вторник, 17 июня 2014 г.

Army Mobile Field Bakery System

MOBILE BAKERY HIGH PERFORMANCE 2500 KG PER DAY

 E-mail: heli-spare@ukr.net

 pp-alex@mail.ru
Ukraine, Kiev
Saksaganskogo str. 133 
tel. +380503838538

  M O B I L E     F I E L D      B A K E R Y



 


DESCRIPTION:
At present, we can supply you with Automotive baking block "AHB-2, 5"(АХБ-2,5) unit is mounted in a semitrailer, and is designed for baking bread in the field, as the parking lot, and when moving (on the go). Consists of a trailer truck ZIL-137-terrain (Formula 10x10) and the back of the semitrailer. Bumper truck mounted crane. Tyre pressure is adjusted depending on the road surface while running. Bakery AHB-2, 5, has no analogues in the world. Since the machine was designed for the army, it is equipped with a light masking agents, autonomous operation of bakery ovens on diesel fuel and firewood, a all-wheel drive 10x10, and reliability in all weather conditions from -50 to +50.
                Bakery
«AHB-2, 5»(АХБ-2,5) can provide bread 5880 people a day at a rate of 425gramm per person (normal Ukrainian Army). With this amount of bread, bakery service only 3 people:  1) The driver-mechanic, 2) Baker, 3) baker's assistant. Supply of food in bakery enough for three hours of continuous operation.
 Field bakery AHB-2, 5, has the ability to work both independently and connect to external sources.

CONSISTS OF
1) Baking  Oven
2) Power plant
3) Set for receiving, storage, sifting flour
4) Dispenser for flour
5) Grinder feed screw
6) Dough preparatory unit
7) Dough device
8) Rack for dough fermentation


















CONTENTS

Page
CONTENTS
2
INTRODUCTION
4
1. INTENDED USE
4
2. ENGINEERING DATA
5
3. units and components OF THE ARTICLE
7
4. ARRANGEMENT AND OPERATION OF THE ARTICLE
7
4.1. General arrangement.
7
4.2. Tractor-trailer unit body
7
4.3. Flour feeding system
9
4.4. Doughing plant
22
4.5. Rack
26
4.6. Fuel feeding arrangement
26
4.7. Salt dissolver
27
4.8. Water supply system
28
4.9. Air feeding system
30
4.10. Bakery travelling oven
31
4.11. Electrical equipment
31
4.12. Preparation of components
34
4.13. The order of operations at doughing
34
4.14. Loading, baking and discharge
35
4.15. Bread making technique
36
HPK-63L Bakery Travelling Oven
39
1. INTRODUCTION
39
2. INTENDED USE
40
3. SPECIFICATIONS
41
4. UNITS AND COMPONENTS OF THE ARTICLE
43
5. ARRANGEMENT AND OPERATION OF OVEN AND ITS CONSTITUENT PARTS
44
6. CONTROL AND MEASURING DEVICES
48
7. ARRANGEMENT AND MOUNTING
49
8. SAFETY PRECAUTIONS
50
9. PREPARATION FOR OPERATION
52
10. OPERATING PROCEDURE AND TECHNOLOGICAL PROCESS DESCRIPTION
54
11. INSPECTION OF TECHNICAL CONDITION
57
12. TYPICAL FAULTS AND REPAIR
59
13. MAINTENANCE (Procedures and Regulations) AT OVEN OPERATION, lubrication arrangement or lubrication chart
63
14. RULES FOR STORAGE, PRESERVATION AND DEPRESERVATION
68
15. TRANSPORTATION
70
16. MARKING AND SEALING
71
17. CONTAINERS AND PACKAGING
72

APPENDICES:
1. Dimensional Drawing.
73
2. Kinematic Scheme.
74
3. Scheme of Flue Gas Movement.
75
4. Lubrication Chart.
79
5. Lubrication Diagram.
78
6. Oven Depreservation Chart.
79
7. Scheme of Oven Flexibility in Railway Clearance.
80





INTRODUCTION
The present technical description and operating instructions are intended for study of the arrangement of and operating rules for the AHB 2.5 marching bakery plants.
First sections refer to the technical description, they contain the background information about the intended use, arrangement and operating principle of the baking unit and the separate assembly units.
The baking unit operating instructions are set out in the following sections. It contains the fundamentals on the safety, operation and maintenance regulations, equipment operation and maintenance instructions, as well as other data necessary for the product operation.


1. INTENDED USE

The baking unit of the AHB 2.5 marching bakery plant is intended for execution of the full cycle of operations in production of the panned loaf in field conditions, being located on the site (at parking) and during driving (on the move) without interruption in the technological process.


2. ENGINEERING DATA
2.1. At 16 loading, baking and discharge cycles a day, the output (design one) of:
а) bread from rye or the rye-wheat flour,
weighed out in 1.7 kg portions, kg                                                2500;
b) bread from the wheaten wholemeal flour,
weighed out in 1.6 kg portions, kg                                                2500;
c) bread from the 2 Grade wheaten (dark wheat) flour,
weighed out in 1.4 kg portions, kg                                                 2500;
d) bread from the 1 Grade wheaten (straight white) flour,
weighed out in 1.2 kg portions, kg                                                2500.
2.2. The store of raw materials, fuel and finished product, which is arranged in one baking unit:
а) rye wholemeal flour, kg                                                            220;
or wheaten graded flour, kg                                                          300;
b) drinking cold water, litres                                                          400;
c) edible salt, kg                                                                          50;
d) salt solution, litres                                                                    26;
e) vegetable oil, litres                                                                   10;
f)  hot water, litres                                                                       56;
g) ready bread, pieces                                                                   90;
h) petrol, litres                                                                             32;
i)  fuel for the injector, litres                                                         40.
2.3. The total capacity of the installed electric motors, kilowatt        9.19;
2.4. Kind of current and voltage of
the electrical equipment, V, three-phase alternating current             220.
2.5. The power supply variants for the electrical equipment of the unit:
а) in parked condition from the industrial network 220/380 V
(380 V through the transformer):   from the petrol-electric set AB-8T-230M.
b) on the move:                           from the petrol-electric set AB-8T-230M.




2.6. Mass of the baking unit consisting of the tractor-trailer unit, van body and equipment mounted in it, kg                                                                17,425        
including the mass of the mounted equipment, kg                           4,455
2.7. Time of the autonomous operation of the baking unit without restocking of raw materials, fuel etc., hours                                                                    3
2.8. Number of production workers, men                                        3
2.9. Outline dimensions, mm
length                                                                    14,820
width                                                                     2,500
height                                                                    3,585.
Figure 1. General Appearance







3. units and components OF THE ARTICLE
3.1. AHB-2.5 baking unit contains:
а) baking unit equipment mounted in K-137B2 body of ZIL-137-137B tractor-trailer unit;
b) portable process equipment:
Ø  PHZ-14 grinder feed screw portable;
Ø  the kit of sleeves and hoses for pumps;
c) portable electrical equipment:
Ø  PHZ 01.230 transformer portable;
Ø  PHZ 01.140 control panel portable;
Ø  the kit of cables, electric conductors and devices for connecting and earthing of the electrical equipment;
d) spare tools and accessories kit for the baking unit;

4. ARRANGEMENT AND OPERATION OF THE ARTICLE
4.1. General arrangement.
All equipment of the baking unit, except for the portable one, is arranged in K-137B2 body mounted on the chassis of ZIL-137-137B tractor-trailer unit.
The general appearance of the baking unit is shown in Figure 1, and the equipment arrangement inside the body - in Figure 2.
4.2. Tractor-trailer unit body
4.2.1. The tractor-trailer unit consists of ZIL-4E-137 truck-tractor and ZIL-137B bolster-type semitrailer.
4.2.2. The van body shell of the frameless panel construction is mounted on the metal welded base and fixed by means of special devices on the tractor-trailer unit chassis.
The body part, which is located over the bolster-type device of the tractor-trailer unit, is separated from the other part by the partition with the door. While in service, access to the body is carried out through the side door. For the equipment installation, as well as for maintenance operation while in service, the body is furnished with the rear double swing door. The aperture is made in the front body wall with the demountable cover for mounting and demounting of the petrol-electric set.
4.2.3. For illumination of the body, there are glazed windows on its side walls and roof chamfers. The night-time illumination is created by ceiling plafonds with 12 volt voltage lamps powered either from the accumulator battery installed in the special container outside of the body, or from the operating main of 220 volt through the reducing transformer installed inside the body. The illumination lamps are installed for creation of local illumination on some equipment, besides, there is one portable lamp.
4.2.4. Ventilating in the body could be natural through the ventipanes, and during parking - through the door, and artificial - by means of 4 electric ventilators, two of which are located in the ceiling part of the body, one of which is in the floor near the petrol-electric set, and one of which is in the front end wall.



Figure 2. Equipment arrangement inside the van body
1 - A1-PHZ-23 air blower; 2 - A1-PHZ-1 installation for flour reception, storages and screening; 3 - board of automatic protection; 4 - baking oven HPK-63 L; 5 - A1-PHZ-24 water tank; 6 - A1-PHZ 0110 control panel; 7 - AP-1 ABCE Class fire extinguisher; 8 - rack for  proofing of dough and bread arrangement; 9 - A1-PHZ 00440 demountable little table; 10 - A1-PHZ 00240 washing stand; 11 - A1-PHZ 00200 wash basin; 12 - containers for stock and instrument; 13 - A1-PHZ 0026 seat 0; 14 - oil can; 15 - A1-PHZ-4 doughing plant; 16 - A1-PHZ-22 salt dissolver; 17 - A1-PHZ-25 flour batcher; 18 - container for electric lamps; 19 - A1-PHZ-01.140 control board; 20 - A1-PHZ-00220 measuring bucket; 21 - A1-PHZ-00140 arrangements for mounting of covers; 22 - A1-PHZ-20 water doser mixer; 23 - A1-PHZ-00410 water funnel; 24 - A1-PHZ-00160 salt box; 25 - electric pump for water; 26 – A1-PHZ-00070 seat-step; 27 - A1-PHZ-00390 fuel funnel; 28 - A1-PHZ-09000 ventilator installation; 29 – AB - 8-T/230/M petro-electric unit; 30 - A1-PHZ-15 01000 - tank of fuel for injector; 31 - ventilator control panel (position 28); 32 - A1-PHZ 01220 switch installation; 33 - petrol tank; 34 - A1-PHZ 00010 terminal box.

4.2.5. The body has no special heating devices, the necessary temperature conditions are created by operation of the bakery oven and operation of forced-air and exhaust ventilators.
4.2.6. The body is linked with the driver's cab by the two-way sonic signalling.
4.2.7. The following equipment is arranged outside of the body:
under the floor - luggage containers, the container with the accumulator battery, supporting brackets for mounting of the big chimney, grinder feed screw, the connecting pipe for connection of the water-supply line of the baking unit to the water service source, the connecting pipe for connection of the air sleeve of the portable grinder feed screw, the pan for drain waters;
Ø  on the back panel - the spare wheel, rear dovetail;



Ø  on the front panel – the tanks for petrol; the tank with fuel for the injector and with the pump for manual fuel injecting; air filters of the air blower; the input box for connection of the electrical equipment of the baking unit to the supply network and for connection of the portable grinder feed screw;
Ø  on the right panel near the door - the side dovetail.
4.3. Flour feeding system
4.3.1. The flour feeding system (Figure З) provides a mechanized or manual flour charging into the baking unit body, creation of its current reserve for securing continuous work, screening it, cleaning from tramp iron and batching it in certain portions into the dough mixing drums for dough kneading.
4.3.2. The flour feeding system includes:
а) installation for flour reception, storage and feeding, consisting of the flour storage bin 1, receiving hopper 4, screener 5 and drive gear 6;
b) grinder feed screw stationary 3;
c) grinder feed screw portable 2;
d) flour batcher 9;
e) feeding products pipeline 7;
f)  return products pipeline 10.       
4.3.3. The flour storage bin represents a welded capacity, inside which are arranged: the access hatch who could be used as a manhole hatch for maintenance of the installation, the filter, device for breaking down of hang-ups. For input into the bin, the products pipeline has the special dressing in the front and rear walls. The bin is connected with the screener by the connecting pipe with the cut-off plate, which serves for the flour feeding control.
The filter serves for separating the compressed air from the flour and exhausting it into the atmosphere. It consists of two (upper and lower) concentric combs, between which the fabric is tightened. The lower comb is connected with the shaking mechanism for periodic cleaning of the filter fabric from the flour dust.
4.3.4. The flour screener is a hexagonal reel installed on the same shaft with the feeding worm. The reel is placed in the body shell, which has: the cover with sealing and two locks, which is opened on joints, the connecting pipe for feeding into the receiving bin with the fold-out blocking and the connecting pipe with the cloth sack for






1-         flour storage bin A1-PHZ-1 01.000;
2-         grinder feed screw portable A1-PHZ-14;
3-         grinder feed screw A1-PHZ-2;
4-         bin receiving A1-PHZ-1 02 000;
5-         body shell of the screener A1-PHZ-1 03000;
6-         drive gear A1-PHZ-1 04000
7-         feeding products pipeline;
8-         connecting pipe pellucid A1-PHZ-25 000.10;
9-         flour batcher A1-PHZ-25;
10-       return products pipeline;
Inscriptions At bottom: Flour Discharge


Inscriptions: from the top downward:
Connector A
Connector B
 At bottom: Flour Loading


Figure 3. Schematic diagram of flour feeding
Note: The arrow designates air supply from the air main.




collection of screened out admixtures.
4.3.5. The installation drive gear consists of: the flange electric motor, reducer and shaft, which is a shaft simultaneously of the feed screw and reel.
The drive gear reducer is a single-stage, worm one. One end of the worm screw is connected with the motor shaft by means of the elastic coupling, and a hand crank is fixed on the second end for barring of the shaft manually. For the purpose of maintenance safety, the hand crank is closed by the fold-out housing.
4.3.6. The receiving bin serves for intermediate arrangement of the sifted flour at the further feeding it through the grinder feed screw into the batcher, as well as for loading of the flour manually from sacks for feeding through the grinder feed screw into the flour storage bin. The receiving bin consists of the housing, cover with the sealing and lock opened on joints, and the lattice preventing penetration of coarse impurities into the grinder feed screw.
4.3.7. Specifications of the installation for flour reception, storage and feeding:
а) capacity of the receiving hopper, m3
0.18;
b) capacity of the flour storage bin, m3
0.6;
c) number of the feeding worm revolutions, rev/min
36;
d) diameter of the feed screw, mm
120;
e) screener productivity, kg/hour
900;
f) electric motor
 - type

АОL 22-4;
 - power, kilowatt
0.4;
g) mass, kg
244.

4.3.8. The grinder feed screw is intended for the flour reception and subsequent feeding by the pneumatic conveying method into the storage bin or into the flour batcher. It consists of the flour feeding chamber, aeration chamber and drive gear.
The flour feeding chamber represents the pipe with the bin connected with the discharge opening of the receiving hopper. One pipe mouth is fastened to the aeration chamber by means of a flange, and another serves as an output of the feed screw shank located inside this pipe.
The aeration chamber consists of the body, which is connected by means of a flange with the bottom, the rotary valve with pull-rod and hand lever, and the aerating partition. The hatch for cleaning, the cock for the condensate discharge are mounted on the chamber, and the back-pressure valve is hingedly suspended on the flour input,



which prevents penetration of the compressed air through the grinder feed screw into the van body.
The aerating partition is installed between flanges of the body and bottom, and the rotary valve is installed in the upper part of the body, the control pull-rod of which is placed inside the body. The compressed air is fed to the chamber bottom, and the upper part of the body has two outputs for mixture of the flour with the compressed air. One output is connected by the products pipeline with the flour storage bin, and second one - with the flour batcher. Feeding direction change is conducted by turning the hand lever of the valve control pull-rod. If the flour discharge is required from the storage bin, then the connecting pipe of branch pipe of flour feeding into the batcher is closed in the upper part, and discharge is made through the rubber-fabric sleeve disengaged from the connector B.
The feeder drive gear consists of the electric motor and double-grooved V-belt transmission from the motor shaft to the feed screw.
4.3.9. Specifications of the grinder feed screw:
а) productivity, tonnes/hour                                        0.9
b) diameter of the feed screw, mm                              60
c) number of the feed screw revolutions, rev/minute     565
d) diameter of the products pipelines, mm                   38
e) electric motor
type                                                                АОL 2-21-4
power, kilowatt                                                         1.1
f)  mass, kg                                                               64.
4.З.10. The portable grinder feed screw allows making a mechanized loading of the flour into the baking unit system from the tent of subsidiary assignment, where the flour is stored, or from the body of a motor vehicle delivering the flour, at a distance about 3-4 metres.
The portable grinder feed screw consists of the bin, feed screw, aeration chamber, two demountable rubber-fabric sleeves, support frame with two carrying handles. A canopy closes the bin from above.
The feeder is driven with the individual electric motor, having the power of 1.1 kilowatts, through two V-type belts. For tightening of the belts, a part of the frame, on which the electric motor is installed, is made as a slider part.
Control of operation of the portable grinder feed screw is realized by means of a packet-type switch installed on the control panel;



The control panel has two plugholes, one of which is connected to the portable bushing cable, and the second one – to the electric motor cable. The bushing cable is connected by the second end to the terminal box located outside – on the front wall of the body. Lighting up of the signalling lamp indicates energising of the control panel. Presence of the second plughole allows connecting portable electro-driven tools to the control panel of the portable grinder feed screw (during unhooking the electric motor cable) during conducting operations out of the van body shell.
The flour is loaded from sacks into the bin and, having passed through the lattice in the central portion of the bin, enters the feed screw. The feed screw feeds the flour into the aeration chamber. The compressed air is delivered into the bottom part of the chamber by means of the demountable rubber-fabric sleeve with the length of 5 metres, from the air network of the baking unit (connector A). The mixture of the flour and compressed air is delivered by means of the same sleeve from the upper part into the flour storage bin (connector B).
4.3.11. Specifications of the portable grinder feed screw:
а) productivity, tonnes/hour                                       1.6;
b) diameter of the feed screw, mm                              60;
c) number of the feed screw revolutions, rev/minute     910;
d) diameter of the products pipelines, mm                    38;
e) electric motor
type:                                                              AOL2-21-4;
power, kilowatt                                                        1.1;
f)  outline dimensions, mm
length                                                   1090;
width                                                    825;
height                                                   790;
g) mass, kg                                                              70.


4.3.12. The portioning volumetric batcher for the flour (see general schematics of the batcher below) is intended for batching the flour for mixing the starter cultures, sponge dough and dough.
The batcher design provides sequential execution of the following operations:
а) receiving and batching the flour to the specified volume;
b) automatic cut-off of feeding into the batcher and switching of its delivery to the return mainline in the flour storage bin;
c) cutting off of electric motors of the batcher and grinder feed screw;
d) switching of the air supply under the aerating bottom and output of the measured flour batch.
4.3.13. The basic part of the batcher is a volumetric glass formed by the cylindrical body 8, to which on flanges are connected from above: the cover 7 and charging section 9 with input and output connecting pipes, and from below - the cover 10 (see the batcher itemised schematics on the batcher itself) with aerating and discharging devices.
The upstream end of the charging section is sequentially connected with the pellucid connecting pipe 1 of the products pipeline and the changeover cock 2. The connecting pipe of the bottom discharge is connected with the pressure-pneumatic chute 17 for delivery of the flour batch into the next dough dish.
There is the round hatch 3 with the hinged hermetical cover in the wall of the batcher body – in the front part on the midpoint of its height, which serves for visual inspection, reconditioning and periodic prophylactic cleaning of the batcher chamber.
The hatch cover is locked by the limit switch VK-6 included into the control circuit of the electric motor of the air blower, thereby eliminating the possibility of opening the hatch in the presence of pressure inside the batcher, as well as preventing start-up of the air blower at the open hatch.
Near the hatch, to the left of it, along all the height of the batcher body, there is the pellucid viewing window 4 with the scale 5 and two sliders for setting the reference mark of the set batch values.
The box with the automobile lamps is mounted on the cover 7 for illumination of the chamber aimed at convenience of observation of the course of batching and discharging process.
Also, the lever device is mounted on the cover for winding and fixing with the latch 25 of the batch cut-off device 32 located in the channel of the charging section.
The pushing electromagnet 26 is mounted near the latch 25, conducting its shut down upon receipt of the signal from the limit switch of the of the batch cut-off transmitter.
The thrust block 34 is hingedly connected with the free end of the lever 27. This thrust block is effected by the lever of the changeover cock 2 at its switching.
The batcher drive gear is mounted in the centre of the batcher cover. It consists of the worm reducer 11 with the flange electric motor 12 that actuates the drive shaft 13 with the impeller 20 and bottom cleanout device 22.
The reducer consists of the cast body with the cover, with the flange electric motor mounted to the cast body, which shaft is connected through the bushing with the rolling pin  imbedded with its second end in



the spherical ball-bearing and leaning by the face on the footstep bearing with the ball and stop screw. The worm screw is freely mounted on the rolling pin. There is a slot on the worm screw face, which engages the protuberance of the bushing. The worm screw has the possibility of a longitudinal travel. The worm screw has an undercut on the opposite end with two bearing ribs, between which mounted on the reducer cover.
The double-arm lever (24 see itemised schematics on the batcher itself) is rigidly fixed on the external end of the lever shaft, with one shoulder of which the tension spring 30 is connected (see itemised schematics on the batcher itself). And the second shoulder has a protuberance, which can impact the pusher of the microswitch 35 (VKZ) at turning of the lever.
For filling and discharge of oil, the oil pressure pipe 29 is provided, being connected to the reducer body at the bottom level and mounted towards the batcher maintenance side. The T-connector with the fill plug and drain plugs is screwed on the pipe end, which ensures filling of the body with oil to a necessary level.
The upper end of the drive shaft 13 (see itemised schematics on the batcher itself) passes through the reducer along the vertical axis. The worm wheel hub is dressed on the shaft. The hub is connected with the shaft by means of the cam clutch.
During batching, the worm reducer rotates the drive shaft clockwise (looking from above). At shifting the impeller to a set level on the scale, the electric motor can be reversed. At the cleanout of the bottom, the shaft rotates anti-clockwise.
The central portion of the shaft represents the screw having acme thread almost along all its length corresponding to the height of the cylindrical part of the body of the batcher 4.
The threaded part of the shaft has keyways on four generatrixes along all the length of the latter.
The shaft enters by its lower end - cylindrical fluting - into the vertical bearing in the body of the outlet valve 16.
The operating impeller of the batcher is located on the threaded shaft section. The impeller has three horizontal radial operating blades.
The impeller level indicator 15 is fastened to the impeller hub by means of the plate. Two rubber cleaning devices are fastened on its ends for cleaning the glass with a scale from the flour.




The lower edge of the indicator lays in a plane of the lower blade edges, and installation of the impeller on the required scale mark is defined by the edge.
The hub of the impeller is cut lengthways and is sitting on the threaded part of the shaft by means of the split screw nut having the acme thread corresponding to the shaft thread. Both halves of the impeller are fastened together with two tightening screws 21 with springs.
For transfer to the impeller of the torsion torque, the cross tongue, which is mobile in the radial direction, is placed in one of the hub halves, moving along the prismatic guides of the body and forming an integral unit with the hub.
The joint tongue is linked with the hinged arm 14, which at rotation of the shaft, depending on a position of the locking guide bar 19, can either pass by the guide bar, or rest against it. At resting against the guide bar, the lever is folded at the joint and draws out the joint tongue from the shaft slot. In this position at rotation of the shaft, the impeller freely moves on the shaft thread upwards or downwards, depending on the direction of its rotation. Turning of the guide bar is made by the handle 18. At turning of the guide bar, the handle 18 is sliding at first in the horizontal section of the slot, and then, as needed, can be shifted either in the upper, or in the lower section of the T-junction. At that, either the upper, or the lower limit switch (VK-2 or VK-7) is turned on, ensuring reversing of the batcher, and consequently, the impeller movement accordingly upwards or downwards. Upon reaching by the lower edge of the impeller indicator of the pre-set scale mark indicated on the pellucid window glass, the handle 18 is released, and it returns to the initial position under the influence of the spring. After that, the lever is straightened, the joint tongue again enters into the shaft key, and the impeller is connected with the shaft. The electric motor of the batcher is simultaneously disconnected.
If at shift of the impeller along the chamber height, the joint tongue of the lever has not entered into the shaft key and has not fixed the impeller on the shaft, then by short-duration turnings on of the electric motor, pressing on the button 43, one should either achieve fixing of the impeller on the shaft, or open the access hatch and manually tighten the impeller till entering of the joint tongue of the lever into the shaft key.
The batcher hanger unit is fastened to the cover on the fixed members. Under the upper cover of the batcher, the charging section 9 (see itemised schematics on the batcher itself) is arranged with the arc-wise channel of the right-angled lateral section for input of the sifted flour in the mixture with the compressed air. The flour moves by the pneumatic system from the grinder feed screw A1-PHZ-2.
The channel is laid on the circular arc of the inner section wall and goes outside tangentially by the connecting pipe, which is connected to the return mainline of the products pipeline leading to the bin A1-PHZ-1.




Immediately behind the upstream end, the channel has the section with the side window opened inwards the chamber. This window is closed by the rotary cut-off device 32 (See itemised schematics on the batcher itself) opened inwards the channel, and at that, the air-flour flow switch movement into the chamber. In this position, the cut-off device fits tight the walls of the channel along its perimeter, thereby protecting from the flour penetrating and depositing in the channel behind the valve.
A hole is cut in the upper (horizontal) channel wall in front of the outlet fitting, which is closed by fold-out rubber valve 36. The valve is opened under pressure of the used conveying air going from the batcher chamber into the return pipeline, and is closed at blowing-down, when the batching is completed, and the valve of the cut-off device is closed.
The changeover cock represents the double plug valve with the cylindrical plug and serves for opening and closing of the input channel for feeding of the pure compressed air under the aerating bottom and the pressure-pneumatic chute at discharge of the batcher.
In order to avoid negative aftereffects from incomplete turn of the cock plug (clogging of the products pipeline, etc.), automatic interlocking of the batcher and the grinder feed screw is provided, which is realized by means of the limit switch closing the control circuit only at a correct position of the plug.
The outlet valve 16 is located in the central part of the aerating bottom of the batcher and serves for opening and closing of the discharge outlet. The valve is guided in the discharge outlet with four ribs and sealed along the seat edge by the conical rubber ring.
The central valve part contains the sealings, lower bearing of the shaft and valve sleeve 38 with the spring-controlled footstep bearing 39, the spring of which ensures initial tightness of the valve fit against the seat.
Prior to mounting, the valve sleeve 38 is topped up with oil, so that at stroke of valve, the oil is partially displaced upward up by the lowering footstep bearing 39 and moved into the oilway for lubrication of the lower end of the shaft.
Oil excesses are inadmissible, as they could be displaced outside on the valve surface and get into the flour and on the surface of the bottom made of cloth.
The valve stroke is made by turn of the hand lever 23. The eccentric 40 is mounted on the same shaft with the hand lever. At turn of the shaft, the eccentric rests against valve sleeve bottom 38 and lifts the valve.



For removal of the flour residues from the batcher walls and bottom after discharge, the special mechanism is provided with two brushes 22, which are fixed by means of the driver pin on the bushing with cams. The bushing is loosely fitted on the shaft 13. The spider 42 with cams is rigidly fixed above the cam bushing on the shaft 13. At stroke of valve 16, the bushings are meshed by cams, and brushes are rotating together with the shaft. Start-up of the shaft is carried out by pushing the button 43 and holding it in the depressed position during the entire cleaning process.
The lower cover of the batcher with the aerating bottom consists of the base - the conical bottom with external and internal flanges.
The ring is clamped between the external (big) flange and the lower flange of the cylindrical body of the batcher, to which the edge of the conical aerating fabric bottom is fastened. The internal edge has the collar dressed on the exhaust neck and fixed on it by the hose clamp with the thick rubber gasket.
In an assembled form, the bottom made of cloth (of a fabric of a high aerodynamic resistance) should be strongly tightened. For best support of the bottom form, 8 rods are sewed in into it along cone generatrixes.
The rotary neck is mounted to the lower flange of the bottom. The pneumatic chute 17 is suspended on the rotary neck by means of two hooks.
For fixing of the pneumatic chute in operating and folded-back positions, the spring clamper is provided.
Besides, the output end of the pneumatic chute can rise, turning about the horizontal axis, which passes across the connecting pipe.
4.3.14. Interacting of mechanisms of the batcher at its operation occurs as follows (in the process of carrying out production operations).
The cock plug is installed by rotation of the hand lever 33 of the changeover cock 2 by the angle 90° (to yourself) into the position of the batcher loading (an arrow on the axis of the cock plug is directed along the products pipeline axis). At that, the channel “products pipeline-batcher” is opened. The cock plug closes normally open contacts of the limit switch VK-1 blocking start-up of the batcher.
By pressing ”Start-up” button (KN2), the air blower is turned on, by pressing KN4 button – the screener is turned on. The toggle switch of illumination is turned on. By pressing KN5 button, the batcher and grinder feed screw are turned on. Flour feeding and batcher loading are beginning.



In the course of the batcher loading, the conveying air from the batcher is removed into the return mainline through the valve 37.
When the flour level approaches directly to the impeller, the blades are raking up, compacting and levelling the flour. The flour is filling wedge-shaped cavities under the blades and is wedged between the blades and compacted surface of the flour.
The torsion torque on the shaft of the worm sprocket reducer is increasing sharply, and reactive force, which is acting along the worm screw, displaces it with stretching the balance spring 30.
The second lever end effects the microswitch 35, which engages the pushing electric magnet 26 of the cut-off device lever, and the pushing electric magnet rotates the latch 25. The latch releases the lever 27, and the spring 36 rotates the lever, and the cut-off device together with it into the closure position. Air-flour mixture is directed towards the internal by-pass canal of the charging section and further through the return products pipeline to the flour storage bin А1-PHZ-1.
After that, the blow-down of the products pipeline is conducted with the air from the air blower continuing to act. One can notice termination of the blow-down, observing the flour movement in the pellucid connecting pipe 1.
After the cut-off and termination of the blow-down, the hand lever of the changeover cock rotates by 90°. At that, the air supply into the batcher will stop, and the channel will be opened for air supply under the aerating bottom.
The hand lever pushes the end of the lever 34 with its opposite end with a roller and places it on the latch 25 – the cut-off device 32 will open access to the batcher for conducting of the following loading cycle.
The cock for air supply into the pneumatic chute is opened.
Pull to the full extent a hand lever of the eccentric 23 for opening the valve. The flour starts to discharge that should be observed through the window of the body.
After termination of the flour discharge by gravity, push the button 43 without releasing it. After completion of cleaning the bottom by brushes (22) and removal of the flour residues, release the button and close fully the discharge valve.
Shake two-three times the pneumatic chute for removal of the flour residues and take aside its discharging end.
Upon termination of operation, the air blower (by Kn1 button) and illumination are turned off, the air supply cock on the main branch line is closed.





4.3.15. Specifications of the flour batcher

а) maximum batch:
by volume, litres                                           80
b) minimum batch:
by volume, litres                                           20
c) inaccuracy of batching, %                                       up to ± 2.5
d) electric motor
type   AOL-12-4
power, kilowatt                                           0.08
e) mass, kg                                                              108.

4.3.16. Products pipelines are made of duralumin tubes with the inner diameter of 38 mm. As a matter of cleaning convenience, the entire products pipeline is assembled from separate pipe segments, which are connected together by couplings. Aimed at flour movement observability, a section of the products pipeline before the batcher is made of the pellucid organic glass 8.


4.4. Doughing plant
Figure 5. Doughing Plant (side-view)
1 Dough mixing drum
2 Carcase with the bin.
3 Dough dividing head
4 Conveyor
5 Stabilisation mechanism
7 STOP Button - dividing head
4.4.1. The doughing plant is intended for mixing and fermentation of the starter culture (sponge dough) and dough, batching of the starter culture and dough dividing into equal mass lumps.
4.4.2. The plant consists of the rotor five-drum conveyor 1, receiving hopper 2, dough dividing device 3, mechanism of stabilisation of the drum dough trough 4, mounting pedestal with the roll drive 5 of drums and separately installed conveyor rotation drive 6.
4.4.3. The dough trough conveyor represents a rotor welded from tubes, which is rotating in the vertical plane. The horizontal shafts of five kneading and fermenting dough troughs of drums are mounted in the bearings placed at ends of the rotor spokes in cantilever fashion. The conveyor is rotating on bearings round the central shaft. The drive gear of the conveyor consists of the frame, electric motor, V-belt transmission, reducer and sprocket meshed with the pin-wheel installed along the rotor perimeter. Turning on of the drive gear of the rotor is reversible, i.e. it can rotate both in a clockwise direction, and counter-clockwise.
4.4.4. The dough dish-drum consists of the welded body of the spherical form with hermetically closed detachable cover. Leakproofness is attained at the expense of the rubber gasket and three locking devices located at an angle of 120° against each other and with heads tightened with a special wrench. There is a valve on the cover for exhaust of gaseous products of fermentation. In the dough dish, two blades are fixed by means of locking bolts. At lateral sides, along the transverse axis, the drum has welded flanges with wrist pins and with holes for fixing of the drum in a certain position. The drum is installed by wrist pins on the fork and can rotate manually about the axis, which is passing through points of support. Fixing of the drum in the necessary position is carried out by means of the spring-controlled arrester of the turn, a dowel of which enters into holes on the drum flange.
Figure 5. Doughing Plant (back view)
6 - conveyor drive
8 - lever for stopping dividing head drum rotation
9 - dividing head rotor
10 - dividing head engaging mechanism

Each drum, except for the manual rotation about the transverse axis, can mechanically be rotated round the longitudinal axis at the expense of rotation of the fork, which has been connected with the fulcrum pin.
4.4.5. The roll drive of drums consists of the electric motor, worm reducer and chain drive (the schematic diagram A1-PHZ-4 ).
The rotation is transmitted from the worm reducer through the chain drive to the sprocket of the unit, which is loosely fitted on the central shaft of the plant




and consists of two sprockets and the gear half-coupling. The second sprocket of the unit is connected through four intermediate sprockets by the chain drive with the sprockets installed on fulcrum pins of drums. One of the intermediate sprockets has a device for regulating the chain tension.
The power-driven sprockets are installed on fulcrum pins of drums on the bronze bushings. Torque transfer to the shaft is carried out at the expense of joint of the cam half-couplings, one of which is connected with the sprocket, and second one is fixed on the fulcrum pin of the drum. Turning on of the coupling is made by spring-controlled pull-rods with a bayonet fastening.
At switched-off state, the cam half-coupling by its slot falls on the protuberance of the suspension arm of the stabilisation ring and fixes the drum fork in the horizontal position - irrespective of rotation or non-rotation of the conveyor.
4.4.6. The dividing device consists of the receiving hopper, dividing head and drive gear.
The bin is made of the sheet steel and represents a capacity of the prismatic form with the angled side walls, located in the central space between the drums. The central shaft of the doughing plant passes through the tube, which has been welded to the end walls, and the feed screw is located in the bottom part of the bin. The dough dividing head with the mechanism of the drive gear is mounted on the front side of the end wall.
The dough dividing head represents the hollow drum, in which the through-the-thickness tube is welded in the direction perpendicular to the rotor shaft. The freely movable piston is mounted in the tube on the feather key. The piston consists of two parts, which are connected with the shaft. By rotating the shaft with the special key, it is possible to draw together or apart parts of the piston, thereby changing a volume occupied by the piston in the tube. The free space of the tube is filled with the dough and defines its weighing out. The range of a possible adjustment at the expense of rotating the shaft is restricted, therefore, there is a replaceable piston and three shafts in the set supplied. The rotor together with the piston is mounted in the cylindrical body of the dividing head, which has the hole for input and output of a twine of dough.



Turning on of the dough dividing device into operation is conducted by the lever located in front of maintenance of the doughing plant, at the lower and left part of the dough dividing head. In an extreme left position of the lever, the dough dividing device is turned off from operation, in the extreme right position it is turned on.
The pinion gear is mounted on the central shaft on the joint tongue. It is meshed with the pinion gear installed on the shaft of the drive gear of the feed screw. The feed screw with the shaft are connected by means of the shank with the wrist pin. That allows pulling out or installing it with a little effort. On the front end of the central shaft, the pinion gear of the dividing head drive gear is mounted. It is meshed with the pinion gear of the single revolution clutch, and the latter is meshed with the pinion gear of the rotor of the dividing head.
Turning on of the single revolution clutch is carried out automatically by means of a system of levers and spring-controlled rotary joint tongue only after filling with dough of the pre-set volume of the cylinder, and shut down is carried out during the moment, when the rotor is installed into a position of the pumping beginning.
4.4.7.        Specifications of the doughing plant
а) productivity, tonnes/day (by dough)
at production of rye or rye-wheat bread                                          2.84;
at production of 1st Grade wheat white bread                                  2.84;
b) number of kneading drums, pieces                                              5;
c) capacity of the kneading drum, litres                                           140;
d) capacity of the bin for dough,     litres                                        120;
e) productivity of the dividing head, lumps/minute                          15;
f)  limits for weighing of dough lumps:
at production of the rye dough, kg                                                 1 to 2;        
at production of the wheat dough, kg                                             0.8 to 1.5;
g) number of the kneading drum revolutions, rev/minute                  12.0;
h) number of the feed screw revolutions, rev/minute                        56.3;
i)  time of full turn of the conveyor, seconds                                   26.5;
j) electric motor of the rotary drive for the drums and dividing head
type                                                                              AOL2-21-4;
power, kilowatts                                                            1.1;



k) electric motor of the rotary drive of the conveyor
type                                                            A0L2-11-4;
power, kilowatt                                           0.6;
l) duration of mixing, minutes                                     up to 10;
m) mass, kg                                                             1115.
4.5. Rack
4.5.1. The rack is intended for installation of baking tins with the dough for proofing before oven loading, and for intermediate arrangement of one bread made lot. There are four drawers for arrangement of the stock and instruments of first necessity in the bottom part of the rack, as well as the section for installation and mounting of the scales with the set of weights.
The compartment for proofing is located in the left upper part of the rack and represents the guides welded on the framework for installation of the baking tins. Each pair of sections of the bread tins is fastened in the slot with one spring-controlled rotary clamper.
The compartment for bread stacking is located below and to the right of the proofing compartment.
Rear and side walls of the rack are made of veneer, and the front one is closed by blinds. For prevention of penetration of cold air into the rack, the left vertical and upper edges of the rack have the rubber valves.
4.5.2. Specifications of the rack
a) capacity of the dough proofing compartment, pieces of baking tins                  90;
b) capacity of the bread arrangement compartment, pieces of round loaves 90;
c) mass, kg                                                                                          178.
4.6. Fuel feeding arrangement
4.6.1. The fuel feeding arrangement is intended for storage of the current store of a wet (diesel) fuel and feeding it to the injector of the bakery oven.
4.6.2. The fuel feeding arrangement consists of the fuel tank mounted on the outside of the front end wall of the body shell, the pump, which is mounted at the same location, for manual injecting of the fuel with the suction hose and discharge hose, and the system of fuel lines with the shut-off cock. The geometrical capacity of the tank is 60 litres, process capacity (with the diesel fuel) is 40 litres.



The fuel tank in the upper part has two adapters closed by blind plugs – the left one with a filter for possibility of fuel filling through the funnel at failure of the manual pump, and the right one with the fuel level indicator of a float type. There is the adapter with the T-connector in the bottom part. The fuel line is connected to the side branch pipe of the T-connector, and the fuel drain from the tank is carried out through the lower branch pipe, which is closed by the blind plug.
For fuel injecting, the suction hose is lowered into the fuel tank, the cover is removed from the adapter with the float gauge, and observation of a level is made according to a height of the float gauge stock rise.
4.7. Salt dissolver
4.7.1. The salt dissolver is intended for preparation of the saturated salt solution necessary at the dough kneading.
A saturated solution of the cooking salt is obtained at the ratio of salt and water 1:3. Proceeding from this ratio, the solution dosing from the salt dissolver is made.
4.7.2. The salt dissolver represents a tank of the right-angled cross-section of the welded construction from sheet noncorrosive steel. The tank has the pyramidal bottom ending with the bleed holder latched with the conical rubber plug, which is fitted to the body of the bleed holder by the spring.
Lifting of the plug is carried out manually with the pull-rod, which goes out through the upper cover, which closes the tank top part. Firmness of the cover fit to the upper flange of the tank is attained by means of clamps.
The air inlet pipe is mounted on the cover, and it reaches the tank bottom. The pipe mouth has 6 branch pipes uniformly arranged on the tank bottom; these branch pipes have at the side, which faces the bottom, a series of small holes for the air outlet into the small tank.
In the cover of the tank there is the hatch through whom filling of the tank with water is ma and salt is load. There is a hatch is the small tank cover, through which the small tank is filled with water and salt. The hatch is closed by the cover, which is furnished with the special connecting pipe for tapping the air delivered into the small tank through the tube of the air main.
The demountable cylindrical filter is inserted in the front wall of the tank, in the right bottom part of it, consisting of the filter bowl with holes and covered with the filtrating fabric. The external face wall-flange of the filter bowl is furnished with the drain connecting pipe, on which the rubber tube is dressed, serving for draining of the salt solution into the capacity (measuring vessel) put under it.




Stopping of the solution draining process is conducted by constricting of the rubber tube by the provided screw clip.
Discharge of the mud, which has been accumulated at the tank bottom, is conducted through the lower down-flow spout (in the tank bottom) locked with the conic rubber plug. This tube is also used at washing the tank.
4.7.3. Specifications of the salt dissolver
а) geometrical capacity of the small tank, litres                      30;
b) quantity of the brew solution, kg                                      33.5;
(water volume - 25 litres, salt mass - 8.5 kg)
c) salt dissolution time, minutes                                            8 – 10.

4.8. Water supply system
4.8.1. The water supply system is intended for water delivery into the body shell of the baking unit, for arrangement of the current water reserve, for preparation of water of the required temperature, for batching of water at its delivery for preparation of the sponge dough or dough into the dough mixing drums, for distribution of water for economic needs.
4.8.2. The water supply system consist of: the portable installation of the BKF-4 manual pump, the centrifugal pump (VSN-1M or other brand), the tank for cold water, the tank for hot water of the bakery oven HPK-63L, the water mixer, the water gauge, water mains.
4.8.3. Feeding of water into the cold water tank is conducted from a water tank truck or any other capacity with water. Pumping-in of water is conducted by the centrifugal or manual pump. The manual pump is installed outside of the van body. Connection of sleeves is made to the connector laid outside through the angled wall of the body part, which is located over the bolster-type device of the tractor-trailer unit (connector A).
At pumping-in of water by the centrifugal pump, the connector A is fastened to the suction hose, having the length of 15 m with the filter on the end. At pumping-in of water by BKF-4 pump, its suction hose, having the length of 8 m with the filter on the end, is put down into a capacity with water, and the delivery sleeve, having the length of 4-5 m, is connected to the connector A. In this case, water delivery is conducted by the bypass mainline.
For prevention of the inverse leak of water on the water delivery mainline, the check valve is installed into the tank for cold water. Water delivery is regulated by the cock. For water discharge from the centrifugal pump at operation interruptions in the winter time, the drain cock is installed on it.




4.8.4. The water tank represents a welded right-angled capacity covered with a heat-insulation layer of microporous rubber, cover with calico from above and painted. The tank is installed on the supporting brackets fixed at the upper part of the HPK-63L bakery oven.
The tank is furnished with two hatches with sight glasses.
The cross ridge partition is installed inside the tank for softening of hydraulic shocks during driving of the baking unit. There are tapped holes in the tank for mounting of the downspout and tubes of the water pipeline.
4.8.5. The hot water tank is a constructive element of the HPK-63L bakery oven. Water heating in the tank is carried out with the hot flue gases passing through the smoke duct located in the tank.
For water level control, the tank is furnished with two pet cocks. For steam removal, the steam pipe line, which goes through the roof of the van body outside, is fastened on the tank cover. The tank is furnished with the tapped holes for mounting of the inlet, outlet, drain and overflow tubes.
4.8.6. The water mixer is intended for proportional feed of hot and cold water into the water gauge. It represents a three-way cock with the dual valve actuated with the hand lever with the eccentric. At installation of the hand lever in extreme left position, the hot water is delivered, in the extreme right position – the cold water is delivered; other positions produce the mixture of hot and cold water in different ratios for obtaining of water of the pre-set temperature.
4.8.7. The water gauge is intended for portioned batching of water in the course of the doughing.
The water gauge represents the capacity equipped with the level indicator of the measured batch, temperature indicator, as well as a device for the batcher installation into the vertical position.
The water gauge is intended for operation only during parking. For water dosing, it is necessary to install the batcher into the vertical position by means of the screw, hinged hanger and niveling plummet.
The front wall of the batcher has the scale, by which a value of the required batch is pre-set by means of the screw. At rotation of the screw, the nut with an arrow-indicator is moving along the screw – together with the end of the flexible down-flow tube fastened to the nut. The second end of the tube is connected with the bleed holder in the front wall of the batcher.



A water level and, consequently, a volume of water in the batcher, is determined by a value of rise of the nut along the screw. The signal of obtaining the required volume is beginning of the water outflow from the bleed holder.
Monitoring of water temperature in the batcher is carried out by means of the kerosene temperature indicator with the limit of readings 0 to 100°С.
4.8.8. Specifications of the water supply system
а) volume of the cold water tank, litres                                 65-400;
b) working volume of the hot water tank, litres                     56.1;
c) volume of the water gauge, litres                                               35;
d) batching limits of the batcher, litres                                  4 – 35;
e) scale graduation value of the batcher, litres                       1.
4.9. Air feeding system
4.9.1. The air feeding system is intended for provision with the compressed air of the flour transportation, breaking down of hang-ups in bins, preparation of the salt solution, creation of air draft at the moment of lighting up the oven injector, as well as improvement of the flour output from the batcher and through the pneumatic chute.
4.9.2. The air feeding system consists of the air blower with air filters and with the electric drive, air mains with fitments, vacuum gauge.
4.9.3. The air blower of the automobile engine is used as an air blower. The air blower is installed on the same frame with the electric motor and connected with it with three V-type belts. Intake lines of the air blower go outside through the front face panel of the body part, which is located over the bolster-type device of the tractor-trailer unit, two air automobile filters, which are closed by the housing, are mounted on the intake lines. The spring pressure-relief valve, which is adjusted on pressure of 0.5 atmospheres, is installed on the delivery tube. The vacuum gauge for pressure control in the mainline is installed at the air main, which goes out of the body part, which is located over the bolster-type device of the tractor-trailer unit, into the van body.
4.9.4. Specifications of air feeding system
a) productivity of the air blower, m3/minute                                    1.5;
b) operating pressure, atmospheres                                                up to 0.5;
c) electric motor
type                                                                              A0L2-32-4;
power, kilowatt                                                              3.0;
d) number of the rotor revolutions of the air blower, rev/minute       1140.



4.10. Bakery travelling oven
4.10.1. The HPK-63L bakery travelling oven is intended for bread making and preparation of hot water for technological needs. The furnace design is analogous to the design of the HPK-50 M2 bakery travelling oven, but, taking into account the specificity of use, there are following differences:
Ø  the charge-discharge window is located on the left side of the oven;
Ø  removal of steams of baking losses from the baking chamber is directed not into the chimney, but outside through the vapour removal tube - through the van body ceiling panel;
Ø  the chimney is manufactured in two variants: one (big) for operation during parking, another (small) for operation on the move;
Ø  the hot water tank has the heat insulation;
Ø  clampers for mounting the bread tins are installed on the swinging trays;
Ø  the electric motor with the reducer are fixed on the floor of the van body;
Ø  the cover of the water-heating tank contains the exhaust steam pipe going outside through the van body ceiling panel;
Ø  heat insulation of the oven shell is enhanced.
Specifications of the bakery oven
Number of the baking tins placed on one swinging tray, pieces                           10
Number of the baking tins placed in the oven, pieces                                90
Fuel consumption rate (kerosene, diesel fuel), kg/ton of bread                    64.
4.11. Electrical equipment
4.11.1. The electrical equipment of the baking unit is intended for support of the power supply, control, operation signalling equipment, baking unit equipment, as well as for illumination.
4.11.2. The electrical equipment of the baking unit can be powered with the electric power from the petrol-electric set installed in the body part, which is located over the bolster-type device of the tractor-trailer unit, as well as from the external power supplies.
4.11.З.   The electrical equipment of the baking unit includes:
a) The control panel, hermetic, hinged with the front door, is intended for arrangement in it of the control apparatus, protection and signalling equipment.



b) The transformer bushing cable (A1-PHZ 01.200) is intended for connection of the reducing transformer to the terminal box of the baking unit (through the bushing cable A1-PHZ 01.180).
c) The grounding electrode (EO-55.08.000) and the ground wire (EO-55.09.020) serve for earthing of the bakery plant at operation during parking.
d) 12 V portable electric lamps are intended for illumination in the van body of the bakery plant and in the subsidiary rooms.
e) The kit of the electrical equipment of the baking unit includes also the electrical equipment of separate machines and plants, as well as connecting leads, cables, dividing boxes.
4.11.4. Wiring scheme of the baking unit
Wiring scheme of the baking unit is developed for power supply from the alternate current main having the voltage of 220 V, frequency of 50 Hz.
Figure 6. Wiring schematic diagram

Designation in the Figure in Russian
Item
АВ
Power automatic breaker
АБ
Battery
А1
20A thermal protection automatic breaker
А2
10A thermal protection automatic breaker
В1
General illumination switch
В2, В3
Background  lighting switch
В4
Rectifier unit switch
ВВ
60A-380V input plug input
ВШ
Earthing rod plug
ВС
Selenium rectifier
ВК
Silicon rectifier
ГШ
Earthing rod inlet
D1-D4
Background  lighting
ЛН1
“Network On” neon glow lamp
ЛН2
“Automatic Breaker On” neon glow lamp
ЛС1, ЛС2
Blackout dome lamp
В5
Light transformer switch
П2
Lights switch
П3, П4
Blackout switch
Л1-Л12
Lighting dome lamp
Р1
12V socket
РИ
Pulse relay
РП
Interposing relay
РТА
Traction automatic breaker relay
К1
“Protection Automatic Breaker Check” button
К2, К3
“Signal to Driver” button
А
20-0-20 A amperometer
ТР1, ТР2
220/12 V transformer
ШР
Plug connector assembly




4.12. Preparation of components.
Preparation of components consists in preparation of water of the required temperature, preparation of a salt solution and in yeast dilution.
Water of the required temperature is prepared in the water gauge by filling it in different ratios with the hot and cold water by means of a mixer.
The salt solution is prepared in the salt dissolver by loading salt in it, adding of water and accelerated dissolution of salt by means of the compressed air.
Yeasts manually dissolve in the warm water in a pail.
4.13. The order of operations at doughing
4.13.1. Put the dough dish for components batching under the airslide conveyor of the flour batcher and install it with the cover upwards. Remove the cover and install it into the cartridge for covers.
4.13.2. At barm-making, measure the required batch according to the scale of the water gauge and feed it into the dough dish by means of the hose.
At doughing, measure and load into the dough dish the necessary quantity of the starter culture from the dough dish, in which it has been prepared.
4.13.3. Measure according to the scale of the flour batcher the required batch and feed it into the dough dish through the airslide conveyor.
4.13.4. At doughing, take from the salt dissolver the necessary solution quantity into the salt solution bucket and infuse it into the dough dish.
4.13.5. At barm-making, fill in the diluted yeasts into the dough dish.
4.13.6. Close the dough dish with the cover, draw it aside from the airslide conveyor, install it in the horizontal position and switch on rotation for mixing.
Mixing duration is 7-10 minutes.
4.13.7. After the mixing completion, install the dough dish with the cover directed upwards and leave it for fermentation.



4.13.8. During the fermentation, turn the drum every 25-30 minutes into the horizontal position and switch on rotation (onto knock-back) for the purpose of removal of the carbon dioxide and decrease of volume. Duration of the knock-back is 1-2 minutes.
4.13.9. After the fermentation completion, transfer the dough dish into the upper position by rotation of the conveyor, open the roof, by tipping discharge the innage into the bin.
4.13.10. Pile the prepared bread tins on the floor near the doughing plant. The baking tins, which are subject to filling with dough, are installed on the little table near the dividing head.
4.13.11. Proceed to the scaling dough process. Make check-weighing of first lumps of dough.
4.13.12. Install the baking tins filled with the dough on the rack of the proofing and fix with clampers. Close the rack blinds.
Duration of the proofing is determined according to the technological process.
4.14. Loading, baking and discharge
4.14.1. Install the baking tins with dough in the bakery oven. Make the loading carefully, so that no subsidence of dough could occur, and as fast as possible, so that not to chill the baking chamber. Begin the loading at the left side at manual rotation of the oven conveyor. Mark in any way the first swinging tray loaded by the baking tins.
At baking the rye bread, in 20-25 minutes after the loading, open the steam exhaust valve for removal of excessive steam from the baking chamber, because the cracks can originate in excessively moistened chamber on the surface of the top crust. At baking the wheat bread, the steam exhaust valve is not opened.
4.14.2. Make rapidly removal of the baking tins with the baked bread out from the oven. Moisten the top crust immediately with water by means of the wiper or brush. Begin removal of the bread from the right side, beginning from the first series, which was loaded into the oven.
4.14.3. For knockout of bread out from the baking tins, use the special demountable little table to be installed for the period of bread knockout out from the baking tins on the oven.
4.14.4. Lay the bread, which has been knocked out from the baking tins, into the rack compartment intended for the bread.
4.14.5. Pile the emptied baking tins on the special flooring made of the metal sheet – for protection of the van body floor from damage.
4.14.6. Prepare the baking tins for the further operation.



4.15. Bread making technique
4.15.1. Bread making is conducted by the two-phase dough process method. The dough from the rye and rye-wheat wholemeal flour is prepared on the starter culture, and the dough from the wheaten flour of all Grades - on the sponge dough.
During the production cycle, the starter culture brewed according to the corresponding formula, after the fermentation time specified by the process conditions, is divided by means of the dividing head (or manually) into three equal parts. One part is used for preparation of the new starter culture in one drum, and two parts – for dough preparation in two drums.
At such mode of dough process starter cultures will constantly occupy three dough dishes, and dough - two dough dishes.
At doughing based on the wheaten flour, at first, the sponge dough for the total volume of the drum is prepared. After fermentation, the sponge dough is divided into two equal parts, which are consumed for dough preparation in two drums.
Exemplary formulas and process conditions of barm-making, sponge dough and dough making from the rye flour, wheaten wholemeal flour and from the wheaten flour of the second Grade are specified in Tables 6 and 7.
The formulas account for the doughing from the flour with moisture of 14.5% and obtaining of the bread according to the characteristics specified in Table 5.
Table 5
Grade of Bread
Mass of Round Loaf, kg
Moisture of Bread, %
Output of Bread, %
Rye wholemeal
1.7
51
155
Wheaten wholemeal
1.6
48
149
Wheaten of 2nd Grade
1.4
46
137
Wheaten of 1st Grade
1.2
45
134

                               
                      
            



Table 6

Exemplary formula and process conditions for barm-making and doughing from the rye wholemeal flour
in the baking unit of AHB-2.5 marching bakery plant
(production cycle)
Raw Materials and Process Conditions

Bulk Starter

Dough

Bulk starter in kg
33
33
Flour in kg
38
30
Water in litres
28
25
Salt in kg
-
0.75
Total in kg
99
88.75
Including:


Flour in kg
57
49
Water in litres
42
39
Moisture in %
50.8
52.0
Quantity of the previous phase %
33.33
37.2
Initial temperature in °С
27-28
28-30
Duration of fermentation in hours and minutes
315 - 400
110 - 120
Final acidity number
14 - 15
10 - 11





Table 7

Exemplary formula and process conditions for sponge dough and dough making from the dark wheat (2nd Grade) flour in the baking unit of AHB-2.5 marching bakery plant

Raw Materials and Process Conditions
Sponge Dough

Dough

Flour in kg
44
23
Water in litres
34
10
Dry yeast or compressed yeast in kg
0.35
-
Salt in kg
-
0.6
Sponge dough
-
39.175
Total in kg
78.35
72.775
Including:


Flour in kg
44
45
Water in litres
34
27
Moisture in %
51.57
46.15
Initial temperature in °С
28 – 29
29 – 30
Duration of fermentation in hours and minutes
315 – 330
115 - 120
Final acidity number
4 – 4.5
3.5 – 4








HPK-63L

Bakery Travelling Oven


1. INTRODUCTION

The operating instructions are intended for study of HPK-63L Bakery Travelling Oven (hereinafter referred to as the "oven").

The present manual specifies device description and operating principle of the oven, its constituent parts, as well as the other data required for the maximum use of the oven engineering capabilities.








2. INTENDED USE

HPK-63L bakery travelling oven is intended for baking of panned loaf from rye flour and wheaten flour in field conditions both during parking, and on the march (on the move). The oven is mounted in the van body, therefore, bread making can be conducted in any weather conditions in different seasons and days.

Working capacity of the oven, as well as of its constituent parts, remains unchanged at air temperature in the van body ranging from +5 to +45 °С and relative humidity up to 90% (at the temperature of +25°С).

The oven-surrounding medium should be explosion-proof, should not contain dust or aggressive gases, or vapour in concentrations, which harmfully affect operation of the oven and its constituent parts, as well as the serving staff.




3. SPECIFICATIONS

3.1. The oven capacity at baking the rye bread or rye-wheat bread, weighed out as 1.7 kg/piece at 16 cycles (bakings) per day,
kg/day                                                                                                  - 2500
3.2. Quantity of the conveyor swinging trays, pieces                                 - 9
3.3. Quantity of the baking tins installed on one swinging tray, pieces        - 10
З.4. Total number of the baking tins placed on 9 swinging trays, pieces      - 90
3.5. Volumetric capability of the hot-water boiler, litres                             - 65
3.6. Electric motor of the 4АH80V8UЗ conveyor drive (AOL2-11-4)
- power                                          0.55 kilowatts
- rotational speed                           11.5 s-1 (675 rev/min)
- voltage                                        220/380 Volts.
3.7. The worm reducer 24-80-80-51-1-2 with the gear ratio                      - 80,
the oil volume, which is filled into the reducer gear box (at one time), litres          - 2
- first oil change              - upon 120 hours of the reducer gear box operation
- subsequent oil changes   - every 400-450 hours.
3.8. The conveyor rotation speed             - 0.003 s-1 (0.2 rev/min)
3.9. AF-65M automatic injector with the electric motor (AOL21-4)
- electric motor power                     - 0.27-10 kilowatts
- rotational speed                           - 24 s-1 (1440 rev/min)
- voltage                                        - 220/380 Volt.
3.10. All electric motors are prepared for connection to the 220 Volt main, the current is three-phase alternating current, and the current frequency is 50 Hz.
3.11. The fuel consumption rate per 1 ton of bread, depending on a Grade of baked bread,
а)   liquid (diesel, kerosene), kg                                              - 64-77
(per hour - depending on a injector sprayer number, kg/hour    - 8-12
b)   solid (fire-wood with the moisture content of 21-33%), m3 - 0.5-0.6
3.12. The temperature          of the medium inside the baking chamber at bread baking (depending on a Grade and weighed out portion), °С                                    200... 250
3.13. The time necessary for heating up the baking chamber to the temperature of 250°С at the ambient air temperature of + 18°С, minutes:
а) at operation on the liquid fuel                                          40-50



b) at operation on fire-woods                                              - 60-90
3.14. Leading dimensions of the oven, mm:
а) length                                                                  - 3030
b) width                                                                   - 1650
c) height (without the chimney)                                  - 1635
d) height with the chimney                                         - 2330
3.15. Mass, kg:
а) oven                                                                    - 1406


4. UNITS AND COMPONENTS OF THE ARTICLE

4.1. List of the basic constituent parts of HPK-63L oven.

No.
Designation
Name
Quantity
Remarks
а) mounted parts
1.
HPK-63L 01.00.00
Baking chamber
1

2.
HPK-63L 02.00.00
Conveyor with the drive
1

3.
HPK-63L 02.02.00
Swinging trays of the conveyor
9

4.
HPK-63L 03.00.00
Fire box
1

5.
HPK-63L 04.00.00
Boiler for water heating
1

b) demountable parts
6.
HPK-63L 02.06.00
Conveyor drive
1

7.
HPK-50М2 02.02.00
Chain guard
1

8.
HPK-63L 05.00.00
Steam exhaust pipe
1

9.
HPK-6ЗL 06.00.00
Marching chimney
1

10.
HPK-63L 07.00.00
Stationary chimney
1

11.
HPK-63L 09.00.00
АF-65М injector (with the control panel)
1

12.
HPK-63L 09.03.00
Pipe duct
1

13.
HPK-63L 09.05.00
Thermostatic controller unit
1

14.
HPK-50M2 09.03.00
Filter supporting bracket (assembled with the filter)
1

15.

Roller chain
67
chain links
с) accessories
16.
HPK-50M2 00.00.01
Fire rake
1
In the oven firebox
17.
HPK-6ЗL 03.04.00
Ash pit
1
In the container #2
d) kit of spare parts
18.
HPK-6ЗL
Spare parts, tools and accessories
1
Inventory equipment sheet is attached





5. ARRANGEMENT AND OPERATION OF OVEN AND ITS CONSTITUENT PARTS

5.1. HPK-6ZL is attributed to a type of bakery ovens of continuous operation with a travelling conveyor and with channel heating of the baking chamber with hot gases, which pass from the firebox sequentially through the conic flue tube, vertical gas flue of the hot-water boiler and horizontal gas flue of the baking chamber, and exhausted through the chimney. During passing, hot gases make convective heat exchange, by which the necessary temperature for bread making is attained inside the baking chamber.
5.2. The oven consists of the mounted and demountable main component parts listed in section “UNITS AND COMPONENTS OF THE ARTICLE".
5.3. The baking chamber is intended for immediate bread making in the baking tins installed on the swinging trays, which are suspended on the conveyor tubes. The conveyor with swinging trays and gas flue are located in the baking chamber.
The baking chamber has a form of the regular cylinder with a horizontal axle and consists of the carcase and demountable end walls.
The baking chamber carcase is a welded construction made of angular steel, closed by sheet steel from outside and inside. At that, the internal sheeting is welded to the carcase, and the external one, with a view of repair simplification, is made of single detachable plates and fastened to the carcase with bolts and screw nuts.
The end walls of the baking chamber from inside and outside are also closed by the sheet steel and connected to the carcase with bolts and screw nuts.
With a view of decreasing heat losses, inter-wall space of the baking chamber and face walls is filled with kaolin wool. The gas flue is provided in the baking chamber, in the upper part, for additional heating of the chamber and removal of gases into the chimney. The butterfly damper is installed for regulating the oven draft at maintenance. By means of the hand lever, the damper can be installed at different angles of inclination, augmenting or diminishing the quantity of removed gases.
A device for removing vapour of baking losses is mounted in the upper central portion of the baking chamber.
There is the loading/unloading window of a rectangular form closed by the door on the left side of the chamber. The door is furnished with the hand lever



fixed in an oven marching position by the special spring mechanism.
Supporting brackets with guides are welded to the carcase face corners of the baking chamber, as well as the bearing rods, on which the support rollers and lower limit stops and special supports are mounted, by means of which the baking chamber is fastened to four boot ends.
5.4. The steam discharge tube is intended for steam removal from the baking chamber outside. The steam discharge tube consists of the connecting pipe, special demountable cap and butterfly damper.
5.5. The chimney is intended for removal of waste gases from the oven firebox and regulation of draft at fuel burning. There are two tubes: one is short (730 mm long), which is installed on the oven on the move, and the long one (2700 mm long), which is installed at bread making during parking. The tubes are fastened to the connecting pipe with the special axles.
The conveyor drive mechanism is intended for the conveyor rotation both manually, and from the electric drive. The drive mechanism consists of the pig-iron body with the special bearings, drive shaft with the sprocket wheel rigidly fitted on it (for meshing with the conveyor) on one end, and the second hollow end of the shaft has the rod with a handle and special joint tongue, the hub with a power-driven hand lever and restrainer, the sprocket wheel (for transmission of rotation from the electric drive). In the home position, the drive mechanism is prepared for operation from the electric drive (the home position is considered such a position, in which the hand lever is in the upper position and locked, the rod is in the normal position).
At rotation manually, the lever handle is put into the horizontal position, and handles of the restrainer and rod are pulled to the full extent from the primal position. At that, the joint tongue of the rod goes into the slot of the hub of the hand lever and is fixed in this position, the sprocket wheel, which is connected by the chain with the electric drive, is released from the joint tongue and can run idle (even if the electric drive is powered up), without transmission of rotation to the conveyor.
The rod of the drive mechanism has three fixed positions:
the normal (initial) position - the joint tongue of the rod is inside the slot of the sprocket wheel (rotation from the electric drive); the medium (not operating) position - the joint tongue of the rod is simultaneously in slots of the sprocket wheel and hub (in this position the safety clutch is checked for actuation); and the extreme position, in which the rod is pulled out to the full extent - the joint tongue of the rod is meshed with the hub of the hand lever (manual rotation).




5.6. The combustion chamber consists of the carcase (central gas flue), pig-iron walls, cylinder, fire bar.
The carcase of the combustion chamber of a welded construction consists of the cylindrical housing (firebox) and the conic flue tube. The wide end of the central gas flue is not fixed and can move along the axle at thermal expansion. The combustion chamber with the pig-iron firebox is located in the central gas flue. The firebox consists of the cylinder, rear and front walls. The rear pig-iron wall and cylinder are freely inserted into the firebox housing and fixed by the front wall, which is fastened by studs with brass screw nuts to the flange of the housing and to the face wall of the baking chamber. The fire bar is mounted in the pig-iron cylinder, forming the fire and ash pit chambers. There are the fire-box and ash pit doors on the front pig-iron wall. The same wall has mounted swinging arm for installation of AF-65M automatic injector.
The upper part of the front wall has a hole with the butterfly valve for feed control of the air delivered into space between the firebox housing and pig-iron cylinder.
5.7. The cold air, which is delivered into the inter-wall space, flows around the cylinder, thereby preventing it from premature burn-out, and delivered through holes in the cylinder into the firebox.
For even distribution of heat in the baking chamber, the shield is mounted on the central gas flue (opposite to the door of the baking chamber).
The special pig-iron cone, which protects the central gas flue from burn-out, is put inside a conic part of the central gas flue.
The expanded end of the central gas flue is connected through the seal with the vertical gas flue, which is passing through the hot-water boiler and connected with the upper gas flue.
There is a special heat-isolating housing outside - on the front wall of the firebox.
5.8. The hot-water boiler is intended for water heating up. The water heating up occurs at the expense of the heat received from removed gases. The boiler of a welded construction, which is made of sheet noncorrosive steel, consists of the body and vertical gas flue. The vertical gas flue borders by its lower expanded end with the end of the central gas flue, its upper narrow end goes into in the horizontal gas flue of the baking chamber. From above and from below of the hot-water boiler, there are special access holes for cleaning from ashes and smut of the central and upper gas flues.
In order to avoid full emptying of the boiler during the oven operation, water



is delivered from the boiler through the vertical pipe with the filter. In such a way, it is impossible to drain all water through the cock, thereby protecting the boiler from its burn-out.
The hot-water boiler, the upper and lower gas flues of the boiler are closed by the special safety housings.
5.9. AF-65M automatic injector is intended for liquid fuel burning inside the oven firebox. The liquid fuel (kerosene, diesel fuel) is delivered by gravity through the filter into the injector, where under the pressure of 700-900 kPa (7-9 kg/cm2), which is created with the pump in the injector, delivered through the sprayer into the firebox in the form of ultimate particles, where it is burnt down. AF-65M injector is mounted on the special supporting bracket allowing folding out the injector aside at operation on a solid fuel. At mounted injector, the fire-box door is in the open position.
The injector supporting bracket axle has the limit switch, which disconnects the injector from the main at its turning (folding-back).



6. CONTROL AND MEASURING DEVICES
6.1. For measurement of temperature inside the baking chamber, the glass liquid expansion thermometer, U 8.5.240.201 GOST 2823-73, is applied with the measurement limits 0 to + 350°С.
The temperature indicator is inside the metal body.
6.2. T32-06 thermostatic controller is applied for automatic temperature control in the baking chamber in the range +200 to +250°С.
The thermostatic controller is efficient at the ambient air temperature from +5 to +55°С and relative humidity of 95%; the dead zone is from 2 to 25°С, basic inaccuracy is + 25%, capillary length is 1.5 m.
The thermal phial of the device is inserted into the baking chamber through the hole in the end wall and is fixed by a special adapter, and the device itself is placed in the special box fastened by means of two bolts on the end wall of the oven - to the right side of the temperature indicator.
The operating principle of the device is based on dependence of a pressure of the filler placed in a hermetically closed thermal system, vs. the baking chamber temperature.
Forced cutting off and transfer of the device into the automatic mode is carried out by means of the lever with “Switch on” inscription.
Before beginning of the oven operation, the limb on the thermostatic controller set opposite to scale mark "250" (the temperature of +250°С should be in the baking chamber) and the lever should be put into ”Switch on” position. Adjustment of setting of the thermostatic controller of the given range should be conducted by comparing readings of the temperature indicator and thermostatic controller. At cutting off by the thermostatic controller of the injector before reaching of the pre-set temperature, it is necessary either to diminish plunging of the thermal phial, or to turn the compensator clockwise. At temperature increase inside the baking chamber over the pre-set one, it is necessary to turn the compensator counter-clockwise. In the time in the oven use, it is necessary to watch readings of the temperature indicator and thermostatic controller, comparing them.
6.3. For check of a fuel pressure in the fuel pump of AF-65M injector, which should be 700-900 kPa (7-9 kg/cm2), the pressure gauge MT-4, type 1, GOST 8625-77, is applied.
The one-arrow pressure gauge in the round body (with the diameter of 60 mm), with the flat dial and circular motion of the arrow in relation to the scale. The upper measurement limit is 1600 kPa (16 kg/cm2).



7. ARRANGEMENT AND MOUNTING
7.1. The oven is mounted in the van body of AHB-2.5 automobile baking unit and fastened to the floor with bolts М12. During lifting and moving of the oven during mounting, it is necessary to use the special cramps located on the end walls. Lifting of the oven behind the water-heating boiler is strictly forbidden.
7.2. A plate with the electric drive is also fastened to the floor near the oven (at the left). At that, it is necessary to preserve parallel alignment of shafts of the drive mechanism and reducer.
The driving sprocket and driven sprocket should be situated in the same plane.




8. SAFETY PRECAUTIONS
8.1. The oven maintenance can be conducted by persons, who are well aware of the oven and assembly unit arrangement and method of operation specified in the present instruction and instructions on complete set articles, who have passed instructing in User Safety Rules for Operating Electrical Equipment.
8.2. The oven should be safely grounded. For this purpose, there is a special nut bolt on the electric drive. The place of earth wire connection is designated by the sign "earth". Earth mounting of the oven is conducted at operation during parking.
8.3. It is forbidden to raise the temperature in the oven baking chamber above + 300°С and to lubricate the rotating parts in the baking chamber.
8.4. The rotating muff, chain gear and safety clutch should be closed by demountable guards. Remove these guards for regulation of the safety clutch and lubricant only at switched off voltage (cutting off).
8.5. The electric circuit diagram of the injector should be bonded on the control panel cover of the AF-65M injector.
8.6. The clearance between starting electrodes the AF-65M injector should be 5 mm.
8.7. At transfer of the switch on the injector control panel into "Manual" position, KN button should be necessarily pressed simultaneously with it.
Delay in turning on of the button results in that unignited fuel is delivered into the firebox that could cause ejection of the flame from the firebox.
8.8. At detection of fuel leakage flow in the system, the further injector operation is forbidden till elimination of the leakage flow. For the period of cleaning and replacement of the sprayer (orifice plug), the fuel should not be delivered into the injector.
8.9. It is necessary to clean regularly a hole in the plug of the oil gauge of the reducer.
8.10. It is necessary to keep serviceability of the filter in the hot-water boiler in order to keep always the required water level at open discharge cock in the boiler.
8.11. During sanitary processing of the oven, it is required to avoid penetration of moisture on the electrical equipment.




8.12. For the purpose of noise abatement and vibration decrease of working electric motors of the drive and injector, safe mounting of these units and secure bolt tightening and screw nuts should be ensured.
8.13. It is forbidden:
a) to use the injector at an out-of-order closing valve or without the valve - in order to avoid the fuel penetration into the firebox from the pump and sprayer;
b) to direct the torch of the flame outside the firebox;.
c) to open the window in the injector and touch high-voltage cables in the time of the injector operation;
d) to use means with a smaller electric power for obtaining a spark at faults of the transformer;
e) to keep the fuel and inflammable fluids near to the injector;
f) to use petrol as a fuel;
g) to fill in the heated firebox with water.




9. PREPARATION FOR OPERATION
9.1. Timely and thorough preparation for operation is prerequisite for the successful and uninterrupted operation of the oven and its component parts.
Preparation for operation begins from inspection of completeness, de-preservation and careful visual inspection of all units of the oven, mounting, correct arrangement and connections thereof.
9.2. Check security of attachment of the guides and correct arrangement of the swinging trays of the conveyor. The swinging trays should hang vertically, without distortions and offset, pins of the swinging trays should be between the guides at rotation of the conveyor.
Ensure free rotation of the conveyor, having turned the conveyor manually not less than 9 times. At rotation of the conveyor manually, the switch handle (lower one) should be pulled to the full extent in order to switch from the electric drive to manual rotation. Having convinced in good operation of the drive and conveyor, switch the handle to the electric drive.
9.3. Check integrity of glass of the temperature indicator.
9.4. Check rotation direction of the electric motors of the reducer and injector. At non-conformity of rotation to the directions specified by arrows, it is necessary to swap two wires of phases of the power supply cable on the power board.
9.5. Check operation of the safety clutch on the reducer. For this purpose, transfer the switching handle into the middle position and, by turning the hand lever of the drive mechanism with the force equal to about 45 kg, check actuation of the safety clutch. At that, the chain guard should be removed, one of half-couplings (with three bolts) should be locked. Make adjustment of the safety clutch by tensioning three springs, having tightened up the corresponding screw nuts.
9.6. Check an oil level in the reducer. For this purpose, the reducer cover contains the special screw nut with the pin, on which there are marks of the upper and lower oil levels. If necessary, add winter transmission oil of GOST 610-72 standard.
9.7. Install the chimney (short or long one), having fixed it with the special locking bars. Check opening of the damper of the chimney and steam outlet pipe, as well as of the baking chamber door.
9.8. Before turning on AF-65M injector, verify serviceability of the fuel system, presence of the dissector fastened on the fire bar,



impermeability of sleeve connections, absence of damages in the control panel and inlet wires, check a clearance between electrodes: it should be not more than 5 mm. Push the button and check presence of a spark on the starting electrodes. It is necessary to take into account that the injector should not work for a long time without fuel (1-2 minutes), as the pump lubricant is absent that could lead to its damage.
9.9. Remove air from the fuel pump. For this purpose, unscrew the screw nut by means of the wrench and turn out the plug of the reducing valve a little. When air bubbles disappear and the liquid fuel appears, seal with the plug.
9.10. In the manual control mode, verify correctness of the injector operation. After 10 minutes of operation in the manual control mode, switch operation of the injector to the automatic control mode. For this purpose, transfer the packet switch into "automatic" position, the injector is started, ignition of fuel will occur automatically if the injector has all its component units serviceable. Combustion rate is observed through the viewing window. Colour of the flame should be yellow-white, without fly ash.
9.11. Heat up the oven to the temperature of 250°С, having set the thermostatic controller limb on "250" before that.
9.12. At operation of the oven on solid types of fuel (fire-wood, peat), move the injector downwards so that the fire-box door be freely closed.



10. OPERATING PROCEDURE AND TECHNOLOGICAL PROCESS DESCRIPTION
10.1. The oven is served by the one baker, who is engaged in loading and removal of the baking tins with bread, and monitoring a temperature condition of the baking chamber.
10.2. At bread making, it is necessary to maintain certain conditions, remove uniformly the vapours of the baking losses at baking of the rye bread (in twenty minutes, in the process of vapour accumulation – to open the steam removal tube damper and keep it open for 3-5 minutes).
10.3. The conveyor rotation could be carried out both from manual rotation, and from the electric drive. At manual conveyor rotation, it is necessary to disengage (to pull till release of the restrainer and then rotate by 90°) the restrainer handle (upper one), and disengage the rod handle (lower one) from meshing with the sprocket wheel, i.e. to pull the handle maximally (till coincidence of marks on hubs of the power-driven hand lever and sprocket wheel).
At rotation of the hand lever of the drive by 360°, one of nine swinging trays is placed so that its base for baking tins installation is facing the bottom part of the baking chamber window (moving from below upwards), at that, the conveyor carcase is turning about its axis by 40°, i.e. will make 1/9 part of the revolution.
At the conveyor rotation from the electric drive, the drive mechanism should be in the home position: the restrainer and rod handles - in the normal fixed position, the hand lever of the drive mechanism should be in the upper position at that.
LOADING AND DISCHARGE OF BAKING TINS WITH BREAD SHOULD BE CONDUCTED ONLY AT MANUAL ROTATION AND ONLY IN FIXED CONVEYOR POSITIONS.
10.4. Using the method of simultaneous loading and discharge, all nine swinging trays of the conveyor are loaded with the baking tins with dough in one step. After that, the loaded conveyor in every 7-8 minutes is rotated manually by one swinging tray during all baking time. Upon baking time ending and bread readiness, the baking tins are discharged from the oven. At that, every swinging tray, which is released from the baking tins with the ready bread, is loaded with the baking tins with dough. After bread removal and new loading of the whole conveyor, the baking process is repeated.
10.5. At all listed bread baking procedures, it is required that each swinging tray with the loaded baking tins with dough should make uniformly



a full circle throughout all the baking time and, in such a way, should be exposed to action of the temperatures that are created in the baking chamber in its various areas.
10.6. Start loading the baking tins with dough from the right side of the swinging tray, put the baking tins on the swinging tray carefully – otherwise, the baking tins may fall from the swinging tray and jam the conveyor. Make discharge of the baking tins from the oven in the reverse order.
10.7. Baking chamber door should be kept open only during bread loading and discharge. At that, the temperature in the baking chamber must not drop below 220°C. The temperature fall below the specified value may lead to defective bread.
10.8. The conveyor rotation should be smooth, without jerks. If difficulties arise at conveyor rotation, examine immediately the baking chamber and determine the cause.
The most common cause of this problem is falling down of the baking tins resulted from negligent installation of the baking tins or sharp turn of the conveyor (jerk). In this case, rotate carefully the conveyor in the reverse direction, remove the baking tin fallen or incorrectly placed on the swinging tray.
At jam of the baking tins and impossibility to rotate the conveyor in the reverse direction, rotate it carefully in the current direction, as a result, fallen out baking tin section is moving under the conveyor. After removal of two-three swinging trays, the fallen out baking tin section is pulled out from the oven.
10.9. Oven operation on the liquid fuel, which is carried out by AF-65N injector, can be performed in the automatic and manual modes.
In the automatic mode, after starting the injector, automatic ignition of the atomized fuel is made by an electric spark of high voltage.
Switching on of the ignition device after formation of a flame tongue and re-ignition of accidentally extinguished flame tongue occurs also automatically. In a case of extinction of the flame tongue, the ignition mechanism is switched on at the ignition electrodes located in front of the orifice, the high voltage current is supplied from the transformer, and spark discharge occurs, thereby igniting the atomized fuel.
At restoring the fuel inflow, the combustion process is resumed. If a normal combustion process is not restored, the injector switches off upon expiration of 20 seconds. In this case, the injector turning off is accompanied with alarm signal (red light is on). The injector starting



can be made only after fault elimination. The injector operation in the automatic mode is controlled by the thermostatic controller T32-06, which is mounted under the mercury thermometer and connected with the injector control unit. Upon reaching the desired temperature in the baking chamber, the injector automatically shuts off. The injector ignition occurs again at lowering the temperature in the baking chamber by 20-25°C.
The amount of fuel combusted is adjusted by setting of the respective sprayers. The injector kit includes sprayers No.8 - 2 pieces (one of which is mounted on the injector) and No. 10 - 1 piece. At the automation system faults, temporary operation of the injector can be allowed under supervision of the servicing staff. To do this, put the packet switch into "Manual" position and immediately press "Manual ignition" button. Press the button repeatedly until the fuel lights up. The injector is switched off by the packet switch. The temperature in the baking chamber in this case is controlled by the mercury thermometer.
WARNING! At burning the liquid fuel, the pig iron dissector is fixed in the combustion chamber at the fire bar.
At fault of AF-65M injector, operating the oven can be carried out on a solid fuel. In this case, the injector is folded down, releasing firebox doors, the dissector is removed.
10.10. After operation, it is necessary to put the oven and its components into the initial position:
a) disconnect the electric motors of the injector and conveyor electric drive;
b) stop the fuel supply to the injector;
c) make a thorough inspection of all oven subassemblies, connections, hoses, wiring - in order to start the subsequent work without delay.
10.10. At operation of the oven during winter, after a long interruption in the operation, it is necessary to bring the oven into the operating condition according to the requirements of paragraphs 9.1 - 9.12 of the present technical description.



11. INSPECTION OF TECHNICAL CONDITION

List of basic inspections of the technical condition of the oven.

No.
Inspection Subjects and Instruments, Devices and Equipment. Inspection Technique.
Technical Requirements.

1.
The operating temperature in the baking chamber is checked by means of the mercury thermometer. (Visually).
The temperature should be up to + 250º C.

2.
The constant level of water and cleanliness of the filter screen in the hot-water boiler are visually checked.
The hot-water boiler should be constantly filled by water.
3.
Intensity of the combustion process is observed visually through inspection window in the front wall of the firebox.
The flame colour should be yellow-white.
4.
Formation of fly ash resulted from imperfect combustion is observed according to the smoke exhausted from the chimney.
The smoke out from the chimney should be hardly noticeable.
5.
The fuel pressure is checked with the pressure gauge on the injector.
The pressure should be 700 to 900 kPa (7 to 9 kgf/cm2).
6.
Serviceability of the closing valve is checked visually after stopping of the electric motor.
The fuel delivery from the sprayer into the firebox should stop.
7.
Correct hand lever rotation of the drive mechanism of the conveyor is checked (manually).
Should rotate smoothly without jam.
8.
Correct arrangement of the swinging trays in relation to the tubes and guides is visually checked.
The swinging trays should hang vertically. Hangers of the swinging trays should be located between washers (protecting against longitudinal displacement). The swinging tray pins should be located over (under) shelves of the guides, not touching them.
9.
Working capacity of the electric motors of the injector and reducer is checked (visually).
At turning on of the corresponding buttons, the electric motors should work.




No.
Inspection Subjects and Instruments, Devices and Equipment. Inspection Technique.
Technical Requirements.

10.
Security of attachment and serviceability status of all assembly units is checked by the external examination.
Screw nuts and bolts should be tightened normally, assembly units should be fastened.
11.
An oil level in the reducer is checked with token oil indicator
There should be a constant oil level marked by graduation lines on the indicator.
12.
A state of the starting electrodes and clearance between them is checked by means of a calliper.
The electrodes should be clean, and the gap between them should be 5 mm.





12. TYPICAL FAULTS AND REPAIR

12.1. The list of the most frequently encountered or possible faults.

No.
Name of Faults, External Manifes-tations and Additional Signs

Probable Cause

Method of Elimination
Re-marks
1.
The oven conveyor does not rotate or rotates hardly        

1. One of the guides is disconnected or bent and the swinging trays of the conveyor touch it.






2. There is no gap between the conveyor rings and restrictors (upper or lower ones)


3. Several support rollers do not rotate or rotate hardly, the conveyor slips by the rings on the rollers.
Determine, which guide is weakened, let the oven to cool, remove the swinging tray.
A repairman lays down on the following swinging tray and gently moves towards the damage (rotate the conveyor manually) and puts the guide in place. If this method cannot solve the problem, one must remove the combustion chamber frame and rectify the fault.


It is necessary to pull out the combustion chamber, install gaps not less than 2 mm, assemble.




Pull out the combustion chamber. Remove a support roller, eliminate fault or substitute by the new one.
Replace the central gas flue with the firebox.





No.
Name of Faults, External Manifestations and Additional Signs

Probable Cause

Method of Elimination
Re-marks


4. Jamming in bearings of the drive shaft.




5. Safety clutch nuts are loose.
Pull out the central gas flue, unscrew the drive, having removed before the hand lever and driven sprocket outside of the baking chamber, to eliminate faults. Assemble back the drive and the central gas flue.

Tighten screw nuts and adjust the safety clutch.


2.
Thermometer does not give readings.
Broken thermometer

Replace the thermometer


3.
A bad draft in the chimney.

1. The damper of the gas flue is insufficiently open.

2. Gas flues are choked with ashes.
Open completely the damper.




Clear gas flues.


4.
A hole appeared on the inner or outer casing of the baking chamber or gas flues

From corrosion affect.

Apply patches, weld or rivet them at the place of the hole.

5.
The hand drive is not switched to the electric drive or vice versa.
Squeezed joint tongue or the joint tongue has come out of the nest.

Disassemble the drive mechanism, eliminate the fault and assemble it back.


6.
Oil dribbles in the reduction gear box glands or in junctions of covers
1. Worn out glands or loosened gland nut.
2. Loosened tightening of bolts.
Tighten the nut and, if necessary, replace glands.

Tighten the bolts.





No.
Name of Faults, External Manifestations and Additional Signs

Probable Cause

Method of Elimination
Re-marks


3. Contaminated drainage holes in the oil-level gage plug.

Clean the holes.

7.
The liquid fuel dribbles in the fuel system sleeves.

Loosened mounting of hose clamps.

Tighten sleeves and clench the hose clamps.

8.
Faulty fire bar, cylinder or fire bar walls - back and front ones.

Burned under high temperature influence.
Substitute with the new ones.

9.
Unusual noise and knocking appeared in the reduction gear box,
bearing units became heated up.
1. Incorrect alignment of the shafts of the reduction gear box and electric motor.

2. Increase or decrease of the bearing clearance.
Perform proper alignment of the shafts.





Adjust the bearing clearance.


NOTE: Faults, which are possible at operating AF-65M injector and temperature controller, are described in the attached instructions on these articles.


12.2. For repair or substitution of assembly units or parts, it is necessary to develop such. The development rules are common for all varieties of the assembly units. As exemplified by the combustion chamber and support rollers dismantling, one can develop a standard technique for dismantling a required assembly unit.
а) At substitution of the fire bar, cylinder, rear or front walls, pig-iron cone, it is necessary to remove the injector assembled with the supporting bracket, having unscrewed for this purpose three screw nuts M12 and two crimped locks, unscrew ten screw nuts M12, remove the front wall of the firebox, pull out the fire bar, cylinder, rear wall of the firebox, pull out the combustion chamber carcase, unscrew (or cut down) three bolts М8 of the pig-iron cone mounting, pull out the cone. Substitute the faulty parts, perform assembling under the procedure reverse to disassembling.



b) At substitution of the support rollers, except the operations set forth above, it is necessary to make the following: to release two hose clamps of the mounting of the water tanks located on the rear end wall of the oven, to remove the injector control panel, temperature indicator, thermostatic controller and filter, to remove the chain guard, chain and the hand lever of the hand drive, to remove the flange of the drive mechanism with the sprocket wheel, to remove the oven end wall, having unscrewed 36 bolts with screw nuts, to remove fastening with a cotter pin and remove swinging trays of the conveyor, to unscrew and remove the conveyor restrictors (upper ones), to unscrew the drive mechanism, to pull out the conveyor from the baking chamber, to unscrew and remove the support rollers, to substitute them, to mount into their place. The further assemblage is conducted in reverse order.
12.3. There is an individual kit of transported repair parts for each oven, which is packaged in containers No. 2 and No. 1 used for the oven repair.
12.4. After repair or substitution of assembly units and assembling thereof, the oven operation inspection is conducted according to the requirements of paragraphs 9.2 - 9.11.
12.5. In case of an accident with the oven, it is necessary to turn off all electric motors and power supply cable, clarify a reason and eliminate faults.



13. MAINTENANCE (Procedures and Regulations) AT OVEN OPERATION, lubrication arrangement or lubrication chart
13.1. Maintenance is carried out in order to maintain the oven in constant serviceable condition. It comprises performance of works, which provide:
- Ongoing technical readiness;
- Safety of use;
- Maximizing the time between overhauls and depreciation periods;
- Early detection and elimination of the causes of deterioration and malfunction of components, parts and appliances;
- Minimum fuel consumption.
13.2. The planned preventive maintenance system should be available, which is based on obligatory carrying out a certain amount of work both in the oven operation process, and during its storage and transportation.
13.3. A complex of the maintenance works includes:
- Cleaning and washing of the oven;
- Check a status of the oven mechanisms and devices and eliminate identified faults;
- Mounting and adjustment works;
- Washing, cleaning and refilling the fuel system;
- Control of the proper connections to electric networks;
- Lubrication works;
- Verification of completeness;
- Verification of the documentation correctness and its keeping.
During the oven maintenance, cleaning and washing, lubricating, control-and-verification and mounting works are performed on a mandatory basis, and filling, adjustment and troubleshooting works are performed as necessary. All deficiencies identified during the oven operation are eliminated during all types of maintenance.
13.4. The following maintenance types are established:
- Walk-around inspection (WAI);
- Daily maintenance (DM);
- Maintenance No. 1 (M-1);
- Maintenance No. 2 (M-2);



- Seasonal maintenance (SM).
13.5. Walk-around inspection (WAI) is carried out before starting the work and during the work.
a) Before starting the work, one should:
- Check the reliability of fastening removable equipment guards, injector, boiler and other equipment;
- Clean the outer surface of the oven from pollution;
- Conduct a visual inspection of the oven;
- Check the fuel and water presence in the water-heating boiler;
- Check correctness of installation of the flame spreader, starting electrodes, cleanliness of the inspection manhole and injector photo cells.
- Check connection of the protective earthing;
- Inspect fuel lines and ensure absence of fuel afterdribble;
- Remove air from the fuel system;
- Check smoothness of the conveyor rotation, direction of rotation of the electric motor of the oven conveyor drive and operation of the safety clutch;
- Check operation and direction of rotation of the electric motor of the injector, fuel pump, ensure the closing valve serviceability, absence of a graze contact of the ventilator impeller, correctness of fuel pulverisation and serviceability of the injector automatic system;
- Eliminate the revealed faults.
b) During the walk-around inspection during operation, it is required to:
- Monitor the temperature in the baking chamber;
- Monitor operation of the electric drive of the oven conveyor, absence of oil afterdribble in the reduction gearbox glands;
- Monitor the presence of baking loss vapours in the baking chamber and periodically release them by means of the damper;
- Check presence of the fuel in the fuel tank;
- Monitor through a viewing window of the injector a gap value and correctness of arrangement of the starting electrodes;
- Watch serviceability of the closing valve of the fuel pump of the injector, operation of the electric motor and automatic system of the injector;
- Regulate the fuel burning quality with the choke valve;
- Check operation of the thermostatic controller by comparing the pre-set



temperature on the thermostatic controller with readings of the mercury temperature indicator;
- Monitor presence of water in the hot-water boiler, absence of water afterdribble in joints and cocks of the water supply system;
- Eliminate the revealed faults.
13.6. Daily maintenance (DM) is conducted in the end of the working day (shift), at that, it is required to:
- Clear the oven from pollution and bread residues, clear the firebox from ashes and smut;
- Check security of attachment of the oven component parts, tighten loosened joints;
- Check operation of the damper for removal the baking loss vapour;
- Check mounting of the swinging trays and guides;
- Check chain tension of the conveyor drive of the oven and its guard mounting;
- Check an oil level in the reduction gearbox of the conveyor drive of the oven;
- Lubricate the chain gear of the oven;
- Clear the starting electrodes of the injector and check correctness of their installation;
- Wipe the window of the inspection manhole and photo cells in the photoresistor unit of the injector;
- Check mounting of the ignition transformer and high-voltage cables;
- Inspect fuel lines and eliminate the fuel afterdribble;
- Check presence of fuel in the fuel tank and refuel as necessary;
- Check serviceability of the closing valve of the injector fuel pump;
- Eliminate the revealed faults.
Labour intensity of daily maintenance in man-hours - 1.0.
13.7. Maintenance No.1 (M-1) is performed every 90-100 hours of the oven operation. At this maintenance, it is necessary to conduct all operations specified for daily maintenance, and besides, it is necessary to:
- Clean the mounting baseline from pollution;
- Clean the oven from pollution, wipe greasy surfaces



with the a brass rag moistened in kerosene or diesel fuel;
- Clean from ashes and smut the central, vertical and upper gas flues and chimney;
- Check tension of springs of the safety clutch;
- Clean the fuel filter and injector spray nozzle;
- Check the pressure created by the fuel pump of the injector in the spray nozzle; substitute the pump gasket at pressure lower than 700 kPa (7 kg/cm2);
- Strip contacts of contactors of the relay and switches;
- Check and adjust operation of the automatic system and thermostatic controller of the injector;
- Clear of a scale deposit and wash out the hot-water boiler;
- Check a state of joints of parts and their mounting, state of protective guards, locks, doors; tighten all bolts and screw nuts;
- Eliminate revealed faults;
- Make a record in the service log on the performed operations. The labour intensity of M-1 in man-hours - 4.0.
13.8. Maintenance No. 2 (M-2) is conducted every 270-300 hours of the oven operation. At this maintenance, it is necessary to conduct all operations specified for maintenance No. 1, and besides, it is necessary to:
- Check a gap between the conveyor rings and restrictors;
- disassemble and clear of corrosion the inner surfaces of bearings of the conveyor support rollers and drive mechanism;
- Wash out with kerosene or diesel fuel the reduction gearbox of the conveyor drive and substitute the oil;
- Check mounting of sheets of the outside skin of the baking chamber;
- Check operation of chimney dampers and steam discharge pipe;
- Check mounting of the chimney in marching position;
- Check a state of locks, doors of the baking chamber, guards of the drive and muff coupling;
- Check operation of the photoresistor unit of the injector;
- Check the fuel pulverisation quality, position and gap between the injector starting electrodes;
- Check operation of the switch of injector operating modes;
- Make partial painting of the oven;



- Make a record in the service log on the preformed operations. The M-2 labour intensity in man-hours is 8.0.
13.9. Seasonal maintenance is performed two times a year at preparation of the oven for the summer and winter operation periods. At preparation of the oven for operation during the summer period, it is necessary to perform the scope of works in maintenance No. 2 and, besides:
- Wash out the fuel filter;
- Check an insulation resistance of electric motors windings and, if necessary, dry them;
- Wash out the reduction gearbox casing and substitute the lubricant.
At preparation of the oven for operation during the winter period, it is necessary to perform the scope of works in maintenance No. 2 and, besides:
- Wash out the fuel filter;
- Check an insulation resistance of electric motors windings;
- Wash out the reduction gearbox casing and substitute the lubricant;
- If necessary, make painting of the oven.
13.10. Lubrication of the oven rotating parts should be performed according to the lubrication chart and lubrication diagram (Appendices 7, 8).



14. RULES FOR STORAGE, PRESERVATION AND DEPRESERVATION
14.1. The oven could be put both on short-duration, and on long-term storage.
For the short-duration storage (up to 3 months), the oven is usually put in the field conditions in interruptions between certain operation periods.
At that, it are necessary to perform the following operations:
- to release the water-heating boiler from water and air dry it;
- to remove the chimney (stationary) and put the short one (marching);
- to clean out the injector from smut.
14.2. Before putting the oven for long-term storage, it is necessary to conduct its preservation. For this purpose, it is required to:
а) Remove the injector together with the supporting bracket, control panel and thermostatic controller, clean it out from smut and dust;
b) Remove the front firebox wall, pull out the deflector, fire bar, cylinder and rear wall, clean out from ashes, smut and calx, cover with black MS-17 enamel;

c) Pull out the combustion chamber carcase, detach the pig-iron cone, clean out from smut, cover the cone with black MS-17 enamel, the rest parts – with drying oil natural GOST 7931-76;
d) Clean out the vertical and upper gas flues, inner surface of the baking chamber, conveyor with the swinging trays and all parts in the baking chamber, and cover with drying oil;
e) Lubricate through oilcans the support rollers and drive mechanism with USsA graphite grease;
f)  Clean out the hot-water boiler from a scale deposit, wipe dry and lubricate with the spindle oil AU GOST 1642-75;
g) Replace oil in the reduction gearbox (fill in winter transmission axle oil GOST 610-72), having previously washed out it with the diesel fuel;
h) Remove, wash out the chain and filter in the diesel fuel.
14.3. Assemble the oven. Cover all non-painted parts, joint and open threaded connections with PVK corrosion-preventing oil. Cover frayed areas of the paint and varnish coating with HV-518 khaki enamel.



14.4. Сheck the spare parts and, if necessary, paint or lubricate them with PVK lubricant, place them back.
14.5. Oven depreservation is performed according to the oven depreservation chart (Appendix 9).




15. TRANSPORTATION

15.1. Ovens can be transported by rail, water and combined transport.
Prior to transporting ovens by any kind of transport, it is necessary to make a thorough inspection of all oven parts, check reliability of fastening of detachable parts.
15.2. Oven dimensions conform to the loading outline dimensions of rolling stock of the USSR and conform to the railcar envelope 02-T (appendix).
15.3. Loading of ovens onto the flat wagons is performed ​​by lifting them with a crane by means of their special brackets. Slinging and lifting ovens by means of their other parts is not permitted.
15.4. Ovens in quantity of 4 pieces are mounted on a flat wagon in such a way that they do not touch each other. To prevent movement of the ovens along the flat wagon, each oven is fixed by four guys. Guys (two-thread wire with the diameter of 6 mm GOST 3282-74) are attached with one end to the oven end walls, with the second end – to the flat wagon rack-mountable brackets.



16. MARKING AND SEALING
16.1. The product information plate is manufactured in accordance with the requirements of state standards GOST 12969-67 and GOST 12971-67 and should be attached to the oven body. The plate of rectangular shape. 16.2. The plate should specify:
a) trademark, name of the manufacturer;
b) make of the product;
c) the serial number;
d) year and month of manufacture;
e) technical specification No.
16.3. The water heating boiler housing, as well as the cover of the inventory box are stencilled with black enamel with indication of the oven designation and number, Quality Department acceptance stamp of the factory-manufacturer on the left side in the figure of "circle" and of the customer representative – on the right side in the figure of "diamond".
16.4. The operating manual is attached at the rear end wall of the oven.
16.5. Directions of the drive chain rotation, coupling, injector electric motor are indicated by arrows.
16.6. The earth sign is indicated at the electric drive plate in accordance with GOST 21130-75.
16.7. Marking of shipping containers should be carried out by stencilling in accordance with GOST 14192-77.
16.8. A box with the injector.

                        



17. CONTAINERS AND PACKAGING

17.1. The oven is shipped without packaging.
17.2. Box for spare inventory reusable injector (box No. 1).
17.3. Boxes of spare parts (cylinder wall furnace fire bar, cones) No. 2 and No. 3 are manufactured in accordance with GOST 2991-76 type U1.
17.4. When packing items such as rollers, pins, sprockets, metal products must be wrapped in waterproof paper GOST 8828-75 and stacked in a box GOST 2991-76 Type 1, which is placed inside the box No. 2.
17.5. All items packed in boxes should be securely packed with stringers.

APPENDICES:
1. Dimensional drawing.
2. Kinematic scheme
3. Scheme of flue gas movement.
4. Lubrication chart.
5. Lubrication diagram.
6. Oven depreservation chart.
7. Scheme of oven flexibility in railway clearance.



Dimensional Drawing                                                                     Appendix 1
Layout of Foundation Bolts





Kinematic Scheme                                                                Appendix 2
Inscriptions: об/мин = revolutions per minute;
4АХ80В8У3 = 4AH80V8U3
Редуктор = Reductor Gear Box




Scheme of Flue Gas Movement                                                      Appendix 3




Lubrication Chart                                                                  Appendix 4



Item Name and No. (in Lubrication Diagram)

Lubricating Material Name and Standard No.


Number of Lubrication Points

Lubricating Material Application Technique

Interval Between Inspections and Relubrica-tion


Notes
At Tempera-ture up to Minus 40 ºC
At Tempera-ture up to Plus 50 ºC
For Long-Term Storage
1. Driving sprocket (mounting seat)

Lubricant LVK GOST 19537-74.

1
Lubricant is applied through a lubricating can with a lubricating- filling gun
Every 24 hours

2. Driving sprocket (mounting seat)

The same

1
The same
The same

3. Driving chain

- “ -

1
Lubricant is applied on to the chain surface
- “ -

4. Bearings of electric motors of injector, drive

Lubricant US GOST 1033-73

5
Lubricant is applied manually at assembling
Every 4000 hours

5. Reduction gear box

Transmission “winter” oil GOST 610-72

1
The oil is filled through a hole in the reduction gear box cover
Topping-up to the proper level every 24 hours, first change – in 120 hours, next ones – in 72 hours of operation.
Oil level is controlled by a level gauge




Lubrication Chart                                                                  Appendix 4



Item Name and No. (in Lubrication Diagram)

Lubricating Material Name and Standard No.


Number of Lubrication Points

Lubricating Material Application Technique

Interval Between Inspections and Relubrica-tion


Notes
At Tempera-ture up to Minus 40 ºC
At Tempera-ture up to Plus 50 ºC
For Long-Term Storage
6. Bearings of the support rollers and drive mechanism

Graphite lubricant USsA GOST 3333-55

5
Lubricant is applied through a lubricating can with a lubricating- filling gun
Lubricant is applied only during the oven storage.
Do not lubricate during operation!

NOTES:
1. Prior to lubrication, wipe lubricating cans and lubricated areas.
2. After lubrication, wipe the lubricant appeared on the outer surface of all parts in order to prevent dust sticking to it.





Lubrication Diagram                                                    Appendix 5


1 Driving Sprocket
2 Driven Sprocket
3 Driving Chain
4 Bearings of Electric Motors of Injector and Drive
5 Reduction Gear Box
6 Bearings of Support Rollers and Drive Mechanism (the lubricant is applied only during the oven storage)







Scheme of Oven Depreservation                                          Appendix 6

Name of Depreservation Areas
Operation for Preservation Coating Removal

Remarks
1. The inner part of the baking chamber, conveyor with swinging trays, rollers, drive mechanism.
Oven heating up to the temperature of 300°С.
The baking chamber door should be open.

2. Inner surfaces of the water-heating boiler.
Flushing with the hot water with the temperature of 85-95°C till full removal of the preservation lubricant.


3. Threaded connections and parts of the spare parts, tools and accessories.
Washing in petrol, careful wiping with clean brass rag.







Scheme of Oven Flexibility in Railway Clearance                         Appendix 7