l

SCHENCK PROCESS (TIAN JIN ) INDUSTRIAL TECHNO L OGY CO . L TO

3.1 MAINTENANCE OF VIBRA TING SCREENS

3 1.1 Please rea d the relevant section s of both the lnstallation and the Mainten2n:-2
Volum e of th is ma nu al prior to co mm encin g maintenance work. as íT' ucr
in fo rmati on relating to in sta ll ation or removal of compon ents is coveíed in the
lnsta ll ati on Vo lume .

3.1 2 WARNING : Repair or clean equipment only after isolation of electrical supply
to the screen drive and material feed system . Never climb on operating
screens .

3 1.3 V ibrating eq ui pme nt operates undE: ;- thc most ardu ous cond ition s. working in
m ateria l that- is often highly abrasive and/or corrosive they perform in excess of
one m ill ion stress cycles per day. lt is vitally importa nt that any defect ar damage
is rectifi ed promptly. A minar problem, if ignared , may rapidly develap inta a
majar structural failure .

3.1.4 A general daily inspection of the screen and a systematic majo r inspection every
200 hours operation will result in lower maintenance costs. less lost production
and more profitable operation .

3.1.5 The Exciter oíl leve! must be checked every 200 hours of o peration and the oli
changed every 1000 hours of operation in accordance w ith Section 3.2.

3.1.6 As a general guide, all bolts must be checked for tightness eve ry 1000 hours of
operation . For sorne deck construction more frequent checking may be requ ired
and Users should undertake more frequent checks until pattern is estab lished

3.1.7 Bolts and self-locking nuts are in general for a single use on ly Discard old
• fasteners after removal and replace with a new self-locking nut and bolt and insta ll
a hardened washer under the item that w1II be rotated to tighten the co nnection .

3.1.8 Bolts fitted into tapped hales must be secured using "Loctite·· 24 2 or eq uivalent.

3.1.g The vibrated structure and ali connected moveable parts (springs. drive shafts etc)
must be able to move freely . No part of the screen should kn oc k on stationary
parts (for example . chutes , platforms) nor work in accumulated feed material.

3.1.1o lnspect the screen deck often and remove adherent material at on ce . Repa ir or
replacement of worn deck panels or loose deck panels sh ould be carried ou t
befare total failure occurs to prevent damage to other screen componen ts or down
stream equipment

File: J \Job 01 85 San Canos Ma nu al 0 185 SLO246 1 SCREcN MANUAL - REV 1 doc Page 59 of , 1
r ~,s docurr•ent s conñd er.tJai and It Is made available as a conñaent1al d1sclosure on tre undersianding tliat 1t shall not De shOwn !,· a,s,-~$$t>J " :~ ,"
rr~c.~'11 ,r. ec to th rd partIes or used fer other purposes w1ihout the wnnen a~proval of Scne 0 ck P0 ocess Ch ina
 schend< ;:,ro-:es ,: 4$t
SCHENCK PROCESS (TIANJIN) INDUSTRIAL TECHNOLOGY CO. LTO

3 .1.11 Replace broken springs Immediately Springs normally have a long life and ,
unless mistreated or material build -up in the coils is allowed to occur, the failure of
one spring may indicate that the entire set of springs is reaching the service limit.
lt is recommended that if one spnng fails then ali springs at that point of support
are re placed .

3 .1.12 Check vee-belt condition and tension every 200 hours operation

3 .1.13 Vibrating screens must never be operated with any of the conditions specified in
the maintenance checklist, Section 3.4: RAPID FAILURE WILL OCCUR As site
conditions vary significantly it is not possible to put a rigid schedule on these
checks . Users should take the above times as a guide, conducting more
frequent inspections until a pattern is established.

3 .1.14 lnspect the side plate (inside and below deck) , crossbeams, deck support rails (
and cleats at every deck change . These components are exposed in the course
of replacing the deck. In any case inspect the deck support rails and cleats at
least every three months .

3 .1.15 Remove any loase sealant from around the cleats inspect for signs of corrosion in
the connections . lf corrosion is evident the connection must be dismantled , the
corrosion removed , the surfaces coated with 25 microns DFT of structural primer,
reassembled with new fasteners and then resealed . Clean the region around the
cleat using Sika Cleaner 205 wiping in one direction only and reseal using Sikaflex
- 260 or Sikaflex - 255 urethane rubber sealant.

\_

File: J \Job 0 185 San Carlos Manual 0185 SLO2461 SCREEN MANUAL - REV 1 doc
Page 60 of 71
Th,s document ,s confident1al and it ,s made ava,lable as a confident1a1 d1sclosure on the understand,ng that ,t shall not oe shOwn to, dlscussed w,tn , or
1ransm,ned to, th1rd part,es, or used for other purposes w,thout tne wnnen approval of Scnenck Process Cn,na
 sche nck.;_Jr':·(E-S:- es- SCHENCK PROCESS (TIANJIN) INDUSTRIAL TECHNOLOGY CO . L TO

3.2 LUBRICATION OF EXCITERS

Exciters are supplied WJTHOUT oil , add oil before use Schenck exciters utilise
3.2.1
oil splash lubrication with interna\ oil flingers , felt oil seals and an externa\ labynnth
that is initially grease packed . New exciters will shed grease from the
labyrinths. This is nota fau\t. The Labyrinth does not require regreasing .

3 .2.2 Exciters are treated with corrosion preventative agent befare del1very Refer
Section 1.2.

3.2 .3 Oil fill plugs are at the top of the housing , the lowest of these is used for d1pst1ck
measurement of the oil leve\ (Refer Figure 3.2 1). Clean the a rea around the plug
befare removing the plug .
t)
3.2.4 The required quantity of oil depends on the installation angle of the Exc1ter (Refer
Figure 3.2.1) and the quantity indicated in Table 3 .2 .2 is a nominal value for
9rdering purposes only .

3 2.5 Final oil leve\ as specified in Table 3 2.2 shall be determined by use of the d ipstick
included in Schenck supply . The Dipstick must be removed from Exciter after
checking oil leve\. Ensure that the oil fill plug replaced .

3.2.6 The viscosity grade and oil type required depends on the actual service
temperature of the Exciter and the recommended viscosity grade and oil type 1s
_listed in Table 3.2.3. The ambient temperature l1sted Is a guide only for the m1t1al
selection of the oil prior to commissioning Final 011 select1on shall be made on the
basis of the measured operating temperature

., 3.2.7 Change oil after the first 50 hours of operat1on and every 1000 hours thereafter (or
at least every 3 months) Schenck recommend an 011 condit1on -monitonng
programme to establish the optimum oil change period for local site cond1t1ons

3.2.8 lf the 011 is very dirty and /or the Exciter is operat1ng at h1gh operat1ng temperature ,
reduce the time between 011 changes and 1mplement an 011 cond1t1on monitoring
programme to establish the optimum oil change penad for local site conditions , a
better grade of oil may be requIred

3.2 9
When chang ing the oil it Is best to drain the 011 from Exciters immed1ately after
shut down and isolation wh1le the 011 1s still hot This maximise the benefit of fresh
011 by removing old oil befare any sed1mentation occurs

File:
J \J ob 0185 Sa n Carl os Man ual 0 185 SLO246 1 SCREEN MANUAL - REV 1 dac

Th1s Oocument 1s conficent1at and 1t 1s made ava1iab1e as a canfident1 at di~rIno, ,._ -

PaopF;1 ,...,., . .
transm1tted lo , third part1es . ar used fa r other puroa~P• ,., •· ·
 schenckprocess -S- SCHENCK PROCESS (TIANJIN) INDUSTRIAL TECHNO LOGY CO. LTO

3.2.1O Frequent oil changes and prem1um quality oil 1ncrease the serv,ce l1fe of the
Exciter.

3.2.11 Replace used sea! washers on dra1n and f1II plugs at the first s1gn of wear they are
much cheaper than new exciters .

3.2.12 Schenck exciters as supplied do not requ1re breathers the add1t1on of a bre ather
is detrimental and voids Schenck warranty

File· J \J00 0185 San Carlos Manual 01 85 SLO2461 SCREEN MANUAL REV1 doc
 1
SCHENCK PROCESS (TIANJIN) INDUSTRIAL TECHNOLOGY CO . LTO

AMBIENT OPERATING
TEMPERATURE
BP MOBIL SHELL
TEMPERATURE
OIL TYPE MINERAL MINERAL MINERAL
ENERGOL MOBIL D, T TELLUS OIL
-30 TO -1 OºC O TO +20ºC HLP 10 E 21 10

VISCOSITY AT 40 ºC IN cSt 11 .0 10.9 10

ENERGOL MOBILGEAR OMALA OIL
-15 TO +20 ºC +15 TO +50ºC GR - XP 68 626 68

VISCOSITY AT 40 ºC IN cSt 68 .0 64 68
ENERGOL MOBILGEAR OMALA OIL
+15 TO +35 ºC +45 TO +65 ºC GR - XP 100 627 100

VISCOSITY AT 40 ºC IN cSt 98 .0
(
99 .0 100
ENERGOL MOBILGEAR OMALA OIL
+40 TO +60 ºC +60 TO +85 ºC GR -XP 220 629 220

VISCOSITY AT 40 ºC IN cSt 220 220 220

OIL TYPE SYNTHETIC SYNTHETIC SYNTHETIC
ENERGOL MOBILGEAR TIVELA OIL
+30 TO +70 ºC +60 TO +100 ºC SG -XP 220 SHC 630 WB

VISCOSITY AT 40 ºC IN cSt 220 220 138

COMPATIBLE WITH MINERAL OIL NO YES NO

TABLE 3.2.2 - OIL TYPE AND VISCOSITY CHART

AMBIENT OPERATING BP MOBIL SHELL

TEMPERATURE TEMPERATURE

ENERGREASE MOBILGREASE ALVANIA

-10TO+30°C +20 TO +60 ºC LS-EP 2 HP EP 2

ENERGREASE MOBILGREASE ALVANIA

+30 TO +70°C +60 TO + 100ºC LS-EP 2 HP EP 2

CONSULT CONSULT CONSULT

+70 TO +90 ºC +100 TO +130°C SCHENCK SCHENCK SCHENCK

TABLE 3.2.3 - GREASE TYPE CHART

F j le : J \Job 0185 San Carlos Manual 0185 SLO2461 SCREEN MANUAL - REV1 doc
Page 64 of 71
- -M Crl ont ,c, I rl ,srlns i, rP. nn the understandrng t~_
a t rt shall not be shown lo , drscussed wrth . or
 schenck. " JCf .:;s ~
SCHENCK PROCESS (TIANJIN) INDUSTRIAL TECHNOLOGY CO. LTO

3.3 200 HOUR INSPECTION

The followtng checklist ,s tntended to be copied and used in routine inspections ro fo rm a recoro of rhe screen condition
at tha t time. We recommend that they are used asan a,d to conditJon monitoring and mamtenance plannmg.

200 HOUR INSPECTION CHECK LIST Da te Checked By

Exciter / Condition Comments

A: 8 :
1 C:
1. Check exc, ter while running far any ind1cation of oil
leakage from the exciter.
DO NOT REMOVE GUAROS 1
NOTE Labyrinths w ill shed grease when exci ter is
new DO NOT regrease Labynnths . They are
replenished by oil from the seals.
2 Check exci ter wh ile runn ing for possible no ise

'9 3 Using non-contacting thermometer, check exci ter for

exce ssive operating temperature.
NOTE : 1 hour running time is requ ired to reach
operating temperature which will vary with ambien t
tem p

Orive And Orive Shafts

1. Check Motor Mountings far any ind ication of
looseness
2. Check Motor Bearings far poss ible noise or excessive
operatinq temperature .
3. Check guards are in good condition
4. Check Lay Shaft Bearings far noise or excessive
operating temperature (30 ºC above ambient is
acce ptable )
5 Check Vee Belts visually far possible breakage or
loss of ten.s ion

Screen Body
1. W ith screen running , check pattern of material flow
Sed must be evenlv distributed over ful! width deck.
2. With screen runn ing , listen far possible loase bolts or

t> parts Stop screen prior to replacing any loose bolts

or parts to avoid possible personal injury
3 Check cond ition of screen decks & liners from outside
the screen .
4. Check far material leakage over the side and back of
the screen , indicates possible chute blocka qe
5. Check far poss ible interference between screen body
and stationary hoppers , chutes , and bu ild ing beams
due to material build up or insufficient operating
clearance .

Supports .
1. Check springs far material bu1ld -up around spn ng
coils , clean out ,f necessary only after stopp ing &
1so latin g drive and feed system .
2 Check springs far ind ication of breakage particularly if
compress ion is unequal each side of screen .
CONDITION A IMMEDIATE ACTION REQUIRED - CONTACT SUPERVISOR
LEGEND B: A TTENTION REQUIRED A T NEXT SCHEDULE O SHUTDOW N - RAISE WORK ORD ER
c SERVICEABLE CONDITION - NO ACTION REQUIRED
 schenckprocess .S, SCHENCK PROCESS (TIANJIN) INDUSTRIAL TECHNOLOGY CO . L TO

3.4 1000 HOUR INSPECTION

· · · · t· · t· t I o"d of the screen condition
The fol!owing checklist 1s rn te nded to be cop1ed and used rn rou me mspecw~s o ,orm a _rec , .
at that time. We re commend that they are used asan aíd to condltJOn monltonng and mamtenance p!annmg.

1000 HOUR INSPECTION Date Checked By

CHECK LIST page 1 of 2
Condition Comments
Exciter A: 8:
C:
1. Check oil level in exciter using dipstick. Remove
dipstick after, replace seal washer & plug .
Oil leve! should be checked prior to start up of screen ,
or in case of continuous operation , screen should be
stopped a sufficient length of time to allow all oil to
drain to bottor:n of mechan ism housing . Change oil after
1000 hours of service .
2. Check for any ind ication of oil leakage from the exciter.
NOTE Labyrinths will shed grease when exciter is new
Do NOT regrease Labyrinths . They are replenished
by oil from the seals .
.3. Check oil in housing for indication of contam ination . lf
present, drain and refill with correct amount new oil.
Mon itor oil. Get oil analysis to determine sourc~ of
contam i nation .
4. Check for possible loose mechanism bolts .
5. Check mechan ism wh ile running for possible no ise.
6 Check mechan ism for poss ible excessive operating
temperature. (30 ºC above ambient is normal)
NOTE:1 hour running time is required to reach
operating temperature which will vary with ambient
tem p.
Orive And Orive Shafts
1. Check Motor Mountings for any indication of looseness.
2. Check Motor Bearings for possible noise or excessive
operatin q tem pe rature
3.

4
Check Orive & lntermed iate Shaft rubber couplings for
possible crackinq at least eve ry 6 months
Check Orive & lntermediate Shaft spline for poss ible
"
~

free plav & re plenish qrease at least eve rv 6months

5. Check guards are in good condition & free from cracks
6. Check Lay shaft Bearing lubrication replen ish with
grease everv 6 months refer Table 3.2.3.
CONDITION A: IMMEDIATE ACTION REQUIRED - CONTACT SUPERVISOR
LEGEND : B: ATTENTION REQUIRED AT NEXT SCHEDULED SHUTDOWN - RAISE WORK ORDER
c SERVICEABLE CONDITION - NO ACTION REQUIRED
 .
schen,;:1<: ::)Tocess -S.
SCHENCK PROCESS (TIANJIN) INDUSTR
IAL TECHNOLOGY CO . LTD

The following checklist is intended to be copied and used in routine inspectio t r,

O
at that time. We recommend that they are used asan aid to condition m •t ns orm a _reco rd of the screen condition
on, onng and ma,ntenance planning.

1000 HOUR INSPECTION

Da te Checked By
CHECK LIST page 2 or 2
Screen Body Condition Comments
A: B:
C:
1. W ith screen runn ing , check pattern of material flow
over decks & liners . Bed should be evenly distributed
over full width of the screen
2. W ith screen runn ing , check for loase bolts or parts .
Stop screen prior to replacing any loase bolts or parts

•
to avo id poss ible personal inj l! ry
3. Check side plates and exciter beam -& cross beams for
poss ible crackinq
4. Check for poss ible interference between screén body
and stationary hoppers , chutes , and bu ild in g beams
due to material bu ild up or insufficient operating
clearance .
5 Check screen lihers for bu ild up of material. Remove
if present
6. Check screen liners for wear or breakage Check hol d
down bolts.
7 Check screen liner bolts for poss ible looseness , or
breaka ge
8. Check externa! pa int for damage and signs of erosion /
corros ion - schedule routine re pair
Supports
1. Check springs for material bu ild -up around spring
coils , clean ouf- if necessary .
2. Check springs for equal compress ion each side of
screen
3. Check springs for indication of breakage particularly if
compression is unequal each side of screen .
4. Check spring mounting for excessive wear.

CONDITION A: IMMEDIATE ACTION REQUIRED - CONTACT SUPERVISOR

LEGEND : B: A TTENTION REQUIRED AT NEXT SCHEDULED SHUTDOWN - RAISE WORK ORDER
c SERVICEABLE CONDITION - NO ACTION REQUIRED
 SCH E"iCK PROCESS tTIAN JI Nl INDUSTR IAL TECHNOLOG Y CO . L TO

35 LUBR ICATION

35 - Lu :3 q 1c.:..T10N SCHEDUL E
ITE •,~ ITE I\~ LUBRICANT PERIOD
LUBRICANT QTY ACTIVITY
Q TY DES CR IPT ION TYPE HOURS
CHECK
OIL ..\S REQ D TO USING DIPST IC I\
-- =-X'.:: -= ~ q :: i= :: i=<. T ..\BL=
,..., " ,...,
..\CH IE\ E LEVEL & :::c10
._: ¿¿ IN T...\SLE 3 2 í TOP-UP IF
REQ D
1
OIL. DRAIN
REFER T•..\B LE 1000
2 =.X:::: -= :;;_ ::;;.::r"ER T,..\BLE 1
&
'"'~ :3 2 1
~
~ L L. REF ILL
.:. \. ,s...:.:_ _ GRcA SE REFEr\
- - 3Cg TOP-UP ·1000
¿_
== .:. .::;;_ ,2 T...\BLE 3 2 3 l
:={ ~.r=S - ..; =-- GR cA SE RE rER
30g TOP-UP -WOO
s=:..1:-. = TABLE 3 2 :3 1

- \ -==-·:·== .:. -=
S -~; =-:- S?' ' ~ =
Gqc...\S:: REFER
30g TOP-UP -4 000
T...\BLF 3 2.3
, ,0 - ~ ,
• ,.,_.., v""'\ GREASE. REFER
2 -- - - :,-: ~~ 1 30g TOP-UP -4000
==..,""'\.""\ 1, ~~ T•..\BLE 3 2 3

LU SRICATION RECORD

ITEM DESCRIPTION DATE LAST COMPLETED

=XC ~E~ 0 1'.. C:,...'. _NG:: 1 1

1 1

G'"'c.,'..·S~ LAY S r~.'...:=-T 1

l
=~=t~G
2R=.AS~ GR!\T= SHAFT 1

S?U N::
1 1

GR =....:..s = IN =K'..i= CIA l e 1

SH.AFT S? LI N'.: '
1 1

2 '.=< :;..s _ 1.10 , o ~ 1 1

=S..:..R1:--: ss 1
1 1
 3 .6 RECOMMENDED SPARE PARTS

3.6.1 MACHINE DESCRIPTION Model No. SERIAL NO.

2.4m x 6 .1m Single Oeck Banana Screen SL02461W 01680901/02/
03

SPARE PARTS LIST

QUANTITY DÉSCRIPTION
( PART NO:
8 Belt - Screen Orive 000-672500-01
4 Couplinq - Rubber Oisc 000-430021-01
12 Bolt- Rubber Oisc 000-532050- 12
12 Bolt_: Rubber Oisc 000-510070-12
24 Washer- Rubber Oisc 000-550003-12
24 Nut- Rubber Oisc 000-540002- 12
1 Orive Shaft 000-410017-01
8 Sprinq 000-300027-02
16 Grommet - Sprinq 000-320001 -01
2 Pluq - Exciter Orain 000-900001 -24
4 Seal - Exciter Orain Pluq 000-900002 -24
2 Pluq - Exciter Fill 000-900001 - 16
000-900002 -1 6
( 4 Seal - Exciter Fill Pluq
2 Seal - Layshaft Bearinq 000-6210 75-01
2 Exciter - OF401 S - 000 -941000-01
12 Nut - Exciter Mountinq 000-540001-24
12 Bolt - Exciter Mountinq 000-510100-24

Quantities shown are for one (1) machine.

The machine Serial Number must be quoted when ordering spare parts.

File: J: \Job 0185 San Carlos Manual 0185 SL02461 SCREEN MANUAL - REV1 .doc Page 69 of 71
Th1s document is confidential and it is made available as a confidential disclosure en the understanding that it shall not be shown to , discussed w1th. ar
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