Lummus Corporation Ginning School - Maintenance Page 1 of 20

MAINTENANCE GUIDELINES


Good record keeping provides valuable, documented history that serves as a source to
identify problems, justify machine and system modifications, and can be used as the
primary planning outline for main repair season.


Gin housekeeping provides a clean, safe work space.
Never repair machinery while it is running (shut it off / lock it out).
Take time to think before attempting repair.
Keep adequate and appropriate repair parts available.
Log downtime and preventive maintenance.
Schedule daily inspection. Between shifts, assign competent employees to perform
critical preventive maintenance and check vital points.






NOTES:

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Lummus Corporation Ginning School - Maintenance Page 2 of 20
DURING OPERATION


After maintenance is complete:

Document work that has been done on each machine.
Note repairs not accomplished.
Alert on-coming ginners to problems or unusual conditions during previous shift.

During operation:

Check for smooth flow and spread of cotton across the machinery.
Check for excessive noise or vibration.
Check for excessive amount of cotton in the trash.
Check Hydraulic systems for leaks or overheating.
Check air systems for leaks or loose connections.
Check for hot bearings, chattering gears or shafts.



NOTES:

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Lummus Corporation Ginning School - Maintenance Page 3 of 20
SEPARATOR & VACUUM




Check:

Screen damage.
Wiper flashing (should touch the screen). Replace if excessively worn.
Bearings; pre-lubricated, sealed bearings do not require additional lubrication.
Vacuum wheel chain drive; align and tension as needed (over tightening will
increase wear); lubricate periodically with a spray of Molykote 557 or equivalent.
If the chain needs replacing, replace sprockets also.
Vacuum wheel flashing and flashing holders.
Fasteners.
Air leaks.


Lummus Corporation Ginning School - Maintenance Page 4 of 20
TOWER DRIER




Check:

Interior for cleanliness, rust and cracks.
Thermocouple mounting bracket for packed cotton seed and trash interfering with
temperature reading.
Inlet and outlet transitions (magnet).









Lummus Corporation Ginning School - Maintenance Page 5 of 20
HOT AIR INCLINED CLEANER


Check:

Adjustment of grids to cylinder spikes.
Missing or bent spikes.
V-belt drives (tension, alignment, wear).
Timing belt drive.
Bearings; pre-lubricated, sealed bearings do not require additional lubrication.
Fasteners
Trash and lint build-up on the grids. Clean every shift.

Lummus Corporation Ginning School - Maintenance Page 6 of 20
STICK MACHINE


Check:

Adjustments.
Missing or damaged channel saws.
Worn brushes.
V-belt drive.
Chain drive.
Fasteners
Trash and lint build-up on the grids and in the trash hopper.

Warning signs:

Excessive seed cotton discharged with the trash (stationary brushes).


Lummus Corporation Ginning School - Maintenance Page 7 of 20
TRASHMASTER



Check:

Adjustments.
Missing or bent spikes.
Damaged or worn channel saws.
Brush cylinder and stationary
brushes.
V-belt and timing belt drives.
Chain drive.
Bearings.
Fasteners
Trash and lint build-up on the
grids and in the trash hopper.
Lummus Corporation Ginning School - Maintenance Page 8 of 20
MODEL 700 FEEDER



Check:

Adjustments.
Missing spikes.
Damaged or worn channel saws.
Brush cylinder and stationary
brushes.
V-belt drive.
Oil level in gear housing.
Fasteners.

Warning signs:

Loss of cleaning efficiency
Excessive cotton discharge with
the trash (stationary brushes).
Uneven feeding of seed cotton on
the feeder apron.
Lummus Corporation Ginning School - Maintenance Page 9 of 20
GIN STAND




Check:

Adjustments.
Gin saws for sharpness and damage. Keep a spare gin saw cylinder on hand.
Gin ribs. Seeds should not pass through at the ginning point.
Breast linkage. The breast must move fully in for proper ginning operation.
Brush cylinder.
V-belt drives (gin motor, agitator motor, picker roller and brush cylinder).
Timing belt drive, if any (agitator roller).
Bearings; pre-lubricated, sealed bearings do not require additional lubrication.
Fasteners.

Lummus Corporation Ginning School - Maintenance Page 10 of 20
LINT CLEANERS 86 AND 108
Check:

Adjustments.
Condenser drum, inside and outside, for cleanliness and damage.
Flashing at condenser doffing rollers and ends of drum.
Grooves of the fluted doffing roller for embedded lint or trash.
Oil level in gear housing.
Saw cylinder for sharpness and damage or embedded seeds.
Brush cylinder for wear. Cylinder must be dynamically balance at operating
speed.
Trash chamber and grid bars for trash build-up. Check suction if needed.
V-belt drives (saw cylinder, brush cylinder, gear reducer).
Chain drives (feed rollers, condenser drum). Lubricate periodically with a spray
of Molykote 557 or equivalent.
All surfaces in contact with the lint for burrs and tags. File and polish off any snag
or rough areas.
Fasteners.
Bearings; pre-lubricated, sealed bearings do not require additional lubrication.

Lummus Corporation Ginning School - Maintenance Page 11 of 20
LINT CLEANERS SENTINEL II

Check:

Adjustments.
Saw cylinder for sharpness and damage or
embedded seeds.
Brush cylinder for wear. Cylinder must be
dynamically balance at operating speed.
Trash chamber and grid bars for trash
build-up. Check suction if needed.
V-belt drives (saw cylinder, brush
cylinder).
All surfaces in contact with the lint for
burrs and tags. File and polish off any
snag or rough areas.
Fasteners.
Bearings; pre-lubricated, sealed bearings
do not require additional lubrication.
Lummus Corporation Ginning School - Maintenance Page 12 of 20
Setting the Sentinel II:

1. SET ALL THE FOLLOWING MECHANICAL ADJ USTMENTS BEFORE
INSTALLING THE GUARD AND GUARDS.

2. THE LOCATION OF THE SAW MUST BE THE SET FIRST. EVERYTHING ELSE
IS LOCATED RELATIVE TO THE SAW. THE CENTERLINE OF THE SAW
SHAFT SHOULD BE SET AT 20" FROM THE FRONT OF THE MACHINE AND
21-3/4" FROM THE BOTTOM OF THE END HEADS.

3. THE REMOVABLE GRID BAR SECTION SHOULD BE FIRMLY SEATED AND
PULLED INTO THE MACHINE WITH THE DRAW BOLTS BEFORE MAKING
ANY GRID BAR ADJ USTMENTS.

4. IN ORDER TO INSURE THE PROPER RANGE OF ADJ USTMENT WHEN
SETTING THE GRID BARS, MAKE SURE THAT THE FOUR (4) SET SCREWS
ON EACH SIDE OF THE REMOVABLE GRID BAR SECTION ARE SET AND
LOCKED TO KEEP THE SIDE PLATES FLUSH WITH THE HEAD OF THE LINT
CLEANER BEFORE BEGINNING THE ADJ USTMENT PROCESS. IT MAY BE
NECESSARY TO LOOSEN THE GRID BAR FASTENERS FIRST.

5. THE FEED BAR SHOULD BE SET 1/16" AWAY FROM THE SAW. IT MAY BE
NECESSARY TO LOOSEN THE FASTENERS ON THE RETAINER PLATE ON
THE BACK OF THE FEED PLATE TO ALLOW ENOUGH MOVEMENT.

6. THE SEPARATOR BRUSH CYLINDER SHOULD BE SET WITH A 1/16"
INTERFERENCE WITH THE SAW. MAKE SURE THAT THE SEPARATOR
BRUSH CYLINDER IS CENTERED BETWEEN THE HEADS OF THE MACHINE
AND THAT THE BEARING LOCK RINGS ARE SECURED. THE RELATIONSHIP
BETWEEN THE SEPARATOR BRUSH CYLINDER AND THE FEED BAR IS NOT
IMPORTANT.

7. AFTER THE SEPARATOR BRUSH CYLINDER IS SET, ADJ UST THE SCREENS
IN TO WHERE THE SCREEN INTERFERES WITH THE BRUSH TIPS OF THE
SEPARATOR BRUSH CYLINDER BY APPROXIMATELY 1/16". THE
INTERFERENCE SHOULD BE UNIFORM ACROSS THE ENTIRE SURFACE OF
BOTH SCREENS. ROTATE THE CYLINDER BY HAND TO ASSURE THE
INTERFERENCE IS THE SAME FOR ALL BRUSHES.

8. SHIM THE DOFFING BRUSH CYLINDER AND ADJ UST UNTIL THE BRUSH
TOUCHES THE TIPS OF THE SAW.

9. SET THE DIVIDER PANEL WITH A 1/16" GAP AWAY FROM THE SAW.
Lummus Corporation Ginning School - Maintenance Page 13 of 20
Lummus Corporation Ginning School - Maintenance Page 14 of 20
Lummus Corporation Ginning School - Maintenance Page 15 of 20
Safety Reminder

Importance Concern for safety must be foremost in the operation and
maintenance of any equipment. This is particularly true of a press
because of the enormous forces involved. Many press
components weigh several tons. Hydraulic pressures of up to
5,000 psi may be used. Electrical wiring and pneumatic piping
run throughout many presses. Be careful.
Clear the Area Clear the area of any personnel who are not required for the job
being done. Post warning signs. Personally check the location of
everyone.
Explain the Job Explain to everyone working with you exactly what will be done
and what hazards are involved. Emphasize the importance of not
taking any action without your approval.
Lock Out Power Before inspecting or working on the machine, turn off control
power; then disconnect and lock out all motor power. Only those
circuits which are actually required for the job should be
energized. All other control and motor circuits should be
disconnected and locked out.
After seeing that no personnel are in danger, operate the push
button or other normal operating controls to assure that the
equipment is not powered. Do not reach inside any machine until
you are sure that power has been turned off and locked out and all
motion has stopped.
Bleed Fluid Systems Before disassembling any part of the hydraulic or pneumatic
systems, temporarily support, mechanically any parts which are
normally supported by fluid or air pressure. Bleed the lines and
be sure the pressure gauges read zero. Operate solenoid valves a
few times to bleed off any pressure that may be in the lines.
Check the pressure on all circuits.
Assume There Is Pressure Even after bleeding the system, assume that there is
pressure in all lines and work accordingly. When loosening any
connection, loosen it only partially. Wait for the flow of fluid or
air to slow to a trickle before completing disassembly.
When separating pipe flanges or components with base plates or
manifolds, first loosen the bolts farthest from you, but only one
turn. Then loosen the bolts closest to you just enough to release
the seating torque. If no fluid flows, then loosen the first bolts a
turn or two.

Lummus Corporation Ginning School - Maintenance Page 16 of 20
Maintenance Checklist

Battery Condenser
o Screen drum is in good condition.
o Flashing around the drum is in good condition.
o Speed of the drum in relation to the ginning speed is correct. If the
drum is too fast, the batt will break and possibly cause an uneven
feed; too slow produces a thick batt which is harder to feed.
o Doffing rollers are in good condition and adjusted to the manufac-
turer's specifications.
o Condenser exhaust fan blade is clean, bearings are in good condi-
tion, and drive is aligned and tensioned.
Lint Slide
o Surfaces are clean of lint build-up.
o Slide is installed at the recommended slope (normally between 36
and 45).
Feed Mechanism
Belt Feed Type
o Belt and lacing are in good condition.
o Brake motor or dynamic brake is functioning properly.
o Chain and belt drives are aligned, tensioned, and in good condition.
Pusher Type
o Seals and O-rings of cylinder and valves are in good condition.
o Valves are functioning properly.
o Guide rollers or pads are aligned and in good condition.
o Limit switches or proximity switches are clean and adjusted.
o Moisture is drained from airlines (pneumatic).
o Oil is clean and filter does not yet need to be replaced (hydraulic)



Lummus Corporation Ginning School - Maintenance Page 17 of 20
Tramper
General
o All safety devices, mechanical and electrical, are secure, adjusted,
and functioning properly.
o Guide rollers, pads, or bushings are aligned and in good condition.
Hydraulic
o Pumping unit is maintained according to manufacturer's recom-
mendations.
o Valves are functioning properly.
o Seals and O-rings on cylinder and valves are in good condition.
Mechanical
o Brake motor or brake assembly is functioning properly.
o V-belts and sheaves are aligned, tensions, and in good condition.
o Chains and sprockets are in good condition, aligned, and lubricated.
o Bearings and bushings are in good condition.
o Oil level in gearbox is correct.
Press
o Safety devices are secure, adjusted, and functioning properly.
o Press frame is level and plumb with all fasteners secure and any
necessary shims in place.
o Bottom thrust bearing and center column bushings are lubricated.
o Power turning drive is aligned and lubricated.
o Boxes are in line with the tramper and ram when latched.
o Door locks are in good condition and doors are lubricated as needed.
o Sensors (limit switches, photocells, etc.) are secure and adjusted.
o Latch for boxes is secure and lubricated.
o Air lines are drained
,
of water and lubricators have enough oil of
proper type.
o Air hoses and piping are secure and free of leaks.
o Cylinder and valve seals and O-rings are in good condition.
o Ram is plumb, centered on the box under it, and all fasteners are
secure.
Lummus Corporation Ginning School - Maintenance Page 18 of 20
Tying System
o Automatic or semiautomatic tying system is maintained according to
manufacturer's recommendations.
Pumping Unit(s)
o Hoses and pipes are secure and free of leaks.
o Valves are in good condition and functioning properly.
o Oil is clean and of correct viscosity for operating temperatures ac-
cording to hydraulic components manufacturers' specifications.
Bale Handling
o Safety devices are secure, adjusted, and functioning properly.
o Limit switches and photocells are secure and adjusted.
o Assemblies are aligned with the pressand each other.
o Drives are aligned, tensioned, lubricated, and in good condition.

NOTES:

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Lummus Corporation Ginning School - Maintenance Page 19 of 20
Spares

Parts Keep on hand a set of recommended spare parts to ensure
operation with a minimum of downtime. As items are used, order
replacements. Refer to the shipping list and/or parts list which
accompanied your

machine for the part numbers.
Lubricants In addition to the parts, it is recommended that a supply of the
following lubricants or their equivalents be kept on hand. Keep
them sealed to prevent contamination.
Lube Oil HD-220 for gear reducers
Molykote 557 for roller chains mounted on machine
Molykote 321-R for roller chains before reassembly
No. 2 Lithium Soap Base Grease for bearings &
bushings with grease fittings. NOTE: Many
manufacturers recommend that sealed, pre-lubricated
bearings not be greased, even if they are equipped with
grease fittings. More bearings are ruined by over-
lubrication than any other cause.
No. 10 Air Line Oil for pneumatic lubricators.
Mobil DTE Oil 25 or equivalent for hydraulic pumping
units operating - below 95 degrees F ambient (35C).
Mobil DTE Oil 26 or equivalent for hydraulic pumping
units operating above 95 degrees F ambient (35C).

NOTES:

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Lummus Corporation Ginning School - Maintenance Page 20 of 20
LUBRICATION COMPARISON CHART
MANUFACTURER
LUBRICATION
GROUP
MOBIL ESSO SHELL SUNOCO TEXACO
Hydraulic oil Mobil
D.T.E. 25

Tellus
Oil 46
Sunvis 821
WR
Rando Oil
HDB 46
(ISO VG 68) Mobil
D.T.E. 26
Nuto H
68
Tellus
Oil 68
Sunvis 831
WR
Rando oil
HDC 68
Gear Oil
(ISO VG 68)
Mobilgear 626 Spartan
EP 68
Omala
Oil 68
Sunep 1050 Meropa 68
(ISO VG 150) Mobilgear 629 Spartan
EP 150
Omala
Oil 50
Sunep 1070 Meropa 150
(ISO VG 220) Mobilgear 630 Spartan
EP 220
Omala
Oil 220
Sunep 1070 Meropa 220
(ISO VG 320) Mobilgear
632
Spartan
EP 320
Omala
Oil 320
Sunep 1090 Meropa 320
Slideway Oil
(ISO VG 68)
Mobil Vactra
No. 2
Febis K
68
Tonna
Oil T68
Way Lube 80 Way Lube 68
(ISO VG 220) Mobil Vactra
No. 4
Febis
K220
Tonna
Oil T220
Way Lube 90 Way Lube
220
Gear Grease Mobilux
EP 023
Esso-
gear
Yield
grease
380\410
(Na) (*)
Special
grease
405\430
(NA) (*)
Sun C890-T


(*)

All Purpose Grease
(NLGI 2)
Mobilux EP 2 Beacon
EP2
Anvania
Grease
EP2
Sunaplex
992 EP
Multifak EP
Special grease Mobilgrease
28 265\320
(Synthetic)

Aero Shell
Grease 16
260\320

(*) NOT DIRECTLY EQUIVALENT TO MOBIL PRODUCT