MMD TWIN SHAFT SIZER 625 Series Installation, Operation And Maintenance Manual

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INSTALLATION, OPERATION, SPARE

PARTS, AND MAINTENANCE MANUAL

MMD 625 SERIES

(625

TWIN SHAFT SIZER

S625-0085, Standard Height & Length, Low Type Blind End Case, 4T x 8R

GOEDEHOOP COLLIERY

Machine Serial Number :

Date Of Manufacture :

Case Designation :

Shafts Designation :

Gearbox Assembly :

Fluid Coupling Type :

Wheel Carriage Assembly :

Centralised Greasing :

Underspeed Sensing :

CENTRES)

CUSTOMER

ANGLO COAL

SOUTH AFRICA

Height:

Length:

Please quote in all correspondence. This number can be found on

the identification plate, and welded onto the machine side plate

THE MMD GROUP OF COMPANIES

MMD Mining Machinery Developments Limited

S625-0085*

November 2000

Std Height Low Blind End

Standard Length

4 Tooth x 8 Ring

MMD R200, 30:1

Voith 487 TVG

Corner Type Units

Customer Supply

Carlo Gavazzi, 110V A.C

™

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Summary of Contents for MMD TWIN SHAFT SIZER 625 Series

Page 1 Customer Supply Underspeed Sensing : Carlo Gavazzi, 110V A.C Please quote in all correspondence. This number can be found on the identification plate, and welded onto the machine side plate THE MMD GROUP OF COMPANIES MMD Mining Machinery Developments Limited...
Page 2 MMD 625 SERIES, 625 BREAKER SHAFT CENTRES TWIN-SHAFT SIZER ™ CUSTOMER ANGLO COAL GOEDEHOOP COLLIERY SOUTH AFRICA MMD JOB NUMBER 15464 MACHINE SERIAL NUMBER S625-0085 S7070435-019 GEARBOX SERIAL NUMBERS S7070435-020 G.A. DRAWING NUMBER 6250424 PREPARED BY :- K.HUDDART POSITION :- CAD DEPARTMENT.
Page 3 CONTENTS GENERAL ARRANGEMENT DRAWING Section 1 SIZER™ ASSEMBLY Section 2 OPERATION & MAINTENANCE Section 3 SIZER™ CASE ASSEMBLY Section 4 GEARBOX ASSEMBLY Section 5 MOTOR / FLUID COUPLING ASSEMBLY Section 6 WHEEL CARRIAGE ASSEMBLY Section 7 AUTO LUBRICATION ASSEMBLY Section 8 UNDERSPEED SENSING ASSEMBLY Section 9...
Page 4 INDEX GENERAL ARRANGEMENT DRAWING SECTION 1 General Arrangement Drawing Page 2 SIZER™ ASSEMBLY SECTION 2 SIZER™ Assembly Page 2 - 3 SIZER™ CASE ASSEMBLY SECTION 4 SIZER™ Case Assembly Page 2 - 5 Side Wearplate Assemblies Page 6 - 9 Left Hand Breaker Shaft Assembly Page 10 - 15 Right Hand Breaker Shaft Assembly...
Page 5 MMD MINING MACHINERY DEVELOPMENTS LIMITED MMD 625 SERIES, 625mm CENTRES TWIN SHAFT SIZER™ General Arrangement Drawing No. - 6250424 REVISION MODIFICATION DATE FIRST ISSUE 14-12-00 Section 1 Revision 1 General Arrangement Drawing, Page 1 of 2...
Page 6 MMD MINING MACHINERY DEVELOPMENTS LIMITED SIZER™ ASSEMBLY SERIAL NUMBER - S625-0085 REVISION MODIFICATION DATE FIRST ISSUE 14-12-00 Section 2 – Revision 1 SIZER™ Assembly, Page 1 of 3...
Page 7 MMD MINING MACHINERY DEVELOPMENTS LIMITED SIZER™ Assembly - Serial Number : S625-0085 Section 2 – Revision 1 SIZER™ Assembly, Page 2 of 3...
Page 8 2,538 (4 Tooth x 8 Ring) 145060084 Heavy Duty Tooth Cap & Fixings Assembly 23.6 111701004 Gear Coupling Assembly 247070435 MMD R200 30:1 Ratio Gearbox Assembly 1,758 146251966 Voith 487 TV Fluid Coupling Assembly 145040240 Wheel Carriage Assembly 1,757 146251983 Centralised Greasing Assembly 22.6...
Page 9 MMD MINING MACHINERY DEVELOPMENTS LIMITED MMD 625 SERIES TWIN SHAFT MINERAL SIZER PRINCIPLES OF OPERATION & MAINTENANCE SCHEDULE REVISION MODIFICATION DATE FIRST ISSUE 14-12-00 Section 3 – Revision 2.3 Operation & Maintenance, Page 1 of 23...
Page 10 Principles Of Operation The MMD Mineral SIZER™ accepts the product in through the top of the SIZER™, delivery being from any angle. The two rotating shafts have attached the appropriate sizing teeth which pass the total product, undersize and oversize, down through the SIZER™.
Page 11 Unless otherwise stated, MMD will not be responsible for the safe siting of the machine, and/or any requirements appertaining to operating codes of practice. MMD will not be responsible for the use or operation of the machine for any purpose other that the specified / accepted operation requirement in the official order.
Page 12 SIZER™ Start-Up Procedure Carry out the specified pre-start checks. The machine can now start. If the motor starts, but the shafts do not rotate, then the machine is either stalled, or a fusible plug has melted in one or both of the fluid couplings. Refer to the Stall Procedure.
Page 13 SIZER™ Stall Test After every operating stall, and after any major overhaul, the fluid coupling must be reset to give optimum performance. This is achieved by carrying out the following; Isolate the machine, by removing the cable from the electric motor. Use lockout procedures. Physically block the breaker shafts, so that they cannot rotate.
Page 14 When this has been done, the machine must be stopped at the first opportunity so that the work carried out. OBVIOUS DAMAGE – 99% of the obvious damage occurring on MMD machines inside the machine aperture is caused by tramp iron. Broken or cracked caps/segments and bolts are the most common form of obvious damage. A vis- ual inspection will determine the cause.
Page 15 Wear Plates - Replacing The MMD SIZER™ has wear plates on the inside of the machine aperture to protect the side plates and bearing housings. These wear plates must be replaced when excessive wear has been detected. Clearance of rotating teeth on the side wear plates should be a minimum of 10mm.
Page 16 Bolt the wear plate into position using the existing set screws. Remove the lifting eyes. Tighten the bolts to the torque rating specified in MMD procedure T056. (Included at the back of this manual). Section 3 – Revision 2.3 Operation & Maintenance, Page 8 of 23...
Page 17 SEALS - Check the condition of all lip seals. If there is any sign of damage, the seals must be replaced. As company policy MMD recommend that all seals be replaced if they are removed for any reason. SEAL SPACER - If there is any grooving on the outside diameter of this spacer, it must be replaced.
Page 18 SEALS - Check the condition of all lip seals. If there is any sign of damage, the seals must be replaced. As company policy MMD recommend that all seals be replaced if they are removed for any reason. SEAL SPACER - If there is any wear grooves on the outside diameter of this spacer, it must be replaced.
Page 19 Re-Assembly (Dowel Located Type) Should every item need replacing, the following procedure should be followed; Remove the old labyrinth from the breaker shaft using oxy-acetylene equipment to apply heat to the labyrinth to assist removal. Care must be taken to ensure that no damage is done to the shaft. Warm the labyrinth in an oil bath to 110 C.
Page 20 Breaker Shafts Move the SIZER™ into the maintenance position, if fitted onto wheels. Thoroughly clean the SIZER™ of all extraneous material, grease, oil, etc. Remove the end wearplates, and side combs (where fitted) from the machine. (See Heading ‘Wear Plates - Replacing’).
Page 21 Position the cap onto the breaker bar. Ensure that the cap is fitted in the correct orientation, as shown on the drawing. Bolt the cap to the breaker bar using new bolts. All bolts must be tightened in accordance with MMD procedure T056.
Page 22 Loosen the nut securing the adjusting screw to the backing plate. Using the adjusting screw, move the cleaning comb into the desired position. Re-tighten the nut, in accordance with MMD procedure T056. Infill Box Adjustment Where Infill boxes are fitted, the side combs mounted on the infill box can be adjusted, by adding or removing the packers.
Page 23 Adjustment is achieved by removing packers as follows; Remove the bolts securing the infill box to the side plate. Add or remove necessary packers to give desired cleaning comb clearance. If the infill box needs to be moved out- wards in order to fit additional packers, it is recommended that lifting equipment be attached to aid in this operation. Refit the existing bolts, (replace with new bolts if too short), which secure the infill box to the side plate.
Page 24 Fit the packers under the correct feet. Reference mark packs to their position. The foot bolts should then be added, and all bolts tightened to the amount specified in MMD procedure T056. Motor Removal (Foot & Flange Mounted Type): The motor can sometimes be removed on the cradle to allow fluid coupling removal.
Page 25 coupling housing. The motor can now be safely lifted out of position. Gearbox Replacement Removal: Remove the motor (See Heading ‘Motor Removal’) Remove the fluid coupling. (See Heading ‘Fluid Coupling Replacement’). Note, that if fitted Oil cooler modules must have their pipes disconnected. Note, that when fitted the Gearbox Temperature Monitoring System must be removed from the gearbox Remove the motor mounting bracket or coupling housing from the gearbox.
Page 26 Ensure ‘O’ rings are correctly seated on the coupling sleeve, and fit the two split clamping rings around the coupling. Tighten bolts in accordance with MMD procedure T056. Fill the gearbox with the correct lubricant to the designated level. (See Maintenance Schedule for Specification).
Page 27 Fit the Fluidrive coupling, in accordance with fluidrive’s installation and operating instructions. MMD Equipment Storage Instructions All MMD equipment is delivered in a stored condition, and is suitable to be stored inside or outside, in normal temperatures for a period of approximately 12 months.
Page 28 Voith Fluid Coupling Design Type: TVSC Coupling At Stand-Still Coupling At Start-Up Coupling Running VOITH DESIGN TYPE: Filler Plug TVSC Flexible Connecting Cpl’g Fusible Plug Outer Wheel Operating Fluid Coupling Shell Delayed Filling Chamber Inner Wheel Delay Chamber Coupling Hub ‘SC’...
Page 29 Operation Design Type: STC Coupling At Stand-Still Coupling Running FLUIDRIVE DESIGN TYPE: STC Adaptor Ball-Bearing Operating Fluid Impeller Casing Fusible Plug Impeller Ante-Chamber Runner Section 3 – Revision 2.3 Operation & Maintenance, Page 21 of 23...
Page 30 The quantity of grease for the bearings is specified in MMD procedure T0132 to each bearing each week. To check that the labyrinth seals are clear, and that the greasing system is functioning normally, grease will be visible at the labyrinths.If the bearing is fed by the autolube...
Page 31 Annual Maintenance; All bolts must be checked for tightness, and re-torqued to the amount specified in the procedure overleaf (MMD Proce- dure T056) if necessary. Where fitted, grease the wheel carriage units at their respective grease points.
Page 32 MMD MINING MACHINERY DEVELOPMENTS LIMITED CASE ASSEMBLY PART NUMBER - 346250424 REVISION MODIFICATION DATE FIRST ISSUE 14-12-00 Section 4 – Revision 1 Case Assembly, Page 1 of 25...
Page 33 MMD MINING MACHINERY DEVELOPMENTS LIMITED Case Assembly - Part Number : 346250424 Section 4 – Revision 1 Case Assembly, Page 2 of 25...
Page 34 MMD MINING MACHINERY DEVELOPMENTS LIMITED Case Assembly - Part Number : 346250424 Section 4 – Revision 1 Case Assembly, Page 3 of 25...
Page 35 MMD MINING MACHINERY DEVELOPMENTS LIMITED Case Assembly - Part Number : 346250424 Section 4 – Revision 1 Case Assembly, Page 4 of 25...
Page 36 MMD MINING MACHINERY DEVELOPMENTS LIMITED Case Assembly - Part Number : 346250424 ITEM PART DESCRIPTION UNIT MASS NUMBER 6251960-85 Side Plate 1,170 6251961-85 Side Plate 1,170 6251244-85 Gearbox Mounting Plate 6251958-06 Standard Bearing Housing 6251959-06 Narrow Bearing Housing 6250208-85 Top Cover Plate...
Page 37 MMD MINING MACHINERY DEVELOPMENTS LIMITED SIDE WEAR PLATE ASSEMBLY PART NUMBER - 146251942 REVISION MODIFICATION DATE FIRST ISSUE 14-12-00 Section 4 – Revision 1 Case Assembly, Page 6 of 25...
Page 38 Side Wear Plate Assembly - Part Number : 146251942 ITEM PART DESCRIPTION UNIT NUMBER 6251942-84 Side Wear Plate 6251070-01 Pyramid (Material - MMD 101) 20.5 TOTAL MASS:- 170.5 kg Section 4 – Revision 1 Case Assembly, Page 7 of 25...
Page 39 MMD MINING MACHINERY DEVELOPMENTS LIMITED SIDE WEAR PLATE ASSEMBLY PART NUMBER - 146251943 REVISION MODIFICATION DATE FIRST ISSUE 14-12-00 Section 4 – Revision 1 Case Assembly, Page 8 of 25...
Page 40 Side Wear Plate Assembly - Part Number : 146251943 ITEM PART DESCRIPTION UNIT MASS NUMBER 6251943-84 Side Wear Plate 6251070-01 Pyramid (Material - MMD 101) 20.5 TOTAL MASS:- 191 kg Section 4 – Revision 1 Case Assembly, Page 9 of 25...
Page 41 MMD MINING MACHINERY DEVELOPMENTS LIMITED LEFT HAND 4 TOOTH x 8 RING BREAKER SHAFT ASSEMBLY PART NUMBER - 246251956 REVISION MODIFICATION DATE FIRST ISSUE 14-12-00 Section 4 – Revision 1 Case Assembly, Page 10 of 25...
Page 42 MMD MINING MACHINERY DEVELOPMENTS LIMITED Left Hand Breaker Shaft Assembly - Part Number : 246251956 ITEM PART DESCRIPTION UNIT MASS NUMBER 146251370 4 Tooth x 8 Ring Heavy Duty Shaft Assembly 2,232 146251952 Fixed Bearing Assembly 146251953 Floating Bearing Assembly...
Page 43 MMD MINING MACHINERY DEVELOPMENTS LIMITED Left Hand Breaker Shaft Assembly - Part Number : 146251370 Section 4 – Revision 1 Case Assembly, Page 12 of 25...
Page 44 MMD MINING MACHINERY DEVELOPMENTS LIMITED Left Hand Breaker Shaft Assembly - Part Number : 146251370 ITEM PART DESCRIPTION UNIT MASS NUMBER 5010151-06 Breaker Shaft 6250204-01 Left Hand Screwed Collar 6250205-01 Right Hand Screwed Collar 5050132-06 4 Tooth Ring - Heavy Duty (0 Degrees)
Page 45 MMD MINING MACHINERY DEVELOPMENTS LIMITED Fixed Bearing Assembly - Part Number : 146251952 ITEM PART DESCRIPTION UNIT MASS NUMBER 6251954-06 Bearing Capsule 6251955-01 Retaining Plate 6251428-01 Labyrinth Spacer 6251358-01 Spacer 6251850-01 Spacer 035000057 Spherical Roller Bearing (24044 CC C3 W33) 30.5...
Page 46 MMD MINING MACHINERY DEVELOPMENTS LIMITED Floating Bearing Assembly - Part Number : 146251953 ITEM PART DESCRIPTION UNIT MASS NUMBER 6251954-06 Bearing Capsule 6251955-01 Retaining Plate 6251428-01 Labyrinth Spacer 6251358-01 Spacer 035000057 Spherical Roller Bearing (24044 CC C3 W33) 30.5 030516050 M16 x 50 Socket Cap Screw (Grade 12.9) 0.11...
Page 47 MMD MINING MACHINERY DEVELOPMENTS LIMITED RIGHT HAND 4 TOOTH x 8 RING BREAKER SHAFT ASSEMBLY PART NUMBER - 246251957 REVISION MODIFICATION DATE FIRST ISSUE 14-12-00 Section 4 – Revision 1 Case Assembly, Page 16 of 25...
Page 48 MMD MINING MACHINERY DEVELOPMENTS LIMITED Right Hand Breaker Shaft Assembly - Part Number : 246251957 ITEM PART DESCRIPTION UNIT MASS NUMBER 146251371 4 Tooth x 8 Ring Heavy Duty Shaft Assembly 2,232 146251952 Fixed Bearing Assembly 146251953 Floating Bearing Assembly...
Page 49 MMD MINING MACHINERY DEVELOPMENTS LIMITED Right Hand Breaker Shaft Assembly - Part Number : 146251371 Section 4 – Revision 1 Case Assembly, Page 18 of 25...
Page 50 MMD MINING MACHINERY DEVELOPMENTS LIMITED Right Hand Breaker Shaft Assembly - Part Number : 146251371 ITEM PART DESCRIPTION UNIT MASS NUMBER 5010151-06 Breaker Shaft 6250204-01 Left Hand Screwed Collar 6250205-01 Right Hand Screwed Collar 5050132-06 4 Tooth Ring - Heavy Duty (0 Degrees)
Page 51 MMD MINING MACHINERY DEVELOPMENTS LIMITED Fixed Bearing Assembly - Part Number : 146251952 ITEM PART DESCRIPTION UNIT MASS NUMBER 6251954-06 Bearing Capsule 6251955-01 Retaining Plate 6251428-01 Labyrinth Spacer 6251358-01 Spacer 6251850-01 Spacer 035000057 Spherical Roller Bearing (24044 CC C3 W33) 30.5...
Page 52 MMD MINING MACHINERY DEVELOPMENTS LIMITED Floating Bearing Assembly - Part Number : 146251953 ITEM PART DESCRIPTION UNIT MASS NUMBER 6251954-06 Bearing Capsule 6251955-01 Retaining Plate 6251428-01 Labyrinth Spacer 6251358-01 Spacer 035000057 Spherical Roller Bearing (24044 CC C3 W33) 30.5 030516050 M16 x 50 Socket Cap Screw (Grade 12.9) 0.11...
Page 53 MMD MINING MACHINERY DEVELOPMENTS LIMITED HEAVY DUTY TOOTH CAP & FIXINGS ASSEMBLY PART NUMBER - 145060084 REVISION MODIFICATION DATE FIRST ISSUE 14-12-00 Section 4 – Revision 1 Case Assembly, Page 22 of 25...
Page 54 Tooth Cap & Fixings Assembly - Part Number : 145060084 ITEM PART DESCRIPTION UNIT MASS NUMBER 5060084-84 Tooth Cap (Material MMD 501) 030536260 M36 x 260 Socket Capscrew 032736012 M36 Hex Nut 1xD Thick TOTAL MASS:- 23.6 kg Section 4 – Revision 1 Case Assembly, Page 23 of 25...
Page 55 MMD MINING MACHINERY DEVELOPMENTS LIMITED GEAR COUPLING ASSEMBLY PART NUMBER - 1117010084 REVISION MODIFICATION DATE FIRST ISSUE 14-12-00 Section 4 – Revision 1 Case Assembly, Page 24 of 25...
Page 56 MMD MINING MACHINERY DEVELOPMENTS LIMITED Gear Coupling Assembly - Part Number 111701004 ITEM PART DESCRIPTION UNIT MASS NUMBER 1701005-01 Coupling Hub 1701006-01 Coupling Hub 17.6 1701007-01 Coupling Sleeve 1701008-91 Split Clamp 032000784 ‘O’ Ring - RM3493-57 0.01 036000002 ¼” BSPT Pressure Plug 0.01...
Page 57 MMD MINING MACHINERY DEVELOPMENTS LIMITED VOITH 487TVG FLUID COUPLING ASSEMBLY PART NUMBER - 146251966 REVISION MODIFICATION DATE FIRST ISSUE 14-12-00 Section 6 – Revision 1 Fluid Coupling Assembly, Page 1 of 3...
Page 58 MMD MINING MACHINERY DEVELOPMENTS LIMITED Fluid Coupling Assembly - Part Number : 1416251966 Section 6 – Revision 1 Fluid Coupling Assembly, Page 2 of 3...
Page 59 MMD MINING MACHINERY DEVELOPMENTS LIMITED Fluid Coupling Assembly - Part Number : 146251966 ITEM PART DESCRIPTION UNIT MASS NUMBER 023300349 Voith 487 TVG (Anodised) c/w EEKE Boss (Osborn Supply) 6251967-85 Motor Mounting Frame 6251968-84 Cover Plate 8.25 1561828-01 Spigot Ring...
Page 60 MMD MINING MACHINERY DEVELOPMENTS LIMITED WHEEL CARRIAGE ASSEMBLY PART NUMBER - 145040240 REVISION MODIFICATION DATE FIRST ISSUE 14-12-00 Section 7 – Revision 1 Wheel Carriage Assembly, Page 1 of 3...
Page 61 MMD MINING MACHINERY DEVELOPMENTS LIMITED Wheel Carriage Assembly - Part Number : 145040240 Section 7 – Revision 1 Wheel Carriage Assembly, Page 2 of 3...
Page 62 MMD MINING MACHINERY DEVELOPMENTS LIMITED Wheel Carriage Assembly - Part Number : 145040240 ITEM PART DESCRIPTION UNIT MASS NUMBER 5040236-85 90 Degree Corner Carriage 5040237-85 90 Degree Corner Carriage 5040238-84 Trapping Bracket 5040239-85 Towing Eye 5040224-01 Wheel 5020060-01 Pin 15.4...
Page 63 MMD MINING MACHINERY DEVELOPMENTS LIMITED CENTRALISED GREASING ASSEMBLY PART NUMBER - 146251983 REVISION MODIFICATION DATE FIRST ISSUE 14-12-00 Section 8 – Revision 1 Centralised Greasing Assembly, Page 1 of 2...
Page 64 MMD MINING MACHINERY DEVELOPMENTS LIMITED Wheel Carriage Assembly - Part Number : 146251983 ITEM PART DESCRIPTION UNIT MASS NUMBER 0063654-01 Grease Pipe Joint Bracket 023060210 4 Way Distribution Block (ZP-A) 023307507 10mm O/D x 1.5mm Wall x 6MT Long Pipe 023307509 1/4”...
Page 65 MMD MINING MACHINERY DEVELOPMENTS LIMITED CARLO GAVAZZI 110 VOLT UNDERSPEED SENSING ASSEMBLY PART NUMBER - 143210000 REVISION MODIFICATION DATE FIRST ISSUE 14-12-00 Section 9 – Revision 1 Underspeed Sensing Assembly, Page 1 of 7...
Page 66 MMD MINING MACHINERY DEVELOPMENTS LIMITED Underspeed Sensing Assembly - Part Number : 143210000 ITEM PART DESCRIPTION UNIT MASS NUMBER Carlo Gavazzi Underspeed Sensing Assembly, 110 143210000 Volt, D.C, – – Comprising of:- 023210001 Sensor - Ref. DJ10G 0.35 023210002 Relay - Ref. S114156115 -100 RPM 023210004 Base - Ref.
Page 67 CARLO GAVAZZI SPEED SWITCH OPERATION & INSTALLATION INSTRUCTIONS The speed switch provided is a Carlo Gavazzi pulse continuity relay, part number S114 156 115. This multiple function control relay operates as a motor speed monitor. The relay receives a pulse from a Carlo Gavazzi proximity sensor, part number DJ10G to monitor motor speed.
Page 68 I. BASIC OPERATION This relay required 115 volts 50/60Hz control power connected to terminals 2 and 10. To connect the proximity sensor connect the brown (+) positive wire to terminal 6 and the blue (-) negative wire to terminal 7. Modes Of Operation: DIP-SWITCH #1 ON;...
Page 69 II. MOMENTARY START CIRCUIT OPERATION The speed switch relay contact (SSR) closes and the time period starts when the start push button is pressed, applying 115 volt control power to the relay (SSR). When an input pulse from the proximity sensor is received the relay continues operating for a full new time period starting at the next impulse.
Page 70 III. MAINTAINED RUN CIRCUIT OPERATION The speed switch relay contact (SSR) closes and the time period starts when the con- trol switch is in the run position, applying 115 volt control power to the relay (SSR). When and input pulse from the proximity sensor is received the relay continues oper- ating for a full new time period starting at the next input pulse.
Page 71 BASIC SPEED SENSOR CIRCUIT The speed switch provided is a Carlo Gavazzi pulse continuity relay, part number S114 166 724 (24 V), S114 156 115 (110 V), or S114 156 230 (220 V). This multiple function control relay operates as a motor speed monitor. The relay receives a pulse from a Carlo Gavazzi proximity sensor, part number DJ10G to monitor motor speed.