GENERAL MACHINERY CORPORAION
MODEL 2501
HYDRAUFLAKER Combination Frozen Meat Manual #2501-1
General Machinery Corporation 1831 N. lgth Street - P. 0 . Box 717 Sheboygan, Wisconsin - USA 53082-071 7 TELEPHONE: 920-458-2189 or 888-2-GENMAC FAx.. 920-458-8316 Internet Address: http:/hvww.ne~tmac.com
NEW MACHINE GUARANTEE GENERAL MACHINERY CORPORATION (GMC) guarantees parts of its manufacture against defect in material and workmanship for a period of one year ( 12 months) from date of invoice. Guarantee is limited to replacement andlor repair of such defective parts. To implement the guarantee, customer must inform GMC of parts defect. If it is determined that replacement is required, GMC will ship and invoice identical or similar parts t o the customer. After replacement parts are installed, and operate satisfactorily, customer must return the faulty part (s) t o GMC at Sheboygan, Wisconsin - USA for evaluation. Upon verification of defect GMC will issue a full credit covering the replacement part (s). Labor, handling and shipping cost's are not included in. the guarantee. Guarantee does not cover cost or liability due t o misuse, abuse, or improper operation of machinery or parts thereof. Guarantee does not include any parts that are not supplied by GENERAL MACHINERY CORPORATION
IMPORTANT NOTICE When wiring the leads to the electrical box, make sure to check the rotation of the cutting drum. When standing at the loading end of the machine, the drum should be turning towards you. If not, reverse the leads.
DO NOT PUT HAND INTO FEED OPENING
PELIGRO
NO PONER LA MAN0 DENTRO DE LA ABERTURA DE ALIMENTACION
SAFE T DECALS give instant warning that sharp blades are in operation alerting the operator as well as employees working near your slicer that a hazard exists. The SAFE T DECALS are made of a tough durable plastic designed t o take the rigorous environment of food processing facilities. Adhesive mounted, SAFE T DECALS can be placed on any slicing machine in your processing line. Order SAFE T DECALS now t o alert your employees of slicing machine hazards.
IMPORTANT SAFETY FIRST READ THESE,INSTRUCTIONS BEFORE INSTALLING, OPERATING, MAINTAINING OR CLEANING EQUIPMENT 1. MARK A MINIMUM "SAFE AREA" AROUND THE MACHINE. 2. ONLY A LICENSED ELECTRICIAN SHOULD CONNECT MACHINE TO POWER SOURCE. 3. TEST SAFETY GUARDS BEFORE OPERATING MACHINE. 4. ONLY AUTHORIZED TRAINED PERSONNEL SHOULD WORK WITH OR NEAR MACHINE. 5. MACHINE SHOULD BE UNDER POWER ONLY WHEN THE PRODUCT IS BEING PROCESSED. 6. IMPORTANT I!! IF FOR ANY REASON, INCLUDING, BUT NOT LIMITED TO, IMPROPER PRODUCT FEED, BLOCKAGE, UNFORESEEN MALFUNCTION, ETC., OCCUR, FIRST PRIORITIES ARE TO: A. TURN POWER OFF! B. SEEK SUPERVISOR'S ASSISTANCE, AND C. ASSURE SAFETY BEFORE RESTARTING. 7. WARNING DECALS ARE PLACED ON ALL GUARDS, REPLACE THEM WHEN WORN. DO NOT OPERATE THE MACHINE WITHOUT SAFETY DECALS IN PLACE.
* * CLEANUP AND MAINTENANCE CREWS* * 1. DISCONNECT ALL POWER TO MACHINE BEFORE MAINTENANCE OR CLEANING. 2. BLOCK CUTTING BLADES AND/OR MOVEABLE PARTS TO PREVENT MOVEMENT DURING MAINTENANCE OR CLEANING. 3. WEAR PROTECTIVE GLOVES. USE LONG HANDLED BRUSHES FOR CLEANING BLADES OR OTHER HAZARDOUS AREA.
IF ASSISTANCE IS REQUIRED CONTACT MANUFACTURER BEFORE OPERATING THE EQUIPMENT
REMEMBER THE SAFEST MACHINE IS ONLY AS SAFE AS YOU WANT IT TO BE!!! PHONE 1-888-2-GENMAC (1-888-243-6622) FAX 920-458-8316 E-Mail: snlesaaenmac.com
IMPORTANT NOTICE
Employ machine only for the purpose advertised by manufacture. Due t o federal laws dealing with safety, GMC requires that operating and safety instructions related t o this machine, be brought t o the attention of any and all personnel who operate, maintain, clean, or supervise or manage its use. If this machine is disposed of or used by any other concern, these instructions must accompany the machine, and be brought t o the attention of such concern.
GMC is t o be promptly notified if the machine is sold or disposed of in any manner:
PHONE: 920-458-2189 FAX: 920-458-8316 Only parts or equipment manufactured by GMC, or authorized by GMC in writing, are t o be employed o n or with this machine.
READ THIS IMPORTANT NOTICE WITH REGARD TO SAFETY Product may contain foreign materials that can damage equipment and1 or cause food contamination. As a precaution, operators must be alerted and metal detectors employed t o check product before and subsequent t o entering equipment. Our engineering department is continually evaluating both new safety equipment and that employed in the field. Consequently, we require immediate notification in regard t o any perceived hazards, and prior t o any modifications, or if the machine is sold, loaned, transferred, or otherwise disposed of. That information will allow us t o maintain accurate files and assure continued safe operation. General Machinery Corporation 1831 N. 1 8thStreet P. 0. Box 717 Sheboygan, WI 53082-0717 USA Phone: 920-458-2189 OR 888-243-6622 Fax: 920-458-8316 E-mail:
[email protected] YOUR ATTENTION PLEASE:
This notice or copy thereof, must be brought t o the attention of all personnel connected with the operation, maintenance, sales and/or disposition of GMC Equipment. Attach t o your permanent records for regular reference.
WARNING DO NOT CONNECT POWER OR OPERATE MACHINE WITHOUT VISUALLY CHECKING TO SEE THAT ALL MOVING PARTS ARE SECURED, AND ANY OBSTACLES ARE REMOVED FROM THE CUTTING AREAS. FOR MACHINES WITH CRANKS, TURN MACHINE OVER MANUALLY TO MAKE SURE ALL MECHANISMS ARE WORKING CORRECTLY. REMOVE CRANK BEFORE STARTING MACHINE DO NOT REMOVE AND/OR MODIFY ANY MACHINE COMPONENTS. ALL COMPONENTS SUCH AS GUARDS, PANELS, GAUGES, ETC. MUST BE IN PLACE AND FUNCTION PROPERLY BEFORE MACHINE IS PUT INTO OPPERATION. ANY MALFUNCTION, OR MISSING COMPONENTS MUST BE BROUGHT TO THE ATTENTION OF THE MANUFACTURER IMMEDIATELY.
This safety notice should be prominently displayed in the work area, given t o the supervisor and operqting personnel in an effort for all employees t o be concerned about safety precautions.
GMC
INSTALLATION MODEL 2501 PNEUMATIC FEED HYDRAUFLAKER WITH AIR CLUTCH & BRAKE
The HYDRAUFLAKER Combination FLAKER and SLICER, prior to shipment, has been fully inspected, and has been operated at the factory. It is necessary when receiving this machine, the crate and machine be checked for external damage in transit.' If damage has occurred, make proper notation on the Bill of Lading, so proper action can be taken, with the freight company. 1. Remove all crating material and skids from machine, recheck machine for possible shipping damage. 2. Move machine to proper location, with machine placed in a level position, in the cross direction, and the feed side of the machine, approximately one inch higher than the discharge side (cutting drum side). All four legs are to firmly contact the floor or support area. 3. Remove protective coating from blades, pusher, etc. 4. The pneumatic system of the HYDRAUFLAKER, is a complete self-contained, and regulated system. It is designed for years of trouble free service. The HYDRAUFLAKER should be operated at approximately 80-PSI air pressure, at 5 CFM air consumption, for proper performance. Air connection is made on the right hand side of the machine, on the filterlregulator. 5. Connect to proper supply line, voltage, phase, and cycle of machine, indicated on the electrical control box. The HYDRAUFLAKER must be properly fused through a disconnect box, and the machine properly grounded for safety. The motor that is operating the HYDRAUFLAKER, is connected through overload switches, which will give the motor ample protection. Upon connecting the machine to proper supply, it is absolutely essential that the direction of rotation of the motor is correct. The cutting drum must revolve toward the feed pusher, or when facing the pulley side of the machine, the drum rotates in the counterclockwise direction (facing motor shaft), motor operates counterclockwise 6. Operate the HYDRAUFLAKER to check the leveling of the machine. If properly leveled and supported, the cutting drum will revolve smoothly, without vibration. Operate the automatic conveyor feed, the pusher will feed towards the cutting drum, and will automatically return.
OM 2501 Air Brake 4-18-06
OPERATING INSTRUCTIONS
The HYDRAUFLAKER is completely lubricated when leaving the factory. It is necessary all bearings are greased a maximum of once a week.
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The motor, valves, and pneumatic cylinder, are self-lubricated, and do not require any further attention. It is advisable, after each day's operation, to thoroughly clean the machine, and cover the knives with vegetable oil. After each day's operation, the knives should be honed and retightened. The drive belts from the motor to the knife drum will require retightening after several days of operation. The taughtness of these belts should be checked periodically, to maintain full cutting power at the cutting drum. The HYDRAUFLAKER has one control station. This is an electrical push control box located at the rear of the machine. The four control buttons are the black button to start the machine, the red button to stop the machine, the green button to actuate the feed pusher, and the yellow button for stopping the pusher & drum in mid cycle. If the pusher is to be retracted, at any time during its forward feed, contact the yellow button. This will automatically retract the pusher, from any position, and stop the drum. The HYDRAUFLAKER as shipped'to you, is adjusted to cut inch thick slices (flakes). For slice thickness change, it is necessary to remove the HFA-120-5 knives. Replace the HFA-113 slice thickness shims, with the size required, and refasten the knives firmly in position. When changing knives, or resetting knives, for different slice thickness, it is imperative that the machine is to be made electrically ino~erative,by disconnecting the disconnect switch. In the cutting of frozen blocks of meat, a smoother operation will result, if the flat side of the frozen block is placed in the down position. The operating sequence of the HYDRAUFLAKER is as follows: 1. Start machine by contacting start button (Black) (P-621-002). The motor will start, but not the cutting drum. 2. Push the frozen block of meat from loading table, onto feed deck. 3. Contact pusher start button (Green) (P-621-001). The cutting drum will start & the pusher will move forward. 4. Upon automatic return of block pusher, load successive blocks and repeat No. 3. 5. Anytime the batching button is pushed (Yellow), the cutting drum will stop, and the pusher will stop, and return to it's start position. When the forward button is pushed (Green), the cutting drum will start up, and the pusher will go forward.
OM 2500 Air Brake 4-7-04
PRIOR TO EACH DAY'S CUTTING OPERATION, KNIVES SHOULD BE SCREWED FIRMLY IN POSITION. TORQUE WRENCH READY 12-FT. LBS.]
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HYDRAUSLICE SLICE THICKNESS CONTROL
The HYDRAUFLAKER is equipped with (8) high alloy special tempered blades, which are adjustable, to cut frozen meat into slice thickness up to %" thick (these blades need to be coated with a mineral oil after the machine is clean). The HYDRAUFLAKER is normally equipped at the factory to cut 118" thick slices. Slice thickness can be changed as desired, by placing appropriate shims (HFA-113, or a combination of shims (HFA-113), under each cutting blade (HFA-120-5), up to a total thickness of114" The following slice thickness shims are furnished with the HYDRAUFLAKER. (16) .032 thick (16) .I25 thick The blades need to be tightened, with F-5 screws, and using shims (HFA-113) shims, if necessary. When tightening F-5 screws, the operator needs to be careful, not to tighten one screw completely before he has tightened the others, to a finger tight fit. If done incorrectly, you could build up stress in the blade, which could lead to premature breakage at the boltholes.
OM 2500 Air Brake 4-7-04
GENERAL WASHING INSTRUCTIONS
[Follow All Safety Instructions in Manual) 1. Open hoods on Flaker (258-0106 & 25C-0112), then take off blades (HFA-120-5) by removing bolts (F-5). Remove shims (HFA-113), if they are used.
2. Cutting drum (FA-114-A-I), can be rotated by hand, to clean out the pockets around the drum circumference. 3. Make sure you spray both sides of swing guard (258-0129-I), to clean off any meat residpe. 4. Make sure to clean behind pusher plate (25C-128-1).
5. After spraying the entire cutting area, you can spray the hood and and 'the rest of the machine.
6. When cleaning is finished, put the blades and shims back onto the drum, and spray with mineral oil.
OM 2500 Air Brake 4-7-04
MODEL 2501 HYDRAUFLAKER
HFA- 1.20-5 ( BLADE.1
OM 2501 Air Brake 4-18-06
MAINTENANCE
The filter regulator (P-690-006) should be drained of water every week. More if necessary, to assure proper operation of the cylinder and solenoid valves. All grease type bearings should be greased each week, using a type of grease, which is approved by the Food Industry (drum-bearing fittings are located on the outside of machine). The cutting blades (HFA-120-5) are made of special high alloy type steel, and should be honed (by hand) regularly. Should blades require grinding, we suggest they be removed for factory grinding. In factory grinding, a minimum material is removed, and all cutting angles are maintained for maximum cutting efficiency. The blades should be coated with food grade mineral oil when not in use, or after wash down. The V-Drive Belts are to be kept tensioned for full power cutting requirements. NOTE: After the first week of operation, the belt tension should be checked and adjusted, if necessary. All component parts are manufactured of the best material available, with top quality workmanship. Should there be any detail information required, pertaining to any of these parts, please contact GENERAL MACHINERY CORPORATION, 1831 N. 18th Street, P. 0. Box 717, Sheboygan, Wisconsin USA 53082-0717. The Phone Number is 920-458-2189 or 888-243-6622. 1. Motor does not operate or stops during operation. a. Check fuses in disconnect boxes. b. Check for low voltage. c. Thermal overload elements have disconnected starter (Reset). d. Check contacts on magnetic starter. 2. Cutting drum slows down. a. Tighten V-Belts. b. Check blades if dull, hone, or resharpen. c. Make sure meat blocks are frozen, and not partially thawed. 3. Drum does not stop, or stops too slow, when the stop button is depressed. a. Tighten V-Belts. b. Check to see that the motor starter is reversing. c. Check adjustment of plugging switch. d. Check starter coils.
OM 2500 Air Brake 4-7-04
4. Cylinder works erratically. a. Solenoid valve is not working. b. Mufflers are clogged. c. Water in line. d. Cylinder seal might need replacing. 5. Pusher (258-0128-1) does not move fonvard. a. Push button (Green) is not contacting - check. b. Flow control valve is shut-off; turn counterclockwise. c. Insufficient pneumatic pressure or air supply. Set at 80 PSI, with 5 cubic feet per minute air supply. d. Relay does not energize to close normally; open contact - replace coil. e. Pneumatic cylinder piston and rod packing worn; replace. 6. Pusher (258-0128-1) does not return. a. Is reed switch operating properly (P-171-002)? b. Relay is not dropping down to close normally; closed contacts. Free up armature to avoid sticking. c. Is the left-hand solenoid on 4-way, operating (P-690-OOI )? d. Could be piston packing (P-170-003) need replacing. e. Drain water from air filter (P-690-006). 7. HYDRAUFLAKER cuts to thick or too thin. a. Replace shims (HFA-113), with shims of proper size. b. Knives (HFA-120-5) dull; hone or resharpen. 8. HYDRAUFLAKER does not flake properly. a. Replace shims (HFA-113), with one or proper size. b. For best cutting results, frozen blocks should have a temperature range throughout, of plus 10 degrees F., to plus 20 degrees F., temper properly. c. Blades are dull; hone or resharpen.
I Start button (Black) starts motor, and energizes all electrical controls. 2. The cutting drum (HFC-114-A-I) is driven by a 10 HP motor, through (3) special high tensile strength V-Belts. The cutting drum (HFC-114-A-I), rotates at a high speed of approximately 500 revolutions per minute. The cutting drum (HFC-114-A-I) is mounted on two heavy-duty, self-aligning sealed bearings, which are lubricated with NEVA Stain Grease (for food machinery application). 3. Push button (Green) energizes the 4-Way Valve Solenoid (push button side) starts the cutting drum and relay, actuating air cylinder, and moves block pusher (258-0128-1) toward cutting drum (HFC-114-A-l ). At foremost position, the cylinder shaft passes the reed switch on the cylinder, this de-energizes the relay, energizing the 4-Way Valve Solenoid, and returns block pusher to rear of machine. 4. The batching button (Yellow) is used, if you want to stop the pusher, prior to completing it's full foward motions, or stops the cutting drum (motor stays running). The pusher will return to the start position. 5. The forward speed of the pusher cylinder, can be adjusted by the flow control valve, located on the 4-Way Valve. 6. The electrical system is NEMA 4, completely enclosed. The magnetic start switch relay, overload controls, wiring diagram, and terminal block, is located in a waterproof switch box (see wiring diagram). 7. The stroke length of the cylinder, can be adjusted by moving the reed switch. 8. To stop the machine completely, push the (Red) button to restart the machine. The button needs to be manually pulled out. 9. When the machine has been completely turned off, the cutting drum will not rotate. The lockout/tagout disconnect, will need to be turned off. When this is done, the drum will be able to be rotated by hand.
INSTRUCTIONS TO ADJUST SAFETY STOP
The air brake and o~tionalclutch safety stop, is incorporated on the HYDRAUFLAKER, to stop the cutting drum within 2 to 3 seconds. This device operates whenever the rnachine is stopped, by depressing the stop button (Red), opening the front or top guard. In the event, the cutting drum, rotates more than 2 or 3 seconds after the power has been cut off by depressing the stop button, the following should be done:
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For increased life of the air operated drum brake, a lubricator is installed in the airline, just before the brake. This lubricator distributes a measured amount of oil mist every time the brake is activated. This will avoid corrosion and condensation. When installed on the brake, the oil fill cap must be to the top of the lubricator. We recommend using non-detergent oil, such as Coilhose ATL032. The lubricator should be filled once a week or sooner, depending on brake usage. Cleaning Instructions are on the following page. 1. Check the drum air brake to be sure it is good condition (Check manual for instructions). 2. Check motor air clutch (Check manual for instructions). SAFETY A SAFE MACHINE IS ONLY AS SAFE AS YOU WANT IT TO BE SAFETY GLASSES MUST BE WORN
The HYDRAUFLAKER is pneumatically operated. The characteristics of air operation, can result in movement of mechanisms, due to air leaking in the control valve. An airline also could fracture, or become dislodged from a fitting, which would cause it to whip around, out of control. Warn operating personnel that airlines must be properly connected. Air pressure should not exceed 1.00PSI. In the event of any blockage, or malfunction, the first priority is to disconnect, or shut off the primary air source, before any attempt is made to remedy the problem. Air is a compressible substance, therefore, somewhat erratic. But, if the movement of the cylinder is noticeably irregular, it may be due to insufficient air supply pressure, improperly adjusted flow control, dirty exhaust silencers, water in the lines, malfunction of the valves, or breakage in the seals of the cylinder. The machine has a filter to prevent water from getting into the system, but must be manually drained, periodically. DO NOT introduce a lubricator into this system, as it is not needed, and will cause problems. If at any time, questions arise, with regard to the operation or safety of the GMC HYDRAUFLAKER, call the manufacturer Toll Free at 1-888-243-66.22
WARNING
The machine can be dangerous, if improperly used. Keep hand out of slicing and discharge zones, while the machine is in operation. Do not remove paneling, except for cleaning or maintenance, and then only, when power is disconnected. "CAUTION" safety decals should be in place on guards, and loading aperture. Instruct operating personnel about prudent safety measures, before they employ the machine. Product temperature should be in the range of 5 degrees to 30 degrees F. throughout. The operating decibels for this type of machine are approximately 90 to 92 dBA. NOTE: Readings are dependent on the type of product being cut, the temperature of the product, and the surrounding condition. Reading is made from load end of the machine, 1 meter from machine at 1.7-meter height. Test was run in plant, with some background noise, from other machines. Product was frozen beef hearts at 10 degrees F. An Edmont hand held sound level meter was used. SAFETY FEATURES 1. The HYDRAUFLAKER is equipped with a push-pull Red Mushroom Head Stop Button (P-621-017). This button need to be manually pulled out after pushing the button, for the machine to be restarted. 2. The machine is enclosed, except for two stainless access panels (258-0111, 25C-0116). 3. The drum area has a front plate (Poly) door (258-0106), and a swing top cover (25C-0112). Both of these are electrically interlocked with two safety switches in series (P-623-001). 4. The motor is totally enclosed and overload protected (P-370-086). 5. Machine has a NEMA 4X disconnect switch (P-626-001). 6. Machine has a 24-volt control circuit. 7. Starters, relay, transformers, terminal blocks, etc., are touch proof type, and are UL approved. 8. Drum bearings can be greased, without the need to remove guards. 9. Operator station is away from the cutting area, with full control of machine, from that point (P-621-015). 10. Cutting drum is dynamically balanced, alleviating the need to bolt machine to the floor, for stability (HFC-114-A-I). 11. This machine uses an air brake on the cutting drum, and air clutch on the motor. When the machine is started, by pushing the (Black) start button; the motor will start, but not the drum. The drum will start when the forward button is pushed (Green). When the batching button is pushed (Yellow); the cutting drum will stop, but the motor will continue to run. When the stop button (Red) is pushed; the complete machine will shut off.
HYDRAUFLAKER BRAKE DOES NOT DISENGAGE: First thing, check to see if you are getting air to the brake, and have enough air pressure. If not, correct. If you do, go to No. 1.
1. Take the airline out of the brake. The brake should release, in addition, you should be able to rotate the drum. If the drum does not rotate; the problem is with the brake. The brake will need to be taken apart, to see what the problem is (see enclosed brake instructions). Necessary parts can be ordered from General Machinery Corporation. 2. If the brake releases, then the problem is either in the electric relay, located in the electrical enclosure, or the Rex Valve, located inside, opposite the belt guard. To check the relay, the machine needs to be on. The relay no. , has a tab located on its front side. When the relay is energized, which it should be when the machine is on, the tab will lean towards the outside edge of the relay. If the relay is not working, the tab will be away from the edge of the relay towards the center of the relay (replace relay if not working), 3. If the relay is energizing, and the brake is not released, then check the Rex Valve, go to #2 (see drawing in manual),. Take the two mufflers out of the Rex Valve, and see if the brake will continue. The valve has a light, which will be on, if is energized. It should be energized, if the machine is on. If this light is not on, you can move the small lever, located on the valve, manually, to see if the valve will shift. If the valve shifts, and releases the brake, after you have moved this lever, you need a new valve. 4. If the brake disengages, but you hear rubbing noises, the compression springs might be broken. (replace).
CLEANING The In-line Lubricator will provide long periods of uninterrupted service as long as both the air and oil supplies are kept clean. However, periodic cleaning is required to assure proper operation. To remove and clean the lubricator:
A
1. Disconnect lubricator form air supply 2. Slowly remove oil fill cap to relieve pressure in oil reservoir and drain oil
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CAUTION: if pressure is released too quickly, oil may spray from reservoir.
3. Remove lubricator from machine. 4. "Back flush" lubricator to blow out any dirt or residue 5. Clean lubricator with warm water and household detergent or nothing stronger than good commercial grade solvent. 6. Make sure all moisture is removed by thoroughly blowing out the body with compressed air. 7. Reinstall lubricator
p u ! lUA. y "AirChamp!'
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MODELS S-450, S-600, S-800, AND S-1000 INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS
WARNING
This unit has rotating parts. Per OSHA regulations, Horton recommends using a guard that will not restrict the flow of cooling air around the unit. Contact your local Horton Distributor for information about guards designed for "Air Champ" brakes.
CONTENTS INSTALLATION---------------------------------------------------------------------------------- - - - - - - - -- 2 AIR CONNECTIONS --------------------- --------------- - - - - - - - - - - - - - - - - - - - - - - - 2 BRAKE GUARD INSTALLATION 3 LUBRICATION ------------------------------- --3 TROUBLESHOOTlNG ---.............................. ---------------------------------------------------------------------- 4 PARTS REPLACEMENT ------------------------------------------------------------------------------------------------- 5 REPLACEMENT PARTS -------------------------------------------------------------------------........................... 6 PARTS LIST---------------------------------------------------- - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - 7 ACCESSORIES ---------------------------------------------------------------------------------------------------Back Cover FACING AND REPAIR KITS -----------------------------------------------------------------------------------Back Cover
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Insert the Key (Item 16) into the shaft keyway (See Figure 1).
1.
Slide the brake over the Key and on the shaft (See Figure 1). 3.
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Install and tighten the three Set Screws (Item 17) (See Figure 1).
4.
Align the brake's air inlet to the six o'clock down position.
5.
Using the four holes in the Air Chamber flange or a torque pin in the slot provided, secure the brake's Air Chamber to prevent brake rotation (See Figure 1).
AIR CONNECTIONS
down position t o allow condensation i n the air A 10-32tapped hole is providedin the Piston Plate (Item 3) to allow auxiliary cooling of the brake's friction surface (See Figure 2). An air hose (Product No:857000) with the proper fittings is available from Horton. Auxiliary cooling will increase the brake's thermal capacity approximately 0.1 HP, per 100 SCFH of cooling air over the brake's rated HP, at any RPM (See Table 1).
EXAMPLE: A 5-1000 develops 1.0 HP, at 200 RPM. Referring to Table 1, 80 psi of cooling air increases the HP, 0.4 per 100 SCFH. RESULT: 1.O = 0.4 = 1.4 HPI NVlC
Use non-lubricated air tapped off the air line ahead of the lubricator for auxiliary cooling.
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0
10 20 30 40 50 60 70 80 SO 100
AIR PRESSURE (PSI) *S1andardcublcfeetperhour.
TABLE 1 FORM NO. L-20087-F-1197
HoseassemblyPm BSIMIO.
1.
Align the mounting holes of the Brake Guard with the four tapped holes in the S Brake Air Chamber (See Figure 3).
2.
Using the four 10-24 X 318 Phillips Head Pan Screws and Internal Tooth Lock Washers, secure the Brake Guard to the S Brake.
3.
If the Brake Guard is not through shaft mounted, place the End Cap over the front of the Brake Guard and bend the tabs around the Brake Guard to hold the End Cap in place (See Figure 3).
FIGURE 3
LUBRICATION I
NOTE Pneumatically actuated devices require clean, pressure regulated, and lubricated air for maximum performance and long life. The most effective and economical way to lubricate Horton Brakes is with an Air Line Lubricator, which injects oil into the pressurized air, forcing an oil mist into the air chamber.
II
Locate the lubricator above and within ten feet of the Brake, and use a low viscosity oil such as SAE-10. Synthetic lubricants are not recommended. - --
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LUBRICATOR DRIP RATE SElTlNGS -.---
NOTE
These settings are for Horton supplied lubricators. If you are not using a Horton lubricator, calibration must replicate the following procedure. 5.
Connect the air line to the unit.
2. Turn the Lubricator Adjustment Knob clockwise three complete turns.
6.
Turn the Lubricator Adjustment Knob counterclockwise until closed.
3.
Open the air line.
7.
Turn the Lubricator Adjustment Knob clockwise one-third turn.
4.
Close the air line to the unit when a drop of oil forms in the Lubricator Sight Gage.
8.
Open the air line to the unit.
1.
Close and disconnect the air line from !he unit.
FORM NO. L-2WB7-F-1197
SYMPTOM
PROBABLE CAUSE Air not being exhausted due to a control valve malfunction.
Failure to engage.
Align the exhaust port to the six o'clock down position to allow condensation to drain out of the exhaust port. Replace the Compression Springs. Check for control valve malfunction and replace it if necessary. Check for air leaks in the air lines and around the O-rings Seals. Replace the air lines or O-ring Seals if necessary. Align the exhaust port to the six o'clock down position to allow condensation to drain out of the exhaust port. Replace the Friction Facings.
Internalcontamination or coriosion. Broken Compression Springs.
Low or lack of air pressure. Failure to disengage.
Internalcontamination or corrosion. Loss of torque.
Worn or dirty Friction Facings.
FIGURE 4 I FORM NO.L-20087-F.1197
SOLUTION Replace the control valve.
4
FRICTION FACINGS 1. Align the holes in the Friction Disc Hub (Item 1) with the
Machine Screws (Item 14) holding the split Friction Facing (Item 5) (See Figure 5). NOTE
The Machine Screws (Item 14) on some older S Brakes are installed with a red anaerobic thread locking compound. If removal Is difficult, strike the end of the screwdrlver with a hammer t o break the crystalline structure of this compound before attempting t o remove the machlne screws. 2.
Removethe old Machine Screws (Item 14) (See Figure 5).
3.
Remove the old split Friction Facings (Item 5) (See Figure 5).
4.
Install the new split Friction Facings.
5. Secure the new split Friction Facings (Item 5) using the new Machine Screws (with locking patch) (Item 14). TABLE 2
Tighten the new Machine Screws to the recommended torque (See Table 2).
6.
BEARING AND O-RING SEALS 1
5
11
2
7
6
9
FIGURE 6 - - - -..- -
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WARNING The Shoulder Bolts (Item 6) are spring loaded. Always wear safety goggles when working with spring or tension loaded fasteners or devices.
when working with spring or tension loaded 5.
Alternately and evenly remove the three old Shoulder Bolts (Item 6) and Compression Springs (Item 7) (See Figure 6).
6.
Separate the Piston Plate (Item 3) and split Friction Facing (Item 5) from the Air Chamber (Item 4) (See Figure 6).
7.
Remove the Piston (Item 2) from the Air Chamber (Item 4) (See Figure 6).
1. Remove the Retaining Ring (Item 9) (See Figure 6). 2.
Press the Friction Disc Hub (Item 1) out'of the Ball Bearing (Item 8) (See Figure 6).
3.
Remove the Retaining Ring (Item 10) (See Figure 6).
4.
Press the old Ball Bearing (Item 8) out of the Air Chamber (Item 4) (See Figure 6). 5
FORM NO. L-20087-F-1197
9.
Clean the bearing bore of the Air Chamber (Item 4) with fresh safety solvent to remove all old LocOtee residue (See Figure 6).
0. Apply an adequate amount of Loctitea680to evenly coat the O.D. of the new Ball Bearing (Item 8) and press the new Ball Bearing into the Air Chamber (Item 4) (See Figure 6). 11. Reinstall the Retaining Ring (Item 10) (See Figure 6).
Piston Plate ana spllr rrlcrlorl raullly \ t t = l l m Air Chamber (See Figure 6).
Y.I.V
.....
16. Clamp the Piston Plate (Item 3) and Air Chamber (Item 4) together with C-clamps. 17. Apply Loctitem242to the threads of three new Shoulder Bolts (Item 6) and install the new Shoulder Bolts and Compression Springs (Item 7) (See Figure 6). 18. Alternately and evenly tighten the three new Shoulder Bolts (Item 6) to the recommendedtorque (See Table 3).
12. Clean the o-ring grooves of the Piston (Item 2) and
o-ringcontact surfaces of the Air Chamber (Item 4); then, lubricate the new O-ring Seals (Items 11 and 12) and the o-ring grooves and contact surfaces of the Piston and Air Chamber with a thin film of fresh o-ring lubricant (See Figure 6). 13. Install the new O-ring Seals (Items 11 and 12) onto the Piston (Item 2) (See Figure 6).
19. Remove the C-clamps.
20. Supporting the inner race of the Ball Bearing (Item a), press the Friction Disc Hub (Item 1) into the Ball Bearing (See Figure 6). 21. Reinstall the Retaining Ring (Item 9) (See Figure 6).
NU1t
Avoid pinching the O-ring Seals when assembling the Piston and Air Chamber. 14. Slide the Piston (Item 2) into the Air Chamber (Item 4) (See Figure 6). TABLE 3
REPLACEMENT PARTS The item or balloon number for all Horton products is used for part identification on all product parts lists, product price lists, unit assembly drawings, bills of materials, and instruction manuals.
FORM NO. L-20087-F-1197
When ordering replacementparts, specify model designation, item number, part description, and quantity. Purchase replacement parts through your local Horton Distributor.
ITEM
DESCRIPTION
QTY
1 2 3 43
Friction Disc Hub Piston Piston Plate Air Chamber Friction Facing Shoulder Bolt Compression Spring Ball Bearing
1 1 1 1 1 3 3 1
51~2
6' 7l 8l
lTEM
9 10 111 12' 133 14112 16 17
DESCRIPTION
QTY
Retaining Ring Retaining Ring O-ring Seal O-ring Seal Dowel Pin Machine Screw Key Set Screw
1 1 1 1 3 6
.
1
3
Denotes ~ s ~Kith items. r Denotes Facing Kit items. Order Air Chamber Assembly in place of Air Chamber (Item 4) and Dowel Pin (Item 13) (See Table 4).
TABLE 4
I I
.
I
In accordance wiUl Horlon's policy of producl improvement,lhe specifications and technical dala contained in lhis manual are subjed lo change without notice and are based on the latest informalionavailable at Ihe lime of printing.
7
FORM NO. L-20387-F-1197
I I I
I
FIGURE 8 BRAKE GUARD
TABLE 5 PRODUCT NUMBERS
FACING AND REPAIR KITS MODEL
FACING KIT
REPAIR KTT
S450
818971
818900
S-600
820571
820500
TABLE 6 'RODUCT NUMBERS
WARRANTY Horton Industrial Products, Inc. (Horton) warrants Its product(s) phe Product(s)] will be free from defects in materialsand workmanship under normaluse and service conditions for a period 01 12 months from the date of shipment. NO OTHER WARRANTIES, WHETHER EXPRESS, IMPLIED, OR STATUTORY, INCLUDINGWITH. OUT LIMITmONWARRANTIES OF MERCHANTABILITY, OR OF FITNESS FOR A PARTICULAR PURPOSE, ARE GIVEN, AND ALL SUCH CTHERWARRANTIES ARE HEREBY EXPRESSLY DISCLAIMED. Conditions This warranty applies only ll: (a) the Product has beeninstalled, used, and maintained in accordance with any applicable Horton installatlonor maintenancemanualfor the Product; (b) the alleged defect is not attributableto normal wear and tear; (c) Ule Product has not been altered, mlsused, or used for purposes other than those for which it was Intended: and (d) the claimant has complied with the warranty claim procedures set out below inWarranty Claim Procedures. ExclusiveRemedy The Sole and exclusive remedy for a breachof this warrant shallbe, at Horton's sole election, repair or replacementof the Product, or issuanceof ;credit i n the amount of the current Hortondiscounted price for the Product. Llmltatlon of Damages Inno event shall Hortonbe liable for any consequential,indirect, incldenlal, or specialdamages of any nature whatsoever, includingwithout limitation, lost profitsarising from the sale or use of the Products. Warranty Claim Procedures I make a claim under this warranty, the claimant must give written notice of the alleged defect to Hortonand deliver the Product to Hortonwithin one year of the date .n which the alleged defect first became apparent.
FORM NO. L-2W87-F.1197
HORTON, INC. MINNEAPOLIS, MN 55440 1-800-843-7445
\
MODEL 2501 DOMESTIC WIAIR BRAKE
PRINT 1 2 3 4 5 6 7 8 9 10 I1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 - 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 ,
ASSBLY
P-030-031 P-330-003 F-5 P-420-001 NOT SHOWN NOT SHOWN P-510-003 P-510-001 P-090-004 P-090-004 P-090-009 P-I 35-003 P-051-100 P-180-004 P-I 8 1-004 P-181-009 P-621-015 P-640-011 P-640-003 P-640-004 P-640-012 P-220-010 P-221-006 P-221-006 P-640-010 P-470-012 P-470-020 P-590-016 P-010-004 P-471-001 P-470-005 P-620-012 P-623-001 P-623-014 P-370-071 P-670-010 P-180-016 P-626-005 P-170-026 P-690-006 P-690-006
DESCRIPTION MANUAL #2501-1
PILLOW BLOCK BRG THREAD INSERT BUTT HD SOC CIS 112 X 2-114 CLEVIS PIN GROMMET MATERIAL HAIRPIN CLIP DRUM SHEAVE MOTORSHEAVE BUSHING FOR DRUM MOTOR BUSHING BRAKE BUSHING 2-112" AIR BRAKE V-BELTS ENCLOSURE 25B-0126 PANEL PANEL DIN RAIL PUSH BUTTON STATION TERM END BRKT TERMINAL BLOCK TERMINAL BLOCK COVER JUMPER LINK 2AMPFUSE FUSE BLOCK FUSE BLOCK COVER HAND TOOL CONTROL RELAY CONTROL RELAY CONTACTOR AUX. CONTACTS RELAY MTG KIT OVERLOAD RELAY N.C. REED SWITCH BUTTON LIMIT SWITCH INTERLOCK SWITCH 10 HP MOTOR 20812301460-24V. TRANSFO JUNCTION BOX DISCONNECT MAG PISTON CYLINDER FILTIREGIAUTO DRAlN FlLTlREG MTG BRKT
I
I
1
REQ'D
2 16 16 4 1 4 1 1 1 I 1 1 4 1 1 I 1 2 20 1 6 I 1 I 1 1 I 1 1 1 1 I 1 2 1 1 1 I I I 1
-
MODEL 2501 DOMESTIC WlAlR BRAKE
PRINT 46 47 48 49 50 51 52 53 - 54 55 56 57 58 59 25A-0004 60 25A-0005 61 25A-0006 62 25A-0008 63 25A-0119 64 25A-0120 65 25A-0127 66 25A-0140 67 25A-0141-3 68 25A-0143 69 25A-0150 70 25A-0151 71 25A-0301 72 25A-0303 73 25A-305 74 25B-00 10-2 75 25B-0106 76 25B-0110-1 77 25B-0111-3 78 25B-0118-1 79 258-0126-2 80 258-0128-1 81 25B-0129-1 82 258-0131-2 83 25B-0131-3 84 25B-0142 85 25B-0145 86 25B-0228 87 25C-0112 88 25C-0116 89 25C-0117 90 25C-0121-15 -
,
ASSBLY P-690-006 P-690-006 P-690-034 P-690-034 P-380-008 P-691-001 P-450-001 NOT SHOWN P-690-044 P-200-052 P-200-053
DESCRIPTION GUAGE MTG. NUT PRESSURE GAUGE AIR VALVE WICONNECT BLANKING CAP 740 MUFFLER SPEED CONTROL QUICK EXHAUST 118" NPT MUFFLER IN LINE LUBRICATOR 318" BULKHEAD FTG 318~112PSW EL DRUM SHAFT COVER DRUM SHAFT COVER LOCK SCREW LOCK KNOB SWITCH SCREW SWITCH SCREW BRKT HOLD DOWN KNOB BEARING SHOULDER CYLINDER BOSS MTG BRKT MICRO SWITCH PRONG BRACKET GREASE MOUNT CYL. SPACER BLOCK CYL. MOUNTING REAR CYLINDER MOUNT DRUM SHAFT FRONT PLATE PANEL LOAD END L.H. PANEL ELEC BOX MTG ELEC ENCLOSURE PUSHER SWING DOOR PUSHER SLIDE L.H. PUSHER SLIDE R.H. VALVE MTG BRKT PANEL BOARD JUNCTION BOX PRINT TOP COVER MOTOR PANEL BELT GUARD WIRING DIAGRAM
I
REQ'D 1 1 3 2 6 2 1 I 1 1 1 2
I
2 2 2 2 1 1 3 2 1 1 1 2 2 1 I 1 1 1 1 1 1 1 1 1 I 1 1 1 1 1 I
MODEL 2501 DOMESTIC WlAlR BRAKE
91 92 93 94 95 96 - 97 98 _ 99 100 101 102 - 103 104 105 106 107
PRINT 25C-0130-10 25R-0200 25C-0235 25C-0236 25C-0238 25R-201 25R-B 3A-36 75A-674 HFA-113 HFA-113-2 HFA-120-5 HFA-217-E HFC-114-A-1 HFC-115-3 31A-071 31A-072
ASSBLY
DESCRIPTION PUSHER MOUNTING MAIN FRAME FRAME ADAPTATION BEARING COVER MOTOR BASE LOAD TABLE & CHUTE ASSEMBLY PRINT SPACERS MTG BRKT SAFETY SWITCH .031 SHIM .I25 BLADE SHIM BLADE PUSHER DRIVE POINT 8 POCKET DRUM DRUM HUB TORQUE PIN BRKT TORQUE PIN
REQ'D 1 1 1 1 1 1 20 2 16 16 8 8 1 2 1 1
9
mm AIR
v
A
AIR BUKE
--
YITH AIR BRAKE
M E T I D 2
FILE SAVE0 LNIER 2X-121-15-1
P XI HI IP
l!umm!
10 L2 TO L3
TO LI
H E 1 2 ff 2
2500 FLAKER W I TH AIR BRAKE
WITH PIN
.
,
251-234
ASSEMBLY PARTS FOR TORQUE PIN BRACKET FOR A R I BRAKE
I
\ ? % Z F ~ SHOUIOER ~ I PLATE '
SEAL KIT
