Schaaf Extrusion

1.

Schaaf Extrusion
Lubrication & Maintenance plan –
Extruder 640
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
...we shape the world!

2.

Lubrication
Process Parts
point
A
Turbo-screw
Turbo-Adapter
Pressure plate
Turbo
Pressure plate
Die
Note:
For the assembly and disassembly of the process parts, the instructions from
the document “Assembly and cleaning of process parts” must be observed”!
Protective hood and vapour exhaust hood dismantled.
Schmierstelle:
Lubrication point:
Extruder-Sleeve
Turbo-Screw
TURBO-Parts
Schmierungsintervall / Lubrication interval
täglich / daily
wöchentlich
/ weekly
monatlich / 1/2 jährlich /
monthly
1/2 yearly
jährlich /
yearly
Schmierstoff / Lubricant
Food-approved, heatresistant lubricant that
protects against
tribocorrosion:
OKS252
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
Schmierwerkzeug /
Lubrication tool
Grease gun, Brush,
Cloth
Anmerkung / Note
Before each restart, wet all surfaces marked in green
with lubricant.
Caution: The threads of the screw and stator as well as
the pressure plates and die must not be wetted with
lubricant!
...we shape the world!
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3.

Lubrication
Process Parts
point
A
O-Ring
Article no.: K40149
Inlet-Sleeve
Extruder-Sleeve
Note:
The Extruder-sleeve and inlet-sleeve should be removed and cleaned once a
week.
For the assembly and disassembly of the stator and inlet stator, please observe
the instructions in the document "Assembly and cleaning of process parts"!
Protective hood and vapour exhaust hood dismantled.
Schmierstelle:
Lubrication point:
Inlet-Sleeve
Extruder-Sleeve
Schmierungsintervall / Lubrication interval
täglich / daily
wöchentlich
/ weekly
monatlich / 1/2 jährlich /
monthly
1/2 yearly
jährlich /
yearly
Schmierstoff / Lubricant
Food-approved, heatresistant lubricant that
protects against
tribocorrosion:
OKS252
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
Schmierwerkzeug /
Lubrication tool
Grease gun, Brush,
Cloth
Anmerkung / Note
Remove and clean Extruder-sleeve and inlet-sleeve
once a week.
Before assembly, check o-rings for wear and wet the
green marked surfaces with lubricant.
...we shape the world!
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4.

Lubrication
Cutting Device
point
B
Grease nipple
The cutting device should be lubricated every 8 hours of operation (once per shift).
Lubrication during operation should be done slowly.
Recommendation:
• Press in 1 stroke of the supplied grease gun in approx. 10s.
• The product, generated during the lubrication process and another 20s, should be discharged
from the production process and discarded.
• For cleaning the lubrication point it is necessary to dismantle the protective hood.
Schmierstelle:
Lubrication point:
Cutting Device
Schmierungsintervall / Lubrication interval
täglich / daily
wöchentlich
/ weekly
monatlich / 1/2 jährlich /
monthly
1/2 yearly
jährlich /
yearly
Schmierstoff / Lubricant
Food-approved lubricant e.g.:
Klübersynth. UH1 64-62
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
Schmierwerkzeug /
Lubrication tool
Grease gun
Anmerkung / Note
Clean the grease nipple before relubrication, slowly
press in the grease while the bearing is running.
Remove excess grease with a cloth.
...we shape the world!
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5.

Lubrication
Drive Cutting Device
point
C
Protective hood and vapour exhaust hood dismantled.
Schmierstelle:
Lubrication point:
Drive Cutting Device
Schmierungsintervall / Lubrication interval
täglich / daily
wöchentlich
/ weekly
monatlich / 1/2 jährlich /
monthly
1/2 yearly
jährlich /
yearly
Schmierstoff / Lubricant
Food-approved lubricant e.g.:
Klübersynth. UH1 64-62
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
Schmierwerkzeug /
Lubrication tool
Grease gun
Anmerkung / Note
Clean the bearings of the three-phase motors annually
and apply new bearing grease.
Please observe manufacturer documentation.
...we shape the world!
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6.

Lubrication
Bearing Circulator Reservoir
point
D
Worm gear motor
Grease nipple
Shaft sealing ring
Article no.: K22075
Schmierstelle:
Lubrication point:
Bearing Circulator
Reservoir
Schmierungsintervall / Lubrication interval
täglich / daily
wöchentlich
/ weekly
monatlich / 1/2 jährlich /
monthly
1/2 yearly
jährlich /
yearly
Schmierstoff / Lubricant
Food-approved lubricant e.g.:
Klübersynth. UH1 64-62
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
Schmierwerkzeug /
Lubrication tool
Grease gun
Anmerkung / Note
Clean the grease nipple before relubrication, slowly
press in the grease while the bearing is running.
Remove excess grease with a cloth.
...we shape the world!
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7.

Lubrication
Drive Circulator Reservoir
point
E
Worm gear motor
Schmierstelle:
Lubrication point:
Drive Circulator
Reservoir
Schmierungsintervall / Lubrication interval
täglich / daily
wöchentlich
/ weekly
monatlich / 1/2 jährlich /
monthly
1/2 yearly
jährlich /
yearly
Schmierstoff / Lubricant
Recommendation:
Food oil ISO VG220
CLP PG H1 220
Klüber UH1 6-220
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
Schmierwerkzeug /
Lubrication tool
Oiler / Oil can
Anmerkung / Note
Check oil level daily.
When changing the oil, follow the manufacturer's
instructions!
...we shape the world!
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8.

Lubrication
Bearing Continuous
point
Moisturiser F
Shaft sealing ring
Article no.: K22032
Grease nipple
Schmierstelle:
Lubrication point:
Bearing Continuous
Moisturiser
Schmierungsintervall / Lubrication interval
täglich / daily
wöchentlich
/ weekly
monatlich / 1/2 jährlich /
monthly
1/2 yearly
jährlich /
yearly
Schmierstoff / Lubricant
Food-approved lubricant e.g.:
Klübersynth. UH1 64-62
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
Grease nipple
Schmierwerkzeug /
Lubrication tool
Grease gun
Anmerkung / Note
Clean the grease nipple before relubrication, slowly
press in the grease while the bearing is running until
fresh grease comes out of the bearing.
Remove excess grease with a cloth.
Recommendation: Lubrication before each production
start.
...we shape the world!
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9.

Lubrication
Drive Continuous Moisturiser
point
G
Bearing
Three-phase motor
Schmierstelle:
Lubrication point:
Drive Continuous
Moisturiser
Schmierungsintervall / Lubrication interval
täglich / daily
wöchentlich
/ weekly
monatlich / 1/2 jährlich /
monthly
1/2 yearly
jährlich /
yearly
Schmierstoff / Lubricant
Food-approved lubricant e.g.:
Klübersynth. UH1 64-62
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
Schmierwerkzeug /
Lubrication tool
Grease gun
Anmerkung / Note
Clean the bearings of the three-phase motors annually
and apply new bearing grease.
Please observe manufacturer documentation.
...we shape the world!
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10.

Lubrication
Double Screw Dosing Unit KT35
point
H
Double Screw Dosing Unit KT35
The bearings of the three-phase motor should be checked
annually, and cleaned and relubricated, if necessary.
Schmierstelle:
Lubrication point:
Double Screw Dosing
Unit KT35
Schmierungsintervall / Lubrication interval
täglich / daily
wöchentlich
/ weekly
monatlich / 1/2 jährlich /
monthly
1/2 yearly
jährlich /
yearly
Schmierstoff / Lubricant
Cassida GL 150 or Berusynth
150 H1
Volume: 0,7 l
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
Schmierwerkzeug /
Lubrication tool
Oiler / Oil can
Anmerkung / Note
Check oil level daily.
When changing the oil, follow the manufacturer's
instructions!
...we shape the world!
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11.

Lubrication
Optional: Double Screw Dosing
point
I
Unit KT20
Optional:
Double Screw Dosing Unit KT20
The bearings of the three-phase motor should be checked
annually, and cleaned and relubricated, if necessary.
Schmierstelle:
Lubrication point:
Optional: Double Screw
Dosing Unit KT20
Schmierungsintervall / Lubrication interval
täglich / daily
wöchentlich
/ weekly
monatlich / 1/2 jährlich /
monthly
1/2 yearly
jährlich /
yearly
Schmierstoff / Lubricant
Cassida GL 150 or Berusynth
150 H1
Volume: 0,7 l
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
Schmierwerkzeug /
Lubrication tool
Oiler / Oil can
Anmerkung / Note
Check oil level daily.
When changing the oil, follow the manufacturer's
instructions!
...we shape the world!
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12.

Lubrication
Hinges swing frame
point
J
Grease nipple
Schmierstelle:
Lubrication point:
Hinges swing frame
Schmierungsintervall / Lubrication interval
täglich / daily
wöchentlich
/ weekly
monatlich / 1/2 jährlich /
monthly
1/2 yearly
jährlich /
yearly
Schmierstoff / Lubricant
Food-approved lubricant e.g.:
Klübersynth. UH1 64-62
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
Schmierwerkzeug /
Lubrication tool
Grease gun
Anmerkung / Note
Clean the grease nipple before relubrication. Remove
excess grease with a cloth.
...we shape the world!
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13.

Lubrication
Fan pneumatic transport
point
K
Schmierstelle:
Lubrication point:
Schmierungsintervall / Lubrication interval
täglich / daily
wöchentlich
/ weekly
monatlich / 1/2 jährlich /
monthly
1/2 yearly
jährlich /
yearly
Schmierstoff / Lubricant
Fan pneumatic
transport
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
Schmierwerkzeug /
Lubrication tool
Anmerkung / Note
Perform regular visual inspection and check for wear.
The bearings are lubricated for life under normal
operating conditions (Lh10 (30,000h)). Observe the
manufacturer's documentation.
...we shape the world!
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14.

Lubrication
Central oil lubrication
point
L head
system Extruder
Motor gear pump unit
Schmierstelle:
Lubrication point:
Central oil lubrication
system Extruder head
Schmierungsintervall / Lubrication interval
täglich / daily
wöchentlich
/ weekly
monatlich / 1/2 jährlich /
monthly
1/2 yearly
jährlich /
yearly
Schmierstoff / Lubricant
Klüberoil 4UH1-220N
Volume: approx. 5,5 l
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
Schmierwerkzeug /
Lubrication tool
Oiler / Oil can
Anmerkung / Note
Check oil level daily.
Change oil annually or every 4000 hours of operation.
...we shape the world!
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15.

Lubrication
Central oil lubrication
point
L head
system Extruder
Oil change Central oil lubrication system :
1.
2.
Make sure that the extruder main motor is secured against unintentional restarting while the oil change is being carried out.
Remove the lower cover plate:
3.
Remove the protective cover on the underside of the mounting plate.
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
...we shape the world!
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16.

Lubrication
Central oil lubrication
point
L head
system Extruder
4.
Open the oil cap :
(The sieve should not be removed)
5.
Before opening the two oil drain plugs, place a suitable collecting container (approx. 10 liters each) under both drain plugs.
Open the two oil drain plugs on the extruder head and on the motor gear pump unit :
Sealing ring
Article no.: R13200
Sealing ring
Article no.: R13200
Oil drain plug 1/2“
Article no.: R37015
Oil drain plug 1/2“
Article no.: R37015
Hexagon socket size 10
Hexagon socket size 10
After approx. 5-10min, all the oil should have run into the collection container.
Attention: When disposing of used oil, please observe the locally applicable regulations!
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
...we shape the world!
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17.

Lubrication
Central oil lubrication
point
L head
system Extruder
6.
Install the two oil drain plugs (Article no.: R37015) in the extruder head and the motor gear pump unit.
At every oil change, the sealing ring (Article no.: R13200) should be replaced to prevent leaks. (Tightening torque approx. 100Nm)
In addition, it is recommended to replace the oil filter (Article no.: P14009) of the motor gear pump unit at every oil change.
Oil Filter
Article no.: P14009
After draining the used oil, it is recommended to perform a "flushing" of the oil circuit.
To do this, proceed as follows:
Fill the container with approx. 5 liters of fresh oil via the filling opening (Klüberoil 4UH1-220N).
Start the motor gear pump unit and let it run for approx. 10-15 minutes.
Then open the two oil drain plugs on the motor gear pump unit and extruder head again and allow the oil, used for flushing, to run into the
collection container with the used oil.
After approx. 5 minutes, the two oil drain plugs can be screwed in.
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
...we shape the world!
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18.

Lubrication
Central oil lubrication
point
L head
system Extruder
7.
Fill the new oil via the filling opening of the motor gear pump unit:
Gehen Sie wie folgt vor:
Fill 4,5 liters of fresh oil (Klüberoil 4UH1-220N) into the tank via the oil filling opening of the motor gear pump unit.
Check the oil drain plug for any leaks.
Start the motor gear pump unit. After approx. 30 minutes of running time, the bearing housing is filled up to the return.
Then top up with approx. 1,0 liters of oil.
Close the oil filling opening with the existing sealing cap.
Finally, check both oil drain plugs for leaks.
Level
Oil Level
Switched off
Level
Min.
Level
Oil Level
Pump production
Oil Level
Oil pump runs
Min.
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
Min.
...we shape the world!
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19.

Lubrication
Central oil lubrication
point
L head
system Extruder
8.
Mount the protective cover on the underside of the mounting plate of the extruder frame:
9.
Mount the lower cover plate:
10. The extruder is ready for operation.
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
...we shape the world!
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20.

Note:
The previously mentioned maintenance, cleaning and lubrication intervals are guidelines for
production in 8-hour single-shift operation. In case of unfavorable operating conditions (dust, vapor,
heat), the intervals may be reduced accordingly.
All seals and bearings must be checked during each lubrication process or oil change.
Replace them if necessary. (Observe manufacturer's instructions!)
We ask you to always use the recommended oil / grease.
Experience has shown that the longest service life for bearings and seals could be achieved with these
oils / greases.
Please note that all maintenance work may only be carried out by trained and instructed personnel!
Please observe the applicable disposal regulations for the disposal of used oils or lubricants!
Schaaf Technologie GmbH - Otto-Hahn-Str. 36 - 65520 Bad Camberg - Tel.: +49 (0) 6434 9172-0
Mail: [email protected] - Internet: www.foodextrusion.com
...we shape the world!
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