3.

Inspection and Maintenance Procedure

3-1. Inspection Before Operation

1) Inspection of lubricants
Visually or with oil level gauge, check if the extrusion screw driving
speed reducer, feed roller driving gears, and other lubrication points are
filled with oil to a specified level and are applied with a proper amount
of grease.

2) Inspection of temperature control unit(Reference)

Inspect the following items before operating the temperature control unit.

(1) Make sure water pressure for the temperature control unit is 0.1 MPa
or higher.

(2) Make sure all the temperature measuring thermocouples are properly installed
to a specified position.

3) Inspection of motor rotating direction

(1) Rotation of each temperature control circulation pump

(2) Rotation of main motor

(3) Rotation of deceleration feed oil pump

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 Inspection and Maintenance Procedure

3-2. Inspection of Feed Roller

To this machine, a feed roller is equipped. The feed roller is maintained and
inspected in the following procedure.

- Inspection and cleaning for feed roller section

1) Perform a periodical inspection and cleaning for the feed roller section once a week,
by opening the cover to clean off any foreign material.
Failure to inspect the feed roller may cause abnormal abrasion and/or breakage.
2) When you close the feed roller cover after cleaning, make sure that there is no foreign
material around the working surface of the feed roller. If any, it may cause breakage
in parts of the gear, gear coupling, rubber guide, etc.
3) Tighten evenly all 4 nuts that secure the feed roller cover. Uneven tightening may
cause breakage in parts similarly as described in the previous clause 2).

(Reference)

Screw

Clean off any foreign material from the

Feed roller working surface.

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 Inspection and Maintenance Procedure

- Adjustment of scraper

(Reference)

φ150～

φ45～φ120

1) To reduce the clearance, untighten bolts A and C and rotate bolt B clockwise.
The clearance is reduced by a decrement of 150,120 : 2.0 mm, 75 : 1.5 mm,
45 : 1 mm per one turn.
Upon completion of adjustment, securely tighten bolts A and C.

2) Reverse the preceding steps to increase the clearance.

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 Inspection and Maintenance Procedure

3-3. How to Install and Remove Pin

1) Installation
The pin is provided with special treatment using special material,
to which utmost care must be taken in handling.
Insert the pin in a pin setting hole on a cylinder at about half deep of the cylinder
wall thickness, apply a plug to the pin end, and then screw the plug in until the
pin tip neck sits on the hole bottom.

(Reference)

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 Inspection and Maintenance Procedure

2) Removal

(1) Apply the sleeve to the pin hole from which the pin in removed.
(2) Drive the bolt into the pin head portion.
(3) Turning the nut clockwise removes the pin.

(Reference)

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 Inspection and Maintenance Procedure

3) Others

(1) Inspection frequency and places

- Inspection frequency
Three rows from the hopper once every two months
Other portions once every six months

(2) Contents of inspection and measuring method

- Visually check the surface condition for any sign of trouble.
If any crack or bend is found, replace.

- Wear

(Reference)

Measure wear with a micrometer.

Pins can be used until the pin diameter
“d” wears to the size specified below.

[Ex.] In a 150 mm extruder,

new one 15 mm 14.55 mm
(3%) (wear included)

Extruder New pin Serviceable

diameter d size
250 mm 25 mm 24.25 mm
200 mm 20 mm 19.45 mm
150 mm 15 mm 14.55 mm
120 mm 12 mm 11.65 mm
90 mm 9 mm 8.75 mm
75 mm 7.5 mm 7.3 mm
60 mm 6 mm 5.8 mm

(3) Replacement
Replace only those which are identified to be abnormal in Sub-section (2).
Even changing locations may extend the life.

(4) Detection of metallic foreign matter

Detect metallic foreign matter of 3 mm or larger for removal.

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 Inspection and Maintenance Procedure

3-4. Removal of Screw Shaft

Be sure to remove all the pins before pulling out the screw or disassembling
the cylinder.
Remove the rotary joint and piping (1) at the rear of the screw, remove
the joint pipe (2) which pulls the screw backwards, and mount the nut (3)
and screw shaft (4) of the shaft removing tool.
Next, using the attached spanner, rotate the screw shaft (4) clockwise.
The screw comes off forwards.
In this event, provide a space to remove the screw (Refer to GENERAL
ASSEMBLY DRAWING) in front of the extruder.

<< Precautions >>

- As the screw is a consumable part, remove it at regular intervals (every six months)
and measure its outside diameter (abrasion wear management).
Inspecting it every three to six months is recommended.
If the screw is left inside for a long time, it gets firmly fixed and becomes difficult to
remove. Therefore, be sure to perform the inspection.

- When fitting it to the speed reducer, apply grease to the hole of its output shaft
before insertion.

- To replace screws, there is a case in which drain in the screw contaminates

the hopper cylinder thrust bearing. Be sure to remove drain and moisture.

- Never attempt to rotate the screw reversely, which may damage pins.

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 Inspection and Maintenance Procedure

(Reference)

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 Inspection and Maintenance Procedure

3-5. Gear Coupling Replacement Procedure

1) Remove the screw cooling rotary joint. In this event, also remove the inner pipe
inserted in the screw.

2) Remove all the cylinder pins with the special-purpose removing tool
( see page 5 of section describing Inspection and Maintenance).

3) Remove the screw to the head side. In this event, use the special-purpose
removing tool ( see page 7 of section describing Inspection and Maintenance).

4) Remove the main motor.

5) Support the hopper cylinder from the bed ( jack up ) or hang with a chain block.

(Reference)

6) Detach bolts which fix the hopper cylinder to the speed reducer.

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 Inspection and Maintenance Procedure

7) Remove bolts which fix the speed reducer to the bed, and shift the speed reducer
about 300 mm backwards.

(Reference)

8)

Shifting the speed reducer backwards causes the gear coupling to come out
together with the output shaft of the speed reducer.

(Reference)

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 Inspection and Maintenance Procedure

9) Detach bolts which fix the coupling to the output shaft of the speed reducer.

(Reference)

φ150～

φ45～φ120

10) After detaching the bolts in Step 9, remove the coupling.

It may sometimes be difficult to remove.

This completes removal of the gear coupling.

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 Inspection and Maintenance Procedure

3-6. Multi Head Inspection Item

1) Check of the contact on the deck plate surface

(1) Inspection point
(Refer to the following figure.)
Deck plate surfaces of the fixed head and top and bottom heads (4 points on the left,
right, top and bottom)

(Reference)

(2) Inspection method

(a) For the hydraulic cylinders for opening/closing the top and middle-top heads, set
the pressure setting to 21 MPa when opening the head, and set it to 10 MPa when
closing the head by adjusting the reducing valve.
(b) Decrease the pressure of the hydraulic cylinder for cotters to 10 MPa.
(Adjust it using the relief valve on the low pressure side.)
(c) Apply red lead uniformly onto either one of the deck plates.
(d) Close the head and clamp, and then insert the cotter.
(e) Fully open the head 1 minute later to make a transcription of the contact
on the deck plate surface. Store it as an inspection check record.

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 Inspection and Maintenance Procedure

(3) Inspection requirements

When the contact area specified in (2) is 60% or less,
adjust the deck plate at the relevant section using a shim,
and grind the surface to face up.

(4) Adjustment method

(a) Measure the clearance between the deck plates with poor contact
in the condition as instructed in (2)-(c), using a feeler gauge.
(b) Prepare some shims made of SUS having a thickness measured in (a),
and insert them under the deck plate at the opposite side of the fixed head
(Use a shim having a uniform thickness overall).
(c) Machine the elevated area on the deck plate.
Repeat it until the overall contact area of 80% is achieved.

Note: When the total thickness of shims exceeds 3 mm after adjustment,

replace the deck plate at the relevant section with a new one.

(d) After adjustment, recover pressure of the cotter hydraulic cylinder to the
original level, apply red lead to the deck plate surface,
head mating surface (in the shape) and the semi-circular surface,
and make sure contact is achieved on the whole surface.

(5) Inspection frequency

Inspect 2 times per year.

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 Inspection and Maintenance Procedure

2) Check of projecting allowance of cotter

(1) Inspection point
(Refer to the following figure.)
Measure the projecting allowance of the cotter from the slide plate
(4 points on the left, right, top and bottom).

(Reference)

(2) Inspection method

Lock the cotter with the clamp closed, and then measure the projecting
allowance of the hydraulic cylinder.

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 Inspection and Maintenance Procedure

(3) Inspection requirements

When the pressing allowance of the hydraulic cylinder is 5 mm or less,
adjust it using liners.

(4) Adjustment method

Insert some liners made of SUS under the slide plate on the top or bottom head side.
A liner of 1 mm in thickness makes an allowance of 5.8 mm for the cylinder stroke.
Note: When the total thickness of liners exceeds 2 mm after adjustment,
replace the side plate at the relevant section with a new one.

(5) Inspection frequency

Inspect once per month.

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 Inspection and Maintenance Procedure

3) Opening dimension of clamp (Reference)

(1) Inspection points
(Refer to the right figure.)
Measure the opening dimension between the
fixed head and clamp contact liner.

(2) Inspection method

(a) Close the clamp and check that
the relevant section contacts.
(b) Once the cotter is inserted in place,
the clamp may open slightly. Measure
and record the opening.

(3) Inspection requirements

When this dimension exceeds 5 mm,
there must be something wrong.
Check the following items, and contact us.

(4) Check points

(a) Check if there is any variation
in the projection speed of the cotter.
(b) Check if the cotter and slide plate are worn out.
(c) Check if the DU bushing for the clamp hinge is worn out.
(d) Check if there is any crack.
(e) Are the inspections specified in 1) and 2) performed appropriately?

(5) Check frequency

Check once per month.

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 Inspection and Maintenance Procedure

4) Others
(1) Pressure of the hydraulic cylinder for cotters
After the inspection specified in 1), increase the pressure to the necessary
minimum level without rubber leakage.
If you inform us of the rubber pressure in the head currently in service,
we will calculate the optimum hydraulic pressure for cotters.

(2) Clean-up
When the head is closed with any foreign material remained on the head
contact surface, half-moon surface, deck plate surface and slide plate surface,
it may result in an accident.
Clean these sections sufficiently each time after opening the head.

(3) Head pressure resistance

The head pressure resistance is designed to be 25 MPa; therefore,
do not use the head at any higher rubber pressure.

(4) Cautions
(a) Before operating the piston cylinder with the wedge tightened,
be sure to check that the base preformer is in place.
When operating the piston cylinder only with the wedge tightened,
the piston may incline, which may cause oil leakage.

(b) Install the base preformer, with the preformer and die plate
assembled completely to the base preformer.
In this step, adjust the unevenness on the back of the base preformer
(contact surface with the head front surface) to be within 0.01 mm.
When tightening the wedge and operating the piston cylinder,
with any large unevenness not adjusted appropriately,
or with the preformer and die plate not assembled completely
to the base preformer; the contact pressure at the elevated area increases,
which may result in damage of the head.

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 Inspection and Maintenance Procedure

3-7. Inspection and Maintenance of Speed Reducer

1) Operate the machine in the following procedure.

(1) Make sure lubricants of the correct type are used.

See the list of recommended lubricants.
( At the shipment from the plant, all lubricants are removed.
Before operation, fill oil with care to prevent entry of foreign matter and
make sure oil is filled to a proper level.)
Grease is filled in bearings, but it is recommended to replenish a small
amount of grease before operation.

(2) Before shipment, running-in operation is thoroughly carried out but before
entering full-scale operation, carry out operation at no load and make sure
there is no abnormality in any place. Thereafter, gradually apply loads.

(3) After delivery, special care must be taken when the machine is stored for
a long time before it is installed and operated.
For gears and bearings, a splash lubrication system ( a grease lubrication
system for part of bearings ) is employed but storing the machine over an extended
period of time without installation or operation may cause oil at bearings to dry up.
During installation operation, repeat jogging at no load several times and then,
carry out operation specified in Step (2).

(4) Measure vibration, temperature, and noise at each portion during full-scale
operation. The data can be used for reference during later maintenance.

2) Inspection and replacement of lubricants

(1) It is necessary to periodically inspect the oil level by an oil level gauge.
To properly measure the oil level, operate 2-3 minutes at no load,
stop the machine, and proceed with measurement.

(2) After 500 hours from the inauguration of operation, replace oil for the
first time. Then, replace oil after 2,500 hours.

(3) Thereafter, every 5,000 hours or every six months, whichever shorter,
renew oil.

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 Inspection and Maintenance Procedure

3) Lubrication and oil drainage

(1) Fill lubricants from oil inlets at the top of the machine with care to prevent
entry of dust and water and fill only to a specified level while checking
the level with the oil level gauges.
Lubricants short of a specified level prevent thorough lubrication and
excessively generously filled lubricants accelerate deterioration due to a rise
in oil temperature.

(2) Remove the oil drainage plug at the machine bottom to discharge waste oil.

4) Inspection and replacement of oil seal

Worn oil seal causes oil leakage. Periodically inspect oil seal and replace in
advance when any abnormality is found.

5) Shutdown over a long time

(1) When the machine is shut down for over a month and reoperated thereafter,
it is necessary to replace lubricants with a specified amount of recommended
lubricants. During shutdown, it is effective to plug air bleeder stoppers to
seal.

(2) When the machine is shut down for over three months, remove lubricants
and fill a proper amount of volatile rust preventive oil ( JIS NP 20 or
equivalent ) in accordance with the manufacturer instructions.

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 Inspection and Maintenance Procedure

6) Forced-feed lubricator (special specifications)

(1) Drive motors for pumps for 3-5 minutes before operating the speed reducer
driving motor, and after lubricants are thoroughly circulated through
bearings, operate the speed reducer driving motor.

(2) A trochoid pump is used for the lubricant pump.

(3) The oil filter is a surface self-cleaning type auto-clean filter, which enables
filter cleaning by rotating the handle.
To the inside, a relief valve is equipped to prevent defective lubrication due
to filter clogging.
Because particularly at the initial stages of operation, plugging is likely to
occur, rotate the handle more than one turn every day to clean the filter.
Sludge collects at the lower part of the filter.
Remove the plug at the bottom to discharge sludge when lubricants are renewed.

(4) Constantly check the lubricating conditions to bearings and gears from the
flow sight.

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 Inspection and Maintenance Procedure

3-8. Miscellaneous

1) When the machine is shut down over a long time, discharge drains from
cylinders, etc. as much as possible.
Particularly during the wintertime, remove drain from the temperature
control pump after completing operation.
( When water in the piping freezes, pumps and pipes may be broken. )

2) When a rubber pressure gauge is equipped, take special care to prevent

damage to the sensor when rubber is cleaned.

3) It will be effective to prevent adhesion of scale to the extruder jacket and pipings
to install a tank for the circulating water of the temperature control unit and
use a rust preventive solution.
For rust inhibitor, it is recommended to use UNIPLOT PC-200, etc.
of Nippon Yuka Kogyo in the concentration of 0.3 % ( 3000 ppm).
Measure the concentration of the tank about once a week and replenish
the shortfall.

4) There is a grease pan placed under the hopper cylinder.

Please clean up the grease pan once a month.

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 Inspection and Maintenance Procedure

3-9. Trouble Shooting

- Screw

Symptoms Possible causes Cures

- Screw dose not - Improper power - Check power supply circuit.

rotate. supply.
- Remaining comp’d. - Check remaining comp’d
the open the head.
 Coupling slip. - Replace Coupling.

☐ Slipping of driving - Check belt for tension

V belt. or wear.

- Speed reducer

Symptoms Possible causes Cures

- High oil - Overload operation. - Check and correct load.

temperature - Excessively short - Align the level to the
or deteriorated indication line of the
lubricant. level gauge.
- Replace to new oil.
- Excessive noise. - Damaged bearings. - Renew lubricants.
- Replace bearings.
- Large vibration. - Worn teeth. - Replace gears.
Contact with manufacturer.
- Worn or damaged - Replace bearings.
bearings. - Retighten bolts.
- Loose fixing bolts.

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 Inspection and Maintenance Procedure

- Feed roller

Symptoms Possible causes Cures

- Roller does - Broken driving teeth. - Replace gears.

not rotate. - Broken bearings. Replace bearings.
- Large amount of - Increased clearance - Adjust the clearance.
rubber comes out between scraper and
from feed roller.
circumference.

- Temperature control unit (Reference)

Symptoms Possible causes Cures

- Temperature - Pump does not rotate. - Check power supply circuit.

does not rise. - Valve is closed. - Check valve opening.
- Heater disconnection. - Replace heater.
- Water does not flow. - Clean strainer and piping.
- Defective solenoid - Replace solenoid valve or
valve. coils.
- Large - Defective opening of - Adjust valve opening.
temperature drain stop valve. ( Reduce the opening. )
variation. -Defective adjustment - Readjust the temperature
of temperature control control.
-Temperature (Press the tuning.)
sensor failure - Replace
the temperature sensor
- Temperature - Low cooling water - Bring water pressure to
remains high pressure. 0.1 Mpa or over.
and does not - Clogging inside piping - Clean strainers and piping.
lower.
- Abnormal - Defective - Replace thermometer.
temperature thermometer. - Retighten thermometer
indication. - Loose thermometer wiring.
wiring.

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