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MAYO 475 Operator's Manual

Surge hopper
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Surge Hopper
Operators Manual

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  • Page 1 Surge Hopper 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 MANUFACTURING, INC. SURGE HOPPER MODEL 475 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 7 SERIAL NUMBER LOCATION Always give your dealer the serial number of your Mayo Surge Hopper when ordering parts or requesting service or other information. The serial number plate is located where indicated. Please mark the number in the space provided for easy reference.

  • Page 9: Table Of Contents

    TABLE OF CONTENTS SECTION DESCRIPTION PAGE Introduction ............1 Safety ..............2 General Safety ............3 Equipment Safety Guidelines ........ 4 Storage Safety ............4 Safety Training ............5 Safety Signs ............5 Preparation ............6 Installation Safety ..........6 Lock-Out Tag-Out Safety........

  • Page 11: Introduction

    1 INTRODUCTION Congratulations on your choice of a Mayo Surge Hopper 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, unloading, processing and storing 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

    GENERAL SAFETY YOU are responsible for the SAFE operation and Read and understand the Oper- maintenance of your Mayo Surge Hopper. YOU must ator's Manual and all safety ensure that you and anyone else who is going to op- signs before supplying power...

  • Page 14: Equipment Safety Guidelines

    EQUIPMENT SAFETY GUIDELINES Safety of the operator and bystanders is one of 9. In addition to the design and configuration of this the main concerns in designing and developing a implement, including Safety Signs and Safety machine. However, every year many accidents oc- Equipment, hazard control and accident preven- cur which could have been avoided by a few sec- tion are dependent upon the awareness, concern,...

  • Page 15: Safety Training

    2.4 SAFETY TRAINING 2.5 SAFETY SIGNS Safety is a primary concern in the design and man- Keep safety signs clean and legible at all times. ufacture of our products. Unfortunately, our efforts to provide safe equipment can be wiped out by a 2.

  • Page 16: Preparation

    2.7 INSTALLATION SAFETY 2.6 PREPARATION Disconnect and remove all mechanical locks, an- Never operate the Surge Hopper and auxiliary chor chains and any other transport devices that equipment until you have read and complete- would hinder or prohibit the normal functioning of ly understand this manual, the auxiliary equip- the Surge Hopper upon start up.

  • Page 17: Operating Safety

    Keep others away. tenance work. 12. Keep the working area clean and dry. 13. Contact Mayo at (218) 773-1234 or 1 (800) 223- 5873 if you have any questions. 14. Review safety instructions annually.

  • Page 18: Hydraulic Safety

    (safety lockout devices are avail- safe condition. able through your Mayo dealer parts depart- ment), relieve hydraulic pressure and wait for 4. Wear proper hand and eye pro- all moving parts to stop before servicing, ad- tection when searching for a high justing, maintaining or repairing.

  • Page 19: Transport Safety

    2.14 TRANSPORT SAFETY Make certain that you are in compliance with local, 10. Wrap up and bind to the frame all loose hydraulic state/provincial and federal regulations regarding and electrical ends. transporting agricultural equipment on public road- ways. Install auxiliary light bar on rear of frame and 11.

  • Page 20: Employee Sign-Off Form

    Mayo Manufacturing, Inc. follows the general Safety Standards specified by the American Society of Agricultural and Biological 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 21: 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 22 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. • Think SAFETY! Work SAFELY! REMEMBER - If Safety Signs have been damaged, removed, become illegible or parts replaced without safety signs, new signs must be applied.
  • Page 23 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. • Think SAFETY! Work SAFELY! REMEMBER - If Safety Signs have been damaged, removed, become illegible or parts replaced without safety signs, new signs must be applied.
  • Page 24 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. • Think SAFETY! Work SAFELY! WARNING Install mechanical lock under boom before...
  • Page 25 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. • Think SAFETY! Work SAFELY! REMEMBER - If Safety Signs have been damaged, removed, become illegible or parts replaced without safety signs, new signs must be applied.
  • Page 26 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. • Think SAFETY! Work SAFELY! D-211 REMEMBER - If Safety Signs have been damaged, removed, become illegible or parts replaced without safety signs, new signs must be applied.
  • Page 27 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. • Think SAFETY! Work SAFELY! PINS AND CLIPS MUST BE IN PLACE BEFORE FILLING BIN OR SERIOUS INJURY MAY...
  • Page 28 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. • Think SAFETY! Work SAFELY! REMEMBER - If Safety Signs have been damaged, removed, become illegible or parts replaced without safety signs, new signs must be applied.

  • Page 29: Operation

    (safety lockout devices are available electrician. through your Mayo dealer parts department), re- lieve hydraulic pressure and wait for all moving • Before applying pressure to the hydraulic sys-...

  • Page 30: Machine Components

    4.2 MACHINE COMPONENTS The Mayo Manufacturing Surge Hopper consists of The hydraulic system pump is on the left side of the a receiving hopper, elevator, telescoping boom and frame and the reservoir is on the right. Hydraulic mo- large hopper/ unloading conveyor for accumulating tors power the variable speed discharge conveyor, potatoes in a conveying system.

  • Page 32: General Operation Theory

    4.3 GENERAL OPERATION THEORY Mayo Surge Hoppers are used to accumulate pota- toes in a conveying line and maintain an even flow of product to the next piece of equipment. Transport trucks place a large quantity of potatoes into the con- veying system in a very short time.

  • Page 33: Machine Break-In

    MACHINE BREAK-IN Although there are no operational restrictions on the Surge Hopper when used for the first time, it is rec- ommended that the following mechanical items be checked: A. Read Surge Hopper and auxiliary equipment manuals before starting. Before starting: 1.

  • Page 34: Pre-Operation Checklist

    Mayo Surge Hopper. The check- list should be performed before operating the Surge Hopper and prior to each operation thereafter.

  • Page 35: 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 36 2. Discharge Conveyor Controls: The controls for the discharge conveyor are mounted on the left side of the frame above the discharge. The pumps must be turned ON before the conveyor can be operated. a. Discharge Conveyor Hand/OFF/Auto: This 3 position rotary switch controls the dis- charge conveyor operating mode.
  • Page 37 3. Center Hydraulic Valves: a. Boom UP/DOWN: Replace with, “This 3 position solenoid op- erated valve with manual override lever con- trols the height of the boom. Operation of this valve is controlled either by the program, when the Control Switch is in the “ON” po- sition, or by the manual override levers with the Control Switch in the “Off”...
  • Page 38 5. Outrigger Position: A 3 valve bank of hydraulic valves is mounted on each side of the frame to raise and lower the out- riggers. Each lever corresponds to the outrigger on that side of the frame. a. Left lever - Left outrigger. b.
  • Page 39 8. Proximity Sensor: The Surge Hopper is designed with 2 proxim- ity sensors mounted to the end of the boom and senses the position of the pile of potatoes in the hopper. It is connected to the machine computer to keep the end of the boom close to the potatoes to minimize drop height and keep hopper full.
  • Page 40 11. Stinger Height: This 3 position spring-loaded-to-neutral-center hydraulic valve controls the height of the Stinger. Move the lever UP and hold to raise the Stinger and move DOWN and hold to lower it. Release the lever and it will return to its neutral position and the Stinger will stop moving.

  • Page 41: Machine Preparation

    MACHINE PREPARATION The machine must be properly prepared prior to use. Before starting the machine, be sure that the follow- ing items are appropriately set for your machine by following ANSI/NFPA 70 Wiring Standard. Power: If the machine will be used in a location with pow- er, have a qualified electrician install the wiring system to provide power at the required voltage, phase and amperage for your machine.

  • Page 42: Operating

    • Turn machine OFF, shut down and lock out pow- electrician. er supply (safety lockout devices are available through your Mayo dealer parts department), re- • Before applying pressure to the hydraulic sys- lieve hydraulic pressure and wait for all moving tem, make sure all components are tight and...
  • Page 43 5. Starting: a. Clear the area of bystanders. Know where ev- eryone is before starting. b. Place all controls in the OFF or neutral po- sition, including the remote controls (if so equipped). c. Turn the power to the machine ON at the mas- ter panel if connected to a hard wired power source.
  • Page 44 8. Surge Hopper Program Controls: The machine is designed with a program to control the position of the boom and keep the accumulat- ing hopper filled. Rotating the Control Switch to “ON” will allow the program to operate the boom position.
  • Page 45 9. Hitch: A solid hitch is attached to the rear of the frame. It is recommended that the hitch be removed when operating to prevent interference in the work area. FIG. 22 HITCH 10. Boom Sensors: The boom is equipped with 4 sensors evenly spaced along the left side of the frame to sense the boom position during operation.
  • Page 46 11. Viewing Ladder: A ladder to see inside the hopper compartment is provided to allow personnel to visually inspect the inside of the compartment. NOTE This is just a viewing ladder. Not an ac- cess or working ladder. Ladder Viewing FIG.
  • Page 47 12. Tractive Drive: Each machine is designed with power gears on the front wheels to move the unit short distances around the worksite. Depress the rods on the pow- er wheel cover to engage the driving gears. Pop the rods out to disengage power wheels if towing. a.
  • Page 48 13. Boom Extending: The boom can be extended manually by using the rear hydraulic valve closest to the main con- trol panel. Move the lever UP and hold to retract boom and DOWN and hold to extend. The Control Switch must be turned to the “OFF” position to operate the manual override levers for the extend / retract functions and the pumps turned ON be- fore the boom can be moved manually.
  • Page 49 14. Frame Jacks/Outriggers: Always support the machine on the frame jacks/ outriggers to provide the necessary stability dur- ing operation. 3 Jacks/outriggers are located on each side of the frame. All must be on the ground to support the frame and prevent overloading. IMPORTANT Be sure to level the machine fore/aft and left/right for proper loading of the accu-...

  • Page 50: Transport

    • Disengage front power gears if towing. Mayo Surge Hoppers are designed to be easily and conveniently moved from location to location. The machine can be towed by a tractor or other power unit in a yard or work site. Each machine is equipped with an integral drive system that is designed to move the unit short distances around the work site.
  • Page 51 6. Raise and stow all jacks/outriggers into their fully UP positions. Unplug and stow the power cord. FIG. 30 JACKS/OUTRIGGERS FULLY UP 8. Raise the boom support and rest the boom on it. Secure support with anchor pins. FIG. 31 BOOM SUPPORT 9.
  • Page 52 12. Connect wiring harness. 13. Install an SMV on the rear frame. 14. Use pilot vehicles and install auxiliary lights on the machine when transporting. 15. Clean all the reflectors. 16. Be sure all bystanders are clear of the machine. 17 .

  • Page 53: Storage

    4.10 STORAGE STORAGE SAFETY Inspect all the electrical cords, lines, junction boxes and motors. Tighten any loose connec- • Store the Surge Hopper on a firm level surface. tions. Replace any cord that is badly cut, nicked or abraded. Replace any damaged components. • If required, make sure the unit is firmly blocked 8. Inspect the conveyor drive systems. •...
  • Page 54 NSF-H1. • Turn machine OFF, shut down and lock out 2. Roller Chain Lubricating Oil: power supply (safety lockout devices are available through your Mayo dealer parts de- Chain Ambient Temperature Range partment), relieve hydraulic pressure and wait Type * 14°F-32°F...

  • Page 55: Service And Maintenance

    5.1.1.1 RECOMMENDED LUBRICANTS MAYO MFG. RECOMMENDS THE FOLLOWING MOBIL PRODUCTS OR THEIR EQUIVALENTS Recommended Recommended Lubricant Type Component Specification Temperature / Lubricant Service Interval ISO 32, All Temperatures/Oil Hydraulic Reservoir Mobil SHC Cibus 32 Synthetic Food DTE FM 32 sample guidance or 12 Grade, NSF-H1 months Hydraulic Oil ISO 32, 10F to 140F/Oil sample Hydraulic Reservoir Mobil DTE FM 32 Food Grade, NSF-H1 guidance or 12 months Greased Bearings/ Food Grade Mobilgrease FM 222 Points Grease All/Weekly or as needed Greased Bearings/ Non-Food Mobilgrease XHP 222 Points...
  • Page 56 5.1.3 SERVICING INTERVALS 8 Hours or Daily Check the conveyor tension. Adjust as required. Elevator Boom Stingers FIG. 35 CONVEYOR TENSION (TYPICAL)
  • Page 57 2. Check conveyor alignment. Adjust as required. Discharge Elevator Boom Stingers 3. Inspect hydraulic system and all components. FIG. 36 CONVEYOR ALIGNMENT 4. Inspect electrical system and all components.
  • Page 58 Weekly or 50 Hours Grease conveyor shaft bearings with 1 shot of grease. 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. Do not give bearing more than 1 shot of grease each time it is greased.
  • Page 59 d. Discharge drive and driven (2 locations each shaft). Drive Driven FIG. 39 DISCHARGE (TYPICAL) e. Elevator dogleg. Left Right FIG. 40 ELEVATOR DOG LEG (TYPICAL)
  • Page 60 2. Oil boom extend/retract roller chain. FIG. 41 ROLLER CHAIN 100 Hours or Annually Check the oil level in the hydraulic reservoir using sight glass. FIG. 42 HYDRAULIC OIL LEVEL SIGHT GLASS 2. Grease steering system plate. FIG. 43 STEERING SYSTEM PLATES...
  • Page 61 3. Check the oil level in each speed reducing gear box in the drive systems (1 location each gear box). Left Stinger Right Stinger Boom Discharge FIG. 44 GEARBOXES (TYPICAL)
  • Page 62 500 Hours or Annually: Change the hydraulic system filter (2 locations). 2. Change the oil in the hydraulic system. FIG. 45 HYDRAULIC SYSTEM FILTERS (TYPICAL) 3. Repack each wheel bearing. FIG. 37 WHEELS (TYPICAL) 4. Clean machine.
  • Page 63 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 CK Conveyor Tension CK Conveyor Alignment IN Hydraulic System and Components IN Electrical System and...

  • Page 64: 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 HYDRAULIC MAINTENANCE 5.2.2 ELECTRICAL SYSTEM INSPECTION A hydraulic system provides power to move the ma- Electricity provides power to all systems on the chine.
  • Page 65 5.2.3 ELECTRIC MOTOR RESTART A magnetic starting system is used on the Surge Hopper and the restart procedure is covered in this section. It is recommended that only a licensed elec- trician perform maintenance work on the electrical system. Magnetic Starter: All electric motors are supplied with power through an individual circuit that includes a circuit breaker, switch, contactor and overload relay that are all in-...
  • Page 66 5.2.4 CHANGING HYDRAULIC OIL & FILTERS Every 500 operating hours or annually, whichever comes first, the oil in the hydraulic system and filter should be changed. To change the oil and filter, follow this procedure: Run the hydraulic pump until the oil is warm. Warm freshly agitated oil removes more contaminants when drained than cold stagnate oil.
  • Page 67 5.2.5 SPEED REDUCER GEARBOX OIL Each conveyor is driven by an electric motor that is attached to a high ratio speed reducing gearbox to give the required operating speed. Each gearbox is equipped with a drain, level and fill plug. Every 100 hours, the oil level should be checked.
  • Page 68 5.2.6 CONVEYOR BELT TENSION /ALIGNMENT OR REPLACEMENT Rubber belts are used to convey material with the Surge Hopper. The tension and alignment of the conveyors should be checked daily to insure proper function. Replace the conveyor belt when damaged or badly worn. To maintain conveyor, follow this pro- cedure: Place all controls in their OFF or neutral position.
  • Page 69 4. Adjusting Conveyors: a. Elevator Elevator - Driven b. Boom Boom (Typical) c. Discharge Discharge d. Stingers Stinger (Typical) FIG. 51 TENSION ADJUSTMENT (TYPICAL)
  • Page 70 4. Alignment: It is properly aligned when the belt runs in the cen- ter of the frame panels and the shafts. Be sure to run the conveyor a full revolution to check the en- tire belt. The belt can move from side-to-side while it is turning as long as it doesn't contact the sides.
  • Page 71 5. Replacement: a. Move one or both of the shafts into their loos- est position. b. Open the conveyor by removing the connect- ing rod on the belt lacing. c. Attach the replacement conveyor to the end of the old conveyor. d.
  • Page 72 5.2.7 EXTENDING / RETRACTING ROLLER CHAIN An anchored roller chain is used to extend and retract the boom. The roller chain must be oiled on a weekly basis and the tension and alignment checked monthly during the season. When maintaining the roller chain, follow this procedure: Weekly oiling: a.
  • Page 73 3. Weekly roller chain tension: Check the tension when the machine is OFF and not moving. The chain should be snug when it is at rest. When checking spring tension, follow this procedure: a. Turn power OFF at the master panel and lock- out before performing any maintenance work.
  • Page 74 5.2.8 PROXIMITY SENSOR SETTINGS The boom is equipped with a series of proximity sen- sors mounted along the frame to identify the position of the boom during operation. There must be a 1/16" (2 mm) spacing (thickness of a nickle) between the sensor and frame.

  • Page 75: Trouble Shooting

    If you encounter a problem that is difficult to solve, even after having read through this trouble shooting section, please contact your local Mayo dealer or the factory. Before you call, please have this Operator’s Manual and the serial number from your machine ready.

  • Page 76: Specifications

    7 SPECIFICATIONS 7 .1 MECHANICAL DIMENSIONS Length: Surge Hopper only 52' 0" With hitch 57’ 4” Witch hitch and 67’ 4” stingers Width: 9’ 10” Height: 11’ 7” POWER Surge Hopper 480 V 3 Ph, 30 A 240 V 3 PH, 60 A Stinger (each) 480 V 3 PH, 5 A 240 V 3 PH, 10 A...

  • Page 77: Bolt Torque

    7 .2 BOLT TORQUE CHECKING BOLT TORQUE The tables 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 78: Hydraulic Fitting Torque

    7 .3 HYDRAULIC FITTING TORQUE TIGHTENING O-RING FITTINGS * Inspect O-ring and seat for dirt or obvious Tube Recommended Nut Size Torque defects. Size Turns To Tighten Across Value* (After Finger Flats 2. On angle fittings, back the lock nut off until Tightening) washer bottoms out at top of groove.

  • Page 79: Electrical Schematic

    7 .4 ELECTRICAL SCHEMATIC 7 .4.1 Line Phasing 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.

  • Page 80: Hydraulic Schematic

    7 .5 HYDRAULIC SCHEMATIC Accessory options can vary for each machine. Please contact factory at 1-800-233-5873 for your machine’s specific hydraulic layout.

  • Page 81: Index

    8 INDEX PAGE PAGE Introduction ............1 Safety 2 Battery Safety ..........9 Electrical Safety ........8 Employee Sign-Off Form ......10 Equipment Safety Guidelines ....4 Operation ............19 General Safety ..........3 Controls ...........23 Installation Safety ........6 General Operation Theory ......21 Hydraulic Safety ........8 Machine Break-In ........22 Lock-Out Tag-Out Safety ......6 Machine Components ......20 Maintenance Safety ........7...
  • Page 84 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: MAY 2024 PART NUMBER: 420-002...

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