Trio 44x32 Twin FMW Operating Manual

8/19/2019 Trio 44x32 Twin FMW Operating Manual

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TRIOE N G I N E E R E D P R O D U C T S

Trio Engineered Products, Inc. • 12823 Schabarum Ave. • Irwindale, CA 91706 • Telephone 626-851-3966 • Fax 626-851-9526

Parts and Operation Manual

Twin 44” Fine Material Washers



Twin4432 Fine Material Washer 2

Twin 44” Fine Material Washers

Size:

Serial number:




H AZARD W ARNING Any machinery may be hazardous tothe user if it is not maintained andoperated properly. The followingprecautions should always beobserved:

CRUSHING MACHINERY

1. Take special care to see that allparts of your body are clear ofmoving parts and pinch pointsbefore starting or operating

machinery.2. Make sure that all rotating

sheaves, pulleys and belts areproperly guarded to preventbeing caught by them.

3. Be sure that the feed anddischarge systems for materialprocessing equipment aredesigned and maintained so thatprocessed materials (rocks,gravel, coal, etc.) are retainedwithin the system. Do not allowany part of your body to enter inor near the material flow.

4. Never sit or stand on anycomponent of the machinerywhile it is in operation to preventinjuries arising from vibration.

5. Verify that the supportingstructure(s) provided by yourcompany for the machinery is

sufficient to support both the total

weight of the equipment and thedynamic load and stressescreated by the equipment.

CONVEYING MACHINERY

1. Be sure that all parts of your bodyare kept clear of movingconveyor belts, especially atpinch points.

2. Do NOT lubricate machinerywhile it is in motion.

3. Never lean over a movingconveyor belt, or ride on aconveyor belt intended only formaterial transport.

4. Always keep clear of feed ordischarge points of all materialconveyor systems.

5. Be sure that all guards aresecurely fastened in place onsheaves, pulleys, and belts

before and during equipmentoperation.

SAFETY EQUIPMENT

Only the safety equipment andguards that are specified by thePurchaser on the Shop Order or theCustomer Order Acknowledgmentare included with the equipment.The Purchaser must furnish all otherrequired safety devices.




GENERAL S AFETY PRACTICES Safety Practices affect everyone.

Any and all personnel who operateor maintain your equipment areexpected to comply with the basicsafety practices that follow.

This manual contains the bestavailable information on properinstallation, operation andmaintenance of the equipment,which it addresses. It does NOT

replace or supersede applicablefederal, state, or local regulations,your company safety rules, orinsurance carrier requirements. Itdefinitely is not intended to replacegood judgment or common sense!

Equipment operators, plantmanagement and safety engineersare required and expected to beaware of potential hazards that mayexist in the specific workplace where

the equipment is installed andoperated. All personnel areexpected to develop, implement andmaintain a safe work environmentcompatible with operating conditions,requirements, and practices.

Additional safety precautions suitedto the specific conditions of the worksite and the equipment installationare the responsibility of the user.

Experience has demonstrated thatthe greatest number of workplaceaccidents are caused by failure tofollow established safety rules. Besure that you are fully familiar withthe safety program requirements

applicable to operating this type ofequipment. Consult your supervisorconcerning any operating procedurethat you are not sure about beforeoperating or working on thisequipment.

Note: It is strongly recommendedthat properly constructed andguarded access platforms be erectedat convenient locations on theequipment installation site to allow

safe inspection, adjustment,maintenance and repair of theequipment described in this manual.It is the responsibility of thepurchaser of this equipment toensure that such platforms complywith applicable federal, state, andlocal standards and regulations.




PERSONAL S AFETY PRACTICES Arrangements for EmergencySituations

Supervisory and operating personnelshould develop an emergencyresponse profile for possibleemergencies on the worksite. Allpersonnel should know the locationof fire-extinguishers, where to obtainfirst-aid assistance and supplies,emergency report telephone

numbers, power shut-off points, andother equipment shut-down controllocations. Appropriate tools andequipment should be available toallow immediate response toemergency situations. Always followthe requirements and regulations ofyour company’s Emergency ActionPlan.

Safe Machinery Installation

1. Read and understand all parts of

this manual including GeneralDimension Drawings.

2. Review your Plant Engineer’sInstallation Drawings for thisequipment.

3. Select, Assemble, and Test thecorrect hoisting and riggingequipment required to move theequipment to the installation sitein your family.

If there is any question regarding theproper rigging of the equipment ornecessary hardware to make thelift/movement of the equipment to its’designated mounting location,contact your local representative toresolve the questions prior tobeginning installation activities.

Know and Understand How theEquipment Works

It is absolutely essential thatmachine operators understandcompletely how the machine works.The operator must know the locationand function of all controls, gauges,indicators and alarms included withthe unit. Operators andmaintenance personnel must becompletely familiar with maintenanceprocedures and schedules. Only ifthe equipment is given maintenance

on the prescribed schedule cancostly and time-consumingbreakdowns be prevented.

DO NOT OPERATE THE MACHINE WHENITS PARTS ARE WORN BEYONDDESIGNATED TOLERANCES. REPAIROR REPLACE THEM BEFORE TROUBLEOCCURS.

Inspect Your Machine BeforeStart-Up

Make a visual inspection of themachine for loose, worn, ordamaged parts or faulty safetydevices. Inspect all drive belts andpulleys for excessive wear. Testalarm systems and check fluidlevels. Make sure that hydraulic, air,and lubrication systems and theirrespective valves, drains, and fittingsare in proper working order. Reportor repair any problem before startingthe machine.

Follow the Recommended

Equipment Start-Up Instructions

Be sure that control systems andalarms are working properly. Checkgauges for proper readings. Checkfor any unusual noises that mayindicate bearing failure or othermechanical problems. Check forsudden rises in lubricanttemperature. Shut the equipment




down immediately if problems aredetected, and report the problem(s)to your supervisor. Always refer tothe Operating Section of this manualif you are unsure about a start-upprocedure or for additionalinformation.

Stop the Machine Properly andSafely

The machine must be completelystopped with power off and locked-out with controls tagged before anycleaning, repairs, adjustments, or

service is performed. All provisionsof your company’s Control ofHazardous Energy (Lock-Out/Tag-Out) program must be followed.

Report the Need for NecessaryRepairs Immediately

Report any situation involving theneed for repair, replacement oradjustment of an equipmentcomponent immediately.Remember, the most minor defectcould result in injuries to yourself orothers or serious damage to themachinery if it is not correctedpromptly.

Do NOT work on the equipmentunless you have been properly andcompletely trained to do the workinvolved.

Prevent Fire Hazards

Never weld or use a cutting torch

near open or exposed fuels,lubricants, or other flammablematerials. Follow your company’sHot Work Policy.

Do not let greasy or oily ragsaccumulate in poorly ventilatedareas. Store oily rags and othercombustible materials in anapproved storage container anddispose of them properly.

Never use an open flame to checkfor fluid leaks in the equipment. Usean approved low voltage electric lightor flashlight.

Never smoke in undesignated areas.Follow your company’s SmokingRules. Always extinguish smokingmaterials properly. Know where thenearest fire extinguisher is located,how to operate it, and what types offires it can be used to extinguish.Make sure that fire extinguishers arein place, are in proper working

condition, and have a current, validinspection tag. If a fire extinguisheris not readily available, or does notmeet these requirements, report thesituation to your supervisor.

Keep Your Work Area Clean

Become fully familiar with theworksite where the equipment isinstalled. Inspect the area daily andsee that unsafe conditions arecorrected. Make sure that all

equipment guards are securelyfastened in place, that steps,stairways, work platforms and barrierrails are sound and free of spills orobstructions. Keep the floor/worksurface clean and free of oil, greasyrags, cables, chains, buckets andother obstructions. Keep tools andloose parts in a toolbox orappropriate storage areas. Use highflashpoint/low toxicity solutions for

cleaning.Handle Tools, Heavy Parts, andMachine Components Properly

Do not toss parts or tools or dropthem off platforms. Do not lower orswing electric or air power tools bytheir power cords or air lines. Use asuitable rope and/or container tolower tools or parts to the floor.Review job activities and arrange to




get help before you attempt to lift,carry or move heavy parts. Forheavy or awkward lifts use properhoisting devices.

Dress Properly for the Job andUse Appropriate PersonalProtective Equipment

Follow your company PersonalProtective Equipment Policy.Discuss personal protectiveequipment requirements with yoursupervisor before operatingequipment or performing service,

repair or adjustment work. Don’twear loose clothes or jewelry, andrestrain long hair.

Follow Your Company Substance Abuse Control Pol icy

Report any use of prescription orover-the-counter medications to yoursupervisor prior to operating thisequipment or making anyadjustments or repairs to it.

ALCOHOL OR OTHER CONTROLLEDSUBSTANCES SHOULD NOT BE USEDPRIOR TO OR DURING WORK ON THISEQUIPMENT.

Avoid Serious Eye/Skin Injur ies

Hydraulic fluid or compressed air canpenetrate or burn the skin or damagethe eyes causing serious injury,blindness, or death.

Mineral-based hydraulic oil ishazardous. Always wear goggles

when working with hydraulic fluid.Flush your skin or eyes thoroughlywith water if you spill or splashhydraulic fluid on yourself. Removeclothing on which hydraulic fluid hassplashed. Get immediate assistanceand report the matter to yoursupervisor. Get appropriatedmedical care. Wear appropriatepersonal protective equipment as set

forth in your company’s PersonalProtective Equipment Policy whenhandling hydraulic fluid. Wash yourhands with soap and water afterhandling hydraulic fluid. Never eat,drink or smoke while handlinghydraulic fluid.

Make sure that all compressed airlines and couplings are in properoperating condition at all times. Besure that all compressed air linesintended for chip or dust removal arefitted with OSHA compliant pressure

relief nozzles. Never usecompressed air to clean yourclothing or any part of your body.

Dispose of All Waste MaterialsProperly

Dispose of all waste materials suchas fuels, lubricants, hydraulic fluid,etc. in accordance with yourcompany waste managementpolicies, and federal, state, and localregulations. If you have a question

concerning proper procedures to befollowed, consult with yoursupervisor, or the company safetyadministrator.




S AFETY AND M AINTENANCE PRACTICES Replace Loose or Defective Parts

Keep the equipment clean and freeof dirt and oil so that loose, broken,defective, or worn parts can beeasily identified. Make daily visualchecks for missing, cracked, orfrayed V-belts. Also check daily forfrayed, broken or kinked cables.Inspect end connections for wear.Replace sheaves with cracked rims

or spokes immediately. Reportsuspected defects to yoursupervisor.

Properly Ground MachineElectrical Components

Check frequently to ensure that theequipment is properly grounded asstipulated in your company electricalsafety rules. Prevent any electriccable from coming in contact withwater in puddles, drainage channels,

etc. Protect power cables fromvehicular traffic such as forklifts andother motor vehicles. Power cablesshould be bridged over traffic lanes.

All permanent electric cables shouldbe in proper conduit or otherapproved insulation. Follow yourcompany electrical safety rules withregard to periodic inspection of thecondition of electric line insulationand couplings. Do NOT use

portable, flexible electric cords todeliver electric power to theequipment.

CONTROL OF HAZARDOUSENERGY (LOCK-OUT/TAG-OUT)

PROGRAM

CAUTION: Purchaser mustimplement a Control of HazardousEnergy (Lock-Out/Tag-Out) Program

that complies with 29 CFR 1910.147and 133 regulations.

It is the responsibility of thepurchaser to provide a suitableControl of Hazardous Energyprogram for the protection of its’employees while they are engaged inthe installation, maintenance, repair,or modification of equipmentpowered by electricity, hydraulic,pneumatic or mechanical energy inorder to meet the regulations of theU.S. Dept. of Labor, OccupationalHealth and Safety Administration(OSHA).

Under certain conditions, and incertain operating environments,regulations concerning this area arepromulgated by the federal MineSafety and Health Administration(MSHA). Certain state, county, or

local regulations may also apply. Assistance in establishing specificregulatory obligations may beobtained from regulatory agencies,insurance carriers, or privateconsultants.

Specific information concerningelectrical operating characteristicssuch as output, rated capacity, etc.of electrical motors supplied with theequipment may be obtained by

review of the technical datacontained in this manual or from thespecific equipment supplierstipulated in the Shop Order.

Obtaining Control of HazardousEnergy Program Materials

Listed below are three possiblesuppliers of materials to aid you indevelopment, documentation andmaintenance of your program.




Inclusion of the names of these firmsin this manual does not represent anendorsement of them. These firmsprovide some of the materialsrequired for a comprehensiveprogram.

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

2. EMED Co., Inc. TelephoneGraphic Communications Products,

Inc.

Buffalo, NY 14240-0369P. O. Box 369Toll Free 800-442-3363Fax Toll Free 800-344-2578

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

The Purchaser has soleresponsibility for safe operation ofthis equipment. The Purchaser isresponsible for ensuring that on-sitemachine operation is in compliancewith any and all applicable federal,state, county or city safety standardsand regulations.

The equipment may be moved fromone site to another a number oftimes by various purchasers,

lessees, etc. Consequently,responsibility for compliance withapplicable safety and environmentalcodes lies with the entity responsiblefor operating the equipment withineach jurisdiction.

Purchaser is wholly responsible forany ancillary or support equipmentsuch as, but not limited to,processed material receivingdevices, and inspection or serviceplatforms.

Purchaser is required to perform

periodic maintenance of the type andon the recommended schedules setforth in this manual. Maintenanceshall include, but is not limited tosafety devices delivered with theequipment set forth in the ShopOrder, and Warning and Instructionlabels affixed to the equipment.Replacement parts including warningand instructional labels are available.

Any modifications or machinery as

designed, manufactured, anddelivered by without the expresswritten approval and consent willvoid all warranties and remove allresponsibility of manufacturer for anyand all damages to persons orproperty.




GENERAL S AND SCREW INFORMATION

INTRODUCTION

This Operation and MaintenanceManual has been prepared to assistin the installation, operation, andmaintenance of sand screws.

The information contained in thismanual is intended to familiarize theoperator with the generalconfiguration and assembly of this

equipment. It should aid in providingthe necessary information for theefficient operation and maintenanceof this machine.

M ACHINE DESCRIPTION

The sand screw is a single screwfine material washer-classifier-dewaterer. Its maximum materialsize is 3/8”.

GENERAL SPECIFICATIONS TW4432

Screw Diameter: 44”

Tub Length: 32’

Driven Sheave:(included with machine)

12.24”

V Belt Section “B”

No. V Belts 4X2

Drive sheave shaft 48mm (h6)

Distance between

centers

44 3/4”

Gearbox ReductionRatio

75:1

Capacity (TPH) 350

Maximum Material Size 3/8” (9 mm)

HP Req’d (Electri c) 25x2

Maximum Water Req’d(GPM @ 25 PSI)

740 (For 200 Mesh Split)



Maximum Water Req’d

(LPM @ 1.7 BARS)


5300 (For 150 Mesh Split)10720 (For 100 Mesh Split)

Screw Speed (RPM) 17

Weight of Washer 36,610




M ACHINE SCHEMATIC

The diagram below presents a general schematic of the machines.




SHIPPING CONDITION The machines are shipped partially assembled. The belt guard, feed chute, tubextensions and weirs are all bolted onto the machine for shipment. Miscellaneous bolts,washers, nuts and gaskets can be found in a box shipped in the sand screw tub.

RECOMMENDED TOOLS

The machines are built using metric sized bolts, washers, and nuts. Consequently, acomplete set of metric sized tools should be readily available for emergency andscheduled repairs. Refer to the parts manual for exact sizes.

REPLACEMENT P ARTS

Replacement parts are available to provide responsive service on replacement andwear part orders.

When ordering parts, please have the following information available:

Sand Screw Model Number

Sand Screw Serial Number

Part Number

Address to Ship Part(s)

Purchase Order Number

The appendix to this manual includes a complete spare parts list for reference when

ordering replacements.




DIMENSIONS

α

Spiral

Diameter

Tub

Length

A B C D E F G H

44”32’

(9,750)

14’-6 7/8”

(4,442)

8’-4 1/8”

(2,542)

16’-8 3/4”

(5,100)

34’-6”

(10,516)

11’-9 3/4”

(3,600)

12’-6”

(3,809)

8’-2 1/4”

(2,496)

4’-1 1/2”

(1,258)18°

Note: Dimensions subject to change without notice: contact factory for certified drawings




INSTALLATION INFORMATION

ASSEMBLY INSTRUCTIONS Upon receipt, inspect the delivery to ensure that all parts are accounted for. Afterunpacking the loose parts, check all installed bolts to ensure that they are installed withthe proper torque.

The fine material washers are shipped from the factory partially assembled. The tubextensions, weirs, feed chute assembly and belt guard are tied onto the machine forshipping purposes (the bolts and gaskets needed for assembly are shipped in a boxlocated inside the tub). To prevent damage from lifting and handling the machine, thereare cross brace stiffeners in the tub which will need to be removed prior to operation.The gearbox is shipped without oil and will need to be filled to the appropriate level prior

to running the machine.Items not included from the factory are motor, dive sheave and v-belts.

LOOSE P ARTS ASSEMBLY DRAWING

FEED CHUTE ASSEMBLY

RIGHT TUB EXTENSION

LOWER BEARING

ASSEMBLY

REAR WEIR

LEFT TUB EXTENSION

GEAR REDUCER

The following parts are shipped form the factory loose and require some assembly.

Feed chute assembly parts Quantity

Feed chute inlet 1

Feed chute flow deflector 1

Baffle plate 1

Tub cross tie 2

Bolts/Nuts /Washers for cross tie 16 sets

Tub Extensions

Right tub extension 1

Left tub extension 1

Seal of tub extensions 2 pieces

Bolts/nuts/washers for tub extensions 146 sets

Rear weir 1




Hardware for each port ion




Assembly Instructions

1. Unpack all parts, taking care to ensure not to damage and of the loose parts when

removing them from their packing condition.2. Make sure all bolts are torqued properly (see bolt tightness below).

3. Install left and right tub extensions using the hardware provided.

4. Install the tub cross tie.

5. Install feed chute assembly.

6. Install rear and side weirs.

7. Install motor and temporarily install motor sheave and drive belts. Be sure to alignsheaves and adjust bolt tension. For detailed drawing, see Drive System section ofthis manual.

DO NOT START MOTOR UNTIL GEARBOX HAS BEEN FILLED WITH OIL

8. Once the position of the motor has been established, remove the belts and sheavesand install belt guard cover by welding to guard cover-mounting bolts.

9. Reinstall sheaves and belts.

10. Check coupling alignments as described in the flexible drive coupling maintenancesection.

11. Place machine in operating position on support leg. (Normal slope is 18°.)

12. Install water piping.

13. Fill gearbox with oil.

14. Grease lower bearing assembly.

BOLT TIGHTNESS

The initial tightening of bolts should prevent premature loosening, but the tightness of allnuts and bolts should be checked regularly to ensure that no loose bolts contribute tomachine down time. The following table illustrates the appropriate tightness for all boltson the Sand Screw:

Bolt Diameter (mm) Torque (ft/LBS)

6 7.7

8 18.7

10 7

12 3514 65

16 160

20 315

24 540

30 1080

36 1880




W ATER PIPING CONFIGURATION

The following diagram illustrates the water piping that needs to be installed before

operating the machines.

FLOW CONTROL VALVE

DRAIN BOARD FLUSH FLOW

VALVE TO SHUT OFF

FLOW TO MACHINE

FLOW CONTROL VALVE

WASH WATER

PRESSURE GAUGE

DO NOT EXCEED 25 P.S.I.CHECK VALVE TO

PREVENT BACKFLOW

OPERATING INSTRUCTIONS

Before operating the Sand Screw, follow these steps:

Check to ensure that there is sufficient oil in the gearbox; check to ensure that themachine’s slope remains 18°. Also, verify that the V-belts are sufficiently tensioned.Check for oversize material in the tub before starting.

Next, open the water valve and allow the tub to fill with water. When tub is full, startmotor and check screw rotation.

There are slotted boltholes on the removable weirs to allow leveling and adjustment.This will enable an operator to correct uneven flows over the weir edges, therebymaximizing the amount of fines retained in the tub.

The rectangular hole in the baffle plate can be opened in order to allow floating debris tosettle at the back of the tub. The flow from the flush inlet at one end of the tub should beadjusted to wash all material down the slope to the bottom of the tub.

Because of the wide variety of material that this machine can accommodate, theoperator should note the type of material being washed, the amount of water in thematerial, the desired wash flow rate, the desired material flow rate, the expected returnflow rate, and the subsequent weir adjustments required to accommodate those flows.

While operating, take continuous care to ensure that in the event of downstreamequipment failure, no material blockage occurs in the Sand Screw.

ASSEMBLIES AND M AINTENANCE




LOWER BEARING ASSEMBLY

DRAWING

Parts List Item# Qty Description Parts # Unit Weight (Lbs)

1 1 Hub SW4432.4-1B 49.5

2 1 Lock Nut KM20 1.503 1 Lock Washer MB20 .254 1 Adapter H3120 3.965 1 Bearing 23120CCK/W33(C3) 11.336 1 Grease Fitting M10X1 GB1152 .0227 1 Seal Housing SW3625.4-2A 112.28 8 Bolt M16X65 GB12/GD4.8 .229 14 Nut M16 GB6170 .0710 14 Lock Washer 16 GB93 .02211 1 Seal Retainer TD1214 12.7612 1 Donut Seal SW3625.4-4 5.2813 1 Stub Shaft TW4432.4-1 191.414 8 Bolt M20X65 GB70 .4415 8 Nut M20 GB6170 .13216 12 Lock Washer 20 GB93 .044

21 1 Gasket SW3625.4-7A .15422 1 Gasket SW3625.4-8A .2223 6 Bolt M16X75 CW4420.2-1 .2924 8 Rubber Washer CW4420.2-3 .1125 4 Bolt M20X90 CW4420.2-2 .5726 1 Stainless Steel Sleeve TW5434.4-2 4.8427 1 Slinger SW3625.4-9 .35228 1 Oil Seal PD115X140X14 HG4-692-67 .229 1 Gasket SW3625.4-10A .11




M AINTENANCE

Before any maintenance can be performed on the lower bearing assembly, the screw’slower end must be supported in place. This is important because the bearing housing(hub) through the bearing supports the lower end of the screw. Use the lower bearingassembly drawing and parts list as a reference.

1. Support screw’s lower end.

2. Remove the six (6) hub bolt nuts.

3. Tighten the two (2) jackscrews on the hub.

4. Slide hub off of bearing. The bearing should be exposed. Protect the bearing fromcontaminates. A visual inspection of the bearing should be made. If you seescratches, corrosion such as pitting, or a large amount of metal flakes in the grease,the bearing should be replaced. To remove the bearing continue as follows:

5. Fold back washer ears.

6. Unscrew bearing nut (#14).

7. Use bearing puller (C-type) to remove bearing. NOTE: The bearing will pop ofquickly. Be sure it will not fall into a contaminated area.

8. Remove the six (6) seal retainer bolts (#4).

9. Remove the seven (7) of the eight (8) end plate bolts (#2).

10. When ready to remove the end plate, take off the last bolt and lift off the end plate.NOTE: The screw must be supported before removing the end plate. Now the sealscan be inspected. The oil seal is on the end plate – if it shows any wear replace it.(Make sure when replacing the oil seal that the orientation is correct, see lowerbearing assembly drawing, page 19.)

11. To inspect the rubber donut seal (#6), slide the slinger (#8) and the donut seal off ofthe stub shaft. If either shows any sign of wear or cracking, replace them.

12. To reassemble, follow instructions in reverse order.




GEAR BOX

DRAWING

PARTS LIST Item# Qty Parts # Description

1 2 GB297-84 (32310) Bearing 7610E, #1 shaft

2 1 SHP900-75-28 Cover, #1 shaft

3 1 SHP900-75-3 #1 Shaft and Pinion






6 2 SHP900-75-28 Cover, #2 shaft

7 2 GB1235-76/120x5.7 O-Ring, #2 shaft

8 1 SHP900-75-7 Gear, #2 shaft

9 1 SHP900-75-26 Gear, #3 shaft

10 2 GB1235-76/170x5.7 O-Ring, #3 shaft

11 1 SHP900-75-25 Spacer, #3 shaft


13 1 SHP900-75-13 Key, #3 shaft

1416

SHP900-75-31GB5782-86/GD8.8

Closure, #4 shaftBolt M8x16

15 1 SHP900-75-22 Key, output

16 1 SHP900-75-17 #4 Shaft

17 2 GB9877.2-88/W120x170x14 Oil seal

18 1 SHP900-75-23 Seal housing, output

19 1 SHP900-75-18 Key, #4 shaft

20 1 SHP900-75-14 Gear, #4 shaft

21 1 SHP900-75-1 Housing, back half

22 1 SHP900-75-2 Housing, front half


24 2 SHP900-75-19 Front shim, #4 shaft

25 24(each) GB5782-86/GD8.8, GB93-87 Bolt M16X40, Washer 16

26 1 SHP900-75-15 Cover, #4 shaft

26a 1 GB1152/M10X1 Grease Fitting

27 1(each) GB297-84 (32221) (30324) Bearings 7521E, 7324E, #4 shaft


29 2 SHP900-75-10 Shim, #3 shaft

30 2 SHP900-75-11 Cover, #3 shaft

31 2 SHP900-75-27 Shim, #2 shaft

32 24(each) GB5782-86/GD8.8, GB93-87 Bolt M12X35, Washer 12


34 1 GB1096-79 Key, #2 shaft

35 1 SHP900-75-5 Seal housing, input

36 1 GB1096-79 Key, input

37 1 SHP900-75-30 Closure, #1 shaft

38 2 GB9877.2-88/W50x80x12 Oil seal

39 4(each) GB5782/GD8.8, GB93 Bolt M6x12, Washer 6

40 2 GB1235-76/114x5.7 O-Ring, #1 shaft

41 2 SHP900-75-6 Shim, #1 shaft

42 20(each)GB5782/GD8.8, GB6170/GD8GB93

Bolt M20X95Nut M20, Washer20




FLEXIBLE DRIVE COUPLING

DRAWING

PARTS LIST (For One Set)

Item# Qty Parts # Description Unit Weight (Lbs)

0 1 K6004.4 Complete coupling assembly

1 1 GB1096-79 Key

2 1 set SW4432-3A Coupling housing 79.2x2

3 6 GB5782/M20x160 Bolt M20X160 1.16 GB93/20 Washer 20 .033

6 GB6170/M20 Nut M20 .14

4 2 SW4432-4 Half Retainer ring .66

5 1 SW4432.4-3A Spider Plate 46.2

6 16 GB32.1/M20x55 Bolt M20X55 .33

16 GB1230/20 Washer 20 .066




M A INTENANCE

This section describes how to replace the drive coupling and check the alignment of the

screw to the gearbox and how to shim the gearbox to adjust for misalignment.

REPLACEMENT OF SPIDER1. Block under conveyor shaft assembly, unbolt spider from conveyor shaft flange andcoupling hub flange.2. Remove present spider. This may be more easily done by shifting conveyor shaftslightly.

3. Replace a new spider on the proper position,4. Tighten cap screws and install lock wires.5. Remove blocking under conveyor shaft.

REPLACEMENT OF WASHER DRIVE COUPLING1. Remove motor guard and V-Belt from end frame.2. Block under conveyor shaft assembly, unbolt coupling from conveyor shaft flange andremove the gear reducer assembly, complete with old coupling, from washer end frame.3. Remove present coupling from gear reducer output shaft.4. Install retaining ring and split driving hub and key on reducer output shaft. Note thatretaining ring and key must be in place before installing hub. Be sure driving hub halves

are drawn up completely together.5. The driving spider can now be bolted to the driving hub with four cap screws. Installlock wires in bolts.6. Replace gear reducer in end frame and align with conveyor shaft to permit installingthe cap screws through the pipe flange into driving spider. This may be more easilydone by shifting conveyor shaft slightly after anchoring reducer. Tighten cap screws andinstall lock wires. Place rubber seal over flanges and wire in place.7. Remove blocking under conveyor shaft and replace motor guard and V-belts.

SPECIAL NOTE ON MAINTENANCE PROCEDURE:




After installing this coupling in machine, the bolts in driving spider must be checked fortightness each day of operation until it is apparent that no looseness is occurring.Thereafter, a regular inspection should be maintained.

The upper ends of the conveyor shafts in Trio Washers are supported from the outputshafts of the gear reducers by means of flexible spider style couplings. The conveyorshaft is bolted to opposing arms on the spider and the driving member on the gearreducer output shaft is attached to the remaining set of arms which are at right angles tothe first.

The flexible drive coupling rarely requires service or replacement. However, whendisassembly is required, correct tightening of the bolts is necessary to insure properoperation. The bolts used in the couplings have a minimum Grade 5 rating and shouldbe torque tightened to the rated capacity.

The "turn of nut" method of tightening is recommended for all bolts used on all sizes ofcouplings. This includes the driving hub bolts and the flex-spider bolts. To torque boltsby this method, draw the bolts to a “snug tight” condition. This is best described as thefull effort 'of a man using an ordinary spud wrench. When all the bolts have been pulledup to "snug tightness”, finish tightening by turning each 1/2 turn (180 degrees plus orminus15 degrees). Table 1 lists the comparable torque values in Ft.-Lbs. This is forreference when a torque measuring tool is available. Note: 44” diameter machines andlarger should have hardened-clipped flat washers on the flex-spider bolts, not lockwashers.

TABLE1 TORQUE (Ft.-Lb.) REQUIRED FOR COUPLING BOLTS

Conveyor Shaft Size 36” 44” 54”

Pipe Diameter 8-5/8” 13-13/16” 14-27/32"

Driving Hub Bolts 309 309 309

Spider Bolts 320 320 600

When the flex-spider coupling bolts are tightened to the proper torque, install new lockwires through the drilled holes in the bolt heads. Two number 16 gauge wires arerecommended and should be placed in a manner which holds the bolt tight. When threebolts are used in each coupling arm they should be wired as a group. In all other cases,the bolts should be wired in pairs to further minimize the possibility of loosening orfailure.

Manufacturing variations, however slight, dictate the need to shim the gear reducer atthe mounting surface to provide optimum shaft alignment and minimum flexing of thespider coupling. When equipment is assembled, the procedures outlined here arefollowed to assure correct coupling alignment on all new machines. When shims arefound under the gear reducer mounting feet, they should be changed only in Case aserious misalignment is detected. Also, when a gear reducer is replaced on themachine, the shims should be replaced exactly as they were removed.




MEASURE TOP

(EXAMPLE, 1.000IN.)

MEASURE BOTTOM

(EXAMPLE, 1.020IN.)

GEAR BOX

FOOT

SHIM

(EXAMPLE, SHIM

FEET .050IN.)

FIGURE 1 FIGURE 2 FIGURE 3

SLOT

SHIMFOOT

To check the coupling alignment, uncover the slots of the spider by folding the rubberseal back over itself. Position the shaft so that the spider plate matches Figure 1. Use a

vernier caliper accurate to ± .0005 to measure the distance between the vertical gaps inthe flanges as shown in figure 2. If the differences between the vertical gaps, top andbottom, are greater than 0.020”, then the gearbox feet must be shimmed 0.025” for

every 0.010” of difference in the vertical misalignment. Once the vertical gap is aligned,repeat the procedure for the horizontal gap. For every 0.010” of horizontal gap, shim thegearbox side feed 0.030”. After this is completed, the screw should be aligned. Seeexamples below.

Example: To remove 0.020” of difference in the vertical misalignment, shim the gearboxtop feet 0.050”, as shown in Figure 3.To remove 0.030” of horizontal misalignment, shim the left gearbox feet 0.090” on theside of the smaller measurement.

Table 2 following, gives a representative indication of the shim thickness required toadjust the coupling gap .010".either vertically or horizontally. Note, these thicknessesare not the same either from vertical to horizontal or for different machines having thesame coupling diameter.

TABLE2 Shim Recommendations for Trio Gear Reducers When AdjustingFlexible Coupling Alignment




Shim Thick. Required to AdjustCoupling GAP .010”

MachineType

MachineSize

CouplingDia.

A B

20”& 24” 10 1/4” 0.023” 0.016”

30”& 36” 12” 0.029” 0.024”

44”& 48” 17 3/4” 0.020” 0.016”

54”* 18-13/16” 0.025” 0.021”

Single &DoubleScrew FineMaterial

66”& 72”* 23 ½” 0.023” 0.018”

36” 12” 0.029” 0.024”Single &Double ScrewCoarseMaterial

44” 17-7/8” 0.025” 0.021”

Example: To remove .018” of coupling misalignment in the “A” direction, use (.018”

÷ .010”) (.023”) = .041” shim thickness for 20” & 24” dia. Washer.




SCREW ASSEMBLY

DRAWING

P ARTS LIST (RIGHT SCREW) COMPLETED: SW4432.4.1 TOTAL:6982 LBS

Item # Quantity Parts # Description Unit Weight (Lbs)

1 1 SW4432.4.1.1 Screw (Shaft w/fFights) 3754

2 16 SW4432.4.1.1-3 Flight 97.68

3 192 SW4432.4.1-1 Flight Shoe 16.9

4 384

384

384

384

GB819/M12X50/GD4.8

GB41/M12/GD5

GB93/12

GB97/12

Bolt M12X50

Nut M12

Washer 12

Washer 12

.099

.0352

.011

.011

P ARTS LIST (LEFT SCREW) COMPLETED: TW4432.4.1 TOTAL:6982 LBS

Item # Quantity Parts # Description Unit Weight (Lbs)1 1 TW4432.4.1.1 Screw(LH) (Shaft w/Flight) 3754

2 16 TW4432.4.1.1-3 Flight (LH) 97.68

3 192 TW4432.4.1-1 Flight Shoe (LH) 16.9

4 384

384

384

384

GB819/M12X50/GD4.8

GB41/M12/GD5

GB93/12

GB97/12

Bolt M12X50

Nut M12

Washer 12

Washer 12

.099

.0352

.011

.011




FEED CHUTE

DRAWING

P ARTS LIST

Item # Quantity Part No. Reference # Description

1 1 TT4200 TW4432.2 Complete feed chute assembly

2 1 TT4220 TW4432.2.2 Feed chute flow deflector

3 1 Debris plate

4 1 TT4201 TW4432.2-1 Baffle/debris plate

5 2

22

TSB1240

TSN12TSL12

GB5782-86/GD8.8

GB6170-86/GD8GB93-87

Bolts/nuts/washers

6 1 TT4202 TW4432.2-2 Tub cross tie

7 1 TT4210 TW4432.2.1 Feed chute inlet

8 2

2

2

TSB1240

TSN12

TSL12

GB5782-86/GD8.8

GB6170-86/GD8

GB93-87

Bolts/nuts/washers




DRIVE SYSTEM

DRAWING

P ARTS LIST

Item # Quantity Description Part # Unit Weight (Lbs)

1 1 Motor 25HP

2 1 Drive sheave 8.95 OD

3 4 V belts B128

4 1 Belt guard cover TW4432.9(L) TW4432.10(R) 81.4 Each

5 1 Driven sheave SW4432-6(4B) 29.7

6 1 Driven bushing Sw4432-5 3.08

7 3 Bolt M12X50

Nut M12

GB5782-86

GB93-87

.154

.015

8 1 Key driven shaft/bushing GB1096-79

The drive system on the washer is equipped with a driven sheave and a belt guardcover. The motor, motor sheave, and drive belts are required but not supplied from thefactory.




LUBRICATION

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

GEARBOX

The oil level is checked at the pipe plug opening on the front of the gearbox. The oillevel is to be checked with the machine not running and in its normal operating position

at an 18° to 21° slope.

The oil level should be regularly checked. Add oil by removing the breather cap to findthe oil fill pipe.

The oil should be changed after the first 80 hours of operation for a new or rebuiltgearbox. Thereafter, change the oil after each 2,500 hours of operation or 6 months ofoperation.

Trio washers are shipped without oil in the gear reducers. Before beginning operation,fill the reducer with premium quality lubrication oil having rust and oxidation inhibitors.Select a product having a viscosity that suits the ambient temperatures for the localclimate. Table 1 shows the recommended lubricants.

TABLE 1. RECOMMENDED LUBRICANT VISCOSITIES AND PRODUCTS

Ambient Temp. ºF 15-50 50-110 Over 110ISO Viscosity Grade 150 220 320

Viscosity @ 100ºF 490-750 SUS 750-1200 SUS 1200-1500 SUS

Manufacturer Lubricant Lubricant Lubricant

Amoco American Ind. 150 American Ind. 220 American Ind. 320

Arco DURO 150 DURO 220 DURO 320

Ashland ETC R&O 70 ETC R&O 100 ETC R&O 150

Chevron Machine Oil AW150

Machine Oil AW220

Machine Oil AW320

Conoco Dectol R & O Oil150

Dectol R & O Oil220

Dectol R & O Oil320

Exxon Teresstic 150 Teresstic 220 Teresstic 320

Mobil DTE Oil ExtraHeavy

DTE Oil BB DTE Oil AA

Pennzoil Pennzbell R&O 150 Pennzbell R&O 220 Pennzbell R&O 320

Shell Turbo Oil 150 Turbo Oil 220 Turbo Oil 320

Texaco Regal R&O 150 Regal R&O 220 Regal R&O 320




Trio recommends that at the time of oil change, only one name brand be used for thecomplete fill so that the oil base stock or additive compatibility will not be of concern.Oils with extreme pressure (EP) additives may be used without harm to the Trioreducer. Multi-grade gear oils may be used, if desired, for a wider range of ambientoperating temperatures.

When the machine is in operating position, and not running, the oil level should be atthe pipe plug opening on the front side of the gear case. Table 2 lists the approximateoil capacities for the various reducer and machine sizes. Fill or add oil to the reducerthrough the pipe nipple that is exposed when the breather cap is removed.

TABLE 2: OIL CAPACITIES

MachineSize

30 & 36 44 54

Oil Capacityin Gallons

14 16.5 30

Note: At low operating speeds, oil may have difficulty reaching the rear outputshaft bearing, so an external grease zirc has been installed on the gearbox at thatpoint (please see page 20 the gear box diagram item 26). Fill 1 once or moregrease once a week. NLGI #2, type EP rated, ASTM D2509 grease isrecommended.

BEARING TEMPERATURE

A properly adjusted bearing should run at about 140 to 160 degrees Fahrenheit. If abearing is suspected of running to hot it should be checked with a surface mountthermometer and checked to see if it is over 165 degrees Fahrenheit. A bearing thatdevelops high temperature after it has been running satisfactorily for some time may becaused by over greasing. A newly installed bearing that overheats is usually caused byimproper adjustments of the running clearance. A failed bearing that is overheating willprobably be accompanied by some other indication such as grinding noises.

LOWER BEARING ASSEMBLY

Every three months lubricate the grease fitting at the each lower bearing housing usingwater resistant grease. Flush this bearing assembly by injecting grease into the slot untilclean grease comes from the relief slot in the lower part of the bearing housing.

TABLE 3: GREASE CAPACITIES

Machine

Size36” Fine

36”Coarse

44” Fine 54” Fine 36” Log 44” Log

Grease Capacity inOnce/500Hours

3~3.5 4 4 5 5 6

Equipment of Trio Engineered Products, Inc., which may be sold to one of its dealers, will be covered by the following Warranty,which will be extended by Trio Engineered Products, Inc. to such dealer:




STANDARD EQUIPMENT WARRANTY

MANUFACTURER'S WARRANTY AND LIMITATION. Trio Engineered Products, Inc. (hereinafter "Trio") warrants Its products to itsauthorized Distributor, as specified herein, and Distributor agrees to extend this same warranty (and no other) to each purchaser of

the products of Trio at the t ime of sale and to notify each purchaser of the terms and conditions of this Warranty and provide a copyof said warranty to each purchaser. Distributor is not authorized by Trio to make any other, different, additional warranty or collateralagreements on behalf of Trio, and any such warranty or collateral agreement given by the Distributor is not binding on Trio.Distributor shall hold Trio harmless from any loss and/or costs (including attorney's fees) arising from failure to observe theseconditions. Trio extends this same Warranty to those, in addition to its authorized distributors, who buy the products of Trio directlyfrom it rather than purchasing from an authorized Distributor.

Trio warrants, commencing with the date of shipment of the goods to the first end-user and for a period of 90 days thereafter, allmachinery manufactured by Trio to be free from defects in workmanship and material. If, within such warranty period, any machineryor parts shall be proved to the satisfaction of Trio to be defective, It shall be repaired or, at Trio's option, repaired at its factory,F.O.B. Irwindale, CA, without charge (providing the defective machinery or parts are returned to Trio, Irwindale, CA, freight prepaid). At its option, Trio may repair, or arrange to have repaired, any defective machinery or parts, at the location of the Distributor, at theyard location or operating site of the first end-user, or at any suitable location at no charge to fi rst end-user and at no charge toDistributor other than those specified in its Distributor's Agreement. The right to have defective machinery or parts repaired orreplaced shall constitute Distributor's and first end-user's sole and exclusive remedy during the term of this warranty.

Trio may, at its sole discretion, refund the purchase price of defective machinery or parts in lieu of repairing or replacing them,providing the defective machinery or parts are returned to Trio, at Irwindale, CA, freight prepaid, and providing such return is

authorized by Trio, Trio may, at its sole discretion, waive the requirement that defective machinery or parts be returned to its factoryin connection with a warranty claim.

Trio's obligation hereunder shall be confined to the described repair or replacement of the defective machinery and parts, and doesnot include any charges, direct or indirect, by Distributor or end-user for field labor, for shipping, for field expenses or equipmentused in removing or replacing defective machinery or parts.

With regard to machinery, parts or accessories that are furnished by Trio, but not manufactured by it, the warranty obligation of Trioshall be limited to and be the same as that of its supplier. No warranty shall apply to the products of Trio, which, in its opinion, havebeen adversely affected by the use, on or with its products, of parts, attachments, equipment or lubricants not either manufactured,sold or authorized by Trio.

No warranty shall apply to any used machinery or to machinery, parts or accessories which have been furnished, repaired or alteredby others so as, in Trio's judgment, to have affected the same adversely or where said machinery, parts or accessories are used forpurposes other than that which they were manufactured or sold for. No warranty shall apply to machinery, parts or accessorieswhich (in the opinion of Trio) have been subject to accident, negligence, or improper operation, installation, maintenance, storage,care or other than normal use or service during and after shipment. With respect to machinery, parts or accessories to Trio's

products which are furnished, but not manufactured by Trio, Trio's warranty obligation shall in all respects conform and be l imited tothe warranties expressed herein.

Trio warrants that field services conducted by it in connection with installation or repair of machinery and parts will be performed in agood and workmanlike manner. The obligation and liability of Trio in connection with field services shall be limited to a refund of theamount it charged for such services, if any.

Inasmuch as the work to be performed by the buyer or end-user with the machinery or parts furnished by Trio will vary according tothe materials used, local conditions and the results required and that such variation will continue throughout the use of 'suchmachinery or parts, it is not possible to (and Trio does not) warrant or represent that machinery and parts furnished by it will handlespecific materials or will produce specific results from such materials. Trio does not warrant that any of its washing plants willseparate coal, slate, shale, clay, caliche, or similar foreign material from sand, gravel, or rock.

Trio is wholly discharged of all liability under the foregoing warranties in the event that purchaser of the machinery or parts fails topay for the goods promptly and in accordance with the terms of the purchase agreement.

Trio's liability hereunder Is conditioned upon Distributor (or in the event of a direct sale to a first end-user, then first end-user) givingnotice in, writing to Trio of any alleged defect, and such notice must be given immediately upon the discovery of such alleged defect;

such notice must be received by Trio not later than 20 days after the discovery of said defect or within 20 days after expiration of thewarranty period, whichever shall occur first.

Trio does not warrant or represent that any machinery, parts, or accessories furnished by it meet any Federal, State, or localstatutes, codes, ordinances, rules, standards or other regulations covering safety, pollution, electrical wiring and so forth.

THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED (EXCEPT THEWARRANTY OF TITLE) INCLUDING BUT NOT LIMITED TO ANY WAR. RANTY OF MERCHANTABILITY, TRIO SHALL NOT BESUBJECT TO ANY OTHER OBLIGATIONS OR LIABILITIES WHATSOEVER WITH RESPECT TO MACHINERY, PARTS, ACCESSORIES OR SERVICES MANUFACTURED OR FURNISHED BY IT OR ANY UNDERTAKINGS, ACTS OR OMISSIONSRELATING THERETO. UNDER NO CIRCUMSTANCES SHALL TRIO BE LIABLE FOR ANY CONSEQUENTIAL OR OTHERDAMAGES, EXPENSES, LOSSES OR DELAYS HOWSOEVER CAUSED. THERE ARE NO WARRANTIES THAT EXTENDBEYOND THE DESCRIPTION ON THE FACE HEREOF.

Trio 44x32 Twin FMW Operating Manual

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