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Technical Documentation

Page 1
CleanSweep® RM125

TECHNICAL DOCUMENTATION

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CleanSweep® RM125

Table of contents

1 ISSUE STATUS / REVISION .................................................................................................................................... 5


2 QUALITY DECLARATION AND NON-DISCLOSURE AGREEMENT .................................................................... 6
2.1 Quality declaration ISO 9001:2000 ................................................................................................................. 6
2.2 Non-disclosure agreement .............................................................................................................................. 6
3 PRODUCT AND FUNCTION DESCRIPTION........................................................................................................... 7
3.1 Product description.......................................................................................................................................... 7
3.2 Function description ........................................................................................................................................ 7
3.3 Guarantee statement ...................................................................................................................................... 8
4 PACKAGING AND TRANSPORT ............................................................................................................................ 9
4.1 Packaging ........................................................................................................................................................ 9
4.2 Transport ......................................................................................................................................................... 9
5 DANGER AND SAFETY NOTICES ........................................................................................................................ 10
6 COMMISSIONING................................................................................................................................................... 11
7 INSTRUCTIONS FOR REPAIR, SERVICE, AND FAULT REMEDY ..................................................................... 13
8 PREVENTIVE MAINTENANCE .............................................................................................................................. 14
8.1 General service points .................................................................................................................................. 14
8.2 Maintenance .................................................................................................................................................. 15
8.2.1 Drive unit ............................................................................................................................................. 15
8.2.2 Steel belt ............................................................................................................................................. 16
8.2.3 Conveyor frame and internal filter cartridge........................................................................................ 16
8.2.4 Inspection, cleaning and maintenance table....................................................................................... 17
9 REPLACEMENT OF COMPONENTS .................................................................................................................... 18
9.1 Removal of the steel belt ............................................................................................................................... 18
9.2 Replacement and adjustment of brushes and wipers ................................................................................... 19
9.3 Removal of the discharge auger ................................................................................................................... 19
9.4 Overview of the drive unit .............................................................................................................................. 20
9.5 Removal of the drive unit .............................................................................................................................. 21
9.6 Removal of the drive shaft ............................................................................................................................ 21
9.7 Removal of the drive bearings ...................................................................................................................... 21
9.8 Removal of the filter cartridge ....................................................................................................................... 21
9.9 Assembly ....................................................................................................................................................... 21
10 CLEANING THE CONVEYOR ................................................................................................................................ 22
11 ELIMINATION OF FAULTS .................................................................................................................................... 23
12 MAIN COMPONENTS AND SPARE PART ORDERS ........................................................................................... 25
12.1 CleanSweep® RM125 main components ...................................................................................................... 25
12.2 Ordering spare parts ..................................................................................................................................... 26

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Table of figures

Figure 1: Conveyor overview ............................................................................................................................................ 7


Figure 2: CleanSweep® RM125 overview ....................................................................................................................... 11
Figure 3: Drive unit .......................................................................................................................................................... 15
Figure 4: Removal of the steel belt ................................................................................................................................. 18
Figure 5: Overview of the drive unit ................................................................................................................................ 20
Figure 6: CleanSweep® RM125 main components ......................................................................................................... 25

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List of tables

Table 1: Issue status / Revision ........................................................................................................................................ 5


Table 2: Drive unit ........................................................................................................................................................... 15
Table 3: Connection of the socket .................................................................................................................................. 16
Table 4 Gear oil data ....................................................................................................................................................... 16
Table 5: Maintenance overview ...................................................................................................................................... 17
Table 6: Removal of the steel belt................................................................................................................................... 18
Table 7: Overview of the drive unit ................................................................................................................................. 20
Table 8: CleanSweep® RM125 main components .......................................................................................................... 25

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1 ISSUE STATUS / REVISION

Change Date Description Name

Rev. 0 09/2015 Newly created H. Werker

Rev. 1 11-2016 Update J. Schuman

Rev. 2 05-2018 Update M. De

Table 1: Issue status / Revision

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2 QUALITY DECLARATION AND NON-DISCLOSURE AGREEMENT


2.1 QUALITY DECLARATION ISO 9001:2000

Mayfran is a company certified in accordance with ISO 9001:2000.


In order to guarantee safe product function, all Mayfran conveyors are subjected to documented test run without load
for a period of one hour prior to delivery to the customers, unless a different process is defined in the final, valid offer
and in the order confirmation.

2.2 NON-DISCLOSURE AGREEMENT

All rights reserved.


No part of this document may be copied, reproduced, recreated, published online, disclosed, transferred, or distributed
in any manner without the prior written consent of the issuing entity, Mayfran International B. V. Landgraaf (hereinafter
referred to as Mayfran).
Mayfran assumes no liability for the exactness of information for any purposes and makes no claims about the
topicality of the information.
The document may contain clerical errors.
Mayfran can make modifications to the described products at any time without prior notification.

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3 PRODUCT AND FUNCTION DESCRIPTION


3.1 PRODUCT DESCRIPTION

Mayfran CleansweepRM conveyors are installed in applications chip-producing machine tools, etc.
They convey metal chips, scrap from a machnine tool to a chip container or a collecting conveyor. The conveyor is
designed with self cleaning maintenance screenbox cartridges used to clean the cooling lubricant applied in the
machining process. The finest chips are transported by means of a patented inner chip handling system in the same
chip tank or collecting conveyor as the coarse chips.

The advantages of CleansweepRM:


• Suitable for all types of metallic chips
• Higher machine availability
• Compact design
• Reduced clean tank maintenance
• Increased service life of coolant, pumps, and tools
• Interchangeable with a standard chip conveyor

This operating manual provides instructions for care, maintenance, and spare part replacement.
The manual is not specific to a conveyor design, which can be designed as straight or have a bend and subsequent
ascending section.

3.2 FUNCTION DESCRIPTION

The conveyed material and contaminated cooling lubricant continually fall to the conveying surface of the conveyor.

Finest dirt
discharge via
auger

Steel belt conveyor

Interchangeable
screen

Figure 1: Conveyor overview

The conveyed material is then continuously transported to the discharge opening. Long chips are discharged from the
steel belt. Small chips and fine dirt are discharged via the internal chip transport system. An interchangeable, low-
maintenance filter cardridge cleans the cooling lubricant before it is discharged in a coolant tank.

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1 Do not use the system for other purposes!


The discharge point must be visible while the machine is in operation.

Q Noise level: < 70 dB (A)

1 Bear in mind that the conveyor is in continuous operation during machine production.

3.3 GUARANTEE STATEMENT

This operating manual must be available to the operator responsible for the conveyor and to the maintenance
personnel.
The guarantee is only valid if these requirements are strictly observed.

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4 PACKAGING AND TRANSPORT


4.1 PACKAGING

CleanSweep® steel belt conveyors are usually delivered fully assembled. Depending on customer wishes or due to its
lengths, the conveyor can also be delivered in multiple parts.
The steel belt is then delivered on one or multiple pallets; small parts such as screws, belt joint, etc. are delivered in
separate crates / cartons.

4.2 TRANSPORT

1 Do not stand under suspended loads! The figures on this page should be considered examples.
The available load suspension devices must always be used for lifting and transporting.

p
Crane transport: Always use the available load suspension devices (M12x20mm).
The lifting eyes are not part of the delivery. Note that they are according to the local safety directive.
For the total weight please check order documents.

o Forklift transport: Always transport the conveyor packed on the wooden pallet and secured
against slipping or falling over.

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5 DANGER AND SAFETY NOTICES

Affix the supplied sticker in an easy visible location on the conveyor!


All information and instructions in the supplied operating manuals must always be followed!

1 Unqualified personnel are prohibited from performing work on the system!


Ensure appropriate fastening for customer-provided chip deflection panels!
Never bypass safety devices!
The function of safety devices must always be assured!

2 Work on the electrical system may only be performed by appropriately qualified experts in
observance of the locally applicable statutory regulations.

U Never stand or reach into the area of the chip discharge opening.

V All covers must be mounted prior to commissioning.


Do not remove covers during operation of the system!

W Do not reach into the ejection opening!

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6 COMMISSIONING

1
Ensure stable and secure machine setup.
Secure the system against sudden, unexpected operation.
Bear in mind the danger of entanglement of hands and loose clothing.

Figure 2: CleanSweep® RM125 overview

1. The conveyor must be aligned precisely. The deviation from the centre line may not exceed 2 mm on either side.

2. The conveyor steel belt and chain must be lightly oiled.

3. Before the conveyor belt is put into operation, the belt tension must be checked.
The belt tension is correct when it is possible to slighlty lift-up the steel belt from the track by 10-20 mm on the
discharge side in the bottom part. Should this not be the case, then please loosen or tighten the belt.
Make sure that the system is not switched on when checking the belt tension.

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To tighten the belt:


Unscrew the screws on both bearings (See chapter 9: figure 5 of the general assembly drawing).
Adjust the belt tension by turning the tensioning screws. The hinge belt must be able to be pressed inwards
manually approximately 15 mm. Pöease make sure that the conveyor is not switched on when checking belt
tension. Then secure the screws with the lock nuts.
Tighten both bearings.

4. The sidewings of the steel belt conveyor must run parallel to each other in the conveying direction. Excessive play
or bent side panels will lead to a jamming of the belt and hooking of the chips.

5. What is the current power supply?

6. Is the current power supply according to the specification of the gear motor?

7. Is the conveyor (especially the overload protection device of the gearmotor) connected correctly to the machine
tool interface according specifications?

8. The conveyor should run without load for at least five hours.
During the run-in, ensure that the steel belt moves freely and do no bend anywhere.

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7 INSTRUCTIONS FOR REPAIR, SERVICE, AND FAULT REMEDY

z Switch off the main switch!

2 Secure the system against inadvertent electrical activation!

D Depressurise the system!

w
Close all gate valves and valves!
Remove all harmful substances!
Cooling lubricant may not be released into the environment!

8 In case of contact with chips:


Use protective clothing, safety shoes, and protective gloves!

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8 PREVENTIVE MAINTENANCE
8.1 GENERAL SERVICE POINTS

With the performance of regular maintenance (regular inspection, cleaning and maintnance intervals) according to
below guidelines, the Mayfran conveyor has a long service life with minimal wear. Please ensure that the steel belt
and chains are always lightly oiled.
The service intervals mentioned in this document are based on normal operating conditions and single shift usage
factors according to the table bleow. Service intervals should be adjusted accordingly when operating conditions and
usage factors change.

Oiling on a monthly basis is adequate for dry machining. If the belt is exposed to the elements, the maintenance work
must be especially diligent.
Check the belt regularly for damage in order to ensure that spare parts can be replaced in good time. Malfunctions
can be avoided as a result.
The maintenance of supplier components, such as pumps, cooling units, etc. must take place according to the
manufacturer's specifications.

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8.2 MAINTENANCE

8.2.1 DRIVE UNIT

Figure 3: Drive unit

Part no.: Description Quantity Comments

1 Drive unit

2 Shaft bearing

3 Guard of roller block chain, axle guard

4 Frame bracket

5 Torque arm

6 Springs of the torque arm

7 Screw for torque transmission

Table 2: Drive unit


The gear unit is intended for installation in dry locations. The gear unit is designed as a slip on gear with hollow shaft.
A torque support is provided for the fastening.
The torque support is fixed in a special fastening construction on the conveyor. It is designed with special disc springs
in order to eliminate errors in the alignment and warping. Harmful impact should also be prevented as a result. The
gears are not subject to any limitations with respect to installation position.
The gear unit is factory pre-filled with sufficient lubrication and then closed for an oil-tight seal. It is operable in a
temperature range between 0°C and 40°C, air humidity below 85%, a barometric elevation of up to 1000m.
To prevent frictional corrosion between the motor journal and the hole of the auger shaft, the motor journal must be
treated with an appropriate lubricant during assembly. The recommended lubricant is KIüber Microlube GL 261.
The gear unit is equipped with an overload protection device (slip coupling). The slip coupling is adjusted to the
necessary torque by the manufacturer.
The microswitch is tested and appropriately adjusted.
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The connection takes place by means of a standard M12x1 plug-type connector (DIN 43650 / ISO 4400) or an
appropriate plug socket as follows:

Number 1 2 3 4

Connection COM in brown NC (normally closed) in white M12x1 plug NO (normally open) in black

Table 3: Connection of the socket


The earthing takes place with an earthing screw on the cover of the shift case.

Gear
Type Gear oil quantity Manufacturer
unit

CMFA020- MOBIL 600W SUPER CYLINDER OIL


1310651 460 ml
230H360GVN (EXXON MOBIL)

Table 4 Gear oil data


The gear unit must be inspected regularly (minimum every three months) for leaks, contamination, and unusual noise.

8.2.2 STEEL BELT


1. The belt must be aligned and tightened after the first 20 days of operation.
The correct belt tension is described under section 3 in chapter 6 'Commissioning'.

2. Re-check the belt tension and tighten as necessary on regular basis, see chapter 6 ‘Commissioning’.

3. Remove the chain guard and check whether there is recongnisable wear or signs of rubbing on the rollers, side
panes, and chains. If this is the case please refer to chapter 11 ‘Elemination of faults’.

4. The drive bearings are provided with life-long grease lubrication for normal loads.

5. Check the correct fixation and position of the brushes and wipers of the inner handling system. See Chapter 9.2.

6. The specified conveying capacity of chips can only be achieved if the conveyor runs continuously. This means that
the conveyor must always be operated simultaneaously with the machine tool.

8.2.3 CONVEYOR FRAME AND INTERNAL FILTER CARTRIDGE


1. The conveyor frame and main components must be free from damages and cleaned on a regular basis. See
chapter 9.

2. Check the bottom plate at the discharge opening and the returning steel belt for chip accumulations. If chips
have accumulated, the respective positions need to cleaned.

3. The inner chip handling system (especially the auger discharge funnel) must be free of chip accumulations
and cleaned on regular basis. See chapter 9.3

4. The inner filter cartridge(s), especially the coolant exit openings must be inspected for chip accumulation and
cleaned as necessary on regular basis. See chapter 9.8

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8.2.4 INSPECTION, CLEANING AND MAINTENANCE TABLE


The service intervals guidelines indicated in this document may vary depending on the type of machining, usage factor
and operating conditions at the enduser.

Activity Operating
Component Service activity Remark
sequence hours*

Check alignment and re-


First use 0 Belt and chain Capter 6
tension belt

Check for damage and


Weekly 40 Frame, belt and chain strange noise, exchange of Chapter 8.2.3 / 8.2.4
parts if necessary

Check and clean filter


Chapter 8.2.4
cartridge coolant exits

Check for damages and


Monthly Belt and chain Chapter 8.2.3
fixation of wiper cleats

Oiling in case of dry


operation, check for
Chapter 8.1
damages, exchange of
parts if necessary

Check for chip


Frame, discharge
3-months 480 accumulation at bottom belt Chapter 8.2.4
section
plate; cleaning

Check for lekage, soiling


Drive unit and noise, exchange if chapter 8.2
necessary

Check brushes and wiper


cleats of visible wear,
Belt chapter 9.2
adjust or replace in case of
visible wear or damages

Remove, check and clean


of chip accumulation or
6-months 950 Filter cartridge Chapter 8.2.4
soiling, exchange if
necessary

Visual chek of the general


General --
condition

1-year 1900 General Full cleaning Chapter 8, 9, 10

Replace all rubber seals


2-years 3800 General --
and gaskets

Table 5: Maintenance overview

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CleanSweep® RM125

9 REPLACEMENT OF COMPONENTS

An overview and list of the main components of the CleanSweep® RM125 are provided in chapter 12.1 'CleanSweep®
RM125 main components'.

9.1 REMOVAL OF THE STEEL BELT

Figure 4: Removal of the steel belt

Part no.: Description Quantity Comments

1 Belt axle

2 Rubber wiper

3 Wiper clamping strip

4 Roller block

5 Belt plate

Table 6: Removal of the steel belt


Remove the left and right chain guard (see figure 5: point 6, 7 and 9).
Move the belt until the joint rod with splint in the bottom part of the drive unit is freely accessible.
Unscrew the screws for the drive bearings (see figure 5: point 5) and unscrew the bolts on the tensioning station
approx. 15 mm. The belt tension decreases. Remove the splint and chain lugs on both sides, as well as the joint rod.
The belt is now opened and can be removed from the frame by briefly switching on the gear motor.

1 It must be ensured that a belt jam is avoided!

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9.2 REPLACEMENT AND ADJUSTMENT OF BRUSHES AND WIPERS

The stell belt comprises special cleats which are composed of a combination of brushes and wipers and which can be
adjusted form the upper side of the belt.
Adjustment is carried out by handpressing the brush or wiper down to the inner chip handling plate in the charge
section of the conveyor. Fixate the bruch or wiper by tightening the bolts firmly and mark their location with a water/oil
proof marker.
The brushes and wipers must be inspected for wear, adjusted as necessary, and possibly replaced on regular basis.

9.3 REMOVAL OF THE DISCHARGE AUGER

The auger and the discharge channel of the CleanSweep conveyor must be inspected periodically for material
accumulation and cleaned as necessary (Figure 4: Removal of the steel belt, position 3).

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9.4 OVERVIEW OF THE DRIVE UNIT

Figure 5: Overview of the drive unit

Part no.: Description Quantity Comments

1 Worm bearing

2 Auger and drive wheel

3 Auger channel

4 Drive unit

5 Bearing shaft

6 Chain guard (sideways)

7 Chain guard (upfront, left side)

8 Shaft

9 Chain guard (upfront, right side)

Table 7: Overview of the drive unit

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9.5 REMOVAL OF THE DRIVE UNIT

The electrical connections must be removed by authorised, qualified personnel for the removal of the gear motor. The
torque support bolt must be loosened for removal of the drive unit (see Figure 4: Removal of the steel belt, position 7).

9.6 REMOVAL OF THE DRIVE SHAFT

The removal of the drive shaft takes place complete with bearing and chain wheels.
For this purpose, the belt and the drive motor must be removed as described under chapter 9.1 (Removal of the steel
belt) and 9.2 (Replacement and adjustment of brushes and wipers).
Now the belt of the drive bearings must be loosened and the shaft can be removed (see chapter Figure 4: Removal of
the steel belt, position 15).

9.7 REMOVAL OF THE DRIVE BEARINGS

The fastening bolts can be loosened from the drive shaft by turning it anti-clockwise with an Allen key. Now the
bearings can be pulled off of the drive shaft by hand (see Figure 4: Removal of the steel blet, position 5).

9.8 REMOVAL OF THE FILTER CARTRIDGE

The filter cartridge must be inspected for material accumulation or wear and cleaned or replaced as necessary. The
filter cartridge is represented in Figure 6: CleanSweep® RM125 main components, position 4 and must also be
removed as necessary.

9.9 ASSEMBLY

Prior to assembly, it must be ensured that all damaged or worn parts have been replaced. Assembly takes place in the
reverse order of the removal.

1 The belt running direction must be observed.

The side panels of the belt must overlap in the conveying direction.

1
For the tension of the belt, it must be ensured that both tensioning stations are tightened evenly so
that the drive shaft is perpendicular to the conveyor frame.
Uneven belt tension leads to increase wear of chains, chain guides, chain wheels, and tracks.

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CleanSweep® RM125

10 CLEANING THE CONVEYOR

Clean the conveyor regularly.


The cleaning intervals depend on the type of machining, single or multiple shift machine use, and the environment of
the conveyor.

1 Secure the conveyor from inadvertent activation.

The following points must be taken into consideration for simple cleaning:
1. Switch off the conveyor.

2. Remove all covers.

3. Clean the belt by hand.


Cleaning under the belt takes place feeding cleaning cloths in the direction opposite the belt running direction.
The cleaning rags are then ejected at the outlet of the bottom plate (drive station underside).
This step can be repeated as often as necessary.
This cleaning may not be carried out during machine operation!

4. Clean the filter cartridge(s) and inner handling system.


Cleaning must be done manually after removing the filter cartridge(s) and auger channel from the conveyor.

5. Mount all covers.

6. Ensure the correct running direction of the belt prior to machine start-up.
More-intensive cleaning can take place after the entire belt has been removed.
Then the belt (on both sides) and the inner sides of the frame can be cleaned with a high pressure cleaner.
The belt can be re-installed after it has been cleaned (see chapter 9.9 Assembly).

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11 ELIMINATION OF FAULTS

Fault Possible cause Remedy

Tighten the tensioning screws and


The belt tension is too low.
lock nuts.

Adjustment of brushes and


Re-adjust the brushes and wipers.
wipers too rigid.

Fixation of brushes and Fixate and re-position brushes and


Excessive jamming without apparent
wipers inadequate or loose wipers
blockage

Chips build-up in the


Clean the discharge area from chips
coneyor discharge area

Check the unit overload


protection device for correct Replace the drive unit
function

Material backup due to Eliminate cause of overloading,


Bent or cracked side wings (left and right). overloading or admission of remove coarse parts, align or replace
coarse parts. side wings.

Excessive wear of the outer sides of the Bent frame or poorly Align the belt and the frame as
side panels. aligned drive shaft. necessary.

Lost lugs Lost splints Replace lugs and splints.

Wear due to rust or


Bent or cracked hinge eyes on the belt Lubricate the hinges, remove coarse
deficient lubrication or
plates parts. Replace belt plates.
coarse parts

The overload coupling is not Run the conveyor until the overload
Error message from the microswitch of the
in the correct or normal coupling jumps back to the correct
overload protection coupling
position. position.

Eliminate the overloading, remove


coarse parts.
Overloading or admission of
coarse parts.
The overload protection coupling triggers. Reset the overload coupling by
intentionally blocking the belt.

Defective drive. Replace the drive.

The cooling lubricant quantity must be


Excessive pump output
reduced and adjusted to the specified
(l/min.)
values.
Cooling lubricant overflow in the charge
section
Removal and cleaning of the
The 'inner chip handling
conveying auger and/or the
system' is clogged.
intermediate bottom panel.

REV. 1 MAYFRAN INTERNATIONAL - POSTFACH 31032 – 6370 AA LANDGRAAF – NETHERLANDS - : + 31 (0) 45 5329 292 - service@mayfran.eu P61-000
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CleanSweep® RM125

Conveyor must be set to continous


The filter cartridge is not mode, brushes and wipers must be
cleaned correctly adjusted correctly, filterbox must be
cleaned

Incorrect cooling lubricant


Replace the cooling lubricant medium
medium (viscosity and
or contact the manufacturer
density)

REV. 1 MAYFRAN INTERNATIONAL - POSTFACH 31032 – 6370 AA LANDGRAAF – NETHERLANDS - : + 31 (0) 45 5329 292 - service@mayfran.eu P61-000
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12 MAIN COMPONENTS AND SPARE PART ORDERS


12.1 CLEANSWEEP® RM125 MAIN COMPONENTS

Figure 6: CleanSweep® RM125 main components

Part no.: Description Quantity Comments

1 Auger bearing

2 Auger and drive wheel

3 Auger channel

4 Filter cartridge

5 Drive unit

Table 8: CleanSweep® RM125 main components

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12.2 ORDERING SPARE PARTS

The following information is required for spare part orders:


• Order number of the conveyor and part number
• Description and
• quantity from the list above
The Mayfran order number can be found on the type plate on the side of the ascending section of the conveyor.

REV. 1 MAYFRAN INTERNATIONAL - POSTFACH 31032 – 6370 AA LANDGRAAF – NETHERLANDS - : + 31 (0) 45 5329 292 - service@mayfran.eu P61-000
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CleanSweep® RM125

http://www.mayfran.com

Mayfran International B.V.


P.O. Box 31032 Edisonstraat 7/ 9
6370 AA Landgraaf 6372 AK Landgraaf
The Netherlands

+31 (0) 45 532 92 92


+31 (0) 45 532 93 00 (fax)

sales@mayfran.eu
www.mayfran.nl

REV. 1 MAYFRAN INTERNATIONAL - POSTFACH 31032 – 6370 AA LANDGRAAF – NETHERLANDS - : + 31 (0) 45 5329 292 - service@mayfran.eu P61-000
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