P.E.P.

8000 Vibrator
Operators Manual

Table of Contents
Sectio n
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disclaimers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page
1
1 1 1 2 2

Installation and Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting eccentric weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Mounting vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Connecting hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Vibrator start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Filter changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Replacement oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Bearing grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Introduction
General
Engineered to provide long service life in rigorous, continuous-duty applications, the P.E.P. 8000 Vibrator is used on high-frequency screens from Astec Mobile Screens, Inc. The following documents are referenced in this manual: The National Electrical Code (NEC) Handbook, National Fire Protection Association, 1 Batterymarch Park, P.O. Box 9101, Quincy, MA., 02269-9101. American National Standards Institute (ANSI) z244.1-1982, American National Standard for Personnel Protection - Lockout/Tagout of Energy Sources - Minimum Safety Requirements, American National Standards Institute, Inc., 1430 Broadway, New York, NY 10018. Federal Register, Volume 54, Number 169, Part IV, 29 CFR Part 1910, Control of Hazardous Energy Source (Lockout/Tagout); Final Rule, Department of Labor, Occupational Safety and Health Administration (OSHA), 32nd Floor, Room 3244, 230 South Dearborn Street, Chicago, IL 60604.

References

Safety

All safety rules defined in the above documents and all owner/employer safety rules must be strictly followed when working on the P.E.P. 8000 Vibrator. The following symbols are used in this manual: !

Symbols

DANGER WARNING CAUTION

Danger: Immediate hazards that will result in severe personal injury. !

injury.

Warning: Hazards or unsafe practices that could result in personal

!
property damage.

Caution: Hazards or unsafe practices that could result in product or

IMPORTANT
Important: Instructions that must be followed to ensure proper installation/operation of equipment.

NOTE
Note: General statements to assist the reader.

Limited warranty

Astec Mobile Screens, Inc. warrants the P.E.P. 8000 Vibrator against defects in materials or workmanship for a period of 12 months from date of purchase. This warranty shall be void unless the product is operated in strict accordance with the instructions given in this manual. The foregoing express warranties are in lieu of all other warranties, expressed or implied, including but not limited to the implied warranties of merchantability and fitness for a particular purpose. Astec Mobile Screens, Inc. hereby disclaims any liability for injuries or damage resulting from use or application of this product contrary to instructions and specifications contained herein. Astec Mobile Screens, Inc.'s liability shall be limited to repair or replacement of product shown to be defective.

Disclaimers

Installation and Start-up IMPORTANT

Read this entire section before beginning work.

NOTE
Weights are set at # 3 setting at factory. This is suitable for most screening applications. !

CAUTION

If adjustment to weights setting is necessary, adjust both sets of weights to the same setting. Failure to set both sets of weights the same will damage the vibrator and void the warranty. Materials required: 5/8-in.-18 NF GR 8 bolts, 5/8-in. lock nuts, torque wrenches.

Adjusting eccentric weights

1. Remove back cover, motor flange, and motor from vibrator. 2. Set eccentric weights as follows: a. Remove 5/16-in. socket head cap screws and SCHNORR Washers from adjustable eccentric (outer) weight. b. Slide outer weight to desired setting (1 through 5) according to Table I. Higher numbers give more force. c. Replace SCHNORR Washers and socket head cap screws.

Figure 1. Eccentric Weight Settings

5 4 3 2 1 5 4 3 2

Left

Right

IMPORTANT
Remember to set both sets of weights. 3. Repeat steps 2a through 2c for second set of weights. 4. Tighten socket head cap screws to 16 ft-lb with 3/8-in. torque wrench.

Table I. Vibrator Settings and Force Output

gpm* (L/m) Eccentric Weight Setting 1 3.00 4150 (11.36) 2 3*** 4 5 Force Output Percent 65 75 85 95 100 Unbalance (inch-lb) 2.72 3.14 3.50 3.92 4.09 Force Output Pounds 1331 1536 1713 1918 2001

rpm**

*Gallons per minute (Liters per minute). **Revolutions per minute of the hydraulic motor. ***Normal setting from factory.

CAUTION

Mounting vibrator

Use new bolts, lock nuts, and compression washers when installing vibrator. Do not reuse old fasteners. Damage to vibrator or mounting structure could result. 1. Make sure mounting surfaces are clean and free of debris before mounting to screen. Mounting surface should be flat (within 1/16 in. across vibrator feet) to prevent internal stress to vibrator casting when tightening bolts. 2. Install bolts, lock nuts, and compression washers in vibrator mounting holes and tighten to 180 ft-lb (25 kgm).

IMPORTANT
Loose vibrator mounting feet can adversely effect the speed of the vibrator.

CAUTION

Connecting hydraulic hoses

Avoid dropping disconnected hydraulic hoses. Dirt and other material can contaminate fittings. Do not over-tighten fittings. Damage to fittings will result. Make sure inlet hose fitting is on inlet motor fitting and outlet hose fitting is on outlet motor fitting. Installing hose fittings incorrectly will cause motor seal failure. DO NOT RUN THE P.E.P. 8000 VIBRATORS WITHOUT A CASE DRAIN. Damage to hydraulic motor seal could result. 1. Make sure hydraulic hoses are secure from hydraulic pump to vibrator. 2. Place hydraulic hose fittings on back of motor and tighten. 3. To connect motor case drain supplied with motor, do the following: a. Connect case drain to the 3/8-in. return line running back to the tank (see Figure 2).

b. Contact Astec Mobile Screens, Inc. for case drain installation on screens manufactured before May 1992.

Figure 2. Case Drain

Case Drain

CAUTION

Vibrator start-up

Maximum operating pressure is 1150 psi (79 bar). Operating motor above this level can cause seal failures. Do not operate the vibrator over 4200 rpm. Operating vibrator over 4200 rpm decreases bearing life substantially. Never exceed 3.0 gpm. This could void the warranty.

NOTE
Vibrator motor rotates counterclockwise when facing motor back end. 1. Check vibrator speed by placing MARTIN VIBRA-TAK Vibration Gauge (available from Astec Mobile Screens, Inc.) on top of vibrator. Run vibrator at lowest speed necessary to screen material. (Running at speeds over 4200 rpm will shorten bearing life.) 2. Check sight temperature gauge on hydraulic reservoir to make sure temperature does not exceed 150F (65C). If temperature is higher, install a heat exchanger or a larger reservoir to allow better cooling. 3. The hydraulic pump is set at the factory to produce 3 gpm (11 L/m) per vibrator. Check flow meter to make sure newly installed vibrator is getting correct oil flow.

Maintenance IMPORTANT
Read entire section before beginning work.

Filter changes Hydraulic fluid

All hydraulic filters need to be changed after the first 50 hours and every 250 hours thereafter. The hydraulic fluid will need to be changed after the first 500 hours and every 1000 hours thereafter with ISO 46 oil or equivalent.

NOTE
Every 1000 hours, while changing the hydraulic fluid, inspect all hydraulic lines and fittings. Kinks or obstructions in any of the hydraulic lines will increase the back pressure in the system. Increased back pressure will cause the vibrators to run slower and will decrease the performance of your P.E.P. screen.

Replacement oil

ISO 46 hydraulic oil is available from Astec Mobile Screens, Inc.

ISO 46 Properties Viscosity @ 104F (40C) Viscosity @ 212F (100C) Viscosity Index Gravity @ 60 degrees Flash Point, C.O.C. Pour Point 46 cSt 6.7 cSt 95 31API 421F (211C) 0F (-18C)

Bearing grease

The P.E.P. 8000 Vibrator has been lubricated for life from the factory. No periodic lubrication is necessary. When replacing bearings use only Klber Isoflex NBU15 grease.

NOTE
Klber grease may be purchased from Astec Mobile Screens, Inc. by calling 800-545-2125.

Part Numbers
10 9 2 1 12 11 14 15 16 18 17

6 13 5 3 4

Item 1 2 3 4 5 6 9 10 11 12 13 Case

Description

Part No. C08100 C08101 C08102 C08103 C08104 C08105 C02008 C08108 C02128 C02129 C02127

Qty 1 1 2 2 2 2 2 1 1 1 2

Item 14 15 16 17 18 * * * * *

Description Flange Motor Washer Compression 5/16 Screw HHC 5/16-24NF x 1-1/4 Motor Hydraulic 2HB Nut Hex 5/16-24NF ZP SCHNORR Washer D8

Part No. C08110 C02000 C02001 C08111 C02003 C08106 C08107 C08109 C02006 C08112

Qty 1 8 4 1 4 10 2 8 2 1

Shaft Eccentric Bearing Seal Dual Lip Oil Weight Eccentric Fixed Weight Eccentric Adjustable Screw HHC 1/4-20NC x 7/8 ZP Back Cap Spider Flexible Key 1/8 x 1/8 x 5/8 Lg Coupling L075 1/8 x 1/16

Screw SHC 5/16-18NC x 1 Screw SHC 5/16-18NC x 3/4 Washer Compression 5/8 Manual Operators

*Not Shown

Figure 3. P.E.P. 8000 Vibrator, P/N 37823-F

2 11 6 16 14 12 5

1 15 13 10 9 8 7 Part No. C02029 2420113 C02035 C02034 C02038 C02042 C02043 C02027 Qty. 8 1 2 1 1 1 1 1 12 13 14 15 16 Item 9 10 11 Spring Ball Plastic Gasket Kit (Amber, Silver, and Gold)* Ball Bearing Snap Ring Shim High-Pressure Oil Seal Snap Ring Description Part No. C0 2 0 2 6 C02025 C02136 C02024 C02036 C02044 C02138 C02037 Qty. 1 1 1 1 3 1 1 1 4 3

Item 1 2 3 4 5 6 7 8

Description 1/4-20 NC x 2-1/4 12 Point Screw 7/16-20 SAE Steel Plug Dowel Pin Dr i v e P i n Woodruff Key Drive Shaft Steel Plug O -Ring

*Each vibrator has one of three gaskets. Replace gasket with a new gasket of the same color.

Figure 4. P.E.P. 8000 Hydraulic Motor, P/N C08111

NOTE
Replacement of parts not listed here will require replacing entire hydraulic motor, P/N C08111.