Operation Manual KH-777 (09-10-2013) - R1 PDF

8
YKL Engineering Sdn Bhd (Reg.no.:568547-U)
YKL GROUP
Operation Manual
KH - 777
Heavy Duty Empty
Fruit Bunch Press
Lot 663, Batu 10, Kampung Paya Panjang, 84300 Bukit Pasir, Muar, Johor. Tel: +606-9859 155 Fax: +606-9857 567
Table of Content
1. Preface 1
2. Safety Precaution
2.1 General Precaution 2
2.2 Precaution Relating to Electrical Section 3–4
2.3 Precaution Relating to Inspection or Maintenance When Trouble Occur 5
2.4 Precaution Relating to Symbol of Machine 6
3. Introduction of Machine
3.1 Specification of Machine 7
3.2 Dimension of Drawing 8
3.2.1 Top View
3.2.2 Elevation View
3.2.3 Side View
3.3 Part of Machine 9
3.3.1 7710 Screw Press Main Shaft 10
3.3.2 7712 Gear Coupling 11
7714 Worm Pressing Set(Direct Pressed-Old Version)
7714 Worm Pressing Set (Indirect Pressed-Old Version)
3.3.3 12 – 15
7714 Worm Pressing Set (Direct Pressed-New Version)
7714 Worm Pressing Set( Indirect Pressed-New Version)
3.3.4 7716 Bearing Housing 16
3.3.5 7718 Housing Sets 17
3.3.6 7720 Support Housing 18
3.3.7 7722 Machine Body 19
3.3.8 7724 Gearbox and Motor 20
3.4 Nameplates or Unit Designation of Motor 21
3.5 Metal Object 21
3.6 Specification of Empty Fruit Bunches (EFB) 21
3.7 Lubricant Grease and Lubricant Oil
3.7.1 Gearbox 22
3.7.2 Bearing Housing 23 – 24
4. System Requirement 25
4.1 Front View
4.2 Side View
5. Operating and Maintenance Instruction
5.1 Point to Check Before Turn Off Power 26
5.2 Point to Check Before Turn On Power 26
5.3 Step for Disclose Heavy Duty Empty Fruit Bunch Press Model KH-777 27 – 31
5.4 Step for Assemble Heavy Duty Empty Fruit Bunch Press Model KH-777 32 – 36
6. Schedule
6.1 Inspection 37
6.2 Wear and Tear Schedule of Spare Part 38
6.2.1 Option A: 7714 n Knife Bar Insert (500 – 600 Running Hours) 39
Option B: 7714 n1-d/7714 n1-i Cone Point Knife (500 – 600 Running Hours) 40
6.2.2 7718 h Front Press Cage (1,300 – 1,500 Running Hours) 41 – 43
6.2.3 7718i Back Press Cage (2,300 – 2,500 Running Hours) 44 – 46
6.2.4 7710 c Main Shaft (5,000 Running Hours) 47
6.2.5 7714 b High Pressure Worm (500 – 600 Running Hours, Recond 8 times) 48 – 49
7714 c-d/7714 c-i/7714 c1-d/7714 c1-I Cone Point (500 – 600 Running Hours,
6.2.6 Recond 8 times) 50 – 51
6.2.7 7714 a Low Pressure Worm (1,100 – 1,200 Running Hours, Recond 8 times) 52 – 53
6.2.8 7718 g Front Housing (1,100 – 1,200 Running Hours) 54 – 55
6.2.9 7714 d-d/7714 d-i Knife (1,200 Running Hours) 56
6.3 Specification of Welding Rode for recondition Spare Parts
6.3.1 NOVA Electrodes NX 100 57
6.3.2 AWS E7018 57
7. Trouble Shooting 58
7.1 Machine
7.2 Gear Unit
1 Preface YKL DON’T LOSS IT
EVEN A DROP OF IT
Thank you for choosing Heavy Duty Empty Fruit Bunch Press Model KH-777 which is
professionally designed and manufactured by YKL Group. We are proud to have you among our YKL
Group of users. In order to assure user safety and make most of its outstanding performance over long
period, the machine must be properly installed, operate and the maintenance procedures must clearly
understand and carefully followed. You are encouraged to study Operation Manual exhaustively
before machine is installed and to keep it on file for future reference. Operation Manual contains
concise information of:-
Safety Precaution
Introduction of Machine
System Requirement
Operating and Maintenance Instruction
Schedule
Trouble Shooting
We are always glad to serve you. And hope you continue supporting every special purpose
machine of our company. If you find any problem that can’t find answer in Operation Manual, please
don’t hesitate to contact our agents or specialists as the following:-
: 606-9859 155 / 606-9857 518 : 606-9857 567 / 606-9857 576
: ykl@khunheng.com : www.khunheng.com
Model and Name of Machine : KH-777 Heavy Duty Empty Fruit Bunch Press
Company Name :
Purchase Order Number :
Date of Purchase :
Machine Serial No. :
M3PSF60KPD Gearbox Serial No. :
100HP 6P Elektrim Motor Serial No. :
Marketer In Charges :
Contact Number :
Email :
Date of Training Provided :
Version of Machine : □ Direct Press (Old Version) □ Indirect Press (Old Version)
□ Direct Press (New Version) □ Indirect Press (New Version)
1|Page
2 Safety Precaution YKL DON’T LOSS IT
EVEN A DROP OF IT
Heavy Duty Empty Fruit Bunch Press Model KH-777 is equipped with safety devices
which serve to protect personnel and the machine itself from hazards arising from unforeseen
accidents. However, operators must not rely exclusively on these safety devices; they must also
become fully familiar with the safety guidelines presented below to ensure accident free operation. Yet,
this Operation Manual and the warning signs attached to the machine cover only those hazards which
YKL Group can predict. Be aware that we don’t cover all possible hazards.
2.1 General Precautions
Keep the machine and area around it clean and tiny.
Never operate machine before reading this Operation Manual.
Never exceed the scope and purpose of machine.
Never operate machine with any of parts removed.
Never disassemble machine or attempt any procedures not described in Operation Manual.
Never access the inside of the control panel, transformer, motor and other.
Never keep combustible materials or metals inside electrical control cabinet or terminal box.
Must follow the Maintenance or Wear and Tear Schedule unless unexpected defect.
Must follow the instructions of someone with sufficient training.
Must check all necessary Lubricating Components before running the machine.
Must check that cable and wires are free of damage.
Must ensure the Safety Precaution Symbols are always available and must be strictly follow.
Must strictly follow Operation Manual for installation, operation and maintenance periodically.
Must memorize the position of the emergency stop button.
Operators must being train professionally, having capability to complete various operation safely.
Wear appropriate clothing while working.
2|Page
2.2 Precaution Relating to Electrical Section
Prepare a primary supply that complies with the following requirements:-

 Voltage : 380 – 415 V
 Kilowatt (KW) or Host Power (HP) : 75 KW or 100 HP
 Power Supply Frequency : 50 – 60 HZ
 Diagram :
3|Page
Control Panel
 Recommended : 100HP 6 Pole Forward Star Delta Control Panel
 Photo :-
 Instruction :
4|Page
2.3 Precaution Relating to Inspection or Maintenance When Trouble Occur
In order to prevent unforeseen accidents, damage to the machine and others, it is essential to
observe the following points when performing inspection or maintenance when trouble has occurred.
Turn the power off before starting inspection or changing parts.
Check and ensure machine stopped before inspection or maintenance during trouble occurs.
Never turn on the power when saw the following sign:-
Consult person responsible for maintenance to determine what corrective measures need to be
taken.
Use only the specified replacement parts and fuses.
If 2 or more person must work together, establish signals so that they can communicate to confirm
safety before proceeding to each new step.
Operators must provide appropriate and clean operational areas without any prejudice to the
operator for the safe operation and routine maintenance.
When parts are removed during inspection or repair work, always replace them as they were and
secure them properly with their screw and others.
When carrying out inspection in which measuring instruments are used (eg: Voltage checks –
ensure the instrument is properly calibrated).
5|Page
2.4 Precaution Relating to Symbol of Machine
Caution Reminder Potential Damage to VCI Corrosion Protection

Property
Oil Plug Drain Plug Air Relieve Valve
Grease Nipple Gearbox is delivered Normal Level of Lubricant

without Lubricant Oil Oil for Gearbox
6|Page
3 Introduction of Machine YKL DON’T LOSS IT
EVEN A DROP OF IT
Empty Fruit Bunches (EFB) produced from Palm Oil Mill process of moisture content of 60%
to 65% can hardly suitable to be utilized for commercial purpose. We have introduce this Heavy Duty
Empty Fruit Bunch Press Model KH-777 to extract and remove the press juice from EFB or shred
EFB fibre to moisture content of 42% to 50%, so they can be used on raw materials for biomass
compost, boiler fuel and others. Besides, the press juice recovered contains a small percentage of
sludge oil which can be marketed on a byproduct.
3.1 Specification of Machine
Machine : Heavy Duty Empty Fruit Bunch Press
Model : KH-777
Capacity : 7 – 8 MT of Empty Fruit Bunches per Hour
Gear Unit : SEW Model M3PSF60KPD
Motor : Elektrim Capacity 75KW / 1,000rpm
Moisture Content : 45% - 50% (Directly Pressed)

42% - 48% (Indirectly Pressed)
Oil Content in Fibre : 1.2% - 1.9% on sample (Wet Basis)
Oil Yield : 0.15% - 0.30% on EFB (Depend on oil content in empty bunches)
Dimension : H 1,900 x L 4,015 x W 1,580mm
Weight : 8,000kg
Patent No. : MY-140402-A
7|Page
3.2 Dimension Drawing of Machine
3.1.1 Top View
3.1.2 Elevation View
3.1.3 Side View
8|Page
3.3 Part of Machine
7714 Worm Pressing Set
7724 Gearbox and Motor
7712 Gear Coupling
7710 Screw Press Main Shaft
7716 Bearing Housing 7720 Support Housing
7722 Machine Body
7718 Housing Set
9|Page
3.3.1 7710 Screw Press Main Shaft
Item Code Description Quantity per Machine
 7710 a Circlip 01 Pc
 7710 b Coupling Key 01 Pc
 7710 c Main Shaft 01 Lgth
 7710 d Spherical R/Bearing (22238) 01 Pc
 7710 e Oil Seal 01 Pc
 7710 f Oil Seal Plate 01 Pc
 7710 g NC Cap Screw 06 Pcs
 7710 h Key (4pcs per set) 01 Sets
Model: KH-777
YKL Engineering Sdn Bhd
Lot 663, Batu 10, Kampung Paya Panjang, 84300, Bukit Pasir, Muar, Johor.
Tel: 606-9859 155 Fax: 606-9857 567
E-mail: ykl@khunheng.com.my website: www.khunheng.com
10 | P a g e
3.3.2 7712 Gear Coupling
 7712 b MS Stud and Nut 02 Sets
 7712 c Cap Screw 01 Pc
 7712 d Coupling (F) 01 Pc
 7712 f Coupling (M) 01 Pc
 7712 h Coupling Cover 01 Pc
 7712 i MS Bolt 03 Pcs
 7712 j MS Bolt and Nut 02 Sets
Model: KH-777
Tel: 606-9859 155 Fax: 606-9857 567
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3.3.3 7714 Worm Pressing Set (Direct Pressed - Old Version)
 7714 a Low Pressure Worm 01 Pc
 7714 b High Pressure Worm 01 Pc
 7714 c-d Cone Point 01 Pc
 7714 d Knife 01 Pc
 7714 e NC Bolt and Spring Washer 04 Sets
 7714 g Thread Collar 01 Pc
 7714 h Bush 01 Pc
 7714 i Half Bush 02 Pcs
 7714 j NC Bolt and Nut 04 Sets
 7714 m GSK L-Key Screw, Nut and Spring Washer 03 Sets
 7714 n Knife Bar Insert (3 pcs per set) 01 Set
Model: KH-777
Tel: 606-9859 155 Fax: 606-9857 567
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7714 Worm Pressing Set (Indirect Pressed - Old Version)
 7714 c-i Cone Point 01 Pc
 7714 d Knife 01 Pc
 7714 e NC Bolt and Spring Washer 04 Sets
 7714 h Bush 01 Pc
 7714 m GSK L-Key Screw, Nut and Spring Washer 03 Sets
 7714 n Knife Bar Insert (3 pcs per set) 01 Set
Model: KH-777
Tel: 606-9859 155 Fax: 606-9857 567
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7714 Worm Pressing Set (Direct Pressed - New Version)
 7714 c1-d Cone Point 01 Pc
 7714 h Bush 01 Pc
 7714 m1-d NC Bolt, Spring Washer 04 Sets
 7714 n1-d Cone Point Knife 02 Pcs
Model: KH-777
Tel: 606-9859 155 Fax: 606-9857 567
14 | P a g e
7714 Worm Pressing Set (Indirect Pressed - New Version)
 7714 c1-i Cone Point 01 Pc
 7714 h Bush 01 Pc
 7714 m1-i NC Bolt, Spring Washer 04 Sets
 7714 n1-i Cone Point Knife 02 Pcs
Model: KH-777
Tel: 606-9859 155 Fax: 606-9857 567
15 | P a g e
3.3.4 7716 Bearing Housing
 7716 a NC Bolt and Spring Washer 06 Sets
 7716 b Oil Seal Cover 01 Pc
 7716 c Oil Seal 01 Pc
 7716 d Spherical R/Bearing (23338) 01 Pc
 7716 e Bearing Housing 01 Pc
 7716 f Thrust Bearing (29430) 01 Pc
 7716 g Thrust Plate 01 Pc
 7716 h Nipple 01 Pc
 7716 i MS Bolt 04 Pcs
Model: KH-777
Tel: 606-9859 155 Fax: 606-9857 567
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3.3.5 7718 Housing Sets
 7718 a Paking Seal 01 Pc
 7718 b Inlet Housing 01 Pc
 7718 c Back Body Cage 01 Pc
 7718 d NC Bolt, Nut and Spring Washer 06 Sets
 7718 f Front Body Cage 01 Pc
 7718 g Front Housing 01 Pc
 7718 h Front Press Cage 01 Pc
 7718 i Back Press Cage 01 Pc
 7718 j NC Bolt, Nut and Spring Washer 04 Sets
 7718 k NC Bolt, Nut and Spring Washer 02 Sets
 7718 l O’ Ring 01 Pc
 7718 s Front Lining Bar 08 Pcs
 7718 t Back Lining Bar 08 Pcs
 7718 u Inlet Lining Bar 08 Pcs
Model: KH-777
Tel: 606-9859 155 Fax: 606-9857 567
17 | P a g e
3.3.6 7720 Support Housing
 7720 a MS Bolt and Spring Washer 06 Sets
 7720 b Oil Seal Cover 01 Pc
 7720 c Oil Seal 01 Pc
 7720 d Support Housing 01 Pc
 7720 e Spherical/R Bearing (22326) 01 Pc
 7720 f Thrust Plate 01 Pc
 7720 g Thrust Bearing (29424) 01 Pc
 7720 h Bearing Cover 01 Pc
 7720 i NC Bolt, and Spring Washer 06 Sets
Model: KH-777
Tel: 606-9859 155 Fax: 606-9857 567
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3.3.7 7722 Machine Body
 7722 a Spacer 04 Pcs
 7722 b Long Stud 04 Lgth
 7722 c Housing Base 01 Pc
 7722 d Adjusting Stud and Nut 04 Sets
 7722 e NC Bolt, Nut and Spring Washer 12 Sets
 7722 f NC Bolt, Nut and Spring Washer 24 Sets
 7722 g NC Bolt, Nut and Spring Washer 10 Sets
 7722 h Body Cage Support 02 Pcs
 7722 k NC Nut 08 Pcs
 7722 m MS Bolt, Nut and Spring Washer 21 Sets
Model: KH-777
Tel: 606-9859 155 Fax: 606-9857 567
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3.3.8 7724 Gearbox and Motor
 7724 a Motor 315S-6 01 Pc
 7724 b 5 SPC Pulley Motor 01 Pc
 7724 c Motor Base 01 Pc
 7724 d MS Adjusting Stud and Nut 02 Sets
 7724 e Gearbox M3PSF60KPD 01 Pc
 7724 f Pulley Cover 01 Pc
 7724 g 5 SPC Pulley Gearbox 01 Pc
 7724 h NC Bolt, Nut, Common Washer and Spring Washer 06 Sets
 7724 i NC Bolt, Nut, Common Washer and Spring Washer 04 Sets
 7724 j MS Bolt, Nut, Common Washer and Spring Washer 04 Sets
 7724 k Top Body Cover 01 Pc
 7724 l Side Body Cover 02 Pcs
 7724 m Back Side Cover 02 Pcs
 7724 n SPC Belting (5 pcs per set) 01 Set
 7724 o MS Adjusting Stud and Nut 01 Set
Model: KH-777
Tel: 606-9859 155 Fax: 606-9857 567
20 | P a g e
3.4 Nameplates or Unit Designation of Motor
3.5 Metal Object

Will caused serious damage to the pressing equipment, especially Worm Pressing Set.
Ensure Conveying System, Elevating System, Silo, Hopper, Empty Fruit Bunch Press and
other equipment or facilities are free from carrying any foreign metal object at all time.
3.6 Specification of Empty Fruit Bunches (EFB)

Hard Bunches and Un-stripped Bunches (USB) should LESS than 2% of Fresh Fruit Bunches.
Empty Fruit Bunches (EFB) should be pre-processed by Double Deck Bunch Crusher Model
KH-7.60 or Heavy Duty FFB/60 Splitter Model KH-7.
Fresh EFB processed on the same day or maximum 2 days directly from Palm Oil Mill.
Density of EFB is 350kg / m3
21 | P a g e
3.7 Lubricant Grease and Lubricant Oil
Lubricant is a substance that reduces friction between moving parts, protecting the surfaces
against wear that composed of oil and additives. Lubricants are usually expected to reduce wear and
often to prevent overheating and corrosion. The basic types of Lubricant are divided into four (4)
classes which included Lubricant Oil, Lubricant Grease, Dry Lubricant and Lubricant Gasses.
Basically, Heavy Duty Empty Fruit Bunch Press Model KH-777 is using Lubricant Grease and
Lubricant Oil in the Bearing Housing and Gearbox which as the following:-
3.7.1 Gearbox
Type of Lubricant Grease = Multi-Purpose Grease (Recommended) or equivalent
Type of Lubricant Oil = Shell Omala 460 (Recommended) or equivalent
Quantity of Lubricant Oil = 84 Litre
= Check Lubricant Oil of Oil Plug every 48 running hours.
Check Lubricant Grease of Grease Nipple every 150

=
running hours.
Drain out the Lubricant Oil from Drain Outlet

=  First 1,000 running hours.
 Every after 2,500 running hours.
= Air Relieve Valve
22 | P a g e
3.7.2 Bearing Housing
Types of Lubricant Grease = Multi-Purpose Grease (Recommended) or equivalent
Types of Lubricant Oil = Shell Omala 460 (Recommended) or equivalent
Quantity of Lubricant Oil = 35 Litre
= Check Lubricant Oil of Oil Plug every 48 running hours.
Check Lubricant Grease of Grease Nipple every 150

=
running hours.
Drain out the Lubricant Oil from Drain Outlet
=  First 1,000 running hours.
 Every after 2,500 running hours.
Fill in mixture of Lubricating Grease (⅙) and Lubricant
=
Oil (⅚) until ⅗ full of Bearing Housing.
23 | P a g e
Special Feature in Bearing Housing
 Filling Lubricant into Oil Holder through Oil Inlet.
 Lubricant inside Oil Holder flows into Bearing Housing.
 About ¾of all 3 pieces bearing are covered with Lubricant to prolong their life span.
 Abrasive bearing and metal particles drop from (A) into Oil Holder and accumulated in
the lower portion of Oil Holder.
 The Lubricant inside Bearing Housing is not contaminated with abrasive bearing, water
and metal particles.
 The advantage of double protection.
 Drain out the Lubricant from Dain Outlet in every 10 month.
24 | P a g e
4 System Requirement YKL DON’T LOSS IT
EVEN A DROP OF IT
Electrical Panel = Star Delta Type System.

Minimum requirement of Platform I-beam Size = W 152 x H 152 x Thk 12mm.
Preferably space between 2 machine = 1.50m
Preferably space between Gearbox and Railing = 1.20m
Minimum height between Feeding Conveyor and machine = 1.0m
Chute inclination angle = 42°
Required maintenance I-beam for maintenance purpose.
The chute has to make it in segmented design.
Electrical Panel completed with Ampere Meter, Button Emergency Stop, and Button Forward.
The better chute inclination direction is as the following:
4.1 Front View
4.2 Side View
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5 Operating and Maintenance Instruction YKL DON’T LOSS IT
EVEN A DROP OF IT
5.1 Point to Check before Turn off Power
Ensure all Empty Fruit Bunches (EFB) have been fed into Remarks:
Machine.
1. Ampere of machine should not more than 130A.
2. Shell poured should be more and more after a while.
Close chute to press fully. 3. Observe output of the Machine.
4. EFB fibre will be squeezed out because of shell poured
5. Continue to poured in shell until all EFB Fibre is
Swith off EFB Feeding Scapper Conveyors. squeezed out (can be read on amp meter).
6. Ampere will become about 50A when all EFB Fibre
has been squeezed out.
Pour dry shell into Machine's Inlet Housing slowly.
Check either EFB Fibre has been transferred into warehouse or

boiler. If yes switch off EFB Fibre Scrapper Conveyors.
Switch of Panel Station.
5.2 Point to Check before Turn on Power
Check conveyors and machine to ensure don't have scrap metal iron,
stones or foreign material within system.
Switch on Panel Station.
Switch on Outgoing Empty Fruit Bunches (EFB) Fibre Scrapper

Conveyors, follow by Press and EFB Feeding Scrapper Conveyors.
Ensure there is don't have EFB remain in Machine and the rotation of
rotor shaft is correct.
Swith on Machine and ensure direction of rotation rotor shaft is correct.
Open Chutes of Machine (EFB Feeding Scarper Conveyor - Top of

Machine)
26 | P a g e
5.3 Step for Disclose Heavy Duty Empty Fruit Bunch Press Model KH-777
Palm Kernel Shell
Step 1 Step 2
Put Palm Kernel Shell into Inlet Housing
Way out 02 pcs Back Side Cover (7724 m).
(7718 b) to clean out EFB Fibre.
Step 3 Step 4
Way out Oil Seal Cover (7716 b) for replace
Relieve 06 sets NC Bolt and Spring Thrust Bearing 29430 (7716 f), and Thrust
Washer (7716 a). Plate (7716 g) .
Step 5 Step 6
Relieve 04 pcs Nut (7722 k) of Long Stud Relieve 07 sets Bolt, Nut, Spring Washer
near Support Housing by Spanner YKL . (7720 j) of Support Housing..
27 | P a g e
Step 7 Step 8
Way out Support Housing (7720 d). Way out Spacer (7722 a).
Step 9 Step 10
Push Long Stud (7722 b) to back. Relieve Thread Collar (7714 g).
Step 11 Step 12
Way out Half Bush (7714 i). Way out Bush (7714 h).
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Step 13 Step 14
Release Top Body Cage Cover (7724 k),
Way out componet Worm Pressing Set
Side Body Cover (7724 l), Back Side Cover
(7714).
(7724 m).
Step 15 Step 16
Relieve 04 sets Bolt, Nut, Spring Washer Relieve 02 sets NC Bolt, Nut and Spring
(7718 j) of Front Housing. Washer (7718 k).
Step 17 Step 18
Relieve 12 sets NC Bolt, Nut and Spring
Washer (7722 f) between Font Body Cage Way out Front Housing (7718 g).
(7718 f) and Front Housing (7718 g).
29 | P a g e
Step 19 Step 20
Relieve 10 sets NC Bolt, Nut and Spring Relieve 12 sets NC Bolt, Nut and Spring
Washer (7722 g). Washer (7722 e).
Step 21 Step 22
Release Body Cage Support (7722 h).
Washer (7718 d).
Step 23 Step 24
Way out Front Body Cage (7718 f) together Way out Back Body Cage (7718 c) together
with Front Press Cage (7718 h). with Back Press Cage (7718 i).
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Step 25 Step 26
Washer (7722 j) and NC Bolt, Nut and Release Inlet Housing (7718 b).
Spring Washer (7722 f).
Step 27 Step 28
Relieve NC Cap Screw (7712 c) and Gear
Coupling (7712 d, f) to 2 direction for way Release Main Shaft (7710 c).
out Circlip (7710 a).
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5.4 Step for Assembly Heavy Duty Empty Fruit Bunch Press Model KH-777
Step 1 Step 2
Restrict NC Cap Screw (7712 c) and Gear
Assemble Main Shaft (7710 c). Coupling (7712 d, f) to 2 direction for
assemble Circlip (7710 a).
Step 3 Step 4
Restrict 12 sets NC Bolt, Nut and Spring
Assemble Inlet Housing (7718 b). Washer (7722 j) and NC Bolt, Nut and
Spring Washer (7722 f).
Step 5 Step 6
Assemble Back Body Cage (7718 c) together Assemble Front Body Cage (7718 f)
with Back Press Cage (7718 i). together with Front Press Cage (7718 h).
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Step 7 Step 8
Assemble Body Cage Support (7722 h).
Washer (7718 d).
Step 9 Step 10
Restrict 12 sets NC Bolt, Nut and Spring Restrict 10 sets NC Bolt, Nut and Spring
Washer (7722 e). Washer (7722 g).
Step 11 Step 12
Assemble Front Housing (7718 g). Washer (7722 f) between Font Body Cage
(7718 f) and Front Housing (7718 g).
33 | P a g e
Step 13 Step 14
Restrict 02 sets NC Bolt, Nut and Spring Restrict 04 sets Bolt, Nut, Spring Washer
Washer (7718 k). (7718 j) of Front Housing.
Step 15 Step 16
Assemble Top Body Cage Cover (7724 k),
Side Body Cover (7724 l), Back Side Cover Install componet Worm Pressing Set (7714).
(7724 m).
Step 17 Step 18
Assemble Bush (7714 h). Assemble Half Bush (7714 i).
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Step 19 Step 20
Restrict Thread Collar (7714 g). Way out Long Stud (7722 b) to back.
Step 21 Step 22
Assemble Spacer (7722 a). Assemble Support Housing (7720 d).
Step 23 Step 24
Restrict 07 sets Bolt, Nut, Spring Washer Restrict 04 pcs Nut (7722 k) of Long Stud
(7720 j) of Support Housing.. near Support Housing by Spanner YKL .
35 | P a g e
Step 25 Step 26
Assemble Oil Seal Cover (7716 b) for
Restrict 6 sets NC Bolt and Spring
replace Thrust Bearing 29430 (7716 f), and
Washer (7716 a).
Thrust Plate (7716 g) .
Step 27
Assemble 2 pcs Back Side Cover (7724 m).
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6 Schedule YKL DON’T LOSS IT
EVEN A DROP OF IT
6.1 Inspection
Daily
 Ensure don’t have scrap metal, iron, stone or foreign material within system.
 Check level of Lubricant Oil Gearbox and Bearing Housing.
Oil Plug Grease Nipple Normal level of Lubricant Oil
 Make sure all Empty Fruit Bunches (EFB) Fibre is squeezes out, before switch off
machine.
 Check belt tension of motor and tighten belt.
 Check tightens bolt and nut of machine.
Weekly
 Check and pump in Lubricant Grease into Bearing Machine, Gearbox and Motor.
 Check Regular Maintenance Period through the following Wear and Tear Spare Part
Schedule and the sticker place in the machine.
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6.2 Wear and Tear Schedule of Spare Part
The standard or recommend Spare Parts Wear and Tear Schedule of Heavy Duty Empty Fruit Bunch
Press Model KH-777 are as the following: -
Code Description Unit Remarks

Knife Bar Insert
7714 n Set New ► 500 – 600 Running Hours
(3 pcs per set)
7714 n1-d
Cone Point Knife Pc New ► 500 – 600 Running Hours
7714 n1-i
7718 h Front Press Cage Pc New ► 1,300 – 1,500 Running Hours
7718 i Back Press Cage Pc New ► 2,300 – 2,500 Running Hours
7710 c Main Shaft Lgth New ► 5,000 Running Hours
7714 b High Pressure Worm (H)1 Pc Recond ► 500 – 600 Running Hours (8 Times)
7714 c-d
7714 c-i
Cone Point (H)1 Pc Recond ► 500 – 600 Running Hours (8 Times)
7714 c1-d
7714 c1-i
7714 a Low Pressure Worm (H)1 Pc Recond ► 1,100 – 1,200 Running Hours (8 Times)
7718 g Front Housing (H)1 Pc Recond ► 1,100 – 1,200 Running Hours
7714 d Knife Pc Recond ► 1,200 Running Hours
7718 c Back Body Cage Pc Standby unit
7718 f Front Body Cage Pc Standby unit
Remarks:
1. The Spare Parts mentioned above are standard item of wear and tear.
2. Other spare parts will be changes depend on its condition.
3. The above mention running hours are only recommendation. It will impart directly by reason
such as:
Capacity Palm Oil Mill
Condition of Fresh Fruit Bunches
Condition of Empty Fruit Bunches
Quantity of Un-stripped Bunches or Hard Bunches
Others
1
H = Hard Facing
38 | P a g e
6.2.1 Option A: 7714 n Knife Bar Insert (500 to 600 running hours)
New Condition Wear and Tear Condition
- Need replace new sets.

Original size are as show in above
drawing. - To prevent fibre stuck which can
cause machine jumped.
Step to Replace Knife Bar Insert (7714 n)
Step 01 Relieve 3 sets of GSK L-K Screw, Nut and Spring Washer (7714 m).
Step 02 Way out 3 pcs of Knife Bar Insert (7714 n).
Step 03 Replace the news 3 pcs Knife Bar Insert (7714 n).
39 | P a g e
Option B: 7714 n1-d / 7714 n1-i Cone Point Knife (500 to 600 running hours)
Figure1: 7714 n1-d Cone Point Knife Figure 2: 7714 n1-i Cone Point Knife

drawing. - To prevent fibre stuck which can
cause machine jumped.
Step to Replace Cone Point Knife (7714 n1-d / 7714 n1-i)
Step 01 Relieve 4 sets of NC Bolt and Spring Washer(7714 m1-d / 7714 m1-i).
Step 02 Way out 2 pcs of Cone Point Knife (7714 n1-d / 7714 n1-i).
Step 03 Replace the news 2 pcs of Cone Point Knife (7714 n1-d / 7714 n1-i).
40 | P a g e
6.2.2 7718 h Front Press Cage (1,300 to 1,500 running hours)

- Original size are as show in above - Hole worm out more than 50% from
drawing. original size.
- Original Size of Hole: - Need replace new sets.
* Small = 4 mm - To prevent fibre stuck at hole, oil come
out from Front Housing and affect
* Big = 6 mm moisture content in fibre.
41 | P a g e
Step to Replace Front Press Cage (7718 h)
Step 01 Put Palm Kernel Shell into Inlet Housing (7718 b) to clean out EFB Fibre.
Step 02 Way out Back Side Cover (7724 m).
Step 03 Relieve 04 pcs Nut (7722 k) of Long Stud near Support Housing by Spanner YKL.
Step 04 Relieve 07 sets Bolt, Nut, Spring Washer (7720 j) of Support Housing.
Step 05 Way out Support Housing (7720 d).
Step 06 Way out Spacer (7722 a).
Step 07 Push Long Stud (7722 b) to back.
Step 08 Relieve Thread Collar (7714 g).
Step 09 Way out Half Bush (7714 i).
Step 10 Relieve Bush (7714 h).
Step 11 Way out Worm Pressing Set (7714).
Step 12 Release Top Body Cage Cover (7724 k), Side Body Cover (7724 l), Back Side Cover (7724 m).
Step 13 Relieve 04 sets Bolt, Nut, Spring Washer (7718 j) of Front Housing.
Step 14 Relieve 02 sets NC Bolt, Nut and Spring Washer (7718 k).
Step 15 Relieve 12 sets NC Bolt, Nut and Spring Washer (7722 f) between Font Body Cage (7718 f) and
Front Housing (7718 g).
Step 16 Way out Front Housing (7718 g).
Step 17 Relieve 10 sets NC Bolt, Nut and Spring Washer (7722 g).
Step 18 Relieve 12 sets NC Bolt, Nut and Spring Washer (7722 e).
Step 19 Release Body Cage Support (7722 h).
Step 20 Relieve 06 sets NC Bolt, Nut and Spring Washer (7718 d).
Step 21 Way out Front Body Cage (7718 f) together with Front Press Cage (7718 h).
Step 22 Cut the place welding between Front Body Cage (7718 f) and Front Press Cage (7718 h).
Step 23 Replace new Front Press Cage (7718 h).
Step 24 Welding between Front Body Cage (7718 f) and Front Press Cage (7718 h) by Welding Rod
E7018
42 | P a g e
Step 25 Assemble Front Body Cage and Front Press Cage (7718 h) with Inlet Housing (7718 b).
Step 26 Welding Front Lining Bar (7718 s) with AWS E7018.
Cut the place welding between Front Replace new Front Press Cage (7718 h).
Body Cage (7718 f) and Front Press Cage
(7718 h).
Welding between Front Body Cage (7718 Assemble Front Body Cage and Front
f) and Front Press Cage (7718 h) by Press Cage (7718 h) with Inlet Housing
Welding Rod E7018 (7718 b).
Welding Front Lining Bar (7718 s) with

AWS E7018.
43 | P a g e
6.2.3 7718 i Back Press Cage (2,300 to 2,500 running hours)

- Hole worm out more than 50% from
original size.
Original Size of Hole is 6mm as show in - Need replace new sets.
above drawing. - To prevent fibre stuck at hole, oil come
out from Front Housing and affect
moisture content in fibre.
44 | P a g e
Step to Replace Back Press Cage (7718 i)
Step 16 Way out Front Housing (7718 g).
Step 17 Relieve 10 sets NC Bolt, Nut and Spring Washer (7722 g).
Step 18 Relieve 12 sets NC Bolt, Nut and Spring Washer (7722 e).
Step 19 Release Body Cage Support (7722 h).
Step 20 Relieve 06 sets NC Bolt, Nut and Spring Washer (7718 d).
Step 21 Way out Front Body Cage (7718 f) together with Front Press Cage (7718 h).
Step 22 Way out Back Body Cage (7718 c) and Back Press Cage (7718 i).
Step 23 Cut the place welding between Back Body Cage (7718 c) and Back Press Cage (7718 i).
Step 24 Replace new Back Press Cage (7718 i)
45 | P a g e
Step 25 Welding between Back Body Cage (7718 c) and Back Press Cage (7718 i) by Welding Rod
7018.
Step 26 Assemble Back Body Cage (7718 c) and Back Press Cage (7718i) with Inlet Housing (7718 b).
Step 27 Welding Back Lining Bar (7718 t) with AWS E7018.
Cut the place welding between Back Replace new Back Press Cage (7718 i).
Body Cage (7718 c) and Back Press Cage
(7718 i).
Welding between Back Body Cage Assemble Back Body Cage (7718 c) and
(7718 c) and Back Press Cage (7718 i) by Back Press Cage (7718i) with Inlet
Welding Rod 7018. Housing (7718 b).
Welding Back Lining Bar (7718 t) with

AWS E7018.
46 | P a g e
6.2.4 7710 c Main Shaft (5,000 running hours)

drawing. - To prevent Main Shaft broken and
capacity of machine drop.
Step to Replace Main Shaft (7710 c)
Kindly refer to Section 6.3 Step to Disclose Heavy Duty Empty Fruit Bunches Press Model
KH-777 (Page 27 to Page 31).
47 | P a g e
6.2.5 7714 b High Pressure Worm (500 to 600 running hours – Rebuild 8 time)

Pointed area need recond with AWS
drawing. E7018 unitl 4mm lesser than original
size .
Recondition Hard Facing

- Can recond for 8 times (depend on condition).
- To prevent its leaf broken or worm out - Weld NOVA NX 100 in pointed area.
that caused machine jammed or capacity
drop. - To increase its wear resistance
48 | P a g e
Step to Recond High Pressure Worm (7714 b)
Step 11 Way out Cone Point (7714 c-d/7714 c-i/7714 c1-d/7714 ci-i), and High Pressure Worm (7714 b).
Step 12 Check the dimension leaf of High Pressure Worm (7714 b) with necassry tools.
Step 13 Welding the wear areas with AWS E7018.
Step 14 Weld NOVA NX 100 for Hard Facing of High Pressure Worm (7714 b).
Step 15 Grind the area Hard Facing
Step 16 Painting.
49 | P a g e
6.2.6 7714 c-d / 7714 c-i / 7714 c1-d / 7714 c1-i Cone Point (500 to 600 running
hours – 8 times)

Pointed area need recond with AWS
drawing. E7018 unitl 6mm lesser than original
size .
Recondition Hard Facing
- Can recond for 8 times (depend on condition). - Weld NOVA NX 100 for Hard
- To prevent capacity drop. Facing.
- To increase its wear resistance
50 | P a g e
Step to Replace Cone Point (7714 c-d/7714 c-i/7714 c1-d/ 7714 c1-i)
Step 11 Way out Cone Point (7714 c-d/7714 c-i/7714 c1-d/7714 ci-i).
Step 12 Relieve 04 sets NC Bolt and Spring Washer (7714 e) if any.
Step 13 Way out Knife Bar (7714 d) if any.
Step 14 Relieve 03 sets GSK L-K Screw, Nut and Spring Washer (7714 m) or 04 sets NC Bolt and
Spring Washer (7714 m1-d/7714m1 -i).
Step 15 Way out 03 pcs Knife Bar Insert (7714 n) or Cone Point Knife (7714 n1-d/7714 n1-i).
Step 16 Check the dimension of Cone Point (7714 c-d/7714 c-i/7714 c1-d/7714 ci-i) with necassry tools.
Step 18 Weld NOVA NX 100 for Hard Facing of Cone Point (7714 c-d/7714 c-i/7714 c1-d/7714 ci-i) .
Step 19 Grind the area Hard Facing.
Step 20 Painting.
51 | P a g e
6.2.7 7714 a Low Pressure Worm (1,100 to 1,200 running hours – 8 time)

- Pointed area need recond with AWS
E7018 unitl 4mm lesser than original
size .
- Can recond for 8 times (depend on condition).
drawing.
- To prevent its leaf broken or worm out
that caused machine jammed or capacity
drop.
52 | P a g e
Step to Recond Low Pressure Worm (7714 a)
Step 11 Way out Cone Point (7714 c-d/7714 c-i/7714 c1-d/7714 ci-i), High Pressure Worm (7714 b) and Low
Pressure Worm (7714 a).
Step 12 Check the dimension leaf of Low Pressure Worm (7714 a) with necassry tools.
Step 14 Weld NOVA NX 100 for Hard Facing of Low Pressure Worm (7714 a).
Step 15 Grind the area Hard Facing
Step 16 Painting.
53 | P a g e
6.2.8 7718 g Front Housing (1,100 to 1,200 running hours)
Original size are as show in above Pointed area need recond with NOVA
drawing. NX 100.
Hard Facing
Recond 1 layer as Hard

Facing with NOVA 100.
54 | P a g e
Step to Recond Front Housing (7718 g)
55 | P a g e
6.2.9 7714 d Knife (1,200 running hours)
Original size are as show in above Will recond where was worm out except
drawing. occur condition as per pointed area.
Step to Recond / Replace Knife (7714 d-d/7714 d-i)
Step 01 Relieve 04 sets NC Bolt, Nut and Spring Washer (7714 e)
Step 02 Way out Knife (7714).
Step 03 Relieve 03 sets of GSK L-K Screw, Nut and Spring Washer (7714 m).
Step 04 Way out 3 pcs of Knife Bar Insert (7714 n).
Step 05 Recond necessary area that worm out.
Step 06 Replace new Knife (7714 d) if the condition can't recond.
56 | P a g e
6.3 Specification of Welding Rode for Recondition Spare Parts
6.3.1 NOVA ELECTRODES NX 100
Temperature : 450° Centigrade

Hardness : 64 – 66 H.R.C
Layer : 2 Layer (Maximum)
Sizes and Amperes :
Sizes 3.20 mm 4.0 mm
Amperes 100 – 120 amp 120 – 160 amp
Special Features:
 Ability to remain its harness even at high temperatures.
 Excellent metal recovery up to 190%.
 Ideal for two (2) layer deposits.
 Provides regular and smooth beads.
 Easy to apply in all positions.
6.3.2 AWS E7018
AWS E7018
Yield Stress : 520N/mm2
Tensile Strength : 590N/mm2
Elongation : 27%
Reduction of Area : 78%
CVN Impact Values : 100J @ -20°C
57 | P a g e
7 Trouble Shooting YKL DON’T LOSS IT
EVEN A DROP OF IT
7.1 Machine
No Problem Reason Solution
 Loosen Thread Collar, forward

Machine jammed when start  EFB remain or stuck in
1 and reserve the rotation of main
up machine machine.
shaft not more than 3 times.
Oil leaking between Front

 Bolt and nut loosen  Tightened bolts and nuts
2 Housing and Front Body
 O’ Ring damage  Replace new O’ Ring
Cage
 Bolt and nut loosen  Tightened bolts and nuts
 Hole of Bolt and Nut become  Grind hole with size bolt at iron
3 Machine shaking bigger tablet and weld with Machine
Base
 Body Cage crack  Replace new Side Body Cage
4 Oil overflow from oil pan  Pan hole stuck with fibre  Clear the fibre or sludge
 Check maintenance schedule

5 Capacity drop  Spare Parts wear and provide maintenance
services if needed
 Consult with mechanical

6 Platform unstable  Platform structure not rigid
technician or contractor.
 Portion Main Shaft in Coupling

 Replace new Main Shaft and
7 Main Shaft broken (M) not rotating.
perform maintenance work.
 Overload
7.2 Gear Unit

No Problem Possible Causes Solution
 High oil level  Correct oil level

Oil Leaking
 Drive operated in incorrect  Mount breather plug
1 * Oil drain plug / valve
mounting position correctly
* Breather plug
 Frequent cold starts (oil foams)
Oil Leaking
 Gasket on cover plate / gearcase
* Cover plate  Tighten bolts on respective
cover / bearing cover / mounting
* Gearcase cover cover plate
2 flange leaking
* Bearing Cover  Vent gear unit
 Sealing lip of oil seal upside down
* Mounting flange  Contact customer services
 Oil seal damaged or worm
* Output, input end oil seal
58 | P a g e
Main Office:
Lot 663, Bt.10 Kampung Paya Panjang
84300 Bukit Pasir, Muar Johor, Malaysia.
Tel : +606-985 9155
: +606-985 9076
: +606-985 7518
Fax : +606-985 7567
: +606-985 7576
Email : ykl@khunheng.com.my
Website :www.khunheng.com
THE TRADE AND PUBLIC are herely informed that the above invention is registered and protected
as patent in Malaysia under Malaysia Patent No: MY-140402-A.
By virtue of the Malaysian Patent Act, 1983, the exclusive rights to make, offer for sale, sell or use
the invention belong to YKL ENGINEERING SDN BHD (Company No. 568547-U).
WARNING NOTICE HERELY GIVEN that, any persons who, or firm or companies which import,
export, manufacture, offer for sale, sell or use the MECHANICAL SCREW PRESS in Malaysia
which does not originate from YKL ENGINEERING SDN BHD (Company No. 578547-U) is an
infringement of the patent and legal proceedings will be taken against such
persons or firm or companies found infringing the patent.

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8

YKL Engineering Sdn Bhd (Reg.no.:568547-U)

: 606-9859 155 / 606-9857 518 : 606-9857 567 / 606-9857 576

Purchase Order Number :

Machine Serial No. :

M3PSF60KPD Gearbox Serial No. :

100HP 6P Elektrim Motor Serial No. :

Date of Training Provided :

2.1 General Precautions

Keep the machine and area around it clean and tiny.

Never operate machine before reading this Operation Manual.

Never exceed the scope and purpose of machine.

Never operate machine with any of parts removed.

Must follow the instructions of someone with sufficient training.

Must check that cable and wires are free of damage.

Must memorize the position of the emergency stop button.

Wear appropriate clothing while working.

Prepare a primary supply that complies with the following requirements:-

Caution Reminder Potential Damage to VCI Corrosion Protection

Oil Plug Drain Plug Air Relieve Valve

Grease Nipple Gearbox is delivered Normal Level of Lubricant

3.1 Specification of Machine

Machine : Heavy Duty Empty Fruit Bunch Press

Capacity : 7 – 8 MT of Empty Fruit Bunches per Hour

Gear Unit : SEW Model M3PSF60KPD

Motor : Elektrim Capacity 75KW / 1,000rpm

Moisture Content : 45% - 50% (Directly Pressed)

Oil Content in Fibre : 1.2% - 1.9% on sample (Wet Basis)

Dimension : H 1,900 x L 4,015 x W 1,580mm

Patent No. : MY-140402-A

3.1.1 Top View

3.1.2 Elevation View

3.1.3 Side View

7712 Gear Coupling

7710 Screw Press Main Shaft

7716 Bearing Housing 7720 Support Housing

7722 Machine Body

7718 Housing Set

3.5 Metal Object

3.6 Specification of Empty Fruit Bunches (EFB)

Type of Lubricant Grease = Multi-Purpose Grease (Recommended) or equivalent

Type of Lubricant Oil = Shell Omala 460 (Recommended) or equivalent

Quantity of Lubricant Oil = 84 Litre

= Check Lubricant Oil of Oil Plug every 48 running hours.

Check Lubricant Grease of Grease Nipple every 150

Drain out the Lubricant Oil from Drain Outlet

= Air Relieve Valve

Types of Lubricant Grease = Multi-Purpose Grease (Recommended) or equivalent

Types of Lubricant Oil = Shell Omala 460 (Recommended) or equivalent

Quantity of Lubricant Oil = 35 Litre

= Check Lubricant Oil of Oil Plug every 48 running hours.

Check Lubricant Grease of Grease Nipple every 150

 Filling Lubricant into Oil Holder through Oil Inlet.

 Lubricant inside Oil Holder flows into Bearing Housing.

 The advantage of double protection.

 Drain out the Lubricant from Dain Outlet in every 10 month.

Electrical Panel = Star Delta Type System.

4.2 Side View

5.1 Point to Check before Turn off Power

Pour dry shell into Machine's Inlet Housing slowly.

Check either EFB Fibre has been transferred into warehouse or

Switch of Panel Station.

5.2 Point to Check before Turn on Power