TrioTIO6203 Screen Manual (207) Banana Doble Deck

TRIO E N G I N E E R E D

Trio Engineered Products, Inc. • 12823 Schabarum Ave.

•

P R O D U C T S

Irwindale, CA

91706 • Telephone 626-851-3966 • Fax 626-851-9526

Huck Bolted Inclined Screens TIO6203

Parts and Operation Manual

Size: Serial Number:

TIO6203 Bolted Inclined Screen

6 X20 X3 ΄

΄

207

1

Haza Hazard rd Warning arni ng Any machinery machinery may be be hazardous hazardous to the user if it is not maintained maintained and and operated operated properly. properly. The following precautions should always be observed:

CRUSHING MACHINERY 1. Take special care to see that all parts of your body are clear of moving parts and pinch points before starting or operating machinery. 2. Make sure that all rotating sheaves, pulleys and belts are properly guarded to prevent being caught by them. 3. Be sure that the feed and discharge systems for material processing equipment are designed and maintained so that processed materials (rocks, gravel, coal, etc.) are retained within the system. Do not allow any part of your body to enter in or near the material flow. 4. Never sit or stand on any component of the machinery while it is in operation to prevent injuries arising from vibration. 5. Verify that the supporting structure(s) provided by your company for the machinery is sufficient to support both the total weight of the equipment and the dynamic load and stresses created by the equipment.

CONVEYING MACHINERY 1. Be sure that all parts of your body are kept clear of moving conveyor belts, especially at pinch points. 2. Do NOT lubricate machinery while it is in motion. 3. Never lean over a moving conveyor belt, or ride on a conveyor belt intended only for material transport. 4. Always keep clear of feed or discharge points of all material conveyor systems. 5. Be sure that all guards are securely fastened in place on sheaves, pulleys, and belts before and during equipment operation.

SAFETY EQUIPMENT Trio Engineered Products, Inc. provides only such safety equipment and guards as are specified by the Purchaser on the Shop Order or the Customer Order Acknowledgment. The Purchaser must furnish all other required safety devices.


2

Haza Hazard rd Warning arni ng Any machinery machinery may be be hazardous hazardous to the user if it is not maintained maintained and and operated operated properly. properly. The following precautions should always be observed:

CRUSHING MACHINERY 1. Take special care to see that all parts of your body are clear of moving parts and pinch points before starting or operating machinery. 2. Make sure that all rotating sheaves, pulleys and belts are properly guarded to prevent being caught by them. 3. Be sure that the feed and discharge systems for material processing equipment are designed and maintained so that processed materials (rocks, gravel, coal, etc.) are retained within the system. Do not allow any part of your body to enter in or near the material flow. 4. Never sit or stand on any component of the machinery while it is in operation to prevent injuries arising from vibration. 5. Verify that the supporting structure(s) provided by your company for the machinery is sufficient to support both the total weight of the equipment and the dynamic load and stresses created by the equipment.

CONVEYING MACHINERY 1. Be sure that all parts of your body are kept clear of moving conveyor belts, especially at pinch points. 2. Do NOT lubricate machinery while it is in motion. 3. Never lean over a moving conveyor belt, or ride on a conveyor belt intended only for material transport. 4. Always keep clear of feed or discharge points of all material conveyor systems. 5. Be sure that all guards are securely fastened in place on sheaves, pulleys, and belts before and during equipment operation.

SAFETY EQUIPMENT Trio Engineered Products, Inc. provides only such safety equipment and guards as are specified by the Purchaser on the Shop Order or the Customer Order Acknowledgment. The Purchaser must furnish all other required safety devices.


2

General Safety Safety Practic ract ice es Safety Practices affect everyone. Any and all personnel who operate or maintain your equipment are expected to comply with the basic safety practices that follow. This manual contains the best available information on proper installation, operation and maintenance of the equipment that it addresses. It does NOT replace or supersede applicable federal, state, or local regulations, your company safety rules, or insurance carrier requirements. It definitely is not intended to replace good judgment or common sense! Equipment operators, plant management and safety engineers are required and expected to be aware of potential hazards that may exist in the specific workplace where the equipment is installed and operated. All personnel are expected to develop, implement and maintain a safe work environment compatible with operating conditions, requirements, and practices. Additional Additional safety precaution precautions s that are suited to the specific specific conditions conditions of the the work site and the equipment’s installation are the user’s responsibility. Experience has demonstrated that the greatest numbers of workplace accidents are caused by failure to follow established safety rules. Be sure that you are fully familiar with the safety program requirements applicable to operating this type of equipment. Consult your supervisor concerning any operating procedure that you are not sure about before operating or working on this equipment. Note: It is strongly recommended that properly constructed and guarded access platforms be erected at convenient locations on the equipment installation site to allow safe inspection, adjustment, maintenance and repair of the equipment described in this manual. It is the responsibility of the purchaser of this equipment to ensure that such platforms comply with applicable federal, state, and local standards and regulations.


3

Personal Safety Practices Ar rangements fo r Emergency Situ ations Supervisory and operating personnel should develop an emergency response profile for possible emergencies on the worksite. All personnel should know the location of fire-extinguishers, where to obtain first-aid assistance and supplies, emergency report telephone numbers, power shut-off points, and other equipment shut-down control locations. Appropriate tools and equipment should be available to allow immediate response to emergency situations. Always follow the requirements and regulations of your company’s Emergency Action Plan.

Safe Machin ery Installatio n 1. Read and understand all parts of this manual including General Dimension Drawings. 2. Review your Plant Engineer’s Installation Drawings for this equipment. 3. Select, Assemble, and Test the correct hoisting and rigging equipment required to move the equipment to the installation site in your family. If there is any question regarding the proper rigging of the equipment or necessary hardware to make the lift/movement of the equipment to its’ designated mounting location, contact your local representative or Trio Engineered Products, Inc. to resolve the questions prior to beginning installation activities.

Know and Understand How the Equi pment Works It is absolutely essential that machine operators understand completely how the crusher works. The operator must know the location and function of all controls, gauges, indicators and alarms included with the unit. Operators and maintenance personnel must be completely familiar with maintenance procedures and schedules. Only if the equipment is given maintenance on the prescribed schedule can costly and time-consuming breakdowns be prevented. DO NOT OPERATE THE MACHINE WHEN ITS PARTS ARE WORN B EYOND DESIGNATED TOLERA NCES. REPAIR OR REPLACE THEM BEFORE TROUBLE OCCURS.

READ THE MANUAL AND UNDERSTAND YOUR MACHINERY Have everyone READ THE MANUAL (and all related literature) furnished with your equipment to learn its operating and maintenance characteristics, capacities, and limitations. Learn the location and function of ALL CONTROLS, indicators, warning devices and WARNING instructions.

READ and OBSERVE the SAFETY DECALS! Replace the decals when it becomes necessary


4

Inspect Your Machin e Before Start-Up Make a visual inspection of the machine for loose, worn, or damaged parts or faulty safety devices. Inspect all drive belts and pulleys for excessive wear. Test alarm systems and check fluid levels. Make sure that hydraulic, air, and lubrication systems and their respective valves, drains, and fittings are in proper working order. Report or repair any problem before starting the machine.


5

Follow th e Recommended Equipment Start-Up Instruc tion s Be sure that control systems and alarms are working properly. Check gauges for proper readings. Check for any unusual noises that may indicate bearing failure or other mechanical problems. Check for sudden rises in lubricant temperature. Shut the equipment down immediately if problems are detected, and report the problem(s) to your supervisor. Always refer to the Operating Section of this manual if you are unsure about a start-up procedure or for additional information.

Stop th e Machine Properly and Safely The machine must be completely stopped with power off and locked-out with controls tagged before any cleaning, repairs, adjustments, or service is performed. All provisions of your company’s Control of Hazardous Energy (Lock-Out/Tag-Out) program must be followed.

Repor t t he Need fo r Necessary Repairs Immediately Report any situation involving the need for repair, replacement or adjustment of an equipment component immediately. Remember, the most minor defect could result in injuries to yourself or others or serious damage to the machinery if it is not corrected promptly. Do NOT work on the equipment unless you have been properly and completely trained to do the work involved.

Prevent Fir e Hazards Never weld or use a cutting torch near open or exposed fuels, lubricants, or other flammable materials. Follow your company’s Hot Work Policy. Do not let greasy or oily rags accumulate in poorly ventilated areas. Store oily rags and other combustible materials in an approved storage container and dispose of them properly. Never use an open flame to check for fluid leaks in the equipment. Use an approved low voltage electric light or flashlight. Never smoke in undesignated areas. Follow your company’s Smoking Rules. Always extinguish smoking materials properly. Know where the nearest fire extinguisher is located, how to operate it, and what types of fires it can be used to extinguish. Make sure that fire extinguishers are in place, are in proper working condition, and have a current, valid inspection tag. If a fire extinguisher is not readily available, or does not meet these requirements, report the situation to your supervisor.

Keep Your Work Area Clean Become fully familiar with the worksite where the equipment is installed. Inspect the area daily and see that unsafe conditions are corrected. Make sure that all equipment guards are securely fastened in place, that steps, stairways, work platforms and barrier rails are sound and free of spills or obstructions. Keep the floor/work surface clean and free of oil, greasy rags, cables, chains, buckets and other obstructions. Keep tools and loose parts in a toolbox or appropriate storage areas. Use high flashpoint/low toxicity solutions for cleaning.


6

Handle Tool s, Heavy Parts, and Machin e Components Properly Do not toss parts or tools or drop them off platforms. Do not lower or swing electric or air power tools by their power cords or air lines. Use a suitable rope and/or container to lower tools or parts to the floor. Review job activities and arrange to get help before you attempt to lift, carry or move heavy parts. For heavy or awkward lifts use proper hoisting devices.

Dress Properly fo r the Job and Use Appr opr iate Perso nal Prot ective Equip ment Follow your company Personal Protective Equipment Policy. Discuss personal protective equipment requirements with your supervisor before operating equipment or performing service, repair or adjustment work. Don’t wear loose clothes or jewelry, and restrain long hair.

Follow Your Company Subst ance Abus e Control Polic y Report any use of prescription or over-the-counter medications to your supervisor prior to operating this equipment or making any adjustments or repairs to it. AL COHOL OR OTHER CONTROLLED SUBSTANCES SHOULD NOT BE USED PRIOR TO OR DURING WORK ON THIS EQUIPMENT.

Av oid Serious Ey e/Ski n In juries Hydraulic fluid or compressed air can penetrate or burn the skin or damage the eyes causing serious injury, blindness, or death. Mineral-based hydraulic oil is hazardous. Always wear goggles when working with hydraulic fluid. Flush your skin or eyes thoroughly with water if you spill or splash hydraulic fluid on yourself. Remove clothing on which hydraulic fluid has splashed. Get immediate assistance and report the matter to your supervisor. Get appropriated medical care. Wear appropriate personal protective equipment as set forth in your company’s Personal Protective Equipment Policy when handling hydraulic fluid. Wash your hands with soap and water after handling hydraulic fluid. Never eat, drink or smoke while handling hydraulic fluid. Make sure that all compressed air lines and couplings are in proper operating condition at all times. Be sure that all compressed air lines intended for chip or dust removal are fitted with OSHA compliant pressure relief nozzles. Never use compressed air to clean your clothing or any part of your body.

Dispose of A ll Waste Materials Prop erly Dispose of all waste materials such as fuels, lubricants, hydraulic fluid, etc. in accordance with your company waste management policies, and federal, state, and local regulations. If you have a question concerning proper procedures to be followed, consult with your supervisor, or the company safety administrator.


7

Safety and Maintenance Practices Replace Loo se or Defective Parts Keep the equipment clean and free of dirt and oil so that loose, broken, defective, or worn parts can be easily identified. Make daily visual checks for missing, cracked, or frayed V-belts. Also check daily for frayed, broken or kinked cables. Inspect end connections for wear. Replace sheaves with cracked rims or spokes immediately. Report suspected defects to your supervisor.

Properly Ground Machine Electrical Compon ents Check frequently to ensure that the equipment is properly grounded as stipulated in your company electrical safety rules. Prevent any electric cable from coming in contact with water in puddles, drainage channels, etc. Protect power cables from vehicular traffic such as forklifts and other motor vehicles. Power cables should be bridged over traffic lanes. All permanent electric cables should be in proper conduit or other approved insulation. Follow your company electrical safety rules with regard to periodic inspection of the condition of electric line insulation and couplings. Do NOT use portable, flexible electric cords to deliver electric power to the equipment.

Control of Hazardous Energy (Lock-out/Tag-out) Program CAUTION: Purchaser must implement a Control of Hazardous Energy (Lock-Out/Tag-Out) Program that complies with 29 CFR 1910.147 and 133 regulations. It is the responsibility of the purchaser to provide a suitable Control of Hazardous Energy program for the protection of its’ employees while they are engaged in the installation, maintenance, repair, or modification of equipment powered by electricity, hydraulic, pneumatic or mechanical energy in order to meet the regulations of the U.S. Dept. of Labor, Occupational Health and Safety Administration (OSHA). Under certain conditions and in certain operating environments, regulations concerning this subject are promulgated by the federal Mine Safety and Health Administration (MSHA). Certain state, county, or local regulations may also apply. Assistance in establishing specific regulatory obligations may be obtained from regulatory agencies, insurance carriers, or private consultants. Specific information concerning electrical operating characteristics such as output, rated capacity, etc. of electrical motors supplied with the equipment may be obtained by review of the technical data contained in this manual or from the specific equipment supplier stipulated in the Shop Order.


8

Obtaining Control of Hazardous Energy Program Materials Listed below are three possible suppliers of materials to aid you in development, documentation and maintenance of your program. Inclusion of the names of these firms in this manual does not represent an endorsement of them by Trio Engineered Products, Inc. These firms provide some of the materials required for a comprehensive program. 1.

SETON Name Plate Company P. O. Box BD - 1331 New Haven, CT 06505-9770 Telephone 203-488-8059 Toll Free 800-243-6624 Fax Toll Free 800-345-7819

2.

EMED Co., Inc. Telephone Graphic Communications Products Buffalo, NY 14240-0369 P. O. Box 369 Toll Free 800-442-3363 Fax Toll Free 800-344-2578

3.

D & G Sign and Label P. O. Box LA - 157 Toll Free 800-356-9269 Northford, CT 06472 Telephone 203-483-0491 Fax 203-488-4770

The Purchaser has sole responsibility for safe operation of this equipment. The Purchaser is responsible for ensuring that on-site machine operation is in compliance with any and all applicable federal, state, county or city safety standards and regulations. The equipment may be moved from one site to another a number of times by various purchasers, lessees, etc. Consequently, responsibility for compliance with applicable safety and environmental codes lies with the entity responsible for operating the equipment within each jurisdiction. Purchaser is wholly responsible for any ancillary or support equipment such as, but not limited to, processed material receiving devices, and inspection or service platforms. Purchaser is required to perform periodic maintenance of the type and on the recommended schedules set forth in this manual. Maintenance shall include, but is not limited to safety devices delivered with the equipment set forth in the Shop Order, and Warning and Instruction labels affixed to the equipment. Replacement parts including warning and instructional labels are available from Trio Engineered Products, Inc. Purchaser is invited to call for availability and current price of such parts and labels at 1-626-851-3966. Any modifications or machinery as designed, manufactured, and delivered by Trio without the express written approval and consent of Trio void all warranties and remove all responsibility of Trio for any and all damages to persons or property.


9

Introduction Installation When installing your screen, be sure that the beams upon which it is mounted or from which it is suspended are level and in line. Provide sufficient rigidity to support the weight of the unit and its load and also to absorb the vibration residue from the live frame. A good “rule of thumb” is to design for 1” of beam depth for each foot of span. Be sure to provide space around the unit so that it may be inspected easily and maintenance operations facilitated. Feed Chut es

Feed chute dimensions will be found on the General Arrangement Drawing for your unit. It is advantageous to have the outer vertical sides of the chute within 1/4”-1/2” of the inner vertical sides of the screen pan (or liner). This will help to prevent material spillage, as well as any tendency for coarse material to wedge between the vibrating plan and stationary chute during operation. Check t he Installation

When the installation is completed, start and stop the machine to check clearances all around. Approximately 3” operating clearance should be allowed above and below the moving live frame and any stationary parts to prevent interference. Start and stop the machine several times to make sure that sufficient clearance exists. Check for Tightness

Keeping all structural members tight is a very important part of all vibrating equipment since the forces generated will tend to loosen parts leading to eventual failure. Due to their high initial tightening torque, heat treated bolts and nuts will not loosen as readily as ordinary ones, but their tightness should be checked occasionally using a torque wrench. If no torque wrench is available, correct tightness may be estimated by drawing the nuts up finger-tight, then tightening one-half turn more.

Operating Clearances

Maintain at least 3” clearance between stationary structures and all parts of the moving live frame, including the pivoted motor base and motor assembly. Torque Requirements

After the first week’s run, recheck the tightness of all bolted connections refer to Appendix A: Bolts Torque Specification s . Spot checks may be conducted at about 200 hour intervals following this initial retightening.


10

Installation Guidelines For ROSTA Motorbases Type JMB 50

Important! The glide bearing has to be on the same side than the drive pulley


1.

ROSTA rubber suspension

2.

Base plate

3.

Clamp type BR 50

4.

Side support right

5.

Side support left

6.

Friction plate

7.

Adjusting block

8.

Jacking bolt M20X1.5

9.

Pretensioning device

10.

Hex. shaft M20

11.

Hex. screw M16

12.

Washer M16

13.

Spring washer M16

14.

Hex. nut M16

15.

Spring washer M20

16.

Hex. nut M20

17.

Tension scale

18.

Glide bearing

19.

Hex. screw M16

20.

Hex. set bolt M10

21.

Spring washer M10

11

Position ing of t he Drive Motor on TRIO ROSTA Motor base The ideal angular positioning of the drive motor on the base is an important factor to utilize the full compensation-arc of the pretensioned ROSTA-element; i. e. the resulting lever-arm between element center-axis and motorshaft shall be sufficiently dimensioned, in order to compensate the max. possible belt elongation without additional retensioning of the base. The two sketches below, are presenting the ideal positioning of the motor on the elastic base (ideal position blue marked). Each motorplate (pos. 2) is equipped with threaded bores for its “Center” and/or “ Off-set” mounting.

“ Center” mounting “ off-set” mounting

Is the driven pulley laterally positioned to the drive pulley (and/or ± 45° below or above the center line), is the “Center” mounting of the plate with motor recommendable.


Is the driven pulley above or below the drive pulley located(see working angles on sketch), then the “ Off-set” mounting of the plate and motor is recommended. In addition, find the ideal plate inclination towards driven pulley in varying block (7) fixation on friction plate (6).

12

Motor base Type JMB 50

Fitting Instructions

Caution: Place motor on base plate (2) only after bolting adjusting block (7) to friction plate (6). 1. Bolt side supports (4) and (5) of motorbase on your machine part. Check whether the alignment of the base plate (2) corresponds to the optimum working position (see page 4), otherwise align with jacking bolt (8) or select a different tensioning position on friction plate (6). 2. Bolt motor to base plate. The drive pull ey must be placed on the glid e bearing side of the motor -base.

3. Turn jacking bolt M 20 (8) clockwise to raise the motor and place the belt(s) on the drive pulley. 4. Turn jacking bolt M 20 (8) counterclockwise to tension the belt(s). Check the belt tension with the data specified by the belt manufacturer. 5. Tighten all locking bolts M 16 (11) of the friction plate after the tensioning process; tightening torque of nuts (14) = 200 Nm. 6. Tighten nuts M 20 (16) for central hex. shaft (10), tightening torque = 360 Nm. 7. In principle, the adjusting block (7) with acking bolt (8) could then be removed by loosening the hex. set bolt M 10 (20) (as protection from possible corrosion and dirt). 8. Fasten the belt guards. Retensioning

ROSTA motorbases are automatically retensioning drive mountings for friction belt drives. Regular retensioning is therefore unnecessary. It is only recommended in the case of very long center distances between driving and driven pulley to check the test pressure on the belts and retension occasionally if necessary.


13

Pretensioning Device JMB 50/70

Internal Glid e Bearin g on J MB 50/70

Find your ideal baseplate (2) inclination in adjusting block (7) fixation on friction plate (6).

The pretensioning device of the ROSTAmotorbase type MB 50/70 is effecting a motion of rotation on the inner profile of the ROSTA-element; this rotation is giving the required pretension effect on the belts and does compensate their elongation. In turning the threaded spindle, the belt tension will be increased or decreased. On the friction plates of both pretensioning devices, there are several positions for the fixation of the adjusting block with spindle. In varying these position, the change of plate-inclination can be effected, in order to get the most compensation effective working angle between drive pulley and driven pulley.


The motor bases type MB 50 and MB 70 are equipped with a cardanic glide bearing between housing and inner profile. This bearing compensates the radial tensile forces of the belts and is keeping the two components in parallel position, even by extremely high tension forces. This fibre reinforced plastic bearing has to be positioned on the pulley-side of the belt drive! (Please check by the assembling of the motorbase!). If this bearing would be installed on the fan-side of the motor, a misalignment of the pulleys would occur, due to the lack of parallelism.

14

Screen Dimensions


15

Screen Assembly Parts Lis t ITEM NO.

PART NO.

DESCRIPTION

QTY.

1

TIO6203.1

Screen Frame

1

2

TIO6203.2

Spring Assembly

4

3

TIO-1406VBR

Vibrator

1

4

JMB50X270

Motor Mount

1

7

TIO6203.3

Flywheel Guard

1

Screen Assembly Parts Lis t ITEM NO.

PART NO.

DESCRIPTION

QTY.

1

TIO6203.1

Screen Frame

1

2

TIO6203.2

Spring Assembly

4

3

TIO-1406VBR

Vibrator

1

4

JMB50X270

Motor Mount

1

7

TIO6203.3

Flywheel Guard

1


16

General Specifications TIO6203

860

Operating Speed (RPM) (Max.) Driven Sheave Size (OD): (included with machine)

23 5/8”

600 mm

(With 60HZ Motor/1770RPM)

(With 50HZ Motor/1470RPM)

Recommended Drive Sheave Size (OD)

289.56 mm

11.40” “C”

V Belt Section

3

No. V Belts Recommended V Belt L ength

122”

Weight(Motor Excluded)


3100mm 140 mm

Replacement Bearing Power Required (Electric)

355.16 mm

25 HP

18.5 KW

15,926 Lbs.

7,239 kg

17

Parts Information


18


19

Frame Parts List ITEM

1

PART#

DESCRIPTION

QTY.

TIO6203.1

Screen Frame

1

JG6203.1.3

Discharge Lip

3

2

Huckbolt 20mmx50mm (3/4”X2”)/GD10.9

136

3

Collar 20mm (3/4”) H = 29mm

196

4

Huckbolt 20mmx60mm (3/4” X2 3/8”)/GD10.9

60

5

TIO6203.2

Spring Assembly

4

8

GB1228/M20X50/GD10.9

Bolt M20X50

34

9

GB1230/20

Washer 20

42

10

GB6184/M20/GD10

Nut M20

42

13

GB5782/M20X70

Bolt M20X70

8

14

GB97.1/20

Washer 20

8

(10)

GB6184/M20/GD10

Nut M20

8

15a

JG6203.1.1-2

Liner

1

15b

GB68/M16x40

Bolt M16x40

8

15c

GB6170/M16

Nut M16

8

15d

GB97.1/16

Washer 16

8

15

JG6203.1.1

Feed Box (Liners included)

1

16

TIH6203D.1.1

Top Deck

1

17

JG6203.1-2

Clamp

2

18

GB5783/M10x30

Bolt M10x30

12

19

GB97.1/10

Washer 10

12

20

JG6203.1-3

Rear Rubber Apron Plate

2

21

TIO6203.1.1

Middle Deck

1

22

TIH6203B.1.4

Spring Bracket

4

23

GB5782/M20X45

Bolt M20X45

16

24

GB6170/M20

Nut M20

16

GB97.1/20

Washer 20

16

25

TIH6203.1-3

Drawplate

30

26

GB12/M20x110

Carriage Bolt (Square Neck)

120

27

93995

Spherical Washer

120

(24)

GB6170/M20

Nut M20

120

28

TIH6203D.1.3

Bottom Deck

1

29

K5100-4

Rubber L=5785 mm

17

(14)


20

Spring Assembly TIO6203.2

Total Weight: 77Kg (169.4 lbs)

Spring Assembly Parts List ITEM

PART#

DESCRIPTION

QTY.

0

TIO6203.2

Spring Assembly

1

K5143.2-1

Clamp

1

2

GB5782/M16X55

Bolt M16X55

4

3

GB6170/M16

Nut M16

4

4

GB93/16

Lock Washer 16

4

5

K5143.2.1A

Upper Spring Keeper

1

6

96419-B

Spring

2

7

TIO6203.2.1

Lower Spring Keeper

1

8

TIH4123.2.1

Snubber Holder

1

9

Dp80

Rubber Spring

1

10

GB5782/M16X65

Bolt M16X65

4

11

GB6170/M16

Nut M16

4

12

GB93/16

Lock Washer 16

4


1 Set

21

Vibrator (Assembly #: TIO-1406VBR) Total Weight = 1371KG = 3016.2Lbs


22

Vibrator Parts Li st ITEM

PART#

DESCRIPTION

QTY.

0

TIO-1406VBR

Vibrator

1

1

GB1096/24X95

Key

2

2

K5160.05-01(3C)

Driven Sheave

1

3

TIO-1406VBR-1

Inner Seal Ring

2

4

TC160X190X15

Oil Seal

2

5

K5167.03-2

Gasket

2

6

TIH6203B.3A.1

Shaft Housing

1

7

JG6203.3-1

Eccentric Shaft

1

8

1406-OBH

Bearing Housing

2

9

22328CA(C4)

Bearing

2

Vibrator Parts Li st ITEM

PART#

DESCRIPTION

QTY.

0

TIO-1406VBR

Vibrator

1

1

GB1096/24X95

Key

2

2

K5160.05-01(3C)

Driven Sheave

1

3

TIO-1406VBR-1

Inner Seal Ring

2

4

TC160X190X15

Oil Seal

2

5

K5167.03-2

Gasket

2

6

TIH6203B.3A.1

Shaft Housing

1

7

JG6203.3-1

Eccentric Shaft

1

8

1406-OBH

Bearing Housing

2

9

22328CA(C4)

Bearing

2

10

TIO-1406VBR-2

Bearing Cover(I) (Flywheel Side)

1

11

TIO-1406VBR.1

Grease Fitting Assembly

2

12

TIO-1406VBR.2

Lub. Gauge Assembly

2

13

GB1096/24X35

Key

2

14

K5160.05-07(US)

Flywheel

1

15

TIH4102.2-2/M12X100

Bolt M12X100

6

16

GB93/12

Lock Washer12

6

17

K5160.05-09(US)

Shaft Cover

2

18

JB/ZQ4347/30X90

Lock Plate

2

19

GB32.1/M12X30

Bolt M12X30

4

20

K5167.03-07

“O” Ring

2

21

GB1228/M20X60/GD10.9

Bolt M20X60

32

22

GB6184/M20/GD10

Nut M20

32

23

GB1230/20

Washer 20

32

24

GB1228/M20X80/GD10.9

Bolt M20X80

24

25

GB1229/M20/GD10

Nut M20

24

GB1230/20

Washer 20

48

26

TIO-1406VBR-3

Spacer

2

27

GB3289.31/10

Drain Plug

2

28

GB32.1/M12X40

Bolt M12X40

12

(23)


23

ITEM

(16)

Note:

PART#

DESCRIPTION

QTY.

GB93/12

Lock Washer12

12

29

TIO-1406VBR-4

Bearing Cover(II) (Driven Sheave Side)

1

30

K5160.05-11(US)

Bushing

2

31

TIO-1406VBR-5

Shaft Housing Guard

1

32

TIO8202D.2-8

Upper Clamp

3

33

TIO8202D.2-9

Lower Clamp

3

34

GB1228/M16X85/GD10.9

Bolt M16X85

12

35

GB1229/M16/GD10

Nut M16

12

36

GB1230/16

Washer16

12

37

K5160.05-08(US)/ δ 30mm(1 3/16”)

Counterweight

4

37

K5160.05-08(US)/ δ 20mm (13/16”)

Counterweight

2

37

K5160.05-08(US)/ δ 12mm (1/2”)

Counterweight

2

38

K5160.05-08(US)/ δ 30mm (1 3/16”)

Counterweight (Spare)

2

39

GB97.1/20

Washer 20

6

40

GB5782/M20X130

Bolt M20X130

6

41

GB5782/M20X160

Bolt M20X160 (Spare)

6

The oil quantity for the vibrator is 3.4 gallon approx imately.

Oil level in the end covers, or shaft housing should be maintained at the center of the sight glass provided if the machine is mounted 20 o sloped. This level should be checked before start-up and at regular schedule intervals. (See Oil Level Diagram below).


24

Lub. Gauge Assembl y Lub. Gauge Assembly Parts L ist ITEM

PART#

DESCRIPTION

QTY.

TIO-1406VBR.2

Lub. Gauge Assembly

1 Set

BRT-1

Breather

1

TIO-1

Breather Adapter

1

2

TIO8203.3.3-1

Pipe

2

3

TIO-1406VBR.2-1

Pipe Holder

2

4

GB5782/M10x65

Bolt M10x65

2

5

GB97.1/10

Washer 10

9

6

GB6184/M10

Nut M10

5

7

JB/ZQ4321/22

U Bolt 22

2

0 1


25

ITEM

PART#

DESCRIPTION

QTY.

8

GB6170/M10

Nut M10

4

9

GB93/10

Lock Washer 10

4

10

TIO5143F.2.1-2

Oil Level Gauge Leg (I)

1

11

G607-05-A-1-2

Oil Level Gauge

1

12

TIO5143F.2.1-3

Oil Level Gauge Leg (II)

1

13

TIO5143F.2.1-4

Clamp

1

14

GB5782/M10x55

Bolt M10x55

3

15

1JN-08-06

Hose Fitting

2

Hose ID=Ø13mm, L=550mm

1

16 17

TIO7202.3.2-6

Connector

1

18

GB97.1/16

Washer 16

2

19

GB6184/M16

Nut M16

2


26

Grease Fitting Assembly Grease Fitti ng As sembly Parts List ITEM

PART#

DESCRIPTION

QTY

0

TIO-1406VBR.1

Grease Fitting Assembly

1

TIO8243F.3.3-1

Connector(I)

1

Hose ID=Ø8mm, L=240mm

1

2

1 Set

3

TIO8243F.3.3-2

Connector(II)

1

4

GB1235/Ø11x1.9

O-Ring

2

5

GB1153/M8X1x45°

Grease Fitting

1

6

GB6170/M14X1.5

Nut M14X1.5

1

7

GB93/14

Lock Washer 14

1

8

TIO8243F.3.3-3

Clamp

1

Note: Fill/pump the grease to the oil seal section to prevent the dust in to the oil t ub and to help the seal in a good w ork con diti ons. This seal shoul d be greased with on e ounce of g rease every fi fty (50) hours o f op eration.


27

Lubrication General Lubrication procedures are performed primarily to deliver grease or oil to rotating or sliding surfaces to reduce friction and carry away heat. Pressure lubrication is also used to expel contaminants from seals and other openings. Certain lubricants are used to protect parts from corrosion.

Oil Lubrication 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 maintained at the center of the sight glass provided. This level should be checked before start-up and at regular schedule intervals. (See Oil Level Diagram below).

At the time if 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 lubrication changes should be scheduled for every 300-500 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.

If, when the 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 oil out of the machine upon shut-down. This will pick up additional contaminants that otherwise would have remained in the system.


28

Oil Level Diagram


29

Change oil every 500 hours or if oil samples show high contaminant levels. Oil samples should be pulled every 250 hours of operation and sent to a professional lab for analysis. The acceptable ranges in PPM (parts per million) are as follows: CONTAMINANT

Acceptable Range

Iron

125-150

Chrome

25-30

Aluminum

45-50

Copper

100-125

Silicone

25-30

Water

0

The lubricating oil is should be extreme pressure lubricant with a non-foaming paraffinic base. It meets the following specifications: Viscosity at 100 F - 824 SUS; at 2 10 F - 80.7 SUS; Timken Load Rating - 50 lb. DO NOT START MOTOR UNTIL EACH WHEEL-CASE HAS B EEN FILLED WITH OIL

The recommended lubricants for your screen are as follows: Average Ambient Temperature

SAE Grad es Lubri cant

95-125º F

85W-140

45-95º F

80W-90

<45º F

75W-90 (Arctic Gear)

Average Ambient Temperature

ISO Grades Lubric ant

115-125º F

460

105-115º F

320

95-105º F

220

45-95º F

150

25-45º F

100

<25º F

68


30

The operating temperature of the bearings should fall between 130º-180º F. If the oil temperature reaches 200º F or higher, determine the cause and make corrective steps to lower the temperature back to the proper range. Some common causes of elevated oil temperatures are: excessive oil in the tube; wrong type or grade of gear lubricant; screen is operating faster than recommended. Overheating could be a sign that the bearings are beginning to fail. Take an oil sample to check for higher than recommended contaminant levels. Inspect and replace bearings if all indicators point to worn bearings.

Storage Instructions

Vibrators in service that are to remain idle for periods longer than two weeks should be given storage treatment to prevent rusting of internal metal parts and drying of seals. Rust preventive oils such as MOBILARMA 524 (MOBIL OIL CORP.) are recommended because the parts need not be cleaned of this compound before placing the unit in operation. Simply drain the excess and refill to the proper oil level with your operating lubricant. If the vibrator is to be idle for an extended period and power is available to drive it while it is attached to the live frame, do the following before shutting down: 1. Drain the operating oil and refill to the proper oil level with MOBILARMA 524 (or equivalent). 2. Run the unit for one hour before shutting down. 3. After shutdown, coat the exposed portion of the oil flinger sleeve on the drive shaft with grease. 4. Keep the rust preventive in the vibrator during the idle period and put the unit in operation every three months for one hour. 5. When operations are resumed; drain the rust preventive and refill with the proper oil.


31

Counterweight Settings

Counterweight Arrangement Table

TIO6203 Status

Counterweight Thickness

Quantity For Sheaves Add

1-3/16”/ δ30mm

2

13/16”/ δ20mm

1

1/2”/ δ12mm

1

Add

1-3/16”/ δ30mm

1

Spare Bolts For 5 Weights

GB5782/M20x160

Initial


Total

Quantity For Flywheels Add

Amplitude （mm）

Total

2 4

1

4

8.5

5

9.8

1 5 3

1

3

32

Drive Assembly

Note: The spacers mu st b e installed.

Drive Assembly Parts List ITEM NO.

1

PART NO.

DESCRIPTION

QTY.

284T

Motor 25 HP, 1770 RPM, 460 V, 60 HZ

1

Y2-180M-4

Motor 18.5 KW, 1470 RPM, 380 V, 50 HZ

1

3C110 (3C11.0-E)

Motor Sheave 11.4” OD (With 1770 RPM Motor)

1

3C Ø345-E

Motor Sheave OD Ø 355.16mm (With 1470 RPM Motor)

1

E 1 7/8(Ø47.7 E)

Motor Sheave Bushing ( With 284T Motor)

1

Ø48 E

Motor Sheave Bushing ( With Y2-180M-4 Motor)

1

Bolt 1/2 “-13UNCx70

3

GB93/1/2”

Lock Washer 1/2”

3

5

C-3100

Recommended V Belt Length 3100 mm

3

6

K5160.05-01(3C)

Driven Sheave

1

7

K5160.05-11(US)

Bushing

1

8

TIH4102.2-2/M12X100

Bolt M12X100

3

9

GB93/12

Lock Washer12

3

10

GB5782/ M12X75

Bolt M12X75

4

11

GB6170 / M12

Nut M12

4

12

GB97.1/ 12

Washer 12

4

13

JMB50X270

Motor Mount

1

2

3

4


33

Screen Cloth Installation

A

B

C

Model mm TIO6203

1880

Inch 74”

mm 1850

Inch 73”

Dim 0

D

Qty for One Deck 0

Dim mm

Inch

1207

47.5”

Qty for One Deck 5

1.

One of the many helpful features of a Trio screen is the ease with which wire cloth can be changed. All decks are built so the wire cloth can be split into equal lengths. This feature increases the service life of the wire cloth. The design provides four wear areas at the feed end rather than two, because the feed-end panel can be turned once when it is worn at the original end, and can then be exchanged with the panel at the discharge end.

2.

To remove the top deck wire cloth on a single crown screen, remove all of the draw bolts and drawplates. Lift the wire cloth out from the top. Loosed the feed plates so that the wire cloth can be pulled from under it. To remove the wire cloth in the middle and bottom decks, remove the draw bolts and drawplates. Pull the wire cloth out from either end of the screen.

3.

Check the channel rubber. If it is worn through, replace it. Replacing the channel rubber when needed helps maximize the screen cloth life.

4.

With the wire cloth and draw plates in place, tighten the draw bolts evenly. Make sure that the ends of the drawplates do not catch on the adjacent draw plates as this will cause them to pull unevenly. Tapping downward on the top edge of the draw plate helps set the wire cloth in position.

5.

The feed pan, tailgate, and all the wire cloth hold downs can now be put in place and tightened. Again, excessive tension on the bolts is harmful. After the screen has run a few hours, retighten all of the bolts.

6.

Hooks are bent up approximately 135º to form an inside angle of 45º, and should not project over 1-1/8” from above the top surface of the wire cloth. Bend to 1/4" radius.


34

Appendix A

Bolts Torque Specifications

For Metric Bolts Diameter (mm)

6 8 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 27 27 30 36 42 48 56 64 72

Grade 8.8

Pitch (mm)

1.5 1.25 1.75 1.25 2 1.5 2 1.5 2.5 1.5 2.5 1.5 2.5 1.5 3 2 3 2

Dry FT-LBS 6.9 17.7 30 32 53 58 85 91 131 140 181 204 256 284 349 383 443 482 648 700 985 1716 2753 4156 6662 9954 14410

N-M 9.3 23.9 41 43 72 78 115 124 178 190 246 276 347 385 473 519 600 654 879 949 1335 2326 3732 5634 9032 13496 19536

Grade 10.9

Lube FT-LBS N-M 5.2 7 13.3 18 24 32 24 33 41 55 44 60 65 88 70 95 101 137 108 146 139 189 156 212 197 267 218 296 268 364 294 399 340 461 371 503 499 676 538 730 741 1004 1290 1749 2070 2806 3124 4236 5009 6791 7484 10147 10835 14689

Dry FT-LBS 9.7 24.9 44 46 77 85 124 134 192 204 265 297 374 415 510 560 647 705 949 1023 1389 2419 3882 5860 9393 14035 20319

Grade 12.9

Lube FT-LBS N-M 7.3 9.9 18.7 25.4 34 46 36 49 60 81 65 88 95 129 103 139 148 200 157 213 204 276 229 310 288 390 319 433 392 532 431 584 497 674 543 736 729 989 787 1067 1044 1416 1819 2466 2919 3957 4406 5973 7063 9575 10553 14307 15277 20712

N-M 13.2 33.8 60 63 105 115 168 181 260 277 359 403 507 563 692 759 877 956 1286 1387 1883 3280 5263 7944 12735 19028 27547

Dry FT-LBS 11.6 29.8 52 55 91 99 145 156 225 240 311 349 439 487 599 657 759 828 1112 1200 1665 2900 4652 7023 11259 16822 24353

Lube N-M 15.7 40.4 71 74 123 134 196 212 305 325 421 473 595 660 812 891 1029 1122 1508 1627 2257 3931 6307 9521 15264 22807 33016

FT-LBS 8.7 22.4 40 42 70 76 111 120 173 184 239 268 338 375 460 505 583 637 856 923 1252 2180 3498 5280 8465 12648 18310

N-M 11.8 30.4 54 57 95 103 151 163 234 250 324 364 458 508 624 685 791 863 1160 1252 1697 2956 4742 7159 11477 17148 24824

ASSUMPTIONS: (1) The maximum torque values are based on 75% of the specified proof strength. (2) The term "lube" includes the application of thread lubricants, cadmium plating,

and the use of hardened washers; regardless of whether standard or lock nuts are used.


35

For SAE (Inch) Bolt s Diameter (inches)

1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2 9/16 9/16 5/8 5/8

N (threads/in )

20 28 18 24 16 24 14 20 13 20 12 18 11 18

S.A. E. Grade 5 Dry FT-LBS 8 10 17 19 31 35 49 55 75 85 109 121 150 170

N-M 11 14 23 26 42 47 66 75 102 115 148 164 203 231

Lube FT-LBS 6 7 13 15 24 27 38 42 58 65 84 93 115 131

S.A. E. Grade 8 Dry N-M 8 9 18 20 33 37 52 57 79 88 114 126 156 178

FT-LBS 12 14 25 27 44 49 70 78 106 120 154 171 212 240

N-M 16 19 34 37 60 66 95 106 144 163 209 232 287 325

Lube FT-LBS 9 11 19 21 34 38 54 60 82 92 118 132 163 185

N-M 12 15 26 28 46 52 73 81 111 125 160 179 221 251

For SAE (Inch) Bolt s Diameter (inches)

N (threads/in )

1/4 1/4 5/16 5/16 3/8 3/8 7/16 7/16 1/2 1/2 9/16 9/16 5/8 5/8 3/4 3/4 7/8 7/8 1 1 1 1/8 1 1/8 1 1/4 1 1/4 1 3/8 1 3/8 1 1/2 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 3

20 28 18 24 16 24 14 20 13 20 12 18 11 18 10 16 9 14 8 14 7 12 7 12 6 12 6 12 5 4.5 4.5 4 4 4

S.A. E. Grade 5 Dry FT-LBS N-M 8 11 10 14 17 23 19 26 31 42 35 47 49 66 55 75 75 102 85 115 109 148 121 164 150 203 170 231 266 361 297 403 430 583 473 641 644 873 704 955 794 1077 891 1208 1120 1519 1241 1683 1469 1992 1673 2269 1949 2643 2194 2975 2286 3100 3438 4662 5027 6817 6875 9323 9321 12639 12313 16696

Lube FT-LBS N-M 6 8 7 9 13 18 15 20 24 33 27 37 38 52 42 57 58 79 65 88 84 114 93 126 115 156 131 178 205 278 229 311 330 447 364 494 495 671 542 735 611 829 685 929 862 1169 954 1294 1130 1532 1287 1745 1500 2034 1687 2288 1758 2384 2644 3585 3867 5244 5288 7171 7170 9723 9472 12844

S.A. E. Grade 8 Dry FT-LBS 12 14 25 27 44 49 70 78 106 120 154 171 212 240 376 420 606 668 909 995 1288 1445 1817 2012 2382 2712 3161 3557 4988 7500 10969 15000 17794 23507

N-M 16 19 34 37 60 66 95 106 144 163 209 232 287 325 510 570 822 906 1233 1349 1747 1959 2464 2728 3230 3677 4286 4823 6764 10170 14874 20340 24129 31875

Lube FT-LBS N-M 9 12 11 15 19 26 21 28 34 46 38 52 54 73 60 81 82 111 92 125 118 160 132 179 163 221 185 251 289 392 323 438 466 632 514 697 699 948 765 1037 990 1342 1111 1507 1398 1896 1548 2099 1832 2484 2086 2829 2432 3298 2736 3710 3837 5203 5769 7823 8438 11442 11538 15646 13688 18561 18082 24519

ASSUMPTIONS: (1) The maximum torque values are based on 75% of the specified proof strength. (2) The term "lube" includes the application of thread lubricants, cadmium plating,

and the use of hardened washers; regardless of whether standard or lock nuts are used.


36

Appendix B


Oil Viscosity Classification

37

SAFETY DECAL KIT

Sample Figure

ITEM NO.

PART NO.

DESCRIPTION

SDK-001

Safety Decal Kit and Charts


QTY.

38

TrioTIO6203 Screen Manual (207) Banana Doble Deck

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