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MAYO 850 Operating Manual

Brush washer
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BRUSH WASHER
OPERATING MANUAL

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  • Page 1 BRUSH WASHER OPERATING 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 850 BED STYLE GRADING TABLE 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.

  • Page 7: Serial Number Location

    SERIAL NUMBER LOCATION Always give your dealer the serial number of your Mayo Bed Style Brush Washer 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 850 Bed Style Brush Washer and welcome to Mayo's quality line of potato handling equipment. This equipment is designed and manufactured to meet the needs of a dis- criminating 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

    YOU are responsible for the SAFE operation and Operator's Manual and all safe- maintenance of your Mayo Bed Style Brush Washer. ty signs before supplying power YOU must ensure that you and anyone else who is to, operating, maintaining or ad- going to operate, maintain or work around the Brush justing the Brush Washer.

  • 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 Bed Style Brush Washer and Disconnect and remove all mechanical locks, auxiliary equipment until you have read and anchor chains and any other transport devices completely understand this manual, the auxiliary that would hinder or prohibit the normal function- equipment Operator's Manual, and each of the ing of the Bed Style Brush Washer upon start up.

  • Page 18: Operating Safety

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

  • Page 19: Electrical Safety

    OFF position before plugging the Brush Washer 4. 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, ad- justing, maintaining or repairing.

  • Page 20: Employee Sign-Off Form

    Mayo Manufacturing, Inc. follows the general Safety Standards specified by the American Society of Agricultural Engineers (ASABE) and the Occupational Safety and Health Administration (OSHA). Anyone who will be op- erating 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! REMEMBER - If Safety Signs have been damaged, removed, become illegible or parts replaced without safety signs, new signs must be applied.

  • Page 25: Operation

    TO THE NEW OPERATOR OR OWNER Follow all safety instructions exactly. Safety is The Mayo Manufacturing Bed Style Brush Washer is everyone's business. By following recommended designed to be used as a stand-alone unit or part procedures, a safe working environment is pro-...

  • Page 26: Machine Components

    MACHINE COMPONENTS The Mayo Bed Style Brush Washer is designed to The water flows over the potatoes and into a collec- wash potatoes in a potato processing plant. It can be tion pan in the bottom of the frame where it can be installed as a stand alone unit or as part of a potato cleaned/filtered and re-used.

  • Page 27: General Operation Theory

    GENERAL OPERATION THEORY Bed Style Brush Washers are designed to roll pota- toes as they move through the wash bed while noz- zles spray water over them. Each side of the potato is turned toward the nozzles as it moves through the machine for cleaning.

  • Page 28: Machine Break-In

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

  • Page 29: Pre-Operation Checklist

    Mayo Brush Washer. The checklist should be performed before operating the Brush Washer and prior to each operation there- after.

  • Page 30: Machine Preparation

    MACHINE PREPARATION The machine must be properly prepared prior to us- ing. Before starting machine, be sure that the follow- ing items are appropriate for your machine and oper- ating requirements: 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 31 4. Access: It is the responsibility of the customer to provide access for personnel to reach the Brush Washer when operating or servicing. Always plan and po- sition the machine for access to all sides of the Brush Washer. Drive Side Wall Spacing FIG.

  • Page 32: Operating

    • Turn machine OFF, shut down and lock out power supply (safety lockout devices are • Keep all electrical components tight, dry and in available through your Mayo dealer parts good repair. department) and wait for all moving parts to stop before servicing, adjusting, maintaining • Before supplying electrical power to the ma- or repairing.
  • Page 33 3. Starting Brush Washer: 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 ON at the mas- ter panel. d.
  • Page 34 6. Equipment Position: Each customer must provide a means of supply- ing a steady flow of potatoes to the Brush Washer. Normally this is done by using another piece of equipment such as a grader, another Brush Washer or washers. When the Brush Washer is used as a component in a conveying system, it is recommended that it be securely attached to the adjacent piece of equipment.
  • Page 35 8. Water Shut-Off Valve: It is recommended that Shut-Off valve to be place in the line bringing water to the machine. Open and close valve as required when operating the Brush Washer. Intake Water Discharge FIG. 13 SHUT-OFF VALVE 9. Auxiliary Equipment: Generally conveyors are used to bring potatoes to and take them away from the Brush Washer.
  • Page 36 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. Bruising during the conveying phase can be minimized by keeping the drop height between each piece of conveying equipment as small as possible.
  • Page 37 12. Operating Hints: a. Be sure that all workers and operators are sup- plied with and use the required safety gear. b. Keep the working area clean and dry to pre- vent slipping and tripping. c. Train all operators before starting. An un- trained operator is not qualified to operate this machine and can expose himself and others to needless hazards.

  • Page 38: Storage

    STORAGE 10. Check the oil level in the gearbox. Top up as required. STORAGE SAFETY 11. Touch up all paint nicks and scratches to prevent rusting. • Store the Brush Washer on a firm level surface. 12. Select a storage area that is dry, level and free of •...

  • Page 39: Service And Maintenance

    • Turn machine OFF, shut down and lock out pow- er supply (safety lockout devices are available through your Mayo dealer parts department), re- lieve hydraulic pressure and wait for all moving parts to stop before servicing, adjusting, main- taining or repairing. •...

  • Page 40: Servicing Intervals

    5.1.3 SERVICING INTERVALS 8 Hours or Daily Check the spray pattern of each nozzle. Clean if any nozzle has a distorted spray pattern. Nozzle Washing FIG. 20 NOzzLE INSPECTION (TYPICAL) 2. Inspect the brushes. Remove any entangled material. FIG. 21 BRUSHES 3.
  • Page 41 150 Hours or Monthly Check the tension of the input drive roller chain (3 locations). FIG. 23 INPUT DRIVE ROLLER CHAIN 2. Check the tension and clearance of the brush roll- er sprocket/chain drive system. Move plastic slid- er closer to chain if chain is slipping a tooth on a sprocket.
  • Page 42 4. Grease Bed Style Brush Washer shaft bearings with one shot of grease (2 locations each shaft). IMPORTANT Only sealed bearings are used on the Brush Washer shaft. 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 43 Annually Clean machine. FIG. 27 MACHINE Bi- Annually or Every Two Years Check the oil level in the speed reducing gearbox in the drive system (1 location). a. Level Plug b. Fill Plug c. Drain Plug FIG. 28 GEARBOXES (TYPICAL) 2.
  • Page 44 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 Nozzle Spray Pattern IN Brushes IN Electrical System 150 Hours or Monthly CK Nozzle Spray Pattern...

  • Page 45: 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 Brush Washer. To maintain the integrity of each system 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 are in good...
  • Page 46 5.2.2 SPEED REDUCER GEARBOX OIL The Brush Washer 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 150 hours, the oil level should be checked.
  • Page 47 5.2.3 BREATHER CLEANING The 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 48 5.2.4 DRIVE CHAIN TENSION/ALIGNMENT OR REPLACEMENT Roller chains are used to transmit rotational power from the gearboxes to the brush rollers under the nozzles. The roller chains and sprockets must be kept in good condition and at the correct tension and alignment to obtain the expected life.
  • Page 49 6. Replacement: a. Remove the Snap Idle to place the chain into its loosest position. b. Remove the connecting clips and side plates on the chain link. c. Remove the old chain. d. Thread the replacement chain around the sprockets. e.
  • Page 50 5.2.5 CHAIN/SPROCKET CLEARANCE 3 electric motors through a gearbox and roller chain drive provides rotational power to 3 brush rollers un- der the nozzles. The 3 rollers turned y the primary drives convey the rotational power across the frame to the other side. On the other side, a roller chain meshing with sprockets turns the adjacent rollers.
  • Page 51 Check the tension of the roller chain annually. 8. Remove a link to shorten the chain when re- quired. Link FIG. 38 CHAIN TENSION...

  • Page 53: Trouble Shooting

    6 TROUBLE SHOOTING The Mayo Brush Washer uses turning rolls to present all sides of potatoes to graders to remove debris and damaged potatoes. In the following section, we have listed many of the problems, causes and solutions to the problems that you may encounter.

  • Page 55: Specifications

    SPECIFICATIONS 7 .1 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 56: Checking Bolt Torque

    BOLT TORQUE CHECKING BOLT TORQUE The Brush Washers 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 57: 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 58: 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 ............15 Installation Safety ........7 General Operation Theory ......17 Lock-Out Tag-Out Safety ......7 Machine Break-In ........18 Maintenance Safety ........8 Machine Components ......16 Operating Safety ........8 Machine Preparation .......20...
  • Page 60 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: DECEMBER 2018 PART NUMBER: 901-001...

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