MAYO 950 Operator's Manual

Hopper unloader

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HOPPER

UNLOADER

OPERATORS MANUAL

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Summary of Contents for MAYO 950

Page 1 HOPPER UNLOADER 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: Warranty Registration
MAYO MANUFACTURING, INC. MODEL 950 HOPPER UNLOADER 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
SERIAL NUMBER LOCATION Always give your dealer the serial number of your Mayo Scale Conveyor 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 ..............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 11: Introduction
INTRODUCTION Congratulations on your choice of a Mayo Model 950 Hopper Unloader 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 13: 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 14: General Safety
(Safety lockout devic- • Do not modify the equipment in any way. es are available through your Mayo dealer parts Unauthorized modification may impair the func- department). tion and/or safety and could affect the life of the equipment.
Page 15: 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, con-...
Page 16: Safety Training
SAFETY TRAINING 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 17: Preparation
PREPARATION INSTALLATION SAFETY Never operate the Hopper Unloader and auxilia- Disconnect and remove all mechanical locks, an- ry equipment until you have read and complete- chor chains and any other locking devices that ly understand this manual, the auxiliary equip- would hinder or prohibit the normal functioning of ment Operator's Manual, and each of the Safety the Hopper Unloader upon start up.
Page 18: Operating Safety
(safety lockout devices are available 2. Turn machine OFF, place all controls in their through your Mayo dealer parts department), OFF position, shut down and lock out power relieve hydraulic pressure and wait for all mov-...
Page 19: Hydraulic Safety
Such repairs power supply (safety lockout devices are avail- will fail suddenly and create a hazardous and un- able through your Mayo dealer parts depart- safe condition. ment), relieve hydraulic pressure and wait for all moving parts to stop before servicing, ad- 4.
Page 20: Tire Safety
2.13 TIRE SAFETY 2.14 TRANSPORT SAFETY Make certain that you are in compliance with local, Inflate tires to proper pressure as specified on the side wall of each tire. Do not overinflate or state/provincial and federal regulations regard- under-inflate. ing transporting agricultural equipment on public roadways.
Page 21: 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 oper- ating and/or maintaining a Mayo built machine must read and clearly understand ALL Safety, Operating and Maintenance information presented in this manual.
Page 23: 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 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! REMEMBER - If Safety Signs have been damaged, removed, become illegible or parts replaced without safety signs, new signs must be applied.
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! REMEMBER - If Safety Signs have been damaged, removed, become illegible or parts replaced without safety signs, new signs must be applied.
Page 29: Operation
• Keep all electrical components tight, dry and in position, shut down and lock out power supply good repair. (safety lockout devices are available through your Mayo dealer parts department), relieve hy- • Use the turnbuckles to set the height of the dis- draulic pressure and wait for all moving parts to charge before loading. stop before servicing, adjusting, maintaining or repairing.
Page 30: Machine Components
MACHINE COMPONENTS The Mayo Manufacturing Hopper Unloader is a belt- Manual turnbuckle jacks are used to set the height ed conveyor used to move potatoes. It is designed of the discharge to minimize drop height. Each front to telescope allowing the hopper to fit under a trans- wheel is driven by a hydraulic motor for moving and port truck discharge.
Page 31: General Operation Theory
GENERAL OPERATION THEORY Potatoes are loaded from transport trucks into the hopper of the unloader. From the hopper, they are carried by belted conveyor into the next conveyor. The top conveyor moves the potatoes onto the bot- tom conveyor which feeds into another conveyor, bin piler or directly into a processing plant for long term storage or processing.
Page 32: Machine Break-In
MACHINE BREAK-IN Although there are no operational restrictions on the Hopper Unloader when used for the first time, it is recommended that the following mechanical items be checked: A. Before Starting: 1. Read Unloader and auxiliary equipment man- uals before starting. 2.
Page 33: Pre-Operation Checklist
Performing the following pre- operation checklist is important for personal safety as well as for continued mechanical soundness and longevity of your new Mayo Unloader. The checklist should be performed before operating the Unloader and prior to each operation thereafter.
Page 34: 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 35 6. Turnbuckle Jacks: Turnbuckle jacks are mounted on each corner of the discharge frame. Use the pawl at the handle base to set the direction of rotation. Extend the turnbuckle to raise the discharge and retract it to lower. Always set the discharge height to reduce potato drop distance and minimize bruising.
Page 36: Operating
• Keep all electrical components tight, dry and in position, shut down and lock out power supply good repair. (safety lockout devices are available through your Mayo dealer parts department), relieve hy- • Use the turnbuckles to set the height of the dis- draulic pressure and wait for all moving parts to charge before loading. stop before servicing, adjusting, maintaining or repairing.
Page 37 3. Starting Hopper Unloader: a. Clear the area of bystanders. Know where ev- eryone is before starting. b. Place all controls in the OFF or neutral position. c. Turn the power to the machine and ON at the master panel. d.
Page 38 6. Equipment Positioning: Hopper Unloaders are positioned at the end of a conveying system to move potatoes from a hopper bottom transport truck. The Hopper Unloader input is designed to be low enough to fit under the truck with clearance for the potatoes to unload. Retract the frame when the Hopper Unloader is not being used.
Page 39 8. Moving: The machine is designed with powered front wheels for moving, turning and positioning the hop- per. Each wheel is equipped with a hydraulic mo- tor drive. Control valves direct the oil to move each wheel independently for or backward for moving or steering.
Page 40 10. Drop Height: Potatoes are sensitive to bruising during the gath- ering, transporting and handling phases of har- vesting. Bruising is kept to a minimum by maintain- ing a full flow of potatoes through each machine and minimizing all drop heights. Use the ratchet jacks on discharge end to set the drop height.
Page 41: Transport
Securely tie down and anchor frame to truck be- • Fully retract the frame. fore moving and transporting. Mayo Hopper Unloaders are designed to be easily and conveniently moved from location to location at the worksite. The action of moving is described in Section 4.7 Operation as part of operating machine.
Page 42: Storage
STORAGE STORAGE SAFETY • Store the Hopper Unloader on a firm level surface. • If required, make sure the unit is firmly blocked • Make certain that all mechanical locks are safely and positively connected before storing. • Store away from areas of human activity. • Do not allow children to play on or around the stored Hopper Unloader. • Lock out power by turning off master control panel or junction box and padlocking the door shut to prevent electrocution or unauthorized start up of the Hopper Unloader.
Page 43: Removing From Storage
8. Inspect all hydraulic hoses, lines, fittings and cyl- inders. Tighten any loose fittings. Replace any hose that is badly cut, nicked, abraded or sepa- rating from any fitting. Replace any damaged components. 9. Apply a light coat of oil to the roller chain to prevent rusting.
Page 45: Service And Maintenance
Turn machine OFF, shut down and lock out pow- er supply (safety lockout devices are available 2. Hydraulic Oil: through your Mayo dealer parts department), re- Use Mobil DTE FM32 Hydraulic Oil or equivalent. lieve hydraulic pressure and wait for all moving parts to stop before servicing, adjusting, main- Reservoir Capacity: 2 US gal (8.5 l).
Page 46: Servicing Intervals
5.1.2 GREASING Refer to Section 5.1.1 for recommended grease. Use the Maintenance Checklist provide to keep a record of all scheduled maintenance. Use only a hand-held grease gun for all greasing. Air powered greasing systems can damage the seals on bearings and lead to early bearing failure. 2.
Page 47 Weekly or 50 Hours Oil each side of frame extend/retract drive system roller chains and check the tension. Drive Driven FIG. 22 EXTEND/RETRACT ROLLER CHAINS 2. Oil each wheel drive roller chain. Right Left FIG. 23 WHEEL DRIVE ROLLER CHAINS...
Page 48 3. Grease top 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 49 5. Grease bottom conveyor shafts: a. Drive. b. Dog leg. c. Return. d. Tail. Drive - Left Side Drive - Right Side Tail - Right Side Return Tail - Left Side FIG. 26 BOTTOM CONVEYOR SHAFTS...
Page 50 6. Grease extend/retract frame drive cross shaft bearings. FIG. 27 CROSS SHAFT Check oil level in speed reducer gearboxes. Bottom FIG. 28 LEVEL PLUGS...
Page 51 100 Hours or Annually Grease the castor wheel spindle bushings. FIG. 29 SPINDLE BUSHINGS 2. Grease the ratchet jacks. Left Right FIG. 30 RATCHET JACKS...
Page 52 500 Hours or Annually Change the oil in the hydraulic system. FIG. 31 HYDRAULIC SYSTEM 2. Clean the breather plugs on each gearbox. Bottom FIG. 32 BREATHER PLUGS 3. Clean machine. FIG. 33 MACHINE...
Page 53: Service Record
5.1.4 SERVICE RECORD See Lubrication and Maintenance sections for details of service. Copy this page to continue record. ACTION CODE: CL CLEAN CK CHECK GREASE R REPACK CH CHANGE Maintenance Hours Serviced by 8 Hours or Daily Conveyor Tension and Alignment CK Hydraulic System CK Electrical System...
Page 54: 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 Hop- per Unloader. To maintain the integrity of each sys- tem and provide a safe working environment for the operator, it is important that a daily inspection be done to make sure that all systems and components...
Page 55 5.2.2 SPEED REDUCER GEARBOX OIL The Hopper Unloader is driven by electric motors attached to a high ratio speed reducing gearboxes to give the required operating speed. Each gearbox is equipped with a drain, level and fill plug. Every 50 hours, the oil level should be checked.
Page 56 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 57 5.2.4 CONVEYOR TENSION/ALIGNMENT OR REPLACEMENT Belts are used to move potatoes with the Hopper Un- loader. The tension and alignment of the Unloader should be checked daily to insure proper function. Replace the Unloader when damaged or badly worn. To maintain Unloader, follow this procedure: Place all controls in their OFF or neutral position.
Page 58 4. Tension Adjustment: Each conveyor belt runs on a drive and tail shaft. Each shaft end is supported on an adjustable bearing housing that is used to adjust tension and alignment. To adjust tension, follow this procedure: a. Loosen jam nuts on adjusting bolt. b.
Page 59 5. Conveyor Belt 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 Hopper Unloader a full revolution to check the entire belt. the belt can move from side-to-side while it is turning as long as it doesn't contact the sides.
Page 60 5.2.5 EXTEND/RETRACT DRIVE ROLLER SYSTEM: The frame extend/retract function on the Hopper Unloader is powered by a hydraulic motor through a roller chain and cross shaft drive system. The system should be oiled every week or 50 hours and tension and alignment checked.
Page 61 2. Weekly Roller Chain Tension: The roller chain drive system is equipped with an adjusting bolt on the end of each chain to maintain the required tension on the chain during opera- tion. Check the tension when the machine is OFF and not moving.
Page 62 5.2.6 WHEEL DRIVE ROLLER CHAIN The wheel drive on the Hopper Unloader is powered by hydraulic motors through a roller chain drive sys- tem. The system should be oiled every week or 50 hours and tension and alignment checked. When maintaining the roller chain drive system, fol- low this procedure: Weekly Oiling: a.
Page 63 2. Weekly Roller Chain Tension: The roller chain drive system is designed with a hydraulic motor on a moveable base to maintain the required tension on the chain during opera- tion. Check the tension when the machine is OFF and not moving. The chain should be snug to the sprockets when the machine is not running.
Page 65: Trouble Shooting
6 TROUBLE SHOOTING The Mayo Hopper Unloader uses a straight telescoping design to convey potatoes. 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 67: Specifications
Per c ustomer s pecification MAYO M FG. R ECOMMENDS T HE F OLLOWING M OBIL P RODUCTS O R T HEIR E QUIVALENTS Recommended Recommended Lubricant ...
Page 68: Checking Bolt Torque
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. Replace hardware with the same strength bolt. ENGLISH TORQUE SPECIFICATIONS Bolt Torque* Bolt...
Page 69: Electrical Schematic
7 .3 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 71: Index
8 INDEX PAGE PAGE Introduction ............1 Safety ............3 Electrical Safety ........9 Employee Sign-Off Form ......11 Equipment Safety Guidelines ....5 General Safety ..........4 Operation ............19 Hydraulic Safety ........9 Controls ...........24 Installation Safety ........7 General Operation Theory ......21 Lock-Out Tag-Out Safety ......7 Machine Break-In ........22 Maintenance Safety ........8 Machine Components ......20...
Page 74 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 2018 PART NUMBER: 950-001...