Ross TC700MC, TC700M Operator's Manual

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MODEL TC700MC
TENDERIZER
MADE IN USA
Midland, Virginia 22728 Phone: (540) 439-3271 (800) 336-6010
Fax: (540) 439-2740
MN700-MC0010
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INTRODUCTION
OPERATOR’S MANUAL
MODEL TC700M/MC TENDERIZER
The ROSS TC700M/MC Tenderizer is a blade-type mechanical tenderizer. The ROSS blades are narrow and very sharp so that they actually cut their way through meat tissues and fibers and not merely punch holes by finding paths of least resistance. The special stainless steel alloy blade has a tensile strength of approximately 300,000 pounds per square inch which provides exceptional edge durability combined with extreme toughness. The ROSS Tenderizers can process bone–in meat that is up to 7” high and 12” wide. The most significant technological breakthrough in mechanical tenderizers has been the ROSS system for tenderizing meat with the bones left in.
The ROSS blades are actuated by magnetic head plates so that each blade is actually driven through the meat by magnetic force. These head plates consist of a sophisticated array of rare-earth magnets and special electrical steel pole pieces. The magnets provide just enough force to drive the blades through the toughest meat, but no more. When a ROSS blade hits anything tougher than meat, the magnetic force is overcome and the individual blade simply stops trying to penetrate – the blade is, therefore, undamaged and the other blades are allowed to fully penetrate the meat.
The 700M/MC Tenderizer provides the utmost in safety to operating personnel by incorporating pivoted guards that completely cover the operating area of the Tenderizer. Magnetically operated switches are built in the guard mechanism in such a manner that both guards must be closed before the machine will operate. If either guard is opened while the machine is running, power will be removed from the main motor and all operation will stop.
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SAFETY FIRST!
DANGER –
THIS SYMBOL INDICATES HIGH VOLTAGE INSIDE MARKED HOUSING
THIS SYMBOL INDICATES SHARP KNIFE INSIDE MARKED HOUSING
Take a moment to note the areas on the machine where serious injury may occur if proper safety precautions are not adhered to.
The ROSS Tenderizer has been carefully designed so that during normal use, the operator is never exposed to dangerous moving parts.
The entire tenderizing head is enclosed by stainless steel safety guards that incorporate an electronic interlock switch. The machine will not operate unless the guards are properly closed.
NEVER operate the Tenderizer if the safety guards have been removed or if the electronic interlock switch is not working properly.
NEVER reach under safety guards while machine is running.
If you have any questions concerning the proper, safe operation of your Tenderizer, please
contact your local ROSS Dealer or the ROSS Customer Service Department.
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DAILY CLEANING PROCEDURE
NOTE:
USE ONLY NEUTRAL pH DETERGENTS AND SANITIZERS.
1) Remove Blade Assemblies from machine.
2) Inspect Blade Assemblies and remove any bent blades.
3) Clean Blade Assemblies with a mild neutral pH detergent solution. Blade Assemblies may be immersed in this solution for up to ten (10) minutes.
4) With Blade Assemblies removed, clean entire machine with a mild neutral pH detergent and a stiff brush. SPECIAL ATTENTION SHOULD BE GIVEN TO THE UNDERSIDE OF THE LOWER GUIDE FRAME.
5) Flush Blade Assemblies and machine with clean hot water or steam. All traces of detergent must be removed.
6) Sanitize entire machine using only neutral pH sanitizers.
7) Rinse machine and Blade Assemblies with clean hot water.
8) Liberally spray the Magnetic Head Plates, Blades, Guide Uprights, Main Uprights and Seals with ROSS 601 Oil.
9) Replace Blade Assemblies in machine.
CAUTION:
NEVER USE CAUSTIC CLEANING SOLUTIONS ON THE ROSS TENDERIZER. DAMAGE TO MAGNETIC HEAD PLATES AND SEALS WILL RESULT.
NEVER LET MAGNETIC HEAD ASSEMBLIES SOAK IN CLEANING SOLUTION LONGER THAN TEN (10) MINUTES.
For more detailed instructions on Cleaning and Lubrication, refer to the Operating Procedures
Section of the Instruction manual.
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TABLE OF CONTENTS
INTRODUCTION.................................................................................................................................................................................i
SAFETY FIRST! .................................................................................................................................................................................ii
DAILY CLEANING PROCEDURE...................................................................................................................................................iii
1 SPECIFICATIONS .........................................................................................................................................................1-1
2 DESCRIPTION................................................................................................................................................................2-1
2.1 MECHANICAL .......................................................................................................................................................2-1
2.2 ELECTRICAL .........................................................................................................................................................2-1
3 INSTALLATION.............................................................................................................................................................3-1
3.1 UNCRATING..........................................................................................................................................................3-1
3.2 INSTALLATION.....................................................................................................................................................3-1
3.3 ELECTRICAL REQUIREMENTS..........................................................................................................................3-2
3.4 POWER PHASING.................................................................................................................................................. 3-3
3.5 INSTALLATION CHART.......................................................................................................................................3-4
4 SPARE PARTS................................................................................................................................................................4-1
5 ILLUSTRATIONS...........................................................................................................................................................5-1
5.1 GUARD/SAFETY SWITCH ...................................................................................................................................5-1
5.2 HEAD CARRIER ASSEMBLY...............................................................................................................................5-2
5.3 HEAD ASSEMBLY.................................................................................................................................................5-3
5.4 CONVEYOR DRIVE ASSEMBLY.........................................................................................................................5-4
5.5 CONVEYOR ASSEMBLY......................................................................................................................................5-5
5.6 MOTOR/REDUCER ASSEMBLY..........................................................................................................................5-6
5.7 CAM DRIVE ASSEMBLY......................................................................................................................................5-7
5.8 CAM ASSEMBLY...................................................................................................................................................5-8
5.9 RETURN SPRING/CAM ASSEMBLY ................................................................................................................... 5-9
5.10 TOGGLE CLAMP/RETURN SPRING ASSEMBLY ........................................................................................... 5-10
5.11 MAIN FRAME/ROCKER BAR CAM FOLLOWER............................................................................................5-11
6 OPERATION...................................................................................................................................................................6-1
6.1 MACHINE OPERATION........................................................................................................................................6-1
6.2 CLEANING AND BLADE REPLACEMENT ........................................................................................................6-2
6.3 HEAD ASSEMBLY INSTALLATION...................................................................................................................6-4
7 MAINTENANCE.............................................................................................................................................................7-1
7.1 INSPECTION...........................................................................................................................................................7-1
7.2 LUBRICATION....................................................................................................................................................... 7-1
7.3 ADJUSTMENTS/SPECIFIC REPAIRS..................................................................................................................7-2
7.3.1 CONVEYOR BOX................................................................................................................................................7-2
7.3.2 HEAD HEIGHT ADJUSTMENT.........................................................................................................................7-3
7.3.3 HEIGHT ADJUST CAM MECHANISM..............................................................................................................7-4
7.3.4 RESET PAD/PLATE CLEARANCE.....................................................................................................................7-4
7.3.5 TOGGLE RING REPLACEMENT.......................................................................................................................7-5
8 TROUBLESHOOTING..................................................................................................................................................8-1
9 WIRING/SCHEMATIC..................................................................................................................................................9-1
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1 SPECIFICATIONS
ROSS
PERFORMANCE IN STAI NLESS
WEIGHT 1000 pounds SIZE Length: 52”; Width: 24”, Height: 62” ELECTRICAL
Voltage: The 700MC can be supplied to operate from any of the standard world wide three phase power system supplying from 208 to 575 volts.
Frequency: The frequency can be either 50 or 60Hz. Full Load current: The full load current depends on the actual line voltage and frequency; two examples
are 7.6 amps @ 208 volts, 60Hz and 4.55 amps @460 volts @ 60Hz. Power cord/Plug cap: The 700MC tenderizer is supplied with a power cord made from approximately 25
ft of SO 4/12 cable terminated with an approved plug cap. Machines ordered for operation on low voltages (208 – 240 volts) are supplied with a plug cap conforming to NEMA L15-20P. Machines for 440 – 480 volts are supplied with a plug cap conforming to NEMA L16-20P. Machines for 575 volts are supplied with a plug cap conforming to NEMA L17-20P. Machines for 380/415 service at 50Hz are supplied with the appropriate pin and sleeve type plug cap conforming to IEC-309.
Branch circuit protection: The installer must provide external branch circuit protection with either time delay fuses or an appropriate motor rated circuit breaker suitable for a 2 HP three phase motor.
PROCESSING RATE: Up to 6500 pounds per hour. Typical rates are 2000 to 3250 pounds per hour. AMBIENT TEMPERATURE FOR OPERATION: 30 TO 80 degrees F. TEMPERATURE RISE IN PRODUCT: None
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2 DESCRIPTION
2.1 MECHANICAL
When the 700MC is turned on with the guard(s) in the closed position, the head assembly reciprocates. The conveyor advances when the blades are fully retracted at the top of each stroke.
The meat to be tenderized is simply placed on the conveyor. The powered conveyor advances the product under the blades. Any blade that strikes a bone will automatically stop its downward stroke while the other blades will continue to penetrate the meat. As the blades return to the top of the stroke, the retracted blades are pushed back into position by the soft plastic reset pads.
The blade assemblies are mounted between two “H” shaped stainless steel frames, the head frame and the guide frame. The head frame is bolted to the top of the one and one-half inch diameter main uprights. The guide frame is mounted below the head frame on the smaller one inch diameter guide uprights.
The main and guide uprights extend through the top of the cabinet and are guided by oil-impregnated bronze bearings. These bearings are held in the main frame casting that is bolted to the underside of the top of the cabinet. The lower ends of the main uprights are bolted to the cam plate. This is driven by a cam roller attached to the crank cam on the output shaft of the transmission. The transmission is driven by a two horse power electric motor. The lower ends of the guide uprights extend through the toggle clamp assemblies and guide raisers. The guide raisers with their cushions are attached to the main uprights and the clamp pivots are attached to the guide uprights.
As the 700MC makes its downward stroke, the head and guide frames descend until the guide frame contacts the meat. At this point, the guide frame stops while the head frame continues downward to the bottom of the stroke. The guide frame is locked on the stationary toggle rods by the toggle assembly. This holds the meat down on the conveyor belt as the head frame travels upward withdrawing the blades. As the main uprights and the guide raisers reach the clamp pivots at the position where the guide frame had been locked, the unlock cushion lifts and levels the toggle clamp. With the toggle clamp level, the toggle rings release allowing the guide uprights and guide frame to rise to the top of the stroke.
The crank cam also actuates the cam follower assembly and rocker arm for the conveyor advancement. The cam follower causes the rocker arm to pull down on the pull rod, operating the bell crank. The bell crank causes the push rod to operate the index arm. As the index arm moves, the pawl on the index arm engages a tooth on the index wheel causing the conveyor to advance one increment. As the index wheel advances, a serpentine track on the cam drive wheel causes the conveyor to move side to side producing the proper interdigitation of the blades to maximize tenderization. The crank cam is designed to have the rocker arm and conveyor drive advance the conveyor just as the head assembly is near the top of its stroke with the blades out of the product.
2.2 ELECTRICAL
The electrical control system is located in a sealed compartment at the input end of the Tenderizer cabinet. The control system includes a control transformer, fuses, motor starter, phase sensor, and relay. The electrical schematic, MN045770, is located at the rear of this manual. The incoming three-phase power is connected between terminals 1, 2 and 3 of the main terminal block. It is then fed through the
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disconnect switch (S1) to the line terminals L1, L2 and L3 of the motor starter (K1) and to terminals 3, 4, and 5 of the phase sensor.
A single-phase connection from the incoming power is applied to the primary of the control transformer (T1) through fuses F2 and F3. The control transformer is designed with tapped primary and secondary windings allowing it to be connected such that a control voltage of approximately 120 VAC may be obtained from a wide range of line voltages. The 120 VAC control voltage is used to energize the coils of the motor starter (K1) and relay (K2) as well as the head adjusting motor circuit.
Power from the secondary of the control transformer is fed through the POWER switch (S2) to fuses F4 and F5. The load side of fuse F5 is connected to terminals 1 and 8 of relay K2 and to one side of the START switch (S3). With the machine connected to the proper electrical power source, the disconnect switch turned on and the POWER switch pulled out, pressing the START switch will energize relay K2 through guard switch S7 providing the guard is closed. When K2 pulls in, contacts 8 – 6 of K2 feed 120 volts to one end of the motor starter’s coil (K1) and contacts 1 - 3 latch K2 in allowing the START switch (S3) to be released. S8 is an E-stop switch mounted at the rear of the machine.
Although the vertical reciprocating motion of the Tenderizer head is unaffected by the rotational direction of the main drive motor, if the motor was to operate in the reverse direction, the drive to the conveyor would occur with the blades partially down. Under these conditions, the conveyor would attempt to move with the blades still inserted in the product. To prevent this from happening, a phase sensor (A1) is incorporated in the electrical system to keep the motor starter from being energized unless the incoming power is correctly phased.
Terminals 3, 4, and 5 of the phase sensor are connected to the incoming power allowing the phase sequence to be sensed. If they are in the correct sequence, an internal solid state relay connects together terminals 1 and 8 of the phase sensor. Terminals 1 and 8 are connected in series between the return side of the motor starter’s coil and the 0 volt connection fromT1, thus with the proper power phasing, the motor starter will pull in applying the three phase power to the main motor and the machine starts operating.
120 volts from the transformer through the POWER switch and fuse F4 is applied to the bridge rectifier (CR1). The DC terminals of CR1 are connected to the head adjusting motor through the HEAD ADJUSTING switch (S4) and limit switches (S5 and S6). S4 is a two position switch with four contact blocks connected so as to allow reversal of the polarity of the DC voltage that is applied to the head adjusting motor (M2) through terminals 4, 5 and 6. One side of M2 is connected to terminal 4 while the other side of the motor is connected through the limit switches (S5 and S6) to terminals 5 and 6. The HEAD ADJUSTING switch has no ‘off’ position, when either the HIGH or STD positions are selected, the motor will operate until the head assembly reaches the selected position and the appropriate limit switch opens.
Once started, the tenderizer will continue to operate until either the disconnect switch is turned off, the POWER switch is pushed in or one of the guards is opened. Restoring any of these devices will NOT allow the machine to start, the START switch must be pressed.
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3 INSTALLATION
3.1 UNCRATING
The 700MC Tenderizer is shipped in an enclosed crate. The Tenderizer is supported by a wooden skid with wooden framing at the ends of the cabinet. The overall assembly is covered with clear polyethylene film and placed in a complete wooden crate.
Prior to uncrating the Tenderizer, inspect the condition of the packing material; any external damage may have resulted in damage to the Tenderizer itself. After the Tenderizer is uncrated and removed from the skid, it should be thoroughly checked for visual damage to the cabinet, casters, safety guards and the head assembly.
Any damage to the Tenderizer should be reported to the shipper immediately. If the external packing material had been disturbed or torn and visual damage to the Tenderizer itself can be seen, the Tenderizer should not be uncrated until the shipper’s representative has been notified.
The Tenderizer is uncrated by first removing the top and sides of the crate and then cutting the two steel bands that hold the base cabinet to the wooden skid. The 2 x 4 end brace is removed from end of the skid frame. The Tenderizer must then be lifted slightly by prying between the side rails of the skid frame and the bottom edge of the base cabinet.
As the cabinet is raised, the support blocks under each end can be removed and the Tenderizer lowered on the skid with the casters supporting it. Before lowering the cabinet, the casters should be aligned so the Tenderizer can easily be rolled from the skid. Use the 2 x 4 end brace that was removed as a step ramp at the end of the skid and roll the Tenderizer slowly from the skid to the floor, being careful not to damage the casters.
3.2 INSTALLATION
The 700MC Tenderizer does not need any installation, as such, since it is considered a portable electrically operated appliance and need simply be rolled into position, have its power cord plugged into a suitable outlet, and it is ready to operate. There are, however, certain site requirements to consider. In as much as the Tenderizer weighs 1,000 pounds and is mounted on casters, the floor on which it is to operate must be sound, level, and capable of supporting the Tenderizer, as well as the operating personnel, meat lugs, etc.
The casters that are furnished with the Tenderizer are designed to support its weight, as well as the shock loads that may be transmitted to them during the normal operation of the machine. The casters allow the Tenderizer to be moved around on any hard, smooth-surfaced floor. Rolling the Tenderizer over uneven floors or over cracks or expansion joints in the floor will greatly shorten the life of the casters. Prior to the actual failure of the casters, they will cease to swivel properly, resulting in extreme difficulty in moving the Tenderizer even on a smooth surfaced floor.
If it is necessary to move the Tenderizer over poor floor surfaces, as much care as possible should be used to avoid excessive shock to the swivel axis of the casters. When moving the Tenderizer, it should be pushed or pulled by the cabinet and NOT by the safety guards or head assembly. Any attempt to
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move the Tenderizer by pushing or pulling on the guard assembly can result in misalignment of the guards. This can result in the safety switches being inoperative, which would prevent the Tenderizer from operating.
3.3 ELECTRICAL REQUIREMENTS
The Model 700MC Tenderizer can be supplied to operate from any of the standard world wide three phase line voltages. This would include the following: 208, 220, 230, 240, 380, 415, 440, 460, 480 and 575 volts. The supply frequency can be either 50 or 60 Hz. When the Tenderizer is ordered, the actual plant line supply must be stated, such as 225 volts at 60 Hz. The tenderizer would then be properly set up to operate from that electrical supply. A subsequent deviation of up to plus or minus 10% would have little or no effect on the operation or longevity of the Tenderizer. An exception to this would be to place an absolute minimum on the operating voltage at 200 volts.
The main drive motor in the 700MC tenderizer will operate from line voltages of 208 through 480 volts at either 50 or 60 Hz. A different motor is required for operation from 575 volt lines. Changing the Tenderizer for operation on any voltage between 208 and 480 volts requires only minor changes and can easily be done in the field. Changing to operation from 575 volt lines requires replacement of the main drive motor. Replacement of the motor can certainly be done in the field, but it is somewhat involved as the cam and transmission must be removed to gain access to the motor. Machines supplied for operation from 575 volt lines are furnished with a motor and transformer designed for that specific voltage.
The various items that may need to be changed or reconnected to match a particular line voltage are: the motor itself, the heaters and overload in the motor starter, the phase sensor and line cord. The chart on page 3-4 illustrates the various items required for different line supplies. The numbers after MAIN MOTOR refers to the part number of the motor required for the selected supply. The MOTOR WIRING refers to the connections in the motor junction box for the selected supply. The actual connections are given on the motor’s nameplate. The numbers after the HEATERS, PHASE SENSOR, LINE CORD ASSEMBLY AND FUSES refer to the part numbers of the affected parts. The OVERLOAD SETTING gives the required adjustment of the overload on the motor starter and is given in percentage corresponding to the dial markings on the overload.
The overload section of the motor starter provides running overload protection for the main drive motor. Fusing the primary and secondary of the control transformer provides protection of the control circuits and the head adjusting motor. There is no protection from direct short circuits in the main motor, this must be provided by the proper external branch circuit protection as defined by the applicable electrical codes relating to a 2 HP three phase motor.
When operating from any of the low voltage ranges (200 – 240 volts), the branch circuit should be protected to 20 amps with either dual element (time delay) fuses or a motor rated time delay three pole circuit breaker. The correct receptacle to be used would be one that meets NEMA L15-20R. The branch circuit protection required for any of the higher voltage ranges should be 20 amps with either dual element (time delay) fuses or a time delay circuit breaker. The correct receptacle to be used would be one that meets NEMA L16-20R for 440-480 volt lines or L17-20R for 575 volt lines.
The Tenderizer is furnished with a power cord made from approximately twenty feet of SO – 4/12 and terminated with the appropriate plug cap. Substitution of the supplied plug cap with a non-approved type is entirely at the owner’s risk and any consequence that may result is the owner’s responsibility.
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NOTE - Always turn the main power switch OFF before connecting the machine to a power source. If
the machine is plugged in with the main power switch ON and the head adjusting motor operating, the primary transformer fuses may blow. This is due to the high magnetizing in-rush current of the transformer added to the reflected starting load of the motor
.
3.4 POWER PHASING
As with all three-phase motors, the phase sequence of the incoming power determines the direction of rotation of the motor in the Tenderizer. Although the vertical reciprocating motion of the Tenderizer head is unaffected by the rotational direction of the motor, if the motor was to operate backwards, the drive to the conveyor would occur when the blades were partially down. Under these conditions, the conveyor would attempt to move with the blades still inserted in the product. To prevent this from happening, a phase sensor is incorporated in the electrical system to prevent the main motor’s starter from being energized unless the incoming power is correctly phased.
After the Tenderizer has been set up and made ready to operate, the phasing of the incoming power should be checked. Plug the power cord into the receptacle provided and pull the main power switch out to the ON position. With the guard completely closed, press the START button. If the machine starts and continues to operate, the phasing of the incoming power is correct and no further changes are necessary. However, if when pressing the START button nothing happens, the phasing of the incoming power may be incorrect.
To correct the phasing, two of the conductors in the power cord must be interchanged. If a separate branch circuit disconnect box is provided for the Tenderizer, then it would be best to interchange two of the wires inside the box; however, if the same circuit is used for other machines that are phase sensitive, then the correction will have to be made in the plug cap on the Tenderizer’s line cord. Disassemble the plug cap and interchange any two of the main conductors (black, white, or red wires). Do NOT change the position of the GREEN wire; this is the ground wire and connects directly to the cabinet of the Tenderizer. Connecting this wire to any other position in the plug cap would result in the Tenderizer cabinet being electrically “hot” with respect to the building ground, an extremely dangerous condition.
After correcting the phasing of the incoming power, check the operation of the Tenderizer again. If it still fails to operate, refer to the TROUBLESHOOTING section of this manual
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3.5 INSTALLATION CHART
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4 SPARE PARTS
SPARES LIST
VOLTAGE-DEPENDENT COMPONENTS IDENTIFIED WITH AN “*”
VOLTAGE DESCRIPTION PART NO.
ALL FUSE, 1 AMP, (F5) 14140013
ALL FUSE, 2A (F4) 14140023 200-219 *FUSE 2.5 AMP 600V, (F2, F3) 14140119 220-240 *FUSE 2 AMP 600V, (F2, F3) 14140195 380/415 *FUSE 1.5 AMP 600V, (F2,, F3) 14140194 440-575 *FUSE 1 AMP 600V, (F2, F3) 14140132 200-480 *PHASE MONITOR (A1) 14160527
575 *PHASE SENSOR ASSEMBLY (A1) 09019180 200-240 *HEATERS FOR K1, 7A (3 EA) 14050070 380-480 *HEATERS FOR K1, 3.7A (3 EA) 14050074
575 *HEATERS FOR K1, 3.3A (3 EA) 14050067
ALL DISCONNECT SWITCH (S1) 14120367
ALL RELAY, (K2) 14050005
ALL TRANSFORMER, (T1) 14080025
ALL START SWITCH, (S3) 09078501
ALL POWER SWITCH, (S2) 09093610
ALL MOTOR STARTER, (K1) 14050066
ALL HEAD ADJUSTING SWITCH (S4) 09093620
ALL RECTIFIER (CR1) 14050016
ALL REED SWITCH (S7) 09019250
ALL PIN 11090021
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SPARES LIST
VOLTAGE-DEPENDENT COMPONENTS IDENTIFIED WITH AN “*”
VOLTAGE DESCRIPTION PART NO.
ALL LIMIT SWITCH (S5, S6) 14120080
ALL ROD END 13070013
ALL BLADE, LONG ANGLE POINT 01019876
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5 ILLUSTRATIONS
5.1 GUARD/SAFETY SWITCH
GUARD/SAFETY SWITCH
P/N
04247621
04177320
02170340
04177332
DESCRIPTION
GUARD, STATIONARY
SPREADER, INLET GUARD
SPREADER, OUTLET GUARD
GUARD, INLET
1
1
1
1
QTYITEM
4
3
1
2
11018508
01177840
02131490
POST W/O REED SW
SPACER, SPREADER
SCREW, SPRDR 1/4−20X5/8
1
10
10
578
6
01165760
POST FOR REED SW
1
09019250
REED SWITCH ASSY
1
9
11090021
PIN, REED MOUNT
1
10
01131480
PIVOT PIN
2
11
09131471
11018516
SCREW, PIVOT1/4−2−X1 1/2
MAGNET W/MOUNT
2
13
12
11018506
11450609
11040011
WASHER, LOCK 1/4
NUT, LOCK 1/4−20
SCREW, MAGNET 1/4−20X1/2
2141
2
14
15
16
19
01448130
NAMEPLATE, OIL HEAD
2
17
01137962
01173751
01220491
16 6
2 5 1
EDGE PROTECTOR
NAMEPLATE, CHECK LIST
NAMEPLATE, CAUTION
2
1
19
18
18
2
20
7
MN4351411B.DWG
18
17
16 6
54
3
12
11
20
15
14
13
10
9
8
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5.2 HEAD CARRIER ASSEMBLY
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5.3 HEAD ASSEMBLY
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5.4 CONVEYOR DRIVE ASSEMBLY
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5.5 CONVEYOR ASSEMBLY
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5.6 MOTOR/REDUCER ASSEMBLY
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5.7 CAM DRIVE ASSEMBLY
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5.8 CAM ASSEMBLY
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5.9 RETURN SPRING/CAM ASSEMBLY
05178000
01219300
14100094
11017718
02219010
01219030
02219020
11450609
11018519
11018520
11040074
RETURN SPRING/CAM ASSEMBLY
CAM PLATE
MOTOR GEAR
SPRING
2 3 1
RETURN SPRING MOUNT INNER
BAR−RETURN SPRING MOUNT
SCREW HHC 3/8−16x1 3/4"LG
4
6 8 7
5
SCREW HHC 1/4−20x1 7/8"LG
SCREW HHC 1/4−20x2.00"LG
RETURN SPRING MOUNT OUTER
NUT HEX LOCKING 3/8−16
WASHER LOCK Ø1/4"
9
11
10
MN4126201B.DWG
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5.10 TOGGLE CLAMP/RETURN SPRING ASSEMBLY
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5.11 MAIN FRAME/ROCKER BAR CAM FOLLOWER
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6 OPERATION
6.1 MACHINE OPERATION
NOTE: The 700MC Tenderizer will not operate unless the safety guard is closed.
Once the Tenderizer has been correctly installed and properly phased, the operation is extremely simple. A. Connect the line cord to a suitable source of power. B. Turn the Disconnect switch located near the center of the electrical access panel, to the ON
position. C. Pull out on the red “POWER” switch. D. Select either the “STD” or “HIGH” position on the Head Adjust switch.
This switch selects the range of product thickness that the tenderizer can accommodate. In the “STD” position, boneless cuts up to 7 1/2” thick or bone-in cuts up to 7” can be processed. The “HIGH” position allows cuts up to 9 1/2” to be processed, however in this position the blades only reach to 2” above the conveyor on their downward stroke requiring the product to be at least 4” thick and it is necessary to turn it over for a second pass through the tenderizer to provide complete tenderization. motors are operating may cause the main motor to turn off. You should wait for the head adjusting motor to reach its destination and stop before changing the switch position.
E. Place the meat centrally on the conveyor.
CAUTION: ATTEMPTING TO PROCESS MEAT THICKER THAN MACHINE CAPACITY OR FORCING MEAT UNDER THE HEAD WILL SERIOUSLY DAMAGE THE MACHINE. NEVER CHANGE THE HEAD ADJUST SWITCH FROM THE “HIGH” TO THE “LOW” POSITION WHILE PROCESSING PRODUCT THAT IS OVER 7 1/2” HIGH OR WHILE SUCH PRODUCT IS IN THE MACHINE.
F. Press the green “START” button. The tenderizer will start and continue to operate until stopped by pushing in on the “POWER” switch.
G. Meat less than one and one half inches thick may not be held in place properly by the guide
frame. Better and more rapid tenderizing will be obtained if such thin cuts are stacked to near machine capacity.
H. It is desirable to keep the conveyor belt filled with meat without any gaps between cuts. Not only does this maximize production, but it also assures that the meat moves intimately with the conveyor and avoids the possibility of over-processing as a result of slippage.
I. To stop machine, push in the red knob on the “POWER” switch. The machine can also be stopped by turning the disconnect switch to the OFF position or by opening a guard. The tenderizer will NOT restart with either of these returned to their operating condition, the “START” switch must be pressed.
NOTE – Changing the position of this switch while the main and head adjusting
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6.2 CLEANING AND BLADE REPLACEMENT
The Tenderizer should be cleaned DAILY with a mild detergent and hot water or steam. The machine is fully sealed and may be liberally flushed without fear of damage. Approved detergents (between 4.5 pH and 10 pH) used in proper concentrations will not damage the finish even though allowed to remain for prolonged periods. However, immediate clean water or steam rinsing is recommended. DO NOT USE CAUSTIC CLEANING SOLUTIONS since these may damage the magnetic head plates and seals. The following is the necessary DAILY cleaning procedure:
1. Stop the machine near the top of the stroke.
2. Turn off the disconnect switch or disconnect power cord.
3. Flush the entire machine with clean hot water or steam concentrating on the blade assembly.
4. Remove the Blade Assemblies:
Remove the detent pins and remove the lower outer guide bars first.
While holding the blade assembly in place, loosen the detent pins and remove the upper outer guide
bars.
Slide the blade assembly out. HOLD BY RETAINING RODS OR TOP ONLY. NEVER PLACE
HANDS UNDER THE HEAD ASSEMBLY.
Remove the two acorn nuts on top of the reset plate using a 1 1/8” wrench.
5. The blade assembly can now be taken to a separate cleaning station and immersed in a mild
detergent solution (100% immersed.) The use of a plastic tub is recommended so as not to damage
the sharp edge of the blades.
DO NOT SET BLADE ASSEMBLY (WITH BLADE TIPS DOWN) ON ANY METAL SURFACE.
The following is the recommended cleaning process: A. Soak blade assembly for a minimum of 15 minutes with a mild hand agitation every 5
minutes. USE CAUTION WHEN HANDLING THE SHARP BLADE TIPS!
B. After soaking, clean the blade assembly with a brush paying attention to the top of the
blades, magnetic head plates and lower blade guides. C. Rinse blade assembly with clean hot water or steam. D. Visually inspect blade assembly paying attention to areas where the blades move through
the magnetic head plates, guides and tops of blades. If any contamination is found, repeat
the above steps. E. Sanitize blade assembly (maximum time in sanitizer 5 minutes). F. Blow dry blade assembly.
6. Oil blade assembly with Ross 601 white mineral oil (or equivalent) paying particular attention to the tops of the blades and magnetic head plates. While the blade assemblies are out, the entire machine can now be cleaned with detergent, or steam and a bristle brush.
SPECIAL ATTENTION SHOULD BE GIVEN TO THE UNDERSIDE OF THE GUIDE FRAME.
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7 The machine’s belt can be manually moved without the blade assemblies in place to allow for the cleaning of the belt with a spray of soap and water. Inspect conveyor belt for damaged sections and replace as required.
8. Reinstall the blade assemblies by sliding the head plate into position on the head frame making sure
that the rib on the magnetic head carrier is positioned in the corresponding slot on the head frame.
9. Install the upper outer guide bar (‘top’ marked on bar – slot goes down)
10. Then slide the lower blade guide into position on the guide frame and install the lower outer guide
bar. To accomplish this sometimes it is necessary to slightly lift the lower blade guide USE CAUTION
NOT TO PUSH HANDS INTO THE BLADES AT THE BOTTOM OF THE LOWER BLADE GUIDES.
11. Check that the installed head assembly moves freely in its installed position. It should slide within the
slots on the guide bar and head/guide frames.
12. Reinstall the Reset Plate and fasten with the original acorn nuts and washers. Tighten to a torque of
50 ft lbs.
13. After every cleaning, spray the blade assemblies, tops of the blades, main uprights and guide
uprights with ROSS 601 white mineral oil (or equivalent).
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6.3 HEAD ASSEMBLY INSTALLATION
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7 MAINTENANCE
7.1 INSPECTION
NATURE AND FREQUENCY
Inspect for and replace bent blades daily. See “cleaning and blade replacement”, page 6-2. Run height control adjustment up and down twice a week to keep running free.
7.2 LUBRICATION
DAILY OR AFTER EVERY CLEANING
The magnetic head plates, tops of the blades, blade assemblies, main uprights and guide uprights should be sprayed with Ross 601 white mineral (or equivalent).
EVERY 200 HOURS OR ONCE EVERY MONTH
TAG OUT, LOCK-OUT POWER. ROTATION OF DRIVE COMPONENTS
WHILE INSIDE TENDERIZER COULD BE FATAL
INSPECT MAIN RETURN SPRINGS FOR CONDITION AND PROPER
ATTACHMENT. WITHOUT MAIN RETURN SPRINGS IN PLACE, THERE IS A DANGER
OF THE DRIVE MECHANISM MOVING ON ITS OWN WEIGHT
WHEN THE MACHINE IS STOPPED WITH THE HEAD IN THE UP POSITION.
The cam plate and cam roller should be lubricated with a high quality, water-resistant grease, such as Chevron SR1 Grease - 2.
NOTE:
The two grease fittings on the cam plate for the Dual Height Range Option Kit must be lubricated every month. One or two pumps from a grease gun containing Chevron SR1-2 or equivalent should be sufficient.
The cover panel on the conveyor box should be removed and the cam drive wheel should be lubricated with Chevron SR1-2 (or equivalent).
EVERY SIX MONTHS OR 500 HOURS OR OPERATION
The side panel should be removed and all moving parts, except the cam plate assembly, should be sprayed with Ross 601 oil.
ONCE A YEAR The oil level in the transmission should be checked. To check oil level, remove the oil level plug on the
far side of the transmission from the main side door.
CRUSHING HAZARD
CRUSHING HAZARD
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To add oil, remove the plug on the top of the transmission and fill with USP extra-heavy white mineral oil (Ross Oil No. 15040014, or Exxon Primol 355, or equivalent) until oil level is even with the oil level plug. Replace the plug on the top and the side of the transmission.
To drain the oil a drain tube may be used from the drain plug on the side of the transmission and placed through the drainage hole nearby in the bottom of the tenderizer cabinet.
7.3 ADJUSTMENTS/SPECIFIC REPAIRS
Conveyor link belt may stretch after use. Do no allow conveyor chain to drag on the tenderizer cabinet. To tighten belt use adjuster screws item number 33 shown on page 5-5 of this Instruction handbook. If there is still too much slack, remove one of the belt links.
Do not allow the chain drive for the height adjusting mechanism to become too loose. If the chain gets loose enough to skip a tooth on the sprocket, a complete readjustment of the height mechanism would be necessary. See “Head Height Adjustment” on next page.
7.3.1 CONVEYOR BOX
This is how the conveyor box should appear when the conveyor is at rest and not advancing. The index arm and pawl has pivoted back almost far enough to drop behind a second tooth. The pull rod (see page 5-11), shown going though the bottom of the box, is being pushed up by the conveyor return spring located inside of the cabinet, and the bell crank is resting against the bell crank stop bolt. See figure on page 5-4.
When the conveyor is fully advanced the index arm is pointing almost straight down.
When set as shown, the conveyor should advance correctly when loaded with product. See the troubleshooting section for problems concerning the conveyor drive system.
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7.3.2 HEAD HEIGHT ADJUSTMENT
(blade-to-belt clearance)
The blade to conveyor clearance has been set at the factory and should not change as a result of normal use. Although unlikely to occur, there are several reasons why this mechanism may need to be checked or adjusted:
If the blades are coming in contact with the conveyor tray or belt.
NOTE: It is normal for the blades to
just touch the knuckle part of the conveyor belt. Some “float” is inherent to the blade design, so that the blade will push up .030 to .060 inches ,(.8 to 1.5 mm), before applying pressure on the blade point.
If the blades are not coming close enough to the conveyor belt in the standard position.
If the blade height adjustment mechanism has to be repaired, or if the adjustment chain slips, (this
will normally bind up the high low mechanism).
To check for proper head height the following step must be followed: The diagrams referred to below in parenthesis are located in the MACHINE INFORMATION section of
this Information Handbook.
Set HEAD ADJUST to the STD (standard) position
Jog (stop and start) machine until head is stopped as close as possible to the down position
Disconnect power to machine
Remove the main side cover
Use a 9/16 inch wrench or socket on the nut welded to the back of the gear box drive motor. Turn the
electric motor until the cam roller (p5-7, item 9), is located directly below the gear box output shaft.
The height of the head frame is controlled by the adjustment of the roller switches, (p5-10, item 29). They are mounted on a switch bracket, (p5-10, item 36). By slightly loosening the two securing screws, (p5-10, item 16), the whole bracket can be carefully shifted in the direction of desired adjustment. DO
NOT OVER-RUN ROLLER SWITCH BY FORCING BRACKET IN THE DIRECTION OF A ROLLER SWITCH BEING CONTACTED. The best way to adjust the switch(es) is given here by the following
example.
EXAMPLE - The head is in the standard position and stopped all the way at the bottom of the stroke
as detailed above. The blades are too low. Turn the HEIGHT ADJUST switch to the HIGH position while watching the blade to belt clearance carefully. When the blades show the proper clearance to the belt, push in the EMERGENCY STOP button. Disconnect the power and remove the main side door to the cabinet. Slightly loosen the switch bracket securing bolts and gently pry the switch bracket in the direction of the closest roller switch. Listen closely for the switch to close. Tighten the bolts and replace the side door. Turn on the machine and allow the head to be raised by the height control motor enough to be sure the guide raiser (p5-10, item 18, actuates roller switches) has cleared the switch. Change the
MN700-MC0010
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switch to the STD setting and observe blade to belt clearance when the head stops its’ travel. Re-adjust if necessary.
The adjustable main upright(s) (p5-11, item 44) should never thread too far into the elevator nut(s) (p5-8, item 7). There should always be 2 to 4 threads showing in the STD position.
CRUSHING HAZARD
TAG OUT, LOCK-OUT POWER. ROTATION OF DRIVE COMPONENTS
WHILE INSIDE TENDERIZER COULD BE FATAL
CRUSHING HAZARD
INSPECT MAIN RETURN SPRINGS FOR CONDITION AND PROPER
ATTACHMENT. WITHOUT MAIN RETURN SPRINGS IN PLACE, THERE IS
DANGER OF THE DRIVE MECHANISM MOVING FROM ITS OWN WEIGHT
WITH THE MACHINE STOPPED WITH THE HEAD IN THE UP POSITION.
7.3.3 HEIGHT ADJUST CAM MECHANISM
The cam assembly is shown on page 5-8. Under normal conditions the DC amperage draw during the function of the high low motor should not exceed the 1.5 amps shown on the motor nameplate. This is checked on every tenderizer from the factory with amperage ranges normally between .7 to 1.25 amps. The following conditions will effect this function:
1. If one main upright is set higher that the other, the high low mechanism will be overworked and will eventually fail. This will only happen if the chain has slipped on one of the lift sprockets . To check for level of the main uprights, remove the head frame and check across the tops of the main
uprights with a straight edge. Disconnect the chain and turn one of the lift sprockets to even main uprights. Reconnect chain and tension.
2. If the high low mechanism is not used on a regular basis, the grease will harden and increase turning resistance.
3. If the chain is adjusted too tight extra effort will be required to turn the mechanism
4. The main uprights must not be allowed to thread too far into the elevator nuts.
Always make sure that the main return springs (p5-9, item 3, p5-10, item 27) are in good condition and firmly attached to their mounts.
7.3.4 RESET PAD/PLATE CLEARANCE
These soft reset pads push the blade assemblies which have been released from their magnet carrier, (p5-3, item 1), to within the magnetic forces of the magnet carrier. They then will be pulled into place by these magnetic forces. If clearance does not exist and the soft reset pads where to be pressed against the end of the blades, eventually the reset pad will be destroyed. Once perforated or torn, the reset pad becomes a place for bacteria and can even damage blade assemblies with this extra force.
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After the head height has been set correctly, the clearance between the tops of the blade assemblies, (p5-3, item 6), and the reset pad, (p5-2, item 2), should be checked. To do this, run the head assembly to the top of the stroke. Open the pivoting guard, (p5-1, item 1), and look for a space between the blade assembles tops and the bottom of the reset pad. Hold onto each retainer bar, (p5-3, item 3), in turn and try to move the head assembly magnet carrier within its’ mounting slot. The head should move around easily without the blade assemblies touching the reset pad. There should be no greater clearance than approximately .06 inches, (1.5 mm), between the tops of the blades and the reset pads.
To correct clearance add or delete shim washers between the top of the reset plate studs, (p5-2, item
16) and the reset plate. Shim washer numbers are:
11451009................................................. Washer, flat 3/4 id x .032 thk
11450116................................................. Washer, flat 3/4 id x .092 thk
There may already be washers on top of the reset posts to adjust the height of the reset plate. The 700M is carefully adjusted at the factory. If, for any reason, the reset plate, head frame or guide frame is removed from the machine, be sure to keep track where each shim washer goes. During reassemble, make sure that the washers go back in exactly the same position.
7.3.5 TOGGLE RING REPLACEMENT
A. Disconnect the machine power cord. Remove the side
cover panel. B. Rotate motor coupling (in direction of arrow) until head assembly is in full down position.
C. Remove unlock cushion D. Remove pivot pin, turn toggle clamp and remove from
shaft
E. Remove toggle ring retainer plate and toggle ring F. Install new toggle ring; replace toggle ring retainer
plate.
NOTE - Always install new toggle rings on both sides.
G. Replace toggle clamp. Install pivot pin
Make sure snap rings are in position
H. Check the snap ring position on the guide uprights. There should be one snap ring above and one below the clamp pivot, the snap rings go in the lower two grooves on the guide uprights
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I. Replace unlock cushion J. Make sure that the guide raisers (page 5-10, item 18), on the main uprights, are seated all the way down on the stabilizer bars and spacers (page 5-11, items 29,30) K. Make sure toggle assembly is centered on toggle rod. L. Check mechanism for free movement. Toggle assembly should pivot up and down approximately 1/8". M. Turn motor coupling (in direction of arrow) so machine makes two complete cycles. Check for proper
clamp and guide operation throughout cycle.
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8 TROUBLESHOOTING
TROUBLESHOOTING CHART
TROUBLE CAUSE REMEDY
1)
Machine plugged in, guards
closed, main power switch pulled out, nothing happens when START button is pressed
No incoming power
Check by measuring voltage at power socket, measure from phase to phase to phase – NOT to ground.
Power cord or plug faulty Disassemble plug cap and check connections or
open electrical compartment and measure voltage from terminals 1 to 2 to 3, do NOT measure from either terminal to ground.
Safety guard switches not operating
With the electrical panel attached to the front of the machine with the plate hook, temporarily connect terminal 7 of relay K2 to ground. Turn the machine on and press the START button. If it starts, then one or both of the guard switches were not operating. Remove the temporary connection and open the main access panel. Disconnect one guard switch at a time and connect together the ends of the wires to which the guard switch had been connected. Attempt to start the machine; if it operates, the guard switch just removed was faulty. Check to see if the guard had been bent—forcing the magnet out of the correct position. Replace the Reed Switch if required.
Fuse, F5 blown
Check the fuse or replace with a known good one.
8-1
MN700-MC0010
TC700MC TENDERIZER
Page 38
TROUBLESHOOTING CHART
TROUBLE CAUSE REMEDY
MN700-MC0010
8-2
1)
(cont.) Machine plugged in,
guards closed, main power switch pulled out, nothing happens when START button is pressed
Transformer, T1 faulty or connected wrong
Check by measuring the voltage between terminals X1 and X3 of the Transformer, this should be 120 VAC.
Power switch S1 faulty Check by measuring the voltage between the
left terminal of the switch and ground, this should be 120 VAC with the switch pulled on.
START switch S2 faulty
Check by measuring the voltage between the right terminal of the START switch and ground with the power switch pulled on and the START switch pressed, this should be 120 VAC.
Relay K2 faulty
Check by measuring voltage between terminals 2 and 7 of the relay while attempting to start the machine, this should be 120 VAC.
2) Machine plugged in, guards
closed, main power switch pulled out, only a small click is heard when the START switch is pressed. (Relay is operating).
Incoming power out of phase Phase Monitor faulty
Exchange gray and black wires in plug cap. Replace phase sensor with a known good unit or temporarily bypass by connecting together the leads that are on terminals1 and 8 of the phase monitor.
Relay contacts faulty Although the relay is pulling in, its contacts may
be faulty, check by measuring the voltage between terminal 6 of the relay and ground. This should be 120 VAC when the relay is energized.
TC700MC TENDERIZER
Page 39
TROUBLESHOOTING CHART
TROUBLE CAUSE REMEDY
MN700-MC0010
8-3
2) (cont.) Machine plugged in,
guards closed, main power switch pulled out, only a small click is heard when the START switch is pressed. (Relay is operating).
Motor starter coil faulty (open)
Check by measuring the voltage across the two coil terminals of the starter after turning the machine on and pressing the START switch. This should be 120 VAC. If the voltage is present and the starter does not pull in, the coil is faulty.
Overload switch in starter open Overload tripped, press reset button on starter.
Tenderizers are normally shipped with the starters set up for automatic reset so if the motor is subjected t overload, it would not be necessary to manually reset the starter.
Overload switch in starter faulty Check by measuring the voltage from the NC
terminal on the starter to ground, this should be 0 volts; if not, the overload section of the starter should be replaced.
3) Machine plugged in, guards
closed, main power switch pulled out, a large click or thump is heard when pressing the START switch but the machine does not start. (Motor starter is pulled in). Motor may hum and draw excessive line current.
One or more heaters in motor starter burned out
Motor faulty or poor connections in motor box
Check by measuring the voltage from terminals T1 to T2, T2 to T3, and T1 to T3; all should be equal and the same as the line voltage.
Check connections in motor box and replace motor as required.
4) Motor operates when START
switch pressed, but machine does not run.
Coupling or key between motor and transmission faulty Transmission faulty
Check visually and replace as required.
Check by noting rotation of input and output shafts on transmission.
TC700MC TENDERIZER
Page 40
TROUBLESHOOTING CHART
TROUBLE CAUSE REMEDY
MN700-MC0010
8-4
5) Machine runs but makes a loud
banging noise at bottom of each stroke. Guide frame may be hitting side of conveyor.
Guide stop worn or broken
Inspect and replace as required.
6) Machine runs but makes a loud
banging noise on the up stroke. Severe vibration. Excessive blade bending.
NOTE: Damage to toggle assemblies and blade will occur if meat to thick for machine capacity is processed.
Toggle not unlocking properly Check toggle and guide raiser assemblies.
Toggle clamp should pivot freely on the clamp pivot, and both assemblies should be centered on the uprights and toggle rod. Inspect for any signs of wear or damage to the toggle and guide raiser assemblies. Check condition of unlock cushions. Replace any worn or damaged parts. Both toggles must unlock at the same time. Check position of snap-rings on main and guide uprights. (See section 7.3 for proper position). NOTE: Severe vibration may loosen
fastenings throughout machine. Check
all nuts
and bolts for tightness.
Toggle ring broken Replace toggle ring. (See p 7-5).
7) Machine runs, but constant
vibration on up and down strokes. Uprights may heat up or be scored.
Bearings and/or uprights worn
Inspect and replace bearings and uprights as required.
TC700MC TENDERIZER
Page 41
TROUBLESHOOTING CHART
TROUBLE CAUSE REMEDY
MN700-MC0010
8-5
8) Machine runs, but conveyor does
not advance, or advances irregularly.
Cam follower out of adjustment
Remove side panel from the cabinet and remove the conveyor box cover panel. Rotate the conveyor drive shaft assembly until it is at the extreme end of its lateral movement (either way is OK). Loosen the lock nut on top of cam follower (located in the center of the main frame). Rotate the motor manually until the cam plate is at the top of its stroke. Adjust the screw at the top of the cam follower so that the index pawl in the conveyor box just contacts a tooth on the index wheel. Tighten the lock nut on the top of the cam follower.
Index pawl broken Replace as required.
Rocker bar spring broken Replace as required.
Pin holding index wheel to drive shaft broken
Replace as required.
9) Conveyor advances further than
normal.
Belt too loose. Tighten belt tensioning screws until overshoot
stops. Tighten both screws the same amount. DO NOT OVER TIGHTEN. If necessary, remove a link from the conveyor chain.
10) Conveyor belt jumps off of drive
shaft
Belt too loose Tighten belt tensioning screws until overshoot
stops. Tighten both screws the same amount. DO NOT OVER TIGHTEN. If necessary, remove a link from the conveyor chain.
TC700MC TENDERIZER
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TROUBLESHOOTING CHART
TROUBLE CAUSE REMEDY
MN700-MC0010
8-6
11) Excessive blade bending. See
Section 6
Operator not removing bent blades promptly
Train operator on the proper cleaning and maintenance of machine. Blade assemblies must be removed for daily cleaning and any BENT OR DAMAGED BLADES REMOVED. See Maintenance Section.
Reset pads worn Replace as required.
12) Meat lifts off of conveyor
Meat too thin to be held down by guide frame Stack thin cuts of meat so they will be held
down by the guide frame. See Operating Procedures Section.
TC700MC TENDERIZER
Page 43
MN700-MC0010
9-1
9 WIRING/SCHEMATIC
Page 44
MN700-MC0010
9-2
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