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MAYO 750 Operator's Manual

Belted screen sizer
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BELTED
SCREEN SIZER
Model 750
OPERATOR'S MANUAL

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  • Page 1 BELTED SCREEN SIZER Model 750 OPERATOR'S MANUAL...
  • Page 2 This warranty does not apply to any machine that has been altered outside the factory in any way so as, in the judgement of Mayo, to affect its operation, reliability or safety, or which has been subject to misuse, neglect or accident.
  • Page 3 MAYO MANUFACTURING, INC. MODEL 750 BELTED SCREEN SIZER WARRANTY REGISTRATION FORM & INSPECTION REPORT WARRANTY REGISTRATION This form must be filled out by the dealer and signed by both the dealer and the customer at the time of delivery. Customer’s Name ____________________________...
  • Page 4 SERIAL NUMBER LOCATION Always give your dealer the serial number of your Mayo Belted Screen Sizer when ordering parts or re- questing service or other information. The serial number plate is located where indicated. Please mark the number in the space provided for easy reference.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION DESCRIPTION PAGE Introduction ............1 Safety ..............3 General Safety ............4 Equipment Safety Guidelines ........ 5 Storage Safety ............5 Safety Training ............6 Safety Signs ............6 Preparation ............7 Installation Safety ..........7 Lock-Out Tag-Out Safety ........
  • Page 6 TABLE OF CONTENTS SECTION DESCRIPTION PAGE Service and Maintenance ......... 38 Service ..............38 5.1.4 Service Record ............ 49 Maintenance ............50 5.2.1 Electrical System Inspection ....... 50 5.2.2 Speed Reducer Gearbox Oil ....... 51 5.2.3 Breather Cleaning ..........52 5.2.4 Drive Chain Maintenance ........

  • Page 7: Introduction

    Safe, efficient and trouble free operation of your new Mayo Screen Sizer requires that you, and anyone else who will be operating or maintaining the Screen Sizer, read, understand and practice ALL of the Safety, Operation, Maintenance and Troubleshooting recommendations contained within this Operator's Manual.

  • Page 9: Safety

    If you have any questions not answered in this manual or require additional copies or the manual is damaged, please contact your dealer or Mayo, P.O. Box 497, Bus Highway 2, East Grand Forks, Minnesota, 56721. (Telephone) 218-773-1234, (FAX) 218-773-6693 or toll free at 1-800-223-5873.

  • Page 10: General Safety

    1. Read understand YOU are responsible for the SAFE operation and Operator's Manual and all maintenance of your Mayo Belted Screen Sizer. YOU safety signs before supplying must ensure that you and anyone else who is going power to, operating, maintain-...

  • Page 11: Equipment Safety Guidelines

    EQUIPMENT SAFETY GUIDELINES 1. Safety of the operator and bystanders is one of 8. Do not modify the equipment in any way. the main concerns in designing and developing Unauthorized modification result in serious injury a machine. However, every year many accidents or death and may impair the function and life of occur which could have been avoided by a few the equipment.

  • Page 12: Safety Training

    SAFETY TRAINING SAFETY SIGNS 1. Safety is a primary concern in the design and 1. Keep safety signs clean and legible at all times. manufacture of our products. Unfortunately, our efforts to provide safe equipment can be wiped 2. Replace safety signs that are missing or have be- out by a single careless act of an operator or come illegible.

  • Page 13: Preparation

    PREPARATION INSTALLATION SAFETY 1. Never operate the Belted Screen Sizer and aux- 1. Disconnect and remove all mechanical locks, an- iliary equipment until you have read and com- chor chains and any other transport devices that pletely understand this manual, the auxiliary would hinder or prohibit the normal functioning equipment Operator's Manual, and each of the of the Belted Screen Sizer upon start up.

  • Page 14: Operating Safety

    (safety lockout devices are avail- 2. Turn machine OFF, shut down and lock out able through your Mayo dealer parts depart- ment), relieve hydraulic pressure and wait for power supply (safety lockout devices are avail-...

  • Page 15: Transport Safety

    4. Turn machine OFF, shut down and lock out fer to specification chart in Section 7.2). power supply (safety lockout devices are avail- able through your Mayo dealer parts depart- 4. Raise elevator fully up before transporting to pre- ment), relieve hydraulic pressure and wait for...

  • Page 16: Employee Sign-Off Form

    2.13 EMPLOYEE SIGN-OFF FORM Mayo Manufacturing, Inc. follows the general Safety Standards specified by the American Society of Agricul- tural Engineers (ASABE) and the Occupational Safety and Health Administration (OSHA). Anyone who will be operating and/or maintaining a Mayo built machine must read and clearly understand ALL Safety, Operating and Maintenance information presented in this manual.

  • Page 17: Safety Sign Locations

    SAFETY SIGN LOCATIONS The types of safety signs and locations on the equipment are shown in the illustrations that follow. Good safety requires that you familiarize yourself with the various Safety Signs, the type of warning and the area, or particu- lar function related to that area, that requires your SAFETY AWARENESS.
  • Page 18 The types of safety signs and locations on the equipment are shown in the illustrations that follow. Good safety requires that you familiarize yourself with the various Safety Signs, the type of warning and the area, or particu- lar function related to that area, that requires your SAFETY AWARENESS. •...
  • Page 19 The types of safety signs and locations on the equipment are shown in the illustrations that follow. Good safety requires that you familiarize yourself with the various Safety Signs, the type of warning and the area, or particu- lar function related to that area, that requires your SAFETY AWARENESS. •...
  • Page 20 The types of safety signs and locations on the equipment are shown in the illustrations that follow. Good safety requires that you familiarize yourself with the various Safety Signs, the type of warning and the area, or particu- lar function related to that area, that requires your SAFETY AWARENESS. •...
  • Page 21 D D A A C C C C C C C C C C C C...

  • Page 23: Operation

    TO THE NEW OPERATOR OR OWNER The Mayo Manufacturing Belted Screen Sizer is de- Follow all safety instructions exactly. Safety is signed to be used as a stand-alone unit or part of everyone's business. By following recommended...

  • Page 24: Machine Components

    MACHINE COMPONENTS The Mayo Belted Screen Sizer is a flat rubber belt with specifically sized holes for sizing potatoes as they pass over it. Generally, the sizer is a part of a potato storage or processing facility. It is used when customers want potatoes of a specific size range with all the over-sized and under-sized removed.
  • Page 25 DRAW INGS SPECIFICATIONS ARE THE PROPERTY Duane N. 8/12/2020 Mayo Manufacturing, Inc. OF MAYO MANUFAC TURING, INC. P.O. Box 4 97, Bus. Hwy 2 CH ECKE D AND SHALL NOT BE REPRODUC ED, East Grand Forks, MN 5 6721 DISTRIBUTED, DISCLOSED OR USED Dave D.

  • Page 26: General Operation Theory

    GENERAL OPERATION THEORY Belted Screen Sizers are designed to be part of a potato conveying line and separate potatoes by size. Belts are designed with holes of a specific size that will allow smaller and correct sized potatoes to drop through the belt sizing hole but retain the larger ones.

  • Page 27: Machine Break-In

    MACHINE BREAK-IN Although there are no operational restrictions on the Belted Screen Sizer when used for the first time, it is recommended that the following mechanical items be checked: A. Before Starting: 1. Read Screen Sizer and auxiliary equipment manuals before starting. 2.

  • Page 28: Pre-Operation Checklist

    Mayo Screen Sizer. The checklist should be performed before op- erating the Screen Sizer and prior to each operation thereafter.

  • Page 29: Controls

    CONTROLS It is recommended that all operators review this sec- tion of the manual to familiarize themselves with the location and function of all machine controls before starting. Some machines may vary slightly due to custom features but they are similar and all controls are labelled.
  • Page 30 Shaker A Off/On: This 2 position selector switch controls the power to the Shaker A motors when the HAND (manual) operating mode is se- lected. Turn CCW (counterclockwise) to turn the shakers off. Turn CW (clockwise) to turn the shakers ON. Shaker A Speed Control: This 270°...
  • Page 31 Emergency STOP (Control Panel): This red two-position push-pull switch controls the power to the machine. Push the switch in to cut power and turn all functions off. Turn the switch 1/4 turn clockwise and the switch will pop out. Either this switch or the frame mounted emergency stop switch will cut the power to the machine but both must be pulled out for the machine to operate.

  • Page 32: Machine Preparation

    MACHINE PREPARATION The machine must be properly prepared prior to us- ing. Before starting machine, be sure that the fol- lowing items are appropriate for your machine and operating requirements: 1. Power: Have a licensed electrician provide power at the required voltage, phase and amperage for your machine by following ANSI/NFPA 70 Wiring Standard.
  • Page 33 3. Controls: Controls for the Screen Sizer are generally part of the system controls and are in the control room. Review and train all personnel in the use of con- trols for stopping, starting or how to stop in any emergency.

  • Page 34: Operating

    Turn machine OFF, shut down and lock out sition before connecting power supply. power supply (safety lockout devices are available through your Mayo dealer parts • Keep all electrical components tight, dry and in department) and wait for all moving parts to good repair.
  • Page 35 3. Starting Screen Sizer: a. Clear the area of bystanders. Know where everyone is before starting. b. Place all controls in the OFF or neutral position. c. Turn the power to the machine ON at the master panel. d. Release both the emergency stop switches. e.
  • Page 36 6. Equipment Position: Each customer must provide a means of supply- ing a steady flow of potatoes to the Screen Sizer. Normally this is done by using another piece of equipment such as a grader, a conveyor or wash- ers. In addition, customers must provide a means to remove small, large and good sized potatoes from the machine.
  • Page 37 Duane N. 8/12/2020 Mayo Manufacturing, Inc. SPECIFICATIONS ARE THE PROPERTY P.O. Box 4 97, Bus. Hwy 2 OF MAYO MANUFAC TURING, INC. AND SHALL NOT BE REPRODUC ED, CH ECKE D East Grand Forks, MN 5 6721 DISTRIBUTED, DISCLOSED OR USED Dave D.
  • Page 38 9. Drop Height: Potatoes are sensitive to bruising during the gathering, transporting and handling phases of harvesting. Bruising is kept to a minimum by maintaining a full flow of potatoes through each machine and minimizing all drop heights. Bruising during the conveying phase can be minimized by keeping the drop height between each piece of conveying equipment as small as possible.

  • Page 39: Transport

    Always use pilot vehicles in front and behind when towing on a public road. Mayo Screen Sizers are designed to be moved from location to location. The term moving is used to de- scribe the action of moving the machine within the working area.
  • Page 40 4. Disconnect and remove all auxiliary equipment / conveyors: a. System bringing potatoes to machine. FIG. 22 SYSTEM b. Systems that remove potatoes from machine. 5. Attach tow unit to hitch using a hardened pin and retainers. Attach safety chain. FIG.
  • Page 41 6. Raise the outriggers. Three outriggers on each side of the frame. 7. Install an SMV on the rear frame if towing with a tractor on a public road. 8. Use pilot vehicles and install extra lights on the machine when transporting. 9.

  • Page 42: Storage

    4.10 STORAGE STORAGE SAFETY • Store the Screen Sizer on a firm level surface. 8. Check the oil level in the gearboxes. Top up as required. • If required, make sure the unit is firmly blocked 9. Touch up all paint nicks and scratches to prevent rusting.

  • Page 44: Service And Maintenance

    • Turn machine OFF, shut down and lock out power supply (safety lockout devices are avail- able through your Mayo dealer parts depart- ment), relieve hydraulic pressure and wait for all moving parts to stop before servicing, adjust- ing, maintaining or repairing.
  • Page 45 5.1.3 SERVICING INTERVALS 8 Hours or Daily 1. Inspect the sizing belt. Remove any entangled material. FIG. 26 SIZING BELT (TYPICAL) 2. Inspect electrical system and all components. Left Side Right Side FIG. 27 ELECTRICAL (TYPICAL)
  • Page 46 150 Hours or Monthly 1. Check the tension of the roller chain drives. Elevator Sizers (Typical) FIG. 28 ROLLER CHAIN DRIVES 2. Check the sizing belt drive roller alignment and wrapping. Adjust if required. Alignment Rollers FIG. 29 BELT DRIVE SYSTEM...
  • Page 47 3. Check oil level in gearboxes. Cross Shaker Inline Sizer Belt (Typical) FIG. 30 LEVEL PLUG (TYPICAL)
  • Page 48 4. Check cross conveyor tension and alignment. FIG. 31 CROSS CONVEYOR 5. Check tension and alignment of elevator conveyor. FIG. 32 ELEVATOR 6. Check tension and alignment of inline conveyors. FIG. 33 INLINE CONVEYOR...
  • Page 49 Annually 1. Grease elevator shaft bearings with one shot of grease (2 locations each shaft). IMPORTANT Only sealed bearings are used on the Screen Sizer shafts. Do not over-grease. Do not give bearing more than one shot of grease each time it is greased. Once the bearing seal is broken, the bearing must be greased each day or the bear- ing will fail.
  • Page 50 3. Grease shaker shaft bearings with 1 shot of grease: a. Drive. Drive b. Driven. Driven FIG. 36 SHAKER SHAFT (TYPICAL) 4. Grease inline conveyor shaft bearings with 1 shot of grease: a. Drive. Drive b. Driven. Driven FIG. 37 INLINE CONVEYOR (TYPICAL)
  • Page 51 5. Grease sizer shaft bearings with 1 shot of grease: a. Drive. Drive b. Center. Center c. Bottom - Front. Bottom - Front d. Bottom - Rear. Bottom - Rear FIG. 38 SIZER SHAFTS (TYPICAL)
  • Page 52 6. Grease both elevator turnbuckles with 2 shots of grease. FIG. 39 TURNBUCKLES (TYPICAL) 7. Clean machine. FIG. 40 MACHINE...
  • Page 53 Bi-Annually or Every Two Years 1. Change the oil in the speed reducing gearboxes in the drive systems. Inline Shaker Sizer Cross FIG. 41 GEARBOXES (TYPICAL)
  • Page 54 7. Clean the gearbox breather. Inline / Cross Belt Drives Shakers FIG. 42 BREATHERS (TYPICAL)

  • Page 55: Service Record

    5.1.4 SERVICE RECORD See Lubrication and Maintenance sections for details of service. Copy this page to continue record. ACTION CODE: CHECK CHANGE CLEAN LUBRICATE REPACK INSPECT Maintenance Hours Serviced by 8 Hours or Daily IN Sizing Belt IN Electrical System 150 Hours or Monthly CK Input Drive Roller Chain CK Sizing Belt Drive Roller...

  • Page 56: Maintenance

    5.2 MAINTENANCE By following a careful service and maintenance pro- gram on your machine, you will enjoy many years of trouble-free use. 5.2.1 ELECTRIC SYSTEM INSPECTION Electricity provides power to all systems on the Belted Screen Sizer. To maintain the integrity of each system and provide a safe working environment for the op- erator, it is important that a daily inspection be done to make sure that all systems and components are...

  • Page 57: Speed Reducer Gearbox Oil

    5.2.2 SPEED REDUCER GEARBOX OIL The Screen Sizer is driven by electric motors that are attached to high ratio speed reducing gearboxes to give the required operating speed. The gearbox is equipped with a drain, level and fill plug. Every 150 hours, the oil level should be checked.

  • Page 58: Breather Cleaning

    5.2.3 BREATHER CLEANING Each gearbox is equipped with a breather in the fill plug that vents the internal pressure to atmosphere. As the gearbox temperature increases and decreas- es during the operating and stopped modes, the pressure in the gearbox will increase or decrease if it is not vented to atmosphere.

  • Page 59: Drive Chain Maintenance

    5.2.4 DRIVE CHAIN TENSION/ALIGNMENT OR REPLACEMENT A roller chain is used to transmit rotational power from the gearboxes to the sizing belt. The roller chain and sprockets must be kept in good condition and at the correct tension and alignment to obtain the expected life.

  • Page 60: Sizing Belt Maintenance

    5.2.5 SIZING BELT TENSION/ALIGNMENT OR REPLACEMENT A rubber belt with specifically sized holes is used to size potatoes with the machine. The tension and alignment should be checked daily to insure proper function. Replace the belt when damaged or badly worn.
  • Page 61 5. Replacement: a. Move all shafts into their loosest position. b. Open the belt by removing the connecting rod. c. Attach the replacement belt to the end of the old belt. d. Slowly pull the old belt out of the machine and thread the new one into position.

  • Page 62: Elevator Belt Maintenance

    5.2.6 ELEVATOR BELT TENSION/ALIGNMENT OR REPLACEMENT A cleated flat conveyor belt is used to convey po- tatoes up the elevator. The tension and alignment of the conveyor should be checked daily to insure proper function. To maintain elevator conveyor, fol- low this procedure: 1.

  • Page 63: Cross Conveyor Maintenance

    5.2.7 CROSS CONVEYOR TENSION/ALIGNMENT OR REPLACEMENT Flat belts are used as cross conveyors to remove small and good potatoes from the machine. The tension and alignment of the conveyor should be checked daily to insure proper function. To maintain the cross conveyors, follow this procedure: 1.

  • Page 64: Inline Conveyor Maintenance

    5.2.8 INLINE CONVEYOR BELT TENSION/ALIGNMENT OR REPLACEMENT Flat belts are used to convey potatoes from under the sizing belt to the cross conveyor for removal from machine. Both sizer belts are equipped with an inline conveyor to remove product that went through holes.

  • Page 65: Trouble Shooting

    6 TROUBLE SHOOTING The Mayo Belted Screen Sizer is designed as a large, flat rubber belt with holes in it set to remove any over and undersized potatoes from the flow. In the following section, we have listed many of the problems, causes and solutions to the problems that you may encounter.

  • Page 67: Specifications

    SPECIFICATIONS MECHANICAL Please contact factory at 1-218-773-1234 or 1-800-223-5873 for your machines particular specifications. SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE...

  • Page 68: Bolt Torque

    7 .2 BOLT TORQUE CHECKING BOLT TORQUE The Screen Sizers shown below give correct torque values for various bolts and capscrews. Tighten all bolts to the torques specified in chart unless otherwise noted. Check tightness of bolts periodically, using bolt torque chart as a guide.

  • Page 69: Electrical Schematic

    ELECTRICAL SCHEMATIC Line phasing, line voltage, control voltage, and accessory options can vary substantially for each machine. Please contact factory at 1-800-223-5873 for your machine's specific electrical layout. SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE...

  • Page 70: Index

    8 INDEX PAGE PAGE Introduction .............1 Safety ............3 Electrical Safety ........9 Employee Sign-Off Form ......10 Equipment Safety Guidelines ....5 General Safety ..........4 Operation ............17 Installation Safety ........7 General Operation Theory .......20 Lock-Out Tag-Out Safety ......7 Machine Break-In ........21 Maintenance Safety ........8 Machine Components ......18 Operating Safety ........8 Machine Preparation .......26...
  • Page 71 MAYO MANUFACTURING CO. BUS HIGHWAY 2 BOX 497 EAST GRAND FORKS, MN 56721 PHONE (218) 773-1234 TOLL FREE (800) 223-5873 FAX (218) 773-6693 PRINTED IN USA ISSUE DATE: OCTOBER 2020 PART NUMBER: 750-001...

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