TRIO EN
GINEERED PRODUCTS
W A S H ER - T W 3 6 2 5 W TS IN S T R U C T I ON M A N U A L
Trio Engineered Products 12823 Schabarum Ave. Irwindale, CA 91706
TRIO E NGINE E RE D PRODUCTS
TW3625WTS Size: Serial Number:
36” x 25’
Trio Engineered Products TRIO ENGINEER E
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12823 Schabarum Ave. Irwindale, CA 91706
To THE OWNER: Congratulations on your selection of a FMW Fine Material Washer. This machine is designed to provide you with years of profitable and dependable To ensure it is mandatory that you, andservice. all personnel workingoptimum with this performance, machine, thoroughly study the Instruction Manual and follow its recommendations.Proper operation and maintenance are essential to prevent injury or damage and to maximize machine life. It is the owner’s responsibility to: Operate and maintain this machine in a safe manner and in o accordance with all applicable local, state and federal codes, regulations and/or laws and in compliance with on-product labeling and Instruction Manual instructions. o
o
Make sure that all personnel have read the Instruction Manual and thoroughly understand safe and correct installation, operation and maintenance procedures. Make sure the machine is installed correctly before being placed into
service, and at regular intervals thereafter, serviced in accordance with procedures outlined in the Instruction Manual. o
Fulfill all warranty obligations so that the warranty is not voided. Please refer to the warranty statement to determine the conditions of Trio Engineered Products warranty.
Trio Engineered Products reserves the right to make product improvements to the equipment at any time.
Trio Engineered Products 12823 Schabarum Ave. Irwindale, CA 91706
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FOREWORD personnel Illustrations and instructions in this Manual guide the operator and maintenance through correct procedures for checking, starting and operating the washer and its accessories. Operating techniques outlined in this book are not all-encompassing. Operating skills and additional maintenance techniques will develop as the operator gains knowledge of the machine and its capabilities. The description and specifications in this manual were in effect at the time this manual was printed. Trio Engineered Products reserves the right to discontinue models at any time and to change specifications or design, without notice and without incurring obligation.
Whenever a question arises regarding your machine or this instruction manual, please consult Trio Engineered Products for the latest information.
SAFETY BE ABSOLUTELY CERTAIN THAT ALL PERSONNEL READ THIS INSTRUCTION MANUAL, THE
QUICK REFERENCE GUIDE, AND ALL RELATED AND LITERATURE, AND FULLY UNDERSTAND SAFE AND PROPER INSTALLATION, OPERATION, MAINTENANCE PRACTICES! UNSAFE PRACTICES OR IMPROPER USE OF THIS MACHINE CAN RESULT IN SERIOUS BODILY HARM OR DEATH!
BASIC RULES REGARDING SAFETY IS OUTLINED IN SECTION 0, “SAFETY”. OPERATOR SAFETY AND THE SAFETY OF OTHERS DEPENDS UPON REASONABLE CARE AND JUDGMENT IN THE OPERATION OF THIS MACHINE.
RECOGNIZING HAZARDS AND TAKING STEPS TO AVOID THEM CAN PREVENT MOST ACCIDENTS BEFORE THEY OCCUR! REGARDLESS OF THE CARE USED IN THE DESIGN AND CONSTRUCTION OF THIS TYPE OF BE EQUIPMENT, UNEXPECTED CIRCUMSTANCES MAY OCCASIONALLY ARISE THAT CANNOT ANTICIPATED OR COMPLETELY PREVENT ED WITHOUT INTERFERING WITH REASONABLE ACCESSIBILITY AND EFFICIENT OPERATION. WARNINGS ARE INCLUDED IN THIS INSTRUCTION MANUAL (AND THE QUICK REFERENCE GUIDE) TO HIGHLIGHT SOME OFTHESE CONDITIONS.
TABLE OF CONTENTS
SAFETY AND GENERAL INFORMATION.... .............. ............. .............. ............. .............. ............. ............... ..............1 A-I
SAFETY.......... .............. .............. ............. .............. .............. .............. ............. .............. ............... ...........1
A-II
GENERAL INFORMATION .............. .............. .............. ............. .............. .............. .............. ............. .8
INSTALLATION & OPERATION DETAILS............ .............. ............. .............. ............. .............. ............. ............... ....9 B-I
MACHINE DESCRIPTION AND SPECIFICATIONS ............ .............. .............. .............. ............. ..9
B-II
INSTALLATION INFORMATION....... .............. .............. .............. .............. .............. .............. ........10
B-III
MACHINE START UP CHECK LIST .............. .............. .............. ............. .............. .............. ...........14
B-IV
OPERATING INSTRUCT IONS .............. .............. .............. ............. .............. .............. .............. .......15
B-V
LUBRICATION...................... .............. .............. .............. ............. .............. .............. ............... ...........17
B-VI
MAINTENANCE SCHEDULE ............. .............. .............. .............. ............. .............. .............. ..........18
B-VII
TROUBLE SHOOTING .............. .............. .............. ............. .............. .............. .............. ............. ........19
ASSEMBLY INSTRUCTION & MAINTENANCE ............. ............. .............. ............. .............. ............. .............. .......20 C-I
LOWER BEARING ASSEMBLY ............ .............. .............. ............. .............. .............. .............. .......20
C-II
GEAR BOX ASSEMBLY ............ .............. .............. ............. .............. .............. .............. ............. ........22
C-III
FLEXIBLE DRIVE COUPLING ASSEMBLY ............ .............. .............. .............. ............. ..............25
C-IV
SCREW ASSEMBLY ............. .............. .............. .............. ............. .............. .............. ............. .............29
C-V C-VI
WEIRS ASSEMBLY........... .............. ............. .............. .............. .............. ............. .............. ............... ..30 DRIVE ASSEMBLY ............. .............. .............. .............. ............. .............. .............. .............. ..............31
GENERAL TECHNICAL INFORMATIONS... .............. ............. .............. .............. .............. ............. ............... ...........32 D-I
WASHER TERMINOLOGY....................... .............. .............. .............. .............. .............. .............. ...32
APPENDIX-A
BOLTS TORQUE SPECIFICATIONS .............. .............. ............. .............. .............. ..............33
APPENDIX-B
OIL VISCOSITY CLASSIFICATION .............. ............. .............. .............. ............. .............. ..35
WARRANTY TERMS AND CONDITIO N........................ .............. .............. .............. .............. .............. .............. ...36
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SAFETY
SAFETY AND GENERAL INFORMATION A-I
A
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
•
STOPPING
•
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..................................................................................................................
OPERATION..................................................................................................................................... SAFELY........................................................................................................................................
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.............................................................................................................
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SAFETY
PERSONNEL SAFETY GENERAL
This portion of the instruction manual is intended to illustrate only basic safety proced ures.
The information in this manual is not intended to replace safety codes, insurance requirements, federal, state and local laws, rules an d regulations. These sections are presented as a helpful guide and show some of thedaily 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 ITALICnotes. Study this manual, the quick reference guide and any other manufacturer’s literature covering your specific equipment. READ ALL WARNING INSTRUCTIONS. Practicesafe 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. 3. 4. 5. 6. 7.
SAFETY EYEWEAR (Glasses orgoggles) SAFETY SHOES EAR PLUGS RESPIRATOR(When required) GLOVES PROTECTIVECLOTHING
Other safety equipment may be required for maintenance of this machine. Find out what items are required and wear them!
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SAFETY
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 andfunction of ALL CONTROLS, indicators, warning devices and WARNING instructions. READ and OBSERVEthe SAFETY DECALS!Replace the decals when becomes it necessa ry.
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 epared pr for operation is unsafe equipment.Perform a careful check athe t 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 unrthe 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. 2. 3. 4.
Walk completelyaround the machine. Be absolutely cer tain that no one is in , on, under, next o, t or near the Machi ne! Look for lockout tags, warning tags,and notices. Observe allsafety decals on the Machine. Warn allnearby personnel that you arestarting theMachine!
IMMEDIATELY AFTER STARTING CHECK 1. Check all instruments and gauges to be sur e everything is oper ating properly. 2. Test allcontrolsfor proper functioning. 3. Listen for any unusual noises or vibrations.
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SAFETY
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 PROVIDED WITH A PERSONAL PADLOCK WITH ONLY ONE(1) 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 the electrical controls, so no one else can start it. Attach warning tags to prevent accidents: If the Machine is unsafe for operation
• •
If are being serviced or replaced If controls 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 ORSKIN IRRITATION.
ALCOHOLIC BEVERAGES AND MEDICATION - DO NOT use alcoholic beverages bef ore coming to work or while on the ob. j - BEWARE of medicines, tranquilizers or other drugs that can make yousleepy orless alert.
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SAFETY
WORK AREA 1. KEEP the floor clean and dry and free of debris and tools. Oily and wet floors, steps and handrails are slippe ry. In winter, watch out for ice and snow. Wet spots, especially nearelectrical 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 adiesel orgasoline engine within an enclosed area unless there is adequate ventilation. Exhaust fumescan 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 eaks l anywhereon 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 FACTORYPARTS.
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 OP ERATED. Only perform the work you’re AUTHORIZED to do. Only work on equipment you THOROUGHLY understand.
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SAFETY
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 s uggested safety pr ocedures for usearound their Machines and related equipment.
DRIVE GUARDS Proper safety precautionsstart with the initial installation ofthe Machine. Machines are driv en by V-belts or by direct couplings to electric motorsor 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 chec k 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 MACHIN E. Do not fasten the operator’s platform to the Machine
ELECTRICAL LOCKOUT THE ELECTRICAL AL POWER SOURCE FOR THE CRUSHING EQUIPMENT SHOULD BE LOCKED OUT WHENEVER WORKING ON IT. Each maintenance worker who normally works on a Machine should beprovided 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 havethe capability of gently and slowly lifting and lowering the various parts that make up aachine. m CHAIN HOISTS should be considered only as a LAST resort to assemble and disassembl e 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 THEBOOM OR TIPPING. Safe ratings are based on operatin g 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 ast ireaches the atmosphere.This vaporized fl uid can quickly become a mas s 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. 6
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SAFETY
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 THE 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 ofthe basic do'sand don’ts when performing maintenance work. 1.
DO NOT perform maintenance on moving machinery. This includes adding lubrica ting oil or greasin g parts of a machine while it is in operation.
2. 3.
DO lockout and tag the equipment before performing maintenance work. 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.
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GENERAL INFORMATION
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 damagewhich 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 factoryparts shouldbe 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. 2. 3. 4. 5.
Model Number The Serial Number of the machine,which is stampedon the nameplate, as well as on the cover of the parts manual. Complete name and part number as shown in the parts manual. Exact quantityof each part ordered. Complete shipping instructions.
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INSTALLATION INFORMATIONS
B
INSTALLATION & OPERATION DETAILS B-I
MACHINE DESCRIPTION AND SPECIFICATIONS
MACHINE DESCRIPTION Fine material washers serve thethree 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
1 2 3 4 5 6
FINE MATERIAL WASHER TW3625WTS Screw Diameter 36” Tub length 25’ Driven Sheave (Mounted on machine) 10.19” X2 V–Belt Section “B” No. of V-Belts 2 X2 Capacity (TPH) 200
7 8
Maximum material Motor Power (HP) size
9
Water requirement
10 11
Screw Speed (RPM) Total Weight
200 mesh split 150 mesh split 100 mesh split
3/8”HP X2 15 360 GPM@25psi 640 GPM@25psi 1250 GPM@25psi 21 24284 Lbs
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180 Metric Ton 9mm 10 Kw X2 1360
[email protected] 2420
[email protected] 4730
[email protected] 11038 Kgs.
WASHER – TW3625WTS
INSTALLATION INFORMATIONS
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 Table to 2-1 Table 2 - 1. WASHER AND SUB-ASSEMBLYWEIGHTS WASHER COMPONENTS
POUNDS
KILOGRAMS
Washer (COMPLETE)
24284
11038
Main Frame
7538
3426
Lower Bearing assembly
308
140
Screw Assembly (Each)
5435
2470
Gear Box Assembly(WithoutMotor & Sheave)
1805
820
The weights shown aboveare approximate.
WATER 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
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INSTALLATION INFORMATIONS
LOOSE PARTS AND HARDWARE DETAILS The following diagram illustrates the quantity of the bolts, nuts and washers for them connection.
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INSTALLATION INFORMATIONS
FINE MATERIAL WASHER TTSW 36X25 Sl. No. A B 1 2 C D 1 2 3 E 1 2 F 1
Description
Qty.
Feed Chute Assembly Tub Extensions Right Tub Extension Left Tub Extension
1 set
Tub Cross member Weirs Right Weir Left Weir Back Weir Drive Parts Driven Sheave and Bushing Drive Guard Hardware For Tub Extension and Weirs - Bolt M12x35, Nut M12, Washer 12 mm
1 set
1 1
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1 1 1 1 1 1 Box 106 each
WASHER – TW3625WTS
INSTALLATION INFORMATIONS
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. 2. 3. 4. 5. 6.
When removing parts with machined or bearing surfaces that mayrust, 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. Use additional care whenhandling any parts that havebearing surfacesor machined surfaces that have close tolerances. When disassembling any parts with bearing or mach ined surfaces, protect these surfaces from coming in contact with the ground by using wooden blocking. Bronze liners or bushings shouldbe handled with extreme care. Excessive ramming or pounding on this soft material may cause warping or springing of the part. Clean thoroughly and oilall machined partsbefore installing themin the machine.Do not replace abearing surface without coating it with oil. When assembling two mating parts that require either a press or sliding fit, coat thecontacting 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 SEE THE PARTS LIST CHECKED “KEY SPARES” OR CONTACT TRIO FOR A SUGGESTED LIST OF SPARE PARTS FOR YOUR PARTICULAR OPERATION. BEFORE STORING ANYSPARE PARTS, CHECK THAT THE PROTECTIVE COATING APPLIED BEFORE SHIPMENT IS STILL INTACT.
BOLT TORQUE CHART Refer Appendix-A. BOLTS TORQUE SPECIFICATION
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START-UP CHECK LIST
B-III
MACHINE START UP CHECK LIST FEATURES
CHECK
A
PRE-START-UP
1
Machine assembly as per Instruction provided.
2
Machine Installation
2.1
Grouting and Leveling
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 Lubricationchart 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 - Counter Clockwise (Looking from the Gear Box Side).
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
REPORT
( 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
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OPERATING INSTRUCTIONS
B-IV
OPERATING INSTRUCTIONS
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 asfollows, • •
Speed (RPM)
: 21 RPM
Directionof 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 RE CORD OF PERIODIC MAINTEN ANCE. Before initially starting the machine, or starting the machine afterrework, 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 start- up after major rework. 2.
3.
4.
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.
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. 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 untilit is fixed. Do not letunauthorized personnel operate the machine! notices. Observe all safety decals on the 1. Be Walk completely machine. machine, and related components. 2. absol utely cearound rtain ththe at no one is in, on, 4. Warn all personnel nearby that you are under, next to, or near the machine! starting the machine! 3. Look for lockout tags, warning tags, and DO NOT START THE MACHINE WITH FEED MATERIAL INSIDE THE MACHINE!
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OPERATING INSTRUCTIONS
STARTING THE MACHINE DO NOT INTRODUCE ANY FEE D TO THE MACHINE BE FORE OR DURING STA RTING! A typical starting procedure is as follows: 3. Check the screw speed and direction of 1. Start the water flow in the tub and let it get rotation. filled up. 2. Start the machine drive (electricmotor).
DURING OPERATION •
NEVERSTANDCLOSERTO THE MACHINEWHEN IT IS RUNNING!
•
DO NOT LEAN OR PLACEYOUR HANDSAGAINST MACHINEWHILEIN OPERATION.
•
NEVERLOOK IN THE FEED HOPPERWHILETHE MACHINEIS RUNNING.
STOPPING SAFELY STOP FEED BEFORE STOPPING MACHINE. Be sure the machine is stopped before: - Cleaning
- Repair and Servicing
- Checking belt tension
- Adjustingmachine setting
- Lubricating
- Attemptingto 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 BEPROVIDED WITH A PERSONAL PADLOCK WITH ONLY ONE KEY.
2.
Always lockout all electricalcontrols before performingany type of maintenancework 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.
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LUBRICATION
B-V
LUBRICATION
LUBRICATION CHART Location Lubricant 1 Interval
Machine drive Gear box Oil EP Gear Oil : For Ambient temp 15-50ºF - ISO 150 (700 SUS @ 100ºF) : For Ambient temp50-110ºF - ISO 220 (1100 SUS @ 100ºF) First change after 80 hrs of initial operation, subsequent change every 2000 hours or if found dirty (see Contamination Limit table)
Qty.
14 gallons (Check Oil level at pipe plug opening at the front side of the Gear case.
Location
Gear box output shaft rear bearing
Lubricant
Grease; Lithium base NLGI No. 1 with 5-10% molybdenum disulfide powder by Volume
Interval
60-80 hours / 1 Week
Qty.
1/2 Oz
Location
Lower bearing assembly, bearings
Lubricant
Grease; Lithium base NLGI No. 1 with 5-10% molybdenum disulfide powder by Vol.
2
3 Interval
500 hours / 3 Months
Qty.
3 Oz, Fully Flush the bearing assembly by injecting the Grease until fresh grease comes out from the lower part of the Bearing housing.
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.
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MAINTENANCE SCHEDULE
B-VI
MAINTENANCE SCHEDULE
8 HOURS DRIVE SYSTEM
MACHINE
•
Check belt alignment andtension.
•
Check the power draw on themotor.
•
Check screw shaft coupling alignment.
•
Check for loose fasteners or connections.
•
Check oil level at the drive Gear box.
•
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
MACHINE
•
Change drive gear box lubrication oil.
•
Check V-belts for wear or cracks.
•
Check belt alignment andtension.
•
Check machine weir setting.
•
Check screw shaft coupling alignment.
•
Check the bearing temperatures.
Every 300 HOURS DRIVE SYSTEM
MACHINE
•
Check belt alignment andtension.
•
Check V-belts for wear or cracks.
•
Check screw shaft coupling alignment.
•
Check machine weir setting.
•
Check oil level and the contamination level at the drive Gear box.
•
Check for unusual noise, indications of wear or undue strain on machine parts.
•
Check the bearing temperatures.
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 to18 21° 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 temperatureafter it has been running satisfactorilyfor some time may be caused by over greasing. • A newly installed bearing that overheats is usually caused by mproper i adjustments of the running clearance. • A failed bearingthat is overheatingwill probably beaccompanied bysome otherindicationsuch as grinding noises.
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TROUBLE SHOOTING
B-VII
TROUBLE SHOOTING
DRIVE GEAR BOX OVERHEATING Insufficient oil in the gear box.
PROBABLE CAUSES
COMMENTS/CORRECTIVE ACTIONS 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 Improper alignment.
COMMENTS/CORRECTIVE ACTIONS 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 tothe output desired.
Improper water contents in the feed.
Check and adjust. Check and adjust the setting to haveequal flow all over the weirs.
Improper weir settings. Improper settings ( Washflow, Return flow)
Check the settings to have thedesired 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 andcompare 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.
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LOWER BEARING ASSEMBLY
ASSEMBLY INSTRUCTION & MAINTENANCE C-I
LOWER BEARING ASSEMBLY
ITEM NO.
PART NO.
DESCRIPTION
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 22 23
SW3625.4B SW3625.4-1B KM17 KB17 H317 22217CCK/W33(C3) GB1152/M10x1 SW3625.4-2A GB12/M16x60 GB6170/M16 GB93/16 TD1214 CW4420.2-3 SW3625.4-4 TW3625.7-1 GB70/M20x65 GB6170/M20 GB93/20 SW3625.4-7A SW3625.4-8A
Lower Bearing Assembly Hub Lock Washer Lock Nut Adapter Bearing Grease FittingM10X1 Seal Housing Square Neck Bolt Nut Lock Washer Seal Retainer Gasket Donut Seal Stub Shaft Bolt Nut Washer Gasket Gasket
24 25 26 27 28 29
CW4420.2-1 CW4420.2-2 TW5434.4-2 SW3625.4-9 HG4-692-67/115x140x14 SW3625.4-10A
Bolt M20X90 M16X75 Bolt StainlessSteel Sleeve Slinger Oil Seal Gasket 20
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QTY. 1 set 1 1 1 1 1 1 1 8 14 14 1 8 1 1 8 12 12 1 1 6 4 1 1 1 1
WASHER – TW3625WTS
LOWER BEARING ASSEMBLY
ASSEMBLY INSTRUCTION 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.
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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.
WASHER – TW3625WTS
GEAR BOX ASSEMBLY
C-II
GEAR BOX ASSEMBLY
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WASHER – TW3625WTS
GEAR BOX ASSEMBLY
ITEM NO. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
PART NO.
DESCRIPTION
QTY.
SHP750-70 GB297-84(32309) K6001.1-30 K6001.1-1 K6001.1-3 GB297-84(32211) K6001.1-31 GB1235-76/ 100x3.1 K6001.1-5 K6001.1-17
Gear Box Assembly Bearing 7609E, #1shaft Cover, #1shaft #1Shaft and Pinion #2 Shaft and Pinion Bearing7511E, #2 shaft Cover, #2 shaft O-Ring, #2 shaft Gear, #2 shaft Gear, #3 shaft
1 2 1 1 1 2 1 2 1 1
GB1235-76/ 150x3.1 K6001.1-20 GB297-84 (30314) K6001.1-16 K6001.1-12 GB5783/M8x25/GD8.8 GB93/8 GB1096/C25x14x1 90 K6001.1-11 K6001.1-14 HG4-692-67(PD100x125x12) K6001.1-13 K6001.1-23 K6001.1-21 K6001.1-9 K6001.1-18 K6001.1-24 K6001.1-25 GB5783/M16x40 GB93/16 K6001.1-22 GB1152-74/M10X1 GB297-84 (32219) LH GB297-84 (32221) RH K6001.1-15 K6001.1-19 GB5782/M12x35/GD8.8 GB93/12 K6001.1-20 K6001.1-7 K6001.1-8 K6001.1-6 K6001.1-4 K6001.1-27 K6001.1-28 HG4-692-67(PD45x70x12) GB5783/M6x16/GD8.8
O-Ring, #3 shaft Cover, #3 shaft Bearing7314E, #3 shaft Key, #3 shaft Closure, #4 shaft Bolt M8x25 Washer 8 Key #4 Shaft Rear spacer, #4 shaft Oil seal PD100x125x12 Seal housing,output Key, #4 shaft Gear, #4 shaft Housing,back half Housing,front half Front spacer, #4 shaft Gasket, #4 shaft Bolt M16x40, Washer 16 Cover, #4 shaft Greases fitting Bearing Bearing #3 Shaft and Pinion Shim, #3 shaft Bolt M12x35 Washer 12 Cover, #3 shaft Cover, #2 shaft Shim, #2 shaft Spacer, #2 shaft Key, #2 shaft Seal housing, #1 shaft Closure,#1 shaft Oil seal PD45x70x12 Bolt M6x16
2 1 2 1 1 4 4 1 1 1 2 1 1 1 1 1 1 2 6 6 1 1 1 1 1 2 24 24 2 1 2 1 1 1 1 2 4
GB93/6 GB12135-76/ 100x3.1 K6001.1-29 GB5782/M20x130/GD8.8 GB6170/M20/GD8 GB93/20
Washer#1 6 shaft O-Ring, Shim, 31 shim Bolt M20x130 Nut M20, Washer20
42 2 16 16 16
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WASHER – TW3625WTS
GEAR BOX ASSEMBLY
ASSEMBLY AND MAINTENCANCE INSTRUCTIONS When performing service or maintenance to the gearbox, thecomplete unit should be removed from thesand 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. 2. 3. 4. 5.
The screw must be supported, this time at the coupling housing end. Next remove the belt guard and the Vbelts from the motor sheave Remove the motor mounting plate. Drain the oil from the gear box. 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. Place the gearbox on a worktable with the sheave facing up.
8.
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. 2. 3.
Remove the sheave and bushings. Remove the sixteen gearbox cover bolts. 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. 5. 6.
Inspect all the gears for wear and damage. Inspect all oil seals and gaskets and replace if required. 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. 2. 3. 4.
Inspect the Gear Box for the proper fitment of gears and bearings. Assemble the top cover with the sixteen gearbox cover bolts. Assemble Sheave and Bushings. Assemble the Gear box on to the machine using proper lifting tools with the help of 4
5. 6. 7. 8.
Assemble Flexible coupling. Refill the Gear box with recommended gear oil. (Refer Lubrication Chart) Assemble the motor mounting plate. Assemble belt guard and V-belts.
mounting bolts. (Refer Appendix ‘A’ for Bolt torques)
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FLEXIBLE DRIVE COUPLING ASSEMBLY
C-III
FLEXIBLE DRIVE COUPLING ASSEMBLY
ITEM NO.
PART NO.
0
DESCRIPTION
Complete coupling assembly 1set Key 1
1
GB1096/C25x14x190
2
SW3625-3A
3
GB5782/M20x140
Couplinghousing Bolt M20X140
6
GB93/20
Lock Washer 20
6
GB6170/M20
Nut M20
6
4
SW3625-4
Half RetainerRing
2
5
SW3625.4-6A
Spider Plate
1
6
GB32.1/M20x50
Bolt M20X50
12
GB1230/20
Washer 20
12
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QTY.
2
WASHER – TW3625WTS
FLEXIBLE DRIVE COUPLING ASSEMBLY
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 tothe first.
ASSEMBLY INSTRUCTIONS Replace Spider 1. 2.
Place blocks under conveyor shaft assembly, unbolt spider from conveyor shaft flange and coupling hub flange. Remove present spider. This may be more easily done by shifting conveyor shaft slightly.
3. 4. 5.
Replace a new spider on the proper position, Tighten cap screws and install lock wires. Remove blocks under conveyor shaft.
Replace Drive Coupling 1. 2.
3. 4.
Remove motor guard and V-Belt from end frame. 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. Remove the coupling from gear reducer
5.
6.
output Install shaft. 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.
7.
The driving spider can now be bolted to the driving hub with four cap screws. Install lock wires in bolts. 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. 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.
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FLEXIBLE DRIVE COUPLING ASSEMBLY
MAINTENANCE Checking Coupling Alignment
GEAR BOX FOOT SHIM (EXAMPLE, SHIM FEET .050IN.)
SLOT MEASURE TOP (EXAMPLE, 1.000IN.)
MEASURE BOTTOM (EXAMPLE, 1.020IN.)
FIGURE 1
FIGURE 2
FIGURE 3
FOOT SHIM
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.
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FLEXIBLE DRIVE COUPLING ASSEMBLY
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 betorque tightened to the rated capacity. 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 Spider Bolts
309 320
309 320
309 600
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 havingthe same coupling diameter. TABLE2
Shim Recommendations
Machine Size
Coupling Dia.
36”
12"
Shim Thick. Required to Adjust Coupling GAP .010” A B 0.029” 0.024”
÷ .010”) (.029”) = .0.052” Example: To remove .018” of coupling misalignment in the “A” direction, use (.018” shim thickness.
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SCREW ASSEMBLY
C-IV
SCREW ASSEMBLY
PART LIST FOR RH SCREW ITEM NO. 0 1 2 3
4
PART NO. SW3625.4.1 SW3625.4.1.1 CW3618.2.1.1-3 SW3625.4.1-1 (K6001.2.1-2) GB819/M12x45 GB41/M12 GB93/12 GB97/12
DESCRIPTION
QTY.
Screw Assembly(RH) Screw (RH) Flight (RH)
1 set 1 16
Flight Shoe (RH)
96
Bolts M12X45 Nuts M12 Lock Washers 12 Washers 12
192 192 192 192
PART LIST FOR LH SCREW ITEM NO.
PART NO.
DESCRIPTION
QTY.
0 1 2
TW3625.7.1 TW3625.7.1.1 TW3625.7.1.1-1
Screw Assembly(LH) Screw (LH) Flight (LH)
1 set 1 16
3
TW3625.7.1-1 GB819/M12x45 GB41/M12 GB93/12
Flight Shoe (LH) Bolts M12X45 Nuts M12 Lock Washers 12
96 192 192 192
GB97/12
Washers 12
192
4
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WASHER – TW3625WTS
WEIRS ASSEMBLY
C-V
WEIRS ASSEMBLY
ITEM NO.
PART NO.
DESCRIPTION
1
TW3625-1
Rear Weir Plate
2
SW3625A.1-3
Side Weir Plate
3
GB5783/ M12X35
Bolt
19
4
GB6170/ M12
Nut
19
5
GB93/12
Lock Washer 12
6
GB5783/ M12X35
Bolt
106
7
GB6170/ M12
Nut
106
8
GB93/12
Lock Washer 12
106
9
Rubberδ=3
Rubber seal
2
10
TW3625WTS.2
Baffle Plate
1
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QTY. 1 2
19
WASHER – TW3625WTS
DRIVE ASSEMBLY
C-VI
DRIVE ASSEMBLY
ITEM NO.
PART NO.
DESCRIPTION
QTY.
1 2
254T 2B-80
Motor 15HP, 1760 RPM Drive sheave 8.35” OD
1 1
3
B-105 TW3625.10 TW3625.11 SW3625-5A(2B) SW3625-8 GB5783/M12X60 GB1076/C12x8x63
B-V belts Belt guard (RH) Belt guard (LH) Driven sheave Bushing Bolt Key
2 1 1 1 1 3 1
4 4A 5 6 7 8
MOTOR, DRIVE SHEAVE AND V-BELTS ARE NOT SUPPLIED ALONG WITH THE WASHER
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GENERAL TECHNICAL INFORMATION
GENERAL TECHNICAL INFORMATIONS D-I
D
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; VBelt or Flexible Coupling. DRIVE GUARD: Safety enclosure for the drive. FEED: Raw material which needs to be washed. FINISHED PRODUCT: The resultant material after it has been processed. GRADATION: The range of sizes contained in a sample of rock.
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APPENDIX A – BOLT TORQUE SPECIFICTIONS
APPENDIX-A
BOLTS TORQUE SPECIFICATIONS
GENERAL RULES: 1. Values shown below are for Dry un-plated condition, for lubricated plated condition torque should be 75% of the values shown below.
METRIC BOLTS GRADE 8.8
DIAMETER
GRADE 10.9
SOCKET HEAD
FT-LB
N-M
FT-LB
N-M
FT-LB
N-M
M6 x1 M 8x1.25
7 18
9 24
10 25
13 34
14 34
19 46
M10x1.5
34
47
48
66
66
89
M12x1.75
60
81
84
114
117
159
M16x2
146
198
206
279
290
393
M20x2.5
284
386
401
544
560
759
M24x3
490
665
692
938
960
1302
M30x
985
1335
1389
1883
1920
2603
M36x
1716
2326
2419
3280
3360
4556
M42x
2752
3732
3881
5263
M48x
4155
5634
5859
7944
M56x
6661
9032
9392
12735
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WASHER – TW3625WTS
APPENDIX A – BOLT TORQUE SPECIFICTIONS
SAE (INCH) BOLTS GRADE 5
GRADE 8
SOCKET HEAD
DIAMETER FT-LB
N-M
FT-LB
N-M
FT-LB
N-M
14
19
29
39
1/4-20
8
11
12
16
1/4-28
10
14
14
19
5/16-18
17
23
24
33
5/16-24
19
26
27
37
3/8-16 3/8-24
30 35
41 47
45 49
61 66
49
66
7/16-14
50
68
70
95
76
103
7/16-20
55
75
78
106
1/2-13
75
102
110
149
113
153
163
221
230
312
400
542
640
868
980
1329
1710
2319
2920
3960
1/2-20
85
115
120
163
9/16-12
110
149
150
203
9/16-18
121
164
171
232
5/8-11
150
203
210
285
5/8-18
170
231
240
325
3/4-10
260
353
380
515
3/4-16
297
403
420
570
7/8-9
430
583
600
814
7/8-14
473
641
668
906
1-8
640
868
910
1234
1-14
704
955
995
1349
1 1/4-7
1120
1519
1820
2468
1 1/4-12
1241
1683
2012
2728
1 1/2-6
1910
2590
3160
4285
1 1/2-12
2194
2975
3557
4823
1 3/4-5
2286
3100
4988
6764
2-4.5
3438
4662
7500
10170
2 1/4-4.5
5027
6817
10969
14874
2 1/2-4
6875
9323
15000
20340
2 3/4-4
9321
12639
17794
24129
3-4
12313
16696
23507
31875
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TRIO EN G I N EER ED
P R ODU C TS
WASHER – TW3625WTS
APPENDIX B –OIL VISCOSITY CHART
APPENDIX-B
OIL VISCOSITY CLASSIFICATION
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TRIO EN G I N EER ED
P R ODU C TS
WASHER – TW3625WTS
WARRANTY
WARRANTY TERMS AND CONDITION Seller warrants all new equipment manufactured by Trio Engineered Products (Trio) against defects in material or workmanship attributed to the srcinal machine manufacturing. No other warranties are expressed or implied. Warranty claims must be made through the dealer or agent responsible for the srcinal 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 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, caused bydetermined negligenceby or Trio, accident. In addition, any product operation, repaired ormaintenance, altered in anystorage way asor reasonably that affects the performance or purpose for which the equipment was srcinally 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.
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TRIO EN G I N EER ED
P R ODU C TS
WASHER – TW3625WTS