Operating and Servicing Instructions
for
Co-Rotating
Twin Screw Extruder Gearbox
DURUMAX
TGE
T1MAX
Date: October 2003
Страница 1: ...Operating and Servicing Instructions for Co Rotating Twin Screw Extruder Gearbox DURUMAX TGE DURUMAX T1MAX Date October 2003 ...
Страница 2: ...0 8 1 Filling with lubricant 10 8 2 Checking the gearbox 11 8 3 The first run 11 8 4 Monitoring the torque 11 8 5 Monitoring the axial load 12 9 Operation 12 10 Down times 12 11 Technical description 13 11 1 General description 13 11 2 Housing 13 11 3 Gear parts and shafts 13 11 4 Bearings 13 11 5 Seals 13 11 6 Lubrication 13 11 7 Noises 13 12 Servicing and inspection 14 12 1 Servicing table 14 12...
Страница 3: ...d understood the operating and servicing instructions and must also observe the operating instructions We accept no liability for damage and malfunctions in operation that are caused by failure to observe the operating instructions In case of doubt the original Ger man version of the operating and servicing instructions is legally binding We reserve the right to make changes to individual modules ...
Страница 4: ...wed to be performed when the gearbox is stationary The drive unit must be secured against inadvertent switch on The operating organization has the obligation to only operate the gearbox when it is in correct working order The drive unit must be switched off immediately if changes on the gearbox are noted during operation e g elevated operating temperatures changes in the noises from the gearbox or...
Страница 5: ...tance is performed in accordance with Henschel regulations or as per the related requirements agreed in the contract The paint finish on the interior and exterior of the gearbox comprises a thick film epoxy metal primer RAL 7032 pebble grey The manufacturer reserves the right to use other products in special cases An additional topcoat can be agreed All bare exterior parts and surfaces are coated ...
Страница 6: ...e kept horizontal so that all points are evenly loaded During transport it is to be ensured that any attachment parts e g pumps coolers or pipes are not damaged Transport is to be performed with extreme care to avoid injury Damage to the gearbox e g due to impacts on the open ends of shafts or due to setting down hard is to be avoided 5 3 Storage Proper storage of the gearbox will prevent prematur...
Страница 7: ...olts must have a minimum strength class of 8 8 The gearbox is not allowed to be placed under stress when the fastening bolts are tightened The alignment of the gearbox must be re checked after tightening the fastening bolts If external forces act on the gearbox it is appropriate to prevent movement using lateral stops All fastening features on the gearbox are to be utilized 6 3 Shafts The coating ...
Страница 8: ...r screws to the gearbox The design and align ment of the sleeves for coupling is customer and gearbox specific The related items are to be found on the installation drawing It is not possible to interchange sleeves for coupling from different gearboxes For the adaptation of the two extruder screws the two sleeves for coupling must be placed in the corresponding position as per the installation dra...
Страница 9: ...ts inside the gearbox may be damaged in this way The maximum permissible belt tension force applied at the middle of the key must not be ex ceeded as otherwise the input shaft may be subject to excessive bending and damage caused to the bearings and seals The values given in the gearbox data sheet are general figures In case of doubt consult Henschel Industrietechnik The belt is only allowed to be...
Страница 10: ...eet and be tested for cor rect function The system is to be checked for oil leaks at operating temperature All threaded fittings are to be checked for tightness 8 Commissioning the gearbox When commissioning the gearbox it is imperative that the instructions in section 3 Safety instruc tions are observed Prior to commissioning the rest of the conservation oil or the running in or test oil is to be...
Страница 11: ...stened to the foundation section 6 2 All rotating parts must be covered in accordance with regulations and secured against acci dental contact section 3 8 3 The first run The gearbox can only be operated in one direction of rotation see installation drawing and gearbox data sheet Operation in the opposite direction of rotation is not allowed The gearbox is only allowed to be placed in operation an...
Страница 12: ...upply system running The servicing work listed in section 12 1 must be performed conscientiously An exact oil level check is only possible with the system stationary When the oil is warm the oil level can be somewhat higher It is not allowed to let the oil level drop below the minimum mark in this case the oil must be topped up section 12 2 If irregularities occur during the operation the system i...
Страница 13: ...eated steel and transmit the torque with adequate safety 11 4 Bearings All shafts have bearing at both ends Axial bearings of varying types are used for absorbing the axial forces from the screws The minimum theoretical bearing service lives for the roller bearings and the thrust bearings are given in the gearbox data sheet These are calculated based on the nominal torque and nominal speed Collect...
Страница 14: ...er approx 250 operating hours See section 12 3 Subsequent oil change every 4000 to 8000 operating hours at the latest however after 12 months See section 12 3 Visual inspection of the gears quarterly The visual inspection of the gears can be per formed by removing the inspection hole covers In case of damage or irregularities the manu facturer must be consulted Check used oil for foreign bodies an...
Страница 15: ... is always to be filled with the type of oil used previously It is not allowed to mix different oils or oils from different manufacturers A funnel with a filter must be used to fill the gearbox filter mesh 40µm Dirt can result in pre mature damage to bearings and gears When changing the oil the old gearbox oil is to be drained if possible when still warm using the oil drain plug provided for this ...
Страница 16: ...whether there is any damage to the parts of the gears e g Pittings and micro pittings on the tooth flanks due to gearbox overloading Scratches and indentations due to the action of dirt Fretting due to inadequate lubrication or overload Visual inspection of the roller bearings Checking the oil supply to the meshing gears and to the roller bearings in the gearbox In case of damage the related parts...
Страница 17: ...uate Check the feed and return clean oil filter or re place Elevated oil tem perature Oil pump is faulty Check pump if necessary replace Oil level is too low Check oil level and adjust Oil is too old Check when the oil was last changed and if nec essary have the oil analyzed and change the oil Bearing faulty Seek advice from Henschel Industrietechnik after sales service Elevated bearing temperatur...
Страница 18: ...oxes They must comply with the mini mum requirements in DIN 51517 3 draft January 2002 In addition the oil must have increased safety against micro pittings The oils must be suitable for the elastomeric materials in the shaft seals and the usual gaskets that are used between bolted surfaces The use of lubricants that do not comply with the stipulated quality requirements may render the warranty vo...
Страница 19: ... s 220 320 460 Manufacturer Degol BG 220 Plus Degol BG 320 Plus Degol BG 460 Plus Aral Degol BMP 220 Degol BMP 320 Degol BMP 460 Castrol Alpha SP 220 Alpha SP 320 Alpha SP 460 Renolin CLP 220 Plus Renolin CLP 320 Plus Renolin CLP 460 Plus Fuchs Renolin CLP 220 Renolin CLP 320 Renolin CLP 460 Mobil Mobilgear XMP 220 Mobilgear XMP 320 Mobilgear XMP 460 Shell Shell Omala F 220 Shell Omala F 320 Shell...
Страница 20: ... VG 460 Kinematic viscosity at 40 C mm 2 s 220 320 460 Manufacturer Aral Degol PAS 220 Degol PAS 320 Degol PAS 460 Castrol Alphasyn EP 220 Alphasyn EP 320 Alphasyn EP 460 Fuchs Renolin Unisyn CLP 220 Renolin Unisyn CLP 320 Renolin Unisyn CLP 460 Mobilgear SHC 630 Mobilgear SHC 632 Mobilgear SHC 634 Mobil Mobilgear SHC XMP 220 Mobilgear SHC XMP 320 Mobilgear SHC XMP 460 Shell Shell Omala HD 220 She...
Страница 21: ...h America Inc 1001 West 31 st Street Doweners Grove IL 60515 USA tel 49 0 2161 909 30 phone 1 630 241 4000 fax 49 0 2161 909 400 fax 1 630 241 1270 mail info castrol industrie com mail info castrol industrie com Castrol web www castrol industrie com web www castrol industrie com FUCHS EUROPE Friesenheimer Str 15 D 68169 Mannheim Germany FUCHS Lubricants CO Main Office Plant USA Harvey Illinois 604...
Страница 22: ...1 West 31 st Street Doweners Grove IL 60515 USA tel 49 0 2161 909 30 phone 1 630 241 4000 fax 49 0 2161 909 400 fax 1 630 241 1270 mail info castrol industrie com mail info castrol industrie com Optimol web www castrol industrie com web www castrol industrie com Ein Unternehmen der Castrol Industrie GmbH Erkelenzer Straße 20 D 41179 Mönchengladbach Germany A company of Castrol Industrial North Ame...
Страница 23: ...y and reliability For damage that results from the use of parts not supplied by us no warranty is provided by Henschel Industrietechnik and all liability excluded Spare parts list Code Description W1 Shaft 1 Input shaft L1W1 Bearing 1 on shaft 1 L2W1 Bearing 2 on shaft 1 DW1 Shaft seal input shaft Shaft 1 W4 Shaft 4 L1W4 Bearing 1 on shaft 4 L2W4 Bearing 2 on shaft 4 ALW4 Axial bearing on shaft 4 ...
Страница 24: ...Operating and servicing instructions 24 24 Schematic layout of the TGE und T1MAX co rotating gearbox Base gearbox Intermediate gearbox ...
