F LASTEST engineered Products apy) tinted Operation, Maintenance ‘Shaping Materials Handling and Parts Manual Tin Astos Company 5x12 OSBORN TELSMITH VIBRO-KING SCREEN Manufactured in South Africa by: Osborn Engineered Products SA (PTY) LTD Please order your parts from your nearest authorised Agent or Branch Osborn. Designers and manufacturers of bulk materials handling and minerals processing plant and equipment. Head Office: Johan 1406, South Africa urg P.O. Box 8182, Bandsfontel ‘Tek +27 11 8207600 Fax +27 11 388-1136 mal: osborng@sborncoza http! / wwwosborncoza Cape Town (021) 558-1470; Durban (031) 569-4431 Welkom (057) 362-3374; Witbank (0136) 923035 ‘Aso Samuel Osborn Zimbabwe and Agents in Cape Town. Kimberley. Kuruman, Rustenburg, Witbank, Zambia, Namibia, Nigeria and GhanaETETETeTEIN cnaincered Products SA (Pty) Limited Table of Contents [ERY 2pir0 Mterias Hanaing as — — — Tan Astec Company CANYON ROCK — SIZE OF SCREEN a x12 | NUMBER OF DECKS ~ ONE SIZE OF VIBRATING UNIT SAKE ‘ORDER No, /SERIAL No. B20087108-STIDEKiZ07 | variables, options, or custom engineering. ‘With Osbom Telsmith’s policy of constantly improving its products, without notice. Actual dimensions, clearances, masses and other specifications may vary due to fabrication ‘Specifications are subject to change TABLE OF CONTENTS INTRODUCTION 1A Purpose 1B _Description of Osborn Telsmith Vibro-King Screen PAGE NUMBER 2. INSTALLATION 24 Shipping 2B Supporting Structure 2C Feed & Chutes 2D Screen Cloths 2E _ Installation of Driving Motor 3. OPERATION 3A Drive Speed & Power 3B Slope of Screening Surface 3C_ General Operating Instructions. 3D_Automatic Balance Wheels Pi vvvjomarrslooe MAINTENANCE 4A Lubrication 4B V-Belt Adjustment 4C__ Direction of Rotation 4D Care & Replacement of Screen Cloths 4E High Strength Bolts 4F _Maintenance of 26SA Unit ‘OPERATING PROBLEMS & SOLUTIONS General Information Trouble Shooting Chart REPAIR PARTS Parts List - Screen Parts List - Vibrating Unit Recommended Spares"5x 12 OSBORN-TELSMITH VIBRO-KING SCREEN REV. 1 NOVEMBER 1998 PAGE 1 WARNING AVOID PERSONAL INJURIES AND PROPERTY DAMAGE BEFORE YOU ASSEMBLY, OPERATE, CLEAN, LUBRICATE OR ADJUST MACHINERY, BE SURE TO READ AND CAREFULLY __ FOLLOW MANUFACTURER'S WRITTEN INSTRUCTIONS5x 12 OSBORN-TELSMITH VIBRO-KING SCREEN REV. 1 NOVEMBER 1998 PAGE2 WELDING THIS IS A ROLLER BEARING MACHINE DO NOT CARRY OUT ANY WELDING OR CUTTING WITH OXYACTYLENE TORCH, WITHOUT FACTORY AUTHORISATION AS THIS MAY INVALIDATE YOUR GUARANTEE WARNING ALL ROTATING POWER PRODUCTS ARE POTENTIALLY DANGEROUS AND MUST BE PROPERLY GUARDED. PLACEMENT OF GUARDS AND OTHER SAFETY EQUIPMENT ARE THE USERS RESPOSIBILITY AND MUST BE INSTALLED AND MAINTAINED WHEREVER APPROPRIATE. IT IS THE RESPONSIBILITY OF PURCHASER TO INSTALL AND USE THE EQUIPMENT IN A SAFE AND LAWFUL MANNER. EQUIPMENT MUST BE OPERATED IN COMPLIANCE WITH APPLICABLE HEALTH AND SAFETY LAWS AND REGULATIONS AND GENERAL STANDARDS OF REASONABLE CARE. SAFETY FIRST DISCONNECT THE POWER SUPPLY TO THE ELECTRIC MOTOR BEFORE ATTEMPTING ANY MAINTENANCE WORK ON THE MACHINE1A. 1B. 5x 12 OSBORN-TELSMITH VIBRO-KING SCREEN REV. 1 NOVEMBER 1998 PAGE 3 INTRODUCTION PURPOSE This Osborn Telsmith Operation, Maintenance and Parts Manual has been developed to give you a better understanding of the installation, operation and maintenance of your Osborn Telsmith Vibro-King Screen, and thus enable you to utilise it to its maximum efficiency. DESCRIPTION OF OSBORN TELSMITH VIBRO-KING SCREENS 1B.1. The Osborn Telsmith Vibro-King Screen is a two bearing, heavy duty screen for wet or dry screening of sand, gravel, crushed stone, all kinds of ores, coal slag, and many other industrial screening applications. The vibration is produced by a straight shaft journalled in two heavy duty series roller bearings which carries four specially designed and patented, automatically operating counterweights. The automatically operating counterweights prevent the screen from ‘jumping’ and provide smooth starts and stops.The 22SA Vibrating unit used on the screen is oil lubricated. 1B.2. The live frame is made of structural steel! and consists of screen trays of welded construction for supporting the screen cloth, reinforced steel side plates and end plates for closing the upper or feed end. The end plates are split for easy removal and quick screen cloth changes. The screen trays are made of heavy plate side members to which are welded heavy cross members or rectangular steel tubes. These cross members carry longitudinal bars capped with rubber nosing on which the wire cloth rests. The wider screens have diagonal bracing at each end of the trays. 1B.3. The screen end plates are secured with high strength friction grip bolts while all other connections are huck bolted thus pro\ 1B.4. Osborn Telsmith Vibro-King Screens are available in single, double and triple deck. Every screen is carefully constructed, assembled, and shop tested before leaving the factory.5x 12 OSBORN-TELSMITH VIBRO-KING SCREEN REV. 1 NOVEMBER 1998 PAGE 4 2 INSTALLATION 2A. SHIPPING 2A.1. Osborn Telsmith Vibro-King Screens are thoroughly tested and carefully and properly loaded at the factory. As soon as the screen is received, before unloading, carefully inspect for any loss or damage that may have occurred during transportation. If any loss or damage is discovered, immediately call it to the attention of the carrier. 2A.2. When unloading, care must be taken in lifting and moving the screen into position to avoid distortion or damage. Proper slings or chains must be provided and attached at the lifting points of the frame as shown in Figure 1 2B. SUPPORTING STRUCTURE ‘The standard method of supporting the Osborn Telsmith Vibro-King Screen is with the base mounted on steel beams as shown in Figure 2. Shim under the corners of the base frame in order to level the screen across its width. Figure 1: Lifting Diagram5 12 OSBORN-TELSMITH VIBRO-KING SCREEN | REV. 1 NOVEMBER 1998 | PAGES | ‘SCREEN BASE IS AN OPTIONAL EXTRA ‘SHIM HERE TOLEVEL ‘SHIM HERE TOLEVEL SUPPORT SPRINGS. Figure 2: Standard Method of Supporting Screen 2C, FEED AND CHUTES 2C.1. The material should be fed evenly aoross the upper end of the screen so as to obtain full screening capacity. When the screen is fed from a conveyor, elevator or long chute, install a hopper or baifle to break the fall and protect the screen cloth from undue wear. An even distribution and steady feed are essential for large capacity and efficient screening. Make sure that the chutes or supports do not contact the vibrating frame as this will interfere with its proper operation and also damage the screen. 2€.2. Screen cloths may be removed and installed from either end of the screen, whichever is the most convenient, however, the discharge chutes should be made easily removable if itis necessary to change screen cloths from the lower end. 2D. SCREEN CLOTHS If screen cloths have to be installed or changed before operation, refer to Maintenance Section page 14+ 15.| 5x 12 OSBORN-TELSMITH VIBRO-KING SCREEN | REV. 1 NOVEMBER 1998 | PAGE 6 2E. INSTALLATION OF DRIVING MOTOR When customer installs motor, the motor support plate has to be slotted and drilled in the field, to correspond to motor holding down bolts. Procedure is as follows: (refer to figure 3) 2E.41. 2E.2. 2E.3. 2E.4. Place motor on support and install drive belts. With a straight edge align belt sheaves and move motor to provide tension on belts. Mark motor support for holes to correspond with motor base. Remove motor and burn slots in support, parallel to screen, to provide movement of motor for additional belt take-up. Refit motor with bolts and install mounting bolts. Adjust motor position until belts are in proper adjustment, (Refer to Drive Belt Adjustment, Page 12 + 13) and tighten the four motor mounting bolts. Figure 3: Drive Motor Installation5x 12 OSBORN-TELSMITH VIBRO-KING SCREEN REV. 1 NOVEMBER 1998 PAGE7 3A. 3B. 3c. OPERATION DRIVE SPEED AND POWER 3A.1. The vibrator shaft may be operated in either direction. A larger volume of aggregate can be handled when the shaft revolves in a forward (with flow) direction. By reversing the Girection of rotation (counter flow) a cleaner screening results, but at some sacrifice in volume. The difference is generally more noticeable with the smaller screen openings than with the large ones. 3A.2. The most efficient operating speed will vary with each installation. This variation may amount to as much as 15 per cent in extreme cases. As a rule the higher speeds are Needed for handling sand and gravel, crushed irregular shaped stone or damp sticky material and for screens with small openings. For screens with large openings a lower ‘speed should be used. 3A.3. Always use the minimum operating speed that will produce the required capacity and cleanliness of product. Higher operating speeds than necessary shorten bearing life, increase screen cloth wear, and increase operating costs. DO NOT OPERATED YOUR SCREEN OVER THE MAXIMUM R.P.M., indicated on the name plate. 3A.4. DETERMINE THE STROKE Motion Analysers are attached to the screen side plates to enable the stroke to be measured. SLOPE OF SCREENING SURFACE The standard slope of the screen deck is 19 Degrees. This slope may be varied slightly. We do not recommend a variation of more than 2 degrees either way, to prevent tippling of the support spring Figure 3. To increase screen slope, shim under base of feed end (A). To decrease the angle of slope shim under discharge end (B) - refer to Figure 2. Special slopes can be made to suit specific requirements. GENERAL OPERATING INSTRUCTIONS 3C.1. Before Operating 3C.1.A. Check to see that all supporting springs are in place. 3C.1.B. A visual inspection should be made to see that the bearings are lubricated. Refer to Lubrication Maintenance Section page 10.5x 12 OSBORN-TELSMITH VIBRO-KING SCREEN REV. 1 NOVEMBER 1998 PAGES 3C.1.C. All bolts and nuts should be checked to see that they are tight and that screen cloths are stretched tight over screen tray. Refer to High Strength Bolts, Maintenance Section page 18. Balance wheel cover capscrews in the ends of the shaft should be checked periodically and kept tight. 3C.2. During Operation 3C.2.A. Check to see that the feed is evenly distributed across the upper end of the screen with batfles to prevent the material striking the screen with too high a velocity. 3C.2.B. See that loading chutes or spouts are delivering the material to the screen properly without spillage and are not touching the vibrating frame. 3C.2.C. Check screen cloths daily for any blinding or clogging due to debris or foreign matter. 3C.2.D. Check daily to see that screen cloths are in good shape, properly secured and not whipping. 3C.2.E. Note- V-belt drive tension during operation and correct immediately if any indication of slipping is noticed. Refer to V-belt Adjustment, Maintenance Section, page 12 + 13. 3D. AUTOMATIC BALANCE WHEELS 3.1. 3D.2. 3D.3. ‘The soreen frame is vibrated by the counterweight in the balance wheels and on ‘screens having the SA type vibrating units with the offcentre weight in the enlarged Portion of the shaft. On screens with 22SA oil iubricated vibrating unit the counterweights are provided with removable shims to vary screen throw. However, consult the factory regarding changes of counterweights and/or operating speeds The two rubber retractors which operate the automatic counterweights shown in Figure 8, are enclosed in each balance wheel. The rubber retractors hold the counterweights in the position shown, (Figure 4) while the screen is not operating. As the shaft picks up speed, the counterweights are pulled out by centrifugal force, reaching the position shown in Figure 4, at full speed. The operation of the counterweights is automatic and the full effect of the counterweights does not come into play until the screen passes through the critical speed at which violent jumping occurs when fixed counterweights are used.30.4. 30.5. 30.6. 5x 12 OSBORN-TELSMITH VIBRO-KING SCREEN REV. 1 NOVEMBER 1998 PAGE 9 Since the counterweights and the rubber retractors are completely enclosed, a visual inspection of the rubber retractors is impossible without removing the covers. However, a broken retractor can usually be detected by a thumping noise inside the balance wheel when it is rotated by hand. If the counterweight has become wedged in the extended position, the balance whee! will be difficult to turn Excessive vibration when starting and stopping also indicates a broken retractor or binding counterweights. Investigate immediately before continuing operation. It is recommended that the balance wheel covers be removed once a month to inspect the rubber retractors. NOTE - There is some tendency for the counterweights in the large Vibro-King units to strike against the rubber bumpers Figure 8, when starting and stopping. This is normal and does not indicate anything wrong. COUNTERWEIGHT UNIT, COVER REMOVED SHOWING POSITION OF WEIGHTS AND RUBBER SPRINGS, WHEN SCREEN IS OPERATING COUNTERWEIGHT UNIT, COVER REMOVED SHOWING POSITION OF WEIGHTS AND. RUBBER SPRINGS, WHEN SCREEN IS AT REST Figure 4: Counterweight Units5x 12 OSBORN-TELSMITH VIBRO-KING SCREEN REV. 1 NOVEMBER 1998 PAGE 10 4 MAINTENANCE 4A. LUBRICATION Two types of vibrating units are used on Osborn Telsmith Vibro-King screens. Screens with 15P. and 18P vibrating unit, used on the smaller size screens, are grease lubricated. Screens with 228A, 26SA, 32SA and 40SA vibrating units are oil lubricated. 4A.1, OIL LUBRICATION OF 22SA VIBRATING UNIT 4A1.A. 4A1.B. 4A1.C. 4A1.D. 4A1.E. 4A1F. 4A1.G. The bearings are filled with the proper amount of oil prior to shipment. Before operating the screen check the oil level by looking at the sight level gauges. Oil level should be in the centre of the gauge. Check oil level weekly, and drain and refill as indicated below. During the break in period, the oil should be changed after the first 80 hours operation and every 500 hours thereafter. To drain oil, remove the drain plug in the bottom of the bearing cap. Refit plug after unit has been drained. To refill, use the oil filler pipe and add the following quantity of oll: 22SA 1,0 litres per side, 2,0 litres total If for any reason the brand of lubricating oil is changed, remove the drain plugs and flush out bearings as described in Para 4A.1(d). Always use a good quality oil of the proper grade, selected from the following list5x 12 OSBORN-TELSMITH VIBRO-KING SCREEN | REV. 1 NOVEMBER 1998 PAGE 11 STANDARD SPECIFICATION FOR ALL OIL LUBRICATED OSBORN TELSMITH EQUIPMENT | The following oils have been Osborn recommended by the Oil Companies as | Telsmith For above 40 Deg.C conforming to be preceding | Mining Spec Ambient Temp. __Speeificatin an are approved _ Spec. 204 | Flash Min. Deg. C GR-XP 150 BP OGI-150 -26 | Pour Point Deg. C Meropa 150 Caltex | oai-150 162 | Viscosity at 40Deg.C | Lubro GEP 150 | Chemico ‘oGi-150. | 16 Viscosity at 100 Deg.C | Mobilgear 629 Engen ‘OGI-150 954 _ | Viscosity index Omala 150 Shell OGit5- 23 | Timken OK kg EP Gear 220 Valvoline OGi-220- Yes | EP Agent Industrial Gear 160 | Zenex Not Listed Yes | Reo Agent ‘otalube GS-15 Total OGI-150 Yes _ | Anti-Foam Agent | Gearoil EP-150 Trek OGI-150 Pass | Copper Strip Corrosion Test | Gengear - 150 | Engen oGi-150 | Yes High Quality Industrial Oil If oils are used which do not conform to the above specification all guarantees for the equipment fall away. If in doubt consult the factory. The unitis filled at the factory with GENGEAR 150 oil. It any oil lubricated screen is to be shut down or stored for a period exceeding 60 days, a preservative oil must be added to the unit. Consult factory for specification Do not operate the screen with preservative oil in the unit as this may cause serious bearing damage. In any event the unit shaft must be rotated weekly.5x 12 OSBORN-TELSMITH VIBRO-KING SCREEN REV. 1 NOVEMBER 1998 PAGE 12 4B. V-BELT ADJUSTMENT 4B.1. 4B.2. 4B.3. 48.4. 4B.5. The driven V-belt sheave (on screen shatt) is bored off centre by half the average stroke of the screen. When starting and stopping, the sheave runs off centre and causes a jerking action on the screen for several revolutions. However, as the screen picks up speed and the automatic counterweights swing out to their operating position and develop a true circular motion, the sheave rotates true to its outer circumference. V-belts must be maintained at proper operating tension to prevent slippage and damage to belts. Belt slippage is not only detrimental to the belts, but also may allow the screen R.P.M. to slow down to a speed at which it will not operate efficiently. Check belt tension during the early stages of operation and make necessary adjustments immediately. After the itial stretch has been removed, check belt ten: after every 60 hours of operation, More belt failures result from improper care in the first few minutes of the initial operation than at any subsequent period. Keep V-belts properly tensioned for longer belt life and more efficient screening. To adjust V-belt tension: 4B.4.A. Loosen the motor mounting bolts sufficiently to permit moving the motor within the limits of the slots. Move the motor to a position at which the V-belts are taut. There are two generally accepted methods for the proper tensioning of V-belt drives on equipment. The first is a simplified method which relies on the experience of a maintenance man who has developed a feel for belt tensioning. He merely applies a force on one of the belts, midway between the vibrating unit sheave and the drive motor. The deflection of the belt at the point should be equal to the thickness of the adjacent V-belt. However, because most manufacturers believe this method to be unreliable, they have developed another method which actually measures the tension in a drive. This method employs the use of spring scales or tension testers. Depending upon the specific requirements of the manutacturer of these belts, we consider that either method is satisfactory for general installations, but because of improved materials and because many operators supply their own belts, itis best to follow the installation instructions furnished with that equipment for proper tensioning. A few simple rules about tensioning will satisfy most of your requirements and possible eliminate tensioning problems. 4B.5.A. Always use a matched set of new belts from one manufacturer. 4B.5.B. The best tension for a V-belt drive is the lowest tension at which the belts will not slip when starting. Too much tension may snub the motion of screen causing erratic operation, or transmit excessive vibration to the supporting structure for the motor. ‘TOO MUCH TENSION SHORTENS BELT AND BEARING LIFE.