Professional Documents
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SAFETY
Gator Machinery Company may not always know exactly how their equipment
is installed, applied and used, and cautions all prospective operators that they
must exercise the greatest care for the safety of individuals that happen in and
around the machinery. Equipment used in the United States must be installed
and operated with regard to safety either, per OSHA or MSHA regulations, or
both.
Operating the equipment beyond its published ratings or without the proper
guards and protection for personnel is foolhardy and subjects the operator to
potentially numerous penalties or imprisonment or both.
The information contained in this manual does not replace or supersede any
local, State or Federal safety guidelines, insurance requirements or company
safety rules.
Gator Machinery Company does not intend this manual to replace common
sense!
MACHINE DESCRIPTION
The screen operates at a fixed angle of 20°. There are three decks capable of
sorting mixed material into four sub classifications. The eccentric weights create
sufficient vibration to carry product across the screens for easy and efficient
product classification. Designed with maintenance ease in mind, the screens
wear and replacement parts are easily accessible and removable. The following
pages provide a more detailed description of the recommended maintenance
procedures.
GENERAL SPECIFICATIONS
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SHIPPING CONDITION
The screens are sold without frames, and as such are shipped fully assembled.
The spring mounts are Huck bolted to the body, the springs, the spring bases,
flywheel guard, sheave guard, stop rubber belt and the pivoting motor base are
all sent loose with the machine.
INITIAL ASSEMBLY
Upon receipt, inspect the delivery to ensure that all parts are accounted for.
Note any shortages or damage on the bill of lading prior to accepting delivery
from the driver. After unpacking the loose parts, check all installed bolts to
ensure that they are installed with the proper torque.
INSTALLATION CHECKLIST
1. Check to machine level and make sure all spring bases are correct for
level and dimensional accuracy. (All springs must be loaded evenly;
otherwise the machine will be racked).
2. Check the lubricant level in the vibrator bearings.
3. Check the belt drive and motor rotation.
4. Check the clearance for start up and shut down amplitudes.
RECOMMENDED TOOLS
The machines are built using metric sized bolts, washers, and nuts. Consequently,
a complete set of metric sized tools should be readily available for installation,
removal, as well as emergency and scheduled repairs. Refer to the parts
manual for exact sizes.
REPLACEMENT PARTS
Gator stocks a suitable supply of replacement parts to provide responsive
service on replacement and wear part orders. When ordering parts, please
have the following information available:
Screen Model Number Screen Serial Number
Part Number Address to Ship Part(s)
Purchase Order Number
The appendix to this manual includes a complete spare parts list for reference
when ordering replacements.
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Part List (I)
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14. RMS62030026 CONTACT BLOCK 4
15. RMS62030027 CONTACT PLATE 2
16. GB5782−86−M16X45 BOLT M16X45 2
17. GB6170−86−M16 NUT M16 2
18. GB93−87−Ø16 LOCK WASHER Ø16 2
19. GB5782−86−M10X30 BOLT M10X30 4
20. GB6170−86−M10 NUT M10 4
21. GB93−87−Ø10 LOCK WASHER Ø10 4
22. GB1152−89−M10X1 GREASE FITTING M10X1 4
23. JB/ZQ4458−86−M10X1 OIL PLUG M10X1 4
24. FCR−4−Ø6 MALE PIPE ADAPTER Ø6 4
25. RMS62030028 BRONZE PIPE Ø6X1−250 2
26. RMS62030029 BRONZE PIPE Ø6X1−350 2
BOLT TIGHTNESS
The initial tightening of bolts should prevent premature loosening, but the
tightness of all nuts and bolts should be checked regularly to ensure that no
loose bolts contribute to
machine down time. Bolt Diameter (mm) Torque (ft/LBS)
The following table illustrates 6 7.7
the appropriate tightness 8 18.7
for all bolts on the Screen:
10 27
12 35
14 65
16 160
20 315
24 540
30 1080
36 1880
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SECTION 2: INSTALLATION AND MAINTENANCE
INFORMATION
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GENERAL ASSEMBLY INSTRUCTIONS
Upon receipt, inspect the delivery to ensure that all parts are accounted for.
After unpacking the loose parts, check all installed bolts to ensure that they are
installed with the proper torque.
OPERATING INSTRUCTIONS
If all of the pre-checks are all right, and all guards are in place, power may be
supplied to the machine. It is normal for the screen to vibrate with greater
amplitude during start-up and shutdown, as the vibrator goes through a critical
speed. This should only last a second or two, and then the machine should settle
into its correct stroke.
When the machine has settled down and if everything looks and sounds OK,
then material may be fed to the feed hopper. Be careful not to overload the
screen and observe that the material flows in a symmetrical pattern as it
progresses from the feed end to the discharge lip. If material tends to flow more
on one side or the other, the spring mounts and screen tensions should be re-
checked.
POTENTIAL PROBLEMS
Once a machine has been set-up and is operating properly, the most likely
problems occur with loosened belts that slow the machine or cause it to
operate sporadically. Overloading the machine will also cause the screen to
appear to slow down. The dampening effect of this overloading actually results
in reduced vibrating amplitude, with the same vibrating speed. That results from
excessive spring compression and should be avoided as much as possible.
a) Rough operating could also originate from an improperly adjusted
motor mount, as well as over-tightened belts. Both cases will cause the
screen to rock.
b) Broken or uneven springs will also cause the machine to run roughly.
Check the spring pivot heads all around the unit.
c) Failure to screen all the fines. If a finer screen has been installed the
feed rate may have to be reduced, or the machine’s slope might be
too great, not allowing enough retention times for the material on the
screen cloth.
If the machine has been serviced - check the motor rotation. Often when a
motor is replaced the phase of the electrical power might have been
inadvertently changed causing the stroke to be up-hill instead of down.
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Screen cloth wear in a certain spot happens occasionally and can usually be
traced to poor spring adjustment, bad bucker bar rubber, poor screen tension,
or all of the above. Tearing of a fine screen cloth is primarily associated with
improper tensioning.
THROW PATTERN
The Gator two bearing machines use a fixed eccentric vibrator shaft and
counter weights that are attached to the drive sheaves. The theoretical shape
of the throw for any two bearing machine will always be more circular then
elliptical.
The position of the vibrator, the stiffness of the support springs, and the
magnitude of the eccentric weights may modify the actual shape. The
important thing to remember with regard to maintenance is that the throw
pattern must be the same as measured on each side of the machine and at the
both ends.
OFF MOTION
If the screen is moving with different throw patterns and/or amplitudes at each
corner it is said to be operating with “off motion”. This condition will lessen the
screen’s efficiency and cause rapid wear and breakdown of the components.
To check for off motion, place a sticky back piece of paper on the machine
side plates at the feed and discharge ends (4 required). Be sure that the paper
is about midway between the top and bottom edges of the side plates. With
the machine running unloaded - hold a pencil or ballpoint pen perpendicular to
the paper, so that the vibrating pattern will be traced on the paper. You will
have to devise a rigid support for the pencil that is not affected by the vibration.
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If the patterns traced on the paper are not the same in each case then some
off motion exists and must be corrected. You should also check to be sure that
there is no side motion of the deck when viewing the machine from the
discharge end.
Inspect the screen mounting springs, the spring pedestal level, and the drive belt
tension for “off motion” producing effects.
RUNNING SPEED
The machine was designed to run at a particular speed for the mounting; slope,
load and other conditions already discussed. It sometimes happens that when
those conditions are altered and the machine exhibits a resulting “off motion”.
To correct for that condition, try varying the drive speed up or down slightly.
Lowering the speed is always more advisable as it will prolong the life of the
machine. In no case should the change be more than 50 RPM either way.
FRAME ASSEMBLY
When moving the machine always lift equally at each corner - using the lifting
legs and spreaders bars to prevent over loading the side plates. At installation,
always provide a minimum of three (3) inches between the vibrating portion
and any fixed structure. Be especially careful at the discharge lip(s) and
associated chutes.
The supporting structure for the machine must be strong enough and rigid
enough not to induce out of sync vibrations or cause dampening of the screen
actions. Whether the base supplied with the machine is used, or a custom base
is used, the base must be installed level so that the screen is not out of balance.
If, after constructing the base, it is found to be out of level, shims should be
installed under the spring mounting plates to correct the condition.
Maintenance for the frame should include a disciplined bolt tightening
procedure, and a weekly inspection for side plate or cross member cracks. Re-
adjust chute clearances whenever necessary to avoid contact.
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SPRING ATTACHMENTS
As indicated earlier the relationship of the springs to the screen and the base is
very important. The upper spring mounts are attached to the sidewalls using
Huck bolts and are pre set at 20°. The spring base must be parallel to the upper
mount to ensure proper mating and to reduce the chance of the springs
coming off the base.
Check for broken springs or for material lodged in coils daily to reduce the
chance of equipment failure or accident.
DRIVE ASSEMBLY
The screen may be driven from either side of the machine. There is a drive hub
on each side of the vibrator for that purpose. All that is necessary is to install the
drive sheave ring, motor and guards in the proper locations. Unless otherwise
noted however, the base will be set-up for right hand drive (that is the right side
when viewing the screen from the feed and looking toward the discharge end).
The sheave is a “SPC” section through the grooves. Always use matched “V”
belts to avoid belt whip and power losses. Also, take care to watch the
operating temperature on the belts, as cooler belts will last longer.
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V-BELT & SHEAVE MAINTENANCE
Always keep the V-belts and sheaves properly aligned. Check to be sure that
all bolts are properly tightened and that the motor base springs are in good
order. Replace belts whenever a belt begins to crack from age or whenever a
belt stretches out of limits. Never allow safety aspects to reach a state of
disrepair.
ALWAYS LOCKOUT THE ELECTRICAL CONTROL WHEN WORKING ON THE MACHINE.
SCREEN CLAMPS
Tensioning the screen cloth in conventional using tension rails and either wedge
bolts or carriage bolts, similar to the sketch below.
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Screen cloth, especially fine mesh stainless cloth, must be tensioned carefully to
eliminate loose spots that might develop but not so tight that as to tear the
cloth. Always keep bucker bar rubbers in good repair and at uniform height for
the length of the screen.
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SECTION 3: VIBRATOR INFORMATION
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VIBRATOR SCHEMATIC
The diagram below presents a general schematic of the machine.
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PARTS LIST (III)
REFERENCE DESCRIPTION QUANTITY
NUMBER PART NUMBER
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GENERAL INFORMATION
This two bearing vibrator is mounted in the side plates of the screen between
the decks. The bearings are carried in separate housings that fit into each end
of the tube weld-ment that holds everything together. The shaft is machined
almost symmetrically except for the difference which allows for “the float” side
to take care of expansion. The eccentricity of the shaft is augmented by
weights bolted into each left and right sheave. The vibrator operates at about
850 RPM, and is grease lubricated.
The vibrator is the one item on the machine that will require scheduled down
time maintenance.
VIBRATOR REMOVAL
Before the vibrator can be taken out of the machine, the both the drive sheave
and the flywheel must be removed.
a) Remove the bolts and sheave retainer from the end of the shaft.
b) Remove the sheave and its associated key. (Use a wheel puller, do not
hammer the sheave)
c) Do the same on the flywheel side. This will expose the bolts holding the
bearing retainer to the side plates and the vibrator tube.
d) Unfasten all of the bolts and withdraw the bearing housing and the
bearing cover (both sides).
CAUTION: When the bearing housing and bearings are removed, there is no
support for the shaft and it must be cared for. More importantly, the vibrator
tube has only the support of the pilot holes in the side plates. As such, it is very
important to have the proper blocks under the shaft.
e) Withdraw the shaft and note its end-for-end relationship, be very
careful not to damage the bearing journals.
f) Withdraw the vibrator tube weld-ment from the side plates and also
note its end for end location.
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REPLACING BEARINGS
a) Screen vibrator bearings are of a special category for the severe
service that they are subjected to. Do not use standard commercial
bearings, they are not adequate. Your best insurance is to use factory
authorized bearings that have the required radial clearance and
correct diametrical tolerance.
b) Keep the bearings in their original packing until just before they are to
be used.
c) If you are using the original bearings, clean them thoroughly in solvent
and pack them with the proper grease in a clean environment.
d) Note: The shaft must have a fixed side and float side of the shaft to
allow for shaft expansion during operation. This is allowed to occur in
the bearing journal on the float side.
e) The oil slingers behind the bearings are machined the same, but
because they are used as spacers they should go back in their original
location.
f) To remove the bearing from the housing requires a spacer plate and a
press. Insert the plate onto the backside of the bearing, block the
housing up on the press and push the old bearing out.
CAUTION: Do not attempt to hammer the bearing in place; doing so may cock
the bearing in its bore, which could result in cracking or chipping of the bearing
races.
REPLACING BEARINGS SCHEMATIC
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VIBRATOR REASSEMBLY
Note: when reinstalling the vibrator, the bearing fixed side is always the drive
side.
a) Thoroughly clean all parts and lay them out for installation.
b) Position the vibrator tube weld-ment into the screen so that the flanges
locate the side plate pilot holes. Block it up so that it is secure.
c) Place the shaft into the tube, observing its original end for end position.
d) Carefully support the shaft and position the oil slingers on the 140mm
bore.
e) While supporting the shaft float end, restart the bearing and housing
onto their respective bores. The bearing is a slip fit onto the shaft and
the housing will slip onto the vibrator tube. These are close fits, so be
careful.
f) Try to insert the above as far as they will go by hand while rotating the
housing to align its bolt holes with the mating holes in the side plate.
g) Temporarily install the set-up bolts through the housing, screen side
plates, and shims so that the assembly is secure. Now do the same
thing for the other bearing housing.
h) When both sides are secure, begin to tighten the set-up bolts so that
the housings are drawn into the vibrator tube and onto the shaft. Do
this evenly working from side to side until the housings have bottomed
out. Replace the set-up bolts with the finished bolts gradually as they
come into range. Be sure to replace all washers and torque bolts per
spec.
i) Rotate the shaft by hand occasionally as you progress through this
latter stage of assembly to make sure nothing has bound up and the
bearings are OK.
j) Next, install the bearing cover and finally the sheave, flywheel, and
end caps. Lubricate all parts as you proceed.
k) Lubricate the bearings lightly to fill the seal cavities via the grease
fittings on each side at the top of the inner seal.
MAINTENANCE
Check the operation of a new bearing assembly carefully for several days after
start-up.
MISCELLANEOUS PARTS
Other than the vibrator assembly, feed and discharge lip liners, screen cloth and
screen tensioning components, the only wear and replacement parts on the
screen are nuts, bolts, and washers. When replacing parts, it is recommended
that you contact your local dealer. Always have model, serial number and
manufacture date when contacting your dealer for parts.
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SECTION 4: LUBRICATION
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GENERAL
Lubrication procedures are performed primarily to deliver grease to rotating or
sliding surfaces to reduce friction and carry away heat. Pressure lubrication is
also used to expel contaminants from seals and other openings. Certain
lubricants are used to protect parts from corrosion.
GREASE LUBRICATION
LUBRICATION SCHEDULING
Maintaining adequate lubrication in your machine is an important maintenance
function. Many premature failures can be traced to inadequate or improper
lubrication; therefore lubrication must be a regularly scheduled part of your daily
maintenance program.
At the time of initial start-up, a new machine should be greased every hour for
the first eight (8) hours of operation. This procedure should be followed if the
screen is allowed to set for an extended length of time. The increased greasing
will expel any contaminants that may have entered the bearing housing during
transit or storage. After the initial start-up the machined should be greased every
eight running hours. To ensure easier starting at the next operating period, we
recommend lubrication in the middle of the shift. Button-head grease fittings are
supplied to allow greasing during operation. For two or three shift operation,
lubricate the bearings during each shift or at lease twice every 24 hours.
GREASE SELECTION
Vibrating screens require a lubricant having specific properties. Different grades
may be required for use under various conditions. The ambient temperature as
well as the operating temperature of the bearings must be considered. Under
normal operating conditions, a high quality, lithium based N.L.G.I. Grade EP2
(Extreme Pressure) grease is recommended. The grease should contain base oil
having a viscosity of not less than 100 SUS at normal bearing operating
temperature.
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SECTION 5: WARRANTY TERMS & CONDITIONS
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Seller warrants all new equipment manufactured by Gator Machinery Company
(Gator) 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 Gator Machinery Company. Claims must be made
within twelve (12) months from the date of readiness for operation, but not more
than eighteen (15) months from the date of shipment from Gator. All parts
claimed to be defective shall be returned to Gator, freight prepaid, for
inspection to determine that the said part or parts are defective.
a) As of June, 2007, we have put a limit on the time frame you can request
warranties on parts and equipment. Our standard Warranty on New
Purchased Equipment is one year from date of start-up, which has not
changed.
b) If you are purchasing replacement parts that you intended to claim
warranty issues on the old parts, you must state that at the time of purchase
on the new parts and from that date of purchase you have 90 days to submit
the Gator Machinery Equipment Warranty request form. The form should be
completed, and have furnished a complete set of digital photos and both of
them sent to the Service, Warranty/Tech Support Mgr and Engineering Dept
via e-mail.
If it is determined that the fault lies with Gator, the customer shall be credited for
the freight costs and Gator will ship a replacement part or parts at no cost. If it is
determined that the fault does not lie with Gator, 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.
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When petitioning for a warranty item, the serial number of the equipment must
be referenced. The serial number must be clearly identifiable on the Gator
name plate on the equipment.
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