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MAYO 8000 Series Operator's Manual

Recirculating tank
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RECIRCULATING
TANK
OPERATORS MANUAL

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Summary of Contents for MAYO 8000 Series

  • Page 1 RECIRCULATING TANK OPERATORS MANUAL...
  • Page 3 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 5 MAYO RECIRCULATING TANK 8000 SERIES WARRANTY REGISTRATION FORM & INSPECTION REPORT WARRANTY REGISTRATION (please print) 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 7: Table Of Contents

    TABLE OF CONTENTS SECTION DESCRIPTION PAGE Introduction..............1 Safety ................2 General Safety ..............3 Installation Safety ............4 Operating Safety ............. 4 Maintenance Safety ............5 Electrical Safety ............... 5 Tire Safety ............... 5 Transport Safety .............. 6 Storage Safety ..............6 Safety Signs ..............

  • Page 8: Section Description Page

    SECTION DESCRIPTION PAGE Transport ..................24 4.10 Storage ................... 26 4.10.1 Placing In Storage ................26 4.10.2 Removing From Storage ..............26 Service and Maintenance ............27 Service ................... 27 5.1.1 Fluids and Lubricants ..............27 5.1.2 Greasing ..................27 5.1.3 Servicing Intervals ................
  • Page 9 SERIAL NUMBER LOCATION Always give your dealer the serial number of your Mayo Recirculating Tank when ordering parts or request- ing service or other information. The serial number plate is located where indicated. Please mark the number in the space provided for easy reference.

  • Page 11: Introduction

    INTRODUCTION Congratulations on your choice of a Mayo Model 8000 Series Recirculating Tank and welcome to Mayo’s quality line of potato handling equipment. This equipment is designed and manufactured to meet the needs of a discriminating buyer in the agricultural industry for the loading and processing of harvest yields.

  • Page 12: 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 13: General Safety

    1. Read and understand the YOU are responsible for the SAFE operation and Operator’s Manual and all safety maintenance of your Mayo Recirculating Tank. signs before supplying power, YOU must ensure that you and anyone else who is operating, maintaining or going to operate, maintain or work around the Tank adjusting Tank.

  • Page 14: Installation Safety

    (safety lockout devices are available through operate the machine while mechanical locking your Mayo dealer parts department), and wait for all devices are still attached. moving parts to stop before servicing, adjusting, maintaining or repairing.

  • Page 15: Maintenance Safety

    (safety lockout devices are available through OFF position before plugging the Recirculating Tank your Mayo dealer parts department), and wait for all moving parts to stop before servicing, adjusting, 4. Turn machine OFF, shut down and lock out power maintaining or repairing.

  • Page 16: Transport Safety

    2.7 TRANSPORT SAFETY 2.8 STORAGE SAFETY 1. Store the Recirculating Tank on a firm level surface. 1. Make certain that you are in compliance with local, state/provincial and federal regulations regarding 2. If required, make sure the unit is firmly blocked up. transporting agricultural equipment on public road- 3.

  • Page 17: Employee Sign-Off Form

    Mayo Manufacturing, Inc. follows the general Safety Standards specified by the American Society of Agricultural Engineers (ASAE) 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 19: Safety Sign Locations

    SAFETY SIGN LOCATIONS The types of safety signs and locations on the equipment are shown in the illustration below. Good safety requires that you familiarize yourself with the various safety signs, the type of warning and the area, or particular function related to that area, that requires your SAFETY AWARENESS. •...
  • Page 20 SAFETY SIGN LOCATIONS (cont’d) The types of safety signs and locations on the equipment are shown in the illustration below. Good safety requires that you familiarize yourself with the various safety signs, the type of warning and the area, or particular function related to that area, that requires your SAFETY AWARENESS.

  • Page 21: Operation

    4. Keep hands, feet, hair and clothing away from all moving parts. 4.1 TO THE NEW OPERATOR OR OWNER The Mayo Manufacturing Recirculating Tank is de- signed to remove dirt, trash and large particle contami- nants from wash water. Be familiar with the machine before starting.

  • Page 22: Machine Components

    4.2 MACHINE COMPONENTS The Mayo Manufacturing Recirculating Tank Clean or recycled water is pumped from above the sump back to the washer. An overflow outlet is on consists of a trash screen, tank, cyclone cleaners the side of the tank to prevent over-filling of the and pumps.

  • Page 23: General Operation Theory

    4.3 GENERAL OPERATION THEORY The Recirculating Tank is normally used in conjunc- tion with a Potato Washer and is used to remove contaminants from the wash water. After the trash and large contaminants are removed, the water is recycled and pumped back to the Washer for re- use.

  • Page 24: Machine Break-In

    A. Read Recirculating Tank, Washer and auxiliary personal safety as well as for continued mechanical equipment manuals before starting. soundness and longevity of your new Mayo Tank. The checklist should be performed before operating B. After operating for 1/2 hour: the machine and prior to each operation thereafter.

  • Page 25: Controls

    4.6 CONTROLS It is recommended that all operators review this section 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 labeled. 1.

  • Page 26: Water System Ball Valves

    Water System Ball Valves: a. Sump Valve: This ball valve controls the flow of water out of the tank sump and into the cyclone cleaners. Place the handle parallel to the line to open it and at right angles to close it or stop the flow.

  • Page 27: Cyclone System Back Pressure

    Recirculation Tri- Valve: This 3 direction ball valve directs the flow of water from the recircula tion pump. Move the handle to point in the direction of flow: i. Point toward the sump to direct the flow to the sump. ii.

  • Page 28: Machine Preparation

    4.7 MACHINE PREPARATION The machine must be properly prepared prior to using. Before starting machine, be sure that the following 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.

  • Page 29: Auxiliary Equipment

    4. Auxiliary Equipment: Each customer must provide a means to collect and hold the slurry being expelled by the cyclones and to remove the trash from the end of the trash conveyor. A barrel(s) or tank work well to collect the slurry. 2 to 5 gallons per minute of slurry can be expected.

  • Page 30: Operating

    2. Turn machine OFF, shut down and lock out power supply (safety lockout devices are 7. Before supplying electrical power to the available through your Mayo dealer parts machine, be sure that you have adequate department), and wait for all moving parts to...

  • Page 31: Stopping Machine

    5.Starting Recirculating Tank: Clear the area of bystanders. Know where everyone is before starting. Place all controls in the OFF or neutral position. Turn the power to the machine ON at the master panel. Turn the master power switch ON (Refer to Section 4.7 Controls).

  • Page 32: Start-Up

    8. Start-Up: At the beginning of each day, it is recom- mended that the recirculation pump be used to flush any sludge out of the sump. After the machine sits for a time (overnight or longer), contaminants can settle out of the water and collect in the sump.

  • Page 33: Dirt Removal

    11. Dirt Removal: Dirt and trash are removed from potatoes as they move through the Washer. They are conveyed to the Recirculating Tank on the flow of wash water for removal. Large particles and debris are removed by the trash conveyor on top of the tank.

  • Page 34: Operating Hints

    13. Operating Hints: Be sure that all workers and operators are supplied with and use the required safety gear. Keep the working area clean and as dry as possible to prevent slipping and tripping. Train all operators before starting. An untrained operator is not qualified to operate this machine and can expose himself and others to needless haz...

  • Page 35: Transport

    12. Always use hazard flashers on the towing vehicle when transporting. Mayo Recirculating Tanks are designed to be easily and conveniently moved from location to location. The term moving is used to describe the action of moving the machine within a storage facility.
  • Page 36 4.9 TRANSPORT (cont’d) 3. Install and secure the tow hitch if removed. 4. Use the ratchet to lower the wheel assembly and raise the frame off the ground. 5. Attach the tow hitch to the ball on the tractor and close the jaws. Be sure to use a mechanical retainer through the hitch.

  • Page 37: Storage

    4.10 STORAGE 7. Lubricate all grease fittings. Make sure all grease cavities have been filled with grease to remove any water residue from the washing. STORAGE SAFETY 8. Inspect all the water hoses, lines, fittings and 1. Store the Recirculating Tank on a firm level nozzles.

  • Page 39: Service And Maintenance

    SAE 40 SAE 40 power supply (safety lockout devices are * Stamped on chain link side plate available through your Mayo dealer parts department), and wait for all moving parts to stop before servicing, adjusting, 4. Storing Lubricants maintaining or repairing.

  • Page 40: Servicing Intervals

    5.1.3 SERVICING INTERVALS 8 Hours or Dally 1. Oil the trash conveyor drive system roller chain (1 location). WARNING ROTATING PART HAZARD KEEP AWAY Fig. 21 TRASH CONVEYOR DRIVE To prevent serious injury or death from rotating parts: 1. Keep all guards and shields in place. 2.
  • Page 41 Hours Weekly 1. Grease trash conveyor drive shaft bearings with 1 shot of grease (2 locations). IMPORTANT Only sealed bearings are used on the conveyor bearings. Sealed bearings should never be greased more often than weekly or every 50 hours. Do not over-grease.
  • Page 42 Weekly or 50 Hours (cont’d) 3. Check the roller chain tension and sprocket align- ment. Fig. 26 ROLLER CHAIN TENSION 200 Hours or Annually 1. Grease the ratchet jacks (2 locations each jack). Fig. 27 RATCHET JACK (TYPICAL)
  • Page 43 2. Grease the electric motor bear ings with 1 shot of grease (2 locations each motor). IMPORTANT Do not over-grease electric motors. Over-greasing can render the electric motor inoperative. Cyclone Pump Recirculation Pump Fig. 28 ELECTRIC MOTORS...
  • Page 44 200 Hours or Annually (cont’d) 3. Change the oil in the speed reducing gear box in the drive system (1 location). WARNING Machine is shown with guards opened for illustrative purposes only. Do not operate with guards opened. Fig. 29 GEAR BOX Breather Plug Oil Level Plug Drain Plug...
  • Page 45 200 Hours or Annually (cont’d) 4. Oil the roller chain in the pump input drive couplers (2 locations). Cyclone Pump Recirculation Pump Fig. 31 PUMP INPUT DRIVE COUPLER...
  • Page 46 200 Hours or Annually (cont’d) 5. Clean the gearbox breather plug (1 plug). Fig. 32 BREATHER PLUG 6. Repack each wheel bearing. Fig. 33 WHEELS (TYPICAL)

  • Page 47: Service Record

    5.1.4 SERVICE RECORD See Lubrication and Maintenance sections for details of service. Copy this page for continuous record. ACTION CODE: √ CHECK CHANGE CLEAN REPACK L LUBRICATE REMOVE INSPECT HOURS SERVICED MAINTENANCE 8 HOURS OR DAILY L Trash Conv Dr. Sys Roller Chain √...

  • Page 48: 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 ELECTRICAL SYSTEM INSPECTION Electricity provides power to all systems on the Recirculating Tank. To maintain the integrity of each system and provide a safe working environ ment for the operator, it is important that a daily inspection be done to make sure that all systems...
  • Page 49 5.2.2 ELECTRIC MOTOR RESTART It is recommended that only a licensed electrician perform maintenance work on the electrical system. All electric motors are supplied with power through an individual circuit that includes a circuit breaker, switch, contactor and overload relay that are all incorporated into a single electrical component inside the control panel.
  • Page 50 5.2.3 SPEED REDUCER GEARBOX OIL The trash conveyor is driven by an electric motor that is attached to a high ratio speed reducing gearbox to give the required operating speed. The gearbox is equipped with a drain, level and fill plug. Every 50 hours, the oil level should be checked.
  • Page 51 5.2.4 BREATHER CLEANING The gearbox is equipped with a breather in the fill plug that vents the internal pressure to atmos- phere. As the gearbox temperature increases and decreases during the operating and stopped modes, the pressure in the gearbox will increase or decrease if it is not vented to atmosphere.
  • Page 52 5.2.5 TRASH CONVEYOR CHAIN TENSION/ALIGNMENT OR REPLACEMENT A drag chain is used on the trash conveyor. The tension and alignment of the conveyor should be checked daily to insure proper function. Replace the conveyor chain when damaged or badly worn. To maintain conveyor, follow this procedure: 1.
  • Page 53 5.2.6 ROLLER CHAIN DRIVES The trash conveyor is driven by a roller chain system with sprockets and an idler or a tightening system. The roller chain must be oiled on a daily basis and the tension and alignment checked weekly during the season. When maintaining the roller chain, follow this procedure: 1.
  • Page 54 5.2.6 ROLLER CHAIN DRIVES (cont’d) 3. Weekly Roller Chain Tension: Each roller chain drive system is equipped with an idler sprocket to maintain the required tension on the chain during operation. Check the idler when the machine is OFF and not moving. The chain should be snug when the machine is at rest.

  • Page 55: Trouble Shooting

    TROUBLE SHOOTING The Mayo Recirculating Tank uses a flow of water through cyclones to remove the dirt in solution. It is a simple and reliable system that requires minimum maintenance. In the following section, we have listed many of the problems, causes and solutions to the problems that you may encounter.

  • Page 56: Specifications

    SPECIFICATIONS 7.1 MECHANICAL DIMENSIONS Length: 9'5" Width: 8'9-1/2" Height: Wheels Retracted: 7'6" Wheels Extended: 8'2" POWER Type: 1 ph, 230v, 63a 3 ph, 23Ov, 40.3a Conveyor: 1-1/2 HP Cyclone Pump: 7-1/2 HP Recirculation Pump: 5 HP WATER SYSTEM Total Volume: 710 Gallons TIRES Size:...

  • Page 57: Bolt Torque

    BOLT TORQUE The tables shown below give correct torque values for various bolts and cap screws. Tighten all bolts to the torques specified in chart unless otherwise noted. Check tightness of bolts periodically, using bolt torque chart as a guide. Replace hardware with the same strength bolt. ENGLISH TORQUE SPECIFICATIONS Bolt Bolt Torque...

  • Page 58: Electrical Schematic

    ELECTRICAL SCHEMATIC...

  • Page 89: Index

    INDEX PAGE PAGE Introduction ..............1 Safety ..............2 General Safety ..........3 Installation Safety ..........4 Operation ..............10 Maintenance Safety ........5 Controls ..............14 Operating Safety ..........4 Cyclone Pump STOP/START ......14 Electrical Safety ..........5 Cyclone System Back Pressure ......
  • Page 92 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: JANUARY 2010 PART NUMBER: 810-001...

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