SIMPLICITY INSTALLATION / OPERATION / MAINTENANCE MANUAL HORIZONTAL SCREEN SN 2516-HS120C-2541 ‘TEREX SIMPLICITY 212 SOUTH OAK STREET DURAND, Mi 48429, PHONE: (089) 288-3121 FAX: (989) 288-4113‘TERMS AND WARRANTY (QUOTATION, ORDERS, PRICES: Unless otherwise stated onthe face hereof in writing, Simpliity’s quotations are subject to acceptance by the Purchasor within (0) days ater date of quotation. Orders will be billed at prices in effect at time of shipment unless otherwise so stated in the quotation, Published prices and discounts are subject, to change without notice. Possession of price discount sheets in no ‘way obligates Simplicity to sell fo the Purchaser possessing such price or discount sheets. Others are subject to final approval and acceptance at Simplicity's factory. Unless otherwise stated on the ‘ace hereof, method of shipment by Simplicity shall in all cases be F.0.8, point of shipment. Should Simpicty's cost for labor ot ‘material increase between the date of Quotation and the date of shipmont, Purchaser agrees to pay Simplicity not only the price shown on the face thereof, but also the amount of any such increase ‘or increases {which payment for increases shall not exceed 10% of the total prices shown on the face hereof, SALES AND SIMILAR TAXES: Simplicity's prices do not include Federal, State or municipal sales, use, excise or addition to the prices specitied herein, the amount of any present or {futur sale or use tax upon goods shall be paid by the Purchaser or jn lieu thereof the Purchaser shall provide Simplicity with a tax ‘exemption certificate acceptable to the taxing authorities. TERMS: Unioss otherwise stated on the face hereot, Purchaser ‘agrees toro ful paymant on ana thirty (80) days basis trom dato of Simplicity’ invoice. A carrying charge of ¢-112% per manth on Invoices outstanding over 30 days willbe charged. DELAYS, DAIIAGE or LOSS: Simplicity is not and shal nt be lable {or delays in shipment or dalivery of goods, detention thereof, loss or ‘damage thereto, when due to Acts of God, acts ofthe Purchaser, acts ‘of civil or miliary authority, priori, US. Governmental restrictions or embargoes, war, riot, fies, trikes, loods, epidemics, quarantine ‘default by delay by supplier, breakdown in facilities, machinery or equipment, delays in icuies in obtaining necessary materia, labor or ties due to such causes or any other cause beyond its reasonable control. . SOLE and EXCLUSIVE WARRANTY: simplicity warrants to Purchaser that the goods manufactured by Simplicity to be delivered fo Purchaser wil be fee fom defects in matrl and workmanship hen used under proper and normal use he meaning of which shall include without imitation oparation or nt grater than an average ot 40 boure per wee) for «prio of one (year on new machines or thirty G0} days on parts and service from date of shipment by Simpisty. Should ary flue to conform tothe sbove pear win the afoesna time after te dat of shipment by Simpy, Simply agrees upon prompt nattiaton thereof (received by: Simplity diving the aforesaid one (¥) year or thity (0) ay period) and confirmation thatthe goods have been stored, Installed, operated Sd maintained in accordance wth eandardIndusty practice, to ‘correct the non-conformity at Simplicity's option elther by repairing Sry defective part or parts of by making avallabe at Smplcty’s planta repaired or replacement part. THE FOREGOING WARRANTY SHALL NOT APPLY TO DAMAGE OR DEFECTS CAUSED BY (ORDINARY WEAR AND TEAR AND IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER WRITTEN, ORAL OR IMPLIED INGLUDING ANY WARRANTY ON MERCHANTABILITY OR FITNESS FOR PURPOSE). THE REMEDIES UNDER THIS WARRANTY ARE EXCLUSIVE AND SIMPLICITY NEITHER ASSUMES NOR AUTHORIZES ANYONE TO ASSUME FORIT ANY OTHER OBLIGATION EXCEPTIONS AND EXCLUSIONS: (1) SOLE REMEDY: THE ABOVE “SOLE” AND EXCLUSIVE WARRANTY HEREINAFTER “WARRANTY") SHALL CONSTITUTE ‘THE SOLE REMEDY OF THE PURCHASER AND THE SOLE LIABILITY OF SIMPLICITY UNDER ANY LEGAL THEORY OR THEORIES WHATSOEVER INCLUDING WITHOUT LIMITATION UNDER WARRANTY, TORT, OR CONTRACT LEGAL THEORY, THE WARRANTY DOES NOT AND SHALL NOT INCLUDE REIMBURSEMENT FOR THE EXPENSES OF __ LABOR, TRANSPORTATION, INSTALLATION, REMOVAL FROM THE LINE OR ANY OTHER EXPENSES WHICH MAY BE INCURRED BY PURCHASER. (2) VIBRATIONS AND WEAR AND TEAR: SIMPLICITY SHALL NOT BE LIABLE IN ANY WAY WHATSOEVER FOR DAMAGES DIRECTLY OR INDIRECTLY CAUSED BY VIBRATION OF SIMPLICITY'S OR ‘ANOTHER MANUFACTURER'S MACHINERY OR GOODS. (@) CONSEQUENTIAL DAMAGES: SIMPLICITY SHALL NOT B= ABLE FOR ANY PENALTY OR FOR ANY SPECIAL, LIQUIDATED, INDIRECT OR CONSEQUENTIAL DAMAGES, SUCH AS BUT NOT LIMITED TO LOST PROFITS OR REVENUES, LOSS OF OTHER GOODS, DOWN TIME COSTS, COSTS ASSOCIATED WITH THE REMOVAL OF GOODS FROM SERVICE OR WITH REINSTALLATION, DISASSEMBLY OR REASSEMBLY. ( ONLY SIMPLICITY GOODS: NO WARRANTY OF ANY KIND WHATSOEVER IS MADE, AND NO LIABILITY OF ANY KIND WHATSOEVER SHALL BE BORNE BY SIMPLICITY, WITH RESPECT TO GOODS, ACCESSORIES, COMPONENT PARTS OR AUXILIARY EQUIPMENT NOT MANUFACTURED BY SIMPLICITY, SUCH BEING SUBJECT ONLY TO WARRANTIES MADE BY THEIR RESPECTIVE MANUFACTURERS. (3) OTHER CAUSES: SIMPLICITY SHALL IN NO EVENT BE RESPONSIBLE OR LIABLE FOR MODIFICATION OR REPAIRS MADE TOITS PRODUCTS OR GOODS BY PURCHASER OR OTHER, OR FOR DAMAGE CAUSED THERETO BY NEGLIGENCE, ACCIDENT OR IMPROPER USE OR INSTALLATION BY PURCHASER OR OTHERS. (@) LIMIT OF LIABILITY TO PRICE: SIMPLICITY’S LIABILITY ON ANY CLAIM OF ANY KINO, WHETHER FOR NEGLIGENCE, BREACH OF CONTRACT, BREACH OF WARRANTY, TORT, OR OTHERWISE FOR ANY DAMAGE OR INJURY TO PERSON OR’ PROPERTY OR LOSS ARISING OUT OF, CONNECTED WITH, OR RESULTING FROM THIS ‘CONTRACT, OR FROM THE PERFORMANCE OR BREACH THEREOF, OR FROM THE MANUFACTURE, SALE, DELIVERY, RESALE, OR REPAIR OR USE OF ANY GOODS COVERED BY OR FURNISHED UNDER THIS CONTRACT, SHALL IN NO CASE EXCEED THE PRICE ALLOGABLE TO THE GOODS OR PART THEREOF WHICH GIVE RISE TO THE CLAIM AND UPON THE EXPIRATION OF SAID ONE (1) YEAR, ALL LIABILITY SHALL TERMINATE. APPLICABLE LAW: This transaction shall be governed by the laws of the state of tlichigan,SIMPLICITY SERVICE QUOTATION RATES When required by the customer, such services are subject to charges as follow: 1. LABOR CHARGES. (a) WEEKDAYS For all hours worked by our employee at customer's plant during Simplicity’s normal work hours, but not exceeding eight (8) hours per day. $75.00/hr. (b) OFF-SHIFT, SATURDAYS, OVERTIME For all hours worked by our employee at customer's plant on Off-Shifts, Saturdays or in excess of eight (8) hours, $105.00/hr. (c) SUNDAYS and HOLIDAYS For all hours worked by our employee at customer's plant on Sundays and legal holidays and holiday time specified by the agreement between Simplicity Engineering. (d) TRAVEL TIME All travel. $135.00/hr. $ 60.00/hr (e) LAYOVER ‘A minimum of eight (8) hours is charged for serviceman layover for Saturdays, Sundays, Holidays or any other customer shutdown. Our servicemen are allowed a reasonable time to load and unload parts at our plant; Also time for job-related paperwork and 1/2 hour daily cleanup time at customers plant or motel. This is reflected in the labor time of the customer billing invoice. NOTE: A MINIMUM OF EIGHT (8) HOURS CHARGE, INCLUDING TRAVEL TIME, PER SERVICE CALL. 2. EXPENSE CHARGES (a) For the actual travel and subsistence expenses by our employee from the time he leaves his home base to the time of his retum to that base. (SUBJECT TO REVISION) ee $ .40 per mile automobile expenses. 3. MINIMUM CHARGES — TECHNICAL and ENGINEERING SERVICES, (a) $600.00 per eight (8) hour day, including travel time, (b) Expense charges — same as above. 4, PURCHASE ORDERS — Alll requests for service must be confirmed by a purchase order.HORIZONTAL SCREEN TABLE OF CONTENTS SECTION "A" - INTRODUCTION AND DESCRIPTION SPECIFICATION TABLE | INTRODUCTION DESCRIPTION SERIAL NUMBER NOMENCLATURE. PARTS ORDERING PROCEDURE SAFETY SECTION "B" - RECEIVING, INSTALLATION AND OPERATION RECEIVING HANDLING STORAGE INSTALLATION Planning Support Design Material Feed Process Chutes and Hoppers Discharge Chute Fines Hopper Walkways Spray Pipes Installing the Vibrating Screen V-Belt Drive Direction of Rotation Operating Speed OPERATION Safety Initial Start-Up Normal Start-Up Shut Down SECTION "C" - LUBRICATION Oil Lubricated Machines & Oil Lubricator Selecting An Oil Lubricant Oil Selection Chart Rule of Thumb Viscosity Check Lubricant Manufacturers List Grease Lubricant Specifications At A-2 A2 A AB Ad B-1 Bel B-1 B-2 B2 B2 B3Cold Weather Operation (Grease) C6 Lubricant Manufacturers (Grease C6 Checking Oil C7 Filling Unit C7 Automatic Lubrication Systems C8 SCHEDULE "D" - MAINTENANCE SCHEDULED MAINTENANCE D. Daily Maintenance D. Weekly Maintenance D- Monthly Maintenance D. Replacement of Rubber Lip Seal D. SECTION "E" - ADJUSTMENTS. V-BELT ADJUSTMENT WITH PIVOT BASE E4 Motor Adjustment E-4 Base Adjustment E4 Screen Cloth Tension E2 Stroke E-2 Speed Adjustment E-2 Timing E2 Assembly Location E-4 SECTION "F" - REMOVAL & REPAIR MOTOR BASE AND MOTOR SHEAVE Ft Inspection Ft Cleaning Fe Bearing & Pivot Shaft Removal Ft Motor Sheave Removal F:2 Motor Sheave Installation Fe2 Change Hand of Drive of Motor Base F-3 SCREEN BODY REPLACEMENT AND REPAIR F-3 Screen Cloth Removal F-3 Screen Cloth Inspection F-4 Screen Cloth Installation F-4 Side Plate Replacement F5 Deck Replacement F6 Back Plate Replacement F-7 Discharge Lip Replacement F-7 Support Spring Replacement F-7 Assembly Mount Plates F8 Fasteners Torque Chart Fo Bearing & Bearing Housing Dim. Chart F-10 iiSECTION "G" - DRAWINGS Feeding Arrangement, Figure 2 Pivot Motor Base, Figure 3 Oil Fill, FIGURE 4 Screen Take-Up Parts Layout, Figure 12 Parts Layout, Figure 124 Lift Arrangement, Figure 13 Bearing Puller Tools, Figure 6 Bearing Pusher Tools, Figure 7 Gear Timing Drawing, Figure 11 SECTION "H" - TROUBLE SHOOTING CHART iii G-1 G-2 G3 G4 G5 G6 G7 G8 G9 G-10SPECIFICATION TABLE | Serer oeses._ SERIALNO. __2516-HS1200-2541 INSTALLATION NO. 14543 MODEL NO. HS120C BEARING SIZE 120 MM. WIDTH SFT LENGTH a6 FT NO. OF DECKS, TIMING ___45 DEGREES OPERATING SPEED. 757 RPM SHIPPING WT. 15,000 LBS STROKE, 3/4 IN ‘SHIPMENT DATE 8/31/2005 RECOMMENDED ANGLE OF INCLINATION Lubrication: ‘SHAFT HOUSING DRIVE SIDE, 3.9 QUARTS OF OIL FLOAT SIDE 3.15 QUARTS OF OIL, GREASE SPECIAL INSTRUCTIONS:SECTION "A" INTRODUCTION AND DESCRIPTIONINTRODUCTION: This manual is for Horizontal Screens and covers the full range of sizes and models. All the information in this manual may or may not pertain to your particular screen. There is information on receiving, storage, maintenance, repair and parts ordering procedure Your Horizontal Screen is one of many different types of mechanically vibrated screens. It is designed for rugged, continuous service for which itis being used. Ifthe information contained in this manual is followed, you should experience trouble free operation. Should you have a particular question, not covered in this manual, please write or call your authorized representative. DESCRIPTION: The Horizontal Screen is a twin shaft unit. The shafts are timed together to produce a straight line motion. The Horizontal Screen is used where head room is a problem and a conveying action is required as well as screening, dewatering, desliming, etc The anti-friction roller bearings are lubricated with oil which is contained in the housing covers or shaft tube. The bearings are mounted in individual housings. The timing gears, if applicable, are mounted generally opposite to the drive. The screen body consists of: Side Plates Decks Backs Feed Backs Discharge lips Corner Supports Oren The unit is supported by coil springs at the comers, generally from below. The drive consists of a motor base, either pivot type or vibrating type, special deep groove machine and motor sheaves, v-belts and belt guard as an option. All locations given as right hand or left hand refer to the observer's position when standing at the feed end looking toward the discharge end. See Figure |. End locations are either "feed end” or "discharge end.”SERIAL NUMBER NOMENCLATURI The first group of numbers give the number of decks, width and length in feet. The second group, consisting of letter/numbers is the model and bearing size. The third group of numbers is the machine number. Example: — 2620-HS140D-0001 Number of Decks Width in Feet 20 = Length in Feet HS140D = Model and Bearing Size 0001 = Machine Number PARTS ORDERING PROCEDURE: The serial number for your machine may be found in the front of this manual and on name plates attached to your machine near the drive pulley and also the side opposite the drive pulley. See serial number nomenclature. On the screen assembly drawing, SECTION "A", and shaft assembly drawing, SECTION "G", parts are identified by ballooned letters. These letters correlate with the parts description. All the parts shown are not necessarily on your particular machine. When ordering parts always supply the following: The serial number. The figure and page number of the screen assembly or shaft assembly you are using The ballooned letter that points to the part you require. The parts description in the bill of material corresponding with ballooned letter. The quantity of parts required. If the part is on the right or left hand side of the machine, (See description for hand of drive nomenclature) If the part is on the feed or discharge end of the machine. Pepe NS = The above information is vital to process your order with speed and accuracy.ARE YOU DRESSED PROPERLY FOR THE JOB? You may need any number of special items - safety hat, safety shoes, safety glasses, goggles, heavy gloves, ear protective devices, etc., for your own protection. Find out what items are required and wear them! Loose clothing can catch in moving parts. Keep sleeves buttoned, jackets belted, and wear your special safety equipment. Keep warm without restricting your movement. Wrist watches and rings can be dangerous. Keep your pockets free of objects which may fall out. DO YOU UNDERSTAND YOUR MACHINERY? READ THE MANUAL furnished with your equipment to learn its operating and maintenance characteristics, capacities and limitations. Leam the location and function of ALL controls, indicators, warning devices and caution instructions. DO YOU HAVE KNOWLEDGE OF WORKING AREAS? Leam - beforehand - as much about your working area as possible: Be a good housekeeper, keep the floor clean, free of oil, grease, rags, cables, chains, buckets, rocks and other hazards. Keep loose parts in a tool box. Use only non-flammable solutions for cleaning. Know the weight limitations for any floors on which you will operate. Know the clearances in the work area. A little time spent checking side and overhead clearances, including power lines, can save a lot of trouble later. Be careful of dust, smoke or fog, which may obscure your vision. ARE YOU PREPARED FOR EMERGENCIES? Plan ahead - stay alert - operate sensibly.- and you will avoid both having and causing personal injury and accidental equipment damage. Ifa careless moment does cause an emergency - react quickly with the tools and skills at hand. Know the location of and how to use a fire extinguisher and a first aid kit Know where to get prompt assistance - an emergency calls for fast action. DON'T STOP YOUR SAFETY PROGRAM WITH THESE GENERAL RULES. BE EQUALLY CONSCIOUS THAT SPECIFIC WORKING CONDITIONS - AND YOUR PARTICULAR EQUIPMENT - CAN REQUIRE ADDITIONAL PRECAUTIONS.— Even a minor defect can become serious, report any machine defects to your supervisor. ‘STOPPING SAFELY: Be sure screen is stopped before cleaning, servicing, lubricating, checking cloth tension, removing covers or making repairs. MAKE NO CHECKS, ADJUSTMENTS OR REPAIRS OF ANY KIND WHILE SCREEN IS IN OPERATION. TIPS FOR SAFE MAINTENANCE: READ AND UNDERSTAND: 1 Instruction manual furnished with the screen, especially SECTION B - “O perating Instructions." 2 Instructions for inspection and maintenance located in SECTION D - "Maintenance." 3. Warning and caution plates provided on the machine. 4. Warning and caution notes in the instruction manual. 5. Guide for periodic lubrication requirements in SECTION C. WARNING TAGS: Before working on a screen be sure to tag and lock out the electrical controls so no one else will start it. Attach warning tags to prevent accidents 1, If screen is unsafe for operation. 2. If controls are being serviced. 3. If machine is being repaired. LOCKOUT ELECTRICAL SERVIC 1. Always lock out all electrical controls before performing any type of maintenance work ‘on the screen. 2, Provide each maintenance man with his own personal padlock and ONE key. ATEQUIPMENT: ib Use the proper tools, handle tools and heavy parts sensibly. 2. Keep all tools and equipment free of dirt, oil and grease. Do not drop or toss them. 3. Use hoisting equipment for heavy lifting. Save your back. 4, Lower parts - do not drop them. 5. To prevent slipping, wipe hand levers and knobs clean of oil or grease. 6. Check for broken, defective or missing parts and replace them. Keep equipment clean and free of dirt and oil so you can spot loose or defective parts. 7. When using cables to move a load, be sure cables are of adequate size and replace any worn, badly frayed, broken or kinked ones, Check end connections for wear. FIRE HAZARDS: 1. DO NOT smoke while refueling - or when handling fuel containers. 2. SHUT OFF engine when refueling - and use extra caution if engine is hot. 3. WHEN pouring fue! into the tank, ground the funnel or spout against the filler neck to avoid static electric spark. 4. DO NOT use gasoline or diesel fuel for cleaning parts. Good commercial non-flammable solvents are preferred 5. DO NOT smoke while using cleaning solvents. 8. DO NOT let greasy, oily rags accumulate in a poorly ventilated area. Store oily rags and other combustible material in a safe place. 7. KNOW where fire extinguishers are kept and how they operate and for what type of fire Check regularly at least monthly to be sure it is in the working area. USE QUALITY PARTS: A replacement part for any item should always be of comparable SIZE, TYPE AND QUALITY as the part being discarded, ADelectrical controls for the screen. Itis most important that only one key be provided for the lock and that key must be in the pocket of the person who is working on the screen. Accidental start-up of the screening equipment with men in the immediate area can be responsible for many accidents on what is supposedly a "clear" machine. CRANE: Screens, like any other type of mechanical equipment, require normal periodic rmaintenance if the operator is to get the most for his money from the use of the machine. One of the most flagrant safety violations is the use of inadequate and unsafe lifting equipment. The parts of a screen should be assembled and disassembled with crane facilities that have the capability of gently and slowly lifting and lowering the various parts that make up a screen. WHEN USING ACRANE, ALWAYS OPERATE WITHIN THE RATED CAPACITY OF THE CRANE. THE SAFE RATED CAPACITY INCLUDES WEIGHT OF HOOK, BLOCK AND ANY MATERIALS HANDLING DEVICES SUCH AS CABLES, SLINGS, SPREADER BARS, ETC. SUBTRACT THE WEIGHT OF ALL THESE TO FIND THE TRUE WEIGHT OF THE LOAD THAT CAN BE HANDLED SAFELY, MOBILE CRANES: WHEN USING A MOBILE CRANE, ALWAYS OPERATE WITHIN THE RATED CAPACITY OF THE MACHINE TO AVOID BUCKLING THE BOOM OR TIPPING. Safe ratings are based on operating the crane on firm, level ground; outriggers should be properly extended and/or lowered whenever possible, Avoid fast swings, hoists or sudden braking; these can cause overloads. Do not handle large heavy loads in strong winds. When moving your crane, check bridges before crossing, make sure they will s upport the weight of the machine. Check clearances under bridges, for overhead electrical lines or any overhead obstruction. Check your hitcher, be sure he's clear before starting lift. Make certain he securely attaches the load. CONVEYOR BELTS: DO NOT USE CONVEYOR BELTS AS WALKWAYS, Conveyor belts leading to and from the screen should be provided with walkways alongside the conveyor. Always pro vide hand rails along the conveyor belt walkway as an added safety precaution PORTABLE PLANTS: If your plant consists of portable equipment, that is crushing and screening equipment mounted on trailers, trailer footing or cribbing is extremely important for safe operation. Check your footing. Your machine should be on as solid level a footing as possible. Use heavy timber mats as needed. Trailers must be raised so that trailer wheels do not touch the around. AllSECTION "B" RECEIVING, INSTALLATION AND OPERATIONRECEIVING: For your protection, inspect the vibrating screen carefully when received. Check each item for damage or shortage, and if found have an appropriate notation made on the bill of lading before sioning for delivery. It is your responsibilty to make claim to the carrier for any shortage or damage. Appropriate notation on the bill of lading should prevent controversy and will expedite any claim for adjustment. HANDLING: The Horizontal Screens have lifting holes at each comer support bracket for lifting the machine. Use chains or cables of sufficient length so that strain is not applied to the side plate. If short chains or cables are used, because of some limitation, a spreader bar must be used to prevent damage to the side plates. See SECTION"G". Figure 13. CAUTION: Refer to the bill of lading or specification sheet for the weight of your vibrating screen to make sure you don't exceed the lifting capacity of your equipment. Do not bump or drop your screen. STORAGE: If you do not plan to install and put the screen into operation within two to three weeks after receipt, take the following steps to insure safe storage of the screen. 1. Place the screen in a building which has a constant temperature and a relatively low humidity. 2. If open storage is required, the following steps are necessary to protect the screen from corrosion due to moisture condensation: 2.1 Paint any bare metal or scratches. 2.2 Onoil bath shaft assemblies, for long term storage greater than 30 days, it is recommended to use a corrosion inhibitor mixed with the oil such as SKF Vapour Phase Corrosion Inhibitor or an equivalent. Corrosion inhibitor is used to protect the internal drive parts thereby minimizing the damage from corrosion which will lead to premature bearing failure. The inhibitor protection is good For one year. Two other methods are as follows: (A) On units with oil sight gauges, the oil should be half way on the sight glass when the unit is setting flat. Periodically rotate the assembly by hand to relubricate the bearing rollers. Be sure the unit is setting level from side to side to insure that the oil level is the same on both B-lNOTE: To remove the support springs, enough clearance must be provided to raise the screen to clear the spring pilots, (approximately 6"). 6. Allow room for deck removal. This can be accomplished at the discharge end by removing discharge chutes, or at the feed end by removal of the feed box and/or back plate. 7. An adequate power source and water, if required, should be available 8. _ Install and connect all electrical components and motors according to local electrical codes. SUPPORT DESIGN: To insure a safe screen operation, all installation and support structure designs should be prepared and approved by qualified engineers. 4. MATERIAL FEED PROCESS: The structure must be strong enough to support the static and dynamic load of the screen at stopping. The natural frequency of the support structure must be above the screen ruining speed by a factor two and one half (2-1/2) times. ‘The most important part of your screen installation is the feeding arrangement. In order to efficiently utilize the screen capacity and minimize screen cloth maintenance, the following steps should be reviewed: a The material should enter the feed area along a line parallel to the center line of the soreen 4. 90 degrees feeding arrangement should be avoided. Feed the material at a uniform rate and evenly distributed across the width of the screen, Conveyors or other feeding devices with a higher velocity should not fee d directly onto the screen without a feed box or some method to siow the material to the travel speed of the screen. Refer to typical feed box arrangement, Figure 2, Page G-1 Chutes or feed boxes distributing the material to the screen should be at least six inches (6") narrower than the deck.SPRAY PIPES: CAUTION: Do not burn holes in the side plates to provide openings for spray pipes. Torch cut holes induce stresses in the area around the hole which could lead to cracking of the side plate. Use a hole saw to cut these openings if they are not ordered with the unit and be sure to dress edges of hole. (On wet screening, the material should come to the screen completely saturated. The prewetting, if fed by a belt should be done in a stationary feed box. The sprays are generally directed against the flow of material at an angle up to approximately 45 degrees. However, the spray nozzles are adjustable and should be adjusted so the spray does not stop the flow of material The number, size and spacing is dependent on type of material, material feed and water available. As a "rule of thumb" guide, 3-5 G.P.M. of water for every ton per hour of feed is sufficient and should be on the high side if clay is present Keep in mind when determining the water requirements that it is easier to valve down than to find additional water capacity. Also, the water pressure should be determined at the nozzle rather than at the pump. Application Engineers will be pleased to give you our recommendation on wet screening, INSTALLING THE VIBRATING SCREEN: CAUTION: Check the total weight of your screen to insure you do not exceed the lifting cap acity of your equipment. Do not use any part of the shaft assembly for lifting The screen support structure should be completed per the instructions on planning the installation, as previously discussed in this manual. The Horizontal Screen has lifting holes in the corner support brackets. Use these holes to secure the lifting cable or chains. Note that the end of the screen where the assembly is. located is heavier and a cable adjustment will be required to lift the screen level - Set the base plate and secure them to the support structure. Set the support springs over the pilots at the four corners. Lower the screen until the pilots start to engage the springs and then check to see that all springs are properly aligned. Adjust the springs if necessary, then continue to lower the screen. Don't disconnect the lifting cables until all springs have been checked for alignment. Check the screen for level. The unit should be level frorn side to side and end to end. Shim under the base plate where necessary. An out of level machine will cause the material to travel to the low side of the machine and can create stresses in the body of the screen. B.SOPERATION: SAFETY: Observe the following safety precautions during repair, overhaul, maintenance and operation of the machine. 1. 2 ‘Always keep the area clean around the soreen. Before using cleaning solvents, read and follow the safety precautions printed on the containers. Never use gasoline as a cleaning agent. The area directly below the screen should be closed off to protect other personnel from falling objects. All personnel working near the equipment should wear approved protective equipment. ‘An emergency stop switch and a start warning system must be provided near the screen. Remove personal jewelry before working on equipment. Bump the jog b utton to see if motor rotation is turning the desired direction. 7 Before performing repairs or scheduled maintenance, lock out the screen and other equipment pertaining to the screening operation. Before the equipment is released for operation, pick up all debris involved in the repair including tools, used parts, etc. INITIAL START UP: Before starting the screen for the first time, perform the following: 1 es Check the lubrication requirements and oil level Check line voltage against motor name plate voltage. Check the angle of inclination and the level across both ends of the screen. Make sure all safety-guards are in place. The vibrating screen body should be free of any obstructions. Place the start/stop switch in the "ON" position. Listen for any unusual noise, such as loose bolts, screen cloth, etc. BTSHUT-DOWN: Le Stop the material feed, allowing the screen to clear before shut down. 2. Place the start/stop switch in the "STOP" position. B-9SECTION "C" ul ATKOIL LUBRICATED MACHINE: Maintaining adequate lubrication in your machine is the most important maintenance function. Many premature failures can be traced to inadequate or improper lubrication. Therefore, lubrication of your machine must be scheduled into your daily maintenance schedule. Oil level in the end covers, or shaft housing should be maintain the center of the sight glass provided. This level should be checked before start-up and at regular scheduled intervals. At the time of initial start-up of a new machine, the oil should be changed after the first forty (40) hours of operation. This procedure should also be followed if the machine has been sitting idle for an extended period of time. Regular lubricant changes should be scheduled for every 300 to 500 hours of operation or every thirty (30) days, whichever comes first. This regular change will rid the mechanism of any condensation or contaminants that would cause trouble later. The oil should be drained immediately upon shut-down so any contaminants are still suspended and will easily flush out. ff, when draining the oil, contaminants are noticed, it is highly recommended that you also flush the mechanism with a light EP oil (EP-2 or EP-3). The flushing procedure is = Fill the mechanism to the proper level with light EP oil and run the machine for approximately fifteen (15) minutes. Immediately drain the oll out of the machine upon shut-down. This will pick up additional contaminants that otherwise would have remained in the system. SELECTING AN OIL LUBRICANT: Some guide lines that should be used in selecting an oil lubricant are as follows: 1. The cil should be a high quality, non-oxidizing petroleum product. 2, The viscosity of the oil should not be less than 105 SSU at the operating temperatures. 3. The oil should have a Timken OK load rating of 50 or more. Oils containing viscosity index improvers should not be used. (No multiple viscosity) Oils should have extreme pressure characteristics and a high stability agai nst oxidation, 6. The oil must have neutralization qualities that will prevent the oil from attacking the highly polished surfaces of the bearings during periods of prolonged opera tion. Cel7. The oil must contain anti-foamant agents. 8. The oll must be suitable for vibrating applications. Oils containing suspended solids such as graphite andlor Molybdenum Disutfide (MoS,) are not recommended for vibrating equipment applications. In cases where extreme ambient temperatures are experienced, (10°F, and below) or (100° F. and above), you are advised to contact us with the details of your application So that all factors can be considered for a proper lubricant selection. Using the guidelines from the list above to attain the proper quality of lubricant, the following chart will lead you to the proper grade of lubricant for your application. Using the bearing size, operating speed and ambient temperature, read across to find the recommended AGMA Grade Number, Units furnished with automatic lubrication will have a supplemental manual to cover the oil circulator/cooler. COLD WEATHER: *DN600 Continental Oi! Company (CONOCO) Polar Start DN-600 *SHC624 — Mobil Oil Company SHC 600 Series SHC626 SHC630 RULE OF THUMB VISCOSITY CHECK: In some cases, machines will operate at higher than expected temperatures. When this occurs, the following methods can be used to determine if the lubricant being used is adequate. 1. The way to do this would be to take the temperature of the bearing housing. The oil generally will be 20° F. hotter than the housing temperature. For example: 'f you get a bearing housing temperature of 186° F., by adding 20° F. to this figure, you will get an oil temperature of 205° F. Another way to determine what the oll temperature would be is to drain o ut a small quantity of oil, then check it with a thermometer. NOTE: Caution should be used as the hot oil could burn your skin and an oil spill Could result. If this method of checking the oil temperature is used, Protective clothing would be required. C-2=30 to +10 425 *DN600 or "SHC626 10 to 30 165 EP-3 30to 50 185 EP-4 140 750 to 900 50 to 70 200 EP-5 70 to 90 215 EPS 90 to 100 225 EP-7 100 to 115 240 EP-8 -30 to +10 135 DN600 or SHC630 10 to 30 185 EP-4 160to 200 650 to 810 30 to 60 200 EP-5 60 to 80 215 EP4 80 to 100 225 EP-7 100 to 115 240 EP-8 C4Grease lubricated screens should be lubricated at least once every ten (10) hours of continuous running, or once every eight (8) hour shift. See the Specification Sheet for the recommended amount. COLD WEATHER OPERATIO! Grease lubricated mechanisms require special care when operated in cold weather. Even though the majority of lubrication manufacturers recommended the same grade of lubricant for both summer and winter operation, thickened grease may overload the motor. In severe cold weather, we recommend lubricating the mechanisms at mid-shift or noon-time. If the mechanism is lubricated at night or in the morning before the unit is started up, it will require additional horsepower to revolve the mechanism. If preheating is necessary, we recommend a series of heat lamps directed towards the bearings and or shaft assembly or a salamander type heater directed towards bearing and or shaft assembly, DO NOT use an acetylene torch. A motor overload may also be due to a heavy concentration of grease in the shaft housing. If this Is the case, to completely clean the shaft housing of all old grease, it will be necessary to dismantle the mechanism. The following is a list of trade names of lubricant manufacturers that conform to the above specifications. Our selection of these lubricants should in no way be considered'an: endorsement of these products exclusively. There are many other equivalent and acceptable products that may be used. . GREASE LUBRICANT MANUFACTURERS: AMBIENT TEMPERATURE, MAXIMUM BRG OPERATING TEMP. 10°F. to 100° F, 190° F. LUBRICATION MANUFACTURERS NAME GRADE Amoco Oil Company Amolith Grease EP.2 Chevron USA, Inc. Chevron Duralith Grease EP.2 Continental Oil Company Super Sta Grease #2 Exon Lidok Grease EP.2 Gulf Oil Company Gulf Crown Grease EP2 Mobil Oil Company Mobilux EP.2 Shell Oil Company Alvania EP-2 Texaco Multifax EP-2 C6Permagear Gulf EP Lubricant Mobilgear Gear Pro 4/EP Omala Sunep Union Extra Duty Gear Lube Permagear Gulf EP Lubricant Mobilgear Gear Pro 5/EP Omala Sunep Meropa Union Extra Duty Gear Lube Permagear Gulf EP Lubricant Mobilgear Gear Pro 6/EP Omala Sunep Meropa Union Extra Duty Gear Lube Permagear Gulf EP Lubricant Mobilgear Gear Pro 7/EP Omala Sunep Meropa Union Extra Duty Gear Lube LUBRICANT 70 150 $-70 HD-150 629 450 4eP 450 Grade 68 Grade 150 1060 150 4eP 450 AGMA NO. 5 LUBRICANT 90 220 $-100 HD-220 630 220 SEP 220 Grade 71 Grade 220 1070 220 220 220 SEP 220 AGMA NO. 6 EP LUBRICAN’ 110 320 $-120 HD-320 632 320 6EP 320 Grade 75 Grade 320 1080 320 320 320 6EP 320 .GMA NO. 7 EP LUBRICANT 140 460 S-150 HD-460 634 460 TEP 460 Grade 77 Grade 460 1110 or 1120 460 460 460 TEP 480 C8 Amoco Gulf Oil Mobil Oil Non-Fluid Shell Oil Texaco Union Oit Amoco Gulf Oil Mobil Oil Non-Fluid Shell Oil Sun Oil Texaco Union Oil Amoco Gulf Oil Mobil Oil Non-Fluid Shell Oil Sun Oil Texaco Union Oi! Amoco Gulf Oil Mobil Oil Non-Fluid Shell Oil Sun Oil Texaco Union OilCHECKING OIL: ‘Your machine is equipped with an oil sight gauge in each end cover for checking the cil. The proper oil level would be to the center of the sight gauge. DRAINING UNIT: Refer to Figure 7, Page C-12 and Figure 8, Page C-13. 1, Remove bottom plug (AS) in cover (AM) and (T). 1.1 Check Specification Table for quantity of oil. 2. Allow oil to drain completely. 3. Replace plug using Permatex on the threads before filing, OIL IN TUBE HOUSING: Refer to Figure 7, Page C-12 and Figure 8, Page C-13. 1. Remove plug (AX) in tube and plug (AS) in cover (AM) and (T). 1.1 Check Specification Table for quantity of oil. 2. Allow oil to drain completely from the tube and covers. 3. Replace all plugs, using Permatex on the threads before filling, FILLING UNIT OIL IN COVERS ONLY: Refer to Figure 7, Page C-12 and Figure 8, Page C-13. 1, Remove vent (AR) on each cover (T) and (AM). 2. Fill each cover to proper level with recommended oil. 2.1 See Specification Table for quantity required. 3. Clean and replace vent (AR). C-10Tabs wv . Smid INaA FB aeSECTION "D" MAINTENANCESCHEDULED MAINTENANCE: Vibrating screens require a minimum of maintenance, however, anything mechanical requires periodical maintenance. We recommend that it be scheduled and performed at regular intervals. A suggested schedule of maintenance is shown below. Daily Maintenance: Itis suggested that this maintenance be performed during mid-shift. 1. Check oil level. 2. Check for oil leaks. 2.1 Anoil leak is an indication of a worn seal. This should be changed as soon as possible, See Section D for this repair. 3. Check cloth for wear and proper tension. 3.1. New screen cloth installation should be retensioned after approximately four (4) hours of operation. 4, Inspect for loose bolts, 5. Listen for unusual sounds that may indicate loose, damaged, or worn parts. 6. Lubricate the bearings on grease lubricated machines. Weekly Maintenance: 1. Inspect all liners, back plates, discharge lips, screen cloth, and take-up rails. 2. Inspect v-belts for wear and proper tension, 3. Check suspension for any broken springs 4, Clean material out of spring coils. 5. Clean material out of belt guard. 6. Check crown bar rubbers for wear. D-l43, _ Install seal retainer (L) and new gasket (M) with bolts (J) and lock washer (K) NOTE: If the drive side cover (T) has been removed a seal alignment tool will be required, Refer to Figure 20 Section F. Seal alignment tool must be used to. properly align cover to shaft before cover bolts can be tightened. 14. Apply a heavy coat of grease to the lip seal (P) and shaft spacer (N). Slide spacer (N) on to shaft. It will go about 1/3 of the way through the lip seal. NOTE In some instances it may be necessary to switch spacers (N) and (V) around. By installing spacer (N) in against spacer (W) it will allow the lip seal to be centered better on spacer (N). Spacer (V) will be between slinger disc (H) and spacer (N) 18. Pack slinger disc (H) with grease and slide onto shaft tight against shaft spacer. 48. Replace key (G) for hub into shaft keyway. Use a chisel in the slot to slightly expand hub, taking care not to crack hub. Slide hub (F) onto shaff, tight against slinger disc (H). Replace end plate (E) with bolts (D) and lock washer (B) NOTE: Some assemblies have a shaft spacer between the hub and slinger disc. Check the parts list for your assembly, 17. Replace sheave (C) with bolt (A) and lockwasher (B). Torque bolts to specifications on following page according to bolt diameter for your screen. 18. Install belts and belt guard. 19, Fill with oil if oil was drained, See oil specifications in this manual for type of oil and machine specifications for quantity. 20. Unlock electrical service to screen.SECTIO! ADJUSTMENTS\V-BELT ADJUSTMENT WITH PIVOT BASE: The v-belts should have enough tension to keep the belts from slipping, but not so much that it will pull the machine out of line. The belt tension is accomplished by the motor being offset on the motor base. If the motor is level or slightly below, approximately 5 degrees, and the belts slip the motor has to be moved on the base. If the motor rails bottom out on the base, causing the belts to slip or the base angle is more than 5 degrees, then the base has to be moved. MoT! DJUSTMENT: Refer to Figure 3, SECTION "G", Page G-2. 4 Remove belt guard. ry Loosen the four (4) mounting bolts (Z), (AA), (BB). 3. Loosen the two (2) rear adjusting set screws (S). 4. Tighten the two (2) front adjusting set screws (S), and slide the motor further past the base center line. This adjustment should be made in 1/4" increments. 5, Tighten the two (2) mounting bolts (Z), (AA), (BB) and check the belt tension. You may have to start the screen. If the belt tension is correct, tighten the remaining two (2) mounting bolts (Z), (AA), (BB). 6. Tighten the two (2) rear adjusting set screws (S). 6.1 These set screws act as locking bolts also, 7. Replace belt guard. CAUTION: Extreme care should be used when operating screen without belt guard for test. BASE ADJUSTMEN 4. Loosen the four (4) foundation bolts (X), (Y) on the bottom legs (K) of base 2. Using a pry-bar, jack, or come-a-long, slide motor and base until motor iss horizontal or slightly below, approximately 5 degrees. 3. Leaving pressure on the base, tighten the four (4) foundation bolts (X), (Y). E-lYour Horizontal Screen was shipped from the factory with the proper timing for most applications. Sometimes changing the stroke angle by retiming will make a difference in movement and screening your product. Do the following steps for changing the timing of your assembly. See Figure 11, Page G-10, Section G. fl Lock out electrical power. 2. Drain oll at plug (AS). 3, Remove bolt (R) and flat washer (8). 4. Remove cover (AM). 5. _ Remove gasket (U). 5.1 This may be a gasket compound which will have to be removed by scraping. 6. Remove bolts (D) and end plate (AJ) on both shafts. 6.1 Stop. 6.2 Note the location of the keyway. This is the present timing angle. 7. Install a 1/2" x 2" x 36" bar on the drive shaft (AA) using the end plate holes. Lift the bar until the keyway on the driven shaft (AB) is in the top vertical position. Sécure bar to keep from turning. See Figure 11, Section "G", Page 11. 8. Pull gear (AL) on the driven shaft using puller tools, see Figure 6, Page G-8 until teeth unmesh. 9. Remove puller tools from gear. 10. Install pusher tools, See Figure 7, Page G-9. 11. Count the number of teeth per gear. Divide the number of teeth into 360 degrees to find the number of degrees per tooth. NOTE: Always time so the keyways slant in the same direction as material is to travel. If the machine is timed at 45 degrees, both keyways will be at 45 degrees toward the discharge end when properly timed 12. To start timing, both shafts will be in a neutral position, or both keyways will be on the top. The counterweight of the shaft will be on the bottom.SECTION REMOVAL AND REPAIRMOTOR BASE AND MOTOR SHEAVE: INSPECTION: Inspect the base when the screen is operating. The base is operating properly if it rocks slightly with the motion. When the screen starts and stops, the base will move considerably more. If the base doesn't operate properly, then look for material build up under the pivot leg, or a pivot bearing may have failed. NOTE: Bearings should be greased with 1/2 ounce of grease every fifty (50) hours CLEANING: Material should be removed from under the motor mount legs. Material build up will restrict movement of the base and allow the v-belts to become loose. BEARING AND PIVOT SHAFT REMOVAL: (Refer to Fig. 3, Pg. G-2, SECTION "G") 1, Remove belt guard 2. Support motor, by blocking or from overhead. 3. Remove nuts (M), lock washer (N), and bolts (P). 4. Remove the two (2) set screws in the bearing (L). 5. Remove bearing (L). 6. Repeat steps 3, 4, and 5 if both bearings need replacing 7. If shaft (G) needs removing this would be the time to do it. 7.1 Remove the two roll pins (R) by pulling out. 7.2. Slide shaft (G) out of pivot legs (F), 7.3. Clean shaft (G) using fine crocus cloth if required. 7.4 Replace shaft (G) by sliding shaft through pivot legs (F). Use a light oil on shaft when reinstalling. 7.5 Align and install roll pins (R) from each direction of the shaft (G). 8 Replace bearings (L) on shaft (G) making sure set screws are loose. FelCHANGE HAND OF DRIVE: When motor has to be relocated the following steps are required: 1. 4 Remove the belt guard Remove the v-belts. Remove the motor. Remove the two (2) roll pins (R) in one pivot leg (F) and shaft (G). Slide pivot leg (F) across the shaft and re-pin with roll pins (R). NOTE: If the shaft (G) is not drilled for this move, the shaft will have to be removed and turned end for end. The pivot leg on the sheave side is the only leg that requires pinning. Respace the floating leg to the proper spacing for your motor. Replace the motor. Replace v-belts. A new belt guard will be required. This can be purchased from the factory. Be sure to state the hand of drive you had and the new hand of drive when ordering. SCREEN BODY REPLACEMENT AND REPAIR: Refer to Figure 12 and 12-A, SECTION "G", Page G-5 and G-6. SCREEN CLOTH REMOVAL: Lock out electrical power If a center hold-down is used, remove bolts (L), securing the hold-down bar (H) and cover plate (J) to the screen deck (F). See Figure 13, Page 7, SECTION "G". The center hold-down nut (k) is brass, secured into a steel bracket that is we Ided to the deck members. This nut will stay fastened to the deck when the bolt is removed See View A, B, and C, Figure 5, SECTION "G", Page G-4. These are the most common screen cloth take-up arrangements, Our standard arrangements illustrated by View B, in Figure 5, so please refer to this F-3spreading the wires or moving them over. Try not to cut or break the wires. 7. Tighten the side take-up rails evenly. Refer to paragraph on screen cloth adjustment. 8. Tighten the center hold-down. 9. Unlock electrical power. ‘SIDE PLATE REPLACEMENT: If just one side plate is going to be replaced, this can be done without removing the deck/decks. 4. Lock out the electrical power. 2. Remove belt guard and v-belts, 3. Remove screen cloth and take-up rails. 4, Raise and block machine high enough to clear the support springs (Y). 5. Remove springs (Y) and corner support side plate brackets (U) and (W). NOTE: Most screens are assembled with non-reusable Huck rivets. Ifa collar cutter is not available, then these fasteners will have to be removed with a cutting torch. 8. You should at this time have a lifting device attached to the side plate. 7. Support the assembly (AB) and remove the fasteners holding the side plate (A) and assembly mount plate (AC). 8. Remove fasteners holding the discharge lip/lips (S) and side plate, leaving the lip attached to the deck (F). 9, Remove fasteners holding the back/backs (T) and (N) and the side plate, leaving the back secured to the deck. 10. Block the deck/decks and remove the fasteners from the side plate. 11, Remove the old side plate and set new side plate in place using drift pin s to align the bolt holes. 12. _ Replace the fasteners from the side plate (A) to the mount plate (AC) first. FSBACK PLATE REPLACEMEN’ Va a 8, Remove fasteners from back (T) and (N) and end of deck (F). Remove fasteners from back side plate (A) Remove old back and replace with new part. Replace fasteners in deck end first, but do not tighten. Align and replace fasteners in the sides of the back and side plates and tighten fasteners. Tighten fasteners in the end of deck. DISCHARGE LIP REPLACEMENT: 4 2. 5. 6. Remove fasteners from side plate (A) to discharge lip sides (S). Remove fasteners from end of deck (F) and discharge lip (8). Remove old discharge lip and replace with new part. Replace fasteners in end of deck and discharge lip, but do not tighten. Align and-replace fasteners in side plate and discharge lip side plate and tighten. Tighten the fasteners in the end of deck. SUPPORT SPRINGS: 1. x Lock out electrical power. Remove belt guard and v-belt. Raise machine to clear springs. Remove old spring/springs (Y) and replace with new spring/springs on pilot, Lower machine slowly, aligning all springs onto the pilots. Replace v-belts and belt guard. F-7TORQUE CHART BOLT SIZE TORQUE VALUE (INCHES) FTILBS. 112 75 5/8 150 3/4 250 4 583. 1-118 782 4-114 1097 CAUTION All threaded fasteners should be re-torqued after a few hours of operation and after the first week, TAPER LOCK TYPE SHEAVES Due to high bursting pressures that may be developed if bolts are over-tightened, connecting sheave hub and shaft bushing, we are recommending the following torque valves for reference: BOLT SIZE RECOMMENDED TORQUE (INCHES) FT/LBS. 5/16" 15 3/8" 30 1/2" 60 3/4" 150SECTION "G" DRAWINGSFigure 2A emnbyaet emsta s31av> ONIN eave u3OVauE!0 (FLOAT SIDE) Jf ® © ow UNSTAUING ORIVEN SHAFT BEARING e Figure 7GEAR MODEL Figure 8SECTION H TROUBLE SHOOTING CHARTTROUBLE SHOOTING CHART TROUBLE [_POSSIBLE CAUSE CORRECTION IMachine Overheating ICheck oil level. Too much or too little oll will cause bearings to overheat, reducing internal clearance, resulting in seizure of bearing. Correct oil level and allow} shaft assembly to coo! before attempting to restart. 'V-Belt Drive Belt breakage or turning over in grooves, or jumping off the sheave Imay result in loss of speed and bogging down of machine. If necessary to replace belts, replace complete set to maintain uniform bett stretch. Check drive and driven sheave for proper alignment. Check belt tension. Adjust to correct tension if required by ladjusting motor on base or moving the base Power Failure Check power source and motor leads, fuses, starter heaters. Wire Cloth Breakage Loose Wire Cloth New wire cloth must be retensioned approximately every our hours until all stretch is removed from the cloth. Properly tensioned cloth has a spring-like reaction when tapped with a hammer,TROUBLE POSSIBLE CAUSE CORRECTION Loose Body Parts (Check all body bolts, See Torque Chart in Parts Manual for proper torque to tighten loose fasteners. ICheck take-up rails (clamp bars) and deck covering for any looseness, \Cable Breakage [Uneven Loading itis necessary that all the stretch be removed from new cables. This| requires rechecking and readjusting after approximately jevery 8 hours of operation until the length is stabilized. Incorrect Assembly of Cable Fittings Refer to instructions for correct assembly of cable fitings Whipping [Adjust or install cable weights. Refer to instructions regarding cable weights, (Cable Length Cable length should not exceed 12 feet nor should it be less than 4 feet. These measurements are taken between fittings Corrosion Inspect cable for possible corrosion and any indication of corrosive action. Spray cable with corrosion preventive lubricant. Loss of Amplitude (Stroke) |Material Build-up Material build-up on vibrating members of the unit will increase the vibrating body weight and decrease the amplitude (stroke). Inspect the unit and clean off all material build-up. Belt Slippage Loss of speed will reduce material travel across the unit, Increasing bed depth and vibrating body weight with the resultant loss in amplitude. H-3TROUBLE POSSIBLE CAUSE CORRECTION | Seal Failure The oll seal may not be assembled in the seal plate properly. ‘There may be a damaged seal, There may be a damaged contact larea. Remove the seal plate and inspect thoroughly. Damaged Gaskets Check all gaskets for leaking or damage.VIBRATING SCREENS Safety and Good Operating Practices ‘Amechanical vibrating screen properly installed, operated and maintained, will normally provide relatively long life and safe, trouble-free operation. Like any heavy power-driven machine, the vibrating screen must be properly operated to insure safety of personnel. ‘The Vibrating Screen Manufacturers Association offers suggestions In this booklet for proper installation, operating and maintenance proceciures.”” These suggestions cover all types of mechanical vibrating screens and feeders. ‘The Operating and Maintenance personnel represent the keys to safety. These persons should be thoroughly familiar with the Screen Manuals pro- vided by the manufacturer, but there will never be any substitute for common Sense and aleriness by an operator. The following suggestions are basic procedures for establishing a safe and economical operaling prograrn. BR eSse use scsi ePROPER MAINTENANCE AND REPAIRS PAY OFF A vibrating screen, as any machine, will operate longer and more satisfactorily whem attended to and serviced according to prearranged Maintenance Schedule and Checklist. Repairs ean be minimized by good maintenance, but abrasion and metal fatigne will take their toll. Plan ahead for repairs so that parts and tools necessary to insure a First Class and Safe repair job will be available. For maintenance: Establish a Maintenance Schedule based upon man- vfacturer’s recommendation, Set a daily time period and routine for lubrication, inspecting cloth for condition and tension, inspect- ing buffer strips. Do not inspect or lubricate a screen that is running. ‘Wipe all fittings before lubrication, Check all bolted connections for proper torque on a routine basis. ‘Use checkoff lists to aid in insuring completion of maintenance duties, Keep good rnaintenance records. Lubricants, oil cans and grease guns must he stored in a dust-resistant room, Use care to avoid putting contaminants in vibrator bearings with the oil or grease. If welding is necessary, properly groiind the vibrat- ing body to avoid arcing the hearings. Keep the sereen area clean, spillage slioveled aways clear away spilled lubricants and discarded screen- ing surfaces. Check to be sure all guards are replaced. For repairs: READ THE INSTRUCTION BOOK FIRST. Plan for safe repairs, If sereen ean be fed by truck or loader, barricade access. Cut off and padlock all power to the screening sta- tion except for repair equipment and tools, A hard hat, safety glasses, gloves, hard-toed shoes and cutting goggles are « must. Clote off area below screen being repaired to avoid injury from falling objects. Provide adequate hoisting capacity and tackle. Stock spare parts and bolts recommended by the manufacturer. Don’t count on re-using gaskets, seals or O-rings. Only use hand tools that ft, and manufacturer's special tools when provided. Cover conveyor belts, wood or rubber linings, before cutting or welding, and have a fire extinguisher on hand. Leave bearings wrapped until ready to install. Clean up work area, destroy oily rags or other waste before restarting the screen. Keen a written renair record.SIMPLICITY BULLETIN: SCREEN SECTION - ORDERING, INSTALLATION AND MAINTENANCE PROCEDURE ORDERING: 1) Specify size, make and serial nunber of the screen for which you are ordering the cloth. 2) Specify the screen section you require (be precise). A, The type and size of opening (direction of slots 4f applicable). B. The diameter of the wire to be used. C. The width and length dimensions of the section. Hook Strip k—™ both bends, —¥ ~ D. Specify the type of hook strips you require. STYLE L-1— Hooked ( Edge Wino Reitoreing @ SEE La — near STYLE Lt. STYLE LS Two sce Hook Sup STYLE LS — square Type With inser NOTE 1: Specify if both hooks are in the same direction or not, especially when ordering cloth for end tensioned machines (one may be facing up and the other facing down: NOTE 2: Be specific about length and angle of hook. E, Give complete information and drawings if available; especially if special construction, i.e. hole punching, ete. is required. INSTALLATION 1) Check the size of the screen sections when received and prior to installation. Check that the screen sections are made to your specifications. 2) Check the support or crown bar rubbers for wear and deterioration each time you change the cloth. Remenber the rubber will wear from the inside on the bar as well as on the outside and wear is not always essily visible. 3) Measuring from the outside of the hooks of the screen section, the . width should be about 1" to 2" less than the distance between the inside of the side plates of the screen to allow for tensioning. (Over)SECTION J OAI20C Revised September 2004OA120C DISASSEMBLY AND REPAIR DISMANTLE DRIVE SIDE Refer to shaf assembly drawing. ‘Lock out the electrical power. ‘Remove the belt guard Remove the V-Belts. ‘Remove drain plug (30) and drain the oil from both covers (16) and (18). Remove bolts and lock washer in the machine sheave (28). 8.1 Insert bolt into the tapped holes of the sheave (28). Tighten the bolts evenly to release the sheave (28) from the taper lock hub (13). Remove bolt, lock washer and end plate (12) 7. With « nylon hammer, tap the hub (13) to remove it from the shaft (26). 7.1 If the hub (13) will not release from the shaft (26), use a chisel in the slot to slightly expand the hub, taking care not to erack the hb. 8. Remove the key (24). Slide stinger (6) off the sha (26), 10. Remove bolts and lock washer from seal retainer (5). ‘The seal (21) and seal retainer (5) will come as a unit. 10.1 Remove seal (21) from the retainer (5) by driving the seal out 10.2 Clean the gasket (19) or gasket eliminator from the housing and/or cover. 11. Remove bolts, lock washers and cover (16). 11.1 Remove gasket (17) or gasket eliminator from the cover. 12, Slide shaft spacers (7), (9) and o-ring (10) from the shaft NOTE: Your assembly may or may not have all of these shaft spacers. Check the parts list for your model. 13, Remove bolts from oil stinger (20) on driven shaft 14, Move to the float (gear side. DISMANTLE FLOAT SIDE, Remove bolts, washer, cover (18), and gasket (19) or gasket eliminator Remove bolts and end plates (11) from both shafts. ‘Before removing the gears (15), mark the match point to ensue the same timing upon reassembly. Tnstall a 72" x 2° x 36" timing bar on the drive shaft (26), using the end plate holes. Lift the timing bar until the keyway on the driven shaft (27) is in the top vertical position. Secure the timing bar to keep it from turning. See Figure 12, Page 12. 5. Attach puller plate (P2), using puller bolts (P3) to gear (15). Refer to illustration Figure 4 and 5, Page 8 and 9, for pusher/puller tools. 6. Insert puller screw (P4) into paller plate (P2). Turn the paller screw mntil i is close to the shaft end. ‘nsert shaft end bushing (P1) into the shaft end plate holes. Hold the bushing by hand until the puller screw engages the bushing. NOTE: The shaft end bushing (P1) has a ball bearing for the end of the pusher screw to ride against. Do not put the ball bearing directly in the shaft center, as it will distort the end. and make it harder to put back into a lathe at a future date.7, With the puller screw handle (P5), proceed to pull the gear. 8. Remove the puller bolts and shafl end bushing from the gear (15) and shafi (27). Also remove the timing bar from shaft (27). Mave to the second gear and repeat Steps 5,6 and 7. 9, Remove bolts from bearing housing (1). NOTE: Before pulling the bearings, punch mark each housing (1), (1,2.3,4) and corresponding ‘mark on tube so the same housing is reassembled in the same place. 10, Attach puller plate (P2) on the side, using puller bolts (PS) to the bearing housing (1). Bring puller serew (P4) up against the shaft end bushing (P6), Make sure the puller screw is against the ball bearing. 41, With the puller screw handle (P5), proceed to pull the bearing housing (1), inner bearing housing (4), inner bearing shaft seal (2) and bearing (29) as a unit NOTE: During the bearing puiting operation, an overhcad lifting device is required to support the shaft. Use a soft sling to keep from marring the shaft, When the bearing housing releases from the tube end, lower the shaft to rest on the tube, 12, Remove the puller tools and proceed to the driven shaft (27) and repeat Steps 10 and 11, 13, Return to the drive side. 14. Remove bolls in the bearing housing (1) and remove retainer (14), NOTE: Some assemblies have a separate set of bolts to hold bearing retainer (14). If this is the case on your assembly, now would be the time to remave these botts. 15, Attach die puller tools on the bearing housing as per Step 10 and proveed to Step 11 and NOTE. following Step 11, Repeat forthe second bearing. 16, Remove bolts from inner bearing housing seal (drive side 3) (float side 4) and inner bearing shaft scal Q). Remove the bearings from the housings. OSCILLATOR SHAFT REMOVAL ‘The oscillating shatls (26) and (27) should be removed for cleaning and inspection. The following steps are required to remove the shafts: 1, Two pieces of tubing are required to remove the shafts. The wail of the tube should be at least 5/16" thick. ‘The length required would be 18” longer than half the width of the machine, the inside iamoter to fit over the bearing journals, Two lifting devices will be required and should be movable. 2. Insert the tubing over the bearing journal on each end of the shaft (26) and (27). Secure the ccable/chains on cach tube near the end of the tube. Lift the shaft and move in either direction uruil the shaft is more than half way out of the housing on one side. Set the shaft down and disconnect the lifiing device opposite the direction of the move, Do not disconnect both devices. Move the fifting, ‘device that was just removed and re-secure, straddling the balance point, using a two-point hookup and lift the shaft the rest of the way out of the housing,‘TABLE BEARING AND HOUSING SPECIFICATIONS Bearing | Tube Housing [Bearing | Bearing Bearing | Shaft Size Bore to wo Diametrical Tube Fit | Housing | Clearance | Outside | Run-Out before ‘Mounting ‘Min___Max 4sMM | 4.875 +4,0005 0005 0030-0039 002 to to +001 =0008 GEMM | 6.6875 “+0005 =0005 ; to to 0036 0047 | 5.5116 002 +001 0008 3.5112 35MM (9.499 “1.005 0 00530071 002 +001 TOMM | 12.000 ¥.0005 to 0064 0083 | 10.2387} .003 +001 10.2353 OMM | 15.065 “¥.0005 to 00750095 | 11.4168 004 4.001 11.4164 160MM | 14.873 +0005 to 00870110 | 13.3852 004 +001 13.3848NOTE: Threaded fasteners on all vibrating screens should be torqued to their full value. See Torque Chart for Grade 5 hardware, TORQUE CHART BOLT SIZE (INCHES) TORQUE VALUE (FT/LBS) 1 73 38 150. 3/4 250. i 383, 18 782 1s 1097 CAUTION: All threaded fasteners should be re-torqued after a few hours of operation and after the first week. TAPER LOCK TYPE SHEAVES Due to high bursting pressures that may be developed if bolts are overtightened, connecting sheave Taub and shaft bushing, we are recommending the following torque valves for reference: BOLT SIZE RECOMMENDED TORQUE (INCHES) FTALBS.) SiS" 15 38 30. a om 3a 150‘OR Si VAL ‘The shaft housing (25) would only have to be removed if the housing is damaged or wor out. The following steps are required for this removal: 1 Resmove the outer perimeter of fasteners. ‘These are usually Huck rivet fasteners that are not reusable. Ifa Huck collar cuter is not available, then these will have i be cut with a torch, Take care not to cout into the assembly mount plate. ‘The assembly mount plate does not have to be removed from the ‘machine body. If Hucking equipment is unavailable, use Grade 5 minimum, threaded hardware of the same diameter as the Huck rivet for replacement. CLEANING AND INSPECTION OF PARTS 1 (Clean all parts with a commercial cleaning solvent, following safety precautions on the container. Dry the parts before inspecting them. Clean the inside of the shaft housing (25). Inspect the inside of the housing for cracks or holes and repair or replace as required If the bearing (29) has turned in the housing (25) or the bearing housing has been working in the tube, leaving dark, rough or worn areas, the housing should be replaced. Inspect gears (15) for wear, broken or chipped tecth. IF rooth breakage has occurred, shafts should be checked for run-out, Total run-out at the extreme gear end of the shaft should not exceed the value shown on Table Il, Page 3. FITTING BEARING HOUSING TO TUBE, ‘Using an inside micrometer, check the bore of the tube (25) ends. If the tube ends check out-of round, the bore should be ground or scraped until i is as round as possible. Hone lightly to smooth the surface Using an inside micrometer, determine the bore dimension, Check Table Tl forthe proper tube bore in the bearing size of your machine. I the bore checks over ths, then an oversize housing (1) will be required with the interference fit as indicated in Table Tl. NOTE; Bearing honsing (1) is marked on the face and outer rim as Size “O”, “+1”, “#2”, efc, ‘Oversize housings are stocked and may be ordered from Simplicity. If customers plan to siock housings for repair of drive units it is suggested they siock oversized housings as they may be machined to the desired size, HITTING BEARING TO HOUSING 1 After determining sizes of honsings (1), or if using old housings, apply a coating of oil to the bearing housing (1) outside diameter and bore of the tube end. Using a hardwood block and hammer, drive the bearing housing (1) into tube end, using guide pins (P10). DO NOT use a steel bar or hammer to hit directly on the bearing housing. Damage and difficulty in honing the housing will occur. ‘The bearing housing must be bolted to the tube end when the bearing is fitted. Coat the bearing and housing with oil when checking for stide it. See Table I. Page 3 for the outside diameter of the bearing you should be using. Always purchase “Select O.D.” bearings, which are held to plus oF ‘minus 0003". Table Il, Page 3 gives the internal clearance desired for this size bearing. Using a micrometer, measure the bearing outside diameter and fit the bearing in the housing. See Table TI for bearing to housing fit.‘REASSEMBLY First thoroughly clean all parts with a non-oil base solvent. Take particular care in removing any honing residue that may be leR. Inspect the inside of the tube end, Bolts must be clean, dry and grade 5. 1. Using Loctite 271 om the bolt threads, fasten two inner bearing housing seals (3) to the drive side ‘housings (1) and two inner bearing housing seals (4) to the float side housings with bolts NOTE: Be sure the inner housing seals are installed in their proper side of the machine. A. quick check (0 determine drive from float seals is to hold seals, groove side toward each other, and compare outer lip length. The seals with Jonger lip (part that extends into the bearing housing next to the bearing) are the drive seals. 2. Determine which side of the machine that the shafts will be installed from, drive side or float side. 2.1 Install shaft (26 & 27). Use a soft sting to lift or put some type of protection on the bearing, journal so the surface is not damaged. 2.2 ‘Apply a coating of oil to the two bearing housings (1) being installed and to the tube end. 2.3 The shaft will have to be lifted up and centered in the tube end so the back seal is not damaged ‘when the bearing housings are driven in 2.4 Afi all four bearing housings (1) are installed, secure the bearing housings with loctite and torque to 75 fs 2.3 Appiy a coating of oil to the shaft journal and io the bore of the inner bearing shaft seal (2) and slide the seal onto the shaft, The shaft will have fo be aised so the groove will Hine up and the shaft seal is tight up against the shaft shoulder. INSTALLATION GS NOTE: If the bearings have been contaminated, they must be thoroughly cleaned before installation, 1. Starting on the drive side, apply a coating of oil to the shaft (26), bearing bore and bearing housing (I) bore. Refer to Figure 5, Page 9 for bearing pusher tools. Push bearing (29) tight against shaft seal Q). Apply Loctite 271 to bolts, install bearing retainers (14), and secure into place. Apply Loctite 271 to bolts and install the oil slinger (20). Torque to 150 {Ibs ‘Move to the float side. Apply ol tothe shafl (27), bearing bore and bearing housing bore. Push bearing (29) tight against the shaft seal (2) using the bearing pusher. Install gear spacer (8) Replace keys (23) for the gears into the shaft keyway. ‘Check the bore ofthe gears for sharp edges. Grind any sharp edges from the gear to eliminate galling ‘of the shaft while pushing the gear on the sha. ‘8. Apply oil to shaft and bore of the gear. No outer bearing retainers are required om the Hat (gear side), Using the pusher tube, Figure 5, push one gear (15) on the driven shaft (27), tight against the space and the bearing inner race. Rotate the shaft with the gear installed so that the second gear can bbe instalied and timing marks matched. Push the second gear on the shaft, aligning the timing ‘marks, until the teeth engage approximately 4". At this point, rotate the shafis one complete revolution to insure thatthe shafts do not hit together. Sce Figure 12, Pagel2. Push the gear the rest of the way onto the shaft, Repiace shaft end plates (11) with boits, using Loctite on the bolt threads torque 10 150 Fibs. NOTE; Refer to Section “E” for timing if the new gears are used or the timing has to be checked or changed.9. Replace the cover gasket (17) o gasket eliminator and gear cover (18) with bolts and lock washers, 10, Return to the drive side. 41. Slide spacers (9) onto the shaft. 12, Replace drive cover (16) and new gasket (17) or gasket eliminator, using the seal-aligning tool, Figure 7, Page 11. Secure in place with bolts and lock washers. 13, On the bench, press the lip sal (21) into seal retainer (5). Install the seal retainer with bolts and lock ‘washers. Put scalant on the bolt threads. Torque to 15 fis, maximum. 14. Apply a heavy coating of grease to lip seal (21). Slide o-ring (10) and spacer (7) onto the shafl. Tt ‘will go about one third af the way through ihe lip seal. Pack slinger disc (6) with grease and slide it ‘onto the shaft, tight against the shaft spacer (7) 15. Replace key (24) for the hub into the shaft keyway. Slide hub (13) onto shaft (26), tight against singer dise (6). Replace end piate (12) with bolls and lock washers. Torque bolts to 150 fV/Ibs. 16, Replace sheave (28) with bolt and lock washer. See Torque chart page 4. Rock the assembly 10 censure that i is free 17. Replace drain plugs (30). Clean vent plug (22). 18, Fill with oil, See the “Oil Specification” section in this manual forthe type of oil and “Machine Specification” for quantity. 419. Replace the vent plug (22) and check all che plugs for leaks. 20, Replace the V-belt and belt guard. 21. Unlock the electrical service to the screen, START-UP AFTER REPAIR 1. Check the screen for loose parts. 2. 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