Trio Lavador Doble CMW Manual (Blade Mill)(SN. 080)

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

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Parts and Operation Manual Twin 36” Blade Mill Washers


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Trio Engineered Products 12823 Schabarum Ave.

Irwindale, CA 91706

Twin 36” Coarse Washers

Size: 36” x 18’ Serial Number: 080



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Irwindale, CA 91706

To the Owner & Operator We have tried to provide information that gives our customers a clear understanding of equipment construction, function, capabilities and requirements. This information is based on the knowledge and experience of qualified people at our company and in our field organization. Proper use of this information provides users of our equipment with high efficiency, maximum service life and low maintenance costs. That is why we strongly recommend that anyone using our equipment be familiar with this manual.

Information presented here should not be considered authoritative in every situation. Users will as a matter of course encounter problems and circumstances that raise questions not anticipated here. Such questions should be directed to their distributor or the manufacturer.

Anyone who uses this equipment for any purpose other than that for which it was intended assumes sole responsibility for dangers encountered and injuries sustained as a result of such misuse.

Federal, state and local safety regulations aim to protect both people and property from accident, injury and harmful exposure. When complied with, such regulations are often effective. Hazards to personnel and property are further reduced when this equipment is used in accordance with all operation and maintenance instructions. Generally:

(1) Read and heed all danger, warning, caution, and notice decals. Know what guards and protective devices are included and see that each is installed and in operational condition. Additional guards and protective devices may be required and must be installed by the user (owner) before operating.

(2) Never attempt to maintain, lubricate or adjust this equipment while it is running. Lock out and tag out all energy sources before doing maintenance, cleaning, adjusting or repairing this equipment. Make it impossible for anyone to start this machine while others are working on it or in it.

(3) Wear personal protective equipment such as hard hats, ear plugs, safety glasses and safety shoes when operating this equipment. Do not wear loose clothing or long hair.

(4) Think safety and act safely. Stay alert at all times. Eliminate or neutralize potential hazards as soon as you spot them. Never allow anyone to engage in horseplay when near this equipment.



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Irwindale, CA 91706

Failure to take these precautions will result in death or severe personal injury.

The following warning applies to equipment supplied with lead-acid batteries:

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm.

Wash hands after handling.

The following warning applies to equipment supplied with diesel powered engines:

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Product Registration: All equipment must be registered within 14 days of start-up to receive warranty coverage.

Registration information will only be accepted from the end-users of the equipment, however dealers can register the equipment for the end-user provided the information registered is the end-user’s information.

In addition to this registration, all cone crushers, vertical shaft impact crushers, and all screens using urethane media must have an application data sheet on file and approved by Trio.

After completion of the registration and application data sheet, if required, all submitted information will be reviewed and a confirmation email sent to the email address provided to Trio.



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Trio Engineered Products

12823 Schabarum Ave. Irwindale, CA 91706

Warranty will be fully enforced upon confirmation of payment and receipt of the above information.

Register online at: http://www.trioproducts.com/register/form or call Trio at +1 626 851 3966.



SAFETY

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TABLE OF CONTENTS

SAFETY AND GENERAL INFORMATION.................................................................................. 2 A-I SAFETY .................................................................................................................................................. 2 A-II GENERAL INFORMATION ............................................................................................................... 9

INSTALLATION & OPERATION DETAILS .............................................................................. 10 B-I MACHINE DESCRIPTION AND SPECIFICATIONS ................................................................... 10 B-II INSTALLATION INFORMATION ................................................................................................... 11 B-III MACHINE STARTUP CHECK LIST ............................................................................................... 15 B-IV OPERATING INSTRUCTIONS ........................................................................................................ 16 B-V LUBRICATION ................................................................................................................................... 18 B-VI MAINTENANCE SCHEDULE .......................................................................................................... 19 B-VII TROUBLE SHOOTING ...................................................................................................................... 20

ASSEMBLY INSTRUCTION & MAINTENANCE ..................................................................... 21 C-I WASHING MACHINE ASSEMBLY LAYOUT ............................................................................... 21 C-II LOWER BEARING ASSEMBLY ...................................................................................................... 22 C-III GEAR BOX ASSEMBLY .................................................................................................................... 25 C-IV FLEXIBLE DRIVE COUPLING ASSEMBLY ................................................................................. 29 C-V SCREW ASSEMBLY .......................................................................................................................... 33 C-VI DRIVE ASSEMBLY ............................................................................................................................ 35 C-VII DISCHARGE CHUTE ........................................................................................................................ 36 C-VIII SAFETY DECAL KIT ......................................................................................................................... 37 C-IX SPARE PART LIST ............................................................................................................................. 38

GENERAL TECHNICAL INFORMATIONS............................................................................... 39 D-I WASHER TERMINOLOGY .............................................................................................................. 39 APPENDIX-A BOLT TORQUE SPECIFICATIONS...................................................................................... 40 APPENDIX-B OIL VISCOSITY CLASSIFICATION .................................................................................... 42 WARRANTY TERMS AND CONDITION ............................................................................................................... 43


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SAFETY AND GENERAL INFORMATION

A-I SAFETY INDEX PERSONNEL SAFETY • GENERAL...................................................................................................................................................... • STOP ACCIDENTS BEFORE THEY STOP YOU............................................................................................ • KNOW YOUR EMPLOYER’S SAFETY PROGRAM! ....................................................................................... • DRESS PROPERLY FOR THE JOB.............................................................................................................. • READ THE MANUAL AND UNDERSTAND YOUR MACHINERY................................................................. • ARE YOU PREPARED FOR EMERGENCIES? ............................................................................................ • BEFORE STARTING CHECK......................................................................................................................... • IMMEDIATELY AFTER STARTING CHECK............................................................................................... • DURING OPERATION..................................................................................................................................... • STOPPING SAFELY........................................................................................................................................ • LOCKOUT ELECTRICAL SERVICE................................................................................................................. • WARNING TAGS........................................................................................................................................... • USE OF EPOXY RESIN..................................................................................................................................... • ALCOHOLIC BEVERAGES AND MEDICATION........................................................................................... • WORK AREA......................................................................................................................................................... • EQUIPMENT.................................................................................................................................................. • FIRE HAZARDS.............................................................................................................................................. • PRESSURIZED SYSTEMS — HYDRAULIC OR AIR.................................................................................... • USE QUALITY PARTS..................................................................................................................................... • REPORT NECESSARY REPAIRS..................................................................................................................

PLANT SAFETY • GENERAL...................................................................................................................................................... • DRIVE GUARDS........................................................................................................................................... • OPERATOR’S PLATFORM.......................................................................................................................... • ELECTRICAL LOCKOUT............................................................................................................................. • CRANES....................................................................................................................................................... • MOBILE CRANES........................................................................................................................................ • CUTTING TORCH AND WELDING EQUIPMENT...................................................................................... • CONVEYOR BELTS..................................................................................................................................... • CLEARING THE MACHINE......................................................................................................................... • GENERAL MAINTENANCE WORK.............................................................................................................

A


SAFETY

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PERSONNEL SAFETY

GENERAL This portion of the instruction manual is intended to illustrate only basic safety procedures. The information in this manual is not intended to replace safety codes, insurance requirements, federal, state and local laws, rules and regulations. These sections are presented as a helpful guide and show some of the daily problems that may be encountered.

STOP ACCIDENTS BEFORE THEY STOP YOU In order to alert you, as operators and maintenance personnel, dangerous or hazardous operations are shown in this instruction manual with BOLD and ITALIC notes. Study this manual, the quick reference guide and any other manufacturer’s literature covering your specific equipment. READ ALL WARNING INSTRUCTIONS. Practice safe operation.

KNOW YOUR EMPLOYER'S SAFETY PROGRAM! Company safety records show that the greatest percentage of accidents is caused by disregard of simple safety rules. Consult your supervisor for specific instructions when starting a job.

DRESS PROPERLY FOR THE JOB Protective clothing is essential to protecting one’s self. Be aware that loose clothing can become entangled in moving parts! Keep warm without restricting movement. Wrist watches, rings, and other jewelry can be dangerous. Keep your pockets free of objects that may fall out. Proper clothing is required while running this machine:

1. HARD HAT 2. SAFETY EYE WEAR (Glasses or goggles) 3. SAFETY SHOES 4. EAR PLUGS 5. RESPIRATOR (When required) 6. GLOVES 7. PROTECTIVE CLOTHING

Other safety equipment may be required for maintenance of this machine. Find out what items are required and wear them!


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READ THE MANUAL AND UNDERSTAND YOUR MACHINERY

Have everyone READ THE MANUAL (and all related literature) furnished with your equipment to learn it’s 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.

ARE YOU PREPARED FOR EMERGENCIES? 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.

BEFORE STARTING CHECK Equipment not properly maintained and prepared for operation is unsafe equipment. Perform a careful check at the beginning of your shift. WALK COMPLETELY AROUND THE MACHINERY AND INSPECT IT. Check for warning and lockout tags! If something needs attention now, do not run the machinery until it is fixed. Do not let unauthorized personnel operate the Machine! DO NOT START THE MACHINE WITH FEED MATERIAL INSIDE THE MACHINE!

1. Walk completely around the machine. 2. Be absolutely certain that no one is in, on, under, next to, or near the Machine! 3. Look for lockout tags, warning tags, and notices. Observe all safety decals on the Machine. 4. Warn all nearby personnel that you are starting the Machine!

IMMEDIATELY AFTER STARTING CHECK 1. Check all instruments and gauges to be sure everything is operating properly. 2. Test all controls for proper functioning. 3. Listen for any unusual noises or vibrations.


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DURING OPERATION • NEVER STAND ANY CLOSER THAN FIVE (5) FEET (1.5 meters) FROM THE MACHINE WHEN IT

IS RUNNING!

• NEVER LOOK IN THE FEED HOPPER WHILE THE MACHINE IS RUNNING.

STOPPING SAFELY Be sure the Machine is stopped before:

• Cleaning • Servicing • Lubricating • Checking belt tension • Opening inspection covers • Adjusting Machine setting • Making repairs • Attempting to clear a plugged Machine

MAKE NO CHECKS, ADJUSTMENTS OR REPAIRS OF ANY KIND WHILE MACHINE IS IN OPERATION!

LOCKOUT ELECTRICAL SERVICE 1. ALL MAINTENANCE PERSONNEL MUST BE 2. Always lockout all electrical controls before

PROVIDED WITH A PERSONAL PADLOCK performing any type of maintenance work on theWITH ONLY ONE (1) KEY. machine.

WARNING TAGS Before working inside a Machine, make sure to tag and lockout the electrical controls, so no one else can start it. Attach warning tags to prevent accidents:

• If the Machine is unsafe for operation • If controls are being serviced or replaced • If the machine is being repaired

USE OF EPOXY RESINS In those areas where epoxy materials/compounds are used, care should be taken when using a cutting torch or when grinding. THE AREA SHOULD BE WELL VENTILATED BECAUSE EPOXY FUMES CAN CAUSE NAUSEA OR POSSIBLE EYE OR SKIN IRRITATION.

ALCOHOLIC BEVERAGES AND MEDICATION

- DO NOT use alcoholic beverages before coming to work or while on the job. - BEWARE of medicines, tranquilizers or other drugs that can make you sleepy or less alert.


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WORK AREA 1. KEEP the floor clean and dry and free of debris

and tools. Oily and wet floors, steps and handrails are slippery. In winter, watch out for ice and snow. Wet spots, especially near electrical equipment, are dangerous.

2. DO NOT let material lie or build up on or around the Machine.

EQUIPMENT 1. 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. Do not use sheaves with rims or spokes that

are cracked. 7. Check for missing, cracked or frayed V-belts. 8. Check for broken, defective, worn or missing

parts and replace them. 9. When using cables to move a load, be sure

the cables are of adequate size. Replace any worn, badly frayed, broken or kinked ones. Check end connections for wear.

3. STORE dangerous fluids in a suitable place - away from unauthorized personnel. ALLOW NO SMOKING IN THE AREA! Use only nonflammable solutions for cleaning.

4. NEVER start a diesel or gasoline engine within an enclosed area unless there is adequate ventilation. Exhaust fumes can kill!

FIRE HAZARDS 1. DO NOT SMOKE while refueling — or when

handling fuel containers 2. DO NOT SMOKE while using cleaning solvents. 3. WHEN pouring fuel into the tank, ground the

funnel or spout against the filter 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. SHUT OFF engine when refueling — and use extra caution if engine is hot.

6. DO NOT let greasy, oily rags accumulate in a poorly ventilated area. Store oily rags and other combustible material in a safe place.

7. NEVER use an open flame to check fuel, battery electrolyte or coolant levels — or to look for hydraulic leaks anywhere on the equipment. Use a sealed flashlight!

8. KNOW where fire extinguishers are kept —and how they operate — and for what type of fire. Check regularly — at least monthly — to be sure they are in the working area.

PRESSURIZED SYSTEMS - HYDRAULIC OR AIR • Relieve ALL pressure before opening or removing any hydraulic or air pressure lines, valves, fittings, etc. • Check for worn hoses or damaged lines. • High pressure oil can be dangerous!

USE QUALITY PARTS A replacement part for any item should always be of comparable SIZE, TYPE AND QUALITY — as the part being discarded. USE GENUINE FACTORY PARTS.

REPORT NECESSARY REPAIRS • If your daily check uncovers any item that needs attention — repair, replacement or adjustment — REPORT IT • NOW! The most minor defect could result in more serious trouble — IF THE MACHINE IS OPERATED. • Only perform the work you’re AUTHORIZED to do. • Only work on equipment you THOROUGHLY understand.


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PLANT SAFETY

GENERAL The safety procedures mentioned in this manual do not eliminate all safety hazards found in the area of crushing plants. Trio welcomes inquiries regarding other suggested safety procedures for use around their Machines and related equipment.

DRIVE GUARDS Proper safety precautions start with the initial installation of the Machine. Machines are driven by V-belts or by direct couplings to electric motors or diesel engines. THE BELT DRIVE OR COUPLING SHOULD HAVE A GUARD AROUND IT. Since the speed of the Machine is quite important for proper operation, most V-belt drive guards usually have a small opening immediately opposite the center of the Machine drive shaft so that a tachometer can be inserted to occasionally check the speed. This opening should be covered with an access door.

OPERATOR’S PLATFORM Since periodic inspection and maintenance must be performed on each Machine, IT IS IMPORTANT THAT SOME TYPE OF PLATFORM BE ERECTED AT A LEVEL CONVENIENT FOR MAINTENANCE PERSONNEL WHO MUST INSPECT AND WORK ON THE MACHINE. Do not fasten the operator’s platform to the Machine

ELECTRICAL LOCKOUT TTHHEE EELLEECCTTRRIICCAALL PPOOWWEERR SSOOUURRCCEE FFOORR TTHHEE CCRRUUSSHHIINNGG EEQQUUIIPPMMEENNTT SSHHOOUULLDD BBEE LLOOCCKKEEDD OOUUTT WWHHEENNEEVVEERR WWOORRKKIINNGG OONN IITT.. Each maintenance worker who normally works on a Machine should be provided with a personal padlock with only one (1) key. When working on any assembly of the Machine, use this padlock to lock out the electrical controls for the Machine. It is 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 Machine.

CRANES This machine, like any other type of mechanical equipment, requires normal periodic maintenance. Internal parts of a machine 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 machine. CHAIN HOISTS should be considered only as a LAST resort to assemble and disassemble a machine. Personnel working with cranes must know proper hand signals.

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.

CUTTING TORCH AND WELDING EQUIPMENT During the use of the cutting torch on, machines which are equipped with hydraulic components should have these components depressurized and adequately covered with flame-proof material so that sparks, weld spatter, etc., cannot reach these areas. Ruptured high pressure hydraulic lines will quickly vaporize the hydraulic fluid as it reaches the atmosphere. This vaporized fluid can quickly become a mass of flames, resulting in severe burns for personnel in the immediate area. ALL MAINTENANCE PERSONNEL WHO NORMALLY USE CUTTING TORCH EQUIPMENT SHOULD BE ADVISED IF THERE ARE HYDRAULIC COMPONENTS IN THE IMMEDIATE AREA IN WHICH THEY ARE WORKING. Rubber lined hoses are not immune to the cutting torch equipment.


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CONVEYOR BELTS Conveyor belts leading to and from the machine should be provided with walkways ALONG SIDE the conveyor. ALWAYS PROVIDE HAND RAILS along the conveyor belt walkway.

DO NOT USE CONVEYOR BELT AS A WALKWAY

CLEARING THE MACHINE There are many events such as power failures, sudden surge of materials, etc., which can cause a machine to become plugged with material and stall. UNPLUGGING THE MACHINE CAN BECOME A VERY SERIOUS POTENTIAL SOURCE OF ACCIDENTS. PROCEED WITH CAUTION! In many instances, the only way in which the machine can be restarted is to dig the material out of the crushing cavity by hand.

GENERAL MAINTENANCE WORK The following points cover some of the basic do's and don’ts when performing maintenance work.

1. DO NOT perform maintenance on moving machinery. This includes adding lubricating oil or greasing parts of a machine while it is in operation.

2. DO lockout and tag the equipment before performing maintenance work. 3. DO NOT look into the machine while the machine is in operation without protection. 4. DO avoid spillage around the machine. Plant operators should make it a habit to keep the area

immediately adjacent to the machine free from this type of spillage which could cause unsuspecting personnel to trip and fall.


GENERAL INFORMATION

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A-II GENERAL INFORMATION

INTRODUCTION This Instruction book has been prepared to assist you, the user, in the installation, operation and maintenance of your machine. This information will serve to acquaint you with the construction of the machine and as an aid in gaining the general knowledge necessary for efficient operation and maintenance. It is strongly recommended that the contents of this book be read, understood and put in practice prior to both installation and operation of the machine.

INITIAL INSPECTION It is recommended that as soon as possible, after receipt of the machine, a careful check be made for any possible damage which might have occurred during transit. A careful check should also be made to be sure that nothing has been lost and that all items on the Bill of Lading, Freight Bill or Manifest can be accounted for.

PARTS MANUAL This manual also illustrates and identifies the major parts used in the assembly of the machine and is to be used when ordering spare or replacement parts.

REPAIR PARTS For proper operation, only genuine factory parts should be installed. For your convenience, a parts ordering form is included in the appendix of this manual. To avoid delay and the possibility of incorrect parts being furnished, the following information should be provided when ordering: 1. Model Number 2. The Serial Number of the machine, which is stamped on the nameplate, as well as on the

cover of the parts manual. 3. Complete name and part number as shown in the parts manual. 4. Exact quantity of each part ordered. 5. Complete shipping instructions.


APPLICATION AND OPERATION GUIDE LINES

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INSTALLATION & OPERATION DETAILS

B-I MACHINE DESCRIPTION AND SPECIFICATIONS

MACHINE DESCRIPTION

Coarse material washers serve the three primary functions of Washing, Dewatering and Classifying.

Washing Removes slimes, slits and clay by allowing the material to roll and tumble. The waste material are absorbed in to the water and discharged over the weirs.

Dewatering Water is allowed to drain from the bottom while screw carries away the material.

Classifying Controls the retention of desirable product by adjusting the weirs height.

MACHINE SPECIFICATIONS

COARSE MATERIAL WASHER TTCW3618E.00A (BLADE MILL) 1 Screw Diameter 36” 2 Tub Length 18’ 3 Driven Sheave (Mounted on machine) 7.3” O.D. 4 V–Belt Section “B” 5 No. of V-Belts 4 X 2 6 Capacity (TPH) 7 Maximum Material Size 2 1/2” 63mm 8 Motor Power (HP) 40 HP X2 30 KW X2

9 Water Requirement 800-1200 GPM@25psi

3030-4540 [email protected]

10 Screw Speed (RPM) 32 11 Total Weight(Exclude Motor) 24178 Lbs 10990 Kgs. 12 Angle of Installation 3 1/4” rise per foot. 15 °

B


INSTALLATION INFORMATIONS

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B-II INSTALLATION INFORMATION

GENERAL INFORMATION The washer can be shipped either as a complete unit or in sub-assemblies. Instructions are provided for the assembly and disassembly of the machine components in the various sections of this manual.

WASHER CLEARANCE One of the major considerations to be given during installation is clearances around the equipment. Enough room should be provided at the side of the washer to remove drive assembly. Consideration should be given to the additional clearance required for the feeding and discharge arrangement. In order to accurately determine machine clearances, refer to the general arrangement drawing.

WASHER AND SUB-ASSEMBLY WEIGHTS Another facto to be considered when designing the foundation, and planning overhead lifting equipment, is the machine weight. A overhead crane, a mobile crane, a chain hoist or other suitable equipment must be provided for handling heavy machine components during erection or replacement of worn parts. Size requirements for hosting equipment including cables, slings and hooks can be calculated by referring to Table 2-1

Table 2 - 1. WASHER AND SUB-ASSEMBLY WEIGHTS

WASHER COMPONENTS POUNDS KILOGRAMS

Washer (Complete) 24178 10990 Main Frame 6076.4 2762 Lower Bearing Assembly 310.2 141 Screw Assembly 6255 2843

Gear drive Assembly (Without Motor & Sheave) 1795 816

The weights shown above are approximate.

WATER PIPING CONFIGURATION The following diagram illustrates the water piping that needs to be installed before operating the machines.

FLOW CONTROL VALVEDRAIN BOARD FLUSH FLOW

VALVE TO SHUT OFFFLOW TO MACHINE

FLOW CONTROL VALVEWASH WATER

PRESSURE GAUGEDO NOT EXCEED 25 P.S.I.

CHECK VALVE TOPREVENT BACKFLOW



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LOOSE PARTS AND HARDWARE DETAILS The following diagram illustrates the quantity of the bolts, nuts, washer and lock washers for them connection.



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WASHER TTCW3618E.00A (BLADE MILL) ITEM No. Description Qty.

A Tub Cross Member 2 set B Weir C Legs 1 Front LH Leg (CW3618E.9) and Front RH Leg (CW3618E.3) 2 2 Rear Support 2 D Drive Parts 1 Driven Sheave and Bushing 2 each 2 Drive Guard 1 E Hardware 1 Box 1 For Front Legs – Bolt M22x50, Nut M22, Lock Washer 22mm. 8 Sets 2 For Tub Cross Member – Bolt M16x130, Nut M16, Lock Washer 16, Washer 16mm. 16 Sets 3 For Rear Support - Bolt M20X35, Lock Washer 20. 8 Sets 4 For Discharge Chute – Bolt M12x40, Nut M12, Lock Washer 12, Washer 12mm. 4 Sets



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DRIVE DETAILS Normally Electric Motor is used to power the machine. V-Belt drive is used to transmit the power from the motor to the machine. V-belt specifications are detailed in the Machined Specification table.

GENERAL PRECAUTIONS DURING INSTALLATION / MAINTENANCE When performing any maintenance work on the machine, the following general precautions should be observed:

1. When removing parts with machined or bearing surfaces that may rust, they should be well oiled or covered with a rust preventative if they are to be kept out of the machine for any length of time.

2. Use additional care when handling any parts that have bearing surfaces or machined surfaces that have close tolerances.

3. When disassembling any parts with bearing or machined surfaces, protect these surfaces from coming in contact with the ground by using wooden blocking.

4. Bronze liners or bushings should be handled with extreme care. Excessive ramming or pounding on this soft material may cause warping or springing of the part.

5. Clean thoroughly and oil all machined parts before installing them in the machine. Do not replace a bearing surface without coating it with oil.

6. When assembling two mating parts that require either a press or sliding fit, coat the contacting surfaces with a light coating of oil. This will act as a lubricant and prevent rusting when in place.

SPECIAL TOOLS Special tools have been furnished with your machine. Additional tools are available as an option.

RECOMMENDED SPARE PARTS CONTACT TRIO FOR A SUGGESTED LIST OF SPARE

PARTS FOR YOUR PARTICULAR OPERATION. BEFORE STORING ANY SPARE PARTS, CHECK

THAT THE PROTECTIVE COATING APPLIED BEFORE SHIPMENT IS STILL INTACT.

BOLT TORQUE CHART Refer Appendix-A. BOLTS TORQUE SPECIFICATION


START-UP CHECK LIST

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B-III MACHINE STARTUP CHECK LIST

FEATURES CHECK REPORT A PRE-START-UP

1 Machine assembly as per Instruction provided.

2 Machine Installation

2.1 Grouting and Leveling ( Angle 15 °)

2.3 Power connection to machine. 2.4 Water Piping connection

2.5 Tub cleaning

3 Drive System

3.1 Gear box Oil fill up. (Refer Lubrication chart for details)

3.2 V-Belt’s drive alignment and tensioning. 3.3 Screw shaft coupling alignment.

4 Lower Bearing Assembly

4.1 Free movement of the Screw.

B JOGGING THE MACHINE

1 Direction of rotation - Refer “Screw speed and Direction of Rotation”

C MACHINE NO LOAD RUN ( 2 Hrs min.)

1 Screw speed (RPM)

2 V-Belt’s drive alignment and tensioning.

3 Screw shaft coupling alignment 4 Lower bearing assembly leakages.

5 Gear box heating. 6 Motor heating

7 Bearing temperatures ( 140-165 °F )

E EIGHT HOUR INTIAL OPERATION ( Follow Operating instructions before operation )

1 V-Belt’s drive alignment and tensioning.

2 Screw shaft coupling alignment

3 Lower bearing assembly leakages. 4 Gear box heating.

5 Weirs settings


OPERATING INSTRUCTION

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B-IV OPERATING INSTRUCTIONS TRIO WASHERS ARE SHIPPED WITHOUT OIL IN THE GEAR REDUCER, MAKE SURE TO

FILL THE RECOMMENDED OIL BEFORE OPERATING THE WASHER. SCREW SPEED AND DIRECTION OF ROTATION The correct speed or revolutions per minute (RPM) is most important for the proper throughput. The speed and direction of rotation are as follows,

• Speed (RPM) : 32 RPM • Direction of Rotation:

RH Screw - Clockwise (Looking from the Gear Box Side) LH Screw – Counter clockwise (Looking from the Gear Box Side)

INITIAL START-UP AND RE START-UP CHECKS KEEP AN ACCURATE WRITTEN RECORD OF PERIODIC MAINTENANCE. Before initially starting the machine, or starting the machine after rework, perform the following operations:

1. If this is an INITIAL INSTALLATION, be absolutely certain that the “initial start-up Check sheet" has been filled out, and signed off. Many of the points on this same check Sheet could also be used for machine startup after major rework.

2. Check that the Drive System is functioning properly (See Section – Drive System). Be sure that the Drive system Gear box has been filled with the correct lubricating oil.

3. Make a final inspection of the machine to be certain that there are no mechanical obstructions, that all fasteners and pipe connections are properly tightened, and that there are no leaks.

4. After all the previous steps have been completed, perform the checks described next, under "BEFORE STARTING CHECK".

BEFORE STARTING CHECK Equipment not properly maintained, and prepared for operation is unsafe equipment. Perform a careful check at the BEGINNING of your shift. Check for warning and lockout tags! If something needs attention now, do not run the machinery until it is fixed. Do not let unauthorized personnel operate the machine!

1. Walk completely around the machine. 2. Be absolutely certain that no one is in, on,

under, next to, or near the machine! 3. Look for lockout tags, warning tags, and

notices. Observe all safety decals on the machine, and related components.

4. Warn all personnel nearby that you are starting the machine!

DO NOT START THE MACHINE WITH FEED MATERIAL INSIDE THE MACHINE!


OPERATING INSTRUCTION

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STARTING THE MACHINE DO NOT INTRODUCE ANY FEED TO THE MACHINE BEFORE OR DURING STARTING! A typical starting procedure is as follows:

1. Start the water flow in the tub and let it get filled up.

2. Start the machine drive (electric motor).

3. Check the screw speed and direction of rotation.

DURING OPERATION • NEVER STAND CLOSER TO THE MACHINE WHEN IT IS RUNNING!

• DO NOT LEAN OR PLACE YOUR HANDS AGAINST MACHINE WHILE IN OPERATION.

• NEVER LOOK IN THE FEED HOPPER WHILE THE MACHINE IS RUNNING.

STOPPING SAFELY STOP FEED BEFORE STOPPING MACHINE. Be sure the machine is stopped before: - Cleaning - Repair and Servicing - Checking belt tension - Adjusting machine setting - Lubricating - Attempting to clear a plugged machine

MAKE NO CHECKS, ADJUSTMENTS OR REPAIRS OF ANY KIND WHILE MACHINE IS IN OPERATION!

LOCKOUT ELECTRICAL SERVICE 1. ALL MAINTENANCE PERSONNEL MUST BE PROVIDED WITH A PERSONAL PADLOCK WITH ONLY

ONE KEY. 2. Always lockout all electrical controls before performing any type of maintenance work on the machine.

WARNING TAGS Before working inside a machine, make sure to tag and lockout all electrical controls, so no one else can start it. Attach warning tags to prevent accidents:

1. If the machine is unsafe for operation. 2. If controls are being serviced or replaced.

3. If the machine is being repaired.

MACHINE SETTING The machine setting depends on the size of product and throughput required. Weir Setting: Use slotted bolt holes on the weir for leveling and adjusting to ensure even flow over the weirs on all sides, there by maximizing the output. Product Setting: As the machine can accommodate wide verity of materials following should be adjusted and checked accordingly,

• Water content along with the feed. • Wash flow rate. • Expected return flow rate. • Material Output.


LUBRICATION CHART

18 TCW3618E.00A

B-V LUBRICATION

LUBRICATION CHART

1

Location Machine drive Gear box

Lubricant See Table Below

Interval First change after 80 hrs of initial operation, subsequent change every 2000 hours or if found dirty (see Contamination Limit table)

Qty. 14 gallons

2

Location Lower bearing assembly, bearings

Lubricant Grease; Lithium base NLGI No. 1 with 5-10% molybdenum disulfide powder by Vol.

Interval 500 hours / 3 Months

Qty. 4 Oz

TO COMPARE DIFFERENT GRADES OF OIL, PLEASE REFER TO ANNEXURE ‘B’.

TRIO WASHERS ARE SHIPPED WITHOUT OIL IN THE GEAR REDUCER, MAKE SURE TO FILL THE RECOMMENDED OIL BEFORE OPERATING THE WASHER.

TABLE. RECOMMENDED LUBRICANT VISCOSITIES AND PRODUCTS Ambient Temp. ºF 15-50 50-110 Over 110

ISO 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 AW 150 Machine Oil AW 220 Machine Oil AW 320 Conoco Dectol R & O Oil 150 Dectol R & O Oil 220 Dectol R & O Oil 320 Exxon Teresstic 150 Teresstic 220 Teresstic 320 Mobil DTE Oil Extra Heavy 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


MAINTENANCE SCHEDULE

19 TCW3618E.00A

B-VI MAINTENANCE SCHEDULE 8 HOURS

DRIVE SYSTEM

• Check belt alignment and tension.

• Check screw shaft coupling alignment.

• Check oil level at the drive Gear box.

MACHINE

• Check the power draw on the motor.

• Check for loose fasteners or connections.

• Check for unusual noise, indications of wear or undue strain on machine parts.

• Check that feed to machine is proper.

• Check the bearing temperatures. 80 HOURS DRIVE SYSTEM

• Change drive gear box lubrication oil.



MACHINE

• Check V-belts for wear or cracks.

• Check machine weir setting.

• Check the bearing temperatures.

Every 300 HOURS DRIVE SYSTEM



• Check oil level and the contamination level at the drive Gear box.

• Check the bearing temperatures.

MACHINE

• Check V-belts for wear or cracks.

• Check machine weir setting.

• Check for unusual noise, indications of wear or undue strain on machine parts.

GEAR BOX OIL LEVEL - The oil level is checked at the pipe plug opening on the front of the gearbox. The oil level is to be checked with the machine not running and in its normal operating position at an 15° slope. BEARING TEMPERATURE - A properly adjusted bearing should run at about 140 to 160 degrees Fahrenheit. Bearing should be checked with a surface mount thermometer.

• A bearing that develops high temperature after it has been running satisfactorily for some time may be caused by over greasing.

• A newly installed bearing that overheats is usually caused by improper adjustments of the running clearance.

• A failed bearing that is overheating will probably be accompanied by some other indication such as grinding noises.


TROUBLE SHOOTING

20 TCW3618E.00A

B-VII TROUBLE SHOOTING DRIVE GEAR BOX OVERHEATING

PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONSInsufficient oil in the gear box. Check oil level and fill if required.

Overloading Check material flow and deposits in the tub, clean if required.

Lower bearing assembly jammed. Check free rotation of the screw, lubricate the bearings.

BEARING OVER HEATING PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS

Improper alignment. Check by freely rotating the screw, align if required to make the screw freely rotate.

Insufficient lubrication Check and lubricate the bearings.

Machine overloading Check material flow and deposits in the tub, clean if required.

LOW OUTPUT (TONNAGE) PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS

Low operating speed (RPM). Check and adjust the speed according to the output desired.

Improper water contents in the feed. Check and adjust.

Improper weir settings. Check and adjust the setting to have equal flow all over the weirs.

Improper settings ( Wash flow, Return flow) Check the settings to have the desired product yield and output.

MACHINE STALLING PROBABLE CAUSES COMMENTS/CORRECTIVE ACTIONS

V-belts too loose. Re-tension V-belts.

Electrical problems with drive motor. Check power draw of machine running empty and compare to power draw of motor running free (without belts). If both readings are close, have electrician check motor.

Screw speed too low. Check for correct screw speed (RPM).

Feed too high. Reduce amount of feed to machine.

ASSEMBLY LAYOUT

21 TCW3618E.00A

ASSEMBLY INSTRUCTION & MAINTENANCE

C-I WASHING MACHINE ASSEMBLY LAYOUT

LOWER BEARINGASSEMBLY

MOTORWEIR TUB CROSS MEMBER BELT GUARD

REAR SUPPORT FRONT LEG DISCHAGE C

GEAR BOX

C


LOWER BEARING ASSEMBLY

22 TCW3618E.00A

C-II LOWER BEARING ASSEMBLY



23 TCW3618E.00A

ITEM NO. PART NO. DESCRIPTION QTY.

CW3618LBA Lower Bearing Assembly 1 set 1 SW4432.4-1B Hub 1 2 SW3625.4-10A Gasket 1 3 GB9160.3/KM20 Lock Nut 1 4 GB9160.4/MB20 Lock Washer 1 5 GB9160.2/H3120 Adapter 1 6 GB288/23120CAK/W33（C3） Bearing 1 7 GB1152/M10X1 Grease Fitting M10X1 1 8 CW4420.2-2 Bolt (Square Neck) M20X90/GD8.8 4 9 GB6170 /M20/GD8 Nut M20 4 10 GB93 /20 Lock Washer 20 4 11 CW4420.2-1 Bolt (Square Neck) M16X75/GD8.8 6 12 GB6170/M16/GD8 Nut M16 6 13 GB93 /16 Lock Washer 16 6 14 CW4420.2-3 Washer 6 15 SW3625.4-2A Seal Housing 1 16 SW3625.4-8A Gasket 1 17 GB12/M16X60/GD8.8 Bolt M16X60 8

(12) GB6170 /M16/GD8 Nut M16 8 (13) GB93 /16 Lock Washer 16 8 (14) CW4420.2-3 Washer 8 18 TD1214 Seal Retainer 1 19 SW3625.4-7A Gasket 1 20 SW3625.4-4 Donut Seal 1 21 SW3625.4-9 Slinger 1 22 CW3618E.2-1B Stub Shaft 1 23 GB70.1 /M20X65/GD8.8 Bolt M20X65 8 (9) GB6170 /M20/GD8 Nut M20 8 (10) GB93/20 Lock Washer 20 8 24 GB13871/TC115X140X14 Oil Seal TC115X140X14 1 25 TW5434.4-2 Stainless Steel Sleeve 1



24 TCW3618E.00A

ASSEMBLY INSTRUCTIONS

Hub Assembly 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 to expose the bearings. Protect the bearing from

contamination. A visual inspection of the bearing should be made, If you see scratches, corrosion such as pitting, or a large amount of metal flakes in the grease, the bearing should be replaced.

Bearing Assembly To remove the bearing, continue as follows:

1. Fold back washer ears.

2. Unscrew bearing nuts.

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

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

5. Remove the seven (7) of the eight (8) end plate bolts.

6. 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 seals can 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.

7. To inspect the rubber donut seal, slide the slinger and the donut seal off of the stub shaft. If either shows any sign of wear or cracking, replace them.

8. To reassemble, follow instructions in reverse order.


GEAR BOX ASSEMBLY

25 TCW3618E.00A

C-III GEAR BOX ASSEMBLY


GEAR BOX ASSEMBLY

26 TCW3618E.00A

ITEM NO. PART NO. DESCRIPTION QTY. Reference No.

SHP750-70 Gear Box Assembly 1 K6001.1 1 32309 Bearing 7609E, #1 Shaft 2 2 GB1235 / ∅100x3.1 O-Ring, #1 Shaft 1 3 SHP750-70-30 Cover, #1 Shaft 1 K6001.1-30 4 SHP750-70-1 #1 Shaft and Pinion 1 K6001.1-1 5 GB70/M12X20 Bolt M12X20 4 6 SHP750-70-3 #2 Shaft and Pinion 1 K6001.1-3 7 32211 Bearing7511E, #2 Shaft 2 8 SHP750-70-31 Cover, #2 Shaft 1 K6001.1-31 9 GB1235 / ∅100x3.1 O-Ring, #2 Shaft 2 10 SHP750-70-5 Gear, #2 Shaft 1 K6001.1-5 11 SHP750-70-17 Gear, #3 Shaft 1 K6001.1-17 12 GB1235 / ∅150x3.1 O-Ring, #3 Shaft 2 13 SHP750-70-32 Cover, #3 Shaft 1 K6001.1-32 14 30314 Bearing7314E, #3 Shaft 2 15 SHP750-70-16 Key, #3 Shaft 20X64 1 K6001.1-16

16 SHP750-70-12 GB5783/M8x25 GB93/8

Closure, #4 Shaft Bolt M8x25 Lock Washer 8

1 4 4

K6001.1-12

17 GB1096/C25x14x190 Key 1 18 SHP750-70-11 #4 Shaft 1 K6001.1-1119 SHP750-70-14 Rear Spacer, #4 Shaft 1 K6001.1-14 20 HG4-692-67 (PD100x125x12) Oil Seal PD100x125x12 2 21 SHP750-70-13 Seal Housing, Output 1 K6001.1-13 22 K6001.1-10 Shim, #4 Shaft 1 23 SHP750-70-23 Key, #4 Shaft 28X112 1 K6001.1-23 24 SHP750-70-21A Gear, #4 Shaft 1 K6001.1-21 25 SHP750-70-9 Housing, Back Half 1 K6001.1-9 26 SHP750-70-18A Housing, Front Half 1 K6001.1-18 27 SHP750-70-34A Oil Spoon 1

28 SHP750-70-26B Oil Retainer 1 GB5783/M6X12 Bolt M6X12 2 GB93/6 Lock Washer 6 2

29 SHP750-70-24 Front Spacer, #4 Shaft 1 K6001.1-24 30 K6001.1-25 Gasket, #4 Shaft 1

31 GB5783/M16x40 GB93/16

Bolt M16x40 Lock Washer 16

6 6

32 SHP750-70-22A Cover, #4 Shaft 1 K6001.1-2233 32219 Bearing 7519E, #4 Shaft 1 34 32221 Bearing 7521E, #4 Shaft 1 35 SHP750-70-15 #3 Shaft and Pinion 1 K6001.1-15 36 K6001.1-19 Shim, #3 Shaft 2

37 GB5783/M12x35 GB93/12

Bolt M12x35 Lock Washer 12

28 28

38 SHP750-70-20 Cover, #3 Shaft 1 K6001.1-20 39 SHP750-70-7 Cover, #2 Shaft 1 K6001.1-7 40 SHP750-70-8 Shim, #2 Shaft 2 K6001.1-8 41 SHP750-70-6 Spacer, #2 Shaft 1 K6001.1-6 42 SHP750-70-4 Key, #2 Shaft 18X54 1 K6001.1-4 43 SHP750-70-27 Seal Housing, #1 Shaft 1 K6001.1-27 44 GB1096/12X8X63 Key 12X8X63 1

45 SHP750-70-28 Closure, #1 Shaft 1 K6001.1-28 GB5783/M6x16 Bolt M6x16 4 GB93/16 Lock Washer 16 4


GEAR BOX ASSEMBLY

27 TCW3618E.00A

ITEM NO. PART NO. DESCRIPTION QTY. Reference No.

46 HG4-692-67 (PD45x70x12) Oil Seal PD45x70x12 2 47 K6001.1-29 Shim, #1 Shaft 2

48 GB5782/M20x130 Bolt M20x130 16 GB6170/M20 Nut M20 16 GB93/20 Lock Washer20 16

49 SHP750-70-2 Spacer, #1 Shaft 1 K6001.1-2


GEAR BOX ASSEMBLY

28 TCW3618E.00A

ASSEMBLY AND MAINTENCANCE INSTRUCTIONS When performing service or maintenance to the gearbox, the complete unit should be removed from the sand screw and transported to a clean working environment. A suitable lifting device should be used to remove and transport the same.

Removing the Gear Box

1. The screw must be supported, this time at the coupling housing end.

2. Next remove the belt guard and the V-belts from the motor sheave

3. Remove the motor mounting plate. 4. Drain the oil from the gear box. 5. Disassemble the flexible coupling.

6. Using a forklift or small crane, support the gearbox by attaching appropriate lifting harness through the two eye bolts on the gearbox.

7. Remove the gearbox’s four mounting bolts and take the gearbox to a clean workspace.

8. Place the gearbox on a worktable with the sheave facing up.

MANUFACTURING VARIATIONS, HOWEVER SLIGHT, DICTATE THE NEED TO SHIM THE GEAR REDUCER AT THE MOUNTING SURFACE TO PROVIDE OPTIMUM SHAFT ALIGNMENT AND MINIMUM FLEXING OF THE SPIDER COUPLING. SHIMS ARE FOUND UNDER THE GEAR REDUCER MOUNTING FEET. WHEN A GEAR REDUCER IS REPLACED ON THE MACHINE, THE SHIMS SHOULD BE REPLACED EXACTLY AS THEY WERE REMOVED. THEY SHOULD BE CHANGED ONLY IN CASE A SERIOUS MISALIGNMENT IS DETECTED.

Opening the Gear Box 1. Remove the sheave and bushings. 2. Remove the sixteen gearbox cover bolts. 3. Lift off the top cover of the gearbox to

expose the gears. (The cover must be lifted vertically, and not wedged sideways, as there are two guide pins that can get damaged.)

4. Inspect all the gears for wear and damage.

5. Inspect all oil seals and gaskets and replace if required.

6. Inspect all bearings for the wear and damages, replace the bearings if required. (Use bearing puller and other proper tools to replace the bearing)

Re-Assemble Gear Box

1. Inspect the Gear Box for the proper fitment of gears and bearings.

2. Assemble the top cover with the sixteen gearbox cover bolts.

3. Assemble Sheave and Bushings. 4. Assemble the Gear box on to the machine

using proper lifting tools with the help of 4 mounting bolts.

5. Assemble Flexible coupling. 6. Refill the Gear box with recommended

gear oil. (Refer Lubrication Chart) 7. Assemble the motor mounting plate. 8. Assemble belt guard and V-belts.

(Refer Appendix ‘A’ for Bolt torques)


FLEXIBLE DRIVE COUPLING ASSEMBLY

29 TCW3618E.00A

C-IV FLEXIBLE DRIVE COUPLING ASSEMBLY


Complete Coupling Assembly 1 1 GB1096/C25x14x190 Key 1 2 CW3618E-2A Coupling Housing 2

3 GB5782 /M20X140/GD8.8 Bolt M20X140 6 GB93 /20 Lock Washer 20 6 GB6170 /M20/GD8 Nut M20 6

4 SW3625-4 (K6001-10) Half Retainer Ring 2 5 CW3618E.2.2 Spider Plate 1

6 GB32.3 /3/4"-16UNFx50/GD10.9 Bolt 3/4”-16 UNFx50/GD10.9 16 GB1230 /20 Washer 20 16 Steel Wire d=Ø2mm, L=1000mm 1



30 TCW3618E.00A

GENERAL MOUNTING DETAILS

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

ASSEMBLY INSTRUCTIONS

Replace Spider 1. Place blocks under conveyor shaft

assembly, unbolt spider from conveyor shaft flange and coupling hub flange.

2. Remove present spider. This may be more easily done by shifting conveyor shaft slightly.

3. Replace a new spider on the proper position,

4. Tighten cap screws and install lock wires. 5. Remove blocks under conveyor shaft.

Replace Drive Coupling

1. Remove motor guard and V-Belt from end frame.

2. Place blocks under conveyor shaft assembly, unbolt coupling from conveyor shaft flange and remove the gear reducer assembly along with the coupling from washer end frame.

3. Remove the coupling from gear reducer output shaft.

4. Install retaining ring and split driving hub and key on reducer output shaft. Note that retaining 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. Install lock wires in bolts.

6. Replace gear reducer in end frame and align with conveyor shaft to permit installing the cap screws through the pipe flange into driving spider. This may be more easily done by shifting conveyor shaft slightly after anchoring reducer. Tighten cap screws and install lock wires. Place rubber seal over flanges and wire in place.

7. Remove blocks under conveyor shaft and replace V-belts and motor guard.

TO INSURE PROPER TORQE ON THE BOLTS, REFER TO THE APPENDIX ‘A’. IN ABSENSE OF TORQUE MEASURING TOOLS, “TURN OF NUT” METHOD COULD BE ADOPTED.

TURN OF NUT METHOD – TIGHTEN THE BOLTS UP TO SNUG TIGHTNESS WITH THE HELP OF SPUD WRENCH, FINISH TIGHTING BY TIGHTING ADDITIONAL 1/2 TURN.

AFTER INSALLING THE COUPLING, THE SPIDER BOLTS SHOULD BE CHECKED EACH DAY UNTILL IT IS APPARENT THAT THERE IS NO MORE LOOSING OF THE BOLTS.



31 TCW3618E.00A

MAINTENANCE Checking Coupling Alignment

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, follow the procedure outlined below,

1. Uncover the slots of the spider by folding the rubber seal back over itself.

2. Position the shaft so that the spider plate matches Figure 1.

3. Use a vernier caliper accurate to ± .0005 to measure the distance between the vertical gaps in the flanges as shown in figure 2. If the differences between the vertical gaps, top and bottom, are greater than 0.020”, then the gearbox feet must be shimmed 0.025” for every 0.010” of difference in the vertical misalignment.

4. Once the vertical gap is aligned, repeat the procedure for the horizontal gap. For every 0.010” of horizontal gap, shim the gearbox side feed 0.030”.

5. After this is completed, the screw should be aligned. See examples below.

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



32 TCW3618E.00A

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

TABLE1 TORQUE (Ft.-Lb.) REQUIRED FOR COUPLING BOLTS Conveyor Shaft Size 36” 44” 54” 66”//72” Pipe Diameter 8-5/8” 13-13/16” 14-27/32" 18"

Driving Hub Bolts 309 309 309 534

Spider Bolts 320 320 600 1,500

When the flex-spider coupling bolts are tightened to the proper torque, install new lock wires through the drilled holes in the bolt heads. Two number 16 gauge wires are recommended and should be placed in a manner which holds the bolt tight. When three bolts 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 or failure.

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

TABLE2 Shim Recommendations

Machine Type Machine Size Coupling Dia. Shim Thick. Required to Adjust Coupling GAP .010” A B

Single Screw Coarse Material 36” 12” 0.029” 0.024”

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

33 TCW3618E.00A

C-V SCREW ASSEMBLY


SCREW ASSEMBLY

34 TCW3618E.00A

PART LIST FOR RH SCREW


CW3618F.2.1 Screw Assembly RH 1 set 1 CW3618E.2.1.1A Shaft 1

2

CW3618E.2.1-2A CW3618E.2.1-3 GB6170/7/8”-9 UNC/GD8.8 GB1230/22 GB7244/22

Flight Hub (RH) U Bolt Nut 7/8”-9 UNC Washer 22 Lock Washer 22

10 10 20 20 20

3 CW3618E.2.1-1 Flight Shoe (RH) 30

4 GB819/ M12X60/GD4.8 GB41/ M12/GD5 GB93/12 GB97.1/12

Bolts M12X60 Nuts M12 Lock Washer 12 Washer 12

90 90 90 90

5

CW3618.2.1-2A CW3618.2.1-1 CW3618.2.1-3 GB6170/M20 GB7244/20 GB1228/ M20X165/GD10.9

Paddle Paddle Hub (RH) Bolt M20X70/GD8.8 Nut M20/GD8 Washer 20 Bolt M20X165

24 24 72 120 120 48

PART LIST FOR LH SCREW


TCW3618F.3.1 Screw Assembly LH 1 set 1 CW3618E.2.1.1A Shaft 1

2

TCW3618E.3.1-2A CW3618E.2.1-3 GB6170/7/8”-9 UNC/GD8 GB1230/22 GB7244/22

Flight Hub (LH) U Bolt Nut 7/8”-9 UNC Washer 22 Lock Washer 22

10 10 20 20 20

3 TCW3618E.3.1-1 Flight Shoe (LH) 30

4 GB819/ M12X60/GD4.8 GB41 /M12/GD5 GB93/12 GB97.1/12

Bolt M12X60 Nuts M12 Lock Washer 12 Washer 12

90 90 90 90

5

CW3618.2.1-2A TCW3618.3.1-1 CW3618.2.1-3 GB6170 /M20 GB7244/20 GB1228 /M20x165/ GD10.9

Paddle Paddle Hub (LH) Bolt M20X70/GD8.8 Nut M20/GD8 Washer 20 Bolt M20X165

24 24 72 120 120 48


DRIVE ASSEMBLY

35 TCW3618E.00A

C-VI DRIVE ASSEMBLY

ITEM NO. PART NO. DESCRIPTION QTY. for each assy.

1 TECO40-18-324T TECO Premium Efficiency TEFC Motor (380V/50HZ) 1

2 4B 110 Drive Sheave 11” O.D. 1 SK 2-1/8 Drive Sheave Bushing SKX2- 1/8 1

3 B116 B Type V Belt B116 4 4 TCW3618E.6A Belt Guard 1 5 CW3618-2A(4B) Driven Sheave 1 6 SW3625-8 Bushing 1 7 GB1096/C12x8x63 Key 1

8 GB5783 /M12X65/GD8.8 Bolt M12X65 3 GB93 / 12 Lock Washer 12 3


DISCHARGE CHUTE

36 TCW3618E.00A

C-VII DISCHARGE CHUTE

ITEM NO. PART NO. DESCRIPTION QTY,

1 TCW3618E.8 Discharge Chute 1 2 GB5783 / M12X40/GD8.8 Bolt M12X40 4 3 GB6170/ M12/GD8 Nut M12 4 4 GB93 / 12 Lock Washer 12 4 5 GB97.1 /12 Washer 12 4


SAFETY DECAL KIT

37 TCW3618E.00A

C-VIII SAFETY DECAL KIT

Sample Figure


1 SDK-001 Safety Decal Kit and Charts 1 Kit

(2 x 11 Stickers)


SPARE PART LIST

38 TCW3618E.00A

C-IX SPARE PART LIST


A Lower Bearing Assembly 5 GB9160.2 /H3120 Adapter 1 6 GB288/23120CAK/W33（C3） Bearing 1 20 SW3625.4-4 Donut Seal 1 21 SW3625.4-9 Slinger 1 24 GB13871 / TC115x140x14 Oil Seal TC115x140x14 1 25 TW5434.4-2 Stainless Steel Sleeve 1 B Gear Box Assembly 2 GB1235/∅100x3.1 O-Ring, #1 Shaft 1 9 GB1235 / ∅100x3.1 O-Ring, #2 Shaft 2 12 GB1235 / ∅150x3.1 O-Ring, #3 Shaft 2 22 K6001.1-10 Shim, #4 Shaft 1 30 K6001.1-25 Gasket, #4 Shaft 1 36 K6001.1-19 Shim, #3 Shaft 2 40 K6001.1-8 Shim, #2 Shaft 2 46 HG4-692-67 (PD45x70x12) Oil Seal PD45x70x12 2 47 K6001.1-29 Shim, #1 Shaft 2 C Coupling Assembly 5 CW3618E.2.2 Spider Plate 1 D Screw Assembly

3 CW3618E.2.1-1 Flight Shoe (RH) 30 TCW3618E.3.1-1 Flight Shoe (LH) 30

5 CW3618.2.1-2A Paddle 24 E Drive Assembly 3 B116 B Type V Belt B116 8 F Safety Decal Kit 1 SDK-001 Safety Decal Kit and Charts (2x11 Stickers) 1 Kit


WASHER TERMINOLOGY

39 TCW3618E.00A

GENERAL TECHNICAL INFORMATIONS

D-I WASHER TERMINOLOGY

CAPACITY: The output of the machine in tons per hour, checked on machine DISCHARGE belt.

DRIVE: Any device used to transmit rotating force from the electric motor or diesel engine to the machine countershaft; V-Belt or Flexible Coupling.

DRIVE GUARD: Safety enclosure for the drive with small opening (opposite countershaft with cover) for tachometer.

FEED: The raw material which is to be washed.

FINISHED PRODUCT: The resultant material after it has been processed.

GRADATION: The range of sizes contained in a sample of rock.

D

BOLT TORQUE SPECIFICATIONS

40 TCW3618E.00A

APPENDIX-A BOLT TORQUE SPECIFICATIONS

FOR METRIC BOLTS

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.

Diameter (mm)

Pitch (mm)

Grade 8.8 Grade 10.9 Grade 12.9 Dry Lube Dry Lube Dry Lube

FT-LBS N-M FT-LBS N-M FT-LBS N-M FT-LBS N-M FT-LBS N-M FT-LBS N-M 6 6.9 9.3 5.2 7 9.7 13.2 7.3 9.9 11.6 15.7 8.7 11.8 8 17.7 23.9 13.3 18 24.9 33.8 18.7 25.4 29.8 40.4 22.4 30.4

10 1.5 30 41 24 32 44 60 34 46 52 71 40 54 10 1.25 32 43 24 33 46 63 36 49 55 74 42 57 12 1.75 53 72 41 55 77 105 60 81 91 123 70 95 12 1.25 58 78 44 60 85 115 65 88 99 134 76 103 14 2 85 115 65 88 124 168 95 129 145 196 111 151 14 1.5 91 124 70 95 134 181 103 139 156 212 120 163 16 2 131 178 101 137 192 260 148 200 225 305 173 234 16 1.5 140 190 108 146 204 277 157 213 240 325 184 250 18 2.5 181 246 139 189 265 359 204 276 311 421 239 324 18 1.5 204 276 156 212 297 403 229 310 349 473 268 364 20 2.5 256 347 197 267 374 507 288 390 439 595 338 458 20 1.5 284 385 218 296 415 563 319 433 487 660 375 508 22 2.5 349 473 268 364 510 692 392 532 599 812 460 624 22 1.5 383 519 294 399 560 759 431 584 657 891 505 685 24 3 443 600 340 461 647 877 497 674 759 1029 583 791 24 2 482 654 371 503 705 956 543 736 828 1122 637 863 27 3 648 879 499 676 949 1286 729 989 1112 1508 856 1160 27 2 700 949 538 730 1023 1387 787 1067 1200 1627 923 1252 30 985 1335 741 1004 1389 1883 1044 1416 1665 2257 1252 1697 36 1716 2326 1290 1749 2419 3280 1819 2466 2900 3931 2180 2956 42 2753 3732 2070 2806 3882 5263 2919 3957 4652 6307 3498 4742 48 4156 5634 3124 4236 5860 7944 4406 5973 7023 9521 5280 7159 56 6662 9032 5009 6791 9393 12735 7063 9575 11259 15264 8465 11477 64 9954 13496 7484 10147 14035 19028 10553 14307 16822 22807 12648 17148

72 14410 19536 10835 14689 20319 27547 15277 20712 24353 33016 18310 24824


41 TCW3618E.00A

For SAE (Inch) Bolts

Diameter (inches)

N (threads/in)

S.A. E. Grade 5 S.A. E. Grade 8 Dry Lube Dry Lube

FT-LBS N-M FT-LBS N-M FT-LBS N-M FT-LBS N-M 1/4 20 8 11 6 8 12 16 9 12 1/4 28 10 14 7 9 14 19 11 15

5/16 18 17 23 13 18 25 34 19 26 5/16 24 19 26 15 20 27 37 21 28 3/8 16 31 42 24 33 44 60 34 46 3/8 24 35 47 27 37 49 66 38 52

7/16 14 49 66 38 52 70 95 54 73 7/16 20 55 75 42 57 78 106 60 81 1/2 13 75 102 58 79 106 144 82 111 1/2 20 85 115 65 88 120 163 92 125

9/16 12 109 148 84 114 154 209 118 160 9/16 18 121 164 93 126 171 232 132 179 5/8 11 150 203 115 156 212 287 163 221 5/8 18 170 231 131 178 240 325 185 251 3/4 10 266 361 205 278 376 510 289 392 3/4 16 297 403 229 311 420 570 323 438 7/8 9 430 583 330 447 606 822 466 632 7/8 14 473 641 364 494 668 906 514 697

1 8 644 873 495 671 909 1233 699 948 1 14 704 955 542 735 995 1349 765 1037

1 1/8 7 794 1077 611 829 1288 1747 990 1342 1 1/8 12 891 1208 685 929 1445 1959 1111 1507 1 1/4 7 1120 1519 862 1169 1817 2464 1398 1896 1 1/4 12 1241 1683 954 1294 2012 2728 1548 2099 1 3/8 6 1469 1992 1130 1532 2382 3230 1832 2484 1 3/8 12 1673 2269 1287 1745 2712 3677 2086 2829 1 1/2 6 1949 2643 1500 2034 3161 4286 2432 3298 1 1/2 12 2194 2975 1687 2288 3557 4823 2736 3710 1 3/4 5 2286 3100 1758 2384 4988 6764 3837 5203

2 4.5 3438 4662 2644 3585 7500 10170 5769 78232 1/4 4.5 5027 6817 3867 5244 10969 14874 8438 11442 2 1/2 4 6875 9323 5288 7171 15000 20340 11538 15646 2 3/4 4 9321 12639 7170 9723 17794 24129 13688 18561

3 4 12313 16696 9472 12844 23507 31875 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.


42 TCW3618E.00A

OIL VISCOSITY CLASSIFICATION APPENDIX-B OIL VISCOSITY CLASSIFICATION


WARRANTY TERMS

43 TCW3618E.00A

WARRANTY TERMS AND CONDITION Seller warrants all new equipment manufactured or imported by Trio Engineered Products, Inc. (Trio) against defects in material or workmanship attributed to the original machine manufacturing. No other warranties are expressed or implied. Warranty claims must be made through the dealer or agent responsible for the original equipment sale, as the equipment will have been registered with them at the time of sale from Trio. Claims must be made within twelve (12) months or 2,000 working hours, whichever occurs first, from the date of readiness for operation, but not more than fifteen (15) months from the date of shipment from Trio. All parts claimed to be defective shall be returned to Trio, freight prepaid, for inspection to determine that the said part or parts are defective. If it is determined that the fault lies with Trio, Trio will ship a replacement part or parts at no cost, but freight charges will be paid by customer. If it is determined that the fault does not lie with Trio, a replacement part or parts will be shipped, freight collect, to the customer with the receipt of a purchase order from the dealer or agent. Trio will not be responsible for freight costs associated with warranty claims. When petitioning for a warranty item, the serial number of the equipment must be referenced. The serial number must be clearly identifiable on the Trio nameplate on the equipment. This warranty is void if:

• The serial number plate and/or other markings identifying the machine as Trio have been altered or removed.

• The machine was not sold under the Trio brand name or another brand name approved by Trio.

• Parts have been used other than those supplied by Trio. Trio makes no warranty with respect to damages or defects in any product caused by improper installation, operation, maintenance, and storage or caused by negligence or accident. In addition, any product repaired or altered in any way as reasonably determined by Trio, that affects the performance or purpose for which the equipment was originally manufactured, will not be covered under this warranty. Under this warranty, the buyer will not be entitled to any labor charges involving the repair of the equipment involving warranty items, unless authorized by Trio in writing. Warranties of merchantability or of fitness for any particular purpose or arising from the course of dealing or usage of trade are specifically excluded. Any affirmation of fact, description of goods, or sample or model referred to in this agreement or elsewhere, whether or not the same relate to production or capability of the goods to perform, are not the basis of this agreement, unless specifically made a party of the agreement in writing. Under no circumstances will Trio be responsible for consequential or punitive damages of any nature, whether based on contract or tort, including but not limited to lost profits, loss of production, delays or other expenses. Under no circumstances shall the liability of Trio exceed the purchase price of the equipment furnished. The laws of the state of California shall govern the warranty. The parties agree that exclusive jurisdiction for any claim for breach of this warranty shall rest in the Los Angeles County Superior Court in the State of California.

Trio Lavador Doble CMW Manual (Blade Mill)(SN. 080)

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