP100XD MK2 STAR DRIVE ASSEMBLY ...

Page 42: ...RP100XD MK2 MIXING STAR ASSEMBLY ...

Page 43: ...FINGER STAR BLADE 4 CU FT PAN RP100 2 28 CR210142 BRACKET FIXED BLADE 1 28A 333104020 NIPPLE GREASE 1 4 BSP STRAIGHT 1 28B 176S01 COVER NIPPLE GREASE 1 29 CR260415 FINGER FIXED BLADE 4 CU FT PAN RP100 1 31 CR53100880 BLADE FIXED 4 CU FT PAN RP100XD MK2 1 32 CR53100881 ANGLE FIXED BLADE MOUNTING RP100XD MK2 1 33 CR639004 COLLAR SPACER 3 33A 10S31 WASHER FLAT AR 33B CR289002 GREASE NIPPLE 1 4 BSP 90...

Page 44: ...RP100XD MK2 MIXING STAR LIFTING ARRANGEMENT ...

Page 45: ...14 CR20100874 CHAIN TILTING 1 14A 134104002 LINK SPLIT CHAIN 1 15 CR200134 BOLT BLOCK DRAW CHAIN 1 16 CR200072 LINK ATTACHMENT CHAIN END 1 17 304712863 KEY PLATE WHEEL BUSH M12 X 8 X 63 1 18A 176S01 COVER NIPPLE GREASE 2 19 8S06H BOLTS PIVOT SHAFT M16 X 60 4 19A 267S08 WASHER FLAT M16 4 19C 61S06 NUT BINX M16 4 19D 105S07 WASHER TAPERED M16 4 20 8S05E BOLT BEARINGS M12 X 45 8 20A 267S07 WASHER FLA...

Page 46: ...RP100XD MK2 COVERS GUARDS ...

Page 47: ...0897 COVER INSPECTION HOUSING SIDE R H NOT ILLUS 1 6A 11S03B SCREW SET M8 X 20 4 6B 17S04 WASHER SPRING M8 4 6C 267S05 WASHER FLAT M8 4 6D CR53100909 COVER INSPECTION HOUSING SIDE L H NOT ILLUS 1 6E 11S03B SCREW SET M8 X 20 4 6F 17S04 WASHER SPRING M8 4 6G 267S05 WASHER FLAT M8 4 7 CR53100875 COVER FRONT HOUSING NOT ILLUSTRATED 1 7A 11S03B SCREW SET M8 X 20 4 7B 17S04 WASHER SPRING M8 4 7C 267S05 ...

Page 48: ...R SIDE RH 1 13A CR54100827 GUARD PAN COVER SIDE LH 1 13B CR54100828 GUARD PAN COVER REAR NOT ILLUSTRATED 1 13C 11S03B SCREW SET M8 X 20 21 13D 17S04 WASHER SPRING M8 21 13E 267S05 WASHER FLAT M8 21 13F 7S03 NUT M8 9 14 CR570019 SEAL RUBBER 1 15 CR53100926 STOP ANGLE STAR ARM CHASSIS NOT ILLUSTRATED 1 15A 8S03B BOLT M8 2 15B 267S05 WASHER FLAT M8 4 15C 61S03 NUT BINX SELF LOCKING 2 RP100XD MK2 COVE...

Page 49: ...PAGE INTENTIONALLY BLANK ...

Page 50: ...FTING 1 9 11S02C SCREW SET M6 X 25 2 10 17S03 WASHER SPRING M6 2 11 267S04 WASHER FLAT M6 2 12 CR54100863 BRACKET PROXIMITY SWITCH PAN 2 13 11S03C SCREW SET M8 X 25 4 14 267S05 WASHER FLAT M8 4 15 17S04 WASHER SPRING M8 2 16 7S03 NUT M8 2 17 7000410 COVER SPIRAL GUARD 6MT 18 143200300 CLIP P 2 19 11S02B SCREW SET M6 X 20 2 20 267S04 WASHER FLAT M6 2 21 17S03 WASHER SPRING M6 2 22 7S02 NUT M6 2 23 ...

Page 51: ...LUE 8 5 144799000 CABLE 1 5MM SQ G Y 6491X H07 4MT 6 144700100 CABLE 1 5MM SQ RED 6491X H07 4MT 7 144798000 CABLE 1 5MM SQ BLACK 6491X H07 4MT 8 CR229103 CABLE 2 5MM SQ RED 6491X H07 3MT 9 CR229104 CABLE 2 5MM SQ YELLOW 6491X H07 3MT 10 CR229105 CABLE 2 5MM SQ BLUE 6491X H07 3MT 11 CR229097 TERMINAL RING CRIMP ON TYPE 2 12 CR229114 LOCK RINGS 20MM 3 13 CR22100879 CONVERTER PG16 M20 2 14 513340800 ...

Page 52: ...RP100XD MK2 DECALS AND LOGOS CROKER CUMFLOW RP100XD 1 2 4 5 6 7 8 9 10 11 12 13 ...

Page 53: ...V2003665 DECAL SLING POINT 4 6 V2003598 DECAL BRITISH MADE 2 7 V2004307 DECAL ELECTRICAL HAZARD 2 8 V2004223 DECAL CE MARK 1 9 V2004229 DECAL OPERATORS HANDBOOK 2 10 V2004744 DECAL EYE PROTECTION 2 11 504694600 DECAL SAFETY 1 12 V2004130 DECAL NOISE 80 LPA 1 13 V2003575 DECAL NOISE 105 LWA 1 RP100XD MK2 DECALS AND LOGOS ...

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Page 55: ...OPERATING AND MAINTENANCE MANUAL SECTION 5 ANCILLARY EQUIPMENT SPARE PARTS ...

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Page 57: ...PAGE INTENTIONALLY BLANK ...

Page 58: ...RP100XD PAN TROLLEY ...

Page 59: ...EEL ASSEMBLY INC ITEMS 5 6 7 2 5A CR440122 WHEEL RIM 2 5B CR440125 BEARING ROLLER 2 6 CR440123 TYRE 2 7 CR440124 TUBE 2 8 CR630105 BOSS WHEEL RETAINER 2 9 69S03G BOLT 3 8 UNF 2 9A 107S14 NUT NYLOC 3 8 UNF 2 10 11S06F SCREW SET 4 10A 267S09 WASHER FLAT 8 10B 61S06 NUT BINX 4 11 69S03G BOLT 3 8 UNF 2 11A 107S14 NUT NYLOC 3 8 UNF 2 RP100XD PAN TROLLEY ...

Page 60: ...RP100XD FOUR WHEEL PAN TROLLEY ...

Page 61: ...BOLT HANDLE RETAINING M8 x 45 2 19 61S03 NUT BINX M8 2 20 CR449001 CASTOR SWIVEL REAR ASSEMBLY 2 INDIVIDUAL WHEEL ITEMS AVAILABLE AS FOLLOWS 20A CR449002 WHEEL ASSEMBLY C W BEARING 1 20B CR449005 WHEEL CENTRE BUSH SPACER 1 20C 11S05P BOLT M12 x 80 1 20D 61S05 NUT BINX M12 1 21 11S04D BOLT CASTOR RETAINING M10 x 30 8 22 267S06 WASHER FLAT M10 8 23 17S05 WASHER SPRING M10 8 24 7S04 NUT M10 8 25 CR44...

Page 62: ...TION 1 2 101S05D RIVET POP 4 3 V2005132 TOOL KIT 1 4 CR54100774 TOOL BOX 1 5 11S04B SCREW SET M10 2 6 17S05 WASHER SPRING M10 2 7 7S04 NUT M10 2 RP100XD MK2 ADDITIONAL PARTS REQUIREMENT MoD ADDITIONAL PARTS LISTED BELOW ARE NOT ILLUSTRATED ...

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Page 64: ...OPERATING AND MAINTENANCE MANUAL SECTION 6 ELECTRICAL SYSTEM ...

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Page 66: ...Electrical Control Circuits dwg 11 03 02 10 55 09 Scaled to fit ...

Page 67: ...V06302 dwg 11 12 02 07 03 44 Scaled to fit ...

Page 68: ...Electrical Power Circuits dwg 11 03 02 10 58 17 Scaled to fit ...

Page 69: ...V06303 dwg 11 12 02 07 04 45 Scaled to fit ...

Page 70: ...General details of Control Panel dwg 11 03 02 11 01 09 Scaled to fit ...

Page 71: ...V06301 dwg 11 12 02 07 02 37 Scaled to fit ...

Page 72: ...Material Parts List dwg 11 03 02 11 03 32 Scaled to fit ...

Page 73: ...V063PL1 dwg 11 12 02 07 01 06 Scaled to fit ...

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Page 75: ...OPERATING AND MAINTENANCE MANUAL SECTION 7 MISCELLANEOUS ...

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Page 77: ...7 1 NOISE DETAILS Measured in accordance with Article V of Directive 2000 14 EC Noise Emission in the Environment by Equipment for Use Outdoors the noise levels should not exceed 105Lwa ...

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