Maintenance Program

Starting the maintenance program on an older machine : 1 - Before the checkbook is handed over, an inspection is always performed. 2 - An inspection is recommended every 1500 hours or every 6 months with a maintenance offer.

Maintenance Program 1.1 Inspection 1.2 Minor maintenance 2.1 Inspection 2.2 Minor maintenance 3.1 Inspection 3.2 Standerd maintenance 4.1 Inspection 4.2 Standerd maintenance 5.1 Inspection 5.2 Standerd maintenance 6.1 Inspection 6.2 Major maintenance 7.1 Inspection 7.2 Major maintenance every every every every every every every every every every every every every every 750 750 1500 1500 3000 3000 4500 4500 6000 6000 15000 15000 30000 30000 hours of operation hours of operation hours of operation hours of operation hours of operation hours of operation hours of operation hours of operation hours of operation hours of operation hours of operation hours of operation hours of operation hours of operation or or or or or or or or or or or or or or every every every every every every every every every every every every every every 3 3 6 6 12 12 18 18 2 2 5 5 10 10 months months months months months months months months years years years years years years

Recommended replacement or overhaul of sub-assemblies:

3000 hours of operation :

Replace or overhaul the SE knife carrier, replace or overhaul the tobacco rod separting drum

4500 hours of operation :

Replace or overhaul the turning drum

6000 hours of operation :

Replace or overhaul the spider

Clean/ maintain/ lubricate and grease

machine group protos 80R protos 80R machine type VE80 SE80 hours ok comments 8 8 machine section (group / unit) suction rod conveyer v-way short text (action) change suction tape clean V-way and inlet guide clean rubber rollers and distributer cylinder clean dia roller ledger holder format clean cutting ledgers change garniture tape clean completely: glue pot;applictor roller and glue roller clean tipping lifter tipping roller roller unit tipping guide tipping cutter unit clean scrapers clean rolling block and rolling drum clean tipping guide clean knife and tipping roller under warm running water damp cloth damp cloth damp cloth damp cloth tooth brush circular brush damp cloth remarks

protos 80R protos 80R protos 80R protos 80R

SE80 SE80 SE80 SE80

8 8 8 8

printer

protos 80R protos 80R protos 80R protos 80R protos 80R protos 80R

MAX80 MAX80 MAX80 MAX80 MAX80 MAX80

8 8 8 8 8 8

gluing unit

Clean/ maintain/ lubricate and grease

machine group protos 80R protos 80R protos 80R machine type MAX80 MAX80 MAX80 hours ok comments 8 8 8 circular knife machine section (group / unit) tipping cutter unit short text (action) clean or change the brushes if necessary clean the cleaning ped change knives for tobacco rod and cig. clean grinding wheels or exchange if necessary glue rollers: grease bearing with a grease gun remarks water use a soft brush

special-purpose wrench cleaning brush

protos 80R

MAX80

protos 80R

MAX80

gluing unit

type: K2R;K2M;KP2R

Clean/ maintain/ lubricate and grease

machine group protos 80R protos 80R protos 80R protos 80R protos 80R protos 80R protos 80R machine type VE80 VE80 SE80 SE80 SE80 MAX80 MAX80 hours ok comments 24 24 24 24 24 24 24 drums MAX filter machine section (group / unit) feed airlock magnetic rail paper run format short text (action) clean feed airlock flap cleaning clean paper guide rollers garniture tape: clean rollers heating bars swash-plate drum + cutting drum clean filter grease the bearing of the glue roller shaft remarks suction air suction air / dry cloth damp cloth damp cloth damp cloth brush / damp cloth suction air grease gun

protos 80R

MAX80

24

Clean/ maintain/ lubricate and grease

machine group protos 80R protos 80R machine type VE80 VE80 hours ok comments 1 week 1 week machine section (group / unit) accelerator roller switch cabinet door Upper air jet chamber lower air jet chamber air jet rails transfer unit (spider) V-way short text (action) clean through of casing deposite clean filter remarks damp cloth suction air / compressed

protos 80R

VE80

1 week

clean of casing deposite

suction air / compressed

protos 80R protos 80R protos 80R protos 80R protos 80R protos 80R protos 80R protos 80R protos 80R protos 80R

SE80 SE80

1 week 1 week 1 week 1 week 1 week 1 week 1 week 1 week 1 week 1 week

clean suction elements through-scan photosensor grinding wheel:clean or exchange if necessary clean filter clean holes of the tipping drum clean grinding wheels or exchange if necessary

brush / damp cloth dry cloth brush and warm water suction air / compressed 1.8 mm drill cleaning brush

SE80 SE80 MAX80 MAX80 MAX80 MAX80 MAX80 MAX80

grinder unit main air unit tipping drum

main fan switch cabinet ejection drum end scanning

clean filter sieve clean filter OTIS sensor sensor suction air / compressed air jet / dry cloth air jet / dry cloth

Clean/ maintain/ lubricate and grease

machine group protos 80R protos 80R protos 80R protos 80R machine type MAX80 MAX80 MAX80 MAX80 hours ok comments 1 week 1 week 1 week 1 week machine section (group / unit) inspection drum cutting drum cig. Cutting drum bobbin changeover system short text (action) inspection caps cutting slots cutting slots remarks suction air / damp cloth compressed air compressed air

clean splice unit

suction air/compressed air

Protos 25 service parts 750 h

No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Maker 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25
Main Section VE VE VE VE VE VE

Sub Section steep angle conveyer steep angle conveyer Needl Roller Needl Roller Needl Roller Picker Roller Trimmer Set Suction Rod Convyer Suction Rod Convyer Ledger Driver Ledger Driver Connecting Fittings Grooved Ball Bearing Garniture Tape Drum Tongue Holder Discharge Drum Shifting Drum Splicer Inspection Drum Grinder Unit Knife Roller Pressure Roller Grooved Ball Bearing

Sub Section No. 144-0-2-DR 144-0-2-DR 105-0-0-DR 105-0-0-DR 105-0-0-DR 12-0-0-DR

Qty 20 40 36 6 6 100 2 0.027 1 2 2 4 1 1 4 1 1 72 4 2 2 4

Unit of Measure pcs pcs pcs pcs pcs pcs

Part No. 144DR56 N1-5X10-FK-14/AL 5DR7-1 DIN6912-M4X20-A2 D1-3.30-2.40 12DR12

121DR154F-1.129 (H12) L=56.0 T=3.0
U17DR154-2 or 168DR168-1

Description Rail Blind rivet Spiked Plate Cheese Head Screw O Ring Pin Trimmer Disk

Service

750 750 750 750 750 750 750 750 750 750 750 750 750 750 750 750 750 750 750 750 750 750 750

VE VE VE SE SE SE SE SE SE MAX MAX MAX MAX MAX MAX MAX MAX

pcs M pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs

5-201-0-DS 5-201-0-DS 23-50-1-DS 23-50-1-DS 15-0-1-DS 340-4-0-FA 173-0-3-FA 544-0-0-FA

7548-1-0-UM 545-1-0-FA 545-1-0-FA

Scraper 1/2915 Loop 5DS384F Leaf Spring DIN912-M6X25-12.9-SC Cheese Head Screw 28DS76 Roller DIN625-608-Z Bearing 15DS8 Drum Lining 38DS425F-1 104 Garniture Tongue 340FA300 Belt 172FA18 Cover 544FA255 Tipping Curler Bar 120FA136 Seal 517FA15 Grinding Wheel 548FA403 Brush 138MAX866 Roller DIN625-6001-2RS Bearing

Protos 25 service parts 1500 h

No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Maker 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25
Main Section VE VE VE VE VE VE

Sub Section steep angle conveyer steep angle conveyer Needl Roller Needl Roller Needl Roller Picker Roller Trimmer Set Trimmer Set Suction Rod Convyer Suction Rod Convyer Ledger Driver Ledger Driver Connecting Fittings Grooved Ball Bearing Garniture Tape Drum Bobbin splicer Bobbin splicer Bobbin splicer Grooved Ball Bearing Glue gun Grinder Unit Grinder Unit Swivelling device Garniture T Tongue Holder Garniture base Transfer unit Transfer unit

Sub Section No. 144-0-2-DR 144-0-2-DR 105-0-0-DR 105-0-0-DR 105-0-0-DR 12-0-0-DR

Qty 20 40 36 6 6 100 2 1 0.027 1 2 2 4 1 1 1 1 8 1 2 2 2 1 1 2 8 1

Unit of Measure Part No.

pcs pcs pcs pcs pcs pcs pcs pcs M pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs

Description 144DR56 Rail N1-5X10-FK-14/AL Blind rivet 5DR7-1 Spiked Plate DIN6912-M4X20-A2 Cheese Head Screw D1-3.30-2.40 O Ring 12DR12 Pin Trimmer Disk Paddle wheel

Service

1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500

VE VE VE VE SE SE SE SE SE SE SE SE SE SE SE SE SE SE SE SE SE SE

121DR154F-1.129 (H12) L=56.0 T=3.0 121 DR 182F (H 22) L=56 TL=22 T=3
U17DR154-2 or 17DR168-1

5-201-0-DS 5-201-0-DS 23-50-1-DS 23-50-1-DS 15-0-1-DS 28-0-1-DS 28-0-1-DS 28-0-1-DS 28-0-1-DS 46-0-5-DS 133-0-1-DS 133-0-1-DS 27-0-1-DS 38-103-2-DS 168-90-1-DS 166-4-5-DS 166-4-5-DS

Scraper Loop Leaf Spring DIN912-M6X25-12.9-SC Cheese Head Screw 28DS76 Roller DIN625-608-Z Bearing 15DS8 Drum Lining 28DS56 Roller 28DS57 Roller 28DS76 Roller DIN625-608-Z-St Bearing 46DS112 Nozzel 133DS32 Grinding Wheel DIN417-M5X8-5.8-A2K Set screw U27DS99-1 Brake lever 38DS1200F-2.101 Cover rial 38DS425F-1 104 Garniture Tongue DIN625-AY9-ZZ-St Bearing 166DS243F-1.102 Trough R43-450H075 Toothed belt 1/2915 5DS384F

Protos 25 service parts 1500 h

No 29 30 31 32 33 34 35 36 37 38 39 40 41 Maker 25 25 25 25 25 25 25 25 25 25 25 25 25
Main Section MAX MAX MAX MAX MAX MAX MAX MAX MAX MAX MAX MAX MAX

Sub Section Discharge Drum Shifting Drum Splicer Inspection Drum Grinder Unit Knife Roller Pressure Roller Grooved Ball Bearing Rolling unit Rolling unit Knife Roller Knife Roller MR-drum

Sub Section No. 340-4-0-FA 173-0-3-FA 544-0-0-FA

7548-1-0-UM 545-1-0-FA 545-1-0-FA 56-0-8-FA 56-0-8-FA 549-0-4-FA-05 7548-1-0-UM 55-0-3-FA

Qty 4 1 1 72 4 2 2 4 1 1 1 3 1

Unit of Measure Part No.

pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs Set pcs pcs

340FA300 172FA18 544FA255 120FA136 517FA15 548FA403 138MAX866 DIN625-6001-2RS 56 FA 114 F 56 FA 158 F W5-HK5024-2RS 138 MAX 665

Description Belt Cover Tipping Curler Bar Seal Grinding Wheel Brush Roller Bearing Rial Rial Knife Roller Needle sleeve Brush

Service

1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500

Protos 26 service parts 750 h Date: Runing Hours: Check by:

Main No Maker Sub Section Section 1 2 3 4 5 6 7 8 9 10 10 11 12 13 14 15 17 18 19 20 21 22 23 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 25 VE VE VE VE VE VE VE VE VE SE SE SE SE SE SE SE MAX MAX MAX MAX MAX MAX MAX
steep angle conveyer steep angle conveyer

Sub Section No.

144-0-2-DR 144-0-2-DR 105-0-0-DR 105-0-0-DR 105-0-0-DR

Qty 20 40 36 6 6 100 2

Unit of Measure pcs pcs pcs pcs pcs pcs pcs M pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs pcs

Done

Part No.

Description OR NOT
Done

comment

Needl Roller Needl Roller Needl Roller Picker Roller Trimmer Set
Suction Rod Convyer Suction Rod Convyer

144DR56 Rail N1-5X10-FK-14/AL Blind rivet 5DR7-1 Spiked Plate

DIN6912-M4X20-A2
Cheese Head Screw

12-0-0-DR

D1-3.30-2.40 12DR12
121DR154F-1.129 (H12) L=56.0 T=3.0
U17DR154-2 or 17DR168-1

O Ring Pin Trimmer Disk Scraper Loop Leaf Spring Leaf Spring Roller Bearing Drum Lining
Garniture Tongue

0.027 2 1 2 2 4 1 1 1 1 Inspection Drum 72 Grinder Unit 4 Knife Roller 7548-1-0-UM 2 Pressure Roller 545-1-0-FA 2 Grooved Ball Bearing 545-1-0-FA 4 Ledger Driver Ledger Driver Ledger Driver 5-201-0-DS Connecting Fittings 23-50-1-DS Grooved Ball Bearing 23-50-1-DS Garniture Tape Drum 15-0-1-DS Tongue Holder Shifting Drum 173-0-3-FA Splicer 544-0-0-FA

1/2915 U5 DS 72 U5 DS 76 28DS76 DIN625-608-Z 15DS8 38DS425F-1 104 172FA18 544FA255 120FA136 517FA15 548FA403 138MAX866 DIN625-6001-2RS

DIN912-M6X25-12.9-SC Cheese Head Screw

Cover
Tipping Curler Bar

Seal
Grinding Wheel

Brush Roller Bearing

Monthly Inspection Sheet for Machine Protos - Monthly Checklist Protos No : Item Check the following : Apron tension and that it runs parallel All toothed belts, V-belts and flat belts for correct tension and wear For leaks at CF feed and return pipe couplings Inside inspection covers for dust accumulation Seals on CF feed pipe supply and return pipe connections Sieve in VE CF receiving chamber Leaking tobacco behind VE Handles Windows Seals Nuts and bolts Condition of paint and covers Safety interlocks operational Listen for any unusual noise from fans Check general condition of fans Check for any loose bolts and footings Check tension of the steep angle conveyer Check of the combs and change the bad ones Grease the following : Grease nipples on knife carrier with grease Check the oil level of hydraulic pump and fill up if necessary Check the oil level of circulation system and fill up if necessary Date : Runing Hours: Time duration Checked Check by: Corrective action