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lhartle Dlwlalon / Middletown, Ohio / Stock Preparation Systems

·The Black Clawwson . Con~pany .

HYDRAPULPER® Parsons-Jurden Foreign Print I


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APPROVAL OF lW AWIN G DOES NOT m:'uE\ •.
MANUFACTU R.ER OF RESPONSI I::3i LlTY f- Or<
ERRm,s OR OMISSiONS.
Gentlemen: -
This manual was prepared for general infonnation and guidance only.
For specific information concerning parts or items, please refer to
the certified prints.

Please distribute copies of this manual to your operating and main-


tenance personnel. They should become thoroughly familiar wi th t he
information it contains.

\ole trust this w·ill be helpful to you in the operation and mainte-
nance of your equipment.

The Black Clawson Company


Shartle Division
Middl etown, Ohio

ISSUE DATE: MARCH 1, 1970


CONTENTS

INTRODUCTION I

GENERAL SPECIFICATIONS II

PRE-INSTALLATIONS III

INSTALLATION IV

OPERATION v

MAINTENANCE VI

DRIVE VII
HYDRAPULPER
i INTRODUCTION
FOREivORD

Your Black Cla1.,;son Hydrapul:per is a high quality machine designed ·to give trouble
free operc!.tion a.lld minimwn maintenance
4 However, certain precautions and pro-
cedures must be observed in h<:.t.n.dling, inste.~ling, operating and servicing the
unit. in order to obtain opti.rn.ur:t perf'or:rua..nce. The information is this manual
should cover most s ituat;ions. Should questions arise that are not covered. in
this booklet, additional infonnation cr:J.n be obtained by contactin(} the Service
Department, The Black Clm!Son Compeny, Sha:rtle Division, Middletmm,. Ohio 45042.

SERIAL NUMBERS

All Hydrapulpe:rs, Hydrapulpe:r Drives <.llld auxiliary equipment (Jun.~ :"lemover,


Ragger, etc.) a:ce assigned SERIAL NU1Vffit"!RS at the Shartle Division. These
identifying nwnbers will be found stamped into nameplates which are attached
to the Hydrapulpel" and the other pieces of equipment.· They will also appear on
the certified dravings which you received pertaining to your particular H;ydra-
pulper.

Sin•2e all records fOl' each Hydrapulper are compiled under its identifying nwnber,
f,LWAYJ3 ST/ITE SERIAL NUJ>IBERS as vell as size a.'ld type of unit when inquiring about
service or maintenance problems.

HENEHAL PARTS

Orders for rene1ml parts should state the serie.l nwnber(s) and include pa.."'t
nwnber and description as shown on the parts list of the certified draving.

SAFETY PRECAL~ION

ro PREVENT ACCIDENTAL S1'ARTING while the Hydra:pulper is being serviced, follow


your prescribed safety procedures.

PAGE l.O
HYDRAPULPER
II GENERAL SPECIFICATIONS
GENERAL DESCRIPTION

The Black Clawson Hydrapulper is a vertical pulping machine. The fUnction is


accomplished by a vaned rotor turning inside a tub which is fitted with perforated
plates. Accepted stock is extracted through the perforated plates in either a
continuous or batch process. Energy for the rotor is transmitted through a
right angle gear box or V-belt drive,

SIZES AND MATERifl.LS

The Hydrapulper is produced in a variety of sizes and materials to meet the needs
of the industry.

COMPONENTS OF THE HYIJRAPULPER

TL~ ASSE,~LY - The tub assembly is the vessel in which the pulping operation is
performed. It contains an extraction chamber which is covered by-perforated
plates. Accepted stock passes through the perforated plates and into the ex-
traction chamber from >ihere it is passed on to the next piece of equipment in
the sys.tem ..

The tub is constructed of cast iron sections, fabrications (steel, stainlass


steel, etc.) or tile.

ROTOR - The rotor is the means of imparting energy to the pulping operation,
It is keyed to the drive shaft and retained by a thrust plate and screw.

DRIVE - The rotor is driven through a right angle gear box or a V-belt drive,
The gear box is usually direct cou;pled to the prime mover. Occasionally it is
coupled to a jack shaft >ihich may be belt driven.

V-belt drives are supported by a right angle bracket fastened to the bottom of
the Hydrapulper tub.

Gear box drives are installed on their 01in foundation and are not connected to
the Hydrapulper tub,

TUB SUPPORT - The required elevation of the tub assembly is maintained by the
tub support, A fabricated steel framework is the most connnon, although concrete
piers are sometimes used.

AUXILIARY EQUIPMENT

RAC-GER - When pulping di.rty mixed papers in a Hydrapulper, a Ragger is used to


·trap and remove rags, wet strength, floating trash, etc. It is installed at the
edge of the Rydrapulper tub to facilitate the inserting and withdrawal of the
rag rope.

PAGE2.0
SPECIFICATIONS HYORAPULPER
AUXILIARY EQUIPMENT (continued)

JUNK REIDVER - A .JUIL~ Remover is used to automatically and continuously remove


heavy junk and trash from the Hydrapulper when pulping dirty mixed papers. It is
installed alongside the Hydrspulper and is connected to an opening in the bottom
of the tub by a junk chute, which permits junk to drop to the boot of the .Junk
Remover. An endless bucket conveyor, operating on the chain and sprocket prin-
ciple, removes the junk from the bottom of the boot as fast as it accumulates
by lifting it above the level of the stock in the Hydrapulper and discharging it
into the junk box.

TYPE OF OPERATION Hydrapulpers are designed to be operated in one .of the


follm<ing ways:

a) BATCH - The Hydrapulper is charged with pulp or clean waste and enough water
to obtain a desired consistency. The charge is left in the Hydrapulper until
the desired degree of defibering has been obtained. The batch is then dumped
and the process is repeated.

b) CONTINUOUS - A continuous Hydrspulper is arranged to permit pulped material to


discharge when correct particle size has been reached. Proportionate amounts
of stock and water are continuously added to replace the discharged pulp to
maintain a constant flD>i of pulped stock at a given consistency.

PAGE 2.1
HYDRAPULPER
Ill PRE-INSTALLATION
GENERAL - The customer is to furnish all piping, anchu2· bolts, lead, <;elding rods,
drive guards, etc. Please refer to the certified inGtaJ..lation drawings for the
correct list of parts to be furnished by Blacl;: Clawson.

FOUNDATION - The certified installation drm-ring uill give the live loP.d for each
su;pport coltunn and for the dr~ve. The elevation of the foundations and the aJ..lov-
ances for grout are also given.

The location of' any auxiliary equipment requ~nng foundations or anchor bolts. '{ill
be sho;m on the certified Hydrapulper installation drawing.

ANCHOR BOLTS - The number and size of' anchor bolts, nuts and ;rashers can be
determined from the certified installation drm-ring. ive recommend imbedding the
the anchor bolts in pipe sleeves, 2-D illustrated .

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LEVELING INSTRUMENT - Use a sensitive, graduated tube spirit level reading to 10


seconds per graduation ( .0006" per foot). One provided with a screw adjustment is
best. The level in an ordinary machinist's square is not accurate enough.

CAUTION - UNDER NO CIRCUMSTANCES SHOULD THE HYDHAPULPER TUB BE BOTirED, GROtlrED,


WELDED OR OTHERWISE CONNECTED TO BUILDING BEAM3, FIOORS, WALTS OR OTHER STATIONARY
MEMBERS. THE TUB MUST BE FREE TO EXPAND OR CONTRACT UNDER VARIOUS TBMPERATURE
AND IOAD CONDITIONS.

•1\GE 3.0
HYDRAPULPER
IV INSTALLATION
INSTALL THE DRIVE

The basic gear unit is shipped from the factory completely assembled. Mating
gear and pinion have been carefully assembled to provide proper tooth contact.
Nothing should be done to disturb this setting.

The entire drive assembly, consisting of the gear unit, a sub-base (to allm< for
rell!Pval of the dr'c ve), motor and motor rails, is ll!Punted on a sole plate.

MOTOR GEAR UNIT

SUB-BASE ,

ELEVATION

1 - Set the Sole Plate - The certified installation prints will give the elevation
of the drive and the amount of grout required.

Extend the leveling screws through the sole plate about 1/2". lDwer the sole
plate over the anchor bolts and place a small steel plate (3" x 3" x l/2")
under each leveling screw. Raise the sole plate to its proper elevation and
level at the same time by using,the leveling screws. Use a flat washer and
nut on each anchor bolt. Pull tight and recheck the level and elevation.
Repeat adjusting the leveling scre,<s until the sole plate is dead level when
the anchor bolts are tight.

Do not grout the sole plate at this time.


2 - Install the sub-base. Insert the hold down screws but' do not dowel.

!N-H-CI
PAGE 4.0 HCV-M-FAB !N-M-FAB
HYDRAPULPER INSTALLATION
DRIVE INSTALLATION (continued)

3 - Reoove all protective shipping covers from the gear unit. The shaft extensions
and outside machined surfaces are protected during shipment by an anti-rust
compound. This can be removed by using a solvent •.

4 - !-bunt both coupling halves. Since an endwise blow on the shaft may damnge
gears and bearings, heat the coupling to about 37~F and slip the proper half
on the motor shaft and drive pinion shaft respectively.

5 - Install the gear unit on the sub-base. Insert the flange bolts but do not
dowel at this time.

6 - M:>ve the motor and motor rails into position and make a rough coupling align-
ment. Usually the motor rails 1rl.ll have to be drilled to suit the motor and
the sole plate will have to be drilled and tapped to suit the motor rails.
These holes can be scribed from the mating pieces after making the rough align-
ment. After the drilling and tapping operations have been performed the motor
and motor rails can be loosely assembled in position.

Do not make a final alignment of the coupling at this time.

NOTE: The motor should be slightly low to allow for shirrnning 1<hen making a
final alignment.

INSTALLATION OF TAILSTAND GEAR DRIVE

If a jack shaft and V-belt drive are used in conjunction with a gear drive,
the installation is similar to that of a direct coupled drive.

NIT

SUB-BASE
T

HV-M-CI
HV-M-FAB HCV-M-FAB PAGE 4.1
INSTALLATION HYDRAPULPER
TUB SUPPORT

The Hydrapu1per tub is supported in one of the following ways:

a) Concrete Piers - Concrete piers shou1d be poured with anchor bolts in p1a.ce
for receiving the tub. Height of the piers shou1d not include the grout.
This will be added after the tub has been 1eveled,

The anchor bolts can also be used as 1eveling screws by installing a nut
and flat washer on each one before assemb1ing the tub.

b) Fabricated Support Columns - Insert leve1ing screws in all the support


co1umns until they extend about 1/2" beyond the bottom of the base. Insta1.1
each column on its anchor bolts and place steel pieces (3" x 3" x l/2")
under each leveling screw. Put a flat washer and nut on each anchor bolt
and tighten until snug. Use the leveling screws to set the top of the
support column at the proper e1evation and 1evel.

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TYPICAL INSTALLATION TYPICAL INSTALLATION


CONCRETE PIER TUB SUPPORTS FABRICATED TUB SUPPORTS

PAGE 4.2 HCV-M-FAB


HYORAPULPER INSTALLATION
TUB AND EXTRACTION CHAMBER

On batch operated Hydrapulpers the extraction chamber is bolted to the underneath


side of the tub bottom. It is necessary, therefore, to lower the extraction
chamber over the drive shaft and allow it to rest on the drive housing while the
tub is being assembled.

EXTRACTION PLATE
B

HCV-BATCH

On continuous units the extraction chamber is bolted to the top side of the tub
bottom and is installed after the tub has been erected.

EXTRACTION HAMBER

HCV- CONTINUOUS

HCV-M-FAB PAGE lt-.3


INSTALLATION HYDRAPULPER
TUB

On sma.ll units the tub is supplied in one piece. Larger tubs are split and must be
welded in the field. Whether the split tubs are welded into a unit before or after
being assembled on the support columns will depend on the availability of space,
handling capabilities, etc. Clips are welded to the outside of the tub along the
splits to permit bolting the sections together in proper alignment for welding.
The tub should be tack welded in several places andthen welded using the back-step
method to hold distortion to a minimum.

Check the certified installation drawing to be sure that any openings are positioned
properly when the tub is assembled on the support columns.

TUB SPLIT

ELEVATION

PAGE 4.4 HCV-M-FAB


HYDRAPULPER INSTALLATION
EA'TRACTION CHAMBER

Refer to the certified installation drawing for the location of the dump opening
before bolting the extraction chamber to the tub bottom. A rubber gasket is
s~p1ied for sealing this fit.

Align the extraction chamber to the drive, considering the following conditions:

a) Radial Alignment - The vertical shaft nrust be centered in the packing box
bore.

b) Elevation - The dimension from the top of the vertical shaft to the top of
the extraction chamber, as shown on the certified print of the cross section
of the rotor assembly, must be held in order to get the proper rotor clearance.

c) Perpendicularity - The vertical shaft must be perpendicular to the top of the


extraction chamber. This can be checked with a dial indicator by attaching
a bar to the vertical shaft and turning the pinion shaft by hand.

ROTOR

The drive shaft should be cleaned and coated with white lead or a prepared graphite
mixture to aid in removal of the rotor. Assemble the rotor 1 rotor cap and thrust
screw.

Check the clearance between the rotor and the extraction plates. The amount of
clearance required is shown on the certified installation drawing.

NOTE: Normally the extraction chamber is shipped with the under rotor wear plate and
the extraction bedplates assembled to it. If' for some reason they were shipped
separately, assemble them before installing the rotor.

GROlJriNG

Make a final check of the rotor clearance and alignment before doing any grouting.

Grout under the drive sole plate.

If the tub is on concrete piers, grout between the tub bottom and the top of the
piers. If fabricated s~port columns are used, grout under each column.

ALIGN THE COUPLING

Using a dial indicator1 align the co~ ling halves. Both angular and parallel align-
ment nrust be within .002" total indicator reading.

Dowel the motor and motor rails after final alignment.

HCV-H-FAB PAGE 4.5


INSTALLATION HYDRAPULPER

P.ACKING OOX

Instal.l the water seal ring. Be sure it is fully inserted end not cocked in any
direction. Insert braided :flax packing o:r the correct size and tighten the packing
gland just enough to compress the packing lightly.

INSTALL AUXILIARY ~UIPMENT

I:f the aydrapulper is equipped with a Junk Remover or Ragger, please re:rer to the
Instruction Manual :ror each.

PAGE 4.6 HCV-M-FAB


HYDRAPULPER INSTALLATION
WATER CONNEX:TIONS - CONTINUOUS HYDRAPUIPERS

1 - P.ACICING :OOX - Connect fresh "ater to the packing box. It is suggested that a
check valve be installed next to the pulper along "ith a visual type rotameter
and a solenoid valve. The check valve will prevent the line from becoming
clogged with stock should there be a loss of water pressure. The visual sight
glass will show if the line becomes plugged and permit cleaning before the shaft
sleeve is damaged. The solenoid valve is tied in with the pulper motor circuit
so it will automatically be on during operation and off when the pulper is down.
Normally, 15 to 20 GPH of water at 35 psi is adequate.

2 - UNDER ROTOR WAS!PUT - Connect the "under rotor washout" line. In most instal-
lations the size opening in the extraction chamber will supply more water than
is needed. It is suggested this be reduced to 1/2" or 3/4". The purpose of
this water is to prevent stock from packing and cutting the underside of the
rotor. It is suggested that a check valve be installed close to the pulper to
prevent the line from becoming clogged with stock should there be a loss of
pressure.

3 - JUNK BOX - Units equipped with a Junk Box should have a control valve installed
as illustrated. Extending the handwheel to the operating floor will aid the
operator. The a.JOOunt of water used must be determined by trial and error. Too
much water will tend to wash junk back into the pulper. Too little water will
permit the box to fill with thickened stock.

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PACKING BOX WATER i · I-------CONTROL Y;\!-VE_
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UNDER ROTO_FU'!_ASHOUT / JUNI< BOX DRAIN
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HCV-M-FAB PAGE 4.7


INSTALLATION HYDRAPULPER

WATER CONN"EX;TIONS - BATCH l:IYilRP.PUIPER

1 - P.ACICING BOX - Connect fresh water to the packing box. It is s~ested that a
check valve be installed next to the pulper along with a visual type rotometer
and a solenoid valve. The check valve will prevent the line from becoming
clogged with stock should there be a loss of' water pressure. The visual sight
glass will show if' the line becomes pl~ed and permit cleaning before the shaft
sleeve is d.amaged. The solenoid valve is tied in with the puJper motor circuit
so it will automatica11,y be on during operation and off when the puJper is down.
Normally, 15 to 20 GPH of water at 35 psi is adequate.

2 - UNDER ROTOR WASHOUT - Connect the "under rotor washout" line. It is suggested
that a check valve be installed next to the pulper along with a solenoid valve
tied into the dump pump circuit so it will operate automatically. If' a solenoid
valve is not used, it is suggested that an "off-on" valve be installed just
outside the tub diameter and the handwheel extended through the floor to aid the
operator.

FILL PIPE
SHUT -OFF VALVE
Jr

..-:::::}

~ALTERNATE VALVE

ROTOMETER - - -
0
SOLENOID VALVE

UNDER ROTOR WASHOUT


PACKING BOX WATER

HCV-M-FAB
P.AGE 4.8
HYDRAPULPER
V OPERATION
EQUIPMENT CHECK

1 - Remove all tools, scaffolding and other loose objects from inside the Hydra-
pu]Jler tub.

2 Open the valve in the water line to the packing box. The packing gland is
properly adjusted when a thin trickle of water seeps through the packing.

3 - Turn on the under rotor water just long enough to make sure it is working;
then turn it off.

4 - Check the drive.


A. Belt Drive

a) Check the belts for alignment and tension.


b) Grease the bearings. Follow the lubrication instructions in 1he
Drive Chapter of this manual.
c) Start the Hydrapulper drive motor and check the rotation of the rotor.
The correct rotation is shown on the certified installation drawing.
d) Check the Hydrapulper tub, tub support, drive and motor for excessive
vibrations.
e) Stop the motor.

B. Gear Box Drive

a) Check the oil. See the lubrication instructions in the Drive Chapter
of this manual.
b) Open the valve in the water line to the oil cooler.
c) Start the oil pUlliJ? and check the oil pressure gauge. Normal operating
pressure will be 20 to 30 PSIG.
NOTE: SPLASH LUBRICATED IlRIVE3 ARE NOT EQUIPPED WITH A PRESSURE
CONTROL AND GAUGE.
d) Start the Hydrapulper drive motor and check the rotation of the rotor.
The correct rotation is shown on the certified installation drawing.
e) Check the Hydrapulper tub, tub support, drive and motor for excessive
vibration.
f) Check the pressure controls for the lube system for de-energizing the
oil PUlliJ? motor. When the oil pressure drops, the Hydrapulper main
drive motor should be shut down automatically. Try starting the
Hydrapulper with the main drive motor switch. It should not start.
If the drive starts with the oil PUlliJ? not operating, the wiring is
incorrect.
g) Upon completion of the drive che<;!k, shut do>m the drive ond oil PUlliJ?
and close the valve in the water line to the oil cooler.

5 - Open and close the ;;ashout valve a few times to be certain it is operating
smoothly.
6 Check the operation of the valve in the discharge line.
7 - Check Auxiliary Equipment (if so equipped). (See instruction manuals for Junk
Remover and Ragger.)
PAGE 5.0
OPERATION HYDRAPULPER
OPERATION OF BATCH TYPE HYDRAPULPER

GENERAL

Batch pulping is performed by charging a HydrapuJ:per with pulp or clean waste and
enough water to obtain a desired consistency. The charge is left in the Hydra-
pulper until the desired degree of defibering has been obtained. Then, the batch
is dumped and the process is repeated.

CYCLE

One complete cycle consists of the charging, pulping, dumping and, if necessary,
the washdown operations. Cycle time is the sum of the times required to perform
the operations.

CAPACITY

The capacity of a Hydrapulper (in tons per day) can be calculated by multiplying
the number of cycles per 24 hours by the average tonnage per cycle.

CHARGING

Charging is the process of filling the Hydrapulper with the desired amount of
furnish and water. The pulper should be filled approximately one-third full of
water with the rotor shut off. The full charge is then added, after which the
rotor is started. As the furnish pulps up, additional water should be added to
bring the level to the desired height or the stock to the desired consistency.
Provision should be made to charge the pulper with water and furnish as fast as
possible to obtain maximum efficiency from the pulper.

PULPING TIME

Pulping time is the time required to defibre the stock until it matches a definite
defibering standard. A hand sheet of pulping standards is compared to a sheet
taken from the Hydrapulper to determine when the desired fibre size has been
reached. Numbers 10 and 20 (on the hand sheet) represent slushed stocks. In the
range from 30 to 50, the stocks are partially defibered; and, the range from 60
to 100 indicates complete defibering.

Pulping time depends on a number of factors, but, in general it is determined by


the type of stock being pulped.

Temperature is also an important factor in pulping and hot water is often used to
speed the process.

PAGE 5.1
HYDRAPULPER OPERATION
BATCH OPERATION (continued)

PULPING STANDARDS

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,
10 20

50 60 100
Actual size photos of hlt.nd sheets showing various degrees of defiberlng.

DUMPING
Dumping is accomplished by opening the valve in the discharge line. This permits
the pulped mater~al to discharge from the tub through a dump opening in the ex-
traction chamber.

WAS!IDOHN

Washdown is not always necessary af'ter each batch is dumped. When the same furnish
is used, batch af'ter batch, washdown is generally eliminated.

PAGE 5.2
OPERATION HYDRAPULPER
BATCH OPERATION (continued)

BATCH OPERATING PROCEDURE

l - Open the water valve to the oil cooler and start the oil pump motor if the
Hydrapulper is equipped with a gear box drive.

2 - Turn on the packing box water.

3 - Open the valve in the line for filling the tub. Close the valve when the tub
is about one-third full,

4 - Determine the amount of furnish for one batch by weight and feed it into the
Hydrapulper.

5 - Start the Hydrapulper main drive motor.

6 - Add water to obtain the desired consistency.


7 - Allo>r the Hydrapulper to operate until the desired amount of defibering has
been reached.

8- When required defibering has been obtained, open the.dump valve and turn on
the stock pump.

NDTE: Keep the main drive motor operating during the dumping operation until
splashing begins; then stop the motor.

9 - When the tub is empty, close the dump valve and shut down the stock pump.

10 - If another batch is to be pulped immediately and a washdown is not necessary,


repeat the process starting with item 3.

ll - When washout is required, open the under rotor washout valve and, if the
Hydrapulper is so equipped, the valve to the washdown shower. When the tub
is clean, turn off the shower and under rotor flush out water and open the
washout valve.

l2 - If the Hydrapulper is to remain idle for awhile, turn off the oil pump on
the drive and the packing box water.

CAUTION: Be sure under rotor washout is off.

PAGE 5.3
HYORAPULPER OPERATION
OPERATION - CONTINUOUS HYDRAPULPER

GENERAL

A continuous Hydrapulper is arranged to permit pulped material to leave the unit


when correct particle size has been reached. Proportionate amounts of stock and
water are continuously added to replace the discharged pulp and maintain a con-
stant flow of pulped stock at the desired consistency.

CHARGING THE HYDRAPULPER

Loose or baled furnish is dumped into the Hydrapulper from a conveyor, skip hoist,
fork lift or hand truck. Except for the initial charging, the furnish is usually
added one bale at a time. Baled material must have the wires cut before it is
dumped into the Hydrapulper. This reduces the pulping time by permitting the
furnish to spread out upon hitting the water.

lfuen the Hydrapulper is equipped with a Ragger, the baling wires must be cut but
should not be removed. They will be picked up in the Hydrapulper in the formation
of the rag rope.

When the Hydrapulper is not equipped with a Ragger, the baling wires must be
removed before the furnish is fed into the Hydrapulper.

CONSISTENCY

Consistency is the percentage of furnish and water.

WATER TEMPERATURE

Hydrapulper capacities are based on a recommended water temperature of 140°F.

PAGE 5.4
OPERATION HYDRAPULPER
CONTINUOUS OPERATION (continued)

CONTINUOUS OPERATING PROCEDURE

1 - Open the water valve to the oil cooler and start the oil pump motor if the
Hydrapulper is equipped with a gear box drive.

2 - Turn on the packing box water.

3 - Turn on the under rotor washout water.


4 - Start the Junk Remover. *(if so equipped)

a) Open the white water inlet valve to the Junk Remover.


b) Open the white water inlet valve to the trash collection box
near the top of the Junk Remover.
c) Start the conveyor drive motor.

5 - Fill the Hydrapulper tub with water to approximately 3-1/2 feet below
the top of the tub.

6 - Start the Hydrapulper main drive motor.


7 - Add furnish to obtain the desired consistency.
8 - Start the Ragger. *(if so equipped)
a) Drop the free end of the rag rope into the Hydrapulper tub.
b) Set the "ON-TIMER" and "OFF-TIMER" to values which will give
the desired operation of the Ragger.
NOTE: If there is no previous experience, the "ON-TIMER" can
be set at 2 seconds and the "OFF-TIMER" at 60 seconds.
c) Set the selector svitch on Automatic.
d) Turn on the ~<hite water used for washing the rag rope.

9 - The desired level in the tub is maintained by adding vater via a level
controller or manual valve.

10 - Adjust the rate of incoming stock and make-up water to obtain desired
production from the Hydrapulper.
NOTE: The major portion of make-up water should enter through the Junk
Remover via the white water.

*Please see the separate instruction manuals for Junk Remover and Ragger.

PAGE 5.5
HYDRAPULPER
VI MAINTENANCE
PERIODIC INSPECTION

A general inspection and tightening of the Hydrapulper should be performed twice


each year. locating and eliminating minor defects will assure long and dependable
service. In many instances, it eliminates costly shut-downs and delays.

l-IARNING: To prevent accidental starting while inspecting or servicing the


Hydrapulper, follow your prescribed safety procedures.

To prepare for a maintenance check, start by emptying the Hydrapulper completely.


Wash dow~ the tub and the rotor.

Inspect the inside of the tub, baffles, rotor vanes, bangor irons, wear plates
and extraction plates for excessive wear or damage.

Inspect and tighten, when necessary, all bolts in the Hydrapulper.

Inspect the drive. On a V-belt drive adjust the tension on the belts. On a gear
drive remove the inspection plates and check the general condition of the internal
drive mechanism.

Inspect gear tooth markings for irregular pattern or uneven wear. Replace the
inspection plates. Lubricate in accordance ~rith the instructions in the drive
section of this manual.

Inspect the packing, packing sleeve, and water seal ring.

PACKING :OOX

A packing box, consisting of a lantern ring, packing and packing gland, is used
to seal the drive shaft where it passes through the extraction chamber. A
packing sleeve is .used to absorb the wear created by the packing. This sleeve is
fitted either to the drive shaft or the O.D. of the rotor hub when it extendc
through the packing area.

The lantern ring contains openings which allow water to reach the packing and sleeve.
A water pressure of 35 lbs. should be maintained at all times when the Hydrapulper
is operating. A constant flow of water will prevent clogging of the ring and pro-
vide proper lubrication of the packing. When the packing box is being repacked,
the water ports in the lantern ring should be cleaned and the water flow to the
packing box tested.

Lantern rings are split to facilitate assembly into the packing box when replace-
ment is mecessary. Be sure it is free to tu;rn when it is fully seated in the
packing box.

After repacking the box, tighten the packing gland until the water flm<s out of the
packing box in a slow steady trickle. 00 NOT TIGHTEN THE PACKING GLAND TOO 14UCH
OR \·lATER WILL NOT FIDW AROUND THE SLEEVE AND LUBRICATE THE PACKING.

PAGE 6.0
MAINTENANCE HYDRAPULPER
REBUILDING 1-KJRN ROTOR VANES

When rebuilding rotor vanes by installing face plates, care must be taken in
locating the face plat~s so as to maintain the proper clearance between the bottom
edge and the extraction plate.

SD (l piece) Rotor

Face plates can best be located on an SD rotor while it is in the Hydrapulper.


Place a piece of .06" shim stock across the extraction plate under one vane.
Allow the bottom edge of the face plate to rest on the shim stock. With the face
plate against the face, of' the rotor vane and set at 10° angle from vertical (the
upper edge being forward) tack weld the face plate to the rotor vane. Repeat
this process until all the face plates are tacked in place. Turn the rotor to be
sure that all vanes clear properly. The rotor can then be removed from the Hydra-
pulper and the space between the face plates and worn vanes filled with weld.

AH-J. (3 piece) Rotor

Since the vane ring in an AW-l rotor may have been adjusted from its original
setting it is best to remove it from the Hydrapul,per and set the face plates to
correspond to the original dimensions to which the vane ring was built.

First remove the vane ring from the rotor body. Set the vane ring on a surface
plate on a set of spacer blocks placed under the bottom df the counterbored area
which fits over the rotor body,

The height of the blocks should be euqal to the original dimension of' the vane
ring as given in the following list:
Vane Ring Dia. Height of Blocks
33.6 l.56
45 l.75
53.5 l.69
57 2.00
67.25 2.06
76.8 2.31
81.6 2.25
86.4 2.50
Allow the bottom edge of the face plate to rest on the surface plate. With the
face plate set against the face of' the rotor vane and set at a 5° angle from
vertical (the upper edge being forward) tack weld the face plate to the rotor vane.
Repeat the process for each vane; then fill in the space between the face plates
and worn vanes with weld.
Welding information and sketches are shown on dra;ring C-SP-1350 which is included
in this manual.
ROTOR CLEARANCE
The clearance between the rotor vane and the extraction plates is set during
installation. Due to wear it may be desirable to reset the clearance. On Hydra-
pul,pers equipped with an AW-l (3 piece) Vokes rotor, the vane ring can be adjusted
down as explained in the Installation section. When a solid (l piece) Vokes rotor
is used the clearance can be adjusted by shimming under the extraction plates.

PAGE 6.1
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MAINTENANCE HYORAPULPER
DRIVE REMlVAL

GEAR BOX DRIVES

Gear box drives are provided with a sub-base or rails to facilitate drive removal.
A procedure for removing the drive follows:

l - Remove the rotor from the drive shaft.

2 - Disconnect the coupling and remove the motor and rails.

3 - Remove the split packing gland, packing and lantern ring.

4- Disconnect oil piping (if required).

5 - Remove the fasteners ;;hich hold the drive to the sub-base and the sub-base
to the base or sole plate.

6 - Insert a lifting eyebolt in the vertical drive shaft.


7 - Using a lifting device, raise the drive slightly to allow removal of the
sub-base.

8 - Place pipe rollers on the base or sole plate and lower the drive onto the
rollers.

9 - Construct a platform of suitable timber at a height level with the drive


base or sole plate to allow the drive to be moved out from under the Hydra-
pulper.

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PAGE 6.3
HYORAPULPER
VII DRIVE

I .

MODEL 300
HYDRAPULPER
DRIVE

IDDEL 300 PAGE 7,0


DRIVE HYDRAPULPER

MODEL 300 HYDRAPULPER DRIVE

CONE HM926740
CUP HM9267100

W/CONE SPACER
CONE 565- CUP 5630

PAGE 7.1 t.PDEL 300


HYDRAPULPER DRIVE
GENERAL SPECIFICATIONS

GEl~L DESCRIPTION

The 1'-bdel Series (150, 300, 500, 700) Hydrapulper drive is a vertical, single
reduction, spiral bevel gear speed reducer. The spiral bevel gearing is designed
and rated in accordance with the American Gear Manufacturers' Association
Standards for Rating spiral bevel gear speed reducers.

Alloy steel material is used for both pinion and gear and is carburized. The
pinion shaft and pinion are integral and are of the same material and heat treat-
ment. Alloy steel is also used for the vertical shaft.

GENERAL DE3IGN FEATURES

HJUSING - The rotating parts of the drive are contained in a split, oil tight
combination cast iron and welded steel housing. The s.u rface of the h<?using split
is machined to a high finish and coat.e d with a fluid sealing compound. The housing
is fastened at the split by cap screws locked by split type lock washers.

BEARING ARRANGEMENT - The vertical shaft is supported by two single row, tapered
roller bearings positioned in an opposed mounting. The. bearings are held in place
by t'WO end caps, each having a shim set between the cap flange 'and the housing
boss. The bearings are adjusted by altering the shim thickness.

The pi;nion shaft bearings are straddle mounted. Both bearings are double tapered
roller bearings with fixed internal clearance.

OIL SEALS - The oil seals used on the shaft extensions are a lip type and are
spring loaded with sealing elements of leather or synthetic rubber.

GE.ARJllG - The pinion and pinion shaft are integral. The gear is manufactured as a
separate ring gear and hub. The alloy steel ring is bolted to ~ steel or semi-steel
center. Bolting is carefully torqued and loclced 1-1ith tab washers or equivalent.
The two piece construction facilitates manufacture, assembly, and field replacement
of gearing members.

CAtJriON

ROTATION OF OUTPUT S.HAFr IS COUNTERCIDCKWISE WHEN VIEWED FROM THE 'IDP.

ro NOT RUN DRIVE BACKWARJl3


DRIVE HYDRAPULPER
INSTAU.ATION INSTRUCTIOf.'S (continued)

I.l'ISTALLTNG THE DRIVE (continued)

5. Install a lifting eyebolt into the vertical shaft. Lower a hoist or chain
hook through the packing box opening in the center of the extraction
chamber and place the hook through the eyebolt.

6. Raise the drive carefully. Remove the pipe rollers and install the s'lb-
l:Jase under the drive.

NOTE: The sub-base is equipped with tvo 10" dil3llleter holes to allm< access
to the bottom of the drive. Assenible the sub-base to the so.le plate so
that these holes are at a 90°angle to the motor.

7. Lower the drive onto the sub-base and bolt securely. Remo"le the hoist or
chain hook.

8. The Hydrapulper drive is installed independent of the HydrapuJ,per its eli'.


Therefore the following condition.<> must be considered C<hen Ell.igning the
d:"ive.

a) Radial Alignment - The vertical shaft must b·e centered in the


packing box bore.
b) Elevation -The dimension from the top of the vertical shaft to
the top of the cxtractio:> chamber, as sho.m on the certified
print of the cross section of the rotor assembly, must be held in
order to get the proper rotor clearance.
c) Perpendicularity - The vertical shaft must be perpendicular to the
top of the extraction chamber. This can be checked with a ciial
indicator hy attaching a bar to the vertical sha.."'t and turning the
pinion shaft by hand.

9. Install the rotor on the drive and check the clearances as shown on the
certified installation prints,

10. After a final check of the Hydra;pulpe1· and the drive, grout the drive sole
plate into place.
CAtlriON: Solid shims should be placed under the sole plate near the
anchor bolts before grouting,

ll, Recheck aligrllllP.nt and clearances; then dovel the drive and drive sub-base
in place,

12. Install the motor hali' t)Ou;pling on the motor shru."t and align with the
pinion shaft using a dial i..ndicator. Both angular and parallel alienmcnt
must be within .002" total indicator reading.
13. Dowel the motor, motor ralls, dirve and dri.ve sub-base in place.
14. Install the drain cock in the bottom of the drive •.
15. Fill the unit with the proper amount and tY',>e of oil (see Lubrication
Section).
HYDRAPULPER
LUBRICATION
LUBRICATION SYSTEM

Hydrapulper. drives are lubricated by a sel:f'-contained circulating oil system •. The


lover gear housing forms the reservoir and the. oil is fed to the bearings and gears
by a positive displacement pump. A filter and cooler are incorporated in the line.

The drive is protected from damage due to lack of oil by a pressure switch and an
electrical interlock of the main drive motor and the oi~ pump motor. The e~ctrical
interlock ensures that the oil pump motor must be operating before the main drive
motor can be started. Further, the pressure switch (set to cut in at 18 psi and
cut ou·t at 15 psi) will not permit the main drive motor to be started until the
required oil pressure has been reached. Should oil pressure fail during operation
the main drive motor will be shut down.

Normal oil pressure is 20-30 psi at operating temperature.

The temperature control which governs the water flow thru the oil cooler sho~ be '
set at llOOF.

TYPE OF LUBRICANT - The. oil used should be an extreme pressure oil equal to AGMA #5EP
specification. In general, it should be a well refined petro~um oil within the
recommended viscosity range. It must be neutral in reaction and must not be cor-
rosive to gears and ball or roller bearings. It should have good defoaming prop-
erties and good resistance to oxidation for high operating temperatures.

TRADE NAMES OF TYPICAL OIIS

MANUFACTURER NAME OF OIL

American Oil Co. Stanogear Compound No. 3


Cities Service Oil Co. Trojan Compound L-2
Gul.f Oil Corp. E. P. Lubricant 95
llbbil llbbilube EP-90
Shell Oil Co, Omala Oil 72
Sinclair Refining co. Opaline Gear Lubricant BX
Standard Oil Division of
American Oil Co. Stanogear Compound No. 3
Standard Oil Co. (Ohio) Sohiolube 90
Sun Oil Co. Sunep 70
Texaco, Inc. Meropa Lubricant 3
Tidewater Oil Co. Veedol Apreslube 86

MOUNT OF OIL
DRIVE CAPACITY
llbdel 150 7.5 Gal.
Model 300 15 Gal.
Model 500 45 Gal.
M:ldel 700 85 Gal.

MODEL 150, 300, 500, 700 P.AG~ '7.6


DRIVE HYORAPULPER
LUBRICATION (continued)
OIL CHANGES
After the initial two weeks of operation, the first oil should be changed. If
desired, this oil rtJE.Y be strained and reused. Do not use a strainer finer than
25 micro inches to avoid filtering out the additives. Very often, due to the
wearing~ in process, srtJE.ll metal particles will show up in the oil. This is not
abnormal.
It is recommended that the gear case be thoroughly flushed out after the original
oil has been drained. Fill the case to the indicated level with SAE 10 straight
mineral flushing oil 1<hich should not contain additives. Unit should be started,
brought up to operating speed (Preferably without load) and immediately shut down.
Drain off the flushing oil and refill with the recommended operating oil to the
proper level. After the break~in procedure outlined above, it is recommended that
oil be changed after each subsequent 2500 hours of operation or 6 months of normal
operation, whichever occurs first.

Unusual environmental or load conditions sometimes necessitate replacement of oil


as frequently as one or two month intervals ~ as determined by inspection of the
oil. Special attention must be givwn when the following conditions exist:

l. High operating temperatures resulting from heavy intermittent loads,


causing the temperature of the gear case to rise rapidly and then cool.
2. Ambient temperature conditions which might tend to cause sweating on the
inside walls of the unit, thus contaminating oil and formin§ sludge.
3. Operating oil temperatures that remain constantly above 160 F.
4. When the unit is exposed to unusually moist atmosphere or vapors.

Precautions should be taken to prevent any foreign matter from entering


the gear case. Dust, dirt, moisture and chamical fumes form sludge which
is the biggest·enemy of proper and adequate lubrication.

CAUTION:
The drive contains two oil drains. One is located in the bottom of the gear case;
the other is in the bottom bearing cap. When changing oil be sure to drain and
flush the drive completely.

OIL SEAIS

Oil seals require a small amount of lubricant to prevent frictional heat and sub~
sequent destruction when the shaft is rotating. The pinion shaft seal is lubri~
cated by the oil splash which lubricates the bearing. Double seals are used on the
vertical shaft and provisions have been made for pumping grease between the seals.
Seals should be greased at least once a month.

Grease should be N.L.G.I. Number 2 consistency and meet the following conditions:

a) Non-corrosive to ball or roller bearings.


b) Neutral in reaction.
c) Contain no grit, abrasive or fillers.
d) Should not precipitate sediment.
e) Should not separate at temperatures up to 300°F.
f) Should have moisture resistant characteristic.
g) Good resistance to oxide:tion.

PAGE 7•7 MODEL 150, 300, 500, 700


~YDRAPULPER DRIVE
START-UP INSTRUCTIONS

When starting up any new piece of equipment, it is wise to proceed cautiously.


Even though the best installation practices are followed, the possibilities of
errors or omissions always exist. Therefore, we recommend that before initial
start-up the following procedures be followed:
1. Have all gauges, breather, etc., been mounted? Often it is necessary to
box these items separately to prevent damage or loss in shipment.

2. J!J:e mounting bolts tight? Check all external bolts 1 screws, accessorj.es,
etc., to make sure they have not loosened in shipping or handling.

3. Is the coupling mounted on shaft extensions correctly with keys and


fasteners in place?

4. Have coupling and seals been greased?

5· Have necessary guards and safety devices been installed at hazardous


locations?

6. Fill with oil to the indicated level. See Lubrication section.


1· Have all inspection covers on the unit been closed and properly fastened?
8. Have required electrical connections been made?
9· Jog the motor to check the rotation. A tag on the bearing block indicates
the direction of rotation. If necessary, reverse electrical leads on the
motor to make shaft rotation conform to what is shown.

START-UP PROCEDURE

1. Make sure clean cooling water is flowing to the heat exchanger. Cooling
water should not exceed 8o°F on entry into 'the cooler unless the cooler
was selected by the manufacturer to permit higher water temperature.

2. Start the oil PU111P motor.

3· Start the unit under as light a load as possible.


4. With the unit operating, it should be checked constantly for un~sual
sounds, excessive vibration, excessive heat or oil leakage. If any of
these develop, it should be shut down innnediately and the cause determined
and corrected. The operating temperature of the unit at ·bhe hottest point
should normally not exceed 160°F.
5· If possible, the drive should be operated under a light load for one or
two days to a.llow final break-in of gears. After this period, the tmit
can be operated under normal load.
DRIVE HYDRAPULPER
PREVENTIVE . MAINTENANCE

After the first 50 hours of operation all external housing and hold-down bolts
should be checkeO. to make sure they have not loosened.

DAILY

The unit should be given a routine visual inspection for oil leaks or unusual
sounds. If either occurs, unit should be shut down and the cause determined.

HEEKLY

Check oil level. Add oi.l if necessary.

l>DNTBLY

Add grease at coupling and seals.

THO },PNTH INTERVAL

Check oil for contamination. Check operation of all gauges, controls, etc.

SIX M:lNTlf OR 2500 HOUR L'fr.ERVAL

Change oil as outlined in the Lubrication section. Change grease at coupling and
seals. Check condition of cooler tubes for build-up of sediment or other deposits
from coolant water. Clean these members if necessary.

EXTENDED SHUT-OOWN PERIOIE

If it becomes necessary to shut down for a period longer than one week, the unit
must be run for at least ten minutes during each 1feek that it is idle. This
periodic operation will keep the gears and bearings coated with oil and will pre-
vent rusting due to condensation of moisture resulting from tel!lPerature changes.
HYDRAPULPER DRIVE
TROUBLE-SHOOTING TIPS

Your Hydrapulper drive will perform satisfactor"ly if the suggestions described


in this booklet are carefully followed. It is estimated that approximatel~, 98
percent of gear reduction failures can be attributed to improper lubrication,
misapplication, and misalignment.

Improper lubrication causes a high precentage of gear reduction unit failures.


Too frequently speed reducers are started up without any lubricant at all. Con-
versely, units are sometimes filled to a higher oil level than specified in the
mistaken belief that better lubrication is obtained. This higher oil level
usually results in more of the input power going into churning of the oil, creat-
ing excessive temperatures with detrimental results to the bearings and gearing.
Insufficient lubrication causes the same results.

Gear failure due to overload is a broad and varied area of misapplication. The
nature of load (input torque, output torque, duration of operating cycle, shocks,
speed, acceleration, etc.) determines the gear unit sizing and other design cri-
teria. Frequently, a gear drive must be larger than the torque output capability
of the prime mover would indicate. An AGMA service factor compensates for varying
severity of application conditions by providing a higher nominal horsep01<er which
in effect increases the size of the gear u_~it. If there is any question in the
user's mind that the actual service conditions may be more severe tha~ originally
anticipated it is recommended that this information be communicated to The Black
Clawson Company before start-up. Often there are remedies that can be suggested
before a gear unit is damaged by overload, but none are effective &"'ter severe
damage.

!.Ptors and other prime movers should be analyzed while driving the gear unit under
fully loaded conditions to determine that the prime mover is not overloaded and
thus putting out more than rated torque. If it is determined that overload does
exist, the unit should be stopped'and steps taken to either remove the overload or
contact The Black Clawsoi! Company to determine suitability of the gear drive under
observed conditions.
JlRJVE HYDRAPULPER
TROUBLE WHAT TO INSPECT ACTION

1. Unit overloaded. Reduce the loading or replace with drive of sufficient capacity.
2. Oil cooler operation. Check coolant and oil flow. Vent system of air. Oil temperatures into unit
should be approximately 110 degrees F. Check cooler internally for build up
of deposits from coolant water.

3. Has recommended oil level Ct1eck oil level indicator to see that housing is accurately filled with lubri·
been exceeded or is level cant to the specified leveL
too low?
4. Are bearings properly ad· Bearings must not be pinched. Adjustable tapered bearings must be set at
jus ted? proper bearing lateral clearance. All shafts should spin freely when dis·
Overheating connected from load.

5. Oil seals or stuffing box. Oil seals should be greased on those units havinc- r:rease fitting for this
purpose. Otherwise, apply small quantity of oil externally at the lip until
the seal is run in. Stuffing box should be gradually tightened to avoid over·
heating. Packing should be a self-lubricating, braided asbestos type.

6. Breather. Breather should be open and clean. Clean breather regularly in a solvent.

7. Grade of Oil. Oil must be of grade specified in lubrication instructions. If it is not, clean
unit and refill with correct grade.

8. Condition of Oil. Check to see if oil is oxidized, dirty, or of high sludge content, change oil
and clean filter.

9. forced feed lubrication Make sure oil pump is functioning. Check that oil passages are clear and
system. permit free flow of lubricant. Inspect oil line pressure regulators, nozzles
and filters to be sure they are free of obstructions. Make sure pump sue·
tion is not sucking air.

10. Coupling Alignment. Disconnect couplings and check alignment Realign as required.
11. Coupling lateral float. Adjust spacing between drive motor, etc., to eliminate end pressure on
shafts. Replace flexible coupling with type allowing required lateral float.

12. Speed of unit excessive? Reduce speed or replace with drive suitable for speed.

1. Type of Coupling used. Rieid couplines can cause shaft failure. Repl.1cc with coupling to providr~
required flexibility and lateral flo..1t.
2. Coupling Alignment Realign equipment as required.
3. Is overhung load excess· Reduce overhung load. Use outboard bearing or replace with unit having
ive? sufficient capacity.
4. Is unit overloaded? Reduce the loading or replace with drive of sufficient capacity.

Shaft Failure 5. Is unit subjected to high Apply couplings capable of absorbing shocks and if necessary, replace with
energy loads or extreme re· drive of sufficient capacity to withstand shock loads.
petitive shocks?
6. Is outboard bearing prop· Realign bearing as required.
erly aligned?

1. Is unit overloaded? See-Overheating (Item 1). Abnormal loading results in flaking, cracks
and fractures of the bearing.
2. Is overhung load excess· See-Shaft Failures {Item 3).
ive?
3. Speed of bearing excess· See--Overheating (Item 12).
ive?
4. Coupling alignment. See-Overheating (!tern 10).
Bearing Failure 5. Coupling lateral float. See-Overheating (Item 11).
6. Are bearings properly ad· See-Overheating (Item 4). If bearing is too free or not SQlJare with axis-
justed? erratic wear pattern will appear in bearing races.

7. Are bearings properly tub· See-Overheating (Items 2, 3, 7, 8, 9). Improper Jubric.3tion causes excess·
ricated? ive wear and discoloration of bearing.

8. Rust formation due to Make necessary provisions to prevent entrance of water. Use lubricant
entrance of water or humi· w"ith good rust inhibit.1ng properties. Make sure bearings are covered with
dity. sufficient lubricant.' Turn over gear unit more frequently during prolonged
shut·dow n periods.
1
'
HYDRAPULPER DRIVE
TROUBlE WHAT TO INSPECT ACTION
·.
9. rs bearing exposed to an Abrasive substance will cause excessive wear, evidenced by dulled balls,
abrasive substance? rollers. and raceways. Make necessary provision to prevent entrance of
Bearing Failure abrasive substance. Clean and flush drive thoroughly and add new oil.
(continued)
10. Has unit been stored im- Prolonged periods of storage in moist. ambient temperatures will cause
properly or damaged by destructive rusting of bearings and gears. When these conditions are found
prolonged shut-down? to llcwe exi'i.ted, the unit must be disassembled, inspected, and damaged
parts either thoroughly cleaned of rust, or replaced.

1. Has recommended oil level Check through level indicator that oil level is accurately at level indicated
been exceeded? on housing.
2. Is breather open? Breather should be open and clean.
3. Are all oil drains open? Check that all oil drain locations are clean and permit free flow. Drains are
normally drilled in the housing between bearings and bearing cap where
shafts extend through caps.
4. Oil Seals Check oil seals and replace if worn. Check condition of shaft under seal and
polish if necessary. Slight leakage normal-required to minimize friction
and heat.
5. Stuffing boxes. AdjuSt Or replace packing. Tighten packing gradually to "break-in".- Check
.condition, of shaft and polish if necessary.
Oil leakage 6. Force feed lubrication to Reduce flaw of lubricant to bearing by adjusting orifices. Refer to factory.
bearing excessive?
7. Plugs at drains, levels, Apply Marseal pipe joint sealant, or equal, and tighten fittings.
etc., and standard pipe fit·
tings.
8. Compression type pipe Tighten fitting or disassemble .and check that collar is properly gripping
fittings. tube. '
9. Housing and caps. Tighten cap screws or bolts. If not entirely effective, remove housing cover
and caps. Clean mating surfaces and apply new sealing compound
(Permatex #2 or equal). Reassemble. Check compression joints by tight·
ening fasteners firmly.

I. Bocklash. Gear set must be adjusted to give proper backlash. Refer to factory.

2. Misalignment of Gears. Check contact pattern to be over approximately 75% of face, preferably
in center area. Check condition of bearings.
3. Housing twisted or dis· Check shimming and stiffness of foundation.
torted?
4. Is unit overloaded? See-Overheating (Item 1).
5. Has recommended oil level See-Overheating (Item 3).
been maintained?
6. Are bearings properly ad· See--Overheating (Item 4).
justed?
7. Grade of Oil. See-Overheating (Item 7).
Gear Wear
8. Condition of Oil. See-Overheating (Item 8).
9. Forced Feed Lubrication. See-Overheating (Item 9).

I tO. Coupling Alignment. See-Overheating (Item 10).


II. Coupling lateral float. Se~~·Overlwating (Item 11).
12. Ex~essive speeds. See-Overheating (Item 12).

13. Rust formation due to Sec-Bearing Failure (Item 8).


entrance of water or humi-
dity,
14. Gears exposed to an a bra· See-Bearing Failure (Item 9).
sive substance.

Noise 1. Unusual or increasing See-Gear Wear (Items 1 to 14) and Bearing Failure (Items 1 to 8).
noise.

MODRT. 1 'i(L :0:00. 'iOO. 700 PAGE 7.12


DRIVE HYDRAPULPER
RECOMMENDED SPARE PARTS

HA.lCIMlm RECOMMENDATION: 1 Assembled Drive

MiiUMUl·i RECO~ll,IEND.A:riON AS !'OUDJ.'S:

QU.AHTITY DESCRIP'riON

1 set Matched gear and pinio:> -:--- to 1 ratio


1 Pinion bearing - outboard
1 Pinion bearing - inboard
1 Lower gear shaft bearing
1 Upper gear shaft bearing
1 Lip seal - for pinion shaft
2 Lip seals - for gear shaft
1 "0" ring - flinger seal
1 Shaft sleeve

IMPORT.AliT

When ordering spare parts, refer to the certified prints and give the item number
and part description along \i'ith the SERIAL NUMBERS OF T"!lE HYDRAPULPER AND DRIVE.

P.AGE 7.13 I•ODEL 150, 300, 500, 700


HYOAAPULPER DRIVE
REBUILDING THE DRIVE

INTRODUCTION

The P'xq>ose of this section is to explain a method of setting the gear and pinion
in proper relation to each other lfhen rebuilding a drive. Correct assembly is
necessary to insure smoothness of operation,. resistance to wear and the maximum of
strength and efficiency. M:mnting distance, backlash and tooth pattern are the
criterion lfhich determine this setting.

i'DUNTING DISTANCE

The axial position of a spiral bevel o~ hypoid gear and pinion in assembly is given
by a dimension called the ~~unting Distance (M.D.). This is the linear dimension
from the axial locating surface of a given member to a crossing point of its axis
with that of its mate. The locating surface is usually the back of the pinion or
gear. Occasionally the pinion mounting distance is measured from the front of the
pinion. In such cases, a flat reference surface is groun:i parallel to the mounting
surface. The mou..'lting distances as determined by the manufacturer are etched on
each member.

MOUNTING DISTANCE OF GEAR

GEAR AXIS

MOUNTING DISTANCE
OF PINION TO FRONT
FLAT

MOUNTING DISTANCE OF PINION


TO BACK SHOULDER

MODEL 150, 300, 500, 700


DRIVE HYDRAPULPER
REBUILDING THE DRIVE (continued)

BACKLASH

Spiral bevel gears are cut to have a definite amount of backlash in assembly. It
is necessary for the safe and proper run."ling of the gears. Excessive or insufficient
backlash may cause the gears to be noisy, wear excessively and possibly score on
the tooth surfaces or even bre~t. The amount of backlash required ls etched on
one or both members of each gear set.

This value is for normal backlash at the tightest point of tooth engagement. ·Nor-
mal backlash is measured at the heel in a direction perpendicular to the tooth sur-
face.

To check the amount of backlash in a set of gears at assembly, rigidly mount a dial
indicator with ohe stem perpendicular to the tooth surface at the extreme heel.
Iock the pinion shaft solidly against rotation and measure the backlash by moving
the gear shaft back and forth. ·

Method of Measuring Backlash

MODEL 1'>0. iOO. SOO. 700


HYDRAPULPER DRIVE
REBUILDING THE DRIVE (continued)

TOOTH PATTERN

Spiral beve·l and hypoid gears are produced to run


with a localized tooth bearing. Since the area
of contact does not cover the whole tooth, a
slight tolerance in positioning the gears in as-
sembly and some displacement under operating (a) Pinion (some on both sides).
loads is possible, without concentration of the
load on the ends of the teeth.

The ideal tooth bearing is slightly high on the


pinion and low on the gear. Its length under
t )L
(b) Gear (same on both sides).

light load is usually about one-half of the tooth Ideal Tooth Patterns
length. M:lreover, since the tooth bearing under
heavy load will generally shift toward the heel
(outer end of the tooth), the gears are cut so as
to place the bearing, with the gears mounted in
correct position, slightly nearer the toe (inner
end of the tooth). The resulting bearing is
called a central toe bearing.

The tooth bearing chart below indicates the corrections to be made, if the proper
bearing (or wear pattern) is not obtained the first time.

The following sketches represent dia,grammatically the possible tooth bearings on


the gear member of a pair of correctly made spiral bevel gears. The sketches in
one column show the opposite side of the tooth sho;;n in the corresponding sketch
in the other column.

Concave Side TOOTH BEARINGS ON DRIVEN GEAR


i
Correct tooth bearing position with accurate
and rigid mounting.

Out of Position Bearing


Cause: Pinion too close to cone center.
Remedy: Move pinion away from cone cen~
ter.

Out of Position Bearing


Couse: Pinion too far from cone center~
Remedy: Move pinion toward cone center.

MODEL 150, 300, 500, 700 PAGE 7.16


DRIVE HYDRAPULPER
REBUILDING THE DRIVE (continued)

DISMAN'l.'LING

Before dismantling the drive, match mark all flanges so no errors will be made when
reassembling.

If convenient, disassemble the drive beneath a hoist or chain fall. As parts are
removed, wash thoroughly, dry and inspect for damage or excessive wear.

1 - Remove and Disassemble the Drive Shaft

A - Remove the umbrella, seals and thru cap.

B - Remove the cap screvs which fasten the housing cover to the gear housing.

C - Using a lift:ng device, remove the housing cover.

D - Insert an eyebolt in the top of the drive shaft and lift the shaft
assembly from the gear housing.

E - Dismantle the bear l ngs 1 gear, etc. 1'rom the shaft as required.

2 - Remove and Disassemble the Pinion Shaft

A - Remove the set screw which holds the inboard pinion bearing.

B - Remove the cap screws which fasten· the bearing cartridge and cap to the
gear housing.

C - Remove the pinion shaft assembly from the gear housing.


NOTE: Retain the spacer shims.

D - Dismantle the bearings as required.

REASSEMBLING THE DRIVE

1 - Reassemble the Drive Shaft

A - Before rebuilding a drive using an existing shaft, it should be thor-


oughly checked, The shaft, with the gear center mounted on it, should
be placed in a lathe between live centers. Runout should be exceed
.002" T.I.R. The face of the gear center must be straight and perpen-
dicular to the shaft axis. If runout exceeds .002" T.I.R. a skim cut
should be taken to true up.

B - Bolt the new gear on the gear center and lock each screw head to prevent
backout.

C - Install the spacer sleeve firmly against the hub of the gear center.
(Not used on all sizes).

PAGE 7.17 MDDEL 150 1 300 1 500, 700


HYDRAPULPER DRIVE
REBUILDiiiG THE DRIVE (continued)

REASSEHBLING THE DRIVE (continued)

D - Heat the upper and lower gear shafc; bearings in oil. ( 2&P - 300°;F),

E - Assemble the lower gear shaft bearing so that it shoulders on the spacer
sleeve.

F - Assemble the upper gear shaft ·aearing.

2 - Reassemble the Pinion Shaft

A - The pinion and pinion shaft are integral.

B - 'rhe pinion shaft is supported by two cwo-row bearing arrangements with


fixed internal clearances. Care should De taken no·t; to omit the sp.s.cerE
when installing ·che bearings.

C - Heat the bearings in oil. (28o0 - 3000).

D - Assemble the inboard bearing on the shil.:ft. Install the retainer plate
to prevent the bearing from backir~ off as it cools.

E - Assemble the outboard bearing on the shaft. Slip on the lockwasher and
tighten the locknut. Keep tight.ening the locknut as the bearing cools
so that it does not back off. Do not bend the tab on the lockwasher to
hold the locknut in place lUltil "the bearing has cooled and the locknut
is pulled tight.

3 - Install the Pinion Shaft

A - When rebuilding a drive in the field ic; is recommended that the pinion
adjusting shims be varied according to the difference in mounting dis-
tance (M.D,) etched on the old and new pinion.

Ex8ll1Ple: If the M.D. on the new pinion is • 003" larger than the M.D. on
the pinion which was reooved, increase the shim thicri:ness by .003"

:a - Install the pinion shaft assembly in the gear housing. Line up ti1e hole
in the cup of the inboard bearing with the tapped hole in the bearing
seat and insert the set screw. This prevents the cup from curning when
the drive is in use.

C - Install the thru CBJ:l and the cap screws which i'asten the cap and bearing
cartridge to the gear housing.

I>:ODEL 150, 300, 500, 700 PAGE 7.18


DRIVE HYDRAPULPER
REBUILDING THE DRIVE (continued)

REASSEl>!BLING TnE DRIVE (continued)

4 - Install the Drive Shaft


A - If the blind cap vas rem::>ved from tile bottom of the gear housing it
shoulcl. be reassembled using the same shims as originally used.

B - Slide the cup and rollers of the lover gear shaft bearing into the
bearing seat.

C - Lover the drive shaft assembly into the housing. Match the marked
teeth on the gear and pinion.

D - Reassemble the housing cover.

E - Place the thru cap over the shaft and allow it to rest on the upper
gear shaft bearing. Tighten the cap screws finger tight.

F - Check the mounting distance, backlash and tooth pattern. (Review


descriptions on pages 7.14, 7.15 and 7.16).
G - After the gear and pinion setting have been finalized, check the gap
between the housing cover and the flange of the thru cap. To this
dimension add • 002" to • 004". This is the shim thickness required to
give proper bearing clearance.

H - Install the oil seals, retainer and umbrella,


I - Refer to the lubrication instructions for oil requirements.

PAGE 7.19 I•DDEL 150, 300, 500, 700