Milnor 42044SR2 Quick start guide

PELLERIN MILNOR CORPORATION Post Office Box 400, Kenner, Louisiana 70063–0400, U.S.A.
Mechanical Parts and
Service
42044SR2, SR3
Manual Number: MCWG4M01
Edition (ECN): 2021066

Pellerin Milnor Corporation i
Contents
1 General Service Information .........................................................................................................7
Limited Standard Warranty .....................................................................................................8
How to Get the Necessary Repair Components ......................................................................9
Trademarks ..............................................................................................................................9
Safety — Divided Cylinder and Staph Guard®Washer-Extractors ......................................10
Safety Alert Messages—Internal Electrical and Mechanical Hazards...........................10
Safety Alert Messages—External Mechanical Hazards.................................................10
Safety Alert Messages—Cylinder and Processing Hazards...........................................10
Safety Alert Messages—Unsafe Conditions ..................................................................11
Damage and Malfunction Hazards .........................................................................11
Hazards Resulting from Inoperative Safety Devices......................................11
Hazards Resulting from Damaged Mechanical Devices ................................12
Careless Use Hazards .............................................................................................13
Careless Operation Hazards—Vital Information for Operator Personnel
(see also operator hazards throughout manual) ..............................13
Careless Servicing Hazards—Vital Information for Service Personnel
(see also service hazards throughout manuals) ..............................13
Torque Requirements for Fasteners .......................................................................................14
Torque Values .................................................................................................................14
Fasteners Made of Carbon Steel ............................................................................14
Without a Threadlocker ..................................................................................14
With a Threadlocker .......................................................................................16
Stainless Steel Fasteners ........................................................................................18
Preparation......................................................................................................................19
How to Apply a Threadlocker ........................................................................................19
Blind Holes.............................................................................................................20
Through Holes ........................................................................................................20
General Assembly 4244SP2 SM................................................................................................22
Disk Brake Maintenance .......................................................................................................28
The Inspection of the Brake ...........................................................................................30
How to Do a Friction Pad Replacement .........................................................................31
How to Do a Caliper Overhaul.......................................................................................32
How to Change Hydraulic Fluid and Remove (Bleed) Air from the Brake
Circuit ............................................................................................................33
How to Adjust the Connection between the Brake Cylinder and the Air
Cylinder ..........................................................................................................36
Operation of Brake Systems...........................................................................................38
How to Apply the Brake for Machines with a "Break Release" Output ................38
How to Release the Brake for Machines with a "Brake Release" Output..............39
How to Apply and then Release the Brake Quickly...............................................39
How the Brake Operates on Divided Cylinder Machines ......................................39
The Second Brake...................................................................................................40
2 Safety-Related Components & Assemblies.................................................................................41
Safety Placard Use and Placement 42031, 42044 SP2/SR2 & SP3/SR3 SINGLE MOTOR
DRIVE ......................................................................................................................42

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Safety Placard Use and Placement ISO 42031, 42044SP2/SR2 & SP3/SR3 SINGLE MOTOR
DRIVE ......................................................................................................................44
Vibration Safety Switch Adjustments ...................................................................................46
What the Vibration Safety Switch Does.........................................................................46
Adjustments....................................................................................................................46
Vibration Safety Switch .........................................................................................................48
3 Drive Assemblies.........................................................................................................................49
Drive Chart 4244SP2 SM (Single Motor)......................................................................................50
Drive Base 4244SP2 SM (Single Motor).......................................................................................55
Jackshaft 4244SP2 SM (Single Motor)..........................................................................................60
Brake Assembly 4244WP2/WR2, 4244SP2/SR2 ...........................................................................62
Drive Pulley and Belt Maintenance .......................................................................................65
Pulley Requirements.......................................................................................................65
Condition of Grooves on Pulleys ...........................................................................65
Pulley and Shaft Position........................................................................................66
Keep Run-Out in Tolerance....................................................................................67
Belt Requirements ..........................................................................................................68
Condition of Belts...................................................................................................68
Tension of Belts......................................................................................................69
The pulleys must stay aligned when you adjust the belt tension....................................70
How to Do Maintenance on Pulleys and Belts...............................................................70
Typical Steps to Replace Pulleys and Belts............................................................71
Examples of Procedures Used at the Milnor®Factory to Align Pulleys................72
4 Bearing Assemblies .....................................................................................................................74
Main Bearing and Seal Replacement for Divided Cylinder Machines .................................74
Removing the Bearing (Front or Rear)...........................................................................76
Removing the Bearing Housing (Bearing and Seal Carrier), Seal Sleeve, and Seals
(Front or Rear)................................................................................................77
Precautions for Bearing Replacement ............................................................................78
Replacing the Bearing Housing, Seal Sleeve, and Seals (Front or Rear).......................78
Measuring Unmounted Clearance and Setting Bearing (Front or Rear) ........................81
Tightening Bearing(s) (Front and/or Rear).....................................................................83
Main Bearing Assembly 42031, 42044 CP2/CP3, NP2/NP3, WP2/WP3, SP2/SP3, DA2/DA3, DP2/
DP3 .........................................................................................................................86
Autospot 4244SP2 SM...............................................................................................................90
Idler Shaft Bearing 42031, 42044SP2/SP3 & 4244SP2 SM ............................................................92
Idler Shaft Bearing Replacement ...........................................................................................94
How to Remove the Bearings ................................................................................................94
How To Install New Bearings ...............................................................................................95
5 Frame, Pivots and Suspension.....................................................................................................96
Suspension Adjustments for Divided Cylinder Machines .....................................................96
How Shell Adjustments are Made..................................................................................96
Shell Hanging Dimensions and Adjustment Procedures................................................97
Push-Down Travel Dimensions and Adjustment Procedures.........................................99
42" Divided Cylinder Machines .............................................................................99
60" Divided Cylinder Machines ...........................................................................100
Hold Down Adjustment 6044SR2/SR3, 6044WR2/WR3, 72044SR2/SR3, 72044WR2/WR3 ............102
Pushdown 4244SP2 SM...........................................................................................................104
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Suspension Cylinder Assemblies 42031,42044,52038,60044,72044 ...........................................106
Suspension Cylinder Locations ...........................................................................................110
6 Shell and Door Assemblies .......................................................................................................112
Shell Doors 42031/42044CP2,NP2,WP2,WP3,SP2,SP3, 4244SP2 SM .............................................113
Door Latch ...........................................................................................................................116
Installation Door Switches 4244SP2, 4244SP2 SM ...................................................................117
Cylinder Assembly 42044WP2, NP2, CP2, SP2 .........................................................................118
Cylinder Doors 42031/42044 CP2,CP3,NP2,NP3,WP2,WP3,SP2,SP3,DA3; 4244WP2 SM,WP3 SM,
SP2 SM ...................................................................................................................120
7 Control and Sensing Assbmlies.................................................................................................122
Excursion Switch 4244SP2 SM ...............................................................................................123
Air Chamber Level Switch 42044WR2,WR3,SR2,SR3; 6044WR2,WR3,SR2, SR3; 72044WR2,
WR3, SR2, SR3 ........................................................................................................124
Temperature Probe 42044SR2, 42044WR2 ...............................................................................125
8 Chemical Supply Devices..........................................................................................................126
Peristaltic Connection 4244SP2, SP3, 4244SP2 SM ...................................................................128
Soap Chute 4244SP2/SP3, 4244SP2 SM.....................................................................................130
Supply Injector Assembly 4244WP2/WP3, 4244WP2 SM, 4244SP2/SP3, 4244SP2 SM ..................132
9 Water and Steam Piping and Assemblies ..................................................................................134
Water and Steam Schematics 4244SP2/SP3, 4244SP2 SM .........................................................136
Water Inlets 42044SR2 ...........................................................................................................138
Flushing Water Supply 4244WP2/WP3, 4244WP2 SM, 4244SP2/SP3, 4244SP2 SM .......................140
Servicing Air Cylinders .......................................................................................................142
Cooldown 4244SP2, 4244SP2 SM .............................................................................................144
Steam Inlet & Sparger 4244SP2, 4244SP2 SM, 6044SP2/SP3, 6044SP2 SM ..................................146
8”X10” Stainless Dump Valve 42044WR2/WR3/SR2/SR3; 60044WR2/WR3/SR2/SR3;
72044WR2/WR3/SR2/SR3 .........................................................................................148
Burket Steam Valve .............................................................................................................151
10 Pneumatic Piping and Assemblies...........................................................................................152
Pneumatic Schematic 4244SP2 ..............................................................................................153
Brake Air Cylinder ..............................................................................................................156
Staphairtrol 4244SP2, 4244SP2 SM...........................................................................................158
Figures
Figure 1 The Bolts in Milnor®Equipment..............................................................................14
Figure 2 Apply Threadlocker in a Blind Hole.........................................................................19
Figure 3 Apply Threadlocker in a Through Hole....................................................................20
Figure 4 Use heat for disassembly of fasteners with threadlocker..........................................20
Figure 5 A typical hydraulic brake system..............................................................................29
Figure 6 The Caliper Components ..........................................................................................32
Figure 7 Pumps Used to Remove Hydraulic Fluid Quickly....................................................34
Figure 8 Typical Tools to Remove Air (Bleed) Brakes and Used Hydraulic Fluid ................35
Figure 9 The Connection between the Brake Cylinder and the Air Cylinder .........................36
Figure 10 The Adjustment between the Brake Rod and the Air Cylinder ................................37
Figure 11 A Typical First and Second Brake on a Divided Cylinder Machine.........................39
Figure 12 Vibration Switch .......................................................................................................47
Figure 13 Exploded view of the caliper and repair kit components..........................................63
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Figure 14 Examples of drives this instruction applies to: one or more V-belts, at-
tached V-belts and tooth belts ...................................................................................65
Figure 15 Pulley Groove Condition ..........................................................................................66
Figure 16 Pulley and Shaft Position..........................................................................................66
Figure 17 Run-out .....................................................................................................................67
Figure 18 Typical Pulley Assembly ..........................................................................................68
Figure 19 Types of Belt Damage...............................................................................................69
Figure 20 A Tension Mechanism that will not Change the Angle of the Pulleys .....................70
Figure 21 Some Pairs of Tension Mechanisms that Can Change the Angle of the
Pulleys.......................................................................................................................70
Figure 22 Use a straight edge, a string, or a laser to make sure that all pulleys are
in the same plane.......................................................................................................72
Figure 23 Use a level to make sure that the pulleys are at the same slope. ..............................73
Figure 24 Dial indicator used to find the axial and radial run-out of a pulley. .........................73
Figure 25 Cross Section View of Front and Rear Bearing Assemblies (Bearing
Assembly for 60" and 72" WED Shown. Others similar.)........................................75
Figure 26 Connection From Hydraulic Pump to Assist in Bearing Removal...........................76
Figure 27 Two Bearing Housing Guide Rods in Position.........................................................77
Figure 28 Bearing Housing Pulling Fixture in Position............................................................77
Figure 29 Installing Seals in Bearing Housing..........................................................................79
Figure 30 Installing Seal Sleeve in Bearing Housing ...............................................................79
Figure 31 Installing the Bearing Housing Setting Fixture onto Housing (42" ma-
chine shown) .............................................................................................................80
Figure 32 Pushing the Bearing Housing into the Shell (60" Rapid-load machine
shown).......................................................................................................................80
Figure 33 Tightening the Bearing Housing into the Shell (42" machine shown) .....................80
Figure 34 Measuring Bearing Unmounted Clearance (bridge for 42" machine
shown).......................................................................................................................82
Figure 35 Tightening the Bearing Lock nut (42" machine shown)...........................................84
Figure 36 Measuring the Mounted Internal Clearance of the Bearing (42" machine
shown).......................................................................................................................84
Figure 37 Hydro-cushion™ Upper Shaft and Adjusting Nuts ..................................................97
Figure 38 Shell Hanging for Divided Cylinder Machines (Left side view of
60044WE shown) .....................................................................................................98
Figure 39 Push-down Travel Adjustment: 42" Div-cyls (42" Staph Guard®) ..........................99
Figure 40 Ring Weldments......................................................................................................101
Figure 41 Using Threaded Rods..............................................................................................142
Figure 42 Ensuring Correct Piston Cup Shape........................................................................143
Tables
Table 1 Trademarks ................................................................................................................9
Table 2 Torque Values for Standard Fasteners with Maximum 5/16-inch Diameters and
No Lubricant ............................................................................................................14
Table 3 Torque Values for Standard Fasteners Larger Than 5/16-inch Diameters and
No Lubricant ............................................................................................................14
Table 4 Torque Values for Plated Fasteners with Maximum 5/16-inch Diameters and
No Lubricant ............................................................................................................15
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Table 5 Torque Values for Plated Fasteners Larger Than 5/16-inch Diameters and No
Lubricant ..................................................................................................................15
Table 6 Threadlocker by the Diameter of the Bolt (see below Note ) ..................................16
Table 7 Torque Values if You Apply LocTite 222 ................................................................16
Table 8 Torque Values if You Apply LocTite 242 ................................................................16
Table 9 Torque Values if You Apply LocTite 262 ................................................................17
Table 10 Torque Values if You Apply LocTite 272 (High-Temperature) ...............................17
Table 11 Torque Values if You Apply LocTite 277 ................................................................17
Table 12 Torque Values for Stainless Steel Fasteners 5/16-inch and Smaller ........................18
Table 13 Torque Values for Stainless Steel Fasteners Larger Than 5/16-inch .......................18
Table 14 Parts List—General Assembly 4244SP2 SM...............................................................27
Table 15 Parts List—Safety Placard Use and Placement 42031, 42044 SP2/SR2 & SP3/SR3
SINGLE MOTOR DRIVE...............................................................................................43
Table 16 Parts List—Safety Placard Use and Placement ISO 42031, 42044SP2/SR2 & SP3/
SR3 SINGLE MOTOR DRIVE ........................................................................................45
Table 17 Effect of Tripping Vibration Safety Switch .............................................................46
Table 18 Parts List—Vibration Safety Switch ........................................................................48
Table 19 Parts List—Drive Chart 4244SP2 SM (Single Motor).....................................................54
Table 20 Parts List—Drive Base 4244SP2 SM (Single Motor) ......................................................58
Table 21 Parts List—Jackshaft 4244SP2 SM (Single Motor) .........................................................61
Table 22 Parts List—Brake Assembly 4244WP2/WR2, 4244SP2/SR2 ..........................................63
Table 23 Typical Tools for Pulley and Belt Maintenance .......................................................70
Table 24 Table of Bearing Clearances ....................................................................................82
Table 25 Parts List—Main Bearing Assembly 42031, 42044 CP2/CP3, NP2/NP3, WP2/WP3,
SP2/SP3, DA2/DA3, DP2/DP3 ........................................................................................88
Table 26 Parts List—Autospot 4244SP2 SM..............................................................................91
Table 27 Parts List—Idler Shaft Bearing 42031, 42044SP2/SP3 & 4244SP2 SM............................93
Table 28 Hanging Dimensions ................................................................................................98
Table 29 Parts List—Hold Down Adjustment 6044SR2/SR3, 6044WR2/WR3, 72044SR2/SR3,
72044WR2/WR3 ........................................................................................................103
Table 30 Parts List—Pushdown 4244SP2 SM..........................................................................105
Table 31 Parts List—Suspension Cylinder Assemblies
42031,42044,52038,60044,72044 ...................................................................................107
Table 32 Parts List—Shell Doors 42031/42044CP2,NP2,WP2,WP3,SP2,SP3, 4244SP2 SM ............114
Table 33 Parts List—Door Latch ..........................................................................................116
Table 34 Parts List—Installation Door Switches 4244SP2, 4244SP2 SM ..................................117
Table 35 Parts List—Cylinder Assembly 42044WP2, NP2, CP2, SP2 ........................................119
Table 36 Parts List—Cylinder Doors 42031/42044 CP2,CP3,NP2,NP3,WP2,WP3,SP2,SP3,DA3;
4244WP2 SM,WP3 SM,SP2 SM ....................................................................................121
Table 37 Parts List—Excursion Switch 4244SP2 SM ..............................................................123
Table 38 Parts List—Air Chamber Level Switch 42044WR2,WR3,SR2,SR3; 6044WR2,WR3,
SR2, SR3; 72044WR2, WR3, SR2, SR3...........................................................................124
Table 39 Parts List—Temperature Probe 42044SR2, 42044WR2...............................................125
Table 40 Parts List—Peristaltic Connection 4244SP2, SP3, 4244SP2 SM ..................................129
Table 41 Parts List—Soap Chute 4244SP2/SP3, 4244SP2 SM ....................................................131
Table 42 Parts List—Supply Injector Assembly 4244WP2/WP3, 4244WP2 SM, 4244SP2/SP3,
4244SP2 SM ..............................................................................................................133
Table 43 Parts List—Water and Steam Schematics 4244SP2/SP3, 4244SP2 SM ........................137
Table 44 Parts List—Water Inlets 42044SR2 ..........................................................................139
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Table 45 Parts List—Flushing Water Supply 4244WP2/WP3, 4244WP2 SM, 4244SP2/SP3,
4244SP2 SM...............................................................................................................141
Table 46 Parts List—Cooldown 4244SP2, 4244SP2 SM ............................................................145
Table 47 Parts List—Steam Inlet & Sparger 4244SP2, 4244SP2 SM, 6044SP2/SP3, 6044SP2
SM ...........................................................................................................................147
Table 48 Parts List—8”X10” Stainless Dump Valve 42044WR2/WR3/SR2/SR3; 60044WR2/
WR3/SR2/SR3; 72044WR2/WR3/SR2/SR3......................................................................149
Table 49 Parts List—Burket Steam Valve ............................................................................151
Table 50 Legend – Pneumatic Schematic 4244SP2.................................................................153
Table 51 Parts List—Pneumatic Schematic 4244SP2..............................................................155
Table 52 Parts List—Brake Air Cylinder .............................................................................157
Table 53 Parts List—Staphairtrol 4244SP2, 4244SP2 SM ..........................................................159
Contents

1 General Service Information
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8Pellerin Milnor Corporation
BMP720097 / 19036 BRUUUM01.1 0000229985 A.3 D.6 12/5/19 11:43 AM Released
General Service Information